Ships Construction GL-Materials and Welding

II
Rules for Classification and Construction Materials and Welding

Metallic Materials
Principles and Test Procedures
Edition 2009
The following Rules come into force on April 1st, 2009 Alterations to the preceding Edition are marked by beams at the text margin. Germanischer Lloyd Aktiengesellschaft Head Office Vorsetzen 35, 20459 Hamburg, Germany Phone: +49 40 36149-0 Fax: +49 40 36149-200 headoffice@gl-group.com www.gl-group.com "General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys). Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd Aktiengesellschaft. Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg Printed by: Gebrder Braasch GmbH, Hamburg
II - Part 1 GL 2009
Table of Contents
Chapter 1 Page 3
Table of Contents
Section 1 A. B. C. D. E. F. G. H.
Principles Covering the Manufacture and Testing of Materials Scope .......................................................................................................................................... Other Relevant Specifications and Documents .......................................................................... Requirements Applied to Manufacturing Works ........................................................................ General Requirements Relating to the Manufacture and Properties of Materials ....................... General Test Conditions ............................................................................................................. Identification and Marking of Products ...................................................................................... Test Documents .......................................................................................................................... Certificates ................................................................................................................................. 111111111 1 1 2 3 4 4 5
Mechanical and Technological Tests Scope .......................................................................................................................................... Testing Machines and Personnel ................................................................................................ Sampling and Specimen Preparation .......................................................................................... Tensile Tests .............................................................................................................................. Notched Bar Impact Tests .......................................................................................................... Technological Tests on Pipes ..................................................................................................... Instructions for the Bend Test, Hardness Test and Drop Weight Test ....................................... Retests ........................................................................................................................................ 2- 1 2- 1 2- 1 2- 2 2- 5 2- 7 2- 9 2- 10
Section 3 A. B. C. D. E. F. G. H. I. J. K. L.
Non-Destructive Testings General Items ............................................................................................................................. Standards and Regulations ......................................................................................................... Requirements Applicable to the Inspection Body ...................................................................... Inspection Personnel, Supervisors .............................................................................................. Test Methods, Equipment and Test Media ................................................................................. Preparation and Performance of Tests ........................................................................................ Certification of Test Results ....................................................................................................... Visual Testing (VT) ................................................................................................................... Magnetic Particle Testing (MT) ................................................................................................. Penetrant Testing ........................................................................................................................ Ultrasonic Testing (UT) ............................................................................................................. Radiographic Testing ................................................................................................................. 3333333333331 1 1 1 1 2 2 2 3 4 5 7
II - Part 1 GL 2009
Section 1
Principles Covering the Manufacture and Testing of Materials
Chapter 1 Page 11
Section 1 Principles Covering the Manufacture and Testing of Materials

A. Scope 3. Subject to the conditions mentioned in 2., GL may sanction the supply of products conforming exclusively to the relevant standard or material specifications. 4. Should differences exist between these Rules and the relevant standards or specifications with regard to their requirements, the tests shall take account of the more stringent requirements.
1. The Rules for Materials apply to materials and products which are intended for the construction, repair and equipping of ships, offshore installations and other structures which are classified by Germanischer Lloyd (GL) or whose classification has been applied for. 2. The scope of these Rules includes all those materials and products whose use is referred to in the Rules for Construction. GL reserve the right to extend the scope of these Rules to materials and products not specifically mentioned in the Rules for Construction. 3. Where there are special grounds for so doing, GL reserve the right to impose more comprehensive requirements with respect to the manufacture, properties and testing of materials and products, where these appear necessary in the light of more recent research or operational experience, and GL likewise reserve the right to sanction departures from the Rules, where these are technically justified. 4. This Section contains principles governing metallic materials and the forms in which these are produced, e.g. plate, strip, sections, rod, pipes, forgings and castings, as well as propellers and anchoring and mooring components, which are to be applied in the course of manufacture and testing. These general principles are to be implemented in conjunction with the specific rules prescribed in the following Sections in reference to the particular products.
C.
Requirements Applied to Manufacturing Works
1. The materials and products covered by these Rules may only be manufactured in works approved by GL for this purpose. To be approved, works shall satisfy at least the following conditions, proof of which shall be furnished to GL during a factory inspection and by submission of relevant documents prior to the commencement of manufacture: 1.1 They shall be equipped with plant enabling the materials to be expertly manufactured and worked in accordance with modern technical practice. 1.2 They shall have the necessary testing equipment and the skilled staff required for its operation in order to perform expertly the tests specified in these Rules for Materials and in the relevant documents. Where, in exceptional cases, individual tests have to be carried out by outside bodies, such tasks shall be entrusted by the manufacturer only to those firms or institutes which also meet the aforementioned conditions and have been approved by GL. 1.3 The works shall, by their own quality control arrangements, ensure that the products are expertly manufactured and processed and that they meet the specified requirements. Testing carried out by GL shall not exonerate the manufacturer from this liability. Where internal quality control departments are established for the performance of these functions, this shall be independent of the management of the production and processing departments. 1.4 As part of their own internal quality control system, works shall keep a constant record of the manufacture and testing of materials and products. 1.5 Where called for in D., works shall demonstrate the properties of their products by preliminary testing of the procedure an/or the product suitability.
B.
Other Relevant Specifications and Documents
1. The properties of products not covered by requirements specified in these Rules are subject to the standards applicable to the product in question or, where appropriate, to the material specifications or conditions of supply which have to be complied with by the manufacturer of the material. 2. Materials or products to national or international standards or to special material specifications may be permitted by GL, if their properties are recognized by it as equivalent to those of the products specified in these Rules for Materials, or where GL has given special approval for their use. In these circumstances, the relevant standards or specifications are considered to be an integral part of these Rules.
Chapter 1 Page 12
Section 1
II - Part 1 GL 2009
2. Manufacturers shall apply in writing to GL for approval. Applications are required to contain the following information: Materials and products for which approval is sought, including the method of manufacture, guide values for the chemical composition, condition in which the materials and products are to be supplied, properties and dimensions. A list of the manufacturing plant and testing equipment used together with descriptions of the quality control system and details of the persons responsible for quality control. Where tests are performed by outside bodies, the addresses of these and their testing facilities are also to be stated. Such testing bodies are subject to GL approval. This condition is deemed satisfied if the testing body is accredited by an authorized institution.
decision of GL, this shall take the form of special procedure tests and/or the presentation of works documentation of tests performed or of expert assessments by independent testing bodies. 1.2 In the case of steel, the well proven techniques referred to in 1.1 include basic oxygen or electric furnace steel-making and continuous, ingot and mould casting. 2. Chemical composition and required properties
Materials and products shall satisfy the requirements relating to chemical composition and properties specified in these Rules for Materials or, where applicable, in the relevant documents. As a rule, the chemical composition is that of the melt. 3. Condition of supply and heat treatment
3. If the assessment by GL yields that the requirements of 1. and 2. are met, the manufacturer will be approved by GL. The approval normally remains valid for 3 years. The manufacturer receives a certificate of approval and will be included in the list of approved material manufacturers, which also contains the scope of approval and the area of validity. The validity may thereafter be extended for a further 3 years where it is demonstrated by repeat testing that the conditions under which the first approval was issued continue to be fulfilled. 4. During the validity period the following cases may give rise to a new decision regarding maintenance of the approval: damages during operation due to the quality of the product discrepancies of the product established between manufacture and assembly ascertained deficiencies in the quality system of the manufacturer changes regarding approval matters carried out by the manufacturer, which have not been agreed with GL indications for major discrepancies during testing of the products
3.1 Products are to be supplied in the prescribed heat-treated condition. Where the final heat treatment is to be performed by the steel user, the condition in which the material is supplied shall be clearly stated in the relevant certificates. 3.2 All heat treatments are to be carried out in suitable furnaces, which shall be efficiently maintained. The furnaces shall be provided with devices for controlling and indicating the temperature; these devices are to be checked at regular intervals. 3.3 If it is intended to apply other treatments in place of the prescribed heat treatments such as normalising or quenching and tempering, the manufacturer shall first prove to GL that, when these other processes are used, the mechanical properties of the products meet the requirements. 4. Freedom from defects
4.1 All materials and products shall be free from defects which have more than an insignificant adverse effect on their use or appropriate further working. Insignificant surface defects may be removed mechanically provided that the dimensional tolerances permitted for these products are not exceeded. 4.2 Defects in the material may be repaired by welding only where this is permitted by the specifications relating to the product in question, the Surveyor has given his consent and the welding technique has been approved by GL. 5. Weldability
D.
General Requirements Relating to the Manufacture and Properties of Materials Manufacture
1.
1.1 All materials shall be manufactured by sufficiently well proven techniques, which ensure that the required properties are achieved. Where new processes are to be employed, preliminary proof of their suitability is to be submitted to GL. According to the
Materials intended for the manufacture of welded structures shall be weldable by standard workshop techniques. Where welding is possible only in special conditions, these shall be determined in agreement with GL and shall be validated by a procedure test.
II - Part 1 GL 2009
Section 1
Chapter 1 Page 13
6.
Approval of materials and products
6.1 The manufacturer shall first prove that the properties of the materials and products made by him fulfil the stipulated requirements. As a rule, this calls for a test of suitability performed on selected products, the scope of which shall be decided by GL in each case. With the consent of GL, account may be taken for this purpose of the reports of other independent testing bodies. 6.2 In the case of standardized materials mentioned in these Rules which correspond to EN or DIN standards, to the iron and steel specifications of the VDEh (Association of German Metallurgists) or to national or international standards of equivalent standing, a test of product suitability may, with the consent of GL, be dispensed with. Materials for the loading and processing equipment of gas tankers, with the exception of austenitic steels, are excluded from this Rule. E. General Test Conditions
which are added in order to guarantee the required mechanical properties. The certificate of the manufacturer is generally recognized as proof of the chemical composition. Where doubts exist as to the composition, GL may also require the performance of product analyses. Possible deviations between the melt and product analyses shall conform to the relevant standards or specifications. 5. All products are to be checked by the manufacturer for compliance with the specified dimensions. They shall also be inspected by him for possible defects and shall, when this is called for, be presented to the Surveyor. For this purpose, the products shall normally be in the prescribed "as delivered" or heat-treated condition and shall have a clean surface, prepared for testing, which is free from coatings or other protective media which impair the detection of defects. Unless otherwise specified in the following Sections or specially agreed, the Surveyor shall perform a random test of the dimensions and surface finish as he sees fit. Products which do not meet the requirements shall be set aside by the manufacturer beforehand. 6. Where in exceptional cases testing cannot be carried out in accordance with the methods stated in these Rules for technical reasons, other equivalent test methods or techniques may, with the consent of GL, be applied. 7. Where products are manufactured in large runs by series-manufacturing techniques and/or using continuous processes with constant, monitored conditions, GL may entrust the manufacturer with the performance of some or all of the tests. This is inter alia subject to the condition that the manufacturer has established and maintains a quality assurance system, e.g. in accordance with ISO 9001, and furnishes proof thereof by a certificate bearing the certifier's mark of accreditation. Furthermore it is amongst others to be demonstrated that the requirements for the product have already been satisfied for several years. Approval of testing on the manufacturer's responsibility is to be applied for in writing to GL Head Office and can only be granted after close examination. 8. If there is reasonable doubt as to the quality of a product, the Surveyor may require additional tests to be performed. 9. GL gives no guarantee that products which have been subjected to testing to the prescribed extent, either individually or grouped together in test batches, fulfil in all respects the requirements contained in these Rules for Materials or in other relevant documents. Products which prove defective in the course of subsequent application or processing may be rejected despite satisfactory previous testing.
1. Acceptance tests shall normally be performed in the manufacturing works in the presence of the Surveyor. For this purpose, the manufacturer shall give the Surveyor access to the manufacturing and testing departments concerned and shall make available to him all the records relating to quality control, in so far as this is necessary for the proper discharge of his duties. The Surveyor is also entitled to witness the manufacturing process, although this shall not interfere with the manufacturing flow. 2. For the testing of mechanical and technological properties, use shall be made of the general methods and test specimens mentioned in Section 2. Test requirements and results shall be stated in SI units. Tests not referred to in Section 2 are to be carried out in accordance with national or international standards, unless otherwise agreed. 3. Where non-destructive tests are specified for the various product types, these shall be performed by the manufacturer and the results together with details of the test method are to be evaluated according to recognized criteria of acceptability and documented in a certificate. The Surveyor is entitled to be present at the tests. Where tests are to be performed by GL, special agreements shall be reached concerning these. 3.1 For acceptance tests according to the GL Rules only materials and products included in the scope of approval shall be submitted. 4. The chemical composition of materials shall normally be demonstrated by the manufacturer by melt analyses, and these shall cover all those elements for which limited values are prescribed in these Rules for Materials or in the other relevant documents, or
Chapter 1 Page 14
Section 1
II - Part 1 GL 2009
F. 1.
Identification and Marking of Products Retraceability
The manufacturer shall introduce a system which enables the product to be identified after every stage of the manufacturing process and be traced back to the heat. This system shall be demonstrated to the Surveyor if he so requests. 2. Marking
3.3 Plates, sections and rods of steel which are grouped into test batches for testing, are to be marked with the "batch stamp", provided that all the requirements have been satisfied:
This stamp may be applied by approved materials manufacturers and suppliers themselves. In exceptional cases, e.g. series-produced steel castings, the letters "GL" may be either cast or stamped in after agreement with GL. 3.4 Products which have to be tested in accordance with other specifications or supply conditions, i.e. which shall not be used within the scope of Classification, are to be marked, irrespective of the extent of the tests prescribed, with the "broad anchor stamp" in the presence of the Surveyor, provided that, when tested, the products have met the requirements stipulated in the specifications or supply conditions:
2.1 Prior to acceptance testing, products shall be provided by the manufacturer at least at one position with the necessary marking as described in the following Sections. The marking shall agree with the details given in the works certificates or delivery documents. 2.2 The marking shall normally be impressed with a punch, unless such marking is precluded by materials with a sensitive surface or which are too thin. In such cases marking may be done with low-stress stamps, paint, rubber stamps, adhesive stickers or electroengraving. 2.3 All marks shall be so applied that their legibility cannot be impaired by the transportation or storage of the products. Where the further processing of the products entails the removal of existing marks, the manufacturer concerned shall apply these to a different spot and shall arrange for the transfer of the GL stamp, unless another solution is adopted. 2.4 As a general rule, every product shall be marked. In the case of small parts of the same type and size which are securely packed in crates, drums or similar containers, and also in the case of steel rods and sections weighing up to 25 kg/m and packed together in bundles, marking of the uppermost unit is sufficient or by a securely fastened, strong tag. 2.5 Wherever possible, marks should be enclosed by a painted surface. In the case of forgings and castings, the area to be marked should be bright machined. 3. Use of the GL stamps
3.5 Should it be shown during subsequent tests or during further processing of the tested products that these have defects or in some way no longer meet the requirements, the GL stamping shall be cancelled in a suitable manner. 4. Stamping of specimens by the works
Manufacturers of materials who have an independent quality control department in accordance with C.1.3 may, with the consent of the GL inspection office, allow members of this department to apply the specimen stamp. The Surveyor shall be notified of the names of the persons authorized for stamping and of the marks identifying their personal stamps. In case of automated production facilities for specimen selection the stamping may be dispensed with, provided the responsible Inspection Office verified the continuous retraceability of specimen marking.
3.1 Specimens and the product from which specimens have been taken are to be marked with the "specimen stamp", unless otherwise agreed in accordance with 4.:
G.
Test Documents
For testing purposes, the manufacturer shall submit to the Surveyor documents referring to the materials or products to be tested. These documents shall contain at least the following information: name of purchaser together with order number newbuilding and project number respectively, where known item numbers and quantities dimension and indication of product material grade, type and specification application and drawing number, where necessary weight of products
3.2 Products for which individual tests of some kind, e.g. tests of mechanical properties and surface finish, internal pressure test and non-destructive testing, are specified are to be marked with the "anchor stamp", provided that all requirements of the GL Rules have been satisfied:
As an exception, shipbuilding steels of grades E and F which are subject to individual testing as well as the non-alloy pipes R 360, R 410 and R 490 may also be stamped in accordance with 3.3.
II - Part 1 GL 2009
Section 1
Chapter 1 Page 15
H.
Certificates
2.1
The type of required certificate is specified in the Rules. 1. Certificates of the manufacturer
Material certificate according to GL Rules (A-type Certificate)
Materials and products intended for use within the scope of Classification have to be delivered with a material certificate according to GL Rules, see A.2. To obtain this material certificate the GL Rules relevant for the material/product shall be satisfied. The manufacturer shall be approved by GL for the material/product. The GL Rules shall be named as test procedure. Normally, stamps are the "anchor stamp" as well as the "batch stamp" . Besides the information listed in G., the certificate shall also specify the following: manufacturing process heat number and chemical composition condition of supply details of heat treatment, where necessary test pressures, where necessary results of special tests to be undertaken, where necessary results of mechanical tests of the delivery at hand Material certificate according to other rules
Where, in accordance with the Rules or special agreements, the task of material testing is left to the manufacturer, the latter shall issue a relevant certificate. In case testing yields that the prescribed requirements are met, the result will be certified by the manufacturer. 1.1 Test report of the manufacturer (C-type Certificate)
Where, in accordance with the Rules or special agreements, a certificate of the manufacturer, independent of the material/product at hand, is required, the manufacturer shall issue a relevant test report (e.g. 2.2 according to EN 10204). The manufacturer shall be approved for the material/product. Besides the information listed in G., the test report shall also specify the following: 1.2 manufacturing process condition of supply details of heat treatment, where necessary marking results of non-specific material testing of current production Manufacturers inspection certificate (Btype Certificate)
2.2
Where, in accordance with the Rules or special arrangements, a certificate of the manufacturer for the material at hand and product respectively is required, the manufacturer shall issue a relevant inspection certificate (e.g. 3.1 according to EN 10204). Also in such cases the manufacturer shall be approved for the material/product. Besides the information listed in G., the inspection certificate shall also specify the following: 2. manufacturing process heat number and chemical composition condition of supply details of heat treatment, where necessary test pressures, where necessary results of special tests to be undertaken, where necessary results of mechanical tests of the delivery at hand GL Certificates
For materials and products which are not to be tested according to GL Rules but to other rules a material certificate may be issued. In this case GL will carry out an acceptance test on behalf of the orderer as neutral third party. The rules which are to be met for the acceptance test have to be named in the material certificate, whereat here the GL Rules shall not be named. If the test requirements are fulfilled a material certificate with the "broad anchor stamp" will be issued. Materials and products with this certificate shall not be used within the scope of Classification. 3. Alternative verification (A-type Certificate)
By agreement, the results may also be attested using the following alternatives: 3.1 Confirmation of the test results on a commonly issued certificate of manufacturer and GL (e.g. inspection certificate 3.2 according to EN 10204). 3.2 In the case of products produced in large quantities and subjected to testing by heat or batch, by confirmation of the Surveyor who appends his stamp and signature to the manufacturer's certificate in token that the tests carried out on the consignment in accordance with the Rules have satisfied the requirements. In addition, the manufacturer shall add by printing in the certificate an appropriate remark and shall also con
Where, in accordance with the Rules or special arrangements, material testing under survey of GL is required, a relevant GL Certificate will be issued. In case testing yields that the prescribed requirements are met, the result will be certified by the Surveyor.
Chapter 1 Page 16
Section 1
II - Part 1 GL 2009
firm that the products listed in the documents have been manufactured in accordance with GL Rules. 4. Issuing of test certificates by a material user or a merchant
These manufacturer's certificates shall be accompanied by a suitable means of identifying the product, so as to ensure that product and certificates can be clearly matched up. If the material user or the merchant has modified the condition or dimensions of the product in any way, these particular new properties shall be confirmed in an additional certificate. The same applies to special requirements in the order which are not shown in the manufacturer's certificates.
If a product is supplied by a material user or a merchant, he shall put the manufacturer's certificates 1 at the disposal of the purchaser without amendment.
1 See standard EN 10204
II - Part 1 GL 2009
Section 2
Mechanical and Technological Tests
Chapter 1 Page 21
Section 2 Mechanical and Technological Tests

A. Scope 3. For pendulum impact testing machines, the total friction with the full swing of the pendulum may not exceed 0,5 % of the available energy. On request, compliance with this value shall be demonstrated to the Surveyor before the machine is used. Pendulum impact testing machines shall be recalibrated at yearly intervals. The calibration of pendulum impact testing machines shall be performed in accordance with ISO 148-2 or another commonly accepted standard. 4. Hardness testing equipment shall be calibrated at yearly intervals. It is to be verified that the acceptable tolerances for the equipment parameters and the indicating accuracy are complied with in accordance with the appropriate standards. 5. Compliance with the above requirements may also be evidenced by the testing laboratory's certificate of accreditation, provided that the accreditation was granted by an accredited institution and the test methods in question are stated in the certificate of accreditation.
1. This Section contains general Rules for the mechanical and technological test methods for metallic materials and for the necessary test specimen shapes which are to be used for materials testing. 2. It is a fundamental requirement that all tests shall be performed in accordance with established national and/or international standards and in conformity with these Rules. 3. Departures from the prescribed test specimen shapes or from the conditions governing sampling and specimen preparation are permitted only in exceptional, technically justified cases where this enables the materials to be subjected to equivalent tests and where GL has given its consent to the change.
B.
Testing Machines and Personnel
1. All tests shall be performed by trained personnel using calibrated testing machines. The testing machines shall be maintained by the owners in a good working condition and shall be calibrated at regular intervals by a testing authority acknowledged by GL. The calibration records shall be kept available for inspection in the test laboratory. 2. Tensile testing machines are subject to the calibration periods and permitted indication errors shown in Table 2.1. Tensile testing machines shall be calibrated in accordance with ISO 7500-1 or another commonly accepted standard. Table 2.1 Indication errors and calibration periods for tensile testing machines
Test class (ISO 7500-1) 1 Permitted indication error, max. 1%
C. 1. 1.1
Sampling and Specimen Preparation Definitions Sample
"Sample" is the term applied to the product, e.g. the plate or pipe, which is selected from the unit test quantity for the purpose of taking specimens. 1.2 Unit test quantity/test batch
"Unit test quantity" or "test batch" is the term describing that portion of a consignment to which the result of the test refers. The term may be applied, for example, to a specific number of products of the same shape and dimensions originating from one melt, or to a length of rolled material (plate or strip) or to a single product (a large forging or casting). 1.3 Test section
Type of tensile testing machines Multi-purpose testing Testing machines for equipment components
Calibration period
1 year
3%
2 years
The term "test section" describes a section of material (e.g. a strip of plate) which is taken from the sample and which serves for the preparation of one or more test specimens.
Chapter 1 Page 22
Section 2
II - Part 1 GL 2009
1.4
Test specimen
"Test specimen" is the term applied to a piece taken from the test section which, in the machined or unmachined condition, has prescribed dimensions and is subjected to the test in question. 2. Marking of test sections and test specimens
The tolerances applicable to the specimen shall be in accordance with ISO 6892-98 or another standard accepted by GL. 5. Preparation of test specimens
2.1 Test sections and test specimens shall be representative of the sample; see 3.1. 2.2 Test sections and test specimens shall be so marked that, after their removal and preparation, it is still clear from which sample they were taken and how they were positioned and orientated in the sample. Where, during the preparation of test sections and test specimens, it is impossible to avoid erasing the original markings, these shall be previously reapplied in another position. 2.3 As a general rule, test sections and test specimens shall be marked by the Surveyor with the test stamp before they are removed from the sample unless some other arrangement has been made with the manufacturing works in accordance with Section 1, F.4. 3. Removal and dimensions of test sections
5.1 All test specimens shall be machined to the prescribed dimensions. Exceptions to this requirement are those test sections, e.g. those of small-diameter pipes and rods, which may be subjected to tensile testing in their entirety. 5.2 When removing test sections or test specimens, deformations and heating up of the material are to be avoided as far as possible. Where test sections or test specimens are removed by thermal cutting or shearing from the sample, a sufficient allowance shall be provided to be removed by machining. 5.3 Machining defects, e.g. notches, grooves and burrs, which occur during the preparation of test specimens and which may affect the test results are to be removed, and the execution of this operation shall respect the dimensional and geometrical tolerances applicable to the specimen shape concerned. 5.4 Where test sections have to be straightened before test specimens are taken, e.g. in the case of transverse specimens from pipes, the straightening operation shall normally be performed in the cold state and shall not significantly affect the mechanical properties of the material. If this is not possible, the test specimens shall be taken in such a way that straightening is unnecessary. Tensile specimens taken from the pipe wall in the longitudinal direction may not be pressed flat between the gauge marks.
3.1 Test sections are to be removed from the sample at specified positions. They shall be large enough to provide material for the test specimens prescribed for the performance of the tests together with the additional test specimens required for possible retests. 3.2 In general, test sections may be removed from the sample only after completion of all the mechanical and/or heat treatments to be applied to the product prior to delivery. In this context, heat treatments which cause no changes in the mechanical properties may be disregarded. 3.3 If, in exceptional cases, the test section cannot remain attached to the sample until the end of the manufacturing process, e.g. where products are machined to their final dimensions before annealing, then the test section shall undergo the same mechanical and/or heat treatments which are applied to the sample itself. Furthermore, the consent of the Surveyor shall be obtained in cases of premature removal of the test sections. 4. Removal and dimensions of test specimens
D. 1.
Tensile Tests Specimen shapes
The following notation is used to specify the dimensions of test specimens. 1.1 A Notation = elongation determined in tensile test for gauge length Lo for short proportional test specimens [%] = elongation required due to conversion for other gauge lengths [%] = diameter of round specimen [mm] = thickness of flat specimen [mm] = width of flat specimen [mm]
= =
The longitudinal axes of test specimens are to be orientated in relation to the main direction of deformation in the manner prescribed in the following sections. Notwithstanding this, the manufacturer may, in order to save test material and after agreement with the Surveyor, take transverse instead of longitudinal test specimens, provided that corresponding requirements are specified for transverse test specimens or the requirements applicable to longitudinal specimens can be satisfied by this means.
Ar do a b Lo Lc
initial gauge length [mm] test length [mm]
II - Part 1 GL 2009
Section 2
Chapter 1 Page 23
So Su r D t 1.2
initial cross-section within test length [mm2]
= smallest specimen cross section after fracture [mm2] = shoulder radius at end of specimen [mm] = outside diameter of pipe [mm] = thickness of product [mm] Dimensional tolerances
For hot-rolled rods and products of similar 1.3.3 shape, the specimen shapes prescribed in 1.3.2 are to be used. In the case of bars with a smaller section, suitable lengths may also be tested in their entirety, i.e. without machining the cross-section.
1.3.4 For plates, strips and sections, flat tensile specimens conforming to EN 10002, Part 1 or as shown in Figure 2.2 are to be used by preference. In these cases the rolled surface of the metal shall be preserved. Where, in testing heavy plate thicknesses, the tensile loading capacity of the machine is insufficient, the thickness of the specimens may be reduced by machining one side to not less than of the product thickness.
r a
The dimensional tolerances shall be those specified in the relevant standards, e.g. EN 10002, Part 1 or ISO 6892. 1.3 Dimensions
1.3.1 Use should preferably be made of short proportional test specimens with an initial gauge length of
Lo = 5,65
So
Lo Lc
or Lo = 5 do, respectively, as the requirements relating to elongation specified in the following sections refer to this gauge length. The test length Lo shall be preferably larger than 20 mm. The gauge length Lo may be rounded to the nearest 5 mm provided that the difference between this gauge length and Lo is less than 10 % of Lo.
1.3.2 For forgings and castings, with the exception of grey cast iron, cylindrical specimens conforming to EN 10002, Part 1 or as shown in Figure 2.1 are to be used.
Dimension
Specimen shape C proportional test specimen t 25 mm 5,65 So Lo + 2 S o 25 mm
a b Lo Lc r
b
Specimen shape D 200 mm specimen t 25 mm 200 mm 225 mm 25 mm
Specimen shape A should be preferred. If this is not possible, the alternative dimensions should be determined as specified for shape B with the specimen diameter do selected being between 10 and 20 mm.
r do
Fig. 2.2 Flat tensile specimens
Otherwise round tensile specimens conforming to Fig. 2.1 are to be used, for which the following is to be observed: In the case of products with a thickness of > 40 mm, round tensile specimens as prescribed in 1.3.2 may also be used. The specimens shall then be taken from the sample in such a way that their axis is located at 1/4 of the product thickness measured from one face or as close as possible to this position.
1.3.5 In the case of pipes, the tensile test may be performed on a sufficiently long section of the entire pipe. To enable the specimen to be secured in the test machine, mandrels have to be inserted into the pipe ends, cf. Figure 2.3, specimen shape E, or the pipe ends have to be pressed flat. Where the pipe diameter precludes testing a length of the entire pipe, tensile specimens of shape F are to be taken from the pipe wall.
Lo Lc Specimen shape A 14 mm round tensile specimen 14 mm 70 mm 85 mm 10 mm

1
Dimension
Specimen shape B alternative specimen --5 do Lo + do 10 mm

1
do Lo Lc r
1
In the case of nodular graphite cast iron and all materials with a minimium elongation A5 10 %, r = 20 mm (specimen shape A) or r = 1,5 do (specimen shape B).
Fig. 2.1 Round tensile specimens
Where the wall thickness of the pipe is sufficient, cylindrical specimens as prescribed in 1.3.2 may also be used. The specimens shall then be taken from the sample in such a way that their axis is located at the mid-point of the wall thickness.
Chapter 1 Page 24
Section 2
II - Part 1 GL 2009
Lo Lc Shape E r
b
1.3.7 Tensile specimens which have their axes vertical to the product face (Z-specimens) are to be prepared as described in Chapter 2 Steel and Iron Materials, Section 1, I.3. 1.3.8 Aluminium alloys
Mandrel
Lo Lc Shape F Specimen shape E (with entire pipe section) ----5,65 So Lo + D --1
For aluminium alloys with product thickness including 12,5 mm flat tensile specimens are to be used. The specimens shall be prepared in such a way that both rolled/pressed surfaces shall be preserved. For product thicknesses exceeding 12,5 mm round tensile specimens may be used. For product thicknesses up to and including 40 mm the longitudinal axis of the round tensile specimen shall be located at of the product thickness measured from face. For product thickness measured from on face. For product thicknesses exceeding 40 mm the longitudinal axis of the round tensile specimen shall be located at of the product thickness measured from one face.
1.3.9 Tensile specimens for wire ropes, single wires and strands are to be performed in accordance with Chapter 4 Equipment, Section 3, E. Specimens containing the entire section and the following dimensions are to be tested:
Dimension
Specimen shape F (Flat specimen from pipe wall) t 12 mm 5,65 So Lo + 2b 10 mm
a b Lo Lc r
1
Lo = 200 mm Lc = Lo + 50 mm
1.4 Tolerances
This value also applies to the minimum distance between the grips of the test machine.
Fig. 2.3 Tensile specimens for pipes
The manufacturing tolerances for specimens shall meet the requirements of ISO 6892-84 or other recognised standard.
2. Performance of tests
In the case of large pipe diameters, flat or cylindrical specimens perpendicular to the pipe axis may also be taken. To this end the test length may not be pressed flat, but the wider ends may be pressed flat to enable the specimen to be secured in the specimen device of the testing machine1.3.6 For grey cast iron, test specimens as shown in Figure 2.4 are to be used. These shall be taken from a separately cast cylindrical test bar with a casting diameter of 30 mm.
25
Tests shall be performed in accordance with established standards. This category includes, for example: EN 10002, Part 1 Tensile Testing
3. Determination of test results
Using the symbols and units of measurement stated below, the test results shall be determined as follows:
3.1 Yield strength ReH
~ 30 102
Generally, the upper yield point ReH [N/mm2] 1 has to be determined. This corresponds to the maximum stress preceding the initial drop in tensile load as the elongation increases. For determining the yield point at room temperature, the rate at which the stress is increased shall be not be less than 6 N/mm2 per
M 30
20
Fig. 2.4 Tensile specimen for grey cast iron
[N/mm2] = [MPa]
II - Part 1 GL 2009
Section 2
Chapter 1 Page 25
second and may not exceed 30 N/mm2 per second for steel. For non-ferrous metals the rate at which the stress is increased shall not be less than 2 N/mm2 per second and may not exceed 10N/mm2 per second. The test result shall be stated accurate to 1 N/mm2.
3.2 Proof stress Rp
3.5
Reduction in area Z
The reduction in area at fracture Z [%] shall be determined only where this is called for in the following sections of the Rules for Materials. Z
S Su = o 100 [ % ] So
In the case of materials without a marked yield point, the proof stress Rp [N/mm2] shall be determined. Generally, the 0,2 % proof stress Rp 0,2 shall be specified. For austenitic steels as well as austenitc-ferritic (= duplex) steels, the 1 % proof stress Rp 1,0 may be stated instead of, or in addition to, Rp 0,2. The rate of loading and the indication of the results shall be as stated in 3.1.
3.3 Tensile strength Rm
The test result shall be stated to an accuracy of 1 %.
E. 1.
Notched Bar Impact Tests General
In determining the tensile strength Rm the rate of elongation, once the yield point or proof stress has been passed, shall not with ductile materials exceed a maximum of 40 % per min.. With brittle materials, e.g. grey cast iron, the rate of stress increase may not exceed 2,5 N/mm2 per second. The test result shall be stated accurate to 1 N/mm2.
3.4 Elongation A
[N/mm2],
As specified for the product in question, 1.1 notched bar impact tests are to be performed either on Charpy V-notch specimens to ISO 148 (EN 10045 Part 1), or on Charpy U-notch specimens to ISO 83 (EN 10045 Part 1), see Figures 2.5 and 2.6.
1.2 Unless otherwise agreed, for products with a thickness of < 10 mm smaller dimension specimens with a specimen width of 7,5 or 5 mm are to be tested. In the case of products with thicknesses of < 6 mm, the notched bar impact test is generally not required.
It not otherwise stated, this relates to short proportional test specimens with Lo = 5,65 So and then is named as A [%]. For test specimens whose gauge length bears a different relationship to the crosssection of the test specimen, the required elongation Ar shall comply either with the minimum values specified for the products in question (e.g. for a gauge length Lo = 200 mm), or with the minimum value calculated by applying the following formula:
So = 2 A Lo
25
The longitudinal axis of the notch shall be made perpendicular to the surface of the product.
2. Dimensions of test specimens
Test specimens shall be machined to the dimensions shown in Figure 2.5 or 2.6 and those stated in Table 2.2. The data given in Table 2.2 should be regarded as being the permitted tolerances for the specimen dimensions.
55 10 r = 0,25
Ar
This conversion formula may only be used for ferritic steels with a strength of 700 N/mm2 which have not been cold formed, cf. also ISO 2566. The value for the elongation is valid if the distance of the fracture from the gauge marks is at least 1,25 times the diameter for round tensile specimens or at least the sum of the width and the thickness in the case of flat tensile specimens. The result of the test shall be stated to an accuracy of 0,5 %. If the elongation is not determined using short proportional test specimens, then the gauge length [mm] shall be stated in the test certificate, e. g. A200 mm = elongation for initial gauge length Lo = 200 mm.
10
45
Fig. 2.5 Charpy V-notch specimen
55
10 5
10
Fig. 2.6 Charpy U-notch specimen
Chapter 1 Page 26
Section 2
II - Part 1 GL 2009
Table 2.2
Permitted tolerances of specimen dimensions
Dimensions Length of specimen Thickness of specimen Width of specimen: Normal specimen Sub-size specimen Sub-size specimen Notch angle Thickness at base of notch Notch radius Distance of notch centre from ends of specimen 1 Angle between plane of symmetry of notch and longitudinal axis Angle between adjacent longitudinal faces
1
V-notch specimen Normal size 55 mm 10 mm Tolerance 0,60 mm 0,06 mm 0,11 mm 0,11 mm 0,06 mm 2 0,06 mm 0,025 mm 0,42 mm 2 2
U-notch specimen Normal size 55 mm 10 mm Tolerance 0,60 mm 0,11 mm 0,11 mm 0,09 mm 0,07 mm 0,42 mm 2 2
10 mm 7,5 mm 5 mm 45 8 mm 0,25 mm 27,5 mm
10 mm 5 mm 1 mm 27,5 mm
90
90
90
90
For pendulum impact testing machines which have automatic specimen positioning, a tolerance of 0,165 is recommended rather than 0,42.
3.
Test machine
Table 2.3
Characteristic quantities of test machine
Wherever possible, use shall be made of a pendulum impact testing machine with an impact energy of 450 J or 300 J (in any case not less than 150 J) and an impact velocity of 5 to 5,5 m/s. The test arrangement is shown in Figure 2.7, with the characteristic quantities of the test machine being given in Table 2.3.
Dimension Clear spacing between supports Radius of curvature of supports Undercut of supports Angle of peen wedge
Requirement
( 40 ) mm (1 ) mm
+ 0,2 0
+ 0,5 0
11 1 30 1
30 55 2 - 2,5 mm
Radius of curvature of peen cutter Maximum thickness of pendulum face Striking velocity of pendulum
( 2 ) mm
+ 0,5 0
18 mm 5 to 5,5 m/s 90 0,1

1
40
Angle between supports and bearing

value of 4,5 to 7 m/s may be agreed.
1 For pendulum impact test machines built before 1983 a
Fig. 2.7 Notched bar impact test
II - Part 1 GL 2009
Section 2
Chapter 1 Page 27
4.
Performance of test
Impact tests using U-notch specimens should 4.1 generally be performed at room temperature (23 5) C. Impact tests on V-notch specimens shall be performed at room temperature or at a lower test temperature, according to specification. With test temperatures below room temperature, the temperatures of the specimens are to be carefully checked. At the moment of fracture they may not vary from the prescribed test temperature by more than 2 C. If the specimens are cooled by placing them in a bath, they shall remain there for at least ten minutes.
4.2 A test is regarded as being performed under normal conditions when the working capacity of the pendulum impact test machine is (300 10) J and when a standard specimen is used. The following abbreviations are assigned to the notch impact energy value which is established under these conditions:
b
H
b/2
Fig. 2.8 Pipe flattening test
The dimensions of the pipe section, the distance H between the flattening plates as well as the position of the welding joint are to be stated. Examples of applicable standards: EN 10233 Pipe Flattening Test or ISO 8492
2. Ring expanding test

5.
KV for a V-notch specimen KU for a U-notch specimen

Determination of test results
Using the symbols shown below, the energy 5.1 absorbed by the impact shall be normally stated in joules (J), accurately rounded to 1 J. Where the test is conducted other than at room temperature, this shall also be stated.
5.2 If required, the crystalline proportion of the fracture surface and/or the lateral expansion at the point of fracture shall also be determined.
To perform this test, sections of pipe measur2.1 ing 10 to 16 mm in length L are expanded to the prescribed diameter C or until fracture occurs using a drift with a taper of about 1:5. Where necessary, more than one test shall be performed with drifts of increasing diameter. The superimposition of several specimens of the same size and steel grade is permitted, see Figure 2.9.
C Dmax Drift
The crystalline proportion of the fracture surface shall then be estimated and expressed as a percentage of the total area of the fracture. The lateral expansion shall be measured to an accuracy of 0,01 mm on the side opposite the notch (cf. also DIN 50115 and ASTM A 370).
K
Specimens
F. 1.
Technological Tests on Pipes Pipe flattening test

Dmin t D Dmax - Dmin K
L
To perform this test, a section of pipe equal 1.1 in length to 1,5 times the pipe diameter, but not less than 10 mm and not more than 100 mm, is flattened between two plates to the prescribed distance H, see Chapter 2 Steel and Iron Materials, Section 2, A.8.5 or until fracture occurs, see Figure 2.8. In the case of welded pipes, the specimen shall be placed in the press in such a manner that the seam is set at 90 to the direction of the pressure, unless agreed otherwise.
1.2 After the test, the specimens shall be thoroughly examined for defects with normal visual acuity. The test shall be satisfactory if the specimen, having been flattened to the prescribed distance, is free from cracks and did not fracture.
= 1:5
Fig. 2.9 Ring expanding test
The intrusion rate of the mandrel may not exceed 30 mm/s. C = Diameter after the the prescribed expansion
Chapter 1 Page 28
Section 2
II - Part 1 GL 2009
The dimensions of the pipe sections, the outer diameter C of the expanded part of the pipe section or the relative expansion [%], as well as the ratio of the taper (if not 1:5) are to be stated. Examples of standards to be applied: EN 10236 Ring Expanding Test on Pipes or ISO 8495
2.2 After the test, the specimens shall be thoroughly examined for defects with normal visual acuity, and the ductility of the pipes shall be assessed by reference to the expansion achieved and, where applicable, to the appearance of the fracture surface.
4.
Drift expanding test
4.1 To perform this test, a tapered drift is forced into the specimen until the outside diameter has increased to the prescribed value C for the product in question, see Figure 2.11. The length of the specimen and the taper angle of the drift shall be as shown in the following Table. The intrusion rate of the taper may not exceed 50 mm/s. 4.2 After the test, the specimens shall be thoroughly examined for defects with normal visual acuity. The test shall be satisfactory if the prescribed expansion has been effected without cracks.
C
The test shall be satisfactory if the specimen reveals no unacceptable defects such as scabs, laps, cracks, grooves or laminations and if the prescribed expansion has been reached.
3. Ring tensile test
b
L
3.1 The sections of pipe measuring about 15 mm in length shall have plane and smoothed ends and shall be at right angle to the pipe axis. To perform this test, the pipe sections are stretched in a tensile testing machine until fracture occurs using two pins with a diameter equal to at least three times the wall thickness of the pipe, see Figure 2.10. In the case of welded pipes, the specimen shall be placed in the tensile testing device in such a way that the welded seam lies at 90 to the direction of the tensile load.
Material Steel
Length of specimen L 2D 1,5 D; min. 50 mm 2D 2D min. 50 mm
Taper angle b 30 45, 60 or 120 45
The rate of the pins may not exceed 5 mm/s.

Pin
Copper and copper alloys Aluminium alloys
60
Specimen Weld, if existent
Fig. 2.11 Drift expanding test
= Diameter after the prescribed expansion
The dimensions of the pipe section, the outer diameter C of the expanded part of the pipe section or the relative expansion [%], as well as the taper angle are to be stated. Examples of standards to be applied:
Fig. 2.10 Ring tensile test
EN 10234 Drift Expanding Test on Pipes or ISO 8493

5. Flanging test
After the test, the specimens shall be thor3.2 oughly examined for defects with normal visual acuity. The test shall be satisfactory if the specimen reveals no unacceptable defects such as scabs, laps, cracks, grooves or laminations and if visible deformation has occurred at the point of fracture. The dimensions of the pipe sections are to be stated. Example of standards to be applied: EN 10237 Ring Tensile Test on Pipes or ISO 8496
To perform this test, a sample of pipe with a 5.1 length L = 1,5 D is worked into a flange in the device shown in Figure 2.12 until the outer diameter C of the flange attains the value prescribed for the product. The radius r shall match that prescribed for the product. The intrusion rate of the tool may not exceed 50 mm/min.
II - Part 1 GL 2009
Section 2
Chapter 1 Page 29
Pre-forming
nesses t exceeding 25 mm the thickness may be reduced by machining the compression side of the bend specimen to not less than 25 mm. For product widths smaller than or equal to 30 mm the specimen width b shall be equal to the product width. For product widths exceeding 30 mm the specimen width b = 30 50 mm. For forgings, castings and semi-finished products the specimen thickness shall be a = 20 mm and the specimen width b = 25 mm.
1.2 For butt-welded joints the bend specimens at right angle to the weld joint shall have the following dimensions for verification of the final pass and the root pass:
90
t D
Flanging
a = t b = 30 50 mm
For side bend specimens the following dimensions do apply:

r
a = 10 mm b = t
For t 40 mm the side bend specimen may be split, with the width of each part being at least 20 mm. For bend specimens with longitudinal direction to the joint the dimensions shall be in accordance with generally accepted standards.
D-2t-1 D-2t C
Before the test
Fig. 2.12 Flanging test 5.2 The test shall be satisfactory if the flange has no apparent cracks. Minor defects on the edges can be disregarded.
D/2
The dimensions of the pipe section, the outer diameter C of the expanded part of the pipe section or the relative expansion [%], as well as the edge radius of the forming tool r are to be stated. Examples of standards to be applied: EN 10235 Flanging Test on Pipes or ISO 8494
50
D+3a
50
After the test
G.
Instructions for the Bend Test, Hardness Test and Drop Weight Test Technological bend test
a
1.
For this test, specimens with thickness a and 1.1 width b are to be prepared, the edges of which may be rounded on the tension side to a radius of 1 2 mm. For plates and sections the specimen thickness a is equal to the product thickness t. For product thick-
Fig. 2.13 Technological bend test
Chapter 1 Page 210
Section 2
II - Part 1 GL 2009
1.3 To perform this test, the test specimen is bent in a continuous operation as shown in Figure 2.13 and using a mandrel of specified radius D/2 until the prescribed bending angle is reached or the initial incipient fracture occurs. For normal strength steels D/2 = 2 a, for higher strength steels D/2 = 3 a. The test shall be satisfactory if the prescribed bending angle is achieved without incipient fracture. If, when the specimen is unclamped, it springs back, the bending operation need not be repeated.
of the specimens in relation to the main direction of deformation of the product is optional, but shall be the same for the set of specimens. Where the testing is performed by heats, specimens shall be taken from the thickest product.
3.3 Specimens shall be tested at the specified test temperature. The test shall be considered satisfactory if neither of the two specimens is fractured or if incipient cracks starting from the weld bead terminate in the parent metal and do not extend to one or both edges.
Example of standard to be applied: ISO 7438

2.
Metallic materials - Bend Test
Where one or both specimens fail to satisfy the aforementioned conditions, a retest may be carried out in accordance with H.4.
3.4 Where drop weight tests are to be performed on products other than those specified in 3.1 or as part of approval tests, the scope of the test shall be specially agreed with GL.
Hardness tests
The tests are to be performed, according to 2.1 specification, to determine the Brinell, Vickers or Rockwell hardness using standardized methods, see for example: ISO 6506 ISO 6507 ISO 6508 Brinell Hardness Test Vickers Hardness Test Rockwell Hardness Test
H. 1.
Retests General
2.2 Hardness tests shall not be considered a substitute for the tensile test. Brinell hardness tests may, however, be permitted for the purpose of comparing mechanical properties provided that, of several products of the same shape, grade of material and heat treatment, at least one has been subjected to the tensile test. 3. Pellini drop weight test
If the test sections or specimens specified for a 1.1 test are not properly taken and prepared, the test results obtained with them shall be invalid. The tests shall then be repeated on properly prepared test specimens.
1.2 If, in a properly performed test, the requirements are not met, then, before the corresponding unit test quantities are rejected, retests may be carried out subject to the conditions stated below. Retests are not allowed if it is suspected that the wrong material is concerned. 1.3 If the unsatisfactory result of a test is due to obvious defects in the execution of the test or to a narrowly defined fault in the test specimen, the result shall be disregarded and the test in question shall be repeated on a test specimen of the same type which shall be taken from the same test section. This also applies to tensile specimens which, when tested, fracture outside the valid measuring length as defined in D.3.4. 1.4 If the unsatisfactory result of a test is attributable to improper heat treatment of the products, they may be resubjected to heat treatment. Subsequently the entire test shall be repeated, and the original test result shall be disregarded. 1.5 The manufacturer may also follow the procedure described in 1.4 in the case of those products which, according to the specifications, may be supplied without heat treatment but which have failed to meet the requirements in this condition. 1.6 If, under test, a large proportion of the products fails because of constantly recurring manufacturing defects, the entire delivery may be rejected.
3.1 This test shall be performed in accordance with Stahl-Eisen-Prfblatt 1325 (Iron and Steel Test Specification 1325), EN 10274, or ASTM-E208 on steels with product thicknesses of 16 mm. The specimen shape will be chosen which most closely matches the product thickness accordingly to Table 2.4. Table 2.4 Specimen dimensions for drop weight test Dimensions [mm]
Specimen shape
P1 P2 P3
360 90 25 130 50 19 130 50 16
The correct specimen thickness shall be achieved by machining one side. The long sides of the test specimens shall be made with a saw cut or, in the case of specimens obtained by thermal cutting, shall be machined with a machining allowance of at least 25 mm.
3.2 At least 2 test specimens shall be prepared from the sample. The position of the longitudinal axis
II - Part 1 GL 2009
Section 2
Chapter 1 Page 211
2. 2.1
Unsatisfactory tensile test specimens (excluding pipes) Individual tests
rejected. With the consent of the Surveyor, the remaining sample quantities in the unit test quantity may, however, be subjected to testing piece by piece.
4. 4.1 Unsatisfactory drop weight test specimens Individual tests
For each unsatisfactory tensile specimen, two substitute specimens shall be tested, which shall be taken from the same test section as the original specimen, or from the same sample. In every case, both specimens shall satisfy the requirements.
2.2 Testing by heats or batches
The manufacturer shall have the option of separating the sample which has yielded unsatisfactory results or of continuing to treat it as part of the unit test quantity. If the sample in question is separated, then, for each unsatisfactory tensile specimen, two substitute specimens shall be tested which shall be taken from different samples of the unit test quantity. If the sample in question continues to be treated as part of the unit test quantity, one of the retests shall be performed on this sample and the other on a different sample. Both retests shall satisfy the requirements.
3. 3.1 Unsatisfactory impact test specimens (excluding pipes) Individual tests
If one or both of the two test specimens fail(s), two similar substitute specimens may be taken from the same sample and tested. Both substitute specimens shall satisfy the requirements. If they fail to do so, the relevant sample shall be rejected.
4.2 Testing by heats
If one or both of the two test specimens to be taken from the thickest sample of the heat fail(s), then, from the same sample and from a different sample of the same thickness - or, if not available, from the next smaller thickness - two specimens of the same type each shall be taken and tested. All four specimens shall satisfy the requirements. If they fail to do so, then the relevant heat shall be rejected. With the consent of the Surveyor, the remaining sample quantities in the rejected heat may, however, be subjected to individual testing.
5. Unsatisfactory results in the testing of pipes Testing by batches
If the average value of 3 impact test specimens fails to satisfy the requirements or if a single value is less than 70 % of the stipulated average value, 3 substitute specimens shall be taken from the same test section and tested. The average value of the 6 individual tests shall then meet the requirements. However, of the 6 individual values only 2 may be below the required average value, of which only one individual value may be less than 70 % of the prescribed average value, failing which the sample in question shall be rejected.
3.2 Testing by heats or batches
5.1
If the average value of 3 impact test specimens fails to satisfy the requirements or if a single value is less than 70 % of the stipulated average value, then the procedure described in 3.1 shall be applied initially. If the retest also produces an unsatisfactory result, the sample tested shall be rejected and two further samples, of the same or the next smaller thickness, from the same unit test quantity shall be tested. If, again, one of the samples fails to satisfy the requirements, then the entire unit test quantity shall be
If, when subjected to the tensile test, the ring test or the notched bar impact test, pipes fail to satisfy the requirements, the test which has produced the unsatisfactory results shall be repeated on the same end of the pipe selected for the test. If the new test fails to satisfy the requirements, the pipe in question shall be discarded. In its place two further pipes shall be taken from the batch concerned and shall be subjected to the full range of tests. If, during testing, one of the requirements is not met, then the entire batch shall be deemed unacceptable. However, with the consent of the Surveyor, the characteristic which failed to meet the requirements may be checked on each individual pipe.
6. Retesting specified in standards
Where a national or international standard specifies a wider scope for the performance of repeat tests; this shall take precedence over the retests described in 5.1.
II - Part 1 GL 2009
Section 3
Non-Destructive Testings
Chapter 1 Page 31
Section 3 Non-Destructive Testings

A. General Items This external inspection body shall be accredited according to ISO/IEC 17025 or shall be part of a manufacturing site certified according to ISO 9001.
1. This Section contains general Rules applicable to the performance of non-destructive tests at semi-finished products and components intended for the installation in ships classed with GL. 2. Type and scope of the non-destructive testings prescribed for the individual products are stated in the appropriate sections.
D. 1.
Inspection Personnel, Supervisors Inspection personnel
B.
Standards and Regulations
1.1 The inspection personnel charged with the non-destructive testing shall be familiar with the test method concerned and shall be qualified and certified to EN 473. 1.2 For the evaluation of results of nondestructive tests only such inspection personnel shall be charged that holds level-2 certificates for the test method concerned which were issued: by an independent certification authority according to EN 473 or ISO 9712 by the employer of the inspection personnel according to ASNT "Recommended Practice No. SNT-TC-1A" Inspection supervisors
1. The standards and regulations indicated in the specific sections are integral part of these Rules and have to be observed when performing the nondestructive testing. 2. Testings according to other comparable standards or regulations require prior consent of GL. For this they shall be submitted to GL for assessment and approval before starting the testing. 3. The manufacturer or purchaser shall state all details of the testing in a testing instruction or specification and deliver it to the GL-Surveyor before starting the testing.
2.
C.
Requirements Applicable to the Inspection Body
For scheduling and monitoring the testings and for evaluating the results an inspection supervisor qualified at least according to 1.2 shall be available. The inspection supervisor shall hold as far as possible a level-3 certificate for the test method concerned according to the Rules indicated in 1.2.
1. For performing non-destructive testings the manufacturer shall set up a qualified inspection body which is independent of the manufacturing departments and part of a manufacturing site certified according to ISO 9001, or which is accredited according to ISO/IEC 17025. 2. The inspection body shall have available the necessary regulations, testing specifications, testing equipment, accessories and, if required, comparators for the surface finish of castings. 3. If the manufacturer has no inspection body available, he shall demonstrate which external inspection body will perform the testings on his behalf if necessary.
E. 1.
Test Methods, Equipment and Test Media Test methods
For detecting surface and/or volumetric discontinuities in the components indicated in A.1. the test methods from Table 3.1 or combinations of them shall be employed in dependence of the material, the geometry of the component, the expected service condition and the possible flaw position.
Chapter 1 Page 32
Section 3
II - Part 1 GL 2009
Table 3.1
Test methods Short name 1 VT MT ET PT UT RT LT
2.2 In case ultrasonic (UT) and or surface crack detecting (MT, PT) shall be performed by the GL Surveyor a special agreement is required. 2.3 The Surveyor shall be informed by the manufacturer of the works performing the further processing about the planned non-destructive testings in time. He will attend the testings in his discretion.
Testing of
Method Visual testing
external condition
Magnetic particle testing Eddy current testing Penetrant testing Ultrasonic testing
G.
Certification of Test Results
internal condition
1
Radiographic testing Leakage testing
Definition according to DIN EN 473.
1. Inspection reports shall be prepared on all performed tests, and these shall be submitted to the Surveyor together with the further documentation (e. g. NDT plans, film position plans, radiographs). The inspection reports shall contain all the necessary details according to I. to L. relating to the particular test method used, the position at which the test was performed and the results obtained. 2. The inspection department shall attest the test results by means of inspection certificate according to EN 10204-3.1.
2.
Equipment and test media
2.1 The equipment and test media used shall conform to the state of art and the relevant standards and shall be in perfect, serviceable condition. The Surveyor shall be presented by request proof of internal and/or external monitoring of the equipment and the test media. 2.2 If testing facilities, equipment and inspection personnel of external inspection bodies are engaged the workshop in question has to ensure that the conditions according to C. and D. are fulfilled.
H.
Visual Testing (VT)
1. The surfaces of the components that shall be subjected to testing shall be at least in the condition specified in F.1. or in the final machined condition. 2. Of the components that shall be tested the entire surfaces shall be visually tested. In doing so internal surfaces such as e.g. bore holes shall be included in the tests. 3. For performing visual testing optical magnifying devices, endoscopes or surface comparators shall be employed if necessary. Specifications concerning testing criteria are contained in the appropriate specific sections of Chapter 2 to 5. 4. The manufacturer or the company performing further processing shall arrange that testing can be performed with adequate illumination. The viewing conditions shall be in accordance with the requirements of ISO 3059 or EN 13018. Light and surface reflections shall be avoided by appropriate means.
F. 1.
Preparation and Performance of Tests Preparation of tests
The surfaces that will be tested shall be free of remnants of the moulding material, scale, grease, dirt, protective coatings and other contaminations which may affect the indication sensitivity of the specific test methods. 2. Performance of tests
2.1 As a rule the prescribed tests shall be performed by the inspection personnel of the inspection body of the manufacturer or of the external body charged with the inspection. The specific components that will be tested shall be subjected to the Surveyor in final machined condition for the visual testing.
II - Part 1 GL 2009
Section 3
Chapter 1 Page 33
I. 1.
Magnetic Particle Testing (MT) Magnetization equipment and method
3.2
Mechanized testing
1.1 The surfaces of the components that shall be subjected to testing shall be at least in the condition specified in F.1. or in the final machined condition. 1.2 The stationary or portable equipment for magnetic particle testing shall be in accordance with the state of art for testing and with the standards ISO 9934-1, ISO 9934-2 and ISO 9934-3 or with other standards which are equivalent to these standards. 1.3 The choice of the method of magnetization and of the current for magnetization depends on the geometry of the component and on the type of surface defect to be detected (cracks, inclusions that are lying open towards the surface or inclusions close towards the surface). 1.4 If possible, magnetization shall be effected by passing a current through the workpiece and/or by yoke magnetization using alternating or direct current. 1.5 Where a current is passed through the workpiece, alternating, direct, impulse or surge current may be used. A combination of the aforementioned methods for the detection of variously orientated defects is allowed. 2. Test media
When mechanized testing is performed the conditions stated in 3.1 shall be provided by an adequate choice or combination of magnetization currents and methods. 3.3 When burn marks on final machined surfaces have to be avoided then for the magnetization by means of prods with alternating current only fusible supply electrodes made of tin-aluminium alloys shall be employed. 3.4 Testing of machinery components in the final machined condition shall preferably be performed by stationary appliances. The appliances for magnetizing employed for this shall fulfil the requirements of ISO 9934-3 or another equivalent standard. On demand of the Surveyor the parameters of magnetization stated in 3.1 shall be proved by the manufacturer by means of measurement of the effective tangential field strength or by means of "Berthold" test blocks. 4. Applying of test media, magnetization
2.1 Suspensions consisting of a carrier liquid (test oils or water with inhibitors) and dispersed magnetic particles (black or fluorescent) shall be used as test media. Only such test media shall be used that conform to the requirements of ISO 9934-2. 2.2 Before magnetic particle testing is commenced the inspector shall verify the test media by means of suitable reference blocks according to ISO 9934-2 and shall prove this to the Surveyor by request. Note 3. 3.1 Reference blocks 1 and 2 according to ISO 9934-2 JIS-test block according to JIS Z 2343 Performance of magnetic particle testing Manual testing
The suspension containing the magnetic particles shall be applied on the surface to be tested by spraying or wetting. When doing so the magnetization shall last at least that long as the surface to be tested is sprayed with the magnetic particle suspension; subsequently magnetization shall be performed (at least 5 seconds) until no movement of the magnetic particle suspension can be detected. Testing when remanence is present (residual magnetism in the component) is not allowed. 5. Illumination of testing surfaces
In order to obtain an adequate contrast of test surface and indication the following requirements according to ISO 3059 for the light intensity and the UV intensity shall be fulfilled and shall be proved on the test surface with adequate and verified measuring devices, e.g. luxmeter or UV intensity meter. The UV intensity on the test surface shall be not less than 10 W/m2, the maximum ambient light intensity shall be 20 Lux. 6. Certification of testing results
The manufacturer or the inspection body charged by him shall issue a certificate concerning the performed magnetic particle test containing at least the following information: name and address of the inspection body (for external inspection bodies) details concerning the accreditation or the approval of the inspection body testing specification to be applied and/or testing instructions
In order to reveal variously orientated defects the magnetization shall be effected in a crosswise manner in two different directions. The angle of the both directions for magnetization should be in the range from 60 to 90. The magnetizing field strength (effective tangential field strength) should be at least 2 kA/m but should not exceed 6 kA/m.
Chapter 1 Page 34
Section 3
II - Part 1 GL 2009
details of the component such as: order no.
3.
Performing penetrant testing
material designation
heat no. specimen no. machining condition
3.1 Before testing is commenced the manufacturer or orderer shall submit to the Surveyor test instructions fulfilling at least the requirements listed in the following. 3.2 Pre cleaning of test surface
surface condition testing scope, inspection zones, severity levels type of magnetization, e.g. according to ISO 9934-3 test equipment, test media, test blocks proof of the magnetization by means of measurement of the effective tangential field strength declaration of the inspection zones and acceptance criteria time of testing evaluation of test results place and date of testing name of the inspector, the inspection supervisor and their qualifications
The surface to be tested shall correspond to the requirements specified in F.1. and shall be cleaned completely with a cleaner adequate for the testing agent system before testing is commenced. Specifications concerning the surface areas for which testing is required are contained in the appropriate specific sections of Chapter 2 to 5. 3.3 Testing temperature
As a rule the temperature of the surfaces to be tested shall be between + 5 C and + 50 C. For lower temperatures pre heating of the test area shall be performed on an extensive surface by which the test area achieves the permitted temperature range from + 5 C and + 50 C. 3.4 Applying the penetrant
The aforementioned details may also be certified by means of works instructions of the manufacturer. They above and the test certificate shall be submitted to the Surveyor together for assessment and acknowledgement. Specifications for the aforementioned acceptance and assessment criteria are contained in the appropriate specific sections of Chapter 2 to 5.
The penetrant may be applied by spraying, brushing or electrostatic spraying depending on the shape and size of the surface or of the geometry of the component to be tested. The test surface shall be completely wetted throughout the entire penetration time. 3.5 Penetration time
The penetration time depends on the properties of the penetrant, testing temperature, the material of the component to be tested and the type of discontinuities that are to be detected and should last from 5 to 60 minutes. 3.6 Intermediate cleaning
J.
Penetrant Testing Following penetration, the surplus penetrant shall be completely removed in an appropriate manner from the test surface in such a way as to leave behind the penetrant lodged in any defects present. 3.7 Developing process
1. Testing is to be performed with a testing agent system consisting of penetrant remover, penetrant and developer in accordance with EN 571-1 or other recognized standards. The employed equipment for this shall fulfil the criteria of ISO 3452-4. 2. Test media and their verification
2.1 The testing agent system required for penetrant testing shall fulfil the requirements of ISO 34524 or of another recognized standard. 2.2 Before penetrant testing is commenced the suitability of the testing agent system is to be verified by means of test blocks e.g. according to ISO 3452-4 and is to be proven on demand to the Surveyor.
The developer is to be applied evenly and as thinly as possible immediately after intermediate cleaning and drying. The test surface should just be completely covered. The developing time should be at least of the same as the time allowed for penetration. The evaluation of the indications shall not start before the developing time has expired.
II - Part 1 GL 2009
Section 3
Chapter 1 Page 35
4.
Illumination of the test surfaces
The test surfaces shall be illuminated adequately and reflection of light from already machined surfaces are to be avoided. Precondition for an adequate evaluation of the indications are the requirements for illumination specified in I.5. 5. Testing criteria, evaluation of indications
name of the inspector, the inspection supervisor and their qualifications
The aforementioned details may also be certified by means of works instructions of the manufacturer. They and the test certificate shall be submitted to the Surveyor together for assessment and acknowledgement.
Discontinuities exceeding the prescribed acceptance criteria by size and quantity as well as cracks of every type are not permitted. Specifications for the evaluation of indications are contained in the appropriate specific sections of Chapter 2 to 5. 6. Cleaning of the test surfaces
K. 1.
Ultrasonic Testing (UT) Methods
After completion of penetrant testing any residuals of the test media shall be removed of the test surfaces. For this a cleaning agent shall be used that corresponds to the prior employed testing agent system and which will not have any effect on the further processing of the component. 7. Certification of test results
1.1 Ultrasonic testing is to be performed with the impulse echo technique in accordance with recognized standards. Such are e.g. EN 12223, EN 27963, EN 12668-3, EN 583-1, EN 10228-3, EN 10160 and EN 12680-1. Other national or international standards may be applied if they provide an equivalent method. 1.2 The methods described here relate to the testing of components and machinery constructions made of ferritic steels. For testing of components made of austenitic or austenitic-ferritic steels special agreements are to be made. 1.3 Alternatively ultrasonic testing may be performed according to the test instructions of the manufacturer or of the orderer on condition that an equivalent test can be achieved. 2. Test specification
The manufacturer or the inspection body charged by him shall issue a certificate concerning the performed penetrant test containing at least the following information: name and address of the inspection body (for external inspection bodies) details concerning the accreditation or the approval of the inspection body testing specification to be applied and/or testing instructions details of the component such as: order no. material designation heat no. specimen no. machining condition
2.1 The manufacturer or the orderer shall prepare a test specification which shall contain at least the following information: state of machining for pre and final testing test method, type of test equipment, type of probes, testing frequencies calibration of equipment surface condition depending on the manufacturing stage, surface roughness (if necessary) position of incidences, if necessary explained by means of sketches heat treatment condition depending on the manufacturing stage determination of testing areas in accordance with the requirements specified in Chapter 2 Steel and Iron Materials, Section 3 or 4 evaluation criteria for the specific testing areas and severity levels, respectively indication of other applicable standards and regulations
surface condition testing scope, testing areas, severity levels employed testing agent systems according to EN 571-1, test blocks according to ISO 3452-3 declaration of the inspection zones and acceptance criteria time of testing evaluation of test results place and date of testing
Chapter 1 Page 36
Section 3
II - Part 1 GL 2009
3.
Test appliances and accessories
6.
Performing ultrasonic testing
Ultrasonic testing appliances and probes shall comply with the state of the art and with recognized standards 1 and shall fulfil at least the following requirements: 3.1 Requirements for the test equipment The ranges of adjustment shall enable the range of at least 20 mm up to 2 m without any intervening gap for longitudinal and transverse waves in steel. The amplification shall be adjustable for a range up to at least 80 dB with switching stages of 2 dB, the accuracy shall be 1 dB. The linearity of the time sweep and the vertical linearity shall be better than 5 % of the adjustment range or of the screen. The test equipment shall be applicable for probes from 1 to 6 MHz nominal frequency for impulse echo technique with straight or SE (twin transducer) probes. Requirements for the probes
Ultrasonic testing of machinery parts is to be performed in accordance with the method, standards and regulations specified in 1.1 and/or according to specifications of the manufacturer or the orderer. 6.1 6.1.1 Calibration of the inspection system Calibration of the distance
The calibration of the distance is to be performed at the calibration block type 1 in accordance with EN 12223 or at the component. The inspection range shall be selected in such a way that the back wall echo of the component thickness to be tested will appear at 80 % of the screen width. 6.1.2 Calibration of sensitivity
Calibration of sensitivity shall be adjusted in such a way that indications to be registered are not smaller than 2/5 of the screen height at the end of the inspection range. The signal-to-noise ratio based on the registration level shall be at least 6 dB. Deviations of these specifications may be agreed on by the orderer and/or manufacturer and GL in technically justified exceptional cases. 6.2 Scanning of the test area and testing velocity Scanning of the test area
3.2
3.2.1 The selection of the probes concerning the nominal frequency and the transducer size depends on the size of the disc-shaped reflector to be detected, the sound path travel distance and the sound attenuation of the material to be tested. 3.2.2 Depending on the geometry of the component and the type and position of discontinuity to be detected straight beam probes and/or angle probes are to be employed; for testing of regions close to the surface SE straight beam probes shall be employed. 3.2.3 For oblique scanning probes with angle of incidence between 35 and 70 shall be employed. Their nominal frequency shall be between 1 and 6 MHz. 4. Calibration blocks
6.2.1
In case scanning of test surfaces without any intervening gap is required, e.g. in case of 100 % volumetric inspection, the test paths shall overlay each other with at least 15 %. 6.2.2 Testing velocity
For verification of the inspection system calibration blocks type 1 according to DIN EN 12223 and calibration blocks type 2 according to DIN EN 27963 or other adequate calibration blocks with reference reflectors are to be used. 5. Coupling media
If ultrasonic testing is performed manually then with regard to optimal localisation of the indications the testing velocity shall not exceed 100 mm/s. 7. 7.1 Evaluation of indications Indications without extension
For inspection the oils, greases or other adequate coupling media recommended by the manufacturer of the equipment shall be used preferably. For calibration of the equipment the same coupling medium shall be used.
1 Recognized standards are e.g. EN 12668-1, EN 12668-2 and EN 12668-3.
The evaluation of indications without extension is to be performed according to the AVG-method (=DGS method = distance gain size method). In doing so the reference reflector size shall be specified as diameter of the equivalent disc shaped reflector (KSR) [mm]. 7.2 Indication with extension
If not otherwise agreed, the determination of the reflector extension shall be performed according to the half-amplitude technique.
II - Part 1 GL 2009
Section 3
Chapter 1 Page 37
Specifications concerning the afore mentioned evaluation and acceptance criteria are contained in Section 3, G. and Section 4, G. of Chapter 2 Steel and Iron Materials. 8. Certification of test results
Radiographic testing can be performed depending on the type of the component to be inspected, its material grade and wall thickness, either with x-rays or gamma rays. 1.2 As a rule radiographic testing is to be performed in accordance with recognized standards such as EN 444, EN 1435 for the radiographic examination of welded joints or EN 12681 for the testing of cast components. 2. Scope of validity
The manufacturer or the inspection body charged by him shall compile a report concerning the test which shall contain at least the following information: name and address of the inspection body (for external inspection bodies) details concerning the accreditation or the approval of the inspection body testing standards to be applied and/or testing specifications details of the component such as: material dimensions component no. heat no. drawing no. condition of supply
The following specifications apply for radiographic testing of components indicated in Chapter 2 Steel and Iron Materials, Section 4. 3. Performing radiographic testing
As a rule radiographic testing is to be performed in accordance with EN 12681, test category A. Thereby the image quality category A according to EN 462-3 shall be fulfilled. Testing in accordance with other national or international standards may be agreed on with GL on condition that the conditions of the standards indicated in 1.2 will be fulfilled. 4. Testing specification
time of testing, testing scope, inspection zones, severity levels the manufacturer and type of the employed testing equipment manufacturer, type, nominal frequency and angle of incidence of the employed probes type of calibration of distance and sensitivity specifications concerning the suitability for ultrasonic testing, surface preparation, correction, values (transfer correction and sound attenuation) coupling media description of the position of reflectors to be recorded by means of sketches, the size of KSR, its extension in length, width and depth as well as the back-wall echo attenuation place and date of testing name of the inspector, the inspection supervisor and their qualifications
4.1 The orderer or the manufacturer shall prepare a testing specification which shall contain the test method and all relevant details. Especially the following information shall be specified: radiation source, focal spot size or dimensions of the employed gamma-ray source radiation energy film system class and screens test category thickness range to be penetrated type and position of the image quality indicator distances between the film and the focal point image quality, density test arrangement explained by means of sketches or drawings
4.2 For cast components where a large amount of radiographing is required the manufacturer shall prepare a film position plan. The specification as well as the film position plan shall be submitted to GL for evaluation. 5. Selection of radiation source
L. 1.
Radiographic Testing Method
1.1 If necessary radiographic testing is to be performed in addition to ultrasonic testing in case doubts exist concerning the evaluation of indications of ultrasonic testing.
The selection of the radiation source depends on the thickness of the tested component to be penetrated, the required test category and the selected radiographic arrangement according to EN 12681.
Chapter 1 Page 38
Section 3
II - Part 1 GL 2009
6.
Selection of film system and intensifying screens
9.
Evaluation of radiographs, evaluation criteria
6.1 The selection of the film class depends on the test category and the thickness to be penetrated. The selection of the intensifying screens depends on the maximum permissible tube voltage of the X-rays or the type of isotopes, see Table 3.2. In case intensifying screens are used close contact between film and screen has to be ensured. 6.2 For the selection of the film class EN 444 is to be observed. A comparison of comparable international standards for film system classes is contained in Table 3.3. 7. Film density
The inspection department shall submit to the Surveyor for evaluation all radiographs and evaluation reports prepared by the inspector. It is up to the Surveyor to evaluate all radiographs or only a specific number of them. The radiographs evaluated by him are to be stamped by him. The testing and acceptance criteria applicable for the evaluation of the radiographs are contained in Chapter 2 Steel and Iron Materials, Section 4, G.9. 10. Certification of the test results
7.1 The parameters for the exposure shall be selected in such a way that in the entire region to be evaluated the density S of the radiographs according to EN 444 is larger than S 2,0 for test category A and larger than S 2,3 for test category B. Reduction of the minimum required density to 1,5 for test category A or to 2,0 for test category B is only permitted on condition that an appropriate agreement between the orderer and the manufacturer is made and that the multiple film technique is employed. This agreement is to be submitted to GL. 7.2 The upper limit for density depends on the brightness of the film illuminator which is employed for the evaluation. 7.3 In order to depict different wall thickness regimes of cast components without loss of quality within the density limits specified in 7.1 on one screen, the procedures for multiple film technique as indicated in EN 12681 shall be employed. 7.4 For evaluation of radiographs the density shall be verified with a densitometer. 8. Verification of image quality
The manufacturer shall compile a report concerning the evaluation of the radiographs which shall contain at least the following information: name and address of the inspection body (for external inspection bodies) details concerning the accreditation or the approval of the inspection body details of the cast component such as: material heat no. pattern no. drawing no. condition of supply
number and name of the testing specification testing standards to be applied and regulations method of radiographing and test categories film position plans, method of marking type of radiation source: tube/isotope, size of focal spot or of the radiation source, respectively tube voltage and anode current or activity of the radiation source exposure time and distance between radiation source and film selected film systems, screens and filters type and position of image quality indicator film density place and date of testing name of the inspector, the inspection supervisor and their qualifications
8.1 The image quality is to be verified by means of image quality indicators such as e.g. wire indicators in accordance with EN 462-1. In case image quality indicators cannot be positioned conforming to standards, i.e. away from the film, the image quality value shall be verified at least once by means of comparative radiographs prepared under the corresponding conditions. 8.2 In general, for steel castings of test category A, the image quality class A and for test category B the image quality class B according to EN 462-3 shall be achieved.
II - Part 1 GL 2009
Section 3
Chapter 1 Page 39
Table 3.2
Film System classes and metal screens in accordance with EN 444 and EN 12681
Penetrated thickness w Film system class 1 class A class B Type and thickness of metal screens class A class B
Radiation source X-ray potentials 100 kV X-ray potentials > 100 kV to 150 kV X-ray potentials > 150 kV to 250 kV Yb 169 Tm 170 X-ray potentials > 250 kV to 500 kV Se-75 Ir 192
None, or front and rear lead screens up to max. 0,03 mm C3 C5 C4 Front and rear lead screens from 0,02 to 0,15 mm w < 5 mm w 5 mm w 50 mm w > 50 mm w > 5 mm C5 C5 w 100 mm C5 None, or front and rear lead screens up to max. 0,03 mm Front and rear lead screens from 0,02 to 0,15 mm Front lead screens from 0,02 to 0,2 mm Front lead screens from 0,1 to 0,2 mm 2 Rear lead screens from 0,02 to 0,2 mm Front and rear lead screens from 0,1 to 0,2 mm Front lead screens from 0,02 to 0,2 mm Front lead screens from 0,1 to 0,2 mm 2 Front and rear lead screens up to max. 0,15 mm
C3 C4 C4 C3 C4 C4 C4 C5 C3 C5 C4 C4 C5
Rear lead screens from 0,02 to 0,2 mm Co 60 X-ray equipment with energy from 1 MeV to 4 MeV X-ray equipment with energy from 4 MeV to 12 MeV C5 Front and rear screens of steel or copper from 0,25 to 0,7 mm 3 Front and rear screens of steel or copper from 0,25 to 0,7 mm 3 Front screens of steel, copper or tantalum up to max. 1 mm 4 Rear screens of steel or copper up to max. 1 mm and tantalum up to max. 0,5 mm 4 Front screens of tantalum up to max. 1 mm 5 C4 C5 No rear screens Front screens of tantalum up to max. 1 mm 5 Rear screens of tantalum up to max. 0,5 mm
w > 100 mm w 100 mm w > 100 mm w 100 mm 100 mm < w 300 mm w > 300 mm w 100 mm 100 mm < w 300 mm w > 300 mm C4 C5 C4 C5 C5
X-ray equipment with energy above 12 MeV
1 2 3 4 5
Film system classes of higher quality may be used, too. Film packaged by the manufacturer with front scrrens up to max. 0,03 mm may be used if in addition a 0,1 mm lead screen is placed between the component to be tested and the film For class A 0,1 to 0,5 mm lead screens may be used, too. For class A 0,5 to 1 mm lead screens may be used if agreed on by the contracting partners.. Tungsten screens may be used if agreed on.
Chapter 1 Page 310
Section 3
II - Part 1 GL 2009
Table 3.3
Comparison of international comparable recognized film system classes (examples)
Manufacturer / film type
ASTM 1
DIN 4
EN 4
ISO 2
RCC-M 5
BS 3
AGFA 6 Structurix Structurix Structurix Structurix Structurix Structurix Structurix D2 D3 D3 s.c. D4 D5 D7 D8 special 1 1 1 1 2 2 G1 G1 G1 G2 G2 G3 G4 Fuji 6 IX 25 IX 50 IX 80 IX 100 IX 150 1 special 1 1 2 G2 G1 G2 G2 G4 Kodak 6 DR M MX125 T200 AA400 CX B
1 2 3
C1 C2 C2 C3 C4 C5 C6
GI GI GI GI G II G III G III
1 1 2 3 34 4 5
A A A A A B B
C3 C1 C3 C4 C6
GI GI GI G II G III
3 1 3 34 45
A A A A B
special 1 1 1 2 3 W-B
G1 G1 G2 G2 G3 G4
C1 C2 C3 C4 C5 C6
GI GI GI G II G III G III G III
ASTM E 94-93 / ASTM E 94-84 A ISO 5579 BS 2600: type A: type B: French standard Equivalent film types from other manufacturers may also be considered, provided that appropriate proof has been furnished. high contrast - very fine grain high contrast - fine grain
4 5 6
classification according to DIN EN 584-1 in comparison to the replaced standard DIN 54117 T1
II
1

Metallic Materials
Steel and Iron Materials
Edition 2009
The following Rules come into force on April 1st, 2009 Alterations to the preceding Edition are marked by beams at the text margin. Germanischer Lloyd Aktiengesellschaft Head Office Vorsetzen 35, 20459 Hamburg, Germany Phone: +49 40 36149-0 Fax: +49 40 36149-200 headoffice@gl-group.com www.gl-group.com "General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys). Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd Aktiengesellschaft. Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg Printed by: Gebrder Braasch GmbH, Hamburg
II - Part 1 GL 2009
Table of Contents
Chapter 2 Page 3
Table of Contents
Section 1 A. B. C. D. E. F. G. H. I. J.
Steel Plates, Strips, Sections and Bars General Rules ............................................................................................................................. Normal and Higher Strength Hull Structural Steels ................................................................... Unalloyed Steels for Welded Structures ..................................................................................... High-Strength Steels for Welded Structures ............................................................................... Steels for Steam Boilers and Pressure Vessels .......................................................................... Steels for Cargo Tanks ............................................................................................................... Stainless Steels ........................................................................................................................... Clad Plates ................................................................................................................................. Steels with Through Thickness Properties ................................................................................. Steel-Aluminium Welding Joints ............................................................................................... 1- 1 1- 5 1- 16 1- 17 1- 21 1- 23 1- 28 1- 30 1- 32 1- 34
Section 2 A. B. C. D. E.
Steel Pipes General Rules ............................................................................................................................. Pipes for General Purpose .......................................................................................................... High-Temperature Steel Pipes .................................................................................................... Pipes Tough at Sub-Zero Temperatures ..................................................................................... Stainless Steel Pipes ................................................................................................................... 2- 1 2- 5 2- 7 2- 10 2- 14
Forgings General Rules ............................................................................................................................. Forgings for Machine Construction and Shipbuilding ................................................................ Forgings for Crankshafts ............................................................................................................ Forgings for Gears ...................................................................................................................... Forgings for Boilers, Pressure Vessels, Process Equipment and Pipelines ................................ Steel Forgings Tough at Sub-Zero Temperatures ....................................................................... Non-destructive Testing of Forged Components ........................................................................ List of Forged Components for which Non-destructive Tests are Required ............................... Classifying of Inspection Zones for Magnetic Particle Testing (MT) ........................................ Classifying of Inspection Zones for Ultrasonic Testing (UT) .................................................... 3- 1 3- 5 3- 6 3- 10 3- 13 3- 15 3- 17 3- 23 3- 24 3- 29
Cast Steel General Rules ............................................................................................................................. Steel Castings for Machine Construction and Shipbuilding ....................................................... Steel Castings for Crankshafts and Connecting Rods ................................................................. Steel Castings for Steam Boilers, Pressure Vessels and Pipelines ............................................. Steel Castings for Use at Low Temperatures ............................................................................. Stainless Steel Castings .............................................................................................................. Non-destructive Testing of Cast Steel Components ................................................................... List of Cast Steel Components for which Non-destructive Tests are Required .......................... Testing Instructions for Hull Structural Parts ............................................................................. Testing Instruction for Diesel Engine Parts ................................................................................ 4- 1 4- 5 4- 8 4- 8 4- 10 4- 13 4- 16 4- 28 4- 29 4- 37
Chapter 2 Page 4
II - Part 1 GL 2009
Section 5 A. B. C.
Cast Iron General Rules .............................................................................................................................. Nodular Cast Iron ....................................................................................................................... Grey Cast Iron ............................................................................................................................. 5- 1 5- 3 5- 8
Section 6 A. B. C.
Fittings and Pressed Parts, Bolts and Nuts Pressed Parts ............................................................................................................................... Pipe Fittings ................................................................................................................................ Bolts and Nuts ............................................................................................................................. 6- 1 6- 4 6- 6
II - Part 1 GL 2009
Section 1
Steel Plates, Strips, Sections and Bars
Chapter 2 Page 11
Section 1 Steel Plates, Strips, Sections and Bars

A. 1. General Rules Scope 4.2 If the material is suitable, products may also be supplied in normalising rolled (controlled rolled) or thermo-mechanically rolled condition (see 4.3), provided that the processes have been checked and approved by GL on the manufacturer's premises. 4.3 Definitions
1.1 General rules to be applied in the manufacture and testing of hot-rolled plates, strips, sections (including hollow sections), rods and bars are contained in A. 1.2 Hot-rolled round bars intended for the manufacture of shafts, tie rods and bolts are subject to Section 3, B. 1.3 Where stated in B. to J. of this Section, steels conforming to national or international standards may be used, provided that they satisfy the minimum requirements of these Rules. 2. Requirements to be met by manufacturers
The processes mentioned in 4.2 are defined as follows: 4.3.1 Normalising rolling
Normalising rolling (controlled rolling) is a rolling process involving final forming in a specific temperature range which results in a material condition equivalent to that achieved by normalising treatment; thus the desired values of the mechanical properties are preserved even after an additional normalising treatment. Products supplied in this condition are designated by the code NW. 4.3.2 Thermo-mechanical rolling
Manufacturers wishing to supply products in accordance with these Rules shall fulfil the requirements set out in Chapter 1 Principles and Test Procedures, Section 1, C., and shall demonstrate this to GL prior to commencing supplies. This applies also for manufacturers of semi-finished products such as ingots, slabs, blooms and billets. 3. Steelmaking process
3.1 The steels are to be manufactured by the basic oxygen process, the electric furnace process or by other methods approved by GL. On request, GL shall be informed of the steelmaking process used. 3.2 The steels may be cast in ingots (static casting) or continuously. Special casting processes require initial appraisal by GL. 4. Condition of supply and heat treatment
Thermo-mechanical rolling is a rolling process incorporating careful monitoring of both the rolling temperature and also the reduction per pass. The greater proportion of reductions per pass is generally carried out close to the upper transformation temperature Ar3 where rolling in the two-phase temperature range may be incorporated. Unlike normalising rolling, the properties produced by thermo-mechanical rolling cannot be reproduced by subsequent normalising or other heat treatments. Products supplied in this condition are designated by the code TM. Accelerated cooling following TM rolling may take place if this process has been approved by GL. The same applies to tempering treatments following TM rolling. Note on TM steels: Any subsequent, continuous heating above 580 C as well as significant long holding times at lower temperatures may impair the strength properties. The manufacturer shall be consulted where there is a requirement to use temperatures above 580 C. Flame straightening will generally be possible. To this effect flame straightening may be carried out by using flame lines/flame tracks on the surface up to 950 C. A flame straightening by short time local through thick-
4.1 All products are to be supplied in the heat treated conditions described in the following individual Sections, unless supply in the as-rolled condition is allowed. This may be the case if, for instance, the product is to undergo further hot forming.
Chapter 2 Page 12
Section 1
II - Part 1 GL 2009
ness heating (hot wedge shapted spots, hot spots) may be carried out by a heating up to 700 C. 5. General characteristics of products
Table 1.1
Permitted minus tolerances for the thickness of plates and wide flats
Permitted minus tolerances 1 [mm] for class A B 0,3 0,3 0,3 0,3 0,3 0,3 0,3 0,3 C 0 0 0 0 0 0 0 0
5.1 All products shall have a smooth rolled surface and shall be free from any defects liable to have more than an insignificantly adverse effect on their workability and intended use, e.g. laminations, cracks, blow holes, scabs and seams. 5.2 Unless otherwise stipulated by the purchaser or prescribed by GL, hot-rolled plates, wide flats and sections shall be subject to the delivery conditions stipulated in EN 10163. 5.3 Unless otherwise specified or agreed, surface defects may only be removed by grinding within the permitted tolerance on the minimum thickness. The depressions caused by grinding shall have a smooth transition to the surrounding surface of the product. 6. Dimensions, dimensional and geometrical tolerances
Nominal thickness [mm]
3 < 5 <
5 8
0,4 0,4 0,5 0,6 0,8 1,0 1,0 1,2
8 < 15 15 < 25 25 < 40 40 < 80 80 < 150
150 250
1 See also EN 10029.
6.1 Plates, strips and wide flats may be delivered with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products for cargo tanks in accordance with F. and clad plates in accordance with H. the permitted minus tolerance is to be agreed when the order is placed. 6.2 The thickness is to be measured at points located at least 25 mm from the edge of the product. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances. 6.3 Unless otherwise agreed in the order, the provisions regarding form tolerances according to EN 10029 apply. 6.4 For sections and bars, the dimensions and the dimensional and geometrical tolerances specified in the standards apply. 7. 7.1 General technical requirements Chemical composition
7.2
Weldability
Steels conforming to these Rules shall be weldable by established workshop methods. Where applicable, this includes the measures necessary to ensure the quality of the welds, e.g. preheating and/or post weld heat treatments. 7.3 Mechanical properties
The mechanical properties stated in these Rules shall be verified by means of tensile tests. 7.4 Notch impact energy
The notch impact energy specified for the individual steels shall be fulfilled by the average value of three specimens, one of which may produce a value below, though not less than 70 % of, the average value. 7.5 Other properties
Where special properties such as resistance to intercrystalline corrosion, resistance to brittle fracture or high-temperature strength are prescribed for certain groups of products, these shall be proved by appropriate tests, as necessary. 8. 8.1 General instructions for testing Testing of chemical composition
The limit values specified in these Rules for the chemical composition apply to the melt analysis. Minor positive or negative excesses beyond the limit values, established by analysis of the product, are acceptable provided that they do not impair the properties of the product and/or the tolerances specified in the other relevant standards are not exceeded.
The manufacturer shall determine the chemical composition of each melt and shall submit a corresponding certificate to the Surveyor. The chemical composition specified for the steel grade shall be shown in the certificate.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 13
In the event of any doubt as to the composition of the products, a product analysis shall be carried out at the request of the Surveyor.
1/4 1/4
8.2
1/2
Testing of mechanical properties and position of specimen
8.2.1 From each test batch, at least one tensile test specimen shall be taken and tested. A test batch shall comprise either the rolled length (the unit subjected to the heat treatment) or the number of items from the same heat specified in the following Sections. 8.2.2 In the case of plates and wide flats with a width of 600 mm, the tensile test specimens shall be taken transverse, in all other products parallel to the rolling direction. The necessary test sections shall be taken from the products at the following points (see Fig. 1.1): plates, wide flats and strip 600 mm wide: from halfway between the centre line and a longitudinal edge wide flats and strip < 600 mm wide: from a position lying 1/3 of the product width from a longitudinal edge sections: wherever possible, from a flange at a position corresponding to 1/3 of the flange width from the longitudinal edge of the flange. In the case of channels and joists, test sections may also be taken from the web at a distance corresponding to 1/4 of the web height from the centre line of the web bulb flats: from the web at a distance from the edge of the web corresponding to 1/3 of the height of the section bars: from a position lying at a distance of 1/6 of the diameter or the diagonal from the surface or the corner respectively
2/3 Angles
1/3
Plates, strip and wide flats 600 mm Wide 2/3 1/3
1/4
1/4
Channels and sections 1/6 1/3
2/3
1/3
Bulb flats
8.2.3 Test sections may normally be taken from products only after the final heat treatment. Where products have to undergo further hot working and testing of the properties in the final heat-treated condition is required, the test sections may be subjected to separate heat treatment. 8.3 Determination of 0,2 % proof stress at elevated temperatures
> 40
I - sections (joists)
2/3 1/3
1/3
1/4
1/4
2/3
1/3
2/3
For products intended for elevated temperature application on the basis of their high-temperature mechanical characteristics, the 0,2 % or 1 % proof stress shall be proved by a hot tensile test performed on at least one specimen from each heat. The test temperature shall be that specified in E. The test may be dispensed with in the case of steels conforming to recognized standards whose mechanical characteristics at high temperature are considered to be already proven.
Flats
Rounds
Fig. 1.1 Examples showing location of test sections 8.4 Notched bar impact tests
8.4.1 The tests shall be performed on Charpy Vnotch specimens with the notch perpendicular to the
> 40
Chapter 2 Page 14
Section 1
II - Part 1 GL 2009
surface of the product. Where the thickness of the product is 40 mm, the specimens shall be located close to the rolled surface. Where the product thickness is > 40 mm, the specimens shall be so located that their longitudinal axis lies 1/4 of the product thickness from the surface. Furthermore, the test specimens shall be taken at a sufficient distance from flame-cut or sheared edges. 8.4.2 With products < 10 mm thick, specimens of reduced size are to be prepared with thicknesses of 7,5 or 5 mm. Unless otherwise specified, e.g. in B.6.3 and F.9.3, the requirements in respect of the impact energy shall be converted proportionally to the specimen cross-section in question: For products < 6 mm thick the test is waived. 8.5 Testing of surface finish and dimensions
clearly identified by the manufacturer in at least one place with the following marks: steel grade manufacturer's mark heat number, manufacturing serial number specimen number (where necessary)
Plates and sections shall be marked with punches. Products with sensitive surfaces or with wall thicknesses of 10 mm may be marked by a different method, e.g. with a coloured impression or with a lowstress or a rubber stamp. Following agreement with the Surveyor, products may also be marked with code numbers, the meaning of which is explained in the covering certificate. 9.2 In the case of shapes and bars weighing 25 kg or less per metre which are bundled together, the marking specified in 9.1 may be applied on a tag. 9.3 Where individually tested rolled lengths (plates) are cut up into sections, each section shall be marked in a manner identifying its relationship to the original rolled length (plate). 10. Certificates
8.5.1 The surface finish and dimensions of all products shall be checked by the manufacturer. Any surface defects may be removed by grinding within the permitted tolerances, see 5. Any products which fail to meet the requirements in respect of surface finish and dimensional tolerances shall be rejected by the manufacturer. 8.5.2 Unless otherwise specified, all plates subject to individual testing shall be submitted to the Surveyor for final testing. The Surveyor may further require that products subject to batch testing be similarly submitted. 8.6 Ultrasonic tests
10.1 The Surveyor shall be given the test certificates or consignment lists for all the materials tested by him in at least three copies. The documents shall be issued separately for each grade or type of steel if necessary. The documents shall at least contain the following details: purchaser and order number where known, the newbuilding and project number respectively item number and quantities size and indication of products steel grade, type or brand name steel making process heat number chemical composition of the heat condition in which supplied if other than the asrolled condition product identifying marks specimen number, where applicable
The tests shall be performed in accordance with EN 10160 or another standard accepted by GL. The testing staff shall be adequately qualified for this task and the Surveyor shall be furnished with proof thereof if he so requests. The Surveyor shall be permitted to take part in the tests at his request. 8.7 Retesting in the event of specimen failure
Where specimens subjected to tensile or impact testing fail to meet the requirements or where, in the impact test, one value is less than 70 % of the required average value, the retesting procedures described in Chapter 1 Principles and Test Procedures, Section 2, H. may be applied before the unit test quantity is rejected. This also applies where specimens fail to meet the requirements in the testing of special characteristics such as shear strength, ductility as measured by the technological bend test applied to clad plates or reduction in area of through thickness tensile test specimens. 9. Marking of products
The certificate shall also state the results of the special tests carried out by the manufacturer, e.g. ultrasonic tests and tests of resistance to intercrystalline corrosion, together with details of the test method used. 10.2 Before the test certificates or consignment lists are countersigned by the Surveyor, the manufacturer shall confirm to the Surveyor in writing that the
9.1 With the exception of the products with small dimensions specified in 9.2, every item shall be
II - Part 1 GL 2009
Section 1
Chapter 2 Page 15
material was manufactured by an approved process and tested in accordance with GL Rules for Materials, and the requirements were satisfied. The name "Germanischer Lloyd" (GL) shall be mentioned in the test certificate. The following wording of the declaration is adequate for this purpose if it is stamped or printed on every test certificate and/or consignment list together with the manufacturer's name and is certified on the manufacturer's behalf by a works employee appointed by him. "We hereby declare that the material has been produced by an approved method and has satisfied Rules of GL for testing." 10.3 Where the steels are not produced and rolled by the same manufacturer, a certificate issued by the steelmaker specifying at least the heat numbers and the chemical compositions shall be handed to the Surveyor.
fatigue strength of a welded joint of higher strength steel may not be greater than that of a welded joint in normal strength steels. 2. Approval
2.1 All materials are to be manufactured at works which have been approved by GL for the grade of steel and the shape of the product which is being supplied. 2.2 The suitability of each grade for forming and welding is to be demonstrated during the initial approval tests at the steelworks. The type and extent of testing required is at the discretion of GL. 2.3 If the steel is not smelted in the mill where it was rolled, a certificate is to be given to the Surveyor in the rolling mill indicating the smelting process used, the name of the steel producer, the heat number and the smelt analysis (ladle analysis). The Surveyor shall be allowed access to the steel producing works. 3. Method of manufacture
B.
Normal and Higher Strength Hull Structural Steels Scope
1.
1.1 These requirements apply to weldable normal strength and higher strength hot-rolled plates, wide flats, sections and bars made of steel designed for shipbuilding use. 1.2 The requirements are primarily intended to apply to steel products with the following thicknesses: for plates and steel wide flats: all grades up to 150 mm thick for sections and steel bars: all grades up to 50 mm thick For greater thicknesses certain variations in the requirements may be allowed or required in particular cases after consideration of the technical circumstances involved. 1.3 Provision is made for four grades of normal strength steel based on the impact test requirements. For higher strength shipbuilding steels provision is made for three strength levels (315, 355 and 390 N/mm2) each subdivided into four grades based on the impact test temperature. 1.4 Steels differing in chemical composition, deoxidation practice, condition of supply and mechanical properties may be accepted, subject to the special approval of GL. Such steels are to be given a special designation. Note The attention of the users shall be drawn to the fact that when fatigue loading is present, the effective
3.1 The steel is to be manufactured by the basic oxygen process, in an electric furnace or by other processes specially approved by GL. 3.2 The deoxidation practice used for each grade is to comply with the appropriate requirements of Tables 1.2 and 1.3. 3.3 The definitions relating to the rolling process in question, such as normalising rolling or thermomechanical rolling, with or without subsequent accelerated cooling are stipulated in A.4.3. 4. Chemical Composition
4.1 The chemical composition of samples taken from each heat is to be determined by the manufacturer in an adequately equipped and competently staffed laboratory and is to comply with the appropriate requirements of Tables 1.2 and 1.3. For plates and wide flats more than 50 mm thick, slight variations in the prescribed chemical composition may be permitted by arrangement with GL. 4.2 The manufacturer's declared analysis will be accepted subject to occasional checks if required by the Surveyor. 4.3 The following special rules apply to TM rolled steels: 4.3.1 The carbon equivalent value Ceq shall be within the tolerances given in Table 1.4. 4.3.2 Rather than using the carbon equivalent value when assessing weldability, the Pcm-value (susceptibility to cold cracking) may also be calculated based
Chapter 2 Page 16
Section 1
II - Part 1 GL 2009
on the following formula:
6.
Mechanical properties
Pcm = C +
Si Mn Cu Ni + + + + 30 20 20 60 Cr Mo V + + + 5 B [% ] 20 15 10
In such cases, the Pcm value shall be agreed with GL.

5. Condition of supply
6.1 For tensile testing either the upper yield strength ReH or, where this is not stipulated, the 0,2 per cent proof stress Rp0,2 is to be determined and the material is considered to satisfy the requirements if one of these values meets or exceeds the prescribed minimum value for the yield strength Re. 6.2 The results obtained from tensile tests shall comply with the appropriate requirements of Tables 1.7 and 1.8.
The condition in which all products are supplied shall correspond to the data given in Tables 1.5 and/or 1.6.
Table 1.2
Chemical composition and deoxidation practice for normal strength steels
Grade
GLA For t 50 mm any method except 1 rimmed steel for t > 50 mm killed
GLB For t 50 mm any method except rimmed steel for t > 50 mm killed
GLD For t 25 mm killed, for t > 25 mm fully killed an fine grain treated
GLE
Deoxidation practice
Fully killed and fine grain treated
Chemical composition (%) (ladle analysis) 4, 7, 8 Cmax Mnmin Simax Pmax Smax Al (acid soluble) min
t = Material thickness
1 2 3 4 5 6
Carbon plus 1/6 of the manganese content is not to exceed 0,40 % 0,21 2 2,5 C 0,50 0,035 0,035 0,21 0,80 3 0,35 0,035 0,035 0,21 0,60 0,35 0,035 0,035 0,015 5, 6 0,18 0,70 0,35 0,035 0,035 0,015 6
Grade GLA sections up to a thickness of 12,5 mm may be accepted in rimmed steel subject to the special approval of GL. Max. 0,23 % for sections. When Grade GL-B steel is impact tested the minimum manganese content may be reduced to 0,60 % When any grade of steel is supplied in the thermo-mechanically rolled condition variations in the specified chemical composition may be allowed or required. For Grade GLD steel over 25 mm thick. For Grade GL-D steel over 25 mm thick and for Grade GL-E steel, the total aluminium content may be calculated in place of the acid soluble part. In such cases, the total aluminium content may not be less than 0,020 %. GL may also specify a maximum limit for aluminium. Other grain refining elements may also be permitted subject to approval. In the melt, the maximum values of the following elements may not be exceeded: Cu : 0,30 % Cr : 0,20 % Ni : 0,40 % Mo : 0,08 % Where the manufacturing process demands the addition of additional elements, their contents are to be indicated in the manufacturer's certificate.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 17
Table 1.3
Chemical composition and deoxidation practice for higher strength steels

GLA32, GLD32, GLE32 GLA36, GLD36, GLE36 GLA40, GLD40, GLE40 Killed and fine grain treated GLF32 GLF36 GLF40
Grade 1
Deoxidation practice Chemical composition (%) 5, 7 (ladle analysis) C max. Mn Si max. P max. S max. Al (acid soluble) min. Nb V Ti max. Cu max. Cr max. Ni max. Mo max. N max. Carbon equivalent value 6
1 2 3
0,18 0,90 1,60 2 0,50 0,035 0,035 0,015 3, 4 0,02 0,05 4 0,05 0,10 4 0,02 0,30 0,20 0,40 0,08
0,16 0,90 1,60 0,50 0,025 0,025 0,015 3, 4
total 0,12 max.
0,02 0,05 4 0,05 0,10 4 0,02 0,30 0,20 0,80 0,08
total 0,12 max.
0,009 (0,012 where Al is present)
The letter "H" may be added to the steel grade designation, e.g. GLAH 36 Up to a thickness of 12,5 mm the minimum manganese content may be reduced to 0,70 %. The total aluminium content may be calculated in place of the acid-soluble part. In such cases the total aluminium content may not be less than 0,020 %. The steel is to contain aluminium, niobium, vanadium or other suitable grain refining elements, either singly or in any combination. When used singly the steel is to contain the specified minimum content of the grain refining element. When used in combination, the specified minimum content of the refining element is not applicable. Where a higher strength steel is supplied in a thermo-mechanically rolled condition, variations in the chemical composition may be approved or required. When required, the carbon equivalent value is to be calculated from the ladle analysis using the following formula: = C + Mn 6 + Cr + Mo + V 5 + Ni + Cu 15
C eq
This formula is applicable only to steels which are basically of the carbon-manganese type and gives a general indication of the weldability of the steel.
7
When the manufacturing process demands the addition of other elements, their content is to be indicated in the manufacturer's certificate.
Chapter 2 Page 18
Section 1
II - Part 1 GL 2009
Table 1.4
Carbon equivalent values for TM rolled, higher strength shipbuilding steels up to a product thickness of 150 mm
Carbon equivalent value [%], max. 1 Steel grade Thickness of product t [mm] t 50 GLA 32, GLD 32, GLE 32, GLF 32 GLA 36, GLD 36, GLE 36, GLF 36 GLA 40, GLD 40, GLE 40, GLF 40
1
50 < t 150 0,38 0,40 0,42
0,36 0,38 0,40
It is up to the manufacturer and material user (yard) to agree lower values in special cases.
Table 1.5
Condition of supply for normal strength steels

Thickness of product t [mm] 50 50 < t 150 50 50 < t 150 35 35 < t 150 150 Condition of supply any normalised, normalising or TM-rolled 1 any normalised, normalising or TM rolled 1 any normalised, normalising or TM rolled 2 normalised, or TM rolled 2
Grade GLA
GLB
GLD GLE
Notes
1 2
Subject to the special approval of GL, plates in Grade GLA and GLB steel may also be supplied in the as-rolled condition, see 13.2. Subject to the special approval of GL, sections in Grade GL-D steel may be supplied in the as-rolled condition provided satisfactory results are consistently obtained from notch impact tests. Accordingly sections in Grade GLE steel may be supplied in the as rolled or normalising rolled condition. The frequency of impact tests is to be determined in accordance with 13.2.2 and 13.3.3 respectively.
Table 1.6
Grades
Condition of supply for higher strength steels

Grain refining elements used Nb or V Thickness range t [mm] 12,5 12,5 < t 150 20 Al alone or with Ti 20 < t 35 35 < t 150 12,5 Condition of supply any normalised, normalising or TM rolled 2 any any, but as-rolled subject to special approval of GL 1 normalised, normalising or TM rolled 2 any normalised, normalising or TM rolled normalised, TM rolled or quenched and tempered any normalised, normalising or TM rolled 2 any any, but as-rolled subject to special approval of GL 1 normalised, normalising or TM rolled 2
GLA 32 GLA 36
GLA 40
any
12,5 < t 50 50 < t 150 12,5 12,5 < t 150 20 20 < t 25 20 < t 150
Nb or V GLD 32 GLD 36 Al alone or with Ti
II - Part 1 GL 2009
Section 1
Chapter 2 Page 19
Table 1.6
Grades
Condition of supply for higher strength steels (continued)

Grain refining elements used any Thickness range t [mm] 50 50 < t 150 50 50 < t 150 150 150 Condition of supply normalised, normalising or TM rolled normalised, TM rolled or quenched and tempered normalised or TM rolled 2 normalised or TM rolled normalised, TM rolled or quenched and tempered normalised, TM rolled or quenched and tempered 3
GLD 40
GLE 32 GLE 36 GLE 40 GLF 32 GLF 36 GLF 40

1 2
any any any
The frequency of impact tests is to be in accordance with 13.2.2. Subject to the special approval of GL, sections in Grade GLA 32, GLA 36, GLD 32 and GLD 36 steels may be supplied in asrolled condition provided satisfactory results are consistently obtained from notch impact tests. Accordingly, sections in grade GLE 32 and GLE 36 steels may be supplied in as-rolled or normalising rolled condition. The frequency of notch impact tests is to be in accordance with 13.2.2 and 13.2.3 respectively. Subject to special approval of GL, sections in Grade GLF 32 and GLF 36 steels with thickness 50 may be supplied in as-rolled condition or normalising rolled condition. The frequency of notch impact tests is to be in accordance with 13.3.3.
Table 1.7
Mechanical properties for normal strength steels
Notched bar impact energy Grade Yield strength ReH Tensile strength Rm Elongation 1 A at Lo = 5,65 So [%] min. KV [J] min. t 50 [mm] [C] +20 235 GLD GLE
t = thickness of product [mm]
1
Test temp.
50 < t 70 [mm] 70 < t 150 [mm] long. 34 4 34 34 34 transv. 24 4 24 24 24 long. 41 4 41 41 41 transv. 27 4 27 27 27
[N/mm2] min. GLA GLB
[N/mm2]
long. 27 3 27 27
transv. 20 3 20 20
400520 2
0 22 20 40
Required elongation for flat tensile test specimens with gauge length Lo = 200 mm, width = 25 mm and a thickness equal to the product thickness: 5 14 >5 10 16 > 10 15 17 > 15 20 18 > 20 25 19 > 25 30 20 > 30 40 21 > 40 50 22
Thickness of product t [mm] Elongation A200 mm [%]

2
For Grade GLA sections the upper limit for the specified tensile strength range may be exceeded at the discretion of GL, irrespective of product thickness. Notch impact tests are generally not required for Grade GLB steels with thickness of 25 mm or less. For Grade GLA products with thickness in excess of 50 mm, notch impact tests are not required provided that the steel has been fine grain treated and normalised. TM rolled steels may also be supplied without notch impact testing provided that GL has waived the need.
3 4
Chapter 2 Page 110
Section 1
II - Part 1 GL 2009
Table 1.8
Mechanical properties for higher strength steels
Notched bar impact energy Grade Yield Tensile strength strength ReH Rm Elongation
1
A
at Lo = 5,65 So
Test temp.
t 50 [mm]
KV [J] min.
50 < t 70 [mm] 70 < t 150 [mm]
[N/mm2] min. GL-A32 GL-D32 GL-E32 GL-F32 GL-A36 GL-D36 GL-E36 GL-F36 GL-A40 GL-D40 GL-E40 GL-F40
[N/mm2]
[%] min.
[C] 0 20 40 60 0 20 40 60 0 20 40 60
long.
transv.
long.
transv.
long.
transv.
315
440570 2
22
31
22
38
26
46
31
355
490630 2
21
34
24
41
27
50
34
390
510660 2
20
41
27
46
31
55
37
t = thickness of product [mm]

1
Required elongation for flat tensile test specimens with gauge length Lo = 200 mm, width = 25 mm and a thickness equal to the product thickness:
Thickness of product t [mm] GL-A32, -D32, -E32, -F32 GL-A36, -D36, -E36, -F36 GL-A40, -D40, -E40, -F40
> 5 14 13 12
> 5 10 16 15 14
> 10 15 17 16 15
> 15 20 18 17 16
> 20 25 19 18 17
> 25 30 20 19 18
> 30 40 21 20 19
> 40 50 22 21 20
Elongation A200 mm [%]
For TM-rolled steels, the tensile strength may be up to 30 N/mm2 below the lower limit for this value without giving cause for complaint.
6.3 The minimum impact energy requirements relate to Charpy V-notch impact test specimens, which are taken in either the longitudinal or transverse directions. Generally only longitudinal test specimens need be prepared and tested. For special applications, if required by GL or the purchaser, transverse specimens are to be tested. The requirements in respect of the transverse test specimens shall be guaranteed by the manufacturer. The tabulated values are for standard specimens 10 mm 10 mm. For plate thicknesses lower than 10 mm, the requirement for performing a notch impact test may be waived with the approval of GL or subsize specimens with reduced requirements may be taken as follows:
Specimen dimensions 10 mm 7,5 mm: 5/6 of the tabulated value
Specimen dimensions 10 mm 5,0 mm: 2/3 of the tabulated value
6.4 The average notch impact energy value obtained from one set of three tests is to comply with the requirements given in Tables 1.7 or 1.8. One individual value only may be below the specified average value provided it is not less than 70 % of that value. 6.5 Notch impact tests are generally no longer required if the product is less than 6 mm thick.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 111
7. 7.1
Freedom from defects and repair of surface defects General characteristics
fects shall be proved by a suitable non-destructive method. 7.3.5 For every repair weld, the manufacturer shall prepare a report containing details of the size and location of the defects, the welding method used and any heat treatment applied, and shall hand this report to the Surveyor. 8. Dimensions, dimensional and geometrical tolerances
7.1.1 All products shall satisfy the requirements applicable to general characteristics set out in A.5.1. Unless otherwise agreed, the surface finish of the products shall be subject to standard EN 10163, specifications relating to the surface finish of hot-rolled steel products (plate, steel wide flat and sections), Class A, or equivalent national or international standard, however, grinding of defects may only be carried out within the limits given in 7.2. 7.1.2 Notwithstanding the provisions of A.5.3, surface defects may be removed not only by grinding but also by welding according to the principles stated below, provided that the defects in question are isolated, of locally limited extent and the sum of the defective areas covers not more than 2 % of the relevant face of the product. 7.2 Repairs by grinding
The provisions of A.6. are applicable. With regard to flat products (plates and steel wide flat) for shipbuilding use, Class B given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. This means that the permitted lower deviation for all product thicknesses is a uniform 0,3 mm. 9. Material identification
9.1 The manufacturer is required to set up an identification system for ingots, slabs and finished products so that the material can be traced back as far as smelting. 9.2 The Surveyor is to be allowed every facility in order to carry out this trace-back procedure as appropriate. 10. Testing and inspection
The manufacturer may, at his discretion, remove surface defects by grinding, provided that the depth of material ground away does not exceed 3 mm in relation to the nominal thickness of the product and provided also that at least 93 % of the nominal thickness remains. In addition, the depressions caused by the grinding shall have a smooth transition to the surrounding surface of the product. 7.3 Repairs by welding
Defects which cannot be removed by grinding may be repaired by chipping and/or grinding with subsequent welding, provided that the Surveyor has consented to the repair and that the following requirements are met. 7.3.1 After chipping or grinding the defect, the remaining thickness shall be equal to at least 80 % of the nominal thickness. The remaining thickness may be less than this limit value only in exceptional cases where the specific application of the product is not thereby impaired. 7.3.2 All welds shall be performed by trained welders using approved methods and electrodes with a controlled low hydrogen content. At least one layer of weld metal is to be welded in excess which shall thereafter be ground flush to the surface level. 7.3.3 Wherever possible, products which are to be supplied in the normalised condition shall be welded prior to the heat treatment. If welding is required after normalising an additional treatment may be requested. Products which are supplied thermo-mechanically treated or hot-rolled are to receive stress-relief heat treatment after welding, if appropriate further processing cannot be ensured. 7.3.4 The repaired items shall be submitted to the Surveyor for final inspection and freedom from de-
10.1 Test facilities The manufacturer is required to allow the Surveyor access to all works departments and to provide all the necessary facilities as may be required to establish the approved manufacturing process, the selection of test material, supervision of tests in accordance with the rules and also to establish the precision of the test equipment. 10.2 Test methods The prescribed tests and surveys shall be conducted at the place of manufacture prior to despatch of products. The test specimens and test methods shall comply with the information given in Chapter 1 Principles and Test Procedures, Section 2. Unless otherwise agreed with GL, the specimens shall be selected by the Surveyor, marked and tested in his presence. Tensile testing of specimens taken in the direction of thickness Where plates and steel wide flats with thicknesses ranging from 15 to 150 mm are ordered with requirements as to the direction of thickness, tensile test specimens shall be prepared and tested with their axis perpendicular to the surface of the product as described in I. 10.4 Non-destructive testing 10.3
10.4.1 Where plates and steel wide flats are ordered with an ultrasonic test certificate, the tests are to be executed in accordance with a standard approved by
Chapter 2 Page 112
Section 1
II - Part 1 GL 2009
GL, e.g. EN 10160. The quality class is to be stipulated when the order is placed. 10.4.2 The seams of welded hollow sections of hull structural steel are to be subjected to non-destructive testing over their entire length. 10.4.2.1 Electrical welded hollow sections The weld seam of hollow sections is to be examined according to one of the following European standards: EN 10246-3, acceptance category E4, except that the technique of rotating pipes or with rotating saddle coils is not permitted EN 10246-5, acceptance category F5, or EN 10246-8, acceptance category U5
11.2.4 The removal of test sections is subject to the rules laid down in A.8.2. 12. 12.1 Specimens for mechanical tests Tensile test samples
10.4.2.2 Submerged-arc welded hollow sections The weld seam of hollow sections is to be examined according to acceptance category U4 in accordance with EN 10246-10, image quality class R2. Butt welds serving to connect strip or plate lengths by spiral submerged-arc welding have to be examined over their entire length according to the same test procedure and shall satisfy the same acceptance criteria as the main weld seam. 10.5 Testing of surface finish and dimensions
The dimensions of the tensile test samples are to be selected from those given in Chapter 1 Principles and Test Procedures, Section 2, D. Full thickness flat tensile test specimens should generally be selected as the test thickness for plates, steel wide flats and sections. Round tensile test specimens may be used where the thickness of the product exceeds 40 mm or in the case of bars and similar products. By way of an alternative to these specimens, full section specimens of a suitable length may also be tested in the case of small bars and sections. 12.2 Impact test specimens
Inspections of surface finish and dimensional checks are the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility. 11. 11.1 Test material Definitions
Impact test specimens shall comply with the Charpy V specimen shape and be taken horizontally with the long side of the specimen 2 mm below the rolling surface. They shall be positioned so that their axes are either "longitudinal" or "transverse" to the main direction of rolling as shown in Tables 1.7 and 1.8. The notch shall be milled in the side of the specimen so that the latters axis is vertical to the surface of the product. The position of the notch may not be less than 25 mm from one flame-cut edge or one shear edge. Where the thickness of the product exceeds 40 mm, the impact test specimens shall be taken in such a way that the axis of the specimen is positioned at 1/4 of the product thickness. 13. 13.1 Number of test specimens Number of tensile tests
11.1.1 "Piece" denotes the rolled product which has been rolled directly from an ingot, billet or slab into a plate, section or bar. 11.1.2 "Batch" denotes a test batch, made up of products of the same kind and originating from the same heat, which has been submitted as a whole for testing. 11.2 Test section
For each batch presented, except where specially agreed by GL, one tensile test specimen is to be taken from one piece (max. weight 50 t from the same heat). Where the weight of finished material is greater than 50 tonnes, one extra test specimen is to be taken from a different piece from each 50 tonnes or fraction thereof. Provision shall be made for additional specimens for every variation of 10 mm in the thickness or diameter of products from the same heat. 13.2 Number of impact tests (except for Grades GLE, GLE 32, GLE 36,GLE 40, GLF 32, GLF 36 and GLF 40)
11.2.1 The material which has been combined in one batch (one test batch) for testing shall have the same shape e.g. plate, steel wide flat, section, originate from the same heat and be delivered in the same condition. 11.2.2 The test sections shall be representative of the material and may only be cut from the test piece following the final heat treatment - unless there are technical reasons why they should not be. 11.2.3 rately. Test sections may not be heat treated sepa-
13.2.1 Except where otherwise specially agreed by GL, for each batch presented (max. 50 t from the same heat), at least one set of three Charpy V-notch test specimens is to be made from one piece. Where the weight of finished material is greater than 50 tonnes, one extra set of three test specimens is to be made from a different piece from each 50 tonnes or fractions thereof.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 113
From plates of grades GLA 40 and GL-D 40 in quenched and tempered condition, one set of impacttests per heat treatment length is to be taken. Where plates, except for those in grade GLA steel, are supplied in thicknesses greater than 50 mm in the normalising rolled condition, the test batch from which specimens are taken is no greater than 25 tonnes or fractions thereof. 13.2.2 When, subject to the special approval of GL, material is supplied in the as rolled condition, the frequency of impact tests is to be increased to one set from each batch of 25 tonnes or fractions thereof. The same applies when plates of grade GL-A steel are supplied in thicknesses greater than 50 mm in the asrolled condition. In this case, one set of three impact test specimens shall be taken for each 50 tonnes or fractions thereof. 13.2.3 The piece selected for the preparation of the test specimens is to be the thickest in the batch. 13.2.4 The test batch quantity depending on supply condition and thickness of product is shown in Tables 1.9 and 1.10. 13.3 Number of impact tests for Grades GL-E, GLE 32, GLE 36, GLE 40, GLF 32, GLF 36 and GLF 40
15.
Branding
15.1 Every finished piece is to be clearly marked by the maker in at least one place with GL's brand and the following particulars: identification mark for the grade steel (e.g. GL A, GLA 36) Steels which have been specially approved by GL and which differ from these requirements (see 1.4) are to have the letter "S" after the above identification mark (e.g. GLA36 S, GLES) Material supplied in the thermo-mechanically controlled processed condition is to have the letters TM added after the identification mark (e.g. GLE 36 TM) name or initials to identify the steelworks heat or other number to identify the piece if required by the purchaser, his order number or other identification mark
13.3.1 For plates supplied in the normalised or TMrolled condition, one set of specimens is to be taken from each rolled length. In the case of quenched and tempered plates, one set of specimens is to be taken from each heat treatment length. 13.3.2 For sections one set of specimens is to be taken from each test unit of 25 tonnes or fractions thereof. 13.3.3 When, subject to the special approval of GL, sections other than those in grade GLE 40 and GLF 40, are supplied in the as rolled or normalising rolled condition, one set of test specimens is to be taken from each batch of 15 tonnes or fractions thereof. 13.3.4 The specimens taken as described in 13.3.1 or 13.3.3 above are to be taken from the thickest piece in each batch. 13.3.5 The test batch quantity depending on supply condition and thickness of product is shown in Tables 1.9 and 1.10. 14. Re-tests
15.2 The above particulars, but excluding the manufacturer's name or trade mark, where this is embossed on finished products, are to be encircled with paint or otherwise marked so as to be easily recognizable. 15.3 Where a number of low-weight products are securely combined in packages or bundles, it is sufficient, subject to approval by GL, to mark only the uppermost piece in the package or robust tag which is securely fastened to the bundle. 15.4 When a product already bears GL brand but has not satisfied the test conditions, said brand shall be unequivocally removed by the manufacturer. 16. Certificates
16.1 The manufacturer shall hand over to the Surveyor either works acceptance test certificates (e.g. in accordance with EN 10204-3.1) or despatch documents for the products accepted by him. Said documentation shall be in triplicate at least. Documentation is to be produced separately for each grade of steel and shall contain the following particulars: purchaser and order number where known, the newbuilding and project number respectively item numbers and quantities size and indication of products identification of rolling mill steel grade weight of products
14.1 Where the requirements are not satisfied in a tensile test, or where the average from three impact test samples fails to meet the conditions, or where an individual value from a notch impact test does not meet the requirements, re-tests are to be carried out as stipulated in Chapter 1 Principles and Test Procedures, Section 2, H. In this case, the conditions specified therein are to be satisfied.
Chapter 2 Page 114
Section 1
II - Part 1 GL 2009
heat number or product number and, where appropriate, specimen number chemical composition of the melt for the elements shown in Tables 1.2 and 1.3 delivery condition, where not supplied in the asrolled condition, e.g. normalised, normalising
rolled, thermo-mechanically rolled or quenched and tempered In the case of grade GLA steel sections up to 12,5 mm, details of whether it is rimmed steel marking of the products test results
Table 1.9
Required condition of supply and number of impact tests for normal strength steels
Grade Deoxidation Practice
Product shape
Condition of supply (Test Batches for Impact Tests) 1, 2 Thickness of product t [mm] 12.5 25 35 not applicable N (-) TM (50), TM (-) 3 NW (50), W* (50) not applicable A (-) A (-) A (50) A (50) A (50) A (50) N (50) TM (50) NW (25), W* (25) not applicable not applicable N (50) N (50) NW (50) TM (50) TM (50) NW (25) N (50) NW (50) TM (50) W* (25) not applicable 50 150
Rimmed
For t 50 mm GL-A Any method except rimmed For t > 50 mm killed For t 50 mm Any method except rimmed GL-B For t > 50 mm killed
Sections Plates Sections Plates Sections Plates, Sections Plates
A (-) A (-) A (-)
Killed
GL-D
Sections
A (50)
Fully killed and fine GL-E grain treated
Plates
N (each rolled length) TM (each rolled length) N (25) TM (25) W* (15), NW* (15) not applicable
Sections
Supply condition: A = any method N = normalised condition NW = normalising rolled condition TM = thermo-mechanically rolled condition W* = hot rolled condition subject to special approval of GL NW* = normalising rolled condition subject to special approval of GL Number of impact tests: One set of test specimens is to be taken from each test batch or parts there of, the weight of the test batch being stated in ( ). Sign (-) means that the impact test is omitted. Subject to special approval of GL, see Table 1.7 note 4.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 115
Table 1.10
Required condition of supply and number of impact tests for higher strength steels
Grain Refining Elements
Product shape
Condition of Supply (Batch for Impact Tests) 1, 2 Thickness of product t [mm] 12.5 20 25 35 50 150
Plates Nb or V Fully killed GL-A32 and fine GL-A36 grain treated Al only or with Ti Sections Fully killed and fine grain treated Plates, Sections Plates Sections Sections
A (50) A (50)
N (50) NW (50), TM (50) N (50) NW (50), TM (50) W* (25) W* (25) N (50), NW (50), TM (50) N (50) NW (50) TM (50) W* (25) N (50) NW (50) TM (50) N (50) NW (50), TM (50) N (50) NW (50), TM (50) W* (25)
W*(25)
N (50), NW (50), TM (50) not applicable not applicable N (50), NW (25), TM (50) not applicable N (50), TM (50) V (for each unit heat treated) N (50), NW (25), TM (50) not applicable not applicable
Plates
A (50)
A (50)
GL-A40
Any
A (50) A (50) A (50)
Nb or V
GL-D32 GL-D36
Fully killed and fine grain treated Al only or with Ti Fully killed and fine grain treated
Plates Sections Plates, Sections Plates
A (50) A (50) N (50) NW (50) TM (50)
N (50), NW (25), N (50), NW (50), TM (50) TM (50) N (50) NW (50), TM (50) W* (25) not applicable N (50), TM (50) V (for each unit heat treated)
GL-D40
Any
Fully killed GL-E32 and fine GL-E36 grain treated
Any Sections Plates Any Sections
Fully killed GL-E40 and fine grain treated
N (each rolled length) TM (each rolled length) N (25) TM (25) W* (15), NW* (15) N (each rolled length) TM (each rolled length) V (for each unit heat treated) N (25) TM (25) V (25)
not applicable
not applicable
Chapter 2 Page 116
Section 1
II - Part 1 GL 2009
Table 1.10
Required condition of supply and number of impact tests for higher strength steels (continued)
Grain Refining Elements
Product shape
Condition of Supply (Batch for Impact Tests) 1, 2 Thickness of product t (mm) 50 150
GL-F32 and fine GL-F36 grain treated
Fully killed
Plates Any Sections
N (each rolled length) TM (each rolled length) V (for each unit heat treated) N (25) TM (25) V (25) NW* (15) N (each rolled length) TM (each rolled length) V (for each unit heat treated) N (25) TM (25) V (25) not applicable
GL-F40
Plates Any Sections
not applicable
Supply condition: A = any N = normalised condition NW = normalising rolled condition TM = thermo-mechanically rolled condition V = quenched and tempered condition W* = hot rolled and tempered condition NW* = normalising rolled subject to special approval of GL Number of impact tests: One set of impact test specimens is to be taken from each test batch or parts there of, the weight of the test batch being stated in ( ). For grades GL-A 32 and GL-A 36 steels a relaxation in the number of impact tests may be permitted by special agreement with GL provided that satisfactory results are obtained from occasional check tests.
16.2 Before the acceptance test certificates or despatch documents are signed by the Surveyor, the manufacturer shall hand over written confirmation that the steel has been produced by an approved method has successfully passed the tests prescribed in the presence of the Surveyor or his representative appointed by GL. In this regard, the following text may be also accepted, either stamped or printed on the certificate or despatch documents, and shall be verified by one of the manufacturer's authorised agents: "We hereby declare that the material has been produced by an approved method and has satisfied the Rules of GL for testing".
which are to be used for welded structures, e.g. in machinery manufacture or in shipbuilding. 1.2 Rolled bars for the manufacture of shafts, shanks, studs, bolts and other rotating parts are governed by Section 3, B. 2. Suitable steels
The following steels may be used with the requirements laid down in the relevant standards: 2.1 Steels conforming to EN 10025, EN 10210 and EN 10219 grades as follows: S235: all grades
Note The grades S235 JR and S235 JR G1 according to EN 10025 : 1990 + A1 : 1993 are excluded from application.
C. 1.
Unalloyed Steels for Welded Structures Scope
1.1 These Rules apply to flat products, sections and bars made from unalloyed steels with minimum nominal yield strengths up to and including 355 N/mm2
S275: all grades S355: all grades
II - Part 1 GL 2009
Section 1
Chapter 2 Page 117
2.2 Weldable fine-grained structural steels conforming to EN 10025-3, in the grades: S275 N, S 275 NL, S355 N, S355 NL (normalised or normalising rolled) and conforming to EN 10025-4 in the grades: S275 M, S275 ML, S355 M, S355 ML (thermo-mechanically rolled)
5.1
Test of chemical composition
The manufacturer shall determine the chemical composition of each heat and shall issue a relevant certificate. 5.2 Tensile test
5.2.1 The mechanical properties shall be verified by tensile test. For the purpose of taking specimens, products of the same shape shall be formed according to heat and within the thickness ranges relevant to the yield strength into test batches of not more than 40 t. A tensile test specimen shall be taken from the thickest item in the test batch. In the case of plates and wide flats with a width of 600 mm, this shall be positioned transverse to the rolling direction. In other products, the test specimen may lie transverse or parallel to the rolling direction. 5.2.2 Where plates are to be tested individually, this shall be specially stipulated in the order. 5.3 Notched bar impact test
2.3 Other steels after their suitability has been determined by GL, provided that they satisfy the following minimum requirements: 2.3.1 The chemical composition [%] of the ladle analysis shall not exceed the following limit values:
C
0,22
Mn
1,70
Si
0,55
Cu
0,30
Cr
0,20
Ni
0,40
Mo
0,08
0,040 0,040
In addition, fine grain treated structural steels shall have an adequate content of grain refining elements, e.g. Al, Nb, V or Ti. 2.3.2 The elongation A5 shall be at least 20 % in tests with longitudinal specimens and 18 % in tests with transverse specimens. 2.3.3 For fine grain treated structural steels, an impact energy of not less than 27 J (average value) shall be achieved in tests with longitudinal Charpy Vnotch specimens at a testing temperature of 20 C, for products supplied in normalised, normalising rolled or thermo-mechanically rolled condition 0 C, 3. for products supplied in as rolled condition. Condition of supply and heat treatment
All products made of fine grain treated steels shall be subjected to notched bar impact tests performed with longitudinal Charpy V-notch specimens at the test temperatures specified in the standards or in 2.3.3. Where, in the case of plates, individual testing has not been agreed, a set of test specimens shall be taken from the thickest piece in the test batch in accordance with 5.2.1. Testing shall be performed for products with a thickness of 6 mm. 5.4 Testing of surface finish and dimensions
The surface finish and dimensions of all products shall be checked by the manufacturers. At the request of the Surveyor, the products shall then be submitted to him for final inspection.
Flat products made of fine grain treated structural steels are to be supplied in normalised, normalising rolled or thermo-mechanically rolled condition. For all other products, the data in the standards apply, unless otherwise specified in the order. 4. Dimensions, dimensional and geometrical tolerances
D.
High-Strength Steels for Welded Structures Scope
1.
A.6. applies, with the following addition: For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply to plates, strips and wide flats, unless otherwise specified in the purchase order. 5. Testing and scope of tests
1.1 These Rules apply to plates and wide flats up to 70 mm thick made of weldable high-strength quenched and tempered steels. The application of these Rules to products with larger thicknesses shall be specially agreed with Germanischer Lloyd (GL). The same applies if products other than plates and wide flats, e. g. sections and pipes, are to be supplied in accordance with these Rules. 1.2 Steels falling within the scope of these Rules are classed into 6 groups indicated by the nominal
The following tests shall be performed:
Chapter 2 Page 118
Section 1
II - Part 1 GL 2009
yield strengths 420, 460, 500, 550, 620 and 690 N/mm2. Each group is further subdivided into the grades A, D, E and F based on the temperature for notched bar impact testing. 1.3 Steels which diverge from these Rules, e.g. with regard to their nominal yield strength, their mechanical properties and their chemical composition, may not be used without the special approval of GL. 1.4 Steels conforming to EN 10025-3 and -4 may also be used in place of grades GLA 420, GLD 420, GLA 460 and GLD 460, viz: for grades GLA 420 and GLD 420: S420 N and S420 NL, EN 10025-3 S420 M and S420 ML, EN 10025-4 for grades GLA 460 and GLD 460: S460 N and S460 NL, EN 10025-3 S460 M and S460 ML, EN 10025-4 2. Approval
The maximum permitted value is to be agreed with GL and shall be indicated in the authorised specification.
3.3 Heat treatment
The steels shall be supplied in quenched and tempered condition. However, for grades GLA 420, GL D 420, GLE 420, GLF 420 and also for GLA 460, GL D 460, GLE 460 and GLF 460, with product thicknesses up to 50 m, normalising or normalising rolling is permitted where the required properties can be achieved thereby. This is to be demonstrated for approval testing. The same applies to thermomechanically rolled steels up to 70 mm thickness with nominal yield strength up to 500 N/mm2.
3.4 Mechanical properties
The requirements applicable to the mechanical properties and the impact energy shall conform to the data in Table 1.12.
3.5 General condition of products
The steels shall be approved by GL. For this purpose, the steel manufacturer shall send GL a material specification containing the required information, such as chemical composition, manufacturing process, mechanical properties, condition of supply, as well as recommendations for welding, hot or cold forming, and heat treatment. GL reserves the right to require initial approval testing. The material manufacturer shall verify the weldability of each grade of steel by appropriate documentation possibly in connection with welding tests. 3. 3.1 Requirements Manufacturing process
A.5. applies. In addition, it should be noted that: Procedures for repair welding and reporting thereon shall be approved by GL. If defects are removed by grinding, the thickness remaining underneath the ground area shall be within the thickness tolerance.
Dimensions, dimensional and geometrical tolerances
3.6
A.6. applies, with the following addition: For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply, unless otherwise specified in the order.
4. 4.1 Testing Testing of chemical composition
The steels shall be manufactured in works approved by GL by the basic oxygen process, in electric arc furnaces, or by another process approved by GL. They shall be cast in killed condition and fine grain treated. 3.2 Chemical composition
The manufacturer shall determine the composition of every heat and shall issue a relevant certificate.
4.2 Tensile test
3.2.1 The chemical composition shall satisfy the requirements stated in the authorized specification and in Table 1.11. Elements used for alloying and fine grain treatment are to be indicated in the manufacturers specification. 3.2.2 To assess weldability, sensitivity to cold cracking may be calculated from the ladle analysis according to the following formula:
4.2.1 From every piece heat-treated in a unit, at least one tensile test specimen shall be taken and tested. If plates are heat-treated by continuous processes, special arrangements may be made with regard to the number of tests required and the making of the test specimens.
Pcm = C +
Si Mn Cu Ni + + + + 30 20 20 60 Cr Mo V + + + 5B % 20 15 10
In the case of products which are not quenched and tempered, one tensile test specimen is to be taken for each rolled length.
4.2.2 Test specimens are to be cut with their longitudinal axes perpendicular to the final direction of rolling, except in the case of sections and wide
II - Part 1 GL 2009
Section 1
Chapter 2 Page 119
Table 1.11
Chemical composition of quenched and tempered steels
Grade, with nominal yield strengths ReH [N/mm2]
grade
Maximum Content of Elements 1 [%]
C GLA GLD GLE GLF 0,21 0,20 0,20 0,18
Si 0,55 0,55 0,55 0,55
Mn 1,70 1,70 1,70 1,70
P 0,035 0,030 0,030 0,025
S 0,035 0,030 0,030 0,025
N 0,020 0,020 0,020 0,020
420 to 690
1 Elements used for alloying and fine grain treatment are to be as details in the approved specification.
flats < 600 mm in width, where longitudinal test specimens are to be taken. For other product forms, the tensile test specimens may be taken in either the longitudinal or the transverse direction as agreed with GL. Normally, flat tensile test specimens are to be used. The tensile-test specimens may be taken from the full or the half product thickness, however, one surface side shall be maintained. For thicknesses above 30 mm round tensile test specimens may be used, the axis of which shall lie at a distance of 1/4 of the product thickness from the surface. 4.3 Impact test
4.5
Surface inspection and dimensions
The manufacturer shall inspect the condition of the surface and the dimensions of the product and shall then submit the products to the Surveyor for inspection. 4.6 Non-destructive testing
4.3.1 From each piece as heat treated or, in the case of products from each rolling length which have not been quenched and tempered, at least one set of three Charpy V-notch impact test specimens in accordance with Chapter 1 Principles and Test Procedures, Section 2, E.2. is to be taken and tested. For continuous heat treated plates special consideration may be given to the number and location of test specimens required. 4.3.2 Unless otherwise accepted by GL, the Vnotch impact test specimens for plates and wide flats 600 mm are to be taken with their axes transverse to the main rolling direction. For other product forms the impact tests are to be in the longitudinal direction. The specimens' axes shall be positioned at a distance of 1/4 of the product thickness from the surface or as near as possible to this position. 4.3.3 For grade GL-A steel products, the number of impact test specimens may be reduced by agreement with GL, where equivalent results are obtained during testing. 4.4 Through thickness tensile test
4.6.1 Where plates and wide flats are ordered with a certificate of ultrasonic examination, the tests are to be carried out according to a standard accepted by GL, e.g. EN 10160. The quality class is to be defined at the time of the order. 4.6.2 The seams of welded hollow sections of hull structural steel are to be subjected to non-destructive testing over their entire length. 4.6.2.1 Electrical welded hollow sections The weld seam of hollow sections is to be examined according to one of the following European standards: EN 10246-3, acceptance category E4, except that the technique of rotating pipes or with rotating saddle coils is not permitted EN 10246-5, acceptance category F5, or EN 10246-8, acceptance category U5
4.6.2.2 Submerged-arc welded hollow sections The weld seam of hollow sections is to be examined according to acceptance category U4 in accordance with EN 10246-10, image quality class R2. Butt welds serving to connect strip or plate lengths by spiral submerged-arc welding have to be examined over their entire length according to the same test procedure and shall satisfy the same acceptance criteria as the main weld seam.
If required by GL, through thickness tensile tests are to be performed using test specimens taken at right angles to the surface of the product in accordance with I.
Chapter 2 Page 120
Section 1
II - Part 1 GL 2009
Table 1.12
Mechanical and technological properties for products with 70 mm maximum thickness
Grades
Yield strength ReH [N/mm2] min.
1, 2
Tensile strength Rm
Elongation 3 at Lo = 5,65 So A [%] min. long.
)
[C]
Impact energy KV [J] min. long. 0 20 transv.
Test temp.
[N/mm2]
transv.
GLA 420 GLD 420 420 GLE 420 GLF 420 GLA 460 GLD 460 460 GLE 460 GLF 460 GLA 500 GLD 500 500 GLE 500 GLF 500 GLA 550 GLD 550 550 GLE 550 GLF 550 GLA 620 GLD 620 620 GLE 620 GLF 620 GLA 690 GLD 690 690 GLE 690 GLF 690
1 2 4
530 680
20
18 40 60 0 20
42
28
570 720
19
17 40 60 0 20
46
31
610 770
18
16 40 60 0 20
50
33
670 830
18
16 40 60 0 20
55
37
720 890
17
15 40 60 0 20
62
41
770 940
16
14 40 60
69
46
Where the yield strength ReH does not mark in the tensile test, the 0,2 % proof stress Rp0,2 is applicable. The permissible ratio between yield strength and tensile strength is to be agreed between the manufacturer and GL. Where flat tensile test specimens 25 mm wide and with a gauge length of 200 mm are used, the minimum requirements in respect of elongation are to be obtained from Table 1.13.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 121
Table 1.13
Minimum values in respect of elongation when using specimens 25 mm wide and with a gauge length of 200 mm
Elongation A200 mm [%]
Nominal yield strength ReH [N/mm2] 420 460 500 550 620 690 10 11 11 10 10 9 9 > 10 15 13 12 11 11 11 10
Thickness of product t [mm] > 15 20 14 13 12 12 12 11 > 20 25 15 14 13 13 12 11 > 25 40 16 15 14 14 13 12 > 40 50 17 16 15 15 14 13 > 50 70 18 17 16 16 15 14
4.7
Retest procedures
2.
Approved steel grades
4.7.1 If one of the tensile tests fails to meet the requirements two additional test specimens are to be taken from the same position of the piece and subjected to the test. The piece will be accepted, if both additional tests are satisfactory. 4.7.2 When the average value of the impact test fails to meet the requirements or more than one value is below the required average value or when one value is below 70 % of the specified average value, the procedure described in Chapter 1 Principles and Test Procedures, Section 2, H. is to be followed. 5. Marking
The materials listed below may be used: 2.1 Flat products made of steels used for pressure vessels conforming to EN 10028-2 "Alloyed and Unalloyed High Temperature Steels". 2.2 Flat products made of steels used for pressure vessels conforming to EN 10028-3, "Weldable finegrained structural steels, normalised". 2.3 Flat products made of GL-steels used for pressure vessels according to Table 1.14 and 1.15. For the 0,2 % proof stress at elevated temperatures, Table 1.16 applies. 2.4 Flat products made of other steels, provided that their suitability for the intended purpose and their properties have been proved to GL. For this, the following requirements are to be satisfied: 2.4.1 The elongation (A) shall have the minimum values which characterise the grade of steel, as specified in the GL report, but shall be not less than 16 %. 2.4.2 The impact energy shall meet or exceed the requirements of EN 10028-2 and -3 respectively for flat products of the same strength, see Table 1.14. In the case of plates to be used for shell rings and heads, the manufacturer and the steel user shall ensure that the values required for the final condition can be complied with. 2.4.3 Proof of weldability shall be furnished by the manufacturer. Details of preheating, temperature control during welding and heat treatment after welding shall be furnished by the manufacturer. 2.4.4 The yield strength at elevated temperature and, where necessary, the long-time rupture stress properties at elevated temperature shall be verified by the manufacturer if they are different from Table 1.16.
Every finished piece is to be clearly marked by the maker in at least one piece with GL brand and the following particulars: Marks of the manufacturer Unified identification mark for the grade of steel (e.g. GLE 620) or manufacturer's trade name Heat number, plate number or equivalent identification mark.
The entire markings are to be encircled with paint or otherwise marked so as to be easily recognized.
E.
Steels for Steam Boilers and Pressure Vessels Scope
1.
These Rules apply to flat products made from ferritic steels, which are intended for the manufacture of steam boilers, pressure vessels, heat exchangers and other process equipment.
Chapter 2 Page 122
Section 1
II - Part 1 GL 2009
Table 1.14
Mechanical and technological properties of flat products made of GL-steels used for pressure vessels 1
Tensile strength Yield strength Rm ReH and Rp0,2 respectively Elongation A Notched bar impact energy Test temp. [C] KV [J] min. transv. 34 34 34 34
Steel grade
Normal delivery condition
[N/mm2]
min. 235 265 295 355
[N/mm2]
360 to 480 410 to 530 460 to 580 510 to 650
[%] min. 25 23 22 21
GL-P235W GL-P265W GL-P295W GL-P355W

1
N N N N
0 0 0 0
N = normalized, T = tempered.
Table 1.15
Steel grade
Chemical composition of GL-steels used for pressure vessels

Chemical composition [%] C Si 0,55 Mn 0,601,70 P 0,025 S 0,015 Altot. 0,020 Cr 0,30 Mo 0,08
all
0,23
Table 1.16
0,2 %-Proof stress at elevated temperatures for flat products made of GL-steels used for pressure vessels
Rp0,2-Yield strength [N/mm2] min.
Steel grade 50 GL-P235W GL-P265W GL-P295W GL-P355W 227 256 285 343 100 214 241 268 323 150 198 223 249 299
Temperature [C] 200 182 205 228 275 250 167 188 209 252 300 153 173 192 232 350 142 160 178 214 400 133 150 167 202
2.5 For plates to be used for shell rings and heads, the following additional requirements apply: For steels for welded boiler drums, the impact energy shall be 31 J at 0 C in tests performed on the finished component, if in the case of plate thicknesses 50 mm the yield strength of these steels is 310 N/mm2 at room temperature. This energy value is an average for three individual tests with (transverse) Charpy V-notch specimens, in which none of the individual values may be more than 15 % lower than the stated average of 31 J. The stated impact energy value at 0 C is a minimum requirement. In
addition, the individual steels shall exhibit their characteristic impact energies. 2.6 Plates to be manufactured into fire tubes shall exhibit adequate formability - elongation (A) 20 % at 20 C . 3. Condition of supply and heat treatment
The products shall be delivered in the heat-treated conditions specified in the standards and/or in the expert's report, unless they are to be further processed at elevated temperature.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 123
4.
Dimensions, dimensional and geometrical tolerances
The test temperatures for flat products complying with EN 10025 are given in the standard. For other steels as per 2.4, the test temperature will be stipulated in the GL approval. 5.5 Testing of surface finish and dimensions
A.6. applies with the following addition: The minus tolerances for the nominal thickness shall be as stated under Class B in Table 1.1. If lower minus tolerances are required for technical reasons, this shall be stated in the order. 5. Testing and scope of tests
The following tests shall be performed: 5.1 Testing of chemical composition
The surface finish and dimensions of all products shall be checked by the manufacturer. The products shall also be submitted to the Surveyor for final inspection; as far as possible, the undersides of the products shall be inspected at the same time. 5.6 Non-destructive testing
The manufacturer shall determine the chemical composition of each heat and issue a relevant certificate. 5.2 Tensile test
The mechanical properties shall be verified by tensile testing. Test specimens shall be taken from the products transverse to the direction of rolling in the following quantity: For sheet and plate, the specimens shall be taken as follows: unalloyed steel sheet 50 mm thick: - one specimen from one end of each rolled length unalloyed steel plate > 50 mm thick: - one specimen from one end if the rolled length is 15 m, one specimen from each end if the rolled length is > 15 m alloy steels with rolled length 7 m: - one specimen from one end, one specimen from each end if the rolled length is > 7 m. For sheets made from hot-rolled wide strip, at least one specimen shall be taken from the outer end of each coil. Tensile test at elevated temperature
Where specified in the order or required in special cases, e.g. in the case of products subject to requirements in the thickness direction in accordance with I., an ultrasonic test shall be carried out in accordance with A.8.6. 6. Marking of products
The manufacturer shall mark the products in the prescribed manner, see EN 10028-1. In the case of plates which are not supplied in bundles, the marking shall be applied 200 to 400 mm from the bottom end in such a way that, looked at from the bottom end of the plate, the characters are upright and therefore indicate the direction of rolling. 7. Strength parameters for calculations
The strength parameters for calculations are: 7.1 For flat products conforming to EN 10028-2 and -3, the values stated in these standards. For flat products made of GL-steels used for pressure vessels according to 2.3, the values stated in Table 1.16. 7.2 For flat products made of other steels as per 2.4, the values approved by GL. 7.3 The strength parameters indicated in the above standards for 100 C are valid up to 120 C. In the other ranges, the values are to be determined by linear interpolation between the stated values, e.g. for 180 C between 100 C and 200 C; rounding up is not allowed.
5.3
The 0,2 % proof stress is to be verified at elevated temperature. A tensile test at elevated temperature shall be performed for each heat. The test temperature shall be 300 C, unless no other temperature is specified in the order. 5.4 Notched bar impact test
F. 1. 1.1
Steels for Cargo Tanks Scope These Rules apply to flat products made from fine-grained structural steels, high strength, quenched and tempered finegrained structural steels,
5.4.1 All products with thicknesses 6 mm shall be impact tested using Charpy V-notch specimens at the test temperature of 0 C. The specimens shall be taken from the products transverse to the direction of rolling. The number of sets (each of 3 specimens) required for this purpose shall be determined in the same way as the number of tensile test specimens prescribed in 5.2.
Chapter 2 Page 124
Section 1
II - Part 1 GL 2009
nickel alloy steels which are tough at low temperatures austenitic steels
2.1 Weldable, fine-grained structural steels conforming to EN 10028-3.

