02-747 part 3

Ministry of DefenceDefence Standard 02-747 (NES 747)

Issue 1 Publication Date 01 April 2000

Incorporating NES 747 Part 3 Category 2

Issue 4 Publication Date November 1999

Requirements For Nickel AluminiumBronze Castings And Ingots

Part 3Nickel Aluminium BronzeCommercial Alloy Ingots

And Sand Castings

DStanDStan is now the publishing authority for all Maritime Standards (formerly NESs). Any reference to any other publishing authority throughout this standard should be ignored.Any queries regarding this or any other Defence Standard should be referred to the DStan Helpdesk as detailed at the back of this document.

AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

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.

Ministry of Defence

Naval Engineering Standard

CATEGORY 2

NES 747 Part 3 Issue 4 November 1999

REQUIREMENTS FOR NICKEL ALUMINIUM BRONZECASTINGS AND INGOTS

PART 3

NICKEL ALUMINIUM BRONZE COMMERCIAL ALLOY INGOTSAND SAND CASTINGS

CROWN COPYRIGHT 1999

This NES Supersedes

DG SHIPS 361ANES 747 PART 3 ISSUE 1NES 747 PART 3 ISSUE 2NES 747 PART 3 ISSUE 3

Record of Amendments

AMDT INSERTED BY DATE

1

2

3

4

5

(i)

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,Defence Procurement Agency,STGSA,Ash 0, #95,MOD Abbey Wood,Bristol BS34 8JH

NES 747 Part 3Issue 4November 1999

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NES 747 Part 3Issue 4

November 1999

(iii)

SCOPE

1. This NES states the requirements for the physical characteristics, test methods andacceptance standards of cast metal nickel aluminium bronze Commercial Alloy ingots andsand castings. (See Clause 1.1 for applicability.)

Submarines

2. This NES does not cover the use of the castings for first level systems and castings that maycome into contact with sea water. (See Clause 1.1.2a.)

NOTE The material covered by this NES suffers from selective phase corrosion in thepresence of sea water, particularly if the material has been weld repaired. Moreexpensive alloys, ie alloys to NES 747 Part 2, NES 747 Part 4 or NES 824 Part 1are available for use where severe corrosion cannot be tolerated in sea watersystems.


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November 1999

(v)

FOREWORD

Sponsorship1. This Naval Engineering Standard (NES) is sponsored by the Defence Procurement Agency,

Ministry of Defence (MOD).

2. 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 withWelding 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 WeldingRestricted to the NonWetted Surface (Class I and II Castings only)

Part 5: The Design andManufacture of Nickel Aluminium Bronze Sand Castings

3. Any user of this NES either within MOD or in industry may propose an amendment to it.Proposals for amendments that are not directly applicable to a particular contract are to bemade to the publishing authority identified on Page (i), and those directly applicable to aparticular contract are to be dealt with using contract procedures.

4. If it is found to be unsuitable for any particular requirement MOD is to be informed in writingof the circumstances.

5. No alteration is to be made to this NES except by the issue of an authorized amendment.

6. Unless otherwise stated, reference in this NES to approval, approved, authorized and similarterms, means by the MOD in writing.

7. Any significant amendments that may be made to this NES at a later date will be indicatedby a vertical sideline. Deletions will be indicated by 000 appearing at the end of the lineinterval.

8. ThisNES has been reissued to reflect changes inDepartmental Nomenclature due to theMODreorganization and the changes in related documents.

Conditions of Release

General9. This Naval Engineering Standard (NES) has been devised solely for the use of the MOD, and

its contractors in the execution of contracts for the MOD. To the extent permitted by law, theMOD hereby excludes all liability whatsoever and howsoever arising (including but withoutlimitation, libability resulting from negligence) for any loss or damage however caused whenthe NES is used for any other purpose.

10. This document is Crown Copyright and the information herein may be subject to Crown orthird party rights. It is not to be released, reproduced or published without written permissionof the MOD

11. The Crown reserves the right to amend or modify the contents of this NES without consultingor informing any holder.

MOD Tender or Contract Process12. This NES is the property of the Crown. Unless otherwise authorized in writing by the MOD

must be returned on completion of the contract, or submission of the tender, in connectionwith which it is issued.

13. When this NES is used in connection with aMOD tender or contract, the user is to ensure thathe is in possession of the appropriate version of each document, including related documents,relevant to each particular tender or contract. Enquiries in this connection may be made tothe authority named in the tender or contract.


