02-747 part 3

Ministry of DefenceDefence Standard 02-747 (NES 747) Issue 1 Publication Date 01 April 2000 Requirements For Nickel Aluminium Bronze Castings And Ingots Part 3 Nickel Aluminium Bronze Commercial Alloy Ingots And Sand Castings Incorporating NES 747 Part 3 Category 2 Issue 4 Publication Date November 1999 AMENDMENT RECORD Amd No Date Text Affected REVISION NOTE This standard is raised to Issue 1 to update its content. HISTORICAL RECORD This standard supersedes the following: Naval Engineering Standard (NES) 747 Part 3 Issue 4 dated November 1999. Signature and Date Ministry of Defence Naval Engineering Standard CATEGORY 2 NES 747 Part 3 Issue 4 November 1999 REQUIREMENTS FOR NICKEL ALUMINIUM BRONZE CASTINGS AND INGOTS PART 3 NICKEL ALUMINIUM BRONZE COMMERCIAL ALLOY INGOTS AND SAND CASTINGS  CROWN COPYRIGHT 1999 This NES Supersedes DG SHIPS 361A NES 747 PART 3 ISSUE 1 NES 747 PART 3 ISSUE 2 NES 747 PART 3 ISSUE 3 Record of Amendments AMDT 1 2 3 4 5 INSERTED BY DATE . Bristol BS34 8JH (i) . MOD Abbey Wood. STGSA.NAVAL ENGINEERING STANDARD 747 REQUIREMENTS FOR NICKEL ALUMINIUM BRONZE CASTINGS AND INGOTS PART 3 ISSUE 4 NOVEMBER 1999 NICKEL ALUMINIUM BRONZE COMMERCIAL ALLOY INGOTS AND SAND CASTINGS This Naval Engineering Standard is authorized for use in MOD contracts by the Defence Procurement Agency and the Defence Logistics Organization Published by: Sea Technology Group. #95. Defence Procurement Agency. Ash 0. NES 747 Part 3 Issue 4 November 1999 (ii) . This NES states the requirements for the physical characteristics.1. particularly if the material has been weld repaired.) NOTE The material covered by this NES suffers from selective phase corrosion in the presence of sea water.) Submarines 2. This NES does not cover the use of the castings for first level systems and castings that may come into contact with sea water. ie alloys to NES 747 Part 2.1 for applicability. (See Clause 1. NES 747 Part 4 or NES 824 Part 1 are available for use where severe corrosion cannot be tolerated in sea water systems.NES 747 Part 3 Issue 4 November 1999 SCOPE 1. More expensive alloys. (See Clause 1. (iii) . test methods and acceptance standards of cast metal nickel aluminium bronze Commercial Alloy ingots and sand castings.2a. NES 747 Part 3 Issue 4 November 1999 (iv) . Enquiries in this connection may be made to the authority named in the tender or contract. The Crown reserves the right to amend or modify the contents of this NES without consulting or informing any holder. This NES has been reissued to reflect changes in Departmental Nomenclature due to the MOD reorganization and the changes in related documents. reproduced or published without written permission of the MOD 11. the MOD hereby excludes all liability whatsoever and howsoever arising (including but without limitation. 10. This NES is the property of the Crown. The complete NES 747 comprises: Requirements for Nickel Aluminium Bronze (NAB) Castings and Ingots Part 1: Nickel Aluminium Bronze Naval Alloy Centrifugally Cast Part 2: Nickel Aluminium Bronze Naval Alloy Ingots and Sand Castings with Welding Permitted to the Wetted Surface Part 3: Nickel Aluminium Bronze Commercial Alloy Sand Castings and Ingots Part 4: Nickel Aluminium Bronze Naval Alloy Sand Castings with Welding Restricted to the Non−Wetted Surface (Class I and II Castings only) Part 5: The Design and Manufacture of Nickel Aluminium Bronze Sand Castings 3. Ministry of Defence (MOD). Conditions of Release General 9. means by the MOD in writing. in connection with which it is issued. Unless otherwise stated. the user is to ensure that he is in possession of the appropriate version of each document. authorized and similar terms. Proposals for amendments that are not directly applicable to a particular contract are to be made to the publishing authority identified on Page (i). and its contractors in the execution of contracts for the MOD. Unless otherwise authorized in writing by the MOD must be returned on completion of the contract. including related documents. 6. relevant to each particular tender or contract. 13.NES 747 Part 3 Issue 4 November 1999 FOREWORD Sponsorship 1. When this NES is used in connection with a MOD tender or contract. To the extent permitted by law. Any significant amendments that may be made to this NES at a later date will be indicated by a vertical sideline. 8. This Naval Engineering Standard (NES) is sponsored by the Defence Procurement Agency. or submission of the tender. libability resulting from negligence) for any loss or damage however caused when the NES is used for any other purpose. No alteration is to be made to this NES except by the issue of an authorized amendment. This Naval Engineering Standard (NES) has been devised solely for the use of the MOD. If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of the circumstances. Any user of this NES either within MOD or in industry may propose an amendment to it. and those directly applicable to a particular contract are to be dealt with using contract procedures. reference in this NES to approval. 