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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 2 Issue 3 dated January 1995.
Ministry of Defence
NES 747
Part 2
Issue 3 (Reformatted)
January 1995
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
Record of Amendments
AMDT
1
2
3
4
5
6
7
8
9
10
INSERTED BY
DATE
ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Sea Systems, Foxhill, Bath BA1 5AB
i
ii
NES 747
Part 2
Issue 3 (Reformatted)
SCOPE
1.
This NES states the requirements for the physical characteristics, test methods and
acceptance standards of cast nickel aluminium bronze naval alloy ingots and sand castings
with welding permitted to the wetted surface. (See Section 1. for applicability.)
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 except as indicated in Clause 1.a.
iii
NES 747
Part 2
Issue 3 (Reformatted)
iv
NES 747
Part 2
Issue 3 (Reformatted)
FOREWORD
Sponsorship
1.
This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Director Naval Architecture (DNA), Section NA 115.
2.
Part 2
Nickel Aluminium Bronze Naval Alloy Ingots and Sand Castings with Welding
Permitted to the Wetted Surface
Part 3
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
Guide to the Design and Manufacture of Nickel Aluminium Bronze Sand Castings
3.
4.
Any user of this NES either within MOD or in industry may propose an amendment to it.
Proposals for amendments which are:
a.
not directly applicable to a particular contract are to be made to the Sponsor of the NES;
b.
5.
6.
Unless otherwise stated, reference in this NES to approval, approved, authorized or similar
terms means by the Ministry of Defence in writing.
7.
Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line
interval.
8.
NES 747
Part 2
Issue 3 (Reformatted)
Conditions of Release
General
9.
This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.
10.
This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.
11.
The Crown reserves the right to amend or modify the contents of this NES without consulting
or informing any holder.
This NES is the property of the Crown and unless otherwise authorized in writing by the MOD
must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.
13.
When this NES is used in connection with a MOD tender or contract, the user is to ensure that
he 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 of
the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.
14.
When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.
Related Documents
15.
In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a.
British Standards
b.
Defence Standards
c.
d.
Other documents
All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.
17.
Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
vi
NES 747
Part 2
Issue 3 (Reformatted)
This NES may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. 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. Where attention is drawn to hazards, those
quoted may not necessarily be exhaustive.
vii
NES 747
Part 2
Issue 3 (Reformatted)
viii
NES 747
Part 2
Issue 3 (Reformatted)
CONTENTS
Page No
TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Submarines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
iii
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
v
vi
vi
vi
vi
vii
vii
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
SECTION
1.
APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
SECTION
2.
2.1
2.2
PHYSICAL CHARACTERISTICS . . . . . . . . . . . . .
Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ingot Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2.1 INGOTSCHEMICAL
COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Casting Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality of Material . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2.2 CASTINGSCHEMICAL
COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.1
2.1
2.3
2.4
2.5
2.1
2.1
2.2
2.2
2.2
SECTION
3.
MECHANICAL PROPERTIES . . . . . . . . . . . . . . . .
TABLE 3.1 PROPERTIES . . . . . . . . . . . . . . . . . . . .
3.1
3.1
SECTION
4.
HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
SECTION
5.
CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1
SECTION
6.
6.1
6.2
6.1
6.1
6.1
ix
NES 747
Part 2
Issue 3 (Reformatted)
SECTION
7.
7.1
7.1.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
7.10
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.11
7.12
TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid-Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiographic/Ultrasonic Examination . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiographic Examination of Non-Designated
Regions on a Sample Basis . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION
8.
8.1
8.1.1
8.2
8.3
8.4
8.4.1
8.4.2
8.5
8.6
8.7
ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . .
Destructive Examination Standards . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Examination Standards . . . . . . . .
Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid-Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1
8.1
8.1
8.1
8.1
8.1
8.1
8.1
8.2
8.2
8.2
SECTION
9.
9.1
9.2
9.1
9.1
9.5
9.6
9.7
9.8
9.9
9.1
9.2
9.2
9.2
9.2
9.2
SECTION
10.
10.1
10.2
10.1
10.1
10.1
SECTION
11.
PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1
ANNEX
A.
RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .
A.1
ANNEX
B.
B.1
ANNEX
C.
C.1
9.3
9.4
7.2
7.2
7.2
9.1
9.1
NES 747
Part 2
Issue 3 (Reformatted)
1.
APPLICABILITY
a.
Propellers.
(2)
Class I and Class II castings which will not come into contact with sea
water.
(3)
Large/complex Class I and Class II castings which may come into contact
with sea water providing that MOD contractual approval is granted.
