Professional Documents
Culture Documents
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) 771 Issue 1 dated July 1991.
Ministry of Defence
NES 771
Issue 1 (Reformatted)
July 1991
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 771
Issue 1 (Reformatted)
SCOPE
1.
This NES specifies the minimum requirements, procedure and inspection standards for the
welding repair of castings in certain copper-based and nickel-based alloys.
iii
NES 771
Issue 1 (Reformatted)
iv
NES 771
Issue 1 (Reformatted)
FOREWORD
Sponsorship
1.
This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Director Naval Architecture (Submarines), (DNA(SM)), Section NA 133.
2.
It is to be applied as required to any Ministry of Defence contract for the Weld Repair of
Castings in certain Copper Alloys and Nickel Alloys.
3.
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.
6.
Unless otherwise stated, reference to 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 side line. Deletions will be indicated by 000 appearing at the end of the line
interval.
Conditions of Release
General
8.
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.
9.
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.
10.
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.
12.
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
NES 771
Issue 1 (Reformatted)
the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.
13.
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
14.
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.
16.
Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
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 771
Issue 1 (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.
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1
SECTION
2.
2.1
2.2
2.3
QUALIFICATION REQUIREMENTS . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Procedure Records . . . . . . . . . . . . . . . . . . .
Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.1 QUALIFICATION
PROCEDURESWELD PREPARATIONS . . . . . .
Welder Qualification . . . . . . . . . . . . . . . . . . . . . . . . .
Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Testing . . . . . . . . . . . . . . . . . . . . . . .
Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.2 QUALIFICATION
PROCEDURESPOSITION OF TEST PIECES
IN 320 125 25mm AND 320 250 40mm
PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.3 QUALIFICATION
PROCEDURESTRANSVERSE TENSILE TEST
PIECES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.4 QUALIFICATION
PROCEDURESALL WELD METAL
TENSILE TEST PIECES . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.5 QUALIFICATION
PROCEDURESIDE BEND TEST PIECE . . . . . .
FIGURE 2.6 QUALIFICATION
PROCEDUREMACRO SECTION . . . . . . . . . . .
Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1
2.1
2.1
2.2
2.4
2.5
2.5.1
2.5.2
2.6
2.6.1
2.7
2.8
vii
2.4
2.5
2.5
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.12
2.12
2.12
2.13
NES 771
Issue 1 (Reformatted)
SECTION
3.
3.1
3.2
3.3
3.4
3.5
3.6
3.1
3.1
3.1
3.2
3.3
3.3
3.3
3.4
3.4
SECTION
4.
RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1
ANNEX
A.
RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .
A.1
ANNEX
B.
B.1
ANNEX
C.
C.1
ANNEX
D.
D.1
ANNEX
E.
E.1
ALPHABETICAL INDEX
viii
NES 771
Issue 1 (Reformatted)
1.
MATERIALS
a.
This NES relates to the weld repair of the following copper-based and
nickel-based alloy castings:
Nickel-copper alloy complying with BS 3071: NA1.
Nickel aluminium bronze (naval alloy) complying with NES 747 Parts 2
and 4 (unless used for propulsors).
Nickel aluminium bronze (commercial alloy) complying with NES 747
Part 3 (unless used for propulsors).
Gunmetal complying with NES 830 Part 1. (see also Clause 2.3c.).
Aluminium silicon bronze complying with NES 834 Part 3.
b.
The weld repair of the following copper-based and nickel-based alloy castings
is the subject of other NES:
Materials for propulsors (see NES 304 Part 5).
Nickel aluminium bronze (naval alloy) centrifugal castings complying
with NES 747 Part 1 (see NES 747 Part 1).
Nickel chromium molybdenum alloy 625 complying with NES 822 Parts 1
and 2 (see NES 823).
Copper nickel chromium complying with NES 824 Part 1 (see NES 825).
1.1
NES 771
Issue 1 (Reformatted)
1.2
NES 771
Issue 1 (Reformatted)
2.
QUALIFICATION REQUIREMENTS
2.1
General
2.2
a.
b.
c.
d.
It is not permissible for the contractor to have the test weldments performed by
another organization. It is permissible however to subcontract any or all of the
work on the preparation of test specimens from the completed weldment and
the performance of non-destructive and mechanical tests, provided that the
contractor accepts responsibility for the results of such work.
e.
f.
All welding procedures and welders employed for weld repairs to castings are to
be subject to previous qualification.
g.
h.
Copies of all approved welding procedures and associated qualification data are
to be forwarded to DNA(SM), Section NA 133 for record purposes.
