AIRBUS ®

AIPS 03-10-001
Issue 3
Page 1 of 9
April 2010

AIPS
Airbus Process Specification

Rectification of metallic materials by shot peening

Published and distributed by :

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

Copyright reserved
Ref. no. AIPS03-10-001

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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

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1 Scope
This Airbus Process Specification defines the requirements for rectification of metallic materials by shot peening.
The purpose of this specification is to give technical requirements to manufacturers. Although the essential
requirements of a process will be described in detail, the specification does not give complete in-house
operating instructions, these shall be given in the manufacturers supporting work instructions.

This specification shall not be used as an inspection document unless parts or 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.
AMS2431A Peening media general requirements.
ASTME112-96 Standard test methods for determining average grain size.
EN9103 Quality management systems - Variation management of key characteristics
ISO4287/1 Geometrical Product Specification- Surface texture: Profile method- terms, definitions and
surface texture parameters.
ISO12085 Geometrical Product Specification- Surface texture: Profile method- Motif parameters.

3 Definition, applicability and limitations

3.1 Definitions
Rectification is a forming process carried out in order to correct any production–related geometric deviation of the
component from the required contour.

Deflection: shape gap between the shape of the obtained part and the shape of the part to be
obtained 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 rectification operation.

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

Shot peening angle: The shot peening angle or the blast angle is the angle between the axis of the impacts
and the surface of the part (plane tangent to surface zone considered).

Coverage ratio: The coverage ratio is expressed by ratio R% where:

Indented surface
R% = x 100
Surface to be shot peened

Above a coverage ratio of 100%, the rectification effect is no longer significant.

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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 AIPS03-10-001 is required it shall be invoked on the drawing by
the words “ (Rectification of metallic materials by shot peening) according to AIPS03-10-001”.

3.3 Limitations of the process

Before shot peening, a non destructive inspection must be performed in order to ensure that cracks, scratches or
surface defects are not present.

The shot peening process shall only be applied on the materials in their final temper conditions.

The shot peening process shall not be applied on protected surfaces (anodising, paint, electrolytic deposit, clad
surfaces, etc.).

Unless permitted by the drawing, shot peening shall not be applied on:
- Edges, countersinks and undeburred hole,
- all critical zones specified by engineering.

4 Requirements
The main requirement for performing the shot peening 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.
Different specimens will be performed with different thicknesses (tests corresponding to the maximum of the
equipment and to the value need for the manufacturing shop) depending on the type of shots.
(See appendix A)

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 the maximum deflection that we can achieve but in accordance with the
roughness requirement and for a coverage ratio ≤ 100%, for each material or materials families. The dimensions
of the specimen will be chosen in order to have a deflection between 2 and 4 mm.

* On another plate specimen, to define X % of the maximum deflection in accordance with an accuracy of
± Y mm.

The requirements are as table 1.

Table 1: Geometry requirements for technical qualification

Aluminium alloys Hard metals

X (Deflection pourcentage) 50 % 50 %

Y (Accuracy) ± 0,1 mm ± 0,1 mm

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4.1.2 Roughness
Using a cut-off of 2.5, measurements of undulation profile (Wt) (ISO12085) and of average roughness (Ra) in
different directions (ISO4287/1) of the shot peened zones are requested.

Test specimen: according to (see appendix A)

The requirements are as table 2.

Table 2: Roughness requirements for technical qualification

Aluminium alloys Hard metals

Wt (waviness profile) ≤ 80 µm ≤ 10 µm

Ra (average roughness) ≤ 15 µm ≤ 4 µm

4.1.3 Material integrity

The following surface defects as scratches, cracks or folds are prohibited.

A control allowing to reveal some surface defects will be done on specimen (see appendix A; the specimens for
roughness or geometry requirements can be used).

Proposition:
For the SEM control, micrographic inspection, different areas must be selected (according to the specification
ASTME112-96).

4.1.4 Surface contamination

The surface must be free from contamination.

Surface examination with SEM : to look for some inlaid foreign bodies or some dirts and to find their chemical
composition (atomic element analysis).

The examination will be done after process implementation, and also after cleaning if it was contaminated after
process implementation.
(see appendix A; the specimens for roughness or geometry requirements can be used).

4.2 Quality requirements for qualification

4.2.1 Shot type

The used shots must be mentioned and the results demonstrated in the process instruction in accordance with
AIPS requirements. For use of this shot type refer to the process instruction.
The designation of shot must be frozen according to the specifications AMS2431A.
If parameters or use conditions are changed, the internal quality department has to be able to demonstrate that the
specification requirements are achieved.

4.2.2 Qualification of the personnel

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

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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 3: Key Characteristics
Product Key Characteristics Process Key Characteristics
Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
Number of reverse forming
1.1

Deflection before process

1.2
Depend on
1 Residual stresses 1.3 Shot peening power Individual 1)
material
Distance between nozzle and
1.4
workpiece
1.5 Beam angle of shot peening
1.6 Media diameter
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.

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.

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7.2 Roughness
Using a cut-off of 2,5, measurements of undulation profile (Wt) (ISO12085) and of average roughness (Ra)
(ISO4287/1) of the shot peened zones are requested.

The requirements are as table 4.

Table 4: Roughness requirements for part inspection

Aluminium alloys Hard metals

Wt (undulation profile) ≤ 80 +40
µm ≤ 10+70 µm
Ra (average roughness) ≤ 15+5 µm ≤ 4+4 µm

To meet the surface finish requirements, surface finish can be improved by trimming.

7.3 Material integrity

Visual control.

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.

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Appendix A
Specimen definition

th

L
Figure A.1 - Specimen definition

Characteristics of the specimen:

L: Length
W: width
th: thickness

with, L ≥ 2W

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RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 New Standard.
02/06

2 §4–9 New AM2534 and incorporation of FPQ

09/09

3 4.3 Implementation of Key Characteristics

04/10

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