Let the sparks fly: 2nd MXS welder certification

Senior Airman Tony Guinn, 2nd Maintenance Squadron aircraft metals technology journeyman, tungsten inert gas, or TIG, welds an aluminum tube mounted on a 45 degree fixture on Barksdale Air Force Base, La., March. 25, 2014. These tubes are part of a five-year welder’s certification. The certification requires a steady hand to ensure proper weld penetration through the walls of the aluminum. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Senior Airman Tony Guinn, 2nd Maintenance Squadron aircraft metals technology journeyman, uses a lathe to de-burr a pipe prior to welding on Barksdale Air Force Base, La., March.25, 2014. Prior to becoming a certified welder, each Airmen must clean their parts to be welded to ensure proper weld fusion. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Senior Airman Tony Guinn, 2nd Maintenance Squadron aircraft metals technology journeyman, grinds a tungsten inert gas, or TIG, welder tip prior to his welding certification on Barksdale Air Force Base, La., March. 25, 2014. The certification requires two pieces of aluminum to be mounted on a fixture at 45 degrees and cannot be repositioned once mounted. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Senior Airman Tony Guinn, 2nd Maintenance Squadron aircraft metals technology journeyman, welds two aluminum tubes as part of his five-year certification on Barksdale Air Force Base, La., March. 25, 2014. The certification requires two pieces of aluminum to be mounted on a fixture at 45 degrees and welded. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Staff Sgt. Josh Martinez, 2nd Maintenance Squadron, non-destructive inspection NCO in-charge, tapes an identification tag onto an aluminum tube being tested for cracks on Barksdale Air Force Base, La., March. 25, 2014. NDI Airmen inspect for cracks within the weld, proper penetration into the weld and porosity, which is gas formations that did not escape prior to the weld. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Senior Airman Leonard Avalos, 2nd Maintenance Squadron non-destructive inspection journeyman, checks the exposure on an X-ray film on Barksdale Air Force Base, La., March. 25, 2014. These X-ray films are used to check for cracks in welds by 2nd MXS metals technology Airmen completing their welding certification. (U.S. Air Force photo/Staff Sgt. Jason McCasland)

Let the sparks fly: 2nd MXS welder certification

Published March 27, 2014
By Staff Sgt. Jason McCasland
2nd Bomb Wing Public Affairs

BARKSDALE AIR FORCE BASE, La. -- Aircraft, ground equipment and jet engines all have one thing in common - metal, which over time can wear out or break. Repairing these items takes skill, precision and certifications.

Airmen from the 2nd Maintenance Squadron Structural Maintenance shop fuse metal together with gas, heat and electricity. By using this combination and welding the over-stressed metal, they are able to salvage and repair equipment worth millions.

"As welders we are required to certify on each type of metal, weld and style every five years," said Senior Airman Tony Guinn, 2nd MXS aircraft metals technology journeyman. "The certification proves we are able to do our job and the feedback from the weld inspection shows us how we can improve our skills. Using this certification we are also able to weld on aircraft engines, which can save the Air Force more than $1.3 million dollars in an engine replacement."

The certification process doesn't begin with welding two aluminum tubes together. There are certain criteria for each welder to complete before and during the weld.

"Each person performing the certification has to first clean up both pieces before they are welded," said Master Sgt. Anthony Fennell, 2nd MXS section chief. "Although they clean and remove burrs from the pipes, they cannot actually change the outside diameter of the pipes. Another thing the certification requires is for the pieces to be mounted on a stand angled at 45 degrees. This is one of the hardest angles for our welders to work with; while on the stand, the pieces cannot be removed or repositioned."

The certification process doesn't stop after the weld is complete. Using specialized skills, Airmen from the 2nd MXS Non-Destructive Inspection shop are responsible for certifying welders.

"After the welder brings us the piece to be certified, we X-ray it, develop the film and finally inspect the film to ensure everything is as it should be," said Staff Sgt. Josh Martinez, 2nd MXS NDI NCO in-charge. "After the weld has been certified, we sign off the welder's certification paperwork, and they retain that credential for five years. We also keep the film as proof of the work done for the certification. If there wasn't an NDI, we would have to send the welded part to an off installation inspection place."

The whole certification can take a few days to complete due to the different offices involved. The return not only saves time, it also saves money and ultimately lives.

"We take every weld certification very seriously," said Martinez. "Our shop is responsible for making sure Air Force assets are protected. If the welders don't complete all the criteria needed to be certified, then our aircraft and equipment could fail because of an improperly welded joint."

The certification follows the same guidelines as the American Welding Society, with some minor changes.

"The AWS requires their welding certifications to be done over seven different categories," said Fennell. "The Air Force however only requires us to certify on one level. They decided that if you are able to accomplish a higher level then you are also able to complete the lower ones as well. We are strict on the welding and our guidelines. Lives are in our hands."

Having on site welders helps reduce aircraft down times, and reduces the cost of maintaining both aircraft and ground equipment.

"We are also able to repair equipment maintainers use to maintain the aircraft. This keeps us from having to order new equipment such as air stairs, engine stands and other equipment," said Guinn.

Aircrew can fly safe knowing each weld metals technology Airmen make, are certified to provide high quality repairs on aircraft, ground equipment and jet engines.