SIST EN 16602-70-39:2019
(Main)Space product assurance - Welding of metallic materials for flight hardware
Space product assurance - Welding of metallic materials for flight hardware
This Standard specifies the processing and quality assurance requirements for the different types of metallic welding (manual, automatic, semi-automatic and machine) for space flight applications.
The Standard covers all welding processes used for joining metallic materials for space applications. This includes, but is not limited to:
• Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG), (process 14)
• Gas Metal Arc Welding (GMAW) / Metal Inert Gas (MIG) (process 13)
• Plasma Arc Welding (PAW) / Plasma of Transferred Arc (PTA), (process 15)
• Electron beam welding (EBW), (process 51)
• Laser beam welding (LBW), (process 52)
• Friction Stir welding (process 43)
• Magnetic Pulse welding (process 442)
• Linear friction welding (process 42)
• Rotary friction welding (process 42)
The specific process numbers mentioned above are listed according to the standard ISO 4063.
This Standard does not cover the weld repair.
This standard may be tailored for the specific characteristic and constrains of a space project in conformance with ECSS-S-ST-00.
Raumfahrtproduktsicherung - Teil 70-39: Anforderungen an Verarbeitung und Qualitätssicherung für das Metallschweißen in Flug-Hardware
Assurance produit spatiale - Soudure de matériaux métalliques pour matériel de vol
La présente Norme spécifie les exigences relatives au traitement et à l'assurance qualité de différents types de soudage métallique (manuel, automatique, semi automatique et mécanisé) pour des applications de vol spatial. La présente Norme peut également être appliquée aux activités de soudage des équipements au sol relatifs au domaine spatial et aux modèles de développement des matériels de vol. La présente Norme couvre tous les procédés de soudage utilisés pour la liaison de matériaux métalliques pour des applications spatiales. Cela comprend, sans toutefois s'y limiter :
- le soudage à l'arc sous gaz avec électrode de tungstène (GTAW)/sous gaz inerte avec électrode de tungstène (TIG), (procédé 14)
- le soudage à l'arc sous gaz avec électrode fusible (GMAW)/sous gaz inerte avec électrode fusible (MIG), (procédé 13)
- le soudage à l'arc au plasma (PAW)/plasma avec arc transféré (PTA), (procédé 15)
- le soudage par faisceau d'électrons (EBW), (procédé 51)
- le soudage par faisceau laser (LBW), (procédé 52)
- le soudage par friction-malaxage (procédé 43)
- le soudage par impulsion magnétique (procédé 442)
- le soudage par friction linéaire (procédé 42)
- le soudage par friction rotative (procédé 42)
Les numéros spécifiques des procédés ci-dessus sont listés selon la norme ISO 4063:2009.
La présente Norme ne donne pas de détails sur les phases de définition et de pré vérification du soudage, y compris les écarts de conception autorisés.
La présente norme peut être adaptée aux caractéristiques et contraintes spécifiques d'un projet spatial conformément à l'ECSS-S-ST-00.
Zagotavljanje varnih proizvodov v vesoljski tehniki - Varjenje kovinskih materialov za letalsko strojno opremo
Ta standard določa zahteve za obdelavo in zagotavljanje kakovosti za različne vrste kovinskega varjenja (ročno, avtomatsko, polavtomatsko in strojno) za letalsko strojno opremo. Standard zajema vse postopke varjenja, ki se uporabljajo za spajanje kovinskih materialov za letalsko strojno opremo. To vključuje, vendar ni omejeno na: • varjenje z volframovo elektrodo (GTAW)/varjenje TIG, (proces 14) • varjenje s taljivo elektrodo (GMAW)/varjenje MIG (proces 13) • plazemsko obločno varjenje (PAW)/varjenje PTA, (proces 15) • varjenje z elektronskim snopom (EBW), (proces 51) • lasersko varjenje (LBW), (proces 52) • varjenje z gnetenjem (proces 43) • magnetno pulzno varjenje (proces 442) • linearno varjenje s trenjem (proces 42) • rotacijsko varjenje s trenjem (proces 42) Zgornje številke procesov so navedene v skladu s standardom ISO 4063. Ta dokument ne zajema popravila zvarov. Ta standard se lahko prilagodi posameznim lastnostim in omejitvam vesoljskega projekta v skladu s standardom ECSS-S-ST-00.
