New welding and technology advancements are reflected in the friction stir welding (FSW) specifications used in the manufacturing sector. A lack of publicly available specifications as one of the reasons that the FSW process has not propagate through the manufacturing sectors. FSW specifications are an integral supporting document to the legal agreement written between two entities for deliverable items. Understanding the process and supporting specifications is essential for a successful FSW manufacturing operation. This viewgraph presentation provides an overview of current FSW standards in the industry and discusses elements common to weld specifications

Ding, Robert Jeffrey

NASA Technical Reports Server

National Aeronautics and Space Administration
Friction Stir Welding
Standards & specifications in today’s U.S. manufacturing and fabrication
R. Jeffrey Ding (robert.j.ding@nasa.gov)
NASA
Marshall Space Flight Center
Huntsville, AL
www.nasa.gov 
https://ntrs.nasa.gov/search.jsp?R=20090015054 2019-08-30T06:38:01+00:00Z
Agenda
• Introduction
O i f t FSW t d d i i d t• verv ew o  curren   s an ar s n n us ry
– Public
Proprietary–
• Elements common to weld specifications
FSW ifi ti AWS D17 3•  spec ca on  .
• Closing remarks and questions
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 2
AWS TSD 1.1:200X, Specification for Preparation of AWS Standards
standard. A document that provides rules or guidelines, is produced by consensus, and is 
approved 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 specific 
subject. A code describes industry-accepted procedures by which it can be determined that the requirements have been met. It 
is written to make it suitable for adoption by governmental entities, trade groups, insurance companies, and other authorities as 
a part of a law or regulation or cited as a normative reference in other standards A typical code is AWS D1 1 Structural Welding               .      . ,   
Code – Steel.
2) specification. A specification details the essential technical requirements for a material, product, system, or service. It specifies 
the procedures, methods, qualifications, or equipment by which it can be determined that the requirements have been met. A 
specification is mandatory when cited as a normative reference by a mandatory document or agreed to be mandatory by the 
concerned 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. A 
typical 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 is 
AWS D3.5, Guide for Steel Hull Welding.
5) recommended practice. A recommended practice document details one or more industry-accepted techniques for performing a 
specific operation procedure or process A typical recommended practice document is AWS D10 12 Recommended Practices
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 3
 , ,  .        . ,   
and Procedures for Welding Low-Carbon Steel Pipe.
FSW licensees in the U.S.
General Dynamics Corporation Square D Brigham Young University
Eclipse Aviation Corporation Spirit AeroSystems Inc University of South Carolina   , .    
Montana Tech Advanced Joining Technologies, Inc. United Defense LP
Concurrent Technologies Corporation Space Exploration Technologies Tower Automotive, Inc.
General Tool Company Transformation Technologies, Inc. Rockwell International Corporation      
University of Montana University of Wisconsin-Madison NASA
Vanderbilt University NSWC Carderock Division Lockheed Martin Corporation
North Carolina A&T State University Nova-Tech Engineering, Inc. EWI
Los Alamos National Laboratory Advanced Metal Products The Boeing Company
MTS Systems Corporation United Launch Alliance Alcoa
Friction Stir Lin, Inc. South Dakota School of Mines Southern Methodist University
General Electric Company Wichita State University Oak Ridge National Laboratory
Old Dominion University Remmele Engineering, Inc.
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 4
FSW specifications in U.S. industry
Publicly available
JSC NASA PRC 0014 R B P S ifi ti f F i ti Sti W ldi1)  -  - , ev. , rocess pec ca on or r c on r e ng
2) 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 Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 5
U.S. companies using FSW specifications
Proprietary
L kh d M ti (TP5511)1) oc ee - ar n 
2) Tower Automotive
3) Advanced Joining Technologies (AJT)
4) General Dynamics Land Systems
5) Eclipse Aircraft
6) Boeing
7) United Space Alliance (USA)
8) Spirit Aviation
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 6
9) General Electric
FSW manufacturing specifications
Written to support customers’ end use and contractual requirements
G d t i t (GSW)1) roun  suppor  equ pmen  
2) FAA – Eclipse jet
3) NASA – Man-rated hardware
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 7
Common elements in FSW weld 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 / i ti• ua y  nspec on
• Acceptance criteria
• Equipment calibration
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 8
 