2. MOD Tender or Contract Process 12. 4. (v) . This document is Crown Copyright and the information herein may be subject to Crown or third party rights. 7. 5. approved. Deletions will be indicated by 000 appearing at the end of the line interval. It is not to be released. c. d. 389 Chiswick High Road. London. G2 8EX. Llanelli. Defence Standards Defence Standardization. DSDC(L). British Standards British Standards Institution. together with the sponsoring Directorate and the Tender or Contract Sponsor. Categories of NES 15. its complement or third parties. Kentigern House. Other documents Tender or Contract Sponsor to advise. Additional Information 21. Current support practice. Category 3. Glasgow. b. In the tender and procurement processes the related documents listed in each section and Annex A can be obtained as follows: a. its systems or equipment. If not applied may have a Critical affect on the following: Safety of the vessel. 20. Where attention is drawn to hazards. Through life costs and support. W4 4AL b. It refers only to technical suitability and in no way absolves either the supplier or the user from statutory obligations relating to health and safety at any stage of manufacture or use.NES 747 Part 3 Issue 4 November 1999 14. Compliance with an NES does not of itself confer immunity from legal obligations. Corporate experience and knowledge. Category 1. This NES may call for the use of processes. 17. standards and drawings.) (vi) . Operational performance of the vessel. (There is no relevant information included. If not applied may have a Significant affect on the following: Safety of the vessel. Category 2. BM & D. CSE SA14 8YP. If not applied may have a Minor affect on the following: MOD best practice and fleet commonality. The Category of this NES has been determined using the following criteria: a. substances and/or procedures that are injurious to health if adequate precautions are not taken. Prime Contractors are responsible for supplying their subcontractors with relevant documentation. All applications to the MOD for related documents are to quote the relevant MOD Invitation to Tender or Contract number and date. 18. users are responsible for their correct application and for complying with contractual and other statutory requirements. Health and Safety Warning 19. its complement or third parties. its systems or equipment. Naval Engineering Standards Dyfed. When NES are incorporated into MOD contracts. 65 Brown Street. Operational performance of the vessel. This NES has been written and is to be used taking into account the policy stipulated in JSP 430: MOD Ship Safety Management System Handbook. Llangennech. those quoted may not necessarily be exhaustive. including specifications. c. Related Documents 16. 5. . . . . . . . . . . .6 1. . . . . . . . . . . .3 1. . . . . Rectification of Surface and Sub-Surface Defects by Welding . . . . . . . . . . .3 1. . . . . . . . . . . . . . . . . .3 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 1. . . . . . . . . . . .1 1. .3. Test Methods . . .5 . . . . (vi) Health and Safety . . . . . .4 1. . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . . . . . .4 1. Rectification of Surface Defects by Blending .1 Table 1. . . Chemical Composition of Ingots .1 1.1 1. . . . . . . . . . . Impregnation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Table 1. . . . . .9 1. . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1. . . . . . . .6. . . . . . . . . .2 1. . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Properties . . . . . . . . Chemical Composition of Castings . . . . . . . . . Ingots . . . . . . . . . . .2 1. .2 1. .5. . . . . . . . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . .1. . (v) Categories of NES . . . . Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (vii) SECTION 1. . . . .2 1. . . . . . . .7 1. . . . . . . . . . . . . . (v) Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Limits on Combined Weld Repairs . . . . . . . . . . . . . . . . . Surface Ships . . . . (vii) 1. . . . . . . . . . . . . . . .3 1. . . . . . . . . . .5. . . . . . . . .4 1. . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . . . Properties . . . . . . . .4 1. . Physical Characteristics . . . . Classification . . . . .NES 747 Part 3 Issue 4 November 1999 CONTENTS Page No TITLE PAGE . . . . .6 1. . . . . . . . . . . . . . . . . . . . . . . . . Quality of Material . . . . . . . . . . . . . . . . . . . . . (vi) Additional Information . . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . . . Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 1. . . . . . . . . . . . . .6. . . . . . . . .3. . . . . . . . . . . . . . . . . . . . . . .3 1. . . Mechanical Tests . . 1. . . . . . . .1 1. . . . . . . . . . . . . . . . . . . . . . . . . . .3 1. . . (vi) CONTENTS . . . . . . . . . . .1. . . . . . .1 1. . . . . Retests . . . . . . . . . Defects and Rectification of Defects . . . . . . Special Repairs .1. . . . .4 1. . . . . . . . . . . . . . . . Submarines . (v) Conditions of Release . .1 1. . . . . . . . . . . . . . . . . . .5 1. Analysis . . . . . . . . . . . . . . . .5. . . . . . . . . . . Castings . . . . . . . . . . . . . . . . . . Limits on Individual Sub-Surface Repairs . . . . .3 PERFORMANCE SPECIFICATION . . . . . . . . . . . . . . . . .3 1. . .5 1. .5. . . . . . . . . . . . . . .4 1. . . . . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . . . . . . . . . . .4 1. . . . . . . . . (vi) Related Documents . . . Rectification of Dimensional Defects by Weld Deposition . . . . . . . . . . . . . . . . . . . . . .1. (iii) FOREWORD . . . . . . . . . . .2 1. . . . . . . . . . . . .1 1. . . .5. . .2 1. . .1 1. . . . . . . . . . . .4 Table 1. .3. . . . .1 1. . . . . . . . . . . . . . . . . . . . .4 1. . . . Defects . . . . . . . . . . . . . . . . . . . . .3 1. . . . . . . .5. . . . . . . . . . . . . . . . . . . . . . .2 1. . . .6. . . .8 1. . . . . . . . . . . . . . . . . . . . (i) SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rectification of Defects . . .3 1. . . . . . . . .2 1. . . . . . . . .5 1. .2 3. . . . . . . . . . . . . . . . SECTION 2.6.2. . . . Non-Destructive Examination Standards . . Liquid Penetrant . NATIONAL/INTERNATIONAL REGULATIONS 2. . . . Destructive Examination Standards . . . . . . .2. . .2 3. . Liquid Penetrant . . . . . . . . . . . . . .5 1. . . Quality Assurance Documentation . . . Ultrasonic Examination . . 3. . . . . . . . . . . . . . . .1. . . . . . . . . .5 1.1. . Ingots . . . .6. . . . . . . .2. . . . . . . . Castings . . . . . . .6. . . CORPORATE EXPERIENCE & KNOWLEDGE . . . . . . . . . . . A. . . . . .2 3. . . . . . . . . . .1 3. . .4 MILITARY STANDARDS/REQUIREMENTS .1 (viii) . . . . . . . . . . . . Visual-Optical . . . . . Radiographic Examination of Non-Designated Regions on a Sample Basis . . . . . . . . . . . . . . . . . . . .1 ANNEX B. . .2. . . . .1 SECTION 3. . . . . . . . . . . . . . . . .3. . . . . . .2. . . . . . .2.3.3 3. . . . . . . . . .1. . . Mechanical Tests . . . . . .2. . . .2 3. Ingots . . . . . . . .1 3. . . . . . . . . . . . . . . . . 3. . . . . . . Packaging . . . . . .7 1. . . . Castings . . Acceptance Standards . . .2 3. . .2 3. . . . . . . . . . Analysis . . RELATED DOCUMENTS . . . .1 3. . . . DEFINITIONS .2. . . . .6. . . . . .1. . . . . . . . . . . . . . . . . . . . . . . . . .2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . .1 1.6.5 1. . . .6 3. .2.1 3. . . . . Dimensional Check . . . . . . . . . . . . .1 ANNEX C. . . .6.1 3.1. .1 3. . . . .1. . . . .1 3. . . . . . . . . .5 3.1. . . . . . . . . .2. . . Radiography . . . . . . . .2 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . .1 3. . . . . . . . . . . . .1. .5 1. . . . . . . . . . . . . . Identification of Ingots and Castings . . . . . . .1. . . . . . . . . . . . .1. . . . . . . . . . . . . . . . . . . . . . .1.2 3. . . . . . . . . . . . . . .5 1. .NES 747 Part 3 Issue 4 November 1999 1. . . Retests . . Visual-Optical .1 SECTION 5. . . . Pressure Tests . Dimensional Check . .2.6. . . . . . . . .1 3. . . Ultrasonics . . . Pressure Tests . . .2 3. Radiography . . .6. .2 1. . . . . . . . . . . . . . . . . . . . . . . .2. . . . .5 1. . . . . . . . . . . . .6. . . .2 3.2. . . . . . . . . . . . . . . . . . . . .4 1. . . . . . .1. . . . . . . . . . . . . . . 5. . . . . . . . .1 3. . . . . . . . . . .3 3. . . .5 1. . . . . . . .8 Non-Destructive Tests . . . . .1 3. . . . . . . . . . . . . . . . . . PROCUREMENT CHECK LIST . . .6 1. DESIGN REQUIREMENTS/GUIDANCE . . .1 3. . . . . . . . . . . . . . . C. . . . . . . .1 3. . . . . . . . . . . .3 SECTION 4. . . . . . . .1 3. . . . .5 1. . .6 ALPHABETICAL INDEX . . . . . . .4 3. . . . . . . . . .1. . . . . . .1. . . . . . .3 3.2 3. . . . . . .2 3. . .3 1. Radiographic/Ultrasonic Examination . . .2 1. . .1 3. . . . . B. . . . . . . .1 1. . . . . . . . INDEX. . 4. . . . . . .2. . . . . . . . . . . .1 3. . . . . . . . . . . .3 3. . . . . . . .1 ANNEX A.2 3. . . . . . . . . . . . . . . . . 1 Silicon − 0. 