Ministry of Defence Standard 02-743 Part V

Ministry of Defence
Defence Standard 02-743 Part 5

Issue 2 Publication Date 1 June 2012
Pipe Manipulation
Part 5: Brazing
Category 2
Def Stan 02-743 Part 5 Issue 2
Contents
Foreword ......................................................................................................................................................v
1 Scope ...............................................................................................................................................1
2 Warning ...........................................................................................................................................1
3 Normative References....................................................................................................................1
4 Terms and Definitions ....................................................................................................................2
5 Design Requirements.....................................................................................................................4
5.1 General ............................................................................................................................................4
5.2 Joint Design ....................................................................................................................................4
5.2.1 General ............................................................................................................................................4
5.2.2 Clearances.......................................................................................................................................5
5.2.3 Design to Facilitate Ultrasonic Examination ...............................................................................8
5.2.4 Surface Finish .................................................................................................................................9
5.3 Heat Treatment................................................................................................................................9
5.4 Brazing Alloys and Fluxes.............................................................................................................9
6 Brazing Requirements ...................................................................................................................9
6.1 General ............................................................................................................................................9
6.2 Brazing Processes..........................................................................................................................9
6.3 Brazing Alloys and Fluxes.............................................................................................................9
6.4 Fittings.............................................................................................................................................9
6.5 Preparation of Fittings ................................................................................................................ 10
6.6 Preparation of Pipes.................................................................................................................... 10
6.6.1 Cutting .......................................................................................................................................... 10
6.6.2 Sizing ............................................................................................................................................ 10
6.6.3 Clearances.................................................................................................................................... 10
6.7 Cleaning........................................................................................................................................ 11
6.8 Fluxing .......................................................................................................................................... 11
6.9 Assembly...................................................................................................................................... 11
6.10 Brazing of Valves......................................................................................................................... 12
6.11 Nitrogen Purge............................................................................................................................. 12
6.12 Tacking ......................................................................................................................................... 12
6.13 Heating.......................................................................................................................................... 12
6.14 Priming ......................................................................................................................................... 13
6.15 Face Feeding................................................................................................................................ 13
6.16 Cooling ......................................................................................................................................... 13
6.17 Marking of Joints ......................................................................................................................... 13
6.18 Heat Treatment after Brazing ..................................................................................................... 13
6.19 Cleaning after Brazing ................................................................................................................ 13
6.20 Examination of Brazed Joints .................................................................................................... 13
6.21 Repair of Joints............................................................................................................................ 13
6.21.1 General ......................................................................................................................................... 13
6.21.2 Repair Techniques....................................................................................................................... 14
6.21.3 Examination ................................................................................................................................. 14
6.21.4 Recording of Repairs .................................................................................................................. 14
6.21.5 Heat Treatment of Repairs.......................................................................................................... 14
6.22 Re-use of Fittings ........................................................................................................................ 14
6.23 Re-use of Pipe.............................................................................................................................. 14
7 Inspection and Test Requirements............................................................................................ 15
7.1 General ......................................................................................................................................... 15
7.2 Pre-Braze Inspections................................................................................................................. 15
7.2.1 Joint Components ....................................................................................................................... 15
7.2.2 Ultrasonic Examination of Fittings before Brazing.................................................................. 15
7.2.3 Gas ................................................................................................................................................ 16
7.2.4 Brazing Procedure....................................................................................................................... 16
7.3 Inspections during Brazing for Joints using Insert Rings ...................................................... 16
7.4 Inspection of Completed Joints ................................................................................................. 16
ii
7.4.1 Visual Examination of Brazed Joints .........................................................................................16
7.4.2 Ultrasonic Examination of Brazed Joints ..................................................................................17
7.4.3 Radiographic Examination of Brazed Joints.............................................................................17
7.4.4 Hydraulic Testing .........................................................................................................................17
7.5 Inspection of Used Fittings Salvaged for Re-use .....................................................................17
7.5.1 Inspection before Re-use ............................................................................................................17
7.5.2 Inspection after Brazing ..............................................................................................................18
7.6 Inspection of Used Pipe Salvaged for Re-use...........................................................................18
7.6.1 Inspection before Re-use ............................................................................................................18