Note: The use of steel grade P460 NH for tanks designed to carry pressure-liquefied ammonia at ambient temperatures is prohibited.
which are intended for the fabrication of cargo tanks and process pressure vessels for carrying liquefied gases. 1.2 Steels conforming to these rules shall be approved by GL for the above-mentioned purpose and design temperature. To this end, the steels listed under 1.1 above shall be subjected to an approval test by GL. GL shall decide on a case to case basis on the need for an approval test on austenitic steels and other special structural steels. 2. Approved steel grades
2.2 Fine-grained structural steels with nominal yield strengths above 335 N/mm2 in accordance with EN 10028-3, -5 and -6. 2.3 Nickel alloy steels which are tough at low temperatures, conforming to EN 10028-4. 2.4 Stainless, austenitic steels conforming to EN 10028-7, provided that they are suitable for the intended design temperature. 2.5 Other weldable steels conforming to other standards or to material specifications of the manufacturer or the purchaser, after initial approval testing by GL.
The following steel grades may be used considering the minimum design temperatures stated in Table 1.17 provided that they satisfy the additional requirements stipulated in these Rules:
Table 1.17
Minimum design temperatures for steels used in the fabrication of cargo tanks
References to standards and rules For chemical composition, see Table 1.18 e.g. according to EN 10028-3, -5 or -6 and Section 8, D. e.g. according to EN 10028-3, -5 or -6 Steels according to EN 10028-4 11MnNi5-3, 13MnNi6-3 15NiMn6 12Ni14 X12Ni5 X7Ni9, X8Ni9 e.g. steels according to EN 10028-7 1.4306 (AISI 304 L) 55 60 2 90 2 105 2 165 Minimum design temperature [C] 0
Steel designation Fine-grained structural steels for ammonia which has been liquefied under pressure Normalized, TM rolled and finegrained structural steels with nominal yield strengths above 355 N/mm2 Other fine-grained structural steels with nominal yield strengths up to 355 N/mm2 Nickel alloy steels containing 0,5 % Nickel 1,5 % Nickel 3,5 % Nickel 5 9 % Nickel % Nickel
45 1
Austenitic steels
1.4404 (AISI 316 L) 1.4541 (AISI 321) 1.4550 (AISI 347)
165
GL reserve the right to approve a lower design temperature (max. 55 C) if suitable properties are demonstrated during approval testing. 2 A lower design temperature may be approved for steels containing 1,5 %, 3,5 % and 5 % nickel if the steels are quenched and tempered. In these cases, the test temperatures will be specially stipulated by GL.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 125
3.
Approval test
6.
Dimensions, dimensional tolerances
3.1 On the subject of approval of materials, the material manufacturer or tank manufacturer shall provide GL with a material specification containing all the particulars needed to evaluate the material. The specification shall give the minimum particulars as follows: material designation/standard material manufacturer recommended values for chemical composition mechanical properties intended minimum design temperature range of product thicknesses delivery condition associated standards or specifications, e.g. for tolerances, surface finish, freedom from defects heat treatments working method
For plates for parts of the tank or vessel shell including the end plates and domes, the minimum thickness shall be the nominal thickness prescribed in the order specification. Plates, strips and wide flats which do not form part of the shell may be supplied with the minus tolerances stated in A.6., Table 1.1, Class A. 7. Freedom from defects and repair of surface defects
The provisions of A.5. are applicable. Surface defects may generally be removed only by grinding, which shall not at any point reduce the thickness below the prescribed minimum. Where defects are to be repaired by welding, this shall be preceded by a welding procedure test, and the conditions for welding shall then be established. 8. 8.1 Requirements applicable to the material Chemical composition
3.2 By means of an approval test, the material manufacturer shall demonstrate that the material is suitable for the intended minimum design temperature, the cargo carried and the intended method of processing, especially if this involves welding. The scope of the approval test is set down by GL on a case by case basis. It shall include notch impact and drop weight tests in the appropriate temperature range, and for quenched and tempered steels with nominal yield strength of 620 and 690 N/mm2 it shall also include fracture mechanics tests on the base metal. 4. Limits to use
8.1.1 The chemical composition shall conform to the data in the recognised standard or the material specification authorised by GL. In addition the limiting values for the chemical composition of fine-grained structural steels with a nominal yield strength of up to 355/Nmm2 used in the fabrication of tanks carrying pressure-liquefied ammonia as given in Table 1.18 are to be met. 8.1.2 On the subject of the evaluation of the weldability of high-strength, quenched and tempered finegrained structural steels, sensitivity to cold-cracking is to be determined from the ladle analysis in accordance with the following formula: Pcm = C + Si Mn Cu Ni + + + + 30 20 20 60 Cr Mo V + + + 5B % 20 15 10
For fabrication of cargo tanks and process pressure vessels, the limit values for the lowest design temperatures as per Table 1.17 shall apply. 5. Condition of supply and heat treatment
All products shall be supplied in the heat treated conditions specified during the approval test and/or in the standards or material specifications.
The boundary value shall be specified when approval is given for the material.
Table 1.18
Chemical composition for fine-grained structural steels suitable for ammonia which has been liquefied under pressure (ladle analysis) [%] maximum in the absence of any other indication 1
C 0,18
1
Si 0,10 0,50
Mn 1,65
P 0,030
S 0,025
Al min 0,020
Cr 0,20
Cu 0,35
Mo 0,04
Ni 2 0,40
V 0,02
For steels with nominal yield strengths of 355 N/mm2, the chemical composition shall be set so that an upper yield strength figure of 440 N/mm2 is not exceeded. Where nickel is intentionally alloyed, the upper boundary value is 0,85 %.
Chapter 2 Page 126
Section 1
II - Part 1 GL 2009
8.2
8.2.1 The requirements applicable to the mechanical properties which are stated in the recognised standard or the authorised material specification shall be verified during testing. 8.2.2 The following also applies to fine-grained structural steels for pressure-liquefied ammonia: The actual yield strength ReH may not exceed 440 N/mm2 or 470 N/mm2 in the case of hot-formed dished ends. Elongation A5 shall be at least 22 %. 8.3 Impact energy
normalised and TM-rolled plates: one specimen from one end of each rolled length. If this is greater than 15 m, one specimen shall be taken from each end. all quenched and tempered plates: one specimen from one end of each heat-treated length. If this is greater than 7 m, one specimen shall be taken from each end. sheets taken from hot-rolled wide strip which do not undergo individual heat treatment: one specimen each from the outer end of the coil. for plates of austenitic stainless steels one specimen of each heat treatment length. If this is greater than 15 m one specimen shall be taken from each end.
The required impact energy values specified in Table 1.19 and 1.20 respectively for the steel grade concerned shall be achieved in tests on Charpy V-notch specimens at the prescribed test temperatures. This requirement also applies to comparable steels conforming to the standards or specifications, irrespective of the values stated therein. 8.4 Brittle fracture behaviour
9.2.3 Specimens taken from the top and bottom ends of a rolled plate may not differ in tensile strength by more than the following amounts: 9.3 rolled lengths of 10 m: 60 N/mm2 rolled lengths of > 10 m: 70 N/mm2 Notched bar impact test
When subjected to Pellini's drop weight test at a test temperature 5 K below the design temperature (but no higher than 20 C), ferritic steels shall display a "no break performance". 8.5 Resistance of austenitic grades to intercrystalline corrosion
In the condition in which they are supplied, austenitic steels shall be resistant to intercrystalline corrosion. Where the materials undergo welding without subsequent heat treatment (solution annealing), only those grades of steel may be used which are corrosionresistant in this condition, e.g. Ti or Nb stabilized steels or steels with carbon contents of C 0,03 %. 9. Testing and scope of tests
9.3.1 All products with thicknesses of 6 mm shall be subjected to the notched bar impact test performed on Charpy V-notch specimens at the test temperatures specified in Table 1.19 and 1.20 respectively. In the case of plates and wide flats with a width of 600 mm the specimens shall be taken transverse to the direction of rolling. For all other products they may be taken parallel or transverse to the rolling direction. The number of sets (each comprising 3 specimens) required shall be determined in the same way as the number of tensile specimens prescribed in 9.2.2. 9.3.2 Where the thickness of the products precludes the preparation of specimens with the standard dimensions (10 mm 10 mm), specimens measuring 7,5 mm 10 mm or 5 mm 10 mm should be used wherever possible. These specimens are subject to the requirements stated in Table 1.20. 9.4 Drop weight test
The following tests are to be performed: 9.1 Test of chemical composition Products made from high-strength, quenched and tempered fine-grained structural steels and steels designed for a minimum design temperature of less than 50 C (with the exception of austenitic steels) are to be tested per heat by means of a drop weight test. For the drop weight test, at least 2 specimens shall be taken from the thickest item from each heat and tested at a temperature of 5 K below the minimum design temperature. The test shall only be performed on products with a thickness of > 16 mm. It is to be conducted in accordance with a recognized standard, e.g. Stahl-Eisen-Prfblatt (Steel-iron test specification) SEP 1325, EN 10274 or ASTM E-208, see also Chapter 1 Principles and Test Procedures, Section 2, G.3.
The manufacturer shall determine the chemical composition of each heat and issue a relevant certificate. 9.2 Tensile test
9.2.1 All products shall be subjected to the tensile test. For this purpose, specimens shall be taken transverse to the direction of rolling in the case of plate, hot-rolled wide strip and wide flats with a width of 600 mm. For all other products they may be taken transverse or parallel to the rolling direction. 9.2.2 The number of specimens shall be determined as follows:
II - Part 1 GL 2009
Section 1
Chapter 2 Page 127
Table 1.19
Impact energy requirements for steels used for cargo tanks

Notched bar impact energy
Steel designation
Product thickness [mm]
Test temperature [C] long.
KV [J] 1 min. transv.
Fine-grained structural steels for ammonia liquefied under pressure Fine-grained structural steels with yield strengths ReH 355 N/mm2 Other fine-grained structural steels, nickel alloy steel containing 0,5 % nickel Nickel alloy steels containing: 1,5 3,5 5 9 % % % % Nickel Nickel Nickel Nickel
40
20
40
20
25 2
5 K below minimum design temperature, not higher than 20 C
41 (29)
27 (19)
25 3
65 95 110 ( 196) 4 196 196
Austenitic steels
1 2
50
Average value of 3 specimens; figures in brackets are minimum individual values. The following test temperatures are applicable to product thicknesses above 25 mm: Product thickness [mm] 25 < t 30 30 < t 35 35 < t 40 10 K 15 K 20 K
Test temperature
below minimum design temperature but not higher than 20 C.
For steels intended for tanks and structural components of tanks with product thicknesses above 25 mm which are subjected to stressrelief heat treatment after welding it is sufficient to apply a test temperature 5 K below the design temperature but not higher than 20 C. For stress-relief heat-treated tank reinforcements and similar welded parts the test temperature may not be higher than that specified for the thickness of the adjoining shell plate.
3
Where, in the case of nickel alloy steels containing 1,5 % Ni, 3,5 % Ni and 5 % Ni, the product thickness exceeds 25 mm, the test temperatures shall be determined in accordance with the data given in footnote 2. They shall not, however, be higher than those shown in the Table. For 9 % nickel steel over 25 mm thick, the requirements shall be specially agreed with GL.
Where 5 % nickel steel is tested and approved for a minimum design temperature of 165 C, the notched bar impact test shall be performed at a test temperature of 196 C.
Chapter 2 Page 128
Section 1
II - Part 1 GL 2009
Table 1.20
Requirements applicable to specimens of reduced size according to impact energy for standard specimens
Necessary impact energy KV with specimens measuring 7,5 mm 10 mm average value [J] min. 22 34 minimum individual value [J] 16 24 5 mm 10 mm average value [J] min. 18 27 minimum individual value [J] 13 22
Necessary impact acc. to Table 1.19 (standard specimens) average value [J] 1 min. 27 (19) 41 (29)
1
Average value of 3 specimens; figures in booklets are minimum individual values..
9.5
Test of resistance to intercrystalline corrosion
Wherever necessary or prescribed in the order, the resistance of austenitic steels to intercrystalline corrosion shall be tested. 9.6 Test of surface finish and dimensions
Zones for longitudinal, circumferential and connection welds over a width equal to the thickness of the plate, but not less than 50 mm in accordance with Class 1, Table 2 according to SEL 072 and quality class E3 according to EN 10160 respectively. Areas for the connection of supporting brackets, lifting lugs and floating securing devices 100 % in accordance with Class 0, Table 1 according to SEL 072 and quality class S3 according to EN 10160 respectively. 9.7.3 A non-destructive test shall be performed on products other than those mentioned in 9.7.1 if this is specified at the time of the order or called for by GL in special cases.
The surface finish and dimensions of all products shall be checked by the manufacturer. They shall also be submitted to the Surveyor for final testing, and in the case of flat products the underside shall also be inspected by means of random sampling. 9.7 Non-destructive tests
9.7.1 The manufacturer shall carry out an ultrasonic test in accordance with A.8.6 on the following products and shall certify the result: plates for pressure-liquefied ammonia plates made from high-strength, quenched and tempered fine-grained structural steels plates which are loaded in the thickness direction, e.g. those used for the central longitudinal bulkheads of bilobe tanks,
G. 1.
Stainless Steels Scope
The purchaser shall indicate these requirements in his order documents. Special arrangements are to be made for the testing of rolled sections for the equator rings of spherical tanks. 9.7.2 Ultrasonic testing is to be carried out according to EN 10160 or as stated in Stahl-EisenLieferbedingungen SEL 072 (Steel-Iron Supply Specifications SEL 072) as follows: Test grid 200 mm or in lines 100 mm apart.
SEL 072 Surface test Class 3, Table 1 Marginal zone test Class 1, Table 2 EN 10160 S1 E3
These Rules are applicable to flat products, sections and bars made of stainless steels which are intended for the fabrication of cargo tanks of chemical tankers, pressure vessels and other vessels, for which chemical stability in relation to the cargo or operating fluid is required, and also for sleeves of rudderstocks, rudder pintles, propeller shafts etc. which are required to be seawater resistant. 2. Selection of steels
2.1 Steels shall be selected in accordance with the operator's list of cargoes, which provides information on the nature of the substances to be transported or stored. 2.2 Furthermore, steels shall be selected in such a way that also depending upon their further processing, e.g. by welding, the required chemical stability in relation to the respective cargo or operating fluid is ensured.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 129
2.3 In the light of 2.1 and 2.2 above, suitable steels may be selected e.g. in accordance with EN 10088 relating to stainless steels, where the products are not required to be supplied in accordance with a specification which has been examined by GL. 2.4 GL reserves the right to demand an approval test for the grade of steel in question. 3. Condition of supply and heat treatment
7.1
Testing of chemical composition
The manufacturer shall determine the chemical composition of each heat and issue a relevant certificate. 7.2 Testing of resistance to intercrystalline corrosion
All products shall be presented in the heat-treated condition appropriate to the material, i.e. ferritic steels shall be annealed or quenched and tempered, while austenitic and austenitic-ferritic steels shall be solution-treated. 4. Dimensional tolerances
All products shall be tested for resistance to intercrystalline corrosion. For this purpose, at least 2 specimens shall be taken from each heat. The test is to be performed in accordance with DIN 50914 or ISO 3651-2 on specimens in the following condition: stabilized steels and steels with a carbon content 0,03 %: sensitized (annealed at 700 C for 30 minutes and quenched in water) all other steels: in the condition in which they are supplied Tensile test
Unless otherwise stipulated in the order specification, plates are to be supplied in accordance with A.6., Class B as indicated in Table 1.1 (permitted thickness tolerance 0,3 mm). For all other products the values stated in the relevant standards shall apply. 5. General condition of products
7.3
7.3.1 At least one tensile test specimen shall be taken from each test batch and tested. A test batch comprises: plates > 20 mm thick: the rolled length plates 20 mm thick: max. 40 rolled plates of approximately the same thickness (deviation max. 20 %) originating from the same heat and the same heat treatment batch with a total weight not exceeding 30 t. strip and plates taken therefrom: one specimen each from the beginning of the coil. all other product shapes: 5000 kg for products of the same shape originating from the same heat and the same heat treatment batch
The provisions of A.5. shall apply. Surface defects may generally only be repaired by grinding. In doing so, the relevant minus tolerance shall not be exceeded at any point. 6. Requirements applicable to material properties Chemical composition
6.1
6.1.1 The limit values for the chemical composition stated in the standards or in the specifications approved by GL shall apply. 6.1.2 For welded structures which cannot be heat treated after welding, only steels which are resistant to intercrystalline corrosion in this condition may be used, e. g. Ti or Nb stabilized austenitic steels or steels with carbon contents of C 0,03 %. 6.2 Mechanical properties
7.3.2 In the case of plates and wide flats with a width of 600 mm, the specimens shall lie in the transverse direction. For all other product shapes they may lie in the longitudinal or transverse directions. 7.4 Notched bar impact test
The requirements applicable to the mechanical properties which are stated in the recognised standard or the approved material specification shall be verified during testing. 6.3 Impact energy
7.4.1 Unless otherwise required by GL or stipulated in the order, a notched bar impact test with Charpy V-notch specimens is required for flat products with a thickness > 20 mm rods and bars with diameters or thicknesses > 50 mm flat products made of austenitic-ferritic steels with thicknesses 6 mm
The requirements applicable to the impact energy which are stated in the recognised standard or the approved material specification shall be satisfied. 7. Testing and scope of tests
The following tests shall be performed:
7.4.2 If the products are used for operating temperatures below 10 C, the impact test temperature shall be agreed with GL.
Chapter 2 Page 130
Section 1
II - Part 1 GL 2009
7.5
Testing of surface finish and dimensions
The surface finish and dimensions of all products shall be checked by the manufacturer. The products shall also be submitted to the Surveyor for final testing. In the case of flat products, the underside shall also be inspected as far as possible. 7.6 Testing for use of correct material
bonding of the cladding material. The type of heat treatment shall be notified to GL. 5. Dimensions and tolerances
The manufacturer shall test his products before delivery by appropriate methods as to whether the correct material has been used and shall confirm this in the acceptance test certificate. 7.7 Other tests
5.1 The nominal thickness of the cladding material shall be at least 2 mm. Where no closer thickness tolerances are specified in the order, the minus tolerances for the thickness shall be as shown in Table 1.21. Table 1.21 Minus tolerances in relation to the thickness of the cladding material Minus tolerance [mm] 0,20 0,25 0,35 0,45 0,50
If there are special requirements regarding resistance to pitting or crevice corrosion, appropriate corrosion tests shall be performed, e.g. to ASTM-G48. The scope of these tests will be determined by GL from case to case.
Nominal thickness [mm]
2,0 2,5 3,0 3,5 4,0
< < < <
2,5 3 3,5 4,0
H. 1.
Clad Plates Scope 5.2 The tolerances for the base materials shall be governed by the requirements for the respective steel grades and product shapes. 6. Surface finish
These Rules are applicable to steel plates clad with cladding materials made of stainless steels and intended for the manufacture of containers and tanks, e. g. for chemical tankers. It may be agreed to apply these rules to plate clad with other materials, e. g. aluminium or copper-nickel alloys. 2. Suitability of cladding process
The manufacturer shall demonstrate by means of an initial test of product suitability that the clad products satisfy the requirements stated in 8. and the required properties of the base material are preserved after cladding. 3. Suitable materials
6.1 The cladding materials shall have a smooth surface consistent with their purpose. The surface shall be free from scale, impurities, annealing colour and such defects as may impair the manufacturing processes applied to the material, its application or its chemical stability. The surface finish of the base material shall comply with A.5. 6.2 On the cladding material, the total surface area of all defects, with the exception of shallow defects as per 7.1, shall not exceed 20 % of the surface area of the cladding. 7. Repair of defects
Steels conforming to B., C. and E. shall be used as base materials. The stainless steels specified in G. and other materials approved by GL for the purpose may be used as cladding materials. 4. Method of manufacture and condition of supply
7.1 Shallow defects in the cladding material, e.g. impressions, grooves and scratches, shall be removed by grinding within the tolerance specified in 5. 7.2 In general points where bonding has not occurred up to an area of 50 cm2 may be tolerated, except where the purchaser requires that certain areas of the plate be repaired. 7.3 Deep defects in the cladding material which cannot be removed by grinding and lack of bonding in excess of 50 cm2 may be repaired by welding provided that the defects are isolated and separated from each other, do not exceed 1200 cm2 in area and do not
4.1 Cladding may be performed by rolling or explosive cladding or by a combination of the two methods. 4.2 Plates clad with austenitic materials shall normally be supplied in the as rolled condition. Where heat treatment is required in special cases, this is governed by the base material. However, the treatment shall not impair either the chemical stability or the
II - Part 1 GL 2009
Section 1
Chapter 2 Page 131
total more than 5 % of the clad surface. Welding shall be subject to the following Rules: 7.3.1 All welds shall be made by qualified welders using a technique approved by GL. 7.3.2 The welds shall be free from cracks, lack of fusion, undercuts, slag and other defects liable to impair the characteristics of the cladding. 7.3.3 After welding, the repaired defect shall be ground flush with the plate. Welding shall be followed by heat treatment if this was specified by the procedure approval test or if called for in the order. 7.3.4 After final machining, the plates shall be submitted to the Surveyor for final testing, and a suitable non-destructive test technique, e.g. dye penetrant inspection, shall be used to prove that the repairs are free from defects. 7.3.5 For each repair weld the manufacturer shall give the Surveyor a report stating the dimensions and location of the defects, the details of the welding technique used, the nature of any heat treatment applied and the results of the test. 8. Requirements applicable to the material
8.4
When subjected to the tensile test, the clad plate shall satisfy at least the following requirements:
pl =
G SG + A SA Spl
= specified minimum value of tensile strength or yield strength or 0,2 % proof stress [N/mm2] = nominal thickness [mm]
Indices: G A pl = base material = cladding material = clad steel
If the tensile test gives a lower value than that calculated by the formula, the requirements applicable to the base material may be verified by means of specimens from which the cladding material has been removed by machining. The elongation specified for the base material concerned shall be verified by tests performed on clad specimens.
8.5 Technological properties
The clad steels shall satisfy the following requirements. 8.1 Elongation
In the case of clad steels where the elongation of the cladding material is less than that of the base material, the cladding material shall attain an elongation A5 of at least 12 % in a tensile test after the base metal has been removed by machining. 8.2 Shear strength
When subjected to the side bend test, the clad plate shall be capable of being bent through 180 over a mandrel with a diameter equal to four times the thickness of the specimen without separation of the cladding material or formation of incipient cracks. Larger bending mandrel diameters may be agreed for other cladding materials, e.g. aluminium.
8.6 Impact energy
The bond between the base and cladding materials shall be adequate to ensure that the cladding material cannot break away from the base material when proper manufacturing processes or service loads are applied. In the case of cladding materials with a tensile strength of < 280 N/mm2, the shear strength shall be at least 50 % of the minimum tensile strength of the cladding material and for all other cladding materials it shall be not less than 140 N/mm2, irrespective of the direction of testing, unless otherwise agreed in the order. 8.3 Bonding
The requirements applicable to the base material shall be capable of being satisfied after cladding has been carried out.
8.7 Resistance to intercrystalline corrosion
For austenitic or austenitic-ferritic cladding materials, the requirements applicable to the relevant grade of steel shall be satisfied.
9. Testing
The proportion of bonded surface shall be at least 95 %, and the area of isolated points where bonding has not occurred shall not exceed 50 cm. For clad steels which are severely stressed during processing, e.g. in the manufacture of dished ends, or while in use, e.g. in tubesheets, it may be necessary for the purchaser to impose more stringent requirements.
The scope of the tests and the number and location of the test specimens are determined by the base material. The following tests are to be performed.
9.1 Test of chemical composition
The manufacturer shall determine the chemical composition of each heat of base and cladding material and shall issue a relevant certificate.
Chapter 2 Page 132
Section 1
II - Part 1 GL 2009
9.2
P
Test specimen
40
In the case of austenitic and austenitic-ferritic cladding materials, the resistance to intercrystalline corrosion shall be verified for each test batch. For this purpose, those plates may be grouped together into a test batch which have been clad in the same manufacturing cycle with cladding materials originating from the same heat. Under test, the clad side shall be subjected to tensile stress.
9.3 Tensile test
10
Cladding material
70 130
The tensile test shall be performed on a transverse specimen from each test batch. Unless otherwise agreed, the cladding material shall be left on the test specimen. The gauge marks shall be applied to the base material side.
9.4 Shear test
Fig. 1.3 Side bend test 9.7 Test of surface finish and dimensions
From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the shear test. The test shall be performed in accordance with a recognized standard, e.g. DIN 50162. The dimensions of the test specimen and the test arrangement are shown in Figure 1.2.
P
The surface finish and dimensions of all plates shall be checked by the manufacturer and the thickness of the cladding shall be measured at the edges and in the middle of the plate. All plates shall be submitted to the Surveyor for final testing and verification of the dimensions.
9.8 Non-destructive testing
10 Cladding material
Shear test specimen
To ascertain the quality of the bond between the base and cladding materials, the manufacturer shall carry out 100 % ultrasonic testing of the surfaces and edges of all plates.
20
10.
Marking
Guide blocks
All plates are to be marked as follows:

4,5 65
manufacturer's mark abbreviated steel grade designation or material number of base and cladding material heat numbers of base and cladding material thickness of base and cladding material specimen no.
25
Fig. 1.2 Shear test 9.5 Side bend test
From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the side bend test. The dimensions of the test specimen and the test arrangement are shown in Figure 1.3. Where the product thickness exceeds 80 mm, the specimens may be reduced to 80 mm by machining the base material side.
9.6 Notched bar impact test
I. 1.
Steels with Through Thickness Properties Scope
The notched bar impact test shall be performed in cases where it is specified for the base material. The number of specimens, their orientation and the test temperature are subject to the same conditions as apply to the base material.
These Rules are supplementary to all Rules applying to plates, strips, wide flats and shapes made of finegrained structural steels for which enhanced deformation properties in the direction of product thickness are required. They apply to products with thicknesses greater than or equal 15 mm. For smaller thicknesses these Rules may be applied at discretion of GL.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 133
2. 2.1
Requirements Reduction in area
The average value of the reduction in area measured on 3 tensile test specimens (Z specimens) lying in the direction of the product thickness shall be at least 25 % for the grade Z25, including one test result which may be lower than 25 % but not less than 20 %. For the grade Z35 the reduction in area has to be at least 35 %, including one test result which may be lower than 35 % but not less than 25 %.
2.2 Freedom from defects
surface of the product (Z specimens). The unit testing quantities shall be taken from Table 1.22 and consist of products of the same heat, same thickness and same heat treatment.
Table 1.22
Product S > 0,005 % Plates Wide flats up to and including 25 mm thickness Wide flats exceeding 25 mm thickness rolled length 10 t
Unit testing quantities

Sulphur content S 0,005 %
All products shall be free from defects liable to impair the required characteristics in the thickness direction, e.g. laminations, major non-metallic inclusions, flakes and segregations. In addition, when subjected to ultrasonic testing flat products shall satisfy the Class 2 test requirements laid down in Stahl-Eisen-Lieferbedingung 072 (Iron and Steel Supply Conditions 072) or Class S2/E3 test requirements according to EN 10160. For sections Class 1.2/23 test requirements according to EN 10306 apply.
Note Iron and Steel Supply Conditions 072 specify the following Class 2 test requirements for the general ultrasonic test: Minimum significant flaw size: Maximum permissible flaw size: Permissible incidence of flaws in relation to area: locally: in relation to total plate area: Maximum permissible length of significant flaws: parallel to edge (edge testing): Permissible incidence of flaws (edge testing): up to 0,5 cm2 1,0 cm2
50 t
20 t
3.1.2 In the case of flat products, the specimens shall be taken from one end in the longitudinal axis of the product, see Fig. 1.4. In both cases the centre of the product shall fall within the test length. In the case of sections, the specimens shall be taken from one end of the product at a distance of 1/3 of the flange width from the outside edge of the flange, see Fig. 1.4.
B/2
2/3
up to 30 m2 up to 15/m2
1/3
Fig. 1.4 Sampling of Z specimens 3.1.3 Tensile test with extension pieces
4 cm 5/m
2.3
Chemical composition
Steel extension pieces, e.g. studs, shall be welded to the two surfaces of the sample which lie perpendicular to the thickness direction of the steel product; see Fig. 1.5. Examples of permissible welding processes are stud or friction welding.
Extension piece
In addition to the requirements of the respective steel specification the sulphur content determined by heat analysis may not exceed 0,008 %.
3. Testing and scope of tests
The following tests shall be performed in addition to the tests prescribed for the product in question.
3.1 Tensile testing of Z specimens
s Sample
20
The test shall be performed on at least 3 ten3.1.1 sile test specimens taken from each unit testing quantity with their longitudinal axes perpendicular to the
Fig. 1.5 Specimen blank, consisting of test piece and welded-on extension pieces
20
Chapter 2 Page 134
Section 1
II - Part 1 GL 2009
Before welding on the extension pieces, the abutting surfaces of the sample and the extension pieces shall be carefully cleaned to remove rust, scale and grease. The heat affected zone due to welding shall penetrate into the sample to the minimum possible depth. The tensile test specimen shall be machined out of the specimen blank in accordance with Fig. 1.6.
Lc HAZ, slightly etched
ately next to the site of the first specimen and subjected to the tensile test. On the basis of the results obtained, a new average value for all 6 specimens shall be calculated. The test shall be regarded as successful if the new average value meets the requirements and no individual value yielded by the additional 3 specimens is below the required average value.
3.1.6 Ultrasonic testing
R3
The manufacturer shall perform an ultrasonic test on the surfaces and edges of each product using a 50 mm grid for the testing of the surfaces. If indications are observed which exceed the permissible limits for flaws stated in 2.2, the decision of GL shall be obtained as to the serviceability of the product.
4. Marking
do
Fig. 1.6 Tensile test specimen with extension pieces
d1
The diameter do of the tensile test specimen shall be as follows: do = 6 or 10 mm in the case of product thicknesses s of 25 mm, = 10 mm in the case of product thicknesses s of > 25 mm. The test length Lc of the tensile test specimen shall be at least 1,5 do and shall not exceed 150 mm.
Note: For further details see EN 10164.
Products which meet these requirements shall be identified by adding the symbol Z25 and Z35 respectively to the designation of the material, e.g. Grade GL-E hull structural steel is given the designation GL-E Z25.
J. 1.
Steel-Aluminium Welding Joints Scope
These requirements apply to explosion-bonded steelaluminium joints for the connection of steel structures with aluminium structures.
2. Manufacturing technique
3.1.4
Tensile test specimen without extension pieces
If the tensile test specimen is machined out of the test section, in the case of product thicknesses s of 150 mm its total length Lt is generally equal to the product thickness. The shape and dimensions of the tensile test specimen are shown in Fig. 1.7. The diameter do of the tensile test specimen is 6 mm in the case of product thicknesses s of 40 mm and 10 mm in the case of product thicknesses s of > 40 mm.
The manufacturer shall demonstrate by means of an initial test of product suitability that the clad products satisfy the requirements stated in 8. and the required properties of the base material are preserved after cladding.
3. Suitable materials
Lc
As base materials steels according to B., C. and E. are to be used. As cladding materials the aluminium alloys according to Chapter 3 Non-Ferrous Metals, Section 1, A. come into question.
4. Method of manufacture and condition of supply
do
Lt = s
R3
Fig. 1.7 Tensile test specimen without extension pieces
4.1 Cladding is performed by explosive cladding without additional heat transfer or change of thickness. 4.2 In general clad materials are to be delivered in untreated, smoothed condition. 5. Dimensions and tolerances
The test length Lc of the tensile test specimen shall be at least 1,5 do and shall not exceed 150 mm.
3.1.5 If the required average value is not achieved under test or if one individual value is less than allowed, 3 further Z specimens shall be taken immedi-
Where no other tolerances are specified in the 5.1 order, the specifications in Table 1.23 apply.
II - Part 1 GL 2009
Section 1
Chapter 2 Page 135
Table 1.23
Permissible tolerances
Product Tolerance [mm] lower upper + 1 + 10 + 10 + 1,5 + 2 + 2 + 5 max. 10
Thickness Length
all all plates
2 0 0 1,5 2 0 0
Width
rods 1 circular blanks
< 25 mm width > 25 mm width < 500 mm diameter > 500 mm diameter
Diameter
plates (difference between the diagonals) Rectangularity rods 1 (perpendicular projection of a longitudinal edge or a transverse edge) 1 m length < 1 m length Straightness of longitudinal edges
1
max. 1,5 max. 5 max. 0,5 % of length max. 5
Evenness (aluminium side)
rods 1
Rods are contrary to plates flat products of a width 300 mm.
5.2 The tolerances for the base materials shall be governed by the requirements for the respective steel grades and product shapes. 6. Surface finish
7.3
Tensile test
The tensile strength of a clad plate subjected to a tensile test shall be at least 60 N/mm2, unless higher values have been agreed in the order.
The surface finish shall meet the respective requirements for the base materials.
7. 7.1 Requirements applicable to the material Shear strength
When subjected to the side bend test, the clad plate shall be capable of being bent through 90 over a mandrel with a diameter of 6 times the thickness of the specimen, without separation of the cladding material or formation of incipient cracks.
8. 8.1 Testing Tensile test
The bond between the base and cladding materials shall be adequate to ensure that the cladding material cannot break away from the base material when proper manufacturing processes and service condition are applied. The shear strength shall be at least 60 N/mm irrespective of the direction of testing, unless higher values have been agreed in the order.
7.2 Bonding
From each end of the original plate 2 specimens with their longitudinal axis perpendicular to the product surface shall be taken and tested. Specimen shape is to be chosen according to I. One specimen of each end is to be heated to 300 C before testing.
8.2 Shear test
The proportion of bonded surface shall be at least 99% and the area of isolated points where bonding has not occurred shall not exceed 650 mm2. Rods and circular blanks of 300 mm or less width and diameter respectively shall not show indications to be registered. If rods or circular blanks are cut from the original plate, the distance to indications to be registered shall be at least 20 mm.
From each test batch a specimen shall be taken with its axis transverse to the rolling direction and this shall be subjected to the shear test. The test shall be performed in accordance with a recognized standard, e.g. DIN 50162. The dimensions of
Chapter 2 Page 136
Section 1
II - Part 1 GL 2009
the test specimen and the test arrangement are shown in Fig. 1.2. One specimen of each end is to be heated to 300 C before testing.
8.3 Side bend test
8.5
Non-destructive testing
To ascertain the quality of the bond between the base and cladding materials, the manufacturer shall carry out 100 % ultrasonic testing of the surfaces and edges of all plates.
9. Marking
If specially agreed in the order, one specimen of each original plate is to be taken and tested. Dimensions of the test specimen and test arrangement are shown in Fig. 1.3. Where the product thickness exceeds 80 mm, the specimens may be reduced to 80 mm by machining the base material side.
8.4 Test of surface finish and dimensions
All plates are to be marked on the base material side as follows: manufacturers mark short name of steel grade designation or material number of base and cladding material heat numbers of base and cladding material thickness of base and cladding material, specimen no.
The surface finish and dimensions of all plates shall be checked by the manufacturer and the thickness of the cladding shall be measured at the edges and in the middle of the plate. All plates shall be submitted to the Surveyor for final testing and verification of the dimensions.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 21
Section 2 Steel Pipes

A. 1. General Rules Scope the welded seam shall be subject to preliminary proof in the form of a procedure approval test the extent of which shall be determined by GL on a case to case basis. GL reserve the right to demand that a test of suitability be carried out in the case of seamless pipes also where these have to meet special requirements, e.g. in respect of their impact energy at low temperatures or their high-temperature strength characteristics. 3. Manufacturing process, condition of supply
1.1 The general Rules contained in A. to be observed in the manufacture of seamless and welded steel pipes apply in conjunction with the following individual requirements B. to E. The scope of these Rules embraces all pipes used in the construction of steam boilers, pressure vessels and equipment as well as for pipelines, accumulators and pressure cylinders. As regards steel pipes for structural applications, Section 1, B., C., D. and G. shall apply respectively. Pipes which are individually manufactured and welded, such as masts, crane posts, pressure vessel shells etc. shall also comply with Part 3 Welding. 1.2 Pipes conforming to national or international standards or to manufacturers' specifications may be approved provided that their properties are equivalent to the properties stipulated in these Rules or where special approval has been granted for their use. References to standardized materials whose use is permitted are contained in the following individual Rules. 1.3 Pipes conforming to these Rules may be designated either in accordance with the relevant standards or with the symbols shown in the Tables. In the latter case, pipes made of carbon and carbonmanganese steels shall be identified by their minimum tensile strength and, where applicable, by the added letter W denoting high-temperature steel or T denoting steel tough at sub-zero temperatures, while alloy pipes, with the exception of the austenitic grades, shall be identified by the symbols denoting their alloy content. 2. Requirements to be met by pipe manufacturers
3.1 Pipe steels shall be made by basic oxygen steelmaking processes, in an electric furnace or by other methods approved by GL. Unless otherwise specified, the steels shall be killed. 3.2 Seamless pipes may be manufactured by hot or cold rolling (cold pilger rolling), by hot pressing or by hot or cold drawing. 3.3 Welded ferritic steel pipes may be manufactured by electrical induction or resistance pressure welding or by fusion welding of strip or plates, and may be subjected to hot or cold reduction. For austenitic steels tough at sub-zero temperatures and austenitic stainless steels, only fusion welding processes may be used. The manufacturing process and the testing shall ensure a weld quality factor of v = 1,0. 3.4 All pipes shall be supplied in a properly heattreated condition over their whole length according to the requirements of B. to E. 4. General characteristics of pipes
2.1 Pipe manufacturers wishing to supply pipes in accordance with these Rules shall be approved by GL. Such approval is conditional upon their fulfilling the requirements stated in Chapter 1 Principles and Test Procedures, Section 1, C. and demonstrating this to GL prior to the commencement of supplies. 2.2 In addition, where welded pipes are manufactured, the characteristics and the required quality of
4.1 Pipes may not display any cracks. Defects liable to have more than an insignificant effect on the use or further treatment of the pipes may be removed by grinding within the minimum permissible wall thickness. Repair welds are not allowed. This Rule may be waived in the case of the seams of fusionwelded pipes. 4.2 Pipes shall have a smooth inside and outside surface consistent with the method of manufacture. Minor depressions or shallow longitudinal grooves due to the manufacturing process may be tolerated provided that they do not impair the serviceability of the pipes and the wall thickness remains within the permitted tolerances.
Chapter 2 Page 22
Section 2
Steel Pipes
II - Part 1 GL 2009
4.3 The upset metal on the outside of pressurewelded pipes shall be removed. In pipes having a bore of 20 mm or more, the height of the upset metal on the inside shall not exceed 0,3 mm. 4.4 On fusion-welded pipes, the inside and outside weld reinforcement shall not exceed a value of 1 + 0,1 seam width (mm). 5. Dimensions, dimensional and geometrical tolerances The dimensions and the dimensional and geometrical tolerances of the pipes shall comply with the requirements specified in the standards. The relevant standards shall be stated in the order and made known to the Surveyor. The ends of pipes shall be cut off perpendicular to the pipe axis and shall be free from burrs. Apart from pipes which are delivered in coils, all pipes shall appear straight to the eye. 6. Integrity of pipes All pipes shall be leak proof at the specified test pressures. 7. General requirements applicable to the material
welded pipes - shall verify the composition of each heat and submit the relevant certificates to the Surveyor. All the elements affecting compliance with the required characteristics shall be specified in the certificates. A product analysis shall be performed if there is any doubt about the composition of pipes submitted for testing. 8.2 Test of mechanical properties
8.2.1 For testing, pipes shall be grouped by steel grades and dimensions - alloy steel pipes also by heats - into test batches of 100 pipes for outside diameters 500 mm and into 50 pipes for outside diameters > 500 mm. Residual quantities of up to 50 pipes may be evenly allocated to the various test batches. Where welded pipes are concerned, a pipe is considered to be a cut length of not more than 30 m. 8.2.2 For the performance of the tensile tests, two pipes each shall be taken from the first two test batches and one pipe each from every subsequent batch. Where a consignment comprises only 10 pipes or less, it shall be sufficient to take one pipe. Normally, longitudinal test specimens shall be taken from the sample pipes. Where the diameter is 200 mm or more, test specimens may also be taken transverse to the pipe axis. From welded pipes additionally test specimens are to be taken transversely to the welded seam. The weld reinforcement shall be machined off over the gauge length. 8.3 Determination of the 0,2% proof stress at elevated temperatures
7.1 Chemical composition The chemical composition of the pipe material (heat analysis) shall conform to the Tables contained in this Section or, where applicable, in the relevant standards. 7.2 Weldability
Pipes in accordance with these Rules shall be weldable by established workshop methods. Wherever necessary, appropriate measures to safeguard quality shall be taken, e.g. preheating and/or subsequent heat treatments, see Part 3 Welding. 7.3 Mechanical properties
The tensile strength, yield strength or proof stress, elongation and, where required, the 0,2 % or 1 % proof stress at elevated temperatures and the impact energy shall conform to the Tables contained in this Section or, where applicable, in the relevant standards. Irrespective of the provisions contained in the standards, pipes made of steels tough at sub-zero temperatures shall at least meet the values specified in D. for the impact energy at the prescribed test temperature. 7.4 Technological properties
Where pipes are designed for use at elevated temperatures on the basis of their high-temperature strength characteristics, the 0,2 % or 1 % proof stress shall be proved by a hot tensile test performed on one test specimen per heat and per pipe size. The test shall be performed at the temperature which approximates most closely to the level of the operating temperature, rounded off to the nearest 50 C. The test may be dispensed with in the case of pipes to recognized standards, the high-temperature mechanical properties of which are regarded as proven. 8.4 Notch bar impact test
Pipes shall meet the requirements for the ring tests specified in 8.5. 8. 8.1 General instructions for testing Test of chemical composition
The pipe manufacturer - and, where appropriate, the manufacturer of the starting material in the case of
Where this test is specified for the individual types of pipe, the number of sets of specimens and the position of the specimens shall be determined in the same way as the tensile test specimens called for in 8.2. The test shall be performed on Charpy V-notch specimens. In case of pipes with wall thickness above 30 mm, the longitudinal axis of the specimens is to be located in a distance of 1/4 of the pipe wall from the outer surface or as close as possible to this location.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 23
Table 2.1
Types of ring test Nominal wall thickness t [mm] t<2 21,3 ring flattening test 1, 3 ring flattening test 1, 3 2 t 16 ring flattening test 1, 3 ring expanding test 1, 3 ring tensile test
2
Outside diameter of pipe [mm]
16 < t 40 ring flattening ring tensile test 2
> 21,3 146 > 146

1 2 3
The drift expanding test may also be applied to welded pipes. Instead of the ring tensile test, the flattening test is applied to pipes with bores of 100 mm. The drift expanding test is applied to seamless and welded pipes in compliance with EN 10305-1 and -2 respectively.
8.5
Technological tests
Table 2.2
Diameter change in the ring expanding test

Minimum expansion [%] for ID/OD ratios of 0,9 0,8 < 0,9 10 0,7 < 0,8 12 0,6 < 0,7 20 0,5 < 0,6 25 0,5
8.5.1 The pipes selected for testing shall be subjected to one of the ring tests specified in Table 2.1 provided that the wall thickness of the pipe does not exceed 40 mm. For the performance of the test, see Chapter 1 Principles and Test Procedures, Section 2, F. The number of test specimens depends on the application of the pipes and is stipulated in the requirements of B. to E. 8.5.2 In the ring flattening test, the prescribed distance between the plates H is calculated by applying the following formula:
Pipe material
C- and CMn-steels Mo-, CrMoand Ni-steels Austenitic steels
30
10
15
30
30
30
H = H a D C
(1 + C) a C + a/D
= distance between the platens [mm] = nominal wall thickness [mm] = outside diameter of pipe [mm] = constant determined by the steel grade (see the provisions relating to technological tests according to B. to E.).
8.5.5 In the drift expanding test applied to austenitic steel pipes a 20 % expansion shall be achieved. Where pipes are made of other steels, the requirements of the other relevant standards shall be achieved. 8.6 Test of surface finish and dimensions
The finish of the inside and outside surface of each pipe shall be inspected by the manufacturer. The diameters and wall thicknesses shall also be measured. The pipes shall then be submitted to the Surveyor for final testing.
8.7 Non-destructive tests
Where ring specimens of welded pipes are tested, the weld shall be set at 90 to the direction of the compressive load.
8.5.3 In the ring expanding test, the change in the diameter of the specimen expanded to the point of fracture shall at least equal the percentages shown in Table 2.2, depending on the material. 8.5.4 When the ring tensile test is applied to specimens of welded pipes, the weld shall be set at 90 to the direction of the tensile load.
8.7.1 The pipes shall be subjected to nondestructive tests of the extent specified in B. to E. Where tests of greater scope are prescribed in the order or in the relevant standards or specifications, these requirements shall be complied with. 8.7.2 Other test specifications require special approval by GL. 8.7.3 The test equipment used for the continuous inspection of pipes shall be regularly calibrated using
Chapter 2 Page 24
Section 2
Steel Pipes
II - Part 1 GL 2009
pipes with artificial defects. The efficiency of the equipment shall be demonstrated to the Surveyor.
8.8 Tightness test
10.
Certificates
10.1 For each consignment the manufacturer shall furnish the Surveyor with a certificate containing the following details:
All pipes shall be tested for leaks by the 8.8.1 manufacturer by applying the internal pressure test or, where GL has given its consent, by a suitable nondestructive testing method, e.g. eddy current or stray flux techniques.
8.8.2 The internal pressure test shall normally be performed at a standard hydraulic test pressure of 80 bar. Where pipes are intended for an operating pressure of 25 bar, the test pressure may be reduced to a standard value of 50 bar. In the case of thin-walled pipes with large outside diameters, the test pressure shall be limited so as to ensure that the yield strength or 0,2 % proof stress of the pipe material at room temperature is not exceeded. Where, in exceptional cases, testing with water is not possible, another testing medium may be used after agreement with the Surveyor. 8.8.3 Where a non-destructive method of testing is to be used instead of the internal hydraulic pressure test it shall be able to cover the whole circumference of the pipe. In addition, the method of testing shall conform to a recognized standard (e.g. EN 10246) or to an approved test specification. The efficiency of the method shall be initially demonstrated to GL. 8.9 Retests in the event of failure of specimens
purchaser and order number newbuilding and project number respectively, where known quantity, dimensions and weight of delivered pipes strength category or pipe grade steel grade or material specification method of pipe manufacture heat numbers chemical composition of the heat condition in which supplied or heat treatment applied marking results of material testing
10.2 The manufacturer shall also certify that all the pipes have been successfully tightness tested and, where applicable, have successfully undergone a nondestructive test and a test of resistance to intercrystalline corrosion. 10.3 If the steels of which the pipes are made are not produced in the pipe works, a steelmaker's certificate shall be handed to the Surveyor indicating the numbers and analyses of the heats. The steelmaker shall have been approved for the grades concerned. In case of doubt, the Surveyor shall be given facilities for carrying out a check. 10.4 Where, in exceptional cases, pipes are tested on the premises of a stockist, the latter shall keep a clear record of the origin of the pipes, which shall bear the marking specified in 9. and, in the case of boiler tubes, the stamp of the works inspector as well. In addition, the Surveyor shall be furnished with a certificate issued by the pipe manufacturer and containing the following details:
If the requirements are not met by specimens subjected to tensile, ring or notched bar impact tests or if, in the notched bar impact test, one individual value falls below 70 % of the stipulated average value, then, before the unit testing quantity is rejected, the procedure for retests described in Chapter 1 Principles and Test Procedures, Section 2, H. may be applied.
9. Marking of pipes
9.1 The manufacturer shall mark each pipe as follows in at least one position about 300 mm from the end:
short designation or material number of the steel grade manufacturer's mark additionally, the heat number or a heat code
number, dimensions and weight of the pipes supplied steel grade or material specification method of pipe manufacture and condition in which supplied or method of heat treatment heat numbers and analyses confirmation that the tightness test and, where specified, the non-destructive test and test of resistance to intercrystalline corrosion have been carried out marking
9.2 Markings shall be applied with punches. Pipes with sensitive surfaces or small wall thicknesses which may be damaged by punches shall be marked by another method, e.g. by coloured imprint, electrical engraving or rubber stamps.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 25
B. 1.
Pipes for General Purpose Scope
3. 3.1
Requirements applicable to the material Chemical composition
1.1 These Rules are applicable to seamless and welded pipes for use in pressure vessels, equipment, pipelines and pressure cylinders. Pipes conforming to these rules are intended for use at normal ambient temperatures.
The chemical composition of the pipe steels shall conform to the data given in Table 2.4 or, where appropriate, in the relevant standards or specifications.
In general for these applications pipe grades according to Table 2.3. are to be used. If the pipes are intended for the manufacture of hydraulic cylinders exposed to low service temperatures, a minimum impact energy of 41 J is to be proven on longitudinal ISO-V specimens, which may lead to the application of steels tough at sub-zero temperatures.
1.2 Pipes conforming to these Rules may be used for the cargo and processing equipment of gas tankers provided that the relevant design temperatures are not below 0 C. 2. Heat treatment
The required values of tensile strength, yield strength and elongation specified in Table 2.5 or, where appropriate, in the relevant standards or specifications shall be met under test at room temperature.
When subjected to the ring tests, the pipes shall display a capacity for deformation which meets the requirements specified in A.8.5.
3.4 Impact energy
The pipes shall at least satisfy the impact energy requirements specified in Table 2.5.
4. Testing and scope of tests
The pipes shall be in a proper heat-treated condition. This is generally to be achieved by normalizing. Subsequent heat treatment need not be applied to hotformed pipes if the hot forming operation ensures a corresponding structure of sufficient uniformity.
The following tests are to be performed:

The manufacturer shall determine the chemical composition of each heat in accordance with A.8.1.
Table 2.3
Standardized pipe grades

Corresponding pipe grade to EN 10216-1 1 or EN 10217-1 2 P235TR2 P265TR2 P275NL1 P355N E355+N EN 10216-3 1 or EN 10217-3 2 EN 10305-1 E235+N EN 10305-2 E235+N E275+N E355+N
Strength category or pipe grade to Table 2.5 GLR 360 GLR 410 GLR 490
1 2
seamless welded
Table 2.4
Chemical composition of unalloyed steel pipes

Chemical composition [%] Cmax. 0,17 0,21 0,22 Simax. 0,35 0,35 0,55 Mn max. 1,20 1,40 1,60 0,025 0,020 0,020 1 Pmax. Smax. Altot.
Strength category or pipe grade GLR 360 GLR 410 GLR 490
1
This requirement does not apply if the steel contains a sufficient fraction of other nitrogen absorbing elements, which is to be specified.
Chapter 2 Page 26
Section 2
Steel Pipes
II - Part 1 GL 2009
Table 2.5
Mechanical and technological properties of unalloyed steel pipes

Elongation A [%] min. long. transv. 23 19 17 41 27 Impact energy 1 KV at 0 C [J] min. long. transv.
Strength category or pipe grade
Tensile strength Rm
Yield strength ReH
[N/mm2]
[N/mm2]
min.
GLR 360 GLR 410 GLR 490

1
360 500 410 570 490 650
235 255 310
25 21 19
For pipes with wall thickness > 10 mm.
4.2
Tensile test
4.6
Non-destructive tests
Specimens of the sample pipes selected in accordance with A.8.2 shall be subjected to the tensile test.
4.3 Technological test
All pipes shall be subjected by the manufacturer to a non-destructive test over their whole length in accordance with EN 10246.
4.6.1 Non-destructive testing of seamless pipes
4.3.1 Pipes with longitudinal weld seams and seamless pipes of grade GLR490 are to be examined according to one of the ring tests specified in A.8.5, namely two pipes of one test batch.
Apart from that for fusion-welded pipes a weld seam bend test in accordance with Part 3 Welding, Chapter 2 Design, Fabrication and Inspection of Welded Joints, Section 5, D. may be carried out, applying a bending mandrel diameter of 3 t.
4.3.2 To calculate the distance between the thrust plates in the ring flattening test, the following values shall be assigned to the constant C in the formula given in A.8.5.2:
The pipes shall be subjected to a non-destructive test for detection of longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C or EN 10246-5, acceptance category F2. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-7, acceptance category U2, subcategory C or shall be cut off.
4.6.2 Non-destructive testing of pressure-welded pipes
GL-R360 and GL-R410:
Pipes of strength category 360: Other pipe grades:

4.4
C = 0,09 C = 0,07
The weld seam of pipe grades GL-R360 and GL-R410 shall be tested over its entire length according to either EN 10246-3, acceptance category E3 or EN 10246-5, acceptance category F3 or EN 10246-7, acceptance category U3, subcategory C or EN 10246-8, acceptance category U3, if applicable. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-8, acceptance category U3 or shall be cut off.
GL-R490:
Notched bar impact test
On the pipes selected in accordance with A.8.2, the notched bar impact test shall be performed on transverse Charpy V-notch specimens if the outside diameter is 200 mm. If the outside diameter is < 200, longitudinal specimens may be used.
Pipes of grade GL-R490 shall be subjected to an ultrasonic test for detection of longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-7, acceptance category U2, subcategory C or shall be cut off.
The tests specified in A.8.6 are to be performed.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 27
4.6.3
Non-destructive testing of fusion-welded pipes
in accordance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case.

4.7 Tightness test
GL-R360 and GL-R410:
The weld seam of SAW pipes of grades GL-R360 and GL-R410 shall be tested either according to EN 10246-9, acceptance category U3 or EN 10246-10 image quality class R2. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test in accordance with EN 10246-9, acceptance category U3 or shall be examined by means of radiographic testing according to EN 10246-10, image quality class R2 or shall be cut off.
All pipes shall be tightness tested by the manufacturer in accordance with A.8.8
C. 1.
High-Temperature Steel Pipes Scope
GL-R490:
These Rules are applicable to seamless and welded pipes made of carbon steel, carbon-manganese steel, Mo steel and Cr Mo steel and intended for steam boilers, pressure vessels, equipment and pipelines. Pipes conforming to these Rules are intended for application at both ambient and elevated temperatures. For these applications, standardized pipe grades are generally to be used. The appropriate pipe grades are shown in Table 2.6.
2. Heat treatment
The weld seam of pipes of grade GL-R490 shall be tested over its entire length according to EN 10246-9, acceptance category U2 or EN 10246-10 image quality class R2. Areas of the weld seam in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or to radiographic testing as specified above or shall be cut off. The base material is to be tested according to EN 10246-15, acceptance category U2. The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end. Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam
Pipes shall be properly heat treated as follows: a) Carbon steel, carbon-manganese steel and 0,3 Mo steel pipes: normalized b) Pipes made of 1 Cr 0,5 Mo and 2,25 Cr 1 Mo steels: quenched and tempered. Subsequent heat treatment need not be applied to hot formed pipes covered by a) if the hot forming operation ensures a corresponding structure of sufficient uniformity. Under these conditions, tempering may be sufficient for the alloy pipes covered by b).
Table 2.6
Standardized pipes made of high-temperature steel grades
Strength category or pipe grade GLR 360 W GLR 410 W GLR 460 W GLR 510 W 0,3Mo 1Cr05Mo 2,25Cr1Mo
Corresponding pipe grade to EN 10216-2 P235GH P265GH 20MnNb6 16Mo3 13CrMo4-5 10CrMo9-10 EN 10217-2 P235GH P265GH 16Mo3 ISO 9329-2 PH 23 PH 26 PH 29 PH 35 16Mo3 13CrMo4-5 11CrMo9-10 ISO 9330-2 PH 23 PH 26 PH 35 16Mo3 13CrMo4-5 11CrMo9-10
Chapter 2 Page 28
Section 2
Steel Pipes
II - Part 1 GL 2009
3. 3.1
3.3
Technological properties
The chemical composition shall conform to the data given in Table 2.7 or, where appropriate, the relevant standards or specifications.
When subjected to the ring tests, the pipes shall display a capacity for deformation which meets the requirements specified in A.8.5.
3.4 Impact energy
The pipes shall at least satisfy the impact energy requirements specified in Table 2.8.
3.5 High-temperature characteristics
The required values of tensile strength, yield strength and elongation specified in Table 2.8 or, where appropriate, in the relevant standards or specifications shall be met under test at room temperature.
The 0,2 % proof stress at elevated temperatures shall satisfy the requirements specified in Table 2.9 or in the other relevant standards or specifications.
Table 2.7
Chemical compositions of high-temperature steel pipes
Strength category or pipe grade GL-R 360 W GL-R 410 W GL-R 460 W GL-R 510 W 0,3Mo 1Cr0,5Mo 2,25Cr1Mo
1
Chemical composition [%] C

0,16 0,20 0,22 0,23
Simax. 0,35 0,40 0,40 0,55 0,35 0,35 0,50
Mn
1,20 1,40 1,40
Pmax.
Smax.
Cr
Mo
Altot.
0,30
0,08
0,020 1
0,80 1,50 0,40 0,90 0,40 0,70 0,30 0,70
0,025
0,020 0,25 0,35

0,040
0,12 0,20 0,10 0,17 0,08 0,14
0,70 1,15 0,40 0,60 2,00 2,50 0,90 1,10
This requirement does not apply if the steel contains a sufficient fraction of other nitrogen absorbing elements, which is to be specified. If titanium is used, the manufacturer shall demonstrate that
Al
Ti 2
0, 20 % .
Table 2.8
Mechanical and technological properties of pipes made of high-temperature steel at room temperature
Tensile strength Rm
Yield strength ReH
(at Lo = 5,65 So )
A [%] min. long. 25 21 23 19 22 22 20 transv. 23 19 21 17 20 20 18
Elongation
Impact energy KV [J] min. long. transv.
[N/mm2]
GLR 360 W GLR 410 W GLR 460 W GLR 510 W 0,3Mo 1Cr0,5Mo 2,25Cr1Mo 360 500 410 570 460 580 510 650 450 600 440 590 480 630
[N/mm2]
min. 235 255 270 355 270 290 280
41
27
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 29
Table 2.9
Minimum values of yield strength Rp0,2 at elevated temperatures

Minimum yield strength Rp0,2 [N/mm2] at a temperature [C] of 100 198 226 312 243 264 249 150 187 213 292 237 253 241 200 170 192 235 264 224 245 234 250 150 171 215 241 205 236 224 300 132 154 175 219 173 192 219 350 120 141 155 200 159 182 212 400 112 134 145 186 156 174 207 450 108 128 135 174 150 168 193 500 146 166 180
Steel grade Material code GL-R360W GL-R410W GL-R460W GL-R510W 0,3Mo 1Cr0,5Mo 2,25Cr1Mo Material number 1.0345 1.0425 1.0471 1.5415 1.7335 1.7380
3.6
Dimensional tolerances for collectors
4.2
Tensile test
Seamless collector pipes and collectors with inside diameters 600 mm are subject to the following dimensional tolerances: on the inner or outer clear width: 1,0 % where the outer clear width is 225 mm, or 1,5 % where the outer clear width is > 225 mm 0 % to + 25 % on the wall thickness the lateral curvature of square pipes shall be as shown in Fig. 2.1
f r s
201 to 300 1,5 301 and over 2,0
Specimens of the sample pipes selected in accordance with A.8.2 shall be subjected to the tensile test.
4.3 Technological test
4.3.1 The pipes, namely two pipes of one test batch, shall undergo one of the ring tests specified in A., Table 2.1 as follows:
For fusion-welded pipes a weld seam bend test in accordance with Part 3 Welding, Chapter 2 Design, Fabrication and Inspection of Welded Joints, Section 5, D. is to be carried out, applying a bending mandrel diameter of 3 t.
4.3.2 To calculate the distance between the thrust plates in the ring flattening test, the following values shall be assigned to the constant C in the formula given in A.8.5.2:
b
b [mm] f [mm] up to 100 0,75 101 to 200 1,0
Pipes of strength categories 360: Other pipe grades:

4.4 Notched bar impact test
C = 0,09 C = 0,07
Fig. 2.1
Tolerance on the lateral curvature of square pipes
In square pipes, the inner corner radius r in relation to the wall thickness s shall be at least:
r
4.
s 8 mm 3
The test is to be carried out at room temperature on the sample pipes selected in accordance with A.8.2, using transverse Charpy V-notch specimens if the outside diameter is 200 mm. If the outside diameter is < 200 mm, longitudinal specimens may be used.
4.5 High-temperature tensile test
Testing and scope of tests

Where stipulated in A.8.3 or in the purchase order, the 0,2 % proof stress shall be determined by a hightemperature tensile test.
The manufacturer shall determine the chemical composition of each heat in accordance with A.8.1.
The tests specified in A.8.6 are to be performed.
Chapter 2 Page 210
Section 2
Steel Pipes
II - Part 1 GL 2009
4.7
All pipes shall be subjected by the manufacturer to a non-destructive test according to EN 10246 over their whole length and cross section, cf. A.8.7.
4.7.1 Non-destructive testing of seamless and pressure-welded pipes
The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end. Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam in accordance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case.
4.8 Tightness test
The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or shall be examined by means of radiographic testing according to the procedures specified above or shall be cut off.
4.7.2 Non-destructive testing of fusion-welded pipes
All pipes shall be tightness tested by the manufacturer in accordance with A.8.8.
D. 1.
Pipes Tough at Sub-Zero Temperatures Scope
The weld seam of the pipes shall be tested over its entire length according to either EN 10246-9, acceptance category U2 or EN 10246-10, image quality class R2 Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or shall be examined by means of radiographic testing according to the procedures specified above or shall be cut off. The base material is to be tested according to EN 10246-15, acceptance category U2.
1.1 These Rules are applicable to seamless or welded pipes made of carbon steel, carbon-manganese steel, nickel alloy steel or austenitic steel tough at subzero temperatures and with wall thicknesses up to 25 mm which are intended for the cargo and processing equipment of gas tankers with design temperatures below 0 C.
For these applications, suitable standardized steel grades may also be used provided that they meet the requirements stated in these Rules, including especially those relating to impact energy at sub-zero temperatures. For the appropriate pipe grades see Table 2.10.
Table 2.10
Comparably suitable pipe grades of steels tough at sub-zero temperatures according to standard
EN 10216-4 1 EN 10216-3 1 or or EN 10217-4 2 EN 10217-3 2 P215NL P255QL P265NL P275NL1 P275NL2 P355NL1 P355NL2 13MnNi6-3 12Ni14 X10Ni9 X2CrNi19-11 X2CrNiMo17-13-2 X6CrNiTi18-10 X6CrNiNb18-10 X6CrNiMoTi17-12-2 13MnNi6-3 12Ni14 X10NiMn9 X2CrNi1810 X2CrNiMo17-12 X6CrNiTi18-10 X6CrNiNb18-10 X6CrNiMoTi17-12 TP 304 L TP 316 L TP 321 TP 347 DIN 17458 1 or DIN 17457 2 ISO 9329-3 1 or ISO 9330-3 2 PL25 ISO 9329-4 1 or ISO 9330-6 2 ASTM 3 A312M
GLR 360 T GLR 390 T GLR 490 T GLR 0,5 Ni GLR 3,5 Ni GLR 9 1.4306 1.4404 1.4541 1.4550 1.4571
1 2 3
Ni
Seamless pipes Welded pipes The notched bar impact energies according to Table 2.14 are to be demonstrated..
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 211
Note: In the case of pipes and connections which are intended for liquefied ammonia at design temperatures above 0 C, the boundary values applicable to chemical composition and strength properties as stated in Section 1, F.8.1.1 or 8.2.2 are to be maintained. 1.2 Where the wall thickness of the pipes exceeds 25 mm, the requirements are subject to special agreement with GL. 1.3 If the pipes are used for cargo and process equipment on gas tankers, the minimum design temperatures specified in Table 2.11 are applicable. Table 2.11 Minimum design temperatures
For austenitic pipes, the heat treatment may be followed by cold drawing entailing small degrees of deformation, provided that the required characteristics can be maintained. Welded austenitic pipes may be delivered in the welded state without post-weld heat treatment provided that a test of the procedure has demonstrated that the characteristics of the material are satisfactory and that the strips or plates used for their manufacture are solution annealed. In addition, any scale, residual slag and temper colours on the inner and outer surfaces shall be carefully removed, e.g. by pickling, grinding or sand blasting. 3. 3.1 Requirements applicable to the material Chemical composition
Strength category or pipe grade GL-R 360 T GL-R 390 T GL-R 490 T GL-R 0,5 Ni GL-R 3,5 Ni GL-R 9 Ni Austenitic pipes
1
Minimum design temperature [ C] 55 1 55 90 165 165
The chemical composition of the pipe steels shall conform to the data in Table 2.13 or, where appropriate, to the other relevant standards or specifications. 3.2 Resistance of austenitic pipe grades to intercrystalline corrosion
Only applicable if the required impact energy has been demonstrated at the time of the approval tests.
Austenitic steel pipes shall be resistant to intercrystalline corrosion. Where welding is not followed by further heat treatment (quenching), only those pipe grades may be used which are corrosion-resistant in the welded condition, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C 0,03 %, see. Table 2.13. 3.3 Mechanical properties
2.
Heat treatment
Depending on the material, the pipes shall be supplied in one of the heat treated conditions specified in Table 2.12. Table 2.12 Heat treatment of steel pipes tough at sub-zero temperatures
Type of heat treatment Normalized or quenched and teampered Normalized Normalized and tempered or quenched and tempered Double normalized and tempered or quenched and tempered Solution annealed and quenched
The values for tensile strength, yield strength or 0,2 % or 1 % proof stress, and elongation specified in Table 2.14 or, where appropriate, in the other relevant standards or specifications shall be satisfied under test at room temperature. 3.4 Technological properties
Strength category or pipe grade GLR 360 T GLR 390 T GLR 490 T GLR 0,5 Ni GLR 3,5 Ni
In the ring tests, the pipes shall exhibit a capacity for deformation which satisfies the requirements stated in A.8.5. 3.5 Low-temperature impact energy
GLR 9 Ni
Seamless austenitic pipes
The required impact energy values specified in Table 2.14 for the pipe grade concerned shall be met at the prescribed test temperatures. This requirement is also applicable to comparable pipe grades conforming to the standards or specifications, irrespective of the values specified therein. 4. Testing and scope of tests
Solution annealed and Welded austenitic pipes quenched or in the welded condition
Chapter 2 Page 212
Section 2
Steel Pipes
II - Part 1 GL 2009
Table 2.13
Chemical composition of steel pipes tough at sub-zero temperatures

Chemical composition [%] Cmax.
0,16 0,16 0,18 0,16 0,15 0,13 0,030 0,030 0,08 1,00 2,00 0,040 0,030 17,0 19,0 9,0 12,0 16,5 18,5 11,0 14,0 2,0 2,5 0,08 0,08

GLR 360 T GLR 390 T GLR 490 T GLR 0,5 Ni GLR 3,5 Ni GLR 9 Ni 1.4306 1.4404 1.4541 1.4550 1.4571
1 2 3
Si
0,40 0,40 0,10 0,50 0,50
Mn
0,40 1,20 0,50 1,50 0,90 0,85 1,70
Pmax.
Smax.
Cr
0,30
Ni
0,3
Mo
0,08
Other elements
Almet 0,015 1, 2 Almet 0,015 1, 3 V 0,05 Ti 5 % C 0,70 Nb 10 % C 1,00 Ti 5 % C 0,80
0,025
0,020
0,025 0,025 0,020
0,015 0,010
0,15
0,30 0,85 3,25 3,75 8,50 9,50
0,10 0,10 2,0 2,5
0,15 0,35 0,30 0,85
17,0 19,0 9,0 12,0 16,5 18,5 11,0 14,0 17,0 19,0 9,0 12,0
Al may be wholly or partly replaced by other fine grain elements. Residual elements: Cu 0,20; total Cr + Cu + Mo 0,45 % Residual elements: Nb 0,05; Cu 0,15; V 0,05; total 0,30
Table 2.14
Mechanical and technological properties of steel pipes tough at sub-zero temperatures
Tensile strength Rm [N/mm2] 360 490 390 510 490 630 490 610 440 620 690 840 480 680 490 690 510 710 510 740 510 710
Yield strength or proof stress ReH or Rp0,2, Rp1,0 1 [N/mm2] min. 255 275 355 355 345 510 215 225 235 240 245
Elongation A [%] min. long. 25 24 22 22 22 20 40 40 35 35 35 transv. 23 22 20 20 20 18 35 35 30 30 30
Impact energy KV 2 [J] min. Test temperature [C] 5 K below design temperature, min. 20 C 60 95 196 41(29) 27(19) long. [J] transv. [J]
GLR 360 T GLR 390 T GLR 490 T GLR 0,5 Ni GLR 3,5 Ni GLR 9 Ni 1.4306 1.4404 1.4541 1.4550 1.4571
1 2
196
Rp0,2 or ReH applies to ferritic steels, Rp1,0.to austenitic steels. Average value of 3 specimens; the values in brackets are the individual minima.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 213
4.1
Table 2.15
The chemical composition of each heat shall be verified by the pipe manufacturer, or, where appropriate in the case of welded pipes, by the manufacturer of the starting material in accordance with A.8.1. 4.2 Test of resistance to intercrystalline corrosion
Strength category or pipe grade GLR 360 T GLR 390 T and GLR 490 T GLR 0,5 Ni GLR 3,5 Ni GLR 9 Ni Austenitic pipes
Constant C 0,09 0,07 0,08 0,06 0,10
4.2.1 The resistance to intercrystalline corrosion shall be tested on austenitic steel pipes where this is called for in the order or where the pipes are made of materials which do not meet the requirements in respect of the limited carbon content or sufficient stabilization with titanium or niobium, see 3.2. 4.2.2 The testing of resistance to intercrystalline corrosion shall be performed in accordance with ISO 3651-2 on at least two samples per heat. The test specimens shall be treated as follows: Steels with C 0,03 % and stabilized steels are to undergo sensitizing heat treatment (700 C, 30 min., water quench). All other grades of steel shall be in the condition in which they are supplied. Tensile test 4.5
Notched bar impact test
4.5.1 On pipes with wall thicknesses 6 mm, the notched bar impact test shall be performed on Charpy V-notch specimens taken from each sample pipe selected in accordance with A.8.2. If the dimensions of the pipe are such that test specimens can be taken without straightening, these shall be taken transverse to the pipe axis. In such cases an additional (transverse) set of specimens shall be taken from fusion-welded pipes so that the notch is located in the middle of the weld metal. In all other cases the specimens shall be taken parallel to the pipe axis. 4.5.2 If the wall thickness of the pipe does not allow the preparation of specimens with the standard dimensions (10 10 mm), specimens measuring 7,5 10 mm or 5 10 mm shall be used. The requirements applicable to these specimens as compared with the standard specimens are shown in Table 2.16. 4.6 Test of surface finish and dimensions
4.3
The tensile test shall be performed on the sample pipes selected in accordance with A.8.2. 4.4 Technological tests
4.4.1 The pipes shall undergo one of the ring tests specified in Table 2.1. For the performance of the tests, specimens shall be taken from one end of two pipes of a test batch. 4.4.2 To calculate the distance between the platens to be used in the ring flattening test, the values according to Table 2.15 shall be assigned to the constant C in the formula given in A.8.5.2:
Tests shall be performed in accordance with A.8.6.
Table 2.16
Impact energy for specimens of reduced size

Required impact energy KV with specimens measuring 7,5 mm 10 mm average value minimum individual value [J] 16 24 5 mm 10 mm average value [J] min. 18 27 minimum individual value [J] 13 22
Required impact energy 1 in Table 2.14 (standard specimens)
[J] min. 27 (19) 41 (29)

1
[J] min. 22 34
Average value of 3 specimens; values in brackets apply to the min. individual value.
Chapter 2 Page 214
Section 2
Steel Pipes
II - Part 1 GL 2009
4.7
All pipes shall be subjected by the manufacturer to a non-destructive test over their whole length according to EN 10246. 4.7.1 Non-destructive testing of seamless and pressure-welded pipes
specified in D., Table 2.13 are appropriate to these applications subject to the following conditions relating to manufacture and testing. 1.2 Pipe grades shall be so selected with regard to subsequent manufacturing operations, e.g. welding, that they possess the chemical stability demanded by the intended application. 2. Heat treatment
The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C or EN 10246-5 (only for ferromagnetic pipe grades), acceptance category F2. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test according to EN 102467, acceptance category U2, subcategory C or shall be cut off. 4.7.2 Non-destructive testing of fusion-welded pipes
The pipes shall be supplied in solution-annealed and quenched condition , although welded pipes may also be supplied without post-weld heat treatment provided that they continue to possess the required chemical stability in this condition and that the conditions stated in D.2. are complied with. 3. 3.1 Requirements applicable to the material Chemical composition
The weld seam of the pipes shall be tested over its entire length according to either EN 10246-9, acceptance category U2 or EN 10246-10, image quality class R2. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test or shall be examined by means of radiographic testing according to the procedures specified above or shall be cut off. The base material is to be tested according to EN 10246-15, acceptance category U2. The pipe ends have to be tested in accordance with EN 10246-17. Laminations in circumferential direction of more than 6 mm length are not permitted within the last 25 mm pipe length at each end. Plate or strip edges adjacent to the weld seam are to be tested within a 15 mm wide zone along the weld seam in accordance with EN 10246-15 or EN 10246-16, acceptance category U2 in each case. 4.8 Tightness test
The chemical composition of the pipe steels shall conform to recognized standards or specifications. 3.2 Resistance to intercrystalline corrosion
In the condition in which they are supplied, the pipes shall be resistant to intercrystalline corrosion. Where the welding is not to be followed by heat treatment (solution annealing), only those pipe grades may be used which are corrosion-resistant in the welded condition, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C 0,03 %. 3.3 Mechanical properties
The required values of tensile strength, 1 % proof stress and elongation shall be satisfied in tests at room temperature in accordance with the standard or the recognized specification. 3.4 Technological properties
In the ring tests, the pipes shall exhibit a capacity for deformation which satisfies the requirements stated in A.8.5. 3.5 High-temperature characteristics
E. 1.
Stainless Steel Pipes Scope
1.1 These Rules are applicable to seamless and welded austenitic and austenitic-ferritic stainless steel pipes to be used for the cargo and processing equipment on chemical tankers and for other lines, vessels and equipment where chemical stability is required. Suitable pipe grades conforming to international or national standards and to established and recognized specifications together with the austenitic pipe grades
Where pipes are used at elevated temperatures, the required values for the 0,2 % or 1 % proof stress prescribed in the relevant standards or recognized specifications shall be met at the corresponding temperature level. 3.6 Impact energy
The required impact energy values shall be satisfied in tests at room temperature in accordance with the relevant standard or the recognized specification.
II - Part 1 GL 2009
Section 2
Steel Pipes
Chapter 2 Page 215
4.
4.4
Technological tests
The following tests are to be performed: 4.1 Test of chemical composition
The chemical composition of each heat shall be demonstrated by the pipe manufacturer, or, where appropriate in the case of welded pipes, by the manufacturer of the starting material in accordance with A.8.1. 4.2 Test of resistance to intercrystalline corrosion
Unless more extensive testing is prescribed in the standards, one of the ring tests specified in A., Table 2.1 shall be performed on one end of 2 % of the pipes. To calculate the distance between the platens to be used in the ring flattening test, a value of 0,10 shall be assigned to the constant C in the formula given in A.8.5.2. 4.5 High-temperature tensile test
Where called for in A.8.3 or stipulated in the purchase order, the 0,2 % or 1 % proof stress shall be determined by a high-temperature tensile test. 4.6 Test of surface finish and dimensions
Depending on the application and grade of the pipes, a test of resistance to intercrystalline corrosion shall be performed on the following pipes: pipes for use on chemical tankers irrespective of the type of material pipes which do not meet the requirements in respect of stabilization or limited carbon content specified in 3.2 pipes made of stabilized steels or steels with limited carbon contents intended for applications not covered, where such testing is specially prescribed in view of the anticipated corrosive attack
Tests shall be performed in accordance with A.8.6. 4.7 Non-destructive tests
All pipes shall be subjected by the manufacturer to non-destructive testing over their entire length according to EN 10246. The pipes shall be subjected to a non-destructive test in order to detect longitudinal defects according to EN 10246-7, acceptance category U2, subcategory C. Areas in way of pipe ends which have not been tested automatically, shall be subjected either to a manual or semi-automatic ultrasonic test according to EN 102466, acceptance category U2, subcategory C or shall be cut off. 4.8 Tightness test
The test conditions shall be as prescribed in D.4.2.2. 4.3 Tensile test
The tensile test shall be performed on specimens of the sample pipes selected in accordance with A.8.2.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 31
Section 3 Forgings
A. 1. General Rules Scope istics, e.g. by laying open the core zone, is not allowed. Necks of shafts, pinions and journals exceeding 1/10 of the outer diameter shall be produced as far as possible by stepped forging. The degree of deformation shall be such that the core zone of the forging undergoes sufficient plastic deformation. Unless otherwise approved the total reduction ratio is to be at least: for forgings made from ingots or from forged blooms or billets, 3 : 1 where L > D and 1,5 : 1 where L < D for forgings made from rolled products, 4 : 1 where L > D and 2 : 1 where L < D for forgings made by upsetting, the length after upsetting is to be not more than one-third of the length before upsetting or, in the case of an initial forging reduction of at least 1,5 : 1, not more than one-half of the length before upsetting for rolled bars, 6 : 1.
This part contains general Rules to be applied in the manufacture and testing of forgings. In conjunction with the individual Rules which follow, this part is also applicable to rolled steel bar, where it is to be used in place of forgings for the manufacture by machining of shafts, arbors, pins and similar parts. 2. Selection of steels
2.1 All steels shall be suitable for their application and shall satisfy the minimum requirements specified in the following individual Rules. Subject to these conditions, steels conforming to the relevant standards or to material specifications approved by GL may be used. 2.2 The steels shall be identified by the standardized designations or the designations given in the specifications. 3. Requirements to be met by manufacturers
L and D are the length and diameter respectively of the part of the forging under consideration. 4.4 Annular and hollow shapes shall be produced from sections cut from the ingot or bloom which have been suitably punched, drilled or trepanned before the parts are rolled or expanded over a suitable mandrel. 4.5 The shaping of forgings or rolled products by flame cutting and flame scarfing and gouging shall be performed using established methods prior to the final heat treatment unless otherwise agreed with GL. Depending on its composition and/or thickness the workpiece shall be preheated. Where necessary, surfaces produced by flame cutting shall be machined. 4.6 Where two or more forgings are to be welded together, details of the welding method shall be submitted for approval. GL reserves the right to call for a welding procedure approval test in these cases. 5. Condition of supply and heat treatment
3.1 Manufacturers wishing to produce forgings to these Rules shall fulfil the conditions stated in Chapter 1 Principles and Test Procedures, Section 1 and shall prove this before the commencement of supplies. In addition, an approval test shall normally be performed on forgings selected for the purpose. The extent of the tests will be determined by GL on a case to case basis. 3.2 Forges without their own steelmaking facility may only use starting material supplied by producers who have been approved by GL. 4. Method of manufacture
4.1 Forging steel shall be produced by a basic oxygen process, in an electric furnace or by other methods approved by GL and shall be killed. On request, GL shall be informed of the steelmaking process used. 4.2 A sufficient amount of material shall be cropped from the top and bottom ends of ingots to ensure that the forgings are free from harmful segregations. This term includes all inhomogeneities liable to impair the required characteristics. 4.3 Given a reasonable machining allowance, workpieces shall as far as possible be forged to the final dimensions. Excessive machining to give the forging its final shape which may impair its character-
5.1 All forgings shall be suitably heat treated according to the material for obtaining a fine grain homogeneous microstructure condition as well as the required mechanical properties. Heat treatments shall be applied in suitable furnaces, which shall be properly and regularly maintained. They shall be fitted with devices for controlling and indicating the temperature; these devices are to be checked at regular intervals. The furnace dimensions shall enable the whole forging to be raised uniformly to the required heat treatment temperature.
Chapter 2 Page 32
Section 3
Forgings
II - Part 1 GL 2009
5.2 All hot forming operations shall be concluded prior to the final heat treatment. Should it be necessary for some reason to reheat a forging for a further hot forming operation, then the final heat treatment shall be repeated. 5.3 Where a forging is subjected to hot or cold straightening after the final heat treatment, subsequent stress relief heat treatment to remove the residual stresses may be required. 5.4 Forgings whose section is substantially altered by machining after the forging operation may only be quenched and tempered after they have undergone adequate rough machining. The weight of the quenched and tempered forging shall not exceed 1,25 times that of the finished part. 5.5 If the prescribed heat treatment is to be replaced by an equivalent temperature cycle during and after the hot forming process, appropriate tests shall be performed to prove to GL that the method is indeed equivalent. 6. General characteristics of forgings
shall be given in the order documents and shall be made known to the Surveyor. 8. Tightness
Hollow forgings subjected to internal pressure by the operating medium shall be leakproof at the specified test pressure. 9. 9.1 General requirements applicable to the material Chemical composition
9.1.1 The chemical composition of forged steels shall conform to the limit values indicated in the Tables given in this section and/or in the relevant standards or specifications. If use is made of standardized steels whose nominal carbon contents agree with the limit values indicated in the Tables, the limits specified in the standards may be recognized. The steels shall also contain the quantities of deoxidizers needed to kill the steel. Where steels are deoxidized by the vacuum-carbon method the lower limits for the Si and Al contents are inapplicable in all the rules specifying chemical composition. 9.1.2 The steelmaker shall take appropriate steps to ensure that elements liable to impair the characteristics of the products cannot enter the heat by way of scrap or other materials used in the steelmaking process. 9.2 9.2.1 Mechanical and technological properties Tensile test
6.1 All forgings shall be free from defects such as flakes, cracks, shrinkage cavities, segregation, peripheral blow holes and major non-metallic inclusions which are capable of having a more than insignificant adverse effect on their application and treatment. Forgings delivered in the unmachined condition shall have a smooth surface consistent with the method of manufacture. 6.2 Minor surface defects may be removed by grinding. The complete removal of the defects shall be proved by a magnetic particle or dye penetrant test. With the consent of the Surveyor, shallow depressions or indentations may be allowed to remain provided that they are ground out to accommodate them to the surrounding area and that their depth, in the case of surfaces which are to be machined, lies within the machining allowance. 6.3 The removal of defects by welding is permitted only in exceptional cases with the agreement of GL if the defects are of limited extent and occur at points which are subject to low operating loads. In these cases, full details of the proposed repair and of the subsequent test method shall be submitted to GL for approval before the start of the repair. In addition, the test report shall be submitted with a description or sketch showing the position and extent of all repairs together with details of the subsequent heat treatment and non-destructive tests applied. 7. Dimensions; dimensional and geometrical tolerances
The requirements indicated in the Tables contained in these Rules or, where applicable, in the relevant standards or specifications shall be met under tensile test. 9.2.2 Notched bar impact test
The impact energy values specified for the various steel grades shall be met by the average result produced by 3 specimens, one of which may give a result below the specified average value although not lower than 70 % of the specified average value. 9.2.3 Other characteristics
Where special characteristics are specified for particular grades of steel, e.g. resistance to intercrystalline corrosion or 0,2 % proof stress at high temperatures, these characteristics shall be verified by appropriate tests. 10. 10.1 Testing Proof of chemical composition
The dimensions and the dimensional and geometrical tolerances are governed by the values given in the drawings accompanying the order or, where applicable, in the relevant standards. Instructions on this point
The manufacturer shall determine the chemical composition of each heat and present a corresponding certificate to the Surveyor. The certificate shall indicate the chemical composition of the heat characteristic of the steel grade concerned.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 33
Should there be any doubt as to the composition or where the connection between the certificate and the forgings cannot be proved, a product analysis shall be performed. 10.2 Test of mechanical properties and selection of specimens
quenched and tempered forgings: per test batch one test section from two forgings. With batches of 10 forgings or less, a test section is required from only one forging.
At least 5 % of all quenched and tempered forgings which undergo batchwise testing shall be subjected to a hardness test. In the case of products 3 m in length and weighing over 4 000 kg in heat-treated condition which do not undergo heat treatment in a continuous furnace, one test section shall be taken from each end of the forging to be tested. 10.2.3.4 Depending on the conditions agreed on placing the order, the test sections shall be taken as follows: from a forging (which is then destroyed in its entirety) from additional material provided on the forging from a sample of similar dimensions from the same heat, which has been forged in the same way as the other forgings and heat treated together with them
10.2.1 The mechanical properties shall be ascertained by tensile test to determine tensile strength, yield strength or 0,2 % proof stress, elongation and reduction in area. 10.2.2 Unless otherwise specified, the impact energy shall be determined by notched bar impact tests on each forging or each test batch, as appropriate. 10.2.3 Unless otherwise specified, the following shall apply to the verification of the mechanical properties with regard to the test batches and the test specimens: 10.2.3.1 Forgings with similar dimensions which originate from the same heat and have been heat treated together shall be grouped into a test batch. 10.2.3.2 Testing of normalized forgings with unit weights of 1000 kg or quenched and tempered forgings with unit weights of 500 kg shall be performed in test batches. Unless otherwise agreed with GL, the size of the test batch shall be as detailed in Table 3.1. Surplus quantities up to 10 % of the number of forgings per test batch can be allotted to a test batch Forgings with unit weights > 1 000 kg (normalized) and > 500 kg (quenched and tempered) shall be tested individually. Table 3.1 Heat treatment weight of individual forging and number of forgings per test batch
10.2.3.5 The location of the test specimens in the cross section of the heat-treated region shall be as follows: The specimens shall be taken starting from the surface at a distance of 1/4 of the diameter or the (wall) thickness, but max. 80 mm, and at a corresponding distance from a further, adjacent surface. 10.2.3.6 It may be necessary to distinguish between the geometrical position of the specimens in the forging and their location in relation to the direction of the fibre. For forgings, the references in the tables to longitudinal, tangential and transverse orientations refer to the position of the specimen in relation to the direction of the fibre and should be understood as follows: Longitudinal: The longitudinal axis of the specimen is parallel to the main direction of elongation of the non-curved fibre pattern; Tangential: The longitudinal axis of the specimen traverses the curved fibre pattern in the form of a chord (and thus "slopes", so to speak, in relation to it); The longitudinal axis of the specimen traverses the fibre pattern at right angles. Specimens with a longitudinal axis lying in the direction of an additional compression (perpendicular to an expansion) of the fibre pattern (socalled location "in the thickness direction") are not covered by the specimen positions termed "transverse".
Heat treatment weight of individual forging [kg] up to 15 > 15 to > 150 to 150 300
Number of forgings per test batch 300 100 50 25
> 300 to 1000
Transverse:
10.2.3.3 The number of test sections required for the tensile test and the notched bar impact test is as follows: normalized forgings: one test section from one forging per test batch.
Chapter 2 Page 34
Section 3
Forgings
II - Part 1 GL 2009
10.2.3.7 Normally, test specimens shall be taken from the test sections forged together with the workpieces. This test section may normally be separated from the forging only after the latter has undergone final heat treatment. In this context, subsequent heat treatment for stress relief may be disregarded. Prior separation is permitted only where the manufacturing process makes this unavoidable. In these circumstances, the forging and the test section shall be heat treated together. 10.2.3.8 All test sections shall be forged with the same degree of deformation to a cross section corresponding to the relevant cross section of the forging. The test sections shall be large enough to provide material not only for the specimens required for the initial test but also for specimens needed for possible retests. All test sections and samples shall be so marked that they can be clearly related to the forgings or test batches which they represent. 10.2.4 For forgings whose method of manufacture is subject to special approval by GL, see 5.5, the number and position of the test sections shall be specially determined with regard to the method of manufacture. 10.3 Test of surface finish and dimensions
10.5
Retests in the event of failure of specimens
If the required values of tensile strength or notched bar impact tests are not achieved or if a notched bar impact test produces an individual value which is lower than 70 % of the required average value, then, before the forging or the unit test quantity is rejected, the procedure for repeat tests prescribed in Chapter 1 Principles and Test Procedures, Section 2, H. may be applied. The additional test specimens shall be taken either from the same test section as the original specimen or from other test sections or samples which are representative of the test batch concerned. 11. Identification and marking
11.1 The manufacturer shall institute a monitoring system enabling all forgings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request. 11.2 Prior to final inspection, all forgings shall be stamped by the manufacturer in at least one place with the following marks: steel grade manufacturer's mark item or heat number, or another mark enabling the manufacturing process to be traced back specimen number date of test
10.3.1 The manufacturer shall inspect each forging for surface finish and compliance with the dimensional and geometrical tolerances and shall then submit the forgings to the Surveyor for final inspection. The inner surfaces of hollow forgings and bores are to be included in these inspections. 10.3.2 The surface of the forgings shall be clean and properly prepared for inspection. Surface defects are to be removed. Where necessary this condition shall be achieved by pickling, local grinding, shot or sand blasting, cleaning with wire brushes or by chemical means, unless the parts are submitted in the rough machined condition. 10.3.3 If the surface condition suggests that welds have been carried out on the forging, the Surveyor may demand local etching to reveal possible welds. 10.4 Non-destructive tests
The area receiving the stamp marks shall be ground. 11.3 In the case of small, series-manufactured forgings, agreement may be reached with the Surveyor to apply stamp marks other than those stated in 11.2. 12. Certificates
For each consignment the manufacturer shall supply to the Surveyor a certificate containing at least the following details: purchaser and order number newbuilding number and project number, if known nature of forging and grade of steel purpose and drawing number, if necessary weight of the forging method of forging item number and number of units heat number chemical composition of the heat condition of supply details of heat treatment
10.4.1 Where non-destructive tests are called for, these are to be performed by the manufacturer and/or finishing plant. Tests may also be arranged by the Society. 10.4.2 Non-destructive tests are to be performed in accordance with the specifications stated in G. in consideration of the specifications in Chapter 1 Principles and Test Procedures, Section 3.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 35
results of the mechanical tests results of any special tests applied, e.g. test of resistance to intercrystalline corrosion, determination of proof stress at elevated temperatures or non-destructive tests
4. 4.1
4.1.1 The chemical composition of the forging steels is subject to the limit values in Table 3.2. Table 3.2 Limit values for the chemical composition of forging steels
Alloyed steels Chemical composition 2 [%]
B.
Forgings for Machine Construction and Shipbuilding Scope
C- and CMn steels Chemical composition 1 [%] Permitted residual elements [%] max. Cu 0,30 Cr 0,30 Ni 0,40 Mo 0,15
1.
These Rules are applicable to forgings made of unalloyed and low alloy steels intended for the manufacture of components and structural parts in machine construction and shipbuilding, e.g. shafts, piston rods, connecting rods, rudderstocks and heel pintles. They are also applicable to rolled round bars for the manufacture of shafts, pins, tie-rods and similar components which are given their final shape by machining. 2. Suitable grades of steel
Cmax. 0,50 3, 4 Simax. 0,45 Mn 0,30 1,70
Cmax. 0,45 3 Simax. 0,45 Pmax. 0,035 Smax. 0,035
Pmax. 0,035 Smax. 0,035

1 2 3
On condition that they meet the requirements specified in 4., the following steels may be used: 2.1 Suitable grades of forging steel conforming to recognized standards, e.g. EN 10083, EN 10250-2, EN 10250-3 and SEW 550. 2.2 Other unalloyed and low alloy steels conforming to other standards or material specifications, provided that their suitability has been confirmed by GL. An initial test of product suitability may be required for this purpose. 3. Condition of supply and heat treatment
Where necessary, grain-refining elements, e.g. aluminium, may be added. For the alloying elements the data given in the standards or approved specifications are applicable. The use of steels with carbon contents of C > 0,50 % and C > 0,45 %, respectively, shall be specially authorized by GL. For welded constructions, rudderstocks and pintles: max. 0,23 % C.
4.1.2 Where forgings are to be used in welded assemblies, the composition shall be specially determined by reference to the welding method used and shall be submitted to GL for approval. 4.2 Mechanical and technological properties
3.1 All forgings shall be properly heat treated. Acceptable methods of heat treatment are: for carbon and carbon-manganese steels: normalizing normalizing and tempering (air quenching and tempering) quenching and tempering
4.2.1 The required values of yield strength, reduction in area and elongation shown in Tables 3.5 and 3.6 respectively in relation to the prescribed minimum tensile strength shall be met. 4.2.2 The strength levels of 40 and 50 N/mm stated in Tables 3.5 and 3.6 respectively should not be regarded as minimum tensile strengths for certain grades of forging steel, but are intended to enable the required property values (yield strength, elongation, reduction in area and impact energy) to be determined by interpolation in relation to the prescribed minimum tensile strengths. 4.2.3 If two test specimens are taken from forgings, the difference between the measured tensile strength values may not exceed the magnitudes stated in Table 3.3.
for alloy steels: quenching and tempering
3.2 Large forgings of complex shape made of carbon or carbon-manganese steel which are to be supplied in normalized condition shall undergo additional stress-relieving heat treatment if they have been extensively machined subsequent to normalizing.
Chapter 2 Page 36
Section 3
Forgings
II - Part 1 GL 2009
Table 3.3
Differences permitted between tensile strength values

Difference permitted between tensile strength values [N/mm2] 70 100 120
5. 5.1
Testing Mechanical testing
Minimum tensile strength Rm [N/mm2] < 600 600 < 900 900
5.1.1 Testing shall be accomplished by tensile tests and notched bar impact tests in accordance with A. 10.2. Quenched and tempered forgings grouped into test batches shall be subjected to additional hardness testing. 5.1.2 Notched bar impact testing of propeller shafts, rudderstocks and heel pintles for ships with ice class symbols shall be carried out with Charpy Vnotch specimens. For all other products, the selection of the specimen shape according to Chapter 1 Principles and Test Procedures, Section 2, E.1. and E.2. shall be at the manufacturer's discretion. 5.1.3 The test specimens may be taken from the samples in longitudinal, tangential or transverse direction in relation to the fibre pattern; cf. Figures 3.1 to 3.3. 5.2 Non-destructive tests
4.3
Impact energy
The required impact energy values shown in Tables 3.5 and 3.6 in relation to the specified minimum tensile strength shall be met. Irrespective of this, for heel pintles and rudderstocks an impact energy of at least 27 J shall be attained with longitudinal Charpy V-notch specimens measured at 0 C for ships with ice class symbols E3 and E4 and at 20 C for ships with the arctic ice class symbols ARC1 to ARC4. One individual value may be below the average value but shall not be less than 19 J. For propeller shafts intended for ships with ice class an impact energy of at least 27 J with longitudinal Charpy V-notch specimens measured at 10 C shall be attained. 4.4 Hardness
The specifications in G. do apply. The components indicated in H. are to be tested according to the scope prescribed there. 5.3 Test of surface finish and dimensions
All forgings shall be presented to the Surveyor in the condition in which they are delivered for testing of the surface finish and the dimensions.
Longitudinal specimen
4.4.1 The hardness values prescribed in the approval drawings or specifications of the forgings are mandatory. The figures shown in Tables 3.5 and 3.6 are guide values only. 4.4.2 Where a hardness test is stipulated, the hardness values measured at different points on the forging or on different units within a unit test quantity respectively may not differ by more than the amounts stated in Table 3.4. If the hardness is measured in other units, the values shall be converted into the corresponding Brinell units. Table 3.4 Differences permitted between hardness values C. 1.
Minimum tensile strength Rm [N/mm2] < 600 600 < 900 900 Difference in hardness Brinell units up to 25 up to 35 up to 42
Transverse specimens
Transverse specimens
Fig. 3.1
Location of specimens in unflanged shafts and rods
Forgings for Crankshafts Scope
These Rules are applicable to solid forged crankshafts and to the forged throws, webs and pins of semi-built crankshafts of unalloyed and low alloy steels. 2. Approved materials
Only materials which have been approved by GL as suitable for the intended application may be used. To this end, the engine manufacturer shall submit to GL for approval specifications and/or drawings containing
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 37
Tangential specimens Transverse specimens
Tangential specimens Longitudinal specimens
Transverse specimen
Fig. 3.2 Location of specimens in flanged shafts with thrust flange
Longitudinal specimen (bore)
Longitudinal specimens
Transverse specimen
Transverse specimen
Fig. 3.3 Location of specimens in flanged shafts
all the data required for evaluating the material, e.g. method of manufacture, chemical composition, heat treatment and mechanical properties. The minimum requirements as per Tables 3.5 and 3.6 are to be satisfied. 3. Requirements applicable to the material
if they achieve the required characteristics. GL shall be advised of the method of manufacture. 4.2 Where crankshaft webs are produced by thermal cutting from forged or rolled flat products, the heat-affected area at the cut faces shall be completely removed by machining. This Rule does not apply to webs which are cut out of the starting material before the specified heat treatment is applied. 4.3 Crankshafts shall normally be supplied in quenched and tempered condition. However, crankshafts and their components which are made of carbon and carbon-manganese steels may also be normalized or normalized and tempered. Where crankshafts are to be surface-hardened, the nature of the heat treatment shall be stated in the manufacturer's specification. 5. 5.1 Testing Tensile test
3.1 With regard to the chemical composition, mechanical properties and required impact energy and hardness values of the steel, the data contained in the approved specification or drawing are applicable. 3.2 The steel shall undergo vacuum degassing following its production to ensure that the hydrogen content of the heat does not exceed 2 ppm. 4. Manufacture and condition of supply
4.1 Wherever possible, the throws of built crankshafts shall be preforged as a flat semi-finished product and then folded in a press to produce a rough forging having a fibre pattern with favourable loading characteristics. However, other processes may be used
The mechanical properties shall be verified by tensile test. Test specimens shall be taken for this purpose in accordance with 5.1.1 to 5.1.4.
Chapter 2 Page 38
Section 3
Forgings
II - Part 1 GL 2009
Table 3.5
Mechanical and technological properties of carbon and carbon manganese steel forgings in normalized or quenched and tempered condition for room temperature
Relevant heat treatment diameter [mm] Yield strength ReH Elongation
So
Minimum tensile strength 1, 2 Rm
( for Lo = 5,65
A [%] min. long.
Reduction in area Z [%] min. KV 3 [J] min.
Impact energy KU [J] min. Brinell hardness HB (Guide values)
[N/mm2]
min.
[N/mm2]
tang. trans. long. tang. trans. long. tang. trans. long. tang. trans. 40 32 25 25 32 25 25 30 25 24 27 25 24 25 20 18 20 20 14 15 15 14 15 15 15 15 15 15 15 15 25 18 18 25 18 18 22 18 18 22 18 14 20 15 13 15 15 12 12 12 12 12 12 12 12 12 12 12 12 38 30 29 38 30 27 35 30 25 32 30 22 30 25 20 25 25 19 20 20 17 20 20 20 20 20 20 20 20 30 25 23 30 25 22 27 25 20 25 25 17 25 20 15 20 20 12 17 17 12 17 17 17 17 17 17 17 17 25 20 18 25 20 17 22 20 15 22 20 12 20 17 11 17 17 10 15 15 10 15 185 230 18 18 15 15 200 240 18 18 15 15 210 250 18 18 15 15 225 265 18 15 175 215 160 200 150 185 135 175 125 160 110 150 95 125
250 360 > 250 500 > 500 1000 250 400 > 250 500 > 500 1000 250 440 > 250 500 > 500 1000 250 480 > 250 500 > 500 1000 250 520 > 250 500 > 500 1000 250 560 > 250 500 > 500 1000 250 600 > 250 500 > 500 1000 640 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 320 17 15 12 40 32 27 300 18 16 13 40 34 27 280 20 17 14 40 34 27 260 21 18 15 45 38 30 240 22 19 16 45 38 30 220 24 21 18 50 42 35 200 26 23 19 50 42 35 180 28 24 20 50 42 35
32 32 40 32 32 38 32 30 35 32 26 32 25 24 25 25 23 18 18 18 18
680
340
16
14
12
40
32
27
720
360
15
13
11
40
32
27
760
1 2 3
380
14
12
10
35
30
24
Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements are to be determined by interpolation, see 4.2.2. The tensile strength determined by testing may not exceed the specified minimum tensile strength, if less than 600 N/mm2, by more than 120 N/mm2. Where the minimum tensile strength is 600 N/mm2 not more than 150 N/mm2 may be exceeded. The propeller shafts, rudderstocks and heel pintles of ships with ice class symbols are subject to the impact energy values stipulated in 4.3.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 39
Table 3.6
Mechanical and technological properties of alloy steel forgings in quenched and tempered condition for room temperature
Elongation Reduction in area Z [%] min. KV 4 [J] min. Impact energy KU 4 [J] min. Brinell hardness HB (Guide values)
Relevant heat treatment diameter [mm]
Yield strength 3 ReH
(for Lo = 5,65
A [%] min. long. 20 18 20 18
So
[N/mm2]
550
[N/mm2]
min.
tang. trans. long. tang. trans. long. tang. trans. long. tang. trans. 18 16 18 16 16 15 15 14 15 13 14 12 13 11 13 11 11 10 11 10 10 10 10 10 16 14 16 14 14 13 13 12 13 11 12 10 11 10 11 10 10 10 10 10 8 8 8 8 40 35 27 40 35 27 40 35 27 40 35 27 40 35 27 45 40 30 45 40 30 45 40 30 50 45 35 50 45 35 50 45 35 50 45 35 41 32 41 32 32 25 32 25 32 25 32 25 27 25 27 25 25 25 25 25 25 25 25 25 32 25 32 25 28 18 28 18 26 18 26 18 23 18 23 18 21 18 21 18 18 18 18 18 24 18 24 18 22 13 22 13 20 13 20 13 18 13 18 13 16 13 16 13 13 13 13 13 35 30 35 30 30 25 30 25 30 25 30 25 29 25 29 25 29 25 25 25 25 25 25 25 30 25 30 25 27 20 27 20 26 20 26 20 25 20 25 20 25 20 22 20 20 20 20 20 24 20 24 20 23 15 23 15 22 15 22 15 20 15 20 15 20 15 18 15 15 15 15 15 320 385 310 375 290 365 275 340 260 320 245 290 235 275 215 260 205 245 190 235 175 215 160 200
250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 250 > 250 500 0,7 minimum tensile strength 0,6 minimum tensile strength
600
18 17 17 16 17 15 15 14 14 13 14 13 13 12 12 12 11 11 11 11
650
700
750
800
850
900
950
1000
1050
1100
1 2 3 4
Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements are to be determined by interpolation, see 4.2.2. The tensile strength determined by testing may not exceed the specified minimum tensile strength, if less than 900 N/mm2, by more than 150 N/mm2. Where the minimum tensile strength is 900 N/mm2 not more than 200 N/mm2 may be exceeded. For case-hardening steels a value of 60 % of the specified minimum tensile strength is sufficient irrespective of the value of the tensile strength. Where the heat treatment diameter is > 500 mm, the requirements shall be agreed with GL.
Chapter 2 Page 310
Section 3
Forgings
II - Part 1 GL 2009
5.1.1 Independently of the selection of test specimens according to test batches as prescribed in 5.1.3, at least one longitudinal or transverse tensile test specimen shall be taken from the driven side of each crankshaft. Where a solid forged crankshaft weighs more than 3000 kg, test specimens shall be taken from both ends, on the driven side as a transverse specimen. The weight applicable is the weight of the crankshaft in the heattreated condition minus the weight of the test sections. 5.1.2 Where the throws are machined or flame cut from a preforged crankshaft, a second set of test specimens shall be taken in the transverse direction from the material removed from the throw furthest from the driven side, cf. Fig. 3.4. The test sections may not be removed prior to quenching and tempering.
Longitudinal specimen Longitudinal specimen
The method of hardness testing and the position of the hardness testing impressions on the forgings shall be agreed with GL. 5.3.2 The differences in the hardness values measured at different points on the forging or on different units within a test batch may not exceed the magnitudes stated in B.4.4.2. 5.4 Test of surface finish and dimensions
The crankshaft manufacturer shall test the surface finish and dimensions of the crankshafts and give the measurement records to the Surveyor. He shall also present the crankshafts to the Surveyor for final inspection and hold in readiness the measuring instruments required for checking the dimensions. 5.5 Non-destructive testing
Crankshafts shall be subjected to non-destructive testing according to the scope stipulated in G.