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14. When NES are incorporated into MOD contracts, users are responsible for their correctapplication and for complying with contractual and other statutory requirements.Compliance with an NES does not of itself confer immunity from legal obligations.

Categories of NES

15. The Category of this NES has been determined using the following criteria:

a. Category 1. If not applied may have a Critical affect on the following:

Safety of the vessel, its complement or third parties.

Operational performance of the vessel, its systems or equipment.

b. Category 2. If not applied may have a Significant affect on the following:

Safety of the vessel, its complement or third parties.

Operational performance of the vessel, its systems or equipment.

Through life costs and support.

c. Category 3. If not applied may have a Minor affect on the following:

MOD best practice and fleet commonality.

Corporate experience and knowledge.

Current support practice.

Related Documents

16. In the tender and procurement processes the related documents listed in each section andAnnex A can be obtained as follows:

a. British Standards British Standards Institution,389 Chiswick High Road,London, W4 4AL

b. Defence Standards Defence Standardization, BM & D,Kentigern House, 65 Brown Street,Glasgow, G2 8EX.

c. Naval Engineering Standards DSDC(L), CSE Llangennech, Llanelli,Dyfed, SA14 8YP.

d. Other documents Tender or Contract Sponsor to advise.

17. All applications to the MOD for related documents are to quote the relevant MOD Invitationto Tender or Contract number and date, together with the sponsoring Directorate and theTender or Contract Sponsor.

18. Prime Contractors are responsible for supplying their subcontractors with relevantdocumentation, including specifications, standards and drawings.

Health and Safety

Warning

19. This NES may call for the use of processes, substances and/or procedures that are injuriousto health if adequate precautions are not taken. It refers only to technical suitability and inno way absolves either the supplier or the user from statutory obligations relating to healthand safety at any stage of manufacture or use. Where attention is drawn to hazards, thosequoted may not necessarily be exhaustive.

20. This NES has been written and is to be used taking into account the policy stipulated in JSP430: MOD Ship Safety Management System Handbook.

Additional Information

21. (There is no relevant information included.)


November 1999

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CONTENTSPage No

TITLE PAGE (i). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCOPE (iii). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FOREWORD (v). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sponsorship (v). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Conditions of Release (v). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Categories of NES (vi). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Documents (vi). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Health and Safety (vi). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Additional Information (vi). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTENTS (vii). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1. PERFORMANCE SPECIFICATION 1.1. . . . . . . . . . .1.1 Applicability 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.1 Surface Ships 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1.2 Submarines 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Classification 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3 Physical Characteristics 1.1. . . . . . . . . . . . . . . . . . . . . . .1.3.1 Ingots 1.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 1.1 Chemical Composition of Ingots 1.1. . . . . . . . . . . . . . . .1.3.2 Castings 1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Table 1.2 Chemical Composition of Castings 1.2. . . . . . . . . . . . . .1.3.3 Quality of Material 1.2. . . . . . . . . . . . . . . . . . . . . . . . . . .1.4 Mechanical Properties 1.2. . . . . . . . . . . . . . . . . . . . . . . .Table 1.3 Properties 1.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Defects and Rectification of Defects 1.3. . . . . . . . . . . . .1.5.1 Defects 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5.2 Rectification of Dimensional Defects by Weld

Deposition 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5.3 Rectification of Surface Defects by Blending 1.3. . . . .1.5.4 Rectification of Surface and Sub-Surface Defects

by Welding 1.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5.5 Limits on Individual Sub-Surface Repairs 1.4. . . . . . .1.5.6 Limits on Combined Weld Repairs 1.4. . . . . . . . . . . . .1.5.7 Rectification of Defects 1.4. . . . . . . . . . . . . . . . . . . . . . .1.5.8 Impregnation 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5.9 Special Repairs 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Test Methods 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.1 Destructive Tests 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.1.1 Analysis 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.1.2 Mechanical Tests 1.4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.1.3 Retests 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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1.6.2 Non-Destructive Tests 1.5. . . . . . . . . . . . . . . . . . . . . . . .1.6.2.1 Dimensional Check 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.2.2 Visual-Optical 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.2.3 Liquid Penetrant 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.2.4 Radiographic/Ultrasonic Examination 1.5. . . . . . . . . . .1.6.2.5 Radiography 1.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6.2.6 Radiographic Examination of Non-Designated

