Ministry of Defence

Defence Standard 02-747 (NES 747)

Issue 1 Publication Date 01 April 2000

Requirements For Nickel Aluminium

Bronze Castings And Ingots

Part 2
Nickel Aluminium Bronze
Naval Alloy Ingots And
Sand Castings With Welding
Permitted To The Wetted Surface

Incorporating NES 747 Part 2 Category 2

Issue 3 Publication Date January 1995
 AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

REVISION NOTE

This standard is raised to Issue 1 to update its content.

HISTORICAL RECORD

This standard supersedes the following:

Naval Engineering Standard (NES) 747 Part 2 Issue 3 dated January 1995.
 Ministry of Defence

Naval Engineering Standard

NES 747 Part 2 Issue 3 (Reformatted) January 1995

REQUIREMENTS FOR
NICKEL ALUMINIUM BRONZE CASTINGS AND INGOTS

PART 2

NICKEL ALUMINIUM BRONZE NAVAL ALLOY INGOTS AND

SAND CASTINGS WITH WELDING PERMITTED TO
THE WETTED SURFACE
 This NES Supersedes

NES 747 PART 2 ISSUE 2

Record of Amendments

AMDT INSERTED BY DATE

10
 NAVAL ENGINEERING STANDARD 747
REQUIREMENTS FOR NICKEL ALUMINIUM BRONZE
CASTINGS AND INGOTS
PART 2
ISSUE 3 (REFORMATTED)
NICKEL ALUMINIUM BRONZE NAVAL ALLOY INGOTS AND SAND
CASTINGS WITH WELDING PERMITTED TO THE WETTED SURFACE

The issue and use of this Standard

is authorized for use in MOD contracts

by MOD(PE) Sea Systems and

the Naval Support Command

ECROWN COPYRIGHT

Published by:

Director of Naval Architecture

Procurement Executive, Ministry of Defence
Sea Systems, Foxhill, Bath BA1 5AB
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SCOPE

1. This NES states the requirements for the physical characteristics, test methods and
acceptance standards of cast nickel aluminium bronze naval alloy ingots and sand castings
with welding permitted to the wetted surface. (See Section 1. for applicability.)

Submarines

2. This NES does not cover the use of the castings for first level systems and castings that may
come into contact with sea water except as indicated in Clause 1.a.

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FOREWORD

Sponsorship

1. This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Director Naval Architecture (DNA), Section NA 115.

2. This NES comprises:

Requirements for Nickel Aluminium Bronze (NAB) Castings and Ingots.

Part 1 Nickel Aluminium Bronze Naval Alloy Centrifugally Cast

Part 2 Nickel Aluminium Bronze Naval Alloy Ingots and Sand Castings with Welding
Permitted to the Wetted Surface

Part 3 Nickel Aluminium Bronze Commercial Alloy Sand Castings and Ingots

Part 4 Nickel Aluminium Bronze Naval Alloy Sand Castings with Welding Restricted to the
Non-Wetted Surface (Class I and II Castings only)

Part 5 Guide to the Design and Manufacture of Nickel Aluminium Bronze Sand Castings

3. If it is found to be unsuitable for any particular requirement the Sponsor is to be informed in

writing of the circumstances with a copy to Director Naval Architecture (DNA),
Section NA 145.

4. Any user of this NES either within MOD or in industry may propose an amendment to it.
Proposals for amendments which are:

a. not directly applicable to a particular contract are to be made to the Sponsor of the NES;

b. directly applicable to a particular contract are to be dealt with using existing

departmental procedures or as specified in the contract.

5. No alteration is to be made to this NES except by the issue of an authorized amendment.

6. Unless otherwise stated, reference in this NES to approval, approved, authorized or similar
terms means by the Ministry of Defence in writing.

7. Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line
interval.

8. This NES has been reissued to reflect changes in technical requirements.

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Conditions of Release
General
9. This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.

10. This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.

11. The Crown reserves the right to amend or modify the contents of this NES without consulting
or informing any holder.
MOD Tender or Contract Process
12. This NES is the property of the Crown and unless otherwise authorized in writing by the MOD
must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.