H
D/4
D/4
H/4
D. 1.
Forgings for Gears Scope
Transverse specimen
Transverse specimen
Driven side
Fig. 3.4 Location of test specimens in crankshafts 5.1.3 Crankshafts of the same dimensions up to a weight in heat-treated condition of 500 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with Table 3.1, A.10.2.3. For quenched and tempered crankshafts, two tensile test specimens shall be taken from each test batch; for normalized shafts, one specimen is sufficient. 5.1.4 Transverse test specimens shall be taken from forged throws. Unless otherwise agreed with GL, at least one specimen shall be taken from each forging. 5.1.5 Where two test specimens are taken from large crankshafts, the difference between the measured tensile strength values may not exceed the magnitudes stated in B.4.2.3. 5.2 Notched bar impact test
These Rules are applicable to forgings made of carbon, carbon-manganese and low alloy steels which are intended for the manufacture of wheels and wheel rims for the gears of the main engine and auxiliary equipment. 2. Suitable grades of steel
On condition that they satisfy the requirements of 6., the following grades of steel may be used: 2.1 Quenched and tempered steels conforming to EN 10083-1, case hardening steels conforming to EN 10084 and nitriding steels conforming to EN 10085, provided that proof has been furnished of the suitability of the individual grade of steel for the intended purpose. Table 3.7 contains a selection of suitable steel grades. 2.2 Steels conforming to other standards, provided that they are comparable with the steel grades specified in 2.1 and proof has been furnished of their suitability for the intended purpose. Table 3.7 Suitable steel grades for gears Standard EN 10083-1
Each forging or unit test quantity, as applicable, shall be subjected to the notched bar impact test. The number of sets of specimens (each comprising 3 specimens) and their position are subject to the conditions stated in 5.1.1 to 5.1.4 for tensile test specimens. 5.3 Hardness testing
Steel grade 42CrMo4 16MnCr5 20MnCr5 18CrNiMo7-6
5.3.1 Where testing is performed in test batches, at least 10 % of the crankshafts shall be subjected to hardness tests.
EN 10084
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 311
2.3 Steels conforming to particular material specifications, provided that GL has authorised their use. To this end, the gear manufacturer shall submit the corresponding specifications for approval. These specifications shall contain all the data required for their evaluation, e.g. method of manufacture, chemical composition, heat treatment, surface hardening and mechanical properties. 3. Welded wheels
4.2.3 Nitriding steels shall be quenched and tempered prior to nitriding. Where possible, nitriding shall be effected by the action of gases. The nature of the heat treatment, the nitriding depth and the hardness range (min/max) shall be stated in a specification. 4.3 The heat treatments and surface hardening processes referred to in 4.2 shall be carried out in such a way as to produce uniform hardening of the depth and hardness stipulated in the specification. GL reserves the right to require the manufacture of samples on which the uniformity, depth and hardness of the surface layer shall be demonstrated. 5. Dimensions, dimensional and geometrical tolerances
Where gear wheels are made up of components welded together, full details of the welding process, the scope of non-destructive testing and the acceptability criteria for welding defects shall be submitted to GL for approval. The characteristics of the welds shall first be demonstrated by a welding procedure specification test. 4. Heat treatment
The data shown in the drawings relating to the order are applicable. 6. 6.1 Requirements applicable to the material Chemical composition
4.1 Forgings for which surface hardening after the cutting of the teeth is not specified shall be quenched and tempered. Carbon and carbon-manganese steels may also be normalized and tempered. 4.2 In the case of forgings which undergo surface hardening after the cutting of the teeth, the heat treatment depends on the nature of the surface hardening process, as follows: 4.2.1 After carburization, case-hardening steels are to be hardened and then tempered at low temperature. The depth of case hardening, the time-temperature cycle and the hardness range (min/max) shall be stated in the specification. 4.2.2 Steels for induction hardening shall normally be quenched and tempered prior to hardening. Carbon and carbon-manganese steels may also be normalized instead of quenching and tempering. The nature of the heat treatment, the depth of hardening, the hardening temperatures, the quenching media and the hardness range (min/max) shall be stated in the specification. Table 3.8
6.1.1 The chemical composition is subject to the limit values specified in the relevant standard or the approved specification. 6.1.2 Where forgings are to be used for welded wheel assemblies, their composition shall be specially determined to suit the method of welding and shall be submitted to GL for approval. 6.2 Mechanical and technological properties
For quenched and tempered steels, the minimum required values for the yield strength, elongation and reduction in area specified in Tables 3.5 and 3.6 in C. shall be met in relation to the prescribed minimum tensile strength. For case-hardening steels, the requirements specified in Table 3.8 apply to specimens which have undergone heat treatment together with the forging (coupons).
Required values for mechanical and technological properties of specimens made of coupons
Elongation Yield Sample strtength dia. ReH [mm] Tensile strength Rm A1 [%] min. l 780 1080 980 1280 10801320 640 940 780 1080 980 1280 10 8 8 11 10 8 t, q 8 6 6 9 8 6 Reduction in area Z1 [%] min. l 40 35 35 40 35 35 t, q 27 27 27 27 27 27 l 22 18 18 22 22 18 Impact energy KV 1 KU 1 [J] min. t, q 16 13 13 16 16 13 l 24 20 20 24 24 20 t, q 18 15 15 18 18 15
Steel grade
[N/mm2]
min. 590
[N/mm2]
[J] min.
16MnCr5 20MnCr5 18CrNiMo7-6 16MnCr5 20MnCr5 18CrNiMo7-6

1
30
690 785 440
63
540 685
Orientation of specimen axis:
l = longitudinal, t = tangential, q = transverse
Chapter 2 Page 312
Section 3
Forgings
II - Part 1 GL 2009
6.3
Hardness
Tangential specimen
For all gear components, the hardness values prescribed for the tooth area in the specification or approval drawing are mandatory. 7. Testing Fig. 3.6 Gear wheel
Tangential specimen
The following tests shall be performed: 7.1 Test of chemical composition
The material manufacturer shall determine the composition of each heat and issue a relevant certificate. 7.2 Tensile test on finally heat-treated, induction-hardened and nitrided forgings
The mechanical properties shall be verified by tensile test. Test specimens shall be taken as follows: 7.2.1 Pinions over 200 mm in diameter:
If the diameter in the area of the teeth is greater than 200 mm, a tangential test specimen shall be taken from a position adjoining the tooth area, see Fig. 3.5. If the dimensions of the blank do not allow a specimen to be taken from this position, then a transverse specimen may be taken from an extension of the bearing journal. If the diameter of the bearing journal is 200 mm or less, then a longitudinal specimen may be taken. If the length of the finished tooth system is more than 1250 mm, test specimens shall be taken from both ends of the blank. 7.2.2 Pinions up to 200 mm in diameter:
Fig. 3.7 Wheel rim If the diameter of the tooth system exceeds 2500 mm or the heat-treated workpiece, excluding the material for testing, weighs more than 3000 kg, specimens shall be taken from two diametrically opposite points on the rim. 7.2.5 Pinion blanks:
In the case of small pinions with diameters of up to 200 mm in the area of the teeth, a longitudinal test specimen shall be taken from the bearing journal, see Fig. 3.5.
Tangential specimen d2 L Tangential specimen
From hollow pinion blanks, the length of whose finished tooth system is 1 250 mm or less, a test specimen shall be taken from one end at right angles to the longitudinal axis of the workpiece; where the length of the tooth system is more than 1 250 mm, specimens shall be taken from both ends, see Fig. 3.8.
Transverse or tangential specimen
Transverse specimen
Longitudinal specimen
d1
L = Length of tooth system D = Diameter of tooth system d1,d2 = Diameter of bearing journal
Fig. 3.5 Pinion 7.2.3 Gear wheels: Fig. 3.8 Hollow pinion A distinction is to be made here according to whether the workpiece has been forged as a solid blank and then drilled or has been produced by piercing a rough forging and opening up the hole over a mandrel. Where the workpiece is drilled, the specimens are considered to be transverse, but where the blank is expanded over a mandrel the specimens are considered to be tangential.
A tangential test specimen shall be taken from gear wheel blanks, see Fig. 3.6. 7.2.4 Wheel rims:
In the case of wheel rims which are normally made by piercing a bar and enlarging the hole by forging or rolling, a tangential test specimen shall be taken, see Fig. 3.7.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 313
7.3
Tensile test on case-hardening steels
7.7
Test of surface finish and dimensions
7.3.1 The respective test sections are to be heattreated together with the associated gear component or the test batch. For this purpose, the test sections are to be machined to a diameter corresponding to the smaller of the following two values: 0,25 diameter of tooth system or 63 mm diameter If the diameter of the test specimen is less than 63 mm, in agreement with the surveyor a test specimen with standardized dimensions may be used (e.g. 30 mm diameter according to DIN 17210). Tensile test specimens shall then be taken from the test sections and tested. 7.3.2 The gear manufacturer has the option of producing test sections with a cross section greater than that specified in 7.3.1. However, for the final hardening and tempering the pieces shall be given the specified dimensions. 7.4 Strength differences in the forging
The gear manufacturer shall check the surface finish and dimensions of the tooth system. The products shall then be presented to the Surveyor for final inspection and he shall be given the measurement records. For retests by the Surveyor, the gear manufacturer shall hold the necessary measuring instruments in readiness. 7.8 Batchwise testing
Forgings with similar dimensions up to a weight in heat-treated condition of 300 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1. Two test sections shall be taken from each test batch for the tensile test and the notched bar impact test. Every forging shall be subjected to a hardness test. 7.9 Non-destructive tests
7.9.1 The manufacturer shall carry out an ultrasonic test on the tooth area of all forgings where the diameter of the tooth system exceeds 200 mm. 7.9.2 The entire tooth system of gear parts with surface-hardened teeth shall be tested for cracks using the magnetic particle or dye penetrant method. The welds of gear wheels built up of separate parts shall be subjected to non-destructive testing of the scope specified at the time of the process approval. The tests shall be performed in comliance with G.
Where two test specimens are taken from large forgings, the difference between the measured tensile strength values may not exceed the magnitudes specified in B.4.2.3. 7.5 Notched bar impact test
Each forging or unit test quantity, as applicable, shall be subjected to the notched bar impact test. The number of sets of specimens (each comprising 3 specimens), the positions in the forgings or test sections from which the specimens are taken and their heat treatment are subject to the provisions of 7.2 and 7.3, as appropriate. The test may be carried out on Charpy V- or Charpy U-notch samples as chosen by the manufacturer. 7.6 Hardness test
E.
Forgings for Boilers, Pressure Vessels, Process Equipment and Pipelines Scope
1.
7.6.1 After heat treatment but before the cutting of the teeth, hardness tests are to be carried out on all forgings at the points specified in the approval drawings. Where the length L of the teeth of a gear component exceeds 500 mm, testing shall be performed at both ends of the tooth system. 7.6.2 On all surface-hardened gear parts, additional hardness tests are to be carried out on the teeth after hardening and grinding. The number of measuring points shall be such that compliance with the specified hardness values can be verified over the periphery and the width of the tooth system. 7.6.3 The differences in the values measured at the prescribed points on a forging or on different units within a test batch may not exceed the magnitudes specified in B.4.4.2.
1.1 These Rules are applicable to unalloyed and alloy steel forgings for the manufacture of flanges, nozzles, valve housings, socket welding and welding neck components. Steel forgings tough at sub-zero temperatures are subject to F. 1.2 In the case of forgings for steam boilers on vessels sailing under the German flag, the "Technical Rules for Steam Boilers" of series TRD 100 shall be complied with. 2. Suitable grades of steel
The following materials may be used: 2.1 Weldable unalloyed structural steels conforming to EN 10250-2 up to an operating temperature of 300 C. 2.2 Forgings made of ferritic and martensitic steels with specified properties at elevated temperatures conforming to EN 10222-2.
Chapter 2 Page 314
Section 3
Forgings
II - Part 1 GL 2009
2.3 Forgings made of weldable fine-grained structural steels conforming to EN 10222-4. 2.4 Austenitic or austenitic-ferritic stainless steel forgings conforming to DIN 17440, EN 10222-5 or "Stahl-Eisen-Werkstoffblatt" (Iron and Steel Material Specification) SEW 400. 2.5 Steel flanges conforming to DIN 2528.
4.3
Resistance to intercrystalline corrosion
Austenitic steel grades shall be resistant to intercrystalline corrosion in the condition in which they are supplied. If forgings for welded assemblies (e.g. weldon valves, flanges) are to be used without post-weld heat treatment, steel grades which are corrosionresistant in this condition as well shall be selected, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C 0,03 %. 5. Testing
2.6 Steels conforming to other standards or material specifications, provided that they are comparable to the steel grades listed in 2.1 to 2.5 and proof has been furnished of their suitability for the intended application. An initial test of product suitability may be requested for this purpose. Ferritic steels shall additionally satisfy the following minimum requirements. 2.6.1 The elongation (A) shall have the characteristic minimum values for the respective steel grades as specified by GL; however, it shall be not less than 14 % in transverse and tangential direction and not less than 16 % in longitudinal direction. 2.6.2 The impact energy shall have the characteristic minimum values for the respective steel grades as specified by GL; however, it shall be not less than 27 J in transverse and tangential direction and 39 J in longitudinal direction at room temperature in tests conducted with Charpy V-notch specimens. This value is an average value from three tests, in which one individual value may be below the prescribed average value but not less than 70 % of the average value. 3. Heat treatment and condition of supply
The forgings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests. With regard to forgings for steam boilers, 1.2 shall be complied with. 5.1 Tensile testing
5.1.1 The mechanical properties shall be verified by a tensile test. For preparing the test specimens, forgings with similar dimensions and nominal weights up to 1 000 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1. For normalized forgings, one specimen shall be taken from each test batch, while for forgings in other heat-treated conditions, 2 specimens shall be taken from each test batch. For quantities of 10, and 30 in the case of nominal weights not exceeding 15 kg, one specimen is sufficient. 5.1.2 For batchwise testing, the hardest and softest forgings in each batch shall be selected for testing, see 5.3. 5.1.3 In the case of forgings with unit weights of more than 1 000 kg, a test specimen shall be taken from every forging. 5.2 Notched bar impact test
All forgings shall be supplied in a heat treated condition appropriate to the grade of steel. In the case of unalloyed steel grades, normalizing may be replaced by an equivalent method of temperature control during or after forging or rolling, provided that GL has approved the method. If parts are manufactured from bars or plates by machining, heat treatment of the starting material is sufficient. 4. 4.1 Requirements applicable to the material General requirements
The forgings shall be subjected to the notched bar impact test. The number of sets of test specimens (3 Charpy Vnotch specimens per set) shall be determined in the same way as the number of tensile test specimens. 5.3 Hardness tests
The chemical composition, mechanical properties, and impact energy and hardness values of the steel shall conform to the standards stated in 2.1 to 2.5 or, where applicable, the data contained in the approved specifications. 4.2 Weldability
5.3.1 In the case of quenched and tempered forgings, with the exception of flanges with standardized dimensions, a hardness test shall be performed on each forging. 5.3.2 Flanges with standardized dimensions shall be subjected to the following scope of testing: normalized steels: at least 3 %, quenched and tempered, and austenitic-ferritic steels: at least 10 % of the same test batch
Steels conforming to these Rules shall be weldable by established workshop methods. Depending on the chemical composition, preheating and/or post-weld heat treatments may be required for this purpose.
5.3.3 In the case of parts not mentioned in paragraphs 5.3.1 and 5.3.2, at least 20 % of each test batch shall be tested.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 315
5.4
The manufacturer shall test the surface finish and dimensions of the products and shall then present the parts to the Surveyor for final acceptance testing. 5.5 Test for use of correct material
which are designed for gas tanks with design temperatures no lower than 0 C, the requirements according to 1.2 apply. 2. Approved steel grades
Alloy steel forgings shall be subjected by the manufacturer to appropriate tests to ensure that the correct material has been used. 5.6 Non-destructive testing
The following grades of steel may be used within the minimum design temperature limits specified in Table 3.9, provided that they satisfy the requirements of 5. 2.1 Standardized steels conforming to Table 3.9.
Forgings with a nominal weight of over 300 kg shall be subjected by the manufacturer to an ultrasonic test and, where necessary, a supplementary test for surface cracks. The tests shall be performed in compliance with G. 5.7 Testing of resistance to intercrystalline corrosion
2.2 Other steels conforming to other standards or material specifications, provided that they are comparable with the steel grades specified in 2.1 and proof has been furnished of their suitability for the intended application. An initial approval test may be required for this purpose. 3. Heat treatment and condition of supply
The manufacturer shall check the resistance to intercrystalline corrosion of austenitic and austeniticferritic steel forgings intended for welded assemblies and - where stipulated in the order - of other austenitic steels as well. Testing shall be carried out in the following conditions: steels containing C 0,0 3% and stabilized steels: after sensitizing heat treatment (700 C, 30 min, quenching in water) all other steels: in the condition of supply. At least two specimens from each heat shall be tested in accordance with a recognized standard (e.g. ISO 3651-2).
All forgings shall be supplied in a heat-treated condition appropriate to the grade of steel, i. e normalized, quenched and tempered, or solution-annealed and quenched. If parts are manufactured from bars or plates by machining, heat treatment of the starting material is sufficient. 4. Dimensions, dimensional and geometrical tolerances
The data in the standards or specifications are applicable. 5. 5.1 Requirements applicable to the material General requirements
F.
Steel Forgings Tough at Sub-Zero Temperatures Scope
The chemical composition, the mechanical properties and the hardness shall conform to the data contained in the relevant standards or approved specifications. 5.2 Weldability
1.
1.1 These Rules are applicable to steel forgings tough at sub-zero temperatures and high-strength, quenched and tempered steel forgings which are intended for cargo and processing equipment on gas tankers, e.g. flanges, valve parts, weld-on and socket welding parts. 1.2 In the case of forgings which are intended for pressure-liquefied ammonia at design temperatures not lower than 0 C, e.g. forged flanges, rings and connections, the boundary values given in Section 1, F.8.1.1, Table 1.18 for chemical composition and in Section 1, F.8.2.2 for mechanical properties are to be observed. The required values for impact energy given in Section 1, F.8.3 shall also apply. 1.3 In the case of high-strength, quenched and tempered fine-grained structural steel forgings having nominal yield strengths of between 420 and 690 N/mm2
Steels conforming to these Rules shall be weldable by established workshop methods. 5.3 Impact energy at low temperatures
The required impact energy values specified in Table 3.10 for the grade of steel concerned shall be met at the test temperatures specified in the table, using Charpy V-notch specimens. 5.4 Resistance to intercrystalline corrosion
Austenitic steel grades shall be resistant to intercrystalline corrosion in the condition in which they are supplied. If forgings are to be used for welded assemblies (e.g. weld-on valves, flanges) without post-weld heat treatment, steel grades which are corrosionresistant in this condition as well shall be selected, e.g. steels stabilized with Ti or Nb or steels with carbon contents of C 0,03%.
Chapter 2 Page 316
Section 3
Forgings
II - Part 1 GL 2009
Table 3.9
Approved grades of forging steels tough at sub-zero temperatures
Type of steel
Approved minimum design temperature
Steel grade or Material no. P285NH
Standard
Weldable fine-grained structural steels
20 C
P285QH EN 10222-4 P355N P355QH
0,5 % 2,25 % 3,5 % 5 9 % %
nickel steel nickel steel nickel steel nickel steel nickel steel
55 C 65 C 90 C
13MnNi6-3 12Ni14 12Ni19 X12Ni5 X8Ni9 1.4301 (304) 3 1.4307 (304 L)
EN 10222-3
105 C 165 C 2 165 C
EN 10222-3
Austenitic steel
165 C
1.4401 (316) 1.4404 (316 L) 1.4541 (321) 1.4550 (347)
EN 10222-5
1 2 3
Lower design temperatures may be established by means of an approval test. The minimum design temperature of 165 C is only valid if this has been demonstrated by an approval test. The numbers in brackets denote comparable steels conforming to AISI standards.
Table 3.10
Required impact energy values for steel forgings tough at sub-zero temperatures
Impact Energy Type of steel Test temperature longitudinal Weldable fine-grained structural steels and 0,5 % nickel steel 2,25 % nickel steel 3,5 % nickel steel 5 5 9
1 2
KV [J] 1 min. transverse 22 (15)
5 K below minimum design temperature but at least 20 C 70 C 95 C 110 C 196 C 196 C 196 C
2
27 (19)
% nickel steel % nickel steel % nickel steel
34 (24)
24 (17)
Austenitic steels
41 (27)
27 (19)
Average value measured on 3 Charpy V-notch specimens; the figures in brackets indicate the minimum individual value. The test temperature of 196 C applies if the 5 % nickel steel has been approved for a minimum design temperature of 165 C.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 317
6.
Testing
6.6
The forgings shall be presented for testing in the finished condition (condition of supply) and subjected to the tests specified below. 6.1 Tensile test
Forgings with a nominal weight of over 300 kg shall be subjected by the manufacturer to an ultrasonic test and, where necessary, a supplementary test for surface cracks. The test shall be performed in compliance with G. 6.7 Test of resistance to intercrystalline corrosion
6.1.1 The mechanical properties shall be tested by tensile test. For preparing the test specimens, forgings with similar dimensions and nominal weights up to 1 000 kg which originate from the same heat and form part of the same heat treatment batch may be grouped into test batches in accordance with A.10.2, Table 3.1. For normalized forgings, one specimen shall be taken from each test batch, while for forgings in other heat-treated conditions, 2 specimens shall be taken from each test batch. For quantities of 10 - and 30 in the case of nominal weights not exceeding 15 kg - one specimen is sufficient. 6.1.2 For the batchwise testing, the hardest and softest forgings in each batch shall be selected for testing, see 6.3. 6.1.3 In the case of forgings with unit weights of more than 1 000 kg, a test specimen shall be taken from every forging.
The manufacturer shall check the resistance to intercrystalline corrosion of austenitic steel forgings intended for welded assemblies and - where stipulated in the order - other austenitic steels as well. Testing shall be carried out in the following conditions: steels containing C 0,03 % and stabilized steels: after sensitizing heat treatment (700 C, 30 min, quenching in water) all other steels: in the condition of supply. At least two specimens from each heat shall be tested in accordance with a recognized standard (e.g. ISO 3651-2).
G. 6.2 Notched bar impact test 1. The forgings shall be subjected to the notched bar impact test using Charpy V-notch specimens. The number of sets of test specimens (3 specimens per set) shall be determined in the same way as the number of tensile test specimens. The tests shall be performed at the test temperatures specified in Table 3.10. 6.3 Hardness testing
Non-destructive Testing of Forged Components Scope of validity
1.1 These Rules apply to the non-destructive testing of forged components for which in B. to F. appropriate requirements are prescribed, and for which no other regulations or manufacturer specifications are agreed upon. A list containing the forged components for which non-destructive testing is required and the specific tests to be performed is contained in H. 1.2 The general requirements for inspection bodies, inspection personnel, testing methods and certification of the results are prescribed in Chapter 1 Principles and Test Procedures, Section 3 and are mandatory for all tests. 1.3 The methods indicated in these Rules concerning the magnetic particle test and ultrasonic tests are limited to the application of forged components made of ferritic steel grades. For forged components made of austenitic or austenitic-ferritic steel grades the methods and acceptance criteria for the ultrasonic and penetrant tests shall be agreed upon with GL individually. This may be performed based on standards or specifications from the manufacturer or the orderer. 1.4 Taking into account the prescriptions in 1.3, in these Rules the following testing methods are described, see Table 3.11.
6.3.1 In the case of forgings in quenched and tempered condition, with the exception of flanges with standardized dimensions, a hardness test shall be performed on every forging. 6.3.2 Flanges with standardized dimensions shall be subjected to the following scope of testing: Normalized steels: at least 3 %, quenched and tempered, austenitic and austeniticferritic steels: at least 10 % of the same test batch
6.3.3 In the case of parts not mentioned in 6.3.1 and 6.3.2, at least 20 % of each test batch shall be tested. 6.4 Test of surface finish and dimensions
The manufacturer shall test the surface finish and dimensions of the products and then present the parts to the Surveyor for final acceptance testing. 6.5 Test for use of correct material
Alloy steel forgings shall be subjected by the manufacturer to appropriate tests to ensure that the correct material has been used.
Chapter 2 Page 318
Section 3
Forgings
II - Part 1 GL 2009
Table 3.11
Test methods
2.
Performing the tests
Testing of
Method Visual testing
Short name 2 VT testing 1 MT PT UT
External condition Internal condition
Magnetic particle Penetrant testing Ultrasonic testing
2.1 After the inspector of the internal or external inspection body in charge of testing has performed the prescribed tests, the final machined forged components shall be presented to the GL-Surveyor for visual testing. 2.2 Concerning the tests it shall be differentiated between pre-testing and acceptance testing. With pretests, where decisions concerning the testability and the employability of the forged component are made, they are in general the business of the manufacturer. Acceptance tests shall be performed preferably on the final machined component after the heat treatment appropriate for the required properties has been performed. If necessary acceptance tests may be performed at a production stage with little machining allowance, and for ultrasonic testing after pre-machining in a condition with less contours. Details for this are to be prescribed in a test specification and to be made known to GL. 2.3 The Surveyor shall be informed by the manufacturer or the company performing the further processing about the intended tests. It is up to the discretion of the Surveyor to attend the tests. 2.4 The tests shall be performed for the zones described for the forged components in H. and J., or for those indicated in the test specification. In case the results indicate that further defects are present in the forged component, the test scope shall be extended according to agreement with the Surveyor. 2.5 Indications exceeding the allowable size, number and position indicated in the tables shall be removed if technically possible. Excavated areas at the surface are to be subjected to retesting. 2.6 In case internal defects or defects close to the surface cannot be removed by grinding with satisfactory results, the manufacturer, the orderer and the GLSurveyor shall decide on the employability of the forged component. 3. Visual testing (VT)
1 only for forged components made of ferritic steel grades 2 definition according to DIN EN 473
1.5 The methods and testing criteria indicated in G. are to be employed by the manufacturers and companies performing the further processing. In case the orderer wants further regulations to be applied on specific forged components e.g. for engines and turbines, he shall state this in a test specification and make this known to the GL Surveyor. Alternatively non-destructive testing may be performed in accordance with test specifications from the manufacturer or the orderer on condition that the methods and acceptance criteria fulfil the following requirements. 1.6 For testing, the forged components shall be classified in inspection zones of type I, II and III, according to the possible effects of defects on the structural integrity. For magnetic particle testing there will be the addition of type IV. In inspection zone I the allowable number and size of indications are the smallest. For classifying in inspection zones the following principles are decisive: the operation loads to be expected the effects of the defects on the reliability of the component possible risk of damage if the component fails Freedom of defects and surface condition after the final machining
For the most important forged components of the propulsion plant the classifying in inspection zones is prescribed in I. and J. 1.7 For forgings where in I. for magnetic particle testing and in J. for ultrasonic testing no classifying in inspection zones is indicated, the manufacturer or orderer shall prescribe the inspection zones in a test specification taking into consideration the principles in 1.6 and shall be make them known to the GL Surveyor. Further, the test specification shall contain details concerning the required acceptance criteria (e.g. quality class according to EN 10228-1, -2, -3).
3.1 The manufacturer shall verify for each production stage of the forged components the external condition and the compliance of the dimensions. Forging defects are to be removed, unless they are removed by the following machining. 3.2 For the acceptance test the forged component are to be presented to the Surveyor in final machined condition.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 319
If necessary an inspection of forged components in raw condition or in premachined condition by the GLSurveyor can be agreed on. 3.3 Discontinuities of the material such as cracks, forging laminations or inclusions open towards the surface are not allowed and shall be repaired. The repaired areas shall be subjected to additional surface crack detection. 3.4 The Surveyor certifies the visual inspection on the GL acceptance test certificate. E.g. the following text can be typed in the test certificate: "The aforementioned forged components were visually tested. The prescribed requirements are fulfilled." 3.5 On demand of the orderer the manufacturer shall issue an inspection certificate according to EN 102043.1 containing the details of the tests and the test results. 4. Magnetic particle testing (MT)
The testing of final machined forged components shall preferably be performed with stationary test appliances. 4.4 In case deviant of 2.1, tests have to be performed before final machining, e.g. before bore holes or lubricating oil channels are realized. This shall be indicated in the test instructions. The acceptance test will be performed by the Surveyor after the final machining of the component. 4.5 The indications of magnetic particle testing shall be evaluated depending on the specific inspection zone I to IV (cf. 1.6) concerning their size and number in accordance with Table 3.12. The reference area for this shall be a rectangle with 148 mm 105 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications). 4.6 Concerning the evaluation it shall be differentiated between isolated and aligned indications. These terms are explained in Fig. 3.9. 4.7 All indications exceeding the registration levels indicated in Table 3.12 are to be reported. Where indications concerning their size and number exceed the indicated values for the appropriate inspection zone (or the appropriate class of quality according to EN 10228-1, respectively), as well as cracks, open forging laps and discontinuities are to be regarded as defects and shall be removed. 4.8 For the circumferential surfaces of grooves and oil bore holes of crankshafts indications of every type in zone I are not allowed. 4.9 In case doubts exist whether an indication is generated by a crack, additional penetrant testing shall be performed.
4.1 The surfaces to be tested shall be free of scale, grease, dirt and protecting paint as well as other contaminations which may affect the detection of indications. 4.2 The roughness of the machined test areas shall not exceed an average roughness of Ra = 12,5 m for premachined surface, and Ra = 6,3 m for final machined surface. 4.3 Contact points visible on the surface are to be ground and to be retested by yoke magnetization if they will not be removed by the following machining. It is not allowed to employ prods on final machined surfaces.
Table 3.12
Acceptance criteria for magnetic particle testing according to EN 10228-1
Acceptance limits for inspection zone IV Parameter for evaluation III II I
appropriate class of quality according to EN 10228-1 1 2 2 8 36 10 31 2 4 24 7 4 2, 3 1 2 5 5 5 20 75 15
Recording level: length of indications [mm] max. allowed length Lg of aligned or isolated indications Ln [mm] max. allowed cumulative length of indications Lk [mm] max. allowed number of indications on the reference area
1 Class of quality not applicable for testing of surfaces with machining allowance exceeding 3 mm. 2 Class of quality not applicable for testing of surfaces with machining allowance exceeding 1 mm. 3 Class of quality not applicable for surfaces of fillets and oil hole bores of crankshafts (cf. G.4.8).
Chapter 2 Page 320
Section 3
Forgings
II - Part 1 GL 2009
148 mm aligned indications
Lg
L1 d1
L2 d2 L5
L3 d3
L4
isolated indications L6
Reference area = L1, L2 and L3 L4, L5 and L6 = =
148 mm 105 mm (d.h. A6-Format) individual lengths of aligned indications lengths of isolated indications (Ln)
d1 < 5L1; d2 < 5L2; d3 > 5L3 Lg = aligned total length of L1, L2 and L3 Lg + L4 + L5 + L6 = cumulative length of indications on the reference area (Lk) Number of indications on the reference area = 4 (identified as Lg, L4, L5, L6)
Fig. 3.9 Reference area and type of indications for magnetic particle testing (MT) according to EN 10228-1
4.10
Repair of defects
Defects are to be removed by suitable measures. In doing so it shall be ensured that the dimensions of the forged component will not exceed the prescribed tolerances. Removal of a defect by grinding shall be performed perpendicular to the defect in such a way that the end of the groove is prepared in a longitudinal direction and smoothly blends to the adjacent surface. The transition radius shall be at least three times the groove depth. 4.11 After the removal of defects by grinding the ground areas are to be subjected again to magnetic particle testing. 4.12 The evaluation of excavated areas concerning their size and position in the specific inspection zones shall be performed by means of manufacturer and/or
orderer specifications. If the dimensions fall below the minus tolerances the consent of the Surveyor shall be requested. 5. Penetrant testing (PT)
5.1 The surfaces to be tested shall be free of scale, grease, dirt and protecting paint as well as other contaminations which may affect the detection of indications. 5.2 Penetrant testing is to be performed on forged components made of austenitic or austenitic-ferritic steel grades. It may be performed on forged components made of ferritic steel grades in addition to magnetic particle testing (MT), nevertheless the results of the magnetic particle tests are decisive concerning the acceptance criteria.
105 mm
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 321
5.3 Testing is to be performed in accordance with Chapter 1 Principles and Test Procedures, Section 3, K. or with other recognized standards such as e.g. EN 571-1 and ISO 3452-2 or EN 10228-2 "Nondestructive testing of steel forgings, Part 2, Penetrant testing". 5.4 The manufacturer shall prepare a test instruction which shall contain at least the following information: details of the forged component including the material grade standards and specifications to be applied description of the test method employed testing agent system qualification of the inspection personnel surface areas to be tested required surface condition test criteria type of testing report
6.3 The tests are to be performed in accordance with Chapter 1 Principles and Test Procedures, Section 3, L. Unless otherwise agreed it may also be performed according to EN 583-1, SEP 1921, SEP 1923, EN 10228-3 and/or other equivalent and recognized standards, manufacturer or orderer specifications. 6.4 Unless no other recording levels were agreed on, all indications exceeding a KSR 1 with diameter = 2 mm shall be registered and evaluated and reported concerning their position, size, number and acceptability. 6.5 For indications which shall be registered, the amplitude of the back wall echo in the area of the indication is to be compared with the adjacent areas free of indications. Attenuations of the back wall echo with 4 dB are to be recorded in the testing report in dB. 6.6 Cracks of any type, size and distribution are not allowed. 6.7 Indications exceeding the limiting values contained in Table 3.14 or 3.15, are to be regarded as defects and in the first instance result in rejection of the forged component by the Surveyor. If the tests are performed in accordance with a manufacturer or orderer specification approved by GL then the limiting values indicated there are decisive and the procedure is accordingly. 6.8 The acceptance of the forged component which in the first instance had been rejected is possible on condition that after further evaluation of the indications performed by the orderer and the Surveyor proof has been furnished that due to their size, position and distribution the defects have no considerable effect on utilization of the forged component. In this case the acceptance of the forged component shall be approved by an acceptance test certificate by both the orderer and the Surveyor. _____________________________
1 KSR = disc shaped reflector (= Kreisscheibenreflektor)
5.5 Unless otherwise agreed the testing according to Chapter 1 Principles and Test Procedures, Section 3, J. shall be performed on the final machined forged component and shall be performed in the presence of the Surveyor. 6. Ultrasonic testing (UT)
6.1 In the areas to be tested an appropriate surface condition shall be achieved which enables a faultless coupling of the probe. Forging fin, scale, paint, dirt, unevenness and mechanical damages shall be removed/corrected. 6.2 For premachined surfaces the average value of the roughness shall be Ra 25 m. It is recommended to agree on the appropriate class of quality for the surface roughness according to Table 3.13.
Table 3.13
Recommendations for the surface quality

Class of quality and roughness Ra [m] Surface quality 1 25 machined 2 12,5 3 12,5 4 6,3
machined and heat treated forged
Note "" indicates the class of quality which can be achieved with the prescribed roughness.
Chapter 2 Page 322
Section 3
Forgings
II - Part 1 GL 2009
Table 3.14
Acceptance criteria for ultrasonic testing of forged components
Forged component
Zone
Size of the max. allowable KSR 1 [mm]
Max. allowable length of indications 3 [mm]
Min. distance between two indications 3 [mm]
Total of all indication lengths [mm] per "m" component length
Propeller shafts Intermediate shafts
I II
outside: 2 inside: 4
10 15 10 15
10 10 10 10
0,05 d 0,10 d 0,15 d 0,20 d
Thrust shafts Rudder stocks and pintles Piston rods 4 Connecting rods 5 Piston rods Cross heads
1 2 3
III I II III
outside: 3 inside: 6
2 4
10 10
10 10
0,05 d 0,15 d (s) 5
KSR = disc shaped reflector The classifying in inspection zones is depicted in Fig. 3.15 to 3.20. For accumulations of 2 or more isolated indications to be recorded the minimum distance between 2 adjacent indications shall be at least of length of the major indication. This applies to distances in axial as well as in thickness direction. Isolated indications with smaller distance are to be regarded as aligned indication.
4 5
Piston rods with shaft diameter larger than 150 mm. For rectangular cross-section "d" corresponds to the smallest side length "s".
Table 3.15
Acceptance criteria for ultrasonic testing of crank shafts
Zone 2
Size of the max. allowable KSR 1
Max. allowable length of indications
Min. distance between two indications 3
Max. number of isolated indications 3, 4
[mm] I II 2
[mm] 10
[mm] 10
[] 0,01 d (D)
Total of all indication length [mm] 4 per pin or journal, or per web or flange, respectively
1 mm 1 mm
0,20 d (D) 0,40 d (D)
III
1 2 3
15
10
0,02 d (D)
KSR = disc shaped reflector The classifying in inspection zones is depicted in Fig. 3.21. For accumulations of 2 or more isolated indications to be recorded the minimum distance between 2 adjacent indications shall be al least of length of major indication. This applies to distance in axial as well as in thickness direction. Isolated indications with smaller distance are to be regarded as aligned indication.
Related to be diameter of crank pin "d" or to the diameter of main journal "D", respectively.
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 323
H.
List of Forged Components for which Non-destructive Tests are Required
Name of the forged component Structural parts concerning the hull: rudder stocks and pintles Parts for diesel engines: crank shafts connecting rods piston rods crossheads piston crowns cylinder covers piston pins tie rods bolts M50 for: X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
Test method to be employed VT MT UT
X X X X X X2 X2 X2 X2 X2 X2 X2 X2 X2 X X X X X X X X X 7, 8 X7 X X 5, 6 X 5, 6 X6 X6
X1 X3 X2 X2 X X X
main bearing connecting rod bearing cross heads cylinder covers camshaft drive gear wheels and chain wheels propeller shafts intermediate shafts thrust shafts gear wheels gear shafts pinions wheel rims rotors rotor discs shafts blades guide vanes and blades turbine casing bolt M50 shafts for e-engines (main) forged components made of steels for use at elevated temperatures made of steels tough at sub-zero temperatures bolts for fixing of propeller blades M50 bolts for superheated steam pipelines
Main shafting and gears: X1 X1 X1 X4 X4 X4 X4 X X X
Turbo machinery (main drive):
Other components: X5 X5

1 2 3 4 5 6 7 8
for diameters 250 mm for diesel engines with cylinder diameter > 400 mm for batchwise testing of small crankshafts ultrasonic testing of the prematerial is sufficient. Small crankshafts are those with gross weights not exceeding 500 kg. for diameter of the gearing or of the shafts > 200 mm for finished weights > 300 kg for austenitic or austenitic-ferritic steels penetrant testing (PT) instead of magnetic particle testing (MT) for main steam temperatures > 350 C Instead of surface crack testing (MT, PT) eddy current testing may be considered, too.
Chapter 2 Page 324
Section 3
Forgings
II - Part 1 GL 2009
I.
Classifying of Inspection Zones for Magnetic Particle Testing (MT)
L L/3 II I L = Length of the tapered portion 250 mm II II II 150 mm II
Fore
I (a) Propeller shaft Fore
II
(b) Intermediate shaft
II
(c) Thrust shaft
Note - For principles for classiying in inspection zones I to IV see G.1.6 - Acceptance criteria are contained in G. table 3.12
Fig. 3.10 Inspection zones for magnetic particle testing of shafts
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 325
L L/3 II
d
3d II
L = Length of the tapered portion (a) Type A
up
3d II
d
II
I (b) Type B Note Welded areas are to be regarded as zone I
up
II
(c) Type C Rudder stock I 100 mm II
up
dm
dg
Pintle
Fig. 3.11 Inspection zones for magnetic particle testing of rudder stocks and accessories
do
Chapter 2 Page 326
Section 3
Forgings
II - Part 1 GL 2009
II
II
II
Cross head L I I II II I I
Tie rods for diesel engines
II
II
II
250 mm
L = Length of thread
Bolts for connecting rods
I 100 mm 100 mm
II
II
Pinion shaft
Fig. 3.12 Inspection zones for magnetic particle testing of machinery components
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 327
III
III
II
II
II L =Length of thread and groove L III Type 1 Type 2 II I
Piston rod
II
200
30
II
II
200
II
III
Type 1 Connecting rod
Type 2
II
Note Threads, oil bore holes and their radii are to be regarded as zone I in the regime of 2 dB. dB = Bore hole diameter
Fig. 3.13 Inspection zones for magnetic particle testing of machinery components
Chapter 2 Page 328
Section 3
Forgings
II - Part 1 GL 2009
A
a
B II
II I
Section A-A
II
a A (a) Solid crankshaft A B
a B
II
Section B-B
II
II
q
I
q
I II II
b
II Section A-A
II b Section B-B
(b) Semi built-up crankshaft Note 1. Areas of 2 db around lubricant bore holes of crank pin or journal are to be regarded as zone 1 (sketch to the right). 2. Explanations to the upper figures: q = 60 a = 1,5 r b = 0,05 d (Peripheral area of the shrinkage fit) as well as r = Radius of the groove d = Pin or journal diameter 3. Identification of the zones: : Zone I : Zone II 4. The above mentional classifying applies accordingly to forged throws.
db
db = Diameter of oil bore hole
Fig. 3.14 Inspection zones for magnetic particle testing of crank shafts
II
I a
I a
2db db db
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 329
J.
Classifying of Inspection Zones for Ultrasonic Testing (UT)
axial 360 radial axial
Zone I
Zone II Scanning directions
250 mm II III
L = Length of the tapered portion 250 mm II III
Fore
III
II (a) Propeller shaft Fore
III
(b) Intermediate shaft
III
(c) Thrust shaft Note 1. UT in premachined rotation symmetric condition before machining the taper and threading. 2. For hollow shafts: 360 radial scanning applies to Zone II. 3. Circumferences of the bolt holes in the flanges are to be treated as Zone II..
Fig. 3.15 Inspection zones for ultrasonic testing of shafts
Chapter 2 Page 330
Section 3
Forgings
II - Part 1 GL 2009
Zone II
Zone III
Scanning directions for Type A and Type B
L L/3 III
d
3d III
II
L = Length of the tapered portion (a) Type A
up
3d III
d
III
II Note 1. Welded areas are to be regarded as zone II 2. d = Diameter of shaft (b) Type B
up
Fig. 3.16 Inspection zones for ultrasonic testing of rudder stocks and accessories
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 331
axial
axial axial III 180 radial axial Scanning directions up
axial 180 radial axial Zone I
axial 90 radial axial Zone II Scanning directions
II
II 100 mm
II 100 mm
dm
dg
Pintle Note Testing in premachined rotation symmetric condition before machining the taper and threading
Fig. 3.17 Inspection zones for ultrasonic testing of rudder stocks and accessories
do
Chapter 2 Page 332
Section 3
Forgings
II - Part 1 GL 2009
axial 180 radial axial Zone II
axial 90 radial axial Zone III Scanning directions
III
Cross head Note In the core zone with diameter D/3 the lower requirements according to table 3.14 do apply. I 100 mm 100 mm
II
II
Pinion shafts Note 1. UT of pinion shafts with D 200 mm, in premachined condition before machinering the gear tooth 2. For zone I 360 radial and 90 axial scanning direction applies
Fig. 3.18 Inspection zones for ultrasonic testing of machinery components
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 333
III
III
II
Type 1 Piston rod
Type 2
Chapter 2 Page 334
Section 3
Forgings
II - Part 1 GL 2009
II
250 mm
II
250 mm
from the end of rhe radii
III
250 mm
III
250 mm
II
II
Type 1 Connecting rod
Type 2
from the end of the radii
II - Part 1 GL 2009
Section 3
Forgings
Chapter 2 Page 335
Scanning directions A a II I I III a II III I III B
III Section A-A
II a
III
III a A
II
II Section B-B
B B a
(a) Solid crankshaft A a II I II

b
III
III I II II
II III I II II B b
III
II
b
III
III
III A
Section A-A
Section B-B
(b) Semi built-up crankshaft Note 1. Explanations to the upper figures: a = 0,1 d or 25 mm, whichever greater b = 0,05 d or 25 mm, whichever greater (position of shrinkage fit) d = Pin or journal diameter. 2. Core areas of crank pins and/or journals within a radius of 0,25 d between the webs are to be regarded as zone II. 3. Identification of the zones: : Zone I : Zone II : Zone III
Fig. 3.21 Inspection zones for ultrasonic testing of crank shafts
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 41
Section 4 Cast Steel

A. 1. General Rules Scope 5. Condition of supply, heat treatment
This Part contains general rules to be applied in the manufacture and testing of steel castings. Also applicable are Chapter 1 Principles and Test Procedures, Sections 1 3. 2. Selection of grades of cast steel
5.1 All castings shall undergo heat treatment appropriate to the material. The heat treatments shall be performed in suitable furnaces. The dimensions of the furnace shall enable the entire casting to be raised uniformly to the required heat treatment temperature. Where, in the case of large castings, the size of the furnace does not allow the entire casting to be normalized at once, other arrangements shall be agreed with GL. 5.2 Where, following final heat treatment, a casting is heated locally or undergoes hot or cold straightening, subsequent stress relief heat treatment may be required to remove residual stresses. 5.3 Flame cutting, flame scarfing or flame gouging to remove excess material or feeders shall be carried out by a recognized method prior to final heat treatment. Preheating shall be applied where the chemical composition and/or the thickness of the casting make this necessary. Where required, the heataffected zones of the casting shall be machined or ground off. 6. General characteristics of castings
2.1 All cast steel shall be suitable for the intended application and shall satisfy the minimum requirements specified in the following individual Rules. Subject to these conditions, grades of cast steel conforming to the relevant standards or to the material specifications approved by GL may be used. 2.2 The grades of cast steel shall be identified by the standardized designations or the designations given in the specifications. 3. Requirements to be met by foundries
3.1 Foundries wishing to supply castings in accordance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufacturing and quality control requirements stated in Chapter 1 Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the commencement of supplies. 3.2 Irrespective of the requirements stated in 3.1, the manufacturer shall demonstrate by approval tests carried out on the products that these can be manufactured in accordance with the conditions imposed. The scope of these tests will be determined by GL. 4. Method of manufacture
6.1 All castings shall have a clean surface compatible with the conditions of manufacture. Minor casting defects such as small sand and slag marks, small cold shuts and small scabs may be trimmed off within the negative tolerance on the wall thickness. 6.2 Defects liable to impair the use and workability of the material to a more than minor degree are not allowed. They may be removed by one of the methods named in 13. 7. Dimensions; dimensional and geometrical tolerances
4.1 Cast steel shall be produced in an electric furnace, by a basic oxygen process, in an induction furnace or by other methods approved by GL. On request, the steel-making process shall be made known to GL for approval. 4.2 Where castings are produced by welding together two or more separate components, details of the method shall be submitted for approval. This normally calls for a test of the welding procedure.
The dimensions and the dimensional and geometrical tolerances are governed by the values specified in the drawings relating to the order or in the relevant standards, as applicable. Appropriate details shall be made known to the Surveyor. 8. Tightness
All castings which are subjected to internal pressure by the operating medium or for which special proof of impermeability is required shall be leakproof at the specified test pressures after being machined.
Chapter 2 Page 42
Section 4
Cast Steel
II - Part 1 GL 2009
9.
General requirements applicable to cast materials Chemical composition
1 250 kg shall be allocated to the preceding test batch. Parts with unit weights > 1 000 kg shall be tested individually. If the finished weight exceeds 10 000 kg, at least two test specimens shall be taken. For this purpose, test samples spaced as widely as possible shall be cast integrally with the casting. 10.2.3 For each casting or for each test batch, as applicable, a sufficient number of samples shall be provided which shall normally be cast integrally with the cast component. The number of samples shall be sufficient to provide material for the test specimens needed for possible retests. The sample may only be removed from the casting after the final heat treatment. The thickness of the sample shall be matched to the relevant wall thickness of the casting, but shall be at least 30 mm. In the case of thick-walled steel castings, the sample thickness need not exceed 100 mm. 10.2.4 Where a number of small castings of approximately the same dimensions are produced from the same heat and are heat treated in the same furnace charge, then, notwithstanding the provisions stated in 10.2.3, specimens may be taken from separately cast samples. For this purpose, at least one sample per furnace charge shall be provided, which shall be heat treated together with the castings to which it relates. 10.2.5 If separately cast samples are used, these shall be cast in moulds made of the same moulding material as that used for the castings themselves. 10.2.6 All samples shall be marked in such a way that they can be clearly related to the castings which they represent. The type of marking shall be agreed with the Surveyor. 10.2.7 Where castings are manufactured by a method subject to the special approval of GL, see 4.1, the number and position of the samples shall be specially agreed so as to take account of the method of manufacture. 10.3 Testing of surface finish and dimensions
9.1
The chemical composition of grades of cast materials shall conform to limit values specified in the Tables contained in this Section and/or in the relevant standards or specifications, as applicable. The manufacturer shall take suitable measures to ensure that the residual elements remain within the permitted limits. 9.2 9.2.1 Mechanical properties Tensile test
The tensile characteristics indicated in the Tables contained in this Section or, where applicable, in the relevant standards or specifications shall be verified by tensile test. 9.2.2 Notch bar impact test
The impact energy specified for the various grades of cast steel shall be satisfied by the average value measured on 3 Charpy V-notch or Charpy U-notch test specimens, one of which may give a result below the required average value although it may not be less than 70 % of the required average value. 9.3 Other characteristics
Where special characteristics are specified for particular grades of cast steel, e. g. resistance to intercrystalline corrosion and mechanical characteristics at elevated temperatures, these shall, where necessary, be proved by appropriate tests. 10. 10.1 Testing Testing of chemical composition
The manufacturer shall determine the chemical composition of each heat or, where necessary, of each ladle and shall present corresponding certificates to the Surveyor. Should there be any doubt as to the chemical composition of the products, a product analysis shall be performed. 10.2 Testing of the mechanical properties and the selection of specimens
10.2.1 The mechanical properties shall be ascertained by tensile test to determine tensile strength, yield strength or 0,2 % proof stress, reduction in area and elongation. The notched bar impact test shall also be performed where specified for particular grades of cast steel. 10.2.2 The tests shall be performed on a heat-byheat basis. Castings from each heat that undergo the same heat treatment shall be grouped into test batches of up to 4 500 kg. Residual quantities of up to
10.3.1 All castings shall be inspected by the manufacturer for surface finish and compliance with the dimensional and geometrical tolerances and shall then be presented to the Surveyor for final inspection. Inside surfaces are to be included in the inspection. 10.3.2 The surface of the castings shall be free from material from the mould and shall be properly prepared for inspection. Where necessary, this conditions shall be achieved by pickling, local grinding, shot or sand blasting, cleaning with wire brushes or by chemical means. Chipping and hammering are allowed only if this does not conceal surface defects.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 43
10.3.3 Where there is reasonable suspicion that welds have been carried out on a casting, the Surveyor may require certain areas of the surface to be etched in order to reveal possible welds. 10.4 Non-destructive tests
purchaser and order number newbuilding and project number, as applicable, if known nature of castings and grade of cast steel purpose and drawing number, if necessary item numbers and numbers of units weight of delivery method of manufacture heat numbers chemical composition condition of supply details of heat treatment test pressures, where applicable results of the mechanical tests results of any special tests applied, e.g. nondestructive tests and test of resistance to intercrystalline corrosion condition of surface Repair of defects Methods
10.4.1 Where non-destructive tests are required, these shall be performed by the manufacturer of the castings and/or the finishing plant. Tests may also be arranged by GL. 10.4.2 Non-destructive tests shall be performed in accordance with the specifications stated in G. to J. in consideration of the specifications in Chapter 1 Principles and Test Procedures, Section 3. 10.5 Retests in the event of failure
If tensile test specimens fail to meet the required values under test, if the specified average value is not achieved in a notched bar impact test or if an individual value is less than 70 % of the required average value, then, before the unit test quantity or the casting is rejected, the procedures for retests prescribed in Chapter 1 Principles and Test Procedures, Section 2, H. may be applied. The additional test specimens shall be taken either from the same test sample as the original specimen or from other samples which are representative of the casting or of the unit test quantity. 11. Identification and marking of castings
13. 13.1
11.1 The manufacturer shall institute a monitoring system enabling all castings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request. 11.2 Prior to final inspection, all castings shall be provided by the manufacturer in at least one place with the following marks: cast steel grade manufacturer's mark heat number, casting number, casting date or an abbreviated symbol enabling the manufacturing process to be traced specimen number date of test test pressure, where applicable
Defects may be repaired by machining, grinding, flame scarfing or gouging, or by welding. The method is to be agreed with the Surveyor except where the approval of the Head Office of GL is required for the welding of highly stressed castings, e.g. diesel engine parts and turbine casings. 13.2 Machining and grinding
The repair shall be performed in such a way as to remove the defect completely and provide a gradual transition between the resulting depression and the contour of the casting. The transition shall be 2 to 3 times the depression. The depth of the repair may not have more than an insignificant effect on the strength of the component and the wall thickness shall not be reduced below the minimum tolerance. 13.3 Flame scarfing and gouging
11.3 In the case of series-manufactured castings, agreement may be reached with the Surveyor to apply marks other than those specified in 11.2. 12. Certificates
Defects may be removed by flame scarfing and gouging. Cast materials liable to hardening shall be appropriately preheated. The depressions caused by the removal of metal shall afterwards be bright ground. The grinding shall be sufficiently thorough to ensure the removal of any metal with a heat-affected structure. 13.4 Fabrication welding
For each consignment the manufacturer shall supply to the Surveyor a certificate or delivery specification containing at least the following details:
13.4.1 If major defects have to be welded on steel castings the details of the proposed welding method
Chapter 2 Page 44
Section 4
Cast Steel
II - Part 1 GL 2009
are to be submitted to GL by means of WPS 1 for approval. The latter shall be amended with sketches or photographs showing the location of major defects which impair the mechanical strength. For the purpose of these Rules, the term "major defect" includes any defects, the depth of which exceeds 25 % of the wall thickness or 2,5 cm, the area of which exceeds 1 250 cm2, and those which due to their amout and distribuition exceed an area of 2 % of the casting surface. The characteristics of the weld shall be verified by welding procedure tests. These are to be performed on test pieces according to Chapter 5 Materials for Propeller Fabrication, Annex B, using filler metals approved by GL. Welding procedure tests and welders qualification tests respectively which have been performed by means of above mentioned test pieces remain valid for 3 years and cover thicknesses up to 1,5 "t", with "t" being the thickness of the test piece. In the case of minor repairs, the decision as to the execution of the repair shall rest with the Surveyor, and the method shall be agreed with him. It is a basic principle that the welding of major defects may only be started after authorization has been granted and the castings have been presented to the Surveyor in the condition prepared for welding. 13.4.2 Companies wishing to carry out fabrication welds on castings shall have available the necessary workshops, lifting gear, welding appliances, preheating and heat treatment facilities, testing instruments and equipment as well as qualified welders and competent welding supervisors so that the work can be properly executed. As a preliminary measure, compliance with these conditions shall be proved to GL and a description of the welding facilities and procedures shall be submitted. 13.4.3 The following conditions shall be complied with in carrying out welding work: Highly stressed parts and alloy steel castings shall be in the prescribed heat-treated condition for welding. This also applies to other castings on which major defects have to be repaired. Defects are to be gouged out in such a way as to provide good accessibility for welding. Having been prepared for welding, the sites concerned shall be subjected to non-destructive tests to establish that the defective material has been completely removed. The castings prepared for welding are to be submitted to the Surveyor. Steel castings shall be suitably preheated for welding. The level of preheating shall be determined in each case by reference to the chemical composition, the carbon equivalent and the wall thickness, see B.4.1.4. Exceptions to this Rule
are austenitic grades of cast steel and, with the consent of the Surveyor, unalloyed grades of cast steel of small wall thickness which because of their composition (C 0,18 %) are considered to be unsusceptible to cracking. All welding work is to be performed by qualified welders, whose work is supervised while in progress, in bays which are protected from draughts and the effects of the weather. Wherever feasible, welding shall be performed in the downhand position. The filler materials to be used shall produce a weld deposit with mechanical characteristics matching those of the casting. In the case of stainless grades of cast steel, the deposit shall ensure the sufficient chemical stability of the weld. Wherever possible the work shall be performed by manual arc welding using basiccoated electrodes with a controlled, low hydrogen content. After welding, the castings shall be properly heat treated as follows: unalloyed steel castings: stress relief heat treatment in temperature range 580 620 C, or renewed normalizing treatment quenched and tempered steel castings: renewed tempering or quenching and tempering ferritic stainless steel and all grades of austenitic steel castings: the heat treatment prescribed in the relevant standard or recognized material specification, as applicable.
Attention shall be paid to the effect of the heat treatment on the mechanical properties of the weld metal. Following welding and heat treatment, the welds and their surrounding areas are to be ground smooth and inspected by the magnetic particle or dye penetrant method. Depending on the nature and size of the original defect, further nondestructive testing by ultrasonic or radiographic inspection may be required. For the evaluation of the indications 10.4.2 is applicable.
13.4.4 After repair and subsequent heat treatment, all castings shall be presented to the Surveyor for reinspection, and the tests for cracks and the ultrasonic tests shall be performed wholly or partly in the Surveyor's presence at his discretion. In the case of radiographic tests, the radiographs shall be submitted to the Surveyor for expert appraisal. 13.4.5 For large welds on highly stressed or alloy steel castings, the manufacturer shall hand the Surveyor a report containing full details of the repair, including the results of the non-destructive tests. In this report he shall also confirm that the weld has been made in accordance with an approved welding procedure.
1 WPS = Welding Procedure Specification
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 45
B.
Steel Castings for Machine Construction and Shipbuilding Scope
1.
These Rules are applicable to castings made of unalloyed and alloyed grades of cast steel which are intended for the manufacture of components and structural parts in machine construction and shipbuilding, e.g. diesel engine components (excluding crankshafts), gears, couplings, and also stem and stern posts, stern tubes, shaft struts, rudder bearings and anchors. 2. Suitable grades of cast steel
3.2 Where castings are subject to special requirements with regard to their geometrical and dimensional stability or to the absence of internal stresses, e.g. diesel engine bedplates, stem and stern post parts, additional stress-relieving heat treatment is required. For carbon and carbon-manganese steels, the heat treatment shall be performed at a temperature of at least 550 C followed by cooling in the furnace to below 300 C. For quenched and tempered steel castings, the heat treatment temperatures shall be specially determined. The stress-relieving heat treatment may be dispensed with in the case of quenched and tempered steel castings where tempering is followed by a cooling rate of up to 15 C/h. 4. 4.1 Requirements applicable to the material Chemical composition
On condition that they meet the requirements specified in 4., the following grades of cast steel may be used: 2.1 General-purpose cast steels conforming to DIN 1681. 2.2 General-purpose cast steels with enhanced weldability and toughness conforming to DIN 17182. 2.3 Quenched and tempered cast steels conforming to DIN 17205. 2.4 High-tensile cast steel with good weldability conforming to "Stahl-Eisen-Werkstoffblatt" SEW 520. 2.5 Other grades of cast steel with minimum impact energy values conforming to other standards or material specifications, provided that they are equivalent to the grades described in 2.1 to 2.4 and their suitability has been confirmed by GL. An initial test of product suitability may be required for this purpose. 3. Condition of supply and heat treatment
4.1.1 Carbon and carbon-manganese steel castings including the grades of cast steel described in 2.1 and 2.5 are subject to the limits for the chemical composition of the heat specified in Table 4.1. Where necessary, the manufacturer may add grain refining elements, e. g. aluminium. 4.1.2 For grades of cast steel conforming to 2.2, 2.3 and 2.4, the limits for the chemical composition specified in the standards are applicable. 4.1.3 For cast alloy steels conforming to 2.5, the limits for the chemical composition specified in the recognised standards or material specifications shall apply. 4.1.4 Where the weldability of the casting is subject to special requirements, the carbon equivalent shall be calculated according to the following formula:
3.1 All castings shall be properly heat treated. Acceptable methods of heat treatment are: normalizing normalizing and tempering quenching and tempering
Cq = C +
Mn Cr + Mo + V Ni + Cu + + 6 5 15
[ %]
Table 4.1
Limits for chemical composition [%]

Residual elements Sum of the max. permissible residual elements
Application
C max.
Si max.
Mn
S max.
P max.
Cu
Cr
Ni
Mo
Castings for general shipbuilding and machinery application Castings for welded structures for shipbuilding
1
0,40 1
0,60
0,501,60
0,040
0,040
0,30
0,30
0,40
0,15
0,80
0,23
0,60
1,60 max.
0,015
0,020
0,30
0,30
0,40
0,15
0,80
for welded structures for machinery application C 0,23 or Ceq 0,49
Chapter 2 Page 46
Section 4
Cast Steel
II - Part 1 GL 2009
4.2
Mechanical and technological properties
the minimum requirements specified in Table 4.4 are applicable to castings made of C and CMn cast steels.
4.2.3 The cast steels shown in Table 4.4 may be supplied with any minimum tensile strength within the limits specified in the table. The values graduated in steps of 40 N/mm2 do not represent the minimum tensile strengths of particular grades of cast steel but are intended to provide means of determining the required mechanical characteristics by interpolation in relation to specified minimum tensile strengths.
4.2.1 For grades of cast steel conforming to 2.1 to 2.4, the requirements specified in the respective standards shall apply, see Table 4.2 (grades of cast steel conforming to DIN 1681) and Table 4.3 (grades of cast steel conforming to DIN 17182). 4.2.2 Other grades of cast steel as per 2.5 shall have the characteristic properties of the respective grade according to the standard or the specification. In addition,
Table 4.2
Mechanical properties of cast steels conforming to DIN 1681
Grade of cast steel
Yield strength ReH [N/mm2] min. 200 230 260 300
Tensile strength Rm [N/mm2] min. 380 450 520 600
Elongation A [%] min. 25 22 18 15
Reduction in area Z [%] min. 40 31 25 21
Impact energy 1 KV [J] 2 min. t 30 mm 3 35 27 27 27 t > 30 mm 3 35 27 22 20
GS38 GS45 GS52 GS60

1 2 3
testing temperature = room temperature For castings for welded structures in shipbuilding the requirements according to Table 4.3 do apply. Average value of 3 tests t = sample thickness
Table 4.3
Mechanical properties of cast steels in the style of DIN 17182
Grade of cast steel
Heattreated condition 1
Wall thickness [mm]
Yield strength 2 ReH
Tensile strength Rm
Elongation A [%] min. 25 25 22 22 20 20 24 24 22 22
N/mm2 min. 260 230 300 260
N/mm2
Impact energy KV [J] 3 min. 65 45 55 40 35 27 70 50 40 30
Transition temp. T [27 J] 5 25 C 15 C 20 C 10 C 0 C RT 30 C 20 C 10 C RT
GS16Mn5
(N)
up to 50 over 50 to 100
430 600 430 600 500 650 500 650 480 630 450 600 500 650 500 650 500 650 480 630
up to 50 GS20Mn5 (N) over 50 to over 100 to over 160 up to 50 GS20Mn5 (Q+T) over 50 to over 100 to over 160
1 2 3 4 5
100 160
(260) 4 (240) 4 360 300 (280) 4 (260) 4
100 160
(N) = normalized; (Q+T) = quenched and tempered If there is no marked yield strength, the 0,2 % proof stress applies. Average value of 3 tests at room temperature (individual value at least 70 %). The values in brackets are only an approximate indication of the minimum yield strength in the casting. Requirements for welded structures for shipbuilding.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 47
Table 4.4
Mechanical properties of cast steels conforming to B.2.5
Grades of steel
Yield strength ReH
Elongation A
[N/mm2]
400 440 Ordinary quality Cand CMn cast steel 480 520 560 600 400 440 Special quality C and CMn cast steel 480 520 560 600
1
[N/mm2]
min. 200 220 240 260 280 300 200 220 240 260 280 300
[%] min.
25 22 20 18 15 13 28 26 24 22 20 18
Reduction in area Z [%] min. 40 30 27 25 20 20 45 45 40 40 35 35
Impact energy 3 KV [J] min. 25 20 18 15 12 10 32 28 25 20 18 15 KU [J] min. 25 22 20 17 15 12 30 27 25 22 20 17
Where the minimum tensile strength of a steel grade falls between two of the graduated values, the requirements may be determined by interpolation. The tensile strength determined by testing may not exceed the specified minimum tensile strength by more than 150 N/mm2 in case of the ordinary qualities and 120 N/mm2 in the case of the special qualities. Average value of 3 tests (individual value not less than 70 %).
4.3
Impact energy
5.3
All grades of cast steel shall meet the energy impact values prescribed for the grade in question. 5. 5.1 Testing Tensile test
5.3.1 In case non-destructive tests are prescribed for castings they shall be performed in accordance with G. to J. 5.3.2 Where castings are welded together, the welds shall be subjected to magnetic particle and ultrasonic or radiographic inspection. The extent of the inspection shall be as specified on the approval drawing or will be determined at the time of approval of the welding procedure. 5.4 Tightness test
The mechanical properties shall be verified by tensile test. The test specimens shall be prepared in accordance with A.10.2.2. 5.2 Notched bar impact test
Notched bar impact testing shall be performed on each test batch or, where applicable, each casting. The test specimens shall be prepared in accordance with A.10.2.2. The type of specimen is governed by the relevant standard or specification.
Castings subjected to internal pressure, e.g. stern tubes, shall be subjected to a hydraulic pressure test. The test shall be performed with the casting in machined condition. The test pressure is to be 1,5 times of the service pressure and for stern tubes uniformly 2 bars. The test pressure shall be kept for at least 10 Min.
Chapter 2 Page 48
Section 4
Cast Steel
II - Part 1 GL 2009
C.
Steel Castings for Crankshafts and Connecting Rods Scope
5. 5.1
Testing Tensile test
1.
These Rules are applicable to throws and webs of built crankshafts and connecting rods made of carbon, carbon-manganese and low-alloy grades of cast steel. 2. Approved grades of cast steel
The mechanical properties shall be verified by tensile test. For preparing the tensile specimens, test samples shall be cast integrally with the casting at a point stipulated in the specification. Each casting shall be tested individually. 5.2 Notched bar impact test
Only grades of cast steel which have been approved by GL as suitable for the intended application may be used. To this end, the engine manufacturer shall submit to GL for approval specifications or drawings containing all the data required for evaluating the castings, e.g. method of manufacture, chemical composition, heat treatment and mechanical properties. 3. Requirements applicable to the material
Notched bar impact specimens shall be taken from every casting and tested. The location of the specimens shall be as described in 5.1. The specimen shape prescribed in the specification (Charpy V-notch or Charpy U-notch specimen) shall be used. 5.3 Non-destructive tests
3.1 With regard to the chemical composition, mechanical properties and required impact energy and hardness values, the data in the approved specifications or drawings are applicable. However, the requirements specified in B.2.5 and, for special quality steel castings, Table 4.4 are to be satisfied as a minimum requirement. 3.2 The cast steel shall undergo vacuum degassing or another suitable treatment after melting, so that the properties mentioned in the specification may be achieved. 4. Method of manufacture and condition of heat treatment
Crank shafts and connecting rods shall be subjected to non-destructive tests according to the requirements stipulated in G. to J. By agreement between the foundry and the crankshaft or connecting rod manufacturer, the tests may be performed both at the foundry and at the manufacturer's works.
D.
Steel Castings for Steam Boilers, Pressure Vessels and Pipelines Scope
1.
4.1 The method of manufacture shall be approved by GL. The details of the approval test are established by GL from case to case. 4.2 All castings shall be in a heat treated condition appropriate to the grade of steel. The following processes are acceptable: normalizing normalizing and tempering quenching and tempering
1.1 These Rules are applicable to castings made from unalloyed and alloyed grades of cast steel and used for the manufacture of valve and pump housings, endplates, flanges, nozzles and pipe fittings. Cast steels for use at low temperatures are subject to E. 2. Suitable grades of cast steel
The following grades of cast steel may be used: 2.1 Grades of cast steel for use at room temperature and high temperatures conforming to EN 10213-2 "Technical Specifications relating to Cast Steel for Pressure Vessels", Part 2. The chemical composition of the commonly used grades of cast steel is given in Table 4.5 and the mechanical properties are stated in Table 4.6. 2.2 Ferritic grades of cast steel GS38 and GS 45 conforming to DIN 1681 up to a wall temperature of 300 C. 2.3 Heat resistant ferritic, ferritic-austenitic and austenitic grades of cast steel as well as Nickel and cobalt based alloys conforming to EN 10295.
Where possible, heat treatment shall be carried out after preliminary machining. If this is not possible, additional stress-relieving heat treatment shall be performed after preliminary machining with the minimum possible cutting allowance. 4.3 Defects shall normally be removed by grinding, gouging and/or machining. Care shall be taken to ensure that the required minimum cross sections are preserved. The removal of defects by welding requires the consent of GL as a matter of principle and may only be considered if the defects cannot be eliminated by the aforementioned measures.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 49
Table 4.5
Grade of cast steel GP240GH GP280GH G20Mo5 G17CrMo5-5
Chemical composition (%) of the commonly used grades of cast steel conforming to EN 10213-2
Si max. 0,60 0,60 0,60 0,60 0,60 P max. 0,030 0,030 0,025 0,020 0,020 S max. 0,020 1 0,020 1 0,020 1 0,020 1 0,020 1
C 0,18 0,23 0,18 0,25 2 0,15 0,23 0,15 0,20
Mn 0,50 1,20 0,80 1,20 2 0,50 1,00 0,50 1,00 0,50 0,90
Cr 1,00 1,50 2,00 2,50
Mo 0,40 0,60 0,45 0,65 0,90 1,20
G17CrMo9-10 0,13 0,20

1 2
In the case of castings having a standard wall thickness of < 28 mm, 0,030 % is permissible. For each 0,01 % reduction in the specified maximum carbon content, a 0,04 % increase of Manganese above the specified maximum content is permissible up to a maximum of 1,40 %.
Table 4.6
Mechanical properties of the commonly used grades of cast steel conforming to EN 10213-2 Notched bar impact test A [%] min. 22 KV 2 [J] min. 27 40 100 100 100 100 280 245 315 400 480 640 440 590 490 690 590 740 22 22 20 18 27 35 27 27 40
Tensile test Grade of cast steel Heat treatment symbol 1 Thickness [mm] max. Rp0,2 [N/mm2] min. 240 Rm [N/mm2]
GP240GH
N QT
100
420 600
GP280GH G20Mo5 G17CrMo5-5 G17CrMo9-10

1
N QT QT QT QT
denotes normalising denotes quenching and tempering
QT =
2
Testing temperature = room temperature (individual value not less than 70 %)
2.4 Other grades of cast steel conforming to other standards or material specifications, provided that they are comparable with the grades of cast steel stated in paragraphs 2.1 to 2.3 and proof has been furnished of their suitability for the intended application. An initial test of product suitability may be required for this purpose. 2.4.1 In addition, ferritic grades of cast steel shall satisfy the following minimum requirements: The elongation A shall have the characteristic minimum elongation values of the steel grade as specified by GL, but shall be not less than 15 %.
The impact energy shall be at least 27 J at room temperature in tests performed with Charpy Vnotch specimens. Ductile fracture behaviour is a fundamental requirement. Where necessary, the yield strength at elevated temperature and the long-time rupture stress properties at elevated temperature shall be verified by the manufacturer, specifying the guide values for the chemical composition.
Proof of weldability shall be furnished by the manufacturer.
Chapter 2 Page 410
Section 4
Cast Steel
II - Part 1 GL 2009
3.
Heat treatment and condition of supply
All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel. 4. External and internal condition
comparative hardness test. The result of the hardness test shall show that quenching and tempering has been carried out homogeneously (the difference in hardness between the hardest and the softest tested component in the test batch shall not exceed 30 HB). 6.4 Non-destructive tests
The requirements pertaining to the external and internal condition are specified in TRD 103. For this purpose, the cast steel shall be classed into quality levels according to the intended working temperature and pressure, see the Technical Rules for Steam Boilers TRD 103 and "AD-Merkblatt" W5 (AD Data Sheet W5). 5. 5.1 Requirements applicable to the material General requirements
The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 4. are met. Unless otherwise agreed, the scope of testing shall conform to TRD 103 or AD data sheet W5, whichever is appropriate. Valves and fittings are subject to TRD 110. In addition the Rules as stated in Chapter 1 Principles and Test Procedures, Section 3 shall be observed.
With regard to the chemical composition, mechanical and technological properties, required impact energy values and hardness of the grades of cast steel, the data contained in the standards mentioned in 2.1 and 2.2 or in the approved specifications shall be applicable. 5.2 Weldability
E.
Steel Castings for Use at Low Temperatures Scope
1.
Grades of cast steel conforming to these Rules shall be weldable by established workshop methods. Preheating and/or post-weld heat treatments may be required for this purpose, depending on the chemical composition. 6. Testing
These rules are applicable to steel castings which are to be used for cargo and processing equipment on gas tankers at design temperatures below 0 C, e.g. flanges, valve parts, weld-on and socket-welding pieces. 2. Approved grades of cast steel
The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests. 6.1 Tensile test
The grades of cast steel stated in Table 4.7 may be used within the limits for the minimum design temperatures, provided that they satisfy the requirements of 5. 2.1 Grades of cast steel for use at low temperatures conforming to EN 10213-3 "Technical Specifications relating to Cast Steel for Pressure Vessels" Part 3. The chemical composition of commonly used grades of cast steel is shown in Table 4.8 and the mechanical properties are stated in Table 4.9. 2.2 Other grades of cast steel
The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1000 kg shall be tested individually. 6.2 Notched bar impact test
The castings shall be subjected to the notched bar impact test. The number of sets of specimens (3 Charpy V-notch specimens per set) shall be determined in the same way as the number of tensile specimens. 6.3 Hardness test
Other grades of cast steel conforming to other standards or material specifications, provided that they are comparable to the grades of cast steel described in 2.1, that they meet the requirements of 3. to 5. and that proof has been furnished of their suitability for the intended application. An initial test of product suitability may be required for this purpose. 3. Heat treatment and condition of supply
All quenched and tempered steel castings which are tested on a heat-by-heat basis shall be subjected to a
All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel, see Table 4.9.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 411
Table 4.7
Approved grades of cast steels for use at low temperatures Permitted minimum design temperature 20 C 1 40 C 1 40 C 1 65 C 90 C Designation or material No. G17Mn5 G20Mn5 GS-10Ni6 G9Ni10 G9Ni14 1.4308
2
Grades of cast steel Weldable cast carbonmanganese steel 1,5 % cast nickel steel 2,25 % cast nickel steel 3,5 % cast nickel steel Austenitic grades of cast steel
1 2 3
Standard EN 10213-3 EN 10213-3 SEW 685 EN 10213-3 EN 10213-3 EN 10213-4 EN 10213-4 EN 10213-4
165 C
1.4408 1.4581 3
A minimum design temperature down to 55 C is possible if this is verified by an approval test. In addition EN 10283 does apply. Unsuitable for carriage of ammonia.
Table 4.8 Grades of cast steel G17Mn5 G20Mn5 G9Ni10 G9Ni14

1
Chemical composition [%] of the commonly used grades of cast steel conforming to EN 10213-3 C 0,15 0,20 0,17 0,23 0,06 0,12 0,06 0,12 Si max. 0,60 0,60 0,60 0,60 Mn 1,00 1,60 1,00 1,60 0,50 0,80 0,50 0,80 P max. 0,020 0,020 0,020 0,020 S max. 0,020 1 0,020 1 0,015 0,015 Ni max. 0,80 2,00 3,00 3,00 4,00
For castings having a standard wall thickness of < 28 mm, 0,030 % S is permissible.
Table 4.9
Mechanical properties of the commonly used grades of cast steel conforming to EN 10213-3 Tensile test at room temperature Notched bar impact test 2 KV [J] min. 27 27 500 650 280 360 480 630 500 650 22 24 20 34 34 40 70 95 Test temp. [C] 40 30
Grade of cast steel
Heat treatment symbol 1
Thickness [mm] max.
Rp0,2 [N/mm2] min. 240 300
Rm [N/mm2] 450 600 480 620
A [%] min. 24 20
G17Mn5 G20Mn5
QT N QT
50 30 100 35 35
G9Ni10 G9Ni14
1 2
QT QT
N = denotes normalizing, QT = denotes quenching and tempering Required impact energy value shown in Table 3.11 shall be complied with!
Chapter 2 Page 412
Section 4
Cast Steel
II - Part 1 GL 2009
4.
External and internal condition
Table 4.11
The external and internal condition shall be subject to quality levels in accordance with Table 4.10 depending on the minimum design temperature. If the evaluation is carried out according to other standards, the requirements shall be equivalent to those specified in Table 4.10. If castings are required to undergo final inspection in accordance with the AD data sheets, proof of the quality levels and scopes of testing is to be furnished in accordance with these Rules. Table 4.10 Assignment of quality levels
Required impact energy values at low temperatures Notched bar impact test
Grade of cast steel
Test temp. [C]

5 K below minimum design temp., not exceeding 20 C
Impact energy KV [J] 1 min. 27 (19)
Weldable cast carbon manganese steel
Minimum design temperature t 105 C
Quality level according to:

1, 2, 3, 4
1,5 % cast nickel steel 2,25 % cast nickel steel 3,5 % cast nickel steel Austenitic grades of cast steel 2
1 2 3
34 (24) 34 (24) 34 (24) 41 (27) 3
SM4, LM4, AM4 1, SP4, CP3, LP4, AP4 2, UV4 3, RV4 4 SM3, LM3, AM3 1, SP3, CP3, LP3, AP3 2, UV3 3, RV3 4 SM011 CP01 2
70 C 95 C 196 C
< 105 C
Welding edges 5
1 2 3 4 5
EN 1369 EN 1371-1 EN 12680-2 EN 12681 and former DIN 1690-2 For surface crack detection linear indications are not allowed.
Average value for 3 specimens. Figures in parentheses indicate lowest individual value. For design temperatures of 105 C and above, verification of the impact energy may be dispensed with. Some austenitic grades of cast steel are subject to higher required impact energy values, see Table 4.13, Part F.
6.1
Tensile test
5. 5.1
Requirements applicable to the material General requirements
The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1 000 kg shall be tested individually. 6.2 Notched bar impact test
The chemical composition and the mechanical properties are subject to the requirements specified in the standards or the approved specifications (see Tables 4.8 and 4.9). 5.2 Weldability
Grades of cast steel conforming to these rules shall be weldable by established workshop methods. 5.3 Impact energy at low temperatures
The castings shall be subjected to the notched bar impact test in compliance with the prescribed test temperature according to Table 4.11. The number of sets of test specimens (3 Charpy V-notch specimens per set) shall be determined in the same way as the number of tensile specimens. The test may be dispensed with in the case of austenitic steel castings with design temperatures of 105C. 6.3 Hardness test
The required impact energy values specified in Table 4.11 for the relevant grades of cast steel shall be met at the test temperatures stated in the table, using Charpy V-notch specimens. 6. Testing
The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests.
All quenched and tempered steel castings which are tested on a heat-by-heat basis shall be subjected to a comparative hardness test. The result of the hardness test shall show that quenching and tempering has been carried out homogeneously (the difference in hardness between the hardest and the softest tested component in the test batch shall not exceed 30 HB).
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 413
6.4
4.
Heat treatment and condition of supply
The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 4. are met. Unless otherwise agreed, the scope of testing shall conform to AD data sheet W5; valves and fittings are subject to AD data sheet AD-W10. In addition the Rules as stated in Chapter 1 Principles and Test Procedures, Section 3 shall be observed.
All steel castings shall be supplied in a heat-treated condition appropriate to the grade of cast steel, i.e. the grades specified in Table 4.13 shall be solutionannealed and quenched in water. 5. External and internal condition
F. 1.
Stainless Steel Castings Scope
Requirements to the external and internal condition shall be agreed on by the orderer and the manufacturer. Requirements to welding edges and special rim zones shall be agreed on separately. In case no agreements were made G.3. does apply. 6. 6.1 Requirements applicable to the material Chemical composition
These Rules are applicable to steel castings made from austenitic and austenitic-ferritic grades of steel which are intended for use in cargo and processing equipment for chemical tankers and other equipment for which chemical stability in relation to the cargo or the operating fluid is required. These Rules also apply to sleeves and bushes for propeller shafts and rudder stocks. The Rules are also applicable in conjunction with E. for austenitic grades of cast steel which are designed for use in cargo and processing systems for gas tankers. 2. Suitable grades of cast steel
6.1.1 The limits stated in Table 4.12 and/or the specifications approved by GL are applicable. 6.1.2 For steel castings for the cargo and processing equipment of chemical tankers, the composition shall be selected so as to ensure the chemical stability required for the particular application, having regard to the intended heat-treated condition of the material. Furthermore, where steel castings are to be used for welded structures, the composition shall be selected so as to ensure that the material is suitable for the proposed welding process and that it remains chemically stable after welding and any post-weld heat treatments which may be applied. In the case of austenitic and austenitic-ferritic grades of cast steel, 6.2 shall be complied with. The manufacturer shall prove the weldability of the material if requested to do so. 6.1.3 If compliance with a minimum value for the aggregate effective chromium value W is required for a particular application, this is calculated as follows:
W [ % ] = [ % ] Cr + 3,3 [ % ] Mo
The following grades of casting may be used, provided that they satisfy the requirements stated in 6. 2.1 Austenitic and austenitic-ferritic grades of steel conforming to EN 10213-4, "Technical Specifications relating to Cast Steel for use in pressure Vessels" as well as the grades indicated in EN 10283, Corrosion resistant steel castings. The chemical composition of these grades of cast steel is shown in Table 4.12 and the mechanical properties are given in Table 4.13. 2.2 Other stainless steels conforming to other standards or specifications after their suitability has been established by GL. An initial test of product suitability on the manufacturer's premises may be required for this purpose. 3. Selection of grades of cast steel
Note This formula is applicable for austenitic cast steel which has a molybdenum content of < 3 %.
6.2 As regards their chemical resistance, the grades of steel shall be selected in accordance with the operator's list of substances, which provides information on the nature of the substances to be transported or stored. 3.1 Where austenitic grades of cast steel are intended for cargo and process equipment for gas tankers, the requirements applicable to castings as stated in E., "Steel castings for use at low temperatures" shall apply.
Resistance to intercrystalline corrosion
Austenitic grades of cast steel shall be resistant to intercrystalline corrosion in the condition in which they are supplied. If it is intended to weld castings without post-weld heat treatment, only grades of cast steel that are corrosion-resistant in this condition as well shall be used, e.g. cast steels stabilized with Nb or containing not more than 0,03 % C. 6.3 Mechanical properties and impact energy
The requirements specified in Table 4.13 or in the approved specifications are applicable.
Chapter 2 Page 414
Designation Si max. 1,50 1,50 1,50 1,50 1,50 1,50 1,00 1,00 1,00 1,00 1,00 0,035 0,025 25,00 to 27,00 1,50 0,035 0,025 24,50 to 26,50 2,00 0,035 0,025 21,00 to 23,00 2,50 to 3,50 2,50 to 3,50 3,00 to 5,00 2,00 0,035 0,025 19,00 to 22,00 2,00 to 2,50 1,50 0,040 0,030 18,00 to 20,00 2,00 to 2,50 1,50 0,040 0,030 18,00 to 20,00 2,00 to 2,50 9,00 to 12,00 9,00 to 12,00 26,00 to 30,00 4,50 to 6,50 5,00 to 7,00 6,00 to 8,00 2,75 to 3,50 max. 1,30 max. 2,00 Nb: 8 C, max. 1,00 N: max. 0,20 N: 0,12 to 0,20 N: 0,12 to 0,22 N: 0,12 to 0,22 2,00 0,035 0,025 18,00 to 20,00 2,00 to 2,50 9,00 to 12,00 1,50 0,040 0,030 18,00 to 20,00 9,00 to 12,00 1,50 0,040 0,030 18,00 to 20,00 8,00 to 11,00 Nb: 8 C, max. 1,00 N: max 0,20 2,00 0,035 0,025 18,00 to 20,00 9,00 to 12,00 N: max. 0,20 max. max. max. elements Mn P S Cr Mo Ni Cu other
Section 4
Grade of cast steel
Material no.
max.
GX2CrNi19-11 1
1.4309 1
0,030
Cast Steel
GX5CrNi19-10 1
1.4308 1
0,07
GX5CrNiNb19-11 1
1.4552 1
0,07
GX2CrNiMo19-11-2 1
1.4409 1
0,030
GX5CrNiMo19-11-2 1
1.4408 1
0,07
GX5CrNiMoNb19-11-2 1
1.4581 1
0,07
GX2NiCrMo28-20-2 1
1.4458 1
0,030
GX2CrNiMoN22-5-3
1.4470
0,030
GX2CrNiMoCuN25-6-3-3
1.4517
0,030
GX2CrNiMoN26-7-4 2
1.4469 2
0,030
According to the intended purpose, e.g. at high or low temperatures, narrower limits may be specified for some elements by agreement between foundary and customer.
Table 4.12 Chemical composition [%] of suitable grades of cast steel in dependence on EN 10213-4 and EN 10283
For this grade of steel a minimum value for the "pitting factor" Pl = Cr + 3,3 Mo + 16 N 40 may be called for.
II - Part 1 GL 2009
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 415
Table 4.13
Mechanical properties of suitable grades of cast steel

Tensile test at room temperature Rp1,0 4 [N/mm2] min. 210 200 200 220 210 210 190 420 5 480 5 480 5 440 640 440 640 440 640 440 440 440 640 440 640 430 630 600 800 650 850 650 850 A [%] min. 30 30 25 30 30 25 30 20 22 22 Notched bar impact test KV 6 [J] min. 80 60 40 80 60 40 60 30 50 50
Designation
Material No.
Heat treatment + AT 1 [C]
Thickness [mm]
Rm [N/mm2]
max. GX2CrNi19-11 GX5CrNi19-10 GX5CrNiNb19-11 GX2CrNiMo19-11-2 GX5CrNiMo19-11-2 GX5CrNiMoNb19-11-2 GX2NiCrMo28-20-2 GX2CrNiMoN22-5-3 GX2CrNiMoCuN25-6-3-3 GX2CrNiMoN26-7-4
1 2 3 4 5 6
1.4309 1.4308 1.4552 1.4409 1.4408 1.4581 1.4458 1.4470 1.4517 1.4469
1050 1150 1050 1150 1050 1150 1080 1150 1080 1150 1080 1150 1100 1180 1120 1150 2, 3 1120 1150 2, 3 1140 1180 2, 3
150 150 150 150 150 150 150 150 150 150
The heat treatment applicable to all grades of steel is + AT + QW (solution annealing + quenching in water). Following solution annealing at high temperature, the castings may be cooled to between 1 040 C and 1 010 C before quenching in water to improve corrosion resistance and prevent cracks in the event of complex shapes. In the case of cast steel intended for pressure vessels, the precipitation-hardened condition is not applicable to austenitic-ferritic steels. Rp0,2 may be estimated by reducing the Rp1,0 value by 25 N/mm2. Rp0,2 Test temperature = room temperature RT (individual value not less than 70 %)
7.
Testing
7.3
The castings shall be presented for testing in finished condition (condition of supply) and shall undergo the following tests: 7.1 Tensile test
The mechanical properties shall be verified by tensile test. The tests shall be performed on a heat-by-heat basis, parts undergoing the same heat treatment being grouped into test batches in accordance with A.10.2.2. A tensile specimen shall be taken from each test batch and tested. Castings with unit weights > 1000 kg shall be tested individually. 7.2 Notched bar impact test
Austenitic and austenitic-ferritic steel castings shall be tested per heat and heat treatment batch for their resistance to intercrystalline corrosion in accordance with ISO 3651-1 or -2. Austenitic-ferritic grades of cast steel shall be tested in accordance with Iron and Steel Test Specification SEP 1877, Method I, or an equivalent method. The test shall be confirmed by the manufacturer by means of a certificate. 7.4 Non-destructive testing
The castings shall be subjected to the notched bar impact test. The number of sets of test specimens (3 Charpy V-notch specimens per set) shall be determined in the same way as the number of tensile specimens.
The manufacturer shall ensure by non-destructive tests on his products that the requirements pertaining to the external and internal condition according to 5. are met. Unless otherwise agreed, the scope of testing shall conform to AD Data Sheet W5. Valves and fittings are subject to TRD 110. In addition the Rules as stated in Chapter 1 Principles and Test Procedures, Section 3 shall be observed.
Chapter 2 Page 416
Section 4
Cast Steel
II - Part 1 GL 2009
G.
Non-destructive Testing of Cast Steel Components Scope of validity
For the most important cast steel components of the hull structure and of the propulsion plant the inspection zones are prescribed in I. and J. 2. Performing the tests
1.
1.1 These Rules apply to the non-destructive testing of cast steel components for which in B. to F. and H. appropriate requirements are prescribed, and for which no other regulations or manufacturer specifications are agreed upon. 1.2 A list containing the cast steel components for which non-destructive testing is required and the specific tests to be performed is contained in H. For propellers made of stainless cast steel the specifications in Chapter 5 Materials for Propeller Fabrication, Section 2 do apply. 1.3 The general requirements for inspection bodies, inspection personnel, testing methods and certification of the results are prescribed in Chapter 1 Principles and Test Procedures, Section 3 and are mandatory for all tests. 1.4 These Rules apply for the following testing methods defined according to EN 473, see Table 4.14: 1.5 Methods and testing, criteria indicated in G. are to be employed by the foundries, companies performing the further processing and the GL Surveyors. 1.6 For testing, the cast steel components shall be classified in inspection zones with different requirements for the severity levels. For classifying one or several of the following principles is/are decisive: the operating loads to be expected the effects of the defects on the reliability of the component possible risk of damage if the component fails required welding security for the welding edges freedom of defects and surface condition after machining Test methods
Symbol VT MT PT UT RT
2.1 After the inspector of the internal or external inspection body in charge of testing has performed the prescribed tests, the cast steel components shall be presented to the GL-Surveyor for visual testing. 2.2 Concerning the tests it shall be differentiated between pre-testing and acceptance testing. With pretests, where decisions concerning the testability and the employability of the cast steel component are made, they are in general the business of the foundry. Acceptance tests shall be performed preferably on the final machined cast steel component after the heat treatment appropriate for the required properties has been performed. The Surveyor shall be informed in time about the intended tests. It is up to the discretion of the Surveyor to attend the tests. 2.3 The tests shall be performed for the zones described in the specification or in the test plan. In case the results indicate that further defects are present in the cast steel component, the test scope shall be extended according to agreement with the Surveyor. 2.4 The cast steel components for which testing is prescribed are listed in H. Concerning the test scope and the severity level requirements for specific hull structural parts and for machinery parts test instructions are prescribed in I. and J. which shall be observed in addition to the manufacturer specifications. 3. Classifying in severity levels
3.1 The classifying in severity levels for the inner and outer condition is performed in accordance with the criterias indicated in the tables for the specific test methods. Table 4.15 sums up the various severity levels. 3.2 The selection of severity levels shall be agreed upon in accordance with EN 1559-1 and EN 1559-2 within the order. As a rule this is business of the orderer, in doing so the inspection zones shall be specified in accordance with 1.6 and the following requirements shall be observed: 3.2.1 Special rim zones such as welding edges shall be classified in the severity levels SM1, LM1, AM1, SP1, CP1, LP1, AP1, UV1 and RV1 over their entire length and over a width of 3 wall thickness, but at least of 50 mm. For welding edges with thickness larger than 50 mm the severity levels SM2, LM2, AM2, SP2, CP2, LP2, AP2, UV2 and RV2 are sufficient. For valve casings DIN 1690 part 10 does apply.
Table 4.14
Testing of 1 Visual testing Magnetic particle testing Penetrant testing Ultrasonic testing Radiography testing
1
For testing of stainless austenitic cast steel only the methods VT, PT and RT are applicable.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 417
Table 4.15
Overview of the severity levels

Test method VT MT Description of severity levels 1 V1, V2, V3, V4 SM1, SM2, SM3, SM4 LM1, LM2, LM3, LM4 AM1, AM2, AM3, AM4 SP1, SP2, SP3, SP4, CP1, CP2, CP3 LP1, LP2, LP3, LP4 AP1, AP2, AP3, AP4 UV1, UV2, UV3, UV4 RV1, RV2, RV3, RV4
Testing of
quirements for the surface condition of surfaces of cast steel components depending on the smallest indication to be registered are listed in Tables 4.16 and 4.17 for the magnetic particle testing and for the penetrant testing. Concerning the surface roughness for non-destructive testings then the following applies: Cast steel components where requirements for the surface roughness were specified are to be tested visually in accordance with 5. Cast steel components which are subjected to radiographic, magnetic particle or ultrasonic testing shall comply at least with the comparators 3 S1 or 4 S2. Cast steel components which are subjected to penetrant testing shall comply at least with the comparators 3 S2. Recommended surface condition for magnetic particle testing
Outer condition
PT
Inner condition
1
UT RT
Table 4.16
according to EN 12454, EN 1369, EN 1371-1, EN 12680-2, EN 12681 and DIN 1690-2
3.2.2 For fabrication weldings as a basic principle the same requirements as for the base material do apply. 3.2.3 For zones of steel castings for machinery parts, for valve casings as well as for dynamically loaded hull structural parts where no higher requirements are prescribed at least the severity levels SM3, LM3 and AM3 are to be met. 3.2.4 Apart from the specifications in 3.2.1 to 3.2.3, and if in the purchasing documents no higher classifying is required, for not specified zones at least severity level V2 does apply. 3.2.5 For the inner and outer condition of cast steel components equivalent severity levels as well as different severity levels may be determined. 3.3 Before testing is commenced the position and dimension of the zones to be tested and the severity levels to be met shall be specified in test plans, drawings or specifications taking into account 1.6, 3.1 and 3.2. These documents are shall be provided to GL. 4. Special agreements for the surface roughness
Dimension of the smallest indication [mm] 1,5 2 3

1 2
Surface comparators 1 BNIF 2 1 S1 2 S1 3 S2 4 S2 2 S1 3 S1 4 S2 5 S2 not specified (rough surface) SCRATA 2 A2 H2 A3 A4 H3
see EN 1370. see Annex A of EN 1369.
Table 4.17
Recommended surface condition for penetration testing
Dimension of the smallest indication [mm] 1,5 2 3

1 2
Surface comparators 1 BNIF 2 1 S1 2 S1 3 S2 4 S2 2 S1 3 S1 4 S2 5 S2 not specified (rough surface) SCRATA 2 A1 H1 A2 H2 A3 A4 H3
For the surface roughness limit values such as e.g. comparators 2 may be agreed upon if requested by the orderer or necessary due to technical reasons. Re
2
Reference to standards:
"Technische Empfehlung (technical recommendation) 359-1 des Bureau de Normalisation de l' Industrie de la Fonderie" "SCRATA comparators for the definition of surface quality of steel castings"; Steel castings Technology International; 7, East Bank road, Sheffield, S2 3PL United Kingdom
see EN 1370. see Annex A of EN 1371-1.
Chapter 2 Page 418
Section 4
Cast Steel
II - Part 1 GL 2009
5.
Visual testing (VT)
the moulding material and the blackening, as well as scale, dust and other contaminations. The required surface condition may be achieved by shot-blasting, grinding or machining. A specific surface roughness that shall be complied with may be agreed upon (cf. 4.). 6.2 The magnetic particle testing is to be performed in accordance with Chapter 1 Principles and Test Procedures, Section 3, I. In case black magnetic particles are employed the surface to be tested shall be coated with a permanent white paint, applied as thinly as possible (max. 20 m). A decrease of the test sensibility shall be observed. 6.3 In order to avoid burn marks on the surface of cast steel components in quenched and tempered condition when magnetization is performed by means of prods with alternating current only fusible supply electrodes made of tin-aluminium alloys shall be employed. Contact points visible on the surface are to be ground if necessary and to be retested by yoke magnetization. On already machined surfaces of the cast steel component testing is only allowed with yoke magnetization. 6.4 The indications of magnetic particle testing shall be evaluated concerning their type, size and number in accordance with Tables 4.19, 4.20 and 4.21. The reference area for this shall be a rectangle with 105 mm 148 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications). In addition for the evaluation the reference figures according to EN 1369 are to be consulted.
5.1 The manufacturer shall verify for each production stage of the cast steel components the external condition and the compliance of the dimensions. Minor casting defects such as small sand and slag inclusions, small cold shuts and small hot tears are to be cleaned out in case they may affect the testability. 5.2 Discontinuities which may affect the employability and the processability appropriate for the material more than irrelevant, such as larger non-metallic inclusions, cavities, gas holes or cracks, are not allowed and shall be repaired. 5.3 After special agreement with GL or if specified in the order the evaluation of the surface condition may be performed by means of comparators in accordance with Table 4.18 (cf. EN 12454 "Visual examination of surface discontinuities Steel sand castings"). 5.4 The Surveyor certifies the visual inspection on the GL acceptance test certificate. E.g. the following text can be typed in the test certificate:
The aforementioned cast steel components were visually tested. The prescribed requirements are fulfilled.
5.5 On demand of the orderer the manufacturer shall issue a test report containing the details of the tests, the prescribed severity levels and the test results. 6. Magnetic particle testing (MT)
6.1 The surfaces of the cast steel component to be tested shall be free of oil, grease, and remnants of
Table 4.18
Allocation of severity levels to the selected comparators 1 for the surface condition Severity Levels Category V1 V2 V3 V4
Designation according to the "Technischen Empfehlung 359-1" 2 Inclusions close to the surface Gas porosity Cold shuts Hot tears Inserts Welds
1 2
B1 C1 D1 E3 F1 J1
B2 C2 D2 E5 F3 J2
B4 C3 D5 J3
B5 C4 J5
The required severity level can be different for each category. See references to standards in 4.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 419
Table 4.19
Nature of discontinuities and the corresponding indications for magnetic particle testing
Types of magnetic particle inspection indications
Nature of discontinuities
Symbol
non-linear SM X X
non-linear LM X X X X
aligned AM X X X X X X
Gas porosity Sand and slag inclusions Cracks Chill chracks Inserts Cold shuts
A B D E F H
Table 4.20
Severity levels for magnetic particle testing - non-linear indications isolated (SM)
Characteristic SM 1 Inspection means Magnification for observation of magnetic particle indication. Length L1 of the smallest indication to be considered [mm]. Non-linear indications (SM)
1
Severity level SM 2 eye 1 1,5 10 21 2 35 41 3 70 61 5 200 10 1 SM 3 SM 4
maximum total surface area allowed [mm2] maximum individual length L2 allowed [mm]
At maximum 2 indications of the designated maximum dimension are permitted.
Note Only values expressed in this table are valid. The reference figures according to EN 1369 Annex B and C are for information only.
6.5 6.5.1
Definition of indications of magnetic particle testing Non-linear indications (SM)
non-linear: the distance between the indications is less than 2 mm and at least 3 indications are registered. linear: the distance between 2 indications is smaller than the length L of the longest discontinuity in a line.
Indications are to be assessed as non-linear if the length L is smaller than 3 times the width W. The symbol for non-linear indications is SM (S for surface and M for magnetic particle). 6.5.2 Linear indications (LM)
Aligned indications are assessed as one single indication. Its length equals the total length L of this line, see Fig. 4.1.
2
Indications are to be assessed as linear if L is equal or larger than 3 times W. The symbol for linear indications is LM (L for linear and M for magnetic particle). 6.5.3 Aligned indications (AM)
1
4 5
In the following cases the indications are assessed as aligned:
Fig. 4.1 Example for L
Chapter 2 Page 420
Section 4
Cast Steel
II - Part 1 GL 2009
Table 4.21
Severity levels for magnetic particle testing - linear (LM) and aligned (AM) indications
Severity levels Characteristic LM 1 AM 1 LM 2 AM 2 eye 1 1,5 I 2 3 5 C 4 6 10 I 4 6 10 2 C 6 12 20 I 6 9 15 3 C 10 18 30 I 10 18 30 5 C 18 27 45 LM 3 AM 3 LM 4 AM 4
Inspection means Magnification for observation of magnetic particle indication Length L1 of the smallest indication to be considered [mm] Arrangement of indications 1 isolated (I) or cumulative (C) Maximum length L2 of linear (LM) and aligned (AM) indications allowed depending on the wall thickness t [mm] Wall thickness class a t 16 mm Wall thickness class b 16 mm < t 50 mm Wall thickness class c t > 50 mm
Figure Figure Figure Figure C.3 C.4 C.5 C.6 Reference figures according to EN 1369 annex C
1 The linear and aligned indications shall be taken into consideration for the calculation of the cumulative length.
Note Only values expressed in this table are valid. The reference figures are according to EN 1369 annex C are for information only.
The symbol for aligned indications is AM (A for aligned and M for magnetic particle).
Note: The total length L equals the distance between the start of the first indication and the end of the last indication. Example: L = 1 +
2
7.2 The surface of the cast steel component to be tested shall correspond to the requirements for the surface condition specified in 6.1 and 4. 7.3 The indications shall be evaluated concerning their type, size and number in accordance with Tables 4.22, 4.23 and 4.24. The reference area for this shall be a rectangle with 105 mm 148 mm (size DIN A6) and shall be placed on the specific most unfavourable area for each case (area with the highest number of indications). In addition for the evaluation the reference figures according to EN 1371-1 part 2, or another recognized standard, may be consulted. 7.4 Definition of indications of penetrant testing Linear indication (LP)
6.6 Defects which concerning their size and number exceed the requirements for the prescribed severity levels as well as cracks are not allowed and shall be removed. Repaired zones shall be retested. 7. Penetrant testing (PT)
7.1 Testing is to be performed with an inspection system consisting of penetrant remover, penetrant and developer in accordance with Chapter 1 Principles and Test Procedures, Section 3, J.
7.4.1
Indication where the largest dimension equals at least 3 times the smallest dimension (i.e. L 3 W).
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 421
Table 4.22
Nature of discontinuities and type of corresponding indications for penetrant testing

Type of corresponding indications for penetrant testing
Nature of discontinuities
Symbol
non-linear isolated SP X X X clustered CP X X
linear LP X X X X
aligned AP X X X X X X
Gas porosity Sand and slag inclusions Cracks Chill cracks Inserts Cold Shuts
A B D E F H
Table 4.23
Severity levels for penetrant testing - non-linear indications 1, isolated (SP) or clustered (CP)
Severity Levels Characteristic SP1 CP1 SP2 CP2 eye 1 1,5 8 2 8 3 12 5 20 SP3 CP3 SP4
Inspection means Magnification for observation of penetrant indication Diameter of the smallest indication to be considered [mm] Maximum number of non-linear indications allowed Maximum size of discontinuity indication A, B and F [mm] isolated indications SP clustered indications CP
1
3 10
6 16
9 25
14
Such that L 3 W where L is the length and W is the width of the indication.
Note Only values expressed in this table are valid. The reference figures according to EN 1371-1 Annex B and C are for information only.
7.4.2
Non-linear indication
Indication where the largest dimension is smaller than 3 times the smallest dimension (i.e. L < 3 W). isolated (SP) cumulative (CP): area with many indications, the distance between the indications can not be measured (seemingly they form only one single indication) Aligned indications (AP) linear: the distance between 2 indications is smaller than the length of the largest defect in the line; or non-linear: the distance between 2 indications is less than 2 mm and at least 3 indications are registered.
7.5 Defects which concerning their size and number exceed the requirements for the prescribed severity levels as well as discontinuities in the material (cracks) are not allowed and shall be removed. Repaired zones shall be retested. For this the same inspection system as before shall be employed. 8. Ultrasonic testing (UT)
7.4.3
8.1 Ultrasonic testing is preferably performed for cast steel components with larger wall thickness and for examination of fabrication weldings as well as in addition to radiographic testing for determining the position in thickness and the dimension of defects, and shall be performed in accordance with Chapter 1 Principles and Test Procedures, Section 3, K.
Chapter 2 Page 422
Section 4
Cast Steel
II - Part 1 GL 2009
Table 4.24
Severity Levels for penetrant testing - linear (LP) and aligned (AP) indications 1
Serverity levels Characteristic LP 1 AP 1 LP 2 AP 2 eye 1 1,5 I 2 3 5 Figure D.3 C 4 6 10 I 4 6 10 Figure D.4 2 C 6 12 20 I 6 9 15 Figure D.5 3 C 10 18 30 I 10 18 30 Figure D.6 5 C 18 27 45 LP 3 AP 3 LP 4 AP 4
Inspection means Magnification for observation of penetrant indication Length L1 of the smallest indication to be considered [mm] Arrangement of indications isolated (I) or cumulative (C) Maximum lenght of linear (LP) and aligned (AP) indications allowed depending on the wall thickness t [mm] Wall thickness class a t 16 mm Wall thickness class b 16 mm < t 50 mm Wall thickness class c t > 50 mm
Following annex D
Note The penetrant indications may grow over a period of time and this should be taken into account.
1 The length L of an aligned indication is the distance between the starting point of the first discontinuity and the opposite end of the last discontinuity (L 3 W).
Note Only values expressed in this table are valid. The reference figures according to EN 1371-1 annex D are for information only.
8.2 All cast steel components shall be presented for testing in heat treated condition. As a rule ultrasonic testing may not be considered for austenitic and austenitic-ferritic cast steel grades. 8.3 In the areas to be tested an appropriate condition of the surface of the cast steel component shall be achieved which enables a faultless coupling of the probe. For this the surface shall be clear of remnants of the moulding material and the blackening, scale, dust and other contaminations which may affect the coupling. A specific surface roughness that shall be complied with according to 4. may be agreed upon. 8.4 Ferritic cast steel components shall only then be subjected to ultrasonic testing if disc shaped reflectors of 3 mm, 4 mm and 6 mm diameter can be veri-
fied definitely for the specific wall thickness regime, cf. Table 4.25. The echo height of these smallest disc shaped reflectors to be verified shall be at least 6 dB higher than the spurious echo at the end of the thickness regime to be evaluated. The fulfilment of the aforementioned conditions shall be proven to the GLSurveyor within the testing. 8.5 If possible zones to be tested shall be tested from both sides. In case only one side is accessible near resolving probes, SE probes, shall be used in order to detect inhomogeneities close to the surface. Testing with SE probes is convenient only for thicknesses up to 50 mm. 8.6 If not otherwise agreed on by the purchaser and the manufacturer for all cast steel components in addition the following zones shall be tested with SEstraight beam and/or angle probes up to 50 mm depth:
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 423
Table 4.25
Ultrasonic testability requirements according to EN 12680-1

Wall thickness [mm] 300 > 300 to 400 > 400 to 600 Smallest flat-bottom hole diameter detectable [mm] 3 4 6
Table 4.26
Registration levels for ultrasonic testing of ferritic steel castings in accordance with EN 12680-1
Reflectors without measurable dimension diameter of the equivalent flat-bottomed hole 1 min. [mm] 4 6 6 3 3 Reflectors with measurable dimension diameter of the equivalent flat-bottomed hole 1 min. [mm] 3 4 6 3 3 6 12
Wall thickness
Inspected area
Attenuation of back wall echo min. [mm]
[mm] 300 > 300 to 400 > 400 to 600 Severity level 1 areas special rim zone
1 Formula for converting the flat-bottomed hole diameter into the side-drilled hole diameter, see EN 12680-1.
Grooves, transitions in wall thickness, zones with outer cooling webs Fabrication weldings, welding edges and special rim zones Fabrication weldings with depths exceeding 50 mm shall be tested in addition with other appropriate angle probes.
will be performed. In the later case the testing shall be repeated. 8.9 For determining the acceptance criteria according to Table 4.27 the cast wall is to be divided in rim and core zones according to Fig. 4.2.
a Rim zone Core zone Rim zone a = t/3 (max. 30 mm)

(The classification of the wall refers to the dimensions of the cast steel component ready for assembling.) Fig. 4.2 Deviation of wall section into zones
8.7 All echo indications and attenuations of the back wall echo shall be registered which are equal to the registration levels indicated in Table 4.26 or exceed them. 8.8 Indications exceeding the acceptance limits contained in Table 4.27 or Fig. 4.3 are not allowed and will result in rejection of the cast steel component by the Surveyor. Nevertheless acceptance of the cast steel component is possible on condition that after further evaluation of the indications performed by the orderer and GL proof has been furnished that in case no repair will be performed the employability of the cast steel component will not be effected considerably, or repair
a a t
Chapter 2 Page 424
Table 4.27
Characteristic UV 1 UV 2 50 > 50 100 50 50 > 100 600 > 50 100 > 100 600 > 50 100 > 100 600 UV 3 UV 4 mm
Unit
Zone (see figure 2)
Severity level
Section 4
Casting wall thickness at the examined area
Largest diameter of equivalent flat-bottomed hole mm
Number of discontinuities to be recorded in a frame 100 mm 100 mm
Cast Steel
mm
Largest diameter of equivalent flat-bottomed hole
Maximum values of dimension in throughwall direction of discontinuities
mm mm2 mm2 mm2
Maximum length without measurable width
Largest individual area 3, 4
Largest total area for a reference area 3
Reflectors without measurable dimension rim 1 3 core rim 3 5 6 6 not used as criterion 32 core not used as criterion Reflectors with measurable dimension rim 1 3 core 15 % of zone thickness rim core 15 % of wall thickness rim 75 75 75 75 75 75 75 75 75 core 75 75 100 75 75 120 100 100 150 rim 600 1000 1000 600 2000 2000 2000 2000 2000 not permitted 10000 10000 15000 15000 15000 20000 15000 15000 20000 core rim 10000 10000 10000 10000 10000 10000 10000 15000 15000 core 10000 15000 15000 15000 20000 20000 15000 20000 20000
Reference area
150000 (390 mm 390 mm)
100000 (320 mm 320 mm)
1 For wall thickness not greater than 50 mm, flat-bottomed holes exceeding 8 mm are unacceptable.
For wall thickness greater than 50 mm the acceptability of flat-bottomed holes exceeding 8 mm in the rim zone shall be agreed between the manufacturer and the purchaser.
2 Accummulated in core zone and rim zone.
3 Indications less than 25 mm apart shall be considered as one discontinuity.
4 If the indication in the core zone is caused by an individual reflector the thickness of which does not exceed 10 % of the wall thickness, (e.g. centreline shrinkage) then, in case of severity
Acceptance limits for ultrasonic testing for volumetric discontinuities following EN 12680-1
II - Part 1 GL 2009
levels 2 to 4, values 50 % higher than those specified in this table, are acceptable and in case of severity level 5, no limit is specified.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 425
900 a [mm2] 800 5 700 600
500
400 300
200 100 0
10
20
30
40 b [mm]
50
Key UV 2 UV 3 UV 4 UV 5 a b Severity level 2 Severity level 3 Severity level 4 Severity level 5 largest acceptable individual indication area [mm2] distance from test surface [mm]
Indications with measureable dimensions are not allowed for severity level 1.
Fig. 4.3
Acceptance criteria for ultrasonic testing for individual planar indications mainly orientated in through-wall direction, detected with angle probes following EN 12680-1
Chapter 2 Page 426
Section 4
Cast Steel
II - Part 1 GL 2009
9.
Radiographic testing (RT)
9.1 Radiographic testing of cast steel components is to be performed in accordance with Chapter 1 Principles and Test Procedures, Section 3, L. 9.2 Selection of radiation source depends on the required testing category and the wall thickness to be penetrated, see Table 4.28. If necessary radiographic testing shall be performed in addition to ultrasonic testing if doubts exist concerning the evaluation of indications of ultrasonic testing.
9.3 Indications which concerning their type and dimension exceed the maximum permissible values indicated in Table 4.29 for the required test category are not allowed and will result in rejection of the cast steel component by the Surveyor. Nevertheless acceptance of the cast steel component is possible on condition that after further evaluation of the indications performed by the orderer and GL proof has been furnished that in case no repair will be performed the employability of the cast steel component will not be affected considerably, or repair will be performed. In the later case the testing shall be repeated.
Table 4.28
Radiation source in dependence of the test class and the penetrated thickness following EN 444 and EN 12681
Penetrated thickness [mm] Radiation source Class A TM 170 Yb 169 Se 75 Ir 192 Co 60
w5 1 w 15 10 w 40 20 w 100 40 w 170 30 w 200 w 50 w 80
Class B
w5 2 w 15 14 w 40 20 w 90 60 w 150 50 w 180 w 80 w 100
X-ray equipment with energy from 1 MeV to 4 MeV X-ray equipment with energy from 4 MeV bis 12 MeV X-ray equipment with energy above 12 MeV
II - Part 1 GL 2009
Table 4.29
Section 4
Defect Wall thickness [mm] RV 1 A1 A1

3
Type RV 2 2 A3 A3 A3 A3 A3 A3 RV 3 2
Code letter as ASTM 1
Assessment as in ASTM 1
Maximum permissible defect for severity level RV 4 2 A4 A4 A4
Blowholes
up to 50 over 50 up to 115 over 115 up to 300 E 446 E 186 E 280 B1 B1

3
Cast Steel
Non-metallic inclusions E 446 E 186 E 280
up to 50 over 50 up to 115 over 115 up to 300 E 446 E 186 E 280 B3 B3 B3 up to 50 over 50 up to 115 over 115 up to 300
B3 B3 B3
B4 B4 B4
Shrinkage
Ca1, Cb1, Ca3, Cb3, Ca4, Cb4, Ca2, Cb2, Cc1, Cd1, Cc3, Cd3, Cc4, Cd4, Cc2, Cd2, Ca1, Cb1, Cc1, Ca3, Cb2, Cc2, Ca3, Cb3, Cc3, Ca4, Cb4, Cc4, 3 Ca2, Cb2, Cc2 Ca3, Cb3, Cc3 Ca4, Cb4, Cc4
Maximum permissible defects for radiographic testing
Cracks up to 50 over 50 up to 115 over 115 up to 300 E 446 E 186 E 280
D+E
Chaplets and iron chills
Not permitted Not permitted Not permitted Not permitted
Not permitted 4 Not permitted Not permitted Not permitted
Not permitted 4 Not permitted 4 Not permitted F15 F15 Not permitted F15 Not permitted
1 Caption: ASTM-E 446 Reference radiographs for steel castings up to 2 in. (51 mm) in thickness, ASTM-E 186 Reference radiographs for heavy walled (2 to 4 1/2 in. (51 to 114 mm) steel castings sowie ASTM-E 280 Reference radiographs for heavy walled (4 1/2 to 12 in. (114 to 305 mm) steel castings. 2 If for example it is shown by ultrasonic testing that the defects are in the core zone (see Fig. 4.1), the specifications for the next higher (numerical) severity level shall apply, unless otherwise specified in the material standard or in the order. 3 The values to be adhered shall be agreed. 4 Unless the minor nature of the cracks is proved by fracture-mechanical tests. 5 Chaplets may be present, but they shall be welded free from cracks at the surface.
Chapter 2 Page 427
Chapter 2 Page 428
Section 4
Cast Steel
II - Part 1 GL 2009
H.
List of Cast Steel Components for which Non-destructive Tests are Required Test methods to be employed
Table 4.30
Test methods to be employed 1 Name of the component VT Structural parts concerning the hull Stern Propeller shaft-nut Rudder horn Rudder bearing Rudder coupling Shaft bracket Ruder shaft Tiller Diesel engine parts Piston crowns Cylinder covers Camshaft drive gear wheels and chain wheels Crank webs and throws Connecting rods Bearing transverse girders Main bearings and bearing covers for main, crossheads and piston rod bearings Starting valve casings MT PT UT RT
() 2 () 2 () 2 () 2 () 2 () 2 () 2
5 5 5
5 5
Further components of the propulsion plant Turbine casings Gear wheels Valve casings Valve casings for pipe class I 3 with NW 100
1 Testing in the prescribed areas. 2 PT may be employed instead of MT. 3 Compare GL Rules for Classification and Construction I Ship Technology, Part 1 Seagoing Ships, Chapter 2 Machinery
Installations, Section 11, A.3.

