WELD CERTIFICATION PLAN FOR THE ALPHA MAGNETIC SPECTROMETER - 02
(AMS-02) SUPER FLUID HELIUM TANK AND CRYOGENIC SYSTEM

+-----------------------------------------------------------------------+
| Space and Life Sciences Directorate                                   |
|                                                                       |
| Mission Planning and Integration Office                               |
|                                                                       |
| July, 2002                                                            |
|                                                                       |
| ![](media/image1.wmf){width="0.9576388888888889in"                    |
| height="0.7909722222222222in"}                                        |
|                                                                       |
| National Aeronautics and                                              |
|                                                                       |
| Space Administration                                                  |
|                                                                       |
| **Lyndon B. Johnson Space Center**                                    |
|                                                                       |
| Houston, Texas                                                        |
+-----------------------------------------------------------------------+

**WELD CERTIFICATION PLAN FOR THE**

ALPHA MAGNETIC SPECTROMETER -- 02 (AMS-02) SUPER FLUID HELIUM TANK AND
CRYOGENIC SYSTEM

**Prepared By:**

> DAN RYBICKI
>
> AMS-02 WELD CERTIFICATION LEAD ENGINEER, LMSO

**Reviewed By:**

> SID McCLURE
>
> AMS-02 WELD SPECIALIST, S. R. McClure & Sons Welding Specialists
>
> ROSS A. HAROLD
>
> AMS-02 MECHANICAL DESIGN LEAD ENGINEER, LMSO
>
> TRENT MARTIN
>
> AMS-02 DEPUTY PROJ. MGR, LMSO
>
> GLENN ECORD
>
> JSC/ES4, MATERIALS AND PROCESS BRANCH, NASA

**WELD CERTIFICATION PLAN FOR THE**

ALPHA MAGNETIC SPECTROMETER -- 02 (AMS-02) SUPER FLUID HELIUM TANK AND
CRYOGENIC SYSTEM

**Approved By:**

> KEN BOLLWEG
>
> AMS-02 PROJECT MANAGER, LMSO
>
> JAMES R. BATES
>
> AMS-02 MISSION MANAGER,
>
> MISSION PLANNING & INTEGRATION OFFICE, NASA/JSC
>
> HANS BIERI
>
> HANS BIERI ENGINEERING
>
> JOHN ROSS
>
> SPACE CRYOMAGNETICS LTD.
>
> PROF. HANS HOFER
>
> ETH, ZURICH

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TABLE OF CONTENTS

[Section]{.underline} [Page]{.underline}

[**ACRONYMS AND ABBREVIATIONS** vii](#acronyms-and-abbreviations)

[1.0 SCOPE 1](#scope)

[2.0 GOVERNING REQUIREMENTS 1](#governing-requirements)

[3.0 APPLICABILITY 1](#applicability)

[4.0 BASE MATERIALS 1](#base-materials)

[5.0 FILLER METAL 1](#filler-metal)

[6.0 TERMS AND DEFINITIONS 2](#terms-and-definitions)

[7.0 TESTING 2](#testing)

[8.0 AUTOMATED WELDING EQUIPMENT 2](#automated-welding-equipment)

[9.0 MANUAL WELDING EQUIPMENT CALIBRATION
2](#manual-welding-equipment-calibration)

[10.0 WELDER AND WELDING OPERATOR PERFORMANCE QUALIFICATION
3](#welder-and-welding-operator-performance-qualification)

[11.0 WELDING PROCEDURE QUALIFICATION
3](#welding-procedure-qualification)

[12.0 DOCUMENTATION 3](#documentation)

[13.0 REQUIRED TESTS 4](#required-tests)

[14.0 TEST PLATE CONFIGURATION 4](#test-plate-configuration)

[15.0 TEST SPECIMEN QUANTITIES 7](#test-specimen-quantities)

