REG MSFC-SPEC-3679-2012 EM30 MSFC TECHNICAL STANDARD PROCESS SPECIFICATION - WELDING AEROSPACE HARDWARE.pdf

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1、 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 MSFC-SPEC-3679 National Aeronautics and BASELINE Space Administration EFFECTIVE DATE: October 11, 2012 George C. Marshall Space Flight Center Marshall Space Fligh

2、t Center, Alabama 35812 EM30 MSFC TECHNICAL STANDARD PROCESS SPECIFICATION -WELDING AEROSPACE HARDWARE Approved for Public Release; Distribution is Unlimited MEASUREMENT SYSTEM ENGLISH/METRIC (SI) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC

3、Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 2 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprog

4、ram/MSFC-SPEC-3679 DOCUMENT HISTORY LOG Status (Baseline/ Revision/ Cancelled) Document Revision Effective Date Description Baseline - 10/11/2012 Baseline Release; document authorized through MPDMS. Baselined by Upper Stage Element Control Board Directive CE4-01-0239, (PCN CE001107, CR CLV-US-0481).

5、 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 3 of 102 CHECK THE MAST

6、ER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 Table of Contents 1.0 SCOPE . 8 1.1 Purpose 8 1.2 Applicability . 8 1.3 Tailoring 9 1.4 Safety 9 1.5 Specific Process Weld Requirements . 9 2.0 APPLICABLE DOCUMENTS 10 2.1 Appli

7、cable Documents 10 2.2 Reference Documents . 12 2.3 Order of Precedence 12 3.0 ACRONYMS AND DEFINITIONS 12 3.1 Acronyms and Abbreviations . 12 3.2 Definitions. 14 4.0 JOINT CLASSES 22 4.1 Class A Joints 23 4.2 Class B Joints 23 4.3 Class C Joints 23 5.0 EQUIPMENT 23 5.1 Welding Equipment 23 5.2 Tool

8、ing and Fixtures . 26 5.3 EB Welding . 27 6.0 MATERIALS 27 6.1 Base Metals . 27 6.2 Filler Metals 27 6.3 Shielding Gas 28 6.4 Tungsten Electrodes 29 6.5 FSW Pin Tools 29 6.6 Anvils and Plug Weld Backing Material 29 6.7 Friction Plugs 30 Provided by IHSNot for ResaleNo reproduction or networking perm

9、itted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 4 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:

10、/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 7.0 WELDER PERFORMANCE AND WELD PROCEDURE QUALIFICATION . 30 7.1 Welder Performance Qualification . 30 7.2 Weld Procedure Specification. 31 7.3 Procedure Qualification Records 33 7.4 Records . 36 8.0 PREWELD OPERATIONS . 36 8.1 Weld Joint De

11、sign . 36 8.2 Preweld Cleaning 36 8.3 Preweld Joint Fitup . 38 8.4 Weld Start and Run-Off Tabs . 38 8.5 Laser and Electron Beam-to-Joint Alignment 39 9.0 PRODUCTION WELDING 39 9.1 Equipment Operational Readiness Check . 39 9.2 Temperature Control . 39 9.3 Tack Welding 40 9.4 Welding Techniques . 40

12、9.5 Welding Procedure 41 10.0 POSTWELD OPERATION . 42 10.1 The Weldment . 42 10.2 General Workmanship Requirements . 42 10.3 Dimensional Requirements . 43 10.4 Weldment Straightening . 46 10.5 Postweld Heat Treatment Requirements . 47 10.6 Weldment Quality Requirements 47 10.7 Repair Welding . 48 10

13、.8 Material Review Board . 48 11.0 VERIFICATION. 49 11.1 General 49 11.2 Postweld Inspection 49 11.3 Records . 51 12.0 PACKAGING .52 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aer

14、ospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 5 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 13.0 NOTES 52 Provided by IHSNot for ResaleNo

15、 reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 6 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORR

16、ECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 Appendices A Procedure Qualification Weld Strength Requirements 53 B Weld Joint Dimensional Requirements . 59 C Weld Nugget Dimensional Requirements . 61 D Weld Quality Requirements . 82 E Weld Procedure Speci

17、fication Information . 91 F Recommended Filler Metals 94 G Preweld Cleaning Methods 101 H Reference Documents 102 List of Figures FIGURE Page Figure 1. Conventional Friction Stir Welding Process 20 Figure 2. Self-Reacting Friction Stir Welding Process 20 Figure 3. Minimum Inspection Requirements 22