13. When this NES is used in connection with a MOD tender or contract, the user is to ensure that
he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made of
the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.

14. When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.

Related Documents
15. In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:

a. British Standards British Standards Institution,

389 Chiswick High Road,
London W4 4AL

b. Defence Standards Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX

c. Naval Engineering Standards CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP

d. Other documents Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

16. All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.

17. Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.

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Health and Safety

Warning

18. This NES may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. It refers only to technical suitability and in
no way absolves either the supplier or the user from statutory obligations relating to health
and safety at any stage of manufacture or use. Where attention is drawn to hazards, those
quoted may not necessarily be exhaustive.

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CONTENTS
Page No

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Submarines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

SECTION 1. APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1

SECTION 2. PHYSICAL CHARACTERISTICS . . . . . . . . . . . . . 2.1

2.1 Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Ingot Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
TABLE 2.1 INGOTS—CHEMICAL
COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.3 Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.4 Casting Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.5 Quality of Material . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
TABLE 2.2 CASTINGS—CHEMICAL
COMPOSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2

SECTION 3. MECHANICAL PROPERTIES . . . . . . . . . . . . . . . . 3.1

TABLE 3.1 PROPERTIES . . . . . . . . . . . . . . . . . . . . 3.1

SECTION 4. HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . 4.1

SECTION 5. CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1

SECTION 6. QUALITY ASSURANCE DOCUMENTATION . . . 6.1

6.1 Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.2 Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

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SECTION 7. TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.1 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.2 Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.3 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.4 Non-Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.5 Dimensional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.6 Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.7 Liquid-Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.8 Radiographic/Ultrasonic Examination . . . . . . . . . . . 7.1
7.9 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.10 Radiographic Examination of Non-Designated
Regions on a Sample Basis . . . . . . . . . . . . . . . . . . . . . 7.2
7.11 Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.12 Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

SECTION 8. ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . . 8.1

8.1 Destructive Examination Standards . . . . . . . . . . . . . 8.1
8.1.1 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.2 Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.3 Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.4 Non-Destructive Examination Standards . . . . . . . . 8.1
8.4.1 Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.4.2 Liquid-Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.5 Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.6 Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
8.7 Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

SECTION 9. DEFECTS AND RECTIFICATION OF DEFECTS 9.1

9.1 Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.2 Rectification of Dimensional Defects by Weld
Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.3 Rectification of Surface Defects by Blending . . . . . . 9.1
9.4 Rectification of Surface and Sub-Surface Defects
by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1
9.5 Limits on Individual Sub-Surface Repairs . . . . . . . 9.2
9.6 Limits on Combined Weld Repairs . . . . . . . . . . . . . . 9.2
9.7 Rectification of Defects . . . . . . . . . . . . . . . . . . . . . . . . 9.2
9.8 Impregnation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
9.9 Special Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

SECTION 10. IDENTIFICATION OF INGOTS AND CASTINGS 10.1

10.1 Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1
10.2 Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1

SECTION 11. PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

ANNEX A. RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . A.1
ANNEX B. DEFINITIONS AND ABBREVIATIONS . . . . . . . . B.1
ANNEX C. PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . C.1

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1. APPLICABILITY
a. This NES may be used for:

(1) Propellers.

(2) Class I and Class II castings which will not come into contact with sea
water.

(3) Large/complex Class I and Class II castings which may come into contact
with sea water providing that MOD contractual approval is granted.

(4) Class III castings in accordance with NES 863.

