ASD-STAN PREN 4677-001-2009 Aerospace series Welded and brazed assemblies for aerospace construction Joints of metallic materials by electron beam welding Part 001 Quality of welde.pdf

1、ASD STANDARD NORME ASD ASD NORM prEN 4677-001 Edition P 1 August 2009 PUBLISHED BY THE AEROSPACE AND DEFENCE INDUSTRIES ASSOCIATION OF EUROPE - STANDARDIZATIONAvenue de Tervuren, 270 - B-1150 Brussels - Tel. + 32 2 775 8126 - Fax. + 32 2 775 8131 - www.asd-stan.orgICS: Descriptors: ENGLISH VERSION A

2、erospace series Welded and brazed assemblies for aerospace construction Joints of metallic materials by electron beam welding Part 001: Quality of welded assemblies Srie arospatiale Assemblages souds et brass pour constructions arospatiales Assemblages de matriaux mtalliques souds par faisceau dlect

3、rons Partie 001 : Qualit des assemblages souds Luft- und Raumfahrt Schwei- und Ltverbindungen fr die Luft- und Raumfahrt Verbindungen metallischer Werkstoffe mittels Elektronenstrahlschweien Teil 001: Qualitt der Schweiverbindungen This “Aerospace Series“ Prestandard has been drawn up under the resp

4、onsibility of ASD-STAN (The AeroSpace and Defence Industries Association of Europe - Standardization). It is published for the needs of the European Aerospace Industry. It has been technically approved by the experts of the concerned Domain following member comments. Subsequent to the publication of

5、 this Prestandard, the technical content shall not be changed to an extent that interchangeability is affected, physically or functionally, without re-identification of the standard. After examination and review by users and formal agreement of ASD-STAN, it will be submitted as a draft European Stan

6、dard (prEN) to CEN (European Committee for Standardization) for formal vote and transformation to full European Standard (EN). The CEN national members have then to implement the EN at national level by giving the EN the status of a national standard and by withdrawing any national standards conflic

7、ting with the EN. Edition approved for publication 31 August 2009 Comments should be sent within six months after the date of publication to ASD-STAN Metallic Material Domain Copyright 2009 by ASD-STAN prEN 4677-001:2009 2 Contents Page Foreword .2 1 Scope3 2 Normative references3 3 Terms and defini

8、tions .4 4 Symbols and acronyms 11 5 General requirements .11 6 Technical requirements for manufacturing new parts 15 7 Technical repair requirements.29 8 Special case.30 Annex A (informative) Imperfections 31 Foreword This standard was reviewed by the Domain Technical Coordinator of ASD-STANs Metal

9、lic Material Domain. After inquiries and votes carried out in accordance with the rules of ASD-STAN defined in ASD-STANs General Process Manual, this standard has received approval for Publication. prEN 4677-001:2009 3 1 Scope This standard defines the rules to be satisfied to ensure the quality of

10、joints of metallic materials by electron beam welding (code 51 according to EN ISO 4063). It applies unreservedly to the manufacturing of new parts or for repair, these operations being under the responsibility of an approved manufacturer or supplier. The final responsibility is with the Design Auth

11、ority 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN ISO 4063, Welding

12、 and allied processes Nomenclature of processes and reference numbers. EN ISO 6507-1, Metallic materials Vickers hardness test Part 1: Test method. EN ISO 14731, Welding coordination Tasks and responsibilities. EN ISO 14744-1, Welding Acceptance inspection of electron beam welding machines - Part 1:

13、 principles and acceptance conditions. EN ISO 14744-2, Welding Acceptance inspection of electron beam welding machines Part 2: Measurement of accelerating voltage characteristics EN ISO 14744-3, Welding Acceptance inspection of electron beam welding machines Part 3: Measurement of beam current chara

14、cteristics. EN ISO 14744-6, Welding Acceptance inspection of electron beam welding machines Part 6: Measurement of stability of spot position. EN ISO 17659, Welding Multilingual terms for welded joints with illustrations. ISO 857-1, Welding and allied processes Vocabulary Part 1: Metal welding proce

15、sses. ISO 4969, Steel Macroscopic examination by etching with strong mineral acids. ISO 8596, Ophthalmic optics - Visual acuity testing Standard optotype and its presentation. ISO 22826, Destructive tests on welds in metallic materials Hardness testing of narrow joints welded by laser and electron b

16、eam (Vickers and Knoop hardness tests). ISO 24394, Aerospace series Qualification test for welders and welding operators Fusion welding of metallic components. EN 875, Destructive tests on welds in metallic materials Impact tests Test specimen location, notch orientation and examination. EN 895, Des

