SAE AMS 2545-2017 Controlled Pneumatic Needle Peening Straightening and Forming.pdf

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1、 _ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising ther

2、efrom, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2017 SAE International All rights reserved. No part of this

3、publication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-49

4、70 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/standards.sae.org/AMS2545 AEROSPACE MATERIAL SPECIFICATION AMS2545 Issued 2017-11 Controlled Pneumatic Needle Pe

5、ening, Straightening and Forming RATIONALE This specification was written so that an industry standard can be used for in-situ needle peening of aerospace engine components as well the needle peening of tight radii on aircraft structural components. 1. SCOPE 1.1 Purpose This specification covers the

6、 requirements for saturation peening, straightening and forming metal parts using controlled pneumatic activated needles. 1.2 Application This process is used to perform localized peening, straightening and reshaping of parts and for cosmetic surface restoration of peened parts but usage is not limi

7、ted to these applications. Use of controlled pneumatic needle peening may require customer approval. 2. APPLICABLE DOCUMENTS The issue of the following documents in effect on the date of the purchase order forms a part of this specification to the extent specified herein. The supplier may work to a

8、subsequent revision of a document unless a specific document issue is specified. When the referenced document has been cancelled and no superseding document has been specified, the last published issue of that document shall apply 2.1 SAE Publications Available from SAE International, 400 Commonweal

9、th Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. ARP1917 Clarification of Terms Used in Aerospace Metals Specifications SAE J442 Test Strip, Holder and Gage for Shot Peening SAE J443 Procedures for Using Standard Shot Peeni

10、ng Almen Test Strip SAE J2277 Shot Peening Coverage Determination SAE INTERNATIONAL AMS2545 Page 2 of 7 3. TECHNICAL REQUIREMENTS 3.1 Equipment 3.1.1 Peening Head The pneumatic needle peening head shall be configured as follows: 3.1.1.1 Size and configuration shall be such that it allows for proper

11、contact against the metal part to be peened. 3.1.1.2 The head shall incorporate a sensor to continuously monitor the movement of each needle to ensure full peening action during the peening process. 3.1.1.3 The peening head shall be equipped with a contact ring constructed of a non-metallic, non-mar

12、king material, to maintain a fixed distance between the peening head and the part to ensure a consistent peening intensity and to protect the part surface from damage. 3.1.1.4 The peening head shall be capable of being positioned and moved on the part manually to obtain the coverage required. An aut

13、omated device or robot may be used for this purpose. In the case of manual peening, the peening head will incorporate an on/off switch to start the peening action. For automated devices/systems, starting the process will be done by the peening controller. 3.1.2 Peening Needles The peening needles sh

14、all have the following characteristics: 3.1.2.1 Needles shall be selected to achieve the Almen test strip intensity range and coverage required for the part. 3.1.2.2 The needle tip shall be made of a material that does not induce ferrous contamination 3.1.2.3 The active life of a set of needles shal

15、l be tracked by the peening controller software. The software shall calculate in real time the remaining needle life. Once the estimated life is exceeded, the needle set shall be removed from the head and inspected at a minimum of 10X magnification. Individual needles that are cracked, missing mater

16、ial or have flattened tips shall be cause for the entire needle set to be replaced. 3.1.2.4 Prior to peening each component, the needles shall be visually inspected at a minimum of 10X magnification. Individual needles that are cracked, missing material or have flattened tips shall be replaced. 3.1.

17、3 Peening Controller The controller shall have the following capabilities: 3.1.3.1 The controller shall incorporate a closed loop feedback system for measuring and continuously adjusting the air pressure provided to the needle system. 3.1.3.2 The controller shall be capable of shutting down within 5

18、 seconds after a detected out of tolerance condition occurs. 3.1.3.3 The controller shall be capable of maintaining the intensity within 0.0015 inches ( 0.038 mm) and capable of initiating a shut down within 5 seconds after a detected out of tolerance condition. 3.1.3.4 When more than 50% of the nee

19、dles are not in motion, the controller shall stop the process. 3.1.3.5 The controller shall provide a means to save process data, user name and user description. SAE INTERNATIONAL AMS2545 Page 3 of 7 3.1.4 Almen Test Strip and Gage Test strips and gage shall conform to SAE J442 for saturation peenin

