SIST EN ISO 25239-4:2020
(Main)Friction stir welding - Aluminium - Part 4: Specification and qualification of welding procedures (ISO 25239-4:2020)
Friction stir welding - Aluminium - Part 4: Specification and qualification of welding procedures (ISO 25239-4:2020)
This document specifies the requirements for the specification and qualification of welding procedures
for the friction stir welding (FSW) of aluminium.
In this document, the term “aluminium” refers to aluminium and its alloys.
This document does not apply to friction stir spot welding which is covered by the ISO 18785 series.
NOTE Service requirements, materials or manufacturing conditions can require more comprehensive
testing than is specified in this document.
Rührreibschweißen - Aluminium - Teil 4: Anforderung und Qualifizierung von Schweißverfahren (ISO 25239-4:2020)
Dieses Dokument legt Anforderungen für die Qualifizierung von Schweißverfahren für das Rührreibschweißen (FSW) von Aluminium fest.
Der Begriff „Aluminium“ bezieht sich in diesem Dokument auf Aluminium und seine Legierungen.
Dieses Dokument ist nicht für das Rührreibpunktschweißen anzuwenden, das in der Normenreihe ISO 18785 abgedeckt ist.
ANMERKUNG Betriebsanforderungen, Werkstoffe oder Herstellbedingungen können umfassendere Prüfungen als in diesem Dokument festgelegt erfordern.
Soudage par friction-malaxage - Aluminium - Partie 4: Descriptif et qualification des modes opératoires de soudage (ISO 25239-4:2020)
Le présent document spécifie les exigences relatives au descriptif et à la qualification des modes opératoires de soudage pour le soudage par friction-malaxage de l'aluminium.
Dans le présent document, le terme «aluminium» se rapporte à l'aluminium et ses alliages.
Le présent document ne s'applique pas au soudage par points par friction-malaxage, qui est couvert par les normes de la série ISO 18785.
NOTE Les exigences de service, les matériaux ou les conditions de fabrication peuvent nécessiter des essais plus complets que ceux spécifiés dans le présent document.
Varjenje z gnetenjem - Aluminij - 4. del: Popis in kvalifikacija varilnih postopkov (ISO 25239-4:2020)
General Information
Relations
Standards Content (Sample)
SLOVENSKI STANDARD
SIST EN ISO 25239-4:2020
01-november-2020
Nadomešča:
SIST EN ISO 25239-4:2012
Varjenje z gnetenjem - Aluminij - 4. del: Popis in kvalifikacija varilnih postopkov
(ISO 25239-4:2020)
Friction stir welding - Aluminium - Part 4: Specification and qualification of welding
procedures (ISO 25239-4:2020)
Rührreibschweißen - Aluminium - Teil 4: Anforderung und Qualifizierung von
Schweißverfahren (ISO 25239-4:2020)
Soudage par friction-malaxage - Aluminium - Partie 4: Descriptif et qualification des
modes opératoires de soudage (ISO 25239-4:2020)
Ta slovenski standard je istoveten z: EN ISO 25239-4:2020
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
SIST EN ISO 25239-4:2020 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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SIST EN ISO 25239-4:2020
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SIST EN ISO 25239-4:2020
EN ISO 25239-4
EUROPEAN STANDARD
NORME EUROPÉENNE
July 2020
EUROPÄISCHE NORM
ICS 25.160.10 Supersedes EN ISO 25239-4:2011
English Version
Friction stir welding - Aluminium - Part 4: Specification
and qualification of welding procedures (ISO 25239-
4:2020)
Soudage par friction-malaxage - Aluminium - Partie 4: Rührreibschweißen - Aluminium - Teil 4: Anforderung
Descriptif et qualification des modes opératoires de und Qualifizierung von Schweißverfahren (ISO 25239-
soudage (ISO 25239-4:2020) 4:2020)
This European Standard was approved by CEN on 12 July 2020.
CEN 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. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway,
Poland, Portugal, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2020 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 25239-4:2020 E
worldwide for CEN national Members.
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SIST EN ISO 25239-4:2020
EN ISO 25239-4:2020 (E)
Contents Page
European foreword . 3
2
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SIST EN ISO 25239-4:2020
EN ISO 25239-4:2020 (E)
European foreword
This document (EN ISO 25239-4:2020) has been prepared by Technical Committee ISO/TC IIW
"International Institute of Welding" in collaboration with Technical Committee CEN/TC 121 “Welding
and allied processes” the secretariat of which is held by DIN.