1.0 Iron* 4. NES 771.1 Ingots a. NES 304 Part 1.2 1.1 Magnesium − 0.1.0 5. see also Annex A.5 Zinc − 0.1 Applicability 1.2 This NES may be used for: (1) Propellers if stated in the contract. NES 729 Part 4.) (2) Class I and II castings provided they are not in contact with sea water.20 Impurities * Nickel content is to be greater than the iron content. NES 863. The classification of castings is defined in NES 863. NES 304 Part 3.5 Nickel* 4. 1. Ingots are to conform to the chemical composition given in Table 1. NES 729 Part 5. Submarines a. Element Per Cent by Weight Not Less Than Not More Than Aluminium 8.5 Manganese − 1.1 Surface Ships a.0 5. (See NES 304 Part 1. (See NES 304 Part 3.1.1. (4) Class I and II large or complex castings if stated in the contract. (3) Class III castings in accordance with NES 863. b. NES 729 Part 1.3.3 Physical Characteristics 1.1 .1 − Chemical Composition of Ingots 1.01 Tin − 0. BS EN 10002−1. BS 6208.5 Copper (by difference) − Remainder Lead − 0. This alloy is not to be used for castings in first level systems and castings that come into contact with sea water. DEF STAN 03−1.NES 747 Part 3 Issue 4 November 1999 1.) Classification a.8 10. Table 1. This alloy may be used for submarine propellers if stated in the contract.05 Total Impurities − 0. 1. PERFORMANCE SPECIFICATION Related Documents: BS 1400. All ingots used are to be stamped. Table 1.05 Total Impurities − 0. are not to be used.0 5. Ingots and the manufacturer’s own approved scrap complying with the definition given in Annex B may be included in the cast. Any ingots.30 Impurities * Nickel content is to be greater than the iron content. on which the stamping or embossing is illegible. Castings are to conform to the chemical composition given in Table 1. or illegible.NES 747 Part 3 Issue 4 November 1999 1. no further additions are permitted prior to pouring into the mould.4 Chemical composition derived from BS 1400 AB2 except the maximum Manganese and Lead levels are lower to improve sea water corrosion resistance and weldability respectively. embossed or have a label affixed with a unique cast number.5 Nickel* 4.01 Tin − 0. Mechanical Properties a.2a.1 Silicon − 0.0 5.3 − Properties 1. Following acceptance of the analysis from the melt.0 Iron* 4. 1.1 Magnesium − 0.2 − Chemical Composition of Castings NOTE 1.2 Castings a.5 Zinc − 0.8 10.5 Manganese − 1.6. are to be as detailed in Table 1. No other scrap is permitted.2% Proof Stress (N/mm2) (N/mm2) (%) 640 250 13 Table 1. or the label has been removed/fallen off.2 .5 Copper (by difference) − Remainder Lead − 0.65S o Gauge Length Tensile Strength 0.3.2.1.3. At room temperature the mechanical properties obtained from test pieces specified in Clause 1. b.3 Quality of Material a. Per Cent by Weight Element Not Less Than Not More Than Aluminium 8. Elongation on 5.3. 3a.4 Blending out of surface defects is preferable to weld repair whenever possible.5. (2) Area of excavation in non-designated regions is to be restricted to 20% of the inner or outer surface area of the region.5. (2) Area of weld deposition in Critical Test Regions and Test Regions to be restricted to 10% of the inner or outer surface area of the region. including the area affected by the fairing.6a. Unacceptable surface defects which cannot be blended out within the limitations of Clause 1. Rectification by blending is not permitted where this encroaches on any bearing or sealing surface. not including flange thicknesses and webs. The depression sides and ends are to be smoothly blended out by a minimum radius of three times the maximum depth of blending and the edge formed with the surface is also to be free from sub-surface defects as revealed by radiography or ultrasonics. Weld build-up exceeding the tolerance on contract drawing section thickness is to be a reason for rejection. not including flange thicknesses and webs. Rectification of Surface Defects by Blending a.1 Defects a. not including flange thicknesses and webs.6a. Rectification of Dimensional Defects by Weld Deposition a.NES 747 Part 3 Issue 4 November 1999 1. and unacceptable sub-surface defects may be repaired by welding using an approved procedure for the material concerned in accordance with NES 771 and within the following limits: (1) Area of excavation in Critical Test Regions and Test Regions is to be restricted to 10% of the inner or outer surface area of the region.5. providing the resulting depression does not reduce the contract drawing section thickness by more than 5mm for section thickness over 50mm. is not to exceed 10% of any designated region or 20% of any non-designated region. The total area subjected to blending. subject to any limitations imposed by Clause 1. in Critical Test Regions and Test Regions. (3) Area of weld deposition in non-designated regions is to be restricted to 20% of the inner or outer surface area of the region not including flange thickness and webs.5.5.2 Any casting may be rejected for defects discovered during subsequent machining notwithstanding that the casting had been passed previously as conforming to this NES. 1. or 10% of section thicknesses up to and including 50mm. NOTE 1. subject to any limitations imposed by Clause 1.3 .5.3 1. 