Aerospace series Aluminium and aluminium- and magnesium- alloys Technical specification Part 3: Aluminium and aluminium alloy bar and section

AECMA/TC Date: 2010-04 prEN 4400-3 AECMA/TC Secretariat: Aerospace series — Aluminium and aluminium- and magnesium- alloys – Technical specification...
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AECMA/TC Date: 2010-04

prEN 4400-3 AECMA/TC Secretariat:

Aerospace series — Aluminium and aluminium- and magnesium- alloys – Technical specification — Part 3: Aluminium and aluminium alloy bar and section Luft- und Raumfahrt — Aluminium und Aluminium- und Magnesiumlegierungen – Technische Lieferbedingungen — Teil 3: Stangen und Pressprofile aus Aluminium und Aluminiumlegierungen Série aérospatiale — Aluminium et alliages d’ aluminium et magnésium – Spécification technique — Partie 3 : Barres et profilés en aluminium et alliages d’ aluminium

ICS: Descriptors:

Document type: European Standard Document subtype: Document stage: CEN Enquiry Document language: E C:\Documents and Settings\fouried\Local Settings\Temp\EN 4400-3 for review 2010.doc STD Version 2.1a

Page 2 prEN 4400-3:2003 (E)

Contents

Page

0

Introduction ............................................................................................................................................3

1

Scope ......................................................................................................................................................4

2

Normative references ............................................................................................................................4

3

Definitions ..............................................................................................................................................6

4

Wording of order....................................................................................................................................6

5

Health and safety ...................................................................................................................................7

6

Technical requirements ........................................................................................................................7

Table 1 — Technical requirements for lines 1 to 29, where appropriate ......................................................9 Table 2 — Technical requirements for lines 30 onwards, where appropriate............................................17 Annex A (normative) Orientation and location of tensile test pieces in bar and sections........................31 Annex B (normative) Orientation and location of bearing stress specimens in bar and sections ..........34

Page 3 prEN 4400-3:2003 (E)

Foreword This document prEN 4400-3 has been prepared by the European Association of Aerospace Manufacturers Standardization (AECMA-STAN). After enquiries and votes carried out in accordance with the rules of this Association, this Standard has received the approval of the National Associations and the Official Services of the member countries of AECMA, prior to its presentation to CEN. This document is currently submitted to the CEN Enquiry. This document will supersede EN 2070-1:1989, EN 2070-1/A1:1993, EN 2070-3:1989.

Page 4 prEN 4400-3:2003 (E)

0

Introduction

This standard is part of the series of EN metallic material standards for aerospace applications. The general organization of this series is described in EN 4258.

1

Scope

This standard defines the requirements for the ordering, manufacture, testing, inspection and delivery of aluminium and aluminium alloy, bar and section, produced by extrusion, rolling or drawing. It shall be applied when referred to and in conjunction with the EN material standard unless otherwise specified on the drawing, order or inspection schedule.

2

Normative references

This European Standard incorporates by dated or undated reference provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies. EN ISO 6506-1, Metallic Materials - Brinell Hardness Test - Part 1: Test Method EN 515,

Aluminium and aluminium alloys – Wrought products – Temper designations

EN 2000,

Aerospace series – Quality assurance – EN aerospace products – Approval of the quality system of manufacturers

EN 2002-1, Aerospace series – Test methods for metallic materials – Part 1: Tensile testing at ambient temperature 1) EN 2002-6, Aerospace series – Metallic materials – Test methods – Part 6: Bend testing 1) EN 2004-1, Aerospace series – Test methods for aluminium and aluminium alloy products – Part 1: Determination of electrical conductivity of wrought aluminium alloys EN 2032-1, Aerospace series – Metallic materials – Part 1: Conventional designation EN 2032-2, Aerospace series – Metallic materials – Part 2: Coding of metallurgical condition in delivery condition EN 2078,

Aerospace series – Metallic materials – Manufacturing schedule, inspection schedule, inspection and test report – Definition, general principles, preparation and approval

EN 2715,

Aerospace series – Macrographic examination of aluminium and aluminium alloy wrought products, forging stock and forgings 1)

EN 2716,

Aerospace series – Test method – Determination of susceptibility to intergranular corrosion – Wrought aluminium alloy products – AL-P2XXX- series, AL-P7XXX- series and aluminiumlithium alloys 1)

EN 2720,

Aerospace series – Test method for metallic materials – Testing of susceptibility to exfoliation corrosion in 2XXX and 7XXX series wrought aluminium alloy products for aerospace constructions 1)

Page 5 prEN 4400-3:2003 (E)

EN 3874,

Aerospace series – Test methods for metallic materials – Constant amplitude force-controlled low cycle fatigue testing 1)

EN 3987,

Aerospace series – Test method for metallic materials – Constant amplitude force-controlled high cycle fatigue testing 1)

EN 3988,

Aerospace series – Test methods for metallic materials – Constant amplitude strain-controlled low cycle fatigue testing 1)

EN 4050-4, Aerospace series – Test method for metallic materials – Ultrasonic inspection of bars, plates, forging stock and forgings – Part 4: Acceptance criteria 1) EN 4258,

Aerospace series – Metallic materials – General organization of standardization – Links between types of EN standards and their use

EN 4259,

Aerospace series – Metallic materials – Definition of general terms 1)

EN 4522,

Aerospace series – Metallic materials – Test methods – Pin-type bearing test of yield strength 1)

EN 4523,

Aerospace series – Metallic materials – Test methods – Compression testing 1)

EN 4524,

Aerospace series – Metallic materials – Test methods – Measurement of fatigue crack growth rates 1)

EN 4525,

Aerospace series – Aluminium and aluminium alloys – Test methods – Shear testing 1)

EN 6018,

Aerospace series – Test methods for metallic materials – Determination of density according to displacement method 1)

EN 6072,

Aerospace series – Metallic materials – Test methods – Constant amplitude fatigue testing 1)

