Ministry of Defence Defence Standard 02-768 (NES 768) Issue 1 Publication Date 1 April 2000 52.0, OF aepe Requirements for the Fabrication, Joinii and Repair of Aluminium Alloy Structiies and Associated Components. : Incorporating NES 768 Catege Issue 1 Publication Date December 1993Ministry of Defence DPAsDLO Technical Enabling Services Working together to detver capebiny UK Defence Standardization Room 1138 Kentigern House 65 Brown Street GLASGOW G2 8EX Telephone 0141-224-2531/2 DFTS — (9)4561 2531/2 Facsimile 0141-224-2503 e-mail enquiries@dstan.mod.uk Ourret Your rof Date 25" October 2006 OBSOLESCENT NOTICE Def Stan: 02-768 Ti Requirements for the Fabrication, Joining and Repair of Aluminium Alloy Structures and Associated Components (Cat 2) This notice has been agreed by the authorities concerned with the use of the above standard. This standard is declared obsolescent as it is no longer suitable for the procurement of new equipment and is only retained for reference purposes in connection with the maintenance of in- service equipment, from the date of this notice. eho WW Graham Walker Tes-DStan-SPM8 for UK Defence Standardization TES iii sve D STAN Q Technical Solutions for Defence On patent SunGarssanTs veerors romeMinistry of Defence Sea Systems Controllerate Naval Engineering Standard NES 768 Issue 1 December 1993 REQUIREMENTS FOR THE FABRICATION JOINING AND REPAIR OF ALUMINIUM ALLOY STRUCTURES AND ASSOCIATED COMPONENTSAmendment 1 This NES Supersedes NES 706 ISSUE 2 SECTION 19 DGS/PS 9023 (IN PART) Record of Amendments AMDT 1 INSERTED BY DATE 1 TF ben is [afr ; 4 10NAVAL ENGINEERING STANDARD 768 [SSUE 1 REQUIREMENTS FOR THE FABRICATION JOINING AND REPAIR OF ALUMINIUM ALLOY STRUCTURES AND ASSOCIATED COMPONENTS ‘The issue and use of this Standard is authorized on behalf of the Controller of the Navy and the Chief of Fleet Support by: Cys. Director Naval Architecture CROWN COPYRIGHT 1993 Published by: Procurement Executive, Ministry of Defence Sea Systems Controllerate Foxhill, Bath BAl SAB 78(WS8/SG)B2 @NES 768 Issue 1 CONDITIONS OF RELEASE General 1. 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 Uabilty (other than lability 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. 2. The copyright in this document is owned by the Crown and the information herein may be subject to Crown or third party rights. It isnot tobe released, reproduced or published without written permission of the MOD. 3. 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 4. This NES is the property of the Crown and unless otherwise authorized in writing uy the ‘MOD must be retumed on completion of the contract, or submission of the tender, in connection with which itis issu 5. When this NES is used in conection with a tender or contract, the user is to ensure that be is in possession of the appropriate version of cach document, including related document elevant to cach aticulaytcder ox contac. Engle 0 this eucneson may be made of the local MOD(PE) Quality Assurance Representative or the Authority named in the tender or contract. 6. When NES are incorporated into 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. 78(WS8/SG)B2 @CONTENTS AUTHORIZATION CONDITIONS OF RELEASE CONTENTS INTRODUCTION SECTION1 SCO! SECTION2 HEALTH AND SAFETY SECTION3 RELATED DOCUMENTS SECTION4 DI ONS SECTIONS MATERIAL Approved Materials ‘Welding Consumables Gases Identification and Control Other Materials SECTION6 JOINING ALUMINIUM AND ITS ALLOY {EXCLUDING WELDING) General Riveting SECTION 7 78(WS8/SG)B2 Rivet Diameters Figure 1. Riveting Forms Mechanical Methods of Joining Bimetallic Connections Figure 2 Aluminium to Steel Joint Riveted and Bolted Joints Structural Aluminium Alloy to Steel Transition Joints Figure 3 Kelocouple Material DESIGN OF WELDED JOINTS Qualification of Joint Desi ¢ tion eee ign, Edge Preparat Backing Bars and Strips Temporary Backing Bars Figure 4 Temporary Backing Bars Permanent Backing Strips igure 5 Permanent Backing Strips Figure 6 Weld Tee Bar as Backing Back Gouging Figure 7 Back Gougi Strength of butt Welds Gi) @ Gi) (vi) wun 10 see i 13 13, NES 768 Issue 1 Clause 0501 0505 0508 0509 0601 0612 0614 0615 0616 0705 0709 o7i1 0716 0717NES 768 Issue 1 SECTION 8 SECTION 78(WS8/SG)B2 Page Figure 8 Stress flow 4 Figure 9 Permissible Change Without Slope 15 Figure 10 Joining Members of Differing Thickness 15 Fillet Welds 11 Obtuse and Acute Angle Fillet Welds 16 Fillet Weld Size Figure 12 Fillet Weld Dimensions 7 Table 1 Factors for Calculating Strength Figure 13 Atochm Edge Minin is i ent Edge Minimum Thickness 18 pared Filet Welds Figure 14 Partial Penetration Tee~Butt Weld 19 ‘Sub-Size Fillet Welds Intermittent Welding Figure 15 Chain Intermittent Fillet Welds 19 Lap Joints Figure 16 Lap Weld 20 Joints using Kelocouple Material Figure 17 Kelocouple Butt Weld 20 Figure 18 Aluminium/Stee! Transition Joint Design Applications 21 CONSUMABLE HANDLING AND MATERIAL 22 FORMING Welding Consumables Forming and Figure 19 Cold Radius Figure 20 Use of Soft Nose Formers WELDING PROCESSES AND TECHNIQUES Oxide Removal ‘Welding Processes Interpass Temperatures St) Tungsten Inert Gas Welding (TIG) General Starting and Stopping (TIG) Joints Made Without Filler (TIG) Figure 21 Joints that can be Welded Without Filler Metal 27 Pulsed TIG Filler Wire (TIG) Tungsten Electrodes Figure 22 Tungsten Electrode Tip Shape and Current Ratings 28 Metal Inert Gas Welding (MIG) Pulsed MIG MIG Welding Wire Inert Gas Shielding MIG and TIG Equipment Filler Rods and Wires for TIG and MIG Welding (iv) 0727 0728 0729 0731 0801 0954SECTION 10 78(WS8/SG)B2 Table 2 Selection of Filler Rods and Wires for the Welding of Wrought and Cast Aluminium Alloy Combinations by the TIG and MIG Processes WELDING REQUIREMENTS ‘Welding Procedures Procedures ‘Non-destructive Examination and Acceptance Standards Procedure Information for Fusion Welds Procedure Information for Stud Welds ‘Weld Fit-Up Cleaning Table 3 General Procedures for Preparing Aluminium Surfaces for Welding ‘Accessibility Figure 23 Use of Silhouettes to Prove Access Figure 24 Examples of Inaccessible Welds Temporary ents Mechanically Fixed Attachments Figure 25 Temporary Attachment ~ Mechanical Welding Attachments Figure 26 Temporary Attachment - Welded Assembly Welding Figure 27 Dressing of Assembly Weld Ends Interpass Temperature ‘Weld Terminations Figure 28 Examples of Run-On and Run-Off Tabs Figure 29 Starting and Stopping Without Tabs Weld Metal Deposition Techniques Figure 30 Stringer Bead Deposition Techniques Figure 31 Example of Weld Metal Overlap Figure 32 Example of Balanced Deposition of Weld Metal Back Gouging Figure 33 Examples of Back Gouging Figure 34 Examples of Back Gouging Templates Weld Dressing Figure 35 Example of Damage due to Over Dressing Peening ‘Weld Toe Dressing Butt Welds in Rolled and Extruded Sections Figure 36 Method of Full Penetration Butt Weld of Tee Bar Butt and Fillet Weld ~ Distortion Figure 37 Butt Weld Plate Overlap Distortion Figure 38 Methods of Controlling Distortion in Butt Welds Figure 39 Distortion Control Technique for Double Fillet Welded Joints ” 31 38 39 40 41 42 42 43 45 46 47 47 1031 1034 1036 1037 1039 1043 1047 1051 1052 1053 1056NES 768 Issue 1 SECTION 11 78(WS8/SG)B2 ‘Welding of Structural Aluminium to Steel Transition Joints Welder Qualification Joints in Kelocouple Material Figure 40 Welding of Structural Aluminium ‘Transition Joint UALIFI ION Approval Requirements General Special Figure 41 Fillet Weld Test Piece in Plate or Sheet Figure 42 Butt Weld Test Piece in Plate or Sheet Figure 43 Circular Insert Test Piece Transfer of terials Table 4 Material Grouping for Welding Procedure and Welder Qualification Purposes Filler Wires Material Thickness Retesting of Welding Procedures Procedure as Test-Pieces for Special Welds Qualification forthe Welding and Weld Repair Hiewe 2 Test Plate for Casting Repair Qualification Examination and Testing of Weld Procedures ‘Non-destructive Examination ‘NDE and Acceptance Requirements Destructive Testing Table 5 Number of Test Specimens Required Preparation and Testing Destructive Examination and Acceptance Requirements Transverse Tensile Test Table 6 Transverse Tensile Strength Requirements for Butt Joints Bend Tests Table 7 Bend Test Former Diameter Macro-examination and Fillet Weld Fracture Test w F 49 St SL 52 53 55 56 S7 538 1131 1133 1136 1137 1138 1141 1142 1143 1144 1146 1147 1152 1154SECTION 12 SECTION 13 SECTION 14 78(WS8/SG)B2 Dissimilar Metal Joints Report of Tests ‘Welder Qualification Qualification Records ‘Welder Qualification Tests Table 8 Welding Position Qualifications ‘Welder Retesting Requalification of Welders Transfer of Welder Qualification Machine Qualifications FABRICATION ASSEMBLY Preparing Plate Edges Fitting, Aligning and Assembly Figure 45 Use of Assembly Aids in Two Modes ‘Assembly Welds Distortion Flanges Correction and Prevention of Distortion Figure 46 Weldin, Completion of Welds Figure 47 Completing Welds Removal of Redundant Fittings Figure 48 Removing Redundant Fittings STUD WELDING General Materials Studs Ceramic Ferrules Inert Gas Shielding Preparation for Work Setting-to-Work Procedure Removal of Temporary or Redundant Studs Evaluation Testing Figure 49 Stud Testing Devices ‘Visual Inspection of Drawn Arc Studs Visual Inspection of Capacitor Discharge Studs Guidance STRUCTURAL AND WELD DEFECT REPAIRS General Structural Defects Figure 50 Stud Welding Defects and Cause Figure 51 Stress Concentration at Weld Edges Repair of Cracked Structure “igure 52 Structural Cracking Figure 53 Structural Cracking Figure 54 Crack Originating from a Weld (ii) z 61 6 Rm eeeee 70 n B NES 768 Issue 1 Clause 1155 1156 1157 1166 1168 1174 1175 1176 1203 1213 1216 1217 1218 1220 1221 1301 1305 1309 1310 1311 1318 1320 1322 1324 1325 1326 1401 1407 1412NES 768 Issue 1 Page Clause Figure $3 Chases Goa from Welds 7 wis ‘igure iginating 4 Butts in Extruded Sections 1421 Figure 56 Preparation of Cracks for Weld Repair 75 Figure 57 Dressing Extruded Section Butt ‘Weld Edges 5 Repairs by Fitting Inserts 1422 Figure 58 Fitting Inserts to Existing Butts and Seams Figure 59 Restoration of Stiffening after Fitting an Insert 7 Figure 60 New Weld Run Out onto Existing Weld 77 Repair of Cruciform Tee Joints 1427 Figure 61 Cruciform Joint ~ Poor Design B Figure 62 Cruciform Joint - Improved Design 78 General and Remedial Actions Square 1429 Figure 63 Replacing Square Comers 8 Fillet Welded Structure 1430 Figure 64 Repair of Fillet Weld Cracking Stiffener Ends 79 Figure 65 Crack at Stiffener End 80 Figure 66 Tapered Stiffener End 80 Repair of Weld Defects 1432 ‘Weld Repair of Material Edges 1435 Figure 67 Repair of Bdge Defects 81 ‘Weld Repair of Pitted Surfaces 1438 SECTION 15 WELD REPAIR OF ALUMINIUM ALLOY 82 CASTINGS 1431 General 1501 Types of Repait 1503 Preparation for Weld Repair Considerations 1504 Excavation Shape 1505 Figure 68 Excavation Shapes Not Extending Through the Wall 1506 Figure 69 Defects in Casting Wall Figure 70 Primary Excavation to Remove Near ‘Surface Defects Figure 71 Secondary Excavation Figure 72 Excavation Details Figure 73 Regularizing of Defect Excavations Extending Through the Wz (including Welded ine) 1507 ‘Weld Metal Through Wall Repairs 1508 Figure 74 Typical Joints for Through the ‘Wall Welding 86 Inserts, Through Wall Repairs 1510 Edge Repairs 1512 RRL FB ‘78(WS8/SG)B2 (viii)ICTION 16 SECTION 17 78(WS8/SG)B2 Figure 75. Welding Inserts Figure 76 Edge Repairs ir of Fractures Figure 77 Free Bar Fracture Repair of Cracks Figure 78 Repair of Cracks Building Up Damaged Comers Defective Edges Welded. Atachineas to Castings ‘Welder Qualification ide Welding Consumables Preheat Pre-weld Cleaning {nner Cleaning Hew 31 L Meaeang Interpass Temperature igure : ferpass Tempera ‘Welding Techni Weld Bead Deposition Sequence Figure 82 Weld Bead Deposition Stops and Starts Figure 83 Stops and Starts Back Gouging Backing Strips and Bars Post-weld Heat Treatment ‘Acceptance Standards DRAWING REQUIREMENTS AND DESIGN CONSIDERATIONS. Temperature ‘Summary of Design Considerations Inspection and Acceptance Requirements QUALITY CONTROL AND INSPECTION OF WELDS: Assembly and Welding Sequences Qualification Supervision Weld History @&) Ce 93 94 95 NES 768 Issue 1 Clause 1603 1605 1606NES 768 Issue 1 ANNEX A 78(WS8/SG)B2 Edge Preparations R Figure 84 Edge Preparation for Hand Prepared Edges Quality Control of Weldi Non-destructive Examination 100 Consumables Extent of Non—destructive Examination Welded Inserts and Penetrations Repair of Welding Renovation by Welding of Pitted Plating Identification of Defects Position Figure 85 Weld Defect Position ~ Marking for Removal Quality Control of Stud Welding 102 Non-destructive Examination of Riveted Joints ALUMINIUM ALLOY 105 ALUMINIUM AND CHARACTERISTICS Physical Mechanical Proof Stress Tensile Strength Table Al Constants and some Physi ical Properties of Very High Purity Aluminium 106 Figure Al Load/Extension Curve, Il the Method of Deriving Proof Stress. lustrating Figure A2 Form of Stress/Strain Curves for Some Aluminium Alloys Elastic Properties Elongation Compressive Strength Bearing Strength Hardness Fatigue 107 Figure A3_ Examples of Stress Concentration 109 Corrosion Resistance Thermal Properties ‘Aluminium Alloy Designation System (BS 1470:1987, Appendix B) Table A2 Aluminium Alloy and Temper Designation Cross-References ‘Temper/Heat Treatment Designations System D) (BS1470:1987 Section 5 and ‘Appendix Non Heat Treatable Alloys (Wrought) ~ SXXX Alloy Hea Teasbic Al Alloys (Wrought) - 6XXK Alloy Group Heat Treatment ‘Annealing & AlaANNEX B ANNEX C 78(WS8/SG)B2 Non-Heat Treated Cast Alloys Heat Treatable Cast Alloys Typical Alloys Heat Treatment Designation System ‘WELDED JOINTS Figure BL Weld Types Butt Welds Figure B2 Butt Weld Preparations Joint Terminology Figure B3 Joint Terminology Edge Preparations Figure B4 Guide for Edge Preparations MATERIAL HANDLING STORAGE AND PRC SING Handling Cleaning and Degreasing Storing Controi Shelves, Racks and Bins Movement of Materials Identification Processing Sawing Figure Cl Band-Saw Blade Figure C2 Modified Circular-Saw Blade Shearing Planing Chisel Types Figure C3 Narrow Chisel Figure C4 Wide Chisel Figure C5 'C Chisel Nibbling Routing Figure C6 radial Arm Routing Machine Grinding Tungsten Burrs Filing Figure C7 Coarse File Drilling Figure C8 Drill Point Angle Plasma Are Cutting Figure C9 Schematic Diagram of the Plasma Are Cutting System Plasma Cat surfaces Metallurgical Effects Water Injection Plasma Are Cutting Gases for Plasma Cutting Gi) 17 117 118 118 119 125 128 128 130 131 132 133 133 134 NES 768 Issue 1 Adz Aas Ad6 Aa9 gggRegeac cs ca C45 C46 a7 cag. cso 53 55 C62NES 768 Issue 1 Page Clause ANNEXD = EQUIPMENT 137 TIG Power Sources DL Figure D1 Schematic Diagram of Equipment for Tie Melding 137 TIG Welding Equipment D2 TIG Welding torch D3 Figure D2 TIG Torch 138 Inert Gas Shielding (TIG) D7 Flowmeter Regulator (TIG) Di2 Settings for TIG Welding Dia Table D1 Typical Settings for TIG Welding 139 TIG Welding Technique Di6 Figure D3 Filler Rod Feeding 140 Manual DC Helium TIG Welding Dai TIG Welding - Problems and How to Avoid Them D24 Table D2 TIG Welding Problems and Causes 141 Figure De Seb Diagram of Equi ee Fi ematic Diagram of Equipment for MIG Welding 143, Maintenance of MIG Power Sources D32 MIG Wire Feed Units D33 MIG Welding Torches and Guns D34 Settings for MIG Weldi D3s Setting-to—Work Procedure (MIG) D36 Table D3 Typical Settings for MIG Welding 145 MIG Welding Technique D37 Figure DS Backing Bar and Strips and Weld Pool Footing 146 Figure D6 Fillet Weld - Vertical Up 147 Figure D7 Ending of a Weld Run 148 MIG Welding - Problems and How to Avoid Them 148 Table D4 MIG Welding Problems and Causes 149 ized MIG Welding D39 ANNEXE WELD PROCEDURE 151 ANNEXF WELD PROCEDURE SUBMISSION FORM 153 Duplicate) WELD PROCEDURE ETC ANNEX G GENERAL GUIDANCE ON DISTORTION 157 Butt Welds G4 Figure G1 Distortion Due to Weld Contraction 157 Fillet Welds Gs Beams and Girders G8 Figure G2 Bowing of a Fabricated Tee Welded ‘Component 158 Figure G3 Back to Back Welding of Components 159 Figure G4 Machinery Seating Top Plate Distortion 159 Machinery Seating G10 Deck Plating Butt Weld Gil ‘78(WS8/SG)B2 (xii)ANNEX H 78(WS8/SG)B2 Figure GS. Deck Plating (Thin) Butt Weld Welding Sequences for Figure G6 Welding Pating Free to Move Figure G7 Welding Plating within Bounding Stru Structure Figure G8. Skip Welding of Beams and Stiffenes to Plating ‘Temporary Stiffening to Maintain Form Figure G9 Principle Stiffening Requirements for a Weldment or Unit Intercostal Structure Figure G10 Scallops Frames of Stiffeners Crossing Butt Welds Figure G11 Structure Crossing a Butt Weld Butt Welds in Structure Joined to Plating Figure G12 Butt Weld in Structure Joined to Plating Cruciform Framing and Stiffener Connections Figure G13 Scallops at Cruciform Joints Figure G14 Welding Comer Joints St topwaters Figure G15 Welded Stopwater Butt Weld in Extruded Sections Thin Coaming Penetrations ‘Welding of Thin Penetrations Figure G16 Circular Coaming - Welding Sequence Figure G17 Rectangular Coaming - Welding Figure G18 Method of Installing Small Penetrations Intersecting Butt Welds Figure G19 Butt Weld Junctions Slot or Pug Welds Figure G20 Slot Weld Tongue Weld Figure G21 Tongue Weld Inserts Figure G22 Rectangular Insert Figure G23 Circular Insert ‘Welding Grillages Figure G24. Welding Grillages STUD WELDING ~ GUIDANCE Design considerations and Applications Figure H1 Drawn Arc Stud Welding Gun Drawn Arc Stud Welding Figure H2 Basic "Equipment for Drawn Are (xiii) 160 161 162 163 164 165 165 166 167 168 169 171 171 172 172 173 174 175 175 177 179 179 180 181 NES 768 Issue 1 Clause Giz G16 Gai G23 G24 G25 G26 G27 G31 G34 G35 G36 G38 HTNES 768 Issue 1 Page Clause Stud Welding Gun Hil ‘Welding Sequence HIS Figure H3 Drawn Arc Stud Welding Sequence 182 Capacitor Discharge Stud Welding HI6 Figure H4 Capacitor Discharge Stud Welding 183 Power Sources His Stud Welding Gun HI9 ANNEXJ GUIDANCE ON DESIGN CONSIDERATIONS 185 Figure J Non-Eccentric Loading 185 Choice of Welded Joint mL tic Strength m2 Fatigue Strength m3 Accessibility m4 Corrosion ms Distortion n6 ANNEXK WELD HISTORY 189 ANNEXL — USABILITY TEST FOR ALUMINIUM ALLOY 191 ELECTRODE WIRE Test Method Li Test-Piece Type and Dimensions 2 Preparation of Test~Piece B Weld a ‘Welding Equipment 1s Table Li Selection of Material for Test-Piece 192 Figure Li Test-Piece Dimensions 193 Permissible Range of Welding Conditions 6 Evaluation of Test Weld Visual Examination 7 Radiographic Examination 1B Re~Test Procedure Lio Related British Standards mi ANNEXM — WELD DEFECTS 195 Defects ML Cracks M2 Figure M1 Longitudinal Centre Cracking 196 Figure M2. Cracking at a Weld Start 196 Figure M3 Longitudinal Edge Crack 197 Figure M4 Transverse Cracking 197 T8CWS8/SG)B2 (xiv)ANNEX N Figure MS Crater Cracking Lack of Fusion Lack of Side Fusion Figure M6 Lack of Side Wall Fusion Lack of Root Fusion Figure M7 Lack of Root Fusion Lack of Inter-Run Fusion Figure M8 Lack of Inter-Run Fusion Incomplete Root Penetration Figure M9 Lack of Fusion Due to Incomplete Penetration Voids Uniform Porosity Figure M10 Uniform Porosity Localized Porosity Figure M11 Localized Porosity ‘True Linear Porosity Elongated Cavity age Voids Figure M12 Three Examples of Linear Porosity Figure M13 Elongated Cavities Inclusions Oxide Inclusions Figure M14 Oxide Inclusions Copper Inclusions Figure M15 Copper inclusions Tungsten Inclusions Miscellaneous inclusions Figure M16 Tungsten Inclusions Imperfect Weld Shapes Undercut, Figure M17 Undercut Excessive Reinforcement Figure M18 Excessive Reinforcement Excessive Penetration Suck-Back Root Shrinkage Figure M19 Root Shrinkage and Suck-Back Incompletely Filled Groove and Bum Through PROCUREMENT CHECK-LIST ALPHABETICAL INDEX 78(WS8/SG)B2 F 199 199 201 208 210 211 215 NES 768 Issue 1 Clause MilNES 768 Issue 1 INTRODUCTION This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry of Defence, Director Naval Architecture (DNA) Section NA115. If it is found to be unsuitable for any particular requirement the Sponsor is to be informed in writing with a copy to Director Naval Architecture NA145. Any user of this NES either within MOD or in industry may propose an amendment to it. for amendments that are not directly applicable to a particular contract are to be made tothe Sponsor ofthe NES and those Giteyapplcabe taper conte re to be dealt with using existing procedures or as specified in the contract. No alteration may be made to this NES except by the issue of an authorized amendment. Unless otherwise stated, reference in this NES to approval, approved, authorized or similar terms means by the Ministry of Defence in writing. 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 intervals. Extracts from British Standards within this NES have included with the permission of the British Standards Institution. This NES supersedes NES 706 Section 19 and DGS/PS9023 where it applies to aluminium and its alloys. 78(WS8/SG)B2 wi)0101. 0102. 0103. 0202. 0203. NES 768 SCOPE This NES covers the requirements for the fabrication, joining and repair of structures and associated components and castings produced in the following MOD(PE) SSC approved aluminium alloys. a aluminium alloy plate strip and sheet to BS 1470 ~ type 5083; b. _bars, extruded round tubes and sections to BS 1474 — type 5083; c. castings to BS 1490 alloy LM6. NOTE: Attention is drawn to NES 155 Part 1 regarding the use of aluminium for ships structure ie it is a non preferred material. It also includes the requirements and guidance on materials, material handling, storage and processing, design of welded joints, drawing preparation and quality control and inspection. The fabrication and joining of pipework is not covered by this NES, reference is to be made to NES 743 Parts 1-4 Manipulation of Pipework Systems for these applications. HEALTH AND SAFETY ¥ARNIN' . WARNING ‘This NES calls 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. Particular attention is drawn to the following hazards although the list may not be exhaustive. a. Radiation hazards, injury or damage to health in particular the skin may be caused by ultraviolet radiation. b. Are flash hazards, injury or damage to health in particular the eyes resulting from the arc flashes created by the welding processes. ¢. Electrical shock hazards, injury or damage to health caused by the operation of the welding processes. 4. Ozone gas hazards, injury or damage to health owing to the high levels of ozone created by the welding processes. €. Fire and explosion hazards, injury or damage to health caused by gases and toxic Enarawel asthe ames directly linked to fire and explosions. Safety precautions are to be taken before welding operations proceed eg Compartments, tanks, cylinders and pipes ventilated and gas freed, combustible materials removed and fire watchers posted. Appropriate protective clothing should be worn. 78(WS8/SG)B2 1.‘NES 768 Issue 1 3. RELATED DOCUMENTS 0301. The following documents and publications are referred to in this NES: See Clause BS EN 10002-1 ¢ Tensile testing of metals A6, A7 (including aerospace materials) BS 499 / ‘Welding terms and symbols 1005 Part 1: Glossary for welding, brazing and thermal cutting BS 1470" Specification for wrought aluminium 0101, 0501, and aluminium alloys for general engineering (0617, Figure 3, purposes~ plate sheet and strip Table A2, Annex A(21), 2), 25), (26), (27), G1), Table L1 BS1471~ Specification for wrought aluminium and Amnex A(31) juminjum alloys for general engineering purposes - drawn tube BS 1472- Specit ion for wrought aluminium and Annex A(31) luminium alloys for general engineering purposes ~ forging stock and forgings BS 1473. Specification for wrought aluminium alloys Annex A(G1) for general engineering purposes ~ rivet, bolt and screw stock BS 1474 © Specification for wrought aluminium and 0101, 0501, aluminium alloys for general engineering Annex AG) purposes ~ bars, extruded round tube and sections BS 1475“ Specification for wrought aluminium and Annex A(G1) aluminium alloys for general engineering purposes ~ wire BS1490 Specification for aluminium and aluminium 0101, 0503, alloy ingots and castings for general 0543, 0549, engineering purposes 1501, Annex A(43), @9) BS 1501 » Steels for fired and unfired pressure vessels: plates Part 1: Specification for carbon and carbon 0617, Figure 3 manganese steels 78(WS8/SG)B2 2.Issue 1 BS 2901 / Filler rods and wires for gas shielded arc 0505, 0506, \ding 0510, 0930, 1131, 1523, Part 4: Specification for Aluminium and 1737, aluminium alloys and magnesium alloys 12), Annex L{11a), Table L1 BS 3019 t TIG welding Part 1: Specification for TIG welding of 1131, aluminium, magnesium and their alloys Figures C3, C4, co BS3451 / Methods of testing fusion welds in 1146, aluminium and aluminium alloys ‘Annex L(11b) BS3S71_ General recommendations for Manual inert-gas metal-arc welding Part 1: 1985 MIG welding of aluminium 1131 and aluminium alloys BS 4620, Specification for rivets for general 0603 engineering purposes BS 4778 / Quality Vocabulary 1702 Part 2: Quality concepts and related definitions BS 4870 ‘Specification for approval testing of 1005, 1104, v welding procedures 1114, 1127, Annex L(1ic) Part 2: TIG or MIG welding of aluminium and its alloys BS 4871 Specification for approval testing of 1104, 1161, welders working to approved welding u procedures Part 2: TIG or MIG welding of aluminium and its alloys BS 4872 ‘Specification for approval testing of 1104, 1161 welders when welding procedure approval is not required Part 2: MIG or TIG welding of aluminium and its alloys BSCP118 Vv ‘The structural use of aluminium Annex J(13) ISO 2107 . Aluminium Magnesium and their Alloys — Annex A(26) Temper Designation 78(WS8/SG)B2 3.NES 768 Issue 1 NES 155 _ NES 162 « NES 706 , NES 722 - NES 729 - NES 743 - NES 769 « NES 1027 » DGS/G/10000B (NES 773)* DEF STAN 80-77 * Not yet issued Requirements for Structural Practices in Steel Surface Ships Part 1: General Requirements Guard and Awning Stanchions, Rails and Associated Fittings Part 1: General stanchions, rails and associated fittings ‘Welding and Fabrication of Ship Structure Requirements for Drawings Requirements for Non-Destructive Examination Methods Radiographic F Current Liquid Penetrant Ultrasonic Se Pipe Manipulation Part 4: ‘Welding, Welding Consumables for Structural Steels ~ Approval System Electromagnetic Compatibility Requirements for instaliston ia Shige Minimum: stance Standards for Welds in HM Ships and Submarines Paint priming, zinc chrome, fire-retardant Types brushing = 0101, 0501 Annex A(32) 0732,1059,1063 1601 0721, 1143, 1708, 4708; 1743, Amex L(8) 0103, 1169, 1730 1060 061s 0721,1103,1115, 1174,1432, 1537,1606,1701, 730,1744,1745 0604 0302. In the tender and procurement processes documents can be obtained as follows: a British Standards - British Standards Institution, Linford Wood, Milton Keynes, MK14 6LE. b. Defence Standards - Directorate of Standardization 78(WS8/SG)B2 Street, Glasgow, G2 8EX. c. Naval Engineering Standards - MOD Library Services (Bath). MOD Library Services (Bath), Foxhill, Bath BA1 SAB can advise in cases of difficulty.4. DEFINITIONS ‘NES 768 Issue 1 0401. For the purpose of this NES the following definitions apply: ‘Age Hardening (natural ageing) Aluminium Annealing Approved or Approval Assembly Welds Cold Work Fabricator Frame or Beam or Stiffener Insert Pads 78(WS8/SG)B2 The property which certain alloys possess of automatically hardening themselves when left for a few days at ordinary temperatures after having been quenched in water. ‘The term aluminium includes aluminium alloys. The process of heating and cooling a metal or alloy from a suitable temperature down to ambient temperature to increase its softness and malleability. Unless otherwise stated means ‘approval of or ‘approved by' MOD Design Authority. Those welds made to full welding procedure requirements to assist assembly and maintain alignments during welding, but are removed and do not form part of the final weld. For this NES is the controlled deformation by rolling of aluminium and its alloys. Such work will harden and strengthen the metal. The effects of cold work can often be reversed by annealing. ‘The Firm, Company, Organization, Establishment or Naval Base working within the scope of this NES. Bar or section strengthening member, normally attached to plating. Inserts required to facilitate securing pipe systems, electrical cables or operating gear through the bull. These may be thicker than the hull or structural plating but tapered at the edges to or near the thickness of the adjacent plating. Castings or forgings which are flanged to provide a welding preparation which is of similar thickness to the adjacent plating are to be treated as insert pads.ao Insert Plates Inspecting Authority Maintenance of Form Precipitation Treatment Quality Assurance Representative (QAR) Softening Solution Treatment Stop Waters 78(WS8/SG)B2 6. Inserts required for blanking holes after the removal of redundant may be the same thickness or slightly thicker than the adjacent plating. The controls to be applied to ensure a welded structure complies with the design dimensions or form. Is a form of controlling hardness and is in essence a form of ageing. The precipitation of a constituent from the Solid solution is controlled to obtain NES a being met The heating of metal to soften it in readiness for working operations such A treatment that changes Sota me by being ittoa perature detopnined by ts character, and maintaining this temperature long enough to ensure the required constituent goes into solid solution. The material is then cooled at a sufficient rate to ensure the required constituent is held in solution (supersaturated) to a higher level than it would normally under equilibrium conditions of slow cooling. A small section of full penetration weld introduced to stop leakage on fillet welded structure, where the weld pierces oil-tight or watertight boundaries.0501. 