4 Random testing according to testing plan 5 For diesel engines with cylinder diameter > 400 mm.
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 429
I.
Testing Instructions for Hull Structural Parts
In the figures 4.4 to 4.11 the specifications for the non-destructive testings are prescribed.
Testing scope: Visual testing: Magnetic particle testing: Radiographic testing: Ultrasonic testing: Severity levels: Visual testing: Magnetic particle testing: Radiographic testing: Ultrasonic testing:
1
entire surface Welding edges ( Welding edges ( Welding edges ( ) ), if permitted by the geometry )
V1 for welding edges; V3 remaining areas SM1; LM1; AM1 for welding edges; SM2; LM2; AM2 remaining areas RV1 up to thickness 50 mm and RV2 for thickness > 50 mm 1 UV2 instead of radiographic testing for thickness > 50 mm 1
Thickness = Thickness of the cast component at the area to be tested.
Fig. 4.4 Testing instruction for stern
Chapter 2 Page 430
Section 4
Cast Steel
II - Part 1 GL 2009
A A-A B-B B B
Testing scope: Visual testing: Magnetic particle testing: Radiographic testing: Severity levels: Visual testing: Magnetic particle testing: Ultrasonic testing: V2 ( ) SM2, LM2, AM2 ( ) SM3, LM3, AM3 remaining areas UV2 entire surface areas marked with ( areas marked with ( ) )
Fig. 4.5 Testing instruction for rudder stock
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 431
Testing scope: Visual testing: Magnetic particle testing: Radiographic testing: Ultrasonic testing: entire surface Welding edges ( Welding edges ( Areas marked with ( ), ( ) ) )
Severity levels: Visual testing: V1 for areas marked with ( V2 for areas marked with ( remaining areas V3 Magnetic particle testing: SM1, LM1, AM1 for ( for areas marked with ( remaining areas RV2 for thickness > 50 mm Ultrasonic testing: UV2; further instead of radiographic testing for thickness > 50 mm ); SM2, LM2, AM2 ); SM3, LM3, AM3 for the ), );
Radiographic testing:
RV1 up to thickness 50 mm and
Fig. 4.6 Testing instruction for stern nut
Chapter 2 Page 432
Section 4
Cast Steel
II - Part 1 GL 2009
Severity levels: Visual testing: Magnetic particle testing: V1 for areas marked with ( remaining areas V3 SM1, LM1, AM1 for ( for areas marked with ( remaining areas RV2 for thickness > 50 mm Ultrasonic testing: UV2; further instead of radiographic testing for thickness > 50 mm ); SM2, LM2, AM2 ); SM3, LM3, AM3 for the ) and
Fig. 4.7 Testing instruction for rudder horn
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 433
Severity levels: Visual testing: Magnetic particle testing: V1 for areas marked with ( remaining areas SM1, LM1, AM1 for ( for areas marked with ( remaining areas RV2 for thickness > 50 mm Ultrasonic testing: UV2; further instead of radiographic testing for thickness > 50 mm ); SM2, LM2, AM2 ); SM3, LM3, AM3 for the ) and V2 for
Fig. 4.8 Testing instruction for upper rudder coupling
Chapter 2 Page 434
Section 4
Cast Steel
II - Part 1 GL 2009
Severity levels: Visual testing: Magnetic particle testing: V1 for areas marked with ( remaining areas SM1, LM1, AM1 for ( for areas marked with ( remaining areas RV2 for thickness > 50 mm Ultrasonic testing: UV2; further instead of radiographic testing for thickness > 50 mm ); SM2, LM2, AM2 ); SM3, LM3, AM3 for the ); V2
Fig. 4.9 Testing instruction for lower rudder coupling
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 435
B-B
"Z"
B A
A-A
B Testing scope: Visual testing: Magnetic particle testing: Radiographic testing: Ultrasonic testing: entire surface Welding edges ( Welding edges ( Areas marked with ( ), ( ) ) )
Severity levels: Visual testing: Magnetic particle testing: V1 for ( SM1, LM1, AM1 for ( for areas marked with ( remaining areas RV2 for thickness > 50 mm Ultrasonic testing: UV2; further instead of radiographic testing for thickness > 50 mm ); V2 remaining areas ); SM2, LM2, AM2 ); SM3, LM3, AM3 for the
Fig. 4.10 Testing instruction for stern frame
Chapter 2 Page 436
Section 4
Cast Steel
II - Part 1 GL 2009
3d
3d
1,75 d
Testing scope: Visual testing: Penetrant testing: Ultrasonic testing: Severity levels: Visual testing: V1 Key way, bore: conical or cylindrical, remaining areas V2 Tillerarms: Contact areas for slide piece and ground, lower and upper plane areas remaining areas remaining areas The indicated areas / zones of slide are to be tested befor machining the slide surface. remaining areas UV3 entire surface ) ) ( Magnetic particle testing: (
Areas marked with
Magnetic particle testing: SM1, LM1, AM1 or Penetrant testing: SP1, CP1, LP1, AP1 Magnetic particle testing: SP2, LM2, AM2 or Penetrant testing: SP2, CP2, LP2, AP2 Ultrasonic testing: UV2
Cracks are not permitted. The machined areas shall not have open sand marks. Whether indications are left as they are, ground or fabrication welded is decided by GL.
3d
3b b
Fig. 4.11 Testing instruction for tiller
t t t
II - Part 1 GL 2009
Section 4
Cast Steel
Chapter 2 Page 437
J.
Testing Instruction for Diesel Engine Parts
In the figures 4.12 and 4.13 the specifications for the non-destructive testings are prescribed.
200
30
Zone I
200
Zone II
Testing scope: Visual testing: Magnetic particle testing: Ultrasonic testing: Penetrant testing: Severity levels: Visual testing: Magnetic particle testing: Ultrasonic testing: Penetrant testing: V1 for zone I and II; remaining areas V2 SM1, LM1, AM1 for zone I and II; remaning areas SM2, LM2, AM2 UV1 for zone I and II; remaining areas UV2 SP2, CP2, LP2, AP2 for areas marked with ( ) entire surface entire surface Shaft and bearing areas machined bearing surfaces ( )
Fig. 4.12 Testing instruction for connecting rods
Chapter 2 Page 438
Section 4
Cast Steel
II - Part 1 GL 2009
G G
Testing scope: Visual testing: Magnetic particle testing: Ultrasonic testing: Penetrant testing: Severity levels: Visual testing: Magnetic particle testing: V1 for ( ), remaining areas V2 ); ) SM1, LM1, AM1, for the areas marked with ( SM2, LM2, AM2, for the areas marked with ( Ultrasonic testing: Penetrant testing: UV1 for the areas marked with ( UV2 for the areas marked with ( ) ) ); entire surface Welding edges ( marked areas with ( marked areas with ( ), ( ) ) )
SP2, CP2, LP2, AP2 for the areas marked with (
Fig. 4.13 Testing instruction for main bearing support
II - Part 1 GL 2009
Section 5
Cast Iron
Chapter 2 Page 51
Section 5 Cast Iron

A. 1. General Rules Scope removal causes a change of structure, e.g. in the case of flame cutting, the cut faces shall afterwards be machined. 4.3 Fabrication and repair welds, be it dissimilar welding by means of fillers with high nickel content or similar welding, i.e. using similar fillers, have to be in any case subject to a welding procedure test at the presence of the Surveyor. GL decides about a cast- or component-specific application of the above mentioned procedure. 4.4 With the consent of the Surveyor, local porous areas on castings not subjected to internal pressure may be corrected applying appropriate procedures, such as inserting filler pieces of similar material. It is a condition that the serviceability of the castings shall not be impaired by this. 5. 3. Requirements to be met by foundries Dimensions; dimensional and geometrical tolerances
General Rules to be applied in the manufacture and testing of nodular and grey cast iron are contained in A. 2. Selection of grades of cast iron
2.1 All castings shall be suitable for their intended purpose and satisfy the minimum requirements specified in the following individual Rules. Subject to these conditions, grades conforming to the relevant standards or to material specifications approved by GL may be used. 2.2 The grades of cast iron shall be identified by the standardized designations or the designations in the specifications.
3.1 Foundries wishing to supply castings in accordance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufacturing and quality control requirements stated in Chapter 1 Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the commencement of supplies. 3.2 Irrespective of the requirements stated in 2.1, the manufacturer shall himself prove by qualification tests carried out on the products that these can be manufactured in accordance with the conditions imposed. The scope of these tests will be determined by GL on a case to case basis. 4. General characteristics of castings
The dimensions and the dimensional and geometrical tolerances are governed by the values specified in the drawings relating to the order or in the relevant standards, as applicable. Appropriate details shall be given in the order documents and shall be made known to the Surveyor. 6. Resistance to leakage
All castings which are subjected to internal pressure by the operating medium or for which special proof of impermeability is required shall be tightness tested at the specified test pressures. 7. General requirements applicable to cast materials Chemical composition
4.1 All castings shall have a clean surface compatible with the conditions of manufacture. Minor casting defects such as sand and slag marks, small cold shuts and scabs may be trimmed off within the negative tolerance on the wall thickness. Castings shall be free from defects liable to impair machining operations and their subsequent use to a more than insignificant extent. In this respect orderer and manufacturer have to agree on specific grade levels according to EN 1369, EN 1371-1, EN 12680-3 and EN 12681. 4.2 Feeders and other excess material shall be removed by suitable methods. Where the method of
7.1
Unless otherwise agreed or specified in the standards, the chemical composition shall be selected by the manufacturer. The manufacturer shall determine the composition in such a way that the required characteristics are achieved. 7.2 Mechanical properties
The values shown in the Tables in B. and C. or in the standards, where applicable, shall be met under test. The impact energy specified for special quality nodular cast iron grades shall be met by the average value measured on 3 specimens.
Chapter 2 Page 52
Section 5
Cast Iron
II - Part 1 GL 2009
8.
Tests
The following tests are to be carried out: 8.1 Test of chemical composition
sure by continuous quality control that the characteristics remain constant. 9. Test of surface finish and dimensions
Where required, the manufacturer shall determine the composition of each treatment batch (ladle) and give the Surveyor a certificate confirming this composition. 8.2 Testing of mechanical properties and selection of specimens
The manufacturer shall inspect each casting with regard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the castings to the Surveyor for final inspection. For this purpose, the surface of the castings shall be free from moulding material and shall be properly prepared for inspection. 10. Non-destructive tests
8.2.1 The mechanical properties shall be ascertained by tensile test. In the case of special quality nodular cast iron for which an impact energy is specified, a notched bar impact test shall also be performed. 8.2.2 For each casting or unit test quantity, as applicable, a sufficient quantity of sample material shall be provided to enable the necessary tests and possible retests to be performed. 8.2.3 For proof of the mechanical properties separately cast samples, integrally cast samples or samples taken from the casting unit may be used. 8.2.4 Type, quantity and location of the respective samples are to be agreed between orderer and manufacturer until acceptance of the order, unless otherwise specified. 8.2.5 For casting units with cast weights of maximum 2000 kg and a determining wall thickness of up to 200 mm integrally cast samples are to be used. If the weight of the casting unit exceeds 2000 kg and the determining wall thickness is larger than 200 mm integrally cast samples or samples taken from the casting unit are to be used. The latter is to be agreed between the manufacturer and the orderer as well as GL under consideration of 8.2.4. 8.2.6 Where separately cast samples are used, these shall be cast in moulds made of the same mould material as that used for the casting itself. The samples may not be removed from the moulds until their temperature has dropped to below 500 C. In the case of chill casting, centrifugal casting and continuous casting, special agreements shall be reached with GL regarding the selection of samples. 8.2.7 All samples are to be marked in such a way that they can be clearly related to the castings which they are intended to represent. 8.2.8 Where castings are supplied in a heat-treated condition, the samples shall be heat treated together with the castings concerned. 8.2.9 Where castings are manufactured in series, the manufacturer may, with the agreement of GL, use other, equivalent methods of testing. In this case, the manufacturer shall have proved the characteristics of the products by a preliminary type test and shall en-
Generally, a non-destructive test shall be performed only where this is specified in the order according to 4.1. Apart from this, the Surveyor may call for suitable non-destructive tests if there are justified doubts that the castings are free from defects. 11. Hydraulic pressure test
Where specified, castings shall be submitted to a hydraulic pressure test. The test is to be performed in the presence of the Surveyor, wherever possible on the rough-machined castings. Where no other test pressure is specified, the test pressure shall be equal to 1,5 times the operating pressure. 12. Retests in the event of failure
If specimens fail to meet the required values in the tensile or notched bar impact test, or if, in the notched bar impact tests, one value is below the level permitted by the specification, then, before the unit test quantity or the casting is rejected, the procedures for retests prescribed in Chapter 1 Principles and Test Procedures, Section 2, H. may be applied. The additional test specimens shall be taken either from the same test sample as the original specimen or from other samples which are representative of the casting or of the unit test quantity. 13. Identification and marking
13.1 The manufacturer shall institute a monitoring system enabling all castings to be traced back to the original heat, and this shall be demonstrated to the Surveyor on request. 13.2 Prior to final inspection, all castings shall be provided by the manufacturer in at least one place with the following marks: 13.3 Grade of cast iron, material symbol and/or material number of the cast material: heat number or mark enabling the manufacturing process of the casting to be traced back manufacturer's name or mark test pressure, where applicable
II - Part 1 GL 2009
Section 5
Cast Iron
Chapter 2 Page 53
13.4 In the case of series-manufactured castings, agreement may be reached with the Surveyor to apply marks other than those specified above. 14. Certificates
3.
Condition of supply and heat treatment
3.1 Apart from the exceptions provided for in 3.2, the castings may be supplied in as cast or heattreated condition. The method of treatment shall be specified at the time of the approval test. 3.2 Cast iron of grades EN-GJS-350-22-LT/-22U-LT to EN-GJS-400-18-LT/-18U-LT or the special qualities according to Table 5.1 with nominal strengths of 350 and 400 N/mm2 shall undergo ferritizing treatment. 3.3 Where castings are subject to special requirements in respect of their dimensional or geometrical stability, any heat treatments needed shall be carried out before the castings are machined. Heat treatments to eliminate casting stresses or for straightening may only be carried out at temperatures up to 550 C because of the danger that the characteristics might be changed. 4. 4.1 Requirements applicable to the material Nodular cast iron conforming to DIN EN 1563
For each consignment, the manufacturer shall supply to the Surveyor a certificate containing at least the following details: orderer and order number newbuilding or project number, where known item number and quantity type of casting units and grade of cast iron application and drawing number, if necessary weight of products manufacturing process heat number or identifying mark chemical composition of the heat condition of supply details of heat treatment, if necessary marking test pressures, if necessary results of mechanical tests
The requirements specified in the standard and given in Table 5.2 for separately cast samples and in Table 5.3 for integrally cast samples are applicable. In case of requirements regarding impact energy, the minimum values specified in Tables 5.4 and 5.5 are to be proven. In addition the requirements in 4.3 and 4.4 apply regarding graphite- or metallic matrix structure respectively. 4.2 Other grades of cast iron
B. 1.
Nodular Cast Iron Scope
These Rules are applicable to nodular cast iron for the manufacture of machinery and pipeline components, e.g. fittings, flanges, housings, hubs, bed-plates and similar parts designed for use and testing at normal ambient temperatures. The requirements for the use of castings at higher operating temperatures or at low temperatures generally below 0 C are subject to the special agreement of GL. 2. Suitable grades of cast iron
4.2.1 The castings shall achieve the mechanical properties specified in Table 5.1 in testing, depending on their minimum tensile strength. The Brinell hardness data are only guide values. 4.2.2 Special quality castings shall meet the required energy impact values specified in Table 5.1. 4.3 Graphite structure
The following grades of cast iron may be used: 2.1 Nodular cast iron conforming to DIN EN 1563 with the characteristics stated in the standard. 2.2 Nodular cast iron grades conforming to other standards, provided that they are equivalent to the grades specified in 2.1 and satisfy the requirements stated in 4.2 to 4.4.
The manufacturing process shall ensure that 90 % of the graphite is precipitated in nodular form according to Form VI of EN ISO 945. The remaining graphite shall have a structure at least of form V according to the above mentioned standard. 4.4 Structure of metallic matrix
The metallic matrix shall have the structure indicated in Table 5.1. The proportion of pearlite in the ferritic grades may not exceed 10 %. The graphite- and metallic matrix structures are to be demonstrated by micrographs.
Chapter 2 Page 54
Section 5
Cast Iron
II - Part 1 GL 2009
Table 5.1
Mechanical properties and structure of nodular cast iron

Impact energy Rp0,2 [N/mm2] min. 230 250 310 320 370 420 480 220 250 A [%] min. 17 15 10 7 3 2 2 22 4 18 4 Hardness HB 10 2 min. 120 180 140 200 160 210 170 240 190 270 230 300 250 350 110 170 140 200 Test temp. [C] - 20 - 20 KV 3 [J] min. 17 (14) 14 (11) Structure of metallic matrix
Minimum tensile strength Rm 1 [N/mm2] 370 400 450 500 600 700 800 350 400
Ordinary qualities
Ferrite Ferrite Ferrite Ferrite/pearlite Ferrite/pearlite Perlite Perlite/sorbite Ferrite Ferrite
Special qualities
1 2 3 4
Where the minimum tensile strength of the casting falls between the graduated values indicated, the requirements may be determined by interpolation. The values are intended only as a guide and are not test requirements. The average value measured on 3 Charpy V-notch specimens. One result may be below the average value but not less than the minimum shown in brackets. In the case of integrally cast samples, the elongation may be 2 percentage points less.
Table 5.2
Mechanical properties determined from samples of separately cast test specimens Tensile strength Rm [N/mm2] min. 350 350 350 400 400 400 400 450 500 600 700 800 0,2-proof stress Rp0,2 [N/mm2] min. 220 220 220 240 250 250 250 310 320 370 420 480 Elongation A [%] min. 22 22 22 18 18 18 15 10 7 3 2 2
Material designation Material code EN-GJS-350-22-LT 1 EN-GJS-350-22-RT 2 EN-GJS-350-22 EN-GJS-400-18-LT 1 EN-GJS-400-18-RT EN-GJS-400-18 EN-GJS-400-15 EN-GJS-450-10 ENGJS-500-7 EN-GJS-600-3 EN-GJS-700-2 EN-GJS-800-2
1 2 2
Number EN-JS1015 EN-JS1014 EN-JS1010 EN-JS1025 EN-JS1024 EN-JS1020 EN-JS1030 EN-JS1040 EN-JS1050 EN-JS1060 EN-JS1070 EN-JS1080
Main structure of metallic matrix Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite Ferrite/Perlite Perlite/Ferrite Perlite Perlite
LT for low temperatures RT for room temperature
Note The values for these materials apply to units cast in sand moulds with comparable temperature conductibility.
II - Part 1 GL 2009
Section 5
Cast Iron
Chapter 2 Page 55
Table 5.3
Mechanical properties determined from samples of integrally cast test specimens

Determining wall thickness t [mm] t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 t 30 30 < t 60 60 < t 200 Tensile strength Rm [N/mm2] min. 350 330 320 350 330 320 350 330 320 400 390 370 400 390 370 400 390 370 400 390 370 450 0,2 % Proof stress Rp0,2 [N/mm2] min. 220 210 200 220 220 210 220 220 210 240 230 220 250 250 240 250 250 240 250 250 240 310 to be agreed 500 450 420 600 600 550 700 700 660 800 320 300 290 370 360 340 420 400 380 480 to be agreed 7 7 5 3 2 1 2 2 1 2 Elongation A [%] min. 22 18 15 22 18 15 22 18 15 18 15 12 18 15 12 18 15 12 15 14 11 10
Material designation
Material code EN-GJS-350-22U-LT 1
Number
EN-JS1019
EN-GJS-350-22U-RT 2
EN-JS1029
EN-GJS-350-22U
EN-JS1032
EN-GJS-400-18U-LT 1
EN-JS1049
EN-GJS-400-18U-RT 2
EN-JS1059
EN-GJS-400-18U
EN-JS1062
EN-GJS-400-15U
EN-JS1072
EN-GJS-450-10U
EN-JS1132
EN-GJS-500-7U
EN-JS1082
EN-GJS-600-3U
EN-JS1092
EN-GJS-700-2U
EN-JS1102
EN-GJS-800-2U
1 2
EN-JS1112
Chapter 2 Page 56
Section 5
Cast Iron
II - Part 1 GL 2009
Table 5.4
Minimum values for impact energy determined from samples with V-notch from separately cast test specimens
Minimum values for impact energy [J] Material designation at RT (23 5) C Material code EN-GJS-350-22-LT 1 EN-GJS-350-22RT 2 EN-GJS-400-18-LT
1
at (20 2) C
at (40 2) C
Number EN-JS1015 EN-JS1014 EN-JS1025 EN-JS1024
Average Individual Average Individual Average Individual value from value value from value value from value 3 tests 3 tests 3 tests 17 14 14 11 12 9 12 9
EN-GJS-400-18-RT 2
1 2
Note The values for these materials apply to units cast in sand moulds with comparable temperature conductibility.
Table 5.5
Minimum values for impact energy determined from samples with V-notch from integrally cast test specimens
Minimum values for impact energy [J]
Material designation
Material code
Number
RT at at Determining (23 5) C (20 2) C (40 2) C wall thickness t Average Indivi- Average Indivi- Average Indivi[mm] dual dual value dual value value value value from value from from 3 tests 3 tests 3 tests t 60 60 < t 200 t 60 60 < t 200 30 < t 60 60 < t 200 30 < t 60 60 < t 200 12 17 15 14 12 14 12 12 10 11 9 7 9 10 7 9
EN-GJS-350-22U-LT 1
EN-JS1019
EN-GJS-350-22U-RT 2
EN-JS1029
EN-GJS-400-18U-LT 1
EN-JS1049
EN-GJS-400-18U-RT 2
1 LT for low temperatures 2 RT for room temperature
EN-JS1059
Note The values for these materials apply as a rule to casting units with thicknesses between 30 and 200 mm.
II - Part 1 GL 2009
Section 5
Cast Iron
Chapter 2 Page 57
5.
Testing
The following tests shall be performed: 5.1 Test of chemical composition

Z 3 Incline K
c h
The manufacturer shall determine and make known to the Surveyor the chemical composition of each heat treatment batch. The analysis report shall cover at least the following elements: C, Si, Mn, P, S and Mg together with Ni and Cu, where these are added to achieve the required characteristics. 5.2 Testing of mechanical properties and selection of specimens
Lt
Dimensions a = 25 mm b = 90 mm c = 40 mm h = 100 mm Lt 200 mm Fig. 5.1
Location of specimen Z = tensile test specimen K = impact test specimen
5.2.1 The mechanical properties such as tensile strength, 0,2 % proof stress and elongation shall be determined by tensile test. In the case of ferritic grades, the yield point revealed by the curve plotted by the testing machine may be stated instead of the 0,2 % proof stress. 5.2.2 For the tensile test, one test specimen each shall be taken from a separately cast U- or a Y-shaped sample piece according to Fig. 5.1 and 5.2 respectively or from an integrally cast sample piece according to Fig. 5.3. The shape of the sample piece shall normally correspond to the standard U or Y2 type with a thickness of 25 mm. In special cases, samples having different dimensions may be agreed. The provision of samples is governed by the following requirements: For heavy casting units with gross weights of minimum 1000 kg one sample plus one sample per treatment batch shall be provided. For casting units with gross weights of less than 1000 kg one sample per treatment batch shall be provided. In case of testing by batch one sample per 1000 kg gross weight of the test batch shall be provided and one additional sample for each further 2000 kg gross weight of the test batch. Precondition is that all casting units are from a series of the same type and have been cast from the same treatment batch and heat treated, where applicable. Where heat treatments are carried out, integrally cast samples may be removed from the casting only after heat treatment. Separately cast samples shall be heat treated together with the casting. Notched bar impact test
K Z
U-type sample piece
Lt
Location of specimen Z = tensile test specimen K = impact test specimen

Dimension
Sizes in [mm] for samples of type Y1 Y2 25 55 40 140 Y3 50 100 50 150 200

Fig. 5.2 Y-type sample piece
Y4 75 125 65 175
a b c h Lt
12 40 25 135
5.3
Where an impact energy is specified for a grade of cast iron, this shall be verified by the notched bar impact test performed on Charpy V-notch specimens at the prescribed test temperature. The requirements regarding impact energy are specified in Table 5.1, 5.4 and 5.5 for the respective grades of cast iron. To carry out the test, one set of specimens shall be taken from each of the samples called for in 5.2.2.
5.4
The manufacturer shall inspect each casting with regard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the casting to the Surveyor for final inspection.
Chapter 2 Page 58
Section 5
Cast Iron
II - Part 1 GL 2009
A)
K Z a
Lt
Location of specimen Z = tensile test specimen K = impact test specimen A) Casting unit (or cast system)
Determining wall thickness of casting unit t 30 < t 60 60 < t 200
Dimensions in mm
Type I II
a 40 70
b 30 52,5
c 20 35
h 40 to 60 70 to 105
a 2
Lt 200 200
If smaller dimensions are agreed, the following correlations apply: b = 0, 75 a and c =
Fig. 5.3 Integrally cast test specimens
C. 1.
Grey Cast Iron Scope
4. 4.1
Requirements applicable to the material Mechanical characteristics
These Rules are applicable to grey cast iron for the manufacture of machinery and pipeline components, e.g. fittings, flanges, housings, hubs, wheel bodies, bed-plates, cylinders, and similar parts. 2. Suitable grades of cast iron
Castings shall normally be supplied with one of the following minimum tensile strengths Rm: 200 N/mm2 250 N/mm2 300 N/mm2 350 N/mm2
The following grades of cast iron may be used: 2.1 Grey cast iron conforming to DIN EN 1561, with the exception of grades EN-GJL-100 and ENGJL-150. 2.2 Grades of cast iron conforming to other standards, provided that they are equivalent to the grades specified in 2.1 and meet the requirements of 4. 3. Condition of supply and heat treatment
Castings with minimum tensile strength values of < 200 N/mm2 are not allowed. The requirements are applicable to specimens with a diameter of 20 mm in accordance with 5.2.4. The requirements regarding minimum tensile strength for separately and integrally cast specimens are specified in Table 5.6. The requirements for specimens taken from the casting (e.g. core specimens) shall be specially agreed between manufacturer and orderer as well as GL. 4.2 Graphite and matrix structure
Castings may be supplied in the as cast or heat-treated condition at the manufacturer's option unless a heat treatment is specified because of special requirements in respect of machinability or geometrical and dimensional stability.
The method of manufacture shall ensure that the graphite is present in uniformly distributed flakes and
II - Part 1 GL 2009
Section 5
Cast Iron
Chapter 2 Page 59
Table 5.6
Tensile strength of grey cast iron
Determining wall thickness Material designation [mm]
Tensile strength Rm values to comply with in separately cast test specimens [N/mm2] in integrally cast test specimens [N/mm2] min. 170 150 140 130 1 210 190 170 160 1 250 220 210 190 1 290 260 230 210 1
Material code
Number
over
up to
EN-GJL-200
EN-JL1030
EN-GJL-250
EN-JL1040
EN-GJL-300
EN-JL1050
EN-GJL-350
EN-JL1060
2,5 2 5 10 20 40 80 150 52 10 20 40 80 150 10 2 20 40 80 150 10 2 20 40 80 150
5 10 20 40 80 150 300 10 20 40 80 150 300 20 40 80 150 300 20 40 80 150 300
200 300 3
250 350 3
300 400 3
350 450 3
1 2 3
These values are guidances. This value is included as lower limit of the range of determining wall thickness. The values refer to test specimens with 30 mm diameter of rough casting. This corresponds to a determining wall thickness of 15 mm.
that a saturation level Sc of 1,0 is not exceeded. The level of saturation shall be determined by applying the following formula:
5.1
Sc =
%C 4,3 0,33 (% Si + % P)
The manufacturer shall constantly monitor the chemical composition and the saturation level of each treatment unit (ladle) and shall pass this information on to the Surveyor on request. Determination of at least the following elements is required: C, Mn, Si, P and S.
5.2 Testing of mechanical properties and selection of specimens
The fracture of tested tensile specimens shall have a uniform grey crystalline appearance.
5.
The tensile strength is to be determined by a 5.2.1 tensile test. For this purpose, separately cast specimens with 30 mm diameter of rough casting and 200 mm minimum length according to Fig. 5.4 may be used as well as integrally cast specimens of type 2 according to DIN EN 1561, see also Fig. 5.5.
Chapter 2 Page 510
Section 5
Cast Iron
II - Part 1 GL 2009
Moulding material
50
Dimensions in mm
50
L 200
50
30
+2 0
50
Fig. 5.4 Mould for separately cast test specimen 5.2.2 The test sample type shall be so selected that about the same conditions for cooling down apply as for the casting unit. 5.2.3 For casting units which determining wall thickness exceeds 20 mm and which gross weight is larger than 200 kg, integrally cast test specimens shall be used. 5.2.4 A test specimen of 20 mm diameter is to be taken from each sample for testing. Thereby the fracture surfaces of the test specimens shall be assessed. For test specimen shape, refer to Chapter 1 Principles and Test Procedures, Section 2, D.1.3.6. 5.2.5 The following number of samples is to be provided:
50
50 5
) 0+1
33 ( 53)
For heavy casting units with gross weights of minimum 1000 kg one sample plus one sample per treatment batch shall be provided. For casting units with gross weights of less than 1000 kg one sample per treatment batch shall be provided. In case of testing by batch one sample per 1000 kg gross weight of the test batch shall be provided and one additional sample for each further 2000 kg gross weight of the test batch. Precondition is that all casting units are from a series of the same type and have been cast from the same treatment batch and heat treated, where applicable.
The numbers in brackets apply to casting units with wall thickness larger or equal 80 mm
Fig. 5.5 Integrally cast test specimen
The details of 5.2.2 shall be observed in this connection. Integrally cast sample pieces may be removed from the casting unit only after heat treatment.
5.3 If casting units are supplied in heat treated condition, the samples shall be heat treated together with the respective casting units.
The manufacturer shall inspect each casting with regard to its surface finish and compliance with the dimensional and geometrical tolerances and shall then present the casting to the Surveyor for final inspection.
R1
(R 25
50 5
II - Part 1 GL 2009
Section 6
Fittings and Pressed Parts, Bolts and Nuts
Chapter 2 Page 61
Section 6 Fittings and Pressed Parts, Bolts and Nuts

A. 1. Pressed Parts Scope 5.1 The manufacturer of the finished part shall have available suitable equipment for the proper execution of the necessary heat treatments. Preliminary proof of this shall be submitted to the Surveyor. 5.2 The heat treatment equipment shall be fitted with a sufficient number of calibrated temperature measuring devices, and fixed items of plant shall be additionally equipped with automatic recording instruments which are to be recalibrated at regular intervals. 5.3 As far as possible, all parts shall be heated or annealed in their entirety. With the consent of the Surveyor, this Rule may be waived where only local forming is performed. In these cases the heat treatment shall, however, embrace the whole area of deformation. 5.4 The temperatures, holding times and heating and cooling rates shall be determined by reference to the data contained in the standards or manufacturer's specifications in accordance with the material and the component concerned. The manufacturer is required to guarantee compliance with the conditions. 5.5 Where the testing of finished parts is allowed to be carried out on separate test sections, provision shall be made to ensure that these receive the same heat treatment as the finished part. For this purpose, the test sections shall be laid on top of the corresponding finished parts for the annealing operation. 6. 6.1 Heat treatment after hot forming Ferritic steels 5. Principles governing hot forming and heat treatment
1.1 These Rules are applicable to the testing of pressed parts for pressure vessels, e.g. pressed heads and shell components fabricated from ferritic or austenitic steel plates by hot forming or by cold forming followed by heat treatment. They are also applicable to the method of heat treatment which may be required after forming has been carried out. 1.2 These Rules are also applicable to pressed parts made from individual parts by welding and subsequent forming. Testing of these welded joints before and after forming is to be carried out according to GL Rules Part 3 Welding. 2. Requirements to be met by manufacturers
Manufacturers wishing to supply products in accordance with these Rules shall be approved by GL. This is conditional upon their fulfilling the manufacturing and quality control requirements specified in Chapter 1 Principles and Test Procedures, Section 1, C. and furnishing proof of this to GL prior to the commencement of supplies. Tests of product suitability shall additionally be performed on selected products. 3. Requirements applicable to the starting plates
3.1 The grades of steel from which the starting plates are made shall be specified in the order. In selecting them, care shall be taken to ensure that they fulfil the requirements to be met by the base material concerned after forming and, where applicable, heat treatment. 3.2 The plates may be supplied in the stipulated final heat-treated condition or in another condition which facilitates the subsequent forming. In the latter case, testing of the starting plates - if required - shall be performed using test specimens which have undergone the heat treatment intended for the finished part. The condition of supply of the plates and the method of heat treatment of the test specimens shall be indicated in the test certificate. 4. Dimensions, dimensional and geometrical tolerances
6.1.1 Hot forming shall normally be followed by renewed heat treatment as prescribed for the base material concerned. This Rule may be waived in the case of normalized and air-quenched and tempered steels with the exception of the steels tough at sub-zero temperatures, provided that the hot forming operation is begun and ended within the temperature range specified for this purpose in the standard or the manufacturer's material specification. In this case, the renewed heat treatment can be dispensed with for normalized steels while tempering can suffice for air quenched and tempered steels.
These are governed by the relevant standards and/or the information in the order documents. The manufacturer shall keep relevant documents ready for the testing.
Chapter 2 Page 62
Section 6
II - Part 1 GL 2009
6.1.2 For the steels tough at sub-zero temperatures, preliminary proof shall be furnished that the intended heat treatment imparts to the finished part the necessary impact energy at the specified test temperature. If this is the case, then, subject to the conditions mentioned in 6.1.1, subsequent heat treatment may be dispensed with for normalized steels, while subsequent tempering may suffice for air quenched and tempered (normalized and tempered) steels, and in the case of 5 % and 9% nickel steels calling for triple heat treatments (12 Ni 19 and X 8 Ni 9), the second normalizing and tempering operation may be sufficient. 6.1.3 For water-quenched and tempered steels, the nature of the heat treatment to be applied after hot forming shall be specially determined. 6.1.4 The exceptional provisions set out in 6.1.1 and 6.1.2 may also be applied where local hot forming is performed, provided that, prior to forming, the plates were in a heat-treated condition appropriate to the material. 6.2 Austenitic steels 1
treatment (normalizing or quenching and tempering) in accordance with the relevant standards or material specifications. 7.1.2 Pressed parts for pressure vessels operated at charging media temperatures below 10 C shall, if the degree of deformation exceeds 2 % in the case of steel grades conforming to EN 10028-2, EN 10028-3, EN 10028-4 and EN 10028-6, with the exception of 12Ni14, 12Ni19, X7Ni9 and X8Ni9, if the degree of deformation exceeds 5 % in the case of steel grades 12Ni14, 12Ni19, X7Ni9 and X8Ni9 conforming to EN 10028-4,
be subjected to heat treatment (normalizing or quenching and tempering) in accordance with the relevant standards or material specifications. 7.1.3 Pressed parts for gas tanks with design temperatures below 0 C shall be treated in accordance with 7.1.2. 7.1.4 Cold-formed heads, including those fabricated from welded round blanks, shall be heat treated (normalized or quenched and tempered) in accordance with the relevant standards or material specifications. 7.1.5 The stipulations of 7.1.1, 7.1.2 and 7.1.4 may be relaxed if proof is furnished that the properties of the materials make them able to withstand the stresses prevailing while the pressure vessel is in service. 7.1.6 Cold-formed dished heads made of steel grades S235 JR, S235 J0, S235 J2 and S235 J2+N according to EN 10025-2, P235 GH and P265 GH to EN 10028-2, P275 N according to EN 10028-3, as well as of other steel grades of comparable strength, do not require heat treatment if the temperature of the charging media is 10 C or above, the design temperature does not exceed 120 C according to GL Construction Rules and the nominal wall thickness is 8 mm. 7.1.7 If the acceptable degrees of deformation are exceeded in cold forming, heat treatment shall as a rule be performed before welding. 7.1.8 In the case of clad pressure vessels or pressure vessel components, heat treatment shall be performed in accordance with the base material, unless special conditions have to be agreed with regard to the cladding. 7.2 Austenitic steels
After hot forming, parts made of austenitic steels shall be subjected to renewed heat treatment which shall normally comprise solution annealing and quenching. This Rule may be waived where the forming operation is begun in the temperature range from 1150 to 1000 C and is ended above 750 C for stabilized steels and steels with a carbon content of C 0,03 % or above 875 C for non-stabilized steels with a carbon content of C 0,08, followed by rapid cooling to ambient temperature. 6.3 Clad plates
Where parts are made of clad plates, the nature of the heat treatment is governed by the base material, see 6.1. Where the cladding material requires a heat treatment different from that of the base material, the details of this shall be specified by the manufacturer of the material and made known to GL. 7. 7.1 Heat treatment after cold forming Ferritic steels
All plates shall be in the prescribed condition of supply before cold forming is carried out, see the individual Rules in Section 1. Due to the changes in material properties which may result from cold forming and ageing, the following procedure applies: 7.1.1 Pressed parts for pressure vessels operated at ambient temperatures or feedstock temperatures down to 10 C shall, if the degree of deformation exceeds 5 % (wall thickness s > 0,05 Dm for cylindrical shell rings and sphere segments), be subjected to heat
1 For further details on heat treatment of austenitic steels, see AD-Merkblatt (AD Data Sheet) HP/7.3.
7.2.1 Acceptable heat treatments are solution annealing with quenching or, for stabilized steels (exception: Mo-alloyed stabilized steels with more than 0,03 % C) and steels with carbon contents of C 0,03 %, stabilization annealing.
II - Part 1 GL 2009
Section 6
Chapter 2 Page 63
Note See AD Data Sheet HP 7/3. 7.2.2 Heat treatment of solution annealed and quenched or stabilization annealed material after cold forming may be dispensed with if: 7.2.2.1 in the case of austenitic steels with required minimum elongation values A of 30 % in respect of the initial material, the degree of deformation does not exceed 15 % or proof is furnished that the residual elongation capacity A after cold forming is at least 15 %. For size ranges in which the required minimum elongation values A are less than 30 %, proof that the residual elongation capacity A is 15 % is deemed to have been furnished if an elongation A of 30 % is shown in the acceptance test certificate; 7.2.2.2 in the case of degrees of deformation higher than 15 %, proof is furnished that the residual elongation capacity A after cold forming is at least 15 %; 7.2.2.3 in the case of dished, ellipsoidal and hemispherical heads, the following elongations A are shown in the acceptance test certificates for the starting materials: 40 % for nominal wall thicknesses 15 mm at design temperatures down to 196 C, 45 % for nominal wall thicknesses > 15 mm at design temperatures down to 196 C, 50 % at design temperatures below 196 C;
8.1.2 Where stress relief heat treatment is sufficient after forming, the test section may be removed from the test piece beforehand and subjected to the same annealing treatment. 8.1.3 Where Table 6.1 specifies testing by test batches, a test batch may only comprise items made from plates originating from the same heat which have been pressed and heat treated in the same way. The wall thicknesses of items within a test batch may vary by 20 % from the mean wall thickness. The number of sets of specimens shall be determined as follows: up to 10 items: up to 25 items: over 25 items: 1 set of specimens 2 sets of specimens 3 sets of specimens.
8.1.4 Where individual testing of the pressed parts is prescribed, testing of the starting material by GL may be dispensed with. 8.1.5 Instead of individual testing of the pressed parts, GL may agree to testing by rolled plate (1 set of specimens per starting plate) provided that the manufacturer of the pressed parts demonstrates to GL by a preliminary test of the manufacturing method used that the requirements can be met and products with constant characteristics can be manufactured. In this case, the starting plates shall be tested. 8.2 Test of surface finish and dimensions
7.2.2.4 in the case of pressure vessel components, except heads, which are operated at design temperatures below 196 C, the degree of deformation does not exceed 10 %. 7.3 Clad plates
The surface finish and dimensions of each finished part shall be checked by the manufacturer. The parts shall then be submitted to the Surveyor for final testing and verification of the dimensions. For this purpose, the manufacturer shall give the Surveyor the measuring records. 9. Marking
Cold-formed finished parts made of clad plates are subject to the conditions stated in 7.1 for the base material concerned. 8. 8.1 Testing Test of mechanical and technological properties
Each part shall be marked by the manufacturer with the manufacturer's mark, the material designation, the heat number and the specimen number. 10. Certificates
8.1.1 The testing of pressed parts shall comprise tensile and notched bar impact tests performed on specimens taken from the finished parts after the final heat treatment transverse to the original rolling direction of the plate. A tolerance of up to 20 from the required specimen orientation can be tolerated. The necessary test sections, the quantity of which is specified in Table 6.1, shall be taken from surplus material at the edges of the pressed parts or from cutouts.
10.1 In the case of pressed parts which are heat treated after forming, the manufacturer shall certify the proper execution of the heat treatment stating the temperatures, the holding times and the type of cooling applied. 10.2 In the case of pressed parts which may be supplied in the hot pressed condition, the manufacturer shall certify that the forming operation was begun and ended within the specified temperature limits and shall indicate the standard or material specification applicable. In addition, the method of cooling and the condition in which the starting material was supplied shall also be stated.
Chapter 2 Page 64
Section 6
II - Part 1 GL 2009
Table 6.1
Scope of tests on pressed parts made from plate
Grades of steel All unalloyed steels with a minimum tensile strength 410 N/mm2 Unalloyed and fine-grained structural steels with a minimum tensile strength 410 < Rm 510 N/mm2, and ReH 355 N/mm2, also 0,3 %-Mo alloy steels Fine-grained structural steels, ReH > 355 N/mm2
Base material according to Section 11 C, E
Test performed on
Extent of tests on pressed parts not required
starting plate
C, E
starting plate pressed part
testing by batches
pressed part
1 set of specimens from each pressed part 2 1 set of specimens from each pressed part 2 1 set of specimens from each pressed part 2
High-temperature CrMo alloy steels
pressed part
Steels tough at sub-zero temperatures Austenitic stainless steels: 20 Thickness [mm] > 20 Clad plates
1 2
pressed part
starting plate G starting plate pressed part
not required testing by batches
The extent of the test depends on the base material
Pressed parts which are designed for the manufacture of tanks carrying pressure-liquefied ammonia are subject to F.8.2.2. Testing by rolled plate may be agreed if the conditions specified in 8.1.5 are satisfied.
B. 1.
Pipe Fittings Scope
These Rules are applicable to saddles, T-shaped fittings, tapered transition pieces and pipe elbows for welding into pipelines which are fabricated from pipe or plate sections made of ferritic or austenitic steels. 2. Starting materials
3.2 Proof shall be furnished to GL, as a preliminary measure, of the suitability of the process and, for fittings welded together from individual components, the characteristics of the welded joints. For this purpose, the manufacturer shall send a process description containing all the details required for evaluating the process to GL for consideration. The nature and scope of the procedure approval inspection shall be determined by GL from case to case. 4. Heat treatment
Suitable plates or pipes are to be selected as starting materials in accordance with Section 1 or 2. Unless otherwise stipulated by GL, the starting materials shall be ordered with inspection certificates conforming to EN 10204-3.1 from manufacturers approved by GL. 3. Manufacture
4.1 All fittings shall be in the heat-treated or hotworked state specified for the material according to GL Rules or other relevant standards or material specifications. 4.2 In the case of ferritic steels for which normalizing is prescribed and which undergo hot forming, subsequent heat treatment may be dispensed with if a corresponding structure can be achieved by the hot forming operation. In the same circumstances, tempering may be sufficient for steels for which quenching and tempering is prescribed.
3.1 Pipe fittings may be hot or cold formed from sections of pipe. They may also be made from sections of plate hot or cold formed into one or more shells and welded together.
II - Part 1 GL 2009
Section 6
Chapter 2 Page 65
4.3 Cold formed parts are generally required to undergo renewed heat treatment following the forming operation. If such treatment is not to be applied, the manufacturer shall prove that the finished part retains the required characteristics. 4.4 Where fittings are welded together from hot or cold formed components, the nature of the heat treatment shall be determined at the time of the procedure approval test. 4.5 If the starting material is in the prescribed heat-treated condition, in the case of pipe elbows manufactured from ferritic or austenitic steels the following procedure may be applied: If these elbows are produced by cold bending with bending radii of rm 1,3 da, subsequent heat treatment is not required if the outside diameter da is 133 mm. The same applies to all elbows manufactured with bending radii of rm 2,5 da. The exceptions are steel pipes tough at sub-zero temperatures with wall thicknesses > 2,5 mm and coldbent pipes which have to be heat treated due to corrosive attack or because stressed parts have to be welded on outside the neutral zone. 5. Requirements applicable to properties
Table 6.2
Test batches for fittings Size da [mm] No. of fittings per test batch 1 200 < 225 < 350 100 50 25
< 100 100 225 350

1
Test batches apply to 90-degree elbows. The number of elbows per test batch is halved in the case of 180-degree elbows and doubled in the case of 45-degree elbows.
6.2.2 The scope of the mechanical tests is as shown in Table 6.3. For preparing the test specimens, either additional fittings shall be provided or fittings of excess length shall be manufactured. Tensile and notched bar impact tests may be performed on either tangential or longitudinal test specimens depending on the geometry of the fittings; the specimens shall be prepared from the hardest and softest fittings determined in the hardness tests. The required values shall be the definitive values for the starting materials. 6.2.3 In the case of steels tough at sub-zero temperatures, the notched bar impact test shall be performed at the appropriate test temperature. 6.2.4 In the case of austenitic or austenitic-ferritic stainless steel fittings for use on chemical tankers, each heat and heat treatment batch shall be tested by the manufacturer for resistance to intercrystalline corrosion in accordance with ISO 3651-2 or an equivalent standard and a test certificate shall be issued. 6.2.5 Alloy steel fittings shall be subjected to appropriate testing by the manufacturer to verify the use of the correct material. 6.2.6 Welded alloy steel fittings with nominal bores > 75 mm shall be subjected by the manufacturer to random radiographic inspection of the welds. Unless stipulated in the specification or the order, the number of fittings to be tested shall be agreed with the Surveyor. These shall be selected in such a way that every size of fitting is included. 7. Marking
In the finished state, the fittings shall possess all the required characteristics specified for the starting material used (pipe or plate). 6. 6.1 Testing Inspection and dimensional check
All fittings shall be inspected and their dimensions checked in the condition of supply. For this purpose, the surface of the fittings shall be in a condition appropriate for inspection which enables major defects to be detected. 6.2 Testing of materials
6.2.1 For performing the mechanical tests, the fittings shall be divided into test batches in accordance with Table 6.2. A test batch in accordance with Table 6.2 consists of fittings made of the same materials and having the same dimensions, and, in the case of alloy steel fittings with a da > 100 mm, originating from the same heat. If final heat treatment is necessary, testing shall also be performed by heat treatment batches. Unalloyed steel fittings from the same heats which have been heat-treated separately but in the same way may be tested together if the uniformity of the fittings has been proved to the Surveyor by means of a hardness test on 10 %, but at least 3, of the fittings.
The fittings shall be marked as follows: manufacturer's symbol material designation where applicable, quality level in the case of boiler tubes heat number or code, if the starting material had a corresponding marking
Chapter 2 Page 66
Section 6
II - Part 1 GL 2009
Table 6.3
Classification into test groups and scope of tests

Scope of tests per test batch
Test groups
Size da [mm] < 100 < 100 100 100 225 (DN 200) > 225 (DN > 200)
Material
Hardness test 1
Tensile test
Notched bar impact test 2 (set of specimens = 3 specimens)
I II III
unalloyed alloyed unalloyed Rm < 500 N/mm2 unalloyed Rm 500 N/mm2 or alloyed 10 % 3 min. on 3 fittings
14 14 2 sets, only if less than 10 fittings 1 set
IV
10 % min. on 3 fittings 100 %

5
2 specimens, only if less than 10 fittings 1 specimen
V
1 2
With austenitic steels, the hardness test is dispensed with if the geometry allows tensile tests to be performed. The notched bar impact test is only performed in the case of materials for which minimum values for the absorbed energy are stated for the starting material. Furthermore, specimens are only taken where the wall thickness is 6 mm and the geometry allows this to be done. Starting with the second batch of a complete final inspection, the scope of hardness testing may be reduced by half if the hardness values measured for the first batch lie within the specified strength range. The tensile test is to be carried out on the starting pipe. For elbows made of 16 Mo 3, 13 Cr Mo 4-5 and 10 Cr Mo 9-10 conforming to EN 10028-2, the scope of hardness testing specified for test group IV is applicable.
4 5
C. 1.
Bolts and Nuts Scope
GL. The steels used in the manufacture of bolts shall have a guaranteed impact energy. Under these conditions, the following materials may be considered: 2.1.1 Bolts and nuts conforming to ISO 898 (EN 20898-1 and -2) up to M39 threads. Exempted thereof are bolts of strength categories for which the standard gives no data in respect of impact energy. 2.1.2 Steels conforming to EN 10269 in conjunction with DIN 267-13. 2.1.3 Steels conforming to DIN 267-13.
1.1 These Rules are applicable to the manufacture, the mechanical properties and the testing of bolts and nuts for boilers, vessels, equipment and pipelines diesel engines, gears, shafting and propellers other components of the machinery plant for which proof of quality is required as specified in the Construction Rules
1.2 The choice of bolts and nuts, together with the form of the requisite material test certificate is set out in the individual Chapters of the Construction Rules and shall be stated in the purchase order. 2. Materials
2.1.4 Stainless steels conforming to ISO 3506-1 and -2. 2.2 Bolts and nuts conforming to other standards or the manufacturers material specifications may be used, provided that GL has confirmed their suitability for the intended application. Unless otherwise specified, the materials shall satisfy the requirements of 4.2.2, 4.2.3 and 4.2.4. 2.3 Free cutting steels with a high sulphur, phosphorous or lead content may not be used.
2.1 Bolts and nuts are to be selected in accordance with recognized standards or the manufacturer's material specifications which have been approved by
II - Part 1 GL 2009
Section 6
Chapter 2 Page 67
3.
Manufacture
3.1 Bolts and nuts may be manufactured by hot or cold forming or by machining. Cold formed bolts shall be subjected to subsequent heat treatment. The same applies to hot formed bolts and nuts with the exception of those made of quenched and tempered steels, provided that the latter are to be used at normal ambient temperatures and the hot forming process results in a uniform structure. Surface smoothing and rolling of the thread are not regarded as cold forming within the meaning of this paragraph. 3.2 Bolts and nuts shall be in the heat-treated condition specified for the material in order to achieve the minimum values. The material shall not undergo unacceptable embrittlement up to the maximum temperature occurring in service. In the case of steels tough at sub-zero temperatures, it shall exhibit toughness even at the minimum design temperature. In the case of quenched and tempered steels, the tempering temperature shall always be a reasonable amount above the maximum in-service temperature. 4. 4.1 Requirements applicable to the material Chemical composition
4.2.5 Steels or semi-finished products for foundation bolts of propulsion plants may be rolled as well as forged, but shall meet the requirements of 4.2.4. For threads exceeding M39 forged semi-finished products are to be used. 4.2.6 The impact energy values shall be average values obtained with three test specimens. Of these only one specimen may have a value which is below the average value but not less than 70 % of the average value. 5. Testing of bolts
5.1 The manufacturer shall demonstrate the chemical composition of each heat according to C.7. 5.2 Tensile testing shall be performed on bolts and, for thread diameters 16 mm, the notched bar impact test shall also be carried out. For preparing the specimens, bolts of the same type and strength category or made from the same material shall be grouped into test batches in accordance with Table 6.4. If proof is furnished that the bolts in a delivery originate from one heat and have undergone the same heat treatment, testing of four sets of specimens is sufficient, regardless of the quantity supplied. Table 6.4 Batch sizes for the testing of mechanical properties
The chemical composition shall satisfy the stipulations according to Section 3.B., Table 3.2 and the relevant standards or specifications respectively. 4.2 Mechanical properties
4.2.1 Bolts and nuts conforming to the standards specified in 2.1.1 to 2.1.4 shall meet the mechanical properties set out in these standards. 4.2.2 Steels tough at sub-zero temperatures for bolts and nuts which are to be used in the construction of gas tanks shall achieve an impact energy of at least 41 Joules at the prescribed test temperature using longitudinal Charpy V-notch specimens. The test temperature is to be determined in accordance with Section 3, F. 4.2.3 Steels for bolts and nuts with threads exceeding M39 as well as according to 2.2 shall have the characteristic values of the material and shall satisfy the following conditions in testing at room temperature with longitudinal specimens. Elongation A 14 %, impact energy using Charpy V-notch specimens 52 Joules for quenched and tempered steels and 40 Joules for unalloyed steels.
Quantity 200 > 200 to 400 > 400 to 800 > 800 to 1200 > 1200 to 1600 > 1600 to 3500 > 3500
No. of sets of specimens for mechanical testing 1 2 3 4 5 6 7
5.3 For the tensile test, specimens may be machined from the sample material, or turned specimens of the type shown in Fig. 6.1 may be used.
r4
d0
r4
4.2.4 Steels for bolts and nuts intended for engine foundation and with threads exceeding M39 as well as according to 2.2 shall have the characteristic values of the material and shall meet the requirements in testing at room temperature with longitudinal specimens according to Section 3, Table 3.5 and Table 3.6.
L0 = 5 d 0
Fig. 6.1 Turned specimen
Chapter 2 Page 68
Section 6
II - Part 1 GL 2009
5.4 Where no heat treatment is performed following machining and the starting material is in the final heat treated condition, testing of the starting material with regard to demonstrating mechanical properties shall suffice. In this case steel bars from the same heat and with the same diameter and heat treatment are to be grouped into test batches of 5000 kg maximum. The performance of the tensile and notched bar impact tests require one set of test specimens to be taken from each test batch. 5.5 Where machining is followed by heat treatment, testing shall be performed in the same way as on the corresponding formed bolts as per 5.2. 5.6 The surface finish, dimensions and compliance with tolerances shall be verified by the Surveyor on at least 20 bolts and on at least 10 bolts in the case of batch sizes of 200. The manufacturer shall supply the gauges and callipers necessary for this purpose. 5.7 The uniformity of the delivery is to be demonstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 bolts from each test batch are to be tested, and at least 10 bolts in the case of quantities 200. The results of the test are to be submitted to the Surveyor. 5.8 For bolts calculated for elevated temperature application on the basis of their high-temperature mechanical characteristics, the 0,2 % or 1 % proof stress shall be proved by a high-temerature tensile test performed on one specimen from each batch. The test shall be performed at the temperature which approximates most closely to the level of the operating temperature, rounded off to the nearest 50 C. The test may be dispensed with in the case of bolts to recognized standards, the high-temperature mechanical properties of which are regarded as proven. 6. 6.1 Testing of nuts Chemical composition
1,06d (1,04d) d
(1:100)
d Test mandrel for 6% expansion (1.06 d) or 4% expansion (1.04 d) of the nut d = m = nominal thread diameter nominal depth of nut force
The chemical composition shall satisfy the stipulations according to Section 3, B., Table 3.2 and the relevant standards or specifications respectively. 6.2 Nuts with nominal thread diameters of up to and including 39 mm are to be subjected to the expansion test using a mandrel with a 1:100 taper, see Fig. 6.2. Before testing, the nuts are to be drilled out to the thread outside diameter. The expansion shall be at least 6 % for nuts with a depth of 0,8 nominal thread diameter d (at least 4 % for nuts with a depth of 0,5 to < 0,8 d). The numbers of test specimens shown in Table 6.4 are applicable, but for quantities of 200 at least 2 nuts shall be tested. 6.3 Nuts with nominal thread diameters > 39 mm are to be subjected to testing of the starting material as specified in 5.2 rather than the expansion test.
1,5 m
1,2 m
hardened
1,1d Test arrangement
Fig. 6.2 Expansion testing of nuts
II - Part 1 GL 2009
Section 6
Chapter 2 Page 69
6.4 The uniformity of the delivery is to be demonstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 nuts from each test batch are to be tested, and at least 10 nuts in the case of quantities 200. The results of the test are to be submitted by the Surveyor. 6.5 The surface finish, dimensions and compliance with tolerances shall be verified by the Surveyor in the same way as described in 5.6. 7. Proof of chemical composition
9.
Retests
9.1 Where one of the test specimens required for carrying out testing of mechanical properties does not satisfy the specified conditions, two additional test specimens or test sets of each are to be taken which shall satisfy the requirements. If these test samples also fail to meet the requirements, the test batch shall be regarded as unacceptable. The manufacturer may, however, heat treat the batch again and present it for retesting. If, however, these test specimens still fail to meet the requirements, the test batch shall be rejected for once and for all. 9.2 Where one of the test specimens required for carrying out hardness testing, non-destructive testing to check for surface defects, or for carrying out a dimensional check fails to meet the requirements, a further random sample of 20 specimens (or 10 specimens in the case of batch sizes of 200) shall be taken of which all the test specimens shall satisfy the requirements. Otherwise the entire test batch shall be regarded as unacceptable. For the hardness test, the manufacturer may present this batch for retesting once he has carried out a further heat treatment. If these test specimens still fail to satisfy the requirements, the entire batch shall be rejected for once and for all. 10. Marking
7.1 For each delivery, the manufacturer shall provide the surveyor with a certificate giving the results of the chemical analysis, heat numbers, dimensions and the as-delivered condition of the starting material processed by him. The name of the steel producer shall also be indicated in the certificate. 7.2 Alloy steel bolts and nuts shall be subjected by the manufacturer to appropriate tests for use of the correct material. 8. Non-destructive tests
The manufacturer shall apply a suitable method of crack detection to the following bolts: turbine casing bolts bolts in main steam lines with temperatures > 350 C propeller blade fixing bolts
10.1 Bolts and nuts are to be marked with the manufacturer's symbol and with the strength category or the steel grade, as well as with the heat number in the case of bolts of M52 size and above. Bolts of M52 size and above are to be individually marked with the GL stamp, which in all other cases is to be applied to the packing label. 10.2 Steel bars over 25 mm in diameter for the machining of bolts and nuts are to be marked at one end with the manufacturer's symbol, the steel grade and the GL stamp, and alloy steel bars are to be additionally marked with the heat number. Where the diameter of the steel bars is 25 mm or less, it is sufficient to apply the corresponding markings to the label attached to the bundle of bars.
and, for diesel engines with cylinder diameters > 400 mm, the following bolts: main bearing bolts connecting rod bolts cross-head bearing bolts cylinder cover bolts
Rule Change Notice regarding Section 1 of the GL Rules for Steel and Iron Materials (II-1-2)
The following paragraphs of Section 1 have been subject to a Rule Change due to the IACS Unified Requirement W13:
Paragraph
A.6.1
Edition 2009
Plates, strips and wide flats may be delivered with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products for cargo tanks in accordance with F. and clad plates in accordance with H. the permitted minus tolerance is to be agreed when the order is placed. The thickness is to be measured at points located at least 25 mm from the edge of the product. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances.
Rules Change, effective 1 December 2011

Plates, strips and wide flats may be delivered either with the minus tolerances shown in Table 1.1 or with no minus tolerance. Where no stipulations are made in the following individual rules, e.g. for shipbuilding steels in accordance with B., flat products made from high-strength steels in accordance with D., flat products for cargo tanks in accordance with F. and clad plates in accordance with H. the permitted minus tolerance is to be agreed when the order is placed. The thickness is to be measured at points located at least 25 mm from the edge of the product, if not stipulated otherwise in the individual rules, e.g. for shipbuilding steels in accordance with B. and flat products made from high-strength steels in accordance with D. Local depressions due to flaws and grinding marks arising from the remedying of defects are not taken into account, provided that they do not exceed the tolerances. The provisions of A.6. are applicable. With regard to flat products (plates and wide flats) for shipbuilding use, the permitted lower deviation from the nominal thickness for all product thicknesses is uniformly 0,3 mm. However, the average thickness, calculated as arithmetic mean from the measurements made in accordance with 10.5.3, shall not be less than the nominal thickness. Alternatively Class C given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. In this case the provisions of 10.5.3 are not applicable. 10.5.1 Inspections of surface finish and dimensional checks are in the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility. 10.5.2 The procedure and the records of measurements are to be made available to the Surveyor and copies provided on request. 10.5.3 For plates and wide flats, at least two lines along the longitudinal edge of the product are to be selected for the thickness measurements and at least three points on each selected line are to be selected for thickness measurement. If more than three points are taken on each line the number of points shall be equal on each line. 1 of 2
A.6.2
B.8.
The provisions of A.6. are applicable. With regard to flat products (plates and steel wide flat) for shipbuilding use, Class B given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. This means that the permitted lower deviation for all product thicknesses is a uniform 0,3 mm.
B.10.5
Inspections of surface finish and dimensional checks are the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility.
Paragraph
B.10.5
Edition 2009
Rules Change, effective 1 December 2011

For automated methods, the measuring points at sides are to be located not less than 10 mm but not more than 300 mm from the transverse or longitudinal edges of the product. For manual methods, the measuring points at sides are to be located not less than 10 mm but not more than 100 mm from the transverse or longitudinal edges of the product.
D.3.6
A.6. applies, with the following addition: For the minus tolerance applicable to the nominal thickness, the values stated under Class A in Table 1.1 apply, unless otherwise specified in the order
The provisions of A.6. are applicable. Unless otherwise specified in the order, the permitted lower deviation from the nominal thickness for all product thicknesses is uniformly 0,3 mm. However, the average thickness, calculated as arithmetic mean from the measurements made in accordance with 4.5.3, shall not be less than the nominal thickness. Alternatively Class C given in Table 1.1 may be considered as the permitted lower deviation from the nominal thickness. In this case the provisions of 4.5.3 are not applicable.
D.4.5
The manufacturer shall inspect the condition of the surface and the dimensions of the product and shall then submit the products to the Surveyor for inspection.
4.5.1 Inspections of surface finish and dimensional checks are in the responsibility of the rolling mill. Acceptance testing by the Surveyor does not release the manufacturer from this responsibility. 4.5.2 The procedure and the records of measurements are to be made available to the Surveyor and copies provided on request. 4.5.3 For plates and wide flats, at least two lines along the longitudinal edge of the product are to be selected for the thickness measurements and at least three points on each selected line are to be selected for thickness measurement. If more than three points are taken on each line the number of points shall be equal on each line. For automated methods, the measuring points at sides are to be located not less than 10 mm but not more than 300 mm from the transverse or longitudinal edges of the product. For manual methods, the measuring points at sides are to be located not less than 10 mm but not more than 100 mm from the transverse or longitudinal edges of the product.
2 of 2
II
3

Welding
General Requirements, Proof of Qualifications, Approvals
Edition 2000
The following Rules come into force on July 1st , 2000 Alterations to the preceding Edition are marked by beams at the text margin. Germanischer Lloyd Aktiengesellschaft Head Office Vorsetzen 35, 20459 Hamburg, Germany Phone: +49 40 36149-0 Fax: +49 40 36149-200 headoffice@gl-group.com www.gl-group.com "General Terms and Conditions" of the respective latest edition will be applicable (see Rules for Classification and Construction, I - Ship Technology, Part 0 - Classification and Surveys). Reproduction by printing or photostatic means is only permissible with the consent of Germanischer Lloyd Aktiengesellschaft. Published by: Germanischer Lloyd Aktiengesellschaft, Hamburg Printed by: Gebrder Braasch GmbH, Hamburg
II - Part 3 GL 2000
Table of Contents
Chapter 1 Page 3
Table of Contents
Section 1 A. B. C. D. E. F. G.
General Rules General ....................................................................................................................................... Other Rules, Standards and Specifications ................................................................................. Information in Working Documents ........................................................................................... Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials ......................................................................... Quality Assurance, Responsibility .............................................................................................. Inspection Tests, Liability .......................................................................................................... 11111111 1 2 2 2 3 4
Requirements for Welding Shops, Approval Approval of Welding Shops ....................................................................................................... Requirements for Welding Shops ............................................................................................... Inspection of Welding Shops ..................................................................................................... Welding Procedure Tests ........................................................................................................... Certification of Approvals, Certificates according to EN 729/ISO 3834 ................................... 222221 2 3 3 4
Section 3 A. B. C. D. E. F.
Welders Qualification Tests General ....................................................................................................................................... Testing Bodies, Certificates ....................................................................................................... Scope of Testing and Range of Approval ................................................................................... Performance of Welder's Qualification Tests ............................................................................. Period of Validity, Repeat Tests ................................................................................................ Other Welder's Tests .................................................................................................................. 3333331 2 2 3 3 4
Section 4 A. B. C. D.
Welding Procedure Tests, Production Tests General ....................................................................................................................................... Performance of Welding Procedure and Production Tests ......................................................... Evaluation of Test Results, Requirements, Repeat Test Specimens, Test Reports ..................... Limits of Application, Period of Validity ................................................................................... 44441 2 5 5
Welding Consumables and Auxiliary Materials General ....................................................................................................................................... Covered Electrodes for Manual Metal-Arc Welding of Hull Structural Steels .......................... (Flux-cored) Wire-Gas Combinations and Flux-Cored Wire Electrodes for SemiMechanized Welding of Hull Structural Steels .......................................................................... Wire-Flux Combinations for Submerged-Arc Welding of Hull Structural Steels ...................... Welding Consumables and Auxiliary Materials for Electrogas and Electroslag Welding of Hull Structural Steels ................................................................................................................. Welding Consumables and Auxiliary Materials for High-Strength (Quenched and Tempered) Structural Steels ....................................................................................................... Welding Consumables and Auxiliary Materials for Steels Tough at Subzero Temperatures ........ Welding Consumables and Auxiliary Materials for High-Temperature Steels ........................... 5- 1 5- 8 5- 15 5- 18 5- 23 5- 25 5- 28 5- 29
Chapter 1 Page 4
Table of Contents
II - Part 3 GL 2000
I. J. K. L.
Austenitic and austenitic-ferritic welding consumables and auxiliary materials for stainless steels, non-magnetic steels and nickel alloy steels tough at subzero temperatures ..................... Welding Consumables and Auxiliary Materials for Aluminium Alloys ...................................... Welding Consumables and Auxiliary Materials for Copper and Copper Alloys ........................ Welding Consumables and Auxiliary Materials for Nickel and Nickel Alloys ...........................
5- 33 5- 38 5- 41 5- 44
Section 6 A. B. C.
Overweldable Shop Primers General ........................................................................................................................................ Testing and Approval of Shop Primers ....................................................................................... Supervising the Use of Shop Primers, Production Tests ............................................................. 6- 1 6- 1 6- 2
Annex A
Application for Approval
Annex B
Description of Welding Shop
Annex C
Assessment Form for Welder Qualification Test Certification
Annex D
Welding Procedure
Annex E
Welding Consumables and Auxiliary Materials
II - Part 3 GL 2000
Section 1
General Rules
Chapter 1 Page 11
Section 1 General Rules

A. 1. General Scope 4. Alterations and additions
1.1 These Rules apply to all welding work performed in the course of new construction, conversion or repairs carried out on ships and their machinery installations, including steam boilers, pressure vessels and pipelines, for which an application for classification has been submitted to Germanischer Lloyd (GL) or which have been classified by GL. Note: The terms "welding", "welding work", welding process etc. used in these rules also cover all other thermal and/or mechanized joining processes such as brazing which, because they are deemed as special processes under the terms of the quality assurance standards, require pre-qualification which has to be carried out by qualified personnel and constantly monitored. These rules shall be applied in an analogous manner to these processes. Where no special provisions are made in the following paragraphs, the nature and scope of the quality assurance measures required will be specified by the Society on a case-bycase basis. 1.2 They also apply to all welding work on components, installations or implements for which the Society has issued rules, regulations or other technical directions in which reference is made to these Welding Rules. 1.3 These Welding Rules shall be applied in analogous manner where other rules, regulations or technical directions issued by the Society contain no special instructions with regard to welding work. 2. Application in other fields
The Society reserves the right to alter or add to these Rules from time to time, should this prove necessary on the basis of more recent knowledge or operating experience.
B. 1.
Other Rules, Standards and Specifications Other relevant standards
1.1 The standards or other technical directions mentioned in the following sections form an integral part of these Welding Rules and shall also be complied with. The same applies to the working documents, e.g. drawings, welding specifications, etc. approved by the Society. 1.2 Where the following sections refer to standards in which a date is specified, the current version shall apply. Where no dates are specified, the version of the standards which shall be applicable shall be the one valid at the time that these rules were issued. The use of later versions of these standards is subject to the consent of the Society. 1.3 Where the following sections and chapters refer to both EN and ISO standards, and if, where they are both specified, the standards are not identical, the EN standards shall take precedence. Where the two standards are identical, either the EN or the ISO standard may be used. 1.4 The application of other rules, standards, regulations or other technical directions is subject to the consent of the Society's head office in each individual case. The Society may make any such approval conditional upon construction and dimensioning also being subject to these directions. 2. Differences in requirements
These Welding Rules may be applied in analogous manner to welding work carried out on structures and components other than those mentioned under 1., the supervision and inspection of which is the concern of the Society. Where necessary, appropriate arrangements shall be made with the Society. 3. Exceptions to these Rules
2.1 If there are differences in requirements between these Rules and other relevant standards or specifications, the requirements of these Welding Rules shall take precedence, unless otherwise stipulated. 2.2 If there are differences between the different language versions of these rules or difficulties in interpretation, the German language version shall take precedence in each case.
Exceptions to these Welding Rules require the consent of the Society's head office in each individual case.
Chapter 1 Page 12
Section 1
General Rules
II - Part 3 GL 2000
C. 1.
Information in Working Documents Drawings, other working documents
D.
Materials, Weldability
1.1 The drawings and other working documents to be submitted before commencing the fabrication work must contain all the necessary details for the preparation, execution and, where applicable, the inspection of the welds. This information shall in particular include details of: Base materials, shapes and dimensions of products Welding processes, welding consumables and auxiliary materials Shapes and dimensions of welds Preheating and heat input during welding Heat treatment after welding Subsequent treatment of the welds Nature and scope of inspections Requirements applicable to the welded joints (e.g. quality grade, weld performance, evaluation category or the like).
1. All materials shall be of proven weldability. They shall be chosen in accordance with the intended application and the conditions of service and shall comply with the requirements stated in Part 1, Metallic Materials. Their properties shall be documented to the specified extent by test certificates, e.g. in conformity with EN 10204. Note: The hull structural steels and rolled products described in Part 1, Metallic Materials, for the manufacture of steam boilers, pressure vessel, pipelines and machinery are deemed to be of proven weldability. 2. If, not withstanding para. 1., materials are to be welded whose properties are not described in the Society's Rules for Materials, the welding shop concerned shall furnish proof of their weldability (e.g. by reference to existing standards) or submit special material specifications for approval. If there is doubt as to the weldability of a material, the welding shop shall specially demonstrate this in the course of the welding procedure tests. 3. The welding shop shall ensure that only materials which meet the requirements of 1. and 2. are used for both original and replacement supplies, and shall furnish proof thereof to the Surveyor on request.
1.2 Provided that in the fabrication of ship's structures, the materials, welding processes, welding consumables, auxiliary materials and the shapes and dimensions of welds conform to normal shipbuilding practice, these Rules and the approvals, these details need not be specified. 2. Additional information and documentation
E.
For particular structures (e.g. liquefied gas tanks), materials (e.g. quenched and tempered structural steels and clad plates) or welding processes, the following additional information and documentation shall be provided as necessary: Weld preparation, assembly, auxiliary (tack) welds Welding positions, welding sequence (drawings) Weld build-up, number of passes Heat input during welding (heat input per unit length of weld)
1. The welding consumables and auxiliary materials shall enable a welded joint to be made which is suited to the base material and the operating conditions. They shall have been tested for product suitability in accordance with Section 5 and approved for the application in question. This provision applies in an analogous manner to brazing metals. 2. Approval shall as a rule have been given by the Society. If, in special cases, e.g. repairs, no welding consumables which have been tested by the Society are available, welding consumables approved by other recognized testing bodies may be used with the Society's consent. Relevant proof of this must be submitted to the Societys surveyor. 3. The welding shop's supervisors shall ensure that only tested welding consumables and auxiliary materials which have been approved by the Society are used and shall furnish proof thereof to the Surveyor on request.
This information shall be combined in a welding specification (see Annex D). For test schedules and specifications for non-destructive testing, please refer to Chapter 2, Section 4.
II - Part 3 GL 2000
Section 1
General Rules
Chapter 1 Page 13
F. 1.
Quality Assurance, Responsibility Compliance with Rules, Quality Inspections
be notified of the placing of subcontracts or the use of contract labour.
3.
1.1 Shipyards or welding shops are responsible for ensuring that the welding work conforms to these and any supplementary rules as applicable, the approved working documents, any conditions as may be stated in the approvals, good shipbuilding practice, and also the state of the art technology relating to welding. 1.2 Shipyards or welding shops must ensure, by means of regular in-house quality inspections during the production process and at the end of the welding work, that such work has been properly and expertly executed. The responsibilities of the welding supervisors are also covered in EN 719/ISO 14731. The tests to be performed by GL surveyors shall not relieve the welding shop of this responsibility. 1.3 The range and extent of the quality inspections required is determined by the structure in question. In each case, however, it is necessary to ensure that the specified materials, welding consumables and auxiliary materials are used and that weld preparation, assembly, performance of tack and welding work, together with the accuracy to size and completeness of the components and welded joints meet the requirements. 1.4 Following inspection by the welding shop and any repairs which may be necessary, the components must be presented to the Societys Surveyor for inspection at appropriate stages of construction, easily accessible and as a rule unpainted. The Surveyor may reject those components which have been inadequately inspected by the welding shop and specify that a component be presented again after a successful inspection by the welding shop and, where necessary repairs. 2. Placing subcontracts
Deviation from approved working documents, repairs
3.1 If alterations to the design compared with the approved drawings or deviations from approved fabrication procedures become necessary, the welding shop shall promptly obtain the Societys consent thereto. The Societys Surveyor shall be notified of any repairs which become necessary during fabrication. 3.2 If, due to inadequate or incorrect information in the production documents (e.g. workshop drawings), the quality or functional capability of a component cannot be guaranteed or is doubtful, the Society may require appropriate repairs to be carried out. 3.3 This shall apply in an analogous manner to supplementary or additional components (e.g. reinforcements) even if these are not specified during the examination of the drawing or could not be specified owing to a lack of detail shown in the "class plans" (cf. Construction Rules I Part 1, Chapter 1, Section 1, G.).
4.
Marking and identification of materials
4.1 The materials shall be marked in such a way that they can be identified and matched up with the test certificates even during and after fabrication. 4.2 If the marking is likely to be erased during manufacture, the welding shop shall promptly see to it that it is transferred to another part of the product. This can be dispensed with in the case of small parts of minor importance such as ribs or bracings, provided that any confusion of materials can be prevented by operational means.
2.1 When placing orders with subcontractors, independent branch companies or suppliers as well as outside companies working in the welding shop who are themselves approved (so-called "contract companies", cf. note to paragraph A.1.1 in Section 2) the "prime contractor" must ensure that the provisions stated in 1. are also complied with by the "subcontractors". 2.2 Where the outside companies working in the welding shop are not themselves approved or where contract labour is used, the welding shop placing the contract shall be responsible for ensuring that the conditions stated in 1. are complied with and that the quality inspections are performed. The Society shall
5.
Marking of welds
5.1 In the fabrication of steam boilers and vessels under internal pressure, each weld section shall be marked with the symbol of the welder who executed it. This may be dispensed with if the welding shop supervisory staff keep a record of the names of the welders who execute the individual weld sections. 5.2 In special cases, the Society may also require marking or record-keeping as described in 5.1 for other components or their welded joints.
Chapter 1 Page 14
Section 1
General Rules
II - Part 3 GL 2000
G. 1.
Inspection Tests, Liability Presentation of components
Test reports and films of the non-destructive tests Certificates of hot-forming and heat treatment, where applicable Results of production tests, intermediate results if necessary. Subsequent defects
The welding shop shall be obliged to present the components to the Surveyor for the required intermediate and final inspections. Steps shall be taken to ensure unimpeded access to the welds. The welds shall not be treated with coatings or preservatives which make it difficult or impossible to assess the condition of the welds. 2. Supplying of test documentation
3.
For the inspections, all the manufacturer's records and documents concerning the quality assurance measures undertaken by him shall be submitted. These include in particular: Drawings (approved if required) and other working documents Material test certificates Welder's and welding procedure test certificates
3.1 The Society gives no guarantee that the products, welded structures or components tested by its Surveyor to the extent laid down (normally random tests) conform to the requirements in every respect and that their manufacture has been performed correctly and in accordance with the tested procedures. 3.2 Products or welded structures which prove defective in subsequent use or in the operation or processes which exhibit deficiencies in use may be rejected even if an earlier inspection was satisfactory, if it is not possible to remedy the defect or deficiency.
II - Part 3 GL 2000
Section 2
Requirements for Welding Shops, Approval
Chapter 1 Page 21
Section 2 Requirements for Welding Shops, Approval

A. Approval of Welding Shops 2. Application for approval
Introductory remark: 1. General Where no special provisions are given in the following paragraphs or, in an individual case, no other arrangements are made, the provisions for "Approval" set out in accordance with these rules shall also apply in an analogous manner to "Certification" in accordance with EN 729/ISO 3834. 2.1 Approval shall be applied for in writing to the Society's head office. The application shall contain the following details, which shall be related to each other as far as possible, (cf. Description of Welding Shop, Annex B, item 2.), of the scope of the desired approval: Nature of the structure and/or components Materials and dimensional ranges Welding procedures and positions Heat treatments (if necessary) Weld factor (for pressure vessels). 2.2 If a certificate of compliance with the welding quality requirements stipulated in EN 729/ISO 3834-2, -3 or -4 is required over and above approval in accordance with these Rules for Welding, this must be expressly noted in the application for approval. 3. Approval documents
1.1 Shipyards and welding shops, including branches and subcontractors, wishing to perform welding work covered by these Rules must have been approved for this work by the Society (cf. Chapter 3). The preconditions for this approval are that the shops satisfy the requirements under B., have been inspected by the Society in accordance with C. and, where necessary, have carried out welding procedure tests in accordance with D. Note: The term welding shop used in the following paragraphs is understood to mean the welding production plant which, due to its space and organisational facilities, can be regarded as an independent unit. Branches and subcontractors shall generally be regarded as independent facilities which have to meet the requirements stated below. In particular, each welding shop must have available its own permanent in-house welding supervisory staff (cf. B.2.) Outside companies working in welding shops may be approved as independent companies. For details of this and contract labour, cf. Section 1, F.2. 1.2 Any approval in accordance with 1.1 covers the most essential welding quality requirements in accordance with the standards EN 729/ISO 3834. For certification under the terms of these standards, the requirements set out in 2.2 and 3.2 must also be met. These additional requirements shall be regarded as having been met when the welding shop has in place a certified quality assurance system in accordance with the series of standards EN 29000/ISO 9000. 1.3 In individual valid exceptions, e.g. in the case of repairs, the Society may grant approval for welding work to be executed even without approval being granted to the welding shop, subject to a time limit and restricted to a specific structure, if the welding shop pre-conditions have been specified for such work and the quality of the welds performed is demonstrated by relevant tests, e.g. non-destructive and/or production tests.
3.1 Welding shops applying for approval to carry out welding work must submit the following documents to the Society's head office with their application for approval (cf. Annex A): A description of the welding shop; cf. the form in Annex B. Copies of the qualification documents of the welding supervisor(s) Copies of the valid welder's certificates or a list of the qualified welders (testing standard, testing body, date of testing, test category, date of last retest) signed by the Surveyor. Copies of documentation as proof of the qualification of supervisory and test personnel, as appropriate. Copies of reports of welding procedure tests performed elsewhere, including the approvals granted, as appropriate.
Chapter 1 Page 22
Section 2
II - Part 3 GL 2000
3.2 For certification in accordance with 2.2, information and documents relating to the elements specified in Annex B to EN 729-1/ISO 3834-1 for the respective grade of requirement (EN 729-2/ISO 38342 = full, -3 = standard, or -4 = basic quality requirements) must also be enclosed with the application for approval (e.g. in the form of relevant procedure instructions): contract review design review treatment of subcontractors equipment maintenance quality inspections nonconformances calibration identification traceability
sumables, or if changes are made to the welding shop supervisory staff, the Society shall be notified voluntarily. As a rule, this necessitates a revision of the approval. 5.2 An approval shall cease to be valid if the preconditions under which it was granted cease to apply. If serious defects are detected in the components or the welds, the Society is entitled to carry out interim re-inspections of the production facilities and may, if necessary, revoke the approval.
B. 1.
Requirements for Welding Shops Technical equipment
If the welding shop operates a certified quality assurance system conforming to the series of standards EN 29000/ISO 9000, the QA manual and - if specified in Annex B to EN 729-1/ISO 3834-1 - documentation relating to the quality assurance measures performed (quality reports) must be submitted to the Society for inspection in place of the above information and documents. 4. Period of validity of approval, renewal
1.1 Welding shops must have at their disposal suitable workshops, equipment, machinery and jigs on a scale necessary for proper performance of the welding work. This includes, for example, the provision of storage facilities and baking equipment for the welding consumables and auxiliary materials, preheating and heat treatment equipment, testing appliances and equipment, and means of weather protection for carrying out welding work in the open air. 1.2 Equipment and facilities not belonging to the welding shop itself, e.g. testing appliances, may be taken into account when evaluating the capabilities of a welding shop, provided that the preconditions necessary to proper fabrication and testing are satisfied and that such equipment is available without restriction. 2. Welding shop supervisory staff
4.1 An approval granted according to these Rules or certification in accordance with EN 729/ISO 3834 shall be valid for three years. Provided that welding work is constantly performed under the Society's supervision during the validity of the approval and that the preconditions on which approval was granted have not changed, approval may be extended on application by the welding shop for further three years subject to an appropriate inspection. 4.2 If no welding work has been carried out under the Society's supervision for more than a year, an application for renewal of the approval, enclosing updated information as specified in 3., must be made no later than the end of the 3-year period of validity. Approval may only be renewed if the necessary preconditions continue to apply, which shall be verified by a re-inspection of the welding shop. The approval may then be renewed for a further period of three years. 5. Changes, revocation
2.1 Welding shops or branches (cf. note to A.1.) shall have at least one fully qualified welding supervisor, who is responsible for ensuring that the welding work is competently performed. Welding supervisors shall have training and experience corresponding to the scope of the fabrication work and shall provide the Society with the necessary documentary proof thereof. 2.2 The names of the welding supervisor in charge and his deputy must be notified to the Society, cf. Annex B "Description of the Welding Shop", 3. If the supervision role is carried out by more than one person, the responsibilities and tasks of each person must be established and specified. The welding supervisor in charge and his deputy shall be recognised by the Society as part of the approval for the welding shop. 2.3 The following persons shall be appointed as welding supervisors depending on the nature and scope of the work:
5.1 If the preconditions under which approval was granted change, e.g. through the use of untested welding procedures, materials and/or welding con-
II - Part 3 GL 2000
Section 2
Chapter 1 Page 23
Welding engineers 1 for fabrication of important components of the hull structure and of offshore installations, also of handling equipment, steam boilers, pressure vessels, pressure lines and engine and transmission components Welding specialists 2 for fabrication of simpler or less heavily stressed components.
4.
Test supervisory staff and test personnel
Where the welding shop has its own test supervisory staff and test personnel (cf. Chapter 2, Section 4, C.), documentary proof of their qualification (e.g. certificates conforming to EN 473/ISO 9712) shall be submitted to the Society.
For information relating to the qualification of the welding supervisory staff, their tasks and responsibilities, cf. EN 719/ISO 14731. 2.4 The welding supervisor(s) shall be permanently employed by the welding shop. Supervision of the welding work by outside staff is not acceptable. 3. Welders and operators
C. 1.
Inspection of Welding Shops Shop inspection
3.1 Welding shops shall be staffed with qualified welders and, for fully mechanized and automatic welding equipment, adequately trained operators. The required number of qualified welders is determined by the size of the welding shop and the scope of the welding work to be performed under the Society's supervision. However, a minimum of two qualified welders are required for each welding process. 3.2 Welders for manual and semi-mechanized welding must have passed a test in accordance with Section 3 and in conformity with a recognized standard (e.g. DIN 8561, EN 287/ISO 9606 or ASME Section IX as applicable). The test shall cover the conditions likely to occur in the fabrication work with regard to the process(es), base material, welding consumable and welding position(s). The production of test pieces in a successfully completed welding procedure or production test may be taken as proof of manual skill for testing of welders, cf. Section 3, B.4. 3.3 Operators of fully mechanised or automatic welding equipment and of welding robots must have been trained in the use of the equipment. They must also be capable of setting or programming and operating the equipment in such a way that the required weld quality is achieved. The qualification of such personnel must be demonstrated in accordance with EN 1418/ISO 14732 on welded test pieces, e.g. in welding procedure or fabrication tests or by means of random tests and operational tests as applicable (please refer to the standards).
Before starting fabrication work, it shall be proved to the Society's Surveyor in the course of an inspection of the welding shop that the requirements applicable to the technical equipment as stated in B.1. are satisfied. For this purpose the Surveyor shall be given access to all departments and laboratories relevant to fabrication and testing. The fabrication and quality control procedures shall also be described and explained to him if he so requests. For certification according to EN 729/ISO 3834, compliance with the additional quality requirements stated in the standards shall be demonstrated to the Surveyor (cf. A.3.2). 2. Submission of documentation
As part of the welding shop inspection procedure, originals of all documents necessary in order to evaluate the fabrication and quality assurance procedures shall be submitted to the Surveyor. These especially include the welding supervisors qualification documents, welder's certificates, reports on previous welding procedure tests, and results of quality tests and welder's retests. For certification according to EN 729/ISO 3834, compliance with the additional quality requirements stated in the standards shall be demonstrated to the Surveyor (cf. A.3.2).
D. 1.
Welding Procedure Tests General provisions
1.1 If welding procedure tests are required, their successful performance shall be a further precondition for the approval of a welding shop or for extending its approval. Requirements for the performance of these tests and requirements applicable to test results are given in Section 4 and in Chapter 3, Section 1 to 5. 1.2 Welding procedure tests shall be performed in such a way that the conditions of fabrication can be covered with regard to materials, welding processes, welding positions, welding consumables and auxiliary materials, wall thicknesses, shapes of welds and heat treatments. The properties of the base materials for the test pieces shall be documented by test certificates.
1 e.g. professional welding engineers as defined in the guidelines of the European Welding Federation (EWF) or engineers with an equivalent level of knowledge e.g. welding technicians or welding experts as defined in the EWF guidelines or, if necessary, other persons with suitable knowledge
Chapter 1 Page 24
Section 2
II - Part 3 GL 2000
2. Note:
Scope of the welding procedure test
Please refer to the detailed information given in Section 4, D. 2.1 In general, a welding procedure test is valid only within the limits specified in the approval and is not transferable from the welding shop where it is performed to a different welding shop. The Society may permit exceptions in the case of a nearby branch welding shop which is under the constant supervision of the main welding shop, where the same fabrication conditions prevail and where the same welding processes are used. 2.2 Welding procedure tests performed in a workshop are in general not simultaneously valid for welding in the field. In such cases, the welding procedure test must be repeated in whole or in part under field conditions as determined by the Society. The Society may waive the repeat testing by prior agreement if the properties of the field welds are documented by production tests. 3. Recognition of other tests
able on the basis of the test results. In such a case, the complete test reports and the approval certificate of the other testing body shall be submitted to the Society for evaluation.
E.
Certification of Approvals, Certificates according to EN 729/ISO 3834
1. The Society issues certificates for the approval of welding shops to carry out welding work and for welding procedure tests if the requirements set out in these rules are satisfied in the tests. These welding shop and welding procedure approvals are valid within the limits stated in the certificates. 2. Where proof has been furnished that the additional requirements listed in A.3.2 according to EN 729/ISO 3834 have been met, the Society issues a certificate based on this in accordance with this standard. 3. If previously issued approval certificates are replaced or supplemented by more recent ones (cf. A.5.1) and the details in the more recent approval certificates contradict those of previous approvals, the details in the more recent certificate shall be valid. This applies especially to the range of application, e.g. for a specific welding process.
Welding procedure tests performed under the supervision of other testing bodies which are independent of the works may be recognized in full or in part by the Society at the welding shop's request if this is accept-
II - Part 3 GL 2000
Section 3
Welders Qualification Tests
Chapter 1 Page 31
Section 3 Welders Qualification Tests

Preliminary remarks: The following rules for the testing of welders conform to or make use of the standards EN 287 resp. ISO 9606, Parts 1 (Steel) and 2 (Aluminium). For other non-ferrous metals, DIN 8561 shall continue to apply until the corresponding parts of EN 287 and ISO 9606 come into force. Where no details of the tests are specified in the following Rules, the tests shall be performed in accordance with these standards. References in the text also refer to these standards unless otherwise specified. Some deviations from the standards have been made with regard to the testing of steel welders (EN 287-1 resp. ISO 9606-1), especially in relation to the ranges of approval for base materials and weld types which have been somewhat narrowed down compared with the standards. As far as the testing of non-ferrous metal welders is concerned, it is chiefly the weld forms which differ from those of the standard. means of random tests and operational tests (cf. the standards). 2. Training, manual skill, knowledge
2.1 Welder's qualification tests may only be taken by welders who have received appropriate previous training (both practical and theoretical) and who have had sufficient opportunity to practise the craft. 2.2 Besides the necessary manual skill, the welder shall also possess the professional knowledge enabling him to perform the welding work competently and safely. Cf. the relevant information in the standards. Note: In accordance with the foreword to DIN EN 287 relating to German practice, the job knowledge tests described in Annex D of the standard (for information purposes) are required for welders taking the test (and employed) in the Federal Republic of Germany. Welders who work in the Federal Republic of Germany and who have not taken a job knowledge test must demonstrate that they at least have knowledge of the area of health and safety at work and accident prevention in accordance with the legislation applicable at the time. Such proof is the responsibility of the welding shop. 3. Lists of welders, symbols
A. 1.
General Required testing (welding processes)
1.1 Welder's qualification tests are required for all welders who are to perform welding work using manually guided welding appliances (as for manual metal arc welding or semi-mechanized gas-shielded metal arc and/or welding using flux-cored electrodes) and where the quality of the welded joints depends mainly on the manual skill of the welder. 1.2 For welders who are required to perform welding work on steam boiler installations, the "Technische Regeln fr Dampfkessel" (Technical Rules for Steam Boilers) TRD 201, Annex 2, Guidelines for testing and supervising boiler welders, shall also be complied with. The inclusions and exclusions specified in these Regulations shall apply hereto. 1.3 The qualification of operators of fully mechanized and automatic welding equipment and of welding robots, shall be demonstrated in accordance with EN 1418/ISO 14732 on welded test pieces e.g. as part of the welding procedure or fabrication tests or by
3.1 Welding shops are required to maintain lists or files which furnish information about the number, names (code number) and test scope of the welders and the dates of their initial and repeat tests (cf. Annex C "Assessment Form"). These lists shall be submitted to the Society for examination on demand together with the relevant original documentation or, where appropriate, together with the description of the welding shop (cf. Section 2, A.3.). 3.2 Each welder shall be assigned an unmistakeable symbol, which shall be recorded in the testing documentation (certificates, lists, etc.). The Society may in addition - depending on the application - require the components and welds to be marked with the symbol of the welder who performed the work; cf. also Section 1, F.5.
Chapter 1 Page 32
Section 3
II - Part 3 GL 2000
B.
Testing Bodies, Certificates
C. 1.
Scope of Testing and Range of Approval Base materials
1.
Initial tests in the welding shop
The initial testing of welders in the welding shop is to be conducted by the welding supervisory staff in the presence of the Society's representative. Following submission of the assessment forms completed by the welding shop and initialled by the Surveyor (cf. Annex C), these tests will be confirmed by the Societys head office in the form of test certificates.
1.1 In the case of base materials - and in contrast to the provisions of the standards EN 287-1 resp. ISO 9606-1 - higher-strength (hull structural) steels with a minimum yield strength ReH of up to 355 [N/mm] (up to 360 [N/mm] in the case of pipe-grade steels) shall only be considered, following testing, as being included in the material category W 01 if the test (using the appropriate welding consumables) was also performed on a higher-strength steel. 1.2 Unless otherwise stipulated by the Society in a particular case, the test categories conforming to the standards shall also apply to the base materials. The Society may, however, require a more precise subdivision of the categories in accordance with the note to Chapter 3, Section 1, F.2. 2. Joint types
2.
Repeat tests in the welding shop
2.1 Repeat tests taken by welders who have been certified by the Society or by those certified by other recognized testing bodies and recognized by the Society may be conducted independently by the welding engineer recognized by the Society in conjunction with the approval granted to the welding shop. Tests conducted by other welding supervisors shall be carried out in the presence of the Society's representative. 2.2 The extension of the validity of a test certified by the Society by a further two years may, however, only be authorised by the Society. For this purpose, a full set of test documentation (welding procedure specification, assessment form and test certificate) must be submitted to the Surveyor. Cf. E.4.
2.1 In the case of joint types - and in contrast to the provisions of the standards - the test performed on butt welds does not also includes fillet welds. Where welders are required to lay down butt welds as well as fillet welds, both weld forms must be included in the test. 2.2 Unless otherwise stipulated by the Society in a particular case, the test categories conforming to the standards shall also apply to the weld forms. 3. Other inclusions and exclusions
3.
Tests conducted by other testing bodies
Welder's qualification tests conducted by other testing bodies (e.g. welding training and testing establishments or welding training establishments, cf the foreword to DIN EN 287) which are independent of the welding shop and which are recognized by the Society will be recognized by the Society subject to the test categories specified below. Such recognition is subject to the submission to the Society of a full set of test documentation, as described in 2.2 above.
Unless otherwise specified by the Society in a particular case, the inclusions and exclusions stipulated in the standards shall otherwise apply. 4. Deviations, special features, particular applications
4.
Tests conducted as part of the welding procedure tests
The testing of welders may be included in the welding procedure tests (cf. Section 4, B.5.3) and their names will then be included in the welding procedure approval. A welders qualification test certificate conforming to the standards may, however, only be issued provided that all the provisions of the standards, e.g. scope of test and jobknowledge testing, have been met and that this is recorded in an assessment form which has been completed accordingly (cf. Annex C).
4.1 If deviations from the standards or these rules for testing are to be included in the welders qualification test, this shall be agreed with the Society beforehand. The kind of the deviation or special feature is to be indicated on the assessment form under "Remarks" and will be noted in the test certificate. 4.2 Welder's qualification tests for particular applications (particular materials, shapes of weld, welding processes) which are not covered by the tests and work assignments described above and in the standards (e.g. for clad plates or offshore pipe junctions) shall be carried out according to a test schedule to be agreed with the Society on a case-by-case basis.
II - Part 3 GL 2000
Section 3
Chapter 1 Page 33
D.
Performance of Welder's Qualification Tests Welding of test pieces, Welding Procedure Specification (WPS)
E. 1.
Period of Validity, Repeat Tests Standard period of validity
1.
For welding test pieces, a "Manufacturers" Welding Procedure Specification (WPS) shall be produced by the welding shop - a separate one for each welding task - in accordance with the Annex C of the standards EN 287 resp. ISO 9606. The welding conditions for testing shall match those during fabrication. 2. Test pieces, specimen types and tests
A welder's qualification test remains valid for two years with effect from the test date, provided that during this period welding work is constantly performed in the range of approval of the test and the work of the welder is monitored by the welding supervisors at all times. This is to be confirmed by the welding supervisors on the welders qualification test certificate at intervals of no more than six months. The provisions given in the standards in this regard shall also apply. 2. Reduced period of validity
The test pieces, the specimen types and the performance of the tests shall conform to the standards. 3. Evaluation of test pieces and specimens, recording of results
2.1 The Society may reduce the validity of the test (e.g. to one year) if the supervision of the welder's work mainly takes the form of visual inspections. 2.2 A repeat test relating to an individual welding process is required where a welder who has been tested in more than one welding process has not used the process in question for longer than six months. 2.3 A repeat test is in any case necessary where a welder has not performed any welding work as defined in para 1. for longer than six months. 2.4 The Society may demand a repeat test at any time should reasonable doubts arise as to a welder's skill. 3. Continuous supervision
3.1 Depending upon the kind and scope of the tests, test pieces and specimens shall be evaluated, conforming to the specifications of the standards, according to the following criteria: Thickness, reinforcement and appearance of weld (external results) Radiograph (internal results) Appearance of fracture (internal results) Mechanical properties, where applicable Metallographic specimen, if required.
3.2 A welder shall be regarded as having passed the test provided that the imperfections fall within the limits of assessment category B conforming to EN 25817 resp. ISO 5817. Exceptions to this rule include the following imperfections: weld reinforcement too large (butt and fillet welds), excessive fillet weld thickness and excessive root reinforcement, to which assessment category C applies. 3.3 A test shall only be passed as successful if all the requirements stated in the standards relating to the test piece in question and the specimens taken from it can be evaluated as having been met. Repeat test pieces and specimens are subject to the specifications of the standards EN 287 resp. ISO 9606. 3.4 The assessment form provided at Annex C is to be used to record the details and results of the tests (p = passed, np = not passed). Additional sheets shall be used as necessary.
3.1 A repeat test may be dispensed with where the quality of the work performed by the welder in the work assignment range corresponding to his test category is systematically and verifiably monitored during fabrication by the welding shop's welding engineer recognized by the Society and this is confirmed, as described above in paragraph 1 above, at intervals of no more than six months. 3.2 For this purpose the following measures shall be implemented at times of which the welder has no prior knowledge and which shall occur at intervals of not more than three months: Destructive tests on test welds or sections of weld produced by the welder (wherever possible, in the most difficult positions), and/or Non-destructive tests for defects on production welds provided that these tests can be documented (e.g. by means of radiographs).
3.3 The results of these tests are to be noted in the lists of welding personnel (cf. A.3.1) and are to be submitted to the Society for examination and confirmation at intervals of not more than one year. Please refer to the standards.
Chapter 1 Page 34
Section 3
II - Part 3 GL 2000
4.
Extensions to the period of validity, repeat tests
4.1 The validity of a welders qualification test certified by the Society may be extended by a further two years at a time only if specified by the Society on the test certificate provided that the preconditions relating to this as stated above resp. in the standards have been met and provided that this was confirmed by the employer (welding supervisor) on the test certificate for the six month period as applicable. 4.2 An extension may only be certified for the range of approval in which the initial test took place. 4.3 If the conditions under which an extension is granted, as specified above, are not met a repeat test is to be carried out conforming in scope to the initial test. If a repeat test is carried out with a restricted scope of testing compared with the initial test, the subsequent range of approval is determined by scope of testing of the repeat test.
work assignments of welders tested in accordance with these tests will be specified in analogous manner to the above Rules, depending on the scope of testing. The period of validity is as specified in E.
1.2 Welder's tests conforming to other rules, standards or codes which have been conducted by an independent testing body in analogous manner to B.3. may be recognized by the Society subject to the foregoing provisions. The relevant welding procedure specifications, test reports, test certificates and, upon request, the relevant rules, standards or codes shall be submitted to the Society for this purpose.
2.
Exceptions
F. 1.
Other Welder's Tests Other rules and standards
1.1 The Society may consent to the performance of welder's qualification tests in accordance with other comparable recognized rules, standards or codes. The
In justified exceptional circumstances (e.g. repairs), the Surveyor may, subject to a specified time limit and to limitation to a particular structure, authorise the employment of well-trained and experienced welders without the documentary qualifications stipulated above, provided that he has reason to believe that the welders concerned are competent to perform the work envisaged and that the quality of the welds produced by them can be verified by suitable, e.g. nondestructive tests.
II - Part 3 GL 2000
Section 4
Welding Procedure Tests, Production Tests
Chapter 1 Page 41
Section 4 Welding Procedure Tests, Production Tests

A. 1. General Welding procedure tests in the user's works 2. Preliminary welding procedure test
1.1 Welding procedure tests shall be carried out under the Society's supervision in the user's works before starting the fabrication work according to the scope described in the relevant sections of Chapter 3 for the different areas of application under workshop conditions. Workplace conditions (weather protection, welding equipment, operating jigs, welders, production allowances etc.) and any intended extreme coldforming operations as well as heat treatments of the materials and/or the welds where applicable shall form an integral part of the welding procedure tests. 1.2 The Society may dispense with a welding procedure test for certain "standard" processes on materials which are easy to weld where the quality of the welded joints essentially depends on the choice of the welding consumables and the manual skill of the welder, e.g. manual metal arc welding (SMAW) or semi-mechanised gas-shielded metal arc welding (GMAW), of normal-strength hull structural steels, comparable construction steels, forgings or steel castings, except for vertical-down (PG) welding. Table 4.1 gives a summary of the documentary proof required for recognition of welding processes in the different areas of application. The provisions in the individual sections of Chapter 3 do, however, take precedence. 1.3 Welding procedure tests which have already been carried out under the supervision of other independent testing bodies and certified by them are subject to the provisions of Section 2, D.3. In such cases the Society reserves the right to demand that supplementary production tests be carried out before the start of fabrication or during production. 1.4 In individual, technically justified exceptional circumstances (e.g. repairs), the Surveyor may, subject to a specified time limit and to limitation to a particular structure, authorise the use of particular welding processes without carrying out a welding procedure test beforehand, provided that proof is furnished by means of other suitable tests (e.g. non- destructive weld tests and/or production tests) that the welding process in question is being applied correctly and safely.
2.1 A preliminary welding procedure test shall be carried out on the premises of manufacturers of welding equipment or welding consumables or at research institutions if, for special reasons, an immediate welding procedure test in the user's works appears inappropriate. In this test, the welding parameters and, where applicable, the post-weld heat treatments shall conform to the conditions prevailing in the user's works. In all other respects, the provisions governing welding procedure tests in the user's works apply. 2.2 The preliminary welding procedure test does not relieve the user's works of the obligation to carry out a definitive welding procedure test. On the basis of the preliminary test, a simplified test schedule for the definitive welding procedure test may be accepted. 3. Production tests
3.1 Production tests shall be performed to the extent described in the relevant sections of Chapter 3 in the course of fabrication to monitor the quality of the welded joints. Test pieces welded at the same time as the production welds (e.g. in the course of a longitudinal weld of a plate, pipe or vessel shell ring) or sections of production welds may be used for this purpose. Where applicable, the test pieces shall as far as possible be heat-treated together with the component. As a rule, the production tests shall comprise both non-destructive tests and mechanical and technological tests. 3.2 Production tests are also required if a particular welding process has not been used under the Society's supervision for a long time or if processes and/or materials to be welded require constant verification of the weld quality. The nature and scope of such production tests shall be established on a case-bycase basis. 3.3 In addition, the Society may require production tests to be carried out if the way in which the welding work is performed gives rise to doubts as to the quality of the welded joints or if individual welding parameters, welding consumables or auxiliary materials have been changed or changes have been made in the welding shop personnel. The scope of such production tests will be established on a case-bycase basis.
Chapter 1 Page 42
Section 4
II - Part 3 GL 2000
3.4 For production tests in conjunction with overweldable shop primers, please refer to Section 6, C.
vessel fabrication, pipeline fabrication, etc.) are described in the relevant sections of Chapter 3 of these Rules, while details of the non-destructive tests are given in Section 4 and details of the mechanical and technological tests in Section 5 of Chapter 2. 2.2 If a test schedule appropriate to the intended field and range of application has already been drawn up by the applicant in accordance with 1.2 and 2.1 as applicable, this must be agreed with the Society before starting the tests. Otherwise such a test schedule must be drawn up by the applicant - with the agreement of the Society - and submitted to the Societys Head Office for final authorisation. 3. Materials, welding consumables and auxiliary materials
B.
Performance of Welding Procedure and Production Tests Application for approval
1.
1.1 Application for approval of a welding process and for the performance of a welding procedure test shall be made to the Society's head office, with simultaneous notification of the competent Surveyor, giving the following details (to be specified in Annex B, item 2 "Description of Welding Shop": Range of application (components, materials, plate/wall thicknesses, pipe diameters, weld factor where applicable) Welding process Welding positions Welding equipment and parameters Weld shapes, weld build-up Welding consumables and auxiliary materials Joint preparation Cold- or hot-forming operations prior to welding Overweldable shop primers Welding jigs and weather protection Preheating and heat input during welding Post-weld heat treatment, other after-treatment Welders (qualification tests) Date of test.
Note:
3.1 The materials used in the welding procedure tests must be unambiguously identifiable on the basis of their marking and certificates. The direction of rolling of the test pieces must be ascertainable. If not, check specimens shall be prepared and tested. 3.2 The welding consumables and auxiliary materials should if possible have already been tested and approved by the Society; however, they may be tested and approved at the same time as the welding process. Cf. Section 5, A.1.4. Approvals of this type are generally restricted to the user's works and are valid for a maximum of one year, unless repeat tests are performed in accordance with Section 5, A.3. 3.3 Welding consumables and auxiliary materials used in the welding procedure tests may only be replaced in the subsequent fabrication work by others of the same kind which bear the Society's approval if this is expressly stated in welding procedure approval certificate; cf. also A.3.3. 4. Test pieces, dimensions, direction of rolling, weld form, welding positions
Annex D contains a form to specify the welding procedure (WPS) and recording the test results (WPAR) in conformity with DIN EN 288/ISO 9956. 1.2 Where possible, the application should enclose a proposal for a test schedule in accordance with the rules set out in Chapter 3 with sketches and dimensions of the test pieces, describing the intended specimens and tests. If the information and parameters stipulated in 1.1 are based on in-house standards or other (welding) specifications, these are also to be enclosed with the application. 2. Scope of testing, requirements, test schedule
4.1 The shape and size of the test pieces shall be compatible with the welding procedure concerned and the number of specimens. The most commonly used test pieces are described in the relevant sections of Chapter 3. The dimensions of the test pieces may be changed if this does not adversely affect the test and is necessary for evaluating the process. Unless otherwise stipulated in an individual case both butt welded and fillet weld test pieces shall be welded in the specified positions for the fabrication process. 4.2 For vertical welding (e.g. electrogas or electroslag welding) the length of the test piece (length of the weld) shall conform to the production welding jig, while with appliances using a fusible wire-guide elec-
2.1 The scope of testing (test pieces, specimens, etc.), tests and requirements for the individual fields of application (shipbuilding, steam boiler and pressure
II - Part 3 GL 2000
Section 4
Chapter 1 Page 43
trode, the length of the test piece shall be geared to the length of the wire-guide electrode or the height of the components to be welded, as applicable. Any special features affecting the application of these processes (e.g. welding operations performed through the deck) shall be allowed for in determining the shape of the test piece. 4.3 The plate thicknesses shall be chosen in accordance with the information on the limits of application in the relevant sections of Chapter 3 in line with the intended range of application. Where possible, two different plate thicknesses should be welded and tested for each range of application. The weld form shall be those to be used in subsequent practice in line with the welding process. 4.4 Where the characteristics of the welding process or the dimensions, and hence the number of passes which these entail, are likely to have a considerable effect on the results of the test, the thickness of the test pieces and the number of passes shall be made to conform to the limit thicknesses for the range of application concerned. In the case of vertical downward welding, the thickness of the test piece shall be the upper limit thickness of the range of application, whereas with a variable number of passes depending on the plate thickness (e.g. with single- and multi-pass welding) the scope of the test shall include the various techniques and the thickness of the test pieces shall be chosen accordingly. The same applies in analogous manner to the weld thicknesses. 4.5 Normally, test pieces shall be welded in all the positions occurring in subsequent practice. Depending on the welding processes and materials concerned, it may be agreed to restrict the test to certain specified welding positions, e.g. in the case of manual arc welding or semi-mechanised gas-shielded metal arc welding the test may be limited to the positions applicable to the corresponding welder's qualification tests as stated in Section 3. The horizontal-vertical position PC (h-v) is, however, always to be included in the welding procedure test for single-side welding. Where overhead welding PE (o) is included, this may be combined with the downhand position PA (d). 4.6 The direction of rolling of the plates shall be parallel to the direction of welding. The orientation of the rolling direction shall be stated in the test report. 5. Welding of test pieces
Difficult fabrication conditions (e.g. limited accessibility) shall be simulated in the welding procedure test. 5.2 Welding shop facilities, welding equipment, aids to assembly and tack welds used in the test shall conform to those used in actual production. In the downhand and vertical positions, account is to be taken of the maximum anticipated angular deviations from the theoretical welding position (e.g. slope of slipway). 5.3 Where possible, several (at least two) welders or two teams of operators shall participate in a welding procedure test. As part of the welding procedure test, each welder or team of operators, as applicable, shall carry out anew the preparation (tack welding) of the test pieces, the alignment of the welding appliances, and the setting of the current supply and feed rate. 5.4 Preheating, heat input per unit length of weld, interpass temperature, electrode changing and the starting and stopping of welding appliances (starting points/end craters) shall conform to subsequent practice. Covered electrodes are to be used down to the clamping butt. 5.5 In welding procedure tests, depositing a backing run on the root side (cap pass), with or without grooving of the root depending on the process, are generally permitted. In single-side welding, the same types of backing shall be used as in the subsequent fabrication work. 5.6 In the case of mechanised welding processes in shipbuilding, an interruption of the welding operation followed by complete cooling of the test piece and restarting of the equipment shall be demonstrated. The machining of the end crater and the preparation of the new starting point shall be carried out in accordance with normal practice. The test results from these weld areas will be evaluated separately. 5.7 Minor welding defects occurring in the course of a welding procedure test may, with the consent of the Surveyor, be repaired or ignored when preparing specimens. In the case of serious defects, the causes shall be established and remedied, after which new test pieces shall be welded. 5.8 The following data shall be recorded when welding the test pieces: Shape of weld and method of preparation Weld build-up and number of passes Welding consumables and auxiliary materials (type, trade name, dimensions, quantities) Method of root grooving and interpass cleaning/treatment
5.1 All welding procedure tests shall investigate, in accordance with workshop practice, the effects of prior cold-forming operations, weld preparation as practised in the welding shop and air gap exactness, restraints together with the use, where applicable, of overweldable production coatings (shop primers).
Chapter 1 Page 44
Section 4
II - Part 3 GL 2000
Preheating, interpass temperatures Welding equipment and parameters (amperage, voltage, welding speed, heat input per unit length of weld) Interruptions/disturbances in the welding sequence Names of welders/operators Special features applying to the tests (e.g. climatic influences, limited accessibility). Post-weld heat treatment, other kinds of after-treatment
tion for external welding defects. Test pieces made from a material other than normal-strength hull structural steel or comparable simple structural steels shall in addition be subjected to testing for surface cracks. 7.4 In contrast to the recording limits stated for the production tests, all welding defects and indications detected during non-destructive ultrasonic testing shall be recorded. 8. Sectioning of test pieces, preparation of specimens
6.
6.1 If post-weld heat treatment of the components (e.g. annealing to relieve stresses) is intended in the subsequent fabrication work, the test pieces are to be subjected to the same post-weld heat treatment. This applies in analogous manner to other types of aftertreatment, e.g., TIG after-treatment of the weld interfaces. If approval of the welding process is desired for both the untreated and after-treated conditions, the test shall be carried out for both conditions. 6.2 Where possible, post-weld heat treatment of the test pieces should be carried out in the annealing furnaces which are to be used for the fabricated components. The equipping of the annealing furnace with a temperature recorder is mandatory. The timetemperature curve shall be recorded. Other types of after-treatment shall be described in the test report. Further information on post-weld heat treatment is given in Chapter 2, Section 3. 7. Non-destructive testing
8.1 Sectioning of the test pieces shall be carried out as described in the relevant sections of Chapter 3. The test pieces shall be sectioned mechanically. If thermal cutting methods are employed, a sufficient machining allowance shall be provided and the heataffected zone must thereafter be machined off. 8.2 The individual specimens shall be marked before sectioning and during machining in a way which enables them to be identified at all times and their orientation in the test piece to be reconstructed. 8.3 From all butt-welded and fillet-welded (cruciform) test pieces for manual and semi-mechanised welding processes, one set of specimens each shall normally be taken and tested. From the test pieces for fully mechanised welding processes, one set of specimens each from the beginning and end of the weld shall be taken and tested. In the case of these latter test pieces, a third set of specimens from the middle of the weld may be additionally demanded in special circumstances, e.g. where long seams are concerned or the welding process has been recently developed. Where single-side submerged-arc welding is performed with flux backing, a third set of specimens shall be subjected to test in every case. 9. Shapes and dimensions of test specimens, mechanical and technological tests
7.1 Prior to sectioning, each butt-welded test piece shall undergo visual and non-destructive testing over the entire length of the weld to detect any external or internal welding defects. Unless otherwise agreed, the test pieces shall be radiographed and those with a thickness of 30 mm or over (10 mm or over in the case of single-side submerged-arc welded test pieces) shall additionally undergo ultrasonic testing. 7.2 Where the base materials or weld metals are liable to crack, surface testing for cracks shall be carried out in addition to the above. If the material is magnetizable, this shall take the form of magnetic particle inspection; otherwise the dye penetrant method shall be used. The Society may require specific testing intervals (e.g. 72 hours) to be adhered to between completion of the welding work and performance of the crack tests. 7.3 Each K-shape or fillet-weld test piece (T-joint or cruciform test piece) shall undergo a visual inspec-
9.1 The shapes and dimensions of the specimens, the preparation and performance of the tests and the determination of the results are subject to the provisions of Chapter 2, Section 5. Furthermore, the corresponding provisions in the Rules for Materials (Part 1, "Metallic Materials", Chapter 1, Section 1 and 2) shall also be complied with. 9.2 All tests shall be carried out by trained staff using calibrated testing equipment. The testing equipment shall be maintained by its owners in fully functional condition and shall be calibrated at regular intervals by an independent testing body.
II - Part 3 GL 2000
Section 4
Chapter 1 Page 45
9.3 Unless otherwise stipulated or agreed, all mechanical and technological tests shall be performed in the presence of the competent Surveyor. The micrographs shall be submitted to him for evaluation.
the causes of the failures shall be investigated. When the faults have been cured, new test pieces shall be welded and fully tested. 3. Reports, storage times
C.
Evaluation of Test Results, Requirements, Repeat Test Specimens, Test Reports Designation of test results
3.1 Reports (cf. Annex B) shall be prepared of all trial welds and tests and submitted to the Society in duplicate, signed by the tester and the testing supervisor. 3.2 The debris of test pieces, specimens and the test documentation are to be kept until all the tests and inspections are concluded by the confirmation of approval issued by the Society. For the storage time of documents relating to the non-destructive testing of welds (e.g. radiographs), see Chapter 2, Section 4.
1.
1.1 To ensure that the description and evaluation of welding processes and positions, test results, etc. are as clear and uniform as possible, use shall be made of the terminology and symbols in the relevant standards (e.g. ISO 857, EN ISO 6947, EN 26520/ISO 6520, EN 25817/ISO 5817, EN 30042/ISO 10042) and, for internal defects, Table 4.1 in Chapter 2, Section 4. The position of a defect or fracture must be indicated and may be designated as follows: 2. WM = in the weld metal
D. 1.
Limits of Application, Period of Validity Works and sub-works
FL
= in the transition zone (fusion line) 1.1 Welding procedure approvals are generally non-transferable. The Society may allow exceptions in the case of a nearby branch works where the welding work is carried out under the constant supervision of the main works, provided that the fabrication work is performed under the same conditions and the same specified welding processes are used. The Society may, however, require proof as to whether the welding processes are being applied correctly and the mechanical properties are adequate by means of nondestructive tests and/or simplified production tests 1.2 Welding procedure tests performed in a workshop are in general not simultaneously valid for welding in the field. In such cases, the welding procedure test must be repeated in full or in part under field conditions as determined by the Society. The Society may dispense with repeat testing by prior agreement if the qualitative properties of the field welds are demonstrated by production tests. 2. Range of application
HAZ = in the heat-affected zone (of the base material) BM = in the base material.
Requirements, repeat test specimens
2.1 The requirements are specified in the relevant sections of Chapter 3. 2.2 If, in the tests, individual specimens fail to meet the requirements or the failure of these specimens is due to localised defects in the specimen or deficiencies in the testing equipment, it is sufficient to test two repeat test specimens or sets of repeat specimens in each case from the same test piece, which must then meet the requirements. 2.3 In the testing of notched bar impact test specimens, unless otherwise specified in a particular case, the average value of three specimens shall apply; none of the individual values may be less than 70 % of the required value. If these conditions are not met and the average value is not less than 85 % of the required value, three repeat test specimens may be tested and the results added to the values originally obtained. The new average value from these six specimens must then meet the requirements. If the average value of the first three specimens is less than 85 % of the required value, six repeat test specimens shall be tested, the average value of which must meet the requirements. 2.4 If the requirements are not met by a sizeable number of specimens and/or in several areas of testing,
2.1 The other materials included in a welding procedure approval on the basis of the testing of a particular material are indicated in the relevant sections of Chapter 3. 2.2 With regard to plate thicknesses, unless otherwise stated in the relevant sections of Chapter 3 or in a particular case a plate thickness range of approx. 0,7 1,7 t (t = tested plate thickness) shall apply to hull structures according to Chapter 3, Section 1 and a range of 0,75 1,5 t shall apply in the other fields of
Chapter 1 Page 46
Section 4
II - Part 3 GL 2000
application according to Chapter 3. The Society may limit this range of application, in accordance with the standards (EN 288/ISO9956), to 0,8 1,1 t or extend it to 0,5 2 t; cf. the Sections in Chapter 3. In the case of vertical downward welding (PG), the thickness of the plate tested shall in each case be regarded as the upper limit of application. 2.3 The welding procedure approval is generally valid for the welding positions tested. Depending on the welding process, particular welding positions may be included; these are stated in the approval document where applicable. 2.4 The welding procedure approval is valid for the welding process, the weld form and weld build-up tested. 2.5 The welding procedure approval is valid for the heat treatment condition for which the test was performed, e.g. untreated, annealed to relieve stresses, normalised. 2.6 Any minimum or maximum design or operating temperatures taken into account during testing are stated in the procedure approval document. The former is generally 5 C above the test temperature. 3. Period of validity
and the relevant sections of Chapter 3. This is, however, always provided that the conditions under which it was granted do not change significantly.
3.2 The welding procedure approval is tied to the approval of the welding shop to perform welding work and expires when the approval of the welding shop expires. For renewal of the welding shop approval document (cf. Section 2, A.4.), it must be demonstrated to the Society that the approved welding processes have not be changed in the current production run and have been used without any significant defects.
3.3 For the production tests necessary in individual fields (e.g. steamboiler, pressure vessel) of application to maintain the validity of a welding procedure approval, please refer to A.3. The Society will check the aforementioned conditions in the course of the three-yearly renewal of the welding shop approval; cf. Section 2.
3.1 A welding procedure approval is generally valid without limit of time or with a time limit - depending upon the range of application; cf. Table 4.1
3.4 The Society may revoke part or all of a welding procedure approval and require a fresh welding procedure test or fresh production tests if doubts arise as to whether a welding process is being applied correctly or safely or if defects in or damage to the welds made by this process lead to the conclusion that the quality of the welded joints is inadequate.
Table 4.1
II - Part 3 GL 2000
Range of application: Pressure bearing parts Pressure bearing parts & parts welded to them & parts welded to them Pipe class III Acceptance of "standard procedures" or based on experience Acceptance based on welding procedure tests II/3/1/4 and II/3/3/4, G. II/3/1/4, A.1.2 and analogously II/3/3/1, B.3 ISO 9956 and DIN EN 288, Parts 6 and 7 ISO 9956 and DIN EN 288, Parts 3 and 4 Acceptance of Acceptance based "standard procedures" on welding or based on experience procedure tests Acceptance based on welding procedure tests Acceptance based on welding procedure tests Pipe classes I + II Bedplates, pedestals, gearbox, casings, wheel bodies, auxiliary deck machinery etc.
Welding of hull structures
Welding of steam boilers
Welding of pressure vessels
Welding of pipelines
Welding of machinery components
Components:
Hull structures, and equipment parts used in shipbuilding
Form and principles for acceptance
Acceptance of Acceptance based "standard procedures" on welding or based on experience procedure tests
Section 4 D
The Society's Welding Rules/ Part/Chapter/ Section II/3/1/4 and II/3/3/2, F. II/3/1/4 and II/3/3/3, F. II/3/1/4, A.1.2 and analogously II/3/3/1, B.3 ISO 9956 and DIN EN 288, Parts 6 and 7 ISO 9956 and DIN EN 288, Parts 3 and 4; AD-HP 2/1 ISO 9956 and DIN EN 288, Part 3 TRD 201, Annex 1
II/3/1/4, A.1.2 and II/3/3/1, B.3
II/3/1/4 and II/3/3/1, F.
II/3/1/4 and II/3/3/5, F. ISO 9956 and DIN EN 288, Parts 3 and 4
Relevant ISO/EN/DIN standard; Rule:
ISO 9956 and DIN EN 288, Parts 6 and 7
ISO 9956 and DIN EN 288, Parts 3 and 4
General preconditions
Approved welding shops, reconised welding supervisors, welders certified to ISO 9606 / DIN EN 287; certified materials from approved manufacturers approved welding consumables and auxiliary materials; authorised welding procedure specifications (pWPS or WPS) conforming to ISO 9956 / DIN EN 288 Part 2
Materials
Normal-strength hull structural steels All All Unalloyed steels Society strength grade 360 and 410 (S235)
All others (see II/3/3/1, F.1.3, footnote 1)
All others (see II/3/3/1 F.1.3, footnote 1)
Normal-strength hull structural steels and comparable unalloyed structural steels, e.g. S235
All others (see II/3/3/1 F.1.3, footnote 1)
Recognition (qualification) of welding processes-summary
Plate/wall thickness; pipe diameters: All All
Depending on the scope of the applicable welder's qualification tests. SAW-T: 4-25, -M: -40 mm
All
Depending on the scope of the applicable welder's qualification tests
All
Depending on the scope of the applicable welder's qualification tests, SAW-T: 4-25, -M: -40 mm
All
Welding process: All All
E-manual, MAG-M and - C (solid and flux-cored wire electrodes), together with single wire submerged arc, except for single-side welding All 1 year Production tests or repeat welding procedure test All 1 year Production tests or repeat welding procedure test
Manual (incl. TIG) and semimechanised welding processes; others as for pipe cl. I + II
All
E-manual, MAG-M and -C (solid and fluxcored wire electrodes), together with single wire submerged arc, except for single-side welding All except for PG (v-d) generally not subject to time limit Proof according to D.3.2 All 1 year Proof of quality e.g. NDT, or repeat welding procedure test
Welding positions:
All except for PG (v-d) PA (d) only for submerged arc
All
All
Validity
generally not subject to time limit
All except for PG (v-d) PA (d) only for submerged arc generally not subject to time limit Proof according to D.3.2
Chapter 1 Page 47
Extension based on:
Proof according to D.3.2
generally not subject to time limit Proof according to D.3.2
generally not subject to time limit Proof according to D.3.2
II - Part 3 GL 2000
Section 5
Chapter 1 Page 51
Section 5 Welding Consumables and Auxiliary Materials

A. 1. General Approval procedure, marking 1.5 Where approval is applied exclusively for auxiliary materials such as ceramic backing strips (i.e. not in conjunction with welding consumables), their properties shall be tested, and where appropriate their effect on the quality of the welded joints established on the basis of the relevant product standards or the manufacturers specifications in accordance with a test schedule to be specified in each individual case. 1.6 If welding consumables and auxiliary materials are to be approved in exceptional cases on the basis of approval tests conducted elsewhere by other bodies recognized by the Society (e.g. other classification societies, Deutsche Bahn AG [German Railways] or Technical Supervisory Authorities) the complete test reports shall be submitted (initial test not older than 5 years and, if applicable, the last 3 annual repeat tests) and - if nothing else has been stipulated by the Society - tests at least corresponding to the compulsory (annual) repeat tests shall be performed. 1.7 In isolated, urgent cases, consent may exceptionally be given for the use of welding consumables and auxiliary materials which have been approved by other recognized classification societies or neutral testing authorities (e.g. Deutsche Bahn AG, Technical Supervisory Authorities), though such consent shall be subject to a time limit and shall be restricted to a particular structure. In the case of larger projects, the manufacturer shall simultaneously apply for approval. 1.8 Applications for approval according to Annex A shall be submitted in one copy to the Society's head office, with simultaneous notification of the competent Surveyor, giving the following information and accompanied by the most recent catalogues resp. technical data sheets with the properties guaranteed by the manufacturer (especially chemical composition, strength and toughness values): Manufacturer's name and manufacturing works (name of licensor, where appropriate) Nature of the welding consumables and auxiliary materials Manufacturer's brand (licensor's designation, where applicable) Dimensions for which approval is applied for (diameters, lengths) Grades for which application is made, including additional symbols
1.1 All welding consumables and auxiliary materials (welding wires and rods, covered electrodes, flux cored wires, (flux cored-) wire-gas or wire-flux combinations, etc.) which are to be used within the range of approval of the Welding Rules or other Rules, regulations, etc. issued by Germanischer Lloyd must be tested and approved by the Society for that purpose in accordance with the following provisions. The same also applies an analogous manner to brazing materials, the tests and requirements for which will be specified on a case-by-case basis. 1.2 Approval is normally granted on the basis of specimen welds and tests carried out on the weld metal and the weld joints on the manufacturers premises under the Societys supervision with each individual product (individual manufacturers brand) in accordance with 1.1, for which approval was applied for. For details of transfers of approvals, cf. 2. 1.3 An inspection of the manufacturers production facilities (production workshops, stores etc.) and especially the internal quality assurance measures applied shall be carried out in the course of normal production in conjunction with the approval tests. Note: The quality requirements relating to the manufacture, supply and marketing of welding consumables and the processes applied are described in EN 12074/ISO 14344. Unless other or contrary provisions relating to this are stipulated in the following paragraphs, the quality requirements stated in this standard may be used as a basis for the inspection of the manufacturers facilities. 1.4 For the approval of welding consumables and auxiliary materials in conjunction with a (preliminary) welding procedure test, see also Section 4, B.3.2. The user must have consented to the approval (on behalf of the manufacturer). In such cases the testing of the pure weld metal shall also be included in the scope of the welding procedure tests. Testing of specimens taken from the welded joint is not regarded as testing of the pure weld metal.
Chapter 1 Page 52
Section 5
II - Part 3 GL 2000
Proposed range of application, including for example base materials, welding processes, welding positions for which approval is sought, heat treatment condition and any special operating conditions (e.g. low temperatures) Instructions for use (welding current, polarity, baking, heat treatment, etc.) Classification to DIN, EN, ISO or other standards Marking, packaging Any previous approvals (e.g. from other classification societies Deutsche Bahn AG [German Railways], Technical Supervisory Authority) Proposed testing laboratory and date of test.
change of supplier shall be promptly notified to the Society and generally necessitates a fresh approval test. 1.12 If welding consumables of the same composition are manufactured by several suppliers and marketed by the applicant under a brand name, the inhouse records and the printing on the packaging (e.g. fabrication number) must clearly identify the manufacturer in question beyond all doubt. The relevant code system used must be notified to the Society. 1.13 On the successful conclusion of the specimen welds and tests, the Society's head office will issue an approval certificate. The Society also maintains and publishes a "List of Approved Welding Consumables". 1.14 With the approval, the manufacturer assumes responsibility for ensuring that during fabrication, the composition and properties of the products conform at all times to those of the tested welding consumables and auxiliary materials; see also Section 1, F.1., and under 3.2. 1.15 Manufacturers are obliged to state in their catalogues at least those items of information from the approval certificate which appear in the "List of Approved Welding Consumables". 1.16 Besides the brand name, identifying marks and the manufacturers details concerning the nature and use of the welding consumable or auxiliary material, the printing on the packaging or the adhesive label or the tag attached to reels, coils of wire etc. must at least indicate the Societys full quality grade and any additional symbols must be visible. The details given in the current approval list published by the Society in accordance with 1.13 shall, however, take precedence in each case. 1.17 Where possible each individual covered electrode, welding wire etc. shall be permanently and distinctively identified by colour-coding, stamping or impressed marking. The marking must match that on the packaging. 2. Transfers of approval
The statements of conformity ("Affidavits") specified in 2.2 shall also be enclosed with any application for transfer of approval. The form provided in Annex E may be used to list the information specified above. Note: Classification to DIN, EN, ISO or other standards is performed by the manufacturer and is included in the approval certificate and in the list of welding consumables and auxiliary materials approved by the Society. Where possible classification is performed to EN standards, but where these are not well-known classification shall be to other rules which have the widest possible circulation. For space reasons, however, only the designation of the standard is generally given in the list (not the title of the relevant standard). Classification is not normally covered by the tests and is therefore not part of the approval granted by the Society; cf. 4. If the Society is also required to check and confirm the classification in accordance with the standards, a separate application should be made to this effect 1.9 The applicant is generally the manufacturer of the welding consumables and auxiliary materials. The manufacturer is the firm which carries out the final quality-influencing stage of the manufacturing process (e.g. coiling in the case of wire electrodes). 1.10 In the case of applicants with several production facilities which have separate organisations and are in separate locations, approval of the welding consumables and auxiliary materials will generally be granted for the plant that manufactured them. If production is relocated, already existing approvals may be transferred to the new plant. The conditions relating to the transfer of approvals specified in 2. shall apply in an analogous manner hereto. 1.11 If the applicant is not the manufacturer of the welding consumables and auxiliary materials, he shall give the Society the names of his suppliers. Any
2.1 On application, an "original approval" once granted may be transferred to welding consumables and auxiliary materials manufactured in the same works but bearing a different brand designation or to welding consumables and auxiliary materials with the same or a different brand designation and produced by other manufacturers (including subsidiary companies) under licence. An approval which has already been based on a transfer of approval cannot be transferred.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 53
2.2 For this purpose, manufacturing and marketing companies as well as licensors and licensees must confirm that the welding consumables are identical in composition, manufacture and the welding properties and quality factors on which approval was based ("Affidavits"), and they must constantly supervise that this identity is preserved in accordance with para. 1.14. Marketing companies are also required to confirm that other welding consumables and auxiliary materials (from other manufacturers) are not marketed under the same brand name; cf. paras. 1.9 to 1.1 and the note to 3.3. 2.3 Transfer of approval is normally conditional upon a previous test corresponding in scope to the prescribed (annual) repeat test. However, a test differing from this in scope and timing may be agreed. A test may be waived where the transfer relates to welding consumables and auxiliary materials manufactured in the same works provided that the prescribed (annual) repeat tests were performed on the manufacturer's premises in the period stipulated. 2.4 The company (marketing company, licensee) in whose name the approval certificate has been issued is responsible for the prescribed (annual) repeat tests. Where welding consumables and auxiliary materials are produced in the same works, repeat tests need not be duplicated, but where welding consumables of the same composition are manufactured by several suppliers (cf. 1.12) repeat tests are required for all suppliers. 2.5 Changes to welding consumables and auxiliary materials or their brand designations, the relocation of manufacturing facilities, or changes in the relationship existing between companies (e.g. in the case of transfers of approval) shall be brought to the Society's attention by each of the companies concerned. The provisions of 1. are to be applied in analogous manner. 3. Period of validity and repeat tests
ance Systems for Welding Consumables which have been jointly drawn up by the IACS classification societies and that satisfactory quality assurance test records are submitted to the Society for inspection at not more than yearly intervals. The Society may also perform interim tests on a random basis in order to satisfy itself that the specified procedure is being followed and that the prescribed requirements are being met. 3.2 The continued validity of the approval is further conditional not only upon the brand designation being retained, but also upon the composition and properties of the starting and end products remaining unchanged in the intervening period, as well as upon the constant monitoring of these products by the manufacturer in accordance with 1.14 and upon the maintenance of verifiable records of this monitoring. The Society may demand sight of these records at any time, may inspect the current production and may also, in case of doubt, call for interim sampling or testing, as appropriate. 3.3 Transfers of approval are generally valid for a year at a time from the date of issue of the certificate, but at the most up to the (annual) repeat test at the premises of the manufacturer (licensor) which follows the issuing of the transfer certificate. Transfers of approval may be extended for a further year at a time on application by the marketing company (licensee) if both the manufacturer (licensor) and the marketing company (licensee) submit appropriate confirmations of identity (affidavits) in accordance with Section 2. Note: The Society may waive the requirement for the submission of annual confirmations of identity (Affidavits) if, in conjunction with the first transfer of approval, the manufacturer (licensor) and marketing company (licensee) both expressly declare that they agree to the Society continuing to certify the annual repeat test(s), (until revoked), i.e. extending the approval(s). 3.4 A transfer of approval to brand designations used for marketing in accordance with 2.1 shall cease to be valid when the approval of the corresponding manufacturer's product expires. A transfer of approval for a product made under licence by another manufacturer may in such cases, on application, continue to be valid, provided that the prescribed (annual) repeat tests continue to be conducted by the licensed manufacturer. 3.5 Repeat tests shall be performed under the Society's supervision and shall be of the scope described for the various welding consumables and auxiliary materials. Unless otherwise agreed, the tests shall be performed at yearly intervals. They relate to a period of one year calculated from the date of the approval and are to be concluded by the end of this
3.1 Provided that the prescribed (annual) repeat tests are performed, approvals of welding consumables and auxiliary materials remain valid indefinitely until revoked. If welding consumables and auxiliary materials do not undergo the prescribed annual repeat tests, the approval shall lapse and they shall be removed from the list of approved products. Equivalent alternative documentary proof may be recognized by the Society by prior special agreement. Note: The Society may accept regular in-house tests performed as part of a recognized quality assurance system as equivalent alternative proof provided that this system meets the recommendations Guidelines for the Acceptance of Manufacturers Quality Assur-
Chapter 1 Page 54
Section 5
II - Part 3 GL 2000
period at the latest. If no welding consumable or auxiliary material is manufactured within this period, i.e. is sold ex stock from a production run that the Society has already inspected, the Society may, on application, defer the repeat test. The Society issues collective certificates covering these repeat tests. Note: If the scheduled repeat test is missed, the subsequent repeat test shall apply retrospectively to the period in which it should have been performed and may be subject to a time limit. The manufacturer is then required to perform subsequent repeat tests at shorter intervals to ensure that on average the prescribed annual test period is once again achieved. Approval is revoked if repeat testing is not performed in two consecutive years. 3.6 Repeat tests for welding consumables and auxiliary materials which have been approved for use in both untreated condition and for one or more heattreated conditions (cf. para. 7.4) shall be carried out according to the prescribed scope for use in untreated condition and for use in each of the heat-treated conditions in question. 3.7 Welding consumables and auxiliary materials which have been tested and approved in conjunction with welding procedure tests conducted on the user's premises (cf. Section 4, B.3.2) or in conjunction with a preliminary welding procedure test (cf. Section 4, A.2.) shall be subjected to annual repeat tests in line with these provisions, which shall be carried out on the premises of either the manufacturer or the user. In the case of welding consumables and auxiliary materials for special welding processes or materials, the scope of the tests applicable will be determined on a case-by-case basis. 4. Classification and designation (quality grades, added symbols)
the weld metal (applies only to quality grades 2, 3 and 4 or higher), With the added symbol S (= semi-automatic) for semi-mechanized welding, With the added symbol T (= two run technique) for welding in one pass on each side, M designating a multirun technique, or TM which covers both (and is applicable only to welding consumables and auxiliary materials for fully mechanized welding), With the added symbol V (= vertical welding process) for electrogas or electroslag welding.
Each higher quality grade includes the one (or those) below. Approval for higher-strength hull structural steels (added symbol Y or Y40) generally encompasses approval for normal-strength hull structural steels; cf. Table 1.1 in Chapter 3, Section 1, E. For welding processes where a high base material content may influence the properties of the weld metal (e.g. in submerged-arc welding using the two-run technique or in electrogas or electroslag welding), the Society may require testing of both categories of material. Approval for semi-mechanized welding (added symbol S) subsumes approval for fully mechanized multirun welding (added symbol M) in flat positions. 4.2 Welding consumables and auxiliary materials for the welding of high-strength (quenched and tempered) structural steels with minimum yield strengths in excess of 390 N/mm2 are subject to classification, designation and approval in analogous manner to para. 4.1, with the following differences: With the quality rating 3 or higher, depending on their notch impact energy and test temperature (see F.), With the added symbol Y and an appended code number designating the minimum yield strength of the weld metal (e.g. Y46 for a minimum yield strength of 460 N/mm2).
4.1 Welding consumables and auxiliary materials for the welding of hull structural steels (including the corresponding grades of steel forgings and castings) and of comparable structural steels are subject to classification, designation and approval as follows: According to their nature (e.g. covered electrode, flux-cored wire electrode, wire-gas combination or wire-flux combination), According to quality grades 1, 2, 3 and 4 or higher, depending on their notch impact energy and test temperature (cf. B. to E.), With the added symbol Y or Y 40 (= yield controlled) for welding of higher-strength hull structural steels, With the added symbol H15(H), H10 (HH) or H5 (HHH) for controlled hydrogen content of
Each higher quality grade includes the one (or those) below. Approval for steels having the minimum yield strength designated by the code number subsumes approval for steels of similar type having the next two lower yield strengths (e.g. approval for a steel with the symbol Y50 subsumes approval for steels with the symbols Y46 and Y42). In the case of steels with minimum yield strengths of 550 N/mm2 and above (symbols Y55, Y62 and Y69), the approval only subsumes the steel with the next lower yield strength. In special cases, welding consumables and auxiliary materials are approved only for specific materials. 4.3 Depending on their nature and condition (type of alloy), welding consumables and auxiliary materials for welding of steels tough at subzero temperatures are classed as equivalent to those for high-
II - Part 3 GL 2000
Section 5
Chapter 1 Page 55
strength (quenched and tempered) structural steels (see F.), for austenitic stainless steels (see I.), or for nickel and nickel alloys (see L.) and are subject to classification, designation and approval as follows: For approvals in accordance with F., according to a quality grade which depends on their notch impact energy and test temperature and, where applicable, with the added symbol Y and the code number for the minimum yield strength (cf. 4.2)
3954 for the welding of steel with the material number 1.3964 X2CrNiMnMoNNb21-16-5-3) For welded joints between these steels and unalloyed or low-alloy (hull) structural steels, for intermediate weld runs in clad plates and buildup welding, according to a quality grade consisting of the abbreviated material number of the welding consumable itself (e.g. quality grade 4370 for the welding consumable with the material number 1.4370 X15CrNiMn-18-8) For welding of nickel alloy steels tough at subzero temperatures, according to a quality grade consisting of the abbreviated material number of the base material to be welded with the product in question (e.g. quality grade 5662 for welding of steel with the material number 1.5662 X8Ni9).
or For approvals in accordance with I., according to a quality grade consisting of the abbreviated material number of the material or material category for which approval was granted (cf. 4.5), also stating the test temperature used for the approval test
or For approvals in accordance with L., according to a quality grade corresponding to the code designation shown in the standard applicable to the welding consumable (cf. 4.8), also stating the test temperature used for the approval test.
The steels also covered by the approval and information on the types of application are shown in I. (Tables 5.21 to 5.24). In special cases, e.g. where the inclusions and exclusions differ, the relevant information is given in the approval certificates. 4.6 Welding consumables and auxiliary materials for welding of aluminium alloys are subject to classification, designation and approval according to a quality grade corresponding to the code designation according to the standard, e.g. quality grade RAlMg 4,5 Mn. For other aluminium alloys covered by the respective approval, see J., Table 5.26. 4.7 Welding consumables and auxiliary materials for welding of copper and copper alloys are subject to classification, designation and approval according to a quality grade corresponding to the code designation for the welding consumable according to the standard (DIN 1733), e.g. quality grade CuNi30Fe. For other base materials covered by the respective approval, see K., Table 5.29. 4.8 Welding consumables and auxiliary materials for welding of nickel and nickel alloys are subject to classification, designation and approval according to a quality grade corresponding to the code designation for the welding consumable according to the standard (DIN 1736), e.g. quality grade NiCu30MnTi. For other base materials covered by the respective approvals, see L., Table 5.31. 4.9 The code numbers and letters indicated in Table 5.1 are used to identify the approved welding positions. In special cases, the approved welding positions are specified individually; for example, an approval applicable only to the vertical-down PG (v-d) position or individual welding positions are also specified or excluded as applicable. For the limitations relating to the use of vertical-down welding, see Chapter 3, Section 1, H.6.
The inclusions and exclusions of the category of welding consumables and auxiliary materials according to which approval was granted apply, unless otherwise stated in the approval certificates. 4.4 Welding consumables and auxiliary materials for welding of high-temperature steels are subject to classification, designation and approval as follows: According to a quality grade corresponding to the code designation for the material or material category for which the approval was granted (see H.).
The materials included in the respective approvals are shown in Table 5.18. 4.5 Austenitic welding consumables and auxiliary materials for welding of stainless and nonmagnetic steels and nickel alloy steels tough at subzero temperatures are subject to classification, designation and approval as follows: For welded joints in (austenitic) stainless steels, according to a quality grade consisting of the abbreviated material number of the base material to be welded with the product (e.g. quality grade 4571 for the welding of steel with the material number 1.4571 X6CrNiMoTi17-12-2) For welded joints in (austenitic) non-magnetic stainless steels, according to a quality grade consisting of the abbreviated material number of the welding consumable itself (e.g. quality grade
Chapter 1 Page 56 Table 5.1
Section 5
II - Part 3 GL 2000
Welding positions
Code No. 1 2 3 4 5 All welding positions
Welding positions, code letters PA (d), PB (h), PC (h-v), PD (h-o), PE (o), PF (v-u), PG (v-d) PA (d), PB (h), PC (h-v), PD (h-o), PE (o), PF (v-u)
All except the vertical-down position
Butt welds in the down-hand position, fillet welds PA (d), PB (h) in the down-hand and horizontal positions Butt welds in the down-hand position and fillet welds in the down-hand position Vertical down-positions and those as for code no. 3 PA (d) PA (d), PB (h), PG (v-d)
4.10 The code letters indicated in Table 5.2 are to be used to designate the type of current approved for use with the relevant welding consumables and auxiliary materials. Table 5.2 Type of current and polarity
Type of current and polarity Direct current, + polarity Direct current, polarity Direct current, + and polarity Alternating current
peated at short notice. If the requirements are still not met, the quality grade will be reduced. In such a case, a renewed upgrading may take place after three months at the earliest (i.e. after thorough revision and improvement of the product) and only after testing as described in 5.1. 5.3 The extension of an existing approval covering the welding of normal-strength hull structural steels to the welding of higher-strength hull structural steels (e.g. from grade 2 to grade 2Y or from grade 3Y to grade 3Y40) requires the performance of a complete new approval test using higher-strength hull structural steel in question as the base material. This requirement applies in analogous manner to other materials as well. 5.4 Extension of an existing approval to include the added symbol H15(H) or the modification of the symbol H15(H) to H10(HH) or H5(HHH) is permissible provided that the weld metal can be proved to contain the stipulated lower quantity of hydrogen by a test in accordance with B.4. Corresponding tests performed elsewhere may be recognized as furnishing the necessary proof, provided that they were carried out not more than three years previously. 6. Physical characteristics, welding performance and packaging
Code letter and symbol DC + DC DC AC
5.
Upgrading and downgrading
5.1 The upgrading of approved welding consumables and auxiliary materials into a higher quality grade shall be applied for by the manufacturer and may suitably be effected on the occasion of the prescribed (annual) repeat tests. Upgrading requires that in addition to the repeat tests, notched bar impact test specimens shall be taken from all the butt-welded test pieces (welded joints) prescribed for the (original) approval test in the various positions and shall be subjected to test. Radiographic examination of the butt-welded test pieces is recommended. 5.2 Downgrading into an appropriately lower quality grade results when the outcome of the prescribed (annual) repeat tests fails to fulfil the requirements, even if the retest specimens are included. Where the earlier test results and the evaluation of all the new test findings point to the likelihood that the failure of the specimens was due to defects in the material or the welding, the repeat test may be re-
6.1 All welding consumables and auxiliary materials must have physical characteristics compatible with the proposed application and conforming to the relevant standards and must display a satisfactory general welding performance. The packaging must be such as to prevent excessive moisture absorption and damage to the contents provided that the materials are properly handled and stored. Verification of these characteristics and testing of the packaging form an integral part of the approval tests and repeat tests.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 57
6.2 In the case of covered electrodes, the coating must encase the core rod concentrically and with uniform thickness. When the electrodes are correctly used, no projecting crater rim may be formed at one side of the coating during welding. The coating shall not display any marked irregularities or surface defects. It must adhere firmly to the core rod and be capable of storage within the specified limit conditions. Subject to proper handling and use, the coating shall not rupture or break away from the core rod. The clamping butt and the arcing end must be free from coating material. 6.3 Welding wires (wire electrodes and welding rods) must have a smooth surface and must be free from surface defects, rust or other contamination which might impair the satisfactory execution of the welding operation (e.g. by impeding the current flow). Although welding wires may be provided with metal coatings, these shall not adversely affect their welding performance or the properties of the weld. Coiled welding wires must be free from buckling and must unwind smoothly. 6.4 Welding fluxes and shielding gases must possess a degree of purity conforming to the relevant standards together with the lowest possible moisture content. Welding fluxes should be granular in consistency and free-flowing to facilitate their smooth passage through the flux supply system. The granulometry of the flux should be uniform and constant from one package to another. Regarding the identity testing of gases and the inspection of shielding gas mixing devices on the user's premises, see C.1.5. 6.5 Other auxiliary materials such as nitrogenhydrogen mixtures and powder or ceramic weld pool supports (backings) should as far as possible be metallurgically neutral and have no effect on the characteristics of the weld. Where such an effect cannot be ruled out (e.g. with powder supports which deplete or add to the alloying constituents), the materials shall be included in the scope of the relevant approval or repeat tests, or shall be tested as part of the (preliminary) welding procedure tests; cf. Section 4, A.2. and B.3.2. 6.6 Welding consumables - where appropriate in conjunction with the corresponding auxiliary materials - must in all positions and even at the limit values of the welding current display a satisfactory and constant welding performance without excessive spatter. The coating of covered electrodes shall not flake off during welding, nor may coated wire electrodes burst open. Should the arc be accidentally interrupted during welding, the slag shall not impede the speedy restoration of the arc. Cooled slag shall be capable of being removed from the weld without undue difficulty. The external characteristics of the weld and its internal features (as revealed by radiography) must meet the
subsequent requirements of fabrication (cf. Chapter 2, Section 4, G.). 7. Performance of approval tests
7.1 Unless otherwise stated below, approval tests shall be conducted in accordance with Section 4. The conditions under which the specimen welds are made (welding parameters, number of runs, weld build-up, etc.) must conform to the manufacturer's recommendations and to normal welding practice and be placed on record. Covered electrodes shall be consumed down to a residual length of approx. 50 mm. The heat input (energy input per unit length of weld E) applied during welding shall be determined by the following formula and shall also be placed on record:
E = U volts I amps welding time min 6 length of seam mm 100
LM kJ OP N mm Q
7.2 The base materials used for approval tests shall be of the chemical composition and strength category for which the welding consumables and auxiliary materials are to be approved. For an approval covering only normal-strength hull structural steels (quality grades 1, 2 or 3), a normal-strength hull structural steel or, failing this, a comparable structural steel possessing the same minimum tensile strength (400 N/mm2) shall be used. For approvals covering higher-strength hull structural steels (quality grades 1Y, 2Y, 3Y or 4Y), a higher-strength hull structural steel or a comparable structural steel (e.g. S 355 (St 52-3) having a tensile strength of at least 490 N/mm2 shall be used. For approvals covering the quality grades 2Y40, 3Y40 or 4Y40, a hull structural steel or a comparable structural steel with a tensile strength of at least 510 N/mm2 shall be used. For testing the pure weld metal, normalstrength hull structural steels or comparable structural steels may generally be used. For welding consumables with a very divergent chemical composition, the side walls of the test piece may, if necessary, be provided with a buffer (e.g. in the case of stainless steels) and a backing strip of the same composition as the plate may be used. For the special features applicable to submerged-arc welding, see D.3.2 and D.3.5. 7.3 Where welding consumables and auxiliary materials are to be approved for welding with both direct and alternating current, this must be specified and the test shall be conducted with alternating current. In special cases, verification of the welding characteristics using direct current may be demanded as an alternative or in addition (e.g. for covered electrodes used for gravity welding with direct and alternating current, and for certain welding processes).
Chapter 1 Page 58
Section 5
II - Part 3 GL 2000
7.4 Post-weld heat treatment of the test pieces or specimens is not allowed where products are to be approved for the untreated condition alone; see also the preliminary remarks relating to B. Excepted from this rule is the heat treatment of tensile specimens to reduce their hydrogen content as described below in relation to the various welding consumables and auxiliary materials. Where welding consumables and auxiliary materials are also to be approved for the heat-treated condition, the prescribed additional test pieces must be prepared (cf. H.1.3) and heat-treated accordingly. Follow-up heat treatment of the specimens once they have been removed from the test pieces is not allowed. 7.5 In special cases, further tests (e.g. hardness measurements, examination of macro- or micrographic specimens to check weld penetration and structural characteristics, etc.) or the testing of notched bar impact test specimens at temperatures lower than those specified may be stipulated in addition to the test pieces and specimens called for in the following paragraphs. In the case of welding consumables and auxiliary materials for austenitic stainless steels, proof is required of resistance to intergranular corrosion and for solid austenitic steels resistance to hot cracks must also be demonstrated. 7.6 Should individual test results fail to meet the requirements, a double quantity of test pieces and specimens of the same kind shall be freshly prepared and subjected to testing. Base materials, welding consumables and auxiliary materials originating from the same delivery as those used for the first test shall be used for this purpose. Should the specimens again fail, approval will not be granted until the reasons have been clarified and a complete new test has been conducted (cf. also 5.2). For the repetition of notched bar impact tests, see the following provisions relating to the various welding consumables and auxiliary materials.
be used. The nature and scope of the necessary verifications shall be determined on a case-by-case basis. In the case of welding consumables for hull structural steels, the test temperature for the base material in question (see Chapter 3, Section 1, Table 1.1 as well as the Rules for the Construction of Ocean-going Vessels, Chapter 1, Section 2) may be assumed to be the minimum load temperature (design temperature). A temperature of 300 C is generally considered to be the maximum load temperature.
1.
General
1.1 The following provisions apply to covered electrodes for manual metal-arc welding of hull structural steels, including the corresponding grades of steel forgings and castings, and of comparable structural steels. Covered electrodes for semi-mechanized gravity welding and spring-loaded welding processes are treated in the same way as those for manual metalarc welding. 1.2 Covered electrodes for normal-strength hull structural steels are approved according to quality grades 1, 2 and 3 depending on the notch impact energy values achieved during the approval tests. Covered electrodes for higher-strength hull structural steels are approved according to quality grades 2Y, 3Y and 4Y or, where applicable, 2Y40, 3Y40 and 4Y40. In special cases, e.g. when the electrodes are also used for steels tough at subzero temperatures, approval may be granted with a higher quality grade, as with welding consumables and auxiliary materials for highstrength (quenched and tempered) structural steels (cf. F. and Table 5.14). Regarding added symbols, inclusions and exclusions, see A.4.1. 2. Testing the weld metal
2.1 For testing the deposited weld metal, two test pieces of the type shown in Fig. 5.1 are to be prepared in the downhand PA (d) welding position. One of the test pieces is to be welded with 4 mm diameter covered electrodes, the other with covered electrodes of the maximum diameter produced, up to a limit of 8 mm. Where the electrodes produced are of one diameter only or do not exceed 4 mm in diameter, one test piece is sufficient. In accordance with the covered electrodes used and normal welding practice, the weld metal shall be laid down in layers comprising single or multiple runs. The layers shall be welded in alternate directions, and the individual runs shall be 2 4 mm thick. Prior to the welding of each new layer, the test piece shall be cooled in still air to 250 C or below, but on no account to below 100 C. The temperature shall be measured at the surface of the centre of the weld.
B.
Covered Electrodes for Manual Metal-Arc Welding of Hull Structural Steels
Preliminary remarks: In normal shipbuilding practice, components are in general not subjected to post-weld heat treatment (e.g. annealing to relieve stresses). Consequently, the welding consumables and auxiliary materials to be used for ship constructions are generally tested and approved for the untreated, i.e. as-welded, condition. Should post-weld heat treatment nevertheless be intended or required in special cases, only welding consumables and auxiliary materials with properties and quality grades which have been proved to be adequate in the respective heat-treated condition shall
II - Part 3 GL 2000
Section 5
Chapter 1 Page 59
2.2 The chemical composition of the deposited weld metal shall be determined by the manufacturer using recognized methods of analysis and shall be certified by him. The analysis shall encompass all the important alloying constituents and impurities (e.g. phosphorus and sulphur). The results of the analysis shall not exceed the limits specified in the standards. In special cases, narrower tolerances for the constituents may be stipulated. 2.3 Following the recommended radiographic examination, one round tensile test specimen as shown in Fig. 5.2 and three ISO V-notch impact test specimens conforming to Fig. 5.3 shall be machined from each weld metal test piece. The longitudinal axis of the round tensile specimen shall be located in the centre of the weld at the mid-point of the plate thickness. The upper lateral surface of the impact test specimens shall lie 5 mm below the surface of the plate with the notch also located in the centre of the weld. To remove the hydrogen from the weld metal, the round tensile specimens may be subjected to a temperature not exceeding 250 C for not longer than 16 hours prior to the tensile test. In the notched bar impact test, the temperature of the specimens for quality grades 2, 2Y, 2Y40, 3, 3Y, 3Y40, 4Y and 4Y40 shall not deviate from the prescribed test temperature by more than 2 C. 2.4 The mechanical properties of the weld metal must meet the requirements stated in Table 5.3. If the
tensile strength exceeds the upper limit, approval of the electrode will be granted only after careful consideration of its other technological properties and the chemical analysis of the weld metal. The mean value for the notch impact energy must meet the requirements of the following sections; an individual value may be below the required mean value but not less than 70% of this value. 2.5 For the carrying out of retests, see A.7.6; the requirements for the notch impact energy test are as follows: If the required notch impact energy values are not attained, but not more than two of the individual values are below the required mean value and not more than one of them is less than 70 % of the required value, three more impact test specimens may be taken from the same or an identical weld metal test piece and tested. The results obtained are to be added to the first results and the resulting new mean value must then meet the requirements. In addition, no more than two of the six individual values in all may be below the required mean value and of these, not more than one may be less than 70 % of the required value. 2.6 Further repeat tests require the consent of the Society in each individual case; see also A.7.6. Such tests, however, shall without exception comprise the welding of a new test piece and the testing of all the specimens originally required, even if some of them gave satisfactory results in the first test.
R Cut
1/2 1/2 100
10 10
20 16 30
10
100
20
K = Notched bar impact test specimen R = Round tensile test specimen
Fig. 5.1 Weld metal test piece
Chapter 1 Page 510 3.
Section 5
II - Part 3 GL 2000
10
10 8
Testing on welded joints
55
r = 0,25
3.1 Tests on welded joints are generally performed on butt-welded test pieces in accordance with Fig. 5.4 resp. Table 5.4. Where covered electrodes are to be approved only for fillet welding (e.g. for gravity welding), fillet-welded test pieces as shown in Fig. 5.7 instead of butt-welded test pieces shall be welded and subjected to test. In special cases, the Society may call for fillet-welded as well as butt-welded test pieces, e.g. for vertical-down welding.
45
Fig. 5.3 ISO V-notch impact test specimen 3.2 Butt-welded test pieces in accordance with Fig. 5.4 shall be welded in the positions and with the electrode diameters shown in Table 5.4 according to the welding positions covered by the approval application (cf. A.4.9 and Table 5.1). For the base materials to be used, see A.7.2; their chemical composition is to be recorded. The two parts of the test piece are to be juxtaposed with sufficient allowance for angular shrinkage. Prior to the welding of each new pass, the test piece shall be cooled in still air to 250 C or below, but on no account below 100 C. The temperature is to be measured at the surface of the centre of the weld. Before the backing pass is laid down, the root is to be grooved - wherever possible by machining - from the rear.
10
gauge length Lo 50 parallel length 60
Fig. 5.2 Round tensile test specimen
Table 5.3
Required properties of the weld metal