2.1
NES 771
Issue 1 (Reformatted)
2.3
Welding Procedure
a.
b.
(2)
Dimensions of test plate used for qualification and type of repair being
qualified.
(3)
(b)
(c)
(4)
(5)
(6)
c.
(a)
(a)
(b)
(c)
(d)
(e)
(f)
(g)
Deposition sequence.
(b)
(2)
2.2
NES 771
Issue 1 (Reformatted)
(3)
Repair simulation
It is not possible to adequately simulate all weld repairs by test plates in
accordance with (1) or (2). In certain circumstances, such as restricted
access or casting geometries resulting in unusual restraint or heat
dissipation, the inspecting authority may rule that plates to (1) or (2) are
inappropriate for qualification purposes. In such instances it is necessary
to simulate the repair using a test plate machined to reproduce the actual
casting wall thickness and repair to be undertaken. The test plate is to
embody as far as possible all essential features regarding access, restraint
and heat dissipation and is subject to approval by the inspecting authority.
A special instance of plates to (1) or (2) being inappropriate for
qualification is the weld repair of gunmetal to NES 830 Part 1. This
material has limited weldability being prone to cracking in the parent
metal when multi-run welding is carried out. For this reason only minor
weld repairs are allowable (excavation depth not to exceed 5mm); plates
to (1) or (2) are inappropriate and simulation of the repair is required.
d.
To ensure that cast-in defects are identified before welding and do not in
themselves subsequently cause rejection of the test weld, test plates are to be
subject to NDE prior to welding. The NDE is to consist of visual and liquid
penetrant examination for all materials and radiography, or where appropriate
ultrasonics, for all materials other than gunmetal to NES 830 Part 1.
e.
f.
g.
2.3
NES 771
Issue 1 (Reformatted)
2.4
NES 771
Issue 1 (Reformatted)
2.4
Welder Qualification
a.
b.
c.
d.
e.
f.
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 using the
approved welding procedure.
2.5
Test Methods
2.5.1
Non-Destructive Testing
a.
b.
c.
Test pieces in gunmetal to NES 830 Part 1 are subject to visual and liquid
penetrant examination. For the other materials covered by this NES test pieces
are, in addition to visual and dye penetrant examination, subject to
radiographic or, where appropriate, ultrasonic examination.
2.5
NES 771
Issue 1 (Reformatted)
2.5.2
Destructive Testing
a.
b.
Subject to satisfactory NDE and acceptance the following destructive tests are
to be carried out in accordance with EN 10 0021 and BS 4206 as appropriate:
(1)
(2)
All weld metal tensile test (see FIGURE 2.2 and FIGURE 2.4).
(3)
(4)
2.6
NES 771
Issue 1 (Reformatted)
2.7
NES 771
Issue 1 (Reformatted)
2.8
NES 771
Issue 1 (Reformatted)
2.9
NES 771
Issue 1 (Reformatted)
2.10
NES 771
Issue 1 (Reformatted)
2.11
NES 771
Issue 1 (Reformatted)
2.6
Acceptance Standards
2.6.1
Non-Destructive Tests
a.
2.7
The acceptance standards for test pieces in gunmetal to NES 830 Part 1 are to
be as for non-designated areas in accordance with NES 745 Part 1. For other
materials the acceptance standards for test pieces are to be as for critical test
regions complying with NES 745 Part 1.
Destructive Tests
a.
Mechanical test specimens in accordance with Clause 2.5.2a. are to show the
following minimum properties shown in TABLE 2.1:
(1)
(2)
The maximum crack length that is acceptable in side bend test specimens
after bending is:
(a)
(b)
Material
Side
Bend
Be
d
Angle (2)
(3)
UTS
N/mm 2
UTS
N/mm 2
Elongation
%
430
460
25
120
620
620
12
35
Nickel aluminium
bronze (commercial
alloy) to NES 747
Part 3
620
620
12
35
Aluminium silicon
bronze to NES 834
Part 3
460
540
12
120
Nickel-copper alloy
to BS 3071:NA1
Nickel aluminium
bronze (naval alloy)
to NES 747 Parts 2
and 4
TABLE 2.1
NOTES
1.
2.
3.
2.12
NES 771
Issue 1 (Reformatted)
2.8
Retests
a.
In the event of test pieces failing to meet the acceptance standards the retest
procedure is to be as follows:
(1)
Where the test piece fails to meet the non-destructive examination test
requirements a further test piece is to be made and tested. Failure of this
further test piece to fully meet the non-destructive and destructive test
acceptance standards is to result in the rejection of the welding procedure
or welder.