(4)
1.1
NES 747
Part 2
Issue 3 (Reformatted)
1.2
NES 747
Part 2
Issue 3 (Reformatted)
2.
PHYSICAL CHARACTERISTICS
2.1
Ingots
a.
Ingots for casting stock are to be cast from virgin metals as follows:
Nickel
Iron
NOTE:
2.2
Aluminium
Copper
to BS 6017CuCath2 or CuETP2
Manganese
Ingot Analysis
a.
Aluminium
8.9
9.6
Iron*
4.0
5.0
Nickel*
4.5
5.5
Manganese
1.0
1.4
Remainder
Impurities
Zinc
0.05
Lead
0.01
Tin
0.05
Silicon
0.05
Magnesium
0.05
Chromium
0.01
Total Impurities
0.20
2.3
Castings
a.
Casting are to be made from ingots and approved scrap (see Clause B.1).
NOTES:
1.
2.
2.1
NES 747
Part 2
Issue 3 (Reformatted)
2.4
Casting Analysis
a.
2.5
Quality of Material
a.
Only the manufacturers own approved scrap complying with Clause B.1 may
be included in the cast. No other scrap is permitted. Following acceptance of the
analysis from the melt, no further additions are permitted prior to pouring into
the mould.
Element
Aluminium
8.8
9.5
Iron*
4.0
5.0
Nickel*
4.5
5.5
Manganese
0.75
1.3
Remainder
Impurities
Zinc
0.05
Lead
0.01
Tin
0.05
Silicon
0.10
Magnesium
0.05
Chromium
0.01
Total Impurities
0.25
2.2
NES 747
Part 2
Issue 3 (Reformatted)
3.
MECHANICAL PROPERTIES
a.
N/mm 2
N/mm 2
Per Cent
Min
Min
Min
620
250
15
3.1
NES 747
Part 2
Issue 3 (Reformatted)
3.2
NES 747
Part 2
Issue 3 (Reformatted)
4.
HEAT TREATMENT
a.
b.
All castings and associated mechanical test pieces are to be heat treated at
675 C 15 C for a minimum period of six hours. The castings are to be
supported as necessary during the heat treatment to prevent excessive
distortion. The furnace temperature must not exceed 300 C when loading the
castings or test pieces. After a minimum of six hours at 675 C 15 C the
castings and test pieces are to be removed from the furnace and cooled to room
temperature in still air. Heat treatment of test pieces may be carried out
separately from the castings they represent.
c.
Only furnaces validated and approved in accordance with NES 746 are to be
used for the heat treatment of castings and test pieces.
4.1
NES 747
Part 2
Issue 3 (Reformatted)
4.2
NES 747
Part 2
Issue 3 (Reformatted)
5.
CLASSIFICATION
a.
5.1
NES 747
Part 2
Issue 3 (Reformatted)
5.2
NES 747
Part 2
Issue 3 (Reformatted)
6.
6.1
Ingots
a.
6.2
Castings
a.
6.1
NES 747
Part 2
Issue 3 (Reformatted)
6.2
NES 747
Part 2
Issue 3 (Reformatted)
7.
TEST METHODS
7.1
Destructive Tests
7.1.1
Analysis
a.
7.2
Mechanical Tests
a.
7.3
7.8
All castings are to be 100% visually inspected, assisted where necessary, by the
use of 5 magnification optics. All imperfections are to be identified and
recorded.
Liquid-Penetrant
a.
b.
Radiographic/Ultrasonic Examination
a.
7.9
All castings are to be fully dimensionally checked to ensure that they comply
with NES 863.
Visual-Optical
a.
7.7
Dimensional Check
a.
7.6
Should the original test specimen fail to meet acceptance standards, two further
heat treated specimens from the same cast may be broken in accordance with
BS EN 10002.
Non-Destructive Tests
a.
7.5
Retests
a.
7.4
The manufacturer is to subject Critical Test Regions and Test Regions to either
100% radiographic or 100% ultrasonic examination.
Radiography
a.
7.1
NES 747
Part 2
Issue 3 (Reformatted)
7.10
7.11
(2)
(3)
Ultrasonic Examination
a.
NOTE:
7.12
Pressure Tests
a.
When stated in the contract the castings are to be subjected to the specified
water pressure test for a minimum period of 15 minutes. Certain castings may
require longer periods of pressure testing. When necessary this will be specified
in the contract.
7.2
NES 747
Part 2
Issue 3 (Reformatted)
8.
ACCEPTANCE STANDARDS
8.1
8.1.1
Analysis
a.