1. Correction of casting dimensions and machining errors may be made by weld deposition using an approved procedure for the material concerned in accordance with NES 771 and shall be within the following limits: (1) Weld deposition thickness to be restricted to 20% of contract drawing section thickness from 12mm to 50mm and to 10mm above 50mm section thickness. b. Rectification of Surface and Sub-Surface Defects by Welding a. Unacceptable surface defects may be blended out by an approved process.5 Defects and Rectification of Defects 1.5. b. 1 Analysis a. (1) Class II castings may be impregnated but only with the written approval of the Project Manager. Figure 2 from the same melt as the casting they represent. (2) Class III castings may be impregnated. Impregnation a.4 .6. 1.7 (1) Total weld repair area of Class I and Class II castings is not to exceed 10% of the surface area of the casting.5.6.5. a full chemical analysis is to be made from a sample piece taken from each cast for ingots and for castings.5. (b) The total area pressure tested in non-designated regions in Class II and Class III castings.1 Destructive Tests 1. Special Repairs a.1. 1. (3) The area of leakage necessitating remedial action does not exceed 10% of: (a) The Test Region containing the defect in Class II castings. All weld repairs are to be fully reinspected in accordance with the requirements of Clause 1. 1. 1. 1.8 Any individual repair in Critical Test Regions shall not exceed 5% of the test area containing the defect. Impregnation will not be accepted as a recovery procedure for Class I castings.6 Limits on Combined Weld Repairs a. eg dimensional correction. surface and sub-surface defects is to be within the following limits: Rectification of Defects a.2 In addition to the normal melt control analysis. Tensile tests in accordance with BS EN 10002−1 are to be made on test samples cast in accordance with BS 1400. Three tensile-test specimens are advised. 1. 1. In Test Regions any individual repair is not to exceed 10% of test area containing the defect. (2) The total weld repair area of Class III castings is not to exceed 20% of the surface area of the casting excluding flange thicknesses and webs. to enable retests in the event of failure of the initial test specimen.1. The results of the examinations are to meet the acceptance standards of Clause 3.NES 747 Part 3 Issue 4 November 1999 1. The rectification of surface and sub-surface defects by welding is to be in accordance with NES 771.5 Limits on Individual Sub-Surface Repairs a.6.5. Mechanical Tests a.6 Test Methods 1. excluding flange thicknesses and webs.5. Impregnation is a recognized recovery procedure for Class II and III castings in accordance with DEF STAN 03−1.1.6.9 The total combined area of weld repairs from all causes. Where the repairs necessary to meet the acceptance standards are more extensive than are permitted by this specification and if it is considered that effective economical repair is possible the Contractor may submit repair proposals in accordance with NES 771 to the Project Manager for decision. Where practicable.2. NOTE The grain structure of cast nickel aluminium bronze may preclude inspection by ultrasonics.2 Non-Destructive Tests a. The suitability for ultrasonic inspection is to be assessed in accordance with BS 6208 Clauses 9. All sub-surface imperfections are to be identified for subsequent assessment in accordance with the acceptance standards. b. Ultrasonic examination is to be carried out in compliance with NES 729 Part 5.2.6. 1. All imperfections are to be identified and recorded. 1. is carried out on all Class I and II castings before any machining operations are commenced to prevent nugatory work. Radiographic Examination of Non-Designated Regions on a Sample Basis a.6. 1.1. 1. 1.2.2 Should any of the original test specimens fail to meet acceptance standards.5 All castings are to be fully dimensionally checked.6.2. (2) Sample positions on large Class II or Class III castings. Typical examples are: (1) Lowly stressed Class II castings.6. All sub-surface imperfections are to be identified for subsequent assessment in accordance with the acceptance standards.6.6. Radiography a. 1.2. A minimum of 10% of the total area examined by ultrasonics is to be radiographed.3 Reference diagrams according to NES 863 are to be provided by the purchaser for all Class I and Class II castings to show Critical Test Regions and Test Regions which are to be subjected to non-destructive testing (NDT). (3) Batch supply of Class III castings.2 and 9.4 a.NES 747 Part 3 Issue 4 November 1999 1.2.7 The manufacturer is to subject Critical Test Regions and Test Regions to either 100% radiographic or 100% ultrasonic examination. 