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 January 2021, and conflicting national standards shall
be withdrawn at the latest by January 2021.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN ISO 25239-4:2011.
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, France, Germany, Greece, Hungary, Iceland,
Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of
North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the
United Kingdom.
Endorsement notice
The text of ISO 25239-4:2020 has been approved by CEN as EN ISO 25239-4:2020 without any
modification.
3
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SIST EN ISO 25239-4:2020
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SIST EN ISO 25239-4:2020
INTERNATIONAL ISO
STANDARD 25239-4
Second edition
2020-06
Friction stir welding — Aluminium —
Part 4:
Specification and qualification of
welding procedures
Soudage par friction-malaxage — Aluminium —
Partie 4: Descriptif et qualification des modes opératoires de soudage
Reference number
ISO 25239-4:2020(E)
©
ISO 2020
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2020
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
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Website: www.iso.org
Published in Switzerland
ii © ISO 2020 – All rights reserved
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 1
4 Development and qualification of welding procedures . 2
4.1 General . 2
4.2 Technical content of a pWPS . 2
5 Qualification based on a welding procedure test . 4
5.1 General . 4
5.2 Test pieces . 4
5.2.1 Shape and dimensions of test pieces . 4
5.2.2 Welding of test pieces . 6
5.3 Examination and testing of test pieces . 6
5.3.1 Extent of testing . 6
5.3.2 Visual testing and acceptance levels . 7
5.3.3 Destructive tests . 7
5.3.4 Re-testing .12
5.4 Range of qualification .12
5.4.1 General.12
5.4.2 Related to the fabricator.12
5.4.3 Other variables .12
5.5 Welding procedure qualification record .12
6 Qualification based on pre-production welding test .13
6.1 General .13
6.2 Test pieces .13
6.3 Examination and testing of test pieces .13
6.4 Range of qualification .13
6.5 Welding procedure qualification record .13
Annex A (informative) Example of a form for preliminary welding procedure specification
(pWPS) and welding procedure specification (WPS) .14
Annex B (informative) Non-destructive testing .15
Annex C (informative) Hammer S-bend test of lap welds .16
Annex D (informative) Example welding procedure qualification record form (WPQR) .18
Bibliography .22
© ISO 2020 – All rights reserved iii
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/ directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/ patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso .org/
iso/ foreword .html.
This document was prepared by IIW, International Institute of Welding, Commission III, Resistance
Welding, Solid State Welding and Allied Joining Process, in collaboration with the European Committee for
Standardization (CEN) Technical Committee CEN/TC 121, Welding and allied processes, in accordance
with the Agreement on technical cooperation between ISO and CEN (Vienna Agreement).
This second edition cancels and replaces the first edition (ISO 25239-4:2011), which has been
technically revised.
The main changes compared to the previous edition are as follows:
— alternative process control methods (e.g. temperature control) have been included;
— the wording of the paragraph on thermal management and heat treatments has been improved;
— the definition for the extraction of test specimens has been modified for all test pieces and the
figures have been revised accordingly;
— the requirement for testing transverse test specimens with as welded surfaces has been deleted;
— in Table 3, a new requirement on the minimum joint efficiency has been added for heat treatable
alloys below 5 mm;
— the pWPS is now to be qualified in accordance with the defined acceptance levels included in
ISO 25239-5;
— acceptance levels have been included in the WPQR form in Annex D.
A list of all parts in the ISO 25239 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/ members .html.
iv © ISO 2020 – All rights reserved
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Introduction
Welding processes are widely used in the fabrication of engineered structures. During the second half
of the twentieth century, fusion welding processes, wherein fusion is obtained by the melting of parent
material and usually a filler metal, dominated the welding of large structures. In 1991, Wayne Thomas
at TWI invented friction stir welding (FSW), which is carried out entirely in the solid phase (no melting).
The increasing use of FSW has created the need for this document in order to ensure that welding is
carried out in the most effective way and that appropriate control is exercised over all aspects of the
operation. This document focuses on the FSW of aluminium because, at the time of publication, the
majority of commercial applications for FSW involved aluminium. Examples include railway carriages,
consumer products, food processing equipment, aerospace structures, and marine vessels.
© ISO 2020 – All rights reserved v
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SIST EN ISO 25239-4:2020
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SIST EN ISO 25239-4:2020
INTERNATIONAL STANDARD ISO 25239-4:2020(E)
Friction stir welding — Aluminium —
Part 4:
Specification and qualification of welding procedures
1 Scope
This document specifies the requirements for the specification and qualification of welding procedures
for the friction stir welding (FSW) of aluminium.
