AIRBUS ®

AIPS01-02-003
Issue 6
Page 1 of 9
August 2010

AIPS
Airbus Process Specification

Preparation of Holes in Metallic Materials for Fastening

Published and distributed by

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

Copyright reserved

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Contents

1  Scope 

2  Normative references 

3  Definition, applicability and limitations 

4  Engineering requirements 

5  Technical qualification 

6  First part qualification 

7  Series production inspection 

8  Rework 

9  Environment, health and safety 

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1 Scope
This Airbus Process Specification defines the Engineering requirements for Preparation of Holes in Metallic
Materials for Fastening.
This specification does not give detailed instructions; these are given in the Process Instructions (PI) / Airbus
Process Instruction (AIPI) and the Work Instructions.
This specification shall not be used as an inspection document.
It shall be applied when mentioned in the relevant standard, material specification or Definition Dossier.

2 Normative references
Only normative references cited in the text are listed hereafter.
The latest issue of the publication referenced shall be used.
Aerospace series - Quality management systems - Variation management of key
EN9103:
characteristics
ABS1707 Hole Geometries for use with Protruding and Countersunk Head Bolts
AIPS09-01-002 Cleaning with liquid non aqueous agents
AITM1-0070 Surface Roughness Measurements Using Surface Contact Stylus Method

3 Definition, applicability and limitations

3.1 Definition
Hole Tolerance The range of variation permitted in maintaining a specified dimension.
Stack A combination of materials to be assembled.

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 AIPS 01-02-003 is required, it shall be invoked on the drawing by
the words “Preparation of holes in metallic materials for fastening in accordance with AIPS 01-02-003”. Process
instructions shall not be called on a drawing.
The processes covered within this specification are drilling, reaming, countersinking and deburring of holes for
fastening operations.

3.3 Limitations of the process

Specific drawing conditions or conditions detailed in fastener specific AIPS documentation prevail over the
requirements quoted in this specification.

Holes produced by advanced or non-conventional processes may not yield the same level of fatigue performance
as those produced by conventional axial drilling and reaming operations. Where such processes are invoked tests
may be required to confirm the design fatigue life can be achieved. Reference shall be made in such cases to M&P
or the appropriate design authority.

4 Engineering requirements
Engineering requirements are minimum requirements specified by Responsible Engineering to ensure optimal
performance of the manufacturing process.
All Engineering requirements have to be met and controlled in production.

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4.1 Performance Requirements

4.1.1 Hole Geometry

4.1.1.1 Hole Tolerance

Holes shall meet the requirements defined in ABS1707, on the drawing and in the fastener specific AIPS.
4.1.1.2 Countersink Angle
Countersunk holes shall meet the requirements defined in Figure 1 unless otherwise stated on the drawing or in the
fastener specific AIPS.

100°±0.5°
100° + 0,5°
or 130°±0.5°
or 130° + 0,5°

Radius and chamfer dimensions

Radius
accordingand chamfer
to ABS1707 dimensions
or respective
fastening AIPS
according e.g for blind fasteners or
ABS1707
solid rivets

Figure 1: Countersink angle

4.1.1.3 Hole / Countersink Coaxiality

The angular misalignment, α, between the hole and countersink center lines shall not exceed 0,5° (reference
Figure 2) unless otherwise specified on the drawing or in the fastener specific AIPS.

CSK Center
LineCSK center
line

Hole center
line

Figure 2: Hole coaxiality

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4.1.1.4 Hole Perpendicularity

Hole perpendicularity, Φ, shall be as defined in Figure 3 and shall generally be 90° ± 0,5°. Where tooling or
accessibility issues require manual drilling operations and the stack thickness is ≤ 6 mm and the fastener diameter
is ≤ 6,35 mm, hole perpendicularity is limited to Φ = 90° ± 1°. This extended limitation shall not be applied to flush
head fasteners installed through aerodynamic surfaces or to fasteners installed in fuel tank boundaries. For slug
and structural rivets (e. g. monel rivets installed in Ti), the hole perpendicularity shall be 90° ± 0,5° in any case.

F
ØD

Figure 3 : Hole Perpendicularity

4.1.1.5 Hole / Countersink Concentricity

The concentricity, a, between hole and countersink center line shall be ≤ 0,05 mm (Figure 4) unless otherwise
specified on the drawing or in the fastener specific AIPS.

Figure 4 : Hole / Countersink Concentricity

4.1.1.6 Burr limits and Deburring

4.1.1.6.1 Burrs at the interface shall not exceed:

- 50µm for Al/Al assembly
- 100µm for Ti/Ti, Ti/CFRP and Al/CFRP assemblies

Burrs exceeding these limits will result in a knock down (KDF) in perfomance (Reference) Chapter
4.1.2.6. For deviation to these requirements (e.g. sleeved fasteners installed in fuel tank areas) refer to
fastener specific AIPS.

4.1.1.6.2 Where the joint has to be dis-assembled following hole preparation for the application of sealant or for
other finishing treatments or as required by the drawing, holes shall be deburred both at faying surfaces
and at the hole exit surface.

4.1.1.6.3 Burrs at hole exit (nut or collar seating) surface shall be removed where ever practical. Where it is not
practical to remove hole exit burrs they shall not exceed 0,10mm. In addition, where burrs are not

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removed they shall not impede the ability to meet fastener seating requirements as defined in the
fastener specific AIPS.

4.1.1.6.4 Excessive chamfering of hole edges during deburring operations shall be avoided. Resultant chamfers
or radii at hole edges shall not exceed 0,20mm.

