ISO 25239-5:2020

Overview

ISO 25239-5:2020 - "Friction stir welding - Aluminium - Part 5: Quality and inspection requirements" defines how to assess and control the quality of friction stir welded (FSW) aluminium products. The standard specifies a method to determine a manufacturer's capability to produce products of specified quality using the FSW process. It covers quality and inspection requirements applicable to aluminium and its alloys, but does not apply to friction stir spot welding (covered by ISO 18785). ISO 25239-5:2020 supports consistent production, verification and traceability of FSW joints across industries such as aerospace, marine, railway, food processing and consumer products.

Key Topics

• Scope and purpose: Method for assessing manufacturer capability and production controls for FSW of aluminium.
• Personnel requirements:
  • Welding operators must be qualified per ISO 25239-3.
  • Inspection and NDT personnel should be qualified (recommendation: ISO 9712 or equivalent).
  • Destructive testing personnel must be trained for the specific test methods.
• Equipment and reproducibility:
  • Equipment must be suitable and maintained; defective equipment must not be used.
  • Reproducibility tests: minimum of three satisfactory test welds required after installation, repair, or relocation of equipment, using a production WPS.
  • Documented equipment maintenance plans focused on items that affect WPS-controlled variables (guides, meters, clamps, thermocouples, control systems).
• Welding procedure specification (WPS): Manufacturers must ensure the WPS is correctly applied in production.
• FSW tool control:
  • Tools must be permanently identified and inspected for correct geometry and cleanliness prior to first use.
• Pre- and post-weld controls:
  • Joint preparation, fit-up, pre-weld cleaning, preheating/interpass temperature control, tack welds, and postweld heat treatment are addressed.
• Inspection and testing:
  • Requirements for testing before, during and after welding, including handling of damaged or non-conforming welds and weld geometry correction.
  • Annex A defines imperfections, testing/examination and acceptance levels (three acceptance levels concept added in the 2020 edition).
• Traceability: Identification and traceability of welds and tooling are required.

Applications

ISO 25239-5:2020 is used by:

• Manufacturers and quality managers deploying friction stir welding (FSW) for aluminium assemblies.
• Welding coordinators and supervisors for production control and capability demonstration.
• NDT inspectors and laboratories performing visual, radiographic, ultrasonic and penetrant testing of FSW joints.
• Procurement and regulatory bodies requiring documented quality and inspection processes for FSW products.

Related Standards

• ISO 25239-1, ISO 25239-3, ISO 25239-4 (other parts of the FSW series)
• ISO 9712 (NDT personnel qualification)
• ISO 17636 / 17637 / 17640 (radiographic, visual, ultrasonic testing)
• ISO 4136, ISO 9015, ISO 9017 (destructive weld testing)
• ISO 3452-1 (penetrant testing)

ISO 25239-5:2020 helps ensure reliable, verifiable FSW production for aluminium through controlled processes, qualified personnel, and documented inspection and traceability.