0506. 0507. 0508. NES 768 Issue 1 Stud Welding ‘The attachment of a stud, or other similarly shaped part, to a metal surface by the production of a weld over the whole area of the stud. Through Penetrations ‘Those penetrations, such as coamings, which effectively pass through the plating to form a structural comnection. Unit A fabricated structure which contains final dimensions or forms part of the ship's form. ‘Weldment A fabricated assembly. MATERIAL Approved Materials The materials by MOD(PE) SSC for structural use are as follows: (See NES 155 Patt 1) a. plate, sheet and strip are to be BS 1470 ~ Alloy No 5083; b. _- bars, extruded round tubes and sections are to be BS 1474 — Alloy No S083. ‘The wrought materials stated in Clause 0S01a and b. are to be in the 'O' and 'H' condition as dictated by their use, strength and forming requirements. Condition ris only tobe used where strength and forming are not criteria. (Refer to Annex A - A2S and A26). |. The material approved by MOD(PE) SSC for castings is BS 1490 - Alloy LM6. }. For more information of aluminium and aluminium alloy characteristics see Annex A. Welding Consumables . Filler wires for approved structural material, (see Clauses 0501 and 0502), are to be to BS 2901 Part 4 — 5056A and 5556A. Either of these filler wires may be used, but for the ‘welding of pressure vessels, only 5556A is to be used. Filler wire for approved casting material, (see Clause 0503), is to be to BS 2901, Part 4 — 4047A. Gases The shielding and purge gas to be used in the welding of approved material is Argon 99.95% pure (minimum). Identification and Control ‘The identification and control of all approved material, whether approved by this NES or as in Clause 0510, is to conform to the requirements of Section 17. 78(WS8/SG)B2 7.NES 768 Issue 1 0509. 0510. 0603. 0605. Other Materials ‘Where the use of materials other than those approved in Clauses 0501 to 0506 is, proposed, details of such alternative requirements, are to be submitted to MOD(PE) SSC for consideration and approval. No work is to be done using other than approved material without the prior approval of MOD(PE) SSC. A list of BS 2901, Part 4 filler wires for the welding of combinations of aluminium and its alloys is given in Section 9 Table 2. JOINING ALUMINIUM AND ITS ALLOYS (Excluding welding) General . When welding is not possible, aluminium alloys may be joined by methods such as bolting, riveting, flush break fasteners (monobolt) or adhesives (where approved). Riveting Holes for rivets are to be drilled, ing is prohibited. All holes are to be drilled undersize and reamed with a spinal fluted reamer to the finished size. Rivets are to be in accordance with BS 4620: 1970 (metric units), and to be of 5154A_ material, not 5083, which is stress corrosion suspect. They are to be driven cold, after dipping in Jeffrey's Jointing Compound No 241A, barium chromate inhibited or Seelastic zinc chromate inhibited. Rivet types are shown in Figure 1. }. The faying surfaces of aluminium alloys are to be degreased, and etch primed, painted with two coats of zinc chromate primer (to Def Stan 80-77) and coated with sealing compound, eg Jeffery's Jointing compound, No 241A barium chromate inhibited or Seelastic zinc chromate inhibited. For watertight work either of the above compounds is. to be spread on Denso tape and the tape and compound combination inserted between the two faying surfaces. Rivet Diameters The ratio of the rivet diameter (D) to the thickness (1) of the thinnest member being joined, influences the strength of the joint. This ratio D:t is not to be greater than 3 or less than 1 for single shear joints. Where holes are counter-sunk D:t is not to be greater than 1.5 or less than 1. Double shear joints may be treated as two single shear joints, if half the thickness of the centre member is equal to that of the outer ones. The governing thickness ({) is to be taken as half the thickness of the central member if this thickness is less than that of the outer members. ._ Rivet lengths are to be such that the hole is completely filled and the desired point formed with no excessive overspill. . Edge distance is generally 2D and is not to be less than 1%D see Figure 1b. . Rivet pitch (spacing) is not to be less than 3D, the maximum for water tightness being 4D or 10t, whichever is smaller see Figure 1b. |. Spacing between staggered rows is not to be less than three-quarters of the pitch. 78(WS8/SG)B2 8.0610. 0611. 0612. 0613. 0614. NES 768 Issue 1 1 2 3 ‘ Ss Rivets: 1, Snap: 2, Universal: 3, Flat: 4, Countersunk: 5, Countersunk end raised countersunk. Rivet lengths to order. Rivet Types Staggered or Reeled FIGURE 1 RIVETING FORMS Holes for small rivets (less than 10 mm dia) are to have holes with minimum clearance for rivet shank. Holes for large rivets (greater than 10 mm dia) are to have a standard clearance of approximately 0.8 mm. Mechanical Methods of J ig Bolts used for connecting are to be of steel, zinc plated and dipped in jointing compound, see Clause 0603. Flush break fasteners such as the Monobolt or rivet pins (known as Huckbolts) may be used. Generally their use is to be confined to structure of minor importance. These of fasteners are available in Aluminium Alloy, Carbon Stee! and Stainless Steel. Bimetallic Connections Aluminium may be preferentially attacked when in contact with other metals commonly used in shipbuilding. This is particularly so with copper and bearing alloys such as brass or bronze, stainless steel, and to a lesser extent with steel, lead and nickel. Bimetallic connections are therefore undesirable, but where they are unavoidable the metals are to be insulated from each other. Two methods of making these joints are detailed, riveted (Figure 2) and welded. The latter method is a structural aluminium to steel transition joint and is detailed in Clauses 0616 to 0622. 78(WS8/SG)B1 9.NES 768 Issue 1 Gasket—Tape/ Rivets/Bolts Spacing to compound x ied WPM Mild Steel Plate Galvanised FIGURE 2 ALUMINIUM TO STEEL JOINT Riveted and Bolted Joints 0615. Rivets are to be of aluminium alloy sce Clause 0603 and bolis, zinc coated, both of which are tobe dipped in Jeffer's Jointing compound 241A, barium chromate inhibited or Sealastic, zinc chromate inhibited. The faying surface of the aluminium is to be coated as. in Clause 0605. Steel structure immediately adjacent to aluminium alloy structure is to be galvanized or zine sprayed fo a thickness of 0.2mm minimum and inserts put between faying surfaces as in Clause 0604. Eich priming is not required for zinc sprayed surfaces. Rivets are to be knocked up on the steel side where practicable. NOTE: In the case of Radio Screened Compartments, special care must be taken to ensure an efficient electrical contact between adjacent aluminium plates, also one comecson between the aluminium par ofthe struct and the eel par The strips are to be fitted in dry positions (eg internally if the structure is exposed to the weather). The method by which this is to be done is given in NES 1027. ‘Structural Aluminium Alloy to Stee! Transition Joints 0616. The proprietary name for this aluminium alloy to steel transition joint is ‘Kelocouple’, manufactured by a subsidiary company of ICI, Nobel's Explosives Company Limited. 0617. The transition joint consists of a composite of aluminium alloy to BS 1470, Grade 5083, pure aluminium to BS 1470, Grade 1200, and steel to BS 1501-224400A’ Figure 3, etallurgcally bonded together by the use of explosives. This type of joint simplifies construction and allows normal welding methods to be used. 78(WS8/SG)B1 10.0618. 0619. 0701. 0702. 0704. NES 768 Issue 1 Al. Alloy BS1470-5083 Pure Al. BS1470-1200 ee “}— Steel BS1501-224-4008 transition joint FIGURE 3 KELOCOUPLE MATERIAL ‘The cutting of Kelocouple material is to be by mechanical methods only. Standard welding procedures and parameters are to be used for the welding of these joints. The ‘tomefane of the aluminium to steel interface is not to 315°C. ). The Kelocouple material can be supplied in plate form or cut into strips or bars in a range of sizes. By special arrangement, sizes not in the range, may be produced. . For the welding of Kelocouple material, see Clause 1063. For the design of joints in dissimilar materials, see Clause 0731. DESIGN OF WELDED JOINTS ‘The following clauses covers the requirements for design of weld joints. The welding processes for which the requirements of this section apply are: a. Metal Inert Gas (MIG) and pulsed MIG. b. Tungsten Inert Gas (TIG) and pulsed TIG. ‘The use of any other process is subject to MOD(PE) SSC approval. The design of joints is a vital part of the welding procedure and the right selection of the welded joint will control distortion and reduce shrinkage which in turn minimize residual stresses. Good fit-up of weld joints is also vital to facilitate good workmanship and produce sound welds economically. In selecting the weld edge preparation, the process to be used, accessibility and the design requirement must all be taken into consideration. Weld joint designs not specified in this section may be employed if approved by the MOD(PE) SSC. This approval may be obtained, together with approval of a welding procedure or a component drawing, provided that the welding procedure or component drawing states that the weld joint design is not included in this NES. For further guidance on the design of welded joints see Annex B. 78(WS8/SG)B2 : 11.NES 768 Issue 1 0705. 0706. 0707. TR(WS! ification of Joint Design, Eds tion Edge preparations are to be qualified for use by being part of the pre-production procedure tests defined in Section 11. Particular cafe & fo be taken inrselecsing edge preparations for use with the MIG or TIG process. The fundamental difference being, the limitation of the TIG process for the thicker materials. ‘Stresses in Welds Joint design and selection must take into account the type of loading the joint must carry, ie static, cyclic, impact or dynamic loading. Stresses in welded structures are to flow through the joint with the least deflection. ‘Abrupt changes of section are to be avoided as they create unacceptable levels of stress concentration. See Clause 0717. ‘Backing Bars and Strips . The use of backing bars and strips may be necessary for thin materials or where the back of the weld is inaccessible for back gouging. Their function is to support the penetration bead during welding and may be temporary or permanent. ‘Temporary Backing Bars |. Metal temporary backing bars are to be made of stainless steel, mild steel or copper. Mild steel or copper bars are not to be used when welding main structure because of the risk of iron, aluminium or copper pick-up. Where these ‘burnt’ spots occur the area will be brittle and sensitive to corrosion and must be avoided. This is not a problem with stainless steel backing bars and they are permissible on minor structure and components. Figure 4 gives details of suitably approved backing bars. used R Yer Material Len na 6.8 ma eaees wy j= a For material > 6.5 mm FIGURE 4 TEMPORARY BACKING BARS. 8/SG)B2 12.NES 768 Issue 1 Permanent Backing Strips 0711. These are in two forms: a. Separate strips of material, of the same specification as that being welded, which become part of the joint by virtue of being penetrated by the weld, Figure’5. — tke [eeseene ese [Tt rT SH G a FF ce © ain. a We 4t or 50mm whichever is less <5 om 5 mm and over. FIGURE 5 PERMANENT BACKING STRIPS b. The backing strip, which is part of a structural member. This is a special extruded section designed for the purpose and shown in Figure 6. 40°-60° Get minimum For t = 3nz and less, no edge preparation is required. Extruded Section FIGURE 6 WELD TEE BAR AS BACKING 0712. Imall instances where backing strips are approved for use they are to be a good fit. The backing is to be in close contact with the plate edges along the whole length. 78(WS8/SG)B1 2B.NES 768 Issue 1 0713. 0714. 0715. 0716. 0717. Where they are used as part of the butt weld in main structure exposed to sea water or other corrosive media, they are to be continuously fillet welded to the plating to avoid the possibility of crevice corrosion. Where other forms of backing are proposed other than those approved inthis standard, such proposals are to be forwarded to MOD(PE) SSC for consideration. The width of the gap of the welded joint must be sufficient to allow access of the electrode to ensure complete root fusion of parent material and backing. This gap is to be established as part of the pre-production qualification requirements. Back Gouging Back gouging is an essential requirement of the welding process when making full tration butt welds. A back gouge, Figure 7, removes the oxidation and other inclusions at the back of the root weld and also removes any lack of root fusion that may have existed. Such back gouging is to be strictly in accordance with the requirements of Clauses 1043 to 1046. FIGURE 7 BACK GOUGING Strength of Butt Welds SSwesses in but welds are to low through the joint with the least deflection. Tis canbe by allowing a gentle taper on the thicker member to the thinner as arranged Figure 8(b). ‘Abrap changes insoton asin Figure Sa) ae toe avoided as they crate unacceptable levels of stress concentrations. giigh stress concentration @ Poor stress flow. Inproved stress flow FIGURE 8 STRESS FLOW 78(WS8/SG)B2 : 14.0718. 0719. 0720. 721. NES 768 Issue 1 ‘Where the difference in material thickness is t/S or less, where t is il to the thickness of the thinner part being joined, tapering is not necessary, but the weld is to be built up to the thicker part to provide the taper, as in Figure 9(a). ‘The joining weld must not be made as shown in Figure 9). The weld metal is to fill the preparation without sharp notches, undercut or excessive overfill. t/S or less @ t = thickness of thinner member being joined Ct > unacceptable notch ) Wrong FIGURE 9 PERMISSIBLE CHANGE WITHOUT SLOPE ‘Where two or more adjoining members of a weldment are of differing thicknesses greater than 1/5 in Clause 0717, they are to be tapered in all dimensions from the largest to the smallest, to a minimum of 1 in 5. In any such transition the thickness steps between adjoining members must not be greater than 50% of the thickness of the thinnest member. ‘Sce Figure 10. In any design situation or for any other reason a department from this restriction is considered necessary, approval from MOD(PE) SSC is to be obtained before any work can proceed. SD |_Slope 1 in 5 D = be 0/2 me iT FIGURE 10 JOINING MEMBERS OF DIFFERING THICKNESS - A butt weld can be considered to be an integral part of the loaded component. It is a full penetration weld with no special analysis problems. Joint overfill does not contribute to joint strength and can be removed as it serves no useful purpose. Full penetration welded joints examined in accordance with NES 729 Parts 1, 3, 4, and 5 and accepted to DG Ships/G/10000B (NES 773), see Section 17, may be considered to ‘have the same inherent strength as the base material of the weaker material. 78(WS8/SG)B2 aNES 768 Issue 1 0722. 0723. 0724. The throat thickness of a butt weld is to be taken as the thickness of the thinner part joined, When both parts are of equal thickness the throat thickness is to be equal to the part of component thickness. Fillet Welds Fillet welds are non~integral in character, and have a shape and orientation relative to the loading which makes simple stress analysis almost impossible. Simplifying assumptions have therefore to be made, these are: a the stress is related to the cross-sectional area. b. the throat plane does not lie at an angle to the load or to the plane of the component, but is parallel to it. Fillet welds are made between plate surfaces nomnally at right angles, Figure B1(b), the angle between the plates may vary from 60° to 120°, Figure 11. For members not at right angles, the mating edge is to be dressed to provide a no-gap fit at the required angle. For structural members required to fit at large angles, the proposed joint configuration is to be submitted to MOD(PE) SSC for approval. © = Fillet angle between member faces L = Fillet weld leg length T = Fillet weld throat thickness FIGURE 11 OBTUSE AND ACUTE ANGLE FILLET WELDS 78(WS8/SG)B2 . 16.NES 768 Issue 1 Fillet Weld Size 0725. Where fillet welds are employed the following requirements are to apply: a Fillet Welds Between 90° Angle Faces (2) ___ Fillet welds of equal leg length, as deposited, are not to be less than the specified dimensions shown on the relevant drawing or weld see Clause 1602, which is to clearly indicate the throat thickness and/or leg length as appropriate. Such dimensions are not to take into account the use of deep penetration processes. (2) Where the profile of equal leg length fillet welds is flat or concave the actual throat thickness as deposited, is not to be less than 0.7 times the specified leg length. Similarly, for convex shaped fillet welds the actual throat thickness is not to exceed either 0.9 times the specified leg length or 1.3 times the specified throat thickness, see Figure 12. (@) When caleulating the strength of filet weld he throat thickness s 10 be (4) Ie the leg length or throat thickness of a fillet weld is not specified, the throat thickness is to be 0.7 times the thinnest member of the joint. b. Fillet Welds Between Acute Angled Faces (1) The minimum angle for an acute angled fillet is to be 60°, see Figure 11. (2) Throat thickness is to be used for strength calculations. The relationship factor between leg length and throat thickness isto be as given in Table 1, and is to be used to calculate acute angled fillet throat size. c. Fillet Welds Between Obtuse and Angled Faces (1) The maximum angle for an obtuse angled fillet is to be 120°, see Figure 11. (2 Thestrength and throat size of obtuse angled fillets is to be found similarly as in Clause 0725b.2 and Table 1. Depeh of penetration Fusion face field toe Specified fitter equal eg length i fillet veld. werd face L (®) Concave fs11e¢ weld. a 1+ Syeiti seen chickens (comes severed concave cheat ehcicess tie wae chinese Measured convex Ls Specttied 1eg length. FIGURE 12 FILLET WELD DIMENSIONS 78(WS8/SG)B1 17.NES 768 Issue 1 See also @ Angle between fusion faces Clause Bua 60-90 | 91-100 | 100-106 | 107-113 | 114-120 ‘Throat Thickness |= Leg length size multiplied (rT) by Flat or Convex Face} 0.70 0.65 0.60 0.55 0.50 Concave Face 0.55 | 0.50 0.45 0.40 0.35 NOTE: Concave faces are only acceptable when allowed for in the design or specified on the drawing. TABLE 1 FACTORS FOR CALCULATING STRENGTH OF FILLET WELDS 0726. The edge thickness of any attachment to structure is to be greater than the specified leg length of the attaching fillet weld. The fillet weld at the edges of such an attachment is not to melt the outer comer or comers of the attachment, thereby reducing the throat thicknesses. See Figure 13. If edge burnt ‘off, size of fillet is difficult to check and throat thickness may be less than design size. Such edges should be rejected. Attachment 1.1t but always greater than the specified leg length. FIGURE 13 ATTACHMENT EDGE MINIMUM THICKNESS Prepared Fillet Welds 0727. A compromise between twin fillet welds and a full penetration butt welds may be required when making a tee connection. Double fillet welded tee connections are adequate for static loading conditions, but for materials 15 mm and above, the fillet weld size becomes unduly large, inducing high residual stresses and increasing distortion. Thus for material 15 mm and over, fillet welds are to be replaced by partial penetration tee butt welds as shown in Figure 14. For tec members over 25 mm, full penetration tee butt welds are to be used (see Figure 31). Where partial penetration tee butt welds are roved, the dimensions are to be as shown in Figure 14, particular care being taken in jeving the weld profile by using a template. 78(WS8/SG)B1 18.0729. NES 768 Issue 1 Template outline FIGURE 14 PARTIAL PENETRATION TEE-BUTT WELD ‘Sub-Size Fillet Welds For welded attachments which do not contribute to the structural strength of the vessel or component, the size of the fillet weld may be reduced, providing there are no other instructions regarding minimum sizes of the welds, and that the proposed weld size is adequate for the strength required, Intermittent Welding Intermittent welding of ship structure is prohibited with possible exceptions such as framing under thin decks or flats in dry spaces, and is not to be used without specific MOD(PE) approval. Where the use of intermittent welding has been approved it is to consist of 100 mm of welding and 100 mm of gap, so arranged in chain intermittent weld form. At the ends of framing or in way of brackets or stiffeners, the welding is to be continuous for the extent of the intersection plus 150 mm, see Figure 15. 100 100, 100, 100, 150 ee tet FIGURE 15 CHAIN INTERMITTENT FILLET WELDS 78(WS8/SG)B* : 19.NES 768 Issue 1 Lap Joints 0730. Lap joints are to be confined to work of minor structural importance. When approved, the length of the overlap is to be four times the thickness of the thinner member. The fillet weld size is to be the largest possible based upon the thinnest material so that the comer is not fused. See Figure 16. Corner to be visible and not fused. Leg length of weld = 0.7¢ Thickness of thinnest member FIGURE 16 LAP WELD Joints using Kelocouple Material 0731. Partial penetration butt weld in kelocouple material is to be as shown in Figure 17. Aluminium alloy Aluminium Steel FIGURE 17 KELOCOUPLE BUTT WELD 0732, Fillet welding ofthe strucare material to Ketocouple sandwich to form a transition joint is to satisfy the requirements of this NES for the aluminium welds, and NES 706 for the steel welds. Design applications are given in Figure 18. 78(WS8/SG)B2 20.| Aluminium alloy # These welds may be required to be partial penetration or full penetration Tee-butt welds. rm | Atusiniua alloy t Aluminium alloy Aluminium Steel Kelocouple material shape cut from plate. ‘Typical arrangement in way of T-junction in structure to avoid butt joint in Kelocouple material at point of T-junction FIGURE 18 ALUMINIUM/STEEL TRANSITION JOINT DESIGN APPLICATIONS 78(WS8/SG)B1 21NES 768 Issue 1 0733. Partial penetration and full penetration tee-butt welds may be required instead of fillet welds for some design applications. Where required they are to satisfy the requirements of this section. 0734. ‘The use of cope holes in way of butt joints in kelocouple material, see Figure 18, is to be kept toa minimum. Wherever possible butt welds in kelocouple material are to be made in the flat position and under cover, and every opportunity taken to weld it to the steel coaming before assembly at ship to avoid as much positional welding as possible, see also Clause 1063. 8. CONSUMABLE HANDLING AND MATERIAL FORMING Welding les 0801. Aluminium welding consumables are high quality products and are usually supplied packaged to prevent surface contamination from moisture or foreign matter. Proper storage is therefore essential if the product is to remain satisfactory for the production of sound welds. a Storage (1) Consumables are to be kept in closed packets in a heated dry storage area. with a uniform temperature suitable to prevent condensation on the metal surface. (2) Once a package has been opened, it is to be retumed to store when no longer required, or at the end of the work period, whichever is the shorter time. b. Handling (Q) Filler wire and studs are to be kept scrupulously clean when handled. Clean gloves are to be used at all times, and in the case of TIG welding, where the wire is passed through the fingers, the operator's hands must be clean and cotton or wool gloves wom. See Clauses 0930 to 0933 and (2) When the MIG welding process is in use and appreciable time delay between welding operations is likely, wire reels are to be protected by a Clean cloth or plastic covering and removed to the store. Onno account is wire to be left on machines that have been in use for which there is n0 foreseeable work. @) Contaminated wires and studs are not to be used. Forming and Bending 0802. The hot bending of non-heat treatable alloys is prohibited. Where such materials are required to be formed, flanged or rolled, it is to be carried out cold. 0803. Where severe forming of tempered material is required, it is to be annealed in accordance with Clause A38 and A40 (see also Clause 0807). 0804. Where severe forming is known to be a requirement at the design stage the material to be formed is to be ordered in the 'O' condition. 78(WS8/SG)B2 22.0807. 0809. 