[16.0 TEST PLATE LAYOUT 7](#test-plate-layout)

list of tables

**[Page]{.underline}**

[Table 13-1 Required Weld Tests to Support SFHe Tank Weld Qualification
on 5083 Al and Pure Al (Tubing)
5](#table-13-1-required-weld-tests-to-support-sfhe-tank-weld-qualification-on-5083-al-and-pure-al-tubing)

[Table 13-1 Required Weld Tests to Support SFHe Tank Weld Qualification
on 300 Series CRES
6](#table-13-1-required-weld-tests-to-support-sfhe-tank-weld-qualification-on-300-series-cres)

[Table 15-1 Required Quantities of Test Specimens From Each Test Plate
7](#table-15-1-required-quantities-of-test-specimens-from-each-test-plate)

# ACRONYMS AND ABBREVIATIONS

AMS Alpha Magnetic Spectrometer

AWS American Welding Society

JSC Lyndon B. Johnson Space Center

LMSO Lockheed Martin Space Operations

MSFC Marshall Space Flight Center

NASA National Aeronautics And Space Administration

NDE Non-destructive Evaluation

PQR Procedure Qualification Records

SOP Standard Operating Procedure

SPEC Specification

STA Structural Test Article

STD Standards

TBD To Be Determined

WOPQR Welding Operators Performance Qualification Records

WPQR Welder Performance Qualification Records

## 1.0 SCOPE

The plan provided herein encompasses the requirements for qualifying all
welding that is performed on hardware for the Super Fluid Helium Tank
and associated cryogenic systems that support the AMS payload and
payload qualification and/or replica ground test units (e.g. Structural
Test Article (STA)).

## 2.0 GOVERNING REQUIREMENTS

The requirements set forth in MSFC-SPEC-504C and MSFC-SPEC-560A for
aluminum and steel alloys respectively, are the referenced documents
that govern the stated requirements in this document. This document is
written so as to be an overview of these requirements. Therefore, the
MSFC and other underlying documents should be referenced when necessary
for clarification of the details of these requirements. Where a conflict
is apparent, the applicable MSFC specification shall preside.

## 3.0 APPLICABILITY

These requirements cover all fusion welds made by arc fusion processes.
Coverage includes any weld made by manual, semiautomatic, automatic, or
robotic applications. All welds shall be qualified to requirements
representing MSFC Class I specifications.

## 4.0 BASE MATERIALS

These requirements cover aluminum alloys and steels that are proposed
for the AMS cryogenic systems. All base materials used for qualification
weld testing shall be procured to the same specifications as the
material used for the flight hardware including trace ability
requirements.

## 5.0 FILLER METAL 

All filler metals and electrodes used for qualification testing shall be
procured and controlled per NASA/JSC SOP-004.5.

## 

## 6.0 TERMS AND DEFINITIONS

Where specific welding terminology and applicable definitions are used,
they shall be per the American Welding Society (AWS) A3.0 standard
(latest version); "Standard Welding Terms and Definitions." Where
specific welding symbols are used, they shall be per the AWS A2.4
standard (latest version); "Standard Symbols for Welding, Brazing, and
Nondestructive Examination."

## 7.0 TESTING

All testing shall be performed in accordance with AWS B4.0; Standard
Methods for Mechanical Testing of Welds." Specialized testing not
covered by the aforementioned shall be performed per TBD. Number and
types of tests shall be per the applicable paragraphs listed herein.
Except for bend tests, all non-destructive evaluation (NDE) and
mechanical testing shall be performed on the samples with the weld in
the final condition it is expected to be in on the production hardware
(i.e., weld reinforcement left intact, weld reinforcement shaved flush,
weld size, etc.).