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2. PHYSICAL CHARACTERISTICS
2.1 Ingots
a. Ingots for casting stock are to be cast from virgin metals as follows:
Nickel — to the chemical composition requirements of BS 375:
Grade R99.9
Iron — Iron of high purity, 99.5% w/w, with a carbon content of
less than 0.05% w/w.
NOTE: ‘Swedish-Iron’ Nails have been found to meet the required purity.
Aluminium — commercially very pure Grade 99.90% w/w
Copper — to BS 6017—Cu−Cath−2 or Cu−ETP−2
Manganese — high purity electrolytic grade.
2.2 Ingot Analysis
a. Ingots analysis is to conform to the chemical composition in TABLE 2.1.
Per Cent By Weight
Element
Not Less Than Not More Than
Aluminium 8.9 9.6
Iron* 4.0 5.0
Nickel* 4.5 5.5
Manganese 1.0 1.4
Copper (by difference) Remainder
Impurities
Zinc − 0.05
Lead − 0.01
Tin − 0.05
Silicon − 0.05
Magnesium − 0.05
Chromium − 0.01
Total Impurities − 0.20

* Nickel must exceed iron

TABLE 2.1 INGOTS—CHEMICAL COMPOSITION

2.3 Castings
a. Casting are to be made from ingots and approved scrap (see Clause B.1).
NOTES: 1. Contamination by graphite can be prevented by coating crucibles
and ladles with an alumina wash. The product Alumina Cement
pure Grade 961, marketed by Morgan Refractories, Neston Wirrall,
Cheshire, or equivalent, has been found suitable.
2. All ingots used are to be stamped, embossed or have a label affixed
with a unique cast number. Any ingots, on which the stamping or
embossing is illegible, or the label has been removed/fallen off, are
not to be used.

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2.4 Casting Analysis

a. Casting Analysis is to conform to the chemical composition in TABLE 2.2.

2.5 Quality of Material

a. Only the manufacturer’s own approved scrap complying with Clause B.1 may
be included in the cast. No other scrap is permitted. Following acceptance of the
analysis from the melt, no further additions are permitted prior to pouring into
the mould.
Per Cent By Weight
Element
Not Less Than Not More Than
Aluminium 8.8 9.5
Iron* 4.0 5.0
Nickel* 4.5 5.5
Manganese 0.75 1.3
Copper (by difference) Remainder
Impurities
Zinc − 0.05
Lead − 0.01
Tin − 0.05
Silicon − 0.10
Magnesium − 0.05
Chromium − 0.01
Total Impurities − 0.25

* Nickel content is to be greater than the iron content

TABLE 2.2 CASTINGS—CHEMICAL COMPOSITION

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3. MECHANICAL PROPERTIES
a. At room temperature the mechanical properties of test pieces, as specified in
Clause 7.2a., are to be as detailed in TABLE 3.1.

0.2% Proof Stress Elongation on 5.65 S o

Tensile Strength (UTS)
(0.2% PS) Gauge Length
N/mm 2 N/mm 2 Per Cent
Min Min Min
620 250 15

TABLE 3.1 PROPERTIES

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4. HEAT TREATMENT
a. Prior to heat treatment the castings are to have been subjected to a
non-destructive examination in accordance with the requirements of
Clauses 7.5a. to 7.11a. inclusive and are to have met the necessary acceptance
standards. Weld repair of any defective areas will be carried out prior to heat
treatment. In the event that further weld repair is required after heat
treatment, the casting is to be heat treated for a second time following the
second repair. No further heat treatments are permitted.

b. All castings and associated mechanical test pieces are to be heat treated at
675° C ± 15° C for a minimum period of six hours. The castings are to be
supported as necessary during the heat treatment to prevent excessive
distortion. The furnace temperature must not exceed 300° C when loading the
castings or test pieces. After a minimum of six hours at 675° C ± 15° C the
castings and test pieces are to be removed from the furnace and cooled to room
temperature in still air. Heat treatment of test pieces may be carried out
separately from the castings they represent.

c. Only furnaces validated and approved in accordance with NES 746 are to be
used for the heat treatment of castings and test pieces.

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5. CLASSIFICATION
a. The classification of castings is to be in accordance with NES 863.

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6. QUALITY ASSURANCE DOCUMENTATION

6.1 Ingots
a. Each consignment of ingots is to be accompanied by Quality Assurance
Documentation providing the results of the melt control analysis and the results
of analysis of a sample piece taken from an ingot within the batch.

