S9074-AQ-GIB-010/248 Rev 1
A-3.5 EVALUATION OF PROCEDURE QUALIFICATION WELDMENTS. This section provides methods for evaluation of the tests required for the qualification of FSW procedures, FSP procedures, and procedures for repair of friction stirred materials. The type and number of destructive tests required for each assembly are shown in table A-2. A-3.5.1 Nondestructive Tests. Prior to performing any destructive tests, all procedure qualification test assemblies shall be nondestructively tested as required in table A-2. Nondestructive testing and acceptance criteria shall be as specified in 4-5 and A-3.5.1.1 through A-3.5.1.3. A-3.5.1.1 Visual Inspection. Prior to any cleaning or grinding, FS welded or FS processed regions shall be visually inspected. A-3.5.1.1.1 Grinding Repair and Surface Preparation. Grinding of weld surfaces is not permitted to meet the acceptance criteria of MIL-STD-2035, but may be performed after acceptable visual inspection to prepare surfaces for other nondestructive tests in accordance with 4-5.1.2 and for removal of acceptable surface irregularities prior to destructive testing. A-3.5.1.2 Liquid Penetrant Inspection. Prior to liquid penetrant inspection, the surface shall be prepared as specified in NAVSEA T9074-AS-GIB-010/271. A-3.5.1.3 Acceptance Standards. Acceptance criteria for visual, radiography, liquid penetrant, and ultrasonic inspections shall be in accordance with class 1 of MIL-STD-2035 for FS. A-3.5.2 Destructive Tests. Destructive testing shall be in accordance with 4-5 and the additional requirements of this section. Test results shall be evaluated as specified in A-3.5.2.1 through A-3.5.2.3. A-3.5.2.1 Transverse Weld Tension Tests. For tensile tests, the recommended specimen dimensions of AWS B4.0 shall be followed. For acceptance, the transverse weld tension test specimens shall have a tensile strength not less than the minimum specified in table A-1, regardless of the failure location. A-3.5.2.2 Guided Bend Tests. FS welds and FS processed regions shall be tested by wrap around bend tests. The elongation used to determine the radius of the mandrel shall be the greater of the minimum specified base material elongation or 10 percent. A-3.5.2.2.1 Criteria for Acceptance. For acceptance, the bend test specimen after bending shall have no cracks or other open defects larger than ⅛ inch. A-3.5.2.3 Macro-Etch Specimens. Specimens shall be removed transverse to the weld, prepared to 800-grit finish, etched to reveal remnant oxides, and examined at 10× magnification to the following requirements: a. For FS welds or FS processed material, discontinuities in the weld or processed area greater in length than ¹⁄ 32 inch or 10 percent of the material thickness, whichever is less, shall be cause for rejection. FS welds are subject to some amount of remnant oxides within the thermomechanically affected zone and shall not be cause for rejection if dispersed and discontinuous within the center of the thermomechanically affected zone. An aligned remnant oxide is rejectable if it has a linear accumulated length greater than ¹⁄ 32 inch or 10 percent of the material thickness, whichever is less, within approximately 5 degrees of a line normal to the surface of the weld. An example of a remnant oxide trace is shown in figure A-4. b. For partial penetration FS welds (such as multi-void extrusions), linear or rounded conditions at the root are acceptable provided they do not reduce the weld thickness below the minimum allowable thickness and provided they do not exceed ¹⁄ 32 inch in length and adjacent linear defects are not closer than ⅛ inch. Root conditions outside the original joint configuration shall not be evaluated. A-3.6 DATA AND REPORTING FOR PROCEDURE QUALIFICATION. This section specifies the requirements for procedure qualification data reporting to obtain approval of a procedure qualification test report for FSW, FSP, and repair of friction stirred material procedure qualification.
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