1. Liquid Penetrant a. Dimensional Check a.5 .6 All castings are to be 100% visually inspected.6. in accordance with NES 729 Part 4. In certain circumstances examination by radiography on a sample basis may be specified by contract or drawings to establish that a satisfactory general quality of product is being supplied. a 100% liquid penetrant inspection is to be undertaken on all surfaces of Class I and Class II castings with the surfaces examined in their finished condition. Radiographic/Ultrasonic Examination Radiography is to be carried out in compliance with NES 729 Part 1. Visual-Optical a.6. 1. Where ultrasonic examination is used the assessment of the casting is to be confirmed by radiography of selected areas.6.3.2.3 Retests a. It is recommended that 100% liquid penetrant examination. two further specimens from the same cast may be broken in accordance with BS EN 10002−1. Ultrasonic Examination a. assisted where necessary by the use of ¢5 magnification optics.1 1. When necessary this will be specified in the contract.6 .6. Certain castings may require longer periods of pressure testing. When stated in the contract the castings are to be subjected to the specified water pressure tests for a minimum period of 15 minutes.2. 1.NES 747 Part 3 Issue 4 November 1999 1.8 Pressure Tests a. 2.NES 747 Part 3 Issue 4 November 1999 2. NATIONAL/INTERNATIONAL REGULATIONS This NES contains no National/International Regulations information.1 . NES 747 Part 3 Issue 4 November 1999 2.2 . Both tensile test results are to conform to Table 1.3 Each chemical analysis is to conform to: Each tensile test result is to conform to Table 1.1.1 Dimensional Check a.3. hot tears or chain-like porosity and surface oxide inclusions in linear formations are not acceptable. On visual-optical inspection (Clause 1.1. in an area of 70 ¢ 70mm does not exceed 24mm or the sum of the diameters of all indications for sections over 50mm in an area of 70 ¢ 70mm does not exceed 36mm. Indications arising from porosity and surface oxide inclusions in non-linear formations are to be assessed as follows: (1) Isolated pinpoint porosity is acceptable except in areas where sealing of a housing against a running shaft is required.2a.1.2.3. 3.2 Dimensions are to comply with the component drawing.2. eg pump glands.1.2. 3.2 (1) Clause 1.NES 747 Part 3 Issue 4 November 1999 3.1.2. (2) Clause 1. for ingots. 3.1 Destructive Examination Standards 3.3b.1 Acceptance Standards 3. 3. 3.3 of this NES.1. (2) Clustered pinpoint porosity and other defects are acceptable provided that the maximum size of any indication is not to exceed 3mm diameter bleed out and the sum of the diameters of all indications for sections up to and including 50mm. and the requirements of NES 863. b. Retests a. propeller shaft seals etc. NES 863. NOTE The indications identified in Clause 3.1 .(2) are acceptable providing that the immediate area of the castings is acceptable when examined for sub-surface defects.1.(1) and 3. for castings. and in flexible couplings. see also Annex A.3 Defects are deemed to be rounded when the aspect ratio of length to width is 3.3 of this NES.1 Analysis a. 3.) the finished condition of all surfaces is to be clean and free from cracks or linear defects. The surface finish is to meet the standard specified in the contract documents and drawings.2.1.1.1. 3.1 or less. NOTE b.2. Indications of cracks.2a.2 Non-Destructive Examination Standards 3. Visual-Optical a.1. Rounded forms of surface defects are unacceptable in Critical Test Regions and Test Regions but may be acceptable in Non-Designated Regions at the discretion of the Project Manager.1.1. Liquid Penetrant a.6.3b. Mechanical Tests a. MILITARY STANDARDS/REQUIREMENTS Related Documents: NES 747 Part 3.1a. 2 Identification of Ingots and Castings 3.3a.1. Pressure Tests a. Where necessary this requirement is to be clearly stated in the contract documents and are to be the subject of discussion between the purchaser and the contractor prior to manufacture of the castings.2. Where the backwall echo is attenuated by 40% or greater. 