Ministry of Defence

Defence Standard 02-822 (NES 822)

Issue 1 Publication Date 01 April 2000

Nickel Chromium Molybdenum

Niobium Alloy 625
Part 2
Sand Castings And Ingots

Incorporating NES 822 Category 2

Issue 2 Publication Date December 1993

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) 822 Part 2 Issue 2 dated December 1993.

Signature and Date

Ministry of Defence

Naval Engineering Standard

NES 822 Part 2

Issue 2 (Reformatted)

December 1993

REQUIREMENTS FOR
NICKEL CHROMIUM MOLYBDENUM NIOBIUM ALLOY 625
PART 2
SAND CASTINGS AND INGOTS

This NES Supersedes

NES 822 PART 2 ISSUE 1

Record of Amendments
AMDT
1
2
3
4
5
6
7
8
9
10

INSERTED BY

DATE

NAVAL ENGINEERING STANDARD 822

REQUIREMENTS FOR NICKEL CHROMIUM MOLYBDENUM
NIOBIUM ALLOY 625
PART 2
ISSUE 2 (REFORMATTED)
SAND CASTINGS AND INGOTS

The issue and use of this Standard

is authorized for use in MOD contracts
by MOD(PE) Sea Systems and
the Naval Support Command

ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Foxhill, Bath BA1 5AB
i

ii

NES 822
Part 2
Issue 2 (Reformatted)

SCOPE
1.

This NES states the requirements for the manufacture, inspection and testing of sand castings
and ingots in Nickel Chromium Molybdenum Niobium Alloy 625.

iii

NES 822
Part 2
Issue 2 (Reformatted)

iv

NES 822
Part 2
Issue 2 (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.

This NES comprises:

Requirements for Nickel Chromium Molybdenum Niobium Alloy 625
a.

Part 1: Centrifugal Castings

b.

Part 2: Sand Castings

3.

If it is found to be unsuitable for any particular requirement the Sponsor is to be informed in

writing of the circumstances with a copy to Director Naval Architecture (DNA), NA 145.

4.

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 be
made to the Sponsor of the NES and those directly applicable to a particular contract are to
be dealt with using existing procedures or as specified in the contract.

5.

No alteration may 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 or similar
terms means by the Ministry of Defence.

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.

This NES has been reissued to reflect the changes in technical requirements.

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.

MOD Tender or Contract Process

12.

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.
v

NES 822
Part 2
Issue 2 (Reformatted)

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

British Standards Institution,

389 Chiswick High Road,
London W4 4AL

b.

Defence Standards

Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX

c.

Naval Engineering Standards

CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP

d.

Other documents

Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

16.

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.

Health and Safety

Warning
18.

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.

vi

NES 822
Part 2
Issue 2 (Reformatted)

CONTENTS
Page No

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v
v
v
v
v
vi
vi
vi

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

SECTION

1.
1.1
1.2
1.3
1.4

PHYSICAL CHARACTERISTICS . . . . . . . . . . . . .
Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality of Material . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 1.1 CHEMICAL COMPOSITION . . . . . .

1.1
1.1
1.1
1.1
1.2
1.2

SECTION

2.

HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

SECTION

3.

MECHANICAL PROPERTIES . . . . . . . . . . . . . . . .
TABLE 3.1 MECHANICAL PROPERTIES . . . . .

3.1
3.1

SECTION

4.

CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

SECTION

5.

QUALITY ASSURANCE DOCUMENTATION . . .