Minimum yield strength [N/mm2] Tensile strength [N/mm2] Minimum elongation (Lo = 5 do) [%] Minimum notch impact energy 2 [J] Test temperature [C] + 20 305 400 560 22 47 (33) 0 20 0 375 490 660 22 47 (33) 20 40 0 400 510 3 690 22 47 (33) 20 40
Qualitygrade 1
1 2 3 2Y 3Y 4Y 2Y40 3Y40 4Y40

1 2 3
For possible higher quality grades, see 1.2. Mean value of three specimens; ( ) for minimum individual values; for this and retests, see 2.4 and 2.5. A tensile strength of 500 [N/mm2] is acceptable if adequate values are achieved in the welded joint.
12
II - Part 3 GL 2000
Section 5
Chapter 1 Page 511
K Z BW
15-20
BD
60
30
5 3 30
= Flat tensile test specimen
BD = Transverse bend test specimen, cover pass in tension BW = Transverse bend test specimen, backing pass in tension
100
2-3
100
= ISO V-notch impact test specimen
Fig. 5.4 Butt-weld test piece
Table 5.4
Butt-weld test pieces, welding positions and electrode diameters

Butt-weld test pieces required . . .
Position(s) applied for approval
. . . in position(s) No. Position PA (d) PF (v-u) PE (o) PG (v-d) PA (d) PF (v-u) PE (o) PA (d) PF (v-u) PA (d) PA (d) 4 3,25 3,25 4 3,25 4 4
. . . with electrode diameter(s) 1 Root pass 4 3,25 3,25 Fill and cover passes 5 to 8 2 4 or 5 4 or 5 acc. to manufacturer's instructions 5 to 8 2 4 or 5 4 or 5 5 to 8 2 4 or 5 5 to 8 2 5 to 8 4 4 4 4 4 4 4 4 Back pass 4 4 4
All positions incl. vertical-down (1) 3 All positions except vertical-down (2) 3 Downhand positions and vertical-up (3) 3 Downhand positions only (4) Horizontal-vertical PC (h-v) position only Other individual positions (x)
1 2 3 4
1 1 1 1 1 1 1 1 1 1 1
PC (h-v)
4 or 5
(x)
as specified above
Electrode diameters in [mm]. Filler passes with 5 or 6 mm size; last two runs including the cover pass with the largest diameter electrodes produced, up to a maximum of 8 mm. Includes the horizontal-vertical PC (h-v) position. Second pass with 5 or 6 mm size; all other filler and cover passes to be made with the largest diameter electrodes produced, up to a maximum of 8 mm..
Chapter 1 Page 512
Section 5
II - Part 3 GL 2000
The length "L" of the test piece shall be such as to permit the melt-off of at least one complete electrode length - namely, the longest produced - with a throat thickness appropriate to the electrode diameter. 3.6 Following visual inspection and assessment, the fillet-weld test pieces shall be sectioned in the manner shown in Fig. 5.7, and the macrographic specimens marked with "M" shall be prepared for evaluation of the weld penetration and measurement of the hardness in accordance with Fig. 5.8. Wherever possible, Vickers hardness measurements (DIN 50133, HV 10) should be performed. 3.7 The hardness of the weld metal obtained with welding consumables and auxiliary materials for higher-strength hull structural steels with minimum yield strengths up to 355 N/mm2 (added symbol Y) shall not be less than 150 HV and the corresponding hardness for higher-strength hull structural steels with a minimum yield strength of 390 N/mm2 (added symbol Y40) shall not be less than 160 HV. The test report shall also record the hardness values measured in the heat-affected zone and the base material. Equivalent values for other methods of measurement shall be agreed. After machining off one of the fillet welds, the two remaining pieces of each fillet-weld test piece shall be broken open on alternate sides and the fracture shall be assessed. The specimen must be free from any major defects such as large pores and slag lines in the root, incomplete penetration, lack of fusion at the side walls, cracks, etc., cf. also Chapter 3, Section 1, G.10.3.4. 4. Hydrogen test
weld width parallel length
Fig. 5.5 Flat tensile test specimen 3.3 Following the recommended radiographic examination, one flat tensile test specimen in accordance with Fig. 5.5, two 30 mm wide transverse bend test specimens (one with the cover pass and one with the backing pass in tension) and three notched bar impact bending test specimens (ISO V-notch specimens conforming to Fig. 5.3) are to be machined from each butt-welded test piece. The parallel length of the flat tensile test specimens shall be equal three times the plate thickness or the weld width plus twice the plate thickness, whichever is the greater. On the tension side, the edges of the transverse bend test specimens may be rounded to a radius of not more than 2 mm. The position of the impact test specimens shall conform to Fig. 5.6. The weld reinforcement shall be machined flush with the surface of the plate on both sides of all specimens.
1/2 1/2 15-20
Fig. 5.6 Position of impact test specimens 3.4 The mechanical properties of the welded joints must meet the requirements stated in Table 5.5. For the performance of the tests and the carrying out of retests, see paras. 2.4 and 2.5. The position of the fracture shall be recorded. Bend test specimens displaying incipient cracks shall be broken open for assessment of the fracture. The Society may stipulate that the bend tests or supplementary bend tests be performed within a set time limit in order to ascertain possible effects of hydrogen. 3.5 Fillet-weld test pieces as shown in Fig. 5.7 shall, if necessary according to 3.1, be prepared in each of the welding positions applied for approval (cf. 3.2). For the base materials to be used, see A.7.2. The first fillet weld is to be made with the largest, the second with the smallest electrode diameter recommended by the manufacturer for the particular welding position and throat thickness concerned. Unless otherwise stipulated or agreed, each fillet weld shall be made in a single pass. Electrodes of the maximum length produced are to be used. The amperages used shall be recorded.
R=
25
35
25
4.1 The hydrogen test to determine the diffusible hydrogen content of the weld metal should, where possible, be conducted according to the mercury method prescribed in DIN 8572 Part 1 and ISO standard 3690-1977 or, with the Society's consent, according to other comparable methods. For an interim period and with the Society's consent, the glycerin method described in para. 4.3 may continue to be used as an alternative for the added symbols H15(H) and H10(HH). Depending on the added symbols H15(H), H10(HH) or H5(HHH) to be appended to the quality grade specified in the approval (cf. A.4.1), the hydrogen content of the weld metal shall not exceed the limits indicated in Table 5.6. 4.2 In the mercury method, the quantity of hydrogen related to the fused weld metal VF shall be determined and recorded in addition to the quantity of diffusible hydrogen related to the deposited weld metal VD (cf. DIN 8572/ISO 3690, Part 1).
II - Part 3 GL 2000
Section 5
Chapter 1 Page 513

20
50
25
1/2 L
1/2
50
150
Fig. 5.7 Fillet-weld test piece
Table 5.5
Required properties of welded joints

Minimum notch impact energy [J] 2 Positions
PA, PC, PE PF. PG
Quality grade 1
Tensile strength [N/mm2]
Test temperature [C] + 20
Minimum bending angle, mandrel diameter = 3 thickness of specimen
(d, h-v, o) 1 2 3 2Y 3Y 4Y 2Y40 3Y40 4Y40

1 2
(v-u, v-d)
400
47 (33)
34 (24)
0 20 0 120 before the first incipient crack, minor pore exposures up to a maximum length of 3 mm allowed.
490
47 (33)
34 (24)
20 40 0
510
47 (33)
41 (29)
20 40
For possible higher quality grades, see 1.2. Mean value of three specimens, ( ) minimum individual valves; for this and retests, see 2.4. and 2.5.
20
150
macrographic specimens
Section 5
II - Part 3 GL 2000
Permissible hydrogen content of weld metal

Permissible hydrogen content of welding material 1 Mercury method 15 cm3/100 g 10 cm3/100 g 5 cm3/100 g Glycerine method 10 cm3/100 g 5 cm3/100 g
3
ables may be baked in the normal manner prescribed by the manufacturer. 4.3.3 Not later than three seconds after the extinction of the arc, the sample is to be quenched in iced water (0 C). During the cooling of the sample in water, the slag and weld spatter are to be removed with a steel brush within 30 seconds. Within the space of a further 30 seconds, the sample shall be removed from the water, cleaned and dried, and each sample shall be placed separately into a test vessel (glass volumetric flask) to catch the escaping hydrogen using glycerin as the sealing liquid. After another 30 seconds the zero level adjustment of the gas collecting vessel must be completed and the measuring time must begin. 4.3.4 During the test, the temperature of the glycerin is to be held at 45 C. The sample bars are to be left immersed in the glycerin for 48 hours, after which they are to be taken out and cleaned with water and alcohol. After drying, the sample bars shall again be weighed to the nearest 0,1 g to determine the quantity of deposited weld metal. 4.3.5 The volume of gas collected in the test vessel is to be measured to the nearest 0,05 cm3 and corrected for a temperature of 0 C and a pressure of 760 mm of mercury. The mean volume of the diffusible hydrogen measured in relation to the deposited weld metal for the four sample bars may not exceed the values indicated in Table 5.6. 5. Hot-cracking test
Added symbol H15(H) 2 H10(HH) 2 H5(HHH) 2

1
Mean value of four specimens, related to the deposited weld metal. Previous added symbols H, HH and HHH should no longer be used, wherever possible. Not to be used.
heat-affected zone weld metal
base material
base material
Fig. 5.8 Hardness measurements 4.3 Where the glycerin method of testing for hydrogen is used, the following procedure shall be adopted: 4.3.1 Four sample bars of normalized steel 1 measuring 125 25 12 mm shall be thoroughly cleaned and weighed to the nearest 0,1 g. A single bead of weld, approximately 100 mm long, is to be laid down on one of the 125 25 mm faces of each sample bar, on each occasion using a new 4 mm diameter covered electrode. 120 to 150 mm of the electrode length shall be consumed in the process. 4.3.2 The welding operation shall be performed with a current of approximately 150 A and the shortest possible arc. Where the welding process is mechanized, the electrode diameter and the amperage shall be so chosen that the thermal input corresponds to that of manual arc welding. Prior to welding, the consum
1 Wherever possible, the steel should not contain more than the following components: 0,15 % C, 0,10 % Si, 1,0 % Mn, 0,03 % P, 0,03 % S.
5.1 Where the Society requires that a hotcracking test be performed, two plates shall for that purpose be welded together in the manner shown in Fig. 5.9. The end face of the web plate must be cut straight and at right angles and must fit snugly against the flat upper surface of the bottom plate. Any unevenness is to be removed. The base plate shall be stiffened by three transverse web plates.
12 - 15
120
tack welds
12 - 15
transverse web plates 80
Fig. 5.9
Test piece for hot cracking
80
II - Part 3 GL 2000
Section 5
Chapter 1 Page 515
5.2 The first fillet weld is to be laid down in a single pass in the downhand PA (d) position. During this operation, the current must be at the upper limit of the range prescribed for the electrode. The second fillet weld on the opposite side shall be laid down immediately after the first, also in the downhand PA (d) position and starting at the end of the test piece where the first fillet weld terminated. Both fillet welds are to be laid down at a uniform speed without weaving of the electrode. 5.3 For the welding of the complete length of each fillet weld (120 mm), the electrode lengths indicated in Table 5.7 are to be molten off. Table 5.7 Molten-off lengths of electrodes
Molten-off lengths 1 fillet weld [mm] 200 150 100
st
C.
(Flux-cored) Wire-Gas Combinations and Flux-Cored Wire Electrodes for SemiMechanized Welding of Hull Structural Steels General
1.
1.1 The following provisions apply to (fluxcored) wire-gas combinations and flux-cored wire electrodes for semi-mechanized welding of hull structural steels, of corresponding grades of steel forgings and castings and of comparable structural steels. Wire-gas combinations for manual tungsteninert-gas (TIG) welding shall be treated analogously to those for semi-mechanized welding. For wire-gas combinations and flux-cored wire electrodes for fully mechanized welding and mesh-wound wire electrodes, see D.1.1. 1.2 (Flux-cored) wire-gas combinations and flux-cored wires for normal- strength hull structural steels are approved according to quality grades 1S, 2S or 3S, depending on the notch impact energy values achieved during the approval tests. Quality grades 2YS, 3YS and 4YS or, where applicable, 2Y40S, 3Y40S and 4Y40S are awarded to wire-gas combinations and flux-cored wires for higher-strength structural steels. For inclusions and exclusions, see A.4. 1.3 Approval is essentially linked to a specific (commercial) brand of wire - where appropriate, in conjunction with a shielding gas conforming to a standard (e.g. to EN 439/ISO 14175) or defined in terms of its composition and purity. An approval relates exclusively to the wire produced by a particular manufacturer and used for the approval tests. The Society is to be notified of the manufacturer and the brand and standard designations of the wire used for the approval test. The marketing of other wires (wires produced by other manufacturers) under the (commercial) brand name stated in the approval certificate is permitted only after a renewed approval test using the other wire. 1.4 Approval may be granted for a (commercial) brand of wire in conjunction with a specific (commercial) brand of shielding gas produced by a particular manufacturer or in conjunction with a shielding gas covered by EN 439/ISO 14175 and defined by its group and code number (e.g. M 21) in accordance with Table 5.8. 1.5 Where a (commercial) brand of (flux-cored) wire is approved in conjunction with a standardized shielding gas in accordance with 1.4, the wire in question may be used with other standardized gases of the same type, provided that these gases are included in the "List of Approved Welding Consumables " (cf. A.1.13) on the basis of an initial verification of iden-
Electrode core wire diameter [mm] 4 5 6
2 nd fillet weld [mm] 150 100 75
After welding, the slag shall at once be removed from the fillet welds. 5.4 Half an hour after welding, at the earliest, i.e. when the test piece has cooled completely through its entire thickness, the fillet welds are to be examined for cracks with a magnifying glass or by a crack-detecting technique. The first fillet weld shall then be removed by machining and the second fillet weld shall be fractured by collapsing the plates (with the root in tension). The fractured seam shall then be examined for hot cracks. When subjected to testing for hot cracks, the fillet welds may not reveal any superficial or internal cracks of any kind. Only end crater cracks may be tolerated. 6. Annual repeat tests
6.1 For covered electrodes for hull structural steels, the annual repeat test called for in A.3.1 requires the preparation of two weld metal test pieces in accordance with 2.1. The test specimens prescribed in 2.3 shall be taken from these. For the tests to be applied and the required properties, see 2.4 and table 5.3. 6.2 In special cases the Society may stipulate more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
Chapter 1 Page 516
Section 5
II - Part 3 GL 2000
tity performed on the manufacturer's premises followed by annual repeat tests of composition and purity. Branch works, cylinder filling stations, etc. shall also be covered by these tests. For gas mixing installations (including those on the user's premises) adequate documentary proof shall be submitted to the Society. 1.6 If in exceptional cases, e.g. where the gas producer makes application for approval for a (fluxcored) wire-gas combination, approval is required to be granted for a specific standard wire in conjunction with a (commercial) brand of gas produced by a particular manufacturer, the brand of wire used in the test will also be noted in the approval confirmation document. The use of other, equivalent (commercial) brands of (flux-cored) wire or standard wire as part of such an approval is only permitted if the particular wire in question has already been tested and approved elsewhere with a gas of the appropriate composition and is included on the "List of approved welding consumables" (cf. A.1.13). Table 5.8
Symbol 1 Group Identification No. Oxidizing CO2 O2 Ar balance 2 balance 2 100 balance > 0 to 5 > 0 to 5 > 0 to 5 > 5 to 25 > 0 to 5 > 5 to 25 >25 to 50 > 5 to 50 100 balance balance 2 balance 2 balance 2 balance 2 balance 2 balance 2 balance 2 balance 2 balance 2 balance 2 balance 2
2.
Testing the weld metal
2.1 For testing the deposited weld metal, two test pieces are to be prepared in the downhand PA (d) welding position in accordance with B.2.1 and Fig. 5.1. One of the test pieces is to be welded with wire of 1.2 mm diameter or the smallest diameter produced for use in shipbuilding. The other is to be welded with wire of 2.4 mm diameter or the largest diameter produced. Where wire of only one diameter is produced, a single test piece is sufficient. The test pieces are to be welded in a manner analogous to that prescribed in B.2.1 (cf. also EN/440/ISO 14341) in such a way that the thickness of the individual passes is at least 2 mm but not more than 6 mm. 2.2 The chemical composition of the deposited weld metal shall be determined and certified in a manner analogous to that prescribed in B.2.2. The results of the analysis shall not exceed the limiting values specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case.
Classification of shielding gases according to EN 439/ISO 14175

Components in percent volume Inert
He
Typical applications Unreactive N2 TIG, plasma arc welding, plasma arc cutting, back shielding MIG, TIG, plasma arc welding, back shielding
Remarks
Reducing H2 > 0 to 15 >15 to 35
1 2 1 2 3 1 2 3 4 1 2 3 4 1 2 3 1 2 1
reducing
100 > 0 to 95 > 0 to 5
inert
M1
> 0 to 3 > 0 to 3 > 3 to 10 > 3 to 10 > 0 to 8 > 10 to 15 > 8 to 15 > 0 to 30
slightly oxidizing
M2
MAG more pronounced oxidation
M3
100 > 0 to 50 balance
F
1 2
plasma arc cutting, back shielding
unreactive reducing
Where components not listed are added to one of the groups in this table, the gas mixture is designated as a special gas mixture and carries the preflix S. Details of the S designation are given in clause 4 of the standard. Argon may be replaced by up to 95 % helium. The helium content is designated by an additional identification number, see, table 5.27.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 517
2.3 The test specimens defined in B.2.3 and Figs. 5.2 and 5.3 shall be machined from the weld metal test pieces and subjected to test. 2.4 The test results must meet the requirements stated in B.2.4 and 2.5 resp. Table 5.3. 3. Testing on welded joints
ing parameters shall comply with the manufacturers recommendations. 5. Hot cracking test
5.1 Where the Society calls for a hot cracking test (cf. B.5.1), a test piece conforming to Fig. 5.9 but 250 mm in length shall be welded. 5.2 The wire diameters, weld thicknesses and weld lengths must conform to Table 5.10. In all other respects, the provisions of B.5.2 B.5.4 shall be applied in analogous manner. 6. Annual repeat tests
3.1 As in the case of covered electrodes for manual arc welding (cf. B.3.1), tests on the welded joint are generally carried out on butt-welded test pieces in accordance with Fig. 5.4 and Table 5.4 and in certain cases on fillet-weld test pieces in accordance with B.3.5 and Fig. 5.7. 3.2 Depending on the welding positions applied for approval (cf. A.4.9), the butt-weld test pieces are to be welded in the positions indicated in Table 5.4, but with the wire diameters shown in Table 5.9. For the base materials to be used, see A.7.2. The test pieces shall be welded in a manner analogous to that prescribed in B.3.2. 3.3 Following the recommended radiographic examination, test specimens in accordance with B.3.3 and Figs. 5.3 5.6 shall be machined from the buttweld test pieces and subjected to test. 3.4 The test results must meet the requirements stated in B.3.4 and Table 5.5. 3.5 If necessary according to B.3.1, fillet-weld test pieces in accordance with Fig. 5.7 shall be welded in each of the welding positions applied for approval (cf. A.4.9). For the base materials to be used, see A.7.2. The test pieces shall be welded in a manner analogous to that prescribed in B.3.5. 3.6 The fillet-weld test pieces are to be sectioned and tested in a manner analogous to that prescribed in B.3.6 and B.3.7. 4. Hydrogen test
6.1 For (flux-cored) wire-gas combinations and flux-cored wires for semi-mechanized welding, the annual repeat test in accordance with A.3.1 shall entail the welding, with medium wire diameters (e.g. 1.2 and 1.6 mm), of a weld metal test piece in accordance with 2.1, from which shall be taken the test specimens called for in para. 2.3. For the tests to be applied and the requirements to be met, see 2.4. Table 5.9
Welding position
Butt-weld test pieces, wire diameters

Filler and cover passes, back pass 2,4 mm or largest diameter produced
Root pass
Downhand 1,2 mm or smallest position diameter produced PA (d) 1 Other position

1
1,2 mm or maximum diameter recommended by the manufacturer for the position concerned
Where approval is required only for the PA (d) position, a second test piece shall be welded in this position with the various wire diameters recommended by the manufacturer.
4.1 (Flux-cored) wire-gas combinations and flux-cored wires whose composition (core material) or structure (e.g. folded flux-cored wire) may result in moisture uptake and consequently a higher concentration of hydrogen in the weld metal shall be subjected to a hydrogen test, unless otherwise agreed. In the case of solid- wire-gas combinations, a hydrogen test is normally unnecessary. 4.2 For the performance of the hydrogen test and the requirements to be met, see B.4; unless otherwise stipulated in a particular case, a wire electrode 1.2 mm in diameter must be used for this purpose. The weld-
Table 5.10
Wire diameter [mm] 1,2 1,6
Wire diameters and weld dimensions

1st fillet weld 2nd fillet weld Weld length [mm] 250
a-dimen- Weld a-dimension length sion [mm] [mm] [mm] 9 9 250 7 7
6.2 In special cases, the Society may require a more extensive repeat test (cf. A.3.2, A.7.4 and A.7.5).
Chapter 1 Page 518 D.
Section 5
II - Part 3 GL 2000
Wire-Flux Combinations for SubmergedArc Welding of Hull Structural Steels General
1.
1.1 The following provisions apply to wire-flux combinations for single-pass and multi-pass submerged-arc (SAW) welding of hull structural steels, of the corresponding grades of steel forgings and castings, and of comparable structural steels. Approvals granted in accordance with these provisions are valid for standard single-wire welding. Approval also covering tandem or multi-wire welding and single-side welding using (flux) backings necessitates the performance of a (preliminary) welding procedure test. (Flux-) wire-gas combinations and flux-cored wires used only for fully mechanized welding and meshwound wire electrodes shall be analogously tested and approved in accordance with these Rules. 1.2 Where there is a requirement to use multiwire flux combinations of a certain, stipulated composition and structure, the Society may require additional test pieces or tests to be performed over and above the standard test described below. The test pieces submitted for these tests must be of this combination and structure. The composition and structure will then be particularly noted in the approval confirmation. 1.3 Wire-flux combinations for normal-strength hull structural steels are approved according to quality grades 1, 2 or 3 depending on the notch impact energy values achieved during the approval tests. Quality grades 1Y, 2Y, 3Y and 4Y or, where applicable, 2Y40, 3Y40 or 4Y40 are awarded to wire-flux combinations for higher-strength hull structural steels. Wireflux combinations for welding in a single pass on each side (two-run technique) are designated by the added symbol T. Those used for multi-run technique receive the added symbol M, and those used for both welding techniques the added symbol TM. For inclusions and exclusions, see A.4. 1.4 Approval is essentially linked to a specific (commercial) brand of flux in conjunction with a (commercial) brand of wire produced by a particular manufacturer, or in conjunction with a standardized wire (e.g. to EN 756) or a wire otherwise identified by its chemical composition and other characteristics. The Society is to be notified of the manufacturer and the brand or standard designation of the wire used for the approval test. 1.5 Where approval is granted with a standardized wire, the type of flux concerned (the commercial brand) may also be used with other standardized wires of the same type (wires produced by other manufacturers who have been checked by the Society in accordance with A.1.2), provided that these wires are in-
cluded in the "List of Approved Welding Consumables " (cf. A.1.13) on the basis of an initial verification of identity followed by annual repeat tests of the chemical composition and other qualitative characteristics. The marketing of wires produced by different manufacturers under a single brand designation approved by the Society is not permitted. 2. Testing the weld metal
2.1 Testing of the deposited weld metal is required only in the case of an approval relating to multi-run technique (added symbol M) or exclusively to the welding of (double) fillet welds. For this purpose, a weld metal test piece as shown in Fig. 5.10 is to be welded in the downhand PA (d) position using wires at least 4 mm or the largest produced diameter. The welding parameters should be as used for ordinary multi-run welding, and individual runs should be laid down in alternate directions. Before each new run, the test piece should be cooled in still air to 250 C or below, but on no account below 100 C. The temperature is to be measured at the surface of the centre of the weld. The thickness of the individual runs should be at least equal to the diameter of the welding wire used and shall not be less than 4 mm. 2.2 The chemical composition of the weld metal shall be determined and certified in a manner analogous to that prescribed in B.2.2. The results of the analysis shall not exceed the limit values specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case. 2.3 Following the recommended radiographic examination, two round tensile test specimens conforming to Fig. 5.2 and three ISO V-notch impact test specimens conforming to Fig. 5.3 shall be machined from the weld metal test piece as shown in Fig. 5.10. For the preparation and heat treatment of the test specimens, see B.2.3. 2.4 The mechanical properties of the weld metal must meet the requirements indicated in Table 5.11. The provisions of B.2.4 and 2.5 apply in analogous manner to the maintenance of the test temperature, the performance of the notched bar impact tests and the carrying out of retests. 3. Testing on welded joints
3.1 Tests on the welded joint are generally performed on butt-weld test pieces as shown in Fig. 5.11 for multi-run technique (added symbol M) and/or Fig. 5.12 for the two-run technique (added symbol T). Where an application relates only to approval for welding in a single run on each side (T), testing of the
II - Part 3 GL 2000
Section 5
Chapter 1 Page 519
deposited weld metal in accordance with 2. may be dispensed with. Where approval is to cover wire-flux combinations used exclusively for fillet welds, the butt-weld test pieces shall be replaced by a fillet-weld test piece analogous to Fig. 5.7 but with dimensions suitable for submerged-arc welding. After inspection for surface cracks, this shall be sectioned and tested in a manner analogous to that described in B.3.6 and B.3.7. The Society may also call for fillet-weld test pieces in addition to butt-weld ones. 3.2 For multi-run technique (added symbol M), a butt-weld test piece conforming to Fig. 5.11 shall be welded in the downhand PA (d) position. Where a wire-flux combination is also to be approved for other positions (e.g. for welding in the horizontal-vertical position), test pieces shall also be welded in these positions. For the base materials to be used, see A.7.2, although grade A hull structural steel shall as a rule be used for approvals with quality grades 1 and 2. The two portions of the test piece shall be juxtaposed with sufficient allowance for angular shrinkage. The weld shall be executed by the multi-run technique using wires of at least 4 mm diameter and the same parameters and method as for the submerged-arc weld metal test piece described in 2.1. Before the back pass is laid down, the root is to be grooved at the back of the weld, if possible by machining. 3.3 Following the recommended radiographic examination in accordance with Fig. 5.11, two flat
tensile test specimens in accordance with Fig. 5.5, four transverse bend test specimens (two with the cover pass, two with the back pass in tension) and three ISO V-notch impact test specimens shall be machined from the M butt-welded test piece (cf. B.3.3). 3.4 The mechanical properties must meet the requirements stated in Table 5.12. The provisions of B.2.4 and 2.5 as well as B.3.4 apply in analogous manner to the performance of the tests, including in particular the maintenance of the test temperatures for the notched bar impact tests and the information on retest specimens. 3.5 For welding one run on each side (two-run technique - added symbol T), two butt-weld test pieces as shown in Fig. 5.12 are to be welded in the downhand PA (d) position using the base materials, plate thicknesses, weld shapes and wire diameters shown in Table 5.13. The chemical composition of the base materials used shall be stated in the test report. The butt-weld test pieces shall be produced by laying down one run on each side. The welding current parameters and the feed rates must be those recommended by the manufacturer for application. After laying down the first run, flux and slag are to be removed and the test piece allowed to cool down to 100 C in still air. The temperature is to be measured at the surface of the centre of the weld. The root should be grooved prior to laying down the second run only if this is expressly prescribed by the manufacturer for the future application.
K R
Cut
1/2 1/2 30
10 10
K = Notched bar impact test specimen R = Round tensile test specimen
200
16 50
10
200
20 - 2
Abb. 5.10 Weld metal test piece for submerged-arc welding
Chapter 1 Page 520
Section 5
II - Part 3 GL 2000
Z BW BD K BW BD Z
20-25
5 3 30 30 10
Z = Flat tensile test specimen
60
5 3
30 30
4
BD = Transverse bend test specimen, cover pass in tension BW = Transverse bend test specimen, backing pass in tension K = ISO V-notch impact test specimen
150
0,5
150
Fig. 5.11 "M" submerged-arc butt-weld test piece for multi-run welding
Z BW BD Z Cut 30
t 7
BW = Transverse bend test specimen, backing pass in tension K = ISO V-notch impact test specimen = Round tensile test specimen ( only required where approval relates exclusively to two-run T welding )
30 10 30 5 3
Z
5 3
BD = Transverse bend test specimen, cover pass in tension
150 150
Fig. 5.12 "T" submerged-arc butt-weld test piece for one run on each side (two-run technique)
II - Part 3 GL 2000 Table 5.11
Section 5
Chapter 1 Page 521
Required properties of the weld metal in submerged-arc welding

Minimum yield strength [N/mm2] Tensile strength [N/mm2] Minimum elongation [%] Minimum notch impact energy 1 [J] Test temperature [C] + 20 305 400 to 560 22 34 (24) 0 20 + 20 0 375 490 to 660 22 34 (24) 20 40 0 400 510 2 to 690 22 41 (29) 20 40
Quality grade 1 2 3 1Y 2Y 3Y 4Y 2Y40 3Y40 4Y40

1 2
Mean value of three specimens; ( ) minimum individual values; for this and retests, see B.2.4 and 2.5 and well as D.2.4. A tensile strength of 500 N/mm2 is acceptable of adequate values are achieved in the welded joint.
Table 5.12
Quality grade 1 2 3 1Y 2Y 3Y 4Y 2Y40 3Y40 4Y40
1
Required properties of submerged-arc welded joints

Tensile strength [N/mm2] Minimum notch impact energy [J] 1 Test temperature [C] + 20 400 34 (24) 0 20 + 20 450 0 34 (24) 20 40 0 510 41 (29) 20 40 120 before the first incipient crack, minor pore exposures up to a maximum length of 3 mm allowed. Minimum bending angle, mandrel diameter = 3 thickness of specimen
Mean value of three specimen, ( ) minimum individual valves; for this and retests, see B.2.4, 2.5 as well as D.3.4 and 3.7.
Section 5
II - Part 3 GL 2000
"T" submerged-arc butt-weld test pieces; base materials, plate thicknesses, weld shapes and wire diameters
Thickness for test piece t 2 [mm] Maximum wire diameter [mm]
Approval applied for quality grades
Base material
Recommended weld preparation 3
1 1Y 1 1Y 2 2Y 2Y40 3 3Y 3Y40 4Y 4Y40 2 2Y 2Y40 3 3Y 3Y40 4Y 4Y40

1 2
A A 32, A 36 A A 32, A 36 A, B, D A 32, A 36, D 32, D 36 A 40, D 40
12 - 15
60
20 - 25 A, B, D, E A 32 to E 36 A 40 to E 40 A 32 to F 36 A 40 to F 40 A, B, D A 32, A 36, D 32, D 36 A 40, D 40 A, B, D, E A 32 to E 36 A 40 to E 40 A 32 to F 36 A 40 to F 40
8-12
70
30 - 35 70
6-14
A 32, D 32, E 32, F 32 only with a tensile strength of at least 490 N/mm2. For approval with quality grades 1 and 1Y for approval with quality grades 2 to 4Y40 : t = 12 - 15 and 20 - 25 mm, : t = 20 - 25 and 30 - 35 mm.
A limitation of a approval to the lower and medium thickness range (up to the maximum welded plate thickness) may be agreed to, and the test pieces shall then be welded from plates of thickness t = 12 - 15 mm und 20 - 25 mm irrespective of the quality grade.
3
Minor deviations in the weld preparation are admissible.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 523
3.6 Following the recommended radiographic inspection in accordance with Fig. 5.12, one round tensile test specimen as shown in Fig. 5.2, two flat tensile test specimens as shown in Fig. 5.5, two transverse bend test specimens (one with the second pass and one with the first pass in tension) and three ISO V-notch test specimens (located as shown in Fig. 5.13) are to be machined from each "T" buttwelded test piece in accordance with Fig. 5.12 (cf. B.2.3 and B.3.3). The round tensile test specimen can be dispensed with if the wire-flux combination is at the same time also being tested for multi-run welding with an additional weld metal test piece conforming to Fig. 5.10. 3.7 The mechanical properties must meet the requirements stated in Table 5.12. The provisions of B.2.4 and 2.5 as well as B.3.4 apply in analogous manner to the performance of the tests, including in particular the maintenance of the test temperatures for the notched bar impact tests and the information on retest specimens.
x 10 x
clamping device shall conform to DIN 8572/ISO 3690, Part 2. 5. Annual repeat tests
5.1 For multi-run technique (M), the annual repeat test shall entail testing of the deposited weld metal in accordance with 2. (submerged-arc weld metal test piece as shown in Fig. 5.10). However, only one round tensile test specimen and three notched bar impact test specimens need to be tested on these occasions. 5.2 For two-run technique (T), a T butt-weld test piece as prescribed in para. 3.5 (Fig. 5.12) shall be prepared and tested in accordance with 3.6 and 3.7. However, only one round tensile test specimen, one flat tensile test specimen, two transverse bend test specimens and three notched bar impact test specimens need to be tested on these occasions. 5.3 For two-run and multi-run technique (TM), the weld metal test piece prescribed in para. 5.1 and the T butt-welded test piece in accordance with para. 5.2 shall be welded and tested. The round tensile test specimen called for in para. 5.2 may, however, be dispensed with. 5.4 Wire-flux combinations used exclusively for fillet welding (cf. 2.1 and 3.1) are to be repeat tested in accordance with 5.1. 5.5 For tandem and multi-wire technique and for single-side welding using (flux) backings, annual repeat tests analogous to those provided for above shall be conducted with the welding method concerned (cf. 1.1 and A.3.7). 5.6 In special cases, the Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
2nd run
2
2nd run
Fig. 5.13 "T" butt-weld test piece; location of notched bar impact test specimens 4. Hydrogen test
30-35
20-25
12-15
E.
Welding Consumables and Auxiliary Materials for Electrogas and Electroslag Welding of Hull Structural Steels General
4.1 Where a hydrogen test is stipulated for a wire-flux combination (or for the flux component), this shall be performed analogously to B.4, although with the altered dimensions for the specimens and the clamping device according to DIN 8572/ISO 3690, Part 2. 4.2 Alternatively, the hydrogen test may, for an interim period, continue to be conducted according to the glycerin method described in B.4.3. Here too, however, the dimensions of the specimens and the
1.
1.1 The following provisions apply to wire-gas combinations, flux-cored wires and wire-flux combinations for fully mechanized electrogas (EG) and electroslag (ES) welding (in the vertical-up position) of hull structural steels, of corresponding grades of steel forgings and castings, and of comparable structural steels. Where consumable nozzle electrodes are used, these are to be included in the test.
Chapter 1 Page 524
Section 5
II - Part 3 GL 2000
1.2 The welding consumables and auxiliary materials referred to in para. 1.1 and used for normalstrength hull structural steels are approved according to quality grades 1V, 2V and 3V depending on the notch impact energy values achieved during the approval tests. Quality grades 1YV, 2YV, 3YV and 4YV or, where applicable, 2Y40V, 3Y40V and 4Y40V are awarded to such welding consumables and auxiliary materials used for higher-strength hull structural steels. For inclusions and exclusions, see A.4.
recorded) and two thicknesses of plate depending on the quality grade applied for. The weld preparation, the wire diameter and the welding parameters must conform to the manufacturer's recommendations for subsequent practice and are to be recorded. The length of the test pieces shall be suited to the welding appliances used and, where appropriate, to the length of the consumable nozzle electrodes. 2.3 Following the recommended radiographic examination, the following shall be removed from each butt-welded test piece according to Fig. 5.14: two flat tensile test specimens to Fig. 5.5, two side bend test specimens (specimen width 10 mm), two round tensile test specimens to Fig. 5.2, three notched bar impact test specimens (ISO V-notch impact test specimens according to Fig. 5.3) each from the centre and side of the weld metal, and two macrographic specimen. When the weld reinforcement has been machined off, the edges of the side bend test specimens may be rounded on the tension side to a radius not greater than 1 mm. The location of the notched bar impact test specimens shall conform to Fig. 5.15. The provisions of B.2.3 and B.3.3 apply in analogous manner.
2.
2.1 The testing of welding consumables and auxiliary materials covered by para. 1.1 and used for electrogas and electroslag welding is performed exclusively on welded joints in a manner analogous to that prescribed in D.3.5 D.3.7 for wire-flux combinations, using butt-weld test pieces conforming to Fig. 5.14. 2.2 Butt-welded test pieces conforming to Fig. 5.14 are to be welded analogously to Table 5.13 using base materials of known composition (to be
R S
Z K KM S Z M
S
R 1/2 1/2 250 250
Z S KM KS M R
= = = = = =
Flat tensile test specimen Side bend test specimen ISO V-notch impact test specimen from centre of weld metal ISO V-notch impact test specimen from side of weld metal Macrographic specimen Round tensile test specimen
Fig. 5.14
Test piece for electrogas/electroslag welding
II - Part 3 GL 2000
Section 5
Chapter 1 Page 525
KM
fine-grained structural steels with minimum yield strengths of more than 390 N/mm2. For fine-grained structural steels with minimum yield strengths of up to 390 N/mm2, the welding consumables and auxiliary materials for the corresponding hull structural steels (e.g. quality grade 3Y40 or 4Y40) may be used.
Note: The chemical composition of the welding consumables and auxiliary materials for high-strength (quenched and tempered) fine-grained structural steels necessary to obtaining weld metal with adequate mechanical properties often also results in good low-temperature properties. In view of this fact and also bearing in mind the increased resistance to brittle fracture which is desirable when welding these steels, the welding consumables and auxiliary materials referred to in 1.1 are generally approved only with a quality grade of 3 or above. Such approval normally also constitutes proof of suitability for low-temperature applications down to a minimum service temperature (design temperature) 5 C above the respective test temperature. Cf. also G.
2
2
KS
Fig. 5.15
Location of notched bar impact test specimens
2.4 The mechanical properties of the welded joint must meet the requirements indicated in Table 5.12. The provisions of B.2.4 and 2.5 as well as B.3.4 apply in analogous manner to the performance of the tests, including in particular the maintenance of the test temperature for the notched bar impact test and the carrying out of retests. 3. Annual repeat tests
3.1 For the annual repeat testing of welding consumables and auxiliary materials covered by 1.1, a butt-welded test piece as shown in Fig. 5.14 with a medium plate thickness (20 25 mm unless otherwise specified) shall be welded in accordance with 2.2. 3.2 One round tensile test specimen, two side bend test specimens and three notched bar impact test specimens from the centre of the weld metal in accordance with para. 2.3 and Fig. 5.15 shall be taken from the test piece prescribed in 3.1. 3.3 For the performance of the tests and the requirements to be met, see 2.4, B.2.4., 2.5 and B.3.4. 3.4 In special cases, the Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
1.2 In a manner analogous to that applied to hull structural steels, welding consumables and auxiliary materials covered by 1.1 are approved according to quality grades 3 9 with the added symbol Y and an appended code number designating the minimum yield strength of the weld metal. The respective base materials will be classified in a manner analogous to that applied to hull structural steels (cf. Chapter 3, Section 1, Table 1.1) depending upon the particular strength and toughness properties in question. For other added symbols, see A.4.1; for inclusions and exclusions, see A.4.2.
2.
Testing of the weld metal
F.
Welding Consumables and Auxiliary Materials for High-Strength (Quenched and Tempered) Structural Steels General
2.1 For testing the deposited weld metal, test pieces analogous to those called for in B.2.1, C.2.1 or D.2.1 shall be prepared, depending on the nature of the welding consumables and auxiliary materials (and according to the welding process). The base metal used shall be a fine-grained structural steel compatible with the properties of the weld metal, or the side walls of the weld shall be buffered with a weld metal of the same composition. 2.2 The chemical composition of the deposited weld metal shall be determined and certified in a manner analogous to that prescribed in B.2.2. The results of the analysis shall not exceed the limit values specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case.
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for welding of normalized or quenched and tempered high-strength
Chapter 1 Page 526
Section 5
II - Part 3 GL 2000
2.3 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the test specimens prescribed in B.2.3, C.2.3 or D.2.3 shall be taken from the weld metal test pieces in a similar manner. 2.4 The mechanical properties must meet the requirements stated in Tables 5.14 and 5.15. The provisions of B.2.4, C.2.4 and D.2.4 apply in analogous manner to the performance of the tests, including in particular the maintenance of the test temperature in the notched bar impact test and the carrying out of retests. Table 5.14 Required properties of the weld metal, quality grades and test temperature Minimum notch impact energy [J] 1
unit length of weld) which are generally necessary, multi-run welding is the only suitable method. Para. 3.1 consequently refers only to the M type butt-welded test piece for multi-run welding in accordance with D.3.1. Where approval is also solicited in exceptional cases for two-run welding (T, with one run on each side), "T" type butt-weld test pieces shall be welded for this purpose in accordance with D.3.5 and tested in a manner similar to that prescribed in D.3.6 and D.3.7. For the same reasons, no reference is made below to the fillet-weld test pieces.
Quality grade 3 (3*) 2 4 5 (5*) 3 6 7 8 9 10

1
Test temperature [C]
3.2 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the butt-weld test pieces called for in para. 3.1 shall be welded in a manner analogous to that prescribed in B.3.2, C.3.2 or D.3.2. The base metal used shall be a high-strength fine-grained structural steel with an appropriate minimum yield strength and tensile strength and compatible with the added symbol for which application is made (cf. Table 5.15). 3.3 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the test specimens described in B.3.3, C.3.3 and D.3.3 shall be taken from the buttweld test pieces. 3.4 The mechanical properties must meet the requirements stated in Table 5.16. The provisions of B.3.4, C.3.4 and D.3.4 apply in analogous manner to the performance of the tests, including in particular the maintenance of the test temperatures in the notched bar impact test and the requirements regarding the retest specimens. 4. Hydrogen test
20 ( 30) 2 40 50 ( 60) 3 60 70 80 90 100
47 (33)
Charpy-V-notch specimens in accordance with EN 100451/ISO 148, mean value of three specimens; ( ) minimum individual values; for this and retests, see B.2.4 and 2.5. Corresponding to the test temperatures for the quality grades of welding consumables and auxiliary materials for the welding of hull structural steels, but not conforming to the standards (e.g. EN 757/ISO 11837), in which a test temperature of 30 C is given for quality grade 3. If the test is performed at a temperature of 30 C, an asterisk (*) will be added to the quality grade. In line with the IACS "Unified Requirements", the Society may call for a test to be performed at 60 C for quality grade 5, in which case an asterisk (*) will be added to the quality grade.
3.
4.1 Welding consumables and auxiliary materials for welding of high-strength (quenched and tempered) fine-grained structural steels with minimum yield strengths of > 390 N/mm2 shall - taking due account of the provisions in C.4.1 - be subjected in every case to a hydrogen test in accordance with the mercury method to DIN 8572/ISO 3690, Part 1 (for covered electrodes, wire-gas combinations and flux-cored wires) or Part 2 (for wire-flux combinations). 4.2 For quality grades or added symbols Y42 to Y50, the diffusible hydrogen content of the weld metal determined in accordance with the provisions of B.4.2 shall not exceed the figure of 10 cm3/100 g weld metal (related to the quantity of metal deposited) specified in Table 5.6 as the maximum for the added symbol H10 (HH). For quality grades or added symbols Y55 to Y69, the maximum figure of 5 cm3/100 g weld metal specified for the added symbol H5 (HHH) shall not be exceeded.
3.1 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the testing on the welded joints shall be performed on butt-weld test pieces in analogous manner to B.3.1, C.3.1 or D.3.1.
Note: In testing welded joints made with wire-flux combinations for submerged-arc welding, it should be assumed that due to the limits on thermal input (heat input per
II - Part 3 GL 2000 5.
Section 5
Chapter 1 Page 527
Annual repeat tests
5.1 The annual repeat tests specified in A.3.1 shall entail the preparation and testing of weld metal test pieces as prescribed under 2. If the basis used for these tests is a reduced tensile strength of the weld metal as prescribed in footnote 1 to Table 5.15, or if the specified tensile strength is not attained, two trans-
verse tensile specimens taken from the welded joint (in the down-hand position only) must also be tested and these must then meet the requirements stipulated in Table 5.15. 5.2 In special cases, the Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
Table 5.15
Required properties of the weld metal, added symbols, strength properties and minimum notch impact energy
Minimum yield strength or 0,2 % proof stress [N/mm2] 420 460 500 550 620 690 Tensile strength reference values 1 [N/mm2] 530 (500 640) 2 570 (530 680) 2 610 (560 720) 2 670 (610 780) 2 720 (690 890) 2 770 (760 960) 2 Minimum elongation A5 [%] 20 20 18 18 18 17 Minimum notch impact energy 3 [J] 47 (33) 47 (33) 50 (35) 55 (38) 62 (43) 69 (48)
Symbols added to quality grade Y42 Y46 Y50 Y55 Y62 Y69
1
The tensile strength of the weld metal may be up to 10 % below the minimum tensile strength of the base material corresponding to the added symbol, provided that the results obtained with the transverse tensile specimens taken from the welded joints meet the minimum tensile strength requirements stated in Table 5.16. The elongation is to be stated in the test report.
Note: For welding very large plate thicknesses where the "supporting effect" of the base material on either side of the weld no longer applies and the tensile strength of the weld metal also determines the tensile strength of the welded joint, it may be necessary, when applying footnote 1 of Table 5.15, to choose welding consumables and auxiliary materials of the next higher strength category (next higher added symbol).
2
The values in brackets denote the tensile strength requirements specified in the standards, for example EN 499 or EN 757/ISO 11837; in the case of the lower values covered in footnote 1, but also where the tensile strength values are too high, these may also be used to evaluate the results. Mean value of three specimens; for minimum individual values ( ) and retests, see B.2.4 and 2.5
Section 5
II - Part 3 GL 2000
Required properties of welded joints
Quality grade
Added symbol Y42 Y46 Y50 Y55 Y62 Y69
Tensile strength [N/mm2] 530 680 570 720 610 770 670 830 720 890 770 940
Minimum notch impact energy, test temperature Depending on the quality grade and added symbol in accordance with Table 5.15
Mandrel diameter Minimum (t = specimen 1 bending angle thickness) 4t 4t 4t 5t 5t 5t
3 to 9 in accordance with Table 5.14
120 or provided that the bending elongation is attained 2
1 2
Bending angle attained before the first incipient crack, minor pore exposures up to a maximum length of 3 mm allowed. If the specified bending angle of 120 is not attained, the requirements will still be regarded as having been met provided that the bending elongation attained with a gauge length of L0 = Ls + t (Ls = width of weld, t = thickness of specimen, see sketch below) before the first incipient crack complies with the elongation requirements given in Table 5.15.
t/2 Ls t/2
Lo
t
r
Ls
d + 2a < d + 3a
G.
Welding Consumables and Auxiliary Materials for Steels Tough at Subzero Temperatures General
Note: According to the Society's Rules for Materials, the steels tough at subzero temperatures used in shipbuilding fall into three categories: low-alloy carbonmanganese steels, nickel alloy steels and austenitic steels. The following paragraphs are therefore concerned with welding consumables and auxiliary materials for these three categories of materials. Other such products are to be treated in analogous manner; for aluminium alloys, see J.
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for welding of steels tough at subzero temperatures in accordance with the GL Rules for Materials governing the fabrication of vessels, pipelines, etc. for liquefied gases.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 529
1.2 Depending on their nature and properties (type of alloy), welding consumables and auxiliary materials for welding of steels tough at subzero temperatures are classified and approved in the same way as those for high-strength (quenched and tempered) structural steels in accordance with F. or those for (austenitic) stainless steels or, where applicable, nickel alloy steels tough at subzero temperatures in accordance with I. No special indication of suitability for low-temperature service is given (except with the quality grade in accordance with F.); individual suitability for low-temperature service (test temperature for the notched bar impact test and proven notch impact energy) is indicated in the approval certificate. In general, the minimum service (design) temperature is 5 C above this test temperature. 2. Testing of the weld metal
according to F.4), it shall be performed in this case too. The requirements stipulated for each individual case apply. 5. Annual repeat tests
5.1 The annual repeat tests specified in A.3.1 shall entail the preparation and testing of weld metal test pieces as prescribed under 2. The Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
H.
Welding Consumables and Auxiliary Materials for High-Temperature Steels General
2.1 Testing of the weld metal shall be carried out in accordance with the nature of the welding consumables and auxiliary materials, as described in F. and I. Unless otherwise stipulated in a particular case, the test temperatures for the notched bar impact test stated in these provisions shall be replaced by the test temperatures shown in Table 5.17. 2.2 The requirements applicable to the strength and elongation of the weld metal are determined by those applying to the base material; cf. II - Rules for Materials, Part 1, Chapter 2, Sections 1, F., 2, D.3, F. and 4, E. If particular base materials are welded with dissimilar welding consumables and auxiliary materials with strength values below those of the base material (e.g. in welding of 9 % nickel steel), the strength values used in the design calculations for the components shall apply. Unless otherwise stipulated, the minimum notch impact energy values at the test temperatures shown in Table 5.17 shall be 47 J (mean value) and 39 J (lowest individual value). 3. Testing on welded joints
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for welding of high-temperature steels in accordance with the GL Rules for Materials governing the fabrication of steam boilers, pressure vessels, pipelines, etc. with high service temperatures.
Note: Under the Societys Rules for Materials, this essentially applies to the carbon-manganese steels P235GH (H I), P265GH (H II), P295GH (17Mn4), P355GH (19Mn6), the molybdenum alloy steel 16Mo3 (15Mo3) and the chromium-molybdenum alloy steels 13CrMo45 (13CrMo4-4), 10CrMo9-10 (10CrMoI-10 ) and 11CrMo9-10 in accordance with EN 10028 Part 2. The following paragraphs are therefore concerned with welding consumables and auxiliary materials for these steels. Other such products are included if they can be classed among the materials also covered by the approval as shown in Table 5.18. Other welding consumables and auxiliary materials for other hightemperature steels are to be treated in analogous manner.
The testing on the welded joints shall be performed in accordance with the nature of the welding consumables and auxiliary materials as described in F. and I. In the case of welding consumables and auxiliary materials for nickel alloy steels, the welded joints shall be made with the base material for which approval has been solicited. In the case of such products for (lowalloy) carbon-manganese steels and austenitic steels, a base material of similar composition may be used. In all other respects, 2.1 and 2.2 apply in analogous manner. 4. Hydrogen test
4.1 If a hydrogen test is stipulated for the welding consumables and auxiliary materials in question (e.g.
1.2 Welding consumables and auxiliary materials for high-temperature steels are classified into the quality grades shown in Table 5.18 according to their chemical composition (type of alloy) and mechanical (strength) characteristics and approved according to these grades. The testing and approval of a steel in the left-hand columns of Table 5.18 encompasses the steel(s) in the right-hand columns. The different hightemperature strength properties are to be borne in mind. The table applies in analogous manner to the corresponding grades of forgings and steel castings.
Section 5
II - Part 3 GL 2000
Minimum design temperatures and test temperatures for the notched bar impact test
Minimum design temperature [C] 0 Test temperature for the notched bar impact test [C] 20
Welding consumables References to Rules and Standards and auxiliary materials relating to Materials for: Fine grain structural steels in accordance with II Rules for for ammonia liquefied Materials, Chapter 2, Section 1, F., under pressure Table 1.16 High-strength (QT) fine grain structural steels with nominal yield strengths of 420 to 690 N/mm2 Other fine grain structural steels with nominal yield strengths of up to 355 N/mm2 Nickel steels with: 0,5 % nickel 1,5 % nickel 3,5 % nickel 5 % nickel 9 % nickel in accordance with manufacturer's specification and II Rules for Materials, Chapter 2, Section 1, F., Table 1.17
20
e.g. to EN 10028, Part 3
45 1
5C below minimum design temperature, but not above 20C
steels conforming to EN 10028 Part 4: 13MnNi6-3 15NiMn6 12Ni14 12Ni19 X8Ni9, X7Ni9 e.g.. to EN ............(AISI) X2CrNi19-11 / 1.4306 (304L) X2CrNiMo17-13-2 / 1.4404 (316L) X6CrNiTi18-10 / 1.4541 (321) X6CrNiNb18-10 / 1.4550 (347)
55 60 90 105 165
2 2 2, 3
60 65 2 95 2 110 2 ( 196) 3 196
Austenitic steels
165
196
The Society may approve lower design temperatures (down to a maximum 55 C) provided that corresponding properties are demonstrated in the approval test. A lower design temperature may be approved for QT steels with a 1,5 %, 3,5 % and 5 % nickel content; in these instances the Society will specify the test temperatures. Steel with a 5 % nickel content may be approved for a minimum design temperature of 165 C subject to the provisions stipulated in the Rules for Materials, Chapter 2, Section 1, F., Table 1.15, footnote 1; the test temperature is then 196 C.
Section 5
Chapter 1 Page 531
Welding consumables and auxiliary materials for high-temperature steels

Testing and approval relating to steel 1: Steels also covered by the approval 2: Designation 1 P235GH P235GH P265GH P235GH P265GH P295GH P235GH P265GH P295GH P355GH 16Mo3 16Mo3 13CrMo4-5 16Mo3 13CrMo4-5 10CrMo9-10 Material No.: 1.0345 1.0345 1.0425 1.0345 1.0425 1.0481 1.0345 1.0425 1.0481 1.0473 1.5415 1.5415 1.7335 1.5415 1.7335 1.7380
Quality grade Designation 235GH 265GH 295GH P235GH P265GH P295GH Material No.: 1.0345 1.0425 1.0481
355GH
P355GH
1.0473
16Mo3
16Mo3
1.5415
13CrMo4-5 10CrMo9-10
13CrMo4-5 10CrMo9-10
1.7335 1.7380
11CrMo9-10
1 2
11CrMo9-10
1.7383
Steel grades in accordance with the Society's Rules for Materials or conforming to EN 10028. Steel grades in accordance with the Society's Rules for Materials or conforming to EN 10028 as well as other grades of forgings and steel castings.
Table 5.19
Required properties of the weld metal at room temperature (+ 20 C)

Minimum yield Minimum tensile strength strength or Rm 0,2 %-proof stress 1 ReL or Rp0,2 [N/mm2] [N/mm2] 285 360 355 355 400 480 520 510 510 520 Minimum elongation A5 [%] 22 22 22 20 18 47 (33) Minimum notch impact energy 2
Quality grade
[J]
235GH 265GH 295GH 355GH 16Mo3 13CrMo4-5 10CrMo9-10 11CrMo9-10

1
The lower yield strength (ReL) shall apply. Where the yield strength is not clearly defined, the 0,2 % proof stress (Rp0,2) must be used. Mean value of three specimens; for minimum individual values ( ) and retests, see B.2.4 and 2.5 as well as H.2.4.
Section 5
II - Part 3 GL 2000
Yield strength resp. 0,2 % proof stress at elevated temperatures Minimum yield strength resp. 0,2 % proof stress 1 at a temperature of C
Quality grade
50
100
150
200
250
300
350
400
450
500
[N/mm2] 235GH 265GH 295GH 355GH 16Mo3 13CrMo4-5 10CrMo9-10 11CrMo9-10

1
206 234 272 318
190 215 250 290
180 205 235 270
170 195 225 255 215 230 215
150 175 205 235 200 220 200 255
130 155 185 215 170 205 170 235
120 140 170 200 160 190 160 225
110 130 155 180 150 180 150 215
145 170 145 205
140 165 140 195
The lower yield strength (ReL) shall apply. Where the yield strength is not clearly defined, the 0,2 % proof stress (Rp0,2) must be used.
1.3 Welding consumables and auxiliary materials for components which are to undergo post-weld heat treatment must be tested and approved separately for the untreated condition and for each heat-treated condition. In general, the relevant conditions are: U = untreated (as-welded condition) and S = annealed to relieve stresses.
2.2 The chemical composition of the deposited weld metal shall be determined and certified in a manner analogous to that prescribed in B.2.2. The results of the analysis shall not exceed the limit values specified in the standards (e.g. DIN 1599, EN 12070 of EN 12071) or by the manufacturer, the narrower tolerances being applicable in each case. 2.3 As a minimum requirement, the test specimens prescribed in B.2.3, C.2.3 or D.2.3 shall be taken from the weld metal test pieces and tested at room temperature. In addition, to determine the yield strength or the 0,2 % proof stress at the highest application temperature and at a second test temperature 100 C lower, two further round tensile test specimens shall be taken from the test pieces and tested.. The Society may require further specimens to be taken and tests to be performed, e.g. determination of the 1,0 % proof stress, creep tests, notched bar impact tests on specimens subjected to ageing treatment or embrittlement tests. 2.4 The mechanical properties at room temperature must meet the requirements stated in Table 5.19 while the yield strength or the 0,2 % proof stresses at elevated temperature must conform to Table 5.20. If further tests are demanded by the Society, the requirements will be stipulated separately on a case-bycase basis. The provisions of A.7.6, B.2.4, C.2.4 and D.2.4 apply in analogous manner to the performance of the tests and any retests which may be required.
In special cases, normalizing (N) or quenching and tempering (V) may be necessary. The annealing temperatures and times shall be those applicable to the subsequent heat treatment of the components according to the standards, material data sheets, etc. Unless more precise data are given in these documents, the annealing temperatures and times specified in Chapter 2, Section 3, Table 3.2 may be used. 2. Testing the weld metal
2.1 The testing of the weld metal shall be performed according to the nature of the welding consumable or auxiliary material (and, where applicable, according to the welding process) using test pieces and specimens in analogous manner to the provisions of B.2, C.2 or D.2. In addition, for determining the 0,2 % proof stress at the maximum application temperature and at intermediate stages according to 2.3 two further round tensile specimens are to be taken from each test piece and tested. For this purpose, the test pieces shall be made correspondingly larger.
II - Part 3 GL 2000 3.
Section 5
Chapter 1 Page 533
I.
3.1 Depending on the nature of the welding consumables and auxiliary materials (and on the welding process conerned), the testing on the welded joints shall be performed on butt-weld test pieces in analogous manner to the provisions of B.3, C.3, D.3 or E.2. 3.2 The butt-weld test pieces shall be prepared in analogous manner to the procedures described in B.3.2, C.3.2, D.3.2 or E.2.2, taking Table 5.19 into account. Wherever possible, the base material should be a high-temperature steel corresponding to the quality grade in question. 3.3 Depending on the welding process, the test specimens described in B.3.3, C.3.3, D.3.3 or E.2.3 shall be taken from the butt-welded test pieces, unless otherwise specified. 3.4 The mechanical characteristics of the welded joint must meet the requirements for the weld metal stated in Table 5.19; except in the case of the yield strength. The provisions of A.7.6, B.3.4, C.3.4, D.3.4 and E.2.4 apply in analogous manner to the performance of the tests and any retests which may be required. 4. Hydrogen test
Austenitic and austenitic-ferritic welding consumables and auxiliary materials for stainless steels, non-magnetic steels and nickel alloy steels tough at subzero temperatures General
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for welding of stainless (austenitic) steels and steel castings, plates clad with these materials and joints of these materials with unalloyed and low-alloy (hull) structural steels. They also apply to welding consumables and auxiliary materials for welding of non-magnetic steels, nickel alloy steels tough at subzero temperatures and other, similar steels. Austenitic welding consumables and auxiliary materials for clad welding and for joining difficult weldable (ferritic) materials are to be treated in analogous manner.
Notes: In (tanker) shipbuilding, the current practice is to use, in the main, the (austenitic or austenitic-ferritic) molybdenum alloy stainless steels listed in the three lefthand columns of Table 5.21. For equipment components, use is also made of, among others, steels of types 5CrNi18-10 (mat. no. 1.4301, AISI 304) and X6CrNiTi18-10 (mat. no. 1.4541, AISI 321). The following paragraphs therefore relate to welding consumables and auxiliary materials for these base materials including their joints with hull structural steels. Furthermore, the welding consumables and auxiliary materials for which the Society had already granted approval have also been included. Welding consumables and auxiliary materials for other base materials should, where applicable, be allocated to the appropriate categories and treated in analogous manner. Inert gases with 1 to 3 % of oxygen added or those with a maximum of 2,5 % CO2 added can be used as shielding gases for welding austenitic welding consumables in the range of application specified in 1.1. Those inert gases with a high level of nitrogen added can be used for steels which contain nitrogen. Gas mixtures of the type M 21 (cf. Table 5.8) with a maximum of 18 % of CO2 added may only be used with slag-forming flux-cored wire electrodes. Approvals for (flux-cored) wire-gas combinations are also granted accordingly.
If a hydrogen test is required, it shall be performed in accordance with B.4. The diffusible hydrogen content shall not exceed 10 ml per 100 g of deposited weld metal. 5. Testing for hot cracks
If testing for hot cracks is required, this shall be performed in accordance with B.5 or the relevant standards (e.g. DIN 50129).
6.
Annual repeat tests
6.1 The annual repeat tests specified in A.3.1 shall entail the preparation and testing of weld metal test pieces as prescribed under 2. The Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5). 6.2 The annual repeat tests shall be performed according to the prescribed scope for both the untreated condition and the various (approved) heattreated conditions (cf. 1.3).
1.2 Welding consumables and auxiliary materials for welded joints uniting (austenitic or austeniticferritic) stainless steels to one another are classified into the quality grades shown in Table 5.21 according to the chemical composition (material no.) and mechanical (strength) characteristics of the base materials to be welded. The testing and approval of a steel in the left-hand column of the table encompasses the
Chapter 1 Page 534
Section 5
II - Part 3 GL 2000
steel(s) in the right-hand column, subject to separate consideration of the corrosion conditions in each case. The table applies in analogous manner to the corresponding grades of forgings and steel castings. 1.3 Welding consumables and auxiliary materials for welding of non-magnetic stainless steels are approved according to a quality grade corresponding to the chemical composition (material no.) of the weld metal. Table 5.22 contains a number of examples. The testing and approval of a steel in the left-hand column encompasses the steel(s) in the right-hand column, subject to separate consideration of the corrosion conditions in each case. The table applies in analogous manner to the corresponding grades of forgings and steel castings. 1.4 Welding consumables and auxiliary materials for joining (austenitic or austenitic-ferritic) stainless steels to unalloyed or low-alloy steels, for intermediate runs in welding of clad plates and for clad welds are approved according to a quality grade corresponding to the chemical composition of the weld metal. Table 5.23 gives a number of examples. Approval is granted with due regard to the mechanical and other properties in relation to the base materials concerned and/or for a particular type of application for which suitability has been proved. 1.5 Austenitic welding consumables and auxiliary materials, including those made of nickel based alloys for welding of nickel steels tough at subzero temperatures are classified into quality grades as shown in Table 5.24 according to the chemical composition (material no.) and mechanical (strength and toughness) characteristics of the base materials to be welded. The testing and approval of a steel in the lefthand column encompasses the steel(s) in the righthand column. The table applies in analogous manner to the corresponding grades of forgings and steel castings. 2. Testing of the weld metal
according to the welding process). The base material used shall be a stainless steel of the same composition, or the side walls of the weld shall be buffered with a weld metal of such composition. 2.2 The chemical composition of the deposited weld metal shall be determined and certified in a manner analogous to that prescribed in B.2.2. As an alternative, the chemical composition may be determined in a manner analogous to DIN 8556, Part 2 by analysis of a build-up weld. The results of the analysis shall not exceed the limits specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case. For the welding consumables and auxiliary materials specified in Tables 5.23 and 5.24, the pitting resistance equivalent (% Cr + 3,3 % Mo) shall be at least 1 % higher than that of the base material on which the test was carried out resp. on which approval was based. The analysis of the weld metal and an average chemical composition determined from the data given in the standards shall be the determining factors in such a case. 2.3 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the test specimens shall be taken from the weld metal test pieces in a manner analogous to the provisions of B.2.3, C.2.3 or D.2.3. 2.4 The mechanical properties must meet the requirements stated in Table 5.25. The provisions of B.2.4, C.2.4 and D.2.4 apply in analogous manner to the performance of the tests and the carrying out of retests. For the welding consumables and auxiliary materials referred to in 1.4, the requirements depend on the particular application and are determined on a case-bycase basis. The notch impact energy values demonstrated during the test and also the test temperatures are indicated in the approval certificate. Welding consumables and auxiliary materials for joining stainless to normal-strength or higher-strength hull structural steels must, as a minimum requirement, meet the requirements relating to those for the latter. For the welding consumables and auxiliary materials referred to in 1.5, G.2.2 and Table 5.17 should also be noted.
2.1 For testing the deposited weld metal, test pieces analogous to those called for in B.2.1 (only one test piece welded in the down-hand position), C.2.1 or D.2.1 shall be prepared, depending on the nature of the welding consumables and auxiliary materials (and
Section 5
Chapter 1 Page 535
Austenitic welding consumables and auxiliary materials for welding of stainless steel
Testing and approval relating to steel Designation X5CrNi18-10 X2CrNi19-11 X2CrNi18-9 X2CrNiMo17-13-2 Mat. No./AISI 1.4301/304 1.4306/304 L 1.4307/304L 1.4404/316 L Steels also covered by the approval Designation X5CrNi 18-10 C2CrNi18-9 GX6CrNi18-9 X5CrNi18-10 X5CrNi18-10 X2CrNi19-11 GX6CrNi18-9 X5CrNiMo17-12-2 GX6CrNiMo18-9 X2CrNiN18-10 X5CrNiMo17-12-2 X2CrNiMo17-13-2 X2CrNiMoN17-12-2 GX6CrNiMo18-9 X2CrNiMo18-14-3 X5CrNiMo17-13-3 X6CrNiMoTi17-12-2 X10CrNiMoTi18-12 X6CrNiNoNb17-12-2 X10CrNiMoNb18-12 X5CrNi18-10 X2CrNi19-11 GX6CrNi18-9 X5CrNiMo17-12-2 X2CrNiMo17-13-2 GX6CrNiMo18-9 X5CrNiMo17-12-2 X2CrNiMo17-13-2 X2CrNiMo18-14-3 X5CrNiMo17-13-3 X2CrNiMoN17-12-2 X2CrNiMoN17-13-2 X2CrNiMo18-16-4 GX2CrNiMoN17-13-4 GX6CrNiMo17-13 X5CrNiMo17-13 X8CrNiMo27-5 X6CrNiMo24-8-2 X4CrNiMoNb25-7 X5CrNi18-10 X2CrNi19-11 GX6CrNi18-9 X6CrNiTi18-10 GX7CrNiNb18-9 X5CrNi18-10 X2CrNi19-11 GX6CrNi18-9 X5CrNiMo7-12-2 X2CrNiMo17-13-2 GX6CrNiMo18-9 X2CrNiMo18-14-3 X5CrNiMo17-13-3 X6CrNiTi18-10 X6CrNiNb18-10 GX7CrNiNb18-9 X10CrNiMoTi18-12 X6CrNiMoNb17-12-2 GX7CrNiMoNb18 -2 X10CrNiMoNb18-12 Mat. No./AISI 1.4301/304 1.4307/3047L 1.4308/ 1.4301/304 1.4301/304 1.4306/304 L 1.4308/ 1.4401/316 1.4408/ 1.4311/303 LN 1.4401/316 1.4404/316 L 1.4406/316 LN 1.4408/ 1.4435/316 L 1.4436/316 1.4571/316 Ti 1.4573/ 1.4580/316 Cb 1.4583/318 1.4301/304 1.4306/304 L 1.4308/ 1.4401/316 1.4404/316 L 1.4408/ 1.4401/316 1.4404/316 L 1.4435/316 L 1.4436/316 1.4406/316 LN 1.4429/316 LN 1.4438/317 L 1.4446/ 1.4448/ 1.4449/317 1.4460/329 1.4463/ 1.4582/329 1.4301/304 1.4306/304 L 1.4308/ 1.4541/321 1.4552/ 1.4301/304 1.4306/304 L 1.4308/ 1.4401/316 1.4404/316 1.4408/ 1.4435/316 L 1.4436/316 1.4541/321 1.4550/347 1.4552/ 1.4573/ 1.4580/316 Cb 1.4581/ 1.4583/318
Quality grade 4301 4306 4307 4404
4429
X2CrNiMoN17-13-3
1.4429/316 LN
4435
X2CrNiMo18-14-3
1.4435/316 L
4438
X2CrNiMo18-16-4
1.4438/317 L
4439
X3CrNiMoN17-13-5
1.4439/(317 LN)
4462
X2CrNiMoN22-5
1.4462/
4550
X6CrNiNb18-10
1.4550/347
4571
X6CrNiMoTi17-12-2
1.4571/316 Ti
Section 5
II - Part 3 GL 2000
Austenitic welding consumables and auxiliary materials for welding of non-magnetic stainless steels
Quality grade
Testing and approval relating to steel 1 Designation Mat. No.
Steels also covered by the approval 1 Designation X4CrNiMnMoN19-13-8 X2CrNiMoN22-15 X2CrNiMoN18-14-3 X2CrNiMo18-15 X2CrNiMnMoNNb21-15-7-3 X2CrNiMoN22-15 X2CrNiMoN18-14-3 X2CrNiMnMoNNb21-6-5-3 Mat. No. 1.3948 1.3951 1.3952 1.3953 1.3914 1.3951 1.3952 1.3964
3954
X2CrNiMnMoNNb21-16-5-3
1.3964
3984
1
X2CrNiMnMoNNb23-17-6-3
1.3974
Steels in accordance with the BWB Material Performance Sheets having the corresponding material number.
Table 5.23
Austenitic welding consumables and auxiliary materials for joining stainless steels to unalloyed or low-alloy steels, for intermediate runs and for clad welds (examples)
Welding consumable (weld metal) Designation 1 Mat. No./AWS Intermediate runs for welded joints between clad plates of similar composition. Welded joints between heat resistant CrNi steels, joints between stainless and unalloyed or low-alloy steels. Clad welds. Joints between stainless and unalloyed or low-allow steels. as for 4370 as for 4332
Quality grade
Usage (Instruction) 2
4332
E 23 12 nC X2CrNi24-12
(1.4332) / 1.4332 /
E 309 L E 309 L
4370 4431 4459

1 2
E 18 8 Mn 6 X15CrNiMn18-8 E 20 10 3 X12CrNiMo19-10 E 23 12 2 X8CrNiMo23-3
(1.4370) / 1.4370 / 1.4431 1.4431 / /
(E 307)
1.4459 / E 309 Mo (1.4459) / (E 309 Mo)
First line (E....): Designation for covered electrode, second line: designation for (flux-cored) wire gas and wire flux combinations The manufacturer's information given for the individual product are decisive abbr. information mentioned in the approval.
Section 5
Chapter 1 Page 537
Austenitic welding consumables and auxiliary materials for welding of nickel steels tough at subzero temperatures (examples)
Quality grade 5637 5680 5662
Testing and approval relating to steel 1 Designation 12Ni14 (3,5 % Ni) 12Ni19 (5 % Ni) X8Ni9 (9 % Ni) Mat. No. 1.5637 1.5680 1.5662
Steels also covered by the approval 1 Designation 12Ni14 (3,5 % Ni) Mat. No. 1.5637 1.5637 1......... 1.5680 1.5637 1......... 1.5680 1.5662
12Ni14 (3,5 % Ni) G9Ni14 (3,5 % Ni) 12Ni19 ( 5 % Ni 12Ni14 G9Ni14 12Ni19 X8Ni9 (3,5 % Ni) (3,5 % Ni) ( 5 % Ni) ( 9 % Ni)
5663
X7Ni9
(9 % Ni)
1.5663
Steels conforming to EN 10028-4.
Table 5.25
Required properties of the weld metal

Minimum 0,2 % proof stress [N/mm2] Tensile strength [N/mm2] 500 510 580 510 510 580 700 710 800 710 710 800 Minimum elongation [%] 30 30 30 30 30 30 25 30 30 30 22 20 18 18 Minimum notch Test temperature impact energy [J] 1 [C]
Quality grade
4306 4404 4429 4435 4438 4439 4462 4550 4571 3954 3984 5637 5680 5662 5663
1 2 3 4
195 205 295 205 205 295 480 205 225 430 510 355 390 490 5 585
47 (33)
+ 20 2
680 900 510 740 500 740 700 950 850 1050 490 640 530 840 640 5 840 680 820
35 (24) 47 (33) 70 (49)
30 + 20 2 + 20 95 3 196 3 110 ( 196) 3, 4 196 3
47 (33)
Means value of three specimens; for individual values ( ) and retests, see I.2.4. In the case of low-temperature applications, special requirements apply: cf. G. (Table 5.17 and G.2.2). Cf. G. (Table 5.17 and G.2.2). If quality grade 5680 (welding of 5 % nickel steel) is to be applied at a minimum design temperature of 165 C. The test temperature shall be 196 C. If the "as dilivered" condition (of the base material) is HT 640, this welding consumable shall also be approved for the as-delivered condition HT 680 of the base materials. In such a case the same minimum requriements as stated for quality grade 5663 shall apply.
Chapter 1 Page 538 3.
Section 5
II - Part 3 GL 2000
of the attack at the grain boundaries shall not exceed 0,05 mm. 4.2 In the case of special corrosion conditions or particular materials, the Society may stipulate other corrosion tests as an additional or alternative measure, e.g. testing of resistance to pitting under corrosive attack by chlorides, e.g. by seawater. 5. Testing for hot cracks
3.1 Depending on their nature (and on the welding process concerned), the testing on welded joints made with the welding consumables and auxiliary materials referred to in 1.2, 1.3 and 1.5 shall be performed on butt-weld test pieces analogous to those prescribed in B.3.1, C.3.1 or D.3.1. For the welding consumables and auxiliary materials covered by para. 1.4, testing of welded joints is required only if the products are used wholly or chiefly for making welded joints or where, in welded joints, they constitute a substantial proportion of the weld section (as in the case of the intermediate runs of welds joining clad plates). However, the Society may call for specimen welds to prove the satisfactory performance of these products in the various positions for which approval is solicited (see also A.6.). For welding consumables and auxiliary materials covered by 1.3 which are used exclusively for clad welding, the scope of the tests to be applied shall be determined on a case-by-case basis. 3.2 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the butt-weld test pieces called for in para. 3.1 shall be welded in a manner analogous to that prescribed in B.3.2, C.3.2 or D.3.2. The base material used shall be a steel of the same or similar composition in accordance with Tables 5.21, 5.22 and 5.24 and shall possess at least the mechanical properties indicated in Table 5.25. An analogous procedure shall be adopted in the case of the welding consumables and auxiliary materials covered by para. 1.4 and Table 5.25. 3.3 Depending on the nature of the welding consumables and auxiliary materials (and according to the welding process), the test specimens prescribed in B.3.3, C.3.3 or D.3.3 shall be taken from the buttwelded test pieces. 3.4 The mechanical properties must meet the requirements stated in Table 5.25. The Society may agree to the application in analogous manner of footnote 1 in Table 5.15 also for the austenitic welding consumables and auxiliary materials covered by this section. The provisions of A.7.6, B.3.4, C.3.4 and D.3.4 apply in analogous manner to the performance of the tests and the carrying out of retests. 4. Testing of resistance to intergranular corrosion
5.1 Testing for hot cracks is to be performed in analogous manner to the provisions of B.5. or DIN 50129 on the (shape 2) test piece prescribed for austenitic welding consumables and auxiliary materials. 5.2 Other methods of testing for hot cracks may be agreed with the Society. 6. Annual repeat tests
6.1 The annual repeat tests specified in A.3.1 shall entail the preparation and testing of weld metal test pieces as prescribed under 2. (determination of the mechanical properties and chemical composition of the weld metal). If the tensile strengths prescribed in Table 5.25 are not attained and footnote 1) in Table 5.15 applies analogously, the repeat test, too, shall include the testing of flat tensile specimens taken from the welded joints. 6.2 In special cases, the Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
J.
Welding Consumables and Auxiliary Materials for Aluminium Alloys General
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for the welding of aluminium alloys for structural components and equipment parts used in shipbuilding and mechanical engineering. Welding consumables and auxiliary materials for the welding of aluminium alloys for lowtemperature applications are dealt with separately, the requirements being specified on a case-by-case basis in accordance with the application conditions. Cf. G.
Note: In the present state of shipbuilding technology only the MIG and TIG inert gas welding methods using argon or helium or their mixtures and plasma arc welding are of practical significance. Because of their suitability for seawater applications, the wrought
4.1 Testing of resistance to intergranular corrosion (IC) shall be performed in accordance with DIN 50914 on test specimens with intersecting butt welds using the copper sulphate - sulphuric acid method (Strauss test). No cracks may be detected and the metallographically measured depth of penetration
II - Part 3 GL 2000
Section 5
Chapter 1 Page 539
alloys indicated in columns 2 and 3 of Table 5.26 are mainly used, cf. II - Rules for Materials, Part 1, Chapter 3, Section 1., A.4. Cast alloys are hardly ever used for load-bearing structural components in shipbuilding. The following paragraphs therefore relate chiefly to wire-gas combinations for the aforementioned wrought alloys. Other welding consumables and auxiliary materials or those for other base materials shall be treated in analogous manner. The requirements are determined by those applicable to the base materials being welded together and are specified on a case-by-case basis.
iary materials (wire (electrode) or filler rod shielding gas combinations) for the welding of aluminium alloys are classified into the quality grades shown in Table 5.26 on the basis of their chemical composition and mechanical (strength) properties. Testing and approval of the base material in the left-hand columns of the table also encompasses the base material(s) shown in the right-hand columns.
1.2 In accordance with European standards drafts existing up to now, welding consumables and auxil-
1.3 Approval is tied up with a specific shielding gas as prescribed in Table 5.27 or with a "special gas" which is defined separately according to its composition and purity. The composition of the shielding gas used in the test is to be recorded.
Table 5.26
Welding consumables for aluminium alloys
Quality grade
Testing and approval relating to the base material 1 Alloy No. Mat. Designation EN AW AlMg3 EN AW AlMg4
Base material alloys also covered by the approval Alloy No. EN AW-5754 EN AW-5754 EN AW-5086 EN AW 6005(A) EN AW 6061 EN AW 6082 EN AW-5754 6 EN AW-5086 6 EN AW-5083 6 EN AW 6005(A) 6 EN AW 6061 6 EN AW 6082 6 Mat. Designation EN AW AlMg3 EN AW AlMg3 EN AW AlMg4 EM AW AlSiMg(A) EN AW AlMgISiCu EN AW AlSilMgMn EN AW AlMg3 6 EN AW AlMg4 6 EN AE AlMg4,5Mn0,7 6 EN AW AlSiMg(A) 6 EN AW AlMglSiCu 6 EN AW AlSiMgMn 6
RAIMg3 RAlMg4
2 3
EN AW-5754 EN AW-5086
RAlMg4,5
EN AW-5083
EN AW AlMg4,5Mn0,7
RAlSi5
EN AW-6082
EN AW AlSilMgMn
RAlMg4,5mod. RAlMg5,5
1 2 3 4
EN AW-5383
AlMg4,5Mn0,7 mod AlMg5,5Mn0,8ZnZr
as for RAlMg4,5 as for RAlMg4,5
5 6
In respect to the bend test (see Table 5.28) it is recommended to carry out the test with base material in soft conditions e. g. welding consumables RAlMg3Mn0,4 / R5018 conforming to EN ......... (at the moment draft European Standard without no.) e. g. welding consumables RAlMg5 / R5119 conforming to EN ......... (at the moment draft European Standard without no.) e. g. welding consumables RAlMg4,5Mn0,7(A) / R5183 or RAlMg4,5MnZr / R5087 conforming to EN ......... (at the moment draft European Standard without no.) e. g. welding consumables RAlSi5(A) / R4043 conforming to EN ......... (at the moment draft European Standard without no.) In the case of less exacting strength requirements, the strength values established during the welding procedure tests shall apply for dimensioning purposes. The values given in Table 5.28 provide an indication.
Section 5
II - Part 3 GL 2000
Shielding gases for the welding of aluminimum alloys
Group I-1 I-2 I-3(1) I-3(2) I-3(3) S

1
Composition of shielding gas (Vol. %) 1 Argon 100 Remainder Remainder Remainder >0 Helium 100 to 33 2
3.2 Depending on the welding positions for which approval is solicited (cf. A.4.9), the butt-weld test pieces shown in Fig. 5.16 shall be welded in the positions indicated in Table 5.4, including as a minimum requirement the downhand PA (d) and verticalup PF (v-u) positions. The wire diameters shall conform to Table 5.9 and the welding parameters to the manufacturer's or supplier's recommendations. The composition of the shielding gas used for the test shall be stated in the report. For the welding of the test pieces, see also DIN 1732, Part 2. The root may be mechanically grooved and back welded. Post-weld heat treatment of the test piece (e.g. in the case of age-hardenable alloys) is only allowed if such heat treatment may and is to be carried out in the future production of welded components (cf. the preliminary remarks to Section 5). Where necessary, the heat treatment must be agreed prior to the test and is to be recorded in the test report. 3.3 Following the recommended radiographic examination, the following test specimens shall be taken from each butt-weld test piece in accordance with Fig. 5.16: four flat tensile test specimens conforming to EN 895/ISO 4136, four transverse bend test specimens (two FBB and two RBB) conforming to EN 910/ISO 5173 and a macrographic specimen. Of the four flat tensile specimens, two shall be tested with the weld reinforcement in place and two with the weld reinforcement machined off. Of the transverse bend tests (with the weld reinforcement machined off), two are to be tested with the cover pass in tension and two with the back pass in tension. 3.4 The mechanical characteristics must meet the requirements stated in Table 5.28. The provisions of A.7.6, B.3.4 and C.3.4 apply in analogous manner to the performance of the tests and the carrying out of retests. The position of the fractures is to be stated in the test report. With the transverse bend test specimens the bending elongation is to be determined. The macrographic specimen shall be examined for defects (such as lack of fusion, cavities, inclusions, pores and cracks). 3.5 Fillet-weld test pieces analogous to those called for in B.3.5 or C.3.5, as applicable, shall be provided for those welding consumables and auxiliary materials (wire-gas combinations) which are to be approved or used exclusively for the execution of fillet welds. In special cases, the Society may call for fillet-weld test pieces in addition to the butt-weld test pieces prescribed in para. 3.1.
> 33 to 66 2 > 66 to 95 2
"Special gas", Composition specified, cf. 1.3
The purity and other properties of the shielding gases must comply with EN 439/ISO 14175. Where argon (up to a max. 95 %) is replaced by helium and the helium content is marked by means of an added symbol, a gas with the following composition must be used for the test.: for (1) = > 0 to 33 % He: an argon-helium mixture containing approx. 15 % helium for (2) = > 33 to 66 % He: an argon-helium mixture containing approx. 50 % helium for (3) = > 66 to 95 % He: an argon-helium mixture containing approx. 75 % helium, Group I-2 is included in this case.
2.
Testing of the weld metal
2.1 Unless otherwise specified (e.g. testing the strength properties of the pure weld metal for the welding together of large wall thicknesses), the testing of the weld metal shall consist of an analysis of the deposited weld metal. 2.2 The chemical composition shall be determined and certified in a manner analogous to that prescribed in B.2.2 using a build-up weld in accordance with EN 26847/ISO6847. The results of the analysis shall not exceed the limits specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case. 3. Testing on welded joints
3.1 The testing on welded joints shall be performed in a manner analogous to that prescribed in para. B.3 resp. C.3, as applicable, on butt-weld test pieces conforming to Fig. 5.16. The base materials indicated in Table 5.26 shall be used. The plate thicknesses shall be 10 12 mm for MIG and plasma arc welding and 4 6 mm for TIG welding.
II - Part 3 GL 2000
Section 5
Chapter 1 Page 541
Z RB
B
FB
Z
B
RB
Z
10-12
FB
Z
B
70
FBB = Transverse bend test specimen, cover pass in tension RBB = Transverse bend test specimen, back pass in tension M = Macrographic specimen
250
Fig. 5.16 Butt-weld test piece
4.
Annual repeat tests
Note: According to the Society's Rules for Materials, besides copper and high-strength brass, the copper-nickel alloys CuNi10Fe1Mn and CuNi30Mn1Fe as well as certain cast copper alloys (used in the manufacture of propellers) are mainly used for welding purposes. In accordance with current approval practice, the following paragraphs therefore relate to welding consumables and auxiliary materials for these base materials; other such products for the welding of other cast alloys are to be treated in analogous manner.
4.1 The annual repeat tests called for in A.3.1 shall entail the preparation and testing of a butt-weld test piece in accordance with 3. welded in the downhand position with wire of 1,2 mm diameter. Half as many specimens may be used in the repeat tests as in the initial test (Fig. 5.16). 4.2 In special cases, the Society may require more extensive repeat tests (e.g. analysis of the weld metal as an additional measure) (cf. A.3.2, A.7.4 and A.7.5).
K.
Welding Consumables and Auxiliary Materials for Copper and Copper Alloys General
1.2 Welding consumables and auxiliary materials for welding of copper and copper alloys are classified into the quality grades shown in Table 5.29 on the basis of their chemical composition (type of alloy) and mechanical (strength) properties. Testing and approval in respect of a base material in the left-hand column of Table 5.29 also encompasses the base material(s) shown in the right-hand column. 2. Testing of the weld metal
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for the welding of copper and copper alloys conforming to the Society's Rules for Materials and used for structural components in shipbuilding (e.g. rudders) and especially for pipelines conveying seawater.
2.1 Unless otherwise stipulated, the testing of the weld metal shall consist of a chemical analysis of the deposited weld metal and a tensile test analogous to that described in B.2 (only one test piece to be welded in the down-hand position).
Section 5
II - Part 3 GL 2000
Requirements applicable to welded joints

Minimum tensile strength 1 [N/mm2] 190 240 275 160 290 300 6t 20 180 180 Diameter of mandrel (t = specimen thickness) 3t 180 or bending elongation achieved 3 Bending elongation 3 [%] 20 17 17 8 17 17
Quality grade
Minimum bending angle 2
RAlMg3 RAlMg4 RAlMg4,5 RAlSi5 RAlMg4,5Mnmod. RAlMg5,5

1 2 3
Using the base materials shown in Table 5.26, columns 2 and 3. Bending angle achieved before first incipient crack, minor pore exposures permitted up to a max. length of 3 mm. Where the bending angle is not achieved, the requirements shall still be regarded as having been met if the elongation achieved with a gauge length L0 = Ls + t before the first incipient crack meets the requirements (Ls = width of seam, t = thickness of specimen, see sketch below)
Note: Because of the different flow behaviour of the base material and the weld metal, incipient cracking of the specimens may occur prematurely - especially with too rapid deformation - when the free bending test according to DIN 50121, Part 1 is carried out. It is recommended that a test rig of the type shown in the following sketch be used in which the bending test specimen, clamped at one end, is "rolled" around the mandrel
Lf
1,5
0,7 d < Lf < 0,9 d
Section 5
Chapter 1 Page 543
Welding consumables and auxiliary materials for copper and copper alloys
Testing and approval related to Designation Mat. No. 2.0882 Materials also covered by the approval Designation CuNi5Fe CuNi10Fe1Mn CuNi20Fe CuNi5Fe CuNi10Fe1Mn CuNi20Fe CU1
1
Quality grade
Mat. No. 2.0872 2.0878 2.0872 2.0878
CuNi30Fe
CuNi30Mn1Fe
CuNi30Mn SCU1 1 SCU2

2
CuNi30Mn1Fe CU1 5 CU2

5
2.0822
SCU3 3
CU3 5
CU1 1 CU2 2 CU1 1 CU2 1 CU3 1
SCU4
1 2 3 4 5
CU4
e. g. Al-bronze or Mn-bronze e. g. Al-bronze or Ni-Mn-bronze e. g. Al-bronze, Ni-Al-bronze or Mn-Al-bronze e. g. Mn-Al-bronze Cast copper alloys (for propeller manufacture) in accordance with the Society's Rules for Materials or other comparable alloys with the appropriate strength properties.
2.2 The chemical composition shall be determined and certified in a manner analogous to that prescribed in B.2.2. The results of the analysis shall not exceed the limits specified in the standards (e.g. DIN 1733) or by the manufacturer, the narrower tolerances being applicable in each case.
4.
Annual repeat tests
4.1 The annual repeat tests called for in A.3.1 shall entail the preparation and testing of a butt-weld test piece in accordance with 3.1 welded in the downhand position as in the case of aluminium alloys (cf. J.4.1). Table 5.30 Required properties of welded joints
3.
3.1 The testing on welded joints shall be performed in a manner analogous to that prescribed in J.3. for welding consumables and auxiliary materials for aluminium alloys or, with the Society's consent, in accordance with the standards (e.g. DIN 1733, Part 2). 3.2 The mechanical properties must conform to the required properties of the base materials shown in Table 5.30. Different values for these properties are only permissible with the Society's consent and are to be taken into account where applicable when dimensioning the components.
Quality grade
Minimum 0,2 %proof stress [N/mm2] 120 120 175 195 245 275
Tensile Minimum strength elongation
[N/mm2] 360 490 360 490 370 min. 410 min. 500 min. 550 min.
[%] 30 30 20 18 16 18
CuNi30Fe CuNi30Mn SCU1 SCU2 SCU3 SCU4
Chapter 1 Page 544 L.
Section 5
II - Part 3 GL 2000
Welding Consumables and Auxiliary Materials for Nickel and Nickel Alloys General
welding process), the test specimens shall be taken from the weld metal test pieces in accordance with the standards and the provisions of B.2.3, C.2.3 and D.2.3. 2.4 The mechanical properties must meet the requirements stated in Table 5.32. For welding of nickel steels tough at subzero temperatures, the notch impact energy requirements stated in G.2.1 and G.2.2 apply. The provisions of A.7.6, B.2.4, C.2.4 and D.2.4 apply in analogous manner to the performance of the tests and any retests that may be necessary. 2.5 The Society may require other tests to be performed or stipulate other values for the required properties if they are more appropriate to the character of the welding consumables and auxiliary materials or are necessitated by the intended use of the material. 3. Testing on welded joints
1.
1.1 The following provisions apply to welding consumables and auxiliary materials for welding of nickel and nickel alloys.
Note: According to current approval practice, the welding consumables and auxiliary materials shown in the left-hand column of Table 5.31 are used. The following paragraphs therefore relate to welding consumables and auxiliary materials for these materials, but also cover such products for joining of different materials by welding (e.g. austenitic steels to ferritic/ perlitic steels) and especially for nickel steels tough at subzero temperatures.
1.2 Welding consumables and auxiliary materials for welding of nickel and nickel alloys, for joining of different materials by welding and for welding of nickel steels tough at subzero temperatures are classified according to their chemical composition (type of alloy) and mechanical properties (mechanical and tensile strength) into the quality grades shown in Table 5.31. The testing and approval of a base material in the left-hand columns of Table 5.31 encompasses the material(s) in the right-hand columns. Suitability for welding of the nickel steels tough at subzero temperatures in low-temperature applications is indicated separately in the approval certificate; cf. G. 2. Testing of the weld metal
3.1 Depending on the nature of the welding consumables and auxiliary materials (and on the welding process concerned), the tests are to be performed on butt-weld test pieces in a manner analogous to B.3., C.3., or D.3 3.2 The butt-weld test pieces shall be welded in accordance with B.3.2, C.3.2 or D.3.2, taking into account the provisions of the above-mentioned standards (cf. 2.1). Wherever possible, the base materials shall be the materials to be welded in the future application; in any case, however, materials of adequate strength must be used. 3.3 Unless otherwise stipulated, the test specimens prescribed in B.3.3, C.3.3 and D.3.3 for the various types of welding consumables and auxiliary materials (and, where applicable, the various welding processes) shall be taken from the butt-weld test pieces. 3.4 The mechanical properties must meet the requirements stated in 2.4 and Table 5.32, with the exception of the proof stresses. The Society may stipulate other values for the required properties; cf. 2.4. 4. Annual repeat tests
2.1 For testing the deposited weld metal, the test pieces described in the standards (e.g. DIN 1736, Part 2 and DIN 32525) shall be prepared according to the provisions of B.2., C.2., and D.2. The provisions of the standards with regard to the base materials to be used, including, where applicable, the buffering of the side walls of the weld, and to the welding parameters shall be complied with. 2.2 The chemical composition of the deposited weld metal shall be determined and certified in a manner analogous to the provisions of B.2.2, taking into account the provisions of the standards. The results of the analysis shall not exceed the limits specified in the standards or by the manufacturer, the narrower tolerances being applicable in each case. 2.3 Depending on the nature of the welding consumables and auxiliary materials (and according to the
4.1 The annual repeat test specified in A.3.1 shall entail the preparation and testing of a weld metal test piece in accordance with 2. The Society may require more extensive repeat tests (cf. A.3.2, A.7.4 and A.7.5).
Section 5
Chapter 1 Page 545
Welding consumables and auxiliary material for nickel and nickel alloys
Quality grade
Testing and approval relating to Designation Mat. No.
Materials also covered by the approval Designation Ni99,2 Ni99,6 LCNi99,6 LCNi99 Mat.-No. 2.4066 2.4056 2.4061 2.4068
NiTi3 (2.4156)
Ni 99,6
2.4060
and joints between different non-ferrous metal alloys and with steels NiTi4 (2.4155) Ni 99,6 2.4060 NiCr15Fe LC-NiCr15Fe NiCr20Ti NiCr20TiAl NiCr23Fe as for NiTi3 2.4816 2.4817 2.4951 2.4952 2.4851
NiCr19Nb (2.4648)
NiCr15Fe
2.4816
and welded joints between different nickel alloys (except for NiCu) and with steels; welded joints in nickel steels tough at subzero temperatures. NiCr20Nb (2.4806) NiCr16FeMn (2.4620) NiCr15Fe NiCr15Fe 2.4816 2.4816 as for NiCr19Nb as for NiCr19Nb NiCr21Mo NiCr22Mo6Cu NiCr22Mo7Cu NiCr21Mo6Cu 2.4858 2.4618 2.4619 2.4641
NiCr20Mo9Nb (2.4621)
NiCr22Mo9Nb
2.4856
nickel steels tough at subzero temperatures NiCr21Mo9Nb (2.4831) NiCu30Mn (2.4366) NiCu30MnTi (2.4377) NiCr22Mo9Nb NiCu30Fe NiCu30Fe 2.4856 2.4360 2.4360 as for NiCr 20 Mo 9 Nb Joints with dissimilar materials, namely with unalloyed structural steels to EN 10025 and boiler steels to DIN 17155
Section 5
II - Part 3 GL 2000
Required properties of the weld metal 1

Proof stresses Tensile strength Rm [N/mm2] min 410 600 600 700 460 25 Elongation A5 [%] min
Quality grade
Rp 0,2 [N/mm2] min 200 360 360 420 200
Rp 1,0 [N/mm2] min 220 380 380 440 220
NiTi3 NiTi4 NiCr19Nb NiCr20Nb NiCr16FeMn NiCr20Mo9Nb NiCr21Mo9Nb NiCu30Mn NiCu30MnTi

1
The notch impact energy stated in 2.4 and, where applicable, G.2.1 and G.2.2.
II - Part 3 GL 2000
Section 6
Overweldable Shop Primers
Chapter 1 Page 61
Section 6 Overweldable Shop Primers

A. General 1. Overweldable shop primers applied to plates, sections, etc. before welding shall not significantly impair the quality of welded joints. Note: Research and practical experience hitherto indicate that the characteristics of welded joints suffer practically no deleterious effects apart from an increased tendency towards porosity in fillet welds. Tests, approvals and supervisory measures are therefore exclusively concerned with this increased tendency towards porosity. 2. Only those overweldable shop primers may be used for which the Society has issued a confirmation of acceptability based on a porosity test relating to overwelding. 3. The requirements relating to shop primers in respect of corrosion protection are covered in the Rules for Classification and Construction, I Ship Technology, Part 1, Chapter 1, Section 35. 4. Even where a confirmation of acceptability has been issued, overweldable shop primers may only be approved for fully mechanized double fillet welding after a special welding procedure test in the user's works. Characteristic pigment base Characteristic binding agent base Data sheet with instructions for use (preparation of surface, methods of application, dry coat thickness, etc.) Documentation relating to previous tests, approvals, etc. Place and date of proposed tests.
1.2 The Society reserves the right to carry out an inspection of the manufacturers work. To this end, the Societys Surveyor shall be granted access to all production and test departments and laboratories. An explanation of the production conditions is to be given to the Surveyor and particularly satisfactory quality assurance measures demonstrated. 1.3 The porosity tests shall be performed by neutral, properly equipped testing authorities recognised by the Society for that purpose or by a suitable test laboratory under the supervision of a Society Surveyor. 1.4 The test is to be performed in accordance with the March 1976 edition of the German Welding Society guideline DVS 0501 "Porosity test relating to the overwelding of shop primers on steel". 1.5 The identity of the coating material submitted for testing shall be established and recorded in the test report. This may be done by, for instance, stating the batch/production number and date of manufacture. In case of doubt, the Society may require a test (e.g. of the chemical composition) to verify the identity of the sample. 1.6 The mean total pore area to be determined in accordance with regulation DVS 0501 shall not exceed 150 mm. Note: The standardized testing of shop primers as prescribed in regulation DVS 0501 leads to heavy porosity not normal in ordinary practice. Together with the number of pores and the mean individual pore area, the mean total pore area has proved to be the most serviceable criterion for the comparative assessment of shop primers, although it does not permit any direct inferences about the degree of porosity to be expected under the particular production conditions applicable.
B. 1.
Testing and Approval of Shop Primers Initial confirmation of acceptance
1.1 Application for a confirmation of acceptability shall be made, unaccompanied by any forms, to the Society's head office together with the following information and supporting documents: Manufacturer (and licensor, where applicable) Brand name (and licensor's brand name, where applicable) together with the original brand name in the case of commercial designations used for marketing Code number / short name / symbol identifying the formulation or product
Chapter 1 Page 62
Section 6
II - Part 3 GL 2000
1.7 The Societys Head Office issues a confirmation of acceptability based on the tests performed and the records relating to these which must be submitted, and also based on the inspection of the manufacturers work where applicable and adopts the shop primer in the list of approved welding consumables. 1.8 The confirmation of acceptability relates to the particular product tested (brand name, formulation, identification number etc.) from a specific manufacturer (production site). It does not relate to any other products or to products from another production process. For information on transferring approval documents, cf. 2. 1.9 With the issue by the Society of a confirmation of acceptability, the manufacturer (or, where applicable, the marketing company) assumes responsibility for ensuring that the composition and characteristics of the shop primer remain constant (cf. Section 1, F.1.). Any modifications shall automatically be drawn to the Society's attention and shall normally necessitate a new test in accordance with para. 1.4. 2. Transferring approval documents
3.2 Proof that regular identity validation checks have been made must be furnished by the manufacturer. The requirement for product validation checks may be satisfied by the submission of the manufacturers quality inspection records and confirmation of outside supervision from a testing authority recognised by the Society for that purpose. 3.3 The Society may demand a repeat test as specified in 1.3 to 1.5 in doubtful cases or where changes have been made to the product or the manufacturing conditions themselves have been altered.
C.
Supervising the Use of Shop Primers, Production Tests
1. By suitable checks carried out in the course of normal production (e.g. measurements of coat thickness, production tests), workshops using shop primers shall ensure that the conditions of use on which the confirmation of acceptability was based are adhered to and that, in fillet welding, no excessive pore formation occurs which adversely affects the application. Note: The pores in fillet welds due to overweldable shop primers occur mainly as strings of pores made up of round or elongated individual pores. They originate at the gap between the web plate and the plating or flange, to which they are usually joined, and seldom extend to the surface. They can therefore practically only be detected by non-destructive or destructive inspection methods. 2. Production tests are to be performed under the Society's supervision on a random basis during normal fabrication, as a supplementary test when a transfer of approval is sought, when a shop primer is changed or when the conditions of use are altered. The Society may demand production tests in doubtful cases. The conditions in which the production test pieces are welded shall be the same as those prevailing in normal fabrication. Fabrication off-cuts may be used as production specimens. 3. T-joints as shown in Fig. 6.1 shall be produced as part of the production test. To facilitate the breaking open of the two welds (if possible, on the bisector of the angle made by the web plate and the plating or flange), the test piece shall be grooved in the manner shown in Fig. 6.1 and shall be divided into test sections each 100 mm long. Alternatively, fillet weld (cruciform) test pieces may be welded in accordance with Chapter 3, Section 1, F.3.2 (Fig. 1.1) and tested in accordance with F.4.5.
2.1 In the case of products which have a different brand name but an identical formulation/identification no. or another manufacturers products (a different production site) with the same brand name, formulation/identification no. etc., the Society may agree to transfer the approval documents for products for which a confirmation of acceptability has already been issued without necessitating a retest of the product as specified in 1.3 and 1.4. 2.2 The information and documentation specified in 1.1 and also a statement of conformity from both manufacturers, together with documentary proof of the identity of the product for which the first confirmation of acceptability was issued and that to which the approval document is to be transferred, must be submitted to the Society with the simple application for the transfer of approval documents. 2.3 Where an approval document is to be transferred to a product from another manufacturer, the Society may also carry out an inspection of the manufacturers work at this other production site in accordance with B.1.2. The Society may also require production tests to be performed in accordance with C. 3. Validity, Extensions to Validity
3.1 Approvals (initial and transferred) are valid for 3 years. On application by the manufacturer they may be extended by a further 3 years at a time. In the application, the manufacturer shall confirm in writing that no changes have been made to the product since the initial approval was granted.
II - Part 3 GL 2000
Section 6
Chapter 1 Page 63
test sections 2nd weld 1st weld
length shall be established and the individual pore areas shall be measured (e.g. as ellipses with the length and breadth of the pore providing the main axes). Pores whose largest main axis is less than 0.5 mm are ignored. 5. The number of pores and individual pore areas are used to calculate the total pore area and this is then related to the area of the weld fracture. The percentage pore area arrived at in this way shall be stated in the test report. The test report shall also state the shop primer material, the coat thickness and the welding parameters. Note: In DASt regulation 006 "Overwelding of shop primers in structural steelwork" issued by the Deutscher Ausschuss fr Stahlbau (German Committee for Structural Steelwork), the maximum permissible relative pore areas are specified as 4 % for dynamic loading and 7 % for static loading. (Positive) Experience to date shows that these figures are "on the safe side". In shipbuilding, somewhat higher figures may be acceptable.
12 - 20
0 - 0,5
6 100
10 60
30
Fig. 6.1 Double fillet weld production test piece 4. The production test piece shall be broken open for assessment. The fracture surfaces of the weld revealing the largest number of pores shall be assessed. The number of pores over a 100 mm weld
50
00 40 1
II - Part 3 GL 2000
Annex A
Chapter 1 Page A1
Annex A Application for Approval
Application for Approval in accordance with the Rules for Welding

We, COMPANY: ADDRESS: hereby make application for approval by Germanischer Lloyd for the welding shop for the welding consumables and auxiliary materials for the welding shop named in the attached description or the products specified in the Annexes, as applicable. The applicant accepts the following conditions: The Rules for Classification and Construction (particularly, in this instance, the Rules for Welding) issued by Germanischer Lloyd (The Society) in the version applicable at the time application is made. The applicant will ensure that all the information required for the approval, and specified in the rules is provided and documents, test results etc. are submitted as applicable and that access to all the relevant workshops and production areas is at all times allowed to the Society's Surveyor to enable him to carry out his inspection functions. In the absence of any written arrangements to the contrary, fees will be calculated based on the Society's rate of charges at the time approval is granted. Fees are payable even if approval fails to be granted due to unsatisfactory test results. Any withdrawal of this application for approval requires notice in writing and will be subject to a charge in line with the scope of services provided at the time of notification of withdrawal. The documents marked with a cross the attached list (Annex to this Annex A of the Rules for Welding) are enclosed with the application for approval of the welding shop; the documents stipulated in the Rules for Welding, Chapter 1, Section 5, A.1.6 are enclosed with the application for approval of the welding consumables and auxiliary materials.
Place
Date
Applicant
Chapter 1 Page A2
Annex A
II - Part 3 GL 2000
Annex to the Application for Welding Approval

List of documents to be submitted or enclosed with the application for approval
Nature of the approval sought: 1. Application from welding shop 2. Description of welding shop in accordance with Annex B, together with Annexes 3. "Range of application" annex(es) to description of welding shop 4. Proof of qualification for welding supervisor 5. Proof of qualifications for deputy welding supervisor 6. Welder qualification test certificates (or list of valid welder qualification tests verified by Surveyor) 7. Descriptions of welding procedures (WPS) 8. Standard submerged-arc welding procedure test record 9. Records of welding procedure tests 10. Records of production tests performed 11. Documents/information on inspection (supervisory) personnel 12. Other available documentary proof, approvals etc. 13. Other (e.g. proof of compliance with the quality requirements conforming to EN 729/ISO 3834)
Approval Approval for welding Extension for welding Extension shop procedure
1)
1)
1) 1)
1) 1) 1) 2) 3) 2) 3) 1) 2)
1)
2)
1) 1)
( )
( )
For Society use only: Surveyor's report following inspection of welding shop Statement of fees
1) Only if changes have been made since the first approval. 2) If stipulated for certain ranges of application e.g. steam boiler and pressure vessel construction. 3) If tests which have already been performed elsewhere are to be used as a basis for approval.
II - Part 3 GL 2000
Annex B
Chapter 1 Page B1
Annex B Description of Welding Shop

Description of Welding Shop for Approval for Welding
Company: Full address: Work/work's division: Full address: Telephone no.: Fax-Nr.: Telex no.: E-mail address:
Manager (name) responsible for the works/work's division: Work's authority (name) (for container repair works only): Number of employees (total): of which welders/operators:
Approval sought for the range of application: Welding of hull structures Welding of steam boilers Welding of pressure vessels Welding of pipelines Welding of machinery components Welding of containers (including repairs) Welding of .................................................
Past activities in the range of application for which application is made (welding production schedule; components, materials, welding process etc. Where applicable attach separate reference list):
1.
Workshop facilities 1)
1.1 Assembly/welding shops and covered assembly bays (number and size):
1.2 Storage facilities for materials and welding consumables (description, e.g. open/covered/heated storage):
________________________
1) Summary, for general information about the work's production capabilities. Alternative or additionally add brochure, leaflet etc.
Chapter 1 Page B2
Annex B
II - Part 3 GL 2000
1.3
Lifting gear (lifting capacity, lifting height):
1.4
Machining equipment and tools:
1.5
Welding and cutting equipment, machines and plant:
1.6
Baking ovens and heatable containers for welding consumables (type, number, maximum temperature):
1.7
Welding jigs (e.g. turntables, manipulators):
1.8
Equipment for preheating, post-weld heat treatment and temperature measurement:
1.9
Available test equipment and test media (for destructive and non-destructive testing, container test bed etc.):
1.10 Other information (e.g. flame descaling/priming facilities):
II - Part 3 GL 2000
Annex B
Chapter 1 Page B3
2.
Scope of approval sought (classification of materials, welding processes [details in accordance with EN 24063/ISO 4063], welding consumables and auxiliary materials etc. If necessary continue on separate sheets): Components: Weld factor 1): Material(s): Plate/wall thicknesses; pipe diameters: Types of weld, weld forms: WPS No.: Welding process: Welding position(s): Welding consumables and auxiliary materials: Heat treatment 2): Other:
1) 2) Where applicable, e.g. for pressure vessels Where applicable, e.g. stress-relief annealing
3. 3.1
Welding Personnel Welding Supervisor(s) (surname(s) and first name(s)): Welding qualifications 1) given as: Date: Area of responsibility: Reporting to (relationship): Place:
3.2
Deputy welding supervisor(s) (surname(s) and first name(s))): Welding qualifications 1) given as: Date: Area of responsibility: Reporting to (relationship): Place:
________________________
1) Vocational training and employment are listed in tabular form and enclosed; copies of certificates are attached.
Chapter 1 Page B4
Annex B
II - Part 3 GL 2000
3.3
Welders/operators (if necessary, continue on separate sheet):

Surname, first name Test basis (Rules, standard etc.) Test designation (e.g. conforming to EN 287/ISO 9606) Initial test date testing body Last repeat test date testing body
No.:
3.4
In-house training for welders:
yes
no
3)
4.
Inspection supervisors and inspection personnel 4):
5.
Existing recognitions, verifications, confirmations, aptitude certificates, certificates, awards, approvals, etc.:
Welding supervisor(s)
Place
Date
Company stamp / signature
Annex(es):
________________________
3) 4) Tick as applicable Proof of qualification attached
II - Part 3 GL 2000
Annex C
Assessment Form for Welder Qualification Test Certification
Chapter 1 Page C1
Annex C Assessment Form for Welder Qualification Test Certification

Schweierprfung nach GL-Schweivorschriften / ISO 9606 / DIN EN 287 Welder's qualification test according to the GL-Rules for Welding / ISO 9606 / DIN EN 287
Hersteller-Schweianweisung (WPS):
Manufacturer's Welding Procedure Specification:
Beleg-Nr. (falls verfgbar)

Reference No. (if applicable) Testgroup:
Schweierprfung in der Prfgruppe: Name:

Name:
Vorname:
Firstname:
Geburtsdatum:
Date of birth:
Geburtsort:
Place of birth:
Legitimation:
Test by order of:
Method of the identification:
Art:
Kind:
Prfung im Auftrag von: Prfstck

Test piece Schweiverfahren Welding process Blech / Rohr Plate / Tube Nahtart Joint type Werkstoffgruppe Material group Zusatzwerkstoff Filler metal type Schutzgas Shielding gas Hilfsstoffe Auxiliaries Prfstckdicke (mm) Test piece thickness Rohrauendurchmesser (mm) Pipe outside diameter Schweiposition Welding posotion Badsicherung / Ausfugen Backing / Gouging /
durchgefhrt am:
carried out on:
Prfdaten
Weld test details
Weitere Informationen zu Werkstoff, Zusatzwerkstoff, Schutzgas usw.

