Kevin, at Boeing in those areas where structural welding was performed on the airplane, test specimans of the same lot of material were fabricated and included with the parts which were to be welded. Those test specimans were welded at the same time the assembly took place using the same weld material and done by the same welder. Those specimans were subjected to several laboratory non-destructive and destructive tests to determine the strength of the weld. The actual weld was also x-rayed for a look and analysis of the actual fusion of the materials by the welder. The lab results, x-rays and welder certification data are permanently stored in the completed records of the airplane longer then the aircraft is in service. We were certainly building too and having to meet different specifications then we are discussing here but that experience has enforced my feelings about welding by novices in lieu of using mechanical fastening hardware and components of known and documented strengths. I hope you enjoy your job as much as I enjoyed my almost 40 year career with Boeing as I wouldn't have traded a day of it for some other line of employment, Hal.
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