Regions on a Sample Basis 1.5. . . . . . . . . . . . . . . . . . . .1.6.2.7 Ultrasonic Examination 1.5. . . . . . . . . . . . . . . . . . . . . . .1.6.2.8 Pressure Tests 1.6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2. NATIONAL/INTERNATIONAL REGULATIONS 2.1

SECTION 3. MILITARY STANDARDS/REQUIREMENTS 3.1. . . .3.1 Acceptance Standards 3.1. . . . . . . . . . . . . . . . . . . . . . . .3.1.1 Destructive Examination Standards 3.1. . . . . . . . . . . . .3.1.1.1 Analysis 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.1.2 Mechanical Tests 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.1.3 Retests 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2 Non-Destructive Examination Standards 3.1. . . . . . . .3.1.2.1 Dimensional Check 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2.2 Visual-Optical 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2.3 Liquid Penetrant 3.1. . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2.4 Radiography 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2.5 Ultrasonics 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1.2.6 Pressure Tests 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Identification of Ingots and Castings 3.2. . . . . . . . . . . .3.2.1 Ingots 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.2 Castings 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Quality Assurance Documentation 3.2. . . . . . . . . . . . . .3.3.1 Ingots 3.2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3.2 Castings 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Packaging 3.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4. DESIGN REQUIREMENTS/GUIDANCE 4.1. . . . . . .

SECTION 5. CORPORATE EXPERIENCE & KNOWLEDGE 5.1.

ANNEX A. RELATED DOCUMENTS A.1. . . . . . . . . . . . . . . . . . . .

ANNEX B. DEFINITIONS B.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ANNEX C. PROCUREMENT CHECK LIST C.1. . . . . . . . . . . . . . .

ALPHABETICAL INDEX INDEX.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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1.1

1. PERFORMANCE SPECIFICATIONRelated Documents: BS 1400, BS 6208, BS EN 100021, DEF STAN 031, NES 304Part 1, NES 304 Part 3, NES 729 Part 1, NES 729 Part 4, NES 729 Part 5, NES 771, NES863; see also Annex A.

1.1 Applicability

1.1.1 Surface Ships

a. This NES may be used for:

(1) Propellers if stated in the contract. (See NES 304 Part 1.)

(2) Class I and II castings provided they are not in contact with sea water.

(3) Class III castings in accordance with NES 863.

(4) Class I and II large or complex castings if stated in the contract.

1.1.2 Submarines

a. This alloy is not to be used for castings in first level systems and castings thatcome into contact with sea water.

b. This alloy may be used for submarine propellers if stated in the contract. (SeeNES 304 Part 3.)

1.2 Classification

a. The classification of castings is defined in NES 863.

1.3 Physical Characteristics

1.3.1 Ingots

a. Ingots are to conform to the chemical composition given in Table 1.1.

ElementPer Cent by Weight

ElementNot Less Than Not More Than

Aluminium 8.8 10.0

Iron* 4.0 5.5

Nickel* 4.0 5.5

Manganese 1.5

Zinc 0.5

Copper(by difference)

Remainder

ImpuritiesLead 0.01

Tin 0.1

Silicon 0.1

Magnesium 0.05

Total Impurities 0.20

* Nickel content is to be greater than the iron content.

Table 1.1 Chemical Composition of Ingots


1.2

1.3.2 Castings

a. Castings are to conform to the chemical composition given in Table 1.2.

b. All ingots used are to be stamped, embossed or have a label affixedwith auniquecast number. Any ingots, onwhich the stamping or embossing is illegible, or thelabel has been removed/fallen off, or illegible, are not to be used.

ElementPer Cent by Weight

ElementNot Less Than Not More Than

Aluminium 8.8 10.0

Iron* 4.0 5.5

Nickel* 4.0 5.5

Manganese 1.5

Zinc 0.5

Copper(by difference)

Remainder

ImpuritiesLead 0.01

Tin 0.1

Silicon 0.1

Magnesium 0.05

Total Impurities 0.30

* Nickel content is to be greater than the iron content.

Table 1.2 Chemical Composition of Castings

NOTE Chemical composition derived from BS 1400 AB2 except the maximumManganese and Lead levels are lower to improve sea water corrosionresistance and weldability respectively.

1.3.3 Quality of Material

a. Ingots and the manufacturers own approved scrap complying with thedefinition given in Annex B may be included in the cast. No other scrap ispermitted. Following acceptance of the analysis from the melt, no furtheradditions are permitted prior to pouring into the mould.