7.7 Inspection of Qualification Test Pieces .....................................................................................18
7.7.1 General ..........................................................................................................................................18
7.7.2 Pre-Braze Inspection....................................................................................................................18
7.7.3 Inspection during Brazing for Joints with Insert Rings ...........................................................18
7.7.4 Visual Examination of Completed Test Pieces .........................................................................18
7.7.5 Bond Assessment ........................................................................................................................18
7.7.6 Ultrasonic Examination ...............................................................................................................18
7.7.7 Peel Tests......................................................................................................................................18
8 Acceptance Standards for Brazed Pipe Joints .........................................................................21
8.1 Faying Surfaces of Pipes.............................................................................................................21
8.2 Faces of Joints using Insert Rings – Before Face Feeding .....................................................21
8.3 Faces of Joints after Face Feeding ............................................................................................21
8.4 Joint Geometry .............................................................................................................................22
8.5 Ultrasonic Examination of Brazed Joints ..................................................................................22
8.5.1 General Fittings ............................................................................................................................22
8.5.2 Special Fittings .............................................................................................................................22
8.6 Fittings Salvaged for Re-use.......................................................................................................22
8.6.1 Visual/Dimensional Examination ................................................................................................22
8.6.2 Dye Penetrant Examination.........................................................................................................23
8.7 Pipe Salvaged for Re-use ............................................................................................................23
8.8 Qualification Test Pieces.............................................................................................................23
8.8.1 Faces of Joints using Insert Rings, before Face Feeding........................................................23
8.8.2 Ultrasonic Examination ...............................................................................................................23
8.8.3 Peel Tests......................................................................................................................................23
8.8.4 Tensile Tests.................................................................................................................................23
9 Qualification..................................................................................................................................23
9.1 General ..........................................................................................................................................23
9.2 Responsibilities of the Manufacturer .........................................................................................24
9.3 Qualification of Brazing Alloys, Fluxes and Combinations thereof........................................24
9.4 Qualification of Automatic Brazing Equipment.........................................................................24
9.5 Qualification of Brazers ...............................................................................................................25
9.5.1 Retests...........................................................................................................................................25
9.5.2 Requalification..............................................................................................................................25
9.6 Qualification of Brazing Procedures ..........................................................................................27
9.6.1 Changes in Brazing Procedures .................................................................................................27
9.6.2 Requalification..............................................................................................................................28
9.7 Requirements for Qualification Tests ........................................................................................28
9.7.1 Qualification of Test Pieces ........................................................................................................28
9.7.2 Range of Qualification .................................................................................................................29
9.7.3 Examination of Completed Test Pieces .....................................................................................29
9.7.4 Additional Tests required only for Qualification of Procedures .............................................29
Annex A Procurement Check List ...........................................................................................................30
Annex B Coefficients of Linear Thermal Expansion for Materials Included in Annexes C to F........31
Annex C Fluxes and Brazing Alloys ........................................................................................................32
Annex D Heat Treatment...........................................................................................................................33
D.1 Fittings...........................................................................................................................................33
D.2 Tubing............................................................................................................................................33
D.2.1 Before Brazing ..............................................................................................................................33
D.2.2 After Brazing .................................................................................................................................33
D.2.3 Furnace Treatment .......................................................................................................................33
iii
Annex E Clearances for Capillary Brazed Joints .................................................................................. 34
Annex F Consumables and Clearances for Aluminium Nickel Silicon Brass (Al-Ni-Si Brass)
Piping used with Aluminium Silicon Bronze (Al-Si Bronze) Fittings ..................................... 37
Annex G Health Protection and Safety Precautions ............................................................................. 39
G.1 General ......................................................................................................................................... 39
G.2 Cadmium Exposure ..................................................................................................................... 39
Annex H Acceptance Standards for the Ultrasonic Inspection of Brazed Joints in
Submarines .................................................................................................................................. 40
H.1 Scope ............................................................................................................................................ 40
H.2 Applicability ................................................................................................................................. 40
H.3 Acceptance Standard for all Material Combinations except Gunmetal ................................. 40
H.3.1 Submarines under construction ................................................................................................ 40
H.3.2 Submarines in Refit ..................................................................................................................... 40
H.3.3 Operational Submarines ............................................................................................................. 40
H.4 Acceptance Standard for Gunmetal Fittings ............................................................................ 41
H.4.1 Submarines in Refit ..................................................................................................................... 41
H.4.2 Operational Submarines ............................................................................................................. 41
H.4.3 Recording Procedure .................................................................................................................. 41
Figures
Figure 1 – Joints using Alloy Insert Rings................................................................................................6