General Information
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Zagotavljanje varnih proizvodov v vesoljski tehniki - Varjenje kovinskih materialov za letalsko strojno opremoRaumfahrtproduktsicherung - Teil 70-39: Anforderungen an Verarbeitung und Qualitätssicherung für das Metallschweißen in Flug-HardwareAssurance produit spatiale - Soudure de matériaux métalliques pour matériel de volSpace product assurance - Welding of metallic materials for flight hardware49.140Vesoljski sistemi in operacijeSpace systems and operations25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 16602-70-39:2018SIST EN 16602-70-39:2019en,fr,de01-februar-2019SIST EN 16602-70-39:2019SLOVENSKI
STANDARD
SIST EN 16602-70-39:2019
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 16602-70-39
November
t r s z ICS
t wä s x rä s râ
v {ä s v r
English version
Space product assurance æ Welding of metallic materials for flight hardware
Assurance produit des projets spatiaux æ Soudage de matßriaux mßtalliques pour matßriel de vol
Raumfahrtproduktsicherung æ Metallschweißen in FlugæHardware This European Standard was approved by CEN on
u September
t r s zä
C Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alterationä Upætoædate lists and bibliographical references concerning such national standards may be obtained on application to the CENæCENELEC Management Centre or to any CEN and CENELEC memberä
translation under the responsibility of a CEN and CENELEC member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Serbiaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey and United Kingdomä
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels y any means reserved worldwide for CEN national Members and for CENELEC Membersä Refä Noä EN
s x x r tæ y ræ u {ã t r s z ESIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 2 Table of contents European Foreword . 6 1 Scope . 7 2 Normative references . 8 3 Terms, definitions and abbreviated terms . 11 3.1 Terms from other standards . 11 3.2 Terms specific to the present standard . 11 3.3 Abbreviated terms. 15 3.4 Conventions. 16 3.5 Nomenclature . 16 3.5.1 Formal verbs . 16 4 Principles . 18 4.1 General . 18 4.2 Classification of weld safety classes . 20 4.2.1 Overview . 20 4.2.2 Safety Class 1 . 20 4.2.3 Safety Class 2 . 20 4.2.4 Safety Class 3 . 20 4.3 Weld sensitivity levels . 20 4.4 Tailoring of the weld acceptance criteria . 20 5 Welding design . 21 5.1 Design of Welded Connections . 21 5.2 Acceptable joints design . 21 6 Welding and inspection personnel . 22 6.1 Welding supervisor . 22 6.2 Qualification and certification of welders and welding operators . 22 6.2.1 Validity limits for operator qualification . 22 6.2.2 Manual arc welding . 23 6.2.3 Mechanised fusion and resistance welding . 23 6.2.4 Mechanised friction stir welding. 23 SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 3 6.3 Qualification and certification of welding inspectors . 23 6.4 Clothing requirements . 23 7 Equipment and facilities . 25 7.1 Qualification of the welding equipment. 25 7.1.1 General requirements . 25 7.1.2 Specific requirements . 25 7.2 Maintenance and repair of the welding equipment . 26 7.3 Materials and consumables . 26 7.3.1 Base materials . 26 7.3.2 Filler materials . 27 7.3.3 Shielding and backing gas . 27 7.3.4 Tooling and fixtures . 28 8 Welding procedure specification (WPS) . 29 8.1 Requirements applicable to all processes . 29 8.1.1 General . 29 8.1.2 Drawings . 29 8.1.3 Welding process . 29 8.1.4 Weld preparation . 29 8.1.5 Cleanliness prior to welding . 30 8.1.6 Tack welds . 30 8.1.7 Backing and shielding gas . 30 9 Weld inspection . 31 9.1 Non-destructive techniques . 31 9.1.1 General . 31 9.1.2 Visual and dimensional examination . 31 9.1.3 Penetrant inspection . 34 9.1.4 Radiographic testing . 34 9.1.5 Ultrasonic inspection . 34 9.1.6 X-ray tomography inspection (CT scan) . 35 9.2 Destructive testing . 35 9.2.1 Metallographic measurement . 35 9.2.2 Hardness measurement . 36 9.2.3 Tensile test . 36 9.2.4 Other tests . 36 10 Weld acceptance criteria . 37 10.1 General . 37 SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 4 10.2 Outer features for fusion welds . 37 10.3 Inner features for fusion welds . 43 10.4 Features for friction stir welds . 46 11 Welding process verification . 48 11.1 Weld Samples . 48 11.1.1 General . 48 11.1.2 Safety Classes 1 and 2: assessment of weld samples . 48 11.1.3 Safety Class 3: assessment of weld samples . 49 11.2 Verification acceptance criteria . 49 11.3 Delta verification . 49 11.3.1 General . 49 11.3.2 Safety Classes 1 and 2: delta verification . 50 11.3.3 Safety Class 3: delta verification . 50 11.4 Re-weld, in process correction . 50 11.5 Repair welding . 51 11.6 Documentation . 51 12 Flight hardware production . 53 12.1 Documentation . 53 12.2 Requirements for flight hardware welding . 53 12.2.1 General . 53 12.2.2 Drawings . 54 12.2.3 Extent of testing to support flight hardware production . 54 13 Quality assurance . 56 13.1 Maintenance of WPS . 56 13.2 Quality control . 56 13.2.1 Reference samples . 56 13.2.2 Documentation of weld parameters . 57 13.2.3 Anomalies and nonconformances occurring during the welding process . 57 13.2.4 Inspection and test methods . 57 Annex A (normative)