## 8.0 AUTOMATED WELDING EQUIPMENT 

Automated welding equipment (automatic and semi-automatic) shall have
valid and current calibrations on all dials, meters, direct reading
electrical control circuits, and recorders that are used to indicate
essential welding parameter settings and/or output. Essential welding
parameters are those process variables that are required to be
controlled during the process within a specific range so as to not
violate the weld qualification. At a minimum, the heat input related
process variables, amperage (current), voltage, and travel speed shall
be considered essential process parameters and therefore shall be
monitored by calibrated instruments. Where welding current is dependent
upon wire feed speed, wire feed speed shall be considered an essential
process parameter and shall be monitored by calibrated instruments.

## 9.0 MANUAL WELDING EQUIPMENT CALIBRATION

Manual welding equipment shall not be required to have calibrated
instrumentation however, reference indicating instrumentation shall be
functional (useful output), in good working order, and the production
ready equipment shall be capable of producing sound welds when used by a
qualified welder performing work to a qualified welding procedure.

## 10.0 WELDER AND WELDING OPERATOR PERFORMANCE QUALIFICATION

Welders and welding operators required to perform production welding
with manual, semiautomatic, and automatic equipment shall be qualified
in accordance with AMS-STD-1595 for the alloy group and filler metal
group applicable to the production welds. In addition, welding operators
shall be qualified on the automatic calibrated production equipment.
Welder and welding operator qualification testing shall be performed
using a qualified welding procedure. However, if during production of a
test plate to qualify a welding procedure, the tests are deemed
acceptable, this shall also qualify the welder or welding operator
within the limits specified by AMS-STD-1595. Wherever practical, it is
recommended that a weld procedure qualification test be used to qualify
a production welder in the expected production orientation (position),
and visa versa (i.e., a welder performance qualification should be used
to qualify a production welding procedure).

## 11.0 WELDING PROCEDURE QUALIFICATION

All welds on production hardware shall be made using a procedure
qualified per AWS B2.1 "Special Test Weldments" (reference Section 3 in
MSFC-SPEC-504C). Special Test Weldments are required to be
representative of the thickness for which the qualification represents,
therefore the test plates shall be produced from the same thickness and
plate orientation as the production hardware is produced from. This
qualification plan takes some exception to this rule by only requiring a
single test plate to cover multiple thickness qualifications, where the
thicknesses are considered to be relatively similar. For multiple pass
weld joints that end up being machined into complex geometries (e.g.,
Helium Vessel Central Ring), testing shall include samples representing
each direction of the thinnest section in each axial direction. As an
alternate approach, full section testing may be performed on the
finished production geometry.

## 12.0 DOCUMENTATION 

Welder Performance Qualification Records (WPQR) and Welding Operators
Performance Qualification Records (WOPQR) shall be documented in a
suitable format and kept on record at the manufacturer until all AMS
flight hardware returns from space. Welding Procedure Qualification
Records (PQR) shall be documented in a suitable format and kept on
record at the manufacturer until all AMS flight hardware returns from
space. All documentation listed above shall also be sent to and
certified by representatives from NASA/LMSO.

## 13.0 REQUIRED TESTS

Table 13-1 outlines the required weld tests to support the Super Fluid
Helium Tank weld qualification on 5083 aluminum and pure aluminum
(tubing).

Table 13-2 outlines the required weld tests to support the Super Fluid
Helium Tank weld qualification on 300 Series CRES.

## 14.0 TEST PLATE CONFIGURATION

AWS B2.1 shall be used as a guideline for test plate minimum size and
configuration for manual weld procedure qualification. To ensure the
validity of the automatic welding procedure qualifications, the test
plate configuration shall be a minimum 2X the length dimension given in
B2.1 and all other dimensions may remain the same. The only exception
will be the 30mm thick qualification test plate. This test plate
configuration shall have the width dimensions adjusted accordingly to
accommodate the higher expected heat inputs required to make this weld
and the potential need for larger than normal tensile specimens to
ensure the validity of the test results.

######### Table 13-1 Required Weld Tests to Support SFHe Tank Weld Qualification on 5083 Al and Pure Al (Tubing)

<table>
<colgroup>
<col style="width: 2%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 8%" />
<col style="width: 11%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 5%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 7%" />
</colgroup>
<tbody>
<tr class="odd">
<td></td>
<td>1</td>
<td>2</td>
<td>3</td>
<td>4</td>
<td>5</td>
<td>6</td>
<td>7</td>
<td>8</td>
<td>9</td>
<td>10</td>
<td>11</td>
<td>12</td>
<td>13</td>
<td>14</td>
<td>15</td>
</tr>
<tr class="even">
<td></td>
<td><strong>THKNS (mm)</strong></td>
<td><strong>THKNS (in)</strong></td>
<td><strong>APPL DRWG</strong></td>
<td><strong>APPL PART NAME</strong></td>
<td><p><strong>WELD</strong></p>
<p><strong>TYPE</strong></p></td>
<td><strong>AUTO WELD</strong></td>
<td><strong>MAN WELD</strong></td>
<td><strong>XRAY</strong></td>
<td><strong>DYE PEN</strong></td>
<td><strong>RT TENSILE</strong></td>
<td><strong>BEND</strong></td>
<td><strong>MACRO</strong></td>
<td><strong>FILLET SHEAR</strong></td>
<td><strong>FRAC TOUGH</strong></td>
<td><strong>CRYO TENSILE</strong></td>
</tr>
<tr class="odd">
<td>A</td>
<td>30</td>
<td>1.170</td>
<td>SCD0905-01</td>
<td>Central Ring</td>
<td>Groove</td>
<td>X</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X*</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="even">
<td>B</td>
<td>3 to 6.3</td>
<td>0.117 to 0.246</td>
<td><p>SCD0905-02 SCD0905-03 and</p>
<p>SCD0905-04 SCD0905-05</p></td>
<td><p>Internal Stiffener Ribs for</p>
<p>Outer/Inner Rings</p></td>
<td>Fillet</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
</tr>
<tr class="odd">
<td>C</td>
<td>4 to 4</td>
<td>0.156 to 0.156</td>
<td>SCD2035</td>
<td>DCLM Transition Socket</td>
<td>Fillet</td>
<td></td>
<td>X</td>
<td></td>
<td>X</td>
<td></td>
<td></td>
<td></td>
<td>X</td>
<td></td>
<td></td>
</tr>
<tr class="even">
<td>D</td>
<td>3 or 4.8</td>
<td><p>0.117</p>
<p>or</p>
<p>0.187</p></td>
<td>SCD0905</td>
<td><p>Welded Socket 20-24 Places and Alum to CRES Trans Sockets and</p>
<p>Thru Tube End Cap to Top/ Bottom Vessel Dish and Burst Thru Disc Port
to Lower End Dish</p></td>
<td>Groove</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="odd">
<td>E</td>
<td>4.65 or 4.8</td>
<td>0.181 or 0.187</td>
<td>SCD0905</td>
<td>Thru Tube End Cap to Top/ Bottom Inner Cyl</td>
<td>Groove</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="even">
<td>F</td>
<td>4</td>
<td>0.156</td>
<td>SCD0905</td>
<td>Thru Tube to Outer Thru Tube End Cap</td>
<td>Groove</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="odd">
<td>G</td>
<td>3</td>
<td>0.117</td>
<td>SCD0905</td>
<td>End Dishes to Upper/Lower Tank Bodies</td>
<td>Groove</td>
<td>X</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="even">
<td>H</td>
<td>4</td>
<td>0.156</td>
<td>SCD0905</td>
<td>Central Ring to Outer Rings</td>
<td>Groove</td>
<td>X</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="odd">
<td>I</td>
<td>6</td>
<td>0.234</td>
<td>SCD0905</td>
<td>Central Ring to Inner Rings</td>
<td>Groove</td>
<td>X</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
<tr class="even">
<td>J</td>
<td>1</td>
<td>0.039</td>
<td>SCD2036</td>
<td>Internal Tubing Arrangement</td>
<td>Groove</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
</tbody>
</table>

\* Full side bends and face/root bends from middle 1/5^th^ of weld
plate.

######### Table 13-1 Required Weld Tests to Support SFHe Tank Weld Qualification on 300 Series CRES

<table>
<colgroup>
<col style="width: 2%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 7%" />
<col style="width: 11%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 5%" />
<col style="width: 4%" />
<col style="width: 7%" />
<col style="width: 5%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 6%" />
<col style="width: 7%" />
</colgroup>
<tbody>
<tr class="odd">
<td></td>
<td>1</td>
<td>2</td>
<td>3</td>
<td>4</td>
<td>5</td>
<td>6</td>
<td>7</td>
<td>8</td>
<td>9</td>
<td>10</td>
<td>11</td>
<td>12</td>
<td>13</td>
<td>14</td>
<td>15</td>
</tr>
<tr class="even">
<td></td>
<td><strong>THKNS (mm)</strong></td>
<td><strong>THKNS (in)</strong></td>
<td><strong>APPL DRWG</strong></td>
<td><strong>PART NAME</strong></td>
<td><p><strong>WELD</strong></p>
<p><strong>TYPE</strong></p></td>
<td><strong>AUTO WELD</strong></td>
<td><strong>MAN WELD</strong></td>
<td><strong>XRAY</strong></td>
<td><strong>DYE PEN</strong></td>
<td><strong>RT TENSILE</strong></td>
<td><strong>BEND</strong></td>
<td><strong>MACRO</strong></td>
<td><strong>FILLET SHEAR</strong></td>
<td><strong>FRAC TOUGH</strong></td>
<td><strong>CRYO TENSILE</strong></td>
</tr>
<tr class="odd">
<td>A</td>
<td>1 or 2</td>
<td><p>0.039</p>
<p>or</p>
<p>0.078</p></td>
<td><p>SCD2032</p>
<p>and</p>
<p>SCD2020</p></td>
<td><p>Pourous Plug Assembly and</p>
<p>Burst Thru Disc Inner Sleeve to Vessel Port Transition Element and
Burst Thru Disc to Inner Sleeve and other similar feed-thru
sections</p></td>
<td>Groove</td>
<td></td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td>X</td>
<td></td>
<td></td>
<td>X</td>
</tr>
</tbody>
</table>

## 15.0 TEST SPECIMEN QUANTITIES

Table 15-1 outlines the required quantities of test specimens to be
taken from each test plate**.**

######### Table 15-1 Required Quantities of Test Specimens From Each Test Plate

  --- -------- -------- -------- ----------- ---------- ----------- ---------- --------- -----------
      1        2        3        4           5          6           7          9         10

      **Weld   **AUTO   **MAN    **RT        **BEND**   **MACRO**   **FILLET   **FRAC    **CRYO
      Type**   WELD**   WELD**   TENSILE**                          SHEAR**    TOUGH**   TENSILE**

  A   Groove   X                 5           4\*\*      2                                2

  B   Groove            X        5           4          2                                2

  C   Fillet   X                                        2           5                    

  D   Fillet            X                               2           5                    
  --- -------- -------- -------- ----------- ---------- ----------- ---------- --------- -----------

\*\* 2 root side and 2 face side bends. Where side bends are used in
place of root/face bends, 4 shall be required.

## 16.0 TEST PLATE LAYOUT

AWS B2.1 shall be used as a guideline for test plate layout. As a
general rule, because multiple types of specimens are to be taken from
each test plate, the specimens should be randomly distributed about the
length of the plate with no one specimen type taken immediately adjacent
to the same specimen type. Specimens shall not be taken within the first
and last 2" of the test plate length, as this area is considered "drop
off" and shall not be subject to the NDE inspection evaluation nor to
the mechanical and metallurgical testing protocol.