1.4 Mechanical Properties

a. At room temperature the mechanical properties obtained from test piecesspecified in Clause 1.6.1.2a. are to be as detailed in Table 1.3.

Tensile Strength 0.2% Proof Stress Elongation on 5.65 SoGauge Length

(N/mm2) (N/mm2) (%)640 250 13

Table 1.3 Properties


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1.3

1.5 Defects and Rectification of Defects1.5.1 Defects

a. Any casting may be rejected for defects discovered during subsequentmachining notwithstanding that the casting had been passed previously asconforming to this NES.

1.5.2 Rectification of Dimensional Defects by Weld Deposition

a. Correction of casting dimensions and machining errors may be made by welddeposition using an approved procedure for the material concerned inaccordance with NES 771 and shall be within the following limits:

(1) Weld deposition thickness to be restricted to 20% of contract drawingsection thickness from 12mm to 50mm and to 10mmabove 50mm sectionthickness.

(2) Area of weld deposition in Critical Test Regions and Test Regions to berestricted to 10% of the inner or outer surface area of the region, notincluding flange thicknesses andwebs, subject to any limitations imposedby Clause 1.5.6a.

(3) Area of weld deposition in non-designated regions is to be restricted to20% of the inner or outer surface area of the region not including flangethickness and webs.

b. Weld build-up exceeding the tolerance on contract drawing section thickness isto be a reason for rejection.

NOTE Blending out of surface defects is preferable to weld repair wheneverpossible.

1.5.3 Rectification of Surface Defects by Blending

a. Unacceptable surface defects may be blended out by an approved process,providing the resulting depression does not reduce the contract drawing sectionthickness bymore than 5mm for section thickness over 50mm, or 10%of sectionthicknesses up to and including 50mm. The depression sides and ends are to besmoothly blended out by aminimum radius of three times the maximum depthof blending and the edge formed with the surface is also to be free fromsub-surface defects as revealed by radiography or ultrasonics, in Critical TestRegions and Test Regions. The total area subjected to blending, including thearea affected by the fairing, is not to exceed 10%of any designated region or 20%of any non-designated region.

b. Rectification by blending is not permitted where this encroaches on anybearingor sealing surface.

1.5.4 Rectification of Surface and Sub-Surface Defects by Welding

a. Unacceptable surface defects which cannot be blended out within thelimitations of Clause 1.5.3a. and unacceptable sub-surface defects may berepaired by welding using an approved procedure for the material concerned inaccordance with NES 771 and within the following limits:

(1) Area of excavation in Critical Test Regions and Test Regions is to berestricted to 10% of the inner or outer surface area of the region, notincluding flange thicknesses andwebs, subject to any limitations imposedby Clause 1.5.6a.

(2) Area of excavation in non-designated regions is to be restricted to 20% ofthe inner or outer surface area of the region, not including flangethicknesses and webs.


1.4

1.5.5 Limits on Individual Sub-Surface Repairs

a. Any individual repair in Critical Test Regions shall not exceed 5% of the testarea containing the defect. InTest Regions any individual repair isnot to exceed10% of test area containing the defect.

1.5.6 Limits on Combined Weld Repairs

a. The total combined area of weld repairs from all causes, eg dimensionalcorrection, surface and sub-surface defects is to be within the following limits:

(1) Total weld repair area of Class I and Class II castings is not to exceed 10%of the surface area of the casting, excluding flange thicknesses and webs.

(2) The total weld repair area of Class III castings is not to exceed 20% of thesurface area of the casting excluding flange thicknesses and webs.

1.5.7 Rectification of Defects

a. The rectification of surface and sub-surface defects by welding is to be inaccordance with NES 771. All weld repairs are to be fully reinspected inaccordance with the requirements of Clause 1.6. The results of theexaminations are to meet the acceptance standards of Clause 3.1.

1.5.8 Impregnation

a. Impregnation will not be accepted as a recovery procedure for Class I castings.Impregnation is a recognized recovery procedure for Class II and III castingsin accordance with DEF STAN 031.

(1) Class II castings may be impregnated but only with the written approvalof the Project Manager.

(2) Class III castings may be impregnated.

(3) The area of leakage necessitating remedial action does not exceed 10% of:

(a) The Test Region containing the defect in Class II castings.

(b) The total area pressure tested in non-designated regions in Class IIand Class III castings.

1.5.9 Special Repairs

a. Where the repairs necessary to meet the acceptance standards are moreextensive than are permitted by this specification and if it is considered thateffective economical repair is possible the Contractor may submit repairproposals in accordance with NES 771 to the Project Manager for decision.