Welding Procedure Specification (WPS) - DRD . 58 A.1.1 Requirement identification and source document . 58 A.1.2 Purpose and objective . 58 A.2 Expected response . 58 A.2.1 Scope and content . 58 A.2.2 Special remarks . 67 SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 5 Annex B (normative) Welding Verification Test Plan (WVTP) - DRD . 68 B.1 DRD identification . 68 B.1.1 Purpose and scope . 68 B.2 Expected response . 68 B.2.1 Scope and content . 68 B.2.2 Special remarks . 69 Annex C (informative) Inner defect calculation . 70 Bibliography . 71
Figures Figure 4-1 Flow chart showing the steps required to produce a verified weld process and flight hardware . 19 Figure 9-1: Discoloration of the inside of austenitic stainless steel tubes . 33
Tables Table 7-1: Acceptable gas purity levels . 27 Table 7-2: Recommended shielding gases for welding . 27 Table 9-1: Colour acceptance criteria for titanium fusion welds . 32 Table 9-2: Examples of weld discoloration for titanium fusion welds (for information only) . 33 Table 10-1: Outer features for fusion welds . 38 Table 10-2: Inner Features for Fusion Welds . 43 Table 10-3: Features for friction stir welds . 46 Table 11-1: Minimum acceptable amount of testing for manual arc welding . 49 Table 11-2: Minimum acceptable amount of testing for all mechanised welding processes class 1 and 2 welds . 49 Table 11-3: Minimum acceptable amount of testing for class 1 and 2 welds (all processes) . 50 Table 12-1: Dew point conditions for welding . 54 Table 12-2: Tests to be performed on parts performed during production of flight hardware . 55
SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 6 European Foreword This document (EN 16602-70-39:2018) has been prepared by Technical Committee CEN/CLC/JTC 5 “Space”, the secretariat of which is held by DIN. This standard (EN 16602-70-39:2018) originates from ECSS-Q-ST-70-39C. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by May 2019, and conflicting national standards shall be withdrawn at the latest by May 2019. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a standardization request given to CEN by the European Commission and the European Free Trade Association. This document has been developed to cover specifically space systems and has therefore precedence over any EN covering the same scope but with a wider domain of applicability (e.g. : aerospace). According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 7 1 Scope This Standard specifies the processing and quality assurance requirements for the different types of metallic welding (manual, automatic, semi-automatic and machine) for space flight applications. This standard can also be used for weld activities on space related ground equipment and development models for flight hardware. The Standard covers all welding processes used for joining metallic materials for space applications. This includes, but is not limited to: • Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG), (process 14) • Gas Metal Arc Welding (GMAW) / Metal Inert Gas (MIG) (process 13) • Plasma Arc Welding (PAW) / Plasma of Transferred Arc (PTA), (process 15) • Electron beam welding (EBW), (process 51) • Laser beam welding (LBW), (process 52) • Friction Stir welding (process 43) • Magnetic Pulse welding (process 442) • Linear friction welding (process 42) • Rotary friction welding (process 42) The specific process numbers mentioned above are listed according to the standard ISO 4063:2009. This Standard does not detail the weld definition phase and welding pre-verification phase, including the derivation of design allowables. This standard may be tailored for the specific characteristic and constraints of a space project in conformance with ECSS-S-ST-00. SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 8 2 Normative references The following normative documents contain provisions which, through reference in this text, constitute provisions of this ECSS Standard. For dated references, subsequent amendments to, or revision of any of these publications do not apply. However, parties to agreements based on this ECSS Standard are encouraged to investigate the possibility of applying the more recent editions of the normative documents indicated below. For undated references, the latest edition of the publication referred to applies.