EN 9133,

Aerospace series - Quality management systems - Qualification Procedure for Aerospace Standard Parts

EN 12258,

Aluminium and aluminium alloys – Terms and definitions

AMS 2750,

Pyrometry2)

ASTM B831, Standard Test Method for Shear Testing of Thin Aluminum Alloy Products3) ASTM E3,

Standard Guide for Preparation of Metallographic Specimens3)

ASTM E112, Standard Test Methods for Determining Average Grain Size3) ASTM E399, Standard Test Method for Linear-Elastic Plane-Strain Fracture Toughness KIc of Metallic Materials3) ASTM E561, Standard Test Method for K-R Curve Determination3) ASTM G34, Standard Test Method for Exfoliation Corrosion Susceptibility in 2XXX and 7XXX Series Aluminum Alloys (EXCO Test)3) ASTM G47, Standard Test Method for Determining Susceptibility to Stress-Corrosion Cracking of 2XXX and 7XXX Aluminum Alloy Products3) ⎯⎯⎯⎯⎯⎯⎯⎯⎯ 1) Published as AECMA Prestandard at the date of publication of this standard 2) This standard is published by: SAE International 400 Commonwealth Drive, Warrendale, PA15096-0001 USA 3) This standard is published by: American Society for Testing and Materials (ASTM International), 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959 USA

Page 6 prEN 4400-3:2003 (E)

TR 2410,

3

Aerospace series – Metallic materials – Relationship between dimensional standards and material standards 4)

Definitions

General definitions, see EN 4259. For definitions of temper designation, see EN 515. For definitions specific to aluminium alloys, see EN 12258 and with the following additions for aluminium alloy bar and section:

3.1

Batch

As defined in EN 4259 with the following additions: Temper

Mass a or No. of final lengths a a

3.2

O, F, H

TXXX

≤ 3 000 kg

≤ 2 000 kg

≤ 250

≤ 200

Whichever is the smaller.

Controlled stretching

Stretching performed after solution heat treatment and quenching for the purpose of reducing internal stresses and/or deviation from straightness/flatness or may be critical to the achievement of the specified mechanical properties. The stretching is defined by a minimum and maximum permanent elongation stated in the material standard. NOTE

4

In certain cases controlled stretching is also critical to the achievement of mechanical properties.

Wording of order

The order shall clearly indicate: ⎯ quantities to be supplied; ⎯ dates of delivery; ⎯ material standard number; ⎯ delivery condition; ⎯ dimensions and tolerances or reference to an appropriate dimensional standard; ⎯ forwarding address; ⎯ nature and type of packing, if required; ⎯ surface protection, if appropriate; ⎯ definition and frequency of any special tests and their retest procedures, if required.

⎯⎯⎯⎯⎯⎯⎯⎯⎯ 4) Published as AECMA Technical Report at the date of publication of this standard

Page 7 prEN 4400-3:2003 (E)

5

Health and safety

Product in the delivery condition shall fulfil the health and safety laws of the area of the country when and where it is to be delivered. A product safety data sheet shall be available.

6

Technical requirements

6.1

General

The product shall be manufactured in accordance with the requirements of the relevant material standard and the applicable requirements of his specification. A manufacturing schedule shall be established and applied in accordance with EN 2078. The product shall satisfy the requirements of the material standard and/or order. Instructions for the use of the material standard are contained in EN 4258. Unless otherwise specified, the requirements in Tables 1 and 2 shall apply in conjunction with those of the relevant material standard. Table 1 relates to lines 1 to 29 (inclusive) of the material standard and Table 2 relates to lines 30 onwards in which the sub-line format is also used. Lines 2 to 98 may also be opened in line 100 if the material standard details specific qualification requirements. If a specific line number is not shown in Tables 1 and 2, the requirement is stated in the material standard and/or order.

6.2

Qualification requirements

Qualification requirements when invoked by the material standard and/or order are detailed in Tables 1 and 2. Unless otherwise agreed between the manufacturer and purchaser the qualification phase shall be as shown below: Qualification phase Starting

Intermediate

1st , 2nd and 3rd batches

4th and 5th batches

6.3

Release requirements

6.3.1

Release tests

Release testing shall be the responsibility of the manufacturer. The purchaser reserves the right to perform any of the inspections and/or tests required by the material standard and/or order. The test samples shall be representative of the product. When required, the manufacturer shall inform the purchaser of the planned dates for extraction of samples and release testing in order that these operations may be witnessed. Tables 1 and 2 detail the requirements for each line of the material standard. Unless otherwise specifically requested by the purchaser, a particular inspection and/or test for release shall be carried out if the corresponding acceptance criteria and/or values are stated in the applicable material standard, but see also section 6.3.5 “Capability clause”.

Page 8 prEN 4400-3:2003 (E)

6.3.2

Retests

If any requirement is not met, retests shall be carried out under the following conditions unless otherwise stated in the material standard or order If the test procedure or test piece preparation is faulty, testing shall be re-applied at the original frequency after rectification of the original cause of failure, on a test sample located near the original one. When failure cannot be attributed to faulty testing, or test piece preparation, further test samples shall be selected at twice the original frequency from the product, one of which shall be that on which the original results were obtained unless already withdrawn by the manufacturer after suitable identification of the cause of failure. If all retest results are satisfactory, the batch shall be accepted. If one or more tests are unsatisfactory, the batch shall be: ⎯ rejected, or ⎯ 100 % retested and the conforming products accepted, or ⎯ partially or fully re-heat treated if heat treatment can rectify the cause of the failure and tested as a completely new batch except for chemical composition. The re-heat treatment shall be stated on the inspection and test report. No product or test sample shall be re-heat treated more than twice. 6.3.3

Rejection

Any failure to meet the requirements of the material standard shall be cause for rejection. 6.3.4

Special tests

Special tests additional to those detailed in the material standard may be required by the purchaser. In such cases, the nature of the test, method, frequency and acceptance criteria shall be specified on the order or inspection schedule and shall be mutually agreed by the manufacturer and the purchaser. 6.3.5

