Ministry of Defence

Defence Standard 02-825 (NES 825)

Issue 1 Publication Date 01 April 2000

Requirements For Welding Copper

Nickel Chromium Sand Castings
(Including Welding Wire)

Incorporating NES 825 Category 2

Issue 2 Publication Date June 1989

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) 825 Issue 2 dated June 1989.

Signature and Date

Ministry of Defence

Naval Engineering Standard

NES 825

Issue 2 (Reformatted)

June 1989

REQUIREMENTS FOR WELDING

COPPER NICKEL CHROMIUM SAND CASTINGS
(INCLUDING WELDING WIRE)

This NES Supersedes

NES 825 ISSUE 1

Record of Amendments
AMDT

INSERTED BY

INCORPORATED

2
3
4
5
6
7
8
9
10

DATE

NAVAL ENGINEERING STANDARD 825

ISSUE 2 (REFORMATTED)
REQUIREMENTS FOR WELDING COPPER NICKEL
CHROMIUM SAND CASTINGS (INCLUDING WELDING WIRE)

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
Sea Systems, Foxhill, Bath BA1 5AB
i

ii

NES 825
Issue 2 (Reformatted)

SCOPE
1.

This NES specifies the minimum requirements, procedure and inspection standards for the
welding repair of Copper Nickel Chromium Sand Castings supplied in accordance with
NES 824 Part 1 and also the procurement specification for welding wire.

iii

NES 825
Issue 2 (Reformatted)

iv

NES 825
Issue 2 (Reformatted)

FOREWORD
Sponsorship
1.

This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Chief Naval Architect (CNA), Section NA 133.

2.

It is to be applied as required by any Ministry of Defence contract for welding Copper Nickel
Chromium Sand Castings and for the procurement of welding wire and is applicable to Surface
Ships and Submarines.

3.

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

informed in writing of the circumstances with a copy to CNA, Section NA 145.

4.

Any user of this NES either within MOD or in outside 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.

directly applicable to a particular contract are to be dealt with using existing procedures
or as specified in the contract.

5.

No alteration is to be made to this NES except by the issue of a formal 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 due to substantial amendments including changes in paragraph
numbering.

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.

NES 825
Issue 2 (Reformatted)

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.

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 825
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
vi
vi
vi
vi

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

vii

SECTION

QUALIFICATION REQUIREMENTS . . . . . . . . . .
Weld Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair by Surface Build-Up . . . . . . . . . . . . . . . . . . .
Repair of Sub-Surface Defects . . . . . . . . . . . . . . . . .
Repair Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 1.1 SURFACE BUILD-UP
WELDER AND PROCEDURE
QUALIFICATION TEST PIECE . . . . . . . . . . . . . . .
FIGURE 1.2 SUB-SURFACE REPAIR
WELDER AND PROCEDURE
QUALIFICATION POSITION OF
TEST SPECIMENS . . . . . . . . . . . . . . . . . . . . . . . . . .
Welder Qualification . . . . . . . . . . . . . . . . . . . . . . . . .

1.1
1.1
1.1
1.1
1.2

TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Examination . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.1 SURFACE BUILD-UP
DETAILS OF SIDE BEND TEST SPECIMEN . . . .
FIGURE 2.2 PROCEDURE QUALIFICATION
TRANSVERSE TENSILE TEST PIECE . . . . . . . . .
FIGURE 2.3 PROCEDURE QUALIFICATION
ALL WELD TENSILE TEST PIECE . . . . . . . . . . .
FIGURE 2.4 WELDER AND PROCEDURE
QUALIFICATION
SIDE BEND PIECE . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1
2.1
2.1

1.
1.1
1.2
1.3
1.4

1.5
SECTION

2.
2.1
2.2

1.3

1.4
1.5

2.2
2.3
2.4
2.5

SECTION

3.
3.1
3.2

ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . .
Non-Destructive Examination . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 3.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1
3.1
3.1
3.1

SECTION

4.

RETESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

vii

NES 825
Issue 2 (Reformatted)

SECTION

5.
5.1
5.2
5.3
5.4
5.5
5.6

WELD REPAIR OF CASTINGS . . . . . . . . . . . . . . .

Welding Limitations . . . . . . . . . . . . . . . . . . . . . . . . . .
General Welding Requirements . . . . . . . . . . . . . . . .
Temperature Measurement . . . . . . . . . . . . . . . . . . . .
Heat Treatment of Weld Repairs . . . . . . . . . . . . . . .
Approved Processes . . . . . . . . . . . . . . . . . . . . . . . . . .
Approved Welding Consumables . . . . . . . . . . . . . . .