1.6 Test Methods

1.6.1 Destructive Tests

1.6.1.1 Analysis

a. In addition to the normal melt control analysis, a full chemical analysis is to bemade from a sample piece taken from each cast for ingots and for castings.

1.6.1.2 Mechanical Tests

a. Tensile tests in accordance withBSEN100021 are to be made on test samplescast in accordance with BS 1400, Figure 2 from the same melt as the castingthey represent. Three tensile-test specimens are advised, to enable retests in theevent of failure of the initial test specimen.


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1.5

1.6.1.3 Retests

a. Should any of the original test specimens fail tomeet acceptance standards, twofurther specimens from the same cast may be broken in accordance with BSEN100021.

1.6.2 Non-Destructive Tests

a. Reference diagrams according to NES 863 are to be provided by the purchaserfor all Class I and Class II castings to show Critical Test Regions and TestRegions which are to be subjected to non-destructive testing (NDT).

1.6.2.1 Dimensional Check

a. All castings are to be fully dimensionally checked.

1.6.2.2 Visual-Optical

a. All castings are to be 100% visually inspected, assisted where necessary by theuse of 5 magnification optics. All imperfections are to be identified andrecorded.

1.6.2.3 Liquid Penetrant

a. It is recommended that 100% liquid penetrant examination, in accordance withNES 729Part 4, is carried out onall Class I and II castings before anymachiningoperations are commenced to prevent nugatory work.

b. Where practicable, a 100% liquid penetrant inspection is to be undertaken onall surfaces of Class I and Class II castings with the surfaces examined in theirfinished condition.

1.6.2.4 Radiographic/Ultrasonic Examination

a. The manufacturer is to subject Critical Test Regions and Test Regions to either100% radiographic or 100% ultrasonic examination.

1.6.2.5 Radiography

a. Radiography is to be carried out in compliance with NES 729 Part 1. Allsub-surface imperfections are to be identified for subsequent assessment inaccordance with the acceptance standards.

1.6.2.6 Radiographic Examination of Non-Designated Regions on a Sample Basis

a. In certain circumstances examination by radiography on a sample basismay bespecified by contract or drawings to establish that a satisfactory general qualityof product is being supplied. Typical examples are:

(1) Lowly stressed Class II castings.

(2) Sample positions on large Class II or Class III castings.

(3) Batch supply of Class III castings.

1.6.2.7 Ultrasonic Examination

a. Ultrasonic examination is to be carried out in compliance with NES 729 Part 5.All sub-surface imperfections are to be identified for subsequent assessment inaccordance with the acceptance standards. Where ultrasonic examination isused the assessment of the casting is to be confirmed by radiography of selectedareas. A minimum of 10% of the total area examined by ultrasonics is to beradiographed.

NOTE The grain structure of cast nickel aluminium bronze may precludeinspection by ultrasonics. The suitability for ultrasonic inspection is to beassessed in accordance with BS 6208 Clauses 9.2 and 9.3.


1.6

1.6.2.8 Pressure Tests

a. When stated in the contract the castings are to be subjected to the specifiedwater pressure tests for aminimum period of 15minutes. Certain castingsmayrequire longer periods of pressure testing. When necessary thiswill be specifiedin the contract.


November 1999

2.1

2. NATIONAL/INTERNATIONAL REGULATIONSThis NES contains no National/International Regulations information.


2.2


November 1999

3.1

3. MILITARY STANDARDS/REQUIREMENTSRelated Documents: NES 747 Part 3, NES 863; see also Annex A.

3.1 Acceptance Standards

3.1.1 Destructive Examination Standards

3.1.1.1 Analysis

a. Each chemical analysis is to conform to:

(1) Clause 1.3.1a. for ingots;

(2) Clause 1.3.2a. for castings.

3.1.1.2 Mechanical Tests

a. Each tensile test result is to conform to Table 1.3 of this NES.

3.1.1.3 Retests

a. Both tensile test results are to conform to Table 1.3 of this NES.

3.1.2 Non-Destructive Examination Standards

3.1.2.1 Dimensional Check

a. Dimensions are to comply with the component drawing, and the requirementsof NES 863.

3.1.2.2 Visual-Optical

a. On visual-optical inspection (Clause 1.6.2.2a.) the finished condition of allsurfaces is to be clean and free from cracks or linear defects. Rounded forms ofsurface defects are unacceptable in Critical Test Regions and Test Regions butmay be acceptable in Non-Designated Regions at the discretion of the ProjectManager.