Capability clause

Where sufficient statistical evidence exists that the required acceptance criteria can be routinely achieved and with the agreement of the purchaser, the “capability clause“ may be invoked when and where stated in the material standard and / or this technical specification. In such cases, the test need not be carried out for release purposes unless specifically requested by the purchaser. However, this in no way reduces the obligations of the manufacturer to fulfil the requirements. If subsequent testing indicates that the product does not comply with the requirements, the batch shall be rejected. If the “capability clause“ is invoked but sufficient statistical evidence does not exist, the test shall be carried out for release purposes at a frequency agreed between the manufacturer and purchaser. 6.3.6

Statistical process control

Reduction in the extent of release testing, other than that defined in 6.3.5 above may be negotiated with the purchaser on the basis of appropriate statistical process control and/or statistical data. 6.3.7

Inspection and test report

The manufacturer shall furnish, with each delivery, a report conforming to the requirements of EN 2078 stating the following: - manufacturer’s name and address and, if appropriate, identification of the plant: - order number; - material standard number; - delivery condition and metallurgical code of the product; - quantity and dimensions; - manufacturing and inspection schedule reference, if appropriate; - cast and batch number; - batch and/or test samples heat treatment, if required by the purchaser; - results of all tests and chemical analysis and re-tests.

Table 1 — Technical requirements for lines 1 to 29, where appropriate Material standard line reference No

Frequency of testing Requirements

Title

Qualification phase

Release

Starting

Intermediate

See EN 2032-1.







1 per cast

1 per cast

1 per cast







Bar and section







1

Material designation

2

Chemical composition

The test samples used for chemical analysis shall be representative of the product and may be taken from the molten metal. Any subsequent analytical checks taken from the solid product shall take into consideration the heterogeneity normal to the alloy. The method of chemical analysis shall be at the discretion of the manufacturer unless otherwise stated in the material standard or order. In cases of dispute, the method of chemical analysis shall be agreed between the manufacturer and purchaser. The measured chemical composition shall meet the requirements of the material standard and shall be stated in the inspection and test report.

3

Method of melting

At the discretion of the manufacturer or unless otherwise stated in the material standard.

Form

4.2

Method of production

Extrusion, rolling or drawing The product shall satisfy the requirements of the relevant material standard and this technical specification. The manufacturer shall define the raw materials, processes and inspection requirements in a manufacturing schedule in accordance with EN 2078 and EN 3042. The manufacturer shall make this available to the purchaser upon request. Changes to any manufacturing schedule agreed during qualification and which may adversely affect the quality of the product shall be advised by the manufacturer and shall be subject to written approval of the purchaser. Each product shall be traceable to the cast, production batch and/or heat treatment batch at all stages of manufacture, testing and delivery. Die (press) quenching of AL-P6XXX series alloys shall be permitted unless specifically precluded by the order or drawing. Die (press) quenching of all other alloys shall not be permitted unless agreed in writing between the manufacturer and purchaser. The use of bridge/porthole dies shall only be permissible when agreed in writing between the manufacturer and purchaser. Multi-hole die extrusion shall be permitted unless specifically precluded by the order. Minor straightening or other rectification of products shall be permitted after controlled stretching unless specifically precluded on the order. Such rectification shall be carried out as soon as possible after solution heat treatment and controlled stretching and before any artificial ageing. The product shall be marked to state whether it is in the Txx10 or Txx11 condition.







4.3

Limit dimension(s)

Minimum and/or maximum size of the product expressed as the nominal thickness a, or nominal thicknesses for multi-legged/flanged sections, or as a nominal diameter, D, of round bar or of the circumscribing circle for regular polygonal bar. The dimensions shall be as given on the drawing. See also line 96.







continued

Page 9 prEN 4400-3:2003 (E)

4.1

Frequency of testing

Material standard line reference No

Title

5

Technical specification Delivery condition

6.1

Requirements

Qualification phase Intermediate

Reference to this technical specification EN 4400-3. In cases of conflict, the requirements of the material standard shall take precedence over those of this technical specification. See also EN 4258.







The product shall be supplied in the delivery condition specified in this line in the material standard and/or as stated on the order. When required, semi-finished product designations shall conform to the requirements of the order. Marking :







The method of marking used shall not cause corrosion, crack initiation, contamination or unacceptable deformation. The marking shall remain permanently visible after handling and contact with protective products. Unless otherwise specified, the nature and colour of marking ink and type of marking characters shall be left to the discretion of the manufacturer. The marking inks shall be removable with cleaning products which do not leave a residue which could affect further processing. The cleaning products shall not give rise to corrosion. All products shall be marked legibly as indicated in the following tables. Additional marking shall be agreed between the manufacturer and purchaser and stated on the order. Product of diameter D, or major sectional dimension > 12,5 mm Continuous marking a, b Material standard Dimensional standard or part/drawing number Delivery condition Manufacturer/plant identification a b c

End marking a, c Batch number Inspection stamp

Ink or similar product shall be used. All information shall be repeated at least every 500 mm. Hard stamping (on one end of the product) shall only be carried out if specifically requested by the purchaser.

Products of diameter or major sectional dimension, a or D ≤ 12,5 mm The information stated in the above table shall be indelibly marked on a durable label attached to each bundle of products.

continued

Release

Starting

Page 10 prEN 4400-3:2003 (E)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued) Frequency of testing

Material standard line reference No 6.1

Requirements

Qualification phase

Title Delivery condition (continued)

Preservation:

Release

Starting

Intermediate













Unless otherwise agreed and stated on the order, the product shall be delivered with corrosion protection. The type of corrosion protection shall be agreed between the purchaser and manufacturer. Packing: All necessary precautions shall be taken to prevent damage to, or corrosion of the product, especially where the delivered surface finish shall be maintained, that is, not subsequently machined. The packing shall be suitable for the type of transportation used. The exterior of the packing shall bear the following information: – name and address of recipient, – mass, – order number and sufficient information to enable the contents to be related to the relevant documentation. Shipment: The responsibility for shipping shall be detailed in a transport contract.