Figure 2 – Face Feed Joints .......................................................................................................................7
Figure 3 – Brazed Flange Joints ................................................................................................................8
Figure 4 – Mechanical Peel Test Specimens and Reduced Section Tensile Test Specimens ......... 20
Figure 5 – Full Section Tensile Test ....................................................................................................... 21
Figure 6 – Qualification Test Piece ......................................................................................................... 26
Figure 7 – Qualification Test Arrangements for Restricted Access.................................................... 27
Tables
Table 1 – Bond Acceptance Standards .................................................................................................. 22

Table 2 – Minimum Acceptance Standards for Percentage Bond in Peel Tests................................ 23
Table 3 – Probable Numbers of Test Pieces required for each Position (Horizontal and
Vertical)......................................................................................................................................... 29
Table 4 – Extent of Qualification ............................................................................................................. 29
Table B.1 – Coefficient of Linear Thermal Expansion of Materials ..................................................... 31
Table C.1 – Brazing Alloys....................................................................................................................... 32
Table C.2 – Fluxes .................................................................................................................................... 32
Table D.1 – Heat Treatment of Fittings ................................................................................................... 33
Table E.1 – Radial Clearances at Room Temperature for Pipes used with Internal Fittings ............ 35
Table E.2 – Radial Clearances at Room Temperature for Pipes used with External Fittings........... 36
Table F.1 – Brazing Alloys for use with Al-Si Bronze Fittings and Al-Ni-Si Brass Pipes.................. 37
Table F.2 – Brazing Flux for use with Al-Si Bronze Fittings and Al-Ni-Si Brass Pipes ..................... 38
Table F.3 – Clearances (Radial) at Room Temperature (Al-Ni-Si Brass Piping with Al-Si
Bronze Fittings) for Proprietary Brazing alloys that have historically been used................ 38
Table G.1 – Occupational Exposure Limits of the Metallic Elements used in Silver Soldering ....... 39
iv
Foreword
AMENDMENT RECORD
Amd No Date Text Affected Signature and Date
REVISION NOTE
This standard is raised to Issue 2 to update its content.
HISTORICAL RECORD
This standard supersedes the following:

Def Stan 02-743 Part 5 Issue 1 April 2000
NES 743 Part 5 Issue 1 April 1989
DPT 1306, Issue 3 January 1990
DGS/PS/9019 April 1974
Sponsorship
1. This Defence Standard (Def Stan) is sponsored by the Defence Equipment and Support, Naval
Authority Group (DES NAG-MT), Ministry of Defence (MOD).
2. The complete Def Stan 02-743 Pipe Manipulation comprises:

Part 1 Bending of Pipes
Part 3 Swaging
Part 5 Brazing
3. Any user of this Defence Standard either within MOD or in industry may propose an amendment to
it. Proposals for amendments that are not directly applicable to a particular contract are to be
made to the publishing authority identified on the back cover, and those directly applicable to a
particular contract are to be dealt with using contract procedures.
4. If it is found to be unsuitable for any particular requirement MOD is to be informed in writing of the
circumstances.
5. No alteration is to be made to this Defence Standard except by the issue of an authorized