0810. NES 768 Issue 1 . Higher alloyed material, such as 5083, may need interstage annealing during severe forming operations. The permissible minimum bend radii (R) for material thickness (t) for 90° cold bends in 5083 alloy, Figure 19 are: Section thickness (Tam)| 1.5 | 3.0 | 4.5 | 6.0 | 9-0 | 12.0 | Temper| Minimum Bend Radius (R)| 0.5t| 1t | it | ait | 2.5] 1.5t/ o it | 1.5t] 1.5t} 1.5t) 2b | 2.5t] H12 ‘Where the minimum radius bend is too large for the design requirements, a redesign incorporating an extruded or fabricated section is to be considered. FIGURE 19 COLD BENDING RADIUS The weld repair of cracks produced by forming or bending is prohibited. Cracks are caused by work hardening resulting from severe forming and bending being done on material not in the O condition or the omission of annealing at each stage of a bending or forming operation. ‘Where machines have been used for materials other than aluminium and its alloys they are to be thoroughly cleaned to remove all traces of foreign matter before being used on aluminium and its alloys. ‘Thick paper or cardboard is to be placed between each face of the forming tool of the machine and the aluminium or aluminium alloy to protect its surface from unnecessary damage. Local straining of 5083 alloy beyond the limits set out in Clause 0806 is prohibited. Knife edge pressing with sharp nosed tools, which locally cause sharp bends or indentations are also prohibited. Soft nosed well rounded tools are to be used. See Figure 20. 78(WS8/SG)B2 : 23.NES 768 Issue 1 WRONG (x) RIGHT () / Well rounded to suit allowable bend radius Local Sharp / bend or indentation Wrong. Knife edge Right. Soft nose bending. bending. Knife edge bending Soft nose bending FIGURE 20 USE OF SOFT NOSE FORMERS 9 WELDING PROCESSES AND TECHNIQUES 0901. This section contains the general considerations for the welding of the aluminium alloys approved for structural work as defined in Section 5. Prior approval is to be sought from DNA NAIIS before the welding of any other class of aluminium alloy. For the welding of castings see Section 15. 0902. The oxyacetylene welding process is not approved for welding materials covered by this NES. (See Clauses 0905 and 0906). Oxide Removal 0903. The highly refractory surface oxide film which has a melting point exceeding 2000°C must be removed before successful welding can take place. ‘This may be removed by Ghemical or electrical means, assed by preliminary wire brushing. See Clauses 1014 to 1 0904. For the TIG (Tungsten Inert Gas) and MIG (Metal Inert Gas) processes, oxide removal is achieved by electrical action within the welding arc. This is more effective and promotes sound welding without the risk of subsequent corrosion. ‘Welding Processes 0905. The MIG and TIG processes are to be used for all work covered by this NES except for stud welding which is to be done in accordance with Section 13. Variations of these processes may be used provided the requirements of weld procedure approval and welder qualifications are fulfilled. 0906. Where an altemative process proposed, such 2s manual metal are (MMA), MOD(PE) approval is to be obtained prior to commencement of work and is to inch procedural approval evidence. Oxy-gas processes are prohibited. 78(WS8/SG)B2 24,0907. 0910. 0911. 0912. 0913. 0914. 0915. 0916. NES 768 Issue 1 For thin aluminium components, resistance spot welding techniques may be used. In selected low strength non-watertight work MIG spot welding can be proposed and is subject to MOD(PE) SSC approval. Interpass Temperatures ‘The interpass temperature when welding aluminium alloys is not to exceed 150°C. Pyrometers only are to be used for measuring i temperature. Temperatures are to be checked 25 mm away from the joint line and 75 mm ahead of the weld. See Clause 1036. For Castings see Clause 1529. Preheating, Heat treatable alloys are not to be preheated without prior approval, and if required, is to form part of the welding procedure. The need to preheat aluminium for joining depends on the welding process, type of alloy, its thickness, and the ambient temperature. For castings see Clauses 1524 and 1525. For ac TIG, preheat is necessary when sections greater than 6 mm are welded, to aid fusion, without the need to use excessive welding currents. Preheating is essential when the temperature of the work falls below 10°C or when the thermal conductivity (mass of parts) is such that the heat is conducted away from the joint area more rapidly than the ‘welding process can supply. Preheating may be used to dry out moisture from the plates to be welded, particularly during early moming hous Where used for this purpose only, heating can stop when material is dry. Preheat will also prevent cold starts. Preheating of aluminium may be achieved by hot air blowers or by gas torches. The former method is clean and effective. A soft reducing flame is to be used with the latter and local overheating must be avoided by keeping the heating torch moving at all times. See also Clause 1525. The prebeat temperature, whichis not exceed 130°C, isto be monitored ath pyromsters and maintained throughout the welding operation. The material surrounding the weld may be covered by a fireproof insulation material to conserve heat. Prior to preheating, standard pre~cleaning procedures are to be carried out, see Clauses 1014 to 1022, followed after preheating and just prior to welding, by local mechanical wire brushing of the weld preparation face. With MIG welding prebcating in dry conditions isnot usually required until the thickness exceeds 25 mm. Preheating for drying, see Clause 0911 is beneficial. Preheating helps in improving weld quality (with respect to porosity) on materials thicker than 9 mm. Tungsten Inert Gas Welding (TI General TIG welding is accomplished with the heat of an electric arc operating between the tungsten electrode and the work, in a shield of inert gas, usually argon. This inert atmosphere prevents oxidation of the molten aluminium so that no welding flux is required; costly post-weld flux removal is eliminated. 78(WS8/SG)B2 25.NES 768 Issue 1 0917. Oxide removal is accomplished by the action of an ac arc, which must be used to prevent the tungsten electrode from overheating and give good penetration. This process is most ‘suitable for use in workshops but it may be used for on-site welding in well sheltered positions. 0918. Any thickness of aluminium may be welded by the TIG process but for economy reasons its general use is in the thickness range of 1.2 to 9.5 mm. It may be used to advantage for the welding of root runs in thick sections before fill up by the MIG process. It is not suitable for prolonged overhead work. Control of penetration is more easily obtainable than with MIG welding, therefore this process is normally favoured for unbacked joints which are accessible from one side only. 0919. Higher heat input and slower welding speed will result in greater distortion from TIG welding than MIG welding for equivalent welds. The process may be automated for butt welding of pipes and large production runs. Starting and Stopping (TIG) 0920. When starting from cold the arc is first to be struck on scrap aluminium to warm the electrode. To commence welding the arc is to be struck and held stationary until a pool forms in the joint before any filler rod is added. This ensures full penetration. See also Clauses 1037, 1038 and Annex D(18) to (20). 0921. All cold starts, oversize or unsound assembly welds are to be removed or defects will occur at these places. No matter how insignificant the defects may appear to be, it cannot be over~emphasised that they are to be removed. 0922. When assembly or intermittent welding is used weld craters at the ends are to be avoided. This is to be done by: a. _ increasing the weld speed or b. reducing the current before extinguishing the arc or ¢. reversing the direction of welding for a short distance. In each case the arc is to be run along the filler wire before it is extinguished. Joints Made Without Filler (TIG) 0923. Only non-heat treated alloys, see ee A27 and Table A2, can be welded without the use of a filler metal. See also Clause 0924. Figure 21 shows the type of joint suitable for welding without filler metal. With these joints the component pars ofthe weld assembly must be jigged to ensure close contac, "The gap between the parts at any point is not to be greater than t/10 where t is the thickness of the thinnest member, otherwise the molten edges will be unable to flow together. 0925. The joint types in Figure 21 will determine the thickness range of material suitable for welding without filler metal and the following ranges are not to be exceeded: a. square butt joints and comer joints 1-3 mm b. flange joints and edge joints 05-3 mm T8(WS8/SG)B2 26.0926. 0930. 0931. 0932. NES 768 Issue 1 Fillet welds and lap welds are not to be made without the use of filler metal. oN FLANGED BUTTS EDGE CLOSE $Q.BUTT FIGURE 21 JOINTS THAT CAN BE WELDED WITHOUT FILLER METAL Pulsed TIG . The essential feature of this process is that a high current pulse is applied, causing rapid penetration of the material. If this high current is maintained excessive penetration and ultimate burn through will occur. Therefore the pulse is terminated after a pre-set time and the weld pool is allowed to solidify under a low background or pilot arc. The weld progresses in a series of discrete steps with a pulse current balanced to the travel speed. . Pulsed TIG is particularly beneficial in controlling penetration of the weld bead even with extreme variation in heat sink, eg thick to thin sections. ). Because of the cycling of high current pulses and low background current there is a lower heat input. This enables greater control of the arc to be achieved with less distortion. It is therefore very suitable for thin plate as well as thick plate. Filler Wire (TIG) Only approved filler wire, Type 056A or Type SSS6A (BS 2901 Part 4) is to be used for the welding of Type 5083 aluminium alloy. The filler wire is to be stored in a warm, dry area, kept covered and clean. Before use wires are to be cleaned with suitable solvent, or abraded with clean, unused stainless steel wire wool. Trichlorethylene or carbon tetrachloride solvents are not to be used for cleaning as these produce phosgene gas. . Clean gloves are to be worn when handling the filler wire. ‘78(WS8/SG)B2 27.NES 768 Issue 1 ‘Tungsten Electrodes 0934. Pure tungsten or zirconiated tungsten electrodes are to be used for welding aluminium. ‘The latter minimizes weld contamination, has a slightly higher current rate, and in gives rise to a more stable arc. They have a longer life than pure tungsten electrodes of ‘equal size, and have a good retention of the balled tip required for welding aluminium. 0935. ‘The size, tip condition and position of the electrode in the torch is important. The size is to be chosen so that the tip is maintained at a temperature near its melting point when welding in any given arc range. 0936. The maximum distance the electrode is to extend beyond the end of the shroud is three times the electrode's diameter for butt welding and slightly further for fillet welding. 0937. The tip of the electrode is to be ground as shown in Figure 22. 0938. Elecode ‘spitting, that is particles of electrode being ejected across the arc, cannot be ated. These partic particles contaminate the weld and reduce the mechanical strength of the Selden. jtting’ may be caused by partial rectification of the ac welding current, or too small an electrode for the current used, or too large an electrode. With the latter, the focal point of the arc wanders over the tip of the electrode and particles of tungsten fly off. Electrode ‘spitting! is fairly easy to detect. Current Amps o < 40 5 > v/2y 60" pan Electrode Tip. 100 ~ 200 we - 200 - 300 | # # Use current slope-in to ; minimise thermal shock that 300 - 400 | ¥ may cause spitting of the electrode. FIGURE 22 TUNGSTEN ELECTRODE TIP SHAPE AND CURRENT RATINGS 0939. The electrode should have a clean silvery appearance. A dirty rough electrode means the gas shield was shut off before the electrode had cooled, or that there was air leakage in the gas supply system or torch, or the electrode tip was contaminated by touching metal. A contaminated electrode may sometimes be cleaned satisfactorily with aluminium oxide abrasive paper. Metal Gas Wel iG) 0940. In the MIG process a de arc of reverse polarity (electrode positive) is struck between the workpiece and a continuously fed aluminium wire which acts as both the filler and electrode. As with TIG welding, fluxes are unnecessary, oxides are removed by the action of the arc which cleans both the weld pool and the filler wire. Re-oxidation is prevented by a shield of inert gas which envelopes the weld area. 0941. ‘The MIG process is used for either manual or machine welding. When the gun is operated manually it is referred to as a semi-automatic process. Once the gun is started and the arc is struck, the welding conditions are automatically controlled by the machine settings, leaving the welder to concentrate on the welding. 7&(WS8/SG)B2 : 28.0942. 0943. 0944. 0949. 0950. 0951. NES 768, Issue 1 The arc is sufficiently self adjusting to allow for small movements of the gun to be accommodated. When welding aluminium, by the MIG process conditions are usually set to give spray transfer, whereby filler metal is projected across the arc into the joint in the form of small globules. High welding speeds, can be achieved by this process. Higher welding speeds means less Diet neat input and therefor less distrdom,gleater weld strength and lower wel i costs for a given job compared with TIG. However the appearance of the weld bead is not as good as with TIG welding. . Material thicknesses of 1.6 mm upwards may be welded with this process in workshops and sheltered sites. Thicknesses below 4 mm are to be welded using pulse welding. Above 4 mm spray or pulse transfer may be used. Pulsed MIG - The operation of pulsed MIG is similar to that of spray MIG welding, excep that the value. The welding current is pulsed from 3 low background current toa high peak steady background current is too low to produce spray transfer necessary for aluminium ‘welding, the peak current is above the spray transtion range and causes one droplet of metal to be transferreé at each pulse. The combination of the two levels of current allows spray transfer to take place at lower welding currents, below those required for conventional spray transfer welding. 7. Pulsed MIG welding allows greater control with reduced heat input and distortion, so thinner sections may be welded Pulsed MIG bridges the transition zone between the TIG and MIG process. Because the heat input can be controlled, larger diameter wires, ie 1.6 mm, can be used with low current values for the welding of a wide range of thicknesses. Apart from the fact that pulsed MIG is characterized by the uniformity of root penetration, being therefore comparable with ac TIG and permitting the deletion of any backing, the flexibility of the process can be advantageous in work where dissimilar thicknesses have to be joined. Pulsed MIG is suitable for mechanization and can replace TIG for many applications. Good fit—up is essential, and providing suitable welding conditions and travel speed are predetermined, high integrity welds can be produced. MIG Welding Wi Only wires approved by MOD(PE) SSC are to be used. See Clauses, 0505, 0506 and 0509. ‘The wire is to be so defined that the date of its production, source and identification of the raw material and details of its manufacturing procedure can be identified. .. The precautions to be observed in the use and storage of reels and wire are as follows: a. Wire reels when not in use, must be kept in closed packets and containers and stored in a dry placed at uniform temperature. During production work, and where appreciable time delay between welding operations is likely, the reels are to be replaced in their packets and retumed to store. 78(WS8/SG)B2 29.NES 768 Issue 1 0953. 10. 1001. 1002. 1003. 1004. T8CWS: b. Onno account is a reel that has become contaminated, be used, it must be discarded and replaced by a new one. The remains of a used contaminated ree! may be cut into suitable lengths and recleaned for use with less critical TIG welding. ¢. Clean gloves are to be wom when leading wire reels into the wire feed unit and when feeding the wire into the torch. Inert Gas Shielding MIG and-TIG Equipment See Annex D. Filler Rods and Wires for TIG and MIG Welding }. Table 2 shows a selection of filler rods and wires for use with combinations of aluminium wrought and cast alloys. The filler selected for any combination may be influenced by the factors listed. a. Maximum weld strength. b. Maximum resistance to corrosion. ¢. Freedom from persistent weld cracking. 4. Colour matching for anodizing. WELDING REQUIREMENTS This section contains the welding requirements for all the materials in Section 5. Attention is drawn to Clauses 0501 to 0507 which list the materials approved for use, and Clause 0509 for other materials. Welding Procedures Written welding procedures are to be produced for all welding to Acceptance Standards Classes 1 and 2 within the scope of this NES. They are to be approved in accordance with Clause 1102 except where specific instructions within any relevant Contract require a welding procedure to be forwarded to DNA NALIS for approval. ‘A welding procedure is a specified course of action to be followed in welding to control the activities and to ensure that the quality of the welding meets the required standard in all respects, Such a procedure must take into account the facilities and equipment available. The design details shown on drawings must be such that viable welding procedures can be written. It is essential that the needs of the welding process chosen and the effects of the heat imparted to the structure or component being welded are allowed for, or controlled. See Section 12. ‘Written welding procedures (See Annex E for typical example), being a complete statement of the welding requirements of a particular drawing or drawings, can contain more information that a workman may need. It is not the intention that everyone associated with a job should have a welding procedure, but that the information which is relevant to each person is communicated to that person in some form, such as a Work Instruction. 38/SG)B2 30.NES 768 Issue 1 Parent | en | enwtton | ves | ure [coma aes |oosr_fsons force [srsan sass [soos Jsies [snes |szo0 | 1350 | soso | tone [some] aaeae) esa] aaa | sore [enon [sen soee | essa | zses | sme ol ‘ {e}} tenet | Cabo} | te (Moe) | Canes (west | Coed] Coca) | anecn| Soh | Cay | CSEah | teh | €Oe3s | te (a | Sax | Sox [Sen | RPY Seta | OY Ssh |) Sed | Stan | san oat | aso | ose SS a of oF [| | fda] ee | Blox] ox ay or [ia 70508 2 [oe foo | [om [oo [om | om | om |o | % | | om | om | om 120 oo |e [oo |e |e | |e |e |e |o | om | | o as be fo» [oe Joe” |e | a | a easeal oo | o» |aou fous f est fees) | fs} Se S| Ses 1 to) fey} te). se [= |e [~ |= |» [= [= |» [» [o _— te [o [oe [oe [oo famsee [oe famscx [oo [awe wen] |e | [ess i essex] (Sch) |S i o es 3 Tas Ge [> | Sasa [eos [suse fsosta oo | oo arena \ {lees (oes) fel feo] ies | Eo | & | ‘SSAA ce [o> [oo |oo oo passe J arses | 00 i. |, st3en | ax wae too) | {a} for nxine we stron 3} fer pain Fesatanct' ta conzeston oe [same (©) tar fava toon paint wale creaing faq (e) fer oti colons atoning for (qos arocising not. applicaste set Rane antl entiation not ee) comendede o TABLE 2 SELECTION OF FILLER RODS AND WIRES FOR THE WELDING OF ‘WROUGHT AND CAST ALUMINIUM ALLOY COMBINATIONS BY THE TIG AND MIG PROCESSES 78(WS8/SG)B1 31.NES 768 Issue 1 Procedures 1005. Written welding procedures are to be prepared in accordance with the relevant requirements of this NES and are to include the relevant information listed in this section or as BS 4870 Part 2 and BS 499 Part 1 Appendix F where considered relevant to the materials, welding process, joint design and dimensions concemed. 1006. ‘The responsibility for the approval of welding procedures is with MOD(PE) SSC. This responsibility may be delegated to the Inspecting Authority or other competent authority as may be decided by MOD(PE) SSC. See also Clause 1102. 1007. The approval of pre-production procedures is to be in two parts. The first part is to relate to that pat ofa procedure dealing with assembly sequence andthe order, in which welds are to be done. The second part is to deal with weld soundness. Where the Approving Authority or Inspecting Authority suspect that the physical weld or base material Properties will not be achieved either from the procedure under consideration or from an approved procedure in use, then the fabricator may be required to prove the procedure by mechanical tests from a test weldment. The quality control of materials and welding consumables is set out in Section 17. 1008. The use of materials and welding consumables other than those approv ten in Clanses 0501 to 0507 are to be approved by MOD(PE) SSC notwithstanding any ted authority. For the processes approved for use see Section 9, and proposals to use any other process is to be submitted to DNA/NA11S for approval. 1009. Fabricators experienced in MOD(PE) SSC work may offer this experience as proof that they have established satisfactory welding procedures and then the requirements of Clause 1005 to 1007 may be waived. The acceptance of such evidence is to rest with the Inspecting Authority. No welding however, is, to be undertaken without an approved welding procedure. See also Clauses 1112 and 1113. Non-destructive Examination and Acceptance Standards 1010. The non-destructive examination and acceptance standards applied to pre-production procedure testing are to be in accordance with the normal fabrication requirements for the particular procedure involved, see Section 17. Procedure Information for Fusion Welds 1011. The following information where relevant is to be contained in all welding procedures for all welds other than stud welding: a. base material, types and conditions; b. _ welding consumables, size and identity; ¢. joint finishing requirements; e. joint design; £ ead deposition sequence; 8. welding process and type of equipment; h. polarity, welding current range, arc voltage range; ‘T8(WS8/SG)B2 32.1012. 1013. 1014. NES 768 Issue 1 i preheat and interpass temperature; k. shielding gas, composition, flow rate; 1 welding position; n. post weld treatment; p. | NDEand acceptance standard; q nozzle size; 1 arctravel speed; s. back gouge methods and requirements; t. other special instructions (ie special materials requirements). Procedure Information for Stud Welds ‘The following minimum information where relevant is to be contained in weld procedures for all stud welding: a. intended applications; b. _ process and type of equipment used; ¢. stud material and size, ferrules; 4. base material; ©. gas shield and flow; £ timer range setting; g maximum cable length; h amperage range; Efficient joint design can be spoilt by poor fit~up between parts. Wide openings at root of welds, and particularly those welds which are unsupported by a backing bar, present a condition which is very difficult for the welder to handle, and excess burn—through and poor quality welds will result. It is the fabricator's responsibility to ensure that the Tequired fit~up is achieved to the satisfaction of Inspecting Authority. See also ‘Clause 1206. Cleaning, Cleaning before welding is an essential practice to reduce the possibility of porosity and unwanted and damaging metallic and non-metallic inclusions in the weld. ‘The area to be cleaned is to extend at least 25 mm from the edges of the weld preparation in all directions. See also Clause 0903 and Annex C. Welding is to take place within 6 hours of cleaning or the cleaning operation is to be repeated. 78(WS8/SG)B2 33.NES 768 Issue 1 1015. 1016. 1017. 1018. 1019. 1020. 1021. 1022. Hydrogen and oxygen can cause porosity and inclusions respectively in welds and are present in water and oils usually found in entrapped dirt, which if left on the edges to be welded, will cause unsound welds having reduced mechanical properties. Cleaning is to be done just prior to welding. Oil and grease films are to be removed chemically by dipping or spraying, or wiping the aluminium with solvents. Mildly alkaline solutions and commercial degreasers that do not emit toxic fumes are to be used. All areas where chemical cleaning is done are to be well ventilated. lll solvents and cleaners are hazardous and it is the fabricator's responsibility to ensure that safe handling practices are used. In difficult to reach areas oil free compressed air can be used for drying, otherwise cloth or absorbent paper is to be used. Welding surfaces are to be dry before welding ‘commences. Aluminium and its alloys rapidly develop self-limiting oxide surface film upon exposure to air. This film (see Clause 0903) can prevent fusion between the filler metal and the base material. Flakes of the oxide can become trapped within the weld metal impairing weld metal properties. This oxide film is to be removed just before welding by mechanical means such as wire brushing, filing, burring, or scraping. For very high quality welds the oxide film may be removed by chemical edge dipping. Where this is done welding is to commence within six hours, otherwise mechanical removal of redeveloped oxide will be required. ‘Where hand or powered wire brushing is employed the brushes are to be of stainless steel. Carbon steel brushes tend to leave iron deposits which can rust, re- inatin the surface being cleaned. All brushes must be clean and kept free from oil or other contaminants. They are not to be used on other material. Pressure on the brush is to be light to avoid bumishing the surface and embedding foreign matter. Small ‘tooth brush' stainless steel brushes are particularly useful for cleaning local and difficult to get at areas. Where power tools are used with rotating wire brushes it is important to ensure that lubricants from the power tool do not contaminate the surface being cleaned. The brushes used with power tools are to be of a suitable stiffness. Bristles which are too hard will damage the surface whereas bristles which are too fine will not remove the oxide. The following are recommended a. for common alloys ~ wire diameters 10-25 micrometres; b. for hard alloys ~ wire diameters - 25-40 micrometres. Table 3 gives the procedure for preparing aluminium surfaces for welding. Where possible, cleaning is to be done before fit~up of the joint because it is difficult to remove solvents and solutions from fitted joints. Clean joint faces are to be protected from the possibility of subsequent contamination by covering the cleaned areas with strips of strong paper at least 60 mm in width, taped in place along their length. The tape is not to come within 25 mm of the joint face, otherwise the adhesive may contaminate the joint and become difficult to remove. Rough surfaces are difficult to clean properly and are to be dressed smooth before cleaning. Although it is only necessary to deoxidize the area to be welded to a minimum of 25 mm from the joint face, it is good practice to degrease all surfaces for a distance of between 75 and 150 mm from the joint edge. 78(WS8/SG)B2 34.NES 768 Issue 1 Overall Cleaning Local Cleaning en Contaminates | (onty Welding Surfaces Cleaned) Cane oi1, Grease, _|Wiping with mild alkaline Vapour degreasing. Moisture and Dust | solution. Spray degreasing. Removal Wiping with hydrocarbon solvents |Steam degreasing. such as acetone, alcohol, etc. |Immersion in alkaline Wiping with proprietary solvents.