1、 Guide for the Approval of Friction Stir Welding in Aluminum GUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM OCTOBER 2011 American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2011 American Bureau of Shipping ABS Plaza 16855 Northchase Dri
2、ve Houston, TX 77060 USA ii ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .2011 Foreword Foreword This Guide provides the guidelines for the approval of friction stir welding procedures, operators and the nondestructive testing requirements for production friction stir welding of al
3、uminum. These guidelines are based on the current knowledge and may be updated as practical experience is gained. The latest knowledge will be considered in approval tests and may require the test program or the range of approval to be adapted accordingly. This Guide becomes effective on the first d
4、ay of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify that this version of this Guide is the most current. We welcome your feedback. Comments or suggestions can be sent electronically by email to 0rsdeagle.org. ABSGUIDE FOR THE APPROVAL OF
5、 FRICTION STIR WELDING IN ALUMINUM .2011 iii Table of Contents GUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM CONTENTS SECTION 1 General 1 1 Scope and Application 1 2 References . 1 3 Definitions. 1 SECTION 2 Weld Procedure Qualification . 3 1 General Considerations 3 1.1 Procedure Qual
6、ification Limits.3 1.2 Test Assembly Size .3 1.3 Rejection of Test Assembly .3 1.4 Transfer of Qualification 3 1.5 Transverse Tensile Test Specimens and Transverse Bend Specimens.3 1.6 Fixturing.3 2 Qualification of Weld Repair Procedures . 5 3 Operator Qualification 5 4 FSW Weld Procedure Specifica
7、tion (WPS) and Welder Performance Qualification Record Requirements (WPQR) . 6 TABLE 1 Essential Elements of a Friction Stir Welding Procedure. 6 TABLE 2 Weld Procedure Qualification Test Requirements . 9 TABLE 3 Operator Qualification Test Requirements. 10 FIGURE 1 Butt Joint Test Assembly 4 FIGURE
8、 2 Location of Test Specimens . 4 SECTION 3 FSW Production Quality Control and NDT Requirements 11 1 Records 11 2 Inspection Before Production FSW 11 2.1 Verification Before Welding .11 2.2 Joint Setup Variability11 3 Inspection During Production FSW 11 iv ABSGUIDE FOR THE APPROVAL OF FRICTION STIR
9、WELDING IN ALUMINUM .2011 4 Inspection After Production FSW Visual Inspection (VT) 11 4.1 Exit Hole Uniformity.12 4.2 Herring Bone or Chevron Marking.12 4.3 Flash12 4.4 Dimensional Requirements12 4.5 Butt Joint Alignment.12 4.6 Irregular Width.12 4.7 Root Reinforcement.12 4.8 Cracks, Porosity, Lack
10、of Penetration12 4.9 Visual Examination Records12 5 Other Inspection After FSW . 13 5.1 Macroetch13 5.2 Penetrant Testing (PT) 13 5.3 Ultrasonic Testing (UT)13 5.4 Radiographic Testing (RT) 13 5.5 Batch Testing Alternative.13 6 FSW NDT Acceptance Requirements 13 6.1 Visual Inspection (VT) .13 6.2 Pe
11、netrant Testing 13 6.3 Ultrasonic Testing (UT)14 6.4 Radiographic Testing (RT) 14 ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .2011 1 Section 1: General SECTION 1 General 1 Scope and Application This Guide has been developed with the objective of setting out the requirements for t
12、he qualification of friction stir welding (FSW) procedures and operators. This Guide also provides guidelines for the production quality control of FSW and the nondestructive testing (NDT) requirements. FSW produces a weld between two abutting workpieces by the frictional heating and plastic materia
13、l displacement caused by a rotating tool that traverses along the weld joint. This Guide is for the application of FSW for aluminum groove welds. No other joint configuration is considered in this Guide. Weld procedure and operator qualification requirements apply for FSW of aluminum alloys identifi
14、ed in Ref. 1. 2 References The following documents form a part of this overall Guide to the extent they are referenced. Reference Number Reference Description 1 ABS Rules for Welding and Materials (Part 2) 2 AWS A3.0 Standard Welding Terms and Definitions 3 ABS Guide for Nondestructive Inspection of
15、 Hull Welds 4 AWS D1.2/D1.2M Structural Welding Code Aluminum 5 AWS D17.3/17.3M Specification for Friction Stir Welding of Aluminum Alloys for Aerospace Applications 6 NASA document PRC-5010C, Process Specification for Pickling, Etching, and Descaling of Metals 3 Definitions Adjustable Probe (Retrac
16、table Pin) Tool Tool probe length, rotation speed, direction of probe rotation are adjustable. Advancing Side of Weld Side of the weld where the direction of tool rotation is the same as the direction of welding. Direction of Tool Rotation Rotation as viewed from the spindle that is rotating the too
17、l. Exit Hole Hole remaining at the end of a weld after the withdrawal of the tool. Flash Material expelled along the weld toe during FSW. Friction Stir Re-weld FSW pass upon FSW pass from one side only. Friction Stir Welding Methods Methods include, but are not limited to, robotic, single spindle, m