5.1
5.1
5.2
5.3
5.3
5.3
5.3

SECTION

6.

NON-DESTRUCTIVE EXAMINATION OF
CASTING WELD REPAIRS . . . . . . . . . . . . . . . . . . .
Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dye Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1
6.1
6.1
6.1

7.1
7.2
7.3

ACCEPTANCE STANDARDS FOR CASTING

WELD REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dye Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1
7.1
7.1
7.1

SECTION

8.

RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1

SECTION

9.

9.1

9.2
9.3
9.4
9.4.1
9.5
9.6
9.7
9.8
9.8.1
9.8.2
9.8.3
9.8.4
9.9
9.10

PROCUREMENT OF WELDING WIRE . . . . . . . .

TABLE 9.1 CHEMICAL COMPOSITION OF
WELDING WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and Tolerances . . . . . . . . . . . . . . . . . . . .
TABLE 9.2 TOLERANCES ON ROUND WIRE . .
Condition of Materials . . . . . . . . . . . . . . . . . . . . . . . .
Quality Assurance Documentation . . . . . . . . . . . . . .
Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free Coil and Helix Test (Spooled Wire Only) . . . .
Welding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Test . . . . . . . . . . . . . . . . . . . . . . . . .
Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free Coil and Helix . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Examination . . . . . . . . . . . . . . . . . .
Identification Markings . . . . . . . . . . . . . . . . . . . . . . .
Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2
9.2
9.3
9.3
9.3
9.3
9.3
9.3
9.4
9.4
9.4
9.4
9.4
9.4
9.4
9.4
9.5

ANNEX

A.

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

A.1

ANNEX

B.

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

B.1

6.1
6.2
6.3
SECTION

7.

9.1

ALPHABETICAL INDEX

viii

NES 825
Issue 2 (Reformatted)

1.

QUALIFICATION REQUIREMENTS

1.1

Weld Procedure
a.

All welding is to be carried out to approved welding procedures for each welding
process or combination of welding processes concerned. Weld procedures,
complete with the test results, are to be submitted through the QAR to the
Design Authority for approval.

b.

Written weld procedures are to be prepared embodying the relevant information

from this NES and are to include all information required to complete sound
welds including the following:

c.

1.2

Parent Material identity and size.

(2)

Welding Process or combination of welding processes.

(3)

Welding Process Parameters as follows:

(a)

Welding position;

(b)

Welding consumables, identity and specification;

(c)

Sketch of weld preparation;

(d)

Welding characteristics including voltage amperage and polarity;

(e)

Pre-heat and interpass temperatures;

(f)

Deposition sequence;

(g)

Shielding gas composition and flow rate;

(h)

Cleaning procedures;

(i)

Heat Treatment;

(j)

NDT and acceptance standard.

In accordance with NES 824 Part 1 Clause 1305 surface and sub-surface weld
repairs to castings will be considered on a concession basis. Prior to any weld
repairs being undertaken weld procedures are to be qualified as follows:

Repair by Surface Build-Up

a.

1.3

(1)

A piece of cast material of minimum size 320mm 125mm 25mm thick is

to be built up under restraint with weld metal to a thickness of approximately
7mm in accordance with FIGURE 1.1.

Repair of Sub-Surface Defects

a.

A piece of cast material of minimum size 320mm 250mm 40mm thick with
an excavated groove in accordance with FIGURE 1.2 is to be welded under
restraint.

1.1

NES 825
Issue 2 (Reformatted)

1.4

Repair Simulation
a.

In addition to 1.2a. and 1.3a. above it is permissible to simulate a proposed weld

repair in a particular casting by using a cast test plate machined to reproduce
the actual casting wall thickness and repair to be undertaken. The test piece is
to embody, as far as possible, all essential features regarding restraint, access
and heat sink. Post weld NDT and destructive testing is to align with 1.2a. or
1.3a. above as appropriate.

Note:
b.

Size of test plates may be increased to suit local tensile testing facilities.
The following requirements apply:
(1)

Prior to welding the test plate is to be heat treated in a furnace validated

in accordance with NES 746 by:
(a)

Preferably heat treating with the associated castings during stress

relief.

or
(b)

Separately by placing in a furnace with temperature not higher than

100 C, raising to 450 C to 500 C at a maximum rate of 200 C/hour,
soaking for two hours and then air cooling.

(2)

The test plate is to be dye penetrant checked and radiographed, after heat
treatment and prior to welding, to ensure cast-in-defects are identified
and do not subsequently cause rejection of the test weld.

(3)

The test plate is to be welded under restraint in accordance with the

proposed welding procedure.

(4)

On completion of welding the test piece is to be non-destructively

examined in accordance with Sections 2. and 3.

(5)

If the examination at (4) is satisfactory the test plate is to be heat treated

again in accordance with Clause 1.4b.

(6)

On completion of (5) the test plate is to be non-destructively re-examined

in accordance with Sections 2. and 7.

(7)

Subject to satisfactory final non-destructive results, in accordance with

Clause 3.1a., the test piece is to be marked with the positions of
destructive test specimens. Mechanical tests are to be carried out in
accordance with Clauses 2.2a. to 2.2c., as appropriate, and results are to
meet the requirements of Clause 3.2a.

1.2

NES 825
Issue 2 (Reformatted)

FIGURE 1.1 SURFACE BUILD-UP

WELDER AND PROCEDURE QUALIFICATION TEST PIECE

1.3

NES 825
Issue 2 (Reformatted)

FIGURE 1.2 SUB-SURFACE REPAIR

WELDER AND PROCEDURE QUALIFICATION POSITION OF TEST SPECIMENS

1.4

NES 825
Issue 2 (Reformatted)

1.5

Welder Qualification
a.

Each welder is to be qualified to meet the appropriate acceptance standard

using the approved welding procedures. No welder is to be employed on work
requiring an acceptance standard beyond his proven capabilities.

b.

The contractor is responsible for qualifying each welder by ensuring that he is

capable of working strictly to the welding procedures under production
conditions to the relevant acceptance standards. The contractor is to ensure
that welders maintain the required standard by checking their work as a result
of the normal production non-destructive testing.

c.

Where a welder is unable consistently to meet the acceptance standards or fails

to work in accordance with the approved procedure, he is not to be employed on
Ministry work. Re-establishment of the welder qualification is subject to
acceptance by the QAR.

d.

Welder qualification test assemblies are to be chosen from those detailed in

Clause 1.1c.

e.

Qualification of a welder is accepted if the visual, dye penetrant and

radiographic examinations meet the requirements of Clause 3.1a. and the side
bend test and macro specimen tests meet the requirements of Clause 3.2a.

f.

Requalification of welders is required if:

(1)

the Acceptance Authority has reason to doubt that the standard or

workmanship in production does not meet the requirements of this NES;
or

(2)
g.

a period of six months has elapsed since the welder was last engaged on
welding the material to the acceptance standards required by this NES.

Weld procedures and welders may be qualified simultaneously.

1.5

NES 825
Issue 2 (Reformatted)

1.6

NES 825
Issue 2 (Reformatted)

2.

TEST METHODS

2.1

Non-Destructive Examination
a.

2.2

On completion of welding and again after subsequent heat treatment the test
plates are to be non-destructively examined in accordance with Section 6.

Destructive Tests
a.

The following mechanical tests are to be carried out in accordance with BS 18

and BS 4206 as appropriate.

b.

Surface Build-Up

c.

(1)

Side Bend Tests (See FIGURE 1.1 and FIGURE 2.1)

(2)

Macro Specimen (10 Magnification) (See FIGURE 1.1)

Sub-Surface Repair
(1)

Transverse Tensile Test (see FIGURE 1.2 and FIGURE 2.2)

(2)

All Weld Metal Tensile Test (see FIGURE 1.2 and FIGURE 2.3)

(3)

Side Bend Test (see FIGURE 1.2 and FIGURE 2.4)

(4)

Macro Section (10 Magnification) (See FIGURE 1.2)

2.1

NES 825
Issue 2 (Reformatted)

FIGURE 2.1 SURFACE BUILD-UP

DETAILS OF SIDE BEND TEST SPECIMEN

2.2

NES 825
Issue 2 (Reformatted)

FIGURE 2.2 PROCEDURE QUALIFICATION

TRANSVERSE TENSILE TEST PIECE

2.3

NES 825
Issue 2 (Reformatted)

FIGURE 2.3 PROCEDURE QUALIFICATION

ALL WELD TENSILE TEST PIECE

2.4

NES 825
Issue 2 (Reformatted)

FIGURE 2.4 WELDER AND PROCEDURE QUALIFICATION

SIDE BEND PIECE

2.5

NES 825
Issue 2 (Reformatted)

2.6

NES 825
Issue 2 (Reformatted)

3.

ACCEPTANCE STANDARDS

3.1

Non-Destructive Examination
a.

3.2

All results are to meet the requirements detailed in Section 7. on the basis that
the weld is in a Critical Test Region.

Destructive Tests
a.

The acceptance standards for destructive tests are as follows:

(1) Mechanical test results are to be equal to or greater than the figures
specified below:
UTS I
N/mm 2

0.2% Proof
Stress
N/mm 2

Elongation
5.65S 0
Gauge Length
%

Transverse
Tensile Test
(See Note)

480

All Weld Metal

Tensile Test

480

300

18

TABLE 3.1
NOTE:(1) Report location of the fracture, whether weld, heat affected zone or parent
metal. If fracture in parent metal, its approximate distance from weld
fusion line to be stated. Record also type and location of any flaws present
on fractured surfaces.
(2) The side bend test is to be accomplished through 180 over a 40mm(5t)
diameter mandrel without total fracture. The maximum acceptable
cracks at 180 are 3mm in any direction in the weld metal, HAZ or fusion
zone. Cracks originating at weld bead undercuts, at slag inclusions or at
casting defects will not be cause for rejection.
(3) The macro specimen is to be rejected if cracks or tears are visible in the
weld or heat affected zone. Cracks originating at casting defects in the
parent material will not be cause for rejection.

3.1

NES 825
Issue 2 (Reformatted)

3.2

NES 825
Issue 2 (Reformatted)

4.

RETESTS
a.

In the event of failure of test specimens to meet the acceptance standards

detailed in Section 3., retest procedure is to be as follows:
(1)

Where a test weldment fails to meet the non-destructive examination

requirements, a new assembly is to be made and tested;

(2)

Where a test weldment fails to meet the destructive test requirements two
further test weldments are to be made and tested and both test weldments
are to meet requirements.

b.

Where the test weldment fails to meet the required mechanical or physical
properties after retest, the procedure is to be rejected.

c.

For any change in an approved weld procedure to be agreed, requalification of

the procedure is to be carried out.

4.1

NES 825
Issue 2 (Reformatted)

4.2

NES 825
Issue 2 (Reformatted)

5.

WELD REPAIR OF CASTINGS

a.

No welding is to be undertaken on castings until a concession has been approved

in accordance with the requirements of NES 824 Part 1 Section 13. Concessions
submitted for consideration are to include:
(1)

Full details of the proposed method of repair including the approved

welding procedure(s) to be used and confirmation that the weldability test
defined in NES 824 Part 1 Clause 1104 has been satisfactory completed
and

(2)

b.

5.1

Sketches of the proposed repair indicating the position, nature, extent and
depth of defects, design wall thickness of the area and thickness of the
original parent material remaining.

The extent of excavations and subsequent weld repair is to be only that

necessary to bring the casting within the acceptance standards of NES 824
Part 1 Section 12. The extent of weld repair is to be limited in accordance with
the following clauses.

Welding Limitations
a.

The rectification of defects by welding is not permitted on any sea water wetted
surface. See also NES 824 Part 1 Clause 1304.

b.

Defects may only be rectified when, after removal of the defect, excavation
depth does not penetrate to within 10mm of the wetted surface. See also
NES 824 Part 1 Clause 1305.

c.

Corrections to casting dimensions and machining errors by surface build-up

will be considered providing the following finished limits are not exceeded.
(1)

5mm maximum build up for wall thicknesses 25mm and under.

(2)

20% of wall thickness maximum build up for wall thicknesses over 25mm
but must not exceed 10mm.

(3)

Area of build up on Class I and Class II castings (see NES 824 Pt 1

Section 7 for definitions) is to be restricted to 10% of the inner or outer
surface area not including flange thicknesses and webs, subject to any
further limitations imposed by Clause 5.1g.

(4)

Areas of build up on Class III castings are to be restricted to 20% of the

inner or outer surface area not including flange thickness and webs.

d.

Unacceptable surface or near surface defects is to be blended out in accordance

with NES 824 Clause 1311.

e.

Defects which cannot be blended out within the required limits are to be treated
as sub-surface defects.

f.

Any individual sub-surface repair in a Critical Test Region is not to exceed 5%

of the test area containing the defect. In Test Regions any individual repair is
not to exceed 10% of the test area containing the defect.

5.1

NES 825
Issue 2 (Reformatted)

g.

The total combined area of weld repairs from all causes, eg dimensional
corrections, machining errors and sub-surface is not to exceed;
(1)

10% of Critical Test Regions

and
(2)
h.

20% of Test Regions and non-designated areas of Class III castings.

When repairs are required which are more extensive than permitted by
Clauses 5.1a. to 5.1g. then the casting is to be either:
(1)

Scrapped

or
(2)

5.2

A special concession submitted which defines the extension of weld repair

beyond the permitted limits and clearly explains the reasons why such
repairs are necessary.

General Welding Requirements

a.

Defects are to be removed by machining or pneumatic chipping and grinding.

Excavation of defects is to commence in sound material at the ends of the defects
and proceed from each end towards the centre.

b.

Excavations are to be finished smooth, tapered at the sides and rounded at the
bottom to facilitate full access for the root run and correct manipulation of the
filler wire.

c.

Before weld action is undertaken a thorough examination of the excavated area

is to be made using radiography and dye penetrant methods to ensure adequate
removal of the defect.

d.

Prior to the deposition of weld material, all contaminants resulting from

non-destructive examination are to be removed with lint free cloth using
acetone or the approved solvent remover for the dye penetrant system used.

e.

Interpass cleaning is to be carried out using a stainless steel wire brush which
has not been used on any other material.

f.

Interpass grinding, when necessary, is to be carried out with resin bonded

alumina grinding wheels or with tungsten carbide burrs.

g.

All welding is to be carried out in the Flat Position in accordance with the
definitions given in BS 499 Part 1.

h.

In order to achieve satisfactory results it is essential that the instructions

detailed in this NES are followed in all repairs to castings and are incorporated
in the appropriate weld procedures.

i.

Stop and start porosity or deep end craters are to be minimized by use of the run
back technique as appropriate to the welding process being used. This
technique is a means of avoiding porosity and crater cracking which can be
caused by the abrupt withdrawal of the welding arc at the end of a weld run. This
technique consists of delaying the consumable at the weld end to fill the crater
and then welding back along the top of the previously deposited weld for a short
distance, thus facilitating the withdrawal of the arc from superfluous weld
metal which is subsequently removed.

5.2

NES 825
Issue 2 (Reformatted)

5.3

j.

Where necessary, extension run-on and run-off plates of the same material
as that to be welded are to be securely welded to the component and grooved to
conform to the actual weld preparation. For the repair of excavations wedge
shaped run-on and run-off plates may be used.

k.

When large areas of weld repair are involved, the weld metal is to be deposited
in such a manner that the final weld pass consists of weld metal to weld metal.

l.

If a casting repair is unsuccessful and the repair requires to be rewelded, not

more than two rewelds are permitted.

m.

The interpass temperature during welding is not to exceed 150 C.

Temperature Measurement
a.

5.4

Heat Treatment of Weld Repairs

a.

NOTE

5.5

After weld repair all castings are to be heat treated by placing them in a furnace
with temperature not higher than 100 C, raising to 450 C to 500 C at a
maximum rate of 200 C/hr, holding for 1 hour per 25mm thickness (minimum
period 2 hours) and then air cooling. The furnace is to be validated in accordance
with NES 746.
The heat treatment requirement for weld repaired areas described above is in
addition to the mandatory Stress Relief heat treatment which is required for
all Copper Nickel Chromium castings in accordance with NES 824 Part 1.

Approved Processes
a.

5.6

Interpass temperature is to be determined by contact pyrometers or

thermocouples; the use of low melting metallic alloys or any temperature
indicating crayons or paints is prohibited.

Welding may be carried out with TIG, MIG, Pulsed MIG or a combination of
these processes.

Approved Welding Consumables

a.

All approved welding consumables are to be readily identifiable so that they can
be positively related to their Quality Assurance documentation.

5.3

NES 825
Issue 2 (Reformatted)

5.4

NES 825
Issue 2 (Reformatted)

6.

NON-DESTRUCTIVE EXAMINATION OF CASTING WELD REPAIRS

a.

6.1

Visual
a.

6.2

The surfaces of all welds are to be inspected visually before any other means of
non-destructive examination. Visual aids such as magnifying lenses (10) and
strong lights are to be used to quantify defects. All imperfections are to be
identified and recorded.

Dye Penetrant
a.

6.3

All castings which have been weld repaired are to be inspected, after heat
treatment, as detailed below. Non-destructive examination methods are to be
in accordance with NES 729 Part 1 and Part 4 where appropriate.

All weld repair and weld build-up areas are to be examined in accordance with
the procedures defined in NES 729 Part 4. Examinations are to be conducted
after grinding or machining the weld surfaces to the required profile.

Radiography
a.

All weld repairs are to be radiographed in accordance with the procedures

defined in NES 729 Part 1 and adherence to sections 20 and 21 is of particular
importance. It is preferred that X Ray is used wherever practicable. All
subsurface imperfections are to be identified for subsequent assessment.

6.1

NES 825
Issue 2 (Reformatted)

6.2

NES 825
Issue 2 (Reformatted)

7.

ACCEPTANCE STANDARDS FOR CASTING WELD REPAIRS

a.

7.1

Visual
a.

7.2

The welds and adjacent parent material is to be free from scale, slag, weld
spatter and arc strikes. The weld is to be of regular surface appearance, ie free
from globular deposits and sharp discontinuities and surface breaking porosity.
Edges of weld are to blend smoothly and gradually into the parent material. The
depth of local undercut or depression resulting from blending is not to exceed
1mm.

Dye Penetrant
a.

7.3

The minimum acceptance standards for casting weld repairs are defined in
Clauses 7.1a. to 7.3d.

The welds and adjacent material are to meet the acceptance standards defined
in NES 824 Part 1 Clause 1206.

Radiography
a.

Cracks and lack of fusion are not acceptable. The maximum length of any single
linear inclusion is not to exceed one half of the design wall thickness in way of
the inclusion. Such inclusions are to be separated by at least:
(1)

2.25 times the thickness of the material in way of the defect.

or
(2)

1.25 times the length of the larger adjacent defect.

b.

If however the distance between the ends of two defects or defective areas is less
than either of the above values, they are to be considered as a single defect
showing an overall length equal to the distance measured between the
extremities of the defects or defective areas.

c.

The total length of inclusions is not to exceed 20% of the maximum dimension
of the area affected by the weld repair.

d.

Loss of wall thickness from localized internal porosity is not to exceed 5% of the
designated wall thickess in Critical Test Regions and 10% in Test Regions and
non-designated areas.

7.1

NES 825
Issue 2 (Reformatted)

7.2

NES 825
Issue 2 (Reformatted)

8.

RECORDS
a.

The contractor is to be responsible for maintaining records of all welding carried

out within the scope of this NES. These are to include:
(1)

Welder qualification.

(2)

Procedure qualification.

(3)

Full fabrication details if appropriate.

(4)

Weld history sheet.

(5)

Details, including accurate sketches, showing location and depth of all

weld repairs.

(6)

Record of heat treatment.

(7)

Record of weld repair inspection results.

(8)

Record of material weldability test.

(9)

Cast number.

8.1

NES 825
Issue 2 (Reformatted)

8.2

NES 825
Issue 2 (Reformatted)

9.

PROCUREMENT OF WELDING WIRE

a.

Welding wire is to conform to the chemical composition detailed in TABLE 9.1.

Wire is to be drawn from billets which have been produced in a vacuum
induction furnace from virgin metals or master alloys as follows;
(1)

Nickel

to the chemical composition requirements of BS 375.

Grade R99.95A or R99.95B.

(2)

Copper

to BS 6017 Designate CuCATH1.

(3)

Manganese

99.9% minimum purity electrolytic manganese flake.

(4)

Silicon

high purity lump silicon (0.3% iron maximum).

(5)

Chromium

99.5% minimum purity electrolytic or thermic chrome.

(6)

Titanium

pure titanium sponge or other solid form, high purity

copper-titanium master alloy or high purity
nickel-titanium master alloy.

(7)

Zirconium

high purity copper-zirconium master alloy or high

purity nickel-zircomium master alloy.

Notes 1.

Contamination by carbon pick-up can be substantially reduced by using

rammed basic linings for electric furnaces and using an alumina wash on
ladles. Finishing additions such as magnesium or calcium are not to be
used. No further additions are to be made to the melt after the final
analytical sample has been taken.

2.

The specification for welding wire defined is under review. Please contact
NA 133 prior to procurement of welding wire to this NES.

9.1

NES 825
Issue 2 (Reformatted)

ELEMENT

PER CENT BY WEIGHT

NOT LESS THAN

NOT MORE THAN

29.00

32.00

Chromium

2.0

2.4

Manganese

1.4

2.0

Silicon

0.20

0.40

Zirconium

0.05

0.15

Titanium

0.1

0.20

Nickel

Copper

Remainder

IMPURITIES
Iron

0.05

Lead

0.0015

Phosphorous

0.005

Bismuth

0.0005

Sulphur

0.003

Carbon

0.006

Cobalt

0.020

Boron

0.001

Selenium

0.0005

Tellurium

0.0005

Arsenic

0.0010

Zinc

0.0020

Total Impurities

0.060

TABLE 9.1 CHEMICAL COMPOSITION OF WELDING WIRE

9.1

Dimensions and Tolerances

a.

The diameter of the wire is to be determined by means of a suitable micrometer

taking the mean of two measurements at right angles made at the same cross
section of a sample taken from any part of the spool or when supplied in one
metre lengths any position on a random sample from each batch.

b.

The difference between the maximum and minimum measurements, taken at

the same cross section is not to exceed the amounts specified in TABLE 9.2.

9.2

NES 825
Issue 2 (Reformatted)

Specified Diameter
Over

Up to
and
including

Tolerance

Difference between
max and min
measurements
not to exceed

mm

mm

mm

mm

0.7

2.00

+0.01
0.04

0.02

+0.01
0.07

0.02

2.00

5.00
TABLE 9.2 TOLERANCES ON ROUND WIRE

9.2

9.3

Condition of Materials
a.

All reeled wire is to be supplied in a cold drawn condition suitable for use in
standard MIG Welding Equipment. If during manufacture the wire is fully
annealed, attention is drawn to the materials ductility trough in the
600 700 C temperature range.

b.

There are to be no joints in the wire.

c.

The wire is to be supplied in a clean condition with the oxide layers removed by
a mechanical process such as diamond shaving or chemical etching process.

d.

The wire is to be free from oil, dirt, grease, chemical contamination or other
foreign matter which would adversely affect the quality of the weld.

e.

The wire is to be supplied in one metre straight lengths for rod or on spools with
the wire precision layer wound. The size of the spool is to be 300mm diameter
or as agreed for each contract of supply.

f.

Spooled wire is to be closely wound in layers so that it is free from kinks, waves
or sharp bends and can be unwound without restrictions caused by overlapping
or wedging. The outside end of the wound wire is to be securely fastened at a
readily located point.

g.

Each batch of wire is to be given a unique number which relates it

unambiguously to the extrusion billet from which it was manufactured. Only
one extrusion billet is to be used for each batch of finished wire.

Quality Assurance Documentation

a.

Each consignment of wire is to be accompanied by Quality Assurance

Documentation giving the actual results of the tests required by
Clauses 9.4.1a.9.7b. together with certificates of compliance with the relevant
acceptance standards detailed in Clauses 9.8.1a.9.8.4b.

9.4

Test Methods

9.4.1

Analysis
a.

9.5

A full analysis is to be made from a sample of the finished wire from each batch.
The analysis is to be recorded.

Free Coil and Helix Test (Spooled Wire Only)

a.

A length of wire sufficient to form at least a 11/8 loop is to be cut and removed
from a spool of wire taken at random, to represent the batch. The wire is to be
allowed to freely unwind from the spool without any undue effort being applied
so that it forms a free coil. The coil is to be placed on a flat surface and the
diameter and pitch (vertical wire separation) recorded.

9.3

NES 825
Issue 2 (Reformatted)

9.6

Welding Test
a.

9.7

Each batch of wire, spooled or straight lengths, is to be tested for weldability by

using a random sample of wire, to represent the batch. The wire is to be
deposited on a 70/30 Cupro Nickel plate of approximately 12mm thickness so
that three beads 100mm long are laid parallel with each other, the third bead
being superimposed over the other two beads. The test weld is to be
radiographed in accordance with NES 729 Part 1.

Non-Destructive Test
a.

The surface of the wire is to be examined, under clean conditions, in the supplied
condition before sealing and packaging. Any indications of oxides staining,
variations in colour or surface roughness are to be recorded.

b.

The outside end of each spool of wire and one straight length from each package
are to be dimensionally checked and the results recorded.

9.8

Acceptance Standards

9.8.1

Analysis
a.

9.8.2

Free Coil and Helix

a.

9.8.3

9.9

For 300mm diameter spools the diameter of the coil measured in Clause 9.5a.
is to be 380mm minimum and 760mm maximum and vertical separation of the
wire (pitch) is not to exceed 25mm. For other sizes of spools the dimensional
limitations are to be as stated in the Contract for supply.

Welding Standard
a.

9.8.4

The chemical analyses are to conform to TABLE 9.1. Any wire failing to meet
the chemical composition detailed in TABLE 9.1 is to be rejected together with
all other wire from the same batch.

The radiographs produced in accordance with Clause 9.6a. are to be examined

in accordance with NES 729 Pt 1 and are to be free from indications of porosity,
cracking or inclusions.

Non-Destructive Examination
a.

The wire examined in accordance with Clause 9.7a. is to be rejected if there is

any evidence of discoloration, surface roughness, oxide, scale, grease, oil or any
loose contamination.

b.

The dimension of the wire tested in accordance with Clause 9.7b. is to be within
the tolerances stated in TABLE 9.2 and to the diameter specified in the Contract
Documents.

Identification Markings
a.

For identification purposes all spools and packages containing copper nickel
chromium wire to this NES are to be legibly marked by the manufacturer in
letters not less than 5mm in height, with the following particulars:
(1)

The unique material batch number used for all quality assurance
documentation associated with this spool or package wire together with
the reference CUNICR and specification NES 825.

(2)

Size and weight of wire on spool.

(3)

Manufacturer.

9.4

NES 825
Issue 2 (Reformatted)

9.10

Packaging
a.

Except where otherwise stated in the Contract Documents all reeled wire is to
be supplied on spools sealed in a plastic envelope for complete protection and
cleanliness. The sealed spools are to be contained in stout cardboard or wooden
boxes. Straight lengths are to be supplied in sealed packages of 2kg each.

9.5

NES 825
Issue 2 (Reformatted)

9.6

NES 825
Issue 2 (Reformatted)

ANNEX A.
RELATED DOCUMENTS
A.1

Reference is made to:

Referred to in Clause
BS 18

Tensile testing of metals (including

aerospace materials)
Refined nickel

2.2a., FIGURE 2.3

BS 499 Pt 1

Welding terms and symbols

Pt 1Glossary for welding, brazing
and thermal cutting

5.2g.

BS 4206

Methods of testing fusion welds in

copper and copper alloys
Copper refinery shapes

2.2a., FIGURE 2.2

Requirements for Non-destructive

Examination Methods
Pt 1Radiographic

6.a., 6.3a., 9.6a.

BS 375

BS 6017
NES 729 Pt 1

Pt 4
NES 746
NES 824 Pt 1

Pt 4Liquid Penetrant
Approval and Control of Heat
Treatment Furnaces
Requirements for the Production of
Copper-Nickel Chromium Sand
Castings and Ingots

A.1

9.a.

9.a.

6.a., 6.2a.
1.4b., 5.4a.
SCOPE 1., 1.1c., 5.a.,
5.b., 5.1a., 5.1b., 5.1d.,
5.4a., 7.2a.

ANNEX A.

NES 825
Issue 2 (Reformatted)

ANNEX A.

A.2

NES 825
Issue 2 (Reformatted)

ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1

For the purpose of this NES the following definitions apply:

Acceptance Authority

the Design Authority for the system concerned;

Contractor

the Firm, Organization, Establishment or HM

Naval Base working within the scope of this NES;
the relevant Section of the Sea System
Controllerate responsible for the systems
concerned;

Design Authority

Interpass Temperature

in a multi-run weld, the interpass temperature is

defined as the temperature of the weld and
adjacent parent metal, immediately prior to the
application of the next run. Interpass
temperature is to be measured on the surface of
the base material on the side from which welding
is to be performed, within 25mm of the weld joint
edge;

Quality Assurance
Representative (QAR)

the MOD(PE) personnel engaged in ensuring that

the requirement of this NES are being met.

B.1

ANNEX B.

NES 825
Issue 2 (Reformatted)

ANNEX B.

B.2

NES 825
Issue 2 (Reformatted)

ALPHABETICAL INDEX

A
Analysis, 9.3, 9.4
Approved processes, 5.3
Approved welding consumables, 5.3
Approved welding procedures, 1.1

C
Certificate of compliance, 9.3
Chemical composition, 9.1
Clean condition of wire, 9.3
Concessions, 5.1, 5.2
Contamination by carbon, 9.1

D
Defects, 5.1
Destructive acceptance standards, 3.1
Destructive tests, 2.1, 3.1
Dye penetrant, 1.2, 5.2, 6.1

F
Free coil and Helix test, 9.3

H
Heat treatment, 1.1, 1.2, 2.1, 5.3, 6.1
Helix test, 9.3

I
Interpass temperature, 5.3, B.1

L
Limitation of weld repair, 5.1, 5.2, 9.4

M
Markings, identification, 9.4
Mechanical test results, 3.1
Mechanical tests, 2.1

INDEX.1

INDEX

NES 825
Issue 2 (Reformatted)

N
Non-destructive acceptance standards, 3.1, 7.1
Non-destructive tests, 2.1

P
Post weld heat treatment, 1.2

Q
Qualification of welders, 1.3
Quality assurance documentation, 9.3

R
Radiography, 1.2, 5.2, 6.1, 7.1
Repairs, 1.1, 5.1
Retests, 4.1

S
Side bend test, 2.1

T
Temperature measurement, 5.3
Tensile test, 2.1, 3.1
Test pieces, 1.1
Tolerances on wire, 9.2

V
Virgin metals, 9.1

W
Weld procedures, 1.1, 5.1
Weld repairs, 5.1, 5.2
Welder qualifications, 1.3
Welding consumables, 5.3
Welding process, 1.1, 5.3
Welding test of wire, 9.4
Welding wire, 9.1

INDEX

INDEX.2

Inside Rear Cover

 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.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/825.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with
a 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 that
users of Defence Standards should ascertain that they are in possession of the latest issue or
amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards
for Defence Part 3 , 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). Any person who, 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.