AIRBUS ®

AIPS03-10-002
Issue 3
Page 1 of 8
April 2010

AIPS
Airbus Process Specification

Rectification of metallic materials by roll forming

Published and distributed by :

AIRBUS S.A.S.
ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

Copyright reserved
Ref. no. AIPS03-10-002

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 2
Issue 3

Contents

1 Scope

2 Normative references

3 Definition, applicability and limitations

4 Requirements

5 Technical qualification

6 First part qualification

7 Series production inspection

8 Rework

9 Environment, health and safety

Appendix

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 3
Issue 3

1 Scope
This Airbus Process Specification defines the requirements for the rectification by roll forming process.

The purpose of this specification is to give design and quality requirements to manufacturers. Although the
essential requirements of a process are defined, the specification does not give complete in-house process
instructions, these shall be given in the manufacturers detailed process instruction and supporting work
instructions.

This specification shall not be used as an inspection document unless parts of assemblies have been
manufactured according to this specification.

It shall be applied when mentioned in the relevant standard, material specification or drawing.

2 Normative references
This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when
incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to
shall be applied.
National standards should be applied if Airbus standards are not available.
AIPS02-04-001 Application of corrosion preventative temporary protective compounds
ASTM-E112-96 Standard test methods for determining average grain size
EN2002-16 Aerospace series – Metallic materials – Test methods – Part 16 : Non-destructive testing –
Penetrant testing
EN9103 Quality management systems - Variation management of key characteristics

3 Definition, applicability and limitations

3.1 Definition
By "straightening", we mean:

- Either the finishing of a forming operation performed previously by various processes,

- Or correction of deformations which may be due to:
• Stress relieving caused by heat treatments,
• Redistribution of internal stresses caused by mechanical machining or chemical milling operations.

Deflection: shape gap between the shape of the obtained part and the theoretical shape for a given point.

Residual deflection: residual gap of shape between the shape of the obtained part and the shape of the part to be
obtained, for a given point, after a straightening operation.

Spring back: shape gap between the shape of the obtained part during the application of stress and the
shape of the part after relaxation of this same stress.

3.2 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS03-10-002 is required, it shall be invoked on the drawing by
the words “ Rectification of metallic materials by roll forming of AIPS03-10-002”. Process instructions shall not be
called on drawing.

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 4
Issue 3

3.3 Limitations of the process

Only materials which have undergone final heat treatment can be rectified by roll forming.

It can be applied only to detail parts.

The rectification by roll forming process is prohibited:

- in-service use exposing the part to temperatures above +120 °C,

- on protected parts (CAA, paint, electrolytic deposit, etc.),
- in case of drain holes and stiffener run-outs,
- on sharp edges.

It is allowed on conversion coating (e.g. temporary Alodine 1 200 protection) according to the specification
AIPS02-04-001.

4 Requirements
The main requirement for performing the roll forming is to rectify the part to the desired shape indicated in the
drawing without change in function of the part and the specified material properties of the relevant material
specification (AIMS).

4.1 Engineering requirements for technical qualification

Qualification is performed on specimen defined and has to show compliance with following requirements.
The qualification should be performed on materials relating to the final application of the process on the real part.
4.1.1 Geometry
A measurement of deflection is requested according to the test specimen (see appendix A).

The trials for this requirement will be:

• On a plate specimen, to define a deflection X with an accuracy of ± Y mm in accordance with the material
integrity requirements, for each material or materials families.

The requirements are as table 1:

Table 1: Geometry requirements for technical qualification

Aluminum alloys Hard metals

X (Deflection) 1 mm 1 mm

Y (Accuracy) ± 0,1 mm ± 0,1 mm

4.1.2 Material integrity

The following surface defects as cracks, scratches, incrustations, indentations, folds or beads are prohibited.
A control allowing to reveal some surface defects will be done on specimen.
Proposition: for dye penetrant inspection, a sensitivity 2 or upper will be used (according to the specification
EN2002-16).

The metallurgical structure will have to be identical in the distorted zone or in the non distorted one.
Proposition: micrographic examination will be done in each zones (according to the specification ASTM-E112-96).

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 5
Issue 3

4.2 Quality requirements for qualification

4.2.1 Qualification of the personnel

Only competent personnel recognized by an approved training program (under Quality Department responsibility)
can perform the process. Qualification of the personnel will be given in the form of a competence sheet or file.

4.3 Key Characteristics

Key Characteristics acc. to EN9103 are defined by responsible engineering based on a risk analysis for parts
manufactured by this process. Key characteristics shall be defined on product level and if necessary also on
process level.
They shall be subject to variation control by production organization according to EN9103.
Key Characteristics do not relieve the production organization from meeting all engineering requirements defined in
this document.
Table 2: Key Characteristics
Product Key Characteristics Process Key Characteristics
Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
Depend on
1 Cracks 1.1 Force Individual 1)
material
2.1 Number of reverse forming
2 Residual stresses No crack Individual 1)
2.2 Deflection before process
1) Limits will be specific to individual geometries and process parameters inside or referenced in
the process instruction (PI)

5 Technical qualification
The Technical Qualification shall be performed according to the relevant Airbus procedure.

6 First part qualification

For the introduction of new structural components or major changes to serial production processes for all parts, a
First Part Qualification (FPQ) according to the relevant Airbus procedure is mandatory. Main objective of a FPQ is
to prove, that the inner quality of a structural part / component meets the requirements defined in the Definition
Dossier taking into account materials and key parameters of the manufacturing process and tooling.

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 6
Issue 3

7 Series production inspection

The shop shall perform the following series production inspections under serial conditions.

7.1 Geometry
The geometry, dimensions and thickness of the part must be in compliance with the drawing or detail specification
approved by the Engineering.

The tolerances are defined by the drawing.

7.2 Material integrity

The part must be free from cracks.
A visual inspection and other controls allowing to reveal some surface defects will be done on the part.
Proposition: for dye penetrant inspection, a sensitivity 2 or upper will be used (according to the specification
EN2002-16).

8 Rework
Not applicable.

9 Environment, health and safety

Process shall be in line with Airbus environmental policy.
Banned substances, as per relevant Airbus procedure, shall not be applied.
Hazardous materials shall comply with rules defined in relevant Airbus procedure.

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 7
Issue 3

Appendix A: Specimen definition

th
L
Figure A.1 – Specimen definition

Characteristics of the specimen:

L: length = 300 mm
H: height = 50 mm
th: thickness = 5 mm

DocMaster: Uncontrolled copy when printed

 AIPS03-10-002 Page 8
Issue 3

RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 New Standard.
03/06

2 §4-9 New AM2534 and incorporation of FPQ

09/09

3 4.3 Implementation of Key Characteristics

04/10

DocMaster: Uncontrolled copy when printed