S9074-AQ-GIB-010/248 Rev 1
A-3.2.4 Position Qualification Limits for Position-Controlled FSW and FSP. For FSW and FSP employing the position-control method, the orientation of the spindle employed for procedure qualification test assemblies shall be classified by reference to the type of machine. The orientation of the spindle for FSW and FSP procedure qualification test assemblies shall be in the least stiff position of the machine. A-3.2.5 Repair of Test Assembly. Assemblies shall not be repair welded. If a test assembly fails to meet the destructive or nondestructive requirements, the test assembly shall be rejected. In such cases, a duplicate test assembly may be welded using the same welding procedure and tested. If the second test assembly fails, that test assembly shall be rejected and an amended weld procedure that corrects the cause of defective welding shall be prepared and qualified as specified herein. A-3.3 WRITTEN PROCEDURE CONTENT FOR FSW, FSP, AND REPAIR OF FRICTION STIRRED MATERIAL (SEE A-3.6.1.1 FOR FS TOOL LIFE PROCEDURE). A-3.3.1 Essential Elements of a FSW Procedure, FSP Procedure, and Procedure for Repair of Friction Stirred Material. The FSW procedure, FSP procedure, and procedure for repair of friction stirred material shall include, at a minimum, the essential elements listed in table A-3. Essential elements for fusion welding repair of friction stirred material shall be per table 7-5 requirements and the applicable requirements from table A-3. A-3.4 SPECIFIC QUALIFICATION REQUIREMENTS. This section provides the requirements for qualification test assembly size, test assembly fabrication, qualification limits, and methods of evaluation for qualification of an FSW procedure in A-3.4.1, an FSP procedure in A-3.4.2, and a procedure for repair of friction stirred material in A- 3.4.3 for both general and special applications. A-3.4.1 Qualification Requirements for FS Welded Butt Joints and Multi-Void Hollow Extrusion Joints. A-3.4.1.1 Base Material. Qualification test assemblies shall conform to the base materials listed in table A-1 and shall be of the same alloy and form (plate, extrusion, etc.) to be welded in production. A-3.4.1.2 Test Assembly Size. The typical test assembly size for an FSW qualification test assembly is shown in figure A-2 for level I qualification. The size of the test assembly shall be sufficient to permit removal of the required test specimens from the nominal start, middle and end of a single weld. The typical test assembly size for level II is shown in figure A-3. The size of the test assembly shall be sufficient to permit the removal of the level II required specimens from a single weld. FSW of additional test assemblies to furnish the required test specimens shall not be permitted. A-3.4.1.3 Test Assembly Fabrication. The test assembly shall be prepared as specified in A-3.4.1.3.1. The test assembly shall be the same base material form and shall be fixtured and welded the same as intended for production welding to the extent possible. For example, the test assembly for a multi-void hollow extrusion should be fabricated on a multi-void hollow extrusion using the fixture and anvil arrangement, tack welding procedure, thermal management controls, and seam tracking, etc. employed during production to ensure that the procedure used is representative of a production weld. A-3.4.1.3.1 Test Assembly Parameters. One test assembly each shall be prepared for the maximum and minimum nominal thickness to be welded in production employing (a) through (e) below such that the maximum anvil gap to be used in production is employed:
a. Minimum probe length. b. Minimum heel plunge depth. c. Minimum plunge depth.
d. Maximum allowable joint gap intended for production. e. Maximum lateral FS tool offset intended for production.
A-3.4.1.3.1.1 Qualification of Thicknesses Between the Maximum and Minimum. Each nominal thickness in between the maximum and minimum nominal thickness to be welded in production requires level II qualification in accordance with A-3.2.3.3 employing the above conditions.
A-4
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