Other information to material, filler metal, shielding gas etc.
Bewertung der Prfstcke Evaluation of the test pieces nach / to DIN EN 25817 / ISO 5817 (Stahl / Steel) DIN EN 30042 / ISO 10042 (Aluminium / Aluminium) Prfung
Material test Durchstrahlung Radiography Sichtprfung Visual test Magnetpulverprfung Magnetic particle test Farbeindringprfung Penetrant test Makroschliff Macro Bruchprfung Fracture test Folgende zustzlichen Regelwerke wurden bercksichtigt (TRD, AD-Merkbltter, usw.): Follow additional rules were considered (TRD, AD-leaflet, etc.): Unterschrift / Signature
Prfung
Material test Biegeprfung Bend test Kehlnaht (a) Fillet weld (a) Zustzliche Prfung Additional test Fachkunde Job knowledge
Ort / Place
Datum / Date
Unterschrift / Signature
II - Part 3 GL 2000
Annex D
Welding Procedure
Chapter 1 Page D1
Annex D Welding Procedure

I. Manufacturer's Welding Procedure Specification (WPS)
Company: Full address: Works/work's division: Full address: Telephone No.: Fax No.: Telex: E-mail address: Responsible welding supervisor: Welding Procedure Specification (WPS) No.: Test report (WPAR) No.: Welding Process: Joint type: Welding position(s): Joint preparation details (sketch): Joint design Welding sequences Method of preparation and cleaning: Parent material(s) specification: Material thickness [mm]: Outside diameter [mm]:
Welding details:
Run Process Size of filler metal Current [A] Voltage [V] Type of current/ polarity Wire feed speed Travel speed* Heat input * [cm/min] [J/cm]
Filler metal classification: Brand name: Manufacturer: Any special baking or drying: Gas / flux: shielding: backing: Brand name: Manufacturer: flux: backing: Gas flow rate shielding: backing: Tungsten electrode type/diameter: Gouging/backing: Preheating temperature: Interpass temperature:
Post-weld heat treatment and/or ageing *: Time, temperature, method: Heating and cooling rate: Other information *, e.g.: Weaving (max. width of run): Oscillation: amplitude, frequency, dwell time: Pulse welding details: Stand-off distance: Plasma welding details: Torch angle: Welding over shop primer *: Brand name: Other:
Manufacturer's welding supervisor

(Name, date signature) * If required
Chapter 1 Page D2
Annex D
Welding Procedure
II - Part 3 GL 2000
II.
Welding procedure test / production test details relating to specimen welds

Test report (WPAR) Nr.: Welding Procedure Specification (WPS) No.:
Company: Location (of specimen welding), works/works division: Welding supervisor: Welder's name: Date of test: Examiner or test body: Welding Process: Welding position(s): Joint preparation details (sketch): Joint design
Parent material(s) specification: Material thickness [mm]: Outside diameter [mm]: Joint type: Method of preparation and cleaning:
Welding sequences
Welding details:
Run Process Size of filler metal Current [A] Voltage [V] Type of current/ polarity Wire feed speed Travel speed* Heat input * [cm/min] [J/cm]
Filler metal classification: Brand name: Manufacturer: Any special baking or drying: Gas / flux: shielding: backing: Brand name: Manufacturer: flux: backing: Gas flow rate shielding: backing: Tungsten electrode type/diameter: Gouging/backing: Preheating temperature: Interpass temperature:
Post-weld heat treatment and/or ageing*: Time, temperature, method: Heating and cooling rate: Other information*, e.g.: Weaving (max. width of run): Oscillation: amplitude, frequency, dwell time: Pulse welding details: Stand-off distance: Plasma welding details: Torch angle: Shop primer*: Other:
We hereby confirm that the specimen welds have been prepared and performed satisfactorily using the data listed above, in accordance with the Rules for Welding issued by Germanischer Lloyd.
Welding supervisor
(Name, date signature)
Society's Surveyor
(Name, date, signature)
* If required
II - Part 3 GL 2000
Annex D
Welding Procedure
Chapter 1 Page D3
III.
Welding procedure test / production test test results

Test report (WPAR) No.: Welding Procedure Specification (WPS) No.:
Company: Examiner or test body:
Non-destructive testing Test method Visual inspection: Radiographic test: Ultrasonic test: Magnetic particle test: Dye penetrant test: -test: Results Test report no.
Tensile tests
Specimen Form/No.: Dimensions [mm] Requirements Crosssection [mm2] Yield or Test load 0,2 % proof Fr stress [N] [N/mm2] Breaking load Fm [N] Tensile strength Rm [N/mm2] Elongation [%] Reduction in area [%] Position of fracture, Remarks
Bend tests Specimen, From/No. Requirements Dimension [mm] Bending mandrel diameter [mm] Bending angle [degrees] Elongation on bending (L0 = .......... mm) [%] Results, Remarks
Notched bar impact test: Specimen, No., Position of notch: Requirements Test temperature [C] 1
Shape of specimens: Individual values [J] 2 3 min min Average value [J]
Sizes: Remarks:
Chapter 1 Page D4
Annex D
Welding Procedure
II - Part 3 GL 2000
Hardness tests
Type, test load: Position of measurement (sketch/diagram)
Base material
HAZ/ Transition zone
Weld metal
Transition zone/HAZ
Base material
Fracture tests: Position of fracture:
butt weld
fillet weld
Results:
Metallographic examinations: Results (if necessary attach photographs/explanations on a separate sheet):
Other tests: Type:
Results:
The trial welds were made and the tests performed in accordance with the requirements of the Rules for Welding issued by Germanischer Lloyd and also the following Rules:
The results meet the requirements
The results do not meet the requirements
Welding supervisor
(Name, date signature)
Examiner or test body

Society's Surveyor
II - Part 3 GL 2000
Annex E
Chapter 1 Page E1
Annex E Welding Consumables and Auxiliary Materials

Information for approval purposes Annex to the Application in accordance with Annex A
Electrode/Wire Manufacturer Supplier Distributor Licenses (where applicable):
Company name, full address: Full address: Telephone No.: Fax No.: E-mail address:
Address for approval certification: Contact / Department: Flux/shielding gas Manufacturer Supplier Distributor Licenses (where applicable):
Company name, full address: Telephone No.: Fax No.: E-mail address:
Address for approval certification: Contact / Department: Details relating to consumable/auxiliary material: Type of consumable/auxiliary material: Filler wire Welding rod Covered electrode Flux-cored wire Other (describe) Brand designation of welding consumable ((flux-cored) wire, electrode, etc.): Brand designation of auxiliary material (shielding gas, flux, etc.): Classification to standards (DIN, EN, ISO etc.): Intended scope of approval / range of application: Quality grade for which application is made and added symbol: Base materials to be joined by welding: Welding positions for which approval is sought: Dimensions for which approval is sought (diameters, lengths of products): Welding current, polarity: (Post-weld) heat treatment conditions: Special application conditions (e.g. minimum or maximum application temperature): Rules for Application (e.g. re-baking, post-weld heat treatment): Marking, Packing: Other information, attached documents. Preconditions for awarting the ""-symbol for the construction supervision field also checked? Verifications of identity ("Affidavits") for transfers of approval attached? Approval test programme attached? Approval test records attached? yes yes yes yes no no no no Solid wire-gas combination Flux-cored wire-gas combination Solid-wire flux combination Flux-cored wire-flux combination
II
3

Welding
Design, Fabrication and Inspection of Welded Joints
Edition 2000
II - Part 3 GL 2000
Table of Contents
Chapter 2 Page 3
Table of Contents
General Design Principles General ....................................................................................................................................... Information Contained in Manufacturing Documents ................................................................ Materials, Weldability ................................................................................................................ Design Details ............................................................................................................................ Dimensioning of Welded Joints ................................................................................................. 111111 1 2 2 4
Section 2 A. B. C. D. E. F. G.
Execution of Welds General ....................................................................................................................................... Weld Preparation, Assembly ...................................................................................................... Weather Protection, Preheating ................................................................................................. Welding Positions, Welding Sequence ....................................................................................... Performance of Welding ............................................................................................................ Straightening, Tolerances ........................................................................................................... Post-Weld-Treatment of Welds .................................................................................................. 22222221 2 2 3 3 3 4
Heat Treatment Scope .......................................................................................................................................... Equipment and Appliances for Heat Treatment ......................................................................... Principles Relating to Heat Treatment ....................................................................................... Weather Protection, Preheating, Heat Input during Welding ..................................................... Post-Weld Heat Treatment ......................................................................................................... 333331 1 1 2 7
Section 4 A. B. C. D. E. F. G. H. I. J. K. L. M. N.
Non-destructive Testing of Welds General ....................................................................................................................................... Test Methods, Appliances and Test Media ................................................................................ Inspection Personnel, Supervisors .............................................................................................. Inspection Schedule, Inspection Reports .................................................................................... Timing of Inspection, Waiting Times ......................................................................................... Preparation and Performance of Tests ........................................................................................ Evaluation of Test Results .......................................................................................................... Extension of the Scope of Inspection ......................................................................................... Repairs, Re-inspection ............................................................................................................... Visual Inspection ........................................................................................................................ Radiographic Inspection ............................................................................................................. Ultrasonic Inspection .................................................................................................................. Magnetic Particle Inspection ...................................................................................................... Liquid Penetrant Inspection ........................................................................................................ 4- 1 4- 1 4- 2 4- 2 4- 3 4- 3 4- 4 4- 4 4- 4 4- 6 4- 7 4- 8 4- 13 4- 14
Chapter 2 Page 4
Table of Contents
II - Part 3 GL 2000
Mechanical and Technological Tests Scope .......................................................................................................................................... Preparation of Specimens and Testing ........................................................................................ Tensile Tests ............................................................................................................................... Bend Tests .................................................................................................................................. Notched Bar Impact Tests (EN 1d5/DIN 50115) ....................................................................... Hardness Testing of Welds (DIN 50163, Part 1) ........................................................................ Metallographic Inspections ......................................................................................................... Inspection reports ........................................................................................................................ 555555551 1 2 3 5 6 6 7
Annex A
Imperfections in Welded Joints in Steel
Annex B
Imperfections in Welded Joints in Aluminium
Annex C
Comparison of Equivalent, Internationally Recognized Film System Classes
II - Part 3 GL 2000
Section 1
General Design Principles
Chapter 2 Page 11
Section 1 General Design Principles

A. 1. General Scope joints and necessary for inspection by the Society. Besides the materials and weld shapes, this comprises the following information: 2. Supplementary Rules B. Information Contained in Manufacturing Documents Joint/weld shapes, symbols The designing and dimensioning of welded joints in the various ranges of application is additionally governed by the component-specific requirements stated in the various sections of Chapter 3 and in the respective Rules for Construction of Germanischer Lloyd. Method of weld preparation (mechanical, thermal, etc.) Welding process, welding positions Welding consumables and auxiliary materials Preheating and, where applicable, heat input during welding Weld build-up and number of passes Welding sequence (in special cases) Grooving of root (method) Post-weld (heat) treatments, if any Number and location of any production specimens to be welded at the same time (where stipulated).
These Rules contain universal principles applicable to the designing and dimensioning of welded joints, and to the information contained in the manufacturing documents.
1.
1.1 The depiction of welded joints and also the shapes of joints and welds shall conform to the standards (e.g. EN 12345/ISO .., EN 22553/ISO 2553 or EN 29692/ISO 9692). They shall be identified in the manufacturing documents (drawings, etc.) in an unambiguous manner, e.g. by means of the standard symbols. 1.2 Non-standard weld shapes or symbols shall be illustrated and, where applicable, explained in detail in the manufacturing documents (drawings, welding schedules or specifications). They must be approved by the Society (e.g. in conjunction with the inspection of drawings or a welding procedure test). 1.3 A weld shape appropriate to, and adequately dimensioned or well designed for the nature (static or dynamic) and magnitude of the forces to be transmitted shall be chosen. Where necessary, documentary proof of the design calculations shall be submitted (cf. the supplementary Rules mentioned in A.2.). 2. Information on fabrication
With regard to the information on the requirements applicable to the welded joints and their inspection, see 3. 2.2 If the preparation and execution of the welds (in conjunction with approved welding procedures, welding consumables and auxiliary materials) conform to normal welding and shipbuilding practice as well as to these Rules and the recognized standards, the Society may waive the requirement that they be specially illustrated or indicated in the manufacturing documents. 3. Requirements for welded joints, inspections
2.1 The manufacturing documents to be submitted for approval shall contain information on fabrication insofar as is relevant to the quality of the welded
3.1 The manufacturing documents (e.g. drawings, welding or inspection schedules) to be submitted for approval shall also indicate the quality requirements for the welded joints. Depending on the range of application, this may be done by means of the weld factor (cf. Chapter 3, Section 2 and 3), or by means of the weld quality grade (cf. Chapter 3, Section 1, I., Table 1.9) or the evaluation category according to EN 25817/ISO 5817 or EN 30042/ISO 10042 (cf. Annexes A and B). The tests (testing methods and scope of testing) to be used to verify the stipulated weld quality shall also be indicated.
Chapter 2 Page 12
Section 1
II - Part 3 GL 2000
3.2 The requirements to be stated also include the leak-tightness to gases and liquids or the corrosion resistance to particular media. 3.3 With regard to the welding procedure and production tests, cf. Chapter 1, Section 4 and the application-specific Section 1 5 of Chapter 3, with regard to non-destructive testing, cf. Section 4 and the application-specific sections of Chapter 3.
D. 1.
Design Details Accessibility, workmanship and fitness for inspection
1.1 Welded joints shall be planned at the design stage to ensure that they are readily accessible during fabrication and can be executed in the optimum welding position and welding sequence. 1.2 Welded joints and welding sequences shall be designed to minimize residual weld stresses and avoid excessive deformation. Welded joints should therefore not be over-dimensioned. 1.3 Welded joints shall be designed to ensure that the proposed weld type and quality (e.g. complete root fusion in the case of single- and double-bevel butt welds) can be satisfactorily achieved under the given fabricating conditions. Failing this, provision shall be made for welds which are easy to execute and their (possibly inferior) load-bearing capacity shall be allowed for when dimensioning the welds. 1.4 Severely stressed welded joints, which are therefore normally subject to compulsory inspection, shall be designed to facilitate application of the most appropriate inspection technique (radiography, ultrasonic or surface crack inspection, possibly in combination) so that tests offering reliable results can be carried out. 2. Location and configuration of welded joints
C. 1.
Materials, Weldability Weldability, processing
Only materials of proven weldability may be used for welded structures. Any conditions linked to the approval of the materials or to the welding procedure tests which impose restrictions on processing and the material manufacturer's recommendations shall be allowed for when designing the welded joint. With regard to the processing and use of TM steels, see the special GL Guidelines. 2. Material-related characteristics
Material-related characteristics, such as the (inferior) strength of rolled products in the thickness direction (cf. D.7.2), the softening of hardened aluminium alloys when welded, or the different degrees of thermal expansion of the various materials, shall be allowed for when designing and dimensioning the components and welded joints. 3. Clad plates
Clad plates where the efficiency of the bond between the supporting and cladding material has been proved by materials testing (cf. Part 1, Chapter 2, Section 1) may generally be treated as solid plates (up to medium plate thicknesses with mostly fillet welds). 4. Pairs of materials, corrosion
2.1 In areas of high stress concentrations resulting from the design - and especially in cases of dynamic loading -, welded joints should be avoided as far as possible or designed in such a way as to provide a generally smooth stress profile without a significant additional notch effect originating from the welding operation. Cf. GL Rules I, "Ship Technology", Part 1, Chaper 1, Section 20 "Fatigue Strength". 2.2 Intersecting butt welds in load-bearing walls of steam boilers and pressure vessels shall be avoided. The longitudinal seams of pipes shall be offset relative to one another at the pipe joints by at least 50 mm. Intersecting butt welds in hull structures are allowed; if possible, however, the first (e.g. longitudinal) welded joint shall be completed and cleanly finished at the ends before the second (e.g. transverse) joint is made. 3. Local clustering of welds, minimum spacing
Where pairs of different materials are exposed to seawater or other electrolytes, e.g. welded joints between unalloyed (hull) structural steels and stainless steels, attention shall be paid to the increased tendency towards corrosion due to the differences in electrochemical potential. Where possible, these welded joints should be located at points where there is less danger of corrosion, or special corrosion protection should be provided (e.g. coating or cathodic protection).
3.1 The local clustering of welds and insufficient distances between welded joints are to be avoided (cf. also Chapter 3, Section 1, G.4). Welds shall not be
II - Part 3 GL 2000
Section 1
Chapter 2 Page 13
over-dimensioned. The thickness of fillet welds shall not exceed 0,7 times the thickness of the thinner of the two parts to be joined. 3.2 Adjacent butt welds should be separated from each other by a distance of at least 50 mm + 4 plate thickness. Fillet welds should be separated from each other and from butt welds by a distance of at least 30 mm + 3 plate thickness. The width of interchangeable sections (strips) of plate should, however, be at least 300 mm or ten times the plate thickness, whichever is the greater. Cf. also Chapter 3, Section 1, G.4.1. 4. Cut-outs, welding apertures
no discontinuities in rigidity and no obstructions to expansion. 6.2 To this end, components with different dimensions shall be adjusted to one another by means of gradual transitions (e.g. by bevelling the edges of the thicker component). Steel castings and forgings must therefore be provided with integrally cast or forged welding flanges. Cf. Chapter 3, Section 1, G.3. and the Rules for Construction. 7. Double-T (cruciform) joints, stress in the thickness direction
4.1 Adequately sized cut-outs (welding apertures) shall be provided when, for instance, stiffeners are applied to platings before the butt joints in the plating are welded. Cf. also Chapter 3, Section 1, G.5. The welding apertures shall be rounded with a minimum radius of 25 mm or 2 plate thickness, whichever is the greater. 4.2 In special cases, e.g. when welding components subject to severe dynamic stresses, instead of providing welding apertures in the area of the butt welds it may be advisable to make a double-bevel weld preparation on the component to be attached to the plating, to weld up to this from both sides and to machine out the resulting root defect in the butt weld from the opposite side (of the plating). 5. Local reinforcements, plate doubling
7.1 Where, in the case of double-T (cruciform) joints, rolled products are stressed in the thickness direction due to the residual weld stresses or the applied loads, suitable measures shall be taken in the design of the structures to prevent lamellar tearing (stratified fractures). Such measures include the use of suitable weld shapes with a minimum weld volume and a welding sequence designed to reduce the shrinkage stresses in the thickness direction. 7.2 Where there are very severe stresses in the thickness direction (e.g. due to bulky single- or double-bevel butt welds), materials with enhanced characteristics in the direction at right angles to the surface of the product are to be used (cf. Part 1, Chapter 2, Section 1). 8. Welding of cold-formed sections
5.1 Where platings (including girder plates and tube or vessel walls) are subjected locally to increased stresses, thicker plates should be used wherever possible in preference to plate doublings. Bearing bushes, hubs, etc. shall invariably take the form of thicker plates, forgings or the like welded into the plating. 5.2 Where doubling plates cannot be avoided, their thickness should not exceed twice the plating thickness and their width should not exceed 30 times the doubling plate thickness. With regard to welding of doubling plates and especially the ends of such plates, cf. Chapter 3, Section 1, G.6. With regard to the design and welding of doubling plates as cut-out reinforcements in pressure vessels, see the Rules for Construction. 6. Stress flow, transitions
Welding of cold-formed sections of (hull) structural steels is permissible provided that the conditions stated in Chapter 3, Section 1, G.8. are complied with. In special cases, post-weld heat treatment may be necessary or documentary proof of adequate toughness after welding may be demanded. 9. Other design measures
9.1 Welds should not be located in channels of sections owing to the danger of the presence of segregations and the residual stresses in these areas arising from the rolling process. 9.2 Welded joints (fillet weld joints) in areas where the risk of corrosion cannot be excluded shall be continuously executed around components, cutouts, etc. to provide a seal. 9.3 If heat treatment is carried out on components with sealed-off hollow spaces necessitated by the design, such as occur in the case of cut-out reinforcements (doublings), mounted loose flanges or suspender rings, a means of venting, e.g. a drilled hole, shall be provided.
6.1 All welded joints on supporting members shall be designed to provide as smooth a stress profile as possible with no major internal or external notches,
Chapter 2 Page 14
Section 1
II - Part 3 GL 2000
E. 1.
Dimensioning of Welded Joints Dimensioning, design calculations
the smaller plate thickness being the ruling dimension. Unless otherwise agreed (e.g. for the fully-mechanised welding of smaller plate thicknesses in appropriate clamping jigs), the minimum fillet weld throat thickness shall be
1.1 Dimensioning shall be carried out in accordance with the Rules for Construction with reference to the shape and quality of the weld in question and the type (static or dynamic) and level of stress. The dimensions of the weld (if required) must be apparent from the manufacturing documents to be submitted for approval. In the case of fillet welds, an indication shall also be given as to whether the dimensional data refer to the throat thickness of the weld "a" or to the leg length "z". 1.2 Where required by the Society (e.g. in the Rules for Construction or as part of the examination of the drawings), mathematical proof (a general stress analysis and/or proof of fatigue strength) shall be furnished that the weld is adequately dimensioned. 2. Minimum thicknesses of fillet welds
a min = t1 t2
t1 + t 2 3
[ mm] , but not less than 3 mm
= smaller (e.g. the web) plate thickness in [mm] = larger (e.g. the flange) plate thickness in [mm]
A smaller minimum fillet weld throat thickness (e.g. 2,5 mm) may be agreed to if its faultless execution is demonstrated by means of a welding procedure test.
3. Machining allowance
Fillet weld throat thicknesses shall conform to the GL Rules or the results of design calculations. Throat thicknesses not established according to the Rules or design calculations shall be executed, as a minimum requirement, with a throat thickness of a = 0,5 plate thickness,
Adequate machining allowances (thicker welds) shall be provided for the subsequent machining of welds to ensure that the prescribed minimum weld thicknesses are achieved on completion of the work. This particularly applies to welds with only partial penetration, as occasionally occur for instance in machinery components, in which case provision shall be made for machining correspondingly deeper joints from the outset. In the case of the notch-free grinding of the welds, which is employed in the case of particular weld quality requirements, correspondingly thicker welds shall be deposited.
II - Part 3 GL 2000
Section 2
Execution of Welds
Chapter 2 Page 21
Section 2 Execution of Welds

A. 1. General Scope, supplementary provisions appropriate to the base material to be welded may be used. The various quality grades corresponding to the different hull structural steels shall be as shown in Table 1.1 in Chapter 3, Section 1. 4.2 Welding consumables and auxiliary materials for particular materials or those intended for special welding processes which have been approved on the basis of a (preliminary) welding procedure test may be used only for the range of application specified in the relevant approval certificate. Any special conditions or rules associated with such applications shall be complied with. 4.3 Welding consumables and auxiliary materials may only be used with the electrode diameters covered by the tests and for the approved welding positions. The manufacturer's instructions and recommendations for use (e.g. the type of current and polarity used) shall be complied with. 4.4 If necessary, welding consumables and auxiliary materials are to be baked, prior to use, in accordance with the manufacturer's instructions (keeping to the specified maximum baking time) and are to be kept dry at the place of work (in heated containers or similar). 5. Overweldable shop primers
1.1 This section contains universal rules applicable to the performance of welding work, extending from the weld preparation to the completion of the welded joints including any finishing operations. For heat treatment see Section 3; for testing of the welded joints, Sections 4 and 5. 1.2 The performance of the welding work is additionally governed by the application- specific requirements stated in the various sections of Chapter 3. The relevant provisions of the respective Rules for Construction shall also be complied with. 2. Welding shop requirements
2.1 All workshops wishing to carry out welding work shall comply with the welding shop requirements stipulated in Sections 2 (Approval), 3 (Welder's Qualification Tests) and 4 (Welding Procedure Tests) of Chapter 1 and, where necessary, Section 4 of Chapter 2 (Non-destructive Testing of Welds). 2.2 Workshops shall maintain up-to-date records of this compliance and shall submit them to the Surveyor at his request. If necessary (e.g. in the case of a prolonged interruption to the work, cf. Chapter 1, Section 2, A.4.2 and Section 3, E.), the Society may reinspect the workshop. 3. Materials, marking
5.1 Overweldable shop primers which are applied to plates, sections, etc. prior to welding and are not removed must be tested and approved in accordance with Chapter 1, Section 6. 5.2 Welding shops shall ensure by suitable checks (especially on the thickness of the coating) and production tests carried out at random during the course of normal fabrication that the quality of the welded joints is not impaired to an unacceptable degree. 6. Manufacturing documents, company standards
3.1 Welding may only be performed on materials whose identity and weldability under the given fabricating conditions can be unequivocally established by reference to markings, certificates, etc. 3.2 In case of doubt, the identity and weldability of the materials shall be verified before welding commences. 4. Welding consumables and auxiliary materials
4.1 Only welding consumables and auxiliary materials tested in accordance with Chapter 1, Section 5, approved by the Society and of a quality grade
6.1 Welds shall be executed in accordance with approved drawings, welding schedules or company standards recognized by the Society. Exceptions to this rule are subject to the Society's consent in each individual case.
Chapter 2 Page 22
Section 2
Execution of Welds
II - Part 3 GL 2000
6.2 Compliance with the manufacturing documents is the responsibility of the welding shop.
B. 1.
Weld Preparation, Assembly Weld preparation
3.2 The permissible edge alignment error depends on the nature, importance and loading of the component concerned and is dealt with in the various sections of Chapter 3. Where special loading conditions or other requirements relevant to the application necessitate a limitation of the edge alignment error, the allowable error shall be stated in the manufacturing documents. 4. Tack welds and preparations for welding
1.1 Weld preparation may be carried out by thermal cutting or machining. Seam edges (groove faces) prepared by thermal cutting shall be finished by machining (e.g. grinding) if a detrimental effect on the welded joint as a result of the cutting operation cannot be ruled out. Welding edges of steel castings and forgings shall always be ground as a minimum requirement; roll scale or casting skin is to be removed. 1.2 Groove faces must be free from impurities and defects liable to impair the quality of the welded joint, e.g. laps, coarse grooves made by the cutting torch and slag. Prior to welding, the welding edges shall be inspected for defects, e.g. cracks, inclusions, blowholes or pores, using non-destructive testing methods if necessary. 2. Weld shapes, root openings (air gaps)
4.1 Tack welds should be used as sparingly as possible and should be made by trained personnel. Where their quality does not meet the requirements applicable to the welded joint, they are to be carefully removed before the permanent weld is made. 4.2 Clamping plates, temporary ties and aligning pins shall be made from the same material as the base material or from a material of similar composition and should not be used more than necessary. Any damage caused during their removal shall be competently repaired. 4.3 With mechanized welding processes or when arc striking and end crater defects in butt welds have to be avoided, run-in and run-off plates shall be provided in continuation of the line of the weld. 4.4 Components must be clean and dry in the area of the welds. Any scale, rust, cutting slag, grease, paint (except for approved overweldable shop primers), moisture or dirt shall be carefully removed before welding.
2.1 When preparing and assembling components, care shall be taken to ensure compliance with the weld shapes and root openings (air gaps) specified in the manufacturing documents. With single- and doublebevel butt welds in particular, care shall be taken to make an adequate root opening to achieve sufficient root penetration. 2.2 The root opening shall not exceed twice the specified gap. If the size of the gap permitted by this rule is exceeded locally over a limited area, the gap may be reduced by build-up welding of the side walls, subject to the consent of the Surveyor. With fillet welds, the "a" dimension shall be increased accordingly, or a single- or double-bevel weld shall be made if the air gap is large. Inserts and wires may not be used as fillers. 3. Alignment of components
C.
Weather Protection, Preheating
1. The areas to be welded shall be adequately protected against climatic influences such as wind, damp and cold and shall be preheated where necessary. 2. The need for and degree of preheating is determined by various factors, such as chemical composition, plate thickness, two- or three-dimensional heat dissipation, ambient and workpiece temperatures, or heat input during welding (energy applied per unit length of weld). Details are given in Section 3 and various sections of Chapter 3. 3. Preheating shall be applied uniformly throughout the thickness of the plate or component over a width of four times the plate thickness, but not less than 100 mm. Preheating may be as necessary for tack and auxiliary welds as for fabricating welds.
3.1 Components which are to be united by butt welding are to be aligned as accurately as possible. Sections welded to plating shall be left unwelded at the ends for this purpose. Special attention shall be paid to the alignment of (abutting) girders which are interrupted by transverse members. If necessary, such alignment shall be facilitated by drilling check holes in the transverse member which are subsequently closed by welding.
II - Part 3 GL 2000
Section 2
Execution of Welds
Chapter 2 Page 23
D.
Welding Positions, Welding Sequence
1. Welding should be performed in the optimum welding position; positional welding is to be limited to the indispensable minimum. The welders employed on positional welding must be qualified for the welding positions concerned. With regard to welding in the vertical-down position, see Chapter 3, Section 1, H.6. 2. The welding sequence shall be chosen to allow shrinkage to take place as freely as possible. Butt joints in areas of plating shall invariably be fully welded prior to attaching girders and stiffeners. The Society may require an assembly procedure or welding sequence schedule to be drawn up in special cases.
6. Single- and double-bevel butt welds may be made according to the design specification either with grooved roots as full penetration welded joints or with a permitted incomplete penetration at the root or defined, unwelded root face subject to the appropriate reduction factors (cf. Chapter 3, Section 1, G.10.2.). The type of weld is to be specified in the drawings in each case and must have received the Society's approval when scrutinizing the drawings. 7. With fillet welds, particular attention shall be paid to good root penetration. The penetration must extend to at least the immediate vicinity of the theoretical root point. The ideal fillet weld section is that of an equal-sided flat-faced weld with smooth transitions to the base material. At the ends of web plates, at cutouts and at welding apertures, the fillet welds shall be formed round the web to form a seal. 8. Major cases of faulty workmanship or defects in the material may only be repaired with the Surveyor's agreement. Minor surface defects shall be removed by shallow grinding. Defects which penetrate more deeply into the material (e.g. cracks, or damage caused by the removal of auxiliary erection equipment) shall be cleanly machined out and where necessary repair-welded with an adequate heat input. 9. Repair (so-called production welds) on steel castings and forgings shall only be made with the consent of the Surveyor. If their volume is considerable, sketches and descriptions of the repair work shall be submitted to the Society's head office for approval, together with details of the analysis of the base material, the welding process and the welding consumables and auxiliary materials. The Society may require stress relief heat treatment or, in special cases, further heat treatment of the components after welding. 10. When working and welding higher-strength hull structural steels, high-strength (quenched and tempered) fine-grained structural steels, austenitic stainless steels and aluminium alloys, attention should be paid to the relevant information and instructions in the various sections of Chapter 3. For this work, the Society may require an appropriate welding specification to be submitted.
E.
Performance of Welding
1. The welding shop shall ensure that the specified welding parameters are adhered to and that the welding work is expertly performed. 2. Components shall not be subjected to any appreciable movements or vibration during welding. Parts to be assembled while suspended from cranes or floating shall be clamped prior to tack-welding of the joints in such a way that no relative movement of the parts is possible. Components which have not been fully welded and which are to be handled or turned must have welded joints of adequate strength. 3. Cracked tack welds may not be welded over, but are to be machined out. In multi-pass welding, the slag of the previous run shall be completely removed before the next pass is laid down. Pores, visible slag inclusions and other welding defects and cracks may not be welded over, but are to be machined out and repaired. 4. Welds must have sufficient penetration and must display a clean, regular surface with "gentle" transitions to the base material. Excessive weld reinforcements and undercuts or notches affecting the edges of plates and cutouts are to be avoided. 5. Butt-welded joints must display full fusion over the entire cross-section, unless otherwise specified in a particular case. For this purpose, the root shall normally be grooved and capped. Following a successful welding procedure test confirmed by the Society, single-side welds, e.g. using ceramic backings, may be regarded as equivalent to butt welds executed from both sides. Other joints welded on one side only, e.g. using permanent backings, are subject to the Society's approval when scrutinizing the relevant drawings.
F.
Straightening, Tolerances
1. Straightening operations (whether thermal or mechanical) shall not impair the quality of the materials and welded joints. The Society may require verification of the suitability of the straightening method (e.g. by means of a welding procedure test). This espe-
Chapter 2 Page 24
Section 2
Execution of Welds
II - Part 3 GL 2000
cially applies to high-strength (quenched and tempered) fine grain structural steels.
G.
Post-Weld-Treatment of Welds
2. Unless specific tolerances are stated in the various sections of Chapter 3 or in the manufacturing documents, the dimensional tolerances for welded structures shall be as specified in the standards, e.g. EN ISO 13920, or in the Manufacturing Standard of the German Shipbuilding Industry; for welded joints conforming to EN 25817/ISO 5817 or EN 30042/ISO 10042, (see Annexes A and B). The degree of fineness and the evaluation category shall be stipulated in the manufacturing documents. The Society may specify other (tighter) tolerances where this is necessary for reasons of strength and/or operational safety.
1. If it is intended to carry out post-weldtreatment of the welds, e.g. to improve the surface finish in the case of dynamic loading, such treatment shall not impair the characteristics (mechanical properties) of the welded joints. The Society may demand documentary proof thereof.
2. For post-weld heat treatment, see Section 3; for the post-treatment of surfaces for non-destructive testing, see Section 4, F.1.
II - Part 3 GL 2000
Section 3
Heat Treatment
Chapter 2 Page 31
Section 3 Heat Treatment

A. Scope lar intervals (at least once a year) and documentary proof of the inspection results submitted to the Society on request. 3. Other heat-treatment equipment
1. These Rules apply to preheating for, and heat input during welding and to post-weld heat treatment of welded components where required. For preheating of hull structural steels, see also Chapter 3, Section 1, H.4. and H.5. 2. Requirements relating to the heat treatment of hot or cold formed welded components (e.g. spherical or dished ends, T-pieces and elbows) are stipulated in the Societys Rules for Materials.
The primary requirements are given in B.1., but depend upon the particular requirements relating to the component or structure. The type and method of the heat treatment in question is subject to the Societys consent. If no heat treatment furnace of sufficient size are available for the heat treatment of components, heat treatment may be carried out in mobile facilities (transportable furnaces) or in equipment which has been specially designed for the purpose, subject to the Societys consent. Such equipment shall comply with the requirements stated in 2.1 and 2.2 with regard to function, temperature control and temperature recording and shall be presented to the Society for inspection before being used. Care shall be taken to ensure that there is adequate insulation of the components or welds needing heat treatment. Unacceptable temperature gradients in the component shall be avoided.
B.
Equipment and Appliances for Heat Treatment Equipment and appliances for preheating
1.
Preheating may be carried out either in heat treatment equipment or by means of mobile heating appliances, e.g. gas burners or electrical induction or resistance heating appliances as applicable (resistance mats). A condition of their use is that the prescribed preheating and interpass temperatures must be capable of being kept constant and monitored throughout the welding operation. The temperature may be monitored by means of suitable appliances or aids, e.g. contact thermometers, temperature sensors or temperature-sensitive crayons. 2. Fixed heat-treatment equipment (heattreatment furnaces)
C.
Principles Relating to Heat Treatment
2.1 The fixed heat-treatment facilities (heattreatment furnaces) must be of suitable size for the particular components and structures in question and be fitted with an appropriate temperature control facility. The furnaces must ensure that the particular heat treatment temperatures stipulated can be guaranteed and that the temperature is evenly and accurately controlled (DIN 17052, quality grade C). 2.2 An adequate number of temperature recorders shall be provided, subject to a minimum of 2 to each furnace. The temperature variation over the period shall be established and recorded. The temperature control device and the temperature and time recording instruments used shall be checked at regu-
1. Heat treatment, temperature measurements and recording shall be performed by competent personnel. For this and the performance of heat treatment operations, cf European draft Standard (Document N 225) "Welding, quality requirements relating to heat treatment in conjunction with welding and forming". 2. The type, temperature and duration of the heat treatment process, in addition to the rates of heating and cooling are determined by the material, the thickness of the material, the production process and the nature of the component or structure. Cf also the provisions of EN 1011 Parts 1 to 4 and in the regulations given in Chapter 3. The information and recommendations provided by the manufacturer of the materials and welding consumables shall be observed.
Chapter 2 Page 32
Section 3
Heat Treatment
II - Part 3 GL 2000
3. Details of the pre- and post-weld heat treatment of a component or structure shall be included in the production documents submitted for inspection by the Society. Where the manufacturers welding procedure specifications (WPS) are used, these shall contain the necessary information relating to preheating, heat input during welding and post-weld heat treatment. 4. The whole of the component is normally subject to post-weld heat treatment. The heat treatment of part or sections of welds or the heat treatment of partial areas, especially pressurized components, require the Societys consent in each individual case. A specification relating to this shall be submitted to the Society for examination. 5. Where welded joints are to be produced between different materials, in the case of complex welded components (e.g. LNG/LPG process pressure vessels and gas tanks), components which have high levels of cold forming (more than 3 %)or extensive structural and repair welds to castings, the need for, type and extent of any heat treatment shall be agreed with the Society. 6. Parts shall be proberly prepared for heat treatment in due order. Flange facings and sealings must be adequately protected against scaling. Precautions shall be taken to protect against component distortions; components and structures shall be positioned accordingly. Unacceptable temperature gradients during the heat treatment process and during heating and cooling shall be avoided.
rapid heat dissipation, e.g. when welding thick-walled components. Wherever possible, no welding should be performed at ambient temperatures below 10 C. 2. Preheating for the welding of ferritic steels
2.1 The need for preheating of ferritic steels and the preheating temperature depend on a number of factors. Chief among these are: the chemical composition of the base material (carbon equivalent) and the weld metal, the thickness of the workpiece and the type of weld joint (two or three dimensional heat flow), the welding process and the welding parameters (energy input per unit length of weld), the shrinkage and transformation stresses, the temperature dependence of the mechanical properties of the weld metal and the heataffected zone, the diffusible hydrogen content of the weld metal.
2.2 The operating temperature to be maintained (minimum preheating temperature and maximum interpass temperature) for (hull) structural steels may be determined in accordance with EN 1011-2. Guide values for the preheating temperature are contained in Figures 3.1 and 3.2 shown below for two different energy inputs per unit length of weld 1 and hydrogen contents HD 2 of the weld metal, together with the various carbon equivalents CET 3.
D.
Weather Protection, Preheating, Heat Input during Welding Weather protection, welding at low temperatures
1 Energy input per unit length of weld:
E = U
1.
volts
amps
welding time min 6 mm 100
1.1 The area in which welding work is performed is to be sheltered from wind, damp and cold, particularly if out of doors. Where gas-shielded arc welding is carried out, special attention is to be paid to ensuring adequate protection against draughts. When working in the open under unfavourable weather conditions it is advisable to dry welding edges by heating. 1.2 At ambient temperatures below + 5 C, additional measures shall be taken, such as shielding of components, extensive preliminary heating and preheating, especially when welding with a relatively low heat input (energy input per unit length of weld), e.g. when laying down thin fillet welds or in the case of
length of weld
LM OP N Q
kJ mm
HD 5 = max. 5 ml diffusible hydrogen per 100 g of weld metal HD 15 = max. 15 ml diffusible hydrogen per 100 g of weld metal
Carbon equivalent:
CET = C + Mn + Mo 10 + Cr + Cu 20 + Ni 40 % in weight
The above formula for calculating the carbon equivalent CET in accordance with EN 1011-2 can be applied to steels which have yield strengths ranging from 300 to 1000 MPa and to the following chemical composition: 0.05 0,32 % C, max. 0,8 % Si, 0,5 1,9 % Mn, max. 0,75 % Mo, max. 1,5 % Cr, max. 0,7 % Cu, max. 2,5 % Ni, max. 0,12 % Ti, max. 0,18 % V, max. 0,005 % B, max. 0,06 % Nb.
II - Part 3 GL 2000
Section 3
Heat Treatment
Chapter 2 Page 33
Minimum preheating temperatures [C]
250 200 150 100 50 0 20 30 40 50 60 70 80 90 100 CET = 0,25 / HD5 CET = 0,30 / HD5 CET = 0,35 / HD5 CET = 0,40 / HD5 CET = 0,25 / HD15 CET = 0,30 / HD15 CET = 0,35 / HD15 CET = 0,40 / HD15
Wall thickness [mm]
Fig. 3.1
Minimum preheating temperatures (operating temperatures) applicable to welding processes with a relatively low heat input (energy input per unit length 1 E 0,5 kJ/mm) as a function of the carbon equivalent CET 3 of the base material and the hydrogen content of the weld metal
250
Minimum preheating temperatures [C]
200
CET = 0,25 / HD5 CET = 0,30 / HD5
150
CET = 0,35 / HD5 CET = 0,40 / HD5
100
CET = 0,25 / HD15 CET = 0,30 / HD15
50
CET = 0,35 / HD15 CET = 0,40 / HD15 20 30 40 50 60 70 80 90 100
0 Wall thickness [mm]
Fig. 3.2
Minimum preheating temperatures (operating temperatures) applicable to welding processes with a relatively high heat input (energy input per unit length 1 E 3,5 kJ/mm) as a function of the carbon equivalent CET 3 of the base material and the hydrogen content of the weld metal
Chapter 2 Page 34
Section 3
Heat Treatment
II - Part 3 GL 2000
Note: Table 3.1 below gives guide values for the carbon equivalents CET 3 of some of the standard grades of steel. Basis were the information of the steel manufacturers. In case of doubt CET has to calculate by the actual analysis. Table 3.1 Guide values for the carbon equivalent CET CET [% in weight] Steel grades Average value 1 0,27 0,26 0,33 0,27 0,27 0,24 0,25 0,34 0,27 0,26 0,38 0,26 0,49 0,34 Maximum value 1 0,28 0,27 0,34 0,28 0,28 0,25 0,27 0,36 0,28 0,38 0,41 0,29 0,55 0,41
2.3 Table 3.2 contains guide values for preheating high temperature Mo or CrMo alloy steels (used for steam boiler) in accordance with the Societys Rules for Materials; cf EN 1011-2. 2.4 Table 3.3 contains guide values for preheating nickel steels tough at sub-zero temperatures in accordance with the Societys Rules for Materials. For details of this and also particulars relating to the use of austenitic or nickel-based welding consumables, cf. EN 1011-2. 2.5 Depending on the complexity of the component, the welding process applied, the level of the residual stresses in the component and the (low) ambient temperature, the preheating temperatures shall be increased or the boundary wall thicknesses reduced as appropriate. For the effect of the various factors on the preheating temperature level, see Table 3.4 2.6 If the temperature of the workpiece is lower than the minimum operating temperature calculated on the basis of the above data, preheating is called for. Various methods are available: continuous heating prior to and during welding, alternate heating and welding, heating only prior to the start of welding, if the heat input during welding is sufficient to maintain the minimum operating temperature.
GLA GLE GLD36 GLE36TM GLD40 GLE40TM S275NL S460NL S460ML (TM) S690QL S890QL 2C22 34CrMo4 GS20Mn5
1
For product thicknesses up to 50 mm.
The heating method may be chosen at will, provided that it does not harm the material by localized overheating or cause a nuisance by making the welding area contaminated.
Table 3.2
Category in accordance with DIN V 1738 (CR 12187)
Guide values for preheating high-temperature steels (used for steam boiler)
Minimum preheating temperature [C] given an H2 content of the weld metal of
Steel grade
Thickness [mm]
5 ml/100 g 16Mo3 15 > 15 30 > 30 15 > 15 15 > 15 20 20 75 20 100 75 100
> 5 10 ml/100 g
> 15 ml/100 g
1.2
20 75 100 100 150 150 200
100 100 not permitted 150 not permitted 200 not permitted
5.1 5.2
13CrMo4-5 10CrMo9-10 11CrMo9-10
II - Part 3 GL 2000
Section 3
Heat Treatment
Chapter 2 Page 35
Table 3.3
Guide values for preheating nickel steels tough at sub-zero temperatures
Category in accordance with DIN V 1738 (CR 12187) 7.2
Steel grade
Thickness [mm] > 10 > 10 > 10 > 10
Minimum preheating temperature [C] given an H2 content of the weld metal of 5 ml/100 g 100 100 100 100 > 5 10 ml/100 g 150 not permitted not permitted not permitted
12Ni14 (3,5 % Ni) 12Ni19 (5 % Ni)
7.3
X8Ni9 (9 % Ni) X7Ni9 (9 % Ni)
Table 3.4
Effect of the various factors on the level of preheating
Shift in the preheating temperature to lower values low alloying element content
Factors influencing preheating chemical composition of the base material (hardenability), e.g. expressed by the carbon equivalent thickness of the workpiece or component (heat dissipation, rigidity, residual stress condition) type of joint, weld shape and dimensions, heat input, heat dissipation ambient or workpiece temperature (heat dissipation) heat input (energy input per unit length of weld) during welding hydrogen content of the weld metal (type and rebaking of the welding consumables and auxiliary materials)
Shift in the preheating temperature to higher values higher alloying element content
thin butt joints (2 planes), thick (multiple run) welds high high
thick T-joints (3 planes) thin (single-run) welds low low
low
high
2.7 Preheating is always necessary for tack and auxiliary welds whenever preheating is needed for the rest of the welding. Possible exceptions to this rule are tack and auxiliary welds where it can be guaranteed that subsequent welds are remelted the heat affected zone, for instance tacks for submerged arc welds. 2.8 Irrespective of the information given above, preheating is always necessary when making major auxiliary erection welds, e.g. when welding on handling lugs and when welding very large wall thicknesses and also thick-walled castings and forgings. 2.9 Preheating shall be applied uniformly throughout the thickness of the plate or component
over a distance of four times the plate thickness, minimum of 100 mm, on both sides of the weld. Localized overheating is to be avoided. Preheating with gas burners should be performed with a gentle, though not sooty, flame in order to prevent dirt being deposited in the area of the weld. For details on the recording of the preheating temperature, cf. EN IS0 13916. 2.10 To prevent cold cracks in higher-strength and high-strength (quenched and tempered) steels, thick-walled components or components of complex design, it is advisable to use measures which give the hydrogen introduced into the weld metal during welding sufficient time to escape. The following methods are well established:
Chapter 2 Page 36
Section 3
Heat Treatment
II - Part 3 GL 2000
Maintenance of a specific minimum preheating and interpass temperature throughout the welding operation, Delayed cooling after welding, Holding at approx. 250 C prior to cooling (hydrogen-reducing heat treatment) or Heat treatment immediately after welding (without cooling in between)
per unit length of weld shall not fall below or exceed the values indicated by the steel manufacturer or those used in the welding procedure tests and specified in the welding procedure specifications (WPS) by any significant amount.
5.
Preheating and heat input during the welding of other steels or metallic materials
2.11 Where hull structural steels or fine-grained structural steels have undergone thermo-mechanical processing (TM steels), the need for and degree of preheating shall be decided on separately on the basis of the carbon equivalent and the results of the approval or welding procedure tests as applicable. Drying of the areas to be welded by heating may be sufficient. 3. Monitoring interpass temperatures
5.1 Preheating is not normally required for austenitic materials. Preheating may be necessary for austenitic-ferritic materials. A maximum permitted interpass temperature which is normally between 150 C and 180 C shall be complied with in order to prevent hot cracks. 5.2 Ferritic and stainless martensitic steels shall be adequately preheated and welded using controlled heat input per unit length of weld. Guide values for the preheating and interpass temperatures are prescribed in EN 1011-3. 5.3 Preheating is not normally required for welding aluminium alloys, but should not exceed 50 C. A maximum permitted interpass temperature of 100 C to 120 C shall be complied with in order to prevent undesirable phase dispersion. EN 1011-4 contains guide values for the preheating temperature to be applied and the interpass temperature.
The guide values contained in Table 3.5 for the interpass temperatures relating to the various steels shall not be significantly exceeded. 4. Welding with controlled heat input per unit length of weld
In addition to controlling the preheating and interpass temperature, the heat input per unit length of weld shall be controlled during welding, especially in the case of weldable, high-strength (quenched and tempered) fine-grained structural steels. The heat input
Table 3.5
Guide values for the maximum interpass temperature during welding

Maximum interpass temperature [C] 250 250 250 250 250 350 250
Category in accordance with DIN V 1738 (CR 12187) 1.1 1.2 1.2 2 3 5 7
Steel grades
Normal-strength hull structural steels and comparable structural steels Higher-strength structural steels and comparable structural steels High-temperature, low Mo alloy steels Normalised or thermo-mechanically processed fine-grained steels with yield strengths of > 360 N/mm2 Quenched and tempered or precipitation-hardened stainless) steels with yield strengths of > 360 N/mm2 (excluding
Steels with a max. Cr content of 10 % and a max. Mo content of 1,2 % Nickel alloy steels with a max. Ni content of 10 %
II - Part 3 GL 2000
Section 3
Heat Treatment
Chapter 2 Page 37
E.
Post-Weld Heat Treatment
1. Welded components shall be subjected to post-weld heat treatment where this is prescribed in Sections 1 to 5 of Chapter 3. Post-weld heat treatment is generally used for ferritic steels, in which case stress relief heat treatment or tempering is normally sufficient. Where consideration also has to be paid to other codes of practice in the manufacture of certain components or structures (e.g. TRD 201 relating to the construction of steam boilers, cf. Chapter 3, Section 2, A.2.2), the provisions relating to post-weld heat treatment contained in these codes of practice shall also be complied with.
Note: The need for and type of post-weld heat treatment is determined by various factors, the most important of which are given below: material characteristics and dimensions (wall thicknesses) minimum anticipated operating temperature (design temperature) type of operating and background environment (e.g. risk of corrosion) build-up of welds to inhibit elongation and shrinkage risk of distortion during subsequent machining
ing), the method of heat treatment shall be specially established in accordance with the material specification and the conditions of use and subject to agreement by the Society. This shall also apply in analogous manner to materials and material combinations other than those dealt with here and also to other methods of stress-relief.
3. The stress relief heat treatment shall be carried out by means of slow, even heating of the components to the prescribed temperature ranges (Table 3.6 contains guide values), holding in these ranges for two minutes per mm of wall thickness (but not less than 30 minutes), slow cooling to 400 C in the furnace or heat treatment appliance, and then complete cooling in still air. For thick-walled components, the holding time need not be more than 150 minutes.
4. If there is a risk of the components being distorted during cooling, the heat treatment may, within certain limits, be carried out at a lower temperature with an increased holding time. The required temperatures and holding times shall be agreed with the Society.
2. If stress relief heat treatment after welding is insufficient and more extensive heat treatment is required (e.g. normalising or quenching and temper-
5. Joints between ferritic and austenitic steels (weld metal) must not, as a general rule, be subjected to heat treatment due to the risk of carbon diffusion, except where the welds are made using nickel-base fillermaterials.
Chapter 2 Page 38
Section 3
Heat Treatment
II - Part 3 GL 2000
Table 3.6
Heat treatment temperatures for stress-relief heat treatment of welded joints using similar filler metals
Category in accordance with DIN V 1738 (CR 12187) 1.1
Steel grades
Examples of appropriate steels in accordance with the Society's Rules or the standards 1
Heat treatment temperature [C]
Normal-strength hull structural steels and comparable structural steels, grade of steel forgings and castings Higher-strength hull structural steels and comparable structural steels, grades of steel forgings and castings High-temperature, low Mo alloy steels Normalised or thermo-mechanically processed fine-grained steels with yield strengths > 360 N/mm2 Quenched and tempered fine-grained structural steels with yield strengths > 360 N/mm2 Steels with a max. Cr content of 10 %, max Mo content of 1,2 %
GL Grade A E
550 600
1.2 1.2 2
GL Grade A 36 - E 36 16Mo3 GL Grade A 39 E 39 S 460 TM S 690 QL
530 580 550 620 530 600
3 5 5.1 5.2 7 7.1 7.2 7.3 7.3 7.3

1 2
530 580
13CrMo4-5 10CrMo9-10, 11CrMo9-10, 13MnNi6-3 (0,5 % Ni) 12Ni14 (3,5 % Ni) 12Ni19 (5 % Ni) X8Ni9 (9 % Ni) X7Ni9 (9 % Ni)
630 680 670 720 530 560 530 560 530 560
2 2
Nickel steels with a maximum Ni content of 10 %
Steel grades not listed here are to be classed together with comparable grades. Heat treatment should be avoided.
II - Part 3 GL 2000
Section 4
Non-destructive Testing of Welds
Chapter 2 Page 41
Section 4 Non-destructive Testing of Welds

A. 1. General Scope 1.2 Unless otherwise stated in the individual application-specific sections of Chapter 3, the following basic requirements apply: Up to a wall or weld thickness of approx. 30 mm, radiographic inspection is the preferred method; for larger thicknesses, ultrasonic inspection is to be used as the primary test method. For wall or weld thicknesses of approx. 10 mm and above, either radiographic or ultrasonic inspections may be performed, in consultation with the Society. For radiographic inspection, X-ray sources shall be used wherever possible. Gamma ray sources may only be used with the Society's consent on the basis of an examination and recognition of the test method; cf. K.1. For magnetic materials, testing for surface cracks shall wherever possible be carried out by magnetic particle inspection; the use of liquid penetrant inspections for magnetic materials requires the Society's consent in each individual case. to be demonstrated (type and position). Cf. the individual application-specific sections of Chapter 3.
1.1 These Rules apply to the performance of the non-destructive tests of welded joints according to the methods and scopes prescribed in the individual sections of Chapter 3 for the various fields of application. Cf. also Chapter 1, Section 1, A.1. and A.2. 1.2 They also apply to the performance of all non-destructive weld tests which are stipulated in other regulations, rules or technical instructions issued by the Society and for which no specific details are given therein. 2. Standards and other codes of practice
2.1 The standards, etc. mentioned in the following paragraphs are an integral part of these Rules and shall also be complied with when performing the nondestructive weld tests. Where the standards contradict these Rules, the latter shall take precedence. 2.2 The performance of tests according to other, comparable codes of practice requires the prior consent of the Society. For this purpose, the relevant codes of practice shall be submitted to the Society together with the other inspection documents (cf. D.1.1) for examination and approval. 3. Requirements applicable to the inspection department
3.1 The works' inspection department shall be as independent and free from the influence of the fabrication department as it is necessary to ensure that the inspection and the evaluation of the inspection results are carried out objectively. This applies in analogous manner to outside inspection bodies.
1.3 The test method must be capable of reliably detecting the external and/or internal defects which may be present. Where necessary, this shall be achieved by using two or more test methods in combination. The particular test method(s) to be used shall be stated in the inspection schedule (cf. D.1.1). 2. Test appliances and media
B. 1.
Test Methods, Appliances and Test Media Test methods
2.1 The test appliances and media used must conform to the state of the art and the relevant standards and must be in perfect, serviceable condition. The Society may require an inspection of the test appliances and/or media used. 2.2 When making use of test equipment, test appliances, etc. owned by other, outside testing bodies, the works shall ensure that the conditions stated in 2.1 are satisfied.
1.1 The choice of the test method to be used in each case is determined among other things by the component or weld shape, the material and the defects
Chapter 2 Page 42
Section 4
II - Part 3 GL 2000
C. 1.
Inspection Personnel, Supervisors Inspection personnel (inspectors)
1.1 The non-destructive weld tests may only be performed by persons trained in the use of the test method concerned and possessing adequate practical experience. The Society shall be supplied with appropriate documentary proof of such training and experience, e.g. conforming to EN 473/ISO 9712. 1.2 Inspection of welds by ultrasonic means shall only be performed by inspectors holding a DGZfP 1 certificate U.2.1 (or equivalent, e.g. ASNT 2 Level II) and having at least 2 years of proven practical testing experience who are recognized by the Society. 1.3 For such recognition, the Society may require verification of the suitability of the ultrasonic inspection personnel and of the test appliances and the test method under practical conditions in the works. In exceptional cases and where necessary for a restricted field of use, the Society may, following successful verification, also recognize inspectors who do not hold the certificates specified in 1.2. 1.4 Application for such verification shall be made to the Society's head office, accompanied by the following information and documents: Documentary proof of the professional training of the inspection personnel and, where applicable, the inspection supervisors A description of the test equipment (appliances, probes, etc.) A description of the test method (instrument setting, angles and scanning directions, instrument sensitivity, etc.) Method of determining the size of defects Form of the inspection report.
in hull structural steels and/or other comparable structural steels. For the performance of further (more difficult) tests (e.g. on other materials and/or on acute-angled tube connections and weld shapes of comparable complexity), the authorization shall be subject to special review and supplementation. 2. Inspection supervisors
2.1 An appropriately qualified works inspection supervisor shall be available for scheduling and monitoring the performance of the non-destructive weld tests and evaluating the results. The name of the inspection supervisor shall be given to the Society; proof of his qualifications (e.g. DGZfP 1 Stage 3, ASNT 2 Level III or, for welding supervisors, to EN 719/ISO 14731 standard with additional NDT training) shall be submitted to the Society. 2.2 The inspection supervisor is responsible for ensuring that the non-destructive weld tests are competently and conscientiously carried out and recorded by suitable inspectors in accordance with these Rules, the relevant standards and the approved inspection schedule. 2.3 When using the services of outside inspection bodies, the works shall ensure that the above conditions are satisfied and shall inform the Society accordingly.
D. 1.
Inspection Schedule, Inspection Reports Inspection schedule
After successful verification, recognition may be linked to authorization of the inspector for the independent performance of certain tests and inspections (materials, weld shapes) under his personal responsibility. The decision lies with the Society. Note: The recognition and authorization of an inspector normally covers the inspection of normal butt and corner joints (e.g. the joints uniting deck stringers and sheer strakes) or approximately right-angled T-joints
1 2 Deutsche Gesellschaft fr Zerstrungsfreie Prfung (German Association for Non-destructive Testing). American Society for Non-destructive Testing.
1.1 Unless already stated in the other manufacturing documents (drawings, parts lists, etc.) to be submitted for approval, an inspection schedule for the non-destructive weld tests shall be drawn up, which must contain the following information: Components and welded joints to be tested Scope and method of testing, areas to be tested, location of testing positions (cf. the applicationspecific sections of Chapter 3) Requirements applicable to the welded joints (for evaluation criteria, cf. the applicationspecific sections of Chapter 3) Testing standards and/or specifications, if it is intended to use standards or specifications different from those mentioned in these rules.
II - Part 3 GL 2000
Section 4
Chapter 2 Page 43
1.2 The location of testing positions shall be subject to agreement between the welding shop and the Societys Surveyor, whereupon the inspection schedule shall be submitted to the Societys Head Office for approval. The Society reserves the right to make changes to this inspection schedule even after approval has been given and especially to change the location of the individual testing positions or to extend the scope of testing (cf. H.) if the production process and/or test results suggest this to be necessary. 2. Inspection reports
lead to misinterpretation of the results shall be remedied before any further tests are performed. Cf. also J.3. 3. Components which are subjected to post-weld heat treatment (e.g. stress relief heat treatment) shall as a general rule be inspected after heat treatment. Inspection of the welds for welding defects before heat treatment as well is recommended. The Society may take previous inspections into account when establishing the final scope of inspection. Details shall be agreed with the Society on a case-by-case basis. 4. In the case of higher-strength and especially high-strength (e.g. quenched and tempered) structural steels where the possibility of delayed cracking (e.g. due to the presence of hydrogen in the weld metal) cannot be ruled out, the tests shall not be carried out earlier than 48 hours after completion of the welding work. The Society may demand longer waiting times (e.g. 72 hours up to a maximum of 7 days) or repetition of the tests (at least on a random sampling basis) after an appropriate waiting time. 5. Repetition of non-destructive tests shall be allowed for or may be demanded if the components or welded joints have been subjected to abnormal stresses (e.g. while in transit or during trial loading or pressure testing) before being stressed in normal service. The type and scope of these tests shall be agreed with the Society on a case-by-case basis.
2.1 Reports shall be prepared on all (initial and repeat) tests, and these shall be submitted to the Surveyor together with the other documentation (e.g. radiographs). The inspection reports must contain all the necessary details according to Sections K. to N. relating to the particular test method used, the position at which the test was performed and the results obtained. Note: Where the test results are to be recognized in place of the prescribed welder's repeat tests in accordance with Chapter 1, Section 3, E.3., the inspection reports shall also state the names or identification numbers of the welders. 2.2 Repeat tests (following repairs) and their results shall be specially identified in the inspection reports; cf. I.2.2. The results and documents relating to the initial test shall be submitted to the Societys Surveyor along with the results and documents relating to the repeat tests and also specifically if the repair was arranged for in-house. 2.3 Inspection reports shall be signed by the inspector and the test supervisor. Reports and documentation shall be kept for six years.
F. 1.
Preparation and Performance of Tests Preparation of areas to be tested
E.
Timing of Inspection, Waiting Times
1. Non-destructive testing of welds shall as a general rule not be carried out until all the welding operations on the component concerned have been completed. In special cases, e.g. in the case of thickwalled components at risk of cracking, it may be advisable to carry out non-destructive tests, e.g. for surface crack examinations, as an interim measure (in the course of the welding work). 2. Before using the test methods described in K. to N., a visual inspection of the welded joints shall be performed. Surface defects which restrict the ability of the tests to produce meaningful results or which may
1.1 The areas to be tested (surfaces of welds and of adjacent parts of the workpiece) must be sufficiently clean and smooth for the respective test method. Irregularities in the welded joint (cf. E.2.), remains of auxiliary welds, welding spatter, fragments of slag, etc. and any protective coatings or preservatives must be removed before the tests if they are liable to prevent them from being performed properly. Note: Cf. information sheet DVS 0709 "Requirements applicable to the surface condition of welded joints in steel for the use of non-destructive test methods". The overweldable shop primers normally used in shipbuilding have been found not to affect the tests and therefore can generally be left in place. With "reprimed" welds, however, the coating should not be significantly thicker than the normal coating thickness.
Chapter 2 Page 44
Section 4
II - Part 3 GL 2000
1.2 In special cases, e.g. ultrasonic testing for transverse defects (cf. L.4.3), grinding of the seam and the surface of the workpiece may be necessary. 2. Performance of tests
2.3 The Society may consent to the use of different evaluation criteria or criteria conforming to other standards, etc. if they are approximately comparable to those mentioned in 2.1 and are suited to the particular test method used. Details shall be agreed with the Society on a case-by-case basis. 3. Evaluation, rating
2.1 Non-destructive testing of welds shall be carried out in the manner described in Sections K. to N. The place and date of the tests shall be notified to the Society's Surveyor in good time. The Surveyor shall be given the opportunity to participate in or supervise the tests if he so wishes. 2.2 The individual positions (sections) to be tested shall be durably marked on the component or the welded joint in such a way that the test findings (e.g. weld defects requiring repair) can be unequivocally localized at any time up to the completion of all tests and, where applicable, repairs. If the dimensions are appropriately indicated (or a similar measure is used) in the drawings, inspection schedules and inspection reports, marking of the component may be dispensed with.
3.1 The inspection results shall be evaluated by the testing department or body and/or the welding supervisory staff. The ultimate evaluation and the decision whether to leave defects in materials and welds as they are or to repair them is reserved for the Society's Surveyor. 3.2 The results may be rated according to Table 4.2 (in the case of radiographic inspection) or, in the case of ultrasonic testing or if a broader statistical evaluation is not required, by "leave as is" or "satisfied" or, as the case may be, "to be repaired" or "not satisfied".
H. G. 1. Evaluation of Test Results Identification of test findings
Extension of the Scope of Inspection
1. If it is not certain that a defect to be repaired ends within the tested section of the weld, the adjacent sections of the weld shall also be inspected. 2. If major defects are found during inspections at random, the scope of inspection shall be extended. Unless otherwise agreed, for each section of weld to be repaired two more of the same length shall be inspected. 3. In the case of ultrasonic testing, the Society reserves the right to carry out control tests at random on the basis of the inspection reports compiled by the firm's inspector or to require control tests to be performed by a second, independent testing authority. If major differences from the results of the initial tests performed in the firm are found, the scope of the control tests may be extended.
1.1 In the case of radiographic testing and, where applicable, the methods of surface testing, the reference numbers and/or symbols conforming to EN 26520/ISO 6520 or, as applicable, in Table 4.1 (extract from the standard) may be used to identify (describe) test findings (e.g. welding defects). With regard to the description of defects in ultrasonic testing, cf. L.5. 2. Evaluation criteria
2.1 Unless otherwise specified for the respective components or welded joints in the applicationspecific sections of Chapter 3, the evaluation categories according to EN 25817/ISO 5817 (Annex A) may be used as evaluation criteria for steel and those according to EN 30042/ISO 10042 (Annex B) for aluminium alloys. 2.2 In the inspection schedules, testing instructions, etc. to be drawn up by the welding shop (cf. D.1.), the evaluation categories to be determined according to the type and level of stress or, where necessary, other individual evaluation characteristics shall be assigned to the individual components and welded joints. With regard to the evaluation of results of ultrasonic testing in conjunction with the stipulations in the above-mentioned standards (evaluation categories), see L.5.
I. 1.
Repairs, Re-inspection Repairs
1.1 Defects requiring repair on the basis of the evaluation shall be carefully grooved over a sufficient length (especially in the case of intersecting welds) and/or re-welded. Where a number of defects needing repair are located close together in a single section of weld, the entire section shall be machined out and rewelded.
II - Part 3 GL 2000
Section 4
Chapter 2 Page 45
Table 4.1
Symbols denoting defects (taken from EN 26520/ISO 6520)
Reference No. / symbol conforming to the IIW X-ray manual 100 101 102 104 2011 2015 2016 2024 301 304 4011 4012 4013 402 5011 5012 5013 502 503 504 507 510 511 515 517
1
Description 1 Crack Longitudinal crack Transverse crack End crater crack Pore Elongated cavity (Gas pocket) Worm hole Crater pipe (End crater cavity) Slag inclusion Metallic inclusion Lack of side-wall fusion Lack of inter-run fusion Lack of root fusion Lack of penetration (Incomplete penetration) Undercut, continuous Undercut, intermittent Shrinkage groove, groove in the root (cf. 515) Excessive weld reinforcement (butt weld) Excessive convexity (fillet weld) Excessive root reinforcement Misalignment of edges Burn-through Incompletely filled groove Root concavity (cf. 5013) Poor restart
E Ea Eb Ec Aa Ab Ab K Ba H D D F F
For explanations and illustrations, cf. EN 26520/ISO 6520.
Chapter 2 Page 46
Section 4
II - Part 3 GL 2000
Table 4.2
Evaluation ratings (for a more comprehensive statistical interpretation) Findings Rating 1 = good Remarks
Weld free from detectable defects Minor defects such as isolated pores and small slag inclusions which do not reduce the strength or tightness of the welded joint Avoidable defects such as small rows or clusters of pores, small slag lines, short root defects and minor lack of fusion Defects which must be avoided, e.g. coarse slag inclusions, accumulations of pores, generally all root defects and lack of fusion, and small isolated cracks Extensive major defects and cracks
2 = serviceable
Repair not recommended for components subject to normal stresses. Short root defects and minor lack of fusion may be left only at non-critical points Repair of defects required. Exceptions only for components without particular requirements on strength and tightness, but not at cracks. Replacement of the section of weld or of the entire welded joint required
3 = leave as is
4 = to be repaired
5 = to be replaced
1.2 Undercuts in need of repair, poor transitions to the surrounding material or other surface defects shall, where possible, be remedied by grinding out with smooth transitions to the surrounding material or, if they are too deep for this, they shall, with the Surveyor's consent, be ground out and repair- welded. 2. Re-inspection
Dimensional accuracy Compliance with the specified weld shape Absence from inadmissible external defects.
2.1 Repaired welds shall be re-inspected. Where welds have been completely remade, retesting at least equal in scope to the initial inspection shall be performed at random in accordance with the Surveyor's instructions. 2.2 Re-inspections shall be specially indicated in the inspection reports and on the radiographs, e.g. by means of an "R" (= repair) next to the title of the film (cf. D.2.2).
2. The dimensional accuracy shall be checked with suitable measuring instruments on a random sampling basis. When measuring fillet weld throat thicknesses, measuring gauges which measure with sufficient accuracy in throats which are not an exact right angle shall be used where necessary. 3. When checking for the correct shape of weld and external defects, attention shall be paid to the following: Weld reinforcement or top bead depression Weld edge angles (transitions to surrounding material) Misalignment of edges Undercuts Visible pores and slag inclusions Fused weld spatter Arc strikes on the surface of the base material Concave root surface and incomplete root fusion Cracks Unequal side lengths (in the case of fillet welds).
J.
Visual Inspection
1. The surfaces and back sides of the welds shall undergo a complete visual inspection, with the aid of optical (magnifying) appliances where necessary, to check their external characteristics. The following characteristics shall be checked: Completeness
II - Part 3 GL 2000
Section 4
Chapter 2 Page 47
With regard to the limits of acceptability, see G.2. and the application-specific sections of Chapter 3. Repairing of visible cracks is mandatory.
3.
Radiographic parameters
K. 1.
Radiographic Inspection Radiation sources, appliances
1.1 Wherever possible, X-ray units shall be used as radiation sources for radiographic inspections. The radiation energy (tube voltage) shall lie within the energy limits specified in EN 1435/ISO 1106. Allowing for the differences in thickness of the component, the radiation energy (tube voltage) should be kept as low as possible within the permissible working range so as to obtain a high-contrast image. 1.2 Where justified in exceptional cases (e.g. by lack of accessibility), gamma ray sources - preferably Ir 192 or Se 75 - may be used as radiation sources, subject to the Society's consent in each instance; cf. 4.4. 2. Films, intensifying screens
3.1 As a general rule, the radiographic parameters prescribed in EN 1435/ISO 1106 for test category A (general inspection procedure) shall be applied in shipbuilding and those for test category B (highersensitivity inspection procedure) shall be applied in steam boiler, pressure vessel and pipeline manufacture (pipe class I and II). In special cases the Society may stipulate application of test category B in shipbuilding as well. For radiographic inspection using X-rays and a film length of 480 mm, the distance between the film and the focal point shall normally be 700 mm, and in any case not less than the length of the film. 3.2 If several films are used to inspect a seam (e.g. for circumferential radiographs), they shall overlap at the ends in such a way that the full pattern of the weld can be traced without interruption. 3.3 When inspecting pipes with an outside diameter 90 mm, elliptical radiographs may be made. Depending on the diameter and wall thickness of the pipe, two or more elliptical radiographs are to be made so that the full length of the weld (the entire circumference of the pipe) is shown in the area of the radiographs capable of evaluation. 3.4 For larger-diameter pipes, either double-wall radiographs or, if the pipe diameter permits, central or single-wall radiographs shall be made. Care shall be taken to ensure that the film is capable of evaluation at both its ends. The area capable of evaluation shall only be the section of the weld in which the rays delimiting the beam do not cover more than 1.1 times the weld thickness that is radiographed with vertical irradiation. The number of radiographs shall be determined accordingly. 3.5 In order to determine the image quality to EN 462-3 standard, at least one image quality indicator to EN 462-1 (wire indicator) shall, for each radiograph, be laid on the side of the weld away from the film and facing the radiation source and shall be radiographed together with the weld. Should this be impossible, the image quality indicator may, with the Society's consent and after the preparation of comparative radiographs designed to determine the changed index of image quality, be fixed to the workpiece on the side close to the film (i.e. between the film and the weld). The film image must be marked with a corresponding identification ("N") to indicate that this arrangement was used, and appropriate mention must be made in the inspection report. 3.6 Each film image must be clearly and unmistakably identified by lead figures or letters simultaneously irradiated and depicted on the film. This identification must be the same as that given in the inspec-
2.1 Class C5 films conforming to EN 584-1 or G III conforming to ISO 5579 may normally be used in shipbuilding for X-raying steel. Class C3 or C4 and GI or GII films, as applicable, are to be used for the radiographic inspection of aluminium alloys and when using gamma rays to inspect steel. The use of class C3 or C4 and GI or GII films, as applicable, is obligatory in steam boiler, pressure vessel and pipeline manufacture (pipe class I and II).
Note: Annex C provides a summary of the classification of the most popular X-ray films currently on the market. This summary does not claim to be exhaustive and manufacturers of other X-ray films are invited to make the classification of their products by independent inspection institutes public and make the appropriate documents available to the Society so that they can supplement the list.
2.2 Front and rear 0,02 mm lead screens shall normally be used when radiographing steel. During radiography, the film and the screens must be kept in intimate contact in suitable cassettes, packs, etc. Radiographs may be made of aluminium alloys up to about 65 mm thick without the use of intensifying screens. 2.3 The use of salt intensifying screens and fluorometal screens is not allowed.
Chapter 2 Page 48
Section 4
II - Part 3 GL 2000
tion schedule and must enable any defects found to be readily located. The marking is to be located outside the weld area to be evaluated (the weld width plus at least 10 mm on each side). 4. Film processing, density, image quality
5.3 The following information is to be given in the inspection report, together with explanatory sketches where necessary: Works number, component, inspection schedule number, inspection position(s) Material, welding process Thickness of workpiece or weld, as appropriate Date and time of test (cf. E.3. and elsewhere) Radiation source and size of tube focus or emitter Tube voltage or activity at time of inspection Radiographic arrangement to 1106, position of wire indicator EN 1435/ISO
4.1 The films must be processed in properly equipped darkrooms in such a way as to avoid any blemishes which interfere with their evaluation (e.g. fogging, scratches, dark crescent-shaped marks due to kinks in the film, etc.). The instructions and recommendations issued by the film and chemical manufacturers are to be followed. Premature interruption of the developing process and reduction with chemicals of over-exposed films is not allowed. 4.2 The radiographic images must have a density D of at least 2,0 over the entire area for evaluation. The upper limit value depends on the brightness of the film viewers available for the evaluation, but should not exceed 2,5 to max. 3,0. Wide differences in density within a single radiograph are to be avoided. 4.3 The image quality shall be determined with an image quality indicator of the type prescribed in para. 3.5 and in accordance with EN 462-1. For category A inspection (cf. 3.1), image quality B is desirable for steel, with image quality A as the minimum requirement. In the case of aluminium alloys and test category B, image quality B must be attained. The criterion in each case is the smallest wire of the image quality indicator which is still visible in the area to be evaluated, the density being uniform. 4.4 The works or the inspection department/ body must demonstrate on request by means of specimen radiographs that the required radiographic parameters and image quality can be attained. 5. Viewing conditions, evaluation, inspection report
Type of film, nature and thickness of intensifying screens Test category, image quality index and image quality class Symbols denoting defects and assessment in accordance with G.
The inspection report must also indicate whether the information relates to an initial radiograph or to a follow-up inspection after repair work has been carried out (cf. D.2.1 and I.2.2). 5.4 The initial evaluation shall be carried out by the welding supervisory staff and/or the works inspection department. Then the films (initial and follow-up radiographs, cf. D.2.1 and I.2.) shall be submitted to the Society's Surveyor for evaluation together with the inspection reports (cf. G.3.1).
L. 1. 5.1 Viewers with a luminous density to EN 25580/ISO 5580 sufficient for the required film density shall be used for the examination and evaluation of radiographs. Stops must be fitted to enable the field of view to be adapted to the film size for, or capable of, evaluation. The brightness must be adjustable. 5.2 The viewing and evaluation of radiographs shall take place in a dimly lit though not completely darkened room. Evaluation should only be performed after a sufficient period has been allowed for adaptation. Bright, dazzling areas within the field of view are to be screened. The use of magnifying glasses for the detection of fine details may be beneficial.
Ultrasonic Inspection Test appliances and accessories
1.1 The test appliances, probes and other accessories (calibration and reference blocks for adjusting the sensitivity, reference scales, etc.) shall conform to the state of the art and the relevant standards (e.g. DIN 54120, EN 27963/ISO 2400, EN 1714 or DIN 54126). 1.2 All possible echo heights within the range of instrument sensitivity used must be capable of being determined with the aid of an amplification control calibrated in dB and a suitable scale marking on the display. The interval between the switching stages shall not exceed 2 dB. Instruments not equipped with a calibrated amplification control may not be used.
II - Part 3 GL 2000
Section 4
Chapter 2 Page 49
1.3 Stepless controls must enable the ranges of adjustment available on the instrument to follow on from one another, as far as possible without any intervening gap. Within each individual range the time sweep must be continuously adjustable. 1.4 With regard to the geometrical characteristics of the sound field, especially the incidence and squint angles, the testing frequency and the resolution, the probes must lie within the tolerances specified in the standards mentioned above. The incidence and squint angles shall not in either case deviate by more than 2 from the nominal value or from the centre line of the probe. The angle of incidence and the probe index (of angle beam probes) shall be verified. 2. Calibration, sensitivity setting
transfer correction shall be stated in the inspection report. 2.5 For more efficient detection of defects it is recommended that testing be performed with a test sensitivity (search sensitivity) increased by approximately 6 dB over the chosen registration level (see para. 5.1). However, the registration level setting is generally to be used when evaluating defect indications. All echo indications to be registered must attain at least 20 % of the display height even at the maximum sonic distance (cf. DIN 54 127, Part 1). In the case of electrogaswelded seams, the inspection shall normally be performed with a sensitivity increased by 12 dB, and this fact shall be expressly stated in the inspection report with a reference to the welding process (e.g. EG + 12 dB). 3. Surface preparation, coupling
2.1 The distance signal (time sweep) may be calibrated in projection distances "PA", shortened projection distances "VPA'" or sonic distances "s" as desired or, if necessary, depth positions "b". Unless otherwise agreed, calibration in shortened projection distances "VPA'" is preferred for weld inspections, or in sonic distances "s" for parts of complex shape. 2.2 For calibration in accordance with 2.1 a calibration block to DIN 54120 or EN 27963/ISO 2400 shall be used when testing (hull) structural steels. Appropriate calibration or reference blocks shall be used for materials having other sound velocities (e.g. high-alloy steels and non-ferrous metals). Bore holes used for calibration shall not be larger than 2 mm and shall lie parallel to the testing surface. Where possible, calibration should not be performed at edges. 2.3 Depending on the intended method of echo height definition, the sensitivity setting shall be performed using calibration reflectors of known shape, position and size (e.g. large flat reflectors, side-drilled holes) in accordance with the provisions of DIN 54 127, Part 1. Unless otherwise agreed, the DGS method of inspection shall be used. With the DGS method, the sensitivity setting is to be carried out in accordance with the instrument manufacturer's instructions using calibration blocks to DIN 54 120 and EN 27963/ISO 2400. Flat-bottom holes and grooves should not be used as calibration reflectors. 2.4 If necessary (e.g. for defects close to the surface), the sensitivity setting is to be corrected in accordance with DIN 54 127, Part 1. When testing unalloyed and low-alloy (hull) structural steels and where the sonic distances are not too far (cf. DIN 54 127, Part 1), the sound attenuation may normally be disregarded. A transfer correction to determine the coupling differences between the surface of the reference block and that of the test piece shall, however, be performed in every case. The value of the
3.1 On both sides of the welded seam (cf. 4.1) the testing surfaces must be smooth and free from impurities liable to interfere with coupling. Rust, scale and weld spatter are to be removed so that the probes lie snugly against the surfaces, which should if necessary be ground. Firmly adhering paint need not be removed provided that it does not interfere with the inspection and quantitative allowance can be made for the resulting loss of sensitivity when evaluating the echo heights. 3.2 Where angle beam probes have to be applied to the surface of the weld for the inspection of transverse defects (see 4.3), this shall also be prepared as a testing surface in the manner described above. Notches, grooves and the like lying across the beam axis which produce false indications and may impair the test are to be removed. 3.3 Coupling to the testing surfaces prepared in accordance with 3.1 should be as uniform as possible and should not vary by more than 4 dB. If greater variations are found, the condition of the surface shall be improved. Where greater variations cannot be avoided, this fact must be stated in the inspection report. Running water, cellulose glue, oils, grease or glycerine may be used as coupling media. 4. Scanning directions, angle of incidence
4.1 Unless otherwise agreed or stipulated, testing for longitudinal defects shall be performed from one surface and from both sides of the weld, as shown in Fig. 4.1. The testing area must embrace the weld metal itself and an area on both sides of the seam equal to about 1/3 of the wall thickness, subject to a minimum of 10 mm and a maximum of 20 mm. The testing surface must encompass a width at least equal to the full skip distance plus twice the length of the probe.
Chapter 2 Page 410
Section 4
II - Part 3 GL 2000
requirements are more stringent - on the face of the weld which has been machined flush with the surface. The Society may require that testing for transverse defects be performed with two probes connected in parallel. Where welds are made with a large weld pool (as in electroslag welding), testing for oblique defects shall also be performed at an angle of approximately 45 (cf. EN 1714).
testing surface testing area
Fig. 4.1 Testing for longitudinal defects 4.2 Depending on the weld geometry and the possible orientation of defects, it may be expedient to perform the test from both surfaces or (e.g. in the case of bevels) from only one side of the seam. With corner and T-joints, the testing shall normally be performed both from the side of the web and from that of the continuous (flange) plate using a standard probe, as shown in Fig. 4.2. Such probe arrangements differing from 4.1 shall be specially noted in the inspection report. The same applies in analogous manner to curved surfaces.
4.4 With plate thicknesses (weld thicknesses) of less than 30 mm, testing may be performed with an angle of incidence of 70. With thicknesses of 30 mm and over, two angles of incidence (70 and 45 or 60) shall be used. Where the surface is curved, the necessary angle of incidence shall be determined in accordance with DIN 54127, Part 1. With very large wall thicknesses (above about 100 mm), the inspection must be performed using a tandem technique (with fixed, mechanical coupling of two similar probes) for different depth zones.
- 20
Fig. 4.3 Testing for transverse defects
5.
Registration level, evaluation of echo indications
Note: Recommendations on the evaluation of the findings of ultrasonic inspections of fusion-welded joints (in steel) according to EN 25817/ISO 5817 are also given in Information Sheet DVS 0704 of the Deutscher Verband fr Schweisstechnik e.V. (German Association for Welding Technology). The information sheet also contains information on the usefulness and performance of ultrasonic inspections and the evaluation of form-related indications.
Fig. 4.2
Testing for longitudinal defects in corner and T-joints
4.3 Testing for transverse defects shall be performed from both sides of the weld in two directions along the seam as shown in Fig. 4.3 or - where the test
5.1 For tests carried out by the DGS method, the registration level (reference reflector size) for longitudinal and transverse defects is given by the diameters of the disc-shaped reflectors specified in Table 4.3 in relation to the wall thickness (weld thickness).
II - Part 3 GL 2000
Section 4
Chapter 2 Page 411
Table 4.3
Registration levels
Wall thickness (weld thickness)
Diameter of disc-shaped reflector 4 MHz 2 MHz 1,5 mm 2,0 mm 3,0 mm 4,0 mm
quiring repair unless they can be unequivocally associated with the indications produced by longitudinal defects and remain below the repair limit values stipulated in Table 4.4. 5.7 Where the evaluation of echo indications gives rise to doubt regarding the need for repair, recourse may be had to radiographic inspection to help in the assessment (cf. B.1.3). However, echo indications obtained with welded seams 30 mm or more in thickness which exceed the repair limit values invariably necessitate repair even if radiographic inspection fails to reveal any defects or fails to reveal them clearly. 6. Inspection reports
from 10 15 mm over 15 20 mm over 20 40 mm over 40 60 mm
1,0 mm 1,5 mm 2,0 mm 3,0 mm
Where the thickness is greater than 60 mm, the registration level will be determined on a case-by-case basis. For tandem testing, the registration level shall be determined by a 6 mm diameter disc-shaped reflector. For other methods of echo height definition (e.g. the reference block method), the registration level shall be determined in accordance with DIN 54127, Part 1. 5.2 The registration of non-form-related echo indications which are observed when inspecting welded joints and whose echo heights attain or exceed the registration level (reference reflector size) specified in para. 5.1 is required only when expressly stipulated by the Society or where subsequent repeat tests have to be performed. Otherwise only those echo indications shall be registered which exceed the repair limit value specified in para. 5.4. 5.3 One characteristic which is to be stated for the classification of echo indications is by how many dB the maximum echo height of the reflections found differs from the registration level defined in 5.1. In the case of the DGS method, the size of the (substitute) disc-shaped reflector may also be stated. Further characteristics to be stated are the registration lengths and half-value depths in accordance with EN 1714. The location of reflections shall be defined by coordinates indicating the "longitudinal and transverse distances from a reference point" and the "depth position". 5.4 Unless otherwise stated in the applicationspecific sections of Chapter 3, echo indications produced by longitudinal defects which exceed the repair limit values shown in Table 4.4 (excess of registration lengths and/or echo heights above the registration level shown in Table 4.3) shall be regarded as weld defects which must be repaired. 5.5 Continuous echo indications which point to systematic weld defects (such as root defects due to incomplete penetration or rows of pores) call for repairs even if the repair limit values are not attained. Echo indications which point to the presence of cracks necessitate repairs in every case. 5.6 Echo indications produced by transverse defects shall in every case count as weld defects re-
6.1 Complete inspection reports as prescribed in EN 1714 and containing the information listed below shall be prepared for all ultrasonic inspections in accordance with the inspection schedule; cf. D.1. The inspection reports must enable the inspections to be repeated identically. They must be signed by the person performing the inspection and the supervisor. 6.2 Inspection reports must contain the following general information: Clear identification of the component, the material, the welded joint inspected together with its dimensions and location (sketch to be provided for complex weld shapes and testing arrangements) and the welding process. Indication of any other rules (e.g. specifications, standards or special agreements) applied to the inspection. Place and time of the inspection, testing body and identification of the person performing the test.
6.3 Inspection reports must contain at least the following specific details relating to the inspection: Make and type of test equipment Make, type, nominal frequency and angle of incidence of probes Distance calibration (testing range) Sensitivity setting (calibration reflector used, instrument sensitivity, registration level) Correction values (for defects close to surface, transfer correction) Test sensitivity Surface preparation, coupling media Testing surfaces, testing directions, angles of incidence
Chapter 2 Page 412
Section 4
II - Part 3 GL 2000
Table 4.4
Repair limit values

Longitudinal defects Transverse defects
Wall Evaluation thickness category (weld according thickness) to G.2.1 [mm]
Number of Max. perNumber of Max. perRegistration Registration defects per m missible excess defects per m missible excess length length of weld seam echo height of weld seam echo height [mm] [dB] [mm] [dB] 10 and 10 20 10 10 20 19 10 25 10 10 30 10 15 30 10 15 30 10 15 50 10 15 50 10 15 50 10 20 50 10 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 6 6 12 5 10 6 5 10 6 5 10 6 3 10 6 3 10 6 3 10 6 3 10 6 3 10 6 3 10 6 3 10 6
10...15
3 and 1 10 and
> 15...20 B > 20...40
3 and 1 10 and 3 and 1 10 and
> 40
3 and 1 10 and
10...20
3 and 1 10 and
> 20...40
3 and 1 10 and
> 40
3 and 1 10 and
10...20
3 and 1 10 and
> 20...40
3 and 1 10 and
> 40
3 and 1
II - Part 3 GL 2000
Section 4
M Non-destructive Testing of Welds
Chapter 2 Page 413
6.4 The test results (where these are to be stated in the inspection report; cf. 5.2) shall, wherever possible, be tabulated or shown on sketches with the following details: Coordinates of defects with indication of reference point Maximum excess echo height (+ ... dB) compared with the given registration level (reference reflector size) or, where applicable, the diameter of the corresponding (substitute) disc-shaped reflector Defect characteristics (registration length, halfvalue depth).
shall be effected by passing a current through the workpiece or, in the case of minor localized inspections, by yoke magnetization using electromagnets or, if no other possibilities are given, permanent magnets. 2.2 In special cases (e.g. where burn marks have to be avoided at all costs or for circumferential welds), it may be expedient to effect magnetization with a live conductor (a cable or coil). A combination of different methods of magnetization for the detection of variously orientated defects is allowed. 2.3 Where a current is passed through the workpiece, alternating, direct, impulse or surge current may be used. AC or DC magnets may be used for yoke magnetization. Where the magnetizing current is passed through the workpiece, fusible supply electrodes should be used to prevent burn marks. Where AC is used, fusible electrodes are obligatory. 2.4 The magnetizing field strength (effective tangential field strength) must be at least 20 A/cm (25 Oe) but shall not exceed 50 A/cm (62,5 Oe). The adequacy of the magnetization shall be checked at the time of the test by suitable means (e.g. test indicator) or with a tangential field strength meter. 3. Preparation of testing surfaces, direction and duration of magnetization
Where echo indications below the repair limit values shown in Table 4.4 are also registered, each defect thus identified is to be allocated an assessment (e.g. leave as is or repair, a = acceptable or na = not acceptable).
M. 1.
Magnetic Particle Inspection Test appliances and media
1.1 The test appliances and media used must conform to the state of the art and the relevant standards (e.g. DIN 54130, 54131, 54132, 54152). The magnetizing equipment must be provided with markings or measuring devices which indicate the magnetizing current strength at any time. The Society may stipulate that measurements be performed to verify these data. Proof of the suitability of the test media shall be furnished on request. 1.2 Magnetic particles suspended in suitable, readily volatile vehicle liquids shall be used as test media for revealing the leakage flux due to discontinuities in the material. These magnetic particles may be black or fluorescent. Where black magnetic particles are used, the surface to be tested shall be coated with a permanent white paint, applied as thinly as possible, to provide a contrast. 1.3 The proportion of magnetic particles in the vehicle liquid must conform to the manufacturer's instructions and shall be verified (e.g. by means of a test indicator or by a separation test using a glass centrifuge vessel to ASTM D 96-73, Fig. 6). Dry test media may only be used for tests at elevated temperatures (e.g. on root passes). 2. Magnetization method and field strength
3.1 The testing surfaces must be free from loose scale, rust, weld spatter and other impurities. Notches, grooves, scratches, edges, etc. which may produce false indications are to be removed prior to inspection. Thin, dry layers of paint (e.g. shop primer, up to a coat thickness of 20 m) may be left in place as long as they do not hinder the inspection. 3.2 Magnetization must be effected, as shown in Fig. 4.4, in two different directions including an angle of not less than 60 and not more than 90 so as to enable variously orientated defects to be located.
60 - 90
2.1 The choice of the method of magnetization depends on the geometry of the component and is to be agreed with the Society. If possible, magnetization
Fig. 4.4
Directions in which magnetization is to be effected
Chapter 2 Page 414
Section 4
II - Part 3 GL 2000
3.3 Magnetization must be continued as long as the testing surface is sprayed with magnetic particle suspension and for as long thereafter as any movement of the magnetic particle suspension can be detected, subject to a minimum of 5 seconds. Testing under conditions of remanent magnetization is not permitted. 4. Evaluation, inspection reports
2.2 Any method of applying the penetrant may be used. Care shall be taken to ensure that the testing surface is completely wetted throughout the entire penetration time. The penetration time shall be chosen in accordance with the manufacturer's instructions, but shall not be less than 15 minutes for workpiece temperatures of 15 C and over or less than 30 minutes where the temperature is below 15 C. The penetrant shall not become dry during the penetration period. 2.3 Following penetration, the surplus penetrant shall be completely removed from the testing surface in such a way as to leave behind the penetrant lodged in any defects present. It is advisable first to wipe off the surplus penetrant with a cloth and quickly to remove only the remains with sparing use of the penetrant remover. The testing surface should then be dried as quickly as possible (max. 50 C). 2.4 The developer is to be applied evenly and as thinly as possible immediately after removal of the surplus penetrant and drying. The testing surface should be just covered. The developing time should be about the same as the time allowed for penetration. Visual inspection for defects shall begin as the developer is applied, but the final inspection can only take place after the expiry of the developing time. M.4.1 applies in analogous manner to the evaluation. 3. Evaluation, inspection reports
4.1 Every accumulation of magnetic particles not due to a false indication indicates a discontinuity or crack in the material which is to be registered in the inspection report and repaired. In the case of small cracks (e.g. end crater cracks) this may be done by grinding. Larger cracks are to be machined out and repair-welded; cf. I.1.2. 4.2 Inspection reports relating to magnetic particle inspections must include the following details: Details of the component and weld concerned Details of magnetization, with amperage where appropriate Test arrangement (directions of magnetization, distance between electrodes or poles) Test media Test results Place and time of the inspection, testing body and identification of the person performing the test.
N. 1.
Liquid Penetrant Inspection Test media
3.1 Should an unequivocal evaluation of the indications be impossible, the entire inspection procedure, starting with preliminary cleaning, must be repeated. Where necessary, the surface quality shall also be improved. The repeat inspection must be performed with the same test system as on the first occasion. The conditions specified in standard EN 571-1 are also applicable. 3.2 Inspection reports relating to penetrant medium inspections must include the following details: Details of the component and weld concerned Test media (type, brand name) Description of the test procedure (temperature of the workpiece, penetrant acting time, etc.) Test results Place and time of the inspection, testing body and identification of the person performing the test.
1.1 Coloured or fluorescent penetrants shall be used as penetrant media. Penetrant removers and developers must be compatible with the penetrant used. Proof of the suitability of the inspection system (penetrant, penetrant remover, developer) shall be furnished to the Society on request. 2. Preparation of testing surfaces, performance of inspection
2.1 To allow the penetrant to enter any defects present, the testing surfaces must be completely free from scale, rust, greases, oils, paints or electrodeposits before the penetrant is applied. During this operation care should be taken to ensure that defects are not mechanically sealed by preliminary cleaning. The testing surfaces must be dry. The temperature of the workpiece shall be between 5 C and 50 C.
Inspection reports shall conform to the form provided in Annex A to EN 571-1.
II - Part 3 GL 2000
Section 5
Chapter 2 Page 51
Section 5 Mechanical and Technological Tests

Preliminary remarks: This section has, for the time being, still been retained in its earlier form despite the fact that more up-to-date EN and ISO standards have since been either issued or are available in draft form relating to the key destructive tests carried out on welded joints in metallic materials. The intention is to delete this section altogether at a later date and instead to make reference only to the new standards in Chapter 1, Section 4, "Welding Procedure Tests" (where the information relating to the mechanical and technological tests is chiefly needed). These standards include: EN 895/ISO 4136 Transverse tensile test (replacement for DIN 50120-1 and 50120-2) EN 876/ISO 5178 Longitudinal tensile testing of the weld metal in fusion welded joints EN 910/(ISO 5173) Bend tests (replacement for DIN 50121-1 and 50121-2) EN 875/ISO 9016 Notched bar impact test (replacmenet for DIN 50122) EN 1043/ISO 9015 Hardness test, miscellaneous parts (Replacement for DIN 50163) EN 1320/ISO 9017 Fracture tests (replacement for DIN 50127) EN 1321 Macroscopic and microscopic examinations EN ISO 8249 Determination of ferrite number A. Scope
1. These Rules relate to the normal methods and forms of test specimens to be used in the mechanical and technological testing of welds, e.g. of test pieces for the welding procedure and workmanship tests, as well as to the metallographic inspections necessary for this purpose. 2. Special methods and forms of test specimens (e.g. for testing the manual skill of welders or testing of welding consumables, auxiliary materials and overweldable shop primers) are specified in the relevant sections. 3. The test methods and forms of specimens indicated in the standards mentioned in the following paragraphs shall be used wherever possible. Methods and forms of specimens conforming to other standards may be used by agreement with the Surveyor, provided that the same results can be achieved.
B.
Preparation of Specimens and Testing
1. All tests are to be performed by trained personnel using calibrated testing machines. The testing machines must be kept in good working order by their owners and are to be calibrated at regular intervals by an independent inspecting authority.
The mechanical and technological tests shall, wherever possible, be performed in accordance with the new standards. For an interim period, or where the new standards are not yet available, the mechanical and technological tests may continue to be performed in accordance with the following provisions, but also in compliance with the information given in Chapter 3. The test records shall state which rules were used as a basis for the test. Where the provisions given in the various rules differ widely, the procedure shall be agreed with the Society.
2. Before being cut out of the test piece, specimens are to be marked by the Surveyor. They shall then be cut out, wherever possible by a mechanical process, and machined to the required dimensions. Where specimens are cut from the test piece by a thermal process, they must be wide enough to ensure that the heat-affected zone can be completely machined off.
3. All mechanical and technological tests are to be performed in the presence of the Surveyor, unless otherwise stipulated or agreed. The photographs of metallographic specimens are to be submitted to him for evaluation.
Chapter 2 Page 52
Section 5
II - Part 3 GL 2000
C. 1.
Tensile Tests Tensile tests on flat tensile specimens (DIN 50120, Part 1)
1.2 The thickness 'a' of the specimen is normally the wall thickness. If this is greater than 30 mm but less than 50 mm, the specimens may be machined down on one side to a thickness of 30 mm. With thicknesses of 50 mm and over, two or more specimens regularly spaced over the section are to be prepared.
B b
gauge length L0 50 parallel length 60
10
gauge length L0 50 parallel length 60
bs Lt
Specimen thickness a Specimen width b Gauge length Lc Head width B Total length Lt Radius at shoulder r
1
5 15
>5 to 10 20
> 10 to 20 25
> 20 to 30 30
Weld width bs + 80 mm 1 25 30 35 40
Lc + 180 35
Weld reinforcements machined off
Lc
Fig. 5.2
Round tensile specimen (weld metal)
Fig. 5.3
Location of specimens in weld metal
bs measured on the side of the weld the greater seam width.
Fig. 5.1
Flat tensile specimen (welded joint)
1.3 Welded joints in aluminium alloys shall be tested using a tensile specimen conforming to DIN 50123. 2. Tensile test on round tensile specimens (EN 10002/DIN 50125)
2.2 If, in exceptional cases, the weld dimensions do not permit the preparation of a 10 mm diameter tensile specimen, specimens with a smaller diameter may be used, provided that the gauge length is 5 times and the parallel length at least 6 times the diameter of the specimen. 3. Tensile tests on cruciform tensile specimens
2.1 This test is carried out to determine the tensile strength, yield strength or 0,2 % proof stress, reduction in area and elongation of the weld metal. Where necessary in the case of high-temperature
3.1 This test is carried out to determine the tensile shear strength ZS of the weld metal. Three specimens with the dimensions shown in Fig. 5.4 shall be tested in each test.
12
12
1.1 This test is carried out to determine the tensile strength, position, type of fracture and, where appropriate, the elongation of specimens located at right angles to the seam. The flat tensile specimen shown in Fig. 5.1 should be used wherever possible.
steels, the 0,2 % proof stress at elevated temperatures shall also be established. Wherever possible, the test should be performed on a 10 mm diameter round tensile specimen of the type depicted in Fig. 5.2, which is to be cut out of the weld metal with its longitudinal axis in the direction of the seam.
5
10
II - Part 3 GL 2000
Section 5
Chapter 2 Page 53
Z remainder for repeat test specimens
SB
= S1/2 or S3/4 depending on location fracture
a1
approx. 400
Fig. 5.5
50 35 35 35
Cruciform tensile specimen, section through welded joint
Fig. 5.4
Cruciform tensile specimens D. 1. Bend Tests Transverse bend test (DIN 50121, Part 1)
3.2 The tensile shear strength ZS is to be determined by the following formula (cf. Fig. 5.5):
a1 + a 2 = fracture sec tion S1 2 a 3 + a 4 = fracture sec tion S 3 4 Tensile shear strength ZS:
= Breaking load F N mm2 SB specimen width
1.1 This test is carried out to determine the ductility of the welded joint across the seam. For this purpose the specimen is bent over a mandrel or prescribed diameter and the angle achieved and, if specified, the bending elongation on the tension side of the specimen are measured. Specimens to Fig. 5.6 are to be prepared for the test.
Section A - B r tension side r a
a
a4
B Lt Specimen thickness a
Dimensions 11 Specimen width b __ d a 3 Specimen length Lt 1 where __ d a =4 __ d a =6 Radius r, side in tension

1
> 11 14 30 250 250 250 2
> 14 17 30 250 250 290 2
> 17 22 1,5 a 250 290 350 3
> 22 27 1,5 a 300 350 430 3
> 27 35 1,5 a 300 430 530 3
20 250 250 250 2
If the specimen lengths Lt cannot be met, the minimum specimen lengths shown in Table 6 of DIN 50 121, Part 1 apply.
Fig. 5.6 Specimen for transverse bend test
Chapter 2 Page 54
Section 5
II - Part 3 GL 2000
1.2 The thickness of the specimen is normally the wall thickness. If this is greater than 30 mm, the specimens may be machined down on one side to a thickness of 30 mm. On the side of the specimen which is in tension during the test, the edges may be rounded to the specified radius r. 1.3 Depending on the test specification, the specimens are to be mounted in the testing device in such a way that either the upper or the lower side of the weld is in tension during the test. The test rig is to be set up as shown in Fig. 5.7. 1.4 If the bending elongation is to be determined, the deformation zone on the tension side of the specimen shall be provided prior to the test with gauge marks set 5 mm apart and these shall be used to measure the elongation when the prescribed bending angle has been reached.
is measured. Specimens to Fig. 5.9 are to be prepared for the test.

2.2 The specimens are to be mounted in the testing device shown in Fig. 5.7 in such a way that the testing load acts in the direction of the original longitudinal axis of the seam. On the side in tension during the test, the long edges of the specimen may be rounded to the specified radius r. 2.3 If welded clad plates are to undergo side bend tests, the form of specimen shown in Fig. 5.10 is to be used. The dimensions are as stated in the table in Fig. 5.9.
saw cut
The gauge length L0 is the weld width plus the wall thickness.
a b
L
t
D/
Section A - B r tension side r a B A
50
D+3a
50
Dimensions Specimen thickness a
Ratio d/a 3 4 10 Product thickness 1 ( 3 ) 1 150 170 200 6
Fig. 5.7 Test rig
If the elongation behaviour of the base mate1.5 rial and the weld metal differ greatly, e.g. in the case of welded aluminium test pieces, the test rig shown in Fig. 5.8 may be used in order to prevent premature incipient cracking of the specimen.
Specimen width b Radius r, side in tension Specimen Lt 2
1 The radius in brackets applies to specimen where the weld reinforcements are not machined off. 2 If the specimen lengths L cannot be met, the minimum specimen t lengths shown in Table 6 of DIN 50121, Part 1 apply
Fig. 5.9 Fig. 5.8 Special test rig 2. Side bend test (DIN 50121, Part 1)
r tension side r a
Specimen for side bend test (Table)
cladding
base material
This test is carried out to determine the duc2.1 tility of the welded joint in the cross-sectional plane. For this purpose the specimen is bent over a mandrel of specified diameter and the bending angle attained
Lt
Fig. 5.10 Form of clad side bend test specimens
II - Part 3 GL 2000
Section 5
Chapter 2 Page 55
3.
Bend test specimens from pipe joints
3.1 If bend test specimens are to be taken from circumferential pipe welds, the side faces must be parallel. If necessary, the side of the specimen which is in compression shall be machined in accordance with Fig. 5.11.
r
Depending on the test specification, the 2. notch shall be located either at the centre of the weld metal, on the fusion line or in the heat-affected zone of the base metal at a specified distance from the fusion line (cf. Fig. 5.12).
3. The test is to be carried out at the specified test temperature. Where the product thickness is < 10 mm, specimens measuring 7,5 10 mm, 5 10 mm and 2,5 10 mm should be used wherever possible. For these specimens the required impact energy E (J) in relation to the standard 10 10 mm test specimen shall be as indicated in the table below. 4. Where specimens are taken from only one side of a double-V weld, they shall be taken from the side of the seam which was welded last. 5. The specimens shall be machined down to the dimensions shown in Fig. 5.13 and compliance with the stipulated tolerances shall be verified. 6. If in technically justified exceptional cases specimens with forms or locations different from those described in paras. 1 to 5 are to be used, the test requirements shall be specially agreed with the Society .
55
10 8
side in compression
Fig. 5.11 Cross section through bend test specimen taken from a pipe
E.
Notched Bar Impact Tests (EN 10045/DIN 50115)
The purpose of this test is to determine the 1. impact energy in joules (J). ISO V-notch specimens shall be used; their location in the test piece shall be such that the longitudinal axis of the specimen is perpendicular to the direction of the seam while the notch axis is at right angles to the surface of the product (cf. Fig. 5.12). In addition, determination of the crystalline portion of the fracture surface and/or of the lateral expansion of the specimen may be agreed.
Cross section of specimen [mm] Standard specimen 10 10 Specimens of reduced section 10 7,5 10 5 Mean impact energy value required E E
10
r = 0,25
45 Nominal size 55 mm 10 mm 10 mm 45 8 mm 0,25 mm 27,5 mm
Dimensions Length Width
Tolerance 0,60 mm 0,11 mm 0,06 mm 2 0,06 mm 0,025 mm 0,42 mm
5/6 E 2/3 E
1
Height Notch angle Height from bottom of notch Notch radius
Notch located on fusion line (KS)

1
1
Distance between centre of notch and ends of specimen Angle between plane of symmetry of notch and longitudinal axis of specimen Angle between adjacent longitudinal specimen surfaces
X Notch located at centre of weld metal (KM) Notch located in heat-affedted zone (K)
90
90
Fig. 5.12 Locations of specimens for notched bar impact testing
Chapter 2 Page 56
Section 5
II - Part 3 GL 2000
55
10 8
10
r = 0,25
45 Nominal size 55 mm 10 mm 10 mm 45 8 mm 0,25 mm 27,5 mm
4. If other test methods are to be used in exceptional cases, the requirements shall be converted in accordance with recognized standards, e.g. DIN 50150.
hO
hW
hG
Length Width Height Notch angle Height from bottom of notch Notch radius Distance between centre of notch and ends of specimen Angle between plane of symmetry of notch and longitudinal axis of specimen Angle between adjacent longitudinal specimen surfaces
0,60 mm 0,11 mm 0,06 mm 2 0,06 mm 0,025 mm 0,42 mm
G
hO hG
W G
W G
hG
hW
90
2
hO = = = distance from the surface distance from the underside distance of the row of hardness measurements for the root area from the surface
90
hG hW
Fig. 5.13 ISO V-notch specimen
Fig. 5.14 Hardness testing with rows of hardness measurements
F.
Hardness Testing of Welds (DIN 50163, Part 1)
G.
Metallographic Inspections
The hardness of welded joints shall be meas1. ured by Vickers hardness tester using a load of 49 or 98 N (HV 5 or HV 10) on polished and etched specimens whose test face is perpendicular to the weld axis. The choice of the test load depends on the grade of material concerned.
2. Normally, the test shall take the form of rows of hardness measurements, one row for fillet welds and at least two rows for butt welds, one of which is at the root and one in the area of the cover pass. Should this be insufficient for an adequate assessment of the hardness of the welded joint, a test with a further row of measurements shall be performed, e.g. in the area of the root and capping passes in the case of butt welds. The arrangement of the rows of hardness measurements shall be as shown in Fig. 5.14. 3. The impressions made by the hardness tester shall be close enough together to give an accurate picture of the hardness curve (cf. Fig. 5.15). The curve shall be plotted as a graph wherever possible.
The macro- and micro-structure shall be 1. evaluated by reference to polished sections. Unless otherwise agreed, the polished face of the sections shall be perpendicular to the weld axis (see also Fig. 5.14).
2. The metallographic specimens shall be of such a size and ground and etched in such a way as to reveal the nature and structure of the crystallization of the weld metal and the heat-affected zone as well as the texture of the base metal and, in the case of micrographs, the grain boundaries in the area under examination. 3. The polished sections shall be photographed and the photos appended to the inspection report. Macrographs shall normally be to a scale of 1 : 1 to 1 : 3; if the cross-sectional area of the weld is small, they may be magnified.
For assessment of the microstructure, at least 3 photographs shall be made of characteristic parts of the weld; these shall generally be the weld metal, the fusion line and the heat-affected zone. The magnification shall be at least 100 : 1.
hW
Dimensions
Tolerance
hO
II - Part 3 GL 2000
Section 5
Chapter 2 Page 57
h2
0, 5
H.
Inspection reports
0,5
The works must prepare reports on the tests, 1. which must contain all the necessary details for assessing the method. These especially include:
Heat-affected zone
h 2
Type of inspection or test (e.g. welding procedure test) Dimensions and numbers of test pieces Base materials Weld preparation Welding processes and positions Welding consumables and their dimensions, auxiliary welding materials Welding current source Welding current strength and voltage Post-weld heat treatment Test methods and forms of specimens Test results
Recommended distance between hardness test impressions in the heat-affected zone Distance between hardness test impressions [mm] 0,7 1
Vickers hardness symbol HV 5 HV 10
Fig. 5.15 Location of hardness test impressions in the heat-affected zone
2. The reports shall be submitted to the Surveyor in at least two copies for his perusal. He shall confirm the proper performance of the inspection and the correctness of the results by applying his stamp and signature.
II - Part 3 GL 2000
Annex A
Chapter 2 Page A1
Annex A Imperfections in Welded Joints in Steel

Limits for imperfections in welded joints in steel in accordance with the international standards EN 25817 / ISO 5815 (reproduced with the kind permission of the Deutsches Institut fr Normung (DIN) e.V., Berlin [German Standards Institute] Amendments or additions to the standards are shaded in grey.
Description of imperfections
Cracks End Crater crack
No.
1 2
Ref. No. in acc. with ISO 6520

100 104
Remarks
All kinds of cracks with the exception of microcracks (h 1 < 1mm2), for crater cracks, cf. No. 2
Limit for imperfections for quality levels

low medium high
C
not permitted
Permitted Not permitted. End crater cavities as occur for example during single-side welding on ceramic backings are regarded as end crater cracks if they appear as distinct linear indications. Nonlinear indications count as pores
Porosity and pores For the evaluation of pores as they occur during the overwelding of shop primers in fillet welds (except for worm holes which extend to the surface), the limits imposed for clusters of pores shall ce relevant.
2011 2012 2014 2017
The following parameters and limits imposed on imperfections shall be observed: a) The maximum figure for the total number of pores on the pictured or broken surface of the irregularity b) The maximum size of an individual pore for - Butt welds - Fillet welds c) The maximum size oa an individual pore 4% 2% 1%
d 0,5 s 0,5 a 5 mm
d 0,4 s 0,4 a 4 mm
d 0,3 s 0,3 a 3 mm
Cluster of pores
2013
The entire pore area within a cluster should be included and calculated as a percentage from the larger of the two areas: envelope curve encompassing all the pore or a circle with a diameter that matches that of the side of the weld. The permitted pore area should be localized. The possibility that other imperfections allowed for. The following parameters and limits imposed on imperfections shall be observed: a) The maximum figure for the total number of pores on the pictured or broken surface of the irrgularity. b) The maximum dimension of a single pore for - Butt welds - Filled welds c) The maximum size for a cluster of pores 16 % 8% 4%
d 0,5 s 0,5 a 4 mm
d 0,4 s 0,4 a 3 mm
d 0,3 s 0,3 a 2 mm
Chapter 2 Page A2
Annex A
II - Part 3 GL 2000
No.
5
Gas pocket Worm holes

2015 2016
Remarks
Long irregularities for - butt welds - fillet welds Max. size for gas pockets and worm holes Short irregularities for - butt welds - fillet welds Max. size for gas pockets and worm holes

low medium high
D
h 0,5 s 0,5 a 2 mm
not permitted
not permitted
h 0,5 s 0,5 a 4 mm or Not Larger Than Thickness (NLTT) h 0,5 s 0,5 a 2 mm
h 0,4 s 0,4 a 3 mm or (NLTT)
h 0,3 s 0,3 a 2 mm or (NLTT)
Solid inclusions (except for copper)
300
Long irregularities for - butt welds - fillet welds Max. size for solid inclusions Short irregularities for - butt welds - fillet welds Max. size for solid inclusions
not permitted
not permitted
h 0,5 s 0,5 a 4 mm or Not Larger Than Thickness (NLTT)
h 0,4 s 0,4 a 3 mm or (NLTT)
h 0,3 s 0,3 a 2 mm or (NLTT)
7 8
Copper inclusions Lack of fusion
3042 401
not permitted Permitted, but only intermittent and none reaching as far as surface
not permitted
II - Part 3 GL 2000
Annex A
Chapter 2 Page A3
No.
9
Incomplete penetration

402
Remarks

low medium high
D
Specified penetration Actual penetration
B
not permitted
Long irregularities: not permitted Depending on their position in relation to the main direction of load, e.g. in the case of welds which are primarily subjected to load parallel to the weld direction, long irregulaities, may be permitted, in which case the dimensional limits imposed on short irregularities shall apply. Short irregularities: h 0,2 s max. 2 mm h 0,1 s max. 1,5 mm
h s Fig. A
h s
Fig. B Actual penetration Specified penetration Fig. C 10 Poor fit-up, fillet welds -An excessive or insufficient gap between the parts being joined Specified penetration Actual penetration
h 1mm h 0,5 mm h 0,5 mm + 0,3 a, + 0,2 a, + 0,1 a, max. max. max. 4 mm 3 mm 2 mm
Gaps in excess of the relevant limit may be compensated in some cases by a correspondingly greater throat thickness. 11 Undercuts 5011 5012 Smooth transition in specified. h 1,5 mm h 1,0 mm h 0,5 mm
Long irregularities: Not more than 10 % of the plate thickness in the case of undercuts vertical to the main direction of load.
Chapter 2 Page A4
Annex A
II - Part 3 GL 2000
Nr.
Description of imperfection Excessive weld reinforcement
Ref. No. in acc. with ISO 6520 502
Remarks
Limits for imperfections for quality levels

low medium high
D
Smooth transition is specified. b h 1 mm + 0,25 b, max. 10 mm h 1 mm + 0,25 b, max. 5 mm
C
h 1 mm + 0,15 b, max. 7 mm h 1 mm + 0,15 b, max. 4 mm
B
h 1 mm + 0,1 b, max. 5 mm h 1 mm + 0,1 b, max. 3 mm
12
13
Excessive convexity
503
Actual weld thickness
Specified weld thickness
14
Excessive weld thickness (fillet weld)
For many applications, a weld thickness which exceeds the specified size is not normally grounds for rejection Actual weld thickness Specified weld thickness
h 1 mm + 0,3 a, max. 5 mm
h 1 mm + 0,2 a, max. 4 mm
h 1 mm + 0,15 a, max. 3 mm
15
Reduced weld thickness (fillet weld)
A fillet weld with an obviously smaller weld thickness should not be regarded as a defect provided that the actual weld thickness is compensated by a deeper penetration and by so doing the specified size is achieved. Actual weld thickness Specified weld thickness
Long irregularities: not permitted Short irregularities: h 0,3 mm + 0,1 a max. 2 mm max. 1 mm
not permitted
16
Excessive root reinforcement If the width or the root is relatively large with "smooth" transition, e.g. as occurs in welds welded on one side using a backing, the weld reinforcement with no. 12 is relevant.
504
h 1 mm + 1,2 b, max. 5 mm
h 1 mm + 0,6 b, max. 4 mm
h 1 mm + 0,3 b, max. 3 mm
II - Part 3 GL 2000
Annex A
Chapter 2 Page A5
No.
17 18
Description of imperfection
Local excess penetration Misalignment of edges

5041 507
Remarks

low medium high
D
Individual excessive root deviations The limits for the deviations relate to the correct position. Unless otherwise prescribed, the correct position is when the centre to the smaller t relates to the smaller thickness
h
C
Permitted
Figure A Plates and longitudinal welds h 0,25 t, h 0,15 t, max. max. 5 mm 4 mm h 0,1 t, max. 3 mm
Fig. A
h
Figure B Circumferential welds h 0,5 t max. 4 mm max. 3 mm max. 2 mm
Fig. B 19 Incompletely filled groove Sagging 511 Smooth transition is required. b 509
h t
Long irregularites: Depending on their position in relation to the main direction of load, e.g. welds mainly subjct to load parallel to the weld direction, long irregularities may be permitted in which case she dimensional limits for the short irregularities shall apply. Short irregularities: h 0,2 t max. 2 mm h 0,1 t max. 1 mm h 0,05 t max. 0,5 mm not permitted
Chapter 2 Page A6
Annex A
II - Part 3 GL 2000
No.
20
Excessively unequal leg lengths of fillet weld

512
Remarks
It is assumed that an asymmetrical fillet weld has not been expressly prescribed h

low medium high
D
h 2 mm + 0,2 a
B
h 2 mm h 1,5 mm + 0,15 a + 0,15 a
z2
z1 21 Root concacity Root notch 515 5013 Smooth transition is required.
h 1,5 mm h 1 mm h 0,5 mm
Long irregularities: No more than 10 % of the plate thickness in the case notches vertical to the main direction of load. Short irregularities permitted
22
Overflowing weld metal
506
not permitted
23 24
Poor restart Arc strikes
517 601
permitted
not permitted
Approval may be influenced by any subsequent treatment. Approval is determined by the type of base material and particularly by the cracking sensitivity Approval depends on application Special parameters may be neccessary for thicknesses s or a 10 mm Overall size of short irregularities S h 0,25 s or 0,25 a, max. 10 mm 0,2 s or 0,2 a, max. 10 mm 0,15 s or 0,15 a, max. 10 mm
25 26
Weld splatter Multiple Imperfections in the section
602 -
h4
h5
h2
h1 h6
h1 + h 2 + h 3 + h 4 + h 5 S h
h4
h 1 + h2 + h3 + h4 + h 5 + h6 S h
h3
h2
h3
h1
h5
II - Part 3 GL 2000
Annex A
Chapter 2 Page A7
Additional information and guidelines for the application of this table. This table, taken from the international standards EN 25817 resp. ISO 5817 specifies the requirements for three classification levels of acceptance for imperfections in welded steel joints of steel for arc welding processes in accordance with the field of application and for weld thicknesses from 3 to 63 mm. It may also be used for other fusion welding processes or weld thicknesses, if applicable. No. 26 shows multiple imperfections, a theoretically possible accumulation of individual imperfections. In this case, the total of all permitted deviations for the determind figures of the several classification levels should be reduced. The value for a single imperfection h, e.g. for an individual pore, should not be exceeded. The table may be used in connection with the IIW catalogue ISO 5817 with realistic illustrations; they show the size of the permitted imperfections of the various classification levels by means of photos of the upper and the root sides and/or reproductions of radiographs and photos of macrographs of the weld cross sections. The catalogue and the reference cards may be used to assess imperfections and when opinions regarding the permitted size deviate from each other.
Symbols The following symbols are used in the table: A area of gas cavity a nominal fillet weld throat thickness (fillet thickness) b width of weld reinforcement d diameter or pore h size (height or weight) of imperfection l lenght of imperfection s nominal butt weld thickness or, in the case of partial penetration, the precribed depth of penetration t wall or plate thickness z nominal leg length of fillet welds (in case of isosceles right angle triangular section z = a 2)
Short imperfection: One or more imperfections of total length not greater than 25 mm in any 100 mm length of the weld or a maximum of 25 % of the weld length for a weld shorter than 100 mm. Long imperfection: One or more imperfections of total length greater than 25 mm in any 100 mm length of the weld or a minimum of 25 % of the weld length for a weld shorter than 100 mm.
II - Part 3 GL 2000
Annex B
Chapter 2 Page B1
Annex B Imperfections in Welded Joints in Aluminium

Limits for imperfections in welded joints in aluminium (alloys) in accordance with the international standards EN 30042 / ISO 10042 (repoduced with the kind permission of the Deutsches Institut fr Normung (DIN) e.V. Berlin [German Standards Institute ] Amendments or additions to the standards are shaded in grey.
No.
1 2 3
Cracks End crater crack Gas inclusion

100 104 201
Remarks
All types of cracks except micro cracks (h 1 < 1mm2), crater cracks, see No. 2

low medium high
C
not permitted
h 0,2 s or 0,2 a
not permitted
Pore
2011
Porosity
2012
The term "gas inclusion" encompasses per 100 mm length: porosity, cluster of pores and pores. The entire A 8 s or A 4 s or A 2 s or pore area within a cluster should be included: 8 a mm2 4 a mm2 2 a mm2 an envelope curve that encompasses all the pores or a circle with a diameter that matches d 0,5 s or d 0,3 s or d 0,25 s or 0,5 a mm2 0,3 a mm2 0,25 a mm2 that of the width of the weld. max. max. max. The permitted pore area should be localized. 5,5 mm 4,5 mm 3,5 mm The possibility that other irregularities are concealed should be allowed for. d 0,5 s + d 0,5 s + d 0,5 s + 0,035 s or 0,02 s or 0,01 s or 0,035 a 0,02 a 0,01 a max. max. max. 1 mm 2 mm 1,5 mm d 0,5 s + d 0,5 s + d 0,5 s + 0,05 s or 0,035 s or 0,02 s or 0,02 a 0,035 a 0,05 a max. max. max. 2 mm 1.5 mm 3 mm per 100 mm length:
A 2 t mm2 A 1 t mm2 A 0,5 t mm2
d 0,5 mm + d 0,5 mm+ d 0,5 mm +
Cluster of pores
2013
Surface pore
2017
0,035 s or 0,035 a max. 2 mm
0,02 s or 0,02 a max. 1,5 mm
0,01 s or 0,01 a max. 1 mm
Solid inclusions (other than copper and tungsten)
300
Solid inclusions include oxide inclusions. If several inclusions h1, h2, h3 ... are present in a section, the sum is Sh = h1+ h2 + h3 ...
Long irregularities: not permitted Short irregularities: S h 0,1 s or 0,1 a max. max. 3 mm 1,5 mm h 0,1 s or 0,1 a max. 3 mm max. 1,5 mm not permitted
Tungsten inclusions
3041
h 0,05 s or 0,05 a max. 0,8 mm
10
Copper inclusions
3042 not permitted
Chapter 2 Page B2
Annex B
II - Part 3 GL 2000
No.
11
Lack of fusion

401
Remarks
Where there are several instances of lack of fusion h1, h2, h3 ... the sum is S h = h1 + h2 + h3 ...

low medium high
C
Long irregularities: not permitted
Short irregularities: not S h 0,1 s or 0,1 a permitted max. max. 3 mm 1,5 mm A small number permitted, but not a regular occurrence h 0,4 s max. 3 mm h 0,2 s max. 2 mm
12
Incomplete penetration
402
h s Fig. A
not permitted
s
Fig. B Fig. C 12.1 Imcomplete penetration (fillet welds) -
Actual penetration Specified penetration
Long irregularities: not permitted Short irregularities: h h 0,3 a max. 2 mm h 0,2 a max. 1,5 mm h 0,1 a max. 1 mm
13
Poor fit-up, fillet welds
An excessive or inadequate gap between the components being joined.
h 1mm h 0,5 mm h 0,5 mm + 0,2 a, + 0,15 a, + 0,1 a, max. max. max. 4 mm 3 mm 2 mm
Gaps exceeding the relevant limit may be compensated by a correspondingly larger throat thickness
II - Part 3 GL 2000
Annex B
Chapter 2 Page B3
No.
14
Undercut

5011 5012
Remarks
Smooth transition is required.

low medium high
D
h
C
Long irregularities:
h 0,6 mm h 0,4 mm h 0,2 mm Short irregularities: h 1,5 mm h 1 mm h 0,5 mm Long and short irregularities: Not more than 10 % of the plate thickness in the case of undercuts vertical to the main direction of load h 1,5 mm h 1,5 mm h 1,5 mm + 0,20 b, + 0,15 b, + 0,1 b, max. max. max. 10 mm 7 mm 5 mm h 1,5 mm h 1,5 mm h 1,5 mm + 0,3 b, + 0,15 b, + 0,1 b, max. max. max. 5 mm 4 mm 3 mm
15
16
Excessive convexity
503
Actual weld thickness Required weld thickness
17
Excessive weld thickness (fillet weld)
For many applications a weld thickness in excess of the specified size does not represent grounds for rejection.
h 1 mm + 0,3 a, max. 7 mm Actual weld thickness Specified weld thickness
Excessive weld reinforcement
502
Smooth transition is required. b
h
b
h 1 mm + 0,2 a, max. 6 mm
h 1 mm + 0,15 a, max. 5 mm
18
Reduced weld thickness (fillet weld)
A fillet weld with an obviously smaller weld thickness should not be regarded as a defect provided that the actual weld thickness is compensated by a deeper penetration and by so doing achieving the specified size.
Long irregularities: not permitted Short irregularities: h 0,2 a max. 1,5 mm h 0,1 a max. 1 mm
Actual weld thickness h 0,3 a max. Required weld 2 mm thickness
19
Excessive root reinforcement
504 b
h 5 mm
h 4 mm
h 3 mm
Chapter 2 Page B4
Annex B
II - Part 3 GL 2000
No.
20
Misalignment of edges
Ref. No. in acc with ISO 6520

507
Remarks
The deviation limits relate to the correct position. Unless otherwise specified, the correct position is when the centre lines coincide.

low medium high
t relates to the smaller thickness
Fig. A - Plates and longitudinal welds h 0,5 t max. 4 mm max. 3 mm max. 2,5 mm
h 0,5 mm h 0,5 mm h 0,5 mm + 0,25 t, + 0,15 t, + 0,1 t, max. max. max. 4 mm 3 mm 2,5 mm
Fig. B - Circumferential welds 21 Incompletely filled groove 511 Smooth transition is required. b Long irregularities: not permitted Short irregularities: h 0,2 t max. 2 mm h 3 mm + 0,3 a h 0,1 t max. 1,5 mm h 0,05 t max. 1,0 mm
22
Excessively unequal leg lengths of fillet welds
512
It is assumed that an asymmetric fillet weld has not been expressly prescribed. h
h 2 mm h 1,5 mm + 0,25 a + 0,2 a
z2
z1 23 Root concavity 515 Smooth transition is required.
Long irregularities: not permitted Short irregularities:
Root notch
5013
h 0,2 t max. 2 mm
h 0,1 t max. 1,5 mm
h 0,05 t max. 1 mm
II - Part 3 GL 2000
Annex B
Chapter 2 Page B5
No.
24
Multiple irregularities in the section

-
Remarks
For thicknesses s 10 mm or a 10 mm, special parameters may be necessary
h4 h5 h2 h1

low medium high
Maximum size of short irregularities S h 0,3 s or 0,3 a, max. 10 mm 0,25 s or 0,25 a, max. 10 mm 0,2 s or 0,2 a, max. 10 mm
h1 + h 2 + h 3 + h 4 + h 5 S h h1
h4
h6
h3
h 1 + h2 + h 3 + h4 + h5 + h6 S h This table, taken from the international standards EN 30042 resp. ISO 10042 specifies requirements for three levels of acceptance for imperfections in joints of aluminium and it's weldable alloys and for thicknesses of 3 mm to 63 mm. It may be used, where applicable, for other fusion welding processes or weld thicknesses. No. 24 shows multiple imperfections, a theoretically possible accumulation of individual imperfections. In this case, the total of all permitted deviations for the determined figures of the several classification levels should be reduced. However, the value of a single imperfection h, e.g. for a single pore, should not be exceeded. The requirements given in this table should not treated as absolute limits but rather as limits that should not be exceeded with more than a defined probability. It should be noted that imperfections exceeding the size limits given are often present in a weld without impairing it's fitness-for-purpose. This table may be used in conjunction with the IIW-Catalogue ISO 10042 which contains realistic illustrations. They show the size of the permissible imperfections for the various quality levels by means of photographs of the face and root side and/or reproductions of radiographs and of photos of macrographs of the cross-section of the welds. The catalogue and it's reference cards may be used to assess the various imperfections and may be employed when opinions differ as to permissible size of imperfections. Symbols The following symbols are used in the table: A area of gas cavity a nominal fillet weld throat thickness (fillet thickness) b width of weld reinforcement d diameter or pore h size (height or weight) of imperfection l lenght of imperfection s nominal butt weld thickness or, in the case of partial penetration, the precribed depth of penetration t wall or plate thickness z nominal leg length of fillet welds (in case of isosceles right angle triangular section z = a 2)
Short imperfection: One or more imperfections of total length not greater than 25 mm in any 100 mm length of the weld or a maximum of 25 % of the weld length for a weld shorter than 100 mm. Long imperfection: One or more imperfections of total length greater than 25 mm in any 100 mm length of the weld or a minimum of 25 % of the weld length for a weld shorter than 100 mm.
h2
h3
h5
II - Part 3 GL 2000
Annex C
Comparison of Equivalent, Internationally Recognized Film System Classes
Chapter 2 Page C1
Annex C Comparison of Equivalent, Internationally Recognized Film System Classes

Manufacturer / Film type
ASTM (1)
DIN (4)
EN (4)
ISO (2)
RCC-M (5)
BS (3)
AGFA (6) Structurix Structurix Structurix Structurix Structurix Structurix Structurix D2 D3 D3 s.c. D4 D5 D7 D8 special 1 1 1 1 2 2 G1 G1 G1 G2 G2 G3 G4 Fuji (6) IX 25 IX 50 IX 80 IX 100 IX 150 1 special 1 1 2 G2 G1 G2 G2 G4 C3 C1 C3 C4 C6 Kodak (6) DR M MX125 T200 AA400 CX B
(1) (2) (3) (4) (5) (6)
C1 C2 C2 C3 C4 C5 C6
GI GI GI GI G II G III G III
1 1 2 3 34 4 5
A A A A A B B
GI GI GI G II G III
3 1 3 34 45
A A A A B
special 1 1 1 2 3 W-B
G1 G1 G2 G2 G3 G4
C1 C2 C3 C4 C5 C6
GI GI GI G II G III G III G III
ASTM E 94-93 / ASTM E 94-84 A ISO 5579 BS 2600: Type A: high contrast very fine-grain Type B: high contrast fine grain Classification in accordance with DIN EN 584-1 as compared with DIN 54117 T1 which has been replaced. French standard Provided that the appropriate proof of suitability is furnished, equivalent film types produced by other film manufacturers may also be considered.
II
3

Welding
Welding in the Various Fields of Application
Edition 2000
II - Part 3 GL 2000
Table of Contents
Chapter 3 Page 3
Table of Contents
Section 1 A. B. C. D. E. F. G. H. I.
Welding of Hull Structures General ....................................................................................................................................... Approval of Shipyards and Welding Shops, Welding Personnel ............................................... Quality Inspection, Responsibility ............................................................................................. Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials ......................................................................... Welding procedure, procedure qualification tests ...................................................................... Design, Dimensioning ................................................................................................................ Execution of Welds .................................................................................................................... Inspection of Welded Joints ....................................................................................................... 1- 1 1- 1 1- 2 1- 2 1- 3 1- 5 1- 24 1- 34 1- 41
Welding of Steam Boilers General ....................................................................................................................................... Approval of Welding Shops, Welding Personnel ....................................................................... Quality Inspection, Responsibility ............................................................................................. Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials ......................................................................... Welding procedure tests ............................................................................................................. Welding Technique .................................................................................................................... Post-Weld Heat Treatment ......................................................................................................... Inspection of Welded Components ............................................................................................ 2222222221 1 1 2 2 3 5 7 8
Welding of Pressure Vessels General ....................................................................................................................................... Approval of Welding Shops, Welding Personnel ....................................................................... Quality Inspection, Responsibility ............................................................................................. Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials ......................................................................... Welding procedure tests ............................................................................................................. Welding Technique .................................................................................................................... Post-Weld Heat Treatment ......................................................................................................... Inspection of Welded Components ............................................................................................ 3- 1 3- 1 3- 2 3- 2 3- 3 3- 3 3- 8 3- 9 3- 10
Welding of Pipelines General ....................................................................................................................................... Approval of Welding Shops, Welding Personnel ....................................................................... Quality inspection responsibility ................................................................................................ Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials ......................................................................... Welding procedure tests ............................................................................................................. Welding Technique .................................................................................................................... Heat treatments after cold or hot working and welding .............................................................. Inspection of Welded Pipelines .................................................................................................. 4- 1 4- 1 4- 2 4- 2 4- 3 4- 3 4- 5 4- 8 4- 10
Chapter 3 Page 4
Table of Contents
II - Part 3 GL 2000
Welding of Machinery Components General ........................................................................................................................................ Approval of Welding Shops, Welding Personnel ....................................................................... Quality Inspection, Responsibility .............................................................................................. Materials, Weldability ................................................................................................................ Welding Consumables and Auxiliary Materials .......................................................................... Welding procedure tests .............................................................................................................. Design, Welding Technique ........................................................................................................ Post-Weld Heat Treatment .......................................................................................................... Inspection of Welded Components ............................................................................................. 5555555551 1 2 3 3 3 8 9 9
II - Part 3 GL 2000
Section 1
Welding of Hull Structures
Chapter 3 Page 11
Section 1 Welding of Hull Structures