3. Each casting is to show no evidence of leakage.2.5a.2.NES 747 Part 3 Issue 4 November 1999 c. The markings detailed in Clause 3. engraved or vibro-etched in the position indicated on the drawing.2. Each ingot is also to be marked with a unique cast number which can be stamped or embossed in easily discernible letters.3 Quality Assurance Documentation 3. or an indelibly marked self adhesive label is to be affixed. Markings are to be as conspicuous as the nature of the casting allows and provision is to be made for transferring identification markings during manufacture such that traceability is maintained throughout the service life of a casting.3b.2a. the examination by ultrasonics is unacceptable and radiography in accordance with Clause 1. Where difficulty is being experienced in satisfactorily applying identification symbols then this is to be resolved by consulting the Project Manager. b.2 .2. 3. require more stringent acceptance standards than those in Clauses 3.1. ie CI. the unique cast number is to positively identify the ingot to its quality assurance documentation. is to be employed. CIII. Any defect that causes a signal greater than or equal to the signal produced by the approved calibration standard is to be deemed unacceptable and the casting rejected. eg Critical Test Regions of the casting. b.2.4 3. 3.1 Ingots a. Acceptance Standards are to be in accordance with that specified in NES 863.2. c.5 There may be instances where machined surfaces of castings manufactured to this NES.2 Each ingot is to be marked with the legend NES 747 Part 3 stamped or embossed in easily discernible letters.3. Radiography a.1. Each casting is to be clearly identified during manufacture and be permanently marked for identification during service life with the following details: (1) Pattern or Ship Identity number plus NES 747 Part 3. (2) Class of castings. 3. Castings a..6. and 3.1. CII. eg in way of a wetted seal area. (3) The unique cast number which can be related to the quality control documentation.1 Ingots a. The markings are not to be made on the highly stressed regions.2.(1) to (3) are to be stamped. Each consignment of ingots is to be accompanied by Quality Assurance Documentation providing the results of the melt control analysis and the results of analysis of a sample piece taken from an ingot within the batch. 3. Except where otherwise stated in the contract. packaging is to be in accordance with the contractor’s normal practice subject to the affixing of a trade warning label and the addition of the following identification details on each package or case: (1) Description of castings.3.2 Castings a.1. (3) Contract Number.4 Each consignment of castings is to be accompanied by Quality Assurance Documentation giving the actual results of the tests required in Clause 1.6 together with a certificate of compliance with the acceptance standards detailed in Clause 3.NES 747 Part 3 Issue 4 November 1999 3. (2) Quantity. 3. 3.3 . Packaging a. 4 .NES 747 Part 3 Issue 4 November 1999 3. DESIGN REQUIREMENTS/GUIDANCE This NES contains no Design Requirements/Guidance information.1 . 4.NES 747 Part 3 Issue 4 November 1999 4. NES 747 Part 3 Issue 4 November 1999 4.2 . NES 747 Part 3 Issue 4 November 1999 5. 5. CORPORATE EXPERIENCE & KNOWLEDGE This NES contains no Corporate Experience & Knowledge information.1 . NES 747 Part 3 Issue 4 November 1999 5.2 . The following documents and publications are referred to in this NES: BS 1400 BS 6208 BS EN 10002−1 Specification for Copper Alloy Ingots and Copper Alloy and High Conductivity Copper Castings Method for Ultrasonic Testing of Ferritic Steel Castings Including Quality Levels Tensile Testing Of Metallic Materials Part 1: Method of Test at Ambient Temperature DEF STAN 03−1 Impregnation of Porous Castings NES 304 Shafting Systems and Propellers Part 1: Design Requirements for Main Propulsion Shafting NES 729 Part 3: Manufacturing and Detail Design Requirements for Propulsion Requirements for Non-Destructive Examination Methods Part 1: Radiographic Part 4: Liquid Penetrant Part 5: Ultrasonic NES 747 Requirements for Nickel Aluminium Bronze Castings and Ingots Part 2: Nickel Aluminium Bronze Naval Alloy Ingots and Sand Castings with Welding Permitted to the Wetted Surface Part 4: Nickel Aluminium Bronze Naval Alloy Sand Castings with Welding Restricted to the Non-Wetted Surface (Class I and II Castings only) NES 771 NES 863 Requirements.1 ANNEX A . RELATED DOCUMENTS A1. Tolerances and General Standards of Acceptance for Copper and Nickel Alloy Castings NES 824 Copper Nickel Chromium Sand Castings and Ingots Part 1: Production Requirements A. Procedure and Inspection for Weld Repair of Copper Alloy and Nickel Alloy Castings Requirements for the Classification. Dimensions.NES 747 Part 3 Issue 4 November 1999 ANNEX A. 2 .NES 747 Part 3 Issue 4 November 1999 ANNEX A A. For sub−contractors. Ingots Large/Complex Castings Pinpoint porosity Project Manager The Section within the DPA or DLO. acting on behalf of the Secretary of State for