Heat treatment

Thermal and/or thermomechanical operations shall be applied to the product as specified in the material standard and are listed in the same order as they are to be applied. Abbreviations and symbols used in the material standard are shown in the following table: all other terms are written in full. Abbreviation/Symbol

Term

Abbreviation/Symbol

temperature

θ

minute

min

time

t

second

s

day

d

water quench

WQ

hour

h

air cool

AC

Unless otherwise specified, heat treatment facilities shall conform to AMS 2750. If a specific temperature (value and tolerance) and time are stated in the material standard or order, these parameters shall be mandatory. If a temperature range is stated, a temperature within that range, reduced by the tolerances of the furnace, shall be selected. The charge shall be maintained at the temperature selected, subject to the furnace tolerances in the following table, for the period stated in the material standard: continued

Page 11 prEN 4400-3:2003 (E)

Term

Frequency of testing

Material standard line reference No

Title

6.1

Heat treatment (concluded)

Requirements

Qualification phase

Release

Starting

Intermediate







See EN 2032-2.







The use condition temper of the product shall be stated in the material standard.













Heat treatment

Temperature range specified in material standard

Maximum tolerance °C

≥ 12 °C ≥ 12 °C < 12 °C

±6 ±6 ±3

Solution heat treatment Artificial ageing

When the material standard defines a temperature range of ≥ 10°C or a temperature with a tolerance of ± 5°C heat treatment facilities calibrated to AMS 2750 Class 2 are acceptable. When the duration of the treatment stage is stated as a range, a time within that range shall be selected. When the duration is not specified, it shall be at the discretion of the manufacturer. Where “ramping” to the treatment temperature is allowed in the material standard and is used, this shall be stated in the inspection and test report. Where controlled stretching after solution heat treatment is required, this is defined as a stage within the heat treatment. A permanent elongation within the range stated in the material standard shall be selected. 6.2 7

Delivery condition code Use condition Heat treatment

− −

If the delivery condition is the use condition, no further heat treatment shall be applied to the product. If the delivery condition is not the use condition, the product shall be subject to heat treatment(s) in the same order as those specified in the material standard. Abbreviations and symbols used in the material standard are shown in the following table: all other terms are written in full. Term

Abbreviation/Symbol

Term

Abbreviation/Symbol

temperature time day hour

θ

minute second water quench air cool

min s WQ AC

t d h

Unless otherwise specified, heat treatment facilities and procedures shall conform to AMS 2750. If a specific temperature (value and tolerance) and time are stated in the material standard or order, these parameters shall be mandatory. If a temperature range is stated, a temperature within that range, reduced by the tolerances of the furnace, shall be selected. The charge shall be maintained at the temperature selected, subject to the furnace tolerances in the following table, for the period stated in the material standard: continued

Page 12 prEN 4400-3:2003 (E)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued) Frequency of testing

Material standard line reference No 7

Requirements

Qualification phase

Title Heat treatment (concluded)

Heat treatment Solution heat treatment Artificial ageing

Temperature range specified in material standard

Maximum tolerance °C

≥ 12 °C ≥ 12 °C < 12 °C

±6 ±6 ±3

Release

Starting

Intermediate













When the material standard defines a temperature range of ≥ 10°C or a temperature with a tolerance of ± 5°C heat treatment facilities calibrated to AMS 2750 Class 2 are acceptable. When the duration of the treatment stage is stated as a range, a time within that range shall be selected. When the duration is not specified, it shall be at the discretion of the manufacturer. Where “ramping” to the heat treatment temperature is allowed in the material standard and is used, this shall be stated on the inspection and test report. Where the use condition is not the delivery condition the inspection and test report shall detail the heat treatment applied to the test samples representing the use condition: see line 8,3. 8.1

Test sample(s)

Page 13 prEN 4400-3:2003 (E)

continued

This line relates to test samples for the tests defined in lines 12 to 16. For machined product, the thickness before machining shall govern the requirements of sampling, testing and determination of acceptance limits. Test samples shall be selected such that they are clear of any stretcher jaw marks. Test samples shall not be worked after removal from the product they represent. Test samples and associated test pieces shall be identified in such a manner that their orientation with respect to the product and traceability to the batch is maintained. Where the product is supplied in the use condition and hardness and/or electrical conductivity testing is used for batch uniformity assessment, see line 82, then such testing shall be carried out prior to selection of the tensile test sample(s). In such cases the product(s) showing the lowest hardness and/ or highest electrical conductivity values shall be selected for tensile testing. Where electrical conductivity measurements (line 32) are used as an indirect assessment of resistance to stress corrosion cracking and/or exfoliation corrosion, such measurements shall be made on the test sample(s) selected for tensile testing.

Material standard line reference No 8.2

Frequency of testing Requirements

Title Test piece(s)

This line relates to test pieces for the tests defined in lines 12 to 16. Test pieces shall be machined from the test samples taken in accordance with the requirements of line 8.1 of this technical specification. Test pieces shall be in the heat treatment condition of the test samples from which they are taken, that is, no further heat treatment shall be carried out. Test piece type and dimensions shall be as specified for the appropriate test/line number in the material standard and/or this technical specification and/or test method.

Qualification phase

Release

Starting

Intermediate







For parallel sided product of a ≤ 10 mm, test pieces shall be flat specimens of full product thickness. For product of a or D > 10 mm, proportional round specimens of the form and one of the sizes in EN 2002-1 shall be used. Heat treatment

If the delivery condition is not the use condition, the test samples shall be subject to heat treatment as specified in line 7 of the material standard. If the delivery condition is the use condition, no further heat treatment shall be applied to the test samples.







9

Dimensions concerned

Nominal thickness, a, or nominal diameter, D, of the product to which the properties, in lines 11 to 26 of the material standard, relate.







