S9074-AQ-GIB-010/248 Rev 1
A-3.6.1 Test Report. The FSW, FSP, and repair of friction stirred material procedure qualification test report shall include the values employed for each of the essential elements of the welding procedure as specified in table A-3 and the destructive and nondestructive test results in sufficient detail to ensure compliance with the requirements of table A-2. Photomacrographs and any work instructions referenced in the procedure or test report that contain the required essential element information shall be submitted with the test report. A-3.6.1.1 FS Tool Life Procedure Requirements. The test report shall include the activity’s written procedure for establishing and tracking FS tool life. The procedure shall include: a. A definition of maximum FS tool life measured in weld length and the testing (nondestructive and destructive) to validate the maximum life for each FS tool design. This shall account for the range of thicknesses to be welded in production with that FS tool. b. The method used to track the FS tool life of each FS tool to ensure that the maximum FS tool life is not exceeded. c. The method and frequency used to inspect, clean, and evaluate the conditions of FS tools. d. Nominal dimensions of all geometrical features of the new FS tool and the used FS tool at the end of its life. This procedure shall be provided for NAVSEA approval. An increase in FS tool life requires resubmission of the procedure to NAVSEA. Any decrease in FS tool inspection frequency or change in cleaning method shall be provided to the authorized representative for review. NAVSEA or the authorized representative may require requalification if there are specific technical concerns. A-3.6.1.2 Control of Anvil Gap. The test report submittal shall include the activity's written procedure for establishing and maintaining the qualified FS tool plunge depth for the actual (not nominal) material thickness, probe length and, if used, heel plunge depth. a. For each FS tool design qualified, define the maximum change in probe length for a given material thickness or the maximum change in material thickness for a given probe length. This change can be given in terms of a probe-to-anvil gap (see figure A-7) for a given FS tool design. This procedure shall account for the range of thicknesses and associated tolerances to be welded in production. b. Define the method used to track material thickness, probe length, plunge depth, and heel plunge depth to ensure that the maximum probe-to-anvil gap is not exceeded. c. Define the method and frequency used to inspect, clean, and measure probe length. d. Define the method and frequency used to evaluate material thickness(es). A-3.6.1.3 Work Instructions. All work instructions or other documents referenced in the qualification procedure or test report that contain essential element information shall be submitted along with the procedure qualification data. A-3.7 CHANGES REQUIRING LEVEL I REQUALIFICATION OF PROCEDURE. New procedure qualification test data shall be submitted to the authorized representative for approval when any of the changes listed herein are made in the FSW or FSP procedure. For changes to repair procedures for friction stirred material, see A- 3.8. For all procedures, changes other than those listed in this paragraph and A-3.8 for level II qualification may be made in a procedure without the necessity for requalification; however, the revised procedure with all changes identified shall be submitted for information to the authorized representative. The changes specified in A-3.7.1 through A-3.7.6 require requalification of the procedure for level I qualification. A-3.7.1 Base Material (Alloy, Product Form, Coating, and Thickness). a. A change from one base material alloy to any other base material alloy. b. A change from one base material form to another base material form. c. The addition or omission of base material coating. d. For FSW, a change in the maximum or minimum nominal base material thickness reported in the qualification test report(s). e. An increase in anvil gap.
A-8
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