EN reference Reference in text Title EN 16601-00-01 ECSS-S-ST-00-01 ECSS system – Glossary of terms EN 16603-32-01 ECSS-E-ST-32-01 Space engineering –Fracture control EN 16601-40 ECSS-M-ST-40 Space management – Configuration and information management EN 16602-10-09 ECSS-Q-ST-10-09 Space product assurance – Nonconformance control system EN 16602-20 ECSS-Q-ST-20 Space product assurance – Quality assurance
AMS 2644:2006 Inspection material, penetrant
ASTM E164-13:2013 Standard Practice for Contact Ultrasonic Testing of Weldments
ASTM E3:2007
Standard Guide for Preparation of Metallographic Specimens
ASTM E340:2013 Standard Test Method for Macroetching Metals and Alloys
ASTM E407:2007 Standard Practice for Microetching Metals and Alloys
AWS D18.2:2009 Guide to weld discoloration levels on inside of austenitic stainless steel tube
DIN 29595:2007-04 Fusion welded metallic components – requirements
DIN 65153:1997-06 Acceptance testing of plasma arc welding equipment.
EN 4179:2009 Aerospace series. Qualification and approval of personnel for non-destructive testing
EN 60974
Arc welding equipment
Part 1:2012 Welding power sources
Part 2:2013 Liquid cooling systems SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 9
Part 3:2013 Arc striking and stabilizing devices
Part 4:2010 Periodic inspection and testing
Part-5:2013 Wire feeders
Part 6:2010 Limited duty equipment
Part 7:2013 Torches
Part 8:2009 Gas consoles for welding and plasma cutting systems
Part 9: 2010 Installation and use
Part 10:2014 Electromagnetic compatibility (EMC) requirements
Part 11:2010 Electrode holders
Part 12:2011 Coupling devices for welding cables
Part 13:2011 Welding clamp
ISO 2553:2013 Welding and allied processes -- Symbolic representation on drawings -- Welded joints
ISO 3452 Non-destructive testing - Penetrant testing
Part 1:2013 General principles
Part 2:2013 Testing of penetrant materials
Part 3:2013 Reference test blocks
Part 4:1998 Equipment
Part 5: 2008 Penetrant testing at temperatures higher than 50 degrees C
Part 6:2008 Penetrant testing at temperatures lower than 10 degrees C
ISO 4063:2009 Welding and allied processes - Nomenclature of processes and reference numbers
ISO 4136:2012 Destructive tests on welds in metallic materials - Transverse tensile test
ISO 6848:2004 Arc welding and cutting - Nonconsumables tungsten electrodes - Classification
ISO 6947:2011 Welding and allied processes - Welding positions
ISO 9015 Destructive tests on welds in metallic materials - Hardness testing (Part 1 and 2)
Part 1:2001 Hardness test on arc welded joints
Part 2:2003 Microhardness testing of welded joints
EN 10204:2004 Metallic products - Types of inspection documents
ISO 11611:2007 Protective clothing for use in welding and allied processes
ISO 14731:2006 Welding coordination - Tasks and responsibilities
ISO 14732:2013 Welding personnel – Qualification testing of welding operators and weld setters for mechanized and automatic welding of metallic materials
ISO 14744 Acceptance inspection of electron beam welding machines SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 10
Part 1:2008 Principles and acceptance conditions
Part 2:2000 Measurement of accelerating voltage characteristics
Part 3:2000 Measurement of beam current characteristics
Part 4:2000 Measurement of welding speed
Part 5:2000 Measurement of run-out accuracy
Part 6:2000 Measurement of stability of spot position
ISO 15614-2:2005 Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 2: Arc welding of aluminium and its alloys
ISO 15616 Acceptance tests for CO2-laser beam machines for high quality welding and cutting
Part 1:2003 General principles, acceptance conditions
Part 2:2003 Measurement of static and dynamic accuracy
Part 3:2003 Calibration of instruments for measurement of gas flow and pressure
Part 4:2008 Acceptance tests for CO2-laser beam machines for high quality welding and cutting - Part 4: Machines with 2-D moving optics
ISO 17636:2013 Non-destructive testing of welds - Radiographic testing
Part 1:2013 X- and gamma-ray techniques with film
Part 2:2013 X- and gamma-ray techniques with digital detectors
EN-ISO 17637:2011 Non-destructive testing of welds - Visual testing of fusion-welded joints
ISO 17640:2010 Non-destructive testing of welds - Ultrasonic testing - Techniques, testing levels, and assessment
ISO 22826:2005 Destructive tests on welds in metallic materials - Hardness testing of narrow joints welded by laser and electron beam (Vickers and Knoop hardness tests)
ISO 22827:2005 Acceptance tests for Nd: YAG laser beam welding machines - Machines with optical fibre delivery
Part 1:2005 Laser assembly
Part 2:2005 Moving mechanism
ISO 24394:2008 Welding for aerospace applications - Qualification test for welders and welding operators - Fusion welding of metallic components
ISO 25239-3:2011 Friction stir welding - Aluminium - Part 3: Qualification of welding operators
ISO 25239-5:2011 Friction stir welding - Aluminium - Part 5: Quality and inspection requirements SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 11 3 Terms, definitions and abbreviated terms 3.1 Terms from other standards a. For the purpose of this Standard, the terms and definitions from ECSS-S-ST-00-01 apply and in particular the following:
1. critical b. For the purpose of this Standard, the terms and definitions from ECSS-E-ST-32-01 apply. 1. fail-safe 3.2 Terms specific to the present standard 3.2.1 acceptable weld weld that has no defects and passes all acceptance criteria 3.2.2 all weld metal tensile test specimen test specimen with the reduced section composed of only weld metal 3.2.3 alpha sample
weld sample produced prior to the start of a production run, used to verify selected aspects of the quality of the weld to be produced during production NOTE The term "pre-weld sample" is synonymous. 3.2.4 base metal part of the welded joint which remains un-melted or un-stirred for friction stir welding, and unaffected by the heat of the process, such that the microstructure and mechanical properties are unaffected 3.2.5 beta sample weld sample produced at the end of a production run, used to verify selected aspects of the quality of the weld to be produced during production NOTE The term "post-weld sample" is synonymous. SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 12 3.2.6 critical structure structure or component, the single failure of which cause significant danger to personnel, loss of system, loss of major component, or loss of control, thus resulting in an operation penalty, or loss of the system, or abortion of the mission 3.2.7 defect unacceptable feature of the weld NOTE This term is defined in the present standard with a different meaning than in ECSS-S-ST-00-01. The term with the meaning defined herein is applicable only to the present standard. 3.2.8 delta verification welding trials performed to extend the range of a previously approved WPS 3.2.9 design authority responsible for the detailed design of the welded part in compliance to an approved specification and authorized to sign certificates of design or certified sealed drawings in accordance with procedures 3.2.10 engineering authority contracting agency or corporate organisation that acts for and on behalf of the customer and responsible for the structural integrity or maintenance of airworthiness of the hardware and compliance with all business agreement documents 3.2.11 fabrication structure manufactured by assembling various parts together 3.2.12 feature geometric or microstructural non-uniformity in the weld or weld zone 3.2.13 filler metal metal supplied in the form of a welding rod, sometimes flux coated, melted by a heat source into a joint between components to be joined 3.2.14 heat affected zone (HAZ) portion of the base metal that was not melted during fusion welding or stirred during friction stir welding but whose microstructure and mechanical properties were altered by the heat applied during the welding process 3.2.15 hybrid welding type of welding process that combines the principles of laser beam welding and arc welding SIST EN 16602-70-39:2019
EN 16602-70-39:2018 (E) 13 3.2.16 in process correction see "re-weld" 3.2.17 job card see "shop traveller" 3.2.18 machine welding welding with equipment that performs the welding operation 3.2.19 maintenance book record of maintenance performed on equipment including any modifications 3.2.20 manual welding welding operation performed and controlled completely by hand 3.2.21 mission critical item whose failure generates a significant operational impact by jeopardizing the ability to successfully complete the assigned mission. NOTE This includes parts which have failure effects that adversely impact mission effectiveness. 3.2.22 non-critical structure structure or component which is non-critical and is contained so that failure does not affect other flight elements or personnel 3.2.23 piece part individual metallic parts to be welded NOTE The term of "piece part" is commonly used in welding. Examples are: sheets, plates and extrusions. 3.2.24 post weld sample see "beta sample" 3.2.25 process material or joint type and dimension or welding process combination which is covered by
...
SLOVENSKI STANDARD
oSIST prEN 16602-70-39:2016
01-april-2016
Zagotavljanje varnih proizvodov v vesoljski tehniki - Varjenje kovinskih materialov
za letalsko strojno opremo
Space product assurance - Welding of metallic materials for flight hardware
Raumfahrtproduktsicherung - Teil 70-39: Anforderungen an Verarbeitung und
Qualitätssicherung für das Metallschweißen in Flug-Hardware
Assurance produit spatiale - Soudure de matériaux métalliques pour matériel de vol
Ta slovenski standard je istoveten z: prEN 16602-70-39
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
49.140 Vesoljski sistemi in operacije Space systems and
operations
oSIST prEN 16602-70-39:2016 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN 16602-70-39:2016
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oSIST prEN 16602-70-39:2016
EUROPEAN STANDARD DRAFT
prEN 16602-70-39
NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2016
ICS 25.160.10; 49.140
English version
Space product assurance - Welding of metallic materials
for flight hardware
Assurance produit spatiale - Soudure de matériaux Raumfahrtproduktsicherung - Teil 70-39:
métalliques pour matériel de vol Anforderungen an Verarbeitung und
Qualitätssicherung für das Metallschweißen in Flug-
Hardware
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/CLC/TC 5.
