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Materials and NDE

Book D

MQPS 4-3

Materials and Qualification Procedures for Ships
Procedure 4-3 Approval of a Works for the Manufacture of Stainless Steel Castings
including Propellers

1

Introduction

1.1

Application for approval

1.1.1

In order that consideration may be given to approval of a foundry for the manufacture of
stainless steel castings, the local Surveyors are to submit a report to Headquarters,
Materials and NDE Department, giving the information listed in Sections 2 and 3 together
with the results of approval tests carried out under their survey.

1.1.2

The names of approved foundries will appear in LR's List of Approved Manufacturers of
Materials, which is published on the intranet.

1.1.3

Approved foundries will be subject to periodic inspection (see Procedure 1-1).

1.2

Scope

1.2.1

The procedure applies to foundries manufacturing stainless steel castings, including
propellers and propeller blades, for use in constructions under LR survey.

1.3

Related Rules

1.3.1

LR's Rules and Regulations for the Classification of Ships (hereinafter referred to as the
Rules for Ships).

1.3.2

LR's Rules for the Manufacture, Testing and Certification of Materials (hereinafter referred
to as the Rules for Materials).

!"#$

© Lloyd’s Register 2002. All rights reserved

Rev. 1

1 Product details 2. (d) Mass (as finished) and for propellers. 2. Welding procedures will require to be qualified !"#$ © Lloyd’s Register 2002. dimensions. (c) Estimated total annual production of finished castings. (b) Details of charge materials and melting practice.2 Details of facilities and procedures 2. diameter of largest casting which can be made. 1 . where applicable.Materials and NDE Book D MQPS 4-3 2 Information required for approval 2.1 The foundry is to provide the following details of their facilities and procedures: (a) Details of number. (c) Brief details of the system employed for the control of chemical composition including the method of chemical analysis and. type of fuel used and facilities for temperature measurement and control. details of the standards used.1 The foundry is to provide the following product related details: (a) Name and address and brief statement of background indicating whether the works is new or long established. type and capacity of each melting furnace. (e) Grades of steels for which approval is required. (e) Details of heat treatment furnaces available.2. (f) Details of the facilities available and general procedures used for the repair of castings by welding.1. including details of the method for attaching thermocouples to the castings. (f) The specified chemical composition for each grade to be approved. (b) Types of castings and steel alloy grades in general production. (d) Types of moulding materials used. All rights reserved Rev.

All rights reserved Rev. 1 . !"#$ © Lloyd’s Register 2002. The lines of responsibility of the Quality Manager and the Production Manager are to be indicated. type number or description. These are to include the name and qualifications of the Quality Manager and the number and qualifications of staff employed on inspection and quality control activities. This is to include information regarding the name of the manufacturer. serial number and calibration status of all machines used for tensile. (h) Details of the system used for the identification of castings and associated test material at all stages of manufacture. metallographic and non-destructive examination. (g) Facilities available for mechanical testing. preferably in the form of an organization chart showing the senior management positions to whom they report.Materials and NDE Book D MQPS 4-3 (see Section 5). chemical analysis. (i) Details of the inspection and quality control systems established in the foundry. impact and hardness testing.

2 Selection of material 3. test specimens and mechanical testing procedures are to be in accordance with the requirements of Ch 2 of the Rules for Materials.Materials and NDE Book D MQPS 4-3 3 Approval test programme 3. details of heat treatment.1 The location and dimensions of test samples. 3.2. (b) Ladle analysis.1.1 Selection of material 3. particularly in way of the blade roots on propellers.2 A minimum of one casting shall be at least 75% of the maximum weight for which approval is required unless this weight exceeds 50 tonnes.1.6 of the Rules for Materials.2 The test samples are to be in accordance with Ch 4. 1 .2.2.1. Where appropriate. (b) Dye penetrant or magnetic particle testing as appropriate of all surfaces after final machining. where appropriate. the foundry is to provide the following information: (a) Sketch showing method of casting with details of gating and feeding system and the arrangements for the provision of suitable mechanical test samples (see 3. Approval will be limited to the types of steel in the castings submitted.2 The following tests and examinations are to be carried out on each casting submitted for approval tests: (a) Visual examination before and after final machining. All rights reserved Rev. 4. 3. 3. one of the castings selected for this purpose should be a propeller with a diameter approaching the maximum which can be manufactured. (d) Tensile tests.2).1.1 Tests.1. test samples and specimens 4.1 Approval tests are to be carried out on at least three castings taken from different heats from current production. 4 Approval tests 4. (c) Ultrasonic or radiographic examination.1 For each casting selected for approval tests. !"#$ © Lloyd’s Register 2002. (c) If applicable.

(d) Welding consumables. 0°C. All rights reserved Rev. (j) Welding parameters: amperage and voltage. For duplex stainless steels this should also include a ferrite count.1. (l) Heat input and interpass temperature. (b) Welding process. (f) Thickness of the parent metal. 5. (c) Parent metal.2 Each welding procedure is to include. the following information: (a) Welding equipment.7.6 of the Rules for Materials. 5 Repair procedures 5. (h) Representative photomicrographs at x100 magnification.1. (g) Welding position. welding speed. (h) Welding sequence (number and order of metal depositions). -20°C and -40°C. (k) Pre-heating and post weld heat treatment.Materials and NDE Book D MQPS 4-3 (e) Charpy V-notch impact tests at +20°C. (g) Intercrystalline corrosion tests in accordance with Ch 3. 1 .1 Welding procedures are to be provided for each type and grade of casting material for which approval is required.1 Welding repairs 5. (e) Type of joint and preparation of the edges to be welded as well as backings. (f) Chemical analysis of the casting. !"#$ © Lloyd’s Register 2002. (-196°C only for austenitic steel) Three specimens are to be tested at each temperature and both the energy absorbed and the percentage crystallinity are to be reported. as a minimum.

It should be noted that all repairs made to castings during manufacture are to be in accordance with the requirements of Ch 4 of the Rules for Materials. see Fig. All rights reserved Rev. !"#$ © Lloyd’s Register 2002. Where no heat treatment is specified. heat affected zone and parent metal and photomicrographs at x100 magnification showing the microstructures of these three regions. 5.5.1. chi and laves phases. then impact tests should be taken from the weld centreline and heat affected zone and exhibit properties equivalent to that specified for the cast material. (e) Two macrographs showing the weld.1. heat affected zone and parent metal. (b) Two root bend and two face bend tests in accordance with Ch 11.1.7 All tests and examinations are to be made after any specified heat treatment has been carried out. 5.5 As an alternative to 5.Materials and NDE Book D MQPS 4-3 5. (d) A hardness survey through the weld. endorsed by the Surveyor.8 Tests and examinations on the welded assembly are to include the following: (a) Two cross-weld tensile tests.3 The welding procedure.4. the weld test sample is to be subjected to a stress relief heat treatment prior to testing. (c) Where the Rules require the cast material to be impact tested. 5.1.8 of the Rules for Materials the specimens after test are to be included in the report. 1 . a welder may be approved on the basis of past experience provided that qualification tests acceptable to the Surveyor are undertaken satisfactorily for each type and grade of material (see also Procedure 0-2).1. 4-3. The tensile strengths of the specimens are not to be less than those of the parent material.1. is to be submitted with the information required by Section 3.1.6 The material to be used in qualification tests is to be cast and of a size suitable to ensure a reasonable heat distribution and equivalence to practical use.4 All welders and welding procedures are to be qualified in accordance with a recognized National or International Standard. as may be the case with austenitic or duplex stainless steels. (f) For duplex stainless steels a ferrite count should be included and the material should be free of deleterious sigma. 5.1. 5.

Materials and NDE Book D MQPS 4-3 6 Validity of approval certificate 6. All rights reserved Rev. 6.1.5 ≤0 h ≤ 2 mm S S mm S HAZ GCHAZ Weld metal Parent metal 4607/14 Fig.2 For the validity to be extended for a further three years the Surveyors should undertake a periodic inspection in accordance with Procedure 1-1.5. . heat affected zone and parent metal of a butt weld !"#$ © Lloyd’s Register 2002. 1 . 4-3.1 Example showing positions of the indentations for hardness testing in the weld.1 The initial approval certificate will have a validity of three years.1.1 Duration 6.