|solvents. Immersion Edge dipping using any of the |in proprietary above. solvents. oxide. Edge. dipping in strong alkaline |Immerson in strong (Use any one solution; then in water; then in alkaline (caustic) method) . nitric acid; and water rinse. |solution; in waters Wiping with proprietary in nitric acid; and deoxidizers. water rinse. Mechanical oxide removal such as:|Inmersion in pro- prietary deoxidizers. a. Edge brushing. Where power tools are used with rotating wire brushes it is important to ensure that lubricants from the power tool do not contaminate the surface being cleaned. The brushes used are to be of suitable stiffness as recommended. b. Filing. ic. Scraping of all joint and adjacent surfaces removing about 0.025 mm surface material, just prior to welding, ‘using no lubricant, is recommended for critical application. 4. Clean Tic filler wire as recommended in Clause 0931. ‘TABLE 3 GENERAL PROCEDURES FOR PREPARING ALUMINIUM SURFACES FOR WELDING Accessibility 1023. The design of joints is to be such as to ensure that they are always accessible to be readily welded and examined to the standard required. This means that suitable access is to be provided to bring all the necessary equipment for welding and examination to the joint. 78(WS8/SG)B2 35.NES 768 Issue 1 1024. The designer needs to have silhouettes to scale, (Figure 23), of the equipment to be used as its operator to establish minimam space requirements. Where t proves difficult to ide adequate access with standard equipment, it may be necessary to provide Specially dealgned attachment such as modified gos-shiciding nozzle for MIG guns, orto adopt one-sided welding techniques. In all cases where departure from established practice is involved, the p to be adopted is to be qualified on a simulated test rig and the results submitted to MOD(PE) SSC inspecting authority for approval. Figure 24 shows examples of inaccessibility. ‘Spool on Gun Sithouerte on ‘Tee’ Joine outline, shovs access to Joint preparation. eo [ J FIGURE 23 USE OF SILHOUETTES TO PROVE ACCESS © Inaccessible Welds FIGURE 24 EXAMPLES OF INACCESSIBLE WELDS 78(WS8/SG)B1 5 36.1025. 1026. 1027. 1028. 11029. NES 768 Issue 1 ‘Temporary Attachments A temporary attachment is a component fixed to a surface by some means, often welded, as an aid to assembly or other purpose. Such attachments are to be removed before the structure or component upon which itis fixed goes into service. (See Clause 1030). These attachments pose a potential danger to the subsequent life of the structure or components, and the possible deleterious effect upon the material properties are to be considered at the design stage. When considered necessary, drawings are to state limitations on their use. Temporary attachments are to be fixed by either mechanical means or by welding. Mechanically Fixed Attachments Within this group of attachments are flame clamps, bolted strong backs, etc. Wherever this type of attachment is used it is important to ensure that it leaves no marks upon the structure which are stress raisers and which could cause fatigue cracks in service. See Figure 25. FIGURE 25 TEMPORARY ATTACHMENT ~ MECHANICAL ‘Welding Attachments ‘Wherever a temporary attachment is to be welded to structure ot a component for whatever purpose, the welding is to be carried out, inspected and accepted to the same standard required for the structure or component onto which it is fixed ‘Temporary attachments are to be fully welded whenever possible to prevent them being knocked off and damaging the surface on which they are fixed. Figure 26. 78(WS8/SG)B2 : 37.NES 768 Issue 1 1030. 1031. 1032. 1033. FIGURE 26 TEMPORARY ATTACHMENT - WELDED ‘Temporary attachments are to be removed with care by sawing, cutting by disc or similar tet ee Clase 122), an then deed Dh (Gee also Annex C). The surface is then to be examined in accordance with the requirements of Section 17. Temporary attachments are not to be knocked off eg by hammer etc. Assembly Welding ‘Assembly welding is to be kept toa minimum. See Clauses 1213 to 1215. The conditions of welding are to be to the seme standard as that required for permanent welds. Where assembly welds are to be removed they are to be dressed flush with the surrounding surface and be treated as for the removal of temporary aftachments in Clause 1030. Assembly welds which are to be incorporated into a finished weld are to be free from cracks and other unacceptable defects and have the ends suitably shaped for incorporation in that weld. Figure 27. Assembly welds which are cracked are to be removed. Welding over a cracked weld is prohibited. ‘Shaped end.to tack weld 4s welded weld end showing crater crack FIGURE 27 DRESSING OF ASSEMBLY WELD ENDS T8(WS8/SG)B1 38.1034. 1035. 1036. 1037. 1038. ‘NES 768 Issue 1 Preheating Preheating may be necessary in certain instances and is to be in accordance with Clauses 0909 to 0915. Close temperature control is to be maintained at all times. Uneven preheating will cause unnecessary distortion due to the high co-efficient of expansion of the material. Interpass Temperature ‘The interpass temperature is the temperature of the previous weld deposit, measured ahead of the position of commencement of the next weld deposit. See also Clauses 0908 and 1529. Weld Terminations ‘Welds are to be started and stopped in a manner that ensures sound welds. See ‘Clauses 0920 to 0922, 1038 and Annex D. Whenever possible, starting and stopping is to be done on extension bars or run-on and run-off tabs. These tabs, Figure 28, are to be removed by mechanical cutting and the ends of the welds made smooth and machined to fit flush with the edges of adjacent parts. When it is not possible to start or stop a weld ona nm-on or run-off tab, due consideration is to be given to the reduced load carrying ability, such a weld ending will have. Weld metal build-up of damaged plate edge FIGURE 28 EXAMPLES OF RUN-ON AND RUN-OFF TABS Fillet weld start technique is to ensure good penetration and freedom from defects. The termination of a fillet weld or cover pass within a joint, is to consist of: a. _ reversing the direction of travel for a minimum distance of 25 mm, Figure 29 or 78(WS8/SG)BL 39.b. _ increasing travel speed to reduce crater size, or c. provide suitable build-up to allow removal of the finishing crater by mechanical means. 725m win. overlap FIGURE 29 STARTING AND STOPPING WITHOUT TABS ‘Weld Metal Deposition Techniques 1039. When weldin; aluminium and its alloys with any process, excessive weaving is undesirable. ‘stringer bead technique (limited weave) is to be used, Figure 30, and it is essential for welds in thick materials except where very high energy processes are used. Stringer bead widths are not to exceed 3-5 wire diameters. 1040. Interpass brushing, see Clause 1019, is mandatory to remove oxide from previously completed beads, and standard techniques for eliminating or reducing craters when stopping weld beads, are to be used. (See Clauses 1037 and 1038). 1041. Weld beads are to be deposited to give an overlap of 30-50%, see Figure 31 and be worked from the sides of the preparation towards the centre in order to reduce overall weld shrinkage effects. Each weld bead deposited is to be scratch brush cleaned and wiped free of dust before the next bead is deposited. 78(WS8/SG)B2 40.NES 768 Issue 1 FIGURE 30 STRINGER BEAD DEPOSITION TECHNIQUES 30-50% weld metal overlap SK FIGURE 31 EXAMPLE OF WELD METAL OVERLAP 1042. It is important to balance the deposition of weld beads around a joint in order to counteract the shrinkage effects of each bead applied. Figure 32 gives examples of such arrangements, and together with the requirements of Section 12 for the assembly sequences, the effects of material and weld metal shrinkage can be controlled and distortion kept to a minimum. 78(WS8/SG)B2 al.NES 768 Issue 1 Butt weld a. Main side weld 2 full b. Back gouge and weld full Partial penetration c. Hain side Tee-Butt Weld finish weld. FIGURE 32 EXAMPLE OF BALANCED DEPOSITION OF WELD METAL Back Gouging 1043. Back gouging provides a means of ensuring that a fully penetrating and properly balanced weld can be made. See Figure 33. Butt weld Full penetration Tee Butt FIGURE 33 EXAMPLES OF BACK GOUGING 78(WS8/SG)B1 : 42.1044, 1045. 1046. 1047. 1048. 1049. NES 768 Issue 1 Back gouging of joints for welding the second side is to be of an adequate depth to ensure the removal of all contaminants and defects beneath the first bead. This usually means the complete removal of the first bead laid. To achieve this requires an understanding of the joint geometry. The use of a template, see Figure 34, whose shape is designed to ensure the minimum removal of unwanted metal, and prepare the shape of the back of the joint to achieve a balance weld, is to be adopted. Such templates gives confidence and control. Datum Lines FIGURE 34 EXAMPLES OF BACK GOUGING TEMPLATES Back gouging can be done using standard air hammers fitted with properly shaped chisels. If the metal chip splits in the form of ‘ram's homs' the root of the weld has not been reached. Back gouging can also be done using portable milling cutters. See also Annex C. ‘When back gouging is complete, the surface is to be examined for defects in accordance with the requirements of Section 17. ‘Weld Dressing Where it is necessary to dress welds for: a. non-destruction examination; b. improved weld shape and strength; c. assembly purposes; care is to be taken to ensure that the surface of the base material is kept free from damage. Weld dressing of the completed weld can be done by grinding, filing, chipping, sawing and burring. Sec Section 8. It can also be done by using a portable shaving machine which has a carbide or high speed milling cutter. This type of tool is capable of producing high quality surface finishes. Careless use of grinding wheels, power brushes, chipping hammers, etc can leave surface scores and undercut which are stress raisers in service and can lead to fatigue or can entrap contaminants causing corrosive breakdown of the material. 78(WS8/SG)BL : 43.NES 768 Issue 1 1050. Where weld dressing is adopted to improve the shape of a defective detail, care is to be 1051. 1052. 1053. 1054. taken not to worsen the component's stress carrying ability. Figure 35. Joint weakened by overdressing Xi FIGURE 35 EXAMPLE OF DAMAGE DUE TO OVER DRESSING Peening ‘The pening of welds is prohibited. ‘Weld Toe Dressing Dressing of the toes of fillet welds to improve service performance is not normally necessary. When such action is proposed, whether required by specification or not, the extent and degrees of dressing is to be agreed with the Inspecting Authority. Butt Welds in Rolled and Extruded Sections The method of butt welding rolled and extruded sections is to be the subject of a weld procedure. This type of section presents particular problems in making a fully penetrated butt joint. It is mandatory that the profile of the section is maintained and is free from ‘surface notches. See also Clause 1605. ‘The butt welding of extruded sections requires correct edge preparations, so that back gouging ensures the removal of defective material. Structural sections are subject to the acceptance standard which applies to plating welds. It is recommended that the following procedure is to be used. (See Figure 36). 78(WS8/SG)B2 : 44.NES 768 Issue 1 BS 1.5mm nosing : T~7] — RO/RO tabs where possible. ‘Half web length min. Meld direction Line of back gouge RO & RO Tabs 4 + Back gouge deep into the face of the table in way of the web to ensure removal of defective material. FIGURE 36 METHOD OF FULL PENETRATION BUTT WELD OF TEE BAR 78(WS8/SG)B1 7 45.NES 768 Issue 1 £ g h Fit run-on (RO) and run-off (RO) tabs (when possible). Weld 1. Back gouge 1 and weld 2. Back gouge weld 2. Weld 3. Back gouge table going deep in way of web. Weld tables, dress surface. Remove RO and RO tabs. 1055. Procedures for other types of sections are to be devised on the above principle. Butt and Fillet Weld ~ Distortion 1056. Ifa butt weld is made between two plates continuously from one end of the joint to the other in a structure where the plates are free to move, shrinkage will take place in the weld metal deposited as the weld proceeds, causing the init ly parallel plates to start to overlap at their free ends. See Figure 37. To avoid this the joint is to be welded using the back step or skip method of welding. See Figure 37, and Figure 38a. and b. direction of welding | @) fomm——___~~~..1 ! I ! | | 1 1 | etrclion of weleing I 0) Ii | (2) Overlap of plate edges due to weld_shrinkage. (0) Overtap avoided by using back-step welding. FIGURE 37 BUTT WELD PLATE OVERLAP DISTORTION 78(WS8/SG)B1 : 46.NES 768 Issue 1 BO 12231415 16.7819 20 pt rt @) [im TOIT (2) Back-step weldin; vigeneFal! divectioh of velding | (2) Back-step velding, | _Genekal! direction of veldt Direction of deposition of each run 14712,8131914)0.5,11, 6 TATA TT rn TMM © «(b) Skip welding General direction of welding FIGURE 38 METHODS OF CONTROLLING DISTORTION IN BUTT WELDS 1057. Where plates are to be butt welded into a structure without freedom of movement, it is essential that they are block welded in place to avoid plate fit-up closing or overlapping in one area and opening up in another. 1058. In double fillet welded joints, movement of the standing member is to be controlled by ‘Suitably balancing the welds on either side as shown in Figure 39. Overwelding of double fillet joints will cause angular distortion of the plate and longitudinal distortion of the attached stiffener. x 1 2| 7 iT 8 4 fs] os 10 3 CT FIGURE 39 DISTORTION CONTROL TECHNIQUE FOR DOUBLE FILLET WELDED JOINTS 78(WS8/SG)B1 : 47.NES 768 Issue 1 1059. 1060. 1061. 1062. 1063. Use of Processes For the welding of the aluminium part of the joint the MIG process is to be used, see Section 9. For welding the steel section, Manual Metal Arc or MIG CO is to be used, in accordance with requirements of NES 706. Consumables For welding the aluminium part of the joint, consumables conforming to Clause 0505 are to be used. The steel section is to be welded using an approved electrode, in accordance with NES 769. Temperature Control No preheat is required except that the joint is not to be made at temperatures below 15°C for the welding of aluminium. During the welding the temperature is to be controlled so that the temperature at the aluminium to steel interface remains below 315°C. Should this temperature be exceeded, undesirable metallurgical features occur due to the interdiffusion of aluminium and iron. Temperatures are to be monitored during the welding operation using pyrometers within calibration test date. ‘Welder ‘ification ‘Welders are to be specially qualified for butt welding aluminium to steel transition joints. ‘See also Section 11. Joints in Kelocouple Material Run-on and run-off (RO/RO) tabs are to be used. See Figure 40. The steel weld is to satisfy the requirements of NES 706 and is to be completed to at least half full, then the aluminium section welded completely, to satisfy the requirements of this NES. The steel weld is then to be completed. Ail the weld deposition is to be stringer bead, in order to aniize bond 2one tmperabres. Stringer beads ae also to be deposited in short lengths to reduce temperature build up. On completion of the welding, the RO/RO tabs tetobe carefully cut off and the unwelded 6 mm or so of the joint, caulked for watertightness. Stage & - Cut off seage 2 = Fully i: 20/80 tabs and dress PO/RO $255 unvelded surface, aul Kelocovple sateris] eld sluminten Stage 1 - Weld ‘Sceel naif full Stage 3. Finish steel FIGURE 40 WELDING OF STRUCTURAL ALUMINIUM TRANSITION JOINT 78(WS8/SG)B2 48.ll. 1101. 1102. 1103. 1104. 1105. 1106. 1107. 1108. 1109. 1110. NES 768 Issue 1 QUALIFICATION ‘The following clauses defines the requirements for the qualification necessary in the control of welding operations carried out within the scope of this NES. Approval Requirements General. sponsor to nominate a MODGPE) re representative ce Pincpal N ‘Naval il Oversee) to act as the inspecting authority provided that personel have sufficient expertise in the processes being employed. Written welding pr are not required for welds subject to Class 3 acceptance standards (DG 0000B (NES 773)). Welders and welding operators need not hold a current quahtation for the type of weld subject to Class 3 acceptance, provi they ave ben uae inthe typeof weld tobe qualified at sometime an olds current qualification in the process to be used. ‘Welding procedures, welders and welding operators may be ied for work within the scope of this NES by meeting the requirements of Part 2 of BS 4870, 4871, 4872, as te, and to the extent of approval specified therein and with agreement of MopeE) 85c- Other internationally re: specifications covering the qualification requirements of this NES may be aan ahcmative, buts ae contingent pon ior approval being given by MOD(PE) SSC. Contractor Responsibility Procedures are the contractors responsibility and approval by inspecting/approving authorities does not mitigate his responsibility for conformance with requirements. ‘The cost of conducting all qualification tests, including approvals, i to be bome by the contractor. The contractor is to certify that the tests have been conducted in accordance With the procedure to be qualified and i to arrange the witnessing of tests to the satisfaction of the inspecting authority. Itis 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. The approval of welding. res by the inspecting authority is also to be applied in principle to subcontracted wo ad The Contractor is to keep the records of relevant welder qualifications as required by Clause 1166. 78(WS8/SG)B2 . 49.NES 768 Issue 1 ‘Welding Procedure Records 1111. Copies of all approved welding procedures and associated qualification data are to be forwarded to DNA/NA1IS for record purposes. Procedural Approval 1112, The approval piven to welding procedures for groups 1,2 and 3 aluminium alloy shown in Table 4 will normally be based on the attainment of weld soundness to the appropriate acceptance standard. Where the inspecting authority suspects the physical weld and base material properties will not be met, or for procedures in physical weld and base material procedure, then the fabricator may be required to prove the procedure by mechanical tests from a test weldment. Mechanical tests are always to be included in the approval for groups 4, 5 and 6 aluminium alloys in Clause 1130. (See also Clauses 1005 to 1009). 1113. Fabricators experienced in MOD(PE) work may offer their experience as vf that they have established satisfactory welding procedures and may apply to MO) SSC to have the testing requirements of this section waived. This waiver, however, is still subject to satisfactory production welding being achieved and the inspecting authority if not so satisfied can cancel the waiver and reinstate the full requirements of this section. ‘No welding is, however, to be done without approved written welding procedures being available, satistying the work to be done as required by Clause 1002 fo 1012. Welding Procedure Qualification 1114. The form of submission for qualifications may be as Annex For as for BS 4870, or as may be acceptable to the inspecting at 1115. The welding of the qualification test-piece is to meet the requirements of DG Ships/G/10000B (NES 773). Repair of a qualification test-piece is not permissible. Defects in welding procedure test-pieces outwith the standard are to be cause for rejection. 1116. The welding for procedure qualification is to be done by a welder qualified and in the process, type of material and type of joint featured in the procedure to be qualified. It is also acceptable, at the same time, to qualify the welder making the test~piece to the requirements of the proposed procedure. See also Clause 1164. Procedure Qualification Approval Testing 1117. Procedure qualification tests are to cover butt and fillet welds and qualify for access, material thickness, base and filler materials and the welding process. 1118. Welding procedures are to be qualified by welding a test plate(s) as shown in Figures 41 and 42, prepared to the basic joint designs, using the welding process, equipment, plate thicknesses, material and welding positions that are required by the proposed procedure. 1119. All the requirements of the proposed procedure are to be met and the results recorded. The proposed welding procedure, together with the test results, are to be forwarded to the Inspecting Authority. See Clauses 1141 to 1156. cial Qualification Tests 1120. Those designs or applications not covered by the qualification tests of Clauses 1117 to 1119 are to be considered special welds, Additionally certain sizes and configurations of common welds are required by this NES to be considered special, see Clause 1122. 78(WS8/SG)B2 50.NES 768 Issue 1 Root run to be stopped and restarted about 75mm from one end(one macro examination position) Line of cuts for specimens Full length Weld one side or wéld this side both as detailed in the procedure. 7 50m 4 i 00m | x 110mm length of 100mm weld when second side welded 225mm FIGURE 41 FILLET WELD TEST PIECE IN PLATE OR SHEET Edge preparation and fit-up as detailed in the welding procedure Discard, T. [oct run to 50mm |be stopped ao and resterted min. Lt Location of* specizens FIGURE 42 BUTT WELD TEST PIECE IN PLATE OR SHEET 1121. Procedure qualification tests are required for each special weld. They are to be submitted to the inspecting authority. 78(WS8/SG)B1 : 51.NES 768 Issue 1 1121. Procedure qualification tests are required for each special weld. They are to be submitted to the inspecting authority. 1122. Special welds are to include the following: a. the welding of circular inserts; (See Figure 43) b. the welding of kelocouple aluminium to steel transition joints. (Special Weld) Plate to be of suit{ble size to allow removal of test spedimens but to have @ minimum dimensionlof.at least 3D Insert 100 or 400 mm dia. FIGURE 43 CIRCULAR INSERT TEST PIECE NOTE 1. Welding sequence to satisfy requirements of Section 12. 2. When destructive testing is required sufficient test plates are to be made to satisfy testing requirements. See Clauses 1144 to 1156. 3. Destructive is not nommally required if procedure welding conditions have been established for material by standard tests. ific iven: 1. 100 mm dia test piece qualifies up to 225 mm. 2. 400 mm dia test piece qualifies 226 mm and above. 3. All other qualifications as stated in this NES. 1123. Where MOD(PE) SSC requires special qualification tests the contractor is to conduct these tests in accordance with the requirements of the inspecting authority and this NES. Clause 1137. 78(WS8/SG)B2 an1124. 1125. 1126. 1127. 1128. 1129. 1130. NES 768 Issue 1 ‘Any organization, including those carrying out design on bebalf ofthe MOD(PE) SSC may propose special qualification tests and these are to be agreed with the MOD(PE) ssc. ‘Transfer of Procedure Approved procedures are transferable from one organization to another provided the organization using the procedure can demonstrate it can work to that procedure to the satisfaction of MOD(PE). Procedures passed by contractors to sub-contractors are governed by the same conditions of demonstration as in Clause 1125. Procedure Requalification Changes affecting approval of a welding procedure are to be as given in BS 4870 Part 2. ‘A welding procedure is to be requalified if the inspecting authority has reason to believe that welding carried out to the procedure is consistently unacceptable because of the procedure, Previously approved qualifications within an organization need not be requalified for use ‘on subsequent components or orders, provided that the MOD(PE) SSC has no reason to believe that any of the approved conditions have been changed. Extent of Approval Materials In Table 4 the aluminium alloys have been divided into six groups. Separate approval for each group of alloys welded to itself is required and for each combination of groups of alloys. This NES is primarily concerned with group 3 material for structural work. If aluminiums not included in Table 4 are required, ‘al for their use and qualification requirements are to be obtained from MOD(PE) SSC. See also Clause 1112. Group Alloy Designation 1 1080A, 1050A, 1200, 3103, 3105 2 5005, 4251, 5154a, 5u54 3 5083 4 }6063, 6061. 6082 5 7020 6 M6, TABLE 4 MATERIAL GROUPING FOR WELDING PROCEDURE AND WELDER QUALIFICATION PURPOSES 78(WS8/SG)B2 33.NES 768 Issue 1 Filler Wires 1131. The filler metal to be used is to be that stated in the procedure and is to be chosen from those given in BS 2901, 3019 and 3571. See Clause 0954 and Table 2. 1132, Where a group of aluminium alloys are qualified as in Clause 1130 from one or more tests, then the appropriate approved filler is also qualified. Material Thickness 1133. For material of equal thickness t the range of thicknesses qualified is 0.75t to 2t. 1134. Where dissimilar thicknesses are to be joined t is the thickness of the thicker member for qualification as in Clause 1133. 1135. Where, in dissimilar thickness joints the thinner member is less than 0.75t, the joint is to be considered ‘special’ and requires separate qualification. This will apply to fillet welds and Tee~butt welds. But welds complying to the requirements of Clause 0718 and 0719 are not to be treated as special welds. Retesting of Welding Procedures 1136. The following retests are to be made for qualification of a procedure where the first test assembly fails, unless the proposed procedure is withdrawn to be replaced by a new one. a ‘Where the test assembly fails to meet the non-destructive requirements set out in Clause 1142, a new assembly is to be made and tested for each assembly which fails. b. Where a test specimen, tensile or bend or a set of impact tests, fail to meet the acceptance standard for a particular destructive test, a further two specimens or ‘two Sets of impact tests, are to be prepared and tested and all of these are to mect the acceptance standard. If a new test-piece is required to be welded to provide the additional samples, itis to pass the requirements of Clause 1142 before destructive testing. The new test-piece is to be welded to identical parameters. Further failure in any destructive test is to be cause for rejection of the welding procedure. jure Qualification Test-Pieces for Special Welds 1137. All special welds are to be non-destructively examined as appropriate to their shape in accordance with Clause 1142 and destructively tested where practicable in accordance with Clauses 1144 to 1156. Unless otherwise specified hereafter, the test~piece is to be either identical with the production weld assembly or is to embody all the essential features, eg dimensions, restraint, access, heat sink effects etc. ification for the Welding and Weld Repair of Castin; 1138. Welding procedures for, and welders employed on, the repair of castings are to be qualified by the test-piece shown in Figure 44. The test-piece is to be of similar material to the casting being welded. 1139. The conditions for welder qualifications are to be similar to those set out in Clauses 1157 to 1175. 