If this draft becomes a European Standard, CEN and CENELEC members are bound to comply with the CEN/CENELEC Internal
Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any
alteration.
This draft European Standard was established by CEN and CENELEC in three official versions (English, French, German). A
version in any other language made by translation under the responsibility of a CEN and CENELEC member into its own
language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,
Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany,
Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.Recipients of this draft are invited to submit, with their comments, notification
of any relevant patent rights of which they are aware and to provide supporting documentation.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.
CEN-CENELEC Management Centre:
Avenue Marnix 17, B-1000 Brussels
© 2016 CEN/CENELEC All rights of exploitation in any form and by any means Ref. No. prEN 16602-70-39:2016 E
reserved worldwide for CEN national Members and for
CENELEC Members.
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oSIST prEN 16602-70-39:2016
prEN 16602-70-39:2016 (E)
Table of contents
European foreword . 6
1 Scope . 7
2 Normative references . 8
3 Terms, definitions and abbreviated terms . 11
3.1 Terms from other standards . 11
3.2 Terms specific to the present standard. 11
3.3 Abbreviated terms . 15
3.4 Conventions . 16
3.5 Nomenclature . 16
3.5.1 Formal verbs . 16
4 Principles . 17
4.1 General . 17
4.2 Classification of weld safety classes . 19
4.2.1 Overview . 19
4.2.2 Safety Class 1 . 19
4.2.3 Safety Class 2 . 19
4.2.4 Safety Class 3 . 19
4.3 Weld sensitivity levels . 19
4.4 Tailoring of the weld acceptance criteria . 19
5 Welding design. 20
5.1 Design of Welded Connections . 20
5.2 Acceptable joints design . 20
6 Welding and inspection personnel . 21
6.1 Welding supervisor . 21
6.2 Qualification and certification of welders and welding operators . 21
6.2.1 Validity limits for operator qualification . 21
6.2.2 Manual arc welding . 22
6.2.3 Mechanised fusion and resistance welding . 22
2
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oSIST prEN 16602-70-39:2016
prEN 16602-70-39:2016 (E)
6.2.4 Mechanised friction stir welding . 22
6.3 Qualification and certification of welding inspectors . 22
6.4 Clothing requirements . 22
7 Equipment and facilities . 23
7.1 Qualification of the welding equipment . 23
7.1.1 General requirements . 23
7.1.2 Specific requirements . 23
7.2 Maintenance and repair of the welding equipment . 24
7.3 Materials and consumables . 24
7.3.1 Base materials . 24
7.3.2 Filler materials . 25
7.3.3 Shielding and backing gas . 25
7.3.4 Tooling and fixtures . 26
8 Welding procedure specification (WPS) . 27
8.1 Requirements applicable to all processes . 27
8.1.1 General . 27
8.1.2 Drawings . 27
8.1.3 Welding process . 27
8.1.4 Weld preparation . 27
8.1.5 Cleanliness prior to welding . 28
8.1.6 Tack welds . 28
8.1.7 Backing and shielding gas . 28
9 Weld inspection . 29
9.1 Non-destructive techniques . 29
9.1.1 General . 29
9.1.2 Visual and dimensional examination . 29
9.1.3 Penetrant inspection . 32
9.1.4 Radiographic testing . 32
9.1.5 Ultrasonic inspection . 32
9.1.6 X-ray tomography inspection (CT scan) . 32
9.2 Destructive testing . 33
9.2.1 Metallographic measurement. 33
9.2.2 Hardness measurement . 34
9.2.3 Tensile test . 34
9.2.4 Other tests . 34
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10 Weld acceptance criteria . 35
10.1 General . 35
10.2 Outer features for fusion welds . 35
10.3 Inner features for fusion welds . 42
10.4 Features for friction stir welds . 44
11 Welding process verification. 46
11.1 Weld Samples . 46
11.1.1 General . 46
11.1.2 Safety Classes 1 and 2: assessment of weld samples . 46
11.1.3 Safety Class 3: assessment of weld samples . 47
11.2 Verification acceptance criteria . 47
11.3 Delta verification . 47
11.3.1 General . 47
11.3.2 Safety Classes 1 and 2: delta verification . 48
11.3.3 Safety Class 3: delta verification . 48
11.4 Re-weld, in process correction . 48
11.5 Repair welding . 49
11.6 Documentation . 49
12 Flight hardware production . 50
12.1 Documentation . 50
12.2 Requirements for flight hardware welding . 50
12.2.1 General . 50
12.2.2 Drawings . 51
12.2.3 Extent of testing to support flight hardware production . 51
13 Quality assurance . 53
13.1 Maintenance of WPS . 53
13.2 Quality control . 53
13.2.1 Reference samples . 53
13.2.2 Documentation of weld parameters . 53
13.2.3 Anomalies and nonconformances occurring during the welding process . 54
13.2.4 Inspection and test methods . 54
Annex A (normative) Welding Procedure Specification (WPS) - DRD . 55
A.1.1 Requirement identification and source document . 55
A.1.2 Purpose and objective . 55
A.2 Expected response . 55