A. General B. Approval of Shipyards and Welding Shops, Welding Personnel Works and subworks
1.
Scope
1.
1.1 These rules apply to all welding work carried out on the ship's hull, including the superstructure and deckhouses, its internal and external structures, and equipment components forming part of the ship's structure, e.g. hatch covers, masts, king posts or crane substructures welded to the ship's hull. See also Chapter 1, Section 1, A.1. and A.2.
1.1 In the following paragraphs, the term "welding shop" refers to the shipyard or welding fabrication shop which may be considered an independent unit with regard to its physical and organizational situation. 1.2 Branches and subcontractors are thus generally deemed to be "independent" welding shops which have to satisfy the requirements prescribed below. In particular, every welding shop must have a welding supervisor who is a permanent member of the welding shop staff (cf. Chapter 1, Section 2). 1.3 Outside firms working in welding shops may be granted approval as independent welding shops. On this and on temporary workers, see also C.3. and Chapter 1, Section 1, F. 2. Requirements, scope of approval
1.2 They also apply in analogous manner to cargo tanks which are not an integral part of the ship's hull and are not pressure vessels within the meaning of Section 3 (e.g. prismatic type A tanks, according to the Rules for Construction I, Part 1, Chapter 6).
2.
Other relevant rules and regulations
The design and dimensioning of welded joints is also governed by the provisions of the Rules for Construction I, Part 1, Chapter 1, Sections 19 "Welded Joints and 20 "Fatigue Strength" and the performance of the work is also subject to the provisions of Section 1, N. of the said Rules for Construction. For other relevant standards, see Chapter 1, Section 1, B. of these Rules for Welding.
2.1 All shipyards and welding shops intending to perform welding work covered by these rules must satisfy the requirements relating to the welding shop and its personnel set out in Section 2 and must have been approved for this work by the Society. Applications for approval shall be submitted by the shipyards and welding shops in good time before starting the welding work, enclosing the information and documentation prescribed in Chapter 1, Section 2, A.3. 2.2 Welding personnel (welders, operators and supervisory staff) and where applicable inspectors and test supervisors must meet the requirements set out in Chapter 1, Section 2, B.2., B.3. and B.4. and be recognized by the Society. For welders qualification tests, see Chapter 1, Section 3. 2.3 The scope of the approval is determined by the capabilities of the welding shop and by the intended range of application (materials, welding processes, welding positions, etc.). The intended range of application shall be specified in the application for approval; cf. the form "Description of Welding Shop" attached at Annex B of Chapter 1. For the period of validity of the approval, see Chapter 1, Section 2, A.4. and A.5.
3.
Weld performance
Welded joints in hull structures shall be prepared, made and inspected in such a way that their quality characteristics are equivalent to those of the base materials to be joined. This means that they may not deviate from the prescribed form and internal condition by more than the limits allowed by the prescribed weld quality grades according to Table 1.9 or by the evaluation categories used as a basis for the notch category classification for the proof of fatigue strength (cf. Rules for Construction I, Part 1, Chapter 1, Section 20). The same applies in analogous manner to the other quality characteristics; cf. also C.
Chapter 3 Page 12
Section 1
II - Part 3 GL 2000
3.
Basic approval, extensions
3.1 For welding hull structures, as a general rule (basic) approval is granted first of all on the basis of a works inspection and, if necessary, welder's qualification tests in accordance with Chapter 1, Section 3 (see also H.2.) normally for manual arc welding (welding process 111) and/or for semi-mechanized metal-arc active gas welding using solid and flux-cored wire electrodes (welding processes 135 and 136) of normalstrength hull structural steels A to D and other comparable grades of forged and cast steel. The thickness range is in this case determined by the scope of the valid welders qualification tests. 3.2 Exceptions to this rule are single-side welding and vertical-down welding using these processes (111, 135, 136), for which welding procedure tests shall be performed in every case. Cf. F. One-wire submergedarc welding (welding process 121) may also be covered in the basic approval described in 3.1 on the basis of documentary proof in accordance with F.1.4 (for conventional welding in one run on each side [two-run technique] on plates 4 to 25 mm thick and for multipass welding up to 40 mm). 3.3 Basic approval may be extended to include any welding procedure approvals on the basis of welding procedure tests as set out in Chapter 1, Section 4 (cf. also F.); in exceptional cases, however, limited approval may also only be granted (in conjunction with a works inspection) for a specific material and/or welding process.
non-approved outside firms working in the welding shop (subcontractors), see Chapter 1, Section 1, F. Subcontracting of work or employment of temporary workers shall be notified to the Society. 4. The scope of the required quality inspections depends on the construction project in question. It is essential to ensure, however, that the intended materials, welding consumables and auxiliary materials are used and that the weld preparation, assembly, execution of the tack and final welds and the dimensional accuracy and completeness of the welded joints meets the requirements stated in para. 2. For non-destructive testing of the welded joints, see I. 5. Following inspection and, if necessary, repair by the welding shop, the components shall be presented to the Society's Surveyor for checking at suitable stages of fabrication. For this purpose they shall be readily accessible and shall normally be uncoated. Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed. 6. If the quality or good working order of a component cannot be guaranteed or is in doubt due to inadequate or missing information in the manufacturing documents (e.g. production drawings), the Society may demand appropriate improvements. This applies in analogous manner to supplementary or additional components (e.g. reinforcements), even if these components were not stipulated when the drawings were scrutinized or could not be stipulated due to insufficiently detailed representation in the "class plans" (cf. the Rules for Construction I, Chapter 1, Section 1, G.). 7. The Society is not responsible for guaranteeing that all the components and welded joints inspected to the prescribed extent (generally on a random basis) by its surveyors have been fabricated in accordance with the conditions and meet the requirements in every respect. Components or welded joints which subsequently turn out to be defective may be rejected or their repair may be demanded even if acceptance testing has already been carried out.
C.
Quality Inspection, Responsibility
1. Shipyards and welding shops shall ensure by means of regular in-house quality inspections during fabrication and on completion of the welding work that this work has been performed competently and satisfactorily (cf. Chapter 1, Section 1, F.). For the duties and responsibilities of the welding supervisor, see also EN 719/ISO 14731. 2. The shipyards and welding shops are responsible for ensuring that the welding work conforms to these Rules, the approved manufacturing documents, any conditions stipulated in the approval documents, good shipbuilding practice and the latest state of welding practice. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops of this responsibility. 3. With regard to quality inspections and the responsibilities involved in awarding subcontracts to independent branches or suppliers or to approved or
D.
1. Welded structures may only be fabricated using base materials of proven weldability. Materials must comply with the Societys Rules for Materials (Code II/1/-5). Other comparable materials (e.g. structural steels conforming to EN 10025) may only be
II - Part 3 GL 2000
Section 1
Chapter 3 Page 13
used after the Society has given its approval in each individual case. 2. Any conditions relating to working and welding imposed by the approval certificate and the recommendations of the material producer shall be complied with. For the selection of materials for the ship's hull, see the Rules for Construction I, Part 1, Chapter 1, Section 2. 3. The weldability of normal-strength hull structural steels of quality grades A, B, D and E tested by the Society is considered proven. No measures above and beyond the provisions of these Rules for Welding are necessary when welding these steels. 4. The weldability of the higher-strength hull structural steels of quality grades A 32 to F 40 approved and tested by the Society in accordance with the Rules for Materials has been checked and can be taken for granted if the work is carried out in accordance with normal shipbuilding practice. 5. High-strength (quenched and tempered) finegrained structural steels, steels tough at subzero temperatures, stainless structural steels and other (alloy) structural steels have to be specially approved by the Society. The weldability of the steel in question must have been verified in combination with welding processes and welding consumables. 6. Steel castings and forgings shall comply with the Rules for Materials and shall have been tested by the Society. The carbon content of components made from carbon and carbon-manganese steels/castings for welded structures shall not exceed 0,23 % C at ladle analysis (check analysis: max. 0,25 % C). 7. Light metal alloys must have been tested by the Society in accordance with the Rules for Materials. Their weldability must have been verified in combination with welding processes and welding consumables. It can generally be taken for granted in the case of the alloys mentioned in the Rules for Materials.
for hull structural steels and other comparable structural steels, forged steels and cast steels. 2. The correlation of the required quality grades of welding consumables and auxiliary materials for welding hull structural steels to the respective hull structural steel quality grades is shown in Table 1.1. The correlation to other comparable structural steels, forged steels and cast steels shall be undertaken in analogous manner. 3. For welding of different quality grades of hull structural steel, welding consumables and auxiliary materials shall be correlated to the steels by their quality grades and added symbols as follows: a) Normal-strength hull structural steels of different quality grades: Welding consumables and auxiliary materials for whichever is the higher-quality (tougher) hull structural steel, e.g. A with D: quality grade 2 .... b) Higher-strength hull structural steels of the same strength but with different quality grades: Welding consumables and auxiliary materials for whichever is the higher-quality, (tougher) hull structural steel, e.g. A 36 with E 36: quality grade 3 Y .... c) Normal-strength with higher-strength hull structural steels with comparable quality grades: Welding consumables and auxiliary materials for the normal-strength hull structural steel quality grade in question, e.g. D with D 36: quality grade 2 .... (without added symbol Y) d) Normal-strength with higher-strength hull structural steels with non-comparable quality grades: Welding consumables and auxiliary materials having a quality grade for the higher-quality (tougher) hull structural steel but the strength of the normal-strength steel, e.g. A with D 36: quality grade 2 .... (without added symbol Y). 4. For welding very thick-walled, rigid components (approx. 30 mm and over) and welding of forgings and steel castings, hydrogen-controlled welding consumables and auxiliary materials of quality grade 3 H15(H) shall be used (for higher-strength hull structural steels, 3Y H10(HH)). 5. The use of hydrogen-controlled welding consumables and auxiliary materials is recommended for welding of higher-strength hull structural steels to one another (and to lower-strength steels) if the carbon equivalent of these steels is over 0,41 %. See also H.5.
E.
1. All the welding consumables and auxiliary materials used (e.g. covered electrodes, wire-gas combinations, wire-flux combinations, etc.) must have been approved by the Society in accordance with Chapter 1, Section 5. The quality grade required depends on the base materials to be welded and is shown in the relevant tables in Chapter 1, Section 5, except
Chapter 3 Page 14
Section 1
II - Part 3 GL 2000
Table 1.1
Correlation of welding consumables and auxiliary materials to hull structural steel quality grades
Hull structural steel quality grades
Quality grades of welding consumables and auxiliary materials (cf. also E.3.) 1; 1S, 1T, 1M, 1TM, 1V 1YS, 1YT, 1YM, 1YTM, 1YV 2, 2S, 2T, 2M, 2TM, 2V 2Y, 2YS, 2YT, 2YM, 2YTM, 2YV 2Y40, 2Y40S, 2Y40T, 2Y40M, 2Y40TM, 2Y40V 3, 3S, 3T, 3M, 3TM, 3V 3Y, 3YS, 3YT, 3YM, 3YTM, 3YV 3Y40, 3Y40S, 3Y40T, 3Y40M, 3Y40TM, 3Y40V 4Y, 4YS, 4YT, 4YM, 4YTM, 4YV 4Y40, 4Y40S, 4Y40T, 4Y40M, 4Y40TM, 4Y40V
1 2 3
A 32/36 D 32/36 E 32/36 F 32/36 A 40
D 40
E 40
F 40
2, 3 3 3
3 3
3 3
3 3
3 3 3
Not to be used if possible, otherwise only with the Societys approval; cf. Chapter 1, Section 5; A.4.1 and A.4.2 apply in analogous manner. For A 32/36, welding consumables and auxiliary materials of quality grade 1 Y ... should where possible only be used when welding thinner plates (up to 25 mm max.). For plates over 50 to 70 mm thick, welding consumables and materials with one quality grade higher shall be used and for those over 70 and up to 100 mm thick those with two quality grades higher shall be used in each case in compliance with the higher base material requirements, cf. Rules for Materials.
Note: For steels F 32, F 36 and A 40 to F 40, no provision is made in the Rules for Materials for plates above 50 mm thick, but these shall be subject to special agreements where appropriate.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 15
6. Hydrogen-controlled welding consumables and auxiliary materials should also be used for components which are subjected to full load immediately after welding (e.g. lifting lugs or as a result of pressure tests) or where allowance has to be made for a high degree of residual stress due to the rigidity of the structure and, where applicable, a high yield strength or strength of a structure. 7. Hydrogen-controlled welding consumables and auxiliary materials shall always be used for welding high-strength (quenched and tempered) finegrained structural steels and steels tough at sub-zero temperatures, cf. Chapter 1, Section 5, F.4. For steels with a yield strength or 0,2 % proof stress of up to 500 N/mm, welding consumables and auxiliary materials with the maximum added symbol H 10 (HH) should be used and for steels with a yield strength or 0,2 % proof stress of over 500 N/mm those with a maximum added symbol H 5 (HHH) should be used. 8. For welding of austenitic stainless steels to one another and to hull structural steels, welding consumables and auxiliary materials shall be selected in accordance with Tables 5.21 to 5.23 in Chapter 1, Section 5 and the manufacturers' recommendations, taking the corrosion resistance and strength requirements and the welding metallurgy (including resistance to hot cracking) into account, and specified in a welding schedule, which is to be submitted for approval. 9. For welding aluminium alloys, the welding consumables and auxiliary materials shall be selected according to the type and condition of the material (cf. Rules for Materials, II/1/3) in accordance with Table 5.28 in Section 5 of Chapter 1 taking the required mechanical properties of the welded joints into account (cf. Rules for Construction I, Part 1, Chapter 1, Section 19, C.2.8) and shall be indicated in the production documents to be submitted for approval. 10. Welding consumables and auxiliary materials specified in a welding shop or procedure approval (cf. F.) may only be replaced by equivalent consumables approved by the Society with an appropriate quality grade if this is explicitly stated in the respective approval document. Failing this, the Society's agreement shall be obtained. 11. The welding consumables and auxiliary materials may only be used in the approved welding positions. The manufacturer's recommendations and instructions for welding (e.g. type of current and polarity) shall be followed. 12. The welding consumables and auxiliary materials (especially hydrogen-controlled, basic covered
electrodes and basic welding fluxes) shall be re-dried before use in accordance with the manufacturer's instructions (observe maximum drying time!) and stored in a dry place (in heated containers or the like) at the workplace.
Note: The guideline DVS 0504 "Handling, storage and redrying of covered electrodes" and guideline DVS 0914 "Use and storage of welding fluxes for submerged-arc and electro-slag welding" issued by the German Welding Society (Deutscher Verband fr Schweitechnik e.V) contain detailed instructions for this.
F.
Welding Procedures, Welding Procedure Tests General
1.
1.1 Only welding procedures whose suitability for the application in question is evident from general experience or has been verified by means of a welding procedure test in accordance with Chapter 1, Section 4 and the following provisions may be used. Table 4.1 in Chapter 1, Section 4 gives a list of the requisite verifications. The welding procedure must have been approved by the Society for the welding shop in question (cf. also B.). Note: In principle, the Society recognizes all welding processes which satisfy the above conditions. General reservations only exist to the extent that the operationally safe handling of these processes and the quality attainable under field conditions is called into question or contradicted by practical experience. For instance, at present no approvals are being granted for vertical-down gas-shielded welding with solid wires under mixed gas containing less than approximately 30 % CO2 due to the risk of lack of side wall fusion. Exceptions to this rule are possible if welding using robots is required, for which the welding parameters and the manipulation of the torch may be prescribed and followed so precisely that it can be verified that welding has been performed with good penetration within the narrow "safe" area. 1.2 The Society may approve specific welding processes such as vertical-down welding, build-up welding on rudderstocks or underwater welding (cf. H.13.3), the use of which is, however, dependent upon authorization, for example following an examination of the load conditions, in each individual case. For welding processes or applications of this nature, the Society may also stipulate restrictions in the operation of the vessel (e.g. in the operating area).
Chapter 3 Page 16
Section 1
II - Part 3 GL 2000
1.3 Welding procedure tests supervised by the Society for verification of satisfactory operational handling and a trouble-free execution of the procedure, and also adequate quality properties for the welded joints made under production conditions at the user's works are in general required for:
conditions (e.g. underwater welding), particular weld shapes, process variants or combinations, and also for particular welding consumables and auxiliary materials. The same applies in analogous manner to other joining processes or (surface) finishing operations such as thermal cutting or flame straightening.
1.6 The information in the preceding and following paragraphs, especially the information on test pieces, specimen shapes, tests and requirements, applies to the normal materials, welding processes and weld shapes in current use in shipbuilding, the behaviour of which under service conditions has been verified by experience and/or test results. In cases of doubt, the Society may call for additional and/or different test pieces, specimen shapes or tests to verify satisfactory suitability for use. 1.7 In the case of welding processes whose characteristics result in weld shapes other than those verified by experience and/or test results (e.g. those with a considerable notch effect), the influence of the weld shape on the fatigue strength behaviour of the welded joints may be investigated in addition to carrying out the prescribed tests. The same applies in analogous manner to other characteristics of the welded joints, e.g. corrosion resistance. 2. Scope of tests, test schedule, limits of application Test schedule, test details
materials 1 other than "simple-to-weld" hull structural steels A to D and comparable structural steels, forged steels and cast steels and also for composite materials, welding processes 2 other than those stated in B.3., which are adequately covered by general experience, welder's qualification tests and approved welding consumables, single-side welding on ceramic, flux or similar backings, welding in the vertical-down position.
1.4 For conventional single-wire submerged-arc butt welding processes using solid wire for welding normal-strength hull structural steels A to D, comparable structural steels, forged steels and cast steels from both sides, proof prior to initial use of the reliability and technical suitability of the method by means of trial welds and non-destructive (e.g. radiographic) tests as directed by the Surveyor is sufficient. The welding consumables and auxiliary materials used must have been approved by the Society. 1.5 The Society may additionally require welding procedure tests for specific (difficult) component shapes or combinations of materials, environmental
2.1
1 Materials: Normal-strength hull structural steels E and F, higher- strength hull structural steels and comparable grades of forged steels or steel castings, high-strength (quenched and tempered) finegrained structural steels, steels tough at subzero temperatures, stainless and clad steels, aluminium alloys and other non- ferrous metals. 2) Welding Processes: Manual welding processes: Vertical-down welding, deep penetration welding, single-side welding with backing, etc. Semi-mechanized welding processes: Gravity arc or auto-contact welding, single-side welding with backing, flux-cored wire metal-arc welding without shielding gas, etc. Fully-mechanized welding processes: Submerged arc welding, fusarc and flux-cored wire metal-arc welding, multiple-electrode submerged arc welding, single-side welding, fillet and double-fillet welding, electroslag welding with and without fusible wire guide nozzle electrode(s), gasshielded metal-arc welding, electrogas welding etc. Special welding processes or special applications: Stud welding, flash butt welding, friction welding, laser-beam welding, build-up welding, orbital welding of circumferential pipe welds, robot welding, etc.
2.1.1 The scope of the welding procedure tests (test pieces, specimens, tests) shall be laid down in a test schedule to be submitted for approval in good time prior to testing, in accordance with Chapter 1, Section 4, B.1. Depending on the nature and application of a welding process, the process details stipulated in Chapter 1, Section 4, B.1.1 shall be taken into account in the tests. Where no further details on the welding procedure tests are given in the following paragraphs, the provisions of Chapter 1, Section 4 and the standards of the series EN 288 / ISO 9956 shall apply. Note: The following rules relating to the welding procedure tests comply with, borrow from in part or refer to the standards of the series EN 288/ISO 9956. Compared with the previous versions of these Rules for Welding, all the details relating to the welding procedure tests which, from the shipbuilding aspect, have been satisfactorily covered in the standards, are no longer contained in these Rules or only by reference to these standards, especially to EN 288-3/ISO 9956-3 "Welding procedure tests .. Steels" and EN 288-4/ ISO 9956-4 "Welding procedure tests aluminium alloys"
II - Part 3 GL 2000
Section 1
Chapter 3 Page 17
Details specific to shipbuilding, such as material groupings, single-side welding or the inclusions and exclusions for welding positions (vertical-down welding) requiring special and specific experience and proven manipulation and which are only inadequately covered in the standards are dealt with in the following paragraphs as a departure from the standards. Under the provisions of the regulations applicable to other ranges of application (e.g. for pressure equipment), the Rules issued by the Society for shipbuilding shall be regarded as the predominant codes of practice. 2.1.2 Depending on the nature of the base material or the influence of the characteristics of the process, the Society may set out specifications which go beyond or deviate from the stipulations given in these rules or in the standards and call for different or additional tests, stipulate requirements or change the scope of application. The Society also reserves the right to interpret the standards accordingly. Where the standards contain information which is different from or contradicts these rules, these rules shall take precedence. 2.2 Base materials, material groups
given in CEN report 12187 or the anticipated followon standards. The Society may stipulate this. 2.2.2 If a welding procedure test is to be carried out for several base materials simultaneously, materials which cover both the various strength categories (...-, ...32, ...36, ...40) and the various degrees of toughness (A/A..., B, D/D..., E/E..., F...) shall be selected for hull structural steels, taking the wall thicknesses into account. The same procedure shall apply in analogous manner to other materials. 2.2.3 Based on their chemical composition (behaviour during welding) and their mechanical characteristics the various hull structural steels may be classified or, as the case may be, grouped into the following three (strength) categories:
Normal-strength hull structural steels A, B, D and E (includes comparable, general structural steels, forged steels and cast steels with minimum yield strengths up to 280 N/mm2) Higher-strength hull structural steels A 32, D 32, E 32, F 32, A 36, D 36, E 36 and F 36 (includes comparable general-purpose structural steels with minimum yield strengths of over 280 N/mm2 up to and including 355 N/mm2) Higher-strength hull structural steels A 40, D 40, E 40, F 40 (includes comparable, generalpurpose structural steels with minimum yield strengths of over 355 N/mm2 up to and including 390 N/mm2).
2.2.1 The welding procedure test shall in principle be carried out by welding the base materials for which application for approval was made. Except for hull structural steels and austenitic-ferritic duplex steels, the base materials for the welding procedure tests may be grouped into material groups in accordance with the standards of the series EN 288/ISO 9956 and the test performed using representative materials from this groups. The provisions set out in the following paragraphs apply to hull structural steels. Duplex steels are regarded as an independent material group and are not covered by the group of austenitic stainless steels Note: The provisional standard DIN V 1738, the German language version of the CEN report CR 12187 (shortly to be available in a revised version as European standard CR TR 15608 or as ISO standard) classifies weldable materials (for general use) into categories with comparable, identifying properties. These categories are finely graded to include in addition special properties such as the behaviour of materials during heat treatment. Austenitic stainless steels and austenitic-ferritic stainless steels are therefore classified into different groups. In preference to the rough classification favoured by the standards of the series EN 288/ISO 9956 (the same applies in analogous manner to the welders qualification tests conforming to EN 287/ISO 9606), it is therefore advisable to use the classification
2.2.4 Unless otherwise specified in a particular case (e.g. for welding processes with a very high heat input, such as electrogas or electroslag welding), the following conditions also apply to the selection of materials:
Within each of the three strength categories in para. 2.2.3, a satisfactory welding procedure test on a material with a higher degree of toughness also covers one steel with a lower degree of toughness Within the same degree of toughness (e.g. A, A 32, A 36, A 40), a satisfactory welding procedure test on a steel of higher strength also covers one steel of lower strength.
2.2.5 If the range of application of a welding procedure encompasses several steels belonging to one strength category or one group of degrees of toughness, the welding procedure test shall be performed on at least two steels from each strength category or each degree of toughness, as applicable. Of these, one shall represent the lowest category or degree and one the highest category or degree.
Chapter 3 Page 18
Section 1
II - Part 3 GL 2000
2.2.6 However, the Society may, when testing several base materials at the same time, dispense with testing certain steels if their influence on the quality of the welded joints is adequately covered by the tests of the other steels (in combination with the various test piece thicknesses if necessary). Some examples of material selection (without taking into account specific process characteristics or as-delivered conditions of materials) are shown in Table 1.2. 2.2.7 Where the characteristics of the process or the base materials have no appreciable influence on the test results due to the shape of the test piece or specimen or the tests performed, the Society may agree to a restriction to a few base materials or only to one. An example of this is the testing of the fillet welding process using cruciform tensile specimens, macrographic specimens and hardness measurements; in this case it is sufficient to perform the test on a steel from the highest strength category intended for the application and with the maximum possible carbon equivalent. Table 1.2 Base material categories structural steels, examples) (hull
2.3
Thicknesses of test pieces, range of wall thicknesses
2.3.1 The thicknesses of the test pieces shall be geared to the range of application and the welding process in such a way as to comply with the conditions specified in Table 1.3. As a general rule, test pieces of at least two different thicknesses shall be welded and tested for each range of application according to Table 1.2 (each base material group). For vertical-down welding, the upper thickness limit for the intended range of application shall be used for the thickness of the test piece. 2.3.2 In conjunction with the test piece thicknesses stated in para. 2.3.1, (cf. also 3.2), the throat thicknesses "a" of fillet welds shall be established such that the approval range from "0,75a" to "1,5a" covers the desired range of application. The throat thicknesses for the test piece shall therefore be selected so that the "a" dimension roughly equals half the thickness of the test piece (half the thickness of the thinner plate where the thicknesses of the plate are unequal). For (test piece) throat thicknesses of 10 mm or more, a range of application a 10 mm applies. 2.3.3 Where, for subsequent use, relatively thin fillet welds are to be applied to very thick components (cf. G.10.3.3), similar test pieces are to be welded and examined for hot cracking, underbead cracks or hardening cracks. This requirement is specially applicable to higher- and high-strength grades of steel and cast steel. 2.3.4 For the reduction of the specified fillet weld throat thicknesses where specially deep penetration is proved, see G.10.3.5. With regard to the increase of the "a" dimension when overweldable shop primers which are particularly liable to cause porosity or processes with inadequate root penetration are used, see G.10.3.6. 2.3.5 Where a fillet welding process is to be applied to plates or sections coated with overweldable shop primer, similarly coated plates are to be used for the fillet weld test pieces required for the welding procedure test. The type and thickness of the coating of shop primer shall be stated in the test report.
Range of application Quality grades Quality grades Quality grades A and B A to D A to E
Base material A or B A and D A and E A 36 and D 36 A 36 and E 36 A 36 and F 36 A 40 and D 40 A 40 and E 40 A 40 and F 40 A, D and D 36 or A, A 36 and D 36 A, D and E 36 or A, E and E 36 or A, A 36 and E 36
Quality grades A 32 to D 36 Quality grades A 32 to E 36 Quality grades A 32 to F 36 Quality grades A 40 to D 40 Quality grades A 40 to E 40 Quality grades A 40 to F 40 Quality grades A to D and A 32 to D 36 Quality grades A to E and A 32 to E 36
II - Part 3 GL 2000
Section 1
Chapter 3 Page 19
Table 1.3
Test piece thickness

Range of application 2, 3
Test piece thickness t 1
Single-run welding (single bead) and welding in one run on each side (Two-run technique) 0,8 t 0,8 t 0,8 t 0,8 t to to to to 1,1 t 1,1 t 1,1 t 1,1 t
Multi-run technique t to 2 t 3 mm to 2 t 0,5 to 2 t, max. 150 mm 0,5 t to 1,5 t
t3 3 < t 12 12 < t 100 t > 100

1
If special cooling conditions have to be complied with or particular weld shapes are prescribed, they shall be taken into account when selecting the test piece thickness; cf. also Chapter 1, Section 4, B.4. For unequal plate thicknesses the following applies: For butt welds, the average of the two plate thicknesses in the weld area weld thickness is the ruling dimension. For fillet weld joints, the lower limit of the range of application of 0,8 times the smaller test piece thickness t1 (e.g. web thickness) and the upper limit of 1,1 times the larger test piece thickness t2 (e.g. flange thickness) is the ruling dimension, but the ratio of plate thicknesses t2 to t1 shall not exceed 3. For the vertical-down welding, the test piece thickness t is always taken as the upper limit of the range of application.
3.
Test pieces, dimensions, direction of rolling, welding positions Shape and size of test pieces, direction of rolling
3.1
3.1.1 Unless other provisions are given in the paragraphs below, the shape and size of test pieces shall be selected in accordance with the series of standards EN 288/ISO 9956. The length of the test pieces shall be appropriate for the welding process and the number of specimens. Where scheduled in the fabrication work for the particular welding process in question, both butt-weld and fillet-weld test pieces shall be made. The direction of rolling of the plates for the test pieces should be parallel to the direction of the weld. 3.1.2 The length of test pieces (length of weld) for manual and semi-mechanized welding processes (cf. F.1.3 2 shall not be less than 350 mm and for fully mechanized and/or automatic welding processes the length of the test piece shall be the same as the weld length to be deposited during later fabrication work, subject to a minimum length of 1000 mm. 3.1.3 For welding in (clamping) jigs, the size of the test piece shall conform to the size of the jig. For single-side welding processes and the fully mechanized and/or automatic double fillet welding (e.g. for stiffeners on platings), the test piece shall be at least 3000 mm long. 3.1.4 In the case of vertical welding, the length of the test piece (the weld length) shall conform to the size of the jig used in fabrication. For jigs using a
fusible wire-guide electrode, the length of the test piece shall conform to the length of the wire-guide electrode or the height of the components to be welded. Any special features affecting the application of these processes (e.g. welding operations performed through the deck) shall be allowed for in the configuration of the test piece. 3.1.5 Where, in order to establish the mechanical and technological characteristics of the welded joints, especially in fully mechanized and/or automatic welding processes, test piece lengths are selected which are considerably smaller than the weld lengths to be laid down during later fabrication, the first fabrication welds shall be included as part of the welding procedure tests and, as a minimum requirement, shall be subjected to a visual inspection and non-destructive testing to ensure a trouble-free welding procedure and to detect any imperfections in the weld. 3.2 Fillet-weld test pieces (T-joint and/or double T-joint (cruciform) test pieces)
3.2.1 Fillet-weld test pieces (T-joint and double Tjoint (cruciform) test pieces) shall be joined with air gaps not greater than 0,5 mm. Depending on subsequent practice, tacks shall also be included in the test (and overwelded where applicable). The throat thickness of the fillet welds should correspond to those used in subsequent fabrication but should not be greater than 0,5 plate thickness (cf. 2.3.2 to 2.3.4). For shop primers, cf. 2.3.5. 3.2.2 Double T-joint test pieces as shown in Fig. 1.1 or Fig. 1.2 (cruciform test pieces) are always re-
Chapter 3 Page 110
Section 1
II - Part 3 GL 2000
quired when the welding procedure test relates to vertical-down welding or to the welding of high-strength steels with minimum yield strengths over 460 N/mm2, clad plates and non-ferrous metals. The Society may also require cruciform test pieces for other processes and/or materials. The throat thickness of the fillet weld "a" shall not exceed 0,5 times the plate thickness. 3.2.3 In order to simplify the process where the test pieces are broken open on alternate sides, welding may be performed on one side only of the double T-joint (cruciform) test pieces on alternate sides in the fracture area, in analogous manner to the stipulations of the codes of practice DVS 1702.
Sets of specimens acc. to F.4.5
merged-arc welding from square butt weld via singleV butt weld to double-V butt weld) are changed during a welding process within the range of application for which application for approval is made, these "shifts" in procedure shall also be allowed for by means of appropriate test pieces. 3.3.2 T-joints with full penetration welded singlebevel or double-bevel butt joints are normally regarded as butt joints, i.e. they are covered by the butt weld test pieces. For welds with incomplete penetration and for special weld forms (e.g. the deep, acuteangled open single-V butt welds used in branch pieces) the Society may, however, call for additional test pieces to at least verify adequate weld penetration and penetration conditions. 3.3.3 Test pieces are normally welded in all the conventional welding positions (for which application for approval is made). For single-side welding, a test piece which has been welded in the PC (h-v) position must always be provided. For information on the welding procedure for the test pieces, any post-weld heat treatment or other finishing work which may be required and the non-destructive tests, cf. the corresponding provisions in Chapter 1, Section 4, B. 4. Sets of specimens, test specimens, mechanical and technological tests Set of test specimens for butt welds - general provisions
100
50 3
1 50
1 50
Remaining fillet welds to be fractured on alternate sides (cf. 3.2.3)
Fig. 1.1
Double T-joint (cruciform) test piece for manual and semi-mechanized welding processes
Sets of specimens acc. to F.4.5
4.1
50
0) 00 3 (
150
0 00 1
4.1.1 For standard manual and semi-mechanized welding, one set of test specimens shall be taken from the butt-welded test pieces in accordance with the above-mentioned standards. For fully-mechanized and/or automatic welding, at least one set each shall be taken from the start and end of the weld, cf. Chapter 1, Section 4, B.8.3. The division of the test pieces into sections (preparation of specimens, marking) and the performance of the mechanical and technological tests, etc. shall be carried out in accordance with the standards or Chapter 2, Section 5 as applicable. 4.1.2 Unless otherwise agreed in a particular case, one set of butt weld specimens shall comprise the following specimens. The specimen shapes and dimensions shall conform to the provisions of the standards or Chapter 2, Section 5 as applicable: 2 transverse tensile test specimens in accordance with EN 895/ISO 4136 (for larger plate thicknesses a correspondingly greater number of specimens shall be provided to cover the full cross-section), 1 round tensile test specimen by analogy to the provisions of Chapter 1, Section 5, B.2.3 (Fig. 5.1 and 5.2) taken lengthwise from the weld
1 50
50 150
Remaining fillet welds to be fractured on alternate sides (cf. 3.2.3)
Fig. 1.2
Double T-joint (cruciform) test piece for fully mechanized welding processes Weld shapes, welding positions, heat treatment, non-destructive testing
3.3
3.3.1 Weld forms which may differ in their manner of joining (e.g. butt weld or T-joint) and plate thickness shall be included in the test. Where weld forms, welding parameters and run build-up (e.g. in sub-
II - Part 3 GL 2000
Section 1
Chapter 3 Page 111
metal if welding consumables and auxiliary materials not approved by the Society are to be used (cf. Chapter 1, Section 4, B.3.2) or if the characteristics of the welding process suggest that the weld metal itself is likely to be considerably affected. A round tensile test specimen is to be prepared in every case (except for aluminium alloys) where the mechanical properties of the weld metal are inferior to those of the base material (e.g. when welding high-strength steels). The diameter "d0" of the specimen shall be as large as possible (but not more than 10 mm) and the gauge length "L0" shall be 5 d0. The provisions of Chapter 1, Section 5, B.2. are to be applied in analogous manner. 4 transverse bend test specimens, in accordance with EN 910/(ISO 5173) half to be bent with the final pass in tension (FBB) and half with the root pass in tension (RBB), or 2 transverse bend test specimens as before and 2 side bend test specimens taken at right angles to the butt weld (SBB) in accordance with EN 910/(ISO 5173) in the case of test pieces over 12 mm thick or: 4 side bend test specimens (SBB) in the case of test pieces 20 mm thick and welding processes liable to give rise to segregations, lack of fusion or similar defects inside the weld (e.g. singleside and vertical-down welding). Note:
In the case of pairs of materials which differ in strength, it may be advisable to use butt-welded longitudinal bend test specimens (FBB and RBB) in accordance with EN 910/(ISO 5173) with the weld seam in the centre of the specimen instead of butt-welded transverse bend test specimens. See also Chapter 2, Section 5. The details of this test and the requirements (as a rule a qualitative assessment of the bending behaviour) shall be agreed on a case-by-case basis.
they shall be taken from both sides. With very large plate thicknesses and welding processes liable to cause segregation in the central zone, an additional 3 notched bar impact test specimens of each type shall be taken from the same areas in middle of the plate thickness. The dimension "a" (cf. EN 875/ISO 9016) shall be such that the point of intersection of the centre line of the specimen and the middle of the notch lies in the coarse-grained area of the heataffected zone. This dimension may be generally taken as 2 mm. Where welding procedure tests are performed on steels tough at subzero temperatures, test specimens with notches located at a = 1 mm, a = 3 mm and a = 5 mm shall be prepared, unless otherwise specified in an individual case. Depending on the base material and welding process concerned, further notched bar impact test specimens from other areas may be stipulated. Notched bar impact test specimens may be partly or wholly dispensed with where the results of these tests in connection with the use of a particular welding process are of minor significance for certain materials (e.g. austenitic stainless steels or aluminium alloys, except for lowtemperature applications). 2 macrographic (if necessary, micrographic) specimens for evaluating the grain structure. Hardness tests (Vickers HV5 or HV10) in accordance with EN 1043-1 (EN 1043-2 in the case of laser welding) shall be carried out where, having regard to the base material and the welding process, the possibility cannot be discounted that preheating and/or the heat flow during welding may affect the hardness values in such a way as to impair the toughness or strength characteristics of the weld. Hardness measurements shall always be performed on higherstrength hull structural steels and on highstrength (quenched and tempered) fine-grained structural steels with minimum yield strengths of more than 355 N/mm2. Set of butt weld test specimens for singleside welding processes
4.2
3 notched bar impact test specimens each (Charpy V-notch specimens with the notch perpendicular to the surface of the plate) in accordance with EN 875/ISO 9016, from the centre of the weld (VWT 0/1), from the fusion boundary/transition zone (VHT 0/1) and from the heataffected zone (VHT 2/1). The notched bar impact test specimens shall be taken from the last side welded, and with larger plate thicknesses
4.2.1 Sets of test specimens as specified in para. 4.1.1 and 4.1.2, but subject to the differences listed below, shall be taken from butt-weld test pieces for single-side welding processes (e.g. manual or semimechanized welding using ceramic backing or submerged-arc welding with flux backing): 2 transverse tensile test specimens, cf. para. 4.1.2.
Chapter 3 Page 112
Section 1
II - Part 3 GL 2000
1 round tensile test specimen taken lengthwise from the weld metal. This is also required when additional welding consumables (e.g. in the form of iron powder and the like) are employed or where the possibility of a metallurgical reaction between the weld metal and the backing material cannot be discounted (cf. 4.1.2) 2 transverse bend test specimens (one FBB and one RBB) and 2 side bend test specimens (SBB), cf. 4.1.2.
2 transverse tensile test specimens, cf. para. 4.1.2. 1 round tensile test specimen taken lengthwise from the weld metal. This is also required when additional welding consumables (e.g. in the form of iron powder and the like) are employed (cf. 4.1.2). 2 transverse bend test specimens (one FBB and one RBB) and 2 side bend test specimens (SBB), cf. 4.1.2.
3 notched bar impact test specimens each additionally from the root zone: from the centre of the weld seam (VWT 0/t-1), the fusion boundary/transition zone (VHT 0/t-1) and heataffected zone (VHT 2/t-1). Cf. para. 4.1.2. 2 macrographic specimens at least one of which - for manual and semi-mechanized welding processes - must pass through a starting point of welding (cf. 4.1.2). Hardness tests, cf. para. 4.1.2
4.2.2 By analogy with the provisions of para. 4.2.1, the following test specimens shall be taken from buttwelded test pieces prepared by manual or semimechanized welding processes already approved by the Society for the range of application concerned (base materials, welding positions) for the sole purpose of extending the said approval to single-side welding with backings: 2 transverse bend test specimens with the root in tension (RBB) and 2 side bend test specimens (SBB). Cf. 4.1.2 3 notched bar impact test specimens each only from the root zone: from the centre of the weld seam (VWT 0/t-1), the fusion boundary/transition zone (VHT 0/t-1) and heataffected zone (VHT 2/t-1) where normalstrength, hull structural steel grade E and/or higher-strength hull structural steels are to be welded or where stipulated for other materials (cf. 4.1.2) 2 macrographic specimens, at least one of which must pass through a starting point of welding in the case of manual and semimechanized welding processes. (cf. 4.1.2). hardness tests, cf. para. 4.1.2. Set of butt weld specimens for vertical welding processes
3 notched bar impact test specimens each from the centre of the weld seam (VWT 0/2), the edge of the weld seam (VWT a/2), the fusion boundary/transition zone (VHT 0/2) and heataffected zone (VHT 2/2). The dimension "a" shall be such that the notch lies in the coarsegrained area of the weld metal (normally about 2 3 mm). With very large plate thicknesses and welding processes liable to cause segregation in the central zone, an additional 4 notched bar impact test specimens of each type shall be taken from the same areas in the middle of the plate thickness. Cf. 4.1.2. 2 macrographic specimens at least one of which must pass through a starting point of welding (cf. 4.1.2). Hardness tests, cf. para. 4.1.2 Set of fillet weld test specimens (set of T-jointed test pieces)
4.4
4.4.1 By analogy with para. 4.1.1, two or more macrographic specimens, as applicable depending on the length of the test piece, shall be taken from the simplified (T-jointed) fillet-welded test pieces in accordance with EN 288/ISO 9956 to evaluate the penetration conditions, any irregularities in the test piece and the grain structure. If necessary, hardness measurements as described in EN 1043-1 and -2 shall be performed (cf. 4.1.2). 4.4.2 The remainder of the test pieces is to be divided into convenient portions which, after removal of one of the welds, are to be broken open on alternate sides for evaluation of the fracture (cf. EN 1320). 4.5 Set of fillet weld specimens (set of double-T jointed (cruciform) test pieces)
4.3
In accordance with Chapter 1, Section 4, B.8.3, one or more sets of test specimens as described in paras. 4.1.1 and 4.1.2 shall be taken from butt-weld test pieces for vertical welding processes (e.g. electrogas or electroslag welding) as follows:
4.5.1 As shown in Figures 1.1 and 1.2, one or more sets of test specimens shall be taken from the (cruciform) fillet-welded test pieces as called for in 4.1.1 depending on the length of the test piece as shown in Fig. 1.3. Preparation of specimens, marking, performance of mechanical and technological tests, etc. shall
II - Part 3 GL 2000
Section 1
Chapter 3 Page 113
be carried out in accordance with the provisions of Chapter 2, Section 5. 4.5.2 A set of (cruciform) fillet weld test specimens as called for in 4.5.1 shall comprise the following specimens. The specimen shapes and dimensions shall conform to the provisions of Chapter 2, Section 5. 3 cruciform tensile test specimens (Z) as shown in Fig. 1.4 for determining the tensileshear strength of the weld metal 2 macrographic specimens (M) for evaluating the penetration conditions, any irregularities in the specimens and the grain structure. If necessary, hardness measurements (cf. 4.1.2) shall be performed in accordance with EN 1043-1 and -2 (cf. 4.1.2).
Z Z Z Remainder for retests
~ 400
5. 5.1
Requirements Hull structural steels
5.1.1 In welding procedure tests and tests on production specimens relating to hull structural steels, butt weld specimens must meet the minimum requirements shown in Table 1.4. Equivalent structural steels, forged steels and cast steels shall be classified in analogous manner according to their chemical composition and mechanical characteristics. 5.1.2 The minimum impact energy values shown in Table 1.4 apply to the centre of the weld metal, the transition zone/fusion boundary and the heat-affected zone. The values for manual and semi-mechanized welding apply to all positions except the vertical-up position (PF). The values applicable to the vertical position (PF) are those for fully mechanized welding (34 J or 41 J resp.).
Note: In the fusion boundary/transition zone and/or the heat affected area of "simple" steels, (for example Grade A steels), difficulties may possibly arise in meeting the required values listed in Table 1.4 which have been derived from the requirements relating to welding consumables. In such cases, the values established during the testing of the base material and during appropriate monitoring checks may be used as reference values. The values established on the welded joint should not fall below these reference values.
50
~35 ~35 ~35
50
Fig. 1.3
Set of double-T (cruciform) test specimens
a1 + a2 = fracture section S1/2 a3 + a4 = fracture section S3/4 Breaking load F Tensile-shear strength = [N/mm2] SB width of specimen SB = S1/2 or S3/4 according to position of fracture
a1
5.1.3 In special cases (e.g. where the working temperature of the component is below 10 C), the test temperatures and impact energy values laid down in the material specifications for the testing of the steels concerned may also be stipulated for welding procedure tests in place of the test temperatures and impact energy values shown in Table 1.4. Unless otherwise agreed, these values shall then apply to all welding positions and notch positions. 5.1.4 Where the plate thickness is less than 10 mm, notched bar impact test specimens with a width corresponding to the plate thickness, and wherever possible 7,5 mm or 5 mm, may be used. In such cases the impact energy values specified in Table 1.4 shall be reduced in accordance with Table 1.5. The notched bar impact test is generally dispensed with for plates less than 5 mm thick. However, other tests of resistance to brittle fracture may be stipulated.
a4
Fig. 1.4
Cruciform tensile test specimen (weld cross section)
4.5.3 The remainder of the test pieces is to be divided into convenient portions which, after removal of one of the welds, are to be broken open on alternate sides for evaluation of the fracture, cf. EN 1320.
Chapter 3 Page 114
Section 1
II - Part 3 GL 2000
Table 1.4
Requirements applicable to hull structural steels

Yield strength (weld metal) Tensile strength Elongation (weld metal. L0 = 5 d0) Impact energy 1 [J] manual and full semimechanized mechanized. Temp. [C] + 20 305 400 22 47 34 0 20 + 20 0 335 440 22 47 34 20 40 + 20 0 375 490 22 47 34 20 40 + 20 0 400 510 22 47 41 20 40 180 22 180 22 180 22 180 22 Bending elongation gauge length 2 LS 3 [%]
Grade [N/mm2] A/B D E A 32 D 32 E 32 F 32 A 36 D 36 E 36 F 36 A 40 D 40 E 40 F 40 [N/mm2]
Bending angle (D = 3 t) 2
[%]
1 Charpy V-notch specimens, average value of three specimens. For minimum individual values and retests, see Chapter 1, Section 4, C.2.3.
With regard to the notch position and the welding positions, see 5.1.2.
2 The Society may consent to the use of a mandrel with a diameter D equal to D = 4 t if this does not adversely affect the reliability of the
test results. For bending angles, see 5.1.5.

3 The gauge length (L ) = the weld width (L ) + half the plate thickness (a/2) on each side adjacent to the weld, cf. EN 910/(ISO 5173). 0 S
Table 1.5
Required impact energy values with specimens of reduced width

Specified impact energy value to be multiplied by: 5/6 2/3
Minor pore exposures or the like up to a maximum length of 3 mm may be tolerated. The fracture surfaces of ruptured test specimens shall be evaluated. 5.1.6 Measured on cruciform tensile test specimens, the minimum tensile (tensile-shear) strength of the weld section (fracture section in accordance with Fig. 1.4) shall meet the requirements stated in Table 1.6. Table 1.6 Requirements applicable to cruciform tensile specimens
Tensile-shear strength [N/mm2] 350 430 450
Specimen section [mm mm] 10 7,5 10 5,0
5.1.5 The bending tests are to be performed using a mandrel with a diameter equal to 3 times the thickness (t) of the specimen. The Society may instead consent to the use of a mandrel with a diameter D of 4 t if this does not impair the reliability of the test results. The required bending angle of 180 under the test conditions specified in EN 910 is deemed to have been attained when the specimen has been thrust between the supporting rolls to the minimum distance indicated in this standard. The required bending elongation must be attained before the first incipient crack appears.
Grades AE A 32 F 36 A 40 F 40
II - Part 3 GL 2000
Section 1
Chapter 3 Page 115
5.2
High-strength (quenched and tempered) fine-grained steels
5.2.1 For welding procedure tests and tests on production specimens relating to high-strength (quenched and tempered) fine-grained steels, the minimum properties specified in Chapter 1, Section 5, F. for the testing of welding consumables and auxiliary materials must be met for butt-weld specimens. Unless otherwise agreed in an individual case, a bending mandrel diameter of 4 times the specimen thickness shall be used for the bending tests. Test temperatures of 20 C or below shall be selected for the notched bar impact test. 5.2.2 Measured on cruciform tensile test specimens (cf. 3.2.2), the minimum tensile strength (tensile-shear strength) of the weld section (fracture section as shown in Fig. 1.4) shall satisfy the requirements relating to the welded joint stipulated in Chapter 1, Section 5, F. 5.3 Austenitic stainless (clad) and austeniticferritic (duplex) steels
thickness may be used for the bending test and a test temperature of + 20 C for the notched bar impact test performed on austenitic stainless steels. Austeniticferritic (duplex) steels shall be tested at a temperature of 30 C. 5.3.3 Measured on cruciform tensile test specimens (cf. 3.2.2), the minimum tensile strength (tensile-shear strength) of the weld section (fracture section as shown in Fig. 1.4) shall satisfy the requirements relating to the welded joint stipulated in Chapter 1, Section 5, I. The throat thickness of the fillet welds on clad plates shall be such ( 0,5 plate thickness) that the fracture always occurs in the weld seam. 5.4 Aluminium alloys
5.3.1 For welding procedure tests and tests on production specimens relating to austenitic stainless (clad) and austenitic-ferritic (duplex) steels, the minimum properties specified in Chapter 1, Section 5, I. for the testing of welding consumables and auxiliary materials must be met for butt weld specimens. In the case of joints between different types of steel, the strength values of the base material which has the lower strength shall be used. 5.3.2 Unless otherwise agreed in an individual case, a bending mandrel diameter of 3 times the specimen Table 1.7
5.4.1 For welding procedure tests and tests on production specimens relating to aluminium alloys, the values specified in Table 1.7 shall be used as guide values for butt weld specimens taken from 5000 and 6000 series alloys as stipulated in the Societys Rules for Materials. The tensile strength of the specimens may not on any account be less than the minimum stipulated value for the base material in its "soft" condition. Different values shall be allowed for where applicable in the design and dimensioning operations. The stipulated tensile strength values apply to test specimens retaining the weld reinforcement. Other aluminium alloys shall be classified in analogous manner and the requirements for these are specified on a case-by-case basis allowing for the characteristics of the base material and the joint efficiency factors stipulated in EN 288-4/ISO 9956-4.
Requirements applicable to aluminium alloys

Base material Welded joints 1 0,2 %-proof stress 2 [N/mm2] 125 100 145 80 160 115 115 125 Tensile strength [N/mm2] 275 240 290 190 300 165 155 185 10 180 18 Bending angle 3 [degree] Bending elongation [%]
Alloy no. EN AW-5083 EN AW-5086 EN AW-5383 EN AW-5754 EN AW-6005A EN AW-6061 EN AW-6082

1 2 3
Material designation AlMg4,5Mn0,7 AlMg4 AlMg4,5Mn0,7mod. AlMg3 AlMg5,5Mn0,8ZnZr AlSiMg(A) AlMgSilCu AlSilMgMn
Using a weld consumable of a quality grade in accordance with the base material according to Chapter 1, Section 5, J. As far as established (on additional samples which are to be agreed). Bending mandrel to be selected depending on the material group and condition according to EN 288-4/ISO 9956-4.
Chapter 3 Page 116
Section 1
II - Part 3 GL 2000
5.4.2 The required bending angle of 180 under the test conditions specified in EN 910 is deemed to have been attained when the specimen has been forced between the supporting rolls to the minimum length specified in this standard. The required bending elongation must be attained before the first incipient crack appears. Minor pore exposures or the like up to a maximum length of 3 mm may be tolerated. The fracture surfaces of ruptured test specimens shall be evaluated. 5.4.3 Measured on cruciform tensile test specimens, the minimum tensile-shear strength of the weld section (fracture section in accordance with Fig. 1.4) shall generally not be less than 60 % of the stipulated tensile strength. For the allowances which may be necessary when dimensioning the fillet-welded joints (if this value is not attained), see G.10.3.2. 5.4.4 For the welding procedure tests and tests on production specimens relating to aluminium alloys, unless otherwise stipulated in individual cases, the notch impact toughness test may be dispensed with. The requirements applicable to low temperature applications will be specified separately. 5.5 Other materials
welds) can be satisfactorily achieved under the given fabricating conditions. Failing this, provision shall be made for welds which are easier to execute and the (possibly lower) load-bearing capacity of these welds shall be allowed for in the dimensional design. 1.3 Severely stressed welded joints, which are therefore normally subject to compulsory inspection, shall be designed such that the most appropriate inspection technique for the detection of defects (radiography, ultrasonic or surface crack inspection) can be applied without restriction so that tests offering reliable results can be carried out. 2. Characteristics related to materials, corrosion
2.1 Characteristics related to materials, e.g. the (inferior) strength of rolled products in the thickness direction (cf. para. 7.) or the softening of hardened aluminium alloys when welded, are to be allowed for when designing and dimensioning the components and the welded joints. 2.2 Clad plates where the efficiency of the bond between the support and the superimposed material is proven may generally be treated as solid plates (up to medium plate thicknesses with mostly fillet welds). 2.3 In thermally stressed composite structures made of different materials (e.g. hull structural and stainless steels in the case of tank heating systems), due allowance shall be made for the differences in the thermal conductivities and especially the rates of thermal expansion of the different steels. 2.4 Where pairs of different materials are exposed to seawater or other electrolytes, e.g. the welded joints between unalloyed and stainless steels in the wear linings of rudder nozzles and in build-up welds on rudderstocks, attention is to be paid to the increased tendency towards corrosion, especially at the weld, due to the differences in electrochemical potential. 2.5 If welded joints of this kind cannot be avoided, they shall whenever possible be located at points where there is less danger of corrosion (e.g. outside tanks) or special corrosion protection shall be provided (e.g. coating or cathodic protection). 3. Stress flow, transitions
The requirements applicable to other materials or other test methods will be determined on a case-by-case basis in a manner analogous to that applied to the materials covered earlier, on the basis of their chemical composition, mechanical properties and other characteristics of the base materials and with due regard for the anticipated operating conditions, such as the lowest anticipated service temperature (design temperature).
G.
Design, Dimensioning
Preliminary remark: The contents of this section are largely identical to the provisions of the Rules for Classification and Construction I, Part 1 " Seagoing Ships", Chapter 1 "Hull Structures", Section 19 "Welded Joints". Because of the time separating the reissues of the different rules, some temporary divergences may arise and in such circumstances the more recent rules shall prevail.
1.
General
1.1 The general design principles described in Chapter 2, Section 1 shall be followed. 1.2 Welded joints shall be designed to ensure that the proposed weld type and quality (e.g. complete root fusion in the case of single- and double-bevel butt
3.1 All welded joints on primary supporting members shall be designed to provide as smooth a stress profile as possible with no major internal or external notches, no discontinuities in rigidity and no obstructions to expansion (cf. also the Rules for Construction of Seagoing Ships, Chapter 1, Section 3, H.).
II - Part 3 GL 2000
Section 1
Chapter 3 Page 117
3.2 This applies in analogous manner to the welding of subordinate components onto primary supporting members whose exposed plate or flange edges should, as far as possible, be kept free from notch effects due to welded attachments. Regarding the inadmissibility of weldments to the upper edge of the sheer strake, see the Rules for Construction of Seagoing Ships, Chapter 1, Section 6, C.3.3. This applies in analogous manner to weldments to the upper edge of continuous hatchway sidecoamings. 3.3 Butt joints in long or continuous external structures, such as bilge keels, fenders, slop coamings, crane rails, hatchway cover running rails, compression bars, etc. attached to primary supporting members are therefore to be welded over their entire cross section. Their ends shall be designed in analogous manner to the ends of the doubling plates (cf. 6.4) with "smooth" transitions into the component underneath. 3.4 Wherever possible, welded joints (especially site joints) in girders and sections shall not be located in areas of high bending stress. Joints at the buckling points of flanges are to be avoided. Full penetration welds uniting three plates with additional fillet welds applied from the rear side in analogous manner to Fig. 1.18 on buckle stiffeners are generally acceptable. 3.5 The transition between differing component dimensions shall be smooth and gradual. Where the depth of web of girders or sections differs, the flanges or bulbs are to be bevelled and the web slit and expanded or pressed together to equalize the depth of the members so that the flanges or bulbs, as applicable, may be satisfactorily welded together. The length of the transition should equal at least twice the difference in depth. 3.6 Where the plate thickness changes at joints running perpendicular to the direction of the main stress, differences in thickness greater than 4 mm (greater than 3 mm where the thickness of the thinner plate is less 10 mm) must be accommodated by bevelling the proud edge in the manner shown in Fig. 1.5 at a ratio of at least 1 : 3 or less according to the notch category (cf. the Rules for Construction of Seagoing Ships, Chapter 1, Section 20, Table 20.3). Differences in thickness up to the values stated above may be accommodated within the weld. 3.7 For the welding on of plates or other relatively thin-walled elements, steel castings and forgings must be appropriately tapered or provided with integrally cast or forged welding flanges in accordance with Fig. 1.6. Failing this, the Society may approve a correspondingly thicker transition piece welded over its entire cross-section to the steel casting or forging in a manner analogous to that for shaft brackets (cf. Fig.
1.24 and 1.25) or to that for the horizontal rudder coupling flanges (cf. Fig. 1.26)
max. 4 (3)
3 1:
Fig. 1.5
Accommodation of differences in thickness

30
Fig. 1.6
Welding flange on steel castings and forgings
3.8 For the connection of shaft brackets to the hub and the shell plating, see 13. and the Rules for Construction of Seagoing Ships, Chapter 1, Section 13, D.1.; for the connection of horizontal coupling flanges to the rudder body, see 14. For the thickened rudderstock collar required with build-up welds and for the connection of the coupling flange, see 9. and 14. respectively and the Rules for Construction of Seagoing Ships, Chapter 1, Section 14, D.2.4. The connection between the rudderstock and the coupling flange must be welded over the entire cross section. 4. Local clustering of welds, minimum spacing, socket weldments
4.1 Local clustering of welds and short distances between welds are to be avoided. Where account has to be taken of higher residual welding stresses due to thicker plates or welds and corresponding rigidity of the components, the preparation should allow for the fact that adjacent butt welds should be separated from each other by a distance of at least 50 mm + 4 plate thickenss Fillet welds should be separated from each other and from butt welds by a distance of at least 30 mm + 2 plate thickenss In this case, the applicable dimensions are edge of fillet weld to edge of fillet weld or edge of fillet weld to centre of butt weld. The width of interchangeable sections (strips) of plates should, however, be at least 300 mm or ten times the plate thickness, whichever is
Chapter 3 Page 118
Section 1
II - Part 3 GL 2000
the greater. Other dimensions shall be subject to approval by the Society in each individual case as part of the examination of the drawings.
Note: In special cases, for example where plating bends over its length (e.g. the inner bottom plating in the fore section of the hull or lateral longitudinal bulkheads in the fore and aft sections of the hull), especially in the lower plate thickness range (up to approx. 20 mm) it may be advisable, in order to improve buckle stiffening - or where the weld throat thicknesses are not too large (up to about 5 mm) - to reduce the distances stated above or even position the buckle stiffening section or the like directly on the plate weld causing the buckling. Although the extra fillet welds on the butt joint produce an additional clustering of welds and thus residual welding stresses, this is relatively minor compared with the residual welding stresses which occur in larger plate thicknesses and the correspondingly larger number of passes and may therefore be acceptable as a way of increasing the strength properties of the design. For permitted tolerances, see H.3.
[t]
r 25 2t
r 25 2t [t]
Fig. 1.7 Welding apertures
Where the welds are completed prior to the 5.2 positioning of transverse members, no welding apertures are needed. Any weld reinforcements present are to be machined off prior to positioning the transverse member, or the members to be positioned are to be notched accordingly.
6. Local reinforcements, plate doublings
4.2 Reinforcing plates, welding flanges, drain unions, mountings and similar components socketwelded into plating should be of the following minimum size:
6.1 Where platings (including girder plates and tube walls) are subjected locally to increased stresses, thicker plates should be used wherever possible in preference to plate doublings. Bearing bushes, hubs, etc. shall invariably take the form of thicker sections welded into the plating (cf. 4.2). 6.2 Where doublings cannot be avoided, the thickness of the doubling plate should not exceed twice the plating thickness. Doubling plates whose width is greater than approximately 30 times their thickness shall be plug-welded to the underlying plating in accordance with 10.5 at intervals not exceeding 30 times the thickness of the doubling plate.
D min = 170 + 3 ( t 10) 170 mm where D t = Diameter of round or length of side of angular socket weldments in [mm] = Plating thickness in [mm]
5.
Welding apertures Fig. 1.8 Weld at the ends of doubling plates 6.3 Along their (longitudinal) edges, doubling plates shall be continuously fillet welded with a throat thickness "a" of 0,3 the doubling plate thickness. At the ends of doubling plates, the throat thickness "a" at the end faces shall equal 0,5 the doubling plate thickness t, but shall not exceed the plating thickness (see Fig. 1.8).
Welding apertures for the (later) execution of 5.1 butt or fillet welds following the positioning of transverse members should be rounded (minimum radius 25 mm or twice the plate thickness, whichever is the greater) and (especially where the loading is mainly dynamic) should be shaped to provide a gentle transition to the adjoining surface and adequately notch-free welding should be carried out around the end faces as shown in Fig. 1.7.
With angular socket weldments, the corner radii should be at least 50 mm or the "longitudinal seams" should be extended beyond the "transverse joints". Socket weldments shall be welded to the surrounding plating over the entire cross-section. For the provisions relating to the increase in stresses due to possible differences in thickness, cf. the Rules for Construction of Seagoing Ships, Chapter 1, Section 20, B.1.3.
b/2
~ 1,5 b
r 2t
2t
II - Part 3 GL 2000
Section 1
Chapter 3 Page 119
6.4 The weld joining the end faces to the plating should make a smooth transition with the latter at an angle of 45 or less.
8.
Welding of cold-formed sections, bending radii
Where proof of fatigue strength is demanded, (cf. Section 20 of Chapter 1of the Rules for Construction of Seagoing Ships) the ends of the doubling plates must be designed so that they comply with the detail category selected.
6.5 Doubling plates are not acceptable in tanks for flammable liquids, gases or chemicals. 7. Transverse members, stress in the thickness direction
8.1 In structural steels with a tendency towards strain ageing, welding of the cold-formed sections with more than 5 % permanent elongation 4 and the adjacent areas with 5 plate thickness should be avoided wherever possible. In case of doubt the Society may demand proof (e.g. in the form of notched bar impact tests) that cold forming and subsequent welding have not caused any unacceptable reduction in toughness characteristics. 8.2 Welding of the cold-formed sections and adjacent areas of hull structural steels and comparable structural steels (e.g. quality groups S.J. or S.K. conforming to EN 10025) may be performed, provided that the minimum bending radii are not less than those specified in Table 1.8. Table 1.8 Minimum bending radii for welding of cold-formed sections
Minimum inner bending radius r 1 1,5 2 3 5 t t t t t
7.1 Where, in the case of members lying transverse to each other, plates or other rolled products are stressed in the thickness direction by residual stresses due to the welding and/or by applied loads, suitable measures shall be taken in the design and fabrication of the structures to prevent lamellar tearing (stratified fractures) due to the anisotropy of the rolled products. 7.2 Such measures include the use of suitable weld shapes with a minimum weld volume and an appropriate welding sequence designed to reduce transverse shrinkage. Other measures are the distribution of the stresses over a larger area of the plate surface by using a build-up weld or the "joining together of several layers" of members stressed in the thickness direction, as exemplified by the deck stringer/sheer strake joint shown in Fig. 1.17. 7.3 Where there are very severe stresses in the thickness direction (due, for example, to the aggregate effect of the shrinkage stresses of bulky single- or double-bevel welds plus high applied loads), plates with guaranteed through thickness strength properties are to be used (higher degree of purity and guaranteed minimum reductions in area of 20 % of tensile test specimens taken in the thickness direction 3. 7.4 Sandwiched flat bar steel positioned transversely to the direction of force (e.g. for use as backings for plug welding or to accommodate excessive air gaps) are not permitted where components intersect.
Plate thickness t 4 mm 8 mm 12 mm 24 mm over 24 mm or less or less or less or less
Note: The bending capacity of the material may necessitate a larger bending radius.
8.3 For other steels and, where applicable, other materials, the necessary minimum bending radius shall, in case of doubt, be established by test. Proof of adequate toughness after welding may be stipulated for steels with minimum yield strengths of more than 355 N/mm2 and plate thicknesses of 30 mm and above which have undergone cold forming resulting in 2 % or more permanent elongation.

3 See the Rules for Materials and Welding, Part, 1, Metallic Materials, Chapter 2, Section 1, I., and also Supply Conditions 096 for Iron and Steel Products, "Plate, strip and universal steel with improved resistance to stress perpendicular to the product surface" issued by the German Iron and Steel Makers' Association. 4 Elongation A in the outer tensile stressed zone:
= 100 1+ 2r / t [%]
r = inner bending radius in [mm] t = plate thickness in [mm]
Chapter 3 Page 120
Section 1
II - Part 3 GL 2000
9.
Build-up welds on rudderstocks and pintles
10. 10.1
Weld shapes and dimensions Butt joints
9.1 Wear-resistant and/or corrosion-resistant build-up welds on the bearing surfaces of rudderstocks, pintles, etc. shall be applied to a thickened collar exceeding by at least 20 mm the diameter of the adjoining part of the shaft. 9.2 Where a thickened collar is impossible for design reasons, the build-up weld may be applied to the smooth shaft provided that relief-turning in accordance with 9.3 is possible (leaving an adequate residual diameter). 9.3 After welding, the transition areas between the welded and non-welded portions of the shaft shall be relief-turned with large radii, as shown in Fig. 1.9, to remove any base material whose structure close to the concave groove has been altered by the welding operation and in order to effect the physical separation of geometrical and "metallurgical" notches.
Built-up weld on thickened collar Transition to be reliefturned after welding
10.1.1 Depending on the plate thickness, the welding process and the welding position, butt joints shall take the form of square, V or double-V welds (double V butt joints) conforming to the standards (e.g. EN 22553, EN 29629, DIN 8551 Part 4, DIN 8552 or DIN 8553). The weld shapes shall be illustrated in the drawings or in other production documents, together with the standard symbols. 10.1.2 Where weld shapes are proposed other than those specified in the standards, these are to be specially described in the drawings. Weld shapes for special welding processes (e.g. submerged-arc, singleside welding, electrogas or electroslag welding) must have been tested and approved in the context of a welding procedure test. 10.1.3 As a matter of principle, the rear sides of butt joints shall be grooved and welded with at least one backing run (capping pass). Exceptions to this rule, as in the case of submerged-arc welding or the welding processes mentioned in para. 10.1.1, require testing and approval in the context of a welding procedure test. 10.1.4 Where the aforementioned conditions cannot be met (e.g. where the welds are accessible from one side only), the joints shall be executed as lesser bevelled welds with an open root and an attached or an integrally machined or cast permanent weld pool support (backing), as shown in Fig. 1.11.
30 30
4 1 : wer llo sha or
Fig. 1.9
Build-up welds applied to rudder-stocks and pintles
9.4 If, during a repair, a build-up weld is exceptionally to be applied to the smooth shaft without relief turning with the special permission of the Society, this weld shall be made in analogous manner to 9.3 (at an adequate distance beyond the zone of maximum bending stress) as shown in Fig. 1.10 in such a way that at least two passes of weld metal remain in the smooth part of the shaft after machining. The transition between the build-up weld and the shaft must be machined cleanly and free of notches.
to be machined off after welding
D/4 min. 50
Fig. 1.11 Single-side welds with permanent weld pool supports (backings) 10.1.5 The effective weld thickness is deemed to be the plate thickness or, where the plate thicknesses differ, the lesser plate thickness. Where proof of fatigue strength is required (see para. 15.3), the detail category depends on the workmanship (geometry and quality) of the weld. 10.1.6 The weld shapes illustrated in Fig. 1.12 shall be used for clad plates. These weld shapes shall be used in analogous manner for corner joints and for joining clad plates to (unalloyed and low-alloy) hull structural steels.
1:4
Fig. 1.10 Repair made by build-up welding 9.5 Build-up welding may only be carried out using a fully mechanized process approved by the Society (e.g. 12, submerged-arc welding) in the circumferential direction on a rotating fixture.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 121
60
60
2-3
h
45
h/3 t
Welding the support material at an adequate disdance from the cladding material
Fig. 1.14 Single- and double-bevel welds with defined incomplete root penetration
Grooving out the clad side of the plate
Welding the clad side of the plate in at least two passes, using special interpass electrodes where necessary
Fig. 1.12 Weld shapes for welding of clad plates 10.2 Corner, T and double-T (cruciform) joints
The effective weld thickness may be deemed to be the thickness t (- f) of the abutting plate, the assumed incomplete root penetration f = 0,2 t, max. 3 mm, being compensated for by means of additional fillet welds of at least equal size applied to each side. As a practical dimension, a leg length of z = h/3 at the root of the weld may be prescribed where h is the depth of the weld as shown in the figure. If proof of fatigue strength is required (see para. 15.3), these welds may also be placed in detail category no. 21 in accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 20, Table 20.3.
10.2.3 Corner, T and double-T (cruciform) joints with an unwelded root face "c" and an incomplete root penetration "f" which is also to be allowed for shall be executed in accordance with Fig. 1.15.
10.2.1 Corner, T and double-T (cruciform) joints with full root penetration connection of the abutting plates shall be executed as single- or double-bevel welds with a minimum root face and adequate air gap, as shown in Fig. 1.13, and with grooving of the root and capping from the opposite side.
The effective weld thickness is deemed to be the thickness of the abutting plate t (c + f), where f is to be assigned a value of 0,2 t subject to a maximum of 3 mm. Where proof of fatigue strength is required (see para. 15.3), and depending on the plate thickness to weld thickness ratio, these welds are to be classified according to type 22 or 23 in accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 20, Table 20.3.
f/2 c f/2 c
2-3
45
2-3
45
f/2
f/2
45
Fig. 1.13 Single- and double-bevel welds with full root penetration
The effective weld thickness is deemed to be the thickness of the abutting plate. Where proof of fatigue strength is required (see 15.3), the detail category depends on the workmanship (geometry and quality) of the weld. These welds are to be classified according to type 21 in accordance with Chapter 1, Section 20, Table 20.3 of the Rules for Construction of Seagoing Ships.
10.2.2 Corner, T and double-T (cruciform) joints with a defined incomplete root penetration "f", as shown in Fig. 1.14 shall be executed as single- or double-bevel welds, as described in para. 10.2.1, with capping from the rear side but without grooving of the root.
45
Fig. 1.15 Single- and double-bevel welds with unwelded root face and defined incomplete root penetration 10.2.4 Corner, T and double-T (cruciform) joints which are accessible from one side only may be executed in accordance with Fig. 1.16 in a manner analogous to the butt joints referred to in para. 10.1.4 using a weld pool support (backing) or as single-side singlebevel welds laid down in a manner similar to that prescribed in para. 10.2.2.
2-3
45
Chapter 3 Page 122
Section 1
II - Part 3 GL 2000
The effective weld thickness shall be determined by analogy with para. 10.1.5 or 10.2.2, as appropriate. Wherever possible, these joints should not be used where proof of fatigue strength is required (see para. 15.3).
45
6 f
2a
2a
5 1
1 5
5 1
1 5
2-3
45
Fig. 1.18 Welding together three plates

t
10.3
Fillet weld joints
Fig. 1.16 Single-side welded T-joints 10.2.5 Where corner joints are flush, i.e. with neither of the plates standing proud, the weld shapes shall be as shown in Fig. 1.17 with bevelling of the perpendicularly juxtaposed plates to avoid the danger of lamellar tearing (stratified fracture, cf. 7.). A similar procedure is to be followed in the case of fitted Tjoints (uniting three plates) where the perpendicular plate illustrated is to be socketed (between two horizontal plates).
15
2-3
2-3 30
15
30
10.3.1 Fillet welds shall normally be made on both sides, and exceptions to this rule (as in the case of closed box girders and predominant shear stresses parallel to the weld) are subject to approval in each individual case. The throat thickness "a" of the weld (the height of the inscribed isosceles triangle) shall be determined in accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 19, Table 19.3 or by calculation in accordance with 15. The leg length "z" of a fillet weld is to be not less than 1,4 the throat thickness "a". For fillet welds at doubling plates, see 6.3; for the welding of deck stringers to sheer strakes, see the Rules for Construction of Seagoing Ships, Chapter 1, Section 7, A.2.1, and for bracket plate connections, see Section 19, C.2.7. 10.3.2 The relative fillet weld throat thicknesses specified in the above-mentioned Table 19.3 relate to normal- and higher-strength hull structural steels and comparable structural steels. They may also be applied to high-strength structural steels and non-ferrous metals provided that the tensile-shear strength of the weld metal used is at least equal to the tensile strength of the base material. Failing this, the "a" dimension shall be increased accordingly and the necessary increment shall be established during the welding procedure test. Alternatively, proof by calculation taking account of the properties of the weld metal may be presented.
Note: In the case of higher-strength aluminium alloys (e.g. AlMg 4,5 Mn), such an increment may be necessary for cruciform joints subject to tensile stresses, as experience shows that in the welding procedure tests the tensile-shear strength of fillet welds (made with matching filler metal) often fails to attain the tensile strength of the base material. Cf. F.5.4.3.
5 4
Fig. 1.17 Flush fitted corner joints 10.2.6 Where, in the case of T-joints (uniting three plates), the direction of the main stress lies in the plane of the horizontal plates (e.g. the plating) shown in Fig. 1.18 and the connection of the perpendicular (web) plates is of secondary importance, welds uniting three plates may be made in accordance with Fig. 1.18 (with the exception of those subjected mainly to dynamic loads).
The effective thickness of the weld uniting the horizontal plates shall be determined by analogy with 10.1.5. The requisite "a" dimension is determined by the joint uniting the vertical (web) plates and shall, where necessary, be determined in accordance with the Rules of Construction of Seagoing Ships, Chapter 1, Section 19, Table 19.3 or by calculation as for fillet welds.
10.3.3 The throat thickness of fillet welds shall not exceed 0,7 times the lesser thickness of the parts to be welded (the web thickness, for instance). The minimum weld thickness is defined by the expression:
II - Part 3 GL 2000
Section 1
Chapter 3 Page 123
a min =
t1 + t 2 mm , 3 but not less than 3 mm
which may be stipulated. The details of this shall be agreed with the Society on a case-by-case basis.
where t1 t2 = lesser (e.g. the web) plate thickness in [mm] = greater (e.g. the flange) plate thickness in [mm]
Cf. Chapter 2, Section 1, E.2.

10.3.4 It is desirable that the fillet weld section should be flat faced with smooth transitions to the base material. Where proof of fatigue strength is required (see para. 15.3), machining of the weld (grinding to remove notches) may be required depending on the detail category. The weld should penetrate at least close to the theoretical root point (cf. Fig. 1.19). 10.3.5 Where mechanized welding processes are used which ensure deeper penetration extending well beyond the theoretical root point and where such penetration is uniformly and dependably maintained under production conditions, approval may be given for this deeper penetration to be allowed for in determining the throat thickness. The effective dimension
10.3.6 When welding on top of shop primers which are particularly liable to cause porosity, an increase of the "a" dimension by up to 1 mm may be stipulated depending on the welding process used. This is especially applicable where minimum fillet weld throat thicknesses are employed. The size of the increase shall be decided on a case-by-case basis allowing for the nature and the severity of the loading according to the results of the examination of the shop primer in accordance with Chapter 1, Section 6 or of the welding procedure tests or production tests, as applicable. This applies in analogous manner to welding processes where provision has to be made for inadequate root penetration. 10.3.7 Strengthened fillet welds continuous on both sides are to be used in areas subjected to severe dynamic loads (e.g. for joining the longitudinal and transverse girders of the engine base to top plates close to foundation bolts, cf. the Rules for Construction of Seagoing Ships, Chapter 1, Section 8, C.3.2.5 and Section 19, Table 19.3) unless single- or double- bevel welds are stipulated in these locations. In these areas the fillet weld throat thickness "a" shall equal 0,7 times the lesser thickness of the parts to be welded. 10.3.8 Intermittent fillet welds may be located opposite each other (chain intermittent welds, possibly with scallops) or may be offset (staggered welding), in accordance with the Rules for Construction of Seaoging Ships, Chapter 1, Table 19.3 (cf. Fig. 1.20). The use of different scallop shapes and dimensions may be agreed on for very small sections.
25
a deep = a +
2 min e 3
mm
shall be ascertained in accordance with Fig. 1.19 and by applying the term "min e", which is to be established for each welding process by a welding procedure test. The throat thickness shall not be less than the minimum throat thickness related to the theoretical root point.
theoretical root point
h 75 4
e 150 e b=e+
Fig. 1.19 Fillet welds with increased penetration

Note: In the case of welding processes where there is a particularly deep, narrow penetration, as occurs for example in laser welding without welding consumable in which no significant fillet weld is produced but the entire welded joint is virtually shifted "inwards", the above requirement for a specific minimum fillet weld thickness may be difficult or impossible to meet. In such cases the extent of the effect of the weld shape (if any) on the characteristics of the welded joint (e.g. resistance to cracking, strength) shall be assessed and/or verified in the welding procedure test, taking into consideration any fatigue strength requirements
e
b=e+
Fig. 1.20 Scallop, chain and staggered welds
In water and cargo tanks, in the bottoms of fuel tanks and of rooms where pools of condensation or spray water may collect, and in hollow components (e.g. rudders) threatened by corrosion, only continuous fillet welds or intermittent welds with scallops shall be
e in m e
[t]
Chapter 3 Page 124
Section 1
II - Part 3 GL 2000
used. The same applies in analogous manner to areas, components or compartments which are exposed to extreme weather conditions or to a corrosive cargo. There shall be no scallops in areas where the plating is subjected to severe stresses (e.g. in the bottom section of the fore ship) and continuous welds are to be preferred where the loading is chiefly dynamic.
10.3.9 The throat thickness au of intermittent fillet welds is to be determined according to the selected pitch ratio b/l by applying the following formula:
determined by analogy with the pitch "b" and the fillet weld length "l" in the intermittent welds covered by para. 10.3. The fillet weld throat thickness "au" may be established in accordance with 10.3.9.
10.5.2 The width of the holes shall be equal to at least twice the thickness of the plate and shall not be less than 15 mm. The ends of the holes shall be semicircular. 10.5.3 Plates or sections placed underneath should at least equal the perforated plate in thickness and should project on both sides to a distance of 1,5 the plate thickness subject to a maximum of 20 mm. Wherever possible, only the necessary fillet welds shall be made, while the remaining void is packed with a suitable filler. 10.5.4 11.
au where a
= a
b 11 , l
mm
= necessary fillet weld throat thickness for a continuous weld conforming to the Rules for Construction of Seaoging Ships, Chapter 1, Table 19.3, or determined by calculation in [mm] = pitch = e + l in [mm]
Lug-joint welding is not permitted.

Welding at the ends of girders and stiffeners
b e
l
= interval between the welds in [mm] = length of fillet weld in [mm]
The pitch ratio b/l may not be greater than 5. The maximum unwelded length (b l with scallop and chain welds or b/2 l with staggered welds) shall not exceed 25 times the lesser thickness of the parts to be welded. However, the length of the scallops shall not exceed 150 mm.
10.4 Lapped joints
As shown in Fig. 1.21, the web at the end of 11.1 intermittently welded girders or stiffeners is to be continuously welded to the plating or the flange plate, as applicable, over a distance at least equal to the depth "h" of the girder or stiffener subject to a maximum of 300 mm. Regarding the strengthening of the welds at the ends, normally extending over 0,15 of the span, see the Rules of Construction for Seagoing Ships Chapter 1, Section 19, Table 19.3.
no scallops
10.4.1 Lapped joints running transversely to the main direction of load should be avoided wherever possible and may not be used for heavily loaded components. Lapped welds may be accepted for components subject to low loads (excluding, however, tanks for chemicals, combustible liquids or gases) provided that wherever possible, they are orientated parallel to the direction of the main stress. 10.4.2 The width of the lap shall be 1,5 t + 15 mm (t = thickness of the thinner plate). Except where another value is determined by calculation, the fillet weld throat thickness "a" shall equal 0,4 times the thickness of the thinner plate, subject to the requirement that it shall not be less than the minimum throat thickness prescribed in para. 10.3.3. The fillet weld must be continuous on both sides and must meet at the ends. 10.5 Plug welding
1,7 h
20
b b b
Fig. 1.21 Welds at the ends of girders and stiffeners 11.2 The areas of bracket plates should be continuously welded over a distance at least equal to the length of the bracket plate. Scallops shall be located only beyond a line imagined as an extension of the free edge of the bracket plate. 11.3 Wherever possible, the free ends of stiffeners shall abut against the transverse plating or the webs of sections and girders so as to avoid stress concentrations in the plating. Failing this, the ends of the stiffeners shall be cut off obliquely and shall be continuously welded in accordance with Fig. 1.21 over a distance of at least 1,7 h, subject to a maximum of 300 mm. Different dimensions may be agreed for very small sections.
10.5.1 In the case of plug welding, the plugs should, wherever possible, take the form of elongated holes lying in the direction of the main stress. The distance between the holes and the length of the holes may be
II - Part 3 GL 2000
Section 1
Chapter 3 Page 125
11.4 Where butt joints occur in flange plates, the flange shall be continuously welded to the web on both sides of the joint over a distance "b" at least equal to the width of the flange.
11.5 In the case of girders lying transversely to each other, e.g. as shown in Fig. 1.21, and section passages, a continuous weld shall also be made, by analogy with 11.1, on the girder depicted in section in the figure on both sides of the point where the girders cross.
Where the joint lies in the plane of the plate, 12.2 it may conveniently take the form of a single-bevel butt weld with fillet. Where the joint between the plate and the section end overlaps, the fillet weld must be continuous on both sides and must meet at the ends. The necessary "a" dimension is to be calculated in accordance with the Rules of Construction for Seagoing Ships, Chapter 1, Section 19, C.2.6. The fillet weld throat thickness shall not be less than the minimum specified in 10.3.3.
13. Welded shaft bracket joints
12.
Joints between section ends and plates
12.1 Welded joints uniting section ends and plates (e.g. at lower ends of frames) may be made in the same plane or lapped. Where no design calculations have been carried out or stipulated for the welded connections, the joints may be made analogously to those shown in Fig. 1.22.
13.1 Unless cast in one piece or provided with integrally cast welding flanges analogous to those prescribed in 3.7 (see Fig. 1.23), strut barrel and struts are to be joined to each other and to the shell plating in the manner shown in Fig. 1.24.
[t]
Fig. 1.23 Shaft bracket with integrally cast welding flanges
d 1,75 h
d h 0,67 h
2
[t]
[t']
2d
200
h
1 1
t'
smoothly rounded joint contours
300 2
t=
plating thickness in accorordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 6, F in [mm] 2/3dmax + 5 3 3 d [mm] for d < 50 mm [mm] for d 50 mm
d 1,5 h 1 0,75 h 2 0,33 h
d 1,5 h 1 0,5 h 2 0,75 h
t' = t' =
Fig. 1.22 Joints uniting section ends and plates
Fig. 1.24 Shaft bracket without integrally cast welding flanges
Chapter 3 Page 126
Section 1
II - Part 3 GL 2000
13.2 In the case of single-strut shaft brackets, no welding may be performed on the arm at or close to the position of constraint. Such components must be provided with integrally forged or cast welding flanges. Alternatively, a design in accordance with Fig. 1.25 may be used, subject to the consent of the Society in each individual case. If so, it is essential to keep the concave groove free from welds or other notches.
Allowance shall be made for the reduced 14.2 strength of the coupling flange in the thickness direction (cf. 2.1 and 7.). In case of doubt, proof by calculation of the adequacy of the welded connection shall be produced.
14.3 The use of horizontal couplings for spade rudders is permitted only if the specified thickness of the coupling flanges is less than 50 mm. If this is not the case, taper couplings shall be used. Taper couplings are the only type permitted for highperformance spade rudders. Cf. also Rules for Construction of Seagoing Ships, Chapter 1, Section 14, D.1.4 and 2.4. 14.4 The welded joint between the rudder shaft (with thickened collar, cf. para. 3.8) and the flange shall be made in accordance with Fig. 1.27 in such a way that the concave groove at the transition to the thickened collar remains absolutely free of welds. Where necessary, the transition shall be machined to remove notches. For larger flange thicknesses, it is advisable to carry out a single-U weld preparation instead of a double- bevel butt weld.
D
10
Fig. 1.25 Single-strut shaft bracket
14.
Rudder coupling flanges
[t]
5 tf 300
[t]
Fig. 1.27 Welded joint between rudder shaft and coupling flange 15. Design calculations applied to welded joints
t=
plating thickness in accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 14, E.3.1 in [mm]. actual flange thickness tf + 5 3 3 tf [mm] for tf < 50 mm [mm] for tf 50 mm
tf =
t' = t' =
Fig. 1.26 Horizontal rudder coupling flanges
15.1 Any calculation relating to welded joints which is stipulated in the Rules or prescribed as an alternative to the rules governing dimensions shall be performed in accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 19, C. Calculations conforming to other rules, standards or codes (e.g. DIN 15018, DIN 18800 or DIN EN V 1993 (Eurocode 3)) are subject to the prior consent of the Society.
2 mm
tf
30
8 mm
to be machined off after welding
5m
14.1 Unless forged or cast steel flanges with integrally forged or cast welding flanges in conformity with 3.7 are used, horizontal rudder coupling flanges are to be joined to the rudder body by plates of graduated thickness and full penetration single- or doublebevel welds as prescribed in 10.2.1 (see Fig. 1.26). Cf. also the Rules for Construction of Seagoing Ships, Chapter 1, Section 14, D.1.4 and 2.4.
R 100
a 1 1 = b 3 5
mm
II - Part 3 GL 2000
Section 1
Chapter 3 Page 127
15.2 Proof by calculation of adequate dimensioning with mainly static loading (a general stress analysis) is required where the thickness of butt welds, T-joints or double-T (cruciform) joints cannot be regarded as equal to the plate thickness (cf. 10.1.5, 10.2.1 to 10.2.4, 10.2.6 and elsewhere) or the throat thicknesses of fillet welds do not conform to the tables (cf. the Rules for Construction of Seagoing Ships, Chapter 1, Section 19, Table 19.3). 15.3 For welded joints subjected to mainly dynamic loads, the permissible loading shall be determined by reference to the number of load alternations, the global loading conditions, the mean stress and the notch category (proof of fatigue strength). The notch category is a function of the geometrical configuration of the welded joint. It is also associated with (graduated degrees of) proof of the absence of serious internal and external notches (welding defects). Cf. the notch category catalogue in the Rules for Construction of Seagoing Ships, Chapter 1, Section 20.
2.3 Welders working with higher-strength hull structural steels, special structural steels, stainless steels or aluminium alloys must be qualified for welding these materials in analogous manner to the provisions of Chapter 1, Section 3. 2.4 Operators for fully mechanized and automatic welding equipment must have received instruction and training in the use of the equipment and must be qualified in accordance with the provisions of Chapter 1, Section 3, A.1.3. The Society may demand that the operators' qualifications be verified in the course of the welding procedure test (cf. Chapter 1, Section 4) or by means of production tests during fabrication. 2.5 Every workshop which performs welding work must have a welding supervisor who is an employee of the workshop, proof of whose technical qualifications shall be furnished (cf. Chapter 1, Section 2). The Society is to be automatically informed of any changes to the welding supervisors. 2.6 The welding supervisor shall supervise the preparation and performance of the welding work in a responsible manner (cf. C.). Wherever these differ from the preceding and following conditions, requirements, etc., he shall take steps to ensure that the quality of the welded joints is consistent and adequate in consultation with the Society. 3. 3.1 Weld preparation and assembly Overweldable shop primers
H. 1.
Execution of Welds General
The general rules prescribed and the instruc1.1 tions given in Chapter 2, Section 2 for the execution of welds shall be complied with.
1.2 For the necessary approvals, inspections and tests of welding shops, welders, welding procedures, welding consumables and auxiliary materials, overweldable shop primers, etc., see the relevant sections and also A. to F. of this section.
3.1.1 Only those overweldable shop primers may be used for which the Society has issued a confirmation of acceptability based on a porosity test. See also Chapter 1, Section 6 and the list of welding consumables and auxiliary materials approved by the Society, VI, 9, 3, Part II. 3.1.2 By means of suitable checks carried out in the course of production (e.g. measurements of coat thickness, production tests), workshops using shop primers shall ensure that the conditions of use on which the confirmation of acceptability was based are adhered to and that, in fillet welding, no excessive pore formation occurs which adversely affects the application. See also Chapter 1, Section 6 (notes). 3.2 Weld shapes, root openings (air gaps)
2.
Welders and supervisors
2.1 Welding work on components governed by these Rules may only be performed by qualified welders who have been approved by the Society and hold valid qualification certificates. Welders and operators (cf.2.3 and 2.4) shall be adequately experienced in the practice of the craft. 2.2 Welders for manual and semi-mechanized welding of normal-strength hull structural steels must be qualified for the relevant welding process and welding positions on both butt welds and fillet welds in accordance with Chapter 1, Section 3. Welders for vertical-down welding must also be qualified for this position.
3.2.1 When preparing and assembling components, care shall be taken to ensure compliance with the weld shapes and root openings (air gaps) specified in the manufacturing documents. With single- and doublebevel welds especially, attention shall be paid to an adequate root opening in order to achieve sufficient root penetration (cf. G.10.2.1 and G.10.2.2).
Chapter 3 Page 128
Section 1
II - Part 3 GL 2000
3.2.2 The root opening shall not exceed twice the specified gap. If the size of the gap permitted by this rule is exceeded locally over a limited area, the gap may be reduced by build-up welding of the side walls, subject to the prior consent of the Surveyor. With fillet welds, the "a" dimension shall be increased accordingly, or a single- or double-bevel weld shall be used if the air gap is large. See also the note to 3.3.2. 3.2.3 With the Surveyor's agreement, large gaps may be closed by means of a strip of plate with a width of at least ten times the plate thickness or 300 mm, whichever is the greater (cf. G.4.). 3.3 Alignment of components, edge misalignment
turing Standard may therefore be considered to represent the maximum permissible upper limit for deviations from the stipulated dimensions.
3.4
Tack welds, auxiliary fixtures
Tack welds should be used as sparingly as 3.4.1 possible and should be made by trained operators. Where their quality does not meet the requirements applicable to the subsequent welded joint, they are to be carefully removed before the permanent weld is made. Cracked tack welds may under no circumstances be welded over.
3.4.2 Clamping plates, temporary ties, aligning pins, etc. must be made of (hull structural) steel of good weldability and should not be used more than necessary. When the components have been permanently welded, they are to be carefully removed to prevent damage to the surfaces of the components. 3.4.3 Clamping plates, temporary ties, aligning pins, etc. may not be welded to components subject to particularly high stresses (e.g. hatchway corners), nor shall they be welded to the edges of flange plates or, especially, to the upper edges of sheer strakes and continuous hatchway sidecoamings. The same applies to the welding of handling lugs and other auxiliary fixtures. 3.4.4 Particularly with mechanized welding processes, and invariably when end craters and defects at the start and end of the weld have to be avoided, run-in and run-off plates of adequate section shall be attached to components and cleanly removed on completion of the weld. 4. Weather protection, welding at low temperatures
3.3.1 Components which are to be united by butt joints shall be aligned as accurately as possible. Sections etc. welded to plating shall be left unfastened at the ends for this purpose. Special attention shall be paid to the alignment of (abutting) girders etc. which are interrupted by transverse members. If necessary, such alignment shall be facilitated by drilling check holes in the transverse member which are later sealwelded. 3.3.2 The permissible edge misalignment depends on the importance and loading of the component concerned (weld quality, cf. I.6.1). With heavily loaded seams (weld quality grade 1) running transversely to the main direction of loading, the edge misalignment of butt welds shall not exceed 10 % of the thickness of the plate or section, subject to a maximum of 3 mm.
Note: A serviceable guide to permissible fabricating tolerances is provided in the standards EN 25817/ISO 5817 (Annex A of Chapter 2) relating to steel and EN 30042/ISO 10042 (Annex B of Chapter 2) relating to aluminium and also in the IACS Shipbuilding and Repair Quality Standard and the "Fertigungsstandard des Deutschen Schiffbaus" (Manufacturing Standard of the German Shipbuilding Industry). In the case of the standards, the assessment category or the individual evaluative criteria to be applied to components or welded joints have to be determined by reference to their loading (cf. Table 1.9). The range of assessment categories, particularly for dynamic loading, is given in code of practice DVS 0705. GL has agreed to the "Manufacturing Standard" subject to the reservation that in particular instances, e.g. where important, highly stressed components are concerned or where there is an accumulation of deviations from nominal dimensions, it may also impose decisions which differ from the Standard and may call for improvements to be carried out. Where the Society raises no objection, the provisions of the Manufac-
4.1 The area in which welding work is performed - particularly outside - is to be sheltered from wind, damp and cold. Where gas-shielded arc welding is carried out, special attention is to be paid to ensuring adequate protection against draughts. When working in the open in unfavourable weather conditions, it is advisable always to dry welding edges by heating. 4.2 At low temperatures (below 5 C), suitable measures shall be taken to ensure the satisfactory quality of the welds. Such measures include the shielding of components, extensive preliminary heating and preheating, especially when welding with a relatively low heat input, e.g. when laying down thin fillet welds or welding thick-walled components. Wherever possible, welding work should be suspended if the temperature falls below 10 C.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 129
5.
Preheating
5.1 The need for and the degree of preheating necessary for welding (cf. Chapter 2, Section 3, D.) are governed by a series of factors. These factors differ in their effect in the manner indicated in Chapter 2, Section 3, D.2.5 (Table 3.4), i.e. they raise or lower the necessary preheating temperature. For information on the measurement of the preheating temperature and the interpass temperatures to be maintained, see also Chapter 2, Section 3, D. 5.2 Apart from the measures prescribed in para. 4.1 and 4.2, normal-strength hull structural steels do not normally require preheating. However, with large cross sections (e.g. steel castings or forgings) and where difficult conditions with regard to design or welding practice apply (e.g. severe distortion of components), it is advisable to carry out uniform preliminary heating of the areas surrounding the welded joints. Cf. 4.1 and 4.2. 5.3 Higher-strength hull structural steels shall generally be preheated if the temperature of the workpiece is less than +5 C. If it is higher than this, preheating shall be carried out upwards of a specific threshold wall thickness, paying due regard to the other factors described in Chapter 2, Section 3, D.2.5 (Table 3.4). For an average carbon equivalent and an average heat input (energy applied per unit length of weld), the threshold wall thicknesses "t" and preheating temperatures "T" shown in Fig. 1.28 may be used as an initial guide. These values, however, are governed by the influencing factors shown in the abovementioned Table 3.4 and have to be adjusted in line
with the prevailing conditions. Where necessary, the need for and degree of preheating shall be determined in accordance with Chapter 2, Section 3, D. or by means of tests (e.g. during the welding procedure tests).
5.4 Tack and auxiliary welds shall be executed to a length of at least 50 mm and require preheating whenever it has to be carried out for the other welds. Exceptions to this are tack and auxiliary welds whose heat-affected zone is reliably and completely remelted during subsequent welding, e.g. tack welds for submerged-arc welding. 5.5 Preheating shall be applied uniformly throughout the thickness of the plate or component and to a distance of 4 times the plate thickness, but not more than 100 mm, on both sides of the weld. Localized overheating is to be avoided. Preheating with gas burners should be performed with a gentle, though not sooty, flame. The preheating temperature shall be kept constant throughout the duration of the welding work. 6. Welding positions, vertical-down welding
6.1 Welding should be performed in the optimum welding position, and positional welding (e.g. in the PE or PD (overhead) positions) shall be limited to the indispensable minimum. 6.2 For similar and repetitive welding operations, it is advisable to use a (rotating) fixture enabling all welds to be made as far as possible in simple positions, such as the flat (PA) or horizontal vertical (PB) position.
Preheating/operating temperature (C)
200 150 100 50 0 10 20 30 40 50 60 70 80 90
non-hydrogen-controlled weld metal low-hydrogen weld metal TM steel(C 0,10 %) low-hydrogen weld metal 100
Plate/wall thickness (mm)
Fig. 1.28
Threshold wall thicknesses and preheating temperatures for higher-strength hull structural steels (guide values)
Chapter 3 Page 130
Section 1
II - Part 3 GL 2000
6.3 Even after a satisfactory welding procedure test and approval of the process (cf. F.1.), verticaldown fillet welding may not be used:
7.
Welding sequence
for joining together continuous primary supporting members interrupted by transverse members (e.g. the longitudinal members of the upper and lower girder); the same applies where transverse loads predominate, for mainly dynamically loaded welded joints (e.g. in the area of engine baseplates, shaft brackets and rudders), on crane components and other lifting gear including their substructures (e.g. crane pillars), at intersections of main girders and in the area of the supports or stoppers of hatchway covers.
7.1 The assembly and welding sequence shall be chosen to allow shrinkage to take place as freely as possible and to minimize shrinkage stresses in the component. Butt joints in areas of plating shall invariably be fully welded, at least on one side, prior to the fastening of girders, stiffeners, etc. 7.2 Where individual plates are later welded into position in areas of plating (as in the case of erection holes in the deck or shell plating), the longitudinal seams shall be left unwelded, or shall be opened up, to a distance of approx. 300 mm beyond the transverse joints. The transverse joints shall be welded first, followed by the longitudinal seams. 7.3 The welding of patches (cf. G.4.2) may be performed in analogous manner, unless angular patches with rounded corners or round patches are used. 7.4 In special cases (e.g. when welding together particularly rigid components) and for similar, repetitive welding operations (e.g. for the welding of masts into ships), it is advisable to set down the assembly procedure or welding sequence in a welding sequence schedule. 7.5 Where welded and riveted joints meet (the same also applies analogously to other mechanical methods of assembly), the welds shall invariably be completed first, then the riveting adjoining the weld shall be carried out. 8. Performance of work
Note: Vertical-down welding may be used for joining secondary components (e.g. stiffeners) to primary supporting members, for fillet-welding floor plates to continuous bottom longitudinal girders, for fillet-welding transverse bulkheads to the shell plating, and for between-decks, interior partitions, etc. which do not affect the longitudinal or local strength of the vessel. In case of doubt, the extent of the vertical-down welding shall be agreed with the Society.
6.4 The Society may permit exceptions to the provisions of 6.3 and increase the extent of verticaldown welding if the welding shop takes special measures to ensure a satisfactory standard of workmanship (particularly the accurate assembly of components without any significant air gaps, adequate root penetration and prevention of lack of fusion defects) even under normal conditions of fabrication. Such measures include:
choosing a suitable welding process and appropriate welding consumables and auxiliary materials which guarantee especially good penetration (cf. F.1.1, note), special training and careful selection of welders for vertical-down welding (see also 2.2), conscientious monitoring of the weld preparation, the welding parameters and the welding work (e.g. electrode control) while welding is in progress, production tests at random (fillet weld fracture specimens) during the course of fabrication.
The areas of the components to be welded 8.1 must be clean and dry. Scale, rust, cutting slag, grease, paint and dirt shall be carefully removed prior to welding (with regard to overweldable shop primers, see 3.1).
8.2 Components shall not be subjected to any appreciable movements or vibrations during welding. Parts to be assembled while floating or suspended from cranes shall be clamped prior to the tacking of the joint in such a way that no further movement of the parts is possible. Components which have not been fully welded and are to be handled or turned must have welded joints of adequate strength. 8.3 Cracked tack welds may not be welded over, but are to be machined out. In multi-pass welding, the slag of the previous run shall be completely removed before the next pass. Pores, visible slag inclusions and other welding defects and cracks may not be welded over, but are to be machined out and repaired.
The Society may demand proof that special measures of this kind have been taken. In addition, the Society may require more extensive monitoring or inspections of the vertical-down welds.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 131
8.4 The welding shop shall ensure that the specified welding parameters are adhered to and that the welding work is expertly performed by competent personnel (cf. 2.5 and 2.6). 8.5 Welds must have sufficient penetration and must display a clean, regular surface with "gentle" transitions to the base material. Excessive weld reinforcements and undercuts (cf. note to 3.3.2) together with notches affecting the edges of plates and cutouts are to be avoided. 8.6 Butt-welded joints must display full fusion over the entire cross section, unless a deviation from this is authorized in a particular case. For this purpose, the root shall normally be grooved and capped.
9.
Welding of higher-strength hull structural steels and high-strength (quenched and tempered) fine-grained structural steels
Preliminary remark: The following provisions apply in analogous manner to the welding of low-alloy steels tough at subzero temperatures used for structural members in shipbuilding, e.g. for cargo tank supports on gas tankers. The tanks themselves are subject to the Rules for Construction of Seagoing Ships, Chapter 6 "Liquefied Gas Tankers". See also Section 3 Welding of Pressure Vessels.
Following a successful welding procedure test confirmed by the Society, single-side welds, e.g. using ceramic backings, may be regarded as equivalent to butt welds executed from both sides. Other joints welded on one side only, e.g. using permanent backings, are subject to approval by the Society when scrutinizing the relevant drawings. For the evaluation of such welded joints see G.10.3.
8.7 Single- and double-bevel welds are to be made according to the design specification either with grooved roots as full-penetration welded joints or with a permitted incomplete penetration at the root or a defined, unwelded root face subject to the appropriate reduction factors (cf. G.10.2). The type of weld is to be specified in the drawings in each case and must have received the Society's approval when the drawings were scrutinized. 8.8 With fillet welds, particular attention shall be given to good root penetration. The penetration must extend at least to the immediate vicinity of the theoretical root point (cf. G.10.3.4 to 10.3.6). The ideal fillet weld section is that of an equal-sided flat-faced weld with smooth (notch-free) transitions to the base material. At the ends of web plates, at cutouts and at welding apertures, the fillet welds shall meet to form a continuous seam around the root face. 8.9 Major cases of faulty workmanship or defects in the material may only be repaired with the Surveyor's agreement. Minor surface defects shall be removed by shallow grinding. Defects which penetrate more deeply into the material (e.g. cracks, or tears left by the removal of welded-on erection aids) shall be cleanly machined, ground and repair-welded with an adequate heat input.
9.1 The steelmaker's instructions and recommendations 5 and any conditions arising from the welding procedure test shall be implemented when welding higher-strength hull structural steels and high-strength (quenched and tempered) fine-grained structural steels. For the use and working of thermo-mechanically rolled (TM) steels, see the appropriate Society rules 6. 9.2 The welding process, welding consumables, weld build-up and thermal practice (preheating, heat input and interpass temperature) etc. shall be suited to the base material being welded and shall be maintained within the appropriate limits during welding. These parameters must match those used during the welding procedure test. Any appreciable deviations require the Society's consent and are normally contingent on additional tests. Wherever possible, multi-pass welding shall be used (particularly for high-strength (quenched and tempered) fine-grained structural steels), the final pass being laid down as a "temper bead" run some 2 mm away from the base material. 9.3 When welding high-strength fine-grained structural steels it may be necessary to verify not only the preheating but also the heat input during welding 7 and the interpass temperatures. These checks shall invariably be carried out and recorded when welding high-strength quenched and tempered fine-grained structural steels. The values must correspond to the energy per unit length of weld established during the welding procedure tests and to be laid down in the welding schedule.
5 See Stahl-Eisen-Werkstoffblatt 088 "Weldable fine-grained structural steels: instructions for use with special attention to welding" issued by the German Iron and Steel Association. Regulations for the use and working of thermo-mechanically rolled (TM) steels issued by Germanischer Lloyd. Determination of heat input (energy applied per unit length of weld) "E":
E = U [ volts] I [amps] welding time [min] 6 length of weld [ mm] 100
6 7
LM OP N Q
kJ mm
Chapter 3 Page 132
Section 1
II - Part 3 GL 2000
9.4 Special attention is to be paid to the generally more sensitive hardening properties and the increased notch sensitivity of higher-strength steels, and especially of high-strength fine-grained structural steels. Unnecessary arc strikes on the surface of the plate, scarring of exposed edges, etc. are to be avoided at all costs. Where necessary, such blemishes shall be cleanly ground out and inspected for incipient cracks. The same applies analogously to auxiliary welds. 9.5 Additional thermal treatments involving a high heat input (e.g. flame gouging and flame straightening) shall not impair the properties of the materials and welded joints and shall, if necessary, be avoided completely. In doubtful cases, proof of the satisfactory performance of thermal treatments may be demanded.
Note: Standard flame straightening carried out on higherstrength hull structural steels up to and including E 36 may generally be regarded as acceptable provided that the straightening temperature does not exceed 700 C and that localized overheating or heating of the whole area over a longer period of time (e.g. using heating blocks) and abrupt cooling (e.g. with water) are avoided. The same applies in analogous manner to the flame straightening of thermo-mechanically rolled (TM) steels. Prior to flame straightening of high-strength (quenched and tempered) fine-grained structural steels, special agreement with the steel manufacturer is required. Cf. also SEW 088 5.
10.5 On the side of the cladding and at the corner joints of clad plates (as in the case of drain wells), at least two layers of stainless weld metal are to be laid down over the support material (cf. G.10.1.6). Where necessary, different welding consumables shall be used for the intermediate and final runs depending on the base material. 10.6 Fused weld spatter is to be avoided for reasons of corrosion. Such fusion can be prevented by applying suitable media (e.g. milk of lime) to the surface of the plate on both sides of the weld. Where necessary, weld spatter is to be machined off and the area ground smooth. 10.7 To achieve corrosion-resistant seams, postweld treatment (pickling or passivation) shall be carried out in accordance with the instructions issued by the steelmaker or the manufacturer of the welding consumables. 11. Welding of steel castings and forgings
11.1 With steel castings and forgings of large section, difficult welding or structural conditions, heavily distorted members and low workpiece temperatures, a sufficient area surrounding the welded joint shall be uniformly preheated throughout the section. 11.2 Welding operations on steel castings and forgings shall be performed continuously and without interruption, if possible in a single heating cycle. Cooling shall take place gradually and appropriate measures shall be taken to prevent over-rapid cooling (screening, wind protection). 11.3 Repair welds (production welds) on steel castings and forgings may only be undertaken with the Surveyor's consent. Where the work concerned is relatively extensive, sketches and a description of the repair shall be submitted to the Society's head office for approval, together with details of the welding process, welding consumables and auxiliary materials, heat treatment and composition of the base material. 11.4 The Society may stipulate stress relief heat treatment or, in special cases, normalizing heat treatment of the components after welding (e.g. for rudderstocks). The preliminary remark to Chapter 1, Section 5, B. applies in analogous manner to the necessary proof of the properties of the welded joint in heattreated condition. 11.5 Welds uniting hull structural steels or comparable forged or cast steels on the one hand to austenitic stainless steels on the other may not be heat-treated. The same applies in analogous manner to build-up welds made with austenitic stainless welding consum-
10.
Welding of stainless and clad steels
During the entire construction period, suitable 10.1 measures shall be taken in transport, storage and fabrication to keep the surface of stainless steels free from impurities and extraneous metallic inclusions (due to abrasion from other components or auxiliary erection supports).
10.2 Welding processes and welding consumables shall be selected with due regard to strength and corrosion aspects, taking into account the recommendations of the makers of the steel and the welding consumables. Unalloyed welding consumables may not be used for welding stainless steels. 10.3 Edges are to be prepared mechanically by cutting or planing. Where a thermal cutting technique such as plasma cutting has to be employed, the edges shall subsequently be machined clean. 10.4 Clad plates shall invariably be tack-welded on the "black" side of the support material. Back-up plates are to be used sparingly and must be made of the material to which they are to be welded.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 133
ables (e.g. on rudderstocks, pintles, etc.). Any postweld heat treatment which may be required for buildup welds made with other (e.g. heat-treatable) welding consumables shall be specified on a case-by-case basis.
12. Welding of aluminium alloys
carefully monitored so as to prevent fusion of the material.

13. Underwater welding
12.1 The foregoing provisions relating to the welding of steels apply in analogous manner to the welding of aluminium alloys above and beyond the provisions stipulated in the following paragraphs. Special attention is to be paid to cleanliness, thorough degreasing and the avoidance of extraneous metallic impurities. For the use of various types of steelaluminium welding transition joints (especially the thermosensitivity of the boundary layer between the steel and aluminium), see Societys working sheets. 12.2 As a rule, welding grooves are to be thoroughly cleaned (e.g. with solvents and/or brushes) immediately before welding. Tools and equipment shall not be used for working on other materials and shall not themselves leave behind extraneous metallic residues. Welding grooves, welding consumables and auxiliary materials must at all costs be dry before welding begins. 12.3 Welded joints on aluminium alloy structural components used in shipbuilding shall, wherever possible, be made by inert gas welding (MIG welding, or, possibly, TIG welding for small components) performed in welding bays protected from the weather. The weld pool must be safely shielded by an adequate supply of inert gas. Winds and draughts are to be avoided. Care shall be taken to achieve the optimum welding speed and to minimize the effect of the heat on the base material (softening). 12.4 To avoid end-crater cracking, especially when making intermittent fillet-welded joints, it is advisable (unless welding equipment with crater-filling devices is used) to retract the bead somewhat prior to withdrawal of the electrode or torch so that the end crater is moved back from the end of the seam to a point on the weld and to fill the crater. 12.5 Extensive preheating of the faces to 100 C 200 C is recommended when welding thick aluminium alloy plates and sections. The welds are to be executed in a suitable sequence, smoothly and speedily and, if possible, without a break. 12.6 Cold straightening operations should be performed only by pressing, not by hammering. Hot straightening may only be carried out on alloys suitable for that purpose in accordance with the aluminium producer's instructions. Heating and straightening are to be performed speedily. Temperatures are to be
13.1 Under certain conditions, the Society may approve the welding (normally fillet welds) of components made of normal-strength hull structural steels which have water behind them. The temperature of the water or component should not be less than 5 C. The welding point must be dry and clean. At least two passes must be laid down, the last of which shall be run as a "temper bead" over the first pass which has been deposited on the "cooled" component such that it performs a "post-weld heat treatment" function. Welds executed in this manner shall be subjected to a crack test. 13.2 As a general principle for underwater welding, only those welding processes and/or welding consumables that guarantee a low hydrogen content in the weld metal shall be used. Welding should be performed in a dry environment (chamber pressurized to 1 bar or high-pressure chamber). The above applies in analogous manner to the temperature of the component, the welding point and the crack test. For the required welding procedure tests, see F. 13.3 Underwater arc welding in which the arc burns in the water or in a small gas vessel and where allowance has to be made for a large amount of hydrogen entering the weld metal may only be used with the explicit authorization of the Society in each individual case (even if welding procedure approval has been granted) and then only for temporary repairs (e.g. sealing welds) to components which are subjected to relatively low loads. Welds executed in this manner shall be replaced by normal welds at the next available opportunity and until such a replacement is made the Society may prescribe restrictions in the operation of the vessel (e.g. in the operating area).
I. 1.
Inspection of Welded Joints General
1.1 In addition to the following provisions, the inspection of welded joints in shipbuilding is governed by the provisions of Chapter 2, Section 4 concerning the preparation and performance of non-destructive weld tests. 1.2 As stipulated in Chapter 2, Section 4, D., an inspection schedule shall be submitted to the Society for approval before commencing the tests. The Society reserves the right to modify this schedule even after it
Chapter 3 Page 134
Section 1
II - Part 3 GL 2000
has been approved, and in particular to extend the scope of the tests and/or change the individual testing positions if necessitated by fabrication operations and/or test results.
2. Workshop inspections, visual examination
3.4 Subject to the provisions of Chapter 2, Section 4, the testing appliances and equipment used shall conform to modern technical practice and the relevant standards. The tests are to be performed by properly qualified and experienced testers. For details of the prescribed proof of qualification of ultrasonic testers see Chapter 2, Section 4, C.1.). 4. Production specimens
2.1 Workshop inspections are to be carefully performed by trained personnel (e.g. welding supervisors, cf. C. and H.2.) to ensure the professionally competent and satisfactory execution (appearance and dimensional accuracy) and the integrity of the welds. 2.2 After welding operations have been completed and subjected to workshop inspection, the work shall be presented to the Surveyor for checking at suitable stages of fabrication. For this purpose, welds shall be readily accessible and shall normally be uncoated. Wherever possible, the results of nondestructive tests shall be presented at this juncture. 2.3 Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed. 3. Non-destructive tests
Production specimens, i.e. test pieces welded 4.1 simultaneously at specified intervals during fabrication, may be called for where the base material, the welding process and/or the loading conditions require proof to be provided that the mechanical or other characteristics of the welded joints made under fabrication conditions are adequate.
4.2 Production specimens shall be welded and tested in a manner analogous to that prescribed in Chapter 1, Section 4 and in F., as applicable, in connection with welding procedure tests. The scope of the tests and the requirements to be met shall be determined on a case-by-case basis. For production specimens in connection with shop primers, see Chapter 1, Section 6, C. 5. Leakage tests
3.1 The necessary weld quality as stipulated in Table 1.9 shall be attested by non-destructive tests, the scope of which shall be at least that specified in 6. Should these tests reveal defects of any considerable extent, the scope of the tests shall be increased. Unless otherwise agreed, tests shall then be performed on two further sections of weld of the same length for every weld section tested and found to be in need of repair. Where it is not certain that a defect is confined to the section of weld under test, the adjoining weld sections shall be additionally tested. 3.2 The Society may stipulate further tests, especially in the event of doubts as to the professionally competent and satisfactory execution of the welds. For the purpose of monitoring and, where necessary, giving instruction to welders, it is recommended that from time to time radiographic inspections should also be carried out on components which are not subject to regular testing. 3.3 The method of inspection to be applied in each instance shall be selected with due consideration for the test conditions (shape and dimensions of the weld, nature and location of possible defects, accessibility) so that any defects may be reliably detected. The method of inspection requires the Society's agreement. The Society may stipulate that two or more inspection techniques be used in conjunction.
5.1 Where required, leakage tests on welded seams are normally to be carried out in accordance with the Rules for Classification and Construction, Part 1, Chapter 1 (e.g. Section 8, B.9.; 12, H.24; A.15., or the Rules for Construction of floating docks) prior to the application of any paint or cement. 5.2 In special cases, and with the approval of the Society, the hydrostatic tests stipulated for the leakage tests may be replaced by other methods (e.g. testing under compressed air or vacuum, gas detection method). The Society may call for such methods as an alternative or in addition to that stipulated. 6. Weld quality grades, scope of tests, test methods, requirements
6.1 According to the nature and severity of the applied loads and their role in ensuring the soundness of the overall structure, welded joints are to be classified by reference to the influencing factors, their materials, design and service environment (e.g. operating temperature) into one of the three weld quality grades shown in Table 1.9 and shall be identified in the inspection schedule. 6.2 The individual welded joints are to be classified into quality grades according to their position in the component concerned, i.e. their position in relation
II - Part 3 GL 2000
Section 1
Chapter 3 Page 135
to the direction of the main stress, as illustrated by the examples cited in Table 1.9. Components and welded joints not mentioned in the Table or in para. 6.5 shall be classified in an analogous manner.
6.3 The scope of the non-destructive tests to be applied to welded joints with quality grade 1 (radiographic and ultrasonic inspection) shall be determined by the following formula according to the type and construction of the ship. The number "A" of test positions to be determined refers in the first place to radiographs with a (film) length of 480 mm. Where, in accordance with para. 6.10 or 6.11, ultrasonic tests are performed instead of radiographic inspection, 1 metre of weld is to be tested in each case in place of the 480 mm length of film.
6.4 The number "A" of test positions determined in accordance with para. 6.3 shall be distributed in such a way that roughly two-thirds of the number "A" established are positioned on the welded joints with quality grade 1 described in Table 1.9 and roughly the remaining third on those joints with quality grade 2. Appropriate consideration shall be given to the individual components specified in para. 6.5. Depending on the loading conditions, a different inspection density (a different distribution of the total number of test positions) for the various weld quality grades or components may be expedient or may be demanded by the Society. 6.5 The welded joints of the particular components listed below are to be classified and tested as follows: Deck stringer/sheer strake joint within 0.5 L of midship: weld quality grade 1, 100 % ultrasonic inspection if full-penetration welding is required in accordance with G.10.2.1. Deck stringer/sheer strake joint outside of 0.5 L of midship: weld quality grade 2, 10 % ultrasonic inspection if full-penetration welding is required in accordance with G.10.2.1. Joints between horizontal rudder coupling plate and rudder body (cf. Fig. 1.26): weld quality grade 1, 100 % ultrasonic inspection and 100 % surface crack inspection. Joints between rudderstock and horizontal coupling plate (cf. Fig. 1.27): weld quality grade 1, 100 % ultrasonic inspection and 100 % surface crack inspection. Full-penetration single- and double-bevel Tjoints (cf. Fig. 1.13): weld quality grade 1 or 2 depending on position of weld, 100 % or 10 % ultrasonic inspection respectively. Restarting points in electroslag or electrogas welds: weld quality grade 1 or 2 depending on position of weld, 100 % radiography or ultrasonic inspection, the latter with the test sensitivity increased by 12 dB (see also Chapter 2, Section 4, L.2.5). Welds for which proof of fatigue strength is required: weld quality grade and inspection depend on detail category (cf. catalogue of notch categories, Rules for Construction of Seagoing Ships, Chapter 1, Section 20, A.3. and Table 20.3).
A = 0,8 A L c P A B c B + A H c H where AL L a0 cp cp = L 16 a 0
>
= length of ship in [m] = L : 500 + 0,48 1,0 in [m ] = 1,5 = 2,0 with transverse frame construction with mixed transverse and longitudinal frame construction (in the area of the upper and lower girder) with longitudinal frame construction
cp AB
= 2,3 =
B 2,5
B cB cB cB
= breadth of ship in[m] = 1,0 = 1,3 for single-hull tankers and comparable main frame cross sections for dry-cargo freighters and bulk carriers for container ships and double-hull (chemical) tankers
= 1,5 H 2,5
AH H cH cH cH
= depth of ship in[m] = 0,5 = 1,3 for dry-cargo freighters for tankers, container ships and bulk carriers for double-hull tankers with additional longitudinal bulkheads
= 1,5
6.6 In the case of ships for which no special proof of (longitudinal) strength has to be submitted (generally ships less than 65 m long; cf. the Rules for Construction of Seagoing Ships, Chapter 1, Section 5), the number "A" (of test positions) may be reduced to 70 %
Chapter 3 Page 136
Section 1
II - Part 3 GL 2000
of the figure prescribed in para. 6.3 and 6.4. The reduction shall be agreed with the Society in every case and is to be specially indicated in the inspection schedule. 6.7 Where the conditions of fabrication remain unchanged, i.e. where to a large extent the same welders are employed in welding the same or similar components (e.g. in repetition shipbuilding) by means of the same welding processes, welding consumables and auxiliary materials, the Society's head office may consent to a reduction of the scope of inspection specified in para. 6.3 and 6.4. This is conditional on proof being supplied of uniformly good results and a relatively low incidence of repairs, as attested by the results of all initial inspections performed on welded joints prior to any repairs. 6.8 Where radiographic inspections are performed randomly, they are to be carried out chiefly at the intersections of longitudinal seams and transverse joints, at sectional joints and at joints presenting difficulty or requiring to be welded in a fixed position. Joints in girders and stiffeners are to be classified similarly to those in plating and are to be included in the inspection. 6.9 Ultrasonic tests may be performed in place of a proportion (to be specified in every case) of the number of radiographs prescribed in paras. 6.3 and 6.4. For wall and plate thicknesses of 30 mm and over, ultrasonic testing is to be preferred to radiography as a method of inspection.
6.10 In special cases, ultrasonic tests may be stipulated as an alternative, or additionally, to radiographic inspection, e.g. where certain defects, owing to their nature and location or to the configuration of the weld, cannot be sufficiently reliably detected or assessed by radiography.
6.11 Surface crack inspections shall generally be carried out following the welding of large sections, particularly those of steel castings and forgings as well as in the case of welds made under stress or at low temperatures, large-volume single- or double-bevel welds (plate thicknesses of about 30 mm and over) and thick fillet welds, e.g. on stern posts, after welding-in of masts and welds on bulkhead stools.
6.12 For the inspection of particular components and their welded joints, see 6.5. The Society may, in addition, call for further tests in conjunction with the approval of drawings.
6.13 Welded joints and components not covered by the foregoing provisions shall undergo nondestructive tests whose scope shall be specified in each individual case. Where certain components (e.g. the masts of cargo handling gear, liquefied gas tanks and the pressure hulls of underwater vehicles) are governed by special rules or codes of practice, the provisions contained in these shall be implemented.
II - Part 3 GL 2000
Section 1
Chapter 3 Page 137
Table 1.8
Weld quality grades, scope of inspection, requirements

1 2 3
Weld quality grade
Loading, importance
Welded joints which are subjected to severe static or mainly dynamic stresses and/or which are essential to the soundness of the overall structure. Transverse joints in the area of the upper and lower flange plate 1 within 0,5 L of midship 2, e.g. in the outer bottom incl. bilge strake, longitudinal girders, longitudinal frames, strength deck incl. sheer strake. Longitudinal girders and beams, longitudinal bulkheads incl. longitudinal stiffeners, hatchway side coamings incl. longitudinal stiffeners. Joints in shell plating and strength deck in the immediate vicinity of fittings and fixtures (traversing the plate), e.g. rudder heels, masts including the welds uniting them to the firstnamed items. Joints in the flanges and webs of main girders, e.g. in hatchway covers, hatch or cantilever girders and in cantilever masts. Joints in tank bulkheads and the bottom structures of bulk carriers including the bulkhead stools. Joints in or on components subjected mainly to dynamic loads, e.g. shaft struts, rudder heels, rudder couplings, (connecting them to the rudder body) and the main girders of engine beds.
Welded joints which are subjected to medium stresses and/or whose failure entails the loss of function of individual components without endangering the structure as a whole. Longitudinal bulkheads 3 in the area of the upper and lower hull flange plate, transverse joints in the area outside 0,5 L of midship 2, and joints in the rest of the shell plating and in the double bottom. Joints in watertight transverse bulkheads of drycargo freighters and in web frames. Joints in hatchway covers, end bulkheads of superstructures and deckhouses, and joints in transverse girders.
Welded joints which are subjected to minor stresses and/or whose failure does not entail the loss of function of important components. Joints in subordinate components such as decks, partitions and their stiffeners not included in the main strength structure, decks of super-structures and deckhouses, joints in bulwarks, etc.
Components, position of welded joints (for individual details relating to particular components and welded joints, see para. 6.5)
Chapter 3 Page 138
Section 1
II - Part 3 GL 2000
Table 1.9
Weld quality grades, scope of inspection, requirements (continuous)

1 2 3
Weld quality grade
Scope and method of Visual inspection and raninspection dom dimensional checks. Non-destructive tests in accordance with 6. (random checks with greater intensity of inspection). Leakage and other tests, where required. Requirements, quality 4 weld Welded seams to be free from cracks, lack of fusion and root defects, slag lines, coarse pore clusters and slag inclusions, prominent undercuts, etc. in conformity with assessment category B in accordance with EN 25871/ISO 5817 relating to steel (Annex A of Chapter 2) and EN 30042/ ISO 10042 relating to aluminium (Annex B of Chapter 2), as applicable.) 5
Visual inspection, random dimensional checks in cases of doubt. Non-destructive tests in accordance with 6. (random checks with lesser intensity of inspection). Leakage and other tests, where required. Welded seams to be free from cracks, major lack of fusion and root defects, long slag lines, coarse slag inclusions, uninterrupted pores, coarse pore clusters, major undercuts, etc. in conformity with assessment category C in accordance with EN 25817/ISO 5817 relating to steel (Annex A of Chapter 2) and EN 30042/ISO 10042 relating to aluminium (Annex B of Chapter 2), as applicable.5
Visual inspection
In cases of doubt, nondestructive tests in accordance with 6. Leakage and other tests, where required. Welded seams to be free from cracks, major root defects and slag inclusions, uninterrupted pores, severe undercutting, etc. in conformity with assessment category D in accordance with EN 25817/ISO 5817 relating to steel (Annex A of Chapter 2) and EN 30042/ISO 10042 relating to aluminium (Annex B of Chapter 2), as applicable.5
In accordance with the Rules for Construction of Seagoing Ships, Chapter 1, Section 3, B., this is the area extending to at least 0.1 H and 0.1 H' above and below respectively. The inspection shall, however, invariably cover the entire sheer strake and bilge strake area together with continuous longitudinal members (e.g. hatchway side coamings and crane rails) above the strength deck. Where partial use is made of higher-strength steel, the inspection shall embrace the whole area of this steel in terms of height, and in the case of container ships and similar vessels it shall cover the entire area of the upper box girders. In ships with large deck openings, i.e. ships with large hatches (such as container ships), the transverse joints in the upper hull girder flange fore and aft of 0.5 L (generally the entire hatchway area) shall also be assigned to weld quality grade 1 where necessary (e.g. because of the torsional stresses imposed). At weld intersections the adjoining 300 mm of longitudinal seam are to be classified identically with the relevant transverse joints. See also the note to H.3.3.2. Comparable provisions contained in other standards, etc., may also be used for assessment purposes, subject to the Society's consent. Where components or welded joints have been dimensioned according to fatigue strength criteria on the basis of a specific detail category R (see Rules for Construction of Seagoing Ships, Chapter 1, Section 20, Table 20.3), the quality grade must also meet the requirements of this detail category. Code of practice 0705 issued by the Deutscher Verband fr Schweitechnik e.V. [German Welding Society] contains instructions for the classification of individual irregularities in correlation to the assessment groups in conformity with EN 25817/ISO 5817 relating to steel.
3 4
With regard to the requirements for ultrasonic testing, see Chapter 2, Section 4, L.5 (Table 4.4).
II - Part 3 GL 2000
Section 2
Welding of Steam Boilers
Chapter 3 Page 21
Section 2 Welding of Steam Boilers