10

Thickness of cladding on each face

Not used for this product







11

Direction of test piece

As specified in the material standard and relates to the direction of the test piece used for tensile testing.







8.3

continued

Page 14 prEN 4400-3:2003 (E)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (continued) Frequency of testing

Material standard line reference No

Requirements

Qualification phase

Title

Intermediate

Lines 12 to 16







As specified in the material standard and relates to the temperature at which the tensile tests are carried out.







Tensile testing shall be carried out in accordance with EN 2002-1. The results shall satisfy the requirements of the material standard. The tensile test piece direction and position within the product shall be in accordance with the following table:

3 test pieces per direction per batch

2 test pieces per direction per batch

1 test piece per batch a, b

Tensile test 12

Temperature

13

Proof stress

14

Strength

15

Elongation

θ

°C

Rp0,2 MPa Rm

MPa

A

%

Release

Starting

a

Bar Longitudinal tests Bar form

a or D mm

b mm

Test sample axis

Figure n° in annex A

Round, square or regular polygon

≤ 40 > 40

− − ≤ 40 > 40 > 40

a/2 or D/2 a/4 or D/4 a/2 and b/2 a/2 and b/4 a/4 and b/4

A.1 A.2 A.3 A.4 A.5

Rectangular

≤ 40 > 40

b

If stated on the order the frequency of release testing shall be increased to 2 per batch : − 1 from product with the lowest electrical conductivity or highest hardness; − 1 from product with the highest electrical conductivity or lowest hardness. If stated on the order, the frequency of release testing shall be increased to one test per extruded/rolled/drawn length.

Transverse tests When tests in this direction are specified in the material standard and where size permits, the test samples shall be selected as in Annex A, Figures A6-A9, or as defined by the purchaser. Section Longitudinal tests

Transverse tests When tests in this direction are specified in the material standard and/or drawing, the location of the test samples shall be defined by the purchaser. continued

Page 15 prEN 4400-3:2003 (E)

For sections of sufficient width and whose minor dimension in the thickest part is : − ≤ 40 mm, see Annex A, Figure A.10; − > 40 mm, see Annex A, Figure A.11; − or as defined by the purchaser.

Material standard line reference No

Frequency of testing Requirements

Title

Qualification phase

Release

Starting

Intermediate

Not normally used for this product







16

Reduction of area

17

Hardness

Material standards for this product do not normally specify mandatory minimum values but hardness measurements may be carried out in order to satisfy batch uniformity requirements. See line 82.

See line 82.

See line 82.

See line 82.

18

Shear strength

For parallel-sided product of a ≤ 10 mm, test in accordance with ASTM B831.

1 per batch where dimensions permit

1 per batch where dimensions permit

Not normally required as a release test

Test in accordance with EN 2002-6

1 per batch

1 per batch

Not normally required as a release test

Not normally used for this product







Lines 21-26







Not normally used for this product







List of indices appearing on page 4 of the material standard which relate to normative and/or interpretative notes which are subsequently explained in line 98 of the material standard.







For product of a or D > 10 mm, test in accordance with EN 4525.

19

Bending

20

Impact strength Creep parameters

θ

21

Temperature

22

Time

23

Stress

σa

MPa

24

Elongation

a

%

25

Rupture stress

σR

MPa

26

Elongation at rupture

A

%

27

Notes

°C h

Page 16 prEN 4400-3:2003 (E)

Table 1 – Technical requirements for lines 1 to 29, where appropriate (concluded)

Table 2 — Technical requirements for lines 30 onwards, where appropriate 30

Microstructure Test method

1

Frequency of testing

2

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

EN 2004-10 Qualification phase

Release testing

Starting

Intermediate

1 sample per batch

1 sample per batch

Not normally required as a release test See EN 2004-10. See EN 2004-10.

Use condition or see material standard. The following etchants shall be used unless otherwise agreed upon by the manufacturer and purchaser: Keller's reagent Composition

Acceptance criteria

7

Barker's reagent Quantity (ml)

Hydrofluoric acid (HF) (55 %)

2

Hydrochloric acid (HCl) (40 %) Nitric acid (HNO3) (70 %) Distilled (or de-ionised) water

3 5 190

Composition or

Quantity

Fluoroboric acid (HBF4) (35 %)

5g

Distilled (or de-ionised) water

200 ml

Barker's reagent is used for microanodizing and subsequent examination of the sample under polarized light.

Unless otherwise stated in the material standard, acceptance criteria shall be agreed between the manufacturer and purchaser.

32

Electrical conductivity Test method

1

Frequency of testing

2

EN 2004-1 Qualification phase Starting

Release testing Intermediate

3 measurements per batch 2 measurements per batch Measurement shall be made on the surface of the samples from which the tensile test pieces are taken. See EN 2004-1.

Sample type Test piece definition

3 4

Heat treatment condition of test piece

5

Testing condition

6

See EN 2004-1.

Acceptance criteria

7

See material standard. For the use of electrical conductivity as an assessment of batch uniformity, see line 82 of the material standard and of this technical specification.

Use condition or see material standard.

Page 17 prEN 4400-3:2003 (E)

34

Grain size (Linear intercept method) Test method

1

Frequency of testing

2

ASTM E112 Qualification phase

Release testing

Starting

Intermediate

1 specimen per batch

1 specimen per batch

Not normally required as a release test

3

Measurement shall be made at the location of a tensile test sample. The grain size shall be measured on a section outside of any peripheral coarse grain zone. Planes to examine : LT-ST and L-ST.

Test piece definition

4

See ASTM E112.

Heat treatment condition of test piece

5

Sample type

Use condition or see material standard.

Testing condition

6

See ASTM E112.

Acceptance criteria

7

Unless otherwise stated in the material standard acceptance criteria shall be agreed between the manufacturer and purchaser.