NOTE Defects are deemed to be rounded when the aspect ratio of length towidthis 3.1 or less.

b. The surface finish is to meet the standard specified in the contract documentsand drawings.

3.1.2.3 Liquid Penetrant

a. Indications of cracks, hot tears or chain-like porosity and surface oxideinclusions in linear formations are not acceptable.

b. Indications arising from porosity and surface oxide inclusions in non-linearformations are to be assessed as follows:

(1) Isolated pinpoint porosity is acceptable except in areas where sealing ofa housing against a running shaft is required, eg pump glands, propellershaft seals etc, and in flexible couplings.

(2) Clustered pinpoint porosity and other defects are acceptable provided thatthe maximum size of any indication is not to exceed 3mm diameter bleedout and the sum of the diameters of all indications for sections up to andincluding 50mm, in an area of 70 70mm does not exceed 24mm or thesum of the diameters of all indications for sections over 50mm in an areaof 70 70mm does not exceed 36mm.

NOTE The indications identified in Clause 3.1.2.3b.(1) and 3.1.2.3b.(2) areacceptable providing that the immediate area of the castings is acceptablewhen examined for sub-surface defects.


3.2

c. There may be instances where machined surfaces of castings manufactured tothis NES, require more stringent acceptance standards than those in Clauses3.1.2.3a. and 3.1.2.3b., eg in way of a wetted seal area. Where necessary thisrequirement is to be clearly stated in the contract documents and are to be thesubject of discussion between the purchaser and the contractor prior tomanufacture of the castings.

3.1.2.4 Radiography

a. Acceptance Standards are to be in accordance with that specified in NES 863.

b. Any defect that causes a signal greater than or equal to the signal produced bythe approved calibration standard is to be deemed unacceptable and the castingrejected. Where the backwall echo is attenuated by 40% or greater, theexamination by ultrasonics is unacceptable and radiography in accordance withClause 1.6.2.5a. is to be employed.

3.1.2.5 Pressure Tests

a. Each casting is to show no evidence of leakage.

3.2 Identification of Ingots and Castings

3.2.1 Ingots

a. Each ingot is to bemarked with the legendNES 747Part 3 stamped or embossedin easily discernible letters. Each ingot is also to be marked with a unique castnumber which can be stamped or embossed in easily discernible letters, or anindelibly marked self adhesive label is to be affixed, the unique cast number isto positively identify the ingot to its quality assurance documentation.

3.2.2 Castings

a. Each casting is to be clearly identified during manufacture and be permanentlymarked for identification during service life with the following details:

(1) Pattern or Ship Identity number plus NES 747 Part 3.

(2) Class of castings, ie CI, CII, CIII.

(3) The unique cast number which can be related to the quality controldocumentation.

b. The markings detailed in Clause 3.2.2a.(1) to (3) are to be stamped, engravedor vibro-etched in the position indicated on the drawing. Markings are to be asconspicuous as the nature of the casting allows and provision is to be made fortransferring identification markings duringmanufacture such that traceabilityis maintained throughout the service life of a casting. The markings are not tobe made on the highly stressed regions, eg Critical Test Regions of the casting.

c. Where difficulty is being experienced in satisfactorily applying identificationsymbols then this is to be resolved by consulting the Project Manager.

3.3 Quality Assurance Documentation

3.3.1 Ingots

a. Each consignment of ingots is to be accompanied by Quality AssuranceDocumentation providing the results of themelt control analysis and the resultsof analysis of a sample piece taken from an ingot within the batch.


November 1999

3.3

3.3.2 Castings

a. Each consignment of castings is to be accompanied by Quality AssuranceDocumentation giving the actual results of the tests required in Clause 1.6together with a certificate of compliance with the acceptance standards detailedin Clause 3.1.

3.4 Packaging

a. Except where otherwise stated in the contract, packaging is to be in accordancewith the contractors normal practice subject to the affixing of a trade warninglabel and the addition of the following identification details on each package orcase:

(1) Description of castings.

(2) Quantity.

(3) Contract Number.


3.4


November 1999

4.1

4. DESIGN REQUIREMENTS/GUIDANCEThis NES contains no Design Requirements/Guidance information.


4.2


November 1999

5.1

5. CORPORATE EXPERIENCE & KNOWLEDGEThis NES contains no Corporate Experience & Knowledge information.


5.2


November 1999

A.1 ANNEX A

ANNEX A.