Preliminary remark: The following rules relating to the welding of steam boilers comply with or incorporate the Technical Rules for Steam Boilers (TRD). Subject to the approval of the Society, other codes of practice such as the ASME Boiler and Pressure Vessel Code, Section 1 may also be adopted for the fabrication and testing of welded steam boilers (the following rules being applicable in analogous manner). Cf. also Chapter 1, Section 1, B.1.4. B. Approval of Welding Shops, Welding Personnel
1. All welding shops intending to perform welding work within the scope of these rules must satisfy the requirements applicable to welding shops and personnel set out in Chapter 1, Section 2 and must have been approved by the Society. Applications for approval shall be submitted by the welding shops in good time before starting the welding work, enclosing the information and documentation prescribed in Chapter 1, Section 2, A.3. 2. The welding personnel (welders and welding supervisors) and, where applicable, inspectors and inspection supervisors must satisfy the requirements set out in Chapter 1, Section 2, B.2., B.3. and B.4 and be recognized by the Society. For the welders qualification tests, see Chapter 1, Section 3.
A. 1.
General Scope
1.1 These Rules apply to the fabrication and testing of welded steam boilers, superheaters, feed water preheaters and similar pressurized components of the steam boiler installation. 2. Other relevant rules
C.
2.1 The provisions of the Rules for Construction I, Part 1, Chapter 2, Section 7a shall also be complied with in the design and dimensioning of steam boiler components. 2.2 For the fabrication and testing of steam boiler installations intended for ships sailing under the German flag, it is essential to comply with the "Technische Regeln fr Dampfkessel" (Technical Rules for Steam Boilers) of series TRD 200 in conjunction with series TRD 100. 3. Assessment of welds
1. The manufacturer shall submit to the Society, for inspection, drawings and other relevant documents containing at least the following information: The materials and welding consumables to be used, The welding process and the location and shape of the weld, The type of heat treatment, if required, The acceptable working pressure, The design temperature, The operating temperature, The test pressure, The weld factor "V" used as a basis for calculation, The nature and scope of the non-destructive tests, The nature and scope of the production tests.
3.1 Tensionally stressed longitudinal welds may generally be assessed with a weld factor up to V = 0,8, provided that they meet the requirements specified in Chapter 1, Section 1 and 2 and the following paragraphs. 3.2 A higher assessment up to V = 1,0 may be applied if a production test and non-destructive testing in accordance with para. I.11. have been successfully performed on the finished component.
2. If the quality or good working order of a component cannot be guaranteed or is in doubt due to inadequate or missing information in the manufacturing documents (e.g. production drawings), the Society may demand appropriate improvements.
Chapter 3 Page 22
Section 2
II - Part 3 GL 2000
3. The welding shops shall ensure by means of regular in-house quality inspections during fabrication and on completion of the welding work that this work has been performed competently and satisfactorily (cf. Chapter 1, Section 1, F.). For the duties and responsibilities of the welding supervisor, see also EN 719/ ISO 14731.
D.
1. The materials selected must be appropriate for the intended purpose, with allowance made for mechanical and thermal stresses. The characteristics of materials subjected to further processing shall be such that they are able to withstand the operating loads. 2. Welded structures may only be fabricated using base materials of proven weldability. The intended materials must comply with the requirements set out in the relevant sections of Part 1, Metallic Materials, Chapter 2. Other comparable materials may only be used after the Society has given its approval in each individual case.
4. The welding shops are responsible for ensuring that the welding work conforms to these Rules, the approved manufacturing documents, any conditions stipulated in the approval documents and the latest state of welding practice. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops of this responsibility.
5. With regard to quality inspections and the responsibilities involved in awarding subcontracts to independent branches or suppliers or to approved or non-approved outside firms working in the welding shop (subcontractors), see Chapter 1, Section 1, F. Subcontracting of work or employment of temporary workers shall be notified to the Society.
E.
6. The scope of the required quality inspections depends on the construction project in question. It is essential to ensure, however, that the intended materials, welding consumables and auxiliary materials are used and that the weld preparation, assembly, execution of the tack and final welds and the dimensional accuracy and completeness of the welded joints meets the requirements stated in para. 3. For non-destructive testing of the welded joints and production tests have to be performed, see I.
1. The welding consumables must enable a welded joint to be made which is appropriate to the base material, the operating temperature and the conditions of service. The suitability of the welding consumables must also have been verified under the conditions prevailing in further processing. 2. All the welding consumables and auxiliary materials used (e.g. covered electrodes, wire-gas combinations, wire-flux combinations, etc.) must have been approved by the Society in accordance with Chapter 1, Section 5. They may also, however, be approved if tested at the same time as the welding procedure and restricted to the users works (cf. Chapter 1, Section 4, B.3.2 and Section 5, A.1.4). 3. For joints between different materials, the welding consumable shall wherever possible be geared to the lower-alloyed material or the material with the lower strength. 4. Welding consumables and auxiliary materials specified in a procedure approval document with a makers or brand name (cf. F.3.5) may only be replaced by equivalent consumables approved by the Society with an appropriate quality grade if this is explicitly stated in the respective approval document. Failing this, the Society's agreement shall be obtained. 5. The welding consumables and auxiliary materials may only be used in the approved welding positions. The manufacturers' recommendations and instructions for welding (e.g. type of current and polarity) shall be followed. 6. The welding consumables and auxiliary materials (especially hydrogen-controlled, basic-covered electrodes and basic welding fluxes) shall be re-dried
7. Following internal inspection and, if necessary, repair by the welding shop, the components shall be presented to the Society's Surveyor for checking at suitable stages of fabrication. For this purpose they shall be readily accessible and shall normally be uncoated. Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed.
8. The Society is not responsible for guaranteeing that all the components and welded joints inspected to the prescribed extent (generally on a random basis) by its surveyors have been fabricated in accordance with the conditions and meet the requirements in every respect. Components or welded joints which subsequently turn out to be defective may be rejected or their repair may be demanded even if acceptance testing has already been carried out.
II - Part 3 GL 2000
Section 2
Chapter 3 Page 23
before use in accordance with the manufacturer's instructions (observe maximum drying time!) and stored in a dry place (in heated containers or the like) at the workplace. Note: The DVS guideline 0504 "Handling, storage and redrying of covered electrodes" and the DVS regulations 0914 "Use and storage of welding fluxes for submerged-arc and electro-slag welding" issued by the German Welding Society (Deutscher Verband fr Schweitechnik e.V) contain detailed instructions on this subject.
2.4 The types of weld and welding positions employed in the fabrication process shall be qualified in the welding procedure test. 2.5 The form and dimensions of the test pieces are specified in EN 288-3/ISO 9956-3 or, where applicable, stipulated in para. 2.6. 2.6 For welding of sockets, nipples, etc., the following shall be made: 2 socket welds in accordance with standard workshop practice or 2 test pieces as shown in Figs. 2.1a) and 2.1b).
2.1a) 2.1b)
F.
Welding procedure tests
Preliminary remark: In contrast to earlier issues of these Rules, welding procedure tests shall be performed in accordance with EN 288 or ISO 9956, as applicable. This paragraph essentially covers requirements applicable to the welding of steam boilers over and above those set out in EN 288-3 and ISO 9956-3. 1. General 3.
Obstruction to welding
20
~200
Obstruction to welding
200
~400 120
Fig. 2.1
Test pieces for welding of sockets and nipples, inserted (left) and through-type (right) Test principles, delimitation of scope
Only those welding procedures shall be employed whose satisfactory operational handling and adequate quality properties have been verified as part of a welding procedure test under production conditions at the users works. The general requirements set out in Chapter 1, Section 4 shall be observed. The welding procedures must have been approved by the Society for the particular welding shop in question. 2. Welding of test pieces, welding procedure specification (WPS)
The qualification of the welding procedure shall be ascertained in accordance with EN 288/ISO 9956 Part 1, para. 5.1.1 by means of welding procedure qualification tests, for steel in accordance with EN 288/ISO 9956 Part 3. The test is valid within the limits described in para. 3.1 to 3.7. The scope of the welding procedure test is specified by the Society in writing. Any exceptions require the performance of a supplementary test, the scope of which shall be decided by the Society. Production tests may be recognized as supplementary tests. 3.1 Material groups
2.1 A preliminary "manufacturers" welding procedure specification (pWPS) setting out all the major parameters shall be produced by the welding shop for the welding of test pieces in accordance with EN 288-2 or ISO 9956-2, as applicable (see Chapter 1, Annex D). 2.2 The Societys expert shall select one of the welders whose names are to be supplied by the manufacturer to weld the test pieces. 2.3 The test pieces shall be made from materials whose properties are proven in accordance with the requirements specified in Part 1, Metallic Materials, Chapter 2. Their strength shall be at least 40 N/mm2 higher than the minimum tensile strength of the material group. Pre-treatment and after-treatment of the welded joints by preheating, heat treatment and the like is only permitted if stipulated for these materials during actual fabrication.
Above and beyond the grouping system of EN 288/ISO 9956 Part 3, para. 8.3.1.1, Table 3, the following provisions shall be observed: a) For materials which have to satisfy particular corrosion conditions (e.g. resistance to caustic cracking) the welding procedure tests shall be geared to these. A welding procedure qualification performed on group 1 killed steel does not apply to unkilled steels unless they were welded using basic covered electrodes or wire-flux combinations with basic flux.
b)
~200
200
20
Chapter 3 Page 24
Section 2
II - Part 3 GL 2000
c)
The materials 15NiCuMoNb5 and 17MnMoV64 shall be classified as group 2 materials.
3.6
Heat treatment
Approval is also granted for the following further material combinations in addition to those stipulated in EN 288/ISO 9956 Part 3, Table 4 but under the following conditions (see Table 2.1). Deviating from EN 288/ISO 9956 Part 3, Table 4, a welding procedure test available for the combination group 9 welded to group 2 does not incorporate the combination group 9 welded to group 3. Depending on material composition and/or the type of post-weld treatment required, the Society may also limit the scope to the base material used in the welding procedure test. 3.2 Welding process
The welding procedure test applies to the heat treated condition existing at the time of the test. Heat treatment of the test piece shall be performed so that a heat treated condition is achieved which is comparable to that of the component. 3.7 Special cases
For special cases, for example projection welds, welding of clad steels, stud welds and difficult repairs to be performed in the course of fabrication on steels which are susceptible to cracking due to hardening of the heat affected zone, welding procedure tests are necessary which are geared to these particular cases. The tests required and their scope are specified by the Society in each individual case. 4. Tests, scope of tests
Recognition applies only to the welding process employed in the welding procedure test. 3.3 Gas welding
In gas welding a test performed on the wall thickness t shall apply to the wall thickness range 0,75 t to 1,25 t. 3.4 Welding parameters
Testing comprises both non-destructive and destructive tests and shall be performed in accordance with EN 288/ISO 9956 Part 3, para. 7. Deviating from EN 288/ISO 9956 Part 3, para. 7.1 and Table 1, the following specimens shall also be taken from the test pieces: a) One all-weld metal tensile test specimen with a diameter of 10 mm and L0 = 5 d shall also be taken in the case of test pieces more than 20 mm thick in materials where the effect of the weld metal caused by the welded joints may be significant. This applies to steels in material groups 4 and 6 and also for the steels specified in para. 3.1.c.
Welding procedure tests performed on multi-pass welds do not apply to single-pass welds. 3.5 Welding consumables and auxiliary material
The requirements of EN 288/ISO 9956 Part 3, para. 8.4.5 do not apply if the filler metal used is of the same type and has been approved by the Society to be under the scope of the welding procedure qualification (cf. E.4.).
Table 2.1
Welding procedure qualification available for a steel group or combination joint 5 (10CrMo9-10) welded with 4 Suitable for the following combination joints 4 welded with 5 (13CrMo4-5) 4 welded with 1 4 welded with 2 (Re < 430 N/mm2) 5 welded with 1 5 welded with 2 6 welded with 5 6 welded with 2 6 welded with 1
6 welded with 4
II - Part 3 GL 2000
Section 2
Chapter 3 Page 25
b)
Notched bar impact test specimens shall be taken from the centre of the weld metal for each welding position in the case of: plates: all materials with a nominal wall thickness > 5 mm tubes: 14 MoV6-3 and X20CrMoV12-1 nominal wall thickness > 10 mm, with a
The welding procedure test shall be repeated if there is a break in the fabrication of steam boilers or steam boiler components lasting longer than one year.
G.
Welding Technique
16 Mo 3 with a nominal wall thickness > 20 mm, all other grades of steel conforming to DIN 17175 and DIN 17177 with a nominal wall thickness > 30 mm, other grades of steel above the nominal wall thicknesses as specified in the standards or in the GL approval document for the base material. c) Micrographic specimen for alloy steels 1. The structure shall be described and verified by means of photographs. Analysis of the weld metal for alloy steels 1. Test requirements
1. Welds must exhibit full penetration over their entire cross section and must not have any cracks or lack of fusion defects. Wherever possible, the root shall be grooved and capped. 2. When welding plates whose thicknesses differ by more than 20 % or more than 3 mm, the thicker plate shall be bevelled to the thickness of the thinner plate at a maximum angle of 30 . 3. In the case of shells consisting of several rings, the longitudinal seams shall be staggered. 4. Fillet welds on lapped joints are only permitted in special cases and are then to be made only as double-sided circumferential welds up to a wall thickness of 15 mm. 5. Corner welds and similar welded joints which are subjected to considerable flexural stresses under adverse conditions of fabrication or service are only allowed if the Society raises no objection to the method of execution. 6. Holes and cut-outs in or immediately adjacent to welds, especially longitudinal welds, shall be avoided wherever possible. 7. Welding of components in cold-formed areas where the outer fibres have been stretched by more than 5 % (Dm < 20 s for cylindrical shell rings) is only allowed if the effects of cold-forming have been eliminated by means of appropriate heat treatment. This generally has to be accomplished by normalizing heat treatment or quenching and tempering. This requirement may be waived if proof is furnished that the properties of the material are no more than insignificantly impaired with regard to the intended use. 8. Every weld in a boiler component shall be marked in such a way that its location remains recognizable and the welder concerned can be identified at any time. Both of these may be evidenced either by stamping the weld accordingly or by making entries in drawings, welding schedules or other records.
d) 5.
The irregularities in the test piece must fall within the limits specified for quality level B in accordance with EN 25817/ISO 5817, exceptions being: excessive weld reinforcement (butt and fillet welds), excessive root reinforcement and excessive fillet weld thickness which fall into quality level C. For the mechanical and technological tests, Table 2.2 applies. 6. Storage of specimens
The tested specimens and the remaining portions of the test pieces shall be stored until the report on the welding procedure test has been completed (cf. also Chapter 1, Section 4, C.3.). 7. Validity, extension of welding procedure tests
The validity of a welding procedure test is generally 1 year provided that the preconditions under which it was granted have not significantly changed. It may be continued by means of regular production tests (see para. I.11). In addition to production tests and tests performed on welded components (cf. para. I.) non-destructive tests may, given certain preconditions, also be recognized by the Society for continuing the validity.
1 For the classification of steels (unalloyed and alloyed), see EN 10020.
Chapter 3 Page 26
Section 2
II - Part 3 GL 2000
Table 2.2
Requirements applicable to the mechanical and technological tests
Type of test Tensile test transversely to weld Hot tensile test on a specimen taken from the weld metal Notched bar impact test 1 on specimen from centre of weld
Requirements As stipulated for the base material or in the test of product suitability for the welding consumable. As stipulated for the base material or in the test of product suitability for the welding consumable. As stipulated for the base material in transverse direction. For welded joints in austenitic steels, 40 J with ISO-V-notch specimens.. The test shall be performed at room temperature. Bending angle Strength category 2 Ferritic steels with a minimum tensile strength < 430 N/mm2 Minimum tensile strength 430/Nmm2 to 460 N/mm2 High-temperature austenitic steels Ferritic steels with a minimum tensile strength 460/Nmm2 Mandrel diameter 2 a
180 3
2,5 a
Technological bend test
180 3
If a bending angle of 180 is not attained, the following applies: 90 Elongation (L0 = width of weld + thickness, symmetrical to weld) minimum elongation A5 of base material. Elongation over width of weld > 30 % 4 and faultless appearance of fracture.
or < 90
The macrographic specimen of the welded joint must reveal a satisfactory weld build-up and full penetration of the weld. Metallographic examination The micrographic section is to be examined for cracks. Cracks are not acceptable. In the case of welded joints in austenitic steels, hot cracks are acceptable provided that they are few in number and widely scattered. The hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks in excess of this figure in narrow transition zones shall not give rise to complaints if the outcome of the technological tests meets the requirements.
Hardness testing
1 2 3 4
For specimens less than the standard 10 mm in width, the impact energy requirements decrease in proportion to the cross section of the specimen. The tensile strength applies to the area of least thickness. The 180 requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and pressure was applied by the supports without cracks appearing. Different values may be agreed on for steels not welded with matching filler.
II - Part 3 GL 2000
Section 2
Chapter 3 Page 27
H.
heat-treated condition is only attained during subsequent fabrication. 2.2 The nominal wall thickness at the joints may not exceed 30 mm. 2.3 In the chemical composition (melt analysis) of the base material and the weld metal, the following contents may not be exceeded: C 0,22 %, Si 0,50 %, Mn 1,40 %, Cr 0,30 %, Cu 0,30 %, Mo 0,50 %, Ni 0,30 %, V 0,20 %,
1. Welded components must be heat-treated after welding in accordance with the stipulations of the relevant standards or the Society's approval document. 1.1 The post-weld heat treatment shall normally consist of stress relief heat treatment. 1.2 Components fabricated from steels which have undergone normalizing heat treatment shall be subjected to normalizing heat treatment if: the required characteristics of the welded joint can only be established by normalizing heat treatment or the component has undergone hot-forming after welding, unless hot-forming was completed within a temperature range equivalent to normalizing heat treatment.
In this context, the following conditions shall also be satisfied: Cr + Ni 0,30 % und Mn + Mo + V 1,6 %.
1.3 Components fabricated from quenched and tempered steels shall be subjected to quenching and tempering if: the required characteristics of the welded joint can only be achieved by quenching and tempering or the component has undergone hot-forming after welding.
These conditions may be relaxed in the case of steels which have been rendered resistant to brittle fracture and hardening by special metallurgical measures. Their suitability and properties shall be demonstrated to the Society after an adequate period of proving. The steels' resistance to brittle fracture, resistance to hardening and weldability must be equivalent to those of steels falling within the above analytical limits. For the weld metal, at a C content 0,10 % the Si content shall be 0,75 %, the Mn content 2,0 % and the sum of the Mn, Mo and V contents 2,5 % if welding consumables are used which produce a weld metal with a particularly high toughness, e.g. by using welding consumables with basic characteristics. 3. Post-weld heat treatment may be dispensed with for butt welds located in the flue gas stream in tubes made of 13CrMo44 steel with no lower limit for the average wall temperature and in pipes made of 10CrMo9 10 steel above an average wall temperature of approx. 490 C, provided that the outside tube diameter does not exceed 63,5 mm and the wall thickness does not exceed 10 mm. Butt welds between the tubes and tube nipples are included under this provision, even if they are not located in the flue gas stream. 4. Components shall generally be heat-treated in their entirety. In the case of stress relief heat treatment and tempering heat treatment, an exception from sentence 1 may be made if in the case of cylindrical components, a sufficiently wide cylindrical section or in the case of longitudinal welds in open shell rings without a circumferential weld, the weld zone over a sufficient width
If, in the case of air-hardened and tempered steels, the hot- forming of the component was on the whole performed under the conditions applicable to normalizing heat treatment, tempering alone is sufficient. 1.4 For such welded joints, preheating and treatment by quenching and tempering or by tempering alone should as a rule be carried out in accordance with the instructions of the material or consumable manufacturer. A special means of heat treatment shall be specified if, for instance, the material or the weld metal is hardened to an unacceptable degree during welding. For high-alloy steels with a ferritic or austenitic structure, the need for and method of heat treatment shall be determined on an individual basis. 2. Post-weld heat treatment may be dispensed with if the following conditions are met: 2.1 Prior to welding, the materials must be in the heat-treated condition specified in the relevant standards or in the Society's approval document. This condition is also deemed to be met if the required
is heat-treated by (continuous) uniform heating, on both sides if possible, provided that the Society's expert raises no objection. In both cases, thermal stresses must not be allowed to shift to parts subject to flexural stresses (e.g. flanges or cut-outs).
Chapter 3 Page 28
Section 2
II - Part 3 GL 2000
5. Welding of small parts into and onto the walls of steam boilers shall generally be carried out prior to heat treatment. This especially applies if: the nominal wall thickness of the basic structure exceeds 30 mm (see para. 2.2), the contents specified in para. 2.3 are exceeded, cold forming takes place in conjunction with welding.
formation afterwards. This test may be dispensed with if the complete longitudinal and circumferential welds have been subjected to non-destructive testing by appropriate means with satisfactory results. 2.2 Where dished drums are fabricated from steel with a minimum tensile strength 440 N/mm2 2 and a minimum yield strength at room temperature 320 N/mm2 and the nominal wall thickness is greater than 30 mm, following the final heat treatment three core samples shall be drilled out of the metal, one being taken from each end of the cylindrical part and one from the middle of the drum. The exact location of the sampling points, which shall be offset relative to each other by approx. 120 if possible, shall be indicated to the drum manufacturer by the steam boiler manufacturer in good time. The core samples shall be at least 60 mm in diameter to enable one specimen for tensile testing and one set of three specimens for notched bar impact testing to be prepared. The specimens shall be cut out transversely to the direction of rolling of the plate; if possible, the tensile test specimen should be located 1/6 of the wall thickness below the surface. Of the three notched bar impact test specimens, one shall be taken from each of the extremities and one from the middle of the core sample. 2.3 Where cold-bent shell rings with a degree of deformation > 5 %, hot-bent shell rings or dished half-drums are fabricated from steel with a minimum tensile strength 440 N/mm2 2 and a minimum yield strength at room temperature 320 N/mm2 and the nominal wall thickness is greater than 30 mm, following heat treatment a sufficiently wide ring shall be cut off, from which one specimen for tensile testing and one set of three specimens for notched bar impact testing shall be taken transversely to the direction of rolling of the plate. Alternatively, the procedure described in para. 2.2 may be followed. 2.4 If, in the situations described in para. 2.2 and 2.3, the final heat treatment consists solely of stress relief heat treatment or if working is carried out only within the stress relief heat treatment range and is not liable to change the properties of the material substantially, the specimens prescribed in para. 2.2 and 2.3 may be prepared beforehand and heat-treated in the same manner. In this case, the temperature of the specimens over their length and the extent of the variation in temperature shall be measured and recorded. 3. The requirements applicable to the mechanical and technological tests stated in para. 1. and 2. are governed by the provisions of Part 1, Metallic Materials, Chapter 2, Section 1, E. and Section 6, A. In testing of the base material after heat treatment, a negative tolerance of 5 % applies in individual cases
When welding in individual small parts, heat treatment may be dispensed with if the properties of the materials to be joined and the welding process enable the making of a satisfactory welded joint which is appropriate to the conditions of service and the working temperature. 6. Documentary proof of the heat treatments described in para. 1.1 to 1.4 shall be provided by means of a works certificate to EN 10204 or ISO 10474, as applicable (DIN 50049), which shall state the method, temperature and duration of the heat treatment and the method of cooling. Any special heat treatment, e.g. temporary cooling after welding prior to tempering treatment, shall be recorded in the works certificate.
I.
Inspection of Welded Components
1. Where no production tests are carried out on welded shell rings which have undergone hot bending or heat treatment, for materials with a minimum tensile strength 440 N/mm2 2 and alloy steels 1 a test piece taken from the plate used and stamped by the Society's expert shall be subjected to the same treatment as the shell ring. A tensile test and a notched bar impact test (three test specimens) shall be performed on specimens from this test piece to establish the ultimate condition of the material of the drum or the shell ring. 2. Fully welded drums for water-tube boilers with upset or prewelded ends shall be subjected to the tests specified in para. 2.1 to 2.4. 2.1 The drums shall be subjected by the Society's expert to a hydraulic pressure test at 1,5 times the working pressure, subject to the limitation that the resulting stress shall not exceed 0,9 times the yield strength at 20 C, taking into account the positive diameter tolerance and the negative wall thickness tolerance. The component shall exhibit no leaks during the hydraulic pressure test and no permanent de
2 The threshold may be raised to 470 N/mm2 if proof is furnished that stress relief heat treatment is not liable to result in an unacceptable reduction in the yield stress.
II - Part 3 GL 2000
Section 2
Chapter 3 Page 29
to the minimum yield strength and the minimum tensile strength if a load in the area of the hightemperature yield strength is applied. The yield strength and tensile strength may be less than the minimum by more than 5 %, up to 10 %, if proof is furnished that heat treatment has been satisfactorily carried out, the requirements applicable to the elongation of the base material are met, the requirements applicable to the impact energy of the base material are met, the dimensional design based on the hightemperature yield strength established is still adequate.
In calculating the out-of-roundness, the elastic deformations arising from the component's own weight shall be discounted. Isolated bulges and dents must also lie within the tolerances. In addition, the bulges and dents must have a flat profile and their depth, measured as a deviation from the normal roundness or from the shell line, as applicable, must not exceed 1 % of the length or width of the dent or bulge. The out-of-roundness need not be determined where the wall thickness is < 1 % of the nominal diameter.
4.3 Camber or flattening
The degree of camber or flattening in the area of the longitudinal welds, measured as a deviation from the normal roundness with a template length of 500 mm, may not exceed the dimension "a". Depending on the ratio of the average diameter dm to the wall thickness se of the drum or shell ring, the following applies: a 10 mm for shell rings:
Where loads in the area of the creep strength are applied, the yield strength and the tensile strength may be less than the specified minimum by max. 10 %. 4. An internal and external inspection shall be carried out on the completed shell rings and drums, and especially of the welds and adjacent areas and the dished ends. For the inspection, the components shall have a smooth external and internal surface corresponding to the condition as manufactured, to ensure that significant surface defects can also be detected; the internal surface is to be descaled. At the same time, measurements shall be carried out to determine: 4.1 External circumference
dm < 40 se dm 40 . se
4.4
a 5 mm for shell rings:

Axial non-linearity
The degree of axial non-linearity may be:

4.5
For shell rings: up to 0,3 % of the cylindrical length For drums: up to 0,5 % of the cylindrical length
Wall thickness of welds and adjoining plate areas
The measurements shall be spaced at approx. 1 m intervals over the entire length of the component. The measurements of the external circumference shall be used to determine the average outside diameter. The outside diameter of the shell rings and drums may not vary from the stipulated outside diameter by more than 1,0 %. 4.2 Out-of-roundness
The wall thickness in the plate must lie within the tolerance permitted for the plate.
5. If special conditions of fabrication apply to the components stated in para. 1 and 2, i.e. where large wall thicknesses or difficult-to-weld steels are used, non-destructive testing of the welds may also be necessary for an evaluation of up to V = 0,8. Welded joints in steels which, according to the report of the Society's expert, are subject to a non-standard method of heat treatment shall undergo the tests stipulated in the report, especially hardness testing and ultrasonic inspection. Proof of the outcome of these tests shall be provided by acceptance test certificate A or B to EN 10204 or ISO 10474, as applicable (DIN 50049) in accordance with the Society's report. 6. An acceptance test certificate A to EN 10204 or ISO 10474, as applicable (DIN 50049) showing that the requirements stated in para. 3. and 4. are met shall be furnished where one of the following limits is exceeded:
The measurements shall be spaced at approx. 1 m intervals over the entire length of the component. The out-of-roundness
U =
2 D max D min D m ax + D min
>
C 100 %
of the drums and shell rings following final heat treatment shall be: For non-heat-treated or stress relief heat-treated drums and shell rings where the wall thickness is > 1 % of the nominal diameter: 1 % max. For normalizing heat-treated, quenched and tempered or dished drums: 2 % max.
Chapter 3 Page 210
Section 2
II - Part 3 GL 2000
Overall length of cylindrical shell ring in excess of 2500 mm, Specified external diameter in excess of 1200 mm, Acceptable working pressure in excess of 16 bar, Weld factor higher than V = 0,8.
7.3
Out-of-roundness
The measurements shall be spaced at approx. 1 m intervals over the entire length of the components. The wall thickness shall invariably be measured at the ends of the shell rings and at any point where a decrease in wall thickness is significant. The out-of-roundness
U = shall not exceed: For corrugated furnaces: 1,0 % For smooth furnaces: 1,5 % up to a maximum of 15 mm. 2 D m ax D min D max + D min
Below these limits, an acceptance test certificate B to EN 10204 or ISO 10474, as applicable (DIN 50049) is sufficient.
7. An internal and external inspection of the completed smooth or corrugated furnaces, and especially of the welds and adjoining areas, shall be carried out. During the inspection the following shall be measured: 7.1 Deviation from specified external circumference
E 100 %
7.4
Non-linearity
The measurements shall be spaced at approx. 1 m intervals over the entire length of the components. The permitted deviations from the external circumference specified in the order in a measurement cross section are: For corrugated furnaces: non-corrugated portion corrugated portion pull-through type other corrugated tubes For smooth furnaces: at the ends of shell rings over a distance of 250 mm in the remainder of the cylindrical shell rings For smooth furnaces with flanged ends: cylindrical portion + 0 mm 75 mm 15 mm + 0 mm 75 mm + 0 mm 75 mm + 15 mm 60 mm 15 mm
The non-linearity shall be measured by placing a length of cord against the wall. It may not exceed 0,3 % of the cylindrical length of the shell rings.
7.5 Wall thickness of welds and adjoining plate areas
The following tolerances apply to the wall thickness of corrugated tubes: the average wall thickness must at least equal the nominal wall thickness within the corrugation pitch. Localized deficiencies of up to 10 % in the wall thickness within the corrugation pitch are permitted. The reduction in wall thickness is to be compensated for when manufacturing the corrugated tubes by means of an appropriate increase in the wall thickness of the original tube. The area A calculated from the specified corrugation depth and the specified wall thickness must be attained. With a corrugation depth w of 75 mm, a deficiency of 5 % in the area A is acceptable. In the flanged portion, a deficiency of up to 20 % in the wall thickness is permitted. In the assessment, defects which in the opinion of the Society's expert are clearly unimportant with regard to safety shall be disregarded. Smooth furnaces are subject to the tolerances applicable to plates.
8. Proof that the requirements stipulated in para. 7. are met shall be furnished by means of an acceptance test certificate A to EN 10204 or ISO 10474, as applicable (DIN 50049). A hydraulic pressure test is not required for furnaces. 9. The cut-out areas of headers certified according to quality grade I under DIN 17175 (cf. Part 1, Metallic Materials, Chapter 2, Section 2, C.) shall be subjected to appropriate non-destructive testing by the boiler manufacturer and the outcome of the testing shall be certified.
7.2
For corrugated tubes, difference between maximum outside diameter and associated inside diameter
The measurements shall be spaced at approx. 1 m intervals over the entire length of the components. For corrugated tubes, the difference between the maximum outside diameter and the inside diameter in the corrugations shall equal the specified dimension with a maximum negative tolerance of 20 mm.
II - Part 3 GL 2000
Section 2
Chapter 3 Page 211
10.
Repair welds
c)
Exceptions to the foregoing rules may be made for repair welds in justified special cases, provided that the Society's expert is informed of the nature and scope of the planned welds before work commences and he has no objections to the planned exceptions.
11. Production test
Notched bar impact test on ISO V-notch specimens to EN 875 (EN 10045) on three specimens taken from the centre of the weld metal with the position of the notch vertical to the surface of the test piece. The test temperature and requirements are shown in Table 2.2.
d)
The production test comprises non-destructive testing of the component and quality inspection of test pieces (mechanical and technological tests).
Structure examination of a specimen (macrographic specimen); for alloy 1 steels, a micrographic specimen is also required. A radiographic inspection to EN 1435 (DIN 54111) shall be carried out prior to sectioning of the test piece.
e)
All longitudinal and circumferential welds shall be subjected to non-destructive testing over their entire length. They shall also be examined for surface cracks if necessary. The tests shall be performed in accordance with Chapter 2, Section 4. For circumferential welds where the wall thickness is < 30 mm, testing of 25 % of the length of the weld is sufficient; however, all junctions with longitudinal welds shall be tested. The tests shall not be performed until the final heat treatment of the component has been carried out. The non-destructive tests shall not reveal any major defects in the weld. Such defects include cracks, lack of sidewall fusion and, in single-side welds, insufficient root penetration. Other defects such as pores and slag shall be assessed in accordance with recognized codes, e.g. AD code HP 5/3 or the ASME Boiler and Pressure Vessel Code, Section I. The results of the non-destructive tests shall be documented and presented to the Society's expert for assessment at the time of the structural inspection.
11.2 Quality testing of test pieces
Also, if the working temperature exceeds 350 C: f) Tensile test to EN 876 (DIN 50145) on a specimen from the weld metal (cylindrical specimen with L0 = 5 d to DIN 50125) for thicknesses 20 mm to determine the 0,2 % proof stress at the working temperature or g) Analysis of the weld metal with regard to the constituents which determine the mechanical properties at elevated temperature
as decided by the Society's expert. For materials with a minimum tensile strength of 440 N/mm2 and alloy 1 steels subjected to postweld heat treatment, a tensile test and a notched bar impact test on specimens taken from the base material transversely to the direction of rolling shall also be performed on the test piece.
11.3 Number, removal and dimensions of the test pieces for quality testing Procedure for the first six shell rings
The following tests shall be carried out on a test piece welded at the same time as the component as an extension of a longitudinal seam (cf. para. 11.3.6 and 11.4): a) Tensile test on two specimens, shape of specimen according to EN 895 (DIN 50120, Fig. 1); however, test length = width of weld + at least 80 mm. Technological bend test to EN 910 (DIN 50121, Part 1, Fig. 2) on four transverse bending test specimens (two specimens each with opposite sides of the weld in tension). On the side in tension, after machining off the weld reinforcement the original surface of the test piece shall be preserved to the greatest possible extent. Sizeable depressions such as undercuts and root notches shall not be repaired.
11.3.1
b)
If the higher evaluation is being made use of for the first time or is being extended through the inclusion of new types or grades of material, a test piece located at one end of each of the first six shell rings shall be welded together with the shell ring and tested. Unless otherwise stipulated, the specimens stated in para. 11.4 shall be taken from this test piece. The test pieces required for these production tests shall be taken from the plates to be used for the component. Every melt shall be covered.
11.3.2 Procedure from the seventh shell ring onwards
The preparation and number of test pieces depends on whether or not post-weld heat treatment is necessary; cf. para. H.2.
Chapter 3 Page 212
Section 2
II - Part 3 GL 2000
11.3.3 For components where heat treatment is unnecessary, the following applies, provided that the analytical limits stated in para. H.2.3. are not exceeded:
11.4
Welding of test pieces, number and removal of test specimens Welding of test pieces
11.4.1
a)
Preparation: The test pieces may be taken from plates of the same type and strength category and approximately the same thickness as those used for the shell ring; a difference of 5 mm is acceptable. The characteristics of the plates must be verified in accordance with Part 1, Metallic Materials, Chapter 2.
The seam of the test piece shall be welded in the course of fabrication together with the last 300 mm of weld of the shell ring. The Society's expert has the right to be present while this weld is made. The test pieces shall undergo a heat treatment which is demonstrably similar to that applied to the component.
11.4.2 Number of test specimens
b)
Number of test pieces: One test piece shall be welded as an extension of one of the longitudinal seams of each component, irrespective of the number of shell rings.
From every welded test piece, specimens for the tests prescribed in para. 11.2 shall be stamped by the Society's expert and removed. The specimens shall alternate with each other and lie adjacent to each other. The remainder of the test piece is intended for retests. It shall also be stamped and marked in such a way that its affiliation can be unequivocally established.
11.5 11.5.1 Requirements Mechanical and technological tests
11.3.4 For components where heat treatment is necessary, the following applies:
a)
Preparation: The test pieces shall be taken from plates to be used for the component in question.
b)
Number of test pieces: One test piece shall be welded as an extension of one of the longitudinal seams of each component, irrespective of the number of shell rings. If the component consists of material from several melts, one test piece shall be welded for each melt. If the analytical values differ only slightly, the Society's expert may reduce the number of test pieces accordingly, even if a component consists of material from several melts.
The mechanical and technological tests are governed by Table 2.2 in conjunction with para. I.3.
11.5.2 Retest specimens
11.3.5 The number and locations of the test pieces are shown in Table 2.3.
If one of the tests listed in para. 11.2 fails to achieve the required result, each unsuccessful test shall be repeated by testing two more specimens of the same type taken from the remainder of the test piece. The test conditions are met if the retest specimens meet the requirements.
11.6 Supplementary tests
After at least 50 production tests per material category, relaxations may be agreed with the Society.
11.3.6 Size of test pieces
The size of each test piece shall be such that the specimens prescribed in para. 11.4.2 and a sufficient number of retest specimens can be taken from it.
Further tests, e.g. notched bar impact tests with the fracture section in the transition zone or radiographic inspections in various directions, shall be performed if considered necessary by the competent expert in special cases for assessment of the weld.
II - Part 3 GL 2000
Section 2
Chapter 3 Page 213
Table 2.3
Number and locations of test pieces

Heat treatment unnecessary necessary
1st to 6th shell ring From 7th shell ring and further components consisting of on shell ring two or more shell rings
One test piece per shell ring taken form the plates to be used for the component. Every melt is to be covered (see para. I.11.3.1)
One test piece per shell ring (see para. I.11.3.2) One test piece per component taken from plates of the same strength category and approx. the same thickness (difference of 5 mm are acceptable). One test piece per component; where different melts are used however, one test piece for each melt from one of the plates to be used for the components.
After at least 50 production tests per material group
Relaxations by agreement with the Society (cf. TRD 201, Appendix 3, para.6)
II - Part 3 GL 2000
Section 3
Welding of Pressure Vessels
Chapter 3 Page 31
Section 3 Welding of Pressure Vessels

Preliminary remark: The following rules relating to the welding of pressure vessels comply with or incorporate the AD codes of practice. Subject to the approval of the Society, other codes of practice such as the ASME Boiler and Pressure Vessel Code, Section VIII may also be adopted for the fabrication and testing of welded pressure vessels (the following rules being applicable in analogous manner). Cf. also Chapter 1, Section 1, B.1.4. 2. Other relevant rules
2.1 The provisions of the Rules for Construction I, Part 1, Chapter 2, Section 8 shall also be complied with in the design and dimensioning of pressure vessels and process equipment. 2.2 Cargo tanks designed to carry chemicals are also subject to the provisions of the rules for Construction I, Chapter 7 - Chemical Tankers, Section 1. 2.3 Cargo tanks and process vessels designed to carry cooled liquefied gases are also subject to the provisions of the Rules for Construction I, Part 1, Chapter 6 - LPG Tankers. 3. Assessment of welds
A. 1.
General Scope
1.1 These Rules apply to the fabrication and testing of the following welded steel tanks, vessels and process equipment which are designed to withstand an internal working pressure: 1.1.1 Tanks, vessels and process equipment fabricated from unalloyed and alloyed ferritic steels with nominal yield strengths up to 380 N/mm2. 1.1.2 Tanks, vessels and process equipment fabricated from austenitic stainless steels. 1.1.3 Cargo tanks 1 and process vessels fabricated from steels tough at subzero temperatures for the carriage of cooled liquefied gases. 1.2 Tanks, vessels and process equipment fabricated from other materials not mentioned in para. 1.1 may be manufactured and tested in accordance with technical codes recognized by the Society. Examples of recognized technical codes are the more comprehensive requirements set out in the AD Codes of Series HP published by the "Arbeitsgemeinschaft fr Druckbehlter" (Pressure Vessel Manufacturing Association). 1.3 The design and testing of tanks, vessels and process equipment joined by other processes (e.g. brazed or bonded) shall be subject to agreement between the manufacturer and the Societys head office in each individual case (cf. also Chapter 1, Section 1, A.1.1).
1 Independent "Type C" tanks.
3.1 Tensionally stressed longitudinal welds in pressure vessels and process equipment, except for such welds in cargo tanks for carriage of liquefied gases, may generally be evaluated according to a weld factor up to v = 0,85, provided that they meet the requirements specified in Chapter 1, Section 1 and 2, and in Sections D, E, G and H. A higher evaluation up to v = 1,0 may be applied if a production test and non-destructive testing in accordance with I.4. have been successfully performed on the finished component. 3.2 Cargo tanks for liquefied gases shall be so constructed that their longitudinal welds can be evaluated according to a weld factor of at least v = 0,95. A further condition is successful performance of the production tests and non-destructive tests specified in I.4. A higher evaluation up to v = 1,0 may be applied if the characteristics of the material, the type of the welded joints, the welding process and the type of loading so permit and the Society has approved the higher evaluation.
B.
Approval of Welding Shops, Welding Personnel
1. All welding shops intending to perform welding work within the scope of these rules must satisfy the requirements applicable to welding shops and personnel set out in Chapter 1, Section 2 and
Chapter 3 Page 32
Section 3
II - Part 3 GL 2000
must have been approved by the Society. Applications for approval shall be submitted by the welding shops in good time before starting the welding work, enclosing the information and documentation prescribed in Chapter 1, Section 2, A.3. 2. The welding personnel (welders and welding supervisors) and, where applicable, inspectors and inspection supervisors must satisfy the requirements set out in Chapter 1, Section 2, B.2., B.3. and B.4. and be recognized by the Society. For the welders qualification tests, see Chapter 1, Section 3.
the latest state of welding practice. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops of this responsibility. 5. With regard to quality inspections and the responsibilities involved in awarding subcontracts to independent branches or suppliers or to approved or non-approved outside firms working in the welding shop (subcontractors), see Chapter 1, Section 1, F. Subcontracting of work or employment of temporary workers shall be notified to the Society. 6. The scope of the required quality inspections depends on the construction project in question. It is essential to ensure, however, that the intended materials, welding consumables and auxiliary materials are used and that the weld preparation, assembly, execution of the tack and final welds and the dimensional accuracy and completeness of the welded joints meets the requirements stated in para. 3. For non-destructive testing of the welded joints and production tests have to be performed, see I. 7. Following internal inspection and, if necessary, repair by the welding shop, the components shall be presented to the Society's Surveyor for checking at suitable stages of fabrication. For this purpose they shall be readily accessible and shall normally be uncoated. Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed. 8. The Society is not responsible for guaranteeing that all the components and welded joints inspected to the prescribed extent (generally on a random basis) by its surveyors have been fabricated in accordance with the conditions and meet the requirements in every respect. Components or welded joints which subsequently turn out to be defective may be rejected or their repair may be demanded even if acceptance testing has already been carried out.
C.
1. The manufacturer shall submit to the Society, for inspection, drawings and other relevant documents containing at least the following information: The materials and welding consumables to be used, The welding process and the location and shape of the weld, The type of heat treatment, if required, The acceptable working pressure, The calculated temperature or, in the case of vessels fabricated from steels tough at sub-zero temperatures, the minimum design temperature, The operating temperature, The test pressure, The weld factor used as a basis for calculation, The nature and scope of the non-destructive tests, The nature and scope of the production tests.
2. If the quality or good working order of a component cannot be guaranteed or is in doubt due to inadequate or missing information in the manufacturing documents (e.g. production drawings), the Society may demand appropriate improvements. 3. The welding shops shall ensure by means of regular in-house quality inspections during fabrication and on completion of the welding work that this work has been performed competently and satisfactorily (cf. Chapter 1, Section 1, F.). For the duties and responsibilities of the welding supervisor, see also EN 719/ISO 14731. 4. The welding shops are responsible for ensuring that the welding work conforms to these Rules, the approved manufacturing documents, any conditions stipulated in the approval documents and
D.
1. The materials selected must be appropriate for the intended purpose, with allowance made for mechanical and thermal stresses. The characteristics of materials subjected to further processing shall be such that they are able to withstand the operating loads. 2. Welded structures may only be fabricated using base materials of proven weldability. The intended materials must comply with the requirements
II - Part 3 GL 2000
Section 3
Chapter 3 Page 33
set out in the relevant sections of Part 1, Metallic Materials, Chapter 2. Other comparable materials may only be used after the Society has given its approval in each individual case. 3. Materials for cargo tanks and process vessels for liquefied gases must also meet the impact energy requirements at the stipulated test temperature; cf. Table 3.3.
7. The welding consumables and auxiliary materials (especially hydrogen-controlled, basiccovered electrodes and basic welding fluxes) shall be re-dried before use in accordance with the manufacturer's instructions (observe maximum drying time!) and stored in a dry place (in heated containers or the like) at the workplace. Note: The DVS guideline 0504 "Handling, storage and redrying of covered electrodes" and the DVS regulations 0914 "Use and storage of welding fluxes for submerged-arc and electro-slag welding" issued by the German Welding Society (Deutscher Verband fr Schweitechnik e.V) contain detailed instructions on this subject.
E.
1. The welding consumables and auxiliary materials must enable a welded joint to be made which is appropriate to the base material, the operating temperature and the conditions of service. The suitability of the welding consumables must also have been verified under the conditions prevailing in further processing and heat treatment. 2. All the welding consumables and auxiliary materials used (e.g. covered electrodes, wire-gas combinations, wire-flux combinations, etc.) must have been approved by the Society in accordance with Chapter 1, Section 5. They may also, however, be approved if tested at the same time as the welding procedure and restricted to the users works (cf. Chapter 1, Section 4, B.3.2 and Section 5, A.1.4). 3. Welding consumables for steels tough at subzero temperatures must also meet the impact energy requirements for the weld metal at the stipulated test temperatures; cf. Table 3.3. 4. If it is necessary, in special cases, to use welding consumables of dissimilar material where the strength of the resulting weld metal is lower than that of the base materials, e.g. when welding 9 % nickel steel with austenitic consumables, appropriate allowance shall be made in the design calculations for the vessels. 5. Welding consumables and auxiliary materials specified in a procedure approval document with a makers or brand name (cf. F.3.5) may only be replaced by equivalent consumables approved by the Society with an appropriate quality grade if this is explicitly stated in the respective approval document. Failing this, the Society's agreement shall be obtained. 6. The welding consumables and auxiliary materials may only be used in the approved welding positions. The manufacturers' recommendations and instructions for welding (e.g. type of current and polarity) shall be followed.
F.
Preliminary remark: In contrast to earlier issues of these Rules, welding procedure tests shall be performed in accordance with EN 288 or ISO 9956, as applicable. This paragraph essentially covers requirements applicable to the welding of pressure vessels over and above those set out in EN 288-3 and ISO 9956-3. 1. General
Only those welding procedures shall be employed whose satisfactory operational handling and adequate quality properties have been verified as part of a welding procedure test under production conditions at the users works. The general requirements set out in Chapter 1, Section 4 shall be observed. The welding procedures must have been approved by the Society for the particular welding shop in question. 2. Welding of test pieces, welding procedure specification (WPS)
2.1 A preliminary "manufacturers" welding procedure specification (pWPS) setting out all the major parameters shall be produced by the welding shop for the welding of test pieces in accordance with EN 288-2 or ISO 9956-2, as applicable (see Chapter 1, Annex D). 2.2 The Societys expert shall select one of the welders whose names are to be supplied by the manufacturer to weld the test pieces. 2.3 The test pieces shall be made from materials whose properties are proven in accordance with the requirements specified in Part 1, Metallic Materials, Chapter 2. Pre-treatment and after-treatment of the test pieces by preheating, heat treatment and the like
Chapter 3 Page 34
Section 3
II - Part 3 GL 2000
is only permitted if stipulated for these materials during actual fabrication. 2.4 The types of weld and welding positions employed in the fabrication process shall be qualified in the welding procedure test. 2.5 The shape and dimensions of the test pieces are specified in EN 288-3/ISO 9956-3 or, where applicable, stipulated in para. 2.6 and 2.7. 2.6 The plate test pieces for cargo tanks designed to carry liquefied gases shall be executed as shown in Fig. 3.1. 2.7 For making fillet welds on tanks for the carriage of liquefied gases, the following shall be made: One fillet-welded test piece approx. 300 mm long for each welding position (see Fig. 3.2) One Y test piece approx. 300 mm long from the joint between the central longitudinal bulkhead and the tank walls for each welding position (see Fig. 3.3) (where applicable, e.g. for bilobe tanks). Test principles, delimitation of scope
The test is valid within the limits described in para. 3.1 to 3.7. The scope of the welding procedure test is specified by the Society in writing. Any exceptions require the performance of a supplementary test, the scope of which shall be decided by the Society. Production tests may be recognized as supplementary tests. 3.1 Material groups
Above and beyond the grouping system of EN 288/ISO 9956 Part 3, para. 8.3.1.1, Table 3, the following provisions shall be observed: a) For materials which have to satisfy particular corrosion conditions (e.g. resistance to caustic cracking) the welding procedure tests shall be geared to these. A welding procedure qualification performed on group 1 killed steel does not apply to unkilled steels unless they were welded using basic covered electrodes or wire-flux combinations with basic flux. Approval is also granted for the following further material combinations in addition to those stipulated in EN 288/ISO 9956 Part 3, Table 4 but under the following conditions (see Table 3.1). Deviating from EN 288/ISO 9956 Part 3, Table 4, a welding procedure test available for the combination group 9 welded to group 2 does not incorporate the combination group 9 welded to group 3.
b)
c)
3.
The qualification of the welding procedure shall be ascertained in accordance with EN 288/ISO 9956 Part 1, para. 5.1.1 by means of welding procedure qualification tests, for steel in accordance with EN 288/ISO 9956 Part 3.
d)
B KM KS KS+1 KS+3 KS+5 G ZSch
Remainder for retests if required
~ 600
Fig. 3.1 Test piece for cargo tanks
II - Part 3 GL 2000
Section 3
Chapter 3 Page 35
macrographic specimen
300
200
Fig. 3.2 Fillet-welded test piece
2 macrographic specimen
3.2
Welding process
Recognition applies only to the welding process employed in the welding procedure test.
50 ~1
3.3
Gas welding
~200
Length of test piece 300 mm
Fig. 3.3 Y test piece e) Depending on material composition and/or the type of post-weld treatment required, the Society may also limit the scope to the base material used in the welding procedure test. For the materials used in the fabrication of cargo tanks and process vessels for liquefied gases, the test applies only to the grade of steel inspected.
Welding procedure tests performed on multi-pass welds do not apply to single-pass welds. 3.5 Welding consumables and auxiliary materials
f)
The requirements of EN 288/ISO 9956 Part 3, para. 8.4.5 do not apply if the filler metal used is of the same type and has been approved by GL to be under the scope of the welding procedure qualification (cf. E.5.).
Table 3.1
Welding procedure qualification available for a steel group of combination joints Suitable for the following combination joints 4 welded with 5 (13CrMo4-5) 4 welded with 1 4 welded with 2 (Re < 430 N/mm2) 5 welded with 1 5 welded with 2 6 welded with 5 6 welded with 2 6 welded with 1
5 (10CrMo9-10) welded with 4
6 welded with 4
120
2 macrographic specimens
Chapter 3 Page 36
Section 3
II - Part 3 GL 2000
3.6
Heat treatment
line in the heat affected zone (KS+1, KS+3, KS+52) for plate test pieces for cargo tanks for the carriage of liquefied gases; cf. Fig. 3.1. 5. Test requirements
For special cases, for example projection welds, welding of clad steels, stud welds and difficult repairs to be performed in the course of fabrication on steels which are susceptible to cracking due to hardening of the heat affected zone, welding procedure tests are necessary which are geared to these particular cases. The tests required and their scope are specified by the Society in each individual case. 4. Tests, scope of tests
The irregularities in the test piece must fall within the limits specified for quality level B in accordance with EN 25817/ISO 5817, exceptions being: excessive weld reinforcement (butt and fillet welds), excessive root reinforcement and excessive throat thickness (fillet welds) which fall into quality level C. For the mechanical and technological tests, Table 3.2 applies. The impact energy requirements for cargo tanks and process vessels designed to carry liquefied gases are given in Table 3.3. 6. Storage of specimens
Testing comprises both non-destructive and destructive tests and shall be performed in accordance with EN 288/ISO 9956 Part 3, para. 7. Deviating from EN 288/ISO 9956 Part 3, para. 7.1 and Table 1, the following specimens shall also be taken from the test pieces: a) One all-weld metal tensile test specimen with a diameter of 10 mm and L0 = 5 d shall also be taken in the case of test pieces more than 20 mm thick in materials where the weld metal may be significantly affected by the welded joints. This applies to steels in material groups 2 (high temperature steels only), 4 and 6. This test shall also be performed on group 7 materials where post-weld heat treatment is stipulated. b) Notched bar impact test specimens shall always be taken from the centre of the weld metal for each welding position in the case of wall thicknesses greater than 5 mm Notched bar impact test specimens shall also be taken from the weld boundary for each welding position in the case of material groups 2, 4, 5, 6, 7 and 9 (proportion of delta ferrite in the weld metal 3 %) and wall thicknesses 10 mm. Micrographic specimen for alloy steels 2. The structure shall be described and verified by means of photographs. Analysis of the weld metal for alloy steels 2. Contrary to the provisions of para. b) and c), 3 notched bar impact test specimens with the notch perpendicular to the surface of the plate shall each be taken from the centre of the weld metal (KM), the weld boundary (fusion line KS) and also 1, 3 and 5 mm away from the fusion
The tested specimens and the remaining portions of the test pieces shall be stored until the report on the welding procedure test has been issued (cf. also Chapter 1, Section 4, C.3.). 7. Validity, extension of welding procedure tests
The validity of a welding procedure test is generally 1 year provided that the preconditions under which it was granted have not significantly changed. It may be continued by means of regular production tests (see para. I.4.). In addition to production tests and tests performed on welded components (cf. para. I.) non-destructive tests may, given certain preconditions, also be recognized by the Society for continuing the validity. The welding procedure test shall be repeated if there is a break in the fabrication of pressure vessels or pressure vessel components lasting longer than one year.
c)
d)
e) f)
2 For the classification of steels (unalloyed and alloyed), see EN 10020.
II - Part 3 GL 2000
Section 3
Chapter 3 Page 37
Table 3.2
Test requirements applicable to welded joints in steel

Requirements Tensile strength as stipulated for the base material or in the assessment of suitability for the welding consumable
Type of test Tensile test transversely to weld
Tensile test on a specimen Yield strength or 0,2 % proof stress, tensile strength and elongation as stipulated for the base of the weld metal material or in the assessment of suitability for the welding consumable Where temperature of medium 1 is 10 C or above: As stipulated for the base material in transverse direction. Test temperature as in testing of the base material, but not lower than 10 C. When using ferritic-austenitic, austenitic and nickelbase welding consumables 40 J
Notched bar impact test on ISO V-notch specimen taken from centre of weld Where temperature of medium 1 is lower than 10 C:
At minimum working temperature, 27 J 2 when using ferritic welding consumables, 32 J when using ferritic-austenitic, austenitic and nickel-base alloy welding consumables Where temperature of medium 1 is 10 C or above: Notched bar impact test on ISO V-notched specimen taken from weld transition zone 27 J 2 ; test temperature as in testing of the base material, but not lower than 10 C Where temperature of medium 1 is lower than 10 C: 16 J 2; at minimum working temperature Bending angle, Degrees Strength category 3 Ferritic steels with: 180
4
Bending mandrel dia. a a a a
min. tensile strength < 430 N/mm2 min. tensile strength 430 to 460 N/mm2 Austenitic stainless steels and austenitic steels tough at subzero temperatures,
2,5 a 2 3 3
180 4
high-temperature austenitic steels, ferritic steels, with a minimum tensile strength 460 N/mm2
If a bending angle of 180 degrees is not attained, the following applies: 90 Elongation (L00 = width of weld + wall thickness, symmetrical to weld) minimum elongation A5 of base materials Elongation over width of weld > 30 % 5 and faultless appearance of fracture
or < 90
The macrographic specimen of the welded joint must reveal a satisfactory weld build-up and full penetration of the weld. Metallographic examination The micrographic section is to be examined for cracks. Only hot cracks are acceptable, and then only if they are few in number and widely scattered and agreement has been reached with the Surveyor as to their acceptability with regard to the material and the range of application. The hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks in excess of this figure in narrow transition zones shall not give rise to complaints if the outcome of the technological tests meets the requirements.
Hardness testing
1
Cargo tanks and process vessels for liquefied gases are subject to the impact energy requirements at the relevant test temperatures as shown in Table 3.3. Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %. The tensile strength value applies to the area of least thickness. The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and pressure was applied by the supports without cracks appearing. For steels welded with dissimilar consumables, e.g. X8Ni9, different values may be agreed with the Society.
2 3 4
Chapter 3 Page 38
Section 3
II - Part 3 GL 2000
Table 3.3
Impact energy requirements for cargo tanks and process vessels for liquefied gases
Notched bar impact test on ISO V specimen KV (J) min.
Type of steel
Minimum design temperature [C]
Thickness t [mm] t 20 20 < t 40 t 25 < t 30 < t 35 < t 25 30 35 40 5K 10 K 15 K 20 K
Test temperature 0 C 20 C below minimum design temperature 1, but not exceeding 20 C
Carbon-manganese steels
Carbon-manganese steel incl. 0,5 % nickel steel Nickel alloy steels containing
1,5 2,25 3,5 5 % % % % Nickel Nickel Nickel Nickel
55
Centre of weld:
60 65 90 105
t 25 < t 30 < t 35 < t
25 30 35 40
5 K below 10 K minimum 15 K design tem20 K perature 2
( 65 C) ( 70 C) ( 95 C) ( 110 C)
for ferritic consumables 27, for austenitic and nickelbase alloy consumables 32 Weld boundary and fusion line:
27
Nickel alloy steels containing

5 9 % Nickel % Nickel 165 165 165
3
Austenitic steels
1
t 25 4 t 25 4 t 25 4
196 C 196 C 196 C
For components subjected to stress relief heat treatment after welding, a test temperature of 5 K below the minimum design temperature or 20 C, whichever is lower, may be adequate. The test temperature shall not exceed the figures stated in brackets. The steel type 5 Ni may only be used for design temperatures down to 165 C after a special test of product suitability. For thicknesses > 25 mm, the requirements shall be agreed with the Society.
2 3 4
G.
Welding Technique
1. Welds must exhibit full penetration over their entire cross section and must not have any cracks or lack of fusion defects. Wherever possible, the root shall be grooved and capped. If backing rings are used when making circumferential welds, they must be removed after welding. This may be dispensed with in the case of small vessels, the inside of which is no longer accessible. 2. When welding plates of the same thickness, the edge misalignment shall not exceed the following values: Seams welded on both sides: 0,15 plate thickness (mm), subject to a maximum of 3 mm Seams welded on one side only: 0,10 plate thickness (mm), subject to a maximum of 2 mm.
For vessels fabricated from clad plates, a smaller edge misalignment tolerance may be necessary depending on the thickness of the cladding. 3. When welding plates whose thicknesses differ by more than 20 % or more than 3 mm, the thicker plate shall be bevelled to the thickness of the thinner plate at a maximum angle of 30. 4. In the case of shells consisting of several rings, the longitudinal seams shall be staggered. As a guide, the amount of stagger should be 4 times the plate thickness, but at least 100 mm. 5. Lapped joints with fillet welds between shell rings, bottoms and tubes are only acceptable in individual cases as circumferential welds with a wall thickness of 8 mm, provided that both sides of the lap are welded. Such joints may not be used in cargo tanks and process vessels for liquefied gases.
II - Part 3 GL 2000
Section 3
Chapter 3 Page 39
6. Corner welds and similar welded joints which are subjected to considerable flexural stresses under adverse conditions of fabrication or service are only acceptable if the Society raises no objection to the method of execution. 7. Holes and cut-outs in or immediately adjacent to welds, especially longitudinal welds, shall be avoided wherever possible. 8. Butt-welded joints in walls under pressure shall not be intersected by fillet welds of fitments. If intersection of fitments with vessel welds cannot be avoided, sufficiently large cut-outs shall be made in the fitments in the area of the butt welds in the vessel. 9. Weld preparation for welds between the vessel wall and domes and between the domes and the corresponding nozzles shall be carried out in accordance with recognized standards. All welds on nozzles, domes and other components which penetrate the pressure vessel and all welds between flanges and vessel or nozzle must be welded with full penetration over the entire wall thickness of the vessel or the nozzle. As an exception, other joints without full penetration may, with the Society's consent, be used for smalldiameter nozzles in the dome. 10. Bearings, tank mountings and other fitments which may induce stresses in the walls of the vessel shall be joined to the vessel wall with adequately dimensioned doubling plates or transition pieces. 11. Fillet welds of sockets, tank stiffeners and fitments which may induce stresses in the walls of the vessel shall be laid down in more than one pass. 12. Doubling plates, flanges, mountings, lifting lugs and other welded fitments must be adapted to the contour of the vessel. All parts must be welded prior to any heat treatment and before pressure testing. An exception to this rule may be allowed in the case of parts subsequently attached to doubling plates or transition pieces. 13. Welding of components from ferritic steels in cold-formed areas where the outer fibres have been stretched by more than 5 % (Dm < 20 s for cylindrical shell rings) is only allowed if the effects of coldforming have been cured by means of appropriate heat treatment. This shall generally be accomplished by normalizing heat treatment or quenching and tempering. This requirement may be waived if proof is furnished that
the properties of the material are no more than insignificantly impaired with regard to the intended use. 14. Every weld in a pressure vessel component shall be marked in such a way that its location remains recognizable and the welder concerned can be identified at any time. Both of these may be evidenced either by stamping the weld accordingly or by making entries in drawings, welding schedules or other records.
H.
1. Welded components must be heat-treated after welding in accordance with the stipulations of the relevant standards or the Society's approval document. 1.1 The post-weld heat treatment shall normally consist of stress relief heat treatment. 1.2 Components fabricated from steels which have undergone normalizing heat treatment shall be subjected to normalizing heat treatment if: the required properties of the welded joint can only be established by normalizing heat treatment
or the component has undergone hot-forming after welding, unless hot-forming was completed within a temperature range equivalent to normalizing heat treatment.
1.3 Components fabricated from quenched and tempered steels shall be subjected to quenching and tempering if: the required properties of the welded joint can only be established by quenching and tempering
or the component has undergone hot-forming after welding.
If, in the case of air-hardened and tempered steels, the hot-forming of the component was on the whole performed under the conditions applicable to normalizing heat treatment, tempering alone is sufficient. 1.4 Cargo tanks for liquefied gases fabricated from carbon- manganese steels or 0,5 % nickel steels and designed for service at temperatures below - 10 C shall be subjected to stress relief heat treatment, unless para. 2.4 applies.
Chapter 3 Page 310
Section 3
II - Part 3 GL 2000
1.5 For high-alloy steels with a ferritic or austenitic structure and nickel alloy steels tough at subzero temperatures with the exception of 0,5 % nickel steel, the need for and method of heat treatment shall be determined separately (see also Chapter 2, Section 3, para. E.). 2. Except in the case of the tanks described in para. 1.4, post-weld heat treatment may be dispensed with if the following conditions are met: 2.1 Prior to welding, the materials must be in the heat- treated condition specified in the relevant standards or in the Society's approval document. This condition is also deemed to be met if the required heat-treated condition is only attained during subsequent fabrication. 2.2 The nominal wall thickness at the joints may not exceed 30 mm.
and subjected with them to stress relief heat treatment before being attached to the tank structure. 3. If carbon-manganese or nickel alloy steels are welded with austenitic consumables, they shall not be heat-treated after welding. 4. Documentary proof of the heat treatments described in para. 1.1 to 1.4 shall be provided by means of a works certificate to EN 10204 or ISO 10474, as applicable (DIN 50049) which shall state the method, temperature and duration of the heat treatment and the method of cooling. Any special heat treatment, e.g. temporary cooling after welding prior to tempering treatment, shall be recorded in the works certificate.
I. 2.3 In the chemical composition (melt analysis) of the base material and the weld metal, the following contents may not be exceeded: C 0,22 %, Cr 0,30 %, Ni 0,30 %, Si 0,50 %, Mn 1,40 %, Cu 0,30 %, Mo 0,50 %, V 0,20 %;
In this context, the following conditions shall also be satisfied: Cr + Ni 0,30 % and Mn + Mo + V 1,6 %. These conditions may be relaxed in the case of steels which have been rendered resistant to brittle fracture and hardening by special metallurgical measures. Their suitability and properties shall be demonstrated to the Society after an adequate period of proving. The steels' resistance to brittle fracture, resistance to hardening and weldability must be equivalent to those of steels falling within the above analytical limits. For the weld metal, at a C content 0,10 % the Si content shall be 0,75 %, the Mn content 2,0 % and the sum of the Mn, Mo and V contents 2,5 % if welding consumables are used which produce a weld metal with a particularly high toughness, e.g. by using welding consumables with basic characteristics. 2.4 If, in the case of cargo tanks for liquefied gases fabricated from carbon-manganese steels or 0,5 % nickel steels and designed for service at temperatures below minus 10 C, heat treatment is on the whole not possible due to the dimensions of the tank, mechanical destressing shall be carried out after welding. For this purpose, individual components of complex design, e.g. domes, sumps, rings and other components which penetrate the casing of the tank, must first be welded to the adjoining shell or bottom plates
1. All tanks, vessels and process equipment shall be subjected to a hydraulic pressure test at 1,5 times the working pressure in the presence of the Surveyor, subject to the limitation that the resulting stress shall not exceed 0,9 times the yield strength at 20 C, taking into account the positive diameter tolerance and the negative wall thickness tolerance. This does not apply to cargo tanks of the type described in para. H.2.4. The component shall exhibit no leaks during the hydraulic pressure test and no permanent deformation afterwards. 2. An internal and external inspection shall be carried out on the completed vessels and process equipment, and especially of the welds and adjoining areas. The components shall have a smooth external and internal surface corresponding to the condition as manufactured, to enable significant surface defects to be detected. Vessels fabricated from austenitic steels must be pickled on the inside. At the same time, measurements shall be carried out to determine: 2.1 External circumference
The measurements shall be spaced at approx. 1 2 m intervals over the entire length of the component, depending on the length of the vessel. The measurements of the external circumference shall be used to determine the average outside diameter. The outside diameter of the shell rings and vessels may not vary from the stipulated outside diameter by more than 1,5 %. 2.2 Out-of-roundness
The measurements shall be spaced at approx. 1 2 m intervals over the entire length of the component.
II - Part 3 GL 2000
Section 3
Chapter 3 Page 311
The out-of-roundness
U =
2 D max D min D max + D min
>
C 100 %
4.
Production tests
The production test comprises non-destructive testing of the component and quality testing of test pieces (mechanical and technological tests).
shall not exceed the following values:

Table 3.4
Ratio of wall thickness Maximum acceptable to diameter out-of-roundness s/D 0,01 0,01 < s/D 0,1 s/D > 0,1 2,0 % 1,5 % 1,0 %
The performance of the tests is subject to the provisions of Chapter 2, Section 4.

4.1.1 Non-destructive testing of cargo tanks for the carriage of liquefied gases
4.1.1.1 The following welds shall be tested:
a)
In calculating the out-of-roundness, the elastic deformations arising from the component's own weight shall be discounted. Isolated bulges and dents must also lie within the tolerances. In addition, the bulges and dents must have a flat profile and their depth, measured as a deviation from the normal roundness or from the shell line, as applicable, must not exceed 1 % of the length or width of the dent or bulge.
2.3 Axial non-linearity
All butt welds in the pressure structure (shells, ends, domes, sumps) shall be subjected to Xray radiographic inspection over their entire length. In addition, at least 10 % of the weld length shall be tested for surface cracks. Fillet welds at the joint between the central longitudinal bulkhead and the tank casing of twin tanks or similar structures shall be subjected to ultrasonic or, where this is not possible, X-ray radiographic inspection over their entire length. In addition, at least 10 % of the weld length shall be tested for surface cracks. 10 % of the butt-welded joints of supporting rings in tanks shall be subjected to X-ray radiographic inspection. In the case of fillet welds between the web and the tank wall and between the web and the girder plate, at least 10 % of the weld length shall be tested for surface cracks. All butt and fillet welds of nozzles weldments, e.g. sockets, domes, sumps, rings, and of reinforcing plates around cutouts shall be tested for surface cracks over their whole length. Fillet welds of fitments welded to the tank which may induce stresses in the tank wall, e.g. lifting lugs, feet, brackets, shall be tested for surface cracks over their whole length. Full root penetration nozzle connections in the pressure structure shall undergo ultrasonic or radiographic inspection if the attachment wall thickness at the pressure structure is > 15 mm and the inside diameter of the nozzle is 120 mm. If cargo tanks are to be mechanically destressed, all points with geometry-related stress concentrations, such as the seams of socket weldments or fitments, shall afterwards be tested for cracks by the magnetic particle or dye penetrant method.
b)
c)
The axial non-linearity shall not exceed 0,5 % of the cylindrical length.
2.4 Camber or flattening
The degree of camber or flattening in the area of the longitudinal welds, measured as a deviation from the normal roundness with a template length of 500 mm, may not exceed the dimension "a". Depending on the ratio of the average diameter dm to the wall thickness se of the vessel or shell ring, the following applies: a 10 mm for shell rings a 5 mm for shell rings dm < 40 , se dm 40 . se
d)
e)
f)
2.5
Wall thickness of the welds and the adjoining plate areas
The wall thickness in the plate must lie within the tolerance permitted for the plate.
3. To show that the requirements stated in paras. 1 and 2 are met, the manufacturer shall issue an acceptance test certificate 3.1B to EN 10204 or ISO 10474, as applicable (DIN 50049 3.1B) and present it to the Surveyor at the final acceptance testing of the vessels.
g)
4.1.1.2 If radiographic inspection is to be partly replaced by ultrasonic inspection, the method and scope must be authorized by the Society beforehand.
Chapter 3 Page 312
Section 3
II - Part 3 GL 2000
4.1.1.3 Notwithstanding para. 4.1.1.2, the Society may require radiographic inspection to be supplemented by ultrasonic testing and vice versa if considered necessary in special cases. 4.1.1.4 Isotopes (Ir 192) may only be used if the use of an X-ray tube is impossible for technical reasons. 4.1.2 Non-destructive testing of pressure equipment with a weld factor v > 0,85
4.2 4.2.1
Quality inspection of test pieces Quality inspection of cargo tanks for the carriage of liquefied gases
4.1.2.1 The following welds shall be inspected:
a)
Longitudinal welds shall be subjected to radiographic inspection over their entire length and circumferential welds over 25 % of their length. In addition, at least 10 % of the weld length shall be tested for surface cracks. All butt and fillet welds of weld-in components and reinforcing plates around cut-outs shall be tested for surface cracks over their entire length. The same applies to fitments if they are capable of inducing stresses in the wall of the vessel. The attachment welds of nozzles with an inside diameter 120 mm and a thickness of the attachment cross section > 15 mm shall undergo radiographic or ultrasonic inspection.
b)
4.2.1.1 On all tanks for the carriage of liquefied gases, one test piece as shown in Fig. 3.4 shall be welded on to every 50 m of butt weld (longitudinal and circumferential welds). The location of the test pieces shall be such that every welding position is covered. Wherever possible, they shall be made as extensions of the vessel seams and shall be welded together with the vessel seam in the same operation. If this is not feasible in exceptional cases, the test pieces shall be attached beside the relevant tank weld and welded immediately on completion of the associated section of the weld under the same conditions as were used for the actual weld. The test pieces shall be stamped by the Society's expert before being removed from the tank. The positions and numbers of the test pieces shall be marked on the tank and indicated in the inspection schedule.
Z KM K G
c)
4.1.2.2 Where the radiographic inspection is to be replaced by ultrasonic inspection, the process and scope of the test must be authorized by the Society beforehand. The Society may prescribe an ultrasonic inspection to supplement the radiographic inspection where there are doubts in interpretation of radiographic exposures.
300
Remainder for retests it required
4.1.3
Non-destructive testing of pressure equipment with a weld factor v 0,85
Fig. 3.4 Test piece for production tests 4.2.1.2 The test pieces shall be subjected to the following tests (for shapes of specimens, see also Chapter 2, Section 5):
The manufacturer shall test the components at random in the course of his quality assurance procedures and shall present the results to the Surveyor at the vessel inspection. For this purpose, around 2 % (10 % in the case of wall thicknesses over 15 mm) of the longitudinal welds shall undergo radiographic or ultrasonic inspection, which shall include the junctions between longitudinal and circumferential welds.
4.1.4 Inspection criteria
a)
Tensile test on one specimen (Z), shape of specimen according to EN 895 (DIN 50120, Fig. 1); however, test length = width of weld + at least 80 mm. Technological bend test (B) to EN 910 (DIN 50121, Part 1, Fig. 2) on two specimens (one specimen each with opposite sides of the weld in tension). On the side in tension, after machining off the weld reinforcement the original surface of the test piece shall be preserved to the greatest possible extent. Sizeable depressions such as undercuts and root notches shall not be repaired. Notched bar impact tests on ISO V-notch specimens in accordance with EN 875
b) The non-destructive testing shall not reveal any major deficiencies in the weld. These include: cracks, lack of sidewall fusion and, in the case of single-side welds, inadequate root penetration. Other defects, e.g. pores and slag, shall be assessed in accordance with recognized codes of practice, e.g. AD Code HP 5/3 or the ASME Boiler and Pressure Vessel Code, Section VIII.
c)
II - Part 3 GL 2000
Section 3
Chapter 3 Page 313
(DIN 50115), taking from each test piece one set of specimens with the notch in the centre of the weld metal (KM) and one set located at a point in the heat-affected zone (K) at which the lowest impact energy values were measured in the welding procedure test. d) e) f) Structure examination (G) of one specimen (macrographic specimen). Hardness testing of the structure examination specimen according to d). A radiographic inspection in accordance with EN 1435 (DIN 54111) shall be performed prior to sectioning of the test pieces.
Quality inspection of pressure equipment with a weld factor v > 0,85
b)
In addition, one set of notched bar impact test specimens shall be taken from the transition zone (K) for: all process pressure vessels with a design temperature below 0 C all alloy steels all unalloyed steels where the wall thickness in the area of the weld is over 30 mm.
4.2.3
Quality inspection of pressure equipment with a weld factor v 0,85
4.2.2
4.2.2.1 In the fabrication of all vessels, a test piece as shown in Fig. 3.4 is to be welded at the same time, regardless of the number of melts used for the plates. Two test pieces are required if there are more than five rings per pressure vessel. 4.2.2.2 The test pieces shall be subjected to the scope of testing described in para. 4.2.1.2; however, the notched bar impact test specimens shall be prepared as follows:
The manufacturer shall perform random quality inspections on his components as part of his quality assurance procedures in accordance with para. 4.2.2. These inspections shall cover 2 % of the components, but shall be performed at least one test piece a year for each material group and welding process. The results of the quality inspections shall be presented to the Society's expert at the acceptance testing of pressure vessels.
4.2.4 Requirements
a)
One set of notched bar impact test specimens with the notch in the centre of the weld (KM) shall be taken from each test piece.
The requirements stated in Table 3.2 and, for cargo tanks and process vessels for liquefied gases, also those stated in Table 3.3 shall be met in the quality inspection. Failing this, the associated section of weld must be machined out and rewelded and its characteristics must be verified by testing of a new test piece.
II - Part 3 GL 2000
Section 4
Welding of Pipelines
Chapter 3 Page 41
Section 4 Welding of Pipelines

A. 1. General Scope stipulated in the following paragraphs or in other relevant rules, as applicable, in relation to the particular pipe class.
1.1 These Rules apply to the fabrication and testing of welded pipelines made of unalloyed steels high-temperature steels steels tough at subzero temperatures stainless steels. 1. All welding shops intending to perform welding work within the scope of these rules must satisfy the requirements applicable to welding shops and personnel set out in Chapter 1, Section 2 and must have been approved by the Society. Applications for approval shall be submitted by the welding shops in good time before starting the welding work, enclosing the information and documentation prescribed in Chapter 1, Section 2, A.3. 2. The welding personnel (welders and welding supervisors) and, where applicable, inspectors and inspection supervisors must satisfy the requirements set out in Chapter 1, Section 2, B.2., B.3. and B.4. and be recognized by the Society. For the welders qualification tests, see Chapter 1, Section 3. 3. The scope of the approval is determined by the capabilities of the welding shop and by the intended range of application (pipe class, materials, welding processes, welding positions, etc.). The intended range of application shall be specified in the application for approval; cf. the form "Description of Welding Shop" enclosed at Chapter 1, Annex B. For the period of validity of the approval, see Chapter 1, Section 2, A.4. and A.5. 4. Basic approval, extensions B. Approval of Welding Shops, Welding Personnel
1.2 Welded pipelines fabricated from other materials not listed in para. 1.1 (e.g. copper-nickel wrought alloys) may be manufactured and tested to other rules or regulations issued by the Society for specific uses or other engineering regulations recognized by the Society. 1.3 The design and testing of pipelines joined by other processes (e.g. brazed or bonded) are subject to agreement between the manufacturer and the Societys head office in each individual case (cf. Chapter 1, Section 1, A.1.1). 2. Other relevant standards
2.1 The provisions of the Rules for Construction I, Part 1, Chapter 2, Section 11 shall also be complied with in the design and dimensioning of pipelines subject to pressure. 2.2 Cargo lines on ships designed for the bulk carriage of chemicals are also subject to the provisions of the rules for Construction I, Chapter 7 "Chemical Tankers", Section 1. 2.3 Cargo and process lines on ships designed to carry cooled liquefied gases are also subject to the provisions of the Rules for Construction I, Part 1, Chapter 6 "LPG Tankers". 3. Pipe classes
Depending upon the nature of the pipe and its content (medium) and also the design pressure and design temperature, pipelines are classified into three pipe classes, see Rules for Construction I, Part 1, Chapter 2, Section 11, Table 11.1. The type of pipe connections, welding requirements, the need for post-weld heat treatment and the scope of the non-destructive tests are
4.1 For the welding of class III pipelines, as a general rule (basic) approval is granted first of all on the basis of a works inspection and, if necessary, welders qualification tests in accordance with Chapter 1, Section 3 normally for the manual arc welding (welding process 111), tungsten inert gas welding (welding process 141), gas welding (welding process 311) and/or semi-mechanized metal-arc active gas welding using solid and flux-cored wire (welding processes 135 and 136) of unalloyed tubular steels in the strength category 360 and 410 (cf. Part 1, Metallic Materials, Chapter 2) and also comparable cast and
Chapter 3 Page 42
Section 4
II - Part 3 GL 2000
forged steels. The range of wall thicknesses for these is determined by the scope of the valid welders qualification tests. 4.2 This does not apply to welding in the vertical down position using these processes, for which welding procedure tests shall be performed in every case. Cf. F. 4.3 A basic approval may be extended to include any welding procedure approvals on the basis of the welding procedure tests in accordance with Chapter 1, Section 4, (cf. also F.); in exceptional cases, however, a limited approval may also be granted, in conjunction with a welding shop inspection, for one specific material and/or one specific welding process only.
4. The welding shops are responsible for ensuring that the welding work conforms to these Rules, the approved manufacturing documents, any conditions stipulated in the approval documents and the latest state of welding practice. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops of this responsibility. 5. With regard to quality inspections and the responsibilities involved in awarding subcontracts to independent branches or suppliers or to approved or non-approved outside firms working in the welding shop (subcontractors), see Chapter 1, Section 1, F. Subcontracting of work or employment of temporary workers shall be notified to the Society. 6. The scope of the required quality inspections depends on the construction project in question. It is essential to ensure, however, that the intended materials, welding consumables and auxiliary materials are used and that the weld preparation, assembly, execution of the tack and final welds and the dimensional accuracy and completeness of the welded joints meets the requirements stated in para. 3. For non-destructive testing of the welded joints, see I. 7. Following internal inspection and, if necessary, repair by the welding shop, the components shall be presented to the Society's Surveyor for checking at suitable stages of fabrication. For this purpose they shall be readily accessible and shall normally be uncoated. Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed. 8. The Society is not responsible for guaranteeing that all the components and welded joints inspected to the prescribed extent (generally on a random basis) by its surveyors have been fabricated in accordance with the conditions and meet the requirements in every respect. Components or welded joints which subsequently turn out to be defective may be rejected or their repair may be demanded even if acceptance testing has already been carried out.
C.
Quality inspection responsibility
1. The manufacturer shall submit to the Society, for inspection, drawings and other relevant documents containing at least the following information: The type of pipeline/medium The pipe grades and welding consumables to be used, The welding process, welding position and shape of the weld, The type of heat treatment, if required, The acceptable working pressure, The design temperature or, in the case of cargo and process pipelines for gas tankers, the minimum design temperature, The operating temperature, The test pressure, The nature and scope of the non-destructive tests,
2. If the quality or good working order of a component cannot be guaranteed or is in doubt due to inadequate or missing information in the manufacturing documents (e.g. production drawings), the Society may demand appropriate improvements. 3. Welding shops shall ensure by means of regular in-house quality inspections during fabrication and on completion of the welding work that this work has been performed competently and satisfactorily (cf. Chapter 1, Section 1, F.). For the duties and responsibilities of the welding supervisor, see also EN 719/ISO 14731.
D.
1. The materials selected must be appropriate for the intended purpose, with allowance made for mechanical and thermal stresses. The characteristics of materials subjected to further processing shall be such that they are able to withstand the operating loads.
II - Part 3 GL 2000
Section 4
Chapter 3 Page 43
2. Welded structures may only be fabricated using base materials of proven weldability. Materials for pipelines (pipes, flanges, adapting pieces, fittings) must comply with the requirements set out in the relevant sections of Part 1, Metallic Materials, Chapter 2. Other comparable materials may only be used after the Society has given its approval in each individual case. 3. Pipeline materials for cargo and process lines for liquefied gases must also meet the impact energy requirements at the stipulated test temperature; cf. Tables 4.1 to 4.3.
in a dry place (in heated containers or the like) at the workplace. Note: The DVS guideline 0504 "Handling, storage and redrying of covered electrodes" and the DVS regulations 0914 "Use and storage of welding fluxes for submerged-arc and electro-slag welding" issued by the German Welding Society (Deutscher Verband fr Schweitechnik e.V) contain detailed instructions on this subject.
E.
F.
Preliminary remark: In contrast to earlier issues of these Rules, welding procedure tests shall be performed in accordance with EN 288 or ISO 9956, as applicable. This paragraph essentially covers requirements applicable to the welding of pipelines over and above those set out in EN 288-3 and ISO 9956-3. 1. General
1. The welding consumables and auxiliary materials must enable a welded joint to be made which is appropriate to the pipeline material, the operating temperature and the conditions of service. The suitability of the welding consumables must also have been verified under the conditions prevailing in any potential heat treatment. 2. All the welding consumables and auxiliary materials used (e.g. covered electrodes, wire-gas combinations, wire-flux combinations, etc.) must have been approved by the Society in accordance with Chapter 1, Section 5. They may also, however, be approved if tested at the same time as the welding process and restricted to the users works (cf. Chapter 1, Section 4, B.3.2 and Section 5, A.1.4). 3. Welding consumables for steels tough at subzero temperatures must also meet the impact energy requirements for the weld metal at the stipulated test temperatures; cf. Table 4.2. 4. Welding consumables and auxiliary materials specified in a procedure approval document with a makers or brand name (cf. F.3.5) may only be replaced by equivalent consumables approved by the Society with an appropriate quality grade if this is explicitly stated in the respective approval document. Failing this, the Society's agreement shall be obtained. 5. The welding consumables and auxiliary materials may only be used in the approved welding positions. The manufacturers' recommendations and instructions for welding (e.g. type of current and polarity) shall be followed. 6. The welding consumables and auxiliary materials (especially hydrogen-controlled, basic-covered electrodes and basic welding fluxes) shall be re-dried before use in accordance with the manufacturer's instructions (observe maximum drying time!) and stored
Only those welding procedures whose suitability for the application in question is evident from general experience or has been verified by means of a welding procedure test in accordance with Chapter 1, Section 4 and the following provisions may be used. Table 4.1 in Chapter 1, Section 4 gives a list of necessary verifications. The welding procedures must have been approved by the Society for the particular welding shop in question as part of the welding shop approval (cf. also B.). 2. Welding of test pieces, welding procedure specification (WPS)
2.1 A preliminary "manufacturers" welding procedure specification (pWPS) setting out all the major parameters shall be produced by the welding shop for the welding of test pieces in accordance with EN 288-2 or ISO 9956-2, as applicable (see Chapter 1, Annex D). 2.2 The Societys expert shall select one of the welders whose names are to be supplied by the manufacturer to weld the test pieces. 2.3 The test pieces shall be made from materials whose properties are proven in accordance with the requirements specified in Part 1, Metallic Materials, Chapter 2. Pre-treatment and after-treatment of the test pieces by preheating, heat treatment and the like is only permitted if stipulated for these materials during actual fabrication.
Chapter 3 Page 44
Section 4
II - Part 3 GL 2000
2.4 The types of weld and welding positions employed in the fabrication process shall be qualified in the welding procedure test. 2.5 The shape and dimensions of the test pieces are specified in EN 288-3/ISO 9956-3. 3. Test principles, delimitation of scope
3.5
Welding consumables and auxiliary materials
The requirements of EN 288/ISO 9956 Part 3, para. 8.4.5 do not apply if the filler metal used is of the same type and has been approved by the Society to be under the scope of the welding procedure qualification (cf. E.4). 3.6 Heat treatment
Except in the case of basic approvals for pipe class III (see B.4.1 and Table 4.1 in Chapter 1, Section 4), the qualification of the welding procedure shall be ascertained in accordance with EN 288/ISO 9956 Part 1, para. 5.1.1 by means of welding procedure qualification tests, for steel in accordance with EN 288/ISO 9956 Part 3. The test is valid within the limits described in paras. 3.1 to 3.7. The scope of the welding procedure test is specified by the Society in writing. Any exceptions require the performance of a supplementary test, the scope of which shall be decided by the Society. 3.1 Base materials, material groups
For special cases, for example difficult repairs to be performed in the course of fabrication on steels which are susceptible to cracking due to hardening of the heat affected zone, welding procedure tests are necessary which are geared to these particular cases. The tests required and their scope are specified by the Society in each individual case. 4. Tests, scope of tests
Above and beyond the grouping system of EN 288/ISO 9956 Part 3, para. 8.3.1.1, Table 3, the following provisions shall be observed: a) For materials which have to satisfy particular corrosion conditions (e.g. resistance to caustic cracking) the welding procedure tests shall be geared to these. A welding procedure qualification performed on group 1 killed steel does not apply to unkilled steels unless they were welded using basic covered electrodes. Depending on material composition and/or the type of post-weld treatment required, the Society may also limit the scope to the base material used in the welding procedure test. For cargo and process pipelines designed to carry liquefied gases, the test applies only to the grade of steel inspected. Welding process
Testing comprises both non-destructive and destructive tests and shall be performed in accordance with EN 288/ISO 9956 Part 3, para. 7. Deviating from EN 288/ISO 9956 Part 3, para. 7.1 and Table 1, the following specimens shall also be taken from the test pieces: a) Notched bar impact test on ISO V-notch specimens to EN 875 (DIN 50115) taken from the centre of the weld metal (KM) (one set of specimens per welding position) as follows: For cargo and process lines for gas tankers where the wall thickness is 4 mm1 For other alloy steels and fine-grained structural steels where the wall thickness is 6 mm.
b)
c)
d)
b)
3.2
Recognition applies only to the welding process employed in the welding procedure test. 3.3 Gas welding c)
Notched bar impact test on ISO V-notch specimens as above, but with the notch in the transition zone (K) where the wall thickness is 6 mm. For austenitic pipe steels, the test is only required for wall thicknesses 10 mm. Macro- and micrographic specimens are required for alloy steels. In particular, micrographic specimens shall be examined for mi-
1 Size of specimen and requirements for wall thickness < 6 mm must be separate agreed.
Welding procedure tests performed on multi-pass welds do not apply to single-pass welds.
II - Part 3 GL 2000
Section 4
Chapter 3 Page 45
crocracks. The metallographic structure is to be described or verified by means of photographs. d) An analysis of the weld metal, except for unalloyed steels. Test requirements
of the same composition as the base metal; with unalloyed and low-alloy pipe grades, they may also, where appropriate, be made of low-carbon steels (C 0,10 %). 3. In the case of pipelines fabricated from austenitic steels and all other pipelines with working pressures in excess of 10 bar and design temperatures of - 10C and below, permanent backing rings may not be used on principle. 4. For butt-welded joints in lines with design temperatures below 10C and for all stainless pipe steels, the root passes shall as a rule be laid down by tungsten inert gas welding with gas shielding on both the inside and the outside of the pipe. 5. Wherever possible, adequately dimensioned pipe fittings shall be used for branches. Where outward flanged pipeline connections are used, the inside diameter ratio shall not exceed 0,8. Outward flanges shall be made by established methods. 6. The preparation of welds must conform to recognized standards. Wherever possible, welding edges shall be prepared by machining or with a mechanically guided cutting torch. Slag, scale, drag lines and other irregularities shall be removed. Where necessary, the same applies to the heat-affected boundary zone in the case of austenitic steels. The welding edges of steel forgings and castings must be machined. 7. Tack welds may only be made with consumables which are also compatible with the pipe material. Where tack welds are to be left in place, they must be of the same quality as the root welds. The rules for preheating shall also apply to tack welding. 8. Flange-pipe joints shall be chosen in accordance with the GL Rules I, Part 1, Chapter 2, Section 11, in relation to the pipe class. 9. Pipeline sections to be welded must be axially aligned. The internal misalignment of the pipe ends may not exceed the values stated in Table 4.4.
5.
The irregularities in the test piece must fall within the limits specified for quality level B in accordance with EN 25817/ISO 5817, exceptions being: excessive convexity and excessive throat thickness (fillet welds) which fall into quality level C. For the mechanical and technological tests, Table 4.1 applies in conjunction with Table 4.2 which indicates the impact energy requirements for cargo and process lines for gas tankers. 6. Storage of specimens
The tested specimens and the remaining portions of the test pieces shall be stored until the report on the welding procedure test has been issued (cf. also Chapter 1, Section 4, C.3.). 7. Validity, extension of welding procedure tests
The validity of a welding procedure test is generally 1 year provided that the preconditions under which it was granted have not significantly changed. It may be continued by means of regular verifications of quality, e.g. the results of non-destructive tests or production tests. The welding procedure test shall be repeated if there is a break in the fabrication of pipelines or pipeline components lasting longer than one year.
G.
Welding Technique
1. Welds must exhibit full penetration over their entire cross section and must not have any cracks or lack of fusion defects. The welds shall be made in the workshop as far as possible. 2. Permanent backing rings shall be of such a shape that they can neither impede the flow nor cause corrosion. Backing rings shall be made of pipe steels
Chapter 3 Page 46
Section 4
II - Part 3 GL 2000
Table 4.1
Requirements as per para. 5 for testing of welded joints in pipelines
Type of Test Tensile test transversely to weld
Requirements Tensile strength as stipulated for the base material or in the assessment of suitability for the welding consumable All pipelines except those indicated below As stipulated for the base material, at least 27 J. Test temperature as for testing of base material. When using ferriticaustenitic, austenitic and nickel-base alloy welding consumables, 40 J. Test temperature as shown in Table 4.2. When using ferritic welding consumables, 27 J 2; when using ferritic-austenitic, austenitic and nickel-base alloy welding consumables, 34 J 2. 27 J 2 test temperature as for testing of base material Test temperature as shown in Table 4.2. 27 J for carbonmanganese steels, 34 J for nickel alloy steels, 41 J for austenitic steels. Strength category Ferritic steels with 180 3 minimum tensile strength < 430 N/mm2 minimum tensile strength 430 to < 460 N/mm
2
Notched bar impact test 1 on ISO V-notch specimens taken from the centre of the weld metal
Cargo and process lines of gas tankers All pipelines except those indicated below
Notched bar impact test 1 on ISO V-notch specimens Cargo and process lines taken from the weld of gas tankers transition zone Bending angle, degrees
Bending mandrel diameter a a a a
2,5 a 2 3 3
Technological bend test 180 3
Austenitic stainless steels and austenitic steels tough at subzero temperatures High-temperature austenitic steels Ferritic steels with a minimum tensile strength 460 N/mm2
If a bending angle of 180 degrees is not attained, the following applies: 90 or < 90 Elongation (L0 = width of weld + wall thickness, simetrically to weld) minimum elongation A5 of base material Elongation over width of weld > 30 % and faultless appearance of fracture
Metallographic examination
The macrographic specimen of the welded joint must reveal a satisfactory weld buildup and full penetration of the weld. Micrographic specimens are to be examined for cracks. Only hot cracks are acceptable, and then only if they are few in number and widely scattered and agreement has been reached with the expert as to their acceptability with regard to the material and the range of application. The hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks in excess of this figure in narrow transition zones shall not give rise to complaints if the outcome of the technological tests meets the requirements.
Hardness testing
1 2 3
For the requirements applicable to specimens with a depth of less than 10 mm, see Table 4.3. Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %. The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and pressure was applied by the supports without cracks appearing.
II - Part 3 GL 2000
Section 4
Chapter 3 Page 47
Table 4.2
Test temperatures for notched bar impact testing of pipe steels tough at subzero temperatures
Minimum design temperature [C] Test temperature [C]
Type of steel
Standard Designation
Standard
Carbon and carbonmanganese steels Nickel alloy steels containing

0,5 % Nickel 3,5 % Nickel 5 9 % Nickel % Nickel
TT St 35 N TT St 35 V
40 50
5 K below minimum design temperature, but not exceeding 20 C
DIN 17173 13MnNi63 10Ni14 12Ni19 X8Ni9 55 90 105 165 60 95 110 196
Austenitic steels 1, 2
(AISI 304 L) (AISI 316 L) (AISI 321) (AISI 347)
1 2
X2CrNi19-11 X2CrNiMo18-14-3 X6CrNiTi18-10 X6CrNiNb18-10
DIN 17457 DIN 17458
165
196
The designations in brackets are comparable pipe steels to AISI standards. Where austenitic pipe steels are used for design temperatures not less than 55 C, a test temperature 5 K below the minimum design temperature but not exceeding 20 C may be agreed upon.
Table 4.3
Impact energy requirements for specimens of reduced size Required impact energy KV for specimen sizes 1 7,5 10 mm [J] 5 10 mm [J]
Required impact energy KV for standard specimens 1 10 10 mm [J]
27 (19) 34 (24) 41 (27)

1 Figures in brackets are for the minimum individual value.
22 (16) 28 (20) 34 (24)
18 (13) 23 (16) 27 (22)
Chapter 3 Page 48
Section 4
II - Part 3 GL 2000
10. Weld reinforcements shall lie within the following tolerances (cf.Fig. 4.1):
H.
Heat treatments after cold or hot working and welding Ferritic steel pipes Heat treatment after cold forming
Cover pass reinforcement:

D 1 + 0,1 B mm
1. 1.1
Root pass reinforcement:

W 1 + 0,3 b mm
(cf. also EN 25817/ISO 5817, quality level B)

B
D
Pipes or pipelines shall normally be subjected 1.1.1 to heat treatment (normalizing heat treatment or quenching and tempering) following cold forming with a degree of deformation 5 % (rm 10 Da) in accordance with the material specification.
1.1.2 Post-forming heat treatment may be dispensed with in the case of unalloyed steel or finegrained structural steel pipes with an outside diameter Da 133 mm which are subjected to cold-bending with a bending radius rm 1,3 Da.
Fig. 4.1 Weld reinforcements
An exception applies to pipes fabricated from steels tough at subzero temperatures with wall thicknesses > 2,5 mm or pipes to which stressed components are welded outside the neutral fibres.
1.2 Heat treatment after hot forming
Welding of pipeline components made of 11. ferritic steels in areas subjected to cold forming where the outer fibres have been stretched by more than 5 % (e.g. where pipe bending is carried out with a radius rm < 10 Da) is only allowed if the effects of coldforming have been eliminated by means of appropriate heat treatment. This shall generally be accomplished by normalizing heat treatment or quenching and tempering. This requirement may be waived if proof is furnished that the properties of the material are no more than insignificantly impaired with regard to the intended use or if the conditions specified in para. H.1. or H.2., as applicable, are met.
Pipes and pipeline components shall be sub1.2.1 jected to heat treatment after hot forming in accordance with the material specification. If the hot forming operation is begun and ended within the temperature range stated in the material specification, normalizing heat treatment may be dispensed with for normalized steels. Subsequent tempering is required in the case of air-hardened and tempered steels.
1.2.2 If the pipe only undergoes localized heating in certain areas during bending, the provisions of para. 1.2.1 still apply; however, the entire pipe must be in the prescribed heat- treated condition.
Table 4.4
Tolerances on internal misalignment of pipe ends
Type of joint
Inside diameter Di [mm] any Di < 150 150 Di < 300 300 Di any
Wall thickness t [mm] any t 6 t 9,5 any t > 9,5
Tolerances on internal misalignment
with permanent backing rings
max. 0,5 mm t/4 t/4 t/4 t/4 max. max. max. max. 1 mm 1,5 mm 2,0 mm 2,0 mm
without backing rings
II - Part 3 GL 2000
Section 4
Chapter 3 Page 49
2. 2.1
Austenitic steel pipes Heat treatment after cold forming
3.
Heat treatment of pipe fittings
The provisions of Part 1, Chapter 2, Section 6, B., Pipe Fittings, apply. 4. Post-weld heat treatment
Heat treatment of pipes subjected to cold bending with a bending radius 1,3 Da is normally not required. 2.2 Heat treatment after hot forming
Renewed heat treatment (solution heat treatment and quenching or stabilization heat treatment) in accordance with the material specification is normally required after hot forming. If the heat treatment is carried out at initial forming temperatures between 1000 C and 1150 C and if the forming operation is completed at a temperature > 750 C in the case of stabilized steels or steels with a carbon content 0,03 % and > 875 C in the case of other steels, follow-up heat treatment may be dispensed with. A condition of this is that the material must be rapidly cooled down from the forming temperature. 2.3 Where more exacting corrosion resistance requirements apply, e.g. to pipelines for chemical tankers, the procedures described in para. 2.12 or 2.2, as applicable, may only be followed if the pipeline fabricator has proved by means of corrosion tests that the required resistance is present after forming. Failing this, renewed heat treatment after cold or hot forming is required.
4.1 Heat treatment shall be applied in accordance with Chapter 2, Section 3. Welded joints in pipelines fabricated from ferritic steels shall be heat-treated after welding in accordance with the stipulations of the relevant standards or the Society's approval document where the conditions stated in para. 4.1.1 and 4.1.2 apply. Unless otherwise stipulated, the post-weld heat treatment shall consist of stress relief heat treatment. 4.1.1 Electrically fusion-welded pipe joints shall undergo stress relief heat treatment if the limit wall thicknesses shown in Table 4.5 in relation to the type of pipe steel are exceeded. 4.1.2 Gas fusion-welded joints shall undergo normalizing heat treatment or quenching and tempering, depending on the type of material, if the wall thickness of the pipe exceeds 3,2 mm or the outside diameter exceeds 88,9 mm. 4.1.3 For pipes made of nickel alloy steels tough at subzero temperatures, the need for post-weld heat treatment and the limit wall thicknesses will be determined during the welding procedure test.
Table 4.5
Limit wall thicknesses for stress relief heat treatment of ferritic steel pipelines Wall thickness of the thicker element [mm] Heat treatment temperature [C]
Steel
Carbon and carbon-manganese stells containing
C + C +
Mn 0,40 6 Mn > 0,40 6 0,3 Mo
20 1 10 15 8 all thicknessses 2 The provisions of Chapter 2, Section 3 apply
1 Cr 0,5 Mo 2,25 Cr 1 Mo
1
The limit wall thickness for heat treatment may be raised if the welding procedure test has proved that the welds of untreated test pieces possess the required mechanical properties. Stress relief heat treatment may be dispensed with where the operating temperature is at least 450 C and where the outside diameter and the wall thickness do not exceed 100 mm and 6 mm respectively.
Chapter 3 Page 410
Section 4
II - Part 3 GL 2000
4.2 For pipelines fabricated from austenitic and austenitic- ferritic steels, post-weld heat treatment is generally unnecessary if the pipeline materials are in the proper heat-treated condition prior to welding.
furnished that the results are consistently good and that the percentage of repairs is relatively low. b) All cargo and process lines of gas tankers with a service temperature below 10C: 100 %. A reduction in the scope of the test may be agreed on application for pipelines with an inside diameter 75 mm or wall thicknesses 10 mm provided that proof is furnished that the results are consistently good and that the percentage of repairs is relatively low. c) All pipelines in pipe class II: 10 %. A reduction in the scope of the test may be agreed on application for pipelines with an inside diameter 100 mm provided that proof is furnished that the results are consistently good and that the percentage of repairs is relatively low. d) Where the execution of welding operations gives rise to doubts as to the quality of the welded joints, the Society may also call for a random radiographic test to be carried out on the butt welds of pipe class III.
I.
Inspection of Welded Pipelines
The inspection shall consist of an internal hydraulic pressure test and non-destructive tests. The nondestructive tests shall be performed in accordance with Chapter 2, Section 4.
1. Completed pipeline sections shall be subjected to a hydraulic pressure test at 1,5 times the working pressure in the presence of the Surveyor. The pipeline section may not exhibit any leaks during the hydraulic pressure test or any permanent deformation afterwards. 2. An external and, wherever possible, also an internal inspection of the completed pipeline sections and especially of the welds shall be performed. For the inspections, the sections shall have a smooth external and internal surface corresponding to the asfabricated condition which enables major surface defects to be detected, and pipelines fabricated from austenitic and austenitic-ferritic steels must be free from harmful temper colours. 3. The misalignment of pipe ends, the external weld reinforcements and - where accessible - the internal weld reinforcements shall be checked. They must lie within the tolerances specified in para. G.9. and G.10. 4. The butt-welded joints of the following pipelines shall be subjected to radiographic inspection as follows:
The radiographic inspection shall as a rule be performed with an X-ray tube. With the Society's consent, radiographic inspection may be replaced by ultrasonic inspection for ferritic steel pipes with wall thicknesses 20 mm.
5. Fillet welds of flanges, sockets and nipples of pipelines in class I, including cargo and process lines of gas tankers, shall be 100 % tested for surface cracks.
For pipelines in pipe class II and III, random testing covering 10 % of the welds is required.
Note: The scope of the tests to be applied to seriesmanufactured pipe fittings is specified separately; cf. Part 1, Metallic Materials, Chapter 2, Section 6, B.
a)
All pipelines in pipe class I: 100%. A reduction in the scope of the test may be agreed on application for pipelines with an inside diameter 75 mm, provided that proof is
II - Part 3 GL 2000
Section 5
Welding of Machinery Components
Chapter 3 Page 51
Section 5 Welding of Machinery Components

A. 1. General Scope B. Approval of Welding Shops, Welding Personnel Works and works divisions dards, etc., see Chapter 1, Section 1, B. of these Rules for Welding.
1.1 These Rules apply to all welding work performed during the fabrication and repair of machinery components such as bedplates, frames, housings for diesel engines, gear boxes, wheel bodies, steering engine housings, quadrants and similar components of a corresponding nature. Note: Since the machinery components listed above are mostly "steel components" which are not significantly different from hull structures in their materials, welding processes and welding works (cf. also Table 4.1 in Chapter 1, Section 4), the specifications set out in Section 1 of this Chapter applicable to the welding of hull structures may also be applied here where no special provisions are prescribed in the following paragraphs. 1.2 They also apply to welding work performed on machinery components such as axles or shafts, pistons, propellers, hubs, machinery tanks, hydraulic cylinders, valve housings, valves etc. where the Society has approved welding work to be carried out on components of this kind either as a general approval or in an individual case. They apply to welding work performed in the course of new fabrications and also to repair welds on machinery components. 1.3 For the use of welding as a production process during the course of the manufacture of materials and/or semi-finished products, such as the "fabrication welding" of the forgings or castings used in machinery components (e.g. propellers), see also the Rules for Metallic Materials and the Iron and Steel Material Specification (Stahl-Eisen-Werkstoffblatt) SEW 110, welding procedure tests for production welds made on cast steel. 2. Other relevant rules and regulations
1.
1.1 In the following paragraphs, the term "welding shop" refers to the welding fabrication shop which may be considered an independent unit with regard to its physical and organizational situation. 1.2 Branches and subcontractors are thus generally deemed to be "independent" welding shops which have to satisfy the requirements prescribed below. In particular, every welding shop must have a welding supervisor who is a permanent member of the welding shop staff (cf. Chapter 1, Section 2). 1.3 Outside firms working in welding shops may be granted approval as independent welding shops. On this and on temporary workers, see also C.3. and Chapter 1, Section 1, F. 2. Requirements, scope of approval
2.1 All welding shops intending to perform welding work covered by these rules must satisfy the requirements relating to the welding shop and its personnel set out in Chapter 1, Section 2 and must have been approved for this work by the Society. Applications for approval shall be submitted by the shipyards and welding shops in good time before starting the welding work, enclosing the information and documentation prescribed in Chapter 1, Section 2, A.3. 2.2 Welding personnel (welders, operators and supervisory staff) and where applicable inspectors and test supervisors must meet the requirements set out in Chapter 1, Section 2, B.2., B.3. and B.4. and be recognized by the Society. For welders qualification tests, see Chapter 1, Section 3. 2.3 The scope of the approval is determined by the capabilities of the welding shop and by the intended range of application (components, materials, welding processes, welding positions, etc.). The in-
The design and dimensions of welded joints and also the welding technique are subject to the provisions of the Rules for Construction I, Part 1, Chapter 2 and other rules or regulations issued by the Society for specific ranges of application. For other relevant stan-
Chapter 3 Page 52
Section 5
II - Part 3 GL 2000
tended range of application shall be specified in the application for approval; cf. the form "Description of Welding Shop" attached at Chapter 1, Annex B. For the period of validity of the approvals, see Chapter 1, Section 2, A.4. and A.5. 3. Basic approval, extensions
2. The welding shops are responsible for ensuring that the welding work conforms to these Rules, the approved manufacturing documents, any conditions stipulated in the approval documents, good machinery building practice and the latest state of welding practice. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops of this responsibility. 3. With regard to quality inspections and the responsibilities involved in awarding subcontracts to independent branches or suppliers or to approved or non-approved outside firms working in the welding shop (subcontractors), see Chapter 1, Section 1, F.; the "prime contractor" shall ensure that "subcontractors" also meet the conditions specified in para. 1. 4. Where non-approved outside firms and temporary staff are employed in the welding shop, the welding shop is responsible for carrying out quality inspections and for compliance with the conditions stated in para. 1. Subcontracting of work or the employment of temporary staff shall be notified to the Society. 5. The scope of the required quality inspections depends on the construction project in question. It is essential to ensure, however, that the intended materials, welding consumables and auxiliary materials are used and that the weld preparation, assembly, execution of welding work and the dimensional accuracy and completeness of the welded joints meets the requirements stated in para. 2. For non-destructive testing of the welded joints, see I. 6. Following inspection and, if necessary, repair by the welding shop, the components shall be presented to the Society's Surveyor for checking at suitable stages of fabrication. For this purpose they shall be readily accessible and shall normally be uncoated. Where the previous inspection has been inadequate, the Surveyor may reject components and require that they be presented again after satisfactory workshop inspection and any necessary repair work has been performed. 7. If the quality or good working order of a component cannot be guaranteed or is in doubt due to inadequate or missing information in the manufacturing documents (e.g. production drawings), the Society may demand appropriate improvements. This applies in analogous manner to supplementary or additional measures, even if these measures were not stipulated when the drawings were scrutinized or could not be stipulated due to insufficiently detailed representation in the production documents.
3.1 For welding machinery components, as a general rule (basic) approval is granted first of all on the basis of a works inspection and, if necessary, welder's qualification tests in accordance with Chapter 1, Section 3 (see also 4.) normally for manual arc welding (welding process 111) and/or for semimechanized metal-arc active gas welding using solid and flux-cored wire electrodes (welding processes 135 and 136) of normal-strength structural steels and other comparable grades of forged and cast steel. The thickness range is in this case determined by the scope of the valid welders qualification tests. 3.2 Welding procedure tests shall be performed for other components, materials and/or welding processes, cf. F. Single-wire submerged arc welding (welding process 121) may also be covered in the basic approval described in 3.1 on the basis of documentary proof of satisfactory operational handling (cf. F.1.3) (for the normal welding in one run on each side [two-run technique] on plates 4 to 25 mm thick and for multi-pass welding up to 40 mm). 3.3 Basic approval may be extended to include any welding process approvals on the basis of welding procedure tests as set out in Chapter 1, Section 4 (see also F.); in exceptional cases, however, limited approval may also only be granted (in conjunction with a works inspection) for a specific material and/or welding process. 4. Welding staff (welders and supervisors) must meet the requirements set out in Chapter 1, Section 2, B.2. and B.3. and be recognized by the Society. For welders qualification tests see Chapter 1, Section 3.
C.
1. Welding shops shall ensure by means of regular in-house quality inspections during fabrication and on completion of the welding work that this work has been performed competently and satisfactorily (cf. Chapter 1, Section 1, F.). For the duties and responsibilities of the welding supervisor, see also EN 719/ISO 14731 (DIN 8563 Part 2).
II - Part 3 GL 2000
Section 5
Chapter 3 Page 53
8. Responsibility for the proper performance of quality inspections and compliance with the conditions stated above lies with the welding shop. The inspections and checks to be performed by the Societys Surveyor do not relieve the welding shops from this responsibility. 9. The Society is not responsible for guaranteeing that all the components and welded joints inspected to the prescribed extent (generally on a random basis) by its surveyors have been fabricated in accordance with the conditions and meet the requirements in every respect. Components or welded joints which subsequently turn out to be defective may be rejected or their repair may be demanded even if acceptance testing has already been carried out.
2. The welding consumables must enable a welded joint to be made which is appropriate to the base material and the type of stress to which it is subjected and also enable trouble-free further processing. For joints between dissimilar materials (with the exception of high-alloy, austenitic steels), the welding consumable should, wherever possible, be geared to the lower alloyed material or the material with the lower strength. 3. For welding very thick-walled, rigid components (approx. 30 mm and over) and welding of forgings and castings, hydrogen-controlled welding consumables and auxiliary materials shall be used wherever possible, e.g. those of quality grade H15(H) or lower or Y.. H10 (HH) or lower for higher-strength structural steels. 4. Hydrogen-controlled welding consumables and auxiliary materials should also be used for components which are subjected to full load immediately after welding (e.g. lifting lugs or as a result of pressure tests) or where allowance has to be made for a high degree of residual stress due to the rigidity of the structure and, where applicable, a high yield strength or strength of a structure.
D.
1. Welded structures may only be fabricated using base materials of proven weldability. Materials must comply with the Societys Rules for Materials. Other comparable materials (e.g. structural steels conforming to the standards) may only be used after the Society has given its approval in each individual case. 2. Any conditions relating to working and welding imposed by the approval certificate and the recommendations of the material producer shall be complied with. For the selection of materials for the ship's hull, see the Rules for Construction I, Part 1, Chapter 2 and in other rules and regulations issued by the Society for specific ranges of application. 3. Steel castings and forgings shall comply with the Rules for Materials and shall have been tested by the Society. The carbon content of components made from carbon and carbon-manganese steels or cast steels for welded structures shall not exceed 0,23 % C at ladle analysis (check analysis: max. 0,25 % C).
F. 1.
Welding procedure tests General
1.1 Only welding procedures whose suitability for the application in question is evident from general experience or has been verified by means of a welding procedure test in accordance with Chapter 1, Section 4 and the following provisions may be used. Table 4.1 in Chapter 1, Section 4 gives a list of the requisite verifications. The welding procedure must have been approved by the Society for the welding shop in question as part of the welding shop approval (cf. also B.). 1.2 Welding procedure tests supervised by the Society for verification of satisfactory operational handling and a trouble-free execution of the procedure, and also adequate quality properties for the welded joints made under production conditions at the user's works are in general required for all materials and welding processes other than those covered by the (basic) approval as described in B.3.1. 1.3 For conventional single-wire submerged-arc butt welding processes using solid wire electrodes for welding normal-strength structural steels, comparable forged steels and cast steels from both sides, proof prior to initial use of the reliability and technical suitability of the method by means of trial welds and non-
E.
1. All the welding consumables and auxiliary materials used (e.g. covered electrodes, wire-gas combinations, wire-flux combinations, etc.) must have been approved by the Society in accordance with Chapter 1, Section 5. The quality grade required depends on the base materials to be welded and is shown in the relevant tables in Chapter 1, Section 5.
Chapter 3 Page 54
Section 5
II - Part 3 GL 2000
destructive (e.g. radiographic) tests as directed by the Surveyor is sufficient. The welding consumables and auxiliary materials used must have been approved by the Society. 1.4 The Society may additionally require welding procedure tests for specific (difficult) component shapes or combinations of materials, particular weld shapes, process variants or combinations, and also for particular welding consumables and auxiliary materials. The same applies in analogous manner to other joining processes or (surface) finishing operations such as thermal cutting or flame straightening. 1.5 The information in the preceding and following paragraphs, especially the information on test pieces, specimen shapes, tests and requirements, applies to the normal materials, welding processes and weld shapes in current use in ship-machine building, the behaviour of which under service conditions has been verified by experience and/or test results. In cases of doubt, the Society may call for additional and/or different test pieces, specimen shapes or tests to verify satisfactory suitability for use. 1.6 In the case of welding processes whose characteristics result in weld shapes other than those verified by experience and/or test results (e.g. those with a considerable notch effect), the influence of the weld shape on the fatigue strength behaviour of the welded joints may be investigated in addition to carrying out the prescribed tests. The same applies in analogous manner to other characteristics of the welded joints, e.g. corrosion resistance. 2. Scope of tests, test schedule, limits of application Test schedule, test details
2.1.3 For welding procedure tests for the welding of (steel) machinery components, the provisions set out in Section 1, F. relating to the welding procedure tests for (hull) structural steels shall apply in analogous manner. This shall also particularly apply with regard to weld types and welding positions. Accordingly, both butt and fillet welds (or other particular weld forms) are also covered in the welding procedure tests, as are all the welding positions encountered. 2.1.4 Welding procedure tests for the (repair) welding of propellers shall be performed in accordance with the provisions applicable to "production welds" in the Rules for Materials issued by the Society. These must also be complied with for the welding consumables and heat treatment recommended and also the areas where welding is not permitted. 2.1.5 For special welding processes, such as flash butt welding, friction welding, electron-beam or laser welding and also for special applications such as build-up welding on shafts, pistons or valves, the type and scope (form and dimensions of the test pieces) of the welding procedure tests and their scope in accordance with the foregoing provisions are specified separately in each individual case. 3. Test pieces, fabrication (welding), (postweld) heat treatment
2.1
3.1 For (steel) machinery components welding shall be performed on butt and fillet weld test pieces (where these are encountered in the production process) in analogous manner to Section 1, F.3. or, by agreement with the Society, in accordance with the standards of the series EN 288/ISO 9956. Test pieces for other components, particular welding processes or applications shall be agreed with the Society in each individual case. 3.2 The direction of rolling of butt and fillet weld test pieces shall generally be parallel to the direction of the weld. The weld shapes shall correspond to those used in the fabrication process. 3.3 For welding, the test pieces shall be made from materials whose properties may be unequivocally proved in accordance with the requirements specified in the Rules for Materials or approved material specifications by the submission of certificates and by marking the material (stamping). In cases of doubt, the Society may call for appropriate material examinations to be carried out. Cf. Chapter 1, Section 4, B.3. 3.4 The welding parameters stipulated in the preliminary welding procedure specification (pWPS) shall be complied with (see Annex D in Chapter 1) and it is necessary to record the parameters used in the
2.1.1 The scope of the welding procedure tests (materials, test pieces, heat treatment, specimens, tests, etc.) shall be laid down in a test schedule to be submitted for approval in good time prior to testing, in accordance with Chapter 1, Section 4, B.1. Depending on the nature and application of a welding process, the process details stipulated in Chapter 1, Section 4, B.1.1 shall be specified and taken into account in the tests. 2.1.2 Where no further details on the welding procedure tests are given in the following paragraphs, the provisions of Chapter 1, Section 4 shall apply. The standards of the series EN 288/ISO 9956 may be applied, however the Society reserve the right to set supplementary or different requirements above and beyond the provisions stated in the following paragraphs, e.g. for the scope of application (materials, weld types, welding positions, cf. 2.1.3).
II - Part 3 GL 2000
Section 5
Chapter 3 Page 55
tests and specify these in the final welding procedure specification. Cf. Chapter 1, Section 4, B.5. 3.5 Pre-treatment and after-treatment of the test pieces by preheating, heat treatment or the like is only permitted if stipulated for these materials during actual fabrication. This treatment shall also be recorded and specified in the final welding procedure specification. Cf. Chapter 1, Section 4, B.6. 4. Non-destructive tests
plied in analogous manner. For plate thicknesses 20 mm the Society may dispense with the round tensile specimen. 4 transverse bend test specimens, in accordance with EN 910/(ISO 5173) half to be bent with the final pass in tension (FBB) and half with the root pass in tension (RBB), or 2 transverse bend test specimens (1FBB and 1RBB) as before and 2 side bend test specimens taken at right angles to the butt weld (SBB) in accordance with EN 910/(ISO 5173) in the case of test pieces over 12 mm thick, or 4 side bend test specimens (SBB) in the case of test pieces more than 20 mm thick and welding processes liable to give rise to segregations, solidification cracking, lack of fusion or similar defects inside the weld (e.g. single-side and vertical-down welding) Note: In the case of pairs of materials which differ in strength, it may be advisable to use butt-welded longitudinal bend test specimens (FBB and RBB) in accordance with EN 910/ISO 5173 with the weld seam in the centre of the specimen instead of butt-welded transverse bend test specimens. See also Chapter 2, Section 5. The details of this test and the requirements (as a rule a qualitative assessment of the bending behaviour) shall be agreed on a case-by-case basis. 3 notched bar impact test specimens each (Charpy V-notch specimens with the notch perpendicular to the surface of the plate) in accordance with EN 875/ISO 9016, from the centre of the weld (VWT 0/1), from the fusion boundary/transition zone (VHT 0/1) and from the heataffected zone (VHT 2/1), taken from the last side welded. Where plate and castings are to be united, the notched bar impact test specimens shall be taken from the fusion boundary/transition zone and heat affected zone of both materials. With very large plate thicknesses, notched bar impact test specimens shall be taken from the surface and back of the weld and in the case of welding processes liable to cause segregation in the central zone, an additional 3 notched bar impact test specimens of each type shall be taken from the same areas in middle of the plate thickness. The dimension "a" (cf. EN 875/ISO 9016) shall be such that the point of intersection of the centre line of the specimen and the middle of the notch lies in the coarse-grained area of the heat-
Prior to sectioning, the test pieces shall undergo comprehensive non-destructive tests to detect welding defects or defects in the welding procedure. The test method or methods (a combination) to be applied are determined by the nature of the test piece or weld and shall be agreed with the Society and stipulated in the test schedule. Cf. Chapter 1, Section 4, B.7. 5. Sectioning of test pieces, type and number of specimens
5.1 The sectioning of test pieces and the preparation of specimens is subject to the provisions of Chapter 1, Section 4, B.8. 5.2 Unless otherwise agreed in a particular case, one set of butt weld specimens shall comprise the following specimens. The specimen shapes and dimensions shall conform to the provisions of the standards or Chapter 2, Section 5 as applicable: 2 transverse tensile test specimens in accordance with EN 895/ISO 4136 (for larger plate thicknesses a correspondingly greater number of specimens shall be provided to cover the full cross-section), 1 round tensile test specimen by analogy to the provisions of Chapter 1, Section 5, B.2.3 (Fig. 5.1 and 5.2) taken lengthwise from the weld metal if welding consumables and auxiliary materials not approved by the Society are to be used (cf. Chapter 1, Section 4, B.3.2), if different materials are to be joined, if welds are made using dissimilar welding consumables or if the characteristics of the welding process suggest that the weld metal itself is likely to be considerably affected. A round tensile test specimen is to be prepared in every case (except for aluminium alloys) where the mechanical properties of the weld metal are inferior to those of the base material (e.g. when welding high-strength steels). The diameter "d0" of the specimen shall be as large as possible (but not more than 10 mm) and the gauge length "L0" shall be 5 d0. The provisions of Chapter 1, Section 5, B.2. are to be ap-
Chapter 3 Page 56
Section 5
II - Part 3 GL 2000
affected zone. This dimension may be generally taken as 2 mm. Where welding procedure tests are performed on steels tough at subzero temperatures, test specimens with notches located at a = 1 mm, a = 3 mm and a = 5 mm shall be prepared, unless otherwise specified in an individual case. Depending on the base material and welding process concerned, further notched bar impact test specimens from other areas may be stipulated. Notched bar impact test specimens may be partly or wholly dispensed with where the results of these tests in connection with the use of a particular welding process are of minor significance for certain materials, e.g. austenitic stainless steels or aluminium alloys (except for lowtemperature applications). 2 macrographic specimens for evaluating the grain structure and if necessary (e.g. for alloy steels) micrographic specimens. Hardness tests (Vickers HV5 or HV10) in accordance with EN 1043-1 (EN 1043-2 in the case of laser welding) shall be carried out where, having regard to the base material and the welding process, the possibility cannot be discounted that preheating and/or the heat flow during welding may affect the hardness values in such a way as to impair the toughness or strength characteristics of the weld. Hardness measurements shall always be performed on higherstrength structural steels and on high-strength (quenched and tempered) fine-grained structural steels with minimum yield strengths of more than 355 N/mm2. Weld metal analysis, if necessary and if agreed with the Society.
3 cruciform tensile test specimens (Z) as shown in Fig. 5.2 for determining the tensileshear strength of the weld metal 2 macrographic specimens (M) for evaluating the penetration conditions, any irregularities in the welded joints and the grain structure. If necessary, hardness measurements (cf. 5.2) shall be performed in accordance with EN 1043-1 and -2. Where necessary (e.g. in the case of alloy steels), micrographic specimens.
The remainder of the test pieces is to be divided into convenient portions which, after removal of one of the welds, are to be broken open on alternate sides for evaluation of the fracture (cf. EN 1320).
Z Z Z Reminder for retests
50
~35 ~35 ~35
50
Fig. 5.1
Set of double T-joint (cruciform) specimens
5.3 Two or more macrographic specimens, as applicable depending on the length of the test piece, shall be taken from the simplified (T-jointed) filletwelded test pieces in accordance with EN 288/ISO 9956 to evaluate the penetration conditions, any irregularities in the welded joints and the grain structure. If necessary, hardness measurements as described in EN 1043-1 and -2 shall be performed (cf. 5.2) and (in the case of alloy steels) micrographic specimens taken. The remainder of the test pieces is to be divided into convenient portions which, after removal of one of the welds, are to be broken open on alternate sides for evaluation of the fracture (cf. EN 1320). 5.4 A set of double T-joint (cruciform) fillet weld test specimens according to Fig. 5.1 shall comprise the following specimens. The specimen shapes and dimensions shall conform to the provisions of Chapter 2, Section 5:
a1 + a2 = fracture section S1/2 a3 + a4 = fracture section S3/4 Tensile-shear strength = Breaking load F [N/mm2] SB width of specimen
SB = S1/2 o r S3/4 according to position of fracture
Fig. 5.2
Cruciform tensile test specimen, weld cross-section
5.5 The specimens and tests for particular components, materials, welding processes and/or their uses (cf. 2.1.5) will be specified separately in accordance with the foregoing provisions in each individual case.
ca. 400
a1 a4
II - Part 3 GL 2000
Section 5
Chapter 3 Page 57
Table 5.1
Requirements applicable to the testing of welded joints 1
Type of test Tensile test transversely to weld
Requirements Tensile strength as stipulated for the base material or in the assessment of suitability for the welding consumable
Tensile test on a specimen Yield strength or 0,2 % proof stress. Tensile strength and elongation as for the base material of the weld metal or as specified in the assessment of suitability for the welding consumable. Notched bar impact test on ISO-V-notch specimens taken from the centre of the weld Notched bar impact test on ISO-V-notch specimens taken from the weld transition zone As specified for the base material in transverse direction or as specified in the assessment of suitability for the welding consumable. When using ferritic-austenitic, austenitic and nickelbase alloy welding consumables, 40 J 2
70 % of the required value for the base material in transverse direction, but at least 20 J 2
Bending angle Degrees
Strength category Ferritic steels with
Bending mandrel dia. a a a
180 3
min. tensile strength < 430 N/mm2 min. tensile strength 430 to 460 N/mm2
2,5 a 2 3
180
Austenitic stainless steels and austenitic steels tough at subzero temperatures Ferritic steels with a minimum tensile strength 460 N/mm2
If a bending angle of 180 degrees is not attained, the following applies: 90 or < 90 Elongation (L0 = width of weld + wall thickness, symmetrical to weld) minimum elongation A5 of base material Elongation over width of weld > 30 % 4 and faultless appearance of fracture
Metallographic examintation
The macrographic specimen of the welded joint must reveal a satisfactory weld build-up and full penetration of the weld. Micrographic specimens are to be examined for cracks. Only hot cracks are acceptable, and then only if they are few in number and widely scattered and agreement has been reached with the Surveyor as to their acceptability with regard to the materials and the range of application The hardness in the heat-affected zones shall not exceed 350 HV 10. Hardness peaks in excess of this figure in narrow transition zones shall not give rise to complaints if the outcome of the technological test meets the requirements
Hardness testing
1 2 3
Where special welding precesses are used as described in para. 2.1.5, the values shall be agreed with the Society. Only one impact energy value may be lower than the minimum mean value, and only by max. 30 %. The 180-degree requirement is deemed to have been met if the bend test was performed according to EN 910/ISO 5173 (DIN 50121) and pressure was applied by the supports without cracks appearing. For steels welded with dissimilar consumables, different values may be agreed with the Society.
Chapter 3 Page 58
Section 5
II - Part 3 GL 2000
6.
Mechanical and technological tests, requirements
thickness of the weld) at an angle of 90 to the mounting plane and welded round at the ends.
6.1 The mechanical and technological tests shall be performed according to the provisions of Chapter 2, Section 5 or to the standards stipulated therein. For retests, see Chapter 1, Section 4, C.2. 6.2 The results of the mechanical and technological tests must satisfy the requirements stated in Table 5.1. The Society may stipulate different or supplementary requirements especially for the specimens and tests described in para. 2.1.5 and 5.5.
90
Fig. 5.3
Welding round of stiffening plates or web plates
G.
Design, Welding Technique
1. The general design principles described in Chapter 2, Section 1 shall be observed. With regard to design and dimensioning (particularly that of (steel) machinery components in accordance with A.1.1), the Society may call for application, in analogous manner, of the provisions Section 1, G. of this Chapter. 2. Butt welds which are critical to the strength of the component must be executed as full-penetration welds. This category includes, for example, the butt welds joining the web and flange plates of engine bedplates and the butt welds uniting bearing brackets and connecting plates. 3. The fillet welds of load-bearing members, e.g. the neck seams of plate girders for uniting flange and web plates, must be capable of being welded without a break. For this purpose, the stiffeners or web plates are either to be added on close to the neck seams at a later date or adequate welding apertures are to be provided. 4. Components shall be designed so as to avoid seam intersections wherever possible. Individual components of complicated shape which, if welded, would result in a clustering of weld seams, e.g. bearing brackets, should either be cast in steel or, if welded, should undergo stress relief heat treatment. Cf. H. 5. All parts to be joined by welding have to be carefully aligned and mounted and tacked in such a way that welding can be carried out with a minimum of distortion and residual stress. Wherever possible, welding should be performed in the downhand position. 6. Wherever possible, stiffening plates and web plates which are open at the ends are to be cut off at the ends as shown in Fig. 5.3 (corresponding to the
7. Castings and forgings that are to be joined to thin-walled components shall be provided with welding flanges which have been cast or forged on. Before welding, the welding edges of castings and forgings must be metallically clean and bright and must have been inspected for material defects using a suitable process. 8. Tack welds which are to be left in place as part of the seam are subject to the same qualitative requirements as root passes. Defective tack welds may not be welded over. They are to be removed. 9. If the thickness of flange plates or web plates changes at butt joints, to give a better transition to the thicker section the edges which stand proud by more than 10 mm shall be bevelled off with a gradient of 1:1 or shallower, as shown in Fig. 5.4. Differences in thickness less than 10 mm may be compensated for in the weld.
1 :1
10 mm 5 mm
a) Butt joint in flange plate
:1
5 mm
:1
b) Butt joint in web plate
Fig. 5.4
Butt-welded joints in plates of different thickness
II - Part 3 GL 2000
Section 5
Chapter 3 Page 59
Where the loading transversely to the weld is predominantly dynamic, the transitions are to be made shallower and in this case the provisions of Section 1, G.3. of this Chapter shall be applied in analogous manner. 10. Welding may be performed in areas of components where cold forming has been carried out, including the adjoining surfaces over a width of 5 times the plate thickness t, provided that the conditions (bending radii) specified in Section 1, G.8. of this Chapter are met. Where components subjected to cold forming undergo normalizing heat treatment prior to welding, these conditions need not be adhered to. 11. Where approved by the Society allowing for the relevant load conditions, build-up welds on machinery components subject to dynamic loads (e.g. shafts) shall be executed in a circumferential direction using a fully-mechanized welding process. The provisions of Section 1, G.9. of this Chapter shall apply in analogous manner.
heat treatment. For the type and performance of the heat treatment, see Chapter 2, Section 3.
I.
1. The manufacturer shall present the components for the required intermediate and final inspections, (cf. also Chapter 1, Section 1, F.1. and G.) in which the following shall be demonstrated to the Societys Surveyor: Proper weld preparation and execution of welding work, The satisfactory external condition of the components and especially of the welds, Use of the prescribed materials and dimensions by presentation of the documents relating to materials, The existence of relevant, valid welder's qualification and welding procedure tests covering the range of application, The proper performance of heat treatments by presentation of the relevant records and/or certificates, Compliance with the specified dimensions and tolerances by presentation of the records of dimensional data.
H.
1. Thick-walled, rigid components or those of complicated design which exhibit high levels of residual stress after joining must be heat-treated after welding in accordance with the relevant standards or the Society's approval document. Examples are bedplates for diesel engines, gear boxes and welded gear wheels. Cf. also G.4. Note: Post-weld heat treatment (stress-relief heat treatment) may be advisable whenever components have, subsequently, to undergo machining and where therefore there is a risk of stresses being produced during the machining process leading to distortion of the components. 2. The heat treatment generally takes the form of stress relief heat treatment. Depending on the material, however, annealing heat treatment or quenching and tempering may also be advisable or necessary. "Black to white" joints between unalloyed steels and austenitic stainless steels may not be subjected to a post-weld
2. The following components shall be subjected to non-destructive testing in every case. The Societys Surveyor may also demand additional tests, as follows: Welded wheel bodies: Ultrasonic and/or radiographic inspections together with surface crack inspections of the scope specified when the drawing was approved. Engine bedplates: Surface crack inspection and random ultrasonic tests applied to the transverse girder welds, especially those of the bearing brackets. Other components: Testing of the scope specified when the drawings were approved or when individual approval was granted.

Ships Construction GL-Materials and Welding

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ships Construction GL-Materials and Welding

Uploaded by

Copyright:

Available Formats

II

Rules for Classification and Construction Materials and Welding

Principles and Test Procedures

Principles Covering the Manufacture and Testing of Materials

Section 1 Principles Covering the Manufacture and Testing of Materials

Requirements Applied to Manufacturing Works

Other Relevant Specifications and Documents

Principles Covering the Manufacture and Testing of Materials

General Requirements Relating to the Manufacture and Properties of Materials Manufacture

Principles Covering the Manufacture and Testing of Materials

Approval of materials and products

Principles Covering the Manufacture and Testing of Materials

Identification and Marking of Products Retraceability

Principles Covering the Manufacture and Testing of Materials

Material certificate according to GL Rules (A-type Certificate)

Principles Covering the Manufacture and Testing of Materials

Mechanical and Technological Tests

Section 2 Mechanical and Technological Tests

Testing Machines and Personnel

Sampling and Specimen Preparation Definitions Sample

Mechanical and Technological Tests

Tensile Tests Specimen shapes

initial gauge length [mm] test length [mm]

Mechanical and Technological Tests

initial cross-section within test length [mm2]

Specimen shape C proportional test specimen t 25 mm 5,65 So Lo + 2 S o 25 mm

Fig. 2.2 Flat tensile specimens

Lo Lc Specimen shape A 14 mm round tensile specimen 14 mm 70 mm 85 mm 10 mm

Specimen shape B alternative specimen --5 do Lo + do 10 mm

Fig. 2.1 Round tensile specimens

Mechanical and Technological Tests

Lo Lc Shape F Specimen shape E (with entire pipe section) ----5,65 So Lo + D --1

Specimen shape F (Flat specimen from pipe wall) t 12 mm 5,65 So Lo + 2b 10 mm

Fig. 2.3 Tensile specimens for pipes

Fig. 2.4 Tensile specimen for grey cast iron

Mechanical and Technological Tests

The test result shall be stated to an accuracy of 1 %.

Notched Bar Impact Tests General

Fig. 2.5 Charpy V-notch specimen

Fig. 2.6 Charpy U-notch specimen

Mechanical and Technological Tests

Permitted tolerances of specimen dimensions

10 mm 7,5 mm 5 mm 45 8 mm 0,25 mm 27,5 mm

Characteristic quantities of test machine

18 mm 5 to 5,5 m/s 90 0,1

Angle between supports and bearing

1 For pendulum impact test machines built before 1983 a

Fig. 2.7 Notched bar impact test

Mechanical and Technological Tests

Fig. 2.8 Pipe flattening test

KV for a V-notch specimen KU for a U-notch specimen

Technological Tests on Pipes Pipe flattening test

Fig. 2.9 Ring expanding test

Mechanical and Technological Tests

Drift expanding test

Length of specimen L 2D 1,5 D; min. 50 mm 2D 2D min. 50 mm

Taper angle b 30 45, 60 or 120 45

The rate of the pins may not exceed 5 mm/s.

Specimen Weld, if existent

Fig. 2.11 Drift expanding test

= Diameter after the prescribed expansion

EN 10234 Drift Expanding Test on Pipes or ISO 8493

Mechanical and Technological Tests

For side bend specimens the following dimensions do apply: