S9074-AQ-GIB-010/248 Rev 1
A-3.4.1.4 Test Assembly Joint Design. The test assembly shall employ the butt joint design to be used in production. Other joint designs shall be qualified in accordance with A-3.2.2. A-3.4.1.5 FS Tool Life. Qualification welding shall be performed with a used FS tool. The FS tool shall be at 85 percent or greater of the proposed FS tool life. See A-3.6.1.1 for FS tool life procedure requirements. A-3.4.1.6 Use of Qualified Procedures for Repair of Friction Stirred Material. A qualified FSW procedure is not qualified for repair of friction stirred material. Procedures for repair of friction stirred material shall be qualified as specified in A-3.4.3. A-3.4.2 Qualification Requirements for FSP. A-3.4.2.1 Base Material. Qualification test assemblies shall conform to the base materials specified in A-3.4.1.1. A-3.4.2.2 Test Assembly Size. The typical test assembly size for an FSP 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 approximate start, middle, and end of a processed region. 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 removal of the required level II test specimens from a single test assembly. FSP of additional test assemblies to furnish the required test specimens shall not be permitted. A-3.4.2.3 Test Assembly Fabrication. The test assembly shall be prepared as specified in A-3.4.2.3.1, and shall be fixtured and fabricated as intended for production, including the tooling and anvil arrangement, control methods, thermal management controls, etc. to the extent possible to ensure that the procedure used is representative of production FSP. A-3.4.2.3.1 Test Assembly Parameters. One test assembly shall be prepared employing the following as intended for production: a. Total number of passes to be used in production. b. Travel direction and orientation of each pass relative to the preceding pass. c. Maximum interpass step-over distance. d. Effective processing size. A-3.4.2.4 Qualification Limits for Interpass Step-Over Distance. The maximum interpass step-over distance shall not exceed the maximum interpass step-over distance recorded in the qualification test report. A-3.4.2.5 FS Tool Life. Qualification welding shall be performed with a used FS tool. The FS tool shall be at 85 percent or greater of the proposed FS tool life. See A-3.6.1.1 for FS tool life procedure requirements. A-3.4.2.6 Use of Qualified FSP Procedures for Repair of Friction Stirred Material. A qualified FSP procedure is not qualified for repair of friction stirred material. Repair of friction stirred material by FSP shall be qualified as specified in A-3.4.3. A-3.4.3 Qualification Requirements for Repair of Friction Stirred Material. A-3.4.3.1 Base Material. Qualification test assemblies shall conform to the base materials specified in A-3.4.1.1 and shall include the number of FS passes employed in the initial friction stirred region intended for production repair. A-3.4.3.2 Test Assembly Size. The typical test assembly size for a repair qualification test assembly is shown in figure A-3. The size of the test assembly shall be sufficient to permit removal of the required test specimens as specified in table A-2 from the repair-welded area that contained the defect. Additional test assemblies to furnish the required test specimens shall not be permitted.
A-5
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