17、tructive tests on welds in metallic materials Transverse tensile test. EN 910, Destructive tests on welds in metallic materials Bend tests. EN 4632-001, Aerospace series Welded and brazed assemblies foor aerospace constructions Weldability and brazeability of materials Part 001: General requirements

18、. prEN 4677-001:2009 4 EN 4632-002, Aerospace series Welded and brazed assemblies for aerospace constructions Weldability and brazeability of materials Part 002: Homogeneous asssemblies aluminium and aluminium alloys. TR 25901, Welding and related processes Vocabulary. 3 Terms and definitions For th

19、e purposes of this document, the terms and definitions are given in ISO 857-1 and ISO 17659. 3.1 electron beam welding fusion welding process using the transformation of the kinetic energy of beam electrons into thermal energy when they strike the material NOTE 1 The electrons are obtained from a ca

20、thode heated under a secondary vacuum (1 Pa to 10-4Pa). NOTE 2 The welding operation may be performed under a controlled atmosphere, generally under a primary vacuum (100 Pa to 1 Pa) or secondary vacuum. 3.2 Weldability 3.2.1 notion of weldability a metallic material is considered to be weldable to

21、a given degree, by a given process or for a given type of application when, provided that the corresponding precautions are taken, it lends itself to the production of a weld which, through its characteristics and the consequences of its presence, meets the required properties chosen as the basis fo

22、r the judgement 3.2.2 degrees of weldability the weldability of materials is assessed according to the following four degrees: degree 1: material with very good weldability, requiring no particular precautions. Preferred. degree 2: material with good weldability but likely to require special welding

23、 precautions (for example, preheating, low feedrate, etc.). degree 3: material with poor weldability, requiring specific development for each type of part and likely to lead to manufacturing problems. Inadvisable. degree 4: material with very poor weldability. To be avoided. 3.3 Technical terms 3.3.

24、1 General 3.3.1.1 flat position PA horizontal welding, with beam axis vertical 3.3.1.2 horizontal-vertical position PB horizontal welding prEN 4677-001:2009 5 3.3.1.3 horizontal position PC horizontal welding, welding axis horizontal 3.3.1.4 horizontal overhead position PD horizontal welding, overhe

25、ad 3.3.1.5 overhead position PE horizontal welding, overhead, welding axis vertical 3.3.1.6 vertical up position PF welding up 3.3.1.7 vertical down position PG welding down 3.3.2 Welding parameters 3.3.2.1 run-out interval encompassing all geometrical irregularities of the joint plane NOTE This int

26、erval is measured on the detail parts, positioned in their welding setup, and is used as a reference to determine the minimum width of the weld zone. 3.3.2.2 beam centering alignment of the beam axis on the joint plane 3.3.2.3 beam deflection controlled movement of the beam in relation to the physic

27、al axis of the gun 3.3.2.4 level distance difference in level (height) between two detail parts at the joint plane 3.3.2.5 firing (working) distance distance between the impact point of the beam on detail parts and a reference surface linked to the gun or the machine (example: middle of the closest

28、focusing coil of the detail part, electron gun base) 3.3.2.6 specific welding energy defined by ratio between the beam power over the welding speed, multiplied by 60 0001(cm/min)60(Ampere)(Volt)VIU(in kJ/cm) 3.3.2.7 slope (or ramp) down operating conditions under which the penetration depth varies d

29、ecrementally prEN 4677-001:2009 6 3.3.2.8 beam deflection controlled movement of the beam in relation to the physical axis of the gun 3.3.2.9 level distance difference in level (height) between two detail parts at the joint plane 3.3.2.10 firing (working) distance distance between the impact point o

30、f the beam on detail parts and a reference surface linked to the gun or the machine (example: middle of the closest focusing coil of the detail part, electron gun base) 3.3.2.11 specific welding energy defined by ratio between the beam power over the welding speed, multiplied by 60 0001(cm/min)60(Am

31、pere)(Volt)VIU(in kJ/cm) 3.3.2.12 slope (or ramp) down operating conditions under which the penetration depth varies decrementally 3.3.2.13 focusing current intensity intensity of the current crossing the focusing coil enabling electron beam concentration on a point called the focusing point NOTE Th

32、e intensity may be constant or modulated. 3.3.2.14 beam current electron flow emitted by the cathode NOTE This current may be constant or modulated. 3.3.2.15 clearance before welding (Fit up) distance measured on a straight section of the joint between the surfaces to be welded 3.3.2.16 slope (or ra