20、g. 3.1.5 Almen Test Strip Holder The Almen test strip holder shown in Figure 1 conforms to SAE J442 except that the longitudinal spacing of the holding screws are extended to ensure coverage of the 1.25 inch (31.75 mm) arc measuring length of the Almen gage. A groove with the thickness and width of

21、the Almen test strip is required to be machined into the holder to ensure that the needle tips are not damaged when peening the edge of the Almen test strip. 3.2 Part Preparation 3.2.1 The following items are the responsibility of the purchaser and shall have been completed on parts prior to peening

22、. 3.2.1.1 Heat treatment. 3.2.1.2 Machining of areas to be peened. 3.2.1.3 Any required nondestructive inspection such as magnetic particle or fluorescent penetrant inspection. 3.2.2 Edge Condition All part edges and corners in the areas to be peened shall be free of sharp edges and burrs. 3.2.3 Coa

23、tings and Damage Parts shall be free from corrosion, mechanical damage and corrosion-preventive coatings such as anodic coatings, plating, or paint. 3.2.4 Cleaning All parts shall be clean and free from contaminants such as grease, dirt, and oil prior to peening. The purchaser shall supply clean par

24、ts to the processor or shall specify the cleaning method to be used. If no cleaning method is specified, the processor may clean the parts using a method acceptable to the purchaser. Halogenated solvents shall not be used to clean titanium alloy parts. 3.2.5 Masking Areas of the part that are design

25、ated to be free from any peening shall be suitably masked or protected from needle tip contact. 3.3 Peening Parts shall be peened to the extent specified. 3.4 Properties 3.4.1 Intensity Peening intensity shall be specified on the engineering drawing, overhaul manual or purchase order and determined

26、in accordance with SAE J443. The standard arc height designation shall be confirmed if it is not specified. Note: customer requirements such as 6A or 18N typically mean 0.006 inch (0.152 mm) A and 0.018 inch (0.046 cm) N respectively, but should be confirmed by the processor. 3.4.1.1 Intensity deter

27、mination shall be performed in conjunction with process setup. The intensity shall be verified prior to peening parts. The Almen strip holder shown in Figure 1, shall be used. SAE INTERNATIONAL AMS2545 Page 4 of 7 3.4.2 Coverage Coverage, except for forming and straightening, shall be specified on t

28、he engineering drawing, overhaul manual or purchase order and determined in accordance with SAE J2277. 3.4.3 Dimensional Requirements When specified, parts peened for straightening or forming shall comply with all drawing dimensional requirements and tolerances in the after peened condition. 3.5 Qua

29、lification of Peening Operators Qualification of peening operators shall consist of providing capability of peening technique, intensity determination, coverage inspection, and part peening procedures. 3.5.1 Intensity Determination Test The operator shall demonstrate proper Almen strip and Almen gag

30、e handling including gage zeroing or pre-bow compensation (if allowed by the cognizant engineering organization) and intensity determination from saturation curves. 3.5.2 Acceptance Criteria for Controlled Pneumatic Needle Peening A saturation curve shall be considered satisfactory when the operator

31、 reproduces an intensity value from a saturation coverage curve that the operator has previously accomplished within 0.0015 inch ( 0.038 mm) Almen A or N and within the required intensity range. In case of failure to reproduce the intensity within that limit, the operator shall be allowed only one r

32、etest. Test failure may require retraining or result in disqualification and must requalify again per 3.5.1. 3.5.3 Part Peening Qualification for Controlled Pneumatic Needle Peening The peening operator shall satisfactorily peen a sample part representative of those commonly peened to demonstrate co

33、verage. 3.5.4 Operator Qualification Record The peening facility is responsible for retaining a written record of the peening operators qualification testing. 3.5.5 Status Maintenance Qualified status of operators shall be maintained by either maintaining record of continued satisfactory workmanship

34、 or by successful re-qualification testing (see 3.5.1) not to exceed 6 months. Periodic re-qualification will not be required for operators when records indicate a satisfactory level is being maintained in production peening. 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Process Control and