RELATED DOCUMENTS

A1. The following documents and publications are referred to in this NES:

BS 1400 Specification for Copper Alloy Ingots and Copper Alloy and HighConductivity Copper Castings

BS 6208 Method for Ultrasonic Testing of Ferritic Steel CastingsIncluding Quality Levels

BS EN 100021 Tensile Testing Of Metallic MaterialsPart 1: Method of Test at Ambient Temperature

DEF STAN 031 Impregnation of Porous Castings

NES 304 Shafting Systems and Propellers

Part 1: Design Requirements for Main Propulsion Shafting

Part 3: Manufacturing and Detail Design Requirements forPropulsion

NES 729 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 SandCastings with Welding Permitted to the Wetted SurfacePart 4: Nickel Aluminium Bronze Naval Alloy Sand Castingswith Welding Restricted to the Non-Wetted Surface (Class I andII Castings only)

NES 771 Requirements, Procedure and Inspection for Weld Repair ofCopper Alloy and Nickel Alloy Castings

NES 863 Requirements for the Classification, Dimensions, Tolerances andGeneral Standards of Acceptance for Copper and Nickel AlloyCastings

NES 824 Copper Nickel Chromium Sand Castings and Ingots

Part 1: Production Requirements


A.2ANNEX A


November 1999

B.1 ANNEX B

ANNEX B.

ABBREVIATIONS AND DEFINITIONS

B1. For the purpose of this NES the following abbreviations apply:

DLO Defence Logistics Organization

DPA Defence Procurement Agency

B2. For the purpose of this NES the following definitions apply:

Approved Scrap Scrap that is derived from nickel aluminium bronze, thecomposition of which has been established with regard tothe complete range of both the alloying elements andimpurity elements and is segregated and identifiable tothe satisfaction of MOD.

Cast A cast is the product of one furnace melt, the product ofone crucible melt, or the product of a number of furnaceor crucible melts where such are aggregated and mixedprior to sampling.

Contractor The Firm, Company, Organization or Establishmentworking within the scope of this NES.

Ingots An ingot is to comprise a mass of metal of proportions tosuit the Founders requirements.

Large/Complex Castings Castings which the Design Authority considers are liableto require weld repair during manufacture.

Pinpoint porosity Any circular bleed out of less than 0.5mm diameterrevealed during liquid penetrant examination inaccordance with NES 729 Part 4.

Project Manager The Section within the DPA or DLO, acting on behalf ofthe Secretary of State for Defence. The Project Managershould be specified in the contract, but where not knownby the contractor, enquiries are to be forwarded to DPASection STGMT2 Abbey Wood, Bristol. Forsubcontractors, the Project Manager may be the PrimeContractor.

So The cross-sectional area of the gauge in a tensile testpiece, before testing, as detailed in BS EN 10002.


B.2ANNEX B


November 1999

C.1 ANNEX C

ANNEX C.

PROCUREMENT CHECK LIST

Notes:C.1 This Check List is to ensure that certain aspects of this Naval Engineering

Standard are consulted when preparing a procurement specification for aparticular applicationparticular application.

C.2 Clauses where a preference for an option is to be used or where specific data isto be added are included in the Check List.

C.3 Each item is to be marked either:

p = includedNA = not applicable

CHECKNo CHECK CLAUSE No p or NA

1 Use for submarine propellers. 1.1.2b.

2 Radiography on a sample basis. 1.6.2.6

3 Pressure tests. 1.6.2.8

4 Liquid penetrant acceptance standards. 3.1.2.3c.

5 Packaging requirements. 3.4


C.2ANNEX C


November 1999

INDEX.1

ALPHABETICAL INDEX

(Note: Page numbers are given)

AAcceptance standards, 3.1

Alumina wash, 1.2

CChemical composition, 1.2

Contamination by graphite, 1.2

DDestructive examination standards, 3.1

Destructive tests, 1.5

Dimensional check, 1.5, 3.1

EElongation, 1.3

IIdentification of castings, 3.2

Identification of ingots, 3.2

Impregnation, 1.4

LLiquid penetrant, 1.5, 3.1

MManufacturers approved scrap, 1.2

Mechanical properties, 1.3

Mechanical tests, 1.5, 3.1

NNondestructive examination standards, 3.1

Nondestructive test, 1.5

OOptical inspection, 1.5, 3.1

PPackaging, 3.3

Physical characteristics, 1.1

Pressure tests, 1.6, 3.2

Proof stress, 1.3

QQuality assurance documentation, 3.2, 3.3

Quality of material, 1.2

RRadiography, 1.5, 1.6, 3.2

Rectification of defects, 1.3

Retest, 1.5, 3.1

TTensile strength, 1.3

Tensile test, 1.5, 3.1

Test specimens, 1.5

UUltrasonics, 1.6, 3.2


INDEX.2

Inside Rear Cover

Crown Copyright 2000

Copying Only as Agreed with DStan

Defence Standards are Published by and Obtainable from:

Defence Procurement AgencyAn Executive Agency of The Ministry of Defence

Directorate of StandardizationKentigern House65 Brown Street

GLASGOW G2 8EX

DStan Helpdesk

Tel 0141 224 2531/2 Fax 0141 224 2503

Internet e-mail [email protected]

File Reference

The DStan file reference relating to work on this standard is D/DStan/69/02/747.

Contract Requirements

When Defence Standards are incorporated into contracts users are responsible for their correctapplication and for complying with contractual and statutory requirements. Compliance witha Defence Standard does not in itself confer immunity from legal obligations.

Revision of Defence Standards

Defence Standards are revised as necessary by up issue or amendment. It is important thatusers of Defence Standards should ascertain that they are in possession of the latest issue oramendment. Information on all Defence Standards is contained in Def Stan 00-00 Standardsfor Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of DefenceStandards and Defence Specifications published annually and supplemented regularly byStandards in Defence News (SID News). Any person who, when making use of a DefenceStandard encounters an inaccuracy or ambiguity is requested to notify the Directorate ofStandardization (DStan) without delay in order that the matter may be investigated andappropriate action taken.

CONTENTSTITLE PAGESCOPEFOREWORDSponsorshipConditions of ReleaseGeneralMOD Tender or Contract Process

Categories of NESRelated DocumentsHealth and SafetyWarning

Additional Information

1. PERFORMANCE SPECIFICATION1.1 Applicability1.1.1 Surface Ships1.1.2 Submarines

1.2 Classification1.3 Physical Characteristics1.3.1 IngotsTable 1.1 -Chemical Composition of Ingots1.3.2 CastingsTable 1.2 -Chemical Composition of Castings1.3.3 Quality of Material

1.4 Mechanical PropertiesTable 1.3 -Properties

1.5 Defects and Rectification of Defects1.5.1 Defects1.5.2 Rectification of Dimensional Defects by Weld Deposition1.5.3 Rectification of Surface Defects by Blending1.5.4 Rectification of Surface and Sub-Surface Defects by Welding1.5.5 Limits on Individual Sub-Surface Repairs1.5.6 Limits on Combined Weld Repairs1.5.7 Rectification of Defects1.5.8 Impregnation1.5.9 Special Repairs

1.6 Test Methods1.6.1 Destructive Tests1.6.1.1 Analysis1.6.1.2 Mechanical Tests1.6.1.3 Retests

1.6.2 Non-Destructive Tests1.6.2.1 Dimensional Check1.6.2.2 Visual-Optical1.6.2.3 Liquid Penetrant1.6.2.4 Radiographic/Ultrasonic Examination1.6.2.5 Radiography1.6.2.6 Radiographic Examination of Non-Designated Regions on a Sample Basis1.6.2.7 Ultrasonic Examination1.6.2.8 Pressure Tests

2. NATIONAL/INTERNATIONAL REGULATIONS3. MILITARY STANDARDS/ REQUIREMENTS3.1 Acceptance Standards3.1.1 Destructive Examination Standards3.1.1.1 Analysis3.1.1.2 Mechanical Tests3.1.1.3 Retests

3.1.2 Non-Destructive Examination Standards3.1.2.1 Dimensional Check3.1.2.2 Visual-Optical3.1.2.3 Liquid Penetrant3.1.2.4 Radiography3.1.2.5 Pressure Tests

3.2 Identification of Ingots and Castings3.2.1 Ingots3.2.2 Castings

3.3 Quality Assurance Documentation3.3.1 Ingots3.3.2 Castings

3.4 Packaging

4. DESIGN REQUIREMENTS/ GUIDANCE5. CORPORATE EXPERIENCE & KNOWLEDGEANNEX A. RELATED DOCUMENTSANNEX B. ABBREVIATIONS AND DEFINITIONSANNEX C. PROCUREMENT CHECK LISTALPHABETICAL INDEX