4.1.1.6.5 For hole edges at fastener head seating surface refer to ABS1707 or fastener specific AIPS.

4.1.2 Hole integrity

4.1.2.1 Surface Finish

Unless otherwise specified on the drawing or in fastener specific AIPS documentation, the maximum permitted
roughness for holes prior to assembly shall be Ra ≤ 1,6μm after final hole preparation (e.g. reaming).

Measurements shall be performed in accordance with AITM1-0070.

4.1.2.2 Overheating
There shall be no overheating during machining, leading to detrimental effects on the material properties.
4.1.2.3 Contamination
Contamination of the hole is not allowed. Lubricants / coolants shall not have any detrimental effects on the
material or quality of the hole and surounding area. Only approved lubricants / coolants shall be used.
4.1.2.4 Damage
There shall be no damage within or around the hole (e. g. helix, tearing of metal or scratches).
4.1.2.5 Cleaning
All parts shall be cleaned to AIPS 09-01-002.
4.1.2.6 Performance
To ensure the mechanical performance of the assembly is not impaired, all process parameters shall be controlled
in compliance with limits defined in this AIPS.
Where its is considered not possible to meet the requirements of this specification this must be identified early in
the design process and prior to first build, and account taken of the associated knock down (KDF) in performance.
4.2 Quality requirements

4.2.1 Manufacturing shop

The Manufacturing Shop shall be approved to the requirements of the Airbus Quality Assurance Function for the
production and supply of parts machined to this process.
4.2.2 Process
All processes shall be qualified in accordance with section 5.

All process parameters shall be frozen at the point of qualification and appropriate process and quality controls put
in place to ensure no deviation from qualification agreed parameters. Any change to process or to qualification
agreed parameters shall be subject to validation via a full first part qualification.
4.2.3 Tooling / Equipment
All tooling / equipment shall be obtained from controlled sources and shall be certified as suitable for intended use
and conforming to the requirements of this specification.
4.2.4 Personnel
All operators shall be trained to perform the preparation of holes in metallic materials for fastening according to this
specification.

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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 1: Key Characteristic

Product Key Characteristics Process Key Characteristics

Requirement/ Sub.- Requirement/
No. Designation Designation
Limit No. Limit
ABS1707, drawing or
1 Hole diameter tolerance
Fastener AIPS
100° ±0,5°
2 Countersink angle
130° ±0,5°
ABS1707, drawing or
3 Chamfer / radius
Fastener AIPS
Coaxiality (csk / cylindr.
4 ≤0,5°
parts)

5 Hole perpendicularity 4.1.1.4

Hole / countersink ≤0,05mm or drawing, fastener AIPS

6
concentricity requirement

7 Burrs 4.1.1.6 Shall be defined in relevant AIPI

1,6 µm max after final hole

Surface finish
8 preparation (e. g. reaming)
roughness
Measurement acc. to AITM1-0070
9 Overheating not allowed
10 Contamination not allowed
No detrimental effect on hole and
11 lubricants / coolants
surrounding areas
Damage (including helix,
tearing of metal,
12 Not allowed
scratches etc.) within or
arround the hole
13 Cleaning AIPS 09-01-002
14 Joint performance 4.1.2.6

5 Technical qualification
The Technical Qualification shall be peformed according to the relevant Airbus Procedure.

Qualification trials shall include the preparation of holes in production representative materials across the full
diameter range and at stack thicknesses corresponding to the minimum and maximum thickness condition
expected in production. Sufficient tests shall be carried out to define and fix tooling and operational parameters,
and to demonstrate robust and repeatable compliance with the requirements defined in section 4 of this document.

In case of burrs limit exceed the values given in chapter 4.1.1.6, fatigue testing are mandatory during the technical
qualification with representative values of the worst case condition from production capability.

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All measuring equipment shall be suitably calibrated and shall be capable of measurement to an accuracy of 10%
of the tolerance defined in this specification.

6 First part qualification

Introducing new structural components or major changes into serial production using special manufacturing
processes (e.g. composite processes, welding processes) may require a decision from Responsible Engineering on
a First Part Qualification (FPQ), according to the relevant Airbus procedure. Main objective of an 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, key parameters of the manufacturing process and tooling.

7 Series production inspection

The manufacturing shop shall ensure appropriate inspection and quality procedures are in place to ensure the
requirements as defined in Section 4 are achived and maintained.

8 Rework
The reworking or oversizing of holes prepared in accordance with this specification shall be carried out under the
cover of non-conformance documentation.

9 Environment, health and safety

The manufacturing process shall be in line with Airbus Health and Safety and ecoefficiency policies.
Compliance with A1091 shall be ensured for all materials, substances and/or articles implemented during process.
In particular, targeted substances according to A1091 shall not be used, if a safer alternative is available.
Uses made of all substances involved in the process shall be documented in Safety Data Sheet as required by
REACh regulation (Registration Evaluation and Authorization of Chemicals).

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RECORD OF REVISIONS

Clause
Issue Description of modification
modified

1 New standard

06/00

2 All Revision of entire standard.

12/06

3 All Revision of entire standard, definition of countersink angle, hole / countersink

06/09 coaxiality, hole perpendicularity, hole / countersink concentricity and burr height
requirements.

4 3.3 Modification related to one way assembly.

12/09
4.1.1.6 Burr limits and deburring refined.

4.1.2.1 Roughness measurement changed according to AITM1-0070.

4.2.2 Fixation of process parameters defined.

6 First part qualification requirement modified.

5 3.3 Modification of the §

04/10
4.1.1.6.2 Link to the interface gap deleted.

4.3 Implementation of key characteristics

6 4.1.1.6 Modification of burrs limits as agreed with Stress department

08/10 4.1.2.6 Modification to inform that KDF can be addressed if limits of this AIPS are not met

5 To ask for fatigue tests during technical qualification for exceed burrs limit

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