S9074-AQ-GIB-010/248 Rev 1
A-3.8.12 Repair of Friction Stirred Material. Any change in fusion welding process, FS variant, FS tool class, or sequence of applied processes, variant, or tool class from that employed for previously qualified procedure. A change from a partial thickness repair to a full thickness repair and vice versa. A-3.8.13 Interpass Step-Over Distance and Direction for FSP. An increase in lateral step-over distance from that recorded in the procedure qualification test report. Also, a change in the direction of the lateral step-over to the opposite side of the FS pass from that recorded in the procedure qualification test report. A-3.8.14 Thickness Mismatch. An increase in thickness mismatch from that recorded in the procedure qualification test report. A change in the location of the thicker member from one side of the joint to the other side of the joint from that recorded in the procedure qualification test report (i.e., a change in the location of the thicker member of a joint in relation [i.e., left or right joint side] to the FS tool travel direction). A-3.8.15 Weld Joint Mismatch. An increase in weld joint mismatch from that recorded in the procedure qualification test report. A-4 FSW PERFORMANCE QUALIFICATION. A-4.1 SCOPE. This section provides the additional requirements for qualification of FS operators. Also included are the requirements for qualification records with suggested record format and forms for data accumulation and reporting. A-4.2 GENERAL REQUIREMENTS. A-4.2.1 Method of Establishing Qualification. The method for establishing qualification of friction stir operators is as follows: a. Each FS operator shall know the FS workmanship and visual inspection requirements of all fabrication documents to which the FS operator will be working. To ensure this knowledge, each FS operator shall be trained and tested in accordance with a program meeting the requirements of A-4.2.1.1. b. Each FS operator shall have satisfactorily FS welded, processed, or repaired the applicable performance qualification test assemblies. c. Each qualification test assembly shall be inspected in accordance with the requirements of this section. d. The results of either the destructive or nondestructive tests, or both, shall be evaluated in accordance with the applicable standards, unless otherwise specified in this document. e. Current records of the extent of each FS operator qualification shall be maintained (see A-4.5.1). A-4.2.1.1 Training Program. Each activity’s training program shall be as specified in 5-2.3.1 and the following: a. Training in FS workmanship and detailed visual inspection requirements of all fabrication documents to which FS is performed to NAVSEA T9074-AS-GIB-010/271. b. Auditing of the entire program by authorized representatives to ensure adequacy. Audits shall be conducted at least once every 2 years and the audit shall specifically address FS operators. A-4.2.1.2 FS Personnel. All personnel working with FSW, FSP, and repairs of friction stirred material shall be given formal instruction, within the limits of their discipline, on procedures for FSW, FSP, and repair of friction stirred material to attain the highest quality product. FS personnel shall include FS operators, nondestructive inspection personnel, the various inspectors responsible for work performance, and materials/welding engineers in production or support positions. Records of personnel training and test results shall be maintained with appropriate review to keep qualification current. A training plan, including methods of review to ensure continuous compliance, shall be submitted for NAVSEA approval.
A-11
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