78(WS8/SG)B2 54,NES 768 Issue 1 8 mm leg length fillet weld 8 mm leg length fillet veld ~ depoetted invvertical-up position deposited in he horizontal- vertical position: 20 weld deposited so flat or Svemnend position t 30° 000 san section at AA FIGURE 44 TEST PLATE FOR CASTING REPAIR QUALIFICATION Examination and Testing of Weld Procedures 1141. Testing for welding procedure qualification is to be by both non-destructive and destructive testing on the same test-piece(s) representing the welding procedure conditions in Clauses 1142 to 1156 are to apply. a. The first and last 25 mm of a test-piece is to be ignored. b. _ Ifatest-piece fails any of the requirements for visual or non~destructive examination, a further test-piece is to be made and subjected to the same examination. If the additional test-piece fails the procedure will have failed. ¢. _ If.atest-piece fails any of the requirements for destructive testing, two further test-pieces are to be made. If either of these additional test~pieces fails the procedure will have failed. d. Failed procedures are to have the cause of failure established. Welder error is not to fail a procedure if otherwise the test is satisfactory. Dependent upon the reason for failure, either the procedure is to be modified without need of retest or new procedure is to be submitted for approval. N 1142. The test-piece, after any post weld heat treatment and prior to the cutting of destructive test specimens, is to have all or part of the following examinations as required by the procedure. If no NDE requirement is specified in the procedure all of the NDE tests apply. 78(WS8/SG)B2 : 55.NES 768 Issue 1 Non-destructive Examination 1142. The test-piece, after any post weld heat treatment and prior to the cutting of destructive test specimens, is to have all or part of the following examinations as required by the procedure. If no NDE requirement is specified in the procedure all of the NDE tests apply. NDE and jrements 1143. Non-destructive examination is to be carried out in accordance with the requirements of NES 729 (Parts 1-5). The results of non-destructive examination are to be subject to the acceptance criteria set out in DGS/G/10000B (NES 773). Destructive Testing 1144, ‘The number of specimens to be tested is to be as given in Table 5. It is permissible to take the test specimen from locations that avoid areas showing defects, although such defects are acceptable to the requirements of DGS/G/10000B (NES 773). Butt joint in sheet or plate of thickness Fillet weld Test specimen in sheet Less than 10 om or plate 10 om and over Macro-examination 1 1 2 Transverse tensile 2 2 1 Root bend 2 (Note 1) : - Face bend 2 (Note 2) : - Side bend = 2 = Fillet weld fracture - - 3 (for test piece with only single side weld) TABLE 5 NUMBER OF TEST SPECIMENS REQUIRED NOTES: 1. Table 5 for joints made from one side only. 2. Table 5 for joints made from both sides. 1145. When more than one specimen of a particular type is required including that for macro— examination, they are to be taken as far as possible from that part of the joint considered to have been welded in the most difficult welding position or from a stop-start position. See Figures 41 and 42. Preparation and Testing 1146. The preparation, shape and dimensions of test specimens and the methods of testing them are to be as described in BS 3451. If backing material forms part of a butt joint, it is to be removed prior to tensile or bend testing. 78(WS8/SG)B2 : 56.1147. 1148. 1149. 1150. 1151. NES 768 Destructive Examination and A juirements ‘Transverse Tensile Test For group 4 alloys, Clause 1130, parent metal in the T6 condition before welding is to be naturally aged after welding, for 3 days at 15°C to 25°C. For group 5 alloys, Clause 1130, parent metal in the T6 condition before welding is to be aged after welding, either naturally for 30 days at 15°C, or artificially for 24 hours at 120°C. (See A25 and A26). ‘The minimum tensile strength is to be as given in Table 6. ae ‘Alloy Minimum tensile strength N/om 1 1080 50 1050 55 1200 70 3103 90 3105 110 2 5005 % 5251 160 5154a 215 5454 215 3 5083 205 4 6063 120 6061 165 6082 165 5 7020 215 6 M6 160 TABLE 6 TRANSVERSE TENSILE STRENGTH REQUIREMENTS FOR BUTT JOINTS For pure aluminium and non-heat treatable alloys, the joint strength is to be comparable to that of the annealed parent metal, irrespective of the temper prior to welding. For heat treatable alloys, the strength is to be greater than that in the annealed condition but less. than that in the solution-freated and naturally aged condition, ‘The location of the fracture is to be recorded. ‘Where post-weld heat treatment is to be applied to groups 4 and 5 alloys, the value obtained in the tensile test is to equal or exceed that used for design purposes. This may require the proof stress to be measured as well as or instead of the tensile strength. 78(WS8/SG)B2 : 57.NES 768 Issue 1 1152. 1153. 1154. 1155. 1156. 1157. Bend Tests Each root, face and side bend test specimen is to be bent through 180° round a former of the appropriate diameter given in Table 7 for the alloy group involved. Where joints are made between materials from different groups, the larger of the two bend test former diameters given in Table 7 is to be used. Groups 4 and 5 alloys in the TF condition (A25, A26 refer) before welding are to be aged as for transverse tensile test. If the parent metal is other than the annealed condition before welding, it is to be annealed after welding. Group | Bend test former diameter 1 3e 2 At 3 6t 4 16t 16t 6 not applicable t is parent metal thickness TABLE 7 BEND TEST FORMER DIAMETER ‘On completion of bending, no crack or other defect on the tension surface is to have a dimension greater than 3 mm. Slight tearing at the edges of the test specimen is not to be a cause for rejection. Macro-examination and Fillet Weld Fracture Test The etched face for macro—examination and the fracture surface from the fillet weld test are to be assessed by examining actual size features by visual examination and are to satisfy the requirements of DGS/G/10000B (NES 773). Dissimilar Metal Joints ‘The tensile strength of a joint between dissimilar materials is not to be less than that of the lesser metal in the as—welded condition. Report of Tests A report of the results assessing each test-piece, including repeat tests, is to be made for cach welding procedure, and forwarded to the inspecting authority for acceptance and approval. ‘Welder Qualification Each welder is to be qualified to meet the appropriate acceptance standard with the ‘welding process or processes to be used in production work. Welders are not to be employed on work requiring an acceptance standard beyond their qualification. 78(WS8/SG)B2 : 58.1158. 1159. 1160. 1161. 1162. 1163. 1164. 1165. 1166. 1167. NES 768 Issue 1 It is the fabricator’s responsibility to ensure each welder is qualified and is capable of working strictly to welding procedures and of welding under production conditions to the relevant acceptance standard. Each welder is also to demonstrate his ability to operate the welding equipment to be used and to carry out day-to-day operational maintenance. ‘The fabricator is responsible for ensuring that the welders he uses on MOD(PE) SSC ‘work maintain the required acceptance standard in production welding by checking the work of individuals during normal production non-destructive examination. Particular care is to be taken in the early stages of a project to establish that the specific standard is being achieved. ‘Where a welder is unable to consistently meet the acceptance standard or fails to work in with the welding procedure, removed from the production work. Re-establishment of the welder qualification for production work will be subject to acceptance by the QAR. ‘The form of submission for qualification may be as for Part 2 of BS 4871 or 4872 as appropriate or as may be acceptable to the QAR. ‘The welding of the qualification test-piece is to meet the requirements of DG Ships/G/10000B (NES 773). Repair of a qualification test-piece is not permissible. Defects in a welder test-piece outwith the standard is to be cause for rejection. Welder qualification is to attract the same range of material, filler metal and material thickness as set out in Clause 1130 to 1135. A welder qualifying a procedure will qualify himself at the same time for production welds using that procedure. ‘Welders and welding operators currently qualified to meet the welding requirements of a recognized authority may, at the discretion of the MOD(PE) SSC, be granted exemption in respect of welder qualification, where the work is of a similar nature and with equivalent material and the same welding process. Qualification Records It is the responsibility of the contractor to keep and maintain records of welder qualification. These records are to include the following information a the welder’s name and number; b. date of test; ¢. joint type and range of qualifications; 4. welding procedure number; €. details of re-tests applicable; f£. NDE records including radiographs; & qualification given with dates; 78(WS8/SG)B2 39.NES 768 Issue 1 1168. 1169. 1170. 171. 1172. 1173. b. qualification authority comments. ‘Welder fic ion Tests, ‘Welders are to be qualified by welding an appropriate test~piece similar to those shown in Figures 41 and 42, or as required by Clause 1169. Such test-piece attract the qualification or range of qualifications shown in Table 8. Position of Test Piece Qualified Position Flat Flat only Horizontal-Vertical Horizontal-Vertical + Flat Vertical up Vertical up + Flat Vertical down Vertical dovn only Overhead Overhead + Horizontal-Vertical + Flat Inclined overhead -45* All. Postion welded from below TABLE 8 WELDING POSITION QUALIFICATIONS For special welds, welder qualification is to be as required by Clause 1120 to 1124. ‘Where a welder holds a current qualification for a special weld such as a circular insert, or for pipe welds, see NES 743 Part 4, consideration will be given to allow the welder to be given a qualification for the welding of plate material, within the same parameters as. the special qualification. When such a cross qualification is approved, it is to be recorded on the qualification documentation for quality assurance purposes. See Clause 1161. If a welder realises that for some reason his test weld is likely to fail the subsequent examination and testing, the welder may withhold the test~piece and make a second test weld. If a welder does choose to make a second test weld, it is the second test-piece that is to be tested the first test-piece being scrapped. Ifa welder test-piece fails and the cause is attributable to the welder's workmanship, the welder is to be regarded as being incapable of achieving the standard required without further training. If the cause of failure of a test-piece is not attributable to welder workmanship and is the metallurgical or extraneous causes a repeat test is to be undertaken. Welder Retesting Where a welder qualification test fails to meet the requirements of Clauses 1143 to 1156, subject to the requirements of Clauses 1157 to 1172, the welder is to perform retests in accordance with either of the following: a. Submit two further qualification tests for each type failed, both of which are to meet the specified requirements. 7E(WS8/SG)B2 60.1174. 1175. 1176. 1177. 1178. 1201. 1202. 1203. NES 768 Issue 1 b. Submit a qualification test-piece on completion of further training or practice. In this case the retest is to be considered as a new test and procedure a. above is to be used in the event of failure. Requalification of Welders Requalification for welders is to be required if: a. __ the QAR has reason to believe that the standard of workmanship in production does not meet the requirement of DGS/G/10000B (NES 773); b. a period of six months has elapsed since the welder was last engaged on: (1) regularly welding aluminium alloys to an acceptance standard regarded by ‘MOD(PE) SSC as equivalent to that required by this NES; (2) __ regularly welding to those procedures for which he was originally qualified. Transfer of Welder Qualification Welder qualification approval is not transferable from one organization to another without the written approval of MOD(PE) SSC. Machine Qualifications It is to be shown by the fabricator that the machines and equipment to be used in production are capable of welding to the required standard, by welding test-pieces similar to those named in Clauses 1118 and 1138, to the appropriate welding procedure and acceptance standard. This can be done in conjunction with the requirements of ‘Clauses 1114 to 1119. Machines are to be regularly serviced and tested to establish that the output of the machines is being maintained and the instrumentation of the machines is reading correctly. Machines which are correctly calibrated and authorized for use are to have a metal label fixed to them showing the date of calibration and signature of the calibrating facility. Machines to be used for production work are to be those used for welding the test~piece. FABRICATION ASSEMBLY ‘The following clauses define the requirements for fabrication, maintenance of dimensional accuracy, use of temporary stiffening, control of weld shrinkage. ‘Welding is to be carried out in the flat and horizontal-vertical position whenever possible. Preparing Plate Edges Plate edges may be prepared by any of the following methods: (see Annex C). a. Machine (planing, milling, etc) b. Plasma arc cutting (machine). 78(WS8/SG)B2 61.NES 768 Issue 1 1204. 1205. 1206. 1207. 1208. 1209. 1210. 1211. 1212. T8(WS: c. Chipping. 4. Cutting, with tungsten burrs. ‘Where c. and d. are used profile templates are to be Pecans oeceiee, ‘The accuracy of the prepared edge isto be checked by use of ‘straight wipe wc wen enon awe pita we peed roti defects and checked for accuracy. Where weld edge preparations do not meet the dimensional requirements specified in the procedure, such deficiencies are to be rectified before assembly for welding. Surface defects are to be repaired by excavating to sound metal and weld repaired in accordance with Clause 1438. not nconporated in a weld are 0 be dressed smooth, All such edges are to be econ ar once! Any defects found are to be repaired. See Clause 1204. Fitting, Aligning and Assembly Fit-up requirements for welded aluminium construction are more restrictive than those employed for steel construction. All joints are to be tight fit, oro more than 1.0 mm gap per 250 mm in any metre length. Root gaps in butt joints are to be zero, or subject to the limitations as defined above. Where the length ofa welded joint is less than 1 metre a zero gap will apply. Such fit-ups are to be maintained during welding to ensure sound welds. ‘See also Clause 1013. Alignment of component parts is to follow normal practice for welded fabrications. ‘Temporary welded assembly aids are to be made from the same material as that being assembled, and subject to the same welding procedure. See Clauses 1025 to 1030. No weld is to be less than 50 mm in length. The alignment of structure for butt welding is generally to be carried out using temporary strongbacks as shown in Figure 45. The design and position of strongbacks is to make adequate allowance for expansion and contraction of the assembly during the welding cycle. Excessive restraint due to transverse weld shrinkage is to be avoided by using arrangements similar to those shown in Figure 45a. and b. Where strongbacks are used to assist in preventing angular distortion of butt welds, they are to be of adequate strength. Strongbacks are to be welded all the way round. See Clauses 1028 to 1030. Other holding devices are permitted, such as clips, wedges and bridges, brackets and long-threaded bolts, clamps, or other mechanical devices. See Clause 1027. Where such devices require to be welded they are subject to the full welding procedure. See Clause 1028. Removal of temporary fittings is to be in accordance with Clauses 1030, 1265 and 1339. 8/SG)B2 62.NES 768 Issue 1 JES el. Bridge a ™ Assembly aids allowing movement. PP LY 1213. 1214. 1215. 1216. 1217. 1218. © Assembly aids preventing movement: FIGURE 45 USE OF ASSEMBLY AIDS IN TWO MODES Assembly Welds Assembly welds are to be made in accordance with the full welding procedure, and are to conform to the requirements of Clauses 1031 to 1033. They are to be not less’ than 50 mm in length. Assembly welds are not to be used where a.” free movement of structure would be prevented; b. other means of holding assembled structure for welding can be used or is necessary. Assembly welding is to be kept to a minimum necessary. Distortion ‘Expansion and contraction occurs throughout the welding cycle, and for aluminium and its alloys these dimensional changes are much greater than for steel. It is the final contraction or weld shrinkage that causes distortion and has to be taken into account in welded structures. See Annex G for general guidance. Flanges ‘Where flanges are required to be welded, the edge preparation (if required) is to be as Figure 46 to give a balanced weld. Where only fillet welds are required they are to be similarly balanced. Correction and Prevention of Distortion The correction of distortion by gas heating or buming torches is prohibited. 78(WS8/SG)B1 63.NES 768 Issue 1 a. Unbalanced weld b. Balanced weld FIGURE 46 WELDING FLANGES 1219. Distortion is to be minimized by the methods outlined in this NES. Completion of Welds 1220. Fillet welds are to be continued around the end of stiffeners, scallops, etc as shown in Figure 47 to provide a sound weld ending. 150 om minimum when intermittently welded Structural endings are to be securely welded to remove the discontinuity at the ends. FIGURE 47 COMPLETING WELDS Removal of Redundant Fitting 1221. Redundant fittings are to be removed by cutting and grinding flush as illustrated in Figure 48. See also Clause 1030. 78(WS8/SG)B1 64,3B. 1301. 1302. 1303. 1304. NES 768 Issue 1 Mark for cutting —y Cut off above welds a Dress smooth ——. FIGURE 48 REMOVING REDUNDANT FITTINGS STUD WELDING General The following clauses covers the requirements for stud welding on to the approved materials shown in Section 5. For the purpose of this NES the definition of stud welding is the attachment of a stud, or other similarly shaped part, to a metal surface by the production of a weld over the whole area of the stud. There are two types of stud welding processes that employ an arc to obtain fusion. These are, drawn arc stud welding and capacitor discharge stud welding. Aluminium studs and fastenings are approved for welding to aluminium components by both methods. Stud welding is used to join a wide variety of mechanical fasteners to structural sections. A welded stud forms a geometric discontinuity and is therefore a potential crack starter. The use of welded studs is to be kept to a minimum and in particular on structural strength members or where strength is important. 78(WS8/SG)B1 : 65.NES 768 Issue 1 Materials ‘Studs 1305. Studs are to be of a composition compatible with the base material aluminium alloy to which they are to be attached. 1306. Aluminium studs differ from steel in that no flux is used on the welding end. 1307. A cylindrical or cone shaped projection is used at the base studs for drawn arc welding. The projection dimensions on the welding end are designed for each size of stud to give the best arc action. The projection serves to initiate the long arc used for aluminium stud welding. A wide variety of special studs is available for the drawn arc process. 1308. With the capacitor discharge stud welding system, studs up to 6 mm diameter may be welded. They have a projection at the base, the tip of which must be intact and must not be altered in any way. A wide variety of studs is available. Ceramic Ferrules 1309. Ferrules are to be used on all studs with the drawn arc system which exceed 6 mm diameter because of their beneficial effect in controlling the arc and concentrating its heat, reducing oxidation of the molten metal, protecting the eyes of the operator from the arc and confining the molten metal to the weld area. They are to be removed at the completion of welding by tapping the ferrule lightly with a hammer. Inert Gas Shielding 1310. Welding grade argon (99.95% minimum purity), helium or mixtures of argon and helium, can be used for aluminium stud welding. When helium or mixtures containing helium are sed, a higher arc voltage, and consequently greater penetration, is obtained than when ing argon gas alone. The shieldin; ling gas flow required is dependent upon the size of sud to be welled aod the movement of, Preparation for Work 1311. All , dirt, oil, water, paint and oxide is to be removed from the surface of the workpiece before studs are applied. See Clause 1014. After degreasing by a suitable solvent (Trichloraethane), oxide is to be removed using one or more of the following: a Chemical deoxidisers. b. Mechanical or hand wire brushing. c. Steel wool or similar means. 1312. If chemicals are used, the parts cleaned are to be rinsed with clean water and the surfaces thoroughly dried before welding. 1313. All traces of oxide particles, steel wool, or other contaminants resulting from abrasive cleaning are to be removed from the surface. 1314. Welding is to take place within six hours of cleaning or the surface preparation is to be repeated. 1315. Studs are to be kept in a ‘closed box’ to exclude contaminants. ‘78(WS8/SG)B2 66.1316. 1317. 1318. 1319. 1320. 1321. 1322. 1323. NES 768 Issue 1 ‘When welding studs in close proximity on a small workpiece there is a danger of overheating the workpiece and it may be necessary to reduce the amperage in such instances to compensate to prevent bum-throughs or other unsatisfactory welds. The position of studs is to be marked on the workpiece. Where accuracy of positioning is important, the position is to be marked lightly with a scriber. The position is not to be marked by centre punching as this will affect the welding conditions. Setting-to-Work Procedure The equipment i to be connected as recommended by the manufacturer and the gun adjusted as required, together with the amperage and voltage on the power source. Approximate recommended settings for drawn arc are shown in Table Hi. Cable lengths (welding cable and earth return) are to be as shor as possible and larg enough to minimize loss of power. The earth return cable is to be clamped to clean bare metal close to the work in hand. ‘Sample stud welds are to be made on scrap plate, at the job site, on every occasion at the commencement and change of a work period and when change of stud size, type or shape is required. The quality of these test stud welds is to be checked by the qualitative method described in Clause 1322. Production stud welding can only start when test studs are deemed satisfactory. Removal of Temporary or Redundant Studs Care is to be taken in the removal of all studs. Studs welded with the capacitor discharge process may be knocked off and the site lightly ground. Studs welded by the drawn arc process or hand welded method are to be removed by cutting above the parent material, the remaining stub is to be ground flush to the parent material. ‘Surface damage arising from removal of all studs is to be faired out by grinding or chipping provided the final depth will not exceed 0.75 mm or 10% of the material thickness, whichever is the smaller. Where defect removal will exceed this depth the area is to be excavated to good material and rectified by welding. See Clauses 1505. Evaluation Testing Test studs are to be welded to a suitable aluminium alloy base, which simulates the work to be done, to establish the welding procedure, see Clause 1005 to 1012. The quality of the weld is to be assessed visually see Clause 1324 and 1325. The test studs are to be bend tested using the tool shown in Figure 49a, and are to be capable of being bent 10°— 15° from their original axis without breaking the stud or weld. When torque testing is specified, test torque values are to satisfy manufacturers figures or design requirements. Figure 49 shows a suitable torque testing rig. Production studs are not to be bent and then straightened because of possible damage to them. Where torque testing is specified for a particular production application it is to be carried out on S of all production stud welds for that particular application, the proof load is to be specified on the design drawing and is to be established by suitable laboratory tests relating applied torque to tensile strength of the stud material 78(WS8/SG)B2 67.i UH = diameter of stud plus distance to Pipe —————"] | re clear weld fillet Stud dia pee) + 0.4 mo a, Tool for Eend Test. b. Torque Test Rig. FIGURE 49 STUD TESTING DEVICES 78(WS8/SG)BL 8.1324. 1325. 1326. 14. 1401. 1403. 1404. 1405. 1406. 1407. NES 768 Issue 1 Visual Inspection of Drawn Arc Studs Visual inspection is to show a good weld fillet formation all round the base of the stud, but this does not necessarily indicate soundness. This inspection is to examine for any sign of undercut or lack of fusion of the stud to the base material, and that the stud is not situated in a deep crater. Various defects are illustrated in Figure 50. ‘Visual Inspection of Capacitor Discharge Studs The amount of molten metal produced by the arc with a capacitor discharge stud weld is limited, and the flow of molten metal during a properly made stud weld will not extend Beyond the perpbey ofthe dando let formed and no undresses Visual inspection is to show a small amount of weld spatter on the base metal all around the stud, before the weld can be considered sound and acceptable. Excessive spatter will indicate excessive penetration, and a hot weld is unacceptable. Absence of any spatter will indicate a poor or cold weld, and is unacceptable. Torque testing may be applied to production stud welds, see Clause 1323, but bend testing of production studs is not permitted. Guidance For further guidance on stud welding refer to Annex H. STRUCTURAL AND WELD DEFECT REPAIRS General Defects may be attributed to poor quality or wrong material, but more usually to inferior workmanship or poor detail design. In both cases there is a right and wrong approach to effecting repairs. Structural defects are usually cracks. The cause of cracking is to be determined and eliminated as part of the repair process. The repair method is to be determined by the cause with the objective of preventing a repeat failure during the service life of the component. Similarly, for weld defects, the type of defect will give an indication of its cause. Corrective action can then be taken to repair the defect and eliminate a repeat of the problem. All repairs carried out by welding are to be in accordance with the requirements of Section 10. All forms of surface material damage are unacceptable and are to be repaired in accordance with Sections 14 and 15. Weld surfaces are to be dressed smooth where poor weld profiles could lead to cracking. The fitting of doubling plates for the repair of structure is prohibited. Structural Defects When severe cracking has occurred, the repair may require areas of structure to be removed and replaced with new. The design of the replacement structure is to be reviewed to eliminate the original problem. 78(WS8/SG)B2 6.NES 768 Issue 1 Satisfactory stud weld with a Hang up — accessories should be good weld fillet formation. realigned to ensure completely free moVement of stud during lift and return. Arc length may also require adjustment waza Plunge too short ~-prior to High heat — power setting and/or welding. The stud should project time cycle should be decreased. gpproriately Sum beyond the bot eld. ‘tom of the si Low heat - ground and all con- Poor alignment ~ stud gun should nections should be checked. be positioned perpendicular to Power setting and/or time setting eure bi the work to assure bottoming of should be increased. It may be the shield. necessary to adjust the arc length. FIGURE 50 STUD WELDING DEFECTS AND CAUSE 78(WS8/SG)B2 ; 70.NES 768 Issue 1 1408. Cracks may initiate at notches and propagate at speeds dependent upon the stress environment. Likely crack starting notches are square comers, rough edges not absorbed into welds, weld starts and stops improperly made and not dressed out, incomplete welds at scallops or stiffener ends, bunched weld deposits and poorly made butt welds. 