33、mp) up operating conditions for which the penetration depth varies incrementally 3.3.2.17 focusing level distance between the beam impact point on the detail parts and the focusing point NOTE Conventionally, this distance is negative when the focusing point is within the detail parts. 3.3.2.18 perve

34、ance ratio of the beam current over the acceleration voltage at power 3/2 tecUI=23prEN 4677-001:2009 7 3.3.2.19 beam power product of the acceleration voltage and the beam current 3.3.2.20 acceleration voltage difference in potential between the cathode and the anode, used to create the electric fie

35、ld intended to accelerate the electrons 3.3.2.21 beam oscillation periodic movement of the beam axis in relation to the weld pool NOTE This oscillation is defined by the signal shape, its amplitude, frequency and direction in relation to that of welding. 3.3.2.22 welding speed length of the weld on

36、beam impact side produced per time unit 3.3.3 Other technical terms 3.3.3.1 welding campaign series of welding operations on identical parts, executed on the same machine, without any changes of welding parameters, without performing other welds on the machine, without interrupting manufacturing for

37、 more than a week 3.3.3.2 welding cycle succession of different welding phases performed by the welding machine to make a weld 3.3.3.3 tacking pass pre-assembling of elementary detail parts using the same process as the one used for welding, consisting of making a slightly penetrating, narrow weld,

38、continuous or discontinuous along the joint plane , with the purpose of maintaining the detail parts in position 3.3.3.4 adjustment verification specimen this is a flat test specimen of the same material, subjected to the same heat treatments as the detail parts, on which a melt run will be made in

39、the middle using the parameters identical to those used for parts, and for which the relationship between the micrographic shape of the cross section cut of the bead and that obtained on test specimens or real parts has been previously defined 3.3.3.5 structural state metal crystalline structural st

40、ate 3.3.3.6 manufacturing performance of welding operations on new parts or repairs to existing assemblies (or products) 3.3.3.7 stabilized manufacturing manufacturing for which the reliability can be established without quality issue over several welding campaigns, of which the number is previously

41、 defined by the appropriate department of the Design Authority prEN 4677-001:2009 8 3.3.3.8 smoothing pass or cosmetic pass remelted surface of the welded zone 3.3.3.9 batch of parts set of parts with the same reference from: the same welding campaign; the same heat treatment batch; traced material

42、(processing, chemical analysis, ). 3.3.3.10 material/parent metal material or metal used to make the detail parts 3.3.3.11 filler metal additional alloy or metal used to make the weld of an assembly or a deposit 3.3.3.12 tooling equipment required to hold and position parts before and during welding

43、 3.3.3.13 beam stopper (catcher) part intended to intercept the residual energy crossing the beam in the case of a through weld NOTE The material making up the beam catcher shall be of a same grade or a grade compatible with the required quality of the assembly. 3.3.3.14 detail part individual eleme

44、nt to be assembled with other elements to make up a complete part 3.3.3.15 part - product assembly comprising several assembled detail parts 3.3.3.16 tack welding pre-assembly of detail parts by welding consisting of a set of tacks along the joint plane, intended to hold the detail parts in position

45、 3.3.3.17 pre-heating heating of detail parts before welding without fusion NOTE This operation will be carried out with an unfocused beam or any other process not involving magnetism. 3.3.3.18 through weld case where the beam crosses all the thickness of parts to weld case where the beam propagates

46、 through all the parts to be welded 3.3.3.19 blind weld case where the beam only crosses part of the thickness of the parts to weld case where the beam only partially propagates through the thickness of the parts to be welded prEN 4677-001:2009 9 3.3.3.20 Qualification test specimen welded assembly

47、to be used for inspection purposes 3.3.3.21 manufacturing test specimen test specimen representing manufactured parts to be welded under the same conditions as those parts; test specimen made from the same material grade, in the same condition, with the same dimensions as the manufactured part. NOTE

48、 Manufacturing test specimens may be actual parts. 3.3.3.22 pool support element positioned on detail parts to prevent the fused metal from overflowing NOTE 1 The material making up the pool support shall be of the same base alloy as the detail parts, to prevent any weld contamination. NOTE 2 The po

49、ol support may be positioned as illustrated below (Figures 4 to 6): Figure 1 Back support Figure 2 Back-side support Figure 3 Front-side support 3.3.3.23 witness lines Alignment lines on both sides (upper and root) of the detail parts to ensure good location and the avoidance of lack of fusion 3.3.3.24 post weld heat treatment treatment intended to provide the parent material and the weld zone with the requisite conditions and properties 3.4 General terms 3.4.1 manufacturer or sub