5.1

SECTION

6.
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8

TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiographic Examination of Non-Designated
Regions on a Sample Basis . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6.1 CAST KEEL BAR FOR TENSILE
TEST PIECE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.1

6.9

vii

6.2
6.2
6.3

NES 822
Part 2
Issue 2 (Reformatted)

SECTION

7.
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8

ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . .
Destructive Examination Standards . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Examination Standards . . . . . . . .
Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.1

SECTION

8.
8.1
8.2
8.3
8.4

8.1
8.1
8.1
8.1

8.6
8.7
8.8
8.9

DEFECTS AND RECTIFICATION OF DEFECTS

Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Defects . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Surface Defects by Blending . . . . . .
Rectification of Dimensional Defects by Weld
Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Surface and Sub-Surface Defects
by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limits on Individual Repairs . . . . . . . . . . . . . . . . . . .
Limits on Weld Repairs . . . . . . . . . . . . . . . . . . . . . . .
Impregnation of Pressure Castings . . . . . . . . . . . . . .
Special Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1
8.2
8.2
8.2
8.3

SECTION

9.
9.1
9.2

IDENTIFICATION OF INGOTS AND CASTINGS

Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1
9.1
9.1

SECTION

10.

PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1

ANNEX

A.

RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .

A.1

ANNEX

B.

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

B.1

8.5

ALPHABETICAL INDEX

viii

8.1

NES 822
Part 2
Issue 2 (Reformatted)

1.

PHYSICAL CHARACTERISTICS

1.1

Ingots
a.

Ingots are produced from pure virgin metal, master alloys or from selected scrap
refined by the argon oxygen decarburization (AOD) process. The virgin metals
and master alloys are to be:

Nickel

complying with the chemical composition

requirements of BS 375Grade R99.9 or an
equivalent specification which is at least as
restrictive.

Chromium

Niobium

high-purity electrolytic or high-purity thermic

chromium or reactor-grade ferro-chromium.
pure molybdenum, ferro-molybdenum or, for AOD
only, molybdenum oxide.
nickel niobium or ferro-niobium master alloys.

Iron

high-purity electrolytic iron.

Molybdenum

The ferro-chromium, molybdenum and niobium master alloys are to be used in

controlled amounts related to the composition limits of the product defined in
Clause 1.4a.
b.

1.2

Castings
a.

1.3

If any other metal refining process is proposed for the manufacturing of ingots,
details are to be forwarded to the Acceptance Authority, and approval obtained
before manufacture commences. The chemical composition of ingots is to
conform to TABLE 1.1.

Castings are to be made from any combination of virgin metals, master alloys
(as detailed in Clause 1.1a.), the manufacturers own approved scrap (see Clause
B1) and ingots so that the final chemical composition conforms to TABLE 1.1.

Quality of Material
a.

No further additions are to be made to a cast after the final analytical sample
has been taken.

b.

No titanium additions are to be made if air melting is used.

NOTE:

Melt contamination can be substantially reduced by using rammed basic

linings for electric furnaces. Ladles with silicate linings are to be given an
alumina wash. Silicious or graphite crucibles are not to be used.

1.1

NES 822
Part 2
Issue 2 (Reformatted)

1.4

Composition
a.

The chemical composition of both ingots and castings is given in TABLE 1.1.
Per cent by Weight

Element

Not Less Than

Not More Than

Nickel

58.0

Chromium

20.0

23.0

Molybdenum

8.0

10.0

Niobium + Tantalum

3.15

4.15

Iron

5.0

Cobalt

1.0

Manganese

0.5

Silicon

0.5

Aluminium

0.4

Titanium

0.4

Carbon

0.03

Tin

0.05

Lead

0.05

Phosphorous

0.015

Sulphur

0.015

Calcium

0.005
TABLE 1.1 CHEMICAL COMPOSITION

1.2

NES 822
Part 2
Issue 2 (Reformatted)

2.

HEAT TREATMENT
a.

Castings and test pieces are to be solution heat treated at 11501220 C for 1
hour/25mm section thickness (2 hours minimum) and then air cooled or water
quenched. Separately cast test pieces are to be heat treated in the same furnace
batch as the castings they represent.

b.

Sufficient accurately calibrated thermocouples are to be provided to ensure

complete coverage, uniform temperature and adequate temperature history.
Sulphur content of furnace atmosphere is to be less than 0.005g/m3.

c.

Should a casting be weld repaired (see Clauses 8.2a. to 8.7b.) solution heat
treatment is not to be carried out until the welding operation is completed.

2.1

NES 822
Part 2
Issue 2 (Reformatted)

2.2

NES 822
Part 2
Issue 2 (Reformatted)

3.

MECHANICAL PROPERTIES
a.

The mechanical properties at room temperature and impact strength at 46 C

of solution heat treated test pieces (as specified in Clause 6.3a.) are to be as
detailed in TABLE 3.1.
Tensile Strength

0 2% Proof Stress
0.2%

Elongation
on 5.65
5 65 S o
Gauge Length

Impact
Strength

N/mm 2

N/mm 2

Per cent

Joules

Min

Min

Min

Min

500

250

25

27

TABLE 3.1 MECHANICAL PROPERTIES

3.1

NES 822
Part 2
Issue 2 (Reformatted)

3.2

NES 822
Part 2
Issue 2 (Reformatted)

4.

CLASSIFICATION
a.

The classification of castings is as defined in NES 863.

4.1

NES 822
Part 2
Issue 2 (Reformatted)

4.2

NES 822
Part 2
Issue 2 (Reformatted)

5.

QUALITY ASSURANCE DOCUMENTATION

a.

Each consignment of ingots or castings is to be accompanied by Quality

Assurance Documentation giving the actual results of the tests required in
Section 6. together with a Certificate of Compliance with the acceptance
standards detailed in Section 7.

5.1

NES 822
Part 2
Issue 2 (Reformatted)

5.2

NES 822
Part 2
Issue 2 (Reformatted)

6.

TEST METHODS

6.1

Destructive Tests

6.2

Analysis
a.

6.3

In addition to the normal melt-control analysis, a full chemical analysis is to be

made from a sample piece taken from each cast for ingots and for castings.

Mechanical Tests
a.

Tests bars are to be cast to comply with FIGURE 6.1, from the same cast as the
castings they represent, and be heat treated to comply with Clause 2.a. Tensile
tests are to comply with BS EN 10002. Charpy V-Notch Test are to comply with
BS EN 100451.

NOTE:

b.

6.4

6.7

All castings are to be fully dimensionally checked where practicable, to ensure

that they comply with NES 863.

Visual-Optical
a.

6.6

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).

Dimensional Check
a.

6.5

It is advisable to cast three test bars to represent each cast to enable

re-testing if necessary to meet the acceptance standard details in
Clause 7.3a.

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.

It is recommended that a 100% liquid penetrant examination, in compliance

with NES 729 Part 4, is carried out on all Class I and Class II castings before any
machining operations are commenced to prevent nugatory work.

b.

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.

c.

If the casting dimensions are such that the internal surface is not accessible for
100% examination, then the extent of examination is to be agreed between
purchaser and manufacturer.

Radiography
a.

Critical Test Regions and Test Regions are to be subject to 100% radiographic
examination to comply with NES 729, Part 1. All sub-surface imperfections are
to be identified for subsequent assessment in compliance with NES 863.
6.1

NES 822
Part 2
Issue 2 (Reformatted)

6.8

Radiographic Examination of Non-Designated Regions on a Sample Basis

a.

6.9

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. 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.

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.

6.2

NES 822
Part 2
Issue 2 (Reformatted)

FIGURE 6.1 CAST KEEL BAR FOR TENSILE TEST PIECE

6.3

NES 822
Part 2
Issue 2 (Reformatted)

6.4

NES 822
Part 2
Issue 2 (Reformatted)

7.

ACCEPTANCE STANDARDS

7.1

Destructive Examination Standards

7.2

Analysis
a.

7.3

Each analysis, determined in compliance with Clause 6.2a. is to conform to

TABLE 1.1.

Mechanical Tests
a.

The mechanical properties determined in compliance with Clause 6.3a. are to

conform to the requirements of TABLE 3.1. Should an original test bar fail to
meet the requirements, two further test bars from the same cast may be tested.
Both results are to conform to the requirements of TABLE 3.1.

7.4

Non-Destructive Examination Standards

7.5

Visual-Optical

7.6

a.

On visual-optical inspection (Clause 6.4a.) the finished condition of all surfaces

is to be clean and free from cracks or linear defects. 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 AA.

b.

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

Liquid Penetrant
a.

Indications of cracks, hot tears or chain-like porosity and surface oxide

inclusions in linear formations are not acceptable.

b.

Indications arising from porosity and surface oxide inclusions in non-linear

formations are to be assessed as follows:
(1)

Isolated pinpoint porosity (minimum separation 50mm) is acceptable

except in areas where sealing of a housing against a running shaft is
required, eg pump glands, propeller shaft seals etc, and in flexible
couplings.

(2)

Clustered pinpoint porosity and other defects are acceptable provided that
the maximum size of any indications does not exceed 3mm diameter bleed
out and the sum of the diameters of all indications in an area of 70
70mm does not exceed 24mm.

NOTE:

7.7

Radiography
a.

7.8

The indications identified in Clause 7.6b.(1) and (2) are acceptable

providing that the immediate area of the castings is acceptable when
examined for sub-surface defects.

See NES 863 Clauses 09050910.

Pressure Tests
a.

Each casting is to show no evidence of leakage.

7.1

NES 822
Part 2
Issue 2 (Reformatted)

7.2

NES 822
Part 2
Issue 2 (Reformatted)

8.

DEFECTS AND RECTIFICATION OF DEFECTS

8.1

Defects
a.

8.2

Rectification of Defects
a.

8.3

Any casting may be rejected for defects discovered during subsequent

machining, notwithstanding that the casting had been passed previously as
conforming to this NES.

All castings may be weld repaired in accordance with NES 823 within the limits
detailed in this NES.

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 section
thickness by more than 5mm for section thickness over 50mm, or 10% of section
thicknesses up to and including 50mm. 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 faired smooth. The
remaining section thickness in way of the depression is to be free from
sub-surface defects as revealed by radiography or ultrasonics, in Critical Test
Regions and Test Regions. The total area subjected to blending, including the
area affected by the fairing, is not to exceed 10% of any designated region or 20%
or any non-designated region.

NOTE:

8.4

Rectification of Dimensional Defects by Weld Deposition

a.

b.

8.5

Blending out of surface defects is preferable to weld repair whenever

possible.

On section thicknesses 12mm and above correction of casting dimensions and

machining errors may be made by weld deposition on both the internal and
external surfaces using an approved procedure for the material concerned in
accordance with NES 823 and is to 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.

(2)

Area of weld deposition in Critical Test Regions and Test Regions to be

restricted to 10% of the surface area of the region, not including flange
thicknesses and webs, subject to any limitations imposed by Clause 8.7a.

(3)

Area of weld deposition in non-designated regions is to be restricted to

20% of the surface area of the region not including flange thickness and
webs.

Weld build-up exceeding the tolerance on contract drawing section thickness is

to be a reason for rejection.

Rectification of Surface and Sub-Surface Defects by Welding

a.

Unacceptable surface defects which cannot be blended out within the

limitations of Clause 8.3a. and unacceptable sub-surface defects may be
repaired by welding using an approved procedure for the material concerned in
compliance with NES 823 and within the following limits:
8.1

NES 822
Part 2
Issue 2 (Reformatted)

8.6

(2)

Area of excavation in non-designated regions is to be restricted to 20% of

the inner or outer surface area of the region, not including flange
thicknesses and webs.

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.

Limits on Weld Repairs

a.

8.8

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, not
including flange thicknesses and webs, subject to any limitations imposed
by Clause 8.7a.

Limits on Individual Repairs

a.

8.7

(1)

The total 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.

b.

After all weld repair has been completed and the casting accepted in compliance
with Section 7. the casting is to be heat treated to comply with Section 2.

c.

After heat treatment all weld repaired areas are to be liquid penetrant tested to
comply with Clause 6.6a. over an area contained by a boundary drawn at a
minimum distance of 50mm from the weld boundary. Repaired areas are also
to be radiographed in accordance with Clause 6.7a.

d.

If after three attempts, the weld repair fails to meet the acceptance standard
before or after heat-treatment, the casting is to be rejected. No casting is to be
heat treated more than three times.

Impregnation of Pressure Castings

a.

Impregnation will not be permitted as a recovery procedure for Class I castings.

b.

Impregnation in compliance with Def Stan 031 is a recognized recovery

procedure for Class II and III castings suffering from leakage during pressure
testing due to micro-porosity. The procedure may be applied to comply with the
requirements of Clause 8.8c.

c.

Class II and Class III castings may be impregnated but only with the written
approval of the Acceptance Authority and providing that the area of leakage
necessitating remedial action does not exceed 10% of:

d.

(1)

the test region containing the defect in Class II castings and

(2)

the total area pressure tested in non-designated test regions in Class II and
III castings.

Pressure tests are to be carried out on the impregnated castings to comply with
Clause 6.9a., acceptance being in compliance with Clause 7.8a. Heat treatment
is not to be carried out after impregnation.
8.2

NES 822
Part 2
Issue 2 (Reformatted)

8.9

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 QAR may submit the contractors
repair proposals in compliance with NES 823 to the Acceptance Authority for
a decision.

8.3

NES 822
Part 2
Issue 2 (Reformatted)

8.4

NES 822
Part 2
Issue 2 (Reformatted)

9.

IDENTIFICATION OF INGOTS AND CASTINGS

9.1

Ingots
a.

9.2

Each ingot is to be marked with the legend 625 and a unique cast number
stamped or embossed in easily discernible letters. The unique cast number is to
positively identify the ingot to its Quality Assurance Documentation.

Castings
a.

Each casting is to be clearly identifiable during manufacture and be

permanently marked for identification during service life with the following
details:
(1)

Pattern or Ships Identity Number plus NES 822 Part 2.

(2)

Class of casting, ie C I, C II, C III (see NES 863).

(3)

The legend 625.

(4)

The unique cast number which will relate the casting to its Quality
Assurance Documentation.

b.

The markings detailed in Clause 9.2a. are to be stamped, engraved or

vibro-etched in the position indicated on the drawing. 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 so that traceability is
maintained throughout the service life of a casting. The markings are not to be
made on the highly stressed regions, eg Critical Test Regions of the casting.

c.

Where difficulty is being experienced in satisfactorily applying identification

symbols, the problem is to be resolved by consulting the Acceptance
Authority/QAR.

9.1

NES 822
Part 2
Issue 2 (Reformatted)

9.2

NES 822
Part 2
Issue 2 (Reformatted)

10.

PACKAGING
a.

Except where otherwise stated in the contract, packaging is to comply with the
contractors 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.

(2)

Quantity.

(3)

Contract Number.

10.1

NES 822
Part 2
Issue 2 (Reformatted)

10.2

NES 822
Part 2
Issue 2 (Reformatted)

ANNEX A.
RELATED DOCUMENTS
A.1

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

See Clause
BS 375

Specification for refined nickel

1.1a.

BS EN 10002

Tensile testing of metallic materials

B.1, 6.3a.

BS EN 100451

Charpy impact test on metallic materials

Test methods (V- and U-notch)
Impregnation of Porous Castings

6.3a.

DEF STAN 031

NES 729

NES 823
NES 863

8.8b.

Requirements for Non-Destructive

Examination Methods
Part 1: Radiographic

6.7a.

Part 4: Liquid Penetrant

B.1, 6.6a.

Requirements for the Welding of Cast Nickel

Alloy 625
Requirements for the Classification,
Dimensions, Tolerances and General
Standards of Acceptance for Copper and
Nickel Alloy Castings

8.2a., 8.4a.,
8.5a., 8.9a.
4.a., 6.3b.,
6.4a., 6.7a.,
7.7a., 9.2a.

A.1

ANNEX A.

NES 822
Part 2
Issue 2 (Reformatted)

ANNEX A.

A.2

NES 822
Part 2
Issue 2 (Reformatted)

ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1

For the purpose of this NES the following definitions apply:

Acceptance Authority (AA)

The Acceptance Authority is as specified in

the Contract. Where this is not known by the
Contractor, enquiries are to be forwarded to
DNA, Section NA 115, Foxhill, Bath.

Approved Scrap

Derived from clean Cast Nickel Chromium

Molybdenum Niobium Alloy 625 foundry
arisings, the composition of which has been
established with regard to the complete range
of both the alloying elements and impurity
elements and segregated and identifiable to
the satisfaction of the MOD Quality
Assurance Representative (QAR)/Acceptance
Authority.
A product of one furnace melt or

Cast

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.
Cast

A product of one furnace melt

or
th product
the
d t off one crucible
ibl melt
lt
or
the product of a number of furnace or
crucible melts where such are aggregated and
mixed prior to sampling.
The Firm, Company, Organization, or
Establishment working within the scope of
this NES.

Contractor

Ingot

A mass of metal of proportions to suit the

Founders re-melting requirements.
Any circular bleed out of less than 0.5mm
diameter revealed during liquid penetrant
examination in accordance with NES 729,
Part 4.

Pinpoint Porosity

Quality Assurance
Representative (QAR)
S0

Any officer duly authorized to act on behalf of

the AA and the Project Manager.
The cross-sectional area of the gauge in a
tensile test piece, before testing, as detailed in
BS EN 10002.

B.1

ANNEX B.

NES 822
Part 2
Issue 2 (Reformatted)

ANNEX B.

B.2

NES 822
Part 2
Issue 2 (Reformatted)

ALPHABETICAL INDEX

A
Acceptance standards, 7.1
Analysis, 6.1, 7.1
Approved scrap, 1.1, B.1

B
Blending, 8.1

C
Castings, 1.1, 9.1
Certificate of compliance, 5.1
Chemical composition, 1.2
Cracks, 7.1

D
Defects, 8.1
Definitions, B.1
Destructive acceptance standards, 7.1
Destructive tests, 6.1
Dimension check, 6.1

H
Heat treatment, 2.1, 8.2

I
Identification of castings, 9.1
Identification of ingots, 9.1
Impregnation, 8.2
Ingots, 1.1, 9.1

L
Linear defects, 7.1
Liquid penetrant, 6.1, 7.1

M
Mechanical properties, 3.1
Mechanical tests, 6.1

INDEX.1

INDEX

NES 822
Part 2
Issue 2 (Reformatted)

N
Non-destructive acceptance standards, 7.1
Non-destructive test, 6.1, 6.2, 7.1

O
Optical inspection, 6.1, 7.1

P
Packaging, 10.1
Physical characteristics, 1.1, 1.2
Pinpoint porosity, 7.1, B.1
Pressure tests, 6.2, 7.1, 8.2
Proof stress, 3.1

Q
Quality Assurance, 5.1
Quality of material, 1.1

R
Radiography, 6.1, 6.2, 7.1, 8.1
Rectification of defects, 8.1, 8.2

S
Sample examination, 6.2
Special repairs, 8.3

T
Tensile strength, 3.1
Tensile test, 6.1
Test pieces, 6.1
Tests, 6.1, 6.2

V
Visual inspection, 6.1, 7.1

W
Weld deposition, 8.1
Weld repair, 8.1, 8.2

INDEX

INDEX.2

Inside Rear Cover

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