35、 Inspection The processor shall supply all samples for processors tests and shall be responsible for the performance of all required tests. When parts are to be tested, the parts shall be supplied by the purchaser. The cognizant engineering organization reserves the right to sample and to perform an

36、y confirmatory testing deemed necessary to ensure that processing conforms to the specified requirements. 4.2 Acceptance Tests Intensity (3.4.1) is an acceptance test and shall be performed as stated in 3.4.1. Coverage (3.4.2) is an acceptance test and shall be performed on each part processed. Dime

37、nsional requirements (3.4.3) when applicable is an acceptance test and shall be performed on each part processed. SAE INTERNATIONAL AMS2545 Page 5 of 7 4.3 Approval The process shall be approved as required by the cognizant engineering organization before parts are peened. Requirements for approval

38、shall include submission of a process plan describing equipment, a saturation curve and descriptions of typical areas to be peened. If the processor makes a significant change to an approved process, or the process control parameters that was used for process approval, all tests shall be performed a

39、nd the results submitted to the cognizant engineering organization for approval. A significant change is one which, in the judgment of the cognizant engineering organization, could affect the properties or performance of the parts. 4.4 Reports The processor shall furnish with each shipment a report

40、stating that the parts have been processed and tested in accordance with the specified requirements and that they conform to specified requirements. This report shall include the purchase order number, AMS2545, quantity and the following: Part number and name Area peened Date peened Type of strip us

41、ed Needle peening size Peening head configuration Needle head configuration and tip diameter Applied pressure and related peening intensity Specified range and actual peening intensity verification Confirmation that specified coverage of part was achieved 5. PREPARATION FOR DELIVERY 5.1 Peened parts

42、 shall be handled and packaged to ensure that the required physical characteristics and properties of the parts will be preserved. 6. ACKNOWLEDGMENT The processor shall mention this specification and its revision letter in all quotations and when acknowledging purchase orders. 7. REJECTIONS Parts no

43、t processed in accordance with this specification, or to modifications authorized by purchaser, will be subject to rejection. SAE INTERNATIONAL AMS2545 Page 6 of 7 8. NOTES 8.1 Revision Indicator A change bar (l) located in the left margin is for the convenience of the user in locating areas where t

44、echnical revisions, not editorial changes, have been made to the previous issue of this document. An (R) symbol to the left of the document title indicates a complete revision of the document, including technical revisions. Change bars and (R) are not used in original publications, nor in documents

45、that contain editorial changes only. 8.2 Terms used in AMS are clarified in ARP1917. 8.3 Dimensions and properties in inch/pound units and the Fahrenheit temperatures are primary; dimensions and properties in SI units and the Celsius temperatures are shown as the approximate equivalents of the prima

46、ry units and are presented only for information. 8.4 Purchase documents should specify not less than the following: AMS2545 Part number and quantity of parts to be peened Cleaning method if necessary (see 3.3.4) Peening intensity (see 3.5.1) Peening coverage (see 3.5.2) 8.5 Part manufacturing operat

47、ions, such as heat treatment, forming, joining, machining, grinding, and polishing, can relieve compressive stress if performed after peening. Magnetic particle and penetrant inspection shall be completed prior to peening. The sequencing of operations should be specified by the cognizant engineering

48、 organization and is not controlled by this specification. 8.6 It is recommended that indenter configuration and motion parameters be established by a test program that considers fatigue life, compressive stress depth, surface cold work and surface finish. PREPARED BY AMS COMMITTEE “B” SAE INTERNATI

49、ONAL AMS2545 Page 7 of 7 Figure 1 - Almen strip holder for Controlled Pneumatic Needle Peening and Forming (all dimensions are in millimeters) 6024.2+0.26.9-0.19.48+0.1193819.05+0.05Xmit A lme nstre if e n N: X=0 .7 9mit A lme nstre if e n A : X=1 .2 9mit A lme nstre if e n C: X=2 .3 9Almen strip N: x = 0.79 -0.05 mm Almen strip A: x = 1.29 -0.05 mm Almen strip C: x = 2.39 -0.05 mm 19min 38 min 60.0 0.2 76