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National Aeronautics and Space AdministrationFriction Stir WeldingStandards & specifications in today’s U.S. manufacturing and fabricationR. Jeffrey Ding (robert.j.ding@nasa.gov)NASAMarshall Space Flight CenterHuntsville, ALwww.nasa.gov

Agendage da Introduction OOverviewioff currentt FSW standardst d d ini industryi d t– Public– Proprietary Elements common to weld specifications FSW specificationifi ti AWS D17D17.33 Closing remarks and questionsNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication2

AWS TSD 1.1:200X,, Specificationpfor Preparationpof AWS Standardsstandard. A document that provides rules or guidelines, is produced by consensus, and isapproved by a recognized body. The term standard encompasses five AWS document formats:1)code. A code is intended to be a mandatory document. It includes a set of conditions and requirements relating to a specificsubject. A code describes industry-accepted procedures by which it can be determined that the requirements have been met. Itis written to make it suitable for adoption by governmental entities, trade groups, insurance companies, and other authorities asa part of a law or regulation or cited as a normative reference in other standardsstandards. A typical code is AWS D1D1.1,1 Structural WeldingCode – Steel.2)specification. A specification details the essential technical requirements for a material, product, system, or service. It specifiesthe procedures, methods, qualifications, or equipment by which it can be determined that the requirements have been met. Aspecificationpis mandatoryy when cited as a normative reference byy a mandatoryy document or agreedgto be mandatoryy byy theconcerned individuals or agencies, such as when used for procurement purposes. A typical specification is AWS D17.1,Specification for Fusion Welding for Aerospace Applications.3)method. A method details industry-accepted procedures for performing a test, sampling technique, analysis, or measurement. Atypical method-type document is AWS B4.0, Standard Methods for Mechanical Testing of Welds.4)guide. A guide provides general information regarding one or more methods to accomplish a specific task. A typical guide isAWS D3.5, Guide for Steel Hull Welding.5)recommended practice. A recommended practice document details one or more industry-accepted techniques for performing aspecific operation,operation procedure,procedure or processprocess. A typical recommended practice document is AWS D10D10.12,12 Recommended Practicesand Procedures for Welding Low-Carbon Steel Pipe.National Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication3

FSWS licenseesce sees in ttheeUU.S.SGeneral Dynamics CorporationSquare DBrigham Young UniversityEclipse Aviation CorporationSpirit AeroSystems,AeroSystems IncInc.University of South CarolinaMontana TechAdvanced Joining Technologies, Inc.United Defense LPConcurrent Technologies CorporationSpace Exploration TechnologiesTower Automotive, Inc.General Tool CompanyTransformation Technologies, Inc.Rockwell International CorporationUniversity of MontanaUniversity of Wisconsin-MadisonNASAVanderbilt UniversityNSWC Carderock DivisionLockheed Martin CorporationNortho CaCarolinao a A&T& SStateaeUUniversityes yNova-Techo a ec Engineering,g ee g, Inc.cEWILos Alamos National LaboratoryAdvanced Metal ProductsThe Boeing CompanyMTS Systems CorporationUnited Launch AllianceAlcoaFriction Stir Lin,, Inc.South Dakota School of MinesSouthern Methodist UniversityyGeneral Electric CompanyWichita State UniversityOak Ridge National LaboratoryOld Dominion UniversityRemmele Engineering, Inc.National Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication4

FSWS specificationsspec cat o s in UU.S.S industrydust yPublicly available1)JSC - NASA PRCPRC-0014,0014 RRev. BB, ProcessPSSpecificationifi ti ffor FrictionF i ti StiStir WWeldingldi2)AWS, Specification for Friction Stir Welding of Aluminum Alloys for Aerospace Hardware(pending)3)MSFC - NASA-STD(I)-5006A, Welding Requirements for Aerospace Flight Hardware (pending)National Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication5

U.S.US cocompaniespa es ususingg FSWS specspecificationscat o sProprietary1)L kh d M ti (TP5511)Lockheed-Martin2)Tower Automotive3)Advanced Joining Technologies (AJT)4)General Dynamics Land Systems5)Eclipse Aircraft6)Boeing7)United Space Alliance (USA)8)Spirit Aviation9)General ElectricNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication6