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A.2.1 Scope and content . 55
A.2.2 Special remarks . 63
Annex B (normative) Welding Verification Test Plan (WVTP) - DRD . 64
B.1 DRD identification . 64
B.1.1 Purpose and scope . 64
B.2 Expected response . 64
B.2.1 Scope and content . 64
B.2.2 Special remarks . 65
Annex C (informative) Inner defect calculation . 66
Bibliography . 67
Figures
Figure 4-1 Flow chart showing the steps required to produce a verified weld process and
flight hardware . 18
Figure 9-1: Discoloration of the inside of austenitic stainless steel tubes . 31
Tables
Table 7-1: Acceptable gas purity levels . 25
Table 7-2: Recommended shielding gases for welding . 26
Table 9-1: Colour acceptance criteria for titanium fusion welds . 30
Table 9-2: Examples of weld discoloration for titanium fusion welds (for information only) . 31
Table 10-1: Outer features for fusion welds . 36
Table 10-2: Inner Features for Fusion Welds. 42
Table 10-3: Features for friction stir welds . 44
Table 11-1: Minimum acceptable amount of testing for manual arc welding . 47
Table 11-2: Minimum acceptable amount of testing for all mechanised welding processes
class 1 and 2 welds . 47
Table 11-3: Minimum acceptable amount of testing for class 1 and 2 welds (all processes) . 48
Table 12-1: Dew point conditions for welding . 51
Table 12-2: Tests to be performed on parts performed during production of flight
hardware . 52
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European Foreword
This document (prEN 16602-70-39:2016) has been prepared by Technical Committee CEN/CLC/TC 5
“Space”, the secretariat of which is held by DIN (Germany).
This document (prEN 16602-70-39:2016) originates from ECSS-Q-ST-70-39C.
This document is currently submitted to the CEN Enquiry.
This document has been developed to cover specifically space systems and will the-refore have
precedence over any EN covering the same scope but with a wider do-main of applicability (e.g. :
aerospace).
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1
Scope
This Standard specifies the processing and quality assurance requirements for the
different types of metallic welding (manual, automatic, semi-automatic and
machine) for space flight applications. This standard can also be used for weld
activities on space related ground equipment and development models for flight
hardware. The Standard covers all welding processes used for joining metallic
materials for space applications. This includes, but is not limited to:
• Gas Tungsten Arc Welding (GTAW) / Tungsten Inert Gas (TIG), (process 14)
• Gas Metal Arc Welding (GMAW) / Metal Inert Gas (MIG) (process 13)
• Plasma Arc Welding (PAW) / Plasma of Transferred Arc (PTA), (process 15)
• Electron beam welding (EBW), (process 51)
• Laser beam welding (LBW), (process 52)
• Friction Stir welding (process 43)
• Magnetic Pulse welding (process 442)
• Linear friction welding (process 42)
• Rotary friction welding (process 42)
The specific process numbers mentioned above are listed according to the
standard ISO 4063:2009.
This Standard does not detail the weld definition phase and welding pre-
verification phase, including the derivation of design allowables.
This standard may be tailored for the specific characteristic and constraints of a
space project in conformance with ECSS-S-ST-00.
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Normative references
The following normative documents contain provisions which, through reference
in this text, constitute provisions of this ECSS Standard. For dated references,
subsequent amendments to, or revision of any of these publications do not apply.
However, parties to agreements based on this ECSS Standard are encouraged to
investigate the possibility of applying the more recent editions of the normative
documents indicated below. For undated references, the latest edition of the
publication referred to applies.
EN reference Reference in text Title
EN 16601-00-01 ECSS-S-ST-00-01 ECSS system – Glossary of terms
EN 16603-32-01 ECSS-E-ST-32-01 Space engineering –Fracture control
EN 16601-40 ECSS-M-ST-40 Space management – Configuration and information
management
EN 16602-10-09 ECSS-Q-ST-10-09 Space product assurance – Nonconformance control
system
EN 16602-20 ECSS-Q-ST-20 Space product assurance – Quality assurance
AMS 2644:2006 Inspection material, penetrant
ASTM E164-13:2013 Standard Practice for Contact Ultrasonic Testing of
Weldments
ASTM E3:2007 Standard Guide for Preparation of Metallographic
Specimens
ASTM E340:2013 Standard Test Method for Macroetching Metals and
Alloys
ASTM E407:2007 Standard Practice for Microetching Metals and Alloys
AWS D18.2:2009 Guide to weld discoloration levels on inside of austenitic
stainless steel tube
DIN 29595:2007-04 Fusion welded metallic components – requirements
DIN 65153:1997-06 Acceptance testing of plasma arc welding equipment.