Sub-tier documents – Normative references
• ANSI Z49.1, Safety in Welding and Cutting and Allied Processes
• ASTM E164 Standard Practice for Ultrasonic Contact Examination of Weldments ,        
ASTM E1417, Standard Practice for Liquid Penetrant Examination
ASTM E1742, Standard Practice for Radiographic Examination
• AWS A1.1, Metric Practice Guide for the Welding Industry
AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Evaluation
AWS A3.0, Standard Welding Terms and Definitions, Including Terms for Brazing, Soldering
AWS QC1, Standard for AWS Certification of Welding Inspectors
AWS B2 1 St d d f W ldi P d d P f Q lifi ti . , an ar s or e ng roce ure an  er ormance ua ca ons
• ASNT SNT-TC-1A, Recommended Practice
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 9
Mandatory supporting documents
AWS A3.0, Standard Welding Terms and Definitions
AWS B2 1 St d d W ldi P d d P f Q lifi ti . , an ar  e ng roce ure an  er ormance ua ca on
AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 10
Specification for friction stir welding of 
l i ll f h da um num a oys or aerospace ar ware
P d b AWS D17 3 b itt• repare  y  .  su -comm ee
• Under the direction of AWS Technical Activities Committee
A d b AWS B d f Di t• pprove  y  oar  o  rec ors
• Approved by ANSI
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 11
Normative references
AIA/NAS document:[1]
NAS 410, NAS Certification & Qualification of Nondestructive Test Personnel
ANSI document:[2]
ANSI Z49.1, Safety in Welding and Cutting and Allied Processes
ASTM documents:[3] 
ASTM E 164, Standard Practice for Ultrasonic Contact Examination of Weldments
ASTM E 1417, Standard Practice for Liquid Penetrant Examination
ASTM E 1742, Standard Practice for Radiographic Examination
AWS documents:[4]
AWS A1.1, Metric Practice Guide for the Welding Industry
AWS A2.4, Standard Symbols for Welding, Brazing, and Nondestructive Examination
AWS A3.0, Standard Welding Terms and Definitions
AWS B2.1, Specification for Welding Procedure and Performance Qualification
AWS B5.1, Specification for the Qualification of Welding Inspectors
AWS QC1 Standard for AWS Certification of Welding Inspectors
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 12
 ,       
General requirements
4. General Requirements
4.1 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 joint The Engineering Authority shall consider material and            .        
process 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 armament 
stores, 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 or 
preclude 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 Engineering 
Authority.
4.3 Drawing Precedence. When requirements in this specification conflict with those on the engineering drawing, then the 
requirements 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, the 
text of this specification shall take precedence.
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 13
Process development
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 14
Welding operator qualification
7.1 Qualification requirements. To become qualified, the welding operator shall demonstrate his skill by producing an acceptable test weld in accordance with an approved WPS.
7.1.1 Vision Test. The welding operator shall have vision acuity of 20/30 or better in either eye and shall be able to read the Jaeger No. 2 Eye Chart at 16 inches [406 mm].
7.1.2 Test Weld. One of the test pieces in Figures 7.1 – 7.4 shall be used for the welding operator qualification test. The test piece shall be welded in accordance with a WPS.
7.1.3 Inspection. The test weld shall be inspected in accordance with the class specified in the WPS, except a two-inch long discard may be taken at the ends of the groove 
and fillet weld coupons in place. Visual inspection shall be accomplished in the as-welded condition.
7.2 Qualification limitations
7.2.1 FSW Methods. A test weld made with any type of friction stir welding method qualifies only for that friction stir welding method.
7.2.2 Base Metals. A test weld made in any aluminum alloy qualifies for all aluminum alloys.
7.2.3 Base Metal Form and Weld Type.
7.2.4 Qualified Thickness Range. A test weld made with any base metal thickness shall qualify the welding operator to weld any base metal thickness.
7 3 Qualification/Certification Validity.  
7.3.1 Initial Certification. Successful completion of welding operator qualification tests shall be justification for issuance of a certification valid for a period of two years 
from the acceptance date of the qualification test results.
7.3.2 Extended Certification.
7.3.3 Disqualification.
7.3.4 Reinstatement. An individual who has been disqualified shall be recertified by meeting the requirements of 7.1
7.3.5 Identification. The Fabricator shall assign a unique number or other identification to each welding operator upon certification.
7.4 Test Records. The Fabricator shall complete a test record containing the essential information required as evidence of welding operator certification. An example of a test 
record form, entitled Welding Operator Qualification Test Record for All Aluminum Alloys, is given in Annex C, Figure C.1.
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 15
Fabrication / process constraints
8. Fabrication.
8.1 Welding Equipment Requirements.
8.1.1 Equipment Capabilities and Performance.   
8.1.2 Calibration.
8.1.3 Reproducibility Tests for Qualified Machine Welding Settings.
8.1.3.1 When to Test.
8.1.3.2 Test Requirements.
8 2 Friction Stir Welding Tool.    .
8.2.1 Identification.
8.3 Preweld Joint Preparation and Fit-up.
8.3.1 Joint Preparation.
8.3.2 Preweld Cleaning.
8.3.3 Root Opening.
8.4 Preheat Temperature Control.
8.5 Tack Welds.
8.6 Welding.
8.7 Postweld Surface Preparation.
8.8 Weld Identification Requirements.
8.8.1 Interim Identification.
8.8.2 Final Identification.
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 16
8.9 Acceptance Inspection.
Inspection
9. Inspection
9.1 General. Three quality levels are given in order to permit application to a wide range of welded
constructions. The quality levels are designated by the symbols A, B, and C. They correspond directly with
Class A, B, and C in subclause 4.1. For example, quality level A corresponds to the highest requirement
on the finished weld. The quality levels refer to production quality and not to the fitness for purpose of the
product manufactured. The choice of quality level shall take into account the design requirements, subsequent
processing (e.g., surfacing), type of stress (e.g. static, dynamic), service conditions (e.g., temperature, corrosion)
and consequences of failure. Economic factors are also important and should include not only the cost of
welding but also of inspection, test, and repair.
9.2 Inspection Personnel
Q f f f S9.2.1 uali ication o  NDT Personnel. Nondestructive testing personnel shall be quali ied to NA  410.
9.2.2 Visual Weld Inspection Personnel. Personnel performing visual weld inspections shall be
certified to the requirements of AWS QC1 or by experience, training, and testing requirements defined in
AWS B5 1 d d b th E i i A th it
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 17
 ,  an  approve  y e ng neer ng u or y.
9.3 Visual Weld Inspection. All welds shall undergo visual inspection for conformance to the requirements of
Table 9.1.
Acceptance criteria
9.5  Acceptance criteria
9.5.1 General. The dimension of any discontinuity shall be defined by its largest dimension. Two or more
discontinuities shall be treated as one when the spacing between them is less than the largest dimension of the
larger discontinuity. Discontinuities that will be removed in subsequent machining shall not be cause for
rejection. Any weld with unacceptable discontinuities, which has gone through a subsequent manufacturing
operation that affects the metallurgical characteristics (other than stress relief or postweld heat treatment)
or that cannot be rewelded without affecting the final metallurgical or surface characteristics, shall be rejected.
Removal of unacceptable weld metal is allowed provided the minimum weld size is met. Incidental removal
of base metal during discontinuity removal is acceptable provided the minimum thickness requirements and any
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 18
other engineering requirement (e.g., surface roughness) are met. When determining the minimum thickness
of the metal i  an area where a discontinuity was removed, in a joint with varying cross section, use the
Closing remarks
Welding and technolog ad ancements ne er before seen in ind str are•   y v  v     u y  
reflected in FSW specifications used in today’s manufacturing sector.
• Lack of publicly available specifications is one of the reasons why the FSW             
process has not propagated through the manufacturing sectors.
• The FSW specification becomes an integral supporting document to the legal 
agreement written between two entities for deliverable items.
• Understanding the process and supporting specifications is essential for a 
successful FSW manufacturing operation   .
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 19
National Aeronautics and Space Administration FSW standards & specifications in today’s U.S. manufacturing and fabrication 20


Friction Stir Welding: Standards and Specifications in Today's U.S. Manufacturing and Fabrication

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