38

Intergranular corrosion Test method

1

Frequency of testing

2

EN 2716 Qualification phase

Release testing

Starting

Intermediate

3 specimens per batch

2 specimens per batch

1 specimen per batch. Subject to written approval from the purchaser, this test may be omitted or the " capability clause " may apply.

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See EN 2716.

Acceptance criteria

7

For alloys with < 3,5 % magnesium, acceptance values shall be agreed between the manufacturer and purchaser unless they are stated in the material standard. For alloys with ≥ 3,5 % magnesium, the results shall satisfy the acceptance criteria specified in EN 2716 unless otherwise stated in the material standard or advised by the purchaser.

See EN 2716. See EN 2716. Use condition or see material standard.

Page 18 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 39

Stress corrosion Test method

1

Frequency of testing

2

ASTM G47 using tensile method Qualification phase Starting

3 test specimens per batch

Release testing Intermediate

2 test specimens per batch

Susceptibility to stress corrosion cracking is normally assessed indirectly by electrical conductivity tests : see line 32 of the material standard and this technical specification. Subject to approval from the purchaser, the test may be omitted or the “capability clause“ may apply, but the test shall be carried out if: a) Such testing is specifically required by the purchaser, that is, there is no agreement that the tests may be omitted and / or if there is no agreement that the “capability clause“ may apply or if there is insufficient statistical evidence that the required acceptance criteria can be met; b) The results of any electrical conductivity testing are unsatisfactory. Whenever stress corrosion tests are carried out, test frequency shall be 3 specimens per batch.

Tests shall be carried out when a or D > 25 mm unless otherwise stated in the material standard. Unless otherwise stated in the material standard, test specimens shall be machined such that the stress is applied in the ST direction.

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See material standard for stress level to be applied.

Acceptance criteria

7

See material standard.

Use condition or see material standard.

Page 19 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) Fracture toughness Test method

1

Frequency of testing

2

ASTM E399 Qualification phase

Release testing

Starting

Intermediate

2 specimens per direction per batch

1 specimen per direction per batch

1 specimen in T-L orientation per batch, if section size permits. (Subject to written approval from the purchaser, the test may be omitted or the test frequency reduced or the "capability clause" may apply).

Sample type

3

Tests shall be carried out when the section size permits a compact tension piece (CT) of minimum thickness a = 12 mm to be taken. The maximum possible thickness shall be used.

Test piece definition

4

For square or rectangular cross-sections, or for sections which can be subdivided into such by machining, (e.g. L, T, H sections), specimens shall be those whose crack plane orientation is described by the standard two letter code nomenclature applied to the three orthogonal axes, S-L, T-L, L-T. The specimen axes shall be central at a/2 unless otherwise shown on the drawing. For cylindrical or regular polygonal sections where deformation is parallel to, and symmetrical about the longitudinal axis, T-L and L-T specimens shall be taken from orientations similar to, and using the same nomenclature as for square/rectangular sections: in this case, the diametrical direction represents the T direction. See diagram below. The specimen axes shall be central at D/2 unless otherwise shown on the drawing. NOTE

The material standards do not use the radial orientations and nomenclature as described in ASTM E399 for cylindrical sections.

a

Extrusion/ Drawing Direction Figure 1

Heat treatment condition of test piece

5

Use condition or see material standard.

Testing condition

6

See ASTM E399.

Acceptance criteria

7

See material standard.

Page 20 prEN 4400-3:2003 (E)

40

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 44

External defects Test method

1

Frequency of testing

2

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

Acceptance criteria

7

Visual inspection Qualification phase

Release testing

Starting

Intermediate

Each product 100 %

Each product 100 %

Each product 100 % − −

Use condition or see material standard. − Type of defect

Acceptance criteria

Score marks, scratches, die lines Die pick-up a Smearing a a Flecking

Not allowed - Length shall be rejected.

Surface inclusions

a

a

Handling damage

Not allowed if present after dressing. Not allowed but removal by dressing is permitted.

Blisters

Not allowed - Length shall be rejected. a

Allowed if damage depth is ≤ 3 % of a or D or ≤ 0,3 mm, whichever is smaller.

Cracks

Not allowed - Length shall be rejected.

Extrusion stop and start marks

Not allowed - Length shall be rejected.

Dressing is allowed providing dimensions remain within tolerances and the surface appearance of the dressed zones is similar to that of the non-dressed surface and does not show any indications if subject to die penetrant flaw detection.

Page 21 prEN 4400-3:2003 (E)

a

Allowed if defect depth is ≤ 3 % of a or D or ≤ 0,3 mm, whichever is smaller. Minor defects not preventing product use are allowed.

Corrosion Surface tears

a

46

Fatigue Test method

1

Frequency of testing

2

Test in accordance with EN 3874, EN 3987, EN 3988 or EN 6072 as appropriate or a method agreed between manufacturer and purchaser. Qualification phase Starting

Release testing Intermediate

S-N in L direction. Minimum of 10 specimens at a range of applied loads per batch

S-N in L direction. Minimum of Not normally required as a release test. 10 specimens at a range of applied loads per batch To be agreed between the manufacturer and purchaser. To be agreed between the manufacturer and purchaser.

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

To be agreed between the manufacturer and purchaser.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

Use condition or see material standard.

49

Exfoliation corrosion Test method

1

Frequency of testing

2

EN 2720 Qualification phase Starting

Release testing Intermediate 1 specimen per batch

3 specimens per batch

2 specimens per batch

(Subject to written approval from the purchaser, this test may be omitted or the "capability clause" may apply) Susceptibility to exfoliation corrosion may also be assessed routinely and indirectly by electrical conductivity measurements subject to written approval from the purchaser: see line 32 of the material standard and this technical specification.

Sample type

3

For section and bar of square or rectangular cross-section of a ≤ 10 mm, test the as-manufactured surface: for a > 10 mm tests shall be carried out on specimens from which a surface layer of thickness a/10 has been removed. For round bar, remove 10 % of diameter and test on machined longitudinal surface.

Test piece definition

4

See EN 2720.