In this document, the term “aluminium” refers to aluminium and its alloys.
This document does not apply to friction stir spot welding which is covered by the ISO 18785 series.
NOTE Service requirements, materials or manufacturing conditions can require more comprehensive
testing than is specified in this document.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 4136, Destructive tests on welds in metallic materials — Transverse tensile test
ISO 5173, Destructive tests on welds in metallic materials — Bend tests
ISO 9017, Destructive tests on welds in metallic materials — Fracture test
ISO 15607:2019, Specification and qualification of welding procedures for metallic materials — General rules
ISO 17637, Non-destructive testing of welds — Visual testing of fusion-welded joints
ISO 17639, Destructive tests on welds in metallic materials — Macroscopic and microscopic examination
of welds
ISO 25239-1, Friction stir welding — Aluminium — Part 1: Vocabulary
ISO 25239-5:2020, Friction stir welding — Aluminium — Part 5: Quality and inspection requirements
ISO/TR 25901 (all parts), Welding and allied processes — Vocabulary
ISO 80000-1:2009, Quantities and units — Part 1: General
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 25239-1 and
ISO/TR 25901 (all parts) apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at http:// www .electropedia .org/
© ISO 2020 – All rights reserved 1
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
4 Development and qualification of welding procedures
4.1 General
Qualification of welding procedures shall be performed prior to production welding.
The abbreviations listed in ISO 15607:2019, Table 1, shall apply.
The fabricator shall prepare a preliminary welding procedure specification (pWPS) and shall ensure
that it is applicable for production using experience from previous production jobs and the general fund
of knowledge of welding technology. The pWPS shall be prepared with the aim of achieving the required
quality acceptance levels specified in ISO 25239-5:2020, Annex A.
A pWPS shall be used as the basis for the establishment of a welding procedure qualification record
(WPQR). The pWPS shall be tested in accordance with one of the methods listed in Clause 5 (welding
procedure test) or Clause 6 (pre-production welding test). Clause 5 shall be used when the production
part or joint geometry is accurately represented by a standardized test piece or pieces, as shown in 5.2.
Clause 6 shall be used when the production part or joint geometry is not accurately represented by the
standardized test pieces, as shown in 5.2. The information required in a pWPS is given in 4.2.
For some applications, it can be necessary to supplement or reduce the content of the pWPS given in 4.2.
A welding procedure specification (WPS) covers a certain range of parent material thicknesses as well
as a range of aluminium alloys.
Ranges and tolerances in accordance with the relevant International Standard (see Clause 2) and the
fabricator's experience shall be specified when appropriate.
An example of a pWPS form for force and position controlled friction stir welding is shown in Annex A.
Alternative process control methods can be used such as temperature control. Essential variables of
the alternative process control method need to be documented in the pWPS.
4.2 Technical content of a pWPS
The following information, as a minimum, shall be included in a pWPS:
a) fabricator information:
— identification of the fabricator;
— identification of the pWPS;
b) parent material type(s), temper(s), and reference standard(s);
c) parent material dimensions:
— thickness of the members comprising the welded joint;
— outside diameter of tube;
d) equipment identification:
— model;
— serial number;
— equipment fabricator;
e) tool identification:
— material;
2 © ISO 2020 – All rights reserved
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
— drawing or drawing number;
f) clamping arrangement:
— method and type of jigging, fixtures, rollers, and backing (dimensions and material);
— tack welding process and conditions, when required;
— the pWPS shall indicate any required tack welding or prohibited tack welding;
— assembly requirements (i.e. welding gap, misalignment);
g) joint design:
— sketch of the welded joint design and dimensions;
— joint configuration;
— weld run sequence and direction;
— run-on and run-off plates, material type, reference standard, dimensions and method of
attachment (if required);
— placement of exit hole;
h) joint preparation and cleaning methods;
i) welding details:
— method (basic, stationary shoulder, bobbin tool, etc.);
— tool motion (e.g. rotation in either the clockwise or anticlockwise direction, rotation speed
including downward and upward motion);
— tool position (e.g. heel plunge depth) or axial force, as applicable;
— tool cooling (internal, external, cooling medium), if applicable;
— tilt angle;
— side tilt angle, lateral offset;
— dwell time at start of weld;
— dwell time at end of weld;
— weld overlap area (WOA) for a butt joint or lap joint in tube;
— lap joint: advancing or retreating side near the upper sheet edge, direction of welding, depth of
probe penetration in lower sheet;
j) welding speed:
— welding speed, including details of any changes during welding;
— ramp-up/ramp-down or upslope/downslope speeds when applied;
k) welding position: applicable welding positions;
l) thermal management:
— details of any pre-weld heat treatment, if applicable;
© ISO 2020 – All rights reserved 3
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
— details of the preheating temperature, preheat maintenance temperature and/or interpass
temperature for the base materials or the friction stir welding tool, if applicable (use of ISO 13916
is recommended);
— details of any postweld heat treatment (e.g. solution heat treatment, ageing, stress relieving), if
applicable;
— details of any methods for managing the cooling rates (e.g. gas flows, liquid environments)
applied prior, during or after welding, if applicable;
m) postweld (mechanical) processing: methods to correct distortion and straighten parts, removal of
toe flash or any other postweld processing of the weldment.
5 Qualification based on a welding procedure test
5.1 General
The preparation, welding and testing of test pieces shall be in accordance with 5.2 and 5.3.
Fulfilment of the requirements of this document can also serve to qualify the welding operator
(see ISO 25239-3).
5.2 Test pieces
5.2.1 Shape and dimensions of test pieces
5.2.1.1 General
The length or number of test pieces shall be sufficient to allow all required tests to be performed.
Test pieces longer than the minimum size may be used to allow for the provision of extra specimens, for
re-testing specimens or both (see 5.3.4).
The rolling direction or extrusion direction shall be marked on the test piece.
To produce a butt joint in flat material, the test piece shall be prepared in accordance with Figure 1. The
length of the test piece should allow a weld length of at least 500 mm.
4 © ISO 2020 – All rights reserved
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Key
b width of components
l length of components
t material thickness
a
Joint preparation and fit-up, as specified in the pWPS.
Figure 1 — Test piece for a butt joint in sheet
5.2.1.2 Butt joint in tube
The test piece shall be prepared in accordance with Figure 2.
Key
D outside diameter of tube
l length of components
t material thickness
a
Joint preparation and fit-up, as specified in the pWPS.
Figure 2 — Test piece for a butt joint in tube
5.2.1.3 Lap joint
The test piece shall be prepared in accordance with Figure 3.
The weld may be either partial or full penetration through all the sheets.
© ISO 2020 – All rights reserved 5
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Key
1 weld
b edge to weld centreline distance of upper sheet, as specified in the pWPS
1
b edge to weld centreline distance of lower sheet, as specified in the pWPS
2
b distance between weld centre and edge of test piece
3
l length of components
t parent material thickness of upper sheet
1
t parent material thickness of lower sheet
2
Figure 3 — Test piece for a lap joint
5.2.2 Welding of test pieces
The test pieces shall be welded in accordance with the pWPS. If tack welds are to be consumed during
friction stir welding of the production joint, then they shall be included in the test specimens. The
location of tack welds shall be clearly marked on the test piece. Samples should be assessed from both
tacked and un-tacked weld areas.
Welding of the test pieces shall be witnessed by an examiner.
5.3 Examination and testing of test pieces
5.3.1 Extent of testing
Testing includes both non-destructive testing (NDT) and destructive testing. Testing shall be
performed in accordance with the requirements of Table 1 or Table 2. Annex B provides additional
information on NDT.
Examination of the test results shall be verified by an examiner.
6 © ISO 2020 – All rights reserved
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SIST EN ISO 25239-4:2020
ISO 25239-4:2020(E)
Table 1 — Examination and testing of the test pieces for butt joints (Figure 1, Figure 2)
Type of examination and testing Extent of examination and testing
a
Visual testing 100 %
b
Transverse tensile test Two test specimens
Transverse bend test for wrought materials Two root test specimens
(in accordance with 5.3.3.4)
Fracture test for cast materials or wrought/cast combinations Two face test specimens
(in accordance with ISO 9017)
Macroscopic examination One test specimen
d
Additional tests (e.g. non-destructive) If required
a
Discarded areas shall not be considered during testing, as shown in Figure 4.
b
For a butt joint in tube, at least one transverse tensile test specimen should be taken from the WOA, if possible.
c
For material over 12 mm in thickness, four transverse side-bend test specimens can be substituted for the two root and
two face-bend test specimens. One longitudinal face-bend test specimen and one longitudinal root-bend test specimen can
be substituted for the four transverse-bend test specimens.
d
Additional tests shall be carried out in accordance with the relevant requirements of the design specification.
Table 2 — Examination and testing of the test pieces for lap joints (Figure 3)
Type of examination and testing Extent of examination and testing
a
Visual testing 100 %
Macroscopic examination Two test specimens
Additional tests (e.g. peel test, shear test, hammer S-bend test,
If required
b
non-destructive test)
a
Discarded areas shall not be considered during testing, as shown in Figure 6.
b
Additional tests shall be carried out in accordance with the relevant requirements of the design specification.
Information on the hammer S-bend test is given in Annex C.
Examination and testing of test pieces including tack welds or start/end areas of a butt joint in tube
shall be in accordance with the design specification.
Specific service, material or manufacturing conditions can require more comprehensive testing in
order to obtain additional test data.
5.3.2 Visual testing and acceptance levels
The test pieces shall be visually tested in accordance with ISO 17637 prior to extracting the test
specimens. The exten
...
SLOVENSKI STANDARD
oSIST prEN ISO 25239-4:2019
01-julij-2019
Varjenje z gnetenjem - Aluminij - 4. del: Specifikacija in kvalifikacija varilnih
postopkov (ISO/DIS 25239-4:2019)
Friction stir welding - Aluminium - Part 4: Specification and qualification of welding
procedures (ISO/DIS 25239-4:2019)
Rührreibschweißen - Aluminium - Teil 4: Anforderung und Qualifizierung von
Schweißverfahren (ISO/DIS 25239-4:2019)
Soudage par friction-malaxage - Aluminium - Partie 4: Descriptif et qualification des
modes opératoires de soudage (ISO/DIS 25239-4:2019)
Ta slovenski standard je istoveten z: prEN ISO 25239-4
ICS:
25.160.10 Varilni postopki in varjenje Welding processes
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
oSIST prEN ISO 25239-4:2019 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
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oSIST prEN ISO 25239-4:2019
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oSIST prEN ISO 25239-4:2019
DRAFT INTERNATIONAL STANDARD
ISO/DIS 25239-4
IIW Secretariat: ISO secretariat
Voting begins on: Voting terminates on:
2019-05-22 2019-08-14
Friction stir welding — Aluminium —
Part 4:
Specification and qualification of welding procedures
Soudage par friction-malaxage — Aluminium —
Partie 4: Descriptif et qualification des modes opératoires de soudage
ICS: 25.160.10
Member bodies are requested to consult relevant national interests in ISO/TC
44/SC 10 before casting their ballot to the e-Balloting application.
This document is circulated as received from the committee secretariat.
ISO/CEN PARALLEL PROCESSING
THIS DOCUMENT IS A DRAFT CIRCULATED
FOR COMMENT AND APPROVAL. IT IS
THEREFORE SUBJECT TO CHANGE AND MAY
This draft International Standard is submitted to all ISO member bodies for
NOT BE REFERRED TO AS AN INTERNATIONAL
voting, as a standard prepared by an international standardizing body in
STANDARD UNTIL PUBLISHED AS SUCH.
accordance with Council Resolution 42/1999. The proposer, the International
IN ADDITION TO THEIR EVALUATION AS
Institute of Welding (IIW), has been recognized by the ISO Council as an
BEING ACCEPTABLE FOR INDUSTRIAL,
TECHNOLOGICAL, COMMERCIAL AND
international standardizing body for the purpose of Council Resolution
USER PURPOSES, DRAFT INTERNATIONAL
42/1999.
STANDARDS MAY ON OCCASION HAVE TO
BE CONSIDERED IN THE LIGHT OF THEIR
POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN
Reference number
NATIONAL REGULATIONS.
ISO/DIS 25239-4:2019(E)
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. ISO 2019
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oSIST prEN ISO 25239-4:2019
ISO/DIS 25239-4:2019(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2019
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
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oSIST prEN ISO 25239-4:2019
ISO/DIS 25239-4:2019(E)
Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Symbols and abbreviated terms . 2
5 Development and qualification of welding procedures . 2
5.1 General . 2
5.2 Technical content of a pWPS . 2
5.2.1 General. 2
5.2.2 Fabricator information . 3
5.2.3 Parent material type(s), temper(s), and reference standard(s) . 3
5.2.4 Parent material dimensions . 3
5.2.5 Equipment identification . 3
5.2.6 Tool identification . 3
5.2.7 Clamping arrangement . 3
5.2.8 Joint design . 3
5.2.9 Joint preparation and cleaning methods . 3
5.2.10 Welding details . 3
5.2.11 Welding speed . 4
5.2.12 Welding position . 4
5.2.13 Thermal management . 4
5.2.14 Postweld (mechanical) processing . 4
6 Qualification based on a welding procedure test . 4
6.1 General . 4
6.2 Test pieces . 4
6.2.1 Shape and dimensions of test pieces . 4
6.2.2 Welding of test pieces . 6
6.3 Examination and testing of test pieces . 6
6.3.1 Extent of testing . 6
6.3.2 Visual testing and acceptance levels . 7
6.3.3 Destructive tests . 7
6.3.4 Re-testing .12
6.4 Range of qualification .12
6.4.1 General.12
6.4.2 Related to the fabricator.12
6.4.3 Other variables .12
6.5 Welding procedure qualification record .12
7 Qualification based on pre-production welding test .13
7.1 General .13
7.2 Test pieces .13
7.3 Examination and testing of test pieces .13
7.4 Range of qualification .13
7.5 Welding procedure qualification record .13
Annex A (informative) Form for preliminary welding procedure specification (pWPS) and
welding procedure specification (WPS) .14
Annex B (informative) Non-destructive testing .15
Annex C (informative) Hammer S-bend test of lap welds .16
Annex D (informative) Welding procedure qualification record form (WPQR) .18
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oSIST prEN ISO 25239-4:2019
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Bibliography .23
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oSIST prEN ISO 25239-4:2019
ISO/DIS 25239-4:2019(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www .iso
.org/iso/foreword .html.
This document was prepared by IIW, International Institute of Welding, Commission III, Resistance
Welding, Solid State Welding and Allied Joining Process.
This second edition cancels and replaces the first edition (ISO 25239-4:2011), which has been
technically revised.
The main changes compared to the previous edition are as follows:
— to be entered closer to publication
A list of all parts in the ISO 25239- series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
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oSIST prEN ISO 25239-4:2019
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Introduction
Welding processes are widely used in the fabrication of engineered structures. During the second half
of the twentieth century, fusion welding processes, wherein fusion is obtained by the melting of parent
material and usually a filler metal, dominated the welding of large structures. Then, in 1991, Wayne
Thomas at TWI invented friction stir welding (FSW), which is carried out entirely in the solid phase (no
melting).
The increasing use of FSW has created the need for this document in order to ensure that welding is
carried out in the most effective way and that appropriate control is exercised over all aspects of the
operation. This document focuses on the FSW of aluminium because, at the time of publication, the
majority of commercial applications for FSW involved aluminium. Examples include railway carriages,
consumer products, food processing equipment, aerospace structures, and marine vessels.
The parts of this document are:
Part 1: Vocabulary, defines terms specific to FSW.
Part 2: Design of weld joints, specifies design requirements for friction stir weld joints in aluminium.
Part 3: Qualification of welding operators, specifies requirements for the qualification of a welding
operator for the FSW of aluminium.
Part 4: Specification and qualification of welding procedures, specifies requirements for the specification
and qualification of welding procedures for the FSW of aluminium. A welding procedure specification
(WPS) is needed to provide a basis for planning welding operations and for quality control during
welding. Welding is considered a special process in the terminology of standards for quality systems.
Standards for quality systems usually require that special processes be carried out in accordance with
written procedure specifications. Metallurgical deviations constitute a special problem. Because non-
destructive testing of the mechanical properties is impossible at the present level of technology, this
has resulted in the establishment of a set of rules for qualification of the welding procedure prior to the
release of the WPS to actual production. ISO 25239-4 defines these rules.
Part 5: Quality and inspection requirements, specifies a method for determining the capability of a
fabricator to use the FSW process for the production of aluminium products of the specified quality. It
defines specific quality requirements but does not assign those requirements to any specific product
group. To be effective, welded structures should be free from serious problems in production and
in service. To achieve that goal, it is necessary to provide controls from the design phase through
material selection, fabrication, and inspection. For example, poor design can create serious and costly
difficulties in the workshop, on site, or in service. Incorrect material selection can result in welding
problems, such as cracking. Welding procedures have to be correctly formulated and qualified to avoid
imperfections. To ensure the fabrication of a quality product, management should understand the
sources of potential trouble and introduce appropriate quality and inspection procedures. Supervision
should be implemented to ensure that the specified quality is achieved.
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oSIST prEN ISO 25239-4:2019
DRAFT INTERNATIONAL STANDARD ISO/DIS 25239-4:2019(E)
Friction stir welding — Aluminium —
Part 4:
Specification and qualification of welding procedures
1 Scope
This part of ISO 25239 specifies the requirements for the specification and qualification of welding
procedures for the friction stir welding (FSW) of aluminium. In this document, the term “aluminium”
refers to aluminium and its alloys.
This document does not apply to friction stir spot welding which is covered by the ISO 18785- series.
NOTE Service requirements, materials or manufacturing conditions can require more comprehensive
testing than is specified in this document.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 209, Aluminium and aluminium alloys — Chemical composition
ISO 857-1, Welding and allied processes — Vocabulary — Part 1: Metal welding processes
ISO 3134 (all parts), Light metals and their alloys — Terms and definitions
ISO 4136, Destructive tests on welds in metallic materials — Transverse tensile test
ISO 5173, Destructive tests on welds in metallic materials — Bend tests
ISO 6520-1, Welding and allied processes — Classification of geometric imperfections in metallic
materials — Part 1: Fusion welding
ISO 9017, Destructive tests on welds in metallic materials — Fracture test
ISO 10042, Welding — Arc-welded joints in aluminium and its alloys — Quality levels for imperfections
ISO 15607:2003, Specification and qualification of welding procedures for metallic materials — General rules
ISO 15613, Specification and qualification of welding procedures for metallic materials — Qualification
based on pre-production welding test
ISO 15614-2, Specification and qualification of welding procedures for metallic materials — Welding
procedure test — Part 2: Arc welding of aluminium and its alloys
ISO 17637, Non-destructive testing of welds — Visual testing of fusion-welded joints
ISO 17639, Destructive tests on welds in metallic materials — Macroscopic and microscopic examination
of welds
ISO/TR 17671-1, Welding — Recommendations for welding of metallic materials — Part 1: General
guidance for arc welding
ISO 25239-1, Friction stir welding — Aluminium — Part 1: Vocabulary
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oSIST prEN ISO 25239-4:2019
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ISO 25239-5:2011, Friction stir welding — Aluminium — Part 5: Quality and inspection requirements
ISO 80000-1:2009, Quantities and units — Part 1: General
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 209, ISO 857-1, ISO 3134,
ISO 6520-1, ISO 10042, ISO 15607, ISO 15613, ISO 15614-2, ISO/TR 17671-1, and ISO 25239-1 apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
4 Symbols and abbreviated terms
For the purposes of qualification of welding procedures, the abbreviations listed in ISO 15607:2003,
Table 1, apply.
5 Development and qualification of welding procedures
5.1 General
Qualification of welding procedures shall be performed prior to production welding.
The fabricator shall prepare a preliminary welding procedure specification (pWPS) and shall ensure
that it is applicable for production using experience from previous production jobs and the general fund
of knowledge of welding technology.
A pWPS shall be used as the basis for the establishment of a welding procedure qualification record
(WPQR). The pWPS shall be tested in accordance with one of the methods listed in Clause 6 (welding
procedure test) or Clause 7 (pre-production welding test). Clause 6 shall be used when the production
part or joint geometry is accurately represented by a standardized test piece or pieces, as shown in 6.2.
Clause 7 shall be used when the production part or joint geometry is not accurately represented by the
standardized test pieces, as shown in 6.2. The information required in a pWPS is given in 5.2.
NOTE For some applications, it can be necessary to supplement or reduce the content of the pWPS given in 5.2.
A welding procedure specification (WPS) covers a certain range of parent material thicknesses as well
as a range of aluminium alloys.
Ranges and tolerances in accordance with the relevant International Standard (see Clause 2) and the
fabricator's experience shall be specified when appropriate.
An example of a pWPS form for force and position controlled friction stir welding is shown in Annex A.
Alternative process control methods can be used such as temperature control. Essential variables of
the alternative process control method need to be documented in the pWPS.
5.2 Technical content of a pWPS
5.2.1 General
The following information, as a minimum, shall be included in a pWPS.
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5.2.2 Fabricator information
— identification of the fabricator
— identification of the pWPS
5.2.3 Parent material type(s), temper(s), and reference standard(s)
5.2.4 Parent material dimensions
— thickness of the members comprising the welded joint
— outside diameter of tube
5.2.5 Equipment identification
— model
— serial number
— Equipment manufacturer
5.2.6 Tool identification
— material
— drawing or drawing number
5.2.7 Clamping arrangement
— method and type of jigging, fixtures, rollers, and backing (dimensions and material)
— tack welding process and conditions, when required — the pWPS shall indicate any required tack
welding or prohibited tack welding
— assembly requirements (i.e. welding gap, misalignment)
5.2.8 Joint design
— sketch of the welded joint design and dimensions
— weld run sequence and direction
— run-on and run-off plates, material type, reference standard, dimensions and method of attachment
(if required)
— placement of exit hole
5.2.9 Joint preparation and cleaning methods
5.2.10 Welding details
— tool motion (e.g. rotation in either the clockwise or anticlockwise direction, rotation speed including
downward and upward motion)
— tool position (e.g. heel plunge depth) or axial force, as applicable
— tool cooling (internal, external, cooling medium), if applicable
— tilt angle
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oSIST prEN ISO 25239-4:2019
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— side tilt angle, lateral offset
— dwell time at start of weld
— dwell time at end of weld
— joint configuration
— weld overlap area (WOA) for a butt joint or lap joint in tube
— lap joint: advancing or retreating side near the upper sheet edge, direction of welding, depth of
probe penetration in lower sheet
5.2.11 Welding speed
— welding speed, including details of any changes during welding
— ramp-up/ramp-down or upslope/downslope speeds when applied
5.2.12 Welding position
— applicable welding positions
5.2.13 Thermal management
— details of any pre-weld heat treatment, if applicable
— details of the preheating temperature, preheat maintenance temperature and/or interpass
temperature for the base materials or the friction stir welding tool, if applicable (use of ISO 13916 is
recommended)
— details of any postweld heat treatment (solution heat treatment, ageing, stress relieving…), if
applicable
— details of any methods for managing the cooling rates (gas flows, liquid environments…) applied
prior, during or after welding, if applicable
5.2.14 Postweld (mechanical) processing
— - methods to correct distortion and straighten parts, removal of toe flash or any other postweld
processing of the weldment
6 Qualification based on a welding procedure test
6.1 General
The preparation, welding, and testing of test pieces shall be in accordance with 6.2 and 6.3.
Fulfilment of the requirements of this part of ISO 25239 can also serve to qualify the welding operator
(see ISO 25239-3).
6.2 Test pieces
6.2.1 Shape and dimensions of test pieces
6.2.1.1 General
The length or number of test pieces shall be sufficient to allow all required tests to be performed.
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Test pieces longer than the minimum size may be used to allow for the provision of extra specimens, for
re-testing specimens or both (see 6.3.4).
The rolling direction or extrusion direction shall be marked on the test piece.
To produce a butt joint in flat material, the test piece shall be prepared in accordance with Figure 1. The
length of the test piece should allow a weld length of at least 500mm.
Dimensions in millimetres
Key
b width of components
l length of components
t material thickness
a
Joint preparation and fit-up, as specified in the pWPS.
Figure 1 — Test piece for a butt joint in sheet
6.2.1.2 Butt joint in tube
The test piece shall be prepared in accordance with Figure 2.
Dimensions in millimetres
Key
D outside diameter of tube
l length of components
t material thickness
a
Joint preparation and fit-up, as specified in the pWPS.
Figure 2 — Test piece for a butt joint in tube
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6.2.1.3 Lap joint
The test piece shall be prepared in accordance with Figure 3.
The weld may be either partial or full penetration through all the sheets.
Dimensions in millimetres
Key
1 weld
b edge to weld centreline distance of upper sheet, as specified in the pWPS
1
b edge to weld centreline distance of lower sheet, as specified in the pWPS
2
b distance between weld centre and edge of test piece
3
l length of components
t parent material thickness of upper sheet
1
t parent material thickness of lower sheet
2
Figure 3 — Test piece for a lap joint
6.2.2 Welding of test pieces
The test pieces shall be welded in accordance with the pWPS. If tack welds are to be consumed during
friction stir welding of the production joint, then they shall be included in the test specimens. The
location of tack welds shall be clearly marked on the test piece. Samples should be assessed from both
tacked and un-tacked weld areas.
Welding of the test pieces shall be witnessed by an examiner.
6.3 Examination and testing of test pieces
6.3.1 Extent of testing
Testing includes both non-destructive testing (NDT) and destructive testing. Tes
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