1409. Fillet weld toes form stress concentrations with the likelihood of cracking propagating along the length of the fillet weld edge. Similarly, butt welds with poor overfill shape will crack along the weld edge in the right stress environment. Figure 51. SC = Stress Concentration nF ~ FIGURE 51 STRESS CONCENTRATION AT WELD EDGES 1410. Figure 52 and 53 illustrate cracking in an area of high stress. The crack in Figure 52 was caused by lack of penetration in the butt weld and in Figure 53 by the fillet weld toe where the secondary structure is fillet welded to the main girder. 1411. A different type of defect is illustrated in Figure 54. Here a crack has propagated from a butt-welded insert in a bulkhead, the most likely cause being lack of penetration in the butt weld. of Cracked Structure 1412. The extent of cracking is to be determined, photographed, and drawings made where cracking involves more than one component. This information, together with a report of the inspection and proposed method of repair, is to be forwarded to MOD(PE) (SSC). TBCWS8/SG)B2 1.NES 768 Issue 1 78(WS8/SG)B1 72.1413. 1414. 1415. 1416. 1417. NES 768 Issue 1 FIGURE 54 CRACK ORIGINATING FROM A WELD Where a crack is contained within a frame space or between two structural members not more than one metre apart, the repair may be locally approved providing that: a. The cause of the defect has been identified and appropriate action taken to remove the defect. b. For cracks less than t/2 in depth (where t is thickness of material) they are gouged out as in Clause 1505. For cracks greater than t/2, the crack is prepared for a full penetration weld in accordance with Section 7 and 10. ¢. Where a fillet weld is cracked, and the crack is contained within the area bounded by the stiffeners or frames, and on removal of the defective weld the crack is completely removed, as established by dye penetrant examination. Inall other cases MOD(PE) SSC approval is required before commencement of repair. Linear Cracks (Simple) ‘Simple cracks may have been arrested from propagation during service by drilling a small hole at one or both ends of the crack. See Figure 55 and Clause 1515. Where bulkhead or deck penetrations or fittings obscure one or both ends of a crack, they are to be removed before a repair is made. A run-off (RO) tab is to be fitted to the end of the crack at the bulkhead or deck aperture as Clause 1037. On completion of the weld repair the tab is to be cut off and the edge of the hole dressed smooth and free from surface defects. 78(WS8/SG)B2 : 7.NES 768 Issue 1 a. Crack from velded insert b. Crack from frame weld. craék arrest hole | | FIGURE 55. CRACKS ORIGINATING FROM WELDS 1418. The line of the crack is to be prepared as for a butt weld and welded in accordance with Section 10. The ends of the crack are to be boated out in the line of the crack ensuring that all traces of the crack are removed on back gouging the weld. See Figure 56. 1419. Where the crack originates from a weld defect in a stiffener, beam or frame, the stiffener, beam or frame is to be removed in way of the crack, not less than 300 mm in length (150 mm either side of the crack). The crack is to be repaired as Clauses 1417 and 1418. ‘On completion of the crack repair, the removed portion of the stiffener, beam or frame is to be replaced, and welded in accordance with Clause 1421. 1420. Where cracking is of a complex nature the whole of the plating area is to removed, and the structure restored by the fitting of an insert. See Clause 1422. Butts in Extruded Sections 1421. Butt weld repairs in extruded sections are to be made in accordance with Clauses 1053 to 1055. Cracks in butt welded extruded sections occur because of: a. _Lack of penetration. b. Poor weld finish. Run-on and run-off tabs are to be removed carefully and the edge profiles of the section properly restored free from defects. Figure 57. 78(WS8/SG)B2 74,NES 768 Issue 1 crack arrest hole FIGURE 56 PREPARATION OF CRACKS FOR WELD REPAIR edge face of extruded section dressed free from defects FIGURE 57 DRESSING EXTRUDED SECTION BUTT WELD EDGES 78(WS8/SG)B2 . 75.1422 Where repairs are made by fitting inserts using existing welded seams, the existing welds are to be gouged out for at least 100 mm past the weld junctions as shown in Figure 58. Edge prepared for bute weld Insert Weld gouged out both sides FIGURE 58 FITTING INSERTS TO EXISTING BUTTS AND SEAMS 1423. Where inserts have framing added before fitting in place, temporary stiffening is to be used. The temporary stiffening is to be of sufficient strength to resist distortion when the frames are welded to the plating, and is to be shaped to the moulded lines of the hull or decks. Alternatively, and providing there is adequate access to the insert when fitted in place, the frames may be initially partially welded, and the welding completed when the insert is fitted. This will reduce distortional problems. 1424. Where framing is fitted to the insert before fitting in place, the closing lengths of frames, stiffeners or seams are not to be less than 300 mm in length. Where a remaining length of frame, stiffener, or beam, to which the closing length is to be fitted, is less than 450 mm, it is to be removed and replaced by a longer closing piece. See Figure 59. 1425. Existing stiffeners, frames or beams are to be cut back for a distance of 150 mm minimum from a butt weld edge and the fillet welds gouged out for a distance of 125 mm, Figures 59 and 60. 78(WS8/SG)B1 . 76.NES 768 Issue 1 = length of existing structure removed because Fe ge Tes chan f36 as ‘Long. FIGURE 59 RESTORATION OF STIFFENING AFTER FITTING AN INSERT SS? FIGURE 60 NEW WELD RUN OUT ON TO EXISTING WELD 78(WS8/SG)B1 . 71.NES 768 Issue 1 1426. 1427. 1428. 1429. 7RCWS! Where repairs are made using inserts fitted into plating and not making use of existing welded butts and seams, they are to be fitted and welded in accordance with Clause 1057. Repair of Cruciform Tee Joints Severe stress concentrations may exist in badly made cruciform joints resulting in cracking. See Figure 61. The improved joint, (see Figure 62) is to be fitted where those in service are cracked. This joint is to be used in all cases where high stress/cyclic loading exists. The welds are to be full penetration welds, and welded in accordance with the requirements of Clauses 1053 and 1055. ES ers FIGURE 61 CRUCIFORM JOINT - FIGURE 62 CRUCIFORM JOINT - POOR DESIGN IMPROVED DESIGN Cracking ~ General and Remedial Actions ‘Square Comers ‘Where cracking has occurred or likely to occur from square comers, the comer is to be cut as in Figure 63a, and a radiused corner fitted as in Figure 63b. R/O tabs : b. FIGURE 63 REPLACING SQUARE CORNERS 8/SG)B1 : 2B.1430. 1431. NES 768 Issue 1 Fillet Welded Structure Repetitive cracking of fillet welded structure is not overcome by cutting out the defective weld and re-welding, but by the replacement of the fillet weld by a full penetration T- butt weld. Where repeated welding repairs have taken place the standard member is to be ccut away and replaced with new material. See Figure 64. The material remaining in the area of the cut-out (ie the deck in Figure 64), is to be dressed smooth, and examined for defects. Where ‘pull outs' have occurred, the area is to be cleaned out and dressed in a manner similar to that detailed in Clause’ 1506 and welded in accordance with Clauses 1039 to 1041 and 1432. The new material insert is to be dealt with in accordance with Clause 1422. Crack Tnserty} 1 dressed out an repaired Bulkhead pre] for insert FIGURE 64 REPAIR OF FILLET WELD CRACKING Stiffener Ends Where stiffeners do not end on a structural member, (see Figure 65), and have cracked at that end, the stiffener is to be cut back and the crack repaired in accordance with this NES. A new length of stiffener is to be fitted to end on another structural member. ‘Where this is not possible, the stiffener is to end on an intercostal introduced for this purpose. As a last resort, where neither of the above is possible, the stiffener end is to be given a longer taper of 1 in 6 down to a nose depth of D/3. See Figure 66. ‘78(WS8/SG)B1 : 79.NES 768 Issue 1 FIGURE 65 CRACK AT STIFFENER END 4 D/3 lin 6 D FIGURE 66 TAPERED STIFFENER END Repair of Weld Defects 1432. Weld repairs are to be carried out when non-destructive examination indicates that acceptance standard requirements DGS/G/10000B (NES 773) have not been met. 1433. Defects found from Clause 1432 are to be investigated to determine the cause and the reason for failure eliminated from the weld repair. 78(WS8/SG)B1 ; 20.1434, 1435. 1436. 1437. ‘NES 768 Issue 1 The position of the defect to be repaired is to be known longitudinally, transversely and in depth before a repair is atempfed, and from this information a welding procedure isto be prepared in accordance with Clause 1002. The excavation requirements are to be detailed and the templates required to control the excavation shown with dimensions, similar to that for back gouging. See Clause 1044. ‘Weld Repair of Material Edges ‘Two types of edge repair may be required a. _ to restore profile where the edge has been damaged, or is defective due to bad welding practice. b. _to provide sound material for welding where defects have been revealed during, plate edge preparation. ‘The limitation on the restoration of edge profile is to be in accordance with Clauses 1732 to 1735. Bdge defects, Figures 67 are to be repaired as follows a. Gouge out defect to sound metal. See Clauses 1505 and 1506. b. Check all traces of defect removed using dye penetrant technique. ©. Weld up excavation in a similar manner to Clause 1532. 4. Dress weld smooth, and non-destructively examine. i 0 om Minimun FIGURE 67 REPAIR OF EDGE DEFECTS 78(WS8/SG)B1 : 81.NES 768 Issue 1 1438. 1439. 1501. 1502. 1503. 1504. 1505. ‘Weld Repair of Pitted Surfaces ‘Where approval is given to weld repair a pitted surface, the surface is to be prepared and welded in accordance with Clauses. 1506 and 1747. Welders are to be suitably qualified in accordance with the requirements of Clauses 1157 to 1175 using deposition techniques in Clause 1041. WELD REPAIR OF ALUMINIUM ALLOY CASTINGS General ‘The following clauses defines the requirements for the weld repair of LM6-M (BS 1490) aluminium alloy castings. Prior approval is to be sought from MOD(PE) SSC before weld repair of any other type of aluminium alloy casting is undertaken. Weld repair of castings is to be limited to 20% of casting external or internal surface area excluding flanges. ‘The shape of a casting may impose unexpected restraints upon local dimensional changes resulting from the application of the heat from welding and a crack may be the outcome. ‘Weld repairs to castings are only to be undertaken with the casting material in the annealed condition and to an approved weld procedure. See Clauses 1005 to 1011. ‘Types of Repair The welding repairs which may be encountered are: a casting defects during manufacture; b. pitted, corroded or damaged castings in service. ‘NOTE: Castings that fracture in service are not to be repaired without prior consultation ‘with MOD(PE) SSC except as an emergency measure. When emergency are undertaken, MOD(PE) SSC is to be notified immediately, followed by full details of the repair. Preparation for Weld Repair Considerations For the successful weld repair of castings the following is to be taken into account. a, The heat sink effect, particularly in bulky castings. b. The high restraint effect of casting shape. c. The presence of acceptable casting defects in the locality of weld repairs which can cause severe welding problems. Excavation Shape Excavations to remove defects are to be regular in shape in order to facilitate satisfactory weld metal deposition. Boat shaped or rectangular excavations are best, Figure 68. The length of an excavation is to be as short as necessary for a satisfactory weld deposit to be ‘78(WS8/SG)B2 82.1506. NES 768 Issue 1 FIGURE 68 EXCAVATION SHAPES ‘Not Extending Through the Wall An excavation on a casting wall, to clear surface and sub-surface defects, requires a methodical approach to satisfy the shape requirements of Clause 1505 as follows: a Determine the extent and depth of the defect by non-destructive examination, Figure 69. Weld repairs of defects deeper than 50% of wall thickness require MOD(PE) SSC approval. Produce an excavation template for the operator prepared the casting for welding. Defects with varying depths are to be looked at with a view to carrying out a primary excavation, Figure 70, to remove the surface and near-surface defects first and then a secondary excavation, Figure 71, to clear the deeper defect. The secondary excavation is welded first, and ground smooth before completing the primary excavation. The weld ending shape of excavations is to be within the maximum and minimum angles shown in Figure 72 with the side walls’ shape as shown. This will allow defect free fusion at the root and side wall, with a good Tun in and run out for weld runs. The weld beads are to overlap by 50 mm, see Clause 1041. Small repairs may only require a groove to clear the defect. Such grooves are to comply with the details shown in Figure 72. When defects are scattered, but are contained within an area permitted by specification for weld repair, the excavation is to be given as rectangular a shape as possible, as in Figure 732. Weld deposits are easier to apply to the shape in Figure 73a than in Figure 73b with less risk of defective welding. 78(WS8/SG)B2 . 83.NES 768 Issue 1 t/2 Max. + tewall thickness see Clause 1506a FIGURE 69 DEFECTS IN CASTING WALL FX ~\_secondary excavation FIGURE 70 PRIMARY EXCAVATION TO REMOVE NEAR SURFACE DEFECTS FIGURE 71 SECONDARY EXCAVATION 78(WS8/SG)B1 : 84.NES 768 Issue 1 K—+4_ Excavation width FIGURE 72 EXCAVATION DETAILS oF S = Q a a = FIGURE 73 REGULARIZING OF DEFECT EXCAVATIONS Extending Through the Wall (Including Welded Inserts) 1507. Where it is necessary to cut right through the wall of a casting, MOD(PE) SSC approval is required and a unique repair welding procedure produced and qualified. The castis ting, edge preparation is to be inspected and prepared in accordance with Clauses 1506 and 1518. T8(WS8/SG)B1 . 85.NES 768 Issue 1 ‘Weld Metal Through Wall Repairs 1508. Where an excavation through the wall is to be filled in with weld metal, the weld preparation is to be designed to: a. give access to the root; b. minimize on the volume of weld metal deposited; ¢. reduce shrinkage stresses and minimize distortion effects; d. _ allow the deposition of defect-free weld metal. 1509. All preparations are to be dimensionally inspected for accuracy. A template is to be made for the back excavation profile of double-sided welds Figure 74, to ensure complete removal of the root runs. Where backing material is used, the side wall preparation is not to have a nose and the backing material is to fit without a gap. See Figure 74. THROUGH WALL CASTING REPAIR 10°min. INSERT IN CASTING WALL ecu os Direction of <\velding ~ = BOAT: | - ELV EI a —1L b— Backing material t= 15am uaz. Back gouge leon G = 10mm min. Qne Sided Weld Using Backing Bat 40° 60° | Lal} Kae > Back excavation shape ‘t = over 15mm. Double Sided Weld similar to front. = 3-Som = well thickness = length of excavation width of excavation jote: Where G exceeds 10mm for double sided. welds the Shape to give side wall gep is to be filled with ‘angles and weld length a tight fitting plug,of and width. similar metal,to a depth equal to the nose size. The plug will be cut out with the back excavation. —— Rg [Feapiate | Back gouge/excavation | ey fl i Temlate L + c x Depth to ensure renoval of root defects. FIGURE 74 TYPICAL JOINTS FOR THROUGH THE WALL WELDING 78(WS8/SG)B2 : 86.1510. 1511. 1512. NES 768 Issue 1 Inserts, Through Wall Repairs For castings where approval has been given to cut a hole to remove defects and to fill the hole with an insert of sound material of a similar composition, see Clause 1507 and Annex G. See Figure 74c. and d. Approval will only be given where adequate access for back gouging is available. Inserts are to be welded using a diagonal balanced sequence as in Figure 75, with each block of weld metal balance deposited as Clause 1042. A template is to be made for the back gouge profile to ensure complete removal of the nosing and minimal removal of root runs to clear root defects. See Figure 74. Edge Repairs Damaged casting edges which have been dressed to remove defects are to be welded using Tun—on and run-off tabs, Figure 76. These tabs are to be made of material that is compatible with the casting material. After fitting, the casting edge may require further dressing to line up with the tab. Weld beads are to be run across the casting edge from run-on tab to run-off tab working from the outside of the excavation towards the centre to minimize shrinkage effects. Contractual stresses are balanced by welding diagonally in. the sequence shown. the periphery is divided into equal lengths es far as possible, within 100 mm max. and 50 mm min. Circular inserts are to be similarly divided and welded in a diametrically opposed sequence. FIGURE 75 WELDING INSERTS 78(WS8/SG)B1 a 87.NES 768 Issue 1 Run on and & fabs fieeed —t F 50% overtap weld to centre from ends FIGURE 76 EDGE REPAIRS Repair of Fractures 1513. The simplest type of fracture is the 'free' bar fracture shown in Figure 77. Each part being separate allows the joint to expand and contract when welded. The fracture ends are to be squared off and the weld preparation applied using a combination of buttering and machining. FIGURE 77 FREE BAR FRACTURE 1514. Correct surface finish and profile of a weld repair will ensure in-service performance is not affected by premature failure due to surface imperfections. Where the distance L in Figure 77 is critical, precautions will need to be taken to ensure that after welding L is maintained. 78(WS8/SG)B1 . 88.NES 768 Issue 1 Repair of Cracks 1515. Cracks are to be traced using dye penetrant or other crack-detecting means. Simple linear cracks may be stopped by drilling a small hole about 5 mm diameter beyond the visible end of the crack as in Figure 78. See also Figure 55. This will help prevent extension of the crack during the repair sequence and can be used as a temporary measure to prevent crack extension prior to repair action. See Clause 1506 or 1507, selecting the appropriate joint and included angle to suit the material thickness. Repairs of this nature ate only suitable for linear cracks. See Clause 1419. For complex cracking systems soe Clause 1420. ia, hole see FIGURE 78 REPAIR OF CRACKS. Building Up Damaged Comers 1516. Damaged comers are to be repaired in a manner shown in Figure 79, sufficient weld metal being added to allow casting to be machined back to its original dimensions. Defective edge Bige begpgred FIGURE 79 REPAIRING DEFECTIVE EDGES 78(WS8/SG)B2 : 89.NES 768 Issue 1 1517. 1518. 1519. 1520. 1521. Welded Attachments to Castings stressing. Figure 80 gives a cpl illustration of @ this. However, heating of the whole casting is pre under controlled Component to be welded Preheat uniformly FIGURE 80 WELDED ATTACHMENTS TO CASTINGS Examination of Excavations After excavating or edge preparing, the area is to be dye penetrant tested to check freedom from defects. It is recommended that sub-surface inspection is carried out in the near vicinity of the weld preparation, to ensure that any defects found are within the casting acceptance standard, and are not significant enough to propagate into unacceptable defects as the result of the proposed weld repair. Welding Requirements Welding Processes For the reasons stated in Clauses 0903 to 0907, welding of aluminium alloy castings is to be by the Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) processes. ‘Welding Procedures Written welding procedures are to be produced and proved in accordance with Clauses 1002 to 1009. ‘Welder Qualification ‘Welder qualification is to be in accordance with Clause 1157 to 1172. 78(WS8/SG)B2 90.1522. 1523. 1524. 1525. 1526. 1527. 1528. 1529. NES 768 Issue 1 Training Welders are to be capable of depositing stringer bead welds in a straight line, with a weld bead overlap that is consistent, in order to control and keep to a minimum the heating of the parent material. It is possible to cause severe damage to the parent metal and the \elds by overheating during welding. Overheating will not occur, however, when procedures established for aluminium are’ followed. to meet the aes ere dtr roscdae will ‘be necessary as in Clause 1039 to 1042. ‘Welding Consumables The approved filer wir for welding LM6—M aluminium alloy castings is 4047A: 1, Part 4. ‘The filler wire and rods are tobe stored, cleaned and used as detailed in Ghause 0801, Preheat Care in the use of preheat is essential. The mechanical properties of the parent alloy decrease with excessive preheat, and with a lack of colour change with rise in temperature to warn against overheating, the metal may collapse under its own weight before there is any indication that anything is wrong. Castings are to be adequately supported to avoid sagging of hot metal. Electric preheating elements, portable hot air blowers or hot cupboards are to be used for eating, Gas or propane bumers may be used, but great care is tobe talento prevent Fecal ovesbeatine ‘The flame must be kept at all times. The preheat spots. moving temperature is to be in the range of 150°-200°C applied evenly throughout the casting. Pre-weld Cleani ‘The weld area, and a band of at least 25 mm all round it, is to be thoroughly cleaned free from oil, dirt and grease and the area swabbed with a degreasing agent, eg acetone or trichloroethane. A tough oxide film forms on the surface of aluminium which prevents the molten filler metal from ‘wetting’ the parent metals. This oxide must be removed before welding, by abrading with aluminium oxide discs, mechanical rotary or manual stainless steel wire brushes: All wire brushes are to be degreased regularly. If welding does not tke place es re a aes oe ceed Se ee iEwelding does not take place within six hours of preparation, leaning is to See also Clauses 1014 to 1022. am . ‘spe Inter-run Cleaning All weld runs are to be thoroughly cleaned (inter—run cleaning) before subsequent runs are made. See also Clause 1040. Interpass Temperature This is the control on heat build-up during welding to avoid damage to the material. Interpass temperature is to be a maximum 100°C for castings of 3-5 mm thickness and 250°C maximum for thicknesses above 5 mm. The interpass temperature is to be measured by pyrometers or thermocouples only and is to be measured before commencing the next deposit. This is to be carried out just ahead of and adjacent to the weld zone as shown in Figure 81. 78(WS8/SG)B2 91.NES 768 Issue 1 qeWeld start FIGURE 81 MEASURING INTERPASS TEMPERATURE Welding Technique 1530. Balanced welding techniques are to be used to minimize distortion. These requirements are to be clearly indicated to the welder. The technique for depositing weld metal is to maintain as low a heat input as possible. Stringer—bead deposits are to be used to minimize contractual stresses and slow down the temperature rise of the parent metal during welding. Weaving is prohibited for the repair of castings. 1531. Assembly welding is to be avoided, but where essential, assembly welds are to be of the same dimensions, and are to be deposited using the same procedures, as the main weld. Assembly welds are to have a minimum length of 25 mm and are not to be incorporated into the main weld unless proven to be defect free. ‘Weld Bead Deposition Sequence 1532. A sequence for weld deposits fr through the thickness weds iso be as Causes 1039 to 1046. For excavations the principle to be applied is one of minimizing weld contractual stresses, welding alternatively from the sides, completing the weld layer in the middle of the excavation using step-back or staggered method techniques as Figure 82. Excavation Groove FIGURE 82 WELD BEAD DEPOSITION ‘78(WS8/SG)BL 5 92.1533. 1534. 1535. 1536. 1537. NES 768 Issue 1 Stops and Starts ‘The beginning and the ending of a weld deposit can produce porosity or crater cracking. To minimize the effect of stops and starts, various techniques are employed. In the case of casting repairs, the weld starts and stops are to terminate on previously deposited weld metal or On the casting. The following method is to be adopted to control weld quality. To start, the arc is to be struck on the line of the weld on the casting and then run as shown in Figure 83, into the excavation, ending in a similar manner. Before the arc is broken, at the end of the weld run, the operator is to hesitate to allow the crater to fill and then run back on to the deposit to break the arc. Stops and starts are to be dressed to good metal before making the next weld run. Start Stop Ist run (at least) Stops after Ist Run + A FIGURE 83 STOPS AND STARTS Back Gouging Non-clogging silicon oxide grinding discs and non~clogging tungsten burrs are to be used for back gouging. In all cases a template is to be used to obtain the correct profile, making it easier for correct weld deposition. See Clause 0716. Backing Strips and Bars ‘Where access to the back of a weld is restricted and a full penetration butt or tee butt weld is required a backing strip may be necessary. These backing strips are to be of the same composition as the casting. They are not to be welded along the edges, and are to be removed on completion of welding. Approval from MOD(PE) SSC is to be obtained for the use of any other material. Non-metal backing bars are to be of non-combustible material and are to be completely removed on completion of welding. Post-weld Heat Treatment Heat treatment is to be applied for the purpose of stress relieving only and the casting is to be held at a maximum of 250°C for one hour per 25 mm of thickness. A Standards The non-destructive examination and acceptance standard for the welding of castings is to be DG Ships/G/10000B (NES 773). 78(WS8/SG)B1 . 93.‘NES 768 Issue 1 16. DRAWING REQUIREMENTS AND DESIGN CONSIDERATIONS 1601. The following clauses contains the requirements for welding information to be included on drawings. It also gives guidance on other aspects to be considered to achieve a satisfactory design, all drawings are to be prepared in accordance with NES 722. 1602. All the information necessary to satisfy the particular welding requirements is to be shown on drawings. This information is to include: a. details of all edge preparations to be used on work covered by the drawing; b. _awelding procedure, containing the information set out in Clauses 1011 and 1012 as relevant which is 0 be par ofthe drawing, and/or c. a welding procedure, containing the information, set out in Clauses 1011 and 1012 as relevant, which is to be separate from the drawing. In this case a reference to the weld procedure is to be shown on the drawing. Annex E shows a typical weld procedure format; da @ note to be placed on the drawing stating "The welding information shown on the renee in the related weld procedure is in with the requirements of NES 768; . material specification; £ location, size and details of all joints; g welding procedure to be used; h. _heat treatments other than those used in the welding procedure; i. special sequences for welding, fabrication and erection; j. details of all inspections and tests. Temperature 1603. The limits of operational temperature applicable to this NES are ~20°C to 100°C. For structures and components operating outside this temperature range, advice and approval 1604. Due allowance is to be made for stresses induced by changes in temperature of structure. Summary of Design Considerations 1605. The following items summarize the activities to be considered in preparing a drawing: a, material to be used to satisfy requirements of design; b. loading forms; c. selection of types of joint to satisfy service requirements, type of inspection and acceptance standards; 78(WS8/SG)B2 94.1606. 