6.2 Castings
a. Each consignment of castings is to be accompanied by Quality Assurance
Documentation giving the actual results of the tests required in Section 7.
together with a certificate of compliance with the acceptance standards detailed
in Section 8.

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7. TEST METHODS
7.1 Destructive Tests
7.1.1 Analysis

a. In addition to the normal melt control analysis, a full chemical analysis is to be

made from a sample piece taken from each cast for ingots and for castings.

7.2 Mechanical Tests

a. Tensile tests in accordance with BS EN 10002 are to be made on a heat treated
test sample cast, in accordance with BS 1400 Figure 2, from the same melt as
the casting it represents. It is advised that three tensile test specimens are made
to enable retests in the event of failure of the initial test specimen.

7.3 Retests
a. Should the original test specimen fail to meet acceptance standards, two further
heat treated specimens from the same cast may be broken in accordance with
BS EN 10002.

7.4 Non-Destructive Tests

a. Reference diagrams according to NES 863 are to be provided by the purchaser
for all Class I and Class II castings to show Critical Test Regions and Test
Regions which are to be subjected to non-destructive testing (NDT).

7.5 Dimensional Check

a. All castings are to be fully dimensionally checked to ensure that they comply
with NES 863.

7.6 Visual-Optical
a. All castings are to be 100% visually inspected, assisted where necessary, by the
use of ¢5 magnification optics. All imperfections are to be identified and
recorded.

7.7 Liquid-Penetrant
a. It is recommended that 100% liquid-penetrant examination, in accordance with
NES 729 Part 4, is carried out on all Class I and Class II castings before any
machining operations are commenced to prevent nugatory work.

b. Where practicable, a 100% liquid penetrant inspection is to be undertaken on

all surfaces of Class I and Class II castings with the surfaces examined in their
finished condition.

7.8 Radiographic/Ultrasonic Examination

a. The manufacturer is to subject Critical Test Regions and Test Regions to either
100% radiographic or 100% ultrasonic examination.

7.9 Radiography
a. Radiography is to be carried out in compliance with NES 729 Part 1. All
sub-surface imperfections are to be identified for subsequent assessment in
accordance with the acceptance standards.

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7.10 Radiographic Examination of Non-Designated Regions on a Sample Basis

a. In certain circumstances examination by radiography on a sample basis may be
specified by contact or drawings to establish that a satisfactory general quality
of product is being supplied. Typical examples are:

(1) Lowly stressed Class II castings.

(2) Sample positions on large Class II or Class III castings.

(3) Batch supply of Class III castings.

7.11 Ultrasonic Examination

a. Ultrasonic examination is to be carried out in compliance with NES 729 Part 5.
All sub-surface imperfections are to be identified for subsequent assessment in
accordance with the acceptance standards. Where ultrasonic examination is
used the assessment of the casting is to be confirmed by radiography of selected
areas. A minimum of 10% of the total area examined by ultrasonics is to be
radiographed.

NOTE: The grain structure of cast nickel aluminium bronze may preclude
inspection by ultrasonics. The suitability for ultrasonic inspection is to be
assessed in accordance with BS 6208 Clauses 9.2 and 9.3.

7.12 Pressure Tests

a. When stated in the contract the castings are to be subjected to the specified
water pressure test for a minimum period of 15 minutes. Certain castings may
require longer periods of pressure testing. When necessary this will be specified
in the contract.

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8. ACCEPTANCE STANDARDS
8.1 Destructive Examination Standards
8.1.1 Analysis

a. Each chemical analysis is to conform to:

(1) TABLE 2.1, ingots.

(2) TABLE 2.2, castings.

8.2 Mechanical Tests

a. The tensile test result is to conform to TABLE 3.1 of this NES.

8.3 Retests
a. Both tensile test results are to conform to TABLE 3.1 of this NES.

8.4 Non-Destructive Examination Standards

8.4.1 Visual-Optical

a. On visual-optical inspection (Clause 7.6a.) the finished condition of all surfaces

is to be clean and free from cracks or linear defects. Rounded forms of surface
defects are unacceptable in Critical Test Regions and Test Regions but may be
acceptable in Non-Designated Regions at the discretion of the AA.

NOTE: Defects are deemed to be rounded when aspect ratio of length to

width is 3:1 or less.

b. The surface finish is to meet the standard specified in the contract documents
and drawings.

8.4.2 Liquid-Penetrant

a. Indications of cracks, hot tears or chain-like porosity and surface oxide

inclusions in linear formations are not acceptable.

b. Indications arising from porosity and surface oxide inclusions in non-linear

formations are to be assessed as follows:

(1) Isolated pinpoint porosity is acceptable except in areas where sealing of

a housing against a running shaft is required, eg pump glands, propeller
shaft seals etc, and in flexible couplings.

(2) Clustered pinpoint porosity and other defects are acceptable provided
that:

(a) the maximum size of any indication is not to exceed 3mm diameter
bleed out;

(b) the sum of the diameters of all indications for sections up to and
including 50mm, in an area of 70 ¢ 70mm does not exceed 24mm;

OR

(c) the sum of the diameters of all indications for sections over 50mm
in an area of 70 ¢ 70 does not exceed 36mm.

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NOTE: The indications identified in Clause 8.4.2b.(1) and 8.4.2b.(2) are

acceptable providing that the immediate area of the castings is
acceptable when examined for sub-surface defects.

c. There may be instances where machined surfaces of castings manufactured to

this NES require more stringent acceptance standards than those in
Clause 8.4.2a. and 8.4.2b. eg in way of a wetted seal area. Where necessary this
requirement is to be clearly stated in the contract documents and are to be the
subject of discussion between the purchaser and the contractor prior to
manufacture of the castings.

8.5 Radiography
a. Acceptance Standards are defined in NES 863.

8.6 Ultrasonics
a. Any defect that causes a signal greater than or equal to the signal produced by
the approved calibration standard is to be deemed unacceptable and the casting
repaired or rejected. Where the backwall echo is attenuated by 40% or greater,
the examination by ultrasonics is unacceptable and radiography in accordance
with Clauses 7.8a. and 7.11a. are to be employed.

8.7 Pressure Tests

a. Each casting is to show no evidence of leakage.

8.2
 NES 747
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9. DEFECTS AND RECTIFICATION OF DEFECTS

9.1 Defects
a. Any casting may be rejected for defects discovered during subsequent
machining notwithstanding that the casting had been passed previously as
conforming to this NES.
9.2 Rectification of Dimensional Defects by Weld Deposition
a. Correction of casting dimensions and machining errors may be made by weld
deposition using an approved procedure for the material concerned and shall be
within the following limits:
(1) Weld deposition thickness to be restricted to 20% of contract drawing
section thickness from 12mm to 50mm and to 10mm above 50mm section
thickness.
(2) Area of weld deposition in Critical Test Regions and Test Regions to be
restricted to 10% of the inner or outer surface area of the region, not
including flange thicknesses and webs, subject to any limitations imposed
by Clause 9.6a.
(3) Area of weld deposition in non-designated regions is to be restricted to
20% of the inner or outer surface area of the region not including flange
thickness and webs.
b. Weld build-up exceeding the tolerance on contract drawing section thickness is
to be a reason for rejection.
9.3 Rectification of Surface Defects by Blending
a. Unacceptable surface defects may be blended out by an approved process,
providing the resulting depression does not reduce the contract drawing section
thickness by more than 5mm for section thickness over 50mm, or 10% of section
thicknesses up to and including 50mm. The depression sides and ends are to be
smoothly blended out by a minimum radius of three times the maximum depth
of blending and the edge formed with the surface is also to be faired smooth. The
remaining section thickness in way of the depression is to be free from
sub-surface defects as revealed by radiography or ultrasonics, in Critical Test
Regions and Test Regions. The total area subjected to blending, including the
area affected by the fairing, is not to exceed 10% of any designated region or 20%
of any non-designated region.
NOTE: Blending out of surface defects is preferable to weld repair whenever
possible.
9.4 Rectification of Surface and Sub-Surface Defects by Welding
a. Unacceptable surface defects which cannot be blended out within the
limitations of Clause 9.3a. and unacceptable sub-surface defects may be
repaired by welding using an approved procedure for the material concerned in
accordance with NES 771 and within the following limits:
(1) Area of excavation in Critical Test Regions and Test Regions is to be
restricted to 10% of the surface area of the region, not including flange
thicknesses and webs, subject to any limitations imposed by Clause 9.6a.
(2) Area of excavation in non-designated regions is to be restricted to 20% of
the inner or outer surface area of the region, not including flange
thicknesses and webs.

9.1
NES 747
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Issue 3 (Reformatted)

9.5 Limits on Individual Sub-Surface Repairs

a. Any individual repair in Critical Test Regions shall not exceed 5% of the test
area containing the defect. In Test Regions any individual repair shall not
exceed 10% of test area containing the defect.

9.6 Limits on Combined Weld Repairs

a. The total combined area of weld repairs from all causes, eg dimensional
correction, surface and sub-surface defects is to be within the following limits:

(1) Total weld repair area of Class I and Class II castings is not to exceed 10%
of the surface area of the casting, excluding flange thicknesses and webs.

(2) The total weld repair area of Class III castings is not to exceed 20% of the
surface area of the casting excluding flange thicknesses and webs.

9.7 Rectification of Defects

a. The rectification of surface and sub-surface defects by welding is to be in
accordance with NES 771.

b. Following heat treatment all weld repairs are to be examined in accordance with
Clauses 7.5a. to 7.12a. The weld repaired casting must satisfy the requirements
of Clause 7.12a.

9.8 Impregnation
a. Impregnation will not be accepted as a recovery procedure for Class I castings.
Impregnation is a recognized recovery procedure for Class II and Class III
castings in accordance with Def Stan 03−1.

(1) Class II castings may be impregnated but only with the written approval
of the Acceptance Authority.

(2) Class III castings may be impregnated with the approval of the Acceptance
Authority.

(3) The area of leakage necessitating remedial action does not exceed 10% of:

(a) The Test Region containing the defect in Class II castings.

(b) The total area pressure tested in non-designated regions in Class II

and Class III castings.

9.9 Special Repairs

a. Where the repairs necessary to meet the acceptance standards are more
extensive than are permitted by this specification and if it is considered that
effective economical repair is possible the contractor’s repair proposals, in
accordance with NES 771 may be submitted to the Acceptance Authority for
decision.

9.2
 NES 747
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Issue 3 (Reformatted)

10. IDENTIFICATION OF INGOTS AND CASTINGS

10.1 Ingots
a. Each ingot is to be marked with the legend ‘NAB’ stamped or embossed in easily
discernible letters. Each ingot is also to be marked with a unique cast number
which can be stamped or embossed in easily discernible letters, or an indelibly
marked self adhesive label is to be affixed. The unique cast number is to
positively identify the ingot to its quality assurance documentation.

10.2 Castings
a. Each casting is to be clearly identifiable during manufacture and be
permanently marked for identification during service life with the following
details:

(1) Pattern or Ship’s Identity Number plus NES 747 Part 2.

(2) Class of casting, ie CI, CII, CIII.

(3) The legend ‘NAB’.

(4) The unique cast number which can be related to the quality control
documentation.

NOTE: Castings subject to validation in accordance with DPT 1311

Specification are to be marked in accordance with that specification
in addition to the requirements of Clause 10.2a.(1)−10.2a.(4).

b. The markings detailed in Clause 10.2a. are to be stamped, engraved or

vibro-etched in the position indicated on the drawing. Markings are to be as
conspicuous as the nature of the casting allows and provision is to be made for
transferring identification markings during manufacture so that traceability is
maintained throughout the service life of a casting. The markings are not to be
made on the highly stressed region, eg Critical Test Regions of the casting.

c. Where difficulty is being experienced in satisfactorily applying identification

symbols, this is to be resolved by consulting the Acceptance Authority.