18、ultiple spindles, adjustable probe (retractable probe) tool, self-reacting (bobbin) tool, and simultaneous two-sided welding. Heel Part of the tool shoulder that is at the rear of the tool relative to its forward motion. Heel Plunge Depth Distance the heel extends into the workpiece. Joint Line Remn
19、ant Unmixed and distorted layer of Aluminum Oxide, occurring at the root of the joint faying surfaces, when the joint is welded from one side using anvil backing. Section 1 General 2 ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .2011 Probe Part of the welding tool that extends into
20、 the workpiece to make the weld. Retreating Side of Weld Side of the weld where the direction of tool rotation is opposite to the welding direction. Self-reacting (Bobbin) Tool Tool with two shoulders separated by a fixed length probe or an adjustable length probe. Sweep Denotes a curve in the horiz
21、ontal plane. Tool Offset The shortest distance from the tool axis to the joint. Tool Shoulder Surface of the tool that contacts the workpiece surface during welding. Tool Rotation Speed Angular speed of the welding tool in revolutions per minute. Welding Tool Rotating component that passes entirely
22、through or partially through the workpiece, and may or may not have a shoulder. ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .2011 3 Section 3: Weld Procedure Qualification SECTION 2 Weld Procedure Qualification 1 General Considerations Prior to production welding, the manufacturer
23、 or contractor shall develop and qualify FSW procedures. A welding procedure qualification test plate schematic with locations for removal of test specimens is shown in Section 2, Figures 1 and 2. The FSW fabricator shall document the essential elements of Section 2, Table 1 when developing a FSW pr
24、ocedure. Section 2, Table 2 provides the required destructive and nondestructive tests for FSW qualification test assemblies. Each FSW manufacturer or contractor is responsible for the FSW done by their organization and shall conduct the qualification tests required in this Section. Every weld proce
25、dure shall be submitted to and Approved by the ABS Materials Department prior to acceptance. Surveyors shall witness the procedure qualification and test results to their satisfaction. 1.1 Procedure Qualification Limits The FSW manufacturer or contractor shall adhere to the procedure qualification l
26、imits for FSW described in Section 2, Table 1. When welding the procedure qualification test assembly, the welding operator shall be under the full control and supervision of the FSW manufacturer or contractor. 1.2 Test Assembly Size The procedure qualification test assembly size shall be as shown i
27、n Section 2, Figure 1 for square groove welds. The size of the test assembly shall be sufficient to permit removal of the required test specimens from the nominal start, middle, and end of a single weld. The intent of this requirement is to obtain property data at various locations along the weld le
28、ngth to observe any property variations that may exist within a single weld. Friction stir welding of additional test assemblies to furnish test specimens shall not be permitted. Multi-pass FSW will be specially considered. 1.3 Rejection of Test Assembly If a procedure qualification fails to meet an
29、y of the requirements, the test assembly shall be rejected. In such cases, two test assemblies may be welded using the same welding procedure and tested. If the second set of test assemblies fails, that FSW procedure shall be rejected and a new FSW procedure shall be written and tested. 1.4 Transfer
30、 of Qualification Qualification resides with the FSW manufacturer or contractor that performed the qualification testing. A FSW manufacturer or contractor may transfer qualified weld procedures from one FSW machine to another when the FSW machine is of identical model and type. The FSW manufacturer
31、or contractor may use qualified FSW procedures at other facilities which are under the manufacturer or contractors operational and quality control. 1.5 Transverse Tensile Test Specimens and Transverse Bend Specimens Transverse tensile test specimens and transverse bend specimens are to be in accorda
32、nce with Ref. 1. The preparation of macroetch specimens is to be to an appropriate standard to reveal the structure of the weld. 1.6 Fixturing Special consideration shall be taken for acceptance of procedures where the weld procedure test piece is a different shape or arrangement than the production
33、 piece. The fixturing arrangement for production work shall be proven to be equivalent to the procedure qualification fixturing to the satisfaction of the attending Surveyor. Section 2 Weld Procedure Qualification 4 ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .2011 FIGURE 1 Butt J