amendment.
6. Unless otherwise stated, reference in this Defence Standard to approval, approved, authorized
and similar terms, means the MOD in writing.
7. Any significant amendments that may be made to this Defence Standard 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. Extracts from British Standards within this Defence Standard have been included with the
permission of the British Standards Institution.
v
Conditions of Release
General
9. This Defence Standard (Def Stan) has been devised solely for the use of the MOD, and its
contractors in the execution of contracts for the MOD. To the extent permitted by law, the MOD
hereby excludes all liability whatsoever and howsoever arising (including but without limitation,
liability resulting from negligence) for any loss or damage however caused when the Defence
Standard 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 Defence Standard without
consulting or informing any holder.
MOD Tender of Contract Process
12. This Defence Standard is the property of the Crown. Unless otherwise authorized in writing by the
MOD it must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.
13. When this Defence Standard 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 to the authority named in the tender or contract.
14. When Defence Standard are incorporated into MOD contracts, users are responsible for their
correct application and for complying with contractual and other statutory requirements.
Compliance with a Defence Standard does not of itself confer immunity from legal obligations.
Categories of Naval Defence Standard
15. The Category of this Defence Standard has been determined using the following criteria:
a) Category 1. If not applied may have a Critical affect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
b) Category 2. If not applied may have a Significant affect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through life costs and support.
c) Category 3. If not applied may have a Minor affect on the following:

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.
vi
Related Documents
16. In the tender and procurement processes the related documents listed in Clause 3 can be
obtained as follows:
a) British Standards British Standards Institution,

389 Chiswick High Road,
London, W4 4AL.
b) Defence Standards Defence Equipment & Support
UK Defence Standardization
Kentigern House,
65 Brown Street,
Glasgow, G2 8EX.
c) Other documents Tender or Contract Sponsor to advise.
17. All applications to the MOD 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.
18. Prime Contractors are responsible for supplying their subcontractors with relevant documentation,
including specifications, standards and drawings.
Health and Safety
Warning
19. This Defence Standard may call for the use of processes, substances and / or procedures that are
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.
20. This Defence Standard has been written and is to be used taking into account the policy stipulated
in JSP 430: MOD Ship Safety Management System Handbook.
vii
This Page is Intentionally Blank
Pipe Manipulation: Part 5 – Brazing
1 Scope
1.1 This Defence Standard defines the requirements for design and production of capillary brazed joints
for piping systems in Surface Ships and Submarines. It does not apply to Reactor Plant Primary System
Pipework.
1.2 It covers only the material combinations listed. The general requirements of the Defence Standard
may be applied to other materials approved by the Design Authority but not yet included in the Defence
Standard.
1.3 The design temperature for piping systems with brazed joints covered by this Defence Standard is not
to exceed 220°C.
2 Warning
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that could
be injurious to health if adequate precautions are not taken. Adherence to those processes and procedures
in no way absolves users from complying with legal requirements relating to Health and Safety at Work.
3 Normative References
3.1 The publications shown below are referred to in the text of this standard. Publications are grouped and
listed in alpha-numeric order.
BS 499 Welding terms and symbols

Part 1: Glossary for welding, brazing and thermal cutting
(Partially superseded by BS EN 13622)
BS 3072 Nickel and nickel alloys: sheet and plate
BS 3073 Nickel and nickel alloys: strip
BS 3074 Nickel and nickel alloys: seamless tube
BS 3075 Specification for Nickel and Nickel alloys: wire
BS 3076 Specification for Nickel and Nickel alloys: bar
BS EN 1045 Brazing – Fluxes for brazing – Classification and technical delivery conditions
BS EN 12163 Copper and copper alloys. Rod for general purposes
BS EN 12164 Copper and copper alloys. Rod for free machining purposes
BS EN 12167 Copper and copper alloys. Profiles and rectangular bar for general purposes
BS EN 12451 Copper and copper alloys. Seamless, round tubes for heat exchangers
BS EN 13133 Brazing. Brazer approval
BS EN 13134 Brazing. Procedure approval
BS EN 13622 Gas Welding Equipment – Terminology – Terms used for Gas Welding Equipment
1
BS EN 14324 Brazing. Guidance on the application of brazed joints
BS EN ISO 17672 Brazing – Filler Metals
Def Stan 02-341 Requirements for the Cleaning of Items, Components and Equipment for Fluid
Systems
Part 1: Cleaning
Def Stan 02-729 Requirements for Non-Destructive Examination Methods

Part 1: Radiographic
Part 5: Ultrasonic
Def Stan 02-834 Requirements for Aluminium Silicon Bronze