18、Figure 4. Welding Techniques . 41 Figure 5. Mismatch and Peaking . 43 Figure 6. Fillet Weld Throats . 45 Figure 7. Fillet Welds 46 Figure 8. Aluminum Fusion Butt Weld . 62 Figure 9. EB Butt Weld . 63 Figure 10. EB Maximum Weld Crown and Root Widths for Penetration Depths up to 1.6 in (41 mm).64 Figu

19、re 11. Minimum EB Weld Root Width for Penetration Depths up to 0.2 in (5 mm) . 65 Figure 12. Minimum EB Weld Root Width for Penetration Depths of 0.2 to 1.6 in (5 to 41 mm) . 66 Figure 13. C-FSW Zone . 67 Figure 14. S-R FSW Zone . 67 Figure 15. Titanium Full-Penetration Joint Welds 68 Figure 16. Tit

20、anium Butt Joint Maximum Allowable Weld Width versus Thickness 70 Figure 17. Titanium Fillet Joint Maximum Allowable Weld Width versus Thickness . 71 Figure 18. Titanium Maximum Fillet Weld Size (where LMIN is equal to the thickness of the thinnest member) 72 Figure 19. Titanium Fillet Weld Dimensio

21、ns For Acute Angle and Drop Through . 72 Figure 20. Weld Size Requirements for Butt Welds (Superalloys) . 73 Figure 21. Class A Butt Weld Fusion Zone Weld Size Limits 74 Figure 22. Class B Butt Weld Fusion Zone Weld Size Limits 75 Figure 23. Class C Butt Weld Fusion Zone Weld Size Limits 76 Figure 2

22、4. Weld Size Requirements for Tee and Corner Welds 77 Figure 25. Class A Tee and Corner Weld Fusion Zone Weld Size Limits 78 Figure 26. Class B Tee and Corner Weld Fusion Zone Weld Size Limits 79 Figure 27. Class C Tee and Corner Weld Fusion Zone Weld Size Limits 80 Provided by IHSNot for ResaleNo r

23、eproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 7 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORREC

24、T VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 Figure 28. External Discontinuities for Aluminum Alloys.86 Figure 29. Internal Defects for Aluminum Alloys . 87 Figure 30. EB Weld Porosity Acceptance Criteria for Steels, Heat Resistant . 89 List of Tables TABL

25、E Page Table 1. Butt Weld Ultimate Tensile Strength Requirements for Aluminum Alloys 54 Table 2. Butt Weld Ultimate Tensile Strength Requirements for Superalloys.57 Table 3. Butt Weld Ultimate Tensile Strength Requirements for Titanium Alloys 58 Table 4. Butt Weld Ultimate Tensile Strength Requireme

26、nts for Stainless Steel Alloys 58 Table 5. Preweld Joint Fitup Requirements . 59 Table 6. Postweld Joint Fitup Requirements . 60 Table 7. Dimensional Requirements for Butt Welds Fusion* 61 Table 8. Dimensional Requirements for Butt Welds . 67 Table 9. Dimensional Requirements (Titanium) . 69 Table 1

27、0. Weld Surface and Volumetric Acceptance Criteria Aluminum Alloys Process 82 Table 11. Surface and Volumetric Weld Acceptance Criteria Steels, Heat Resistant 88 Table 12. Weld Surface and Volumetric Acceptance Criteria Titanium Alloys 89 Table 13. Recommended Parameters to be Recorded in WPS 90 Tab

28、le 14. Filler Alloys Recommended for Welding Aluminum Alloys and Combinations . 93 Table 15. Filler Alloys Recommended for Welding Carbon and Low Alloy Steels and Combinations 94 Table 16. Filler Alloys Recommended for Welding Stainless Steels and Combinations 96 Table 17. Filler Alloys Recommended

29、for Welding Nickel- and Cobalt-Base Alloys and Combinations 97 Table 18. Filler Alloys Recommended for Welding Copper Alloys and Combinations . 99 Table 19. Filler Alloys Recommended for Welding Titanium Alloys and Combinations. 99 Table 20. Acceptable Preweld and Postweld Cleaning Methods 100 Provi

30、ded by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 8 of 102 CHECK THE MASTER LIS

31、T VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 1.0 SCOPE This process specification establishes uniform requirements for the design, fabrication, and inspection of welds in flight and ground support hardware. This process specific