EN 4179:2009 Aerospace series. Qualification and approval of
personnel for non-destructive testing
EN 60974 Arc welding equipment
Part 1:2012 Welding power sources
Part 2:2013 Liquid cooling systems
Part 3:2013 Arc striking and stabilizing devices
Part 4:2010 Periodic inspection and testing
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Part-5:2013 Wire feeders
Part 6:2010 Limited duty equipment
Part 7:2013 Torches
Part 8:2009 Gas consoles for welding and plasma cutting systems
Part 9: 2010 Installation and use
Part 10:2014 Electromagnetic compatibility (EMC) requirements
Part 11:2010 Electrode holders
Part 12:2011 Coupling devices for welding cables
Part 13:2011 Welding clamp
ISO 2553:2013 Welding and allied processes -- Symbolic representation
on drawings -- Welded joints
ISO 3452 Non-destructive testing - Penetrant testing
Part 1:2013 General principles
Part 2:2013 Testing of penetrant materials
Part 3:2013 Reference test blocks
Part 4:1998 Equipment
Part 5: 2008 Penetrant testing at temperatures higher than 50
degrees C
Part 6:2008 Penetrant testing at temperatures lower than 10 degrees
C
ISO 4063:2009 Welding and allied processes - Nomenclature of
processes and reference numbers
ISO 4136:2012 Destructive tests on welds in metallic materials -
Transverse tensile test
ISO 6848:2004 Arc welding and cutting - Nonconsumables tungsten
electrodes - Classification
ISO 6947:2011 Welding and allied processes - Welding positions
ISO 9015 Destructive tests on welds in metallic materials -
Hardness testing (Part 1 and 2)
Part 1:2001 Hardness test on arc welded joints
Part 2:2003 Microhardness testing of welded joints
EN 10204:2004 Metallic products - Types of inspection documents
ISO 11611:2007 Protective clothing for use in welding and allied
processes
ISO 14731:2006 Welding coordination - Tasks and responsibilities
ISO 14732:2013 Welding personnel – Qualification testing of welding
operators and weld setters for mechanized and
automatic welding of metallic materials
ISO 14744 Acceptance inspection of electron beam welding
machines
Part 1:2008 Principles and acceptance conditions
Part 2:2000 Measurement of accelerating voltage characteristics
Part 3:2000 Measurement of beam current characteristics
Part 4:2000 Measurement of welding speed
Part 5:2000 Measurement of run-out accuracy
Part 6:2000 Measurement of stability of spot position
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ISO 15614-2:2005 Specification and qualification of welding procedures for
metallic materials - Welding procedure test - Part 2: Arc
welding of aluminium and its alloys
ISO 15616 Acceptance tests for CO2-laser beam machines for high
quality welding and cutting
Part 1:2003 General principles, acceptance conditions
Part 2:2003 Measurement of static and dynamic accuracy
Part 3:2003 Calibration of instruments for measurement of gas flow
and pressure
Part 4:2008 Acceptance tests for CO2-laser beam machines for high
quality welding and cutting - Part 4: Machines with 2-D
moving optics
ISO 17636:2013 Non-destructive testing of welds - Radiographic testing
Part 1:2013 X- and gamma-ray techniques with film
Part 2:2013 X- and gamma-ray techniques with digital detectors
EN-ISO 17637:2011 Non-destructive testing of welds - Visual testing of
fusion-welded joints
ISO 17640:2010 Non-destructive testing of welds - Ultrasonic testing -
Techniques, testing levels, and assessment
ISO 22826:2005 Destructive tests on welds in metallic materials -
Hardness testing of narrow joints welded by laser and
electron beam (Vickers and Knoop hardness tests)
ISO 22827:2005 Acceptance tests for Nd: YAG laser beam welding
machines - Machines with optical fibre delivery
Part 1:2005 Laser assembly
Part 2:2005 Moving mechanism
ISO 24394:2008 Welding for aerospace applications - Qualification test
for welders and welding operators - Fusion welding of
metallic components
ISO 25239-3:2011 Friction stir welding - Aluminium - Part 3: Qualification
of welding operators
ISO 25239-5:2011 Friction stir welding - Aluminium - Part 5: Quality and
inspection requirements
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Terms, defi
...
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