34、oint Test Assembly L1t1L1L2Notes: 1 Joint preparation and fit-up, as specified in WPS L1Minimum 150 mm (6 in.) L2Minimum 500 mm (20 in.) t Production material thickness FIGURE 2 Location of Test Specimens (8)82765431Section 2 Weld Procedure Qualification ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WE
35、LDING IN ALUMINUM .2011 5 FIGURE 2 (continued) Location of Test Specimens (8)Notes: 1 Discard at least 50 mm (2 in.) from each end of the test assembly 2 Direction of welding 3 Start area for: 1 tensile test specimen root and face bend test specimens (1) macroetch specimen 4 Middle area for: 1 tensi
36、le test specimen root and face bend test specimens (1) macroetch specimen 5 End area for: 1 tensile test specimen root and face bend test specimens (1) macroetch specimen 6 Not used 7 Weld 8 150 mm (6 in.) minimum between Start area 3 and Middle area 4 and between Middle area 4 and End area 5 Note 1
37、: For welds fabricated from both sides, side bend specimens may be substituted. 2 Qualification of Weld Repair Procedures Welding repair of friction stir welds by either FSW or arc welding processes requires qualification as indicated in Section 2, Table 1, Essential Elements 26 or 27. The repair pr
38、ocedure shall include the details of repair including the qualified Weld Procedure Specification (WPS). If base material nominal tolerances are outside the qualified thickness range, a change in material thickness 5% from that qualified does not require requalification so long as all other essential
39、 elements remain unchanged and the base material thickness is within the nominal tolerances. The repair WPS procedure qualification test assembly size shall be as shown in Section 2, Figure 1. The size of the test assembly shall be sufficient to permit removal of the required test specimens from the
40、 nominal start, middle, and end of the repair weld. The intent of this requirement is to obtain property variability that may exist for the various regions of a single friction stir weld repair. Friction stir welding of additional weld repair test assemblies to furnish test specimens is not permitte
41、d. For a given weld repair method, the entire thickness range may be qualified by testing at the minimum and maximum thickness for a given defect type for each alloy and temper combination identified in Section 2, Table 1. 3 Operator Qualification The FSW fabricator shall perform the destructive and
42、 nondestructive tests for FSW operator qualification test assemblies in accordance with Section 2, Table 3. The FSW fabricator shall adhere to the performance qualification limits described in Section 2, Table 1. Section 2, Table 1 indicates the material thickness range over which a weld operator ma
43、y be qualified using a specific weld procedure. The operator qualification test assembly size shall be as shown in Section 2, Figure 1. The size of the test assembly shall be sufficient to permit removal of the required test specimens from the nominal start, middle, and end of the repair weld. The i
44、ntent of this requirement is to obtain property data for various regions along the weld length. Friction stir welding of additional test assemblies to furnish test specimens is not permitted. Section 2 Weld Procedure Qualification 6 ABSGUIDE FOR THE APPROVAL OF FRICTION STIR WELDING IN ALUMINUM .201
45、1 4 FSW Weld Procedure Specification (WPS) and Welder Performance Qualification Record Requirements (WPQR) The FSW Weld Procedure Specification (WPS) and Performance Qualification Requirements (WPQR) that are developed in accordance with Subsections 2/1 through 2/3 and Ref. 1 shall be provided to AB
46、S. TABLE 1 Essential Elements of a Friction Stir Welding Procedure Element Limits(1) Requires Requalification (2) Notes 1. Base material composition or condition Specific alloy used in qualification test Change in alloy or temper (to a higher-strength temper within the same alloy group) 2. Base mate
47、rial thicknessSpecific thickness used in qualification test Change in material thickness 5% (3)3. Base material cleaning Identified method Change in method from abrasive to chemical or vice-versa Shall include degreasing and removal of oxides from plate edges within 8 hours of welding 4. Applicable
48、joint designs gap and sweep of adjoining members (reference or sketches) Joint type used in qualification testing sets limits Change in joint type or variations allowable range 1 mm (0.039 in.) A min/max range may be qualified. 5. Process Shall indicate whether fixed-probe or self-reacting/ bobbin o
49、r adjustable probe/ retractable pin mode is employed Change from the qualified mode 6. Machine model and type Specific model, type, and cooling method Change to a different model type, or cooling method 7. Tool holder model and type Specific model, type, and cooling method Change to a different model or type Shall include whether tool holder employs active cooling 8. Fixturing method (2)Limits to method applied Change to method applied Shall include method of fixturing (e.g., clamping, etc.). Shall include whether fixtur