Heat treatment condition of test piece

5

Testing condition

6

See EN 2720.

Acceptance criteria

7

See material standard.

Use condition or see material standard.

Page 22 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 61

Internal defects Test method

1

Frequency of testing

2

EN 4050-4 Qualification phase

Release testing

Starting

Intermediate

Each product 100 %

Each product 100 %

Each product 100 %

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

Top surface resolution shall be ≤ 3 mm.

Acceptance criteria

7

The tests shall satisfy the requirements of class 3.

Test method

1

Method to be agreed between manufacturer and purchaser.

Frequency of testing

2

Tests shall be carried out on the following product: 2 i) Section with a cross-sectional area ≥ 650 mm and minor dimension a ≥ 12 mm ii) Bar of D ≥ 30 mm. For machined product, testing shall be carried out before machining. See EN 4050-4. Testing shall normally be carried out after final solution heat treatment and quenching but may also be carried out in the aged condition.

64

Surface condition roughness

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

Acceptance criteria

7

Release testing

Starting

Intermediate

2 products per batch

1 product per batch

1 product per batch (Subject to written approval from the purchaser, this test may be omitted or the "capability clause" may apply) − −

Use condition or see material standard. The surface roughness of the product shall be measured transversely with respect to the direction of working. Unless otherwise stated in the material standard, drawing or order, the results shall meet the following requirements: 2 Ra ≤ 3,2 µm for section ≤ 650 mm Ra ≤ 6,3 µm for section > 650 mm2

Page 23 prEN 4400-3:2003 (E)

Sample type

Qualification phase

68

Density Test method

1

Frequency of testing

2

EN 6018 Qualification phase

Release testing

Starting

Intermediate

1 test per cast. Density values shall also be calculated from the measured chemical composition.

1 test per cast. Density values shall also be calculated from the measured chemical composition.

If a satisfactory correlation with measured values has been shown, density values may be calculated from the measured chemical composition in lieu of direct measurement, unless otherwise required by the purchaser. If direct measurement is required, 1 test per cast.

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See EN 6018.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

See EN 6018. Prior to testing, the surfaces shall be removed by machining off a layer at least 2 mm thick. Use condition or see material standard.

69

Young’s Modulus Test method

1

Frequency of testing

2

EN 2002-1 Qualification phase Starting

Release testing Intermediate

3 specimens in L direction per batch 2 specimens in L direction per batch

Not normally required as a release test

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See EN 2002-1.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

See EN 2002-1. See EN 2002-1. Use condition or see material standard.

Page 24 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 70

Compression proof stress, Rc0,2 Test method

1

Frequency of testing

2

EN 4523 Qualification phase Starting

Release testing Intermediate

2 specimens in L direction per batch 1 specimen in L direction per batch

Not normally required as a release test

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See EN 4523.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

See EN 4523. See EN 4523. Use condition or see material standard.

71

Crack propagation Test method

1

Frequency of testing

2

Sample type

3

EN 4524 Qualification phase

Release testing

Starting

Intermediate

2 specimens in L-T direction per length per batch, if product size permits.

1 specimen in L-T direction per length per batch, if product size permits.

Not normally required as a release test

See EN 4524. See EN 4524.

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

See EN 4524.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

Use condition or see material standard.

Page 25 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) Batch uniformity Test method

1

Electrical conductivity measurements shall be in accordance with EN 2004-1 or by a method agreed upon by the manufacturer and purchaser. Brinell hardness measurements shall be in accordance with EN ISO 6506-1. The method used shall be at the discretion of the manufacturer unless a specific method is stated in the material standard or defined by the purchaser.

Frequency of testing

2

Electrical conductivity measurement Qualification phase

Release testing

Starting

Intermediate

One measurement every metre along each product per batch

One measurement at each end on the cross-section (if practical), for each product in the batch in addition to one measurement every metre along the length for 25 % of the products in each batch

Form

Number and location of measurements per length

Frequency of testing

Bar of circular cross-section and diameter ≥ 30 mm

One at each end on the cross-section

Each product in each batch

Bar with square or rectangular cross-section of side ≥ 25 mm

One at each end on the cross-section and at metre intervals along the product

Each product in each batch and 25 % of products in each batch

Section, if shape and dimensions enable measurements to be made

One at each end on cross-section (if practical) or on a flat surface at each end of the section

25 % of products in each batch

Hardness testing Qualification phase

Release testing

Starting

Intermediate

One measurement at each end of each length per batch

One measurement at each end of each length per batch

Length ≤ 4 000 mm: one end of each length per batch Length > 4 000 mm: each end of each length per batch

Sample type

3



Test piece definition

4



Heat treatment condition of test piece

5

Use condition or see material standard.

Testing condition

6

Electrical conductivity and hardness measurements shall be made at approximately the same location with respect to the width. Measurements across the width for exceptionally wide extrusions shall be subject to agreement between the manufacturer and purchaser.

Acceptance criteria

7

Electrical conductivity: The difference between the lowest and highest electrical conductivity measurement shall not exceed 1,0 MS/m per length, 1,5 MS/m per batch. Any significant deviation from the typical value stated in the material standard shall be cause for further investigation. NOTE In addition to the above batch uniformity requirements the material standard may also state mandatory electrical conductivity requirements (line 32) as an indirect indication of resistance to stress corrosion cracking or exfoliation corrosion.

Hardness: Values shall conform with the maximum variations specified in the material standard. Typical hardness values are usually stated in the material standard but failure to achieve these shall not be used alone as a cause of rejection. Where hardness is used for batch uniformity assessment, the length showing the lowest hardness shall be selected for tensile testing: see line 8.1.

Page 26 prEN 4400-3:2003 (E)

82

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 85

Bearing stress Test method

1

Frequency of testing

2

EN 4522 Qualification phase

Release testing

Starting

Intermediate

2 specimens in L direction per e/D ratio per batch

1 specimen in L direction per e/D ratio per batch

Not normally required as a release test

Sample type

3

See EN 4522.