FSWS manufacturinga u actu g specspecificationscat o sWritten to support customers’ end use and contractual requirements1)GGroundd supportt equipmentit (GSW)2)FAA – Eclipse jet3)NASA – Man-rated hardwareNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication7

CommonCoo elementse e e ts in FSWS welde d specs Supporting sub-tier documents General requirements Process development– Process Qualification Record (PQR)– Weld Process Specification (WPS)– Certified WPS Weld operator qualification Fabrication / process constraints Q lit / inspectionQualityiti Acceptance criteria Equipment calibrationNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication8

Sub-tierSubt e documentsdocu e ts – Normativeo at e referencese e e ces ANSI Z49.1, Safety in Welding and Cutting and Allied Processes ASTM E164E164, Standard Practice for Ultrasonic Contact Examination of WeldmentsASTM E1417, Standard Practice for Liquid Penetrant ExaminationASTM E1742, Standard Practice for Radiographic Examination AWS A1.1, Metric Practice Guide for the Welding IndustryAWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive EvaluationAWS A3.0, Standard Welding Terms and Definitions, Including Terms for Brazing, SolderingAWS QC1, Standard for AWS Certification of Welding InspectorsAWS B2.1,B2 1 StandardsSt d d ffor WWeldingldi ProcedurePdanddPPerformancefQualificationsQ lifi ti ASNT SNT-TC-1A, Recommended PracticeNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication9

Mandatorya dato y supposupportingt g docudocumentse tsAWS A3.0, Standard Welding Terms and DefinitionsAWS B2.1,B2 1 StandardSt d d WWeldingldi PProceduredanddPPerformancefQQualificationlifi tiAWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive ExaminationNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication10

Specification for friction stir welding ofaluminuml ialloysllffor aerospace hhardwared PPrepareddbby AWS D17D17.33 sub-committeebitt Under the direction of AWS Technical Activities Committee AApproveddbby AWS BBoardd off DirectorsDi t Approved by ANSINational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication11

Normativeo at e referencese e e cesAIA/NAS document:[1]NAS 410, NAS Certification & Qualification of Nondestructive Test PersonnelANSI document:[2]ANSI Z49.1, Safety in Welding and Cutting and Allied ProcessesASTM documents:[3]ASTM E 164, Standard Practice for Ultrasonic Contact Examination of WeldmentsASTM E 1417, Standard Practice for Liquid Penetrant ExaminationASTM E 1742, Standard Practice for Radiographic ExaminationAWS documents:[4]AWS A1.1, Metric Practice Guide for the Welding IndustryAWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive ExaminationAWS A3.0, Standard Welding Terms and DefinitionsAWS B2.1, Specification for Welding Procedure and Performance QualificationAWS B5.1, Specification for the Qualification of Welding InspectorsAWS QC1,QC1 Standard for AWS Certification of Welding InspectorsNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication12

GeneralGee a requirementsequ e e ts4.General Requirements4.1 Classification. All welds produced in accordance with this specification shall be classified as Class A, Class B, or Class C.Classification is based on the function and the use of the welded jointjoint. The Engineering Authority shall consider material andprocess aspects that affect mission or systems requirements.A weld joint may be zoned with multiple classifications.Class A – Critical application. A welded joint whose failure would cause significant danger to personnel, loss of the flight vehicle,loss of control, loss of a system, loss of a major component, unintentional release of critical stores, inability to release armamentstores, abortion of the mission, or an operating penalty.Class B – Semicritical application. A welded joint whose failure would reduce the overall strength of the equipment or system orpreclude the intended functioning or use of equipment, but loss of the system or the endangerment of people would not occur.Class C – Noncritical application. A welded joint whose failure would not affect the efficiency of the system or endanger people.4.2 Approval. All references to the need for approval shall be interpreted to mean approval by the Customer or EngineeringAuthority.4.3 Drawing Precedence. When requirements in this specification conflict with those on the engineering drawing, then therequirements on the drawing shall take precedence.4.4 Specification Precedence. In the event of a conflict between the test of this specification and the references cited herein, thetext of this specification shall take precedence.National Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication13

Processocess dedevelopmente op e tNational Aeronautics and Space AdministrationFSW standards & specifications in today’s U.S. manufacturing and fabrication14