8.2
(1)
(2)
Mechanical Tests
a.
8.3
Retests
a.
Both tensile test results are to conform to TABLE 3.1 of this NES.
8.4
8.4.1
Visual-Optical
a.
b.
8.4.2
The surface finish is to meet the standard specified in the contract documents
and drawings.
Liquid-Penetrant
a.
b.
(2)
(b)
(c)
the sum of the diameters of all indications for sections over 50mm
in an area of 70 70 does not exceed 36mm.
OR
8.1
NES 747
Part 2
Issue 3 (Reformatted)
NOTE:
c.
8.5
Ultrasonics
a.
8.7
Radiography
a.
8.6
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
repaired or rejected. Where the backwall echo is attenuated by 40% or greater,
the examination by ultrasonics is unacceptable and radiography in accordance
with Clauses 7.8a. and 7.11a. are to be employed.
Pressure Tests
a.
8.2
NES 747
Part 2
Issue 3 (Reformatted)
9.
9.1
Defects
a.
9.2
b.
9.3
(2)
(3)
9.4
(2)
9.1
NES 747
Part 2
Issue 3 (Reformatted)
9.5
9.6
9.7
9.8
The total combined area of weld repairs from all causes, eg dimensional
correction, 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 the
surface area of the casting excluding flange thicknesses and webs.
Rectification of Defects
a.
b.
Following heat treatment all weld repairs are to be examined in accordance with
Clauses 7.5a. to 7.12a. The weld repaired casting must satisfy the requirements
of Clause 7.12a.
Impregnation
a.
9.9
Any individual repair in Critical Test Regions shall not exceed 5% of the test
area containing the defect. In Test Regions any individual repair shall not
exceed 10% of test area containing the defect.
Class II castings may be impregnated but only with the written approval
of the Acceptance Authority.
(2)
Class III castings may be impregnated with the approval of the Acceptance
Authority.
(3)
The area of leakage necessitating remedial action does not exceed 10% of:
(a)
(b)
Special Repairs
a.
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 contractors repair proposals, in
accordance with NES 771 may be submitted to the Acceptance Authority for
decision.
9.2
NES 747
Part 2
Issue 3 (Reformatted)
10.
10.1
Ingots
a.
10.2
Each ingot is to be marked with the legend NAB stamped or embossed in easily
discernible letters. Each ingot is also to be marked with a unique cast number
which can be stamped or embossed in easily discernible letters, or an indelibly
marked self adhesive label is to be affixed. The unique cast number is to
positively identify the ingot to its quality assurance documentation.
Castings
a.
(2)
(3)
(4)
The unique cast number which can be related to the quality control
documentation.
NOTE:
b.
c.
10.1
NES 747
Part 2
Issue 3 (Reformatted)
10.2
NES 747
Part 2
Issue 3 (Reformatted)
11.
PACKAGING
a.
Description of castings.
(2)
Quantity.
(3)
Contract Number.
11.1
NES 747
Part 2
Issue 3 (Reformatted)
11.2
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX A.
RELATED DOCUMENTS
A.1
2.a.
BS 1400
7.2a.
BS 6017
2.a.
BS 6208
BS EN 10002
NES 729
NES 746
NES 771
NES 863
DPT 1311
A.1
7.11a.
B.1, 7.2a.,
7.3a.
9.8a.
7.9a.
B.1, 7.7a.
7.11a.
4.c.
9.4a., 9.7a.,
9.9a.
1.a., 5.a.,
7.4a., 7.5a.,
8.5a.
10.2a.
ANNEX A.
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX A.
A.2
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1
Approved Scrap
Cast
A cast is:
the product of one furnace melt
or
the product of one crucible melt
or
the product of a number of
furnace or crucible melts where
such are aggregated and mixed
prior to sampling.
Contractor
Ingots
Large/Complex castings
Pinpoint Porosity
Wetted Surface
B.1
ANNEX B.
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX B.
B.2
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX C.
PROCUREMENT CHECK LIST
Notes:
1.
This Check List is to ensure that certain aspects of this Naval Engineering
Standard are consulted when preparing a Statement of Technical
Requirements for a particular application.
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.
List
Each item is to be marked either
2.
3.
= included
NA
= not applicable
CHECK
CHECK
No
1
Radiographic Examination of Non-Designated
Regions on a Sample Basis
2
Pressure Tests
3
Packaging
CLAUSE No
! or NA
7.10a.
7.12a.
8.4.2c.
11.a.
C.1
ANNEX C.
NES 747
Part 2
Issue 3 (Reformatted)
ANNEX C.
C.2