1607. 1608. 17. 1701. 1702. NES 768 Issue 1 d. method of joining material and joining process; e. accessibility for making joints, assembly, examination and maintenance; £ maximum use of flat and horizontal-vertical welding positions; 2. the design of the interface between aluminium and its alloys and to any other material; bh. erection and welding sequences to minimize distortion and provide reasonable working conditions, j. use of material forming and extruded sections to minimize welding and improve joint configuration; Kk. the use of jigs and fixtures and temporary stiffening as an aid to erection and assembly; m. machining allowances; n. _ heat treatments ~ preheat, post heat, stress relief and associated precautions; p. care, handling, treatment and preparation of material whilst being used for manufacture and in service. Inspection and Acceptance Requirements Details of all inspection and test requirements and acceptance standards are to be shown on the drawings. The requirement for non-destructive examination is to be detailed and be in accordance with Section 17. The acceptance standard is to be DG Ships/G/10000B (NES 773). Any special inspection requirements over and above those required by the Contract are to be clearly indicated on the drawings. Further guidance on design considerations can be found in Annex J. QUALITY CONTROL AND INSPECTION OF WELDS The following clauses set out the requirements for quality control and the inspection and acceptance standards for all production welding of non-destructive examination and the appropriate acceptance standard for welds is contained in DG Ships/G/10000B (NES 773). Quality ‘Within the content of this NES the word ‘quality’ is used in the ‘fitness for " sense and is defined in BS 4778 as "The totality of features and characteristics of a product or service that bear on its ability to satisfy a given need’. This need is to include economic requirements as well as availability, maintainability, reliability, design and other characteristics. 78(WS8/SG)B2 95.NES 768 Issue 1 Quality Control 1703. Quality Control is that aspect of Quality Assurance that concerns the practical means of securing the product quality as required by this NES and as may be required by the Contract or other relevant specification. 1704. Each organization is to maintain an independent Inspection and Quality Control system to ensure the requirements of this NES are met. Records of welds are to be kept in the form of a Weld History - Annex K, see Clause 1727. Approved procedures and welder qualification details are to be maintained and open for inspection by the Acceptance Authority or representative. 1705. Each organization is to retain for a minimum of five years, from the completion of a contact ll quality records relating to welding Records are tobe suplied 10 the MOD(PE) SSC on request at any time within this period. An organization wishing to dispose of any records earlier than that permitted is to obtain prior MOD(PE) SSC approval and disposal instructions. Welding 1706. The following are to be checked before welding commences. a. Materials to be used including consumables to ensure that they meet the requirements of the specification in respect of composition, heat treatment, surface defects, physical tests etc, and are to be available together with the quality documentation. b. Materials and welding consumables are being stored in a suitable environment and are identified and issued by an approved system to ensure against use of ‘wrong materials. cc. The joining process is in accordance with the design requirements. 4. The welding procedures are to be available, approved and understood by all concerned. . Equipment for cutting, forming, assembly and welding is available and of a satisfactory forthe job to be done, and qualified where requised by this specification. £ Operators are trained and qualified and competent to operate equipment required. g- Equipment to be used is within its routine service period, see also Clause 1176 to 1178. b. The edges of material are accurately prepared in accordance with the design requirements and approved weld procedure. j. Assembly and welding sequences are prepared, available and understood by all concerned. k. Each person has available all the relevant information for his job before start date. m. — Welding equipment parameters and power supplies are checked prior to commencement of work. n. _Pre-welding requirements of the procedure are carried out and the condition maintained up to the start of welding. 78(WS8/SG)B2 96.NES 768 Issue 1 Pre-weld non-destructive testing checks are made, as required by specification or other contractual document. Errors, omissions and defects found as a result of the foregoing are corrected before commencement of welding. Quality documentation is initiated including a weld history sheet - see Annex D for typical document. Asrangements for water and draught proofing welding areas to prevent disruption of the welding process, by ingress of moisture to the weld area, and loss of gas shielding, is complete and tested. ‘An inspection has been carried out on all areas that will become inaccessible as a result of the welding operation. 1707. The following checks are to be made during welding: oO b. © m. voltage and amperage readings, where relevant, and recorded; care, handling and type of welding consumable; cleanliness standards; draughts and moisture levels; removal of assembly welds and weld end dressing if assembly welds are to be incorporated in the weld. See Clause 1031 to 1033; stops and starts conform to Clause 1037 and 1038 and that they are removed correctly together with crater cracks and weld overrun and blended into the weld bead before the next run is deposite interpass cleaning is adequately and correctly done; back gouge templates are available to ensure minimal yet correct gouging of butt welds. See Clauses 1043 to 1046; a where preheating is required, careful monitoring has been carried out to ensure that local over-heating is avoided and that correct temperature levels are removal of temporary fixing aids is in accordance with this specification and that damage to material surfaces resulting from incorrect removal of temporary aids or other causes is investigated by the inspecting authority and action initiated to ensure future avoidance of such damage; quality documents are completed as required. 1708. The following are to be checked after welding: a b. temporary attachments are removed as in Clause 1221. where damage to material surfaces results from whatever cause and repair action is necessary, the repair is done in accordance with an approved procedure; 78(WS8/SG)B2 97.NES 768 Issue 1 1709. 1710. 1711. 1712. 1713. im4. 1715. 1n6. 1717. 1718. 1719. 1720. 1721. 1722. 1723. c. welds are prepared for non-destructive examination in accordance with the requirements of NES 729; d. non-destructive examination of welds is in accordance with Clause 1741 to 1747; ¢. quality documentation is completed including the weld history sheet as required by this NES and the Contract. Riveting Materials to be used are to meet the requirements of the specification in all respects and are to be available together with their required quality documentation. ‘The joining process is to be in accordance with the design requirements. Equipment for cutting, forming, assembly and riveting is to be available and is to be of a type satisfactory for the job to be done. Operators are to be trained and qualified as necessary and competent to operate equipment required. Equipment being used is to be within the current service period. ‘The edges of material are to be accurately prepared. Assembly sequences where necessary are to be prepared, available and understood by all ‘concerned. Each person is to have available relevant job information in good time before the job starts. Equipment is to be checked for operational efficiency. Non-destructive checks on material are to be done as may be required by specification or contractual documents. Errors, omissions and defects found are to be corrected before commencement of assembly. Quality documents are to be initiated and completed at intervals required. An inspection is to be carried out on all areas that will become inaccessible on completion of the work. Care in the handling of material is important. Surface damage resulting from arly cause is to be examined by the inspecting authority and where a repair is necessary this is to be done in accordance with an approved procedure. See Section 14. Non-destructive examination of riveted joints is to be done in accordance with Clause 1753. 78(WS8/SG)B2 98.1724. 1725. 1726. 1727. 1728. 1729. 1730. 1731. 1732. 1733. NES 768 Issue 1 Design and Drawings Drawings are to conform to the requirements of Section 16 and are to show the shape and dimensions of each weldment, and where the structure or component consists of a number of weldments joined together or has a preferred sequence of assembly, the drawings are to include erection and assembly information. Joint details are to be shown on drawings where appropiate together with the sie, shape and relative position of each weld. Appropriate welding symbols are also to be included. Related welding processes are to be referenced or included as part of the drawing. ‘Welding Procedures Welding procedures are to be available as detailed in Section 10. They may be for one joint or part or complete assemblies as necessary. Assembly and Welding Sequences Assembly and welding sequences are to allow for the effect on dimensional accuracy of distortion due to weld shrinkage. See Sections 10 and 12. Qualification Procedural and performance qualification tests as set out in Section 11 are to be observed. ‘Additional tests within the scope of this specification may be required by the inspection authority as necessary in the interests of achieving the minimum quality standard for the structure or component in question. Supervision Control of welding quality largely depends upon the quality and welding knowledge of the welding superticor and those Supervisors responsible for preparing material for welding. Such personnel are to have a thorough knowledge of the requirements of this NES and of the welding process, procedures and related documents. See Section 3. Weld History ‘Weld history documentation is to be raised and completed for all work done within the scope of this NES except for work of a minor nature which is subject entirely to Class 3 acceptance standards of DG Ships/G/10000B (NES 773) or level 4 systems a8 defined in 743 Part 4. See also Annex K. ‘Where work subject to class 3 acceptance standards is welded to work of a higher acceptance level, the attachment welds are to be accepted to the higher standard or level. ‘Weld history documentation is also required. Edge Preparations The choice of edge preparation will influence the weld quality, economy and final dimensional accuracy of the assembly. The type of edge preparation is to be chosen to meet design requirements. See Section 7. age preparations made by hand are tobe checked for accuracy using a gauge set against tum line marked on the material surface parallel to the preparation nosing and normally not less than 75 mm from the plate edge being checked. See Figure 84. 78(WS8/SG)B2 99.NES 768 Issue 1 Datun/ Reference line Max. of nose FIGURE 84 EDGE PREPARATION FOR HAND PREPARED EDGES 1734. Where localized poorly formed or damaged edge preparations are found they may be 1735. 1736. 1737. restored by buttering and re—forming the edge to an approved welding procedure. Where extensive lengths of incorrect edge preparation are to be repaired the plate is to be re— prepared and the loss of plate area allowed for elsewhere, Extensive buttering of plate edges is not to be done without the prior approval of the MOD(PE) SSC. Where approval is sought, proposals for repair are to include a weld procedure. Edge datum lines are to be lightly scribed onto the plate surface and buffed out on completion of the job. These datums are to be used in identifying the position of weld defects needing repair, sec Clauses 1432 to 1434, and for back gouging, see Clause 1044. The datums may need to be marked on both sides of the material, particularly for butt welds. Quality Control of Welding Consumables Aluminium alloy welding wire is to be the subject of a quality test to establish the usability of such wire for the following purposes. a. _As part of a purchase specification for aluminium welding wire. b. _ Asa receipt inspection procedure for checking batches of wire on a sample or random basis. c. AS.ameans of evaluating batches of suspect wire. ‘The requirement in Clause 1736 is in addition to, and is to be used in conjunction with, the specification requirement used for the original purchase of the wire, for example BS 2901. 78(WS8/SG)B2 : 100.1737. 1738. 1739. 1740. 1741. 1742. 1743. 1744. 1745. 1746. 1747. 1748. NES 768, Issue 1 The requirement in Clause 1736 is in addition to, and is to be used in conjunction with, the specification requirement used forthe orginal purchase of the wire, for example For the of this NES a batch of wire is defined as ‘a quantity of wire which is _ defined by the supplier as a unique and identifiable quantity of his production for quality control purposes’: A batch is to be so defined that the date of its production, source and identification of the raw material, and details of its manufacturing procedure can be identified. ‘The quality test required by Clause 1736 is given at Annex L, ‘Usability Test for Aluminium Alloy Electrode Wire 8 = Non-destructive Examination ‘The following clauses defined the requirements for non-destructive examination and the ate standards for all ion welding within the of this NES. ‘ined M contlas information regarding the various detec: pes, thei cates, and Significance. ‘The methods of carrying out non-destructive examination are to be in accordance with NES 729 (all parts), except for stud welds which are to be examined as defimed in Section 13 of this NES. ‘Welds are not to be examined before the weld area has reached ambient temperature. Extent of Non~destructive Exami The minimum irements for the extent of non-destructive examinations will be defined in the Contract Documents, or ss required by DG Shipo]G/10000B (NES 173). The standard is to be as stated in the Contract. Where the accey ‘standard isnot $0 sated DG Ships/G/100008 (NES 775) 6 coaply. Pianos Where vessels are being modified or refitted the welding isto be examined tothe same degree and to the same extent as required by Clauses 1744 and 1745. Where doubt exists MOD(PE) SSC is to be consulted. At the time of examining new welds, all existing welds within a distance of 150 mm are to be visually examined for surface cracking. ‘Welded Inserts and Penetrations Contractual requirements will be as Clauses 1744 and 1745. The general requirements for surface ships are however as follows: a. Small Inserts and Penetrations ~ Those whose longest dimension or diameter is 600 mm or less. @) 100% Visual examination - plus; @) 100% Radiography. Large Inserts and Penetrations @) Visual examination 100% — plus; (2) Radiography 78(WS8/SG)B2 101.NES 768 Issue 1 1749. 1750. 1751. (@) at each comer and any T-junction ~ plus; (b) at any one intermediate position on any dimensions exceeding mm; (© at not less than four positions on any circular or non-rectangular insert. Repair of Weldin; The non-destructive examination requirements and acceptance standards are to be in accordance with Clause 1743 except that the repair of weld defects is to be examined 100% by the appropriate methods. Renovation by Welding of Pitted Plating This is to be kept to a minimum and is prohibited on the heat~treatable materials. Where large areas of plating are pitted and need repair they are to be cut out and replaced. ‘Where weld renovation is agreed by the design authority to be done it is to be the subject of a weld procedure and is to be ultrasonically and/or crack detected at the discretion of the inspecting authority. I ification of Defects Position ‘The use of datum lines for edge preparations can be used in the identification of defects found in radiography. Providing the position of the radiographic film is known in relation to the datum lines, the centre of the weld can be identified and from a tracing of the defects on the radiograph the vertical positions of the defects can be transferred to the material surface. This allows accurate removal of defects once the depth of defect is established. This can often be judged by experience in radiographic interpretation, a sgund knowledge ofthe joint geometry andthe welding procedure. Soe Figure 85 and lause 1733. Dou Lines | it rc FIGURE 85 WELD DEFECT POSITION - MARKING FOR REMOVAL 78(WS8/SG)B2 102.NES 768 Issue 1 Quality Control of Stud Welding 1752. Aluminium stud welding is to use the following to assure good reliability and limit weld failure. a Correctly designed studs and matched material for stud and component. Power sources and welding equipment of sufficient capacity for stud size. ‘Surfaces that are clean and free from contaminants and oxides. Proper positioning of the welding gun on the work surface, and correct lift and plunge setting. ‘An approved welding procedure. Properly earthed equipment, connected as close as possible to the work in Progress. ‘Welding cables of sufficient size with good connections. ‘Welders trained and qualified to use the equipment. Non—destructive Examination of Riveted Joints 1753. Riveted joints are to be examined: a by a hammer test to find loose rivets; 100% visual examination to eliminate errors and omissions in joint design; in highly stressed regions the material under the rivet head is to be checked for cracking by an approved method and associated procedure, 78(WS8/SG)B2 103,NES 768 Issue 1 78(WS8/SG)B2 104.NES 768 Issue 1 ANNEX A ALUMINIUM AND ALUMINIUM ALLOY CHARACTERISTICS AL AA. A6. Az. PHYSICAL Aluminium alloys are light in weight, have good tensile strength (some have strengths comparable to mild steel), good ductility, high resistance to corrosion and are weldable. They have different characteristics from that of steel, each of which are to be understood if they are to be used and welded successfully. Aluminium (and its alloys) is a very different material from steel and is to be treated as such in both design and construction. Aluminium as extracted from its ore is of commercial purity and is soft and ductile at normal temperatures, increasing in ductility until about 500°C. Strength and hardness are increased by cold working. The density of aluminium is about one-third that of steel, copper or zine, its thermal and electrical conductivities are high and it resistant to corrosion. ‘Tos alloying of vations meals with alumssioms inreanes fs bardaess sod tensile properties with some sacrifice of ductility. Physical properties of aluminium alloys vary with alloying elements form, size, shape and temper or heat treatment condition. The samt apply to mechanical properties, the physical properties are not usually limited by specification. Where it essential fo obtain accurate figures for particular alloys in particular forms, the aluminium producer is to be consulted. The mechanical properties of heat teatable aluminium alloys depend upon te aplied a a ‘treatment, quenching, cold working, and artificial or natural ageing, depending upon the specific alloy. The mechanical properties of non-heat treatable alloys depend upon their alloy compositions and the degree of cold work or strain hardening introduced during manufacture or in production. ‘The figures given in Table Al are for high purity aluminium and provide a basis for the understanding of aluminium and its alloys. MECHANICAL PROOF STRESS Unlike many steels, in which the metal yields suddenly, the elastic limit for aluminium is not clearly defined. In these cases, a standard is adopted, called the ‘proof stress, and is defined in BS EN 10002-1 as the stress which produces, while the load is still applied a non-proportional extension equal to a specified percentage of the extensometer gauge length. For aluminium the extension specified is 0.2%, ic the stress/strain curve departs from the straight line of proportionality by an amount equal to 0.2% of the gauge length (Figure Al). This stress is analogous to the yield of structural steel. Figure A2 gives stress/strain curves for some aluminium alloys. TENSILE STRENGTH Tensile strength is determined for aluminium alloys, as for other metals, by the stress requited 10 break a standard test piece ina tensile testing machine, in accordance with BS 78(WS8/SG)B2 108. ANNEX ANES 768 Issue 1 Crystal Structure face centre cubic Latent heat of fusion 94.6 cal/g Nelting point 660.2°c Boiling point /2480°C Mean specific heat 0.219 cal/g*C Thermal conductivity 0.57 cal/cm s°C ‘Temperature coefficient of linear 23.5 x 10-6 per *c expansion Electrical resistivity at 20°C 2.69 pO cm ‘Temperature coefficient of resistance |4.2 x 10-3 per * Density at 20°C 2.6898 g/cn3 Tensile strength 80 Nom -? Yield strength 50 Num -2 Modulus of elasticity (Young's 71 x 103 Nam -2 modulus) Modulus of torsion 25.5 x 103 Nom -2 [Poisson's ratio 0.34 Elongation 43% TABLE Al CONSTANTS AND SOME PHYSICAL PROPERTIES OF VERY HIGH PURITY ALUMINIUM ANNEX A T8(WS8/SG)B2 106.NES 768 Issue 1 2 va Loree eof 21 Fee s I : gm sea a > a 80} A rman FIGURE Al LOAD/EXTENSION CURVE, ILLUSTRATING THE METHOD OF DERIVING PROOF STRESS ony STRESS MPa | [adiaa-T STRAIN % FIGURE A2 FORM OF STRESS/STRAIN CURVES FOR SOME ALUMINIUM ALLOYS MPa ~ mega pascals (MIN/nr) TE(WS8/SG)B2 107. ANNEX ANES 768 Issue 1 AB. Al0. All. Al2. Al. ELASTIC PROPERTIES ‘The strain pr unit increase of ses is much higher for aluminium alloys than fog steel The elastic modulus is about one-third that of steel, being about 71 x 10> N/mm?. means that in relation to steel its elastic deflection will be about three times greater. Ths relatively low stiffness is an advantage under shock or impact loads, by virtue of the ‘energy absorption in producing the large deflection. Where it is required for the aluminium alloy section to have equal stiffness to that of steel, its weight will be increased to,about half that of the steel member. The torsion modulus of aluminium alloy is 25.5 x 103 N/mm“. Poisson's Ratio is 0.34. All these values vary only slightly for the different alloys. INGATION Elongation is the percentage permanent increase in the gauge length of a tensile test piece measured after fracture. Typical elongation values for non-heat treatable aluminium lye vay fom 2% leaned teal os ite 3% uly sind intend metal. The heat treated alloys, even the strongest, possess a fair elongation, around 8% in the fully heat treated condition. ae COMPRESSIVE STRENGTH Compressive strength proof stress of aluminium alloys, for most practical purposes, may be taken as the same as that for tension. It is not easy to measure the compressive ‘strength of ductile materials like aluminium, which in structural members is rarely experienced, because buckling normally takes place before compressive yielding occurs. BEARING STRENGTH Bearing yield strength in riveted or bolted connections is usually taken as the stress which produced 1% permanent elongation based on the hole diameter. It is general practice to a edge distances are maintained, the factor varying from 1.2 to 1.8 according to the composition of the material. HARDNESS: Resistance to surface indentation is only an approximate guide to hardness, and is mainly used as an inspection measure. Hardness readings are not to be regarded as quantitative index to tensile strength. as is often done with steels, for in aluminium the relation between these two properties is extremely variable. FATIGUE ‘Structures subjected to fluctuations of load may be liable to suffer fatigue failure which, if the number of applications of load is large, may occur at stresses much lower than the permissible static stress. Fatigue failure is usually initiated in the vicinity of a stress Concentration and appears as a crack, which slowly propagates through the material and/or connected members. Stress concentrations may be inherent in the shape of the component and may reduce the effective strength. Roughness of surface, weld ripples, ‘stops and starts, bunched welds at intersections, toes of fillet welds, all promote stress concentrations.’ See Figure A3. ANNEX A. ‘78(WS8/SG)B2 108.Temporary attachment Ala. ALS. Al6. Al7. ‘NES 768 Issue 1 Notch’ Noteh Notch Noteh Misoligned plating weld undercut Notches \ beasts ed off Bodly cut rodius comer FIGURE A3 EXAMPLES OF STRESS CONCENTRATION Aluminium alloys do not usually have a fatigue limit, which is a stress below which fatigue failure will not occur. Designers are to ensure that the maximum stress induced is consistent with a fatigue endurance that will not be reached within the projected life of the component. CORROSION RESISTANCE Aluminium and some of its alloys have a high resistance to corrosion. In a marine environment the alloys can often be used without protection. Aluminium has a great chemical affinity for oxygen and a film of oxide forms spontaneously on any surface exposed to the air. ‘The film is vary stable and protects the metal from further attack. Resistance of individual alloys is determined mainly by their composition but is also influenced by condition of temper. Exposure of the bare metal to any atmosphere must after a period, that will depend on the circumstances, impair its original lustre and ‘smoothness, and in severe conditions surface deposits and slight pitting may appear. The corrosion resistance of aluminium can be increased by the application of an anodic film. Special precautions are necessary when aluminium alloys are to be in contact with other metals. The continuous oxide film which forms as soon as a fresh surface of metal is exposed in air, cannot be reduced during welding. Its melting point exceeds 2000°C and its density is the same as that of the metal. This means that for satisfactory welded joints it must be removed before and during welding. See Clause 0903. ‘78(WS8/SG)B2 109. ANNEX A.NES 768 Issue 1 Als. Als. THERMAL PROPERTIES Pure aluminium melts at 660°C and the fusion range of most of the alloys lies between this figure and about 520°C. This means that the metal temperatures concemed are about 800°C lower than those for the welding of steel. Such temperatures are not within the visible light range, and hence there are no changes of colour that would indicate when melting temperatures are being approached. Although the melting point is low, the amount of heat required to melt aluminium is about the same as for steel, weight for weight. The thermal conductivity of pure aluminium is about five times that of steel, and that of the alloys from three to five times: hence pre-heating may be necessary in order to maintain sufficient heat in the region of the weld, ly where the TIG process is used for welding the thicker materials. Aluminium expands on heating to about twice the extent of steel, size for size, over the same temperature range. In addition the volume of weld metal shrinks during solidification by about 5% (1/20th). This means that unless precautions are taken the welds may be subjected to considerable sess during both welding and subsequent ing. STRENGTH Aluminium and its alloys begin to suffer a loss of strength at temperatures above 100°C. ‘Some aluminium alloys (castings) have been specially developed for the service at high temperatures and operate indefinitely at that higher range. In many cases the original strength after heating is not restored on cooling. Heating changes the structure of the metal and removes the effects of work hardening. Prolonged heating under stress also induces plastic flow or creep. Aluminium in its pure form has low strength and requires the addition of alloying elements to improve its mechanical properties. The addition of specific alloying elements to pure aluminium produces two distinct alloy groups: non-heat treatable and heat treatable: a. Non-heat treatable — represented in BS 1470: 1987. Table A2. See also ‘Clauses A27 and A42. b. Heat treatable ~ represented in BS 1470: 1987. Table A3. See also Clauses A30 and A45. ALUMINIUM ALLOY DESIGNATION SYSTEM (BS 1470: 1987, Appendix B) ‘Wrought aluminium and its alloys are specified in a series of British Standards. An international four-digit system is used classifying the alloys by chemical com The first of the four-digits indicates the alloy group according to the major element as follows XXX Aluminium 99.00 per cent minimum purity 2XXK Copper 3XXX Manganese 4XXX Silicon SXXX Magnesium ANNEX A 78(WS8/SG)B2 110.6XXX TXXX 8XXX 9XXX 23, 2XXX to SXXX ‘NES 768 Issue 1 Magnesium and Silicon Zine Other elements Unused series groups. In these groups the last two of the four digits have no special Significance but serve only to identify different alloys in the group, ie 5083 originally NS8. ‘The second digit indicates alloy modifications, if it is zero it indicates the original alloy. A24, Where national variations of existing alloys are registered, they are identified by a letter after the numerical designation. The letters are assigned in alphabetical sequence with A for the first national variation registered by omitting I, O and Q, ie 51544. A25. The new alloy designations in BS 1470: 1987 are shown against the old British Standard designations, ISO designations and old and new BS temper designations in Table A2. 78(WS8/SG)B2 1. ANNEX ANES 768 Issue 1 180 alloy BS temper 01d BS teaper nei Old BS attoy | designation | designation designation Juasiieyee 10804 sta Jar 99.8 10508 sin Jar 99-5 1200 sxe jar 99.0 3203 s3 nme fF: om wiz: wat: |: 0: was ms Hs lan6: m8: ae: 3105 Previously NSS in [Aue Jo: maz: ma ps 4300/6 ns. 5005, Previously NsAL in [amar lo: wuz: wid; wns: fos aa: why [ps 4300/7, 5083 58 Janes 5 Jp: 0: mae: wot: fu: 0; ma: mts 52450 ss Jaimes 5 Jes mas wa 5252 se Jaime sas Previously NS51 in |AINE3¥0 rs 0: mez: nab: Bs 4300/8 jaonka sis arcutsine lo: re: Jere 20188 Hea arcutsing Jo: 1B: 3P: clad a1 99.5 2028 sot previeusty in |arcutmer lo: 73: 1351: les a - Bs 3870 Jctaa 2028 JNot previously in jaicutmet Jo: 3 - Jas 1870 clad AL 99.5 (Conta) ‘TABLE A2 ALUMINIUM ALLOY AND TEMPER DESIGNATION CROSS-REFERENCES ANNEX A 78(WS8/SG)B2 112.NES 768 Issue 1 (conta) 150 alley BS tesper ‘oud BS temper alsa) ord BS alioy | eaignation | designation designation 6082 is30 Jausiamem fo; Ta: 16: lo: mp: wr: =: 6063 lug see 3s 2873 ames Jor tas 15: 16: for mms Er tre oss woo see ps at7h — aumprsicu fos tas 75: 76: fox tm: te: Pr NOTE: The ‘old’ BS alloy designations vere those used prior to the issue in June 1980 of Amendment No 1, which introduced the A-digit alloy designation systes. ‘TABLE A2 ALUMINIUM ALLOY AND TEXPER DESIGNATION CROSS-REFERENCES 26. TEMPER/HEAT TREATMENT DESIGNATIONS SYSTEM (BS 1470: 1987 Section 5 and APPENDIX D) ‘The temper designations adopted by British Standards is that given as ‘the alternative’ system in ISO 2107. The basic temper designations consist of eters, see below, and mumerical subdivisions where required. These designate specific sequences of basic treatment, but only y operations which significant nunc: the characteristics of the proauet ae inde “The temper designation follows the alloy designation, the two Eeing separated by a hyphen, eg 5083-Fi24. For further details see Section 6 and Append D of BS 1470: 1987. F As fabricated © Annealed #12 HI4 Strain-hardened ) Hi8) 22) ) a4 } Strain-hardened and partially annealed 28) NOTE: The H1 and H2 designations are in increasing order of tensile strength. T3 Solution heat-treated, cold worked and naturally aged. T4 Solution heat-treated and naturally aged. NOTE: The properties of some alloys in this temper are unstable. 78(WS8/SG)B2 re ANNEX A.NES 768 Issue 1 TS — Cooled from an elevated temperature shaping process and then artificially aged. T6 Solution heat-treated and artificially aged. A27. NON-HEAT TREATABLE ALLOYS (WROUGHT) - SXXX ALLOY GROUP ‘These are the aluminium magnesium alloys, with small additions of iron and silicon, and are listed in Table 2, and Table 2 of BS 1470: 1987. The addition of magnesium, through solution hardening, increases the strength of the alloy. These alloys have good corrosion resistance and are readily weldable. These alloys are hardened when subjected to cold working, a factor which must be considered when any cold forming takes place, especially if the manufacturing process includes a requirement for severe deformation. ‘A28. The work hardening characerstics of these alloys i used inthe manufacturing stage of these materials to increase the strength. By applying varying levels of strain to get this hardness, a range of strengths is produced in the same alloy. Each strength is denoted by alletter and a figure as shown in Clause A26. A29. When welded, the heat affected zone (HAZ) is de-graded to that of the annealed condition. A30. HEAT TREATABLE ALLOYS (WROUGHT) - 6XXX ALLOY GROUP ‘The mechanical properties of het weatable aluminium alloys depend upon the specific combination of alloying elements and the applied thermal and mechanical treatments given under carefully controlled conditions. If such an alloy is subsequently heated in the Shipyard to facilitate working, then the material retums to the soft condition and its ies destroyed. These alloys in the soft (annealed) condition are much softer than the non-heat treatable alloys in the annealed (soft) condition. A31. These alloys have limited marine use and are shown in Table A2 and BS 1470 to 1475. Only two, 6063 and 6082, are suitable for use under marine conditions, the remainder have copper contents in excess of 0.1% and are susceptible to corrosion. A32. Where heat treatable alloys are used for their increased strength properties, such as ladders and guard rail stanchions, any welding, or other operations involving the application of heat, is strictly prohibited. See also NES 162 Part 1. A33. HEAT TREATMENT ‘The only thermal treatment permitted is that of annealing the non-heat treatable alloys. ‘A34, Heat treatment may be carried out to soften a tempered alloy for severe forming operations, or at an interstage when severe forming is required, to prevent premature fracture before completion of the final forming operation. A35. The requirement for heat treatment is to be specified on the drawing or on the work authorization document. Severe forming is to be avoided wherever possible, by using an extrusion, or re-design. A36. Where material is to be heat treated it is to be subjected to the full quality control procedures, by the establishment performing the work. 37. Where severe forming is required then material is to be ordered in the O (Annealed) condition. ANNEX A. 78(WS8/SG)B2 114.A40. A4l. A42. AaB. AM. AAS. A46. NES 768 Issue 1 ANNEALING ‘Annealing is a thermal treatment for softening alloys that have been hardened by cold ‘work or by heat treatment. It is generally used to enable the metal to be cold worked. To avoid excessive gran growth the metal is o be heated tothe annealing temperature as rapidly as possible, and held at that temperature only as long as necessary. giain growth reduces the mechanical properties of the metal and may give a rough ‘orange-peel' effect on the surface when the material is subsequently worked. The annealing temperature and time for the MOD(PE) SSC approved alloy $083 is 360°C for twenty minutes. Other alloys are to be dealt with as required by Clause. After annealing, the non-heat treatable alloys remain soft, they do not regain any of their original strength by ageing. CASTINGS ‘The choice of alloying compositions for aluminium castings is determined by additional factors to those required to give the resulting mechanical properties, eg fluidity of the liquid metal, soundness of the finished product, and the shrinkage on the cooling which should not produce cracking. Elements which are used in aluminium casting alloys are: silicon to assist castability; copper and magnesium, or a combination of both, to produce high temperature properties, resistance to corrosion and to provide heat treatment NON-! TED ALLOYS Alloys ofthis group ae those contsining 9-13% Silicon. They have good resistance to corrosion, moderate strength (155-230 ‘Nimm) and high fluidity, ie running freely when being poured, making them suitable for intricate castings. ‘Modification’ by the addition of about 0.1% Sodium to the liquid metal produces a fine grain structure and reduces . This group is not subject to any form of heat treatment. BS 1490: 1970 lists the alloys into two groups ~ General Purpose Alloys, and Special Purpose Alloys. Of these alloys only LM6, a General Purpose Alloy, is approved for use, because of its excellent castability and its high resistance to corrosion. ‘Typical applications are, ‘on deck’ castings, water cooled manifolds and jackets, thin walled and intricate instrument cases, switch boxes, motor housings, very large castings such as doors and panels. HEAT TREATABLE CAST ALLOYS ‘The heat treatments available in this range are the same as for the heat-treatable wrought alloys, ie solution treatment, and precipitation treatment, and where both these are involved it is termed a full heat treatment. TYPICAL ALLOYS 10% Magnesium: this provides one of the toughest of the aluminium alloys with a high corrosion resistance. The magnesium renders casting more difficult. The heat treatment is one of solution treatment by heating to a temperature of 425°C and holding for about ight hours followed by an oil quench at 100°C. 78(WS8/SG)B2 115. ANNEX ANES 768 Issue 1 A47. 4% copper, 1.5% Magnesium, 2% Nickel: referred to as the Y-alloys. The main use for this casting alloy is pistons and cylinder heads. These alloys are given the full heat treatment consisting of solution treatment at 515°C for six hours, quenching in boiling water, followed by a re-heat to 100°C for two hours. ‘A48. All such heat treatments are applied under strictly controlled conditions in plant designed specifically for the purpose. A49. HEAT TREATMENT DESIGNATION SYSTEM Castings to BS 1490: 1970 are supplied in one of the following conditions as specified by the purchaser, and listed below: ‘Symbol Description M As cast Ts Stress relieved only TE Precipitation treated 1B Solution treated B7 Soiution treated and stabilized TF Solution treated and precipitation treated TF7 Fall heat treatment plus stabilization ANNEX A 78(WS8/SG)B2 116.j a ANNEX B WELDED JOINTS Bl. There are only two types of welds: a b. Butt weld. Fillet weld. {Al welded joints are made with variations of hese two basic weld types. They aris because of the structural configuration to be joined and the stresses to be For example, the ‘tee’ joints in thick materials, a partial penetration tee butt weld, Figure B1d, is better than a fillet weld, Figure B1b, having improved stress Where such joints, due to thickness or structural importance, are subject to cyclic or dynamic loadings, then a full penetration ‘tee butt’ weld is essential, Figure Bic. 5 } (a) Butt Weld (b) Fillet Weld (c) Full Penetration (4) Partial Penetration Tee Butt Weld Tee Butt Weld FIGURE B1 WELD TYPES B2. BUTT WELDS The choice of preparation requires the following considerations: a b. c Material thickness ~ 'U' or 'V' preparation. Volume of weld metal - economy and distribution. Balanced deposition ~ minimize distortion. Accessibility. Process. 78(WS8/SG)B2 117. ANNEX BNES 768 The general rules are: a. For materials approaching 20 mm and over use 'U' preparations. b. Use double preparations wherever possible, U/v or V/v, Figure B2, to balance the weld. ©. keep the included angle to a minimum. [x] DO U/v Preparation V/v Preparation FIGURE B2 BUTT WELD PREPARATIONS B4. JOINT TERMINOLOGY Butt weld terminology is illustrated in Figure B3 with the following description: Included_Angie x Side Wall ‘Angle o Radius Land NZ at Nose| _| Cap Width ose Single Bevel 'U Preparation 45° FIGURE B3 JOINT TERMINOLOGY ANNEX B 78(WS8/SG)B2 118.NES 768 Issue 1 a. The depth of nosing is related to the power of the welding process. It is to be kept to a minimum, so that the root run just fuses through. This ensures minimum back gouging. b. The gap width is to allow penetration. Due to weld shrinkage this is difficult to maintain and is therefore a somewhat illusory requirement. Tight butts will require a minimal increase in back gouging depth, but ing will determine nose depths for complete root fusion and hence minimal back gouging. cc. Side wall angle. MIG and TIG welding will want a greater angle than that for the manual metal arc process using flux coated electrodes. This angle is critical, and is to be kept to a minimum. Too large an angle increases the distortional effect and too small an angle gives rise to lack of side wall fusion. Procedural testing will enable the correct angle to be specified related to the process used and the material thickness. To increase accessibility to the root, it is not always necessary to widen the side wall angle or increase the root radius. An increase in the land’ width will increase accessibility without changing the side wall angle or the root radius. The side wall angle is to be such that complete side wall fusion can be consistently achieved. d. Root radius. This is to be kept as small as possible commensurate with an adequate land and the best side wall angle. EDGE PREPARATIONS Recommended edge preparations are given in Figure B4 for TIG welding and MIG welding. The choice of the edge preparation is dependent upon: a. the process; b. the material thickness. All edge preparations are to be qualified by the appropriate procedural test, to determine all the relevant parameters, see Section 10. t |Process: om AC TIG: Pulsed MIG Remarks lup to 3 |Square butt without Backing Penetration from one side jor with Te Backing Bar jonly can be achieved. Tee eins tess eee eee to be in accordance with NoGa =---— those given in Clause 0709 and 0711. (Contd) FIGURE B GUIDE FOR EDGE PREPARATIONS 78(WS8/SG)B2 1g. ANNEX BNES 768 Issue 1 (Contd) t Process: ma AC TIG: Pulsed MIG Remarks 3 to _|Single Vee without Backing TIG welding is limited in 12.7 ‘thickness. See Clause 0918. 792 Pee Back gouging to sound metal j 4-600 is required before adding | | back weld. Where backing bars are used INo Gap they are to be in accordance lor with Temporary Backing Bar [with Clause 0709 to O711. | over {Double Vee Back gouge to sound metal 12.7 702-90° before adding back weld. Double Vee No root gap <__ 30" lup to 3 [Permanent Back Strip For AC TIG the root gap is 1} times the electrode diameter. I For Pulsed MIG the roct gap Ss is twice the diameter of the filler wire being used. Permanent backing strips are to be in accordance with Clauses 0711 to 0715. 3 to Permanent Backing Strip AC TIG is limited in 12.7 thickness. See Clause 0918. The root gap is the same as COPS for ‘up to 3 mm'. Pulsed MIG for 5 mm and over. Root gap three times the diameter of the filler wire. ee The root gap width affects > the included angle. Permanent backing strips - = are to be in accordance with Clauses 0711 to 0715. (Conta) FIGURE B4 GUIDE FOR EDGE PREPARATIONS ANNEX B 78(WS8/SG)B2 120.NES 768 Issue 1 (Contd) t Process: mn {AC TIG: Pulsed MIG ae lover 3 | Controlled Penetration The precise joint detail is without Backing to be determined by pre- oes [production procedural qualification testing, where the depth of the nose (N) and the width of the land (L) can be determined. ait lis weld is all positional, R = 1.6 mm No gap N = 1.6 mm such as that for a pipe. 3 to 6 |Vertical Weld Double srator |Full penetration weld with- out back gouge. Tack weld VBE the joint at 150 am intervals, to maintain = alignment of joint. Procedure and welder to be fully qualified for this No Gap N = 1.6 mm type of weld. Process: Conventional MIG 1.5 to Backing bars as detailed in 3 Square Butt Temporary Clauses 0709 and 0711. ack’: Sighting V if required It is essential that these - = joints are close fitting by clamping or other means all No Gap along the joint being welded. over 3 [Single vee Full penetration welds fron Rd one side. Temporary backing K jas detailed in Clauses 0709 (REV ie root g to 0710. Pino With temporary backing For welds without backing, N= 2 mm jgouge to sound metal before Without backing N= t/3 adding back weld. 78(WS8/SG)B1 (Contd) FIGURE Bl GUIDE FOR EDGE PREPARATIONS . 121. ANNEX BNES 768 Issue 1 (Conta) t — [Process: mn AC TIG: Pulsed MIG paaeree) 5 to 10 Full penetration weld from Square Butt Without Backing [FUth Penetration wetd gouging. Sighting vees required. Procedure and operators to be fully No Gap qualified for this type of Sighting V's if required ee 12 to 25] poubte Vee Full penetratjon weld. Weld ~ 692-909 main weld to 3/4 full, back YY gouge to sound metal and complete back weld, then Lie | complete main weld. 3 Double sided welds almost tt nave the volume of weld Wo inoot eee 2m metal compared to a single vee. Full penetration welds in materials over 20 mm thickness. U preparations further economize in weld metal and minimize distortion. Nose depth to be determined by procedure qualification. No root gap ‘The minimum angle required for access to the root is to be determined by procedural qualification. A good root fusion is essential for minimum back gouge. Balanced welding will reduce distortion. ANNEX B 78(WS8/SG)B2 (Conta) FIGURE B4 GUIDE FOR EDGE PREPARATIONS 122.NES 768 Issue 1 (Contd) t — |Process: om |AC TIG: Pulsed MIG emer Over 25 Full Penetration Tee Butt Accessibility to the root is critical. Root radius 'R' to be determined by procedural tests. Optimum 300 Min |Padius and angle of edge R=Smm’ prep’ to be determined that ys either are no larger than no root gap necessary - 12 and | Full Penetration Tee Butt Where full penetration of below thinner members is required. ron Welds should be balanced to = minimize distortion. [Back gouge to sound metal no root gap before completing weld. 78(WS8/SG)B1 : 123. FIGURE B4 GUIDE FOR EDGE PREPARATIONS ANNEX BNES 768 Issue 1 ANNEX B 78(WS8/SG)B2 124.NES 768 Issue 1 ANNEX C MATERIAL HANDLING STORAGE AND PROCESSING Cl. The aluminium oxide film, which gives aluminium its high corrosion resistance, begins to form immediately the metal is exposed to air and slowly increases in thickness until, after some days, no further oxidation takes place unless the film is ruptured. The film is hard but strongly adherent. It forms more rapidly and attains a greater thickness at high temperature. The invisible oxide layer protects the underlying surface indefinitely though it requires protection from dirt. Humidity affects the growth and thickness of the film, and prolonged exposure to a moist atmosphere causes slight corrosion, with a visible film which is white to grey according to the elements present. This im & usally easy to rob chlorides and soft material and dit, git corrosion products, swarf flings of other metals ec, can cause surface damage, especially during transit. These damaging products canbe held ina gzease film and may even become embedded in the ©. HANDLING The majority of handling problems arise with sheet products, because large areas Lie in close contact when sheets are stacked. This can result in moisture, which may condense on metal, even inside cases, penetrating by capillary attraction in between the sheets and causing corrosion. C3. Where tissue paper or other form of packaging is interleaved between plates or sheets, it is to be removed on receipt; this is to prevent such packaging from absorbing moisture from the air and thereby establishing premature corrosion. C4. Castings and forgings are to be protected when in store. CLEANING AND DEGREASING Q Loose particles are to be removed by blowing with clean, dry compressed air. C6. For small amounts of grease, alkaline solutions of low alkalinity may be used if a longer cleaning time can be allowed. Dip the plate into a tank of 5% alkaline solution (0.054 Ke sodium hydroxide per litre of water) at 70°C for 20 to 60 seconds, followed by rinsing in fresh cold water, followed by dipping plate in tank of concentrated nitric acid at room re for 30 seconds, with final rinse in cold water, following with hot water. Dry in an oil free air blast. NOTE:Strong alkaline solutions corrode aluminium. C7. Oil and grease can be removed by emulsions or solvents such as trichloroethane, which leaves surfaces dry as well as grease free. C8. For cleaning by hand, white spirit, petroleum solvents or kerosene are to be used. of kerosene with an emulsifier are useful because they can easily be washed away by water. TRWSBISGYB2 12s, ANNEX CNES 768 Issue 1 C10. ci. C13. c14. cis. c16. cis. C19. STORING Aluminium material is to be stored in clean and dry conditions, away from possible ‘overhead water drips (the drainage of water from copper or copper alloy roofs or condensation off copper pipes on to aluminium causes corrosion). Dry wooden battens (not oak or chestnut) or other inert material are to be used as supports. ‘There is to be an adequate flow of air. Such air flow is to be free from contaminants, such as fumes from nearby workshops, flues and open fires, which accelerate corrosion. ‘Where the storage area is part of a working area, there is to be protection from airbome dust or particles of abrasive matter on the surface of the finished product. ‘Where cutting with a caulking hammer (chipping) of other materials is in progress nearby, stored aluminium is to be screened, to prevent arisings from the cutting or chipping landing on or in between the aluminium. Aluminium is at all times to be kept separate from other materials. CONTROL Plate and sheet are to be stored vertically with space to allow unrestricted circulation of air. Thin sheeting is to be prevented from distorting and causing damage to edges due to its own weight. This may mean special arrangements so that each shect lies flat, or edge protection and general support to each sheet to allow preferred vertical storage. Material is to be stored clear of outside walls to avoid condensation, and must not be covered with any material which eliminates or impedes air flow. Sections and tubes are to be stored vertically. Horizontal storing usually involves removing a section by dragging, which damages the surface. Castings are to be so stored that no undue weight bears upon thin unsupported sections. ‘Surfaces which have been machined ‘are to be 60 placed that they cannot be scratched or otherwise damaged. Cutting lubricants are to be removed (see Clauses CS—C8). For lengthy storage periods, protection by a lanolin or other grease film may be necessary. Small items such as rivets and other small articles are best stored in wooden or plastic bins or boxes. Those with interlocking parts such as screw threads are to be separated in packing so that they do not rub. SHELVES, RACKS AND BINS Shelves racks and bins are to be of seasoned timber (not acid bearing woods such as oak or chestnut) and faced with soft aluminium sheet. Where steel racks are used, they are to be faced with wood in places where aluminium alloys are likely to make contact with them. Wooden storage appliances reduce the risk of condensation. Plastics may be used as an alternative to wood without aluminium facings. All woodwork likely to be in contact with aluminium is to be given a minimum of two coats of lead-free paint to render it impermeable to moisture. ANNEX C 78(WS8/SG)B2 126.29. Gi. C2. NES 768 Issue 1 All screw heads, nails, bolts, etc are to be at least 2 mm below the surface of the wood or plastic to avoid damage to the aluminium. All such fastenings are to be protected against Corrosion, by coatings or plating, to prevent damage to the stored aluminium. MOVEMENT OF MATERIALS Aluminium is easily damaged, it is therefore very important that Specific precautions are ‘taken. When material is moved from the storage area to the workshop, or between operators, it tobe lifted, not dragged. It is not to be dropped or thrown, as such action damages the surface, and this-damage can become crack initiators in service. Individual pats are tobe lied from racks by smooth-grp clamps. Where light enough for manhandling this method is preferred providing that appropriate precautions are taken, eg wearing of gloves. Wher items ae lifted by crane, nylon or emp slings are to be used whenever possible, otherwise wire slings may be used provided the aluminium is adequately protected from damage by the slings. Under no circumstances are chain slings to be used or toothed clamps or any other device which might damage the aluminium surface. IDENTIFICATION Because of aluminium and its alloys areal similar in appearance, they are to be given an identification marking immediately stock is received. A uniform identification marking all over the material is ideal to avoid loss of identity when material is cut. If, however, identification will be lost by cutting or for any other reason, the unmarked piece is to have its material identity re-established. PROCESSING Consideration is to be given to the effects of the relatively high coefficient of expansion of aluminium in measuring, marking out and assembly, particularly when temperature variations are large. Marking-off areas are to be clear of all foreign matter, and smooth and flat, to prevent any scoring of the material's surface. A wooden surface is preferable, with no embedded foreign matter to score the aluminium. Soft brooms or brushes are to be provided for leaning purposes and kept adjacent to the work area. Marking out tecniques ae similar to those for steel work, excep that centre punching is only permitted to locate holes for drilling and for the locating of essential datums. Si centre punch marking is to be carried out using a light punch. Paint crayons and oer contaminants must not be used. Pencil or chalk is permitted, but such marks are to be completely removed from weld areas in accordance with the cleaning requirements of Clause C8. Fine serbing ins are permissible except on critically sessed areas of thin m Cutting by sawing and machining are the most commonly used methods for aluminium, a material that is easily and smoothly cut, providing the equipment is in good condition. ‘Woodcutting power tools may be used providing they are of adequate power. ‘The plasma arc cutting process may also be employed. This method is fast and accurate and is most economical when cutting thick materials or stack cutting. ‘78(WS8/SG)B2 127. ANNEX C