Part 3: Ingots and Castings
Def Stan 02-878 Non-Ferrous Tubes and Pipes for use in HM Submarines and Surface Ships not in
Class
BR 3013 Admiralty Pipework Standard
JSP430 MOD Ship Safety Management System Handbook
3.2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. For some standards the most recent editions shall always apply due to safety and regulatory
requirements. An example is Def Stan 00-970.
3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Correct application of standards is as defined in the ITT or contract.
3.4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
4 Terms and Definitions

Brazing nomenclature and definitions are to conform generally to BS 499, Part 1 with the additions below.
4.1
Brazer
An individual who is producing brazed joints.
4.2
Brazing Procedure
A written instruction containing the essential information for brazing to this standard.
4.3
Capillary Flow
The phenomenon which causes molten brazing alloy to be drawn along the gap between the faying surfaces.
4.4
Clearance
The radial gap between pipe and fitting when located concentrically.
4.5
Consumables
Brazing alloy and flux.
4.6
Design Authority
The approved firm, MOD establishment or branch responsible for the detailed design of materiel to approved
specifications and authorized to sign a certificate of design or certify sealed drawings.
2
4.7
Design Temperature
The maximum temperature for which the piping system is designed, which is not to be exceeded.
4.8
Examiner or Examining Body
Person or organization appointed to verify compliance with the applicable standard. The examiner or
examining body may be a notified body or recognized third party, if required.
4.9
External Fitting
A fitting designed so that the pipe is inserted into a socket in the fitting and brazed into place.
4.10
Face Feeding
Manual addition of brazing alloy at the intersection of fitting and pipe.
4.11
Faying Surfaces
Machined surfaces of fitting that will form the capillary joint with the pipe.
4.12
Filleting
Addition of brazing alloy at the intersection of fitting and pipe after the initial brazing operation to ensure that
a fillet of alloy is present around the inter-section.
4.13
Fitting
A pressure-containing component of a piping system such as a tee, elbow etc or a valve, flange, strainer,
sleeve etc.
4.14
Insert Rings
Rings of brazing alloy for insertion, before assembly of the joint, into a groove prepared in the fitting wall
adjacent to the faying surfaces.
4.15
Internal Fitting
A fitting designed to be inserted into the pipe bore and brazed into place.
4.16
Level
See System Levels.
4.17
Manufacturer
The person or organization responsible for the manufacture of the brazed joints.
4.18
Peel Test
A destructive test to allow a visual assessment of the bonded area in a joint.
4.19
Priming
Manual addition of a small amount of flux at the intersection of fitting and pipe to help break surface tension
and promote alloy flow from the insert ring.
4.20
Qualified
Approved as required by this standard.
4.21
Repairing
Reheating the joint to melt the brazing alloy in order to seal leaks, improve percentage bond or correct
alignment. Includes supplementary face feeding where required.
3
4.22
Special Fittings
These fittings have an undesirable profile and require an alternative ultrasonic examination and percentage
bond acceptance standard. Examples being hexagon and two land joints where only one land joint is
accessible.
4.23
Supplementary Face Feeding
Addition of brazing alloy at the intersection of fitting and pipe after the initial brazing operation. Usually used
with insert rings.
4.24
System Levels:
Level 1 A system in which failure of brazed joints could lead to uncontrollable flooding, immobilization of
the vessel or serious hazard to personnel.
Level 2 A system in which failure of brazed joints could lead to severe but controllable flooding, serious
disruption of weapon systems, main propulsion machinery or important auxiliaries.
Level 3 A system in which failure of brazed joints does not constitute an immediate significant hazard.
Level 4 A system in which failure of brazed joints does not constitute a hazard.
5 Design Requirements
5.1 General
a) It is not intended that this Defence Standard should exclude any design, manufacturing process, material
or process that can be proved to meet the quality requirements. Approval must be obtained from the
Design Authority before any design, process etc not covered by this Defence Standard is issued for
production.
b) Any conflict between this Defence Standard, the drawings, the procedures and the contract is to be
referred to the Design Authority.
c) Drawings are to indicate the location of each brazed joint, the ‘level’ of the system and, when appropriate
the approved brazing procedure. The system levels are defined in clause 4.24.
d) Systems containing brazed joints are to be designed so that wherever possible, brazing is carried out in
the workshop. Brazing in situ is to be kept to a minimum.
e) Adequate access is to be allowed for assembly, brazing, inspection and repair. Particular care is
required to facilitate any brazing in situ.
f) Further guidance on brazed joint design is given in BS EN 14324.
5.2 Joint Design
5.2.1 General
a) Each brazed joint is to be designed so that with a perfect braze but with the maximum end clearances
allowed (see Figures 1, 2 and 3) the joint, under axial loads, is 1.8 times as strong as the weaker of the
pipe and fitting and is also sufficiently strong to carry any bending loads which may be applied.
b) A realistic ‘rule of thumb’ is:

1) The total length of faying surfaces is to be between three and four times the thickness of the thinner
component, with a minimum practical length of 3mm and a maximum length of 20mm for each
faying surface, i.e. when one alloy insert ring is used, the total faying surface can consist of two
lengths of 20mm, one on each side of the insert ring groove. When face feeding is used, the total
faying surface is not to exceed 20mm in length;
2) Under normal conditions, silver brazing alloy will not flow more than 20mm through a capillary gap.
4
c) Permanent joints in brazed piping systems are to be socket or sleeve joints as shown in Figures 1 and 2.
d) Sleeve and socket joints are to use alloy insert rings unless specific approval for an alternative design
has been obtained from the Design Authority. Any sleeve or socket joint which is not designed to use
pre-inserted alloy rings is to be individually identified as such on the drawings.
e) Fittings designed for face feeding are not to be machined to take insert rings without the approval of the
Design Authority.
f) Joints in brazed piping systems that may need to be dismantled are to be flanged joints as shown in
Figure 3.
5.2.2 Clearances
a) The clearances required at the brazing temperature vary from alloy to alloy and are usually specified by
the alloy manufacturers. This variation and the variation in melting temperatures between different alloys
need to be taken into account when calculating the cold clearances required to give the correct
clearances at brazing temperatures. It is also necessary to allow for differential expansion when pipe
and fitting are of different materials.
b) Fittings are to be designed for the largest diameter of pipe that could be supplied, within the limits of the
pipe specification, for the nominal pipe size called up. The bore of the pipe recess is to allow acceptable
clearances, as specified in Annexes E and F, with the largest pipe that can be supplied against the
nominal pipe size called up.
Note: In production, the ends of pipes below the maximum diameter will be enlarged before brazing to give the
correct clearance.
c) Joint design is to be checked to ensure that correct cold clearances can be obtained by acceptable
enlargement of any diameter of pipe which could be supplied within the limits of the pipe specification for
the nominal size called up. The enlargement is not to exceed 1 per cent for pipes over 25mm OD or
0.5mm for pipes of 25mm OD or less.
d) Where cold clearances are to be specified on a drawing and Annexes E and F do not contain the
required information, any proposed clearances are to be proved by qualifying a brazing procedure as
laid down in clause 9.
5
Notes:
1. Dimensions in mm.
2. For pipe below 25mm OD, G is not to exceed 1mm. For pipe 25 OD and over, G is
not to exceed 3mm.
Figure 1 – Joints using Alloy Insert Rings
6
Notes:
2. For pipe below 25mm OD, G is not to exceed 1mm. For pipe 25 OD and over, G is
not to exceed 3mm.
Figure 2 – Face Feed Joints
7
Note: For flange and pipe materials and for

design requirements, refer to BR 3013.
Figure 3 – Brazed Flange Joints
5.2.3 Design to Facilitate Ultrasonic Examination

a) Fittings for use with pipe of 12mm OD or larger are to be designed to allow full ultrasonic examination of
the faying surfaces as laid down in clause 7.4.2.
Note: Ultrasonic examination of a brazed joint is practicable only when the:

1) pipe OD is not less than 12mm;
2) pipe wall is not less than 1.5mm;
3) fitting is cylindrical adjacent to the pipe, concentric with it, not less than 15mm OD extending to at
least 6mm beyond the end of the pipe with a surface finish on the OD equivalent to 6.3 µm or better
and free from waviness or burrs.
b) To allow accurate assessment of the results of ultrasonic examinations of brazed joints, it is necessary to
carry out an ultrasonic examination of the fitting before brazing, as laid down in Clause 7.2.2, in order to
locate any defects in the fitting which could hamper or prevent adequate ultrasonic examination of the
completed joint. Ultrasonic examination of brazing fittings is to be specified on the drawing. The
examination may be carried out by the manufacturer provided that he is capable of meeting the relevant
requirements in clause 7.
8
5.2.4 Surface Finish
The faying surfaces of brazing fittings are to be fine turned as this finish produces a better joint than smooth
or polished surfaces. Cold drawn surfaces also produce satisfactory joints.
5.3 Heat Treatment
Drawings are to contain adequate instructions and sufficient information to ensure that the required heat
treatment is correctly carried out as laid down in Annex D.
5.4 Brazing Alloys and Fluxes
a) Brazing alloys or fluxes specified on the drawing, are to be selected from the list of approved brazing
materials in Annex C.
b) Materials not listed are not to be used without specific approval by the Design Authority. Tests may be
required to prove and qualify the materials and the brazing procedure before approval is given.
6 Brazing Requirements
6.1 General
a) All brazing is to be carried out by suitably qualified brazers in accordance with qualified, written brazing
procedures, in accordance with the requirements of Clause 9.
b) Whenever practicable, brazing is to be carried out in the workshop.
6.2 Brazing Processes
a) Brazing may be carried out by one of the following processes:
1) Manual torch brazing;

2) Automatic/Mechanical torch brazing.
b) Approval is required for the use of any other process.
6.3 Brazing Alloys and Fluxes
The brazing alloy and flux, where not specified on the drawing, are to be selected from those listed in
Annex C, as suitable for use with the pipe and fitting material combination.
Note: The fluxes listed have a limited life at brazing temperature. When a joint is heated above 600°C the effective
working life of the listed fluxes is about 25 minutes.
6.4 Fittings
a) The following types of fitting may be used:
1) Socket and sleeve types as shown in Figure 1 and Figure 2;

2) Flange types as shown in Figure 3.
b) All brazed fittings other than flange types are to be designed for use with pre-inserted alloy rings unless
otherwise specified on the drawing.
c) Fittings designed for face feeding are not to be modified to take insert rings.
9
6.5 Preparation of Fittings
a) Before brazing, wrought fittings are to be annealed and cast fittings are to be stress relieved. Fittings are
normally purchased annealed or stress relieved, as appropriate. Should the certification not cover this
(see clause 7.2.1) the fittings are to be heat treated as laid down in Annex D.
b) If a suitable certificate of ultrasonic examination is not supplied with any fitting for use with pipe of 12mm
OD or larger, (see clause 7.2.1), an ultrasonic examination is to be carried out before brazing, as laid
down in clause 7.2.2.
c) In order to permit satisfactory ultrasonic examination, the outer surface of the fitting is to be smooth and
uniform. If the outer surface is not suitable, the fitting is to be rejected unless a concession and repair
procedure has been approved to allow machining of the fitting.
d) If fittings are to be plated before brazing, carry out the plating as laid down in the Brazing Procedure and
in Annex F.
6.6 Preparation of Pipes
6.6.1 Cutting
Pipe ends are to be square, free from burrs, parallel and within specified dimensional limits before
expansion. Care is required when cutting to avoid reducing the pipe wall thickness and forming a taper on
the end of the pipe.
6.6.2 Sizing
a) Pipe ends are to be cylindrical and may be enlarged, using suitable parallel pipe expanders, to eliminate
ovality and obtain the required clearances.
b) Pipe ends are to be sized to provide a joint clearance that will promote capillary flow of the molten
brazing alloy in the gap between the pipe and fitting at the brazing temperature.
6.6.3 Clearances
a) The clearances required at the brazing temperature vary from alloy to alloy. This variation and the
variation in melting temperatures between different alloys need to be taken into account when
calculating the cold clearances to give the correct clearances at the brazing temperatures. It is also
necessary to allow for any differential expansion between pipe and fitting.
b) Clearances required at brazing temperatures are