(2)
2.13
NES 771
Issue 1 (Reformatted)
2.14
NES 771
Issue 1 (Reformatted)
3.
3.1
Welding Limitations
a.
b.
c.
3.2
(1)
(2)
Sketches of the proposed repair indicating the position, nature, extent and
depth of defects, design wall thickness of the area and thickness of the
parent material remaining.
Weld repair of castings is only to be carried out using welding procedures and
welders which have been qualified using test plates in accordance with
Clause 2.3c. and approved by MOD(PE) as being appropriate to the type of
repair being undertaken.
b.
c.
To ensure that any defects remaining after excavation are identified and do not
in themselves subsequently cause rejection of the weld, all excavated areas are
to be subject to NDE prior to welding. This NDE is to consist of visual and dye
penetrant examination for all excavated areas and in addition it is mandatory
to carry out radiographic or, where appropriate, ultrasonic examination of
excavated areas in test regions and critical test regions.
d.
e.
f.
3.1
NES 771
Issue 1 (Reformatted)
3.3
g.
h.
Weaving increases the heat input during weld repair which is undesirable.
Stringer bead deposits are to be made at all times with a weld bead width not
exceeding three times the electrode or wire diameter.
i.
Stop/start porosity or deep end craters are to be minimized by use of the run
back technique. 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.
j.
Inter-run cleaning is to be carried out using a bronze wire brush which has not
been used on any other material.
k.
l.
m.
n.
In multi-run welds the weld metal is to be deposited in such a manner that the
final weld run consists of weld metal to weld metal.
o.
3.2
NES 771
Issue 1 (Reformatted)
3.4
Approved consumables are detailed in the following Tables; the use of these
materials is not however mandatory and alternative consumables may be
submitted to DNA(SM)/NA 133 for approval.
Parent Material
Approved Consumables
TIG/MIG/Pulsed MIG
Supplier of
Approved
Consumables
Nickel-copper alloy to
BS 3071:NA1
Monel FM 60
Greengrove Welding
Wires Ltd
Stratford-upon-Avon
Bostrand AT 246
Murex Welding
Products Ltd
Waltham Cross
Stubs A 3444
Gunmetal to
NES 830 Part 1
Aluminium silicon bronze
to NES 834 Part 3.
Stubs A 320
Delta Alloy W 23
TABLE 3.1
Parent Material
Approved Consumables
MMA
Supplier of
Approved
Consumables
Nickel-copper to
BS 3071:NA1
Monel 190
Greengrove Welding
Wires Ltd
Stratford-upon-Avon
Gunmetal to
NES 830 Part 1
Stubs 320
TABLE 3.2
b.
c.
d.
Covered electrodes which have been exposed to the atmosphere for a period in
excess of two hours are to be re-dried for a minimum period of two hours before
use or in accordance with the manufacturers instructions. Electrodes which
have their coating chipped or other wise damaged, or have exceeded their
recommended shelf life, are not to be used.
e.
f.
Shielding gas for use with the MIG and TIG welding process is to be welding
quality argon of 99.95% minimum purity. Requests to use other gas mixtures
are to be forwarded to DNA(SM), Section NA 133 for approval.
3.3
NES 771
Issue 1 (Reformatted)
3.5
Castings in nickel aluminium bronze which have been weld repaired are
required to be subsequently heat treated. In such instances the required heat
treatments are detailed in the relevant material specifications:
Nickel aluminium bronze (naval alloy) to NES 747 Part 2.
Nickel aluminium bronze (naval alloy) to NES 747 Part 4.
b.
3.6
Non-Destructive Examination
a.
b.
c.
All weld repairs are subject to visual and dye penetrant inspection.
d.
Weld repairs to test regions and critical test regions are subject to radiographic
or, where appropriate, ultrasonic inspection.
e.
f.
g.
If after three attempts a weld repair fails to meet the acceptance standards the
Design Authority is to be consulted before proceeding further.
3.4
NES 771
Issue 1 (Reformatted)
4.
RECORDS
a.
(2)
(3)
(4)
Welder qualification.
(5)
(6)
(7)
4.1
NES 771
Issue 1 (Reformatted)
4.2
NES 771
Issue 1 (Reformatted)
ANNEX A.
RELATED DOCUMENTS
A.1
BS 499
BS 3071
BS 4206
BS 4870
*NES 304
NES 729
NES 745
NES 747
NES 822
NES 823
NES 824
2.5.2a.
B.1B.2
1.a., 3.3a.,
3.4a.
2.5.2a.
2.3e.
1.b.
2.6.1a., 3.1a.,
3.1b., 3.6f.
1.a., 2.7a.,
3.1e., 3.4a.
1.a., 2.7a.,
3.1e., 3.4a.,
3.5a.
2.5.1a., 3.6b.
1.b.
1.a., 2.7a.,
3.1e., 3.4a.,
3.5a.
1.b.
1.b.
A.1
ANNEX A.
NES 771
Issue 1 (Reformatted)
NES 825
NES 830
NES 834
1.b.
1.a., 2.7a.,
3.1e., 3.4a.,
3.5b.
ANNEX A.
A.2
1.a., 2.3c.,
2.3d., 2.5.1c.,
2 5 2b
2.5.2b.,
2.6.1a., 3.1e.,
3.3a., 3.4a.
NES 771
Issue 1 (Reformatted)
ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1
B.2
Contractor
Design Authority
Inspecting Authority
Quality Assurance
Representatives (QAR)
Welding terms used in this NES, unless defined, comply with BS 499 Part 1.
B.1
ANNEX B.
NES 771
Issue 1 (Reformatted)
ANNEX B.
B.2
NES 771
Issue 1 (Reformatted)
ANNEX C.
RECORD OF QUALIFICATION TEST OF WELDING PROCEDURE TO NES 771
C.1
ANNEX C.
NES 771
Issue 1 (Reformatted)
(Organizations symbol or
logo)
Record of qualification
Test record No
test of welding procedure
to NES 771
1. Test results
State acceptable, non-acceptable (with reasons or give numerical results)
Non-destructive tests
Visual
Radiography
Penetrant
Ultrasonics
Destructive tests
Tensile
Tensile strength
(Units)
Radius of former
Fracture location
Transverse Tensile
All weld Metal
Tensile
Bend
Angle at which
first indication of
cracking occurs
The statements in this record are correct. The test welds were prepared,
welded and tested in accordance with the requirements of NES 771.
Manufacturers representative
Inspecting Authority
Position
Witnessed by
Date
ANNEX C.
Date
C.2
NES 771
Issue 1 (Reformatted)
ANNEX D.
WELD PROCEDURE SUMISSION FORM
D.1
ANNEX D.
NES 771
Issue 1 (Reformatted)
Copy No
Contd
ANNEX D.
D.2
NES 771
Issue 1 (Reformatted)
D.2
D.3
The originator must not use the procedure in production until approved. Procedures
in use without an attached submission form are to be considered unapproved.
D.3
ANNEX D.
NES 771
Issue 1 (Reformatted)
ANNEX D.
D.4
NES 771
Issue 1 (Reformatted)
ANNEX E.
RECORD OF QUALIFICATION TEST OF WELDER TO NES 771
E.1
ANNEX E.
NES 771
Issue 1 (Reformatted)
ANNEX E.
E.2
NES 771
Issue 1 (Reformatted)
ALPHABETICAL INDEX
A
Acceptance standards, 2.6, 2.7, 3.4
B
Blending, 3.1
C
Cast test plates, 2.2, 2.3
Cast-in defects, 2.3, 2.7, 3.1
Cosmetic repair, 3.1
D
Definitions, B.1
Destructive test methods, 2.5
E
Excavation, 3.1
F
Flat position welding, 3.1
G
General welding requirements, 3.1, 3.2
H
Heat treatment of weld repairs, 3.4
M
Multi-run welds, 3.2
N
Non-destructive examination of weld repairs, 3.4
Non-destructive examination prior to welding, 2.3, 3.1
Non-destructive test methods, 2.5, 3.4
INDEX.1
INDEX
NES 771
Issue 1 (Reformatted)
P
Photomacrographs , D.1
Preheat, 3.1, 3.2
Pressure testing, 3.4
Q
Qualification requirements, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7
R
Records, 4.1
Requalification, 2.4
Retests, 2.7
Run back technique, 3.2
S
Shielding gas, 3.3
Side bend test, 2.5, 2.7
Stop/Start porosity, 3.2
Stringer bead deposits, 3.2
T
Tensile tests, 2.5, 2.7
Transfer of qualified welding procedures, 2.3
W
Weaving, 3.2
Weld repair of castings, 3.1, 3.2, 3.3, 3.4
Welder qualification, 2.4
Welding consumables, 3.3
Welding limitations, 3.1
Welding procedure, 2.2, 2.3, 2.4
Welding procedure records, 2.1
Welding processes, 3.2
INDEX
INDEX.2