10.1
NES 747
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10.2
 NES 747
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11. PACKAGING
a. Except where otherwise stated in the contract, packaging is to be in accordance
with the contractor’s normal practice subject to the affixing of a trade warning
label and the addition of the following identification details on each package or
case:

(1) Description of castings.

(2) Quantity.

(3) Contract Number.

11.1
NES 747
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11.2
 NES 747
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ANNEX A.
RELATED DOCUMENTS
A.1 The following documents and publications are referred to in this NES:
See Clause
BS 375 Specification for refined nickel 2.a.
BS 1400 Specification for copper alloy ingots and 7.2a.
copper alloy and high conductivity copper
castings
BS 6017 Specification for copper refinery shapes 2.a.
BS 6208 Method for ultrasonic testing of ferritic steel 7.11a.
castings including quality levels
BS EN 10002 Tensile testing of metallic materials B.1, 7.2a.,
7.3a.
DEF STAN 03−1 Impregnation of porous castings 9.8a.
NES 729 Requirements for Non-Destructive
Examination Methods:
Part 1: Radiographic 7.9a.
Part 4: Liquid Penetrant B.1, 7.7a.
Part 5: Ultrasonic 7.11a.
NES 746 Approval and Control of Heat Treatment 4.c.
Furnaces
NES 771 Requirements Procedure and Inspection for 9.4a., 9.7a.,
Weld Repair of Copper Alloy and Nickel Alloy 9.9a.
Castings
NES 863 Requirements for the Classification, 1.a., 5.a.,
Dimensions, Tolerances and General 7.4a., 7.5a.,
Standards of Acceptance for Copper and 8.5a.
Nickel Alloy Castings
DPT 1311 Validation Procedure for Existing Finished 10.2a.
Machined Castings

A.1 ANNEX A.
NES 747
Part 2
Issue 3 (Reformatted)

ANNEX A. A.2
 NES 747
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Issue 3 (Reformatted)

ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1 For the purpose of this NES the following definitions apply:
Acceptance Authority (AA) The Acceptance Authority is as
specified in the contract. Where this is
not known by the Contractor, enquiries
are to be forwarded to DNA,
Section NA 115, Foxhill, Bath.
Approved Scrap Scrap that is derived from nickel
aluminium bronze, the composition of
which has been established with regard
to the complete range of both the
alloying elements and impurity
elements and is segregated and
identifiable to the satisfaction of the
MOD(PE)/AA.
Cast A cast is:
the product of one furnace melt
or
the product of one crucible melt
or
the product of a number of
furnace or crucible melts where
such are aggregated and mixed
prior to sampling.
Contractor The Firm, Company, Organization, or
Establishment working within the
scope of this NES.
Ingots A mass of metal of proportions to suit
the Founder’s requirements.
Large/Complex castings Castings which the Design Authority
considers are liable to require weld
repair on the wetted surfaces during
manufacture.
Pinpoint Porosity Any circular bled out of less than
0.5mm diameter revealed during liquid
penetrant examination in accordance
with NES 729 Part 4.
S The cross-section area of the gauge in a
tensile piece, before testing as detailed
in BS EN 10002.
Wetted Surface A surface that will come into contact
with sea water.

B.1 ANNEX B.
NES 747
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Issue 3 (Reformatted)

ANNEX B. B.2
 NES 747
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ANNEX C.
PROCUREMENT CHECK LIST

Notes:
1. This Check List is to ensure that certain aspects of this Naval Engineering
Standard are consulted when preparing a Statement of Technical
Requirements for a particular application.
2. Clauses where a preference for an option is to be used or where specific data is
to be added are included in the Check List.
List
3. Each item is to be marked either

! = included

NA = not applicable

CHECK
CHECK CLAUSE No ! or NA
No
1 Radiographic Examination of Non-Designated 7.10a.
Regions on a Sample Basis
2 Pressure Tests 7.12a.
3 Acceptance Standards for Machined Surfaces 8.4.2c.
4 Packaging 11.a.

C.1 ANNEX C.
NES 747
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ANNEX C. C.2
Inside Rear Cover
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