32、ation combines the lessons learned from extensive Agency-wide welding engineering experiences and combines the requirements of project, Center, other government, and industry documents used for the manufacture of historic spaceflight hardware such as Saturn, the Space Shuttle, and the International

33、Space Station. When this process specification is specified on contract documents, the contractor may submit an alternative, corporate, detailed weld process specification that meets the intent of this specification. Industry, government, and company specifications may be used for welding hardware i

34、n lieu of this specification if approved by the responsible National Aeronautics and Space Administration (NASA) Technical Authority. The content of this process specification meets the intent of NASA-STD-(I)-5006A. 1.1 Purpose The purpose of this process specification is to establish the minimum pr

35、ocess control requirements for the design, fabrication (including the qualification of welders, welding operators, and welding procedure specifications), and quality assurance of manual, semiautomatic, mechanized, and automatic welds in flight and ground support hardware used by or for Marshall Spac

36、e Flight Center (MSFC). 1.2 Applicability This process specification is approved for use by MSFC and may be cited in contract, program, and other documents as a technical requirement. This process specification may also apply to contractors and subcontractors to the extent specified or referenced in

37、 their contracts. Requirements are numbered and indicated by the word “shall.” Explanatory or guidance text is indicated in italics beginning in section 4. 1.2.1 Applicable Processes This process specification is applicable to weld processes used for joining metallic materials. These include, but ar

38、e not limited to, the following: a. Arc Welding: Gas Tungsten Arc (GTAW), Gas Metal Arc (GMAW), Plasma Arc (PAW), Variable Polarity Plasma Arc (VPPA), Shielded Metal Arc (SMAW) Submerged Arc (SAW) Flux Core Arc Welding (FCAW) and the pulsed derivatives b. Solid-State Welding: Friction, Friction Stir

39、 (FS), Inertia, Plug (FPW) Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MSFC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Pa

40、ge 9 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 c. Resistance Welding d. High-Energy Density Welding: Electron Beam (EB) and Laser Beam (LB). 1.2.2 Applicable Materials This process specification cov

41、ers all metallic materials used in the manufacture of flight hardware. 1.3 Tailoring Tailoring of this process specification for application to a specific assembly or subassembly shall be formally documented on the engineering drawing and approved by the responsible NASA Technical Authority. 1.4 Saf

42、ety 1.4.1 Industrial Safety a. Appropriate personal protective equipment shall be used in all hazardous processes. b. All hazardous materials and processes that are required in compliance with provisions of this process specification and that are located or performed at sites other than MSFC are sub

43、ject to applicable federal, State, and local safety codes, standards, and regulations. c. All hazardous materials and processes that are required in compliance with provisions of this process specification and that are located or performed at MSFC shall be subject to MPR 8715.1, Marshall Safety, Hea

44、lth, and Environmental (SHE) Program. 1.4.2 System Safety a. System safety engineering (SSE) shall identify critical and catastrophic hazards and mitigations to eliminate and/or control the hazards of the welding operations. b. SSE shall participate within the various program working groups, panel r

45、eviews, and procedures and drawing reviews of welding systems and processes. c. SSE shall participate in welding process reviews and decisions to ensure that safety concerns are addressed and appropriate safety requirements and design criteria are implemented in accordance with applicable program Sa

46、fety, Reliability, and Quality Plan. 1.5 Specific Process Weld Requirements 1.5.1 Resistance Welding Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MSFC Technical Standard EM30 Title: Process Specification Welding Aerospace Hardware Document No.: MS

47、FC-SPEC-3679 Revision: Baseline Effective Date: August October 11, 2012 Page 10 of 102 CHECK THE MASTER LIST VERIFY THAT THIS IS CORRECT VERSION BEFORE USE at https:/repository.msfc.nasa.gov/docs/multiprogram/MSFC-SPEC-3679 Resistance welding shall be in accordance with AWS D17.2/D17.2M, Specificati

48、on for Resistance Welding for Aerospace Applications, or SAE AMS-W-6858A, Welding, Resistance: Spot and Seam. 1.5.2 Laser Beam Welding LB welding shall be in accordance with AWS C7.4/C7.4M, Process Specification and Operator Qualification for Laser Beam Welding. 1.5.3 Friction or Inertia Welding Direct drive friction or inertia welding shall be in accordance with AWS C6.1, Recommended Practices for Friction Welding. 2.0 APPLICABLE DOCUMENTS The latest issues of the following documents form a part of this specification to the extent spec