Test piece definition

4

Bearing stress test pieces with e/D ratios of both 1,5 and 2,0 shall be used. The location of the test pieces shall be in accordance with the following tables and annex B, unless this is prevented by section size and/or configuration in which case locations shall be defined by the purchaser. All tests shall be carried out in the longitudinal direction. Tests pieces shall be taken adjacent to tensile test pieces. Bar Bar form Round, square or regular polygon

a or D mm

b mm

≤ 40



> 40 ≤ 40

Rectangular > 40 a b



Specimen axis a/2 or D/2 a/4 or D/4

Figure n° in annex B

a

B.1

a,b

B.2

≤ 40

a/2 and b/2

B.3

> 40

a/2 and b/4

B.4

> 40

a/4 and b/4

B.5

For regular polygonal sections, the plane of the test specimen shall be parallel to a flat side of the section. For round sections, the plane of the test specimen shall be coincident with the section diameter.

Sections

Heat treatment condition of test piece

5

Testing condition

6

See EN 4522.

Acceptance criteria

7

Unless otherwise stated in the material standard, acceptance values shall be agreed between the manufacturer and purchaser.

Use condition or see material standard.

Page 27 prEN 4400-3:2003 (E)

For sections of sufficient width and whose minor dimension in the thickness part is: − ≤ 40 mm, see Annex B, Figure B.6. − > 40 mm, see Annex B, Figure B.7.

87

Extrusion back-end defect Test method

1

Frequency of testing

2

EN 2715 Qualification phase

Release testing

Starting

Intermediate

1 specimen per length per batch

1 specimen per length per batch

1 specimen per length per batch. (Subject to written approval from the purchaser, this frequency may be reduced or turned into the "capability clause").

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

The full cross-section shall be examined.

Acceptance criteria

7

The cross-section shall be free from defects prejudicial to use. If any specimen fails this criteria, additional specimens may be taken and examined until a location is reached on the product which is free from defects. The remainder of the product may be accepted if it meets the length stated on the order.

The specimen shall be taken from the back end of extruded/extruded and drawn lengths. The specimen shall be prepared transversely to examine the LT-ST plane. Use condition

Page 28 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (continued) 88

Peripheral coarse grain Test method

1

Frequency of testing

2

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Testing condition

6

Acceptance criteria

7

EN 2715 Qualification phase

Release testing

Starting

Intermediate

1 specimen per product per batch

1 specimen per product per batch

1 specimen per product per batch. (Subject to written approval from the purchaser, this frequency may be reduced or turned into the "capability clause")

The same specimen as that used for examination of back end defect may be used (line 87) although this is not mandatory. The specimen shall be prepared transversely to examine the LT-ST plane. Solution treated or solution treated and aged conditions Peripheral coarse grain depth measurements shall be made as specified in the following table: Round bar and regular polygons

Rectangular bar

Along the radius (round bar) or perpendicular to and at the centres of the flats (regular polygons)

Perpendicular to and at the centre of the major dimensional face

Corners of non-round bar

Hollow and complex sections

Not required unless specified in the material standard, order or drawing

The maximum depth of the peripheral coarse grain zone for round, square and rectangular bar and regular polygons shall be in accordance with the following table, level A or B, as defined by the material standard. Dimensions in millimetres

a or D

Maximum depth of peripheral coarse grain zone Level A

a or D < 1,3

Values to be agreed between the manufacturer and purchaser

1,3 ≤ a or D < 10

0,25 (a or D) or 1,5 a

0,5 (a or D) or 3,0 a

10 ≤ a or D < 50

1,5

3,0

50 ≤ a or D < 80

2,5

5,0

80 ≤ a or D < 100

3,0

6,0

a or D ≥ 100

4,0

8,0

Whichever is the lower value

The maximum depth of the peripheral coarse grain zone for hollow or complex sections shall be agreed between the manufacturer and purchaser.

Page 29 prEN 4400-3:2003 (E)

a

Level B

95

Marking inspection Test method

1

Frequency of testing

2

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5

Visual inspection Qualification phase

Release testing

Starting

Intermediate

Each product

Each product

Sufficient to certify compliance − − −

Testing condition

6



Acceptance criteria

7

The requirements of sub-line 6.1 of this technical specification shall be met.

Test method

1

Measuring equipment and procedures suitable for the tolerances shall be used.

Frequency of testing

2

96

Dimensional inspection Qualification phase

Release testing

Starting

Intermediate

Each product

Each product

10 % of products in the batch unless otherwise stated on the order − −

Sample type

3

Test piece definition

4

Heat treatment condition of test piece

5



Testing condition

6



Acceptance criteria

7

Dimensions and tolerances shall conform to the requirements of the dimensional standard or order or the relevant standard given in TR 2410.

98

Notes



Normative and/or interpretive notes appearing on pages 4 and 5 of the material standard.

99

Typical use



This line is not normally completed for aluminium and aluminium alloys.

100

Qualification



For approval of the manufacturer's quality systems, see EN 2000. For product qualification, see EN 3042.

Page 30 prEN 4400-3:2003 (E)

Table 2 – Technical requirements for lines 30 onwards, where appropriate (concluded)

Page 31 prEN 4400-3 :2008

Annex A (normative) Orientation and location of tensile test pieces in bar and sections All dimensions in millimetres

Figure A.1

Figure A.2

Figure A.3

Figure A.4

Figure A.5

Page 32 prEN 4400-3:2008

All dimensions in millimetres

Figure A.6

Figure A.7

Figure A.8

Figure A.9

Figure A.10

Page 33 prEN 4400-3 :2008

Figure A.11

Page 34 prEN 4400-3:2008

Annex B (normative) Orientation and location of bearing stress specimens in bar and sections All dimensions in millimetres

Figure B.1

Figure B.2

Figure B.3 Figure B.4

Figure B.6

Figure B.5

Figure B.7

Page 35 prEN 4400-3 :2008