Defence. Contractor The Firm. Organization or Establishment working within the scope of this NES. Castings which the Design Authority considers are liable to require weld repair during manufacture. the product of one crucible melt. So The cross-sectional area of the gauge in a tensile test piece. For the purpose of this NES the following abbreviations apply: DLO Defence Logistics Organization DPA Defence Procurement Agency For the purpose of this NES the following definitions apply: Approved Scrap Scrap that is derived from nickel aluminium bronze. or the product of a number of furnace or crucible melts where such are aggregated and mixed prior to sampling. B. the composition of which has been established with regard to the complete range of both the alloying elements and impurity elements and is segregated and identifiable to the satisfaction of MOD. Company. the Project Manager may be the Prime Contractor. before testing. Bristol. enquiries are to be forwarded to DPA Section STGMT2 Abbey Wood. The Project Manager should be specified in the contract. B2.1 ANNEX B . Cast A cast is the product of one furnace melt. as detailed in BS EN 10002. Any circular bleed out of less than 0. ABBREVIATIONS AND DEFINITIONS B1.NES 747 Part 3 Issue 4 November 1999 ANNEX B. An ingot is to comprise a mass of metal of proportions to suit the Founder’s requirements. but where not known by the contractor.5mm diameter revealed during liquid penetrant examination in accordance with NES 729 Part 4. 2 .NES 747 Part 3 Issue 4 November 1999 ANNEX B B. 3c.4 C. 1.2.2.6.8 4 Liquid penetrant acceptance standards. 3.1.1.NES 747 Part 3 Issue 4 November 1999 ANNEX C.3 Each item is to be marked either: p = included NA = not applicable CHECK CHECK No 1 Use for submarine propellers. 5 Packaging requirements.2b.2. CLAUSE No p or NA 1. C. 1.2 Clauses where a preference for an option is to be used or where specific data is to be added are included in the Check List.6 3 Pressure tests.1 This Check List is to ensure that certain aspects of this Naval Engineering Standard are consulted when preparing a procurement specification for a particular application. 2 Radiography on a sample basis.1 ANNEX C .6. application C. PROCUREMENT CHECK LIST Notes: C. 3. NES 747 Part 3 Issue 4 November 1999 ANNEX C C.2 . 6. 1. 1. 1.5.6. 3. 1.3 Destructive tests.5.2 Proof stress. 3.1 .1 Ultrasonics. 1. 1. 3. 1.1 Pressure tests. 1. 3. 3.5 Acceptance standards. 1. 3.2 Identification of ingots. 1. 3. 1.5.2 U Mechanical properties.1 M Test specimens.1 Non−destructive test. 3.3 Mechanical tests. 1. 3.2 Elongation.2 INDEX. 3. 3.1 C P Chemical composition. 3.2 Rectification of defects.5.1 Tensile strength. 1.5 Q Dimensional check. 3. 1. 3. 1.3 Quality of material.1 E Quality assurance documentation.5. 1.2 Contamination by graphite.3 Tensile test.2 Impregnation. 1.2 Optical inspection. 3.4 R Radiography. 1.3 Physical characteristics.1 O Alumina wash.5.2.NES 747 Part 3 Issue 4 November 1999 ALPHABETICAL INDEX (Note: Page numbers are given) A N Non−destructive examination standards. 1. 1. 1.6. 1. 1. 3.3 I Identification of castings.2 Packaging.5.1 T L Liquid penetrant. 1.1 D Destructive examination standards.3 Retest.5 Manufacturer’s approved scrap. 1. 3. NES 747 Part 3 Issue 4 November 1999 INDEX.2 . Inside Rear Cover . Revision of Defence Standards Defence Standards are revised as necessary by up issue or amendment.mod. Compliance with a Defence Standard does not in itself confer immunity from legal obligations. Contract Requirements When Defence Standards are incorporated into contracts users are responsible for their correct application and for complying with contractual and statutory requirements. when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of Standardization (DStan) without delay in order that the matter may be investigated and appropriate action taken. Information on all Defence Standards is contained in Def Stan 00-00 Standards for Defence Part 3 .uk File Reference The DStan file reference relating to work on this standard is D/DStan/69/02/747. . Any person who. Index of Standards for Defence Procurement Section 4 ‘Index of Defence Standards and Defence Specifications’ published annually and supplemented regularly by Standards in Defence News (SID News). It is important that users of Defence Standards should ascertain that they are in possession of the latest issue or amendment.© Crown Copyright 2000 Copying Only as Agreed with DStan Defence Standards are Published by and Obtainable from: Defence Procurement Agency An Executive Agency of The Ministry of Defence Directorate of Standardization Kentigern House 65 Brown Street GLASGOW G2 8EX DStan Helpdesk Tel 0141 224 2531/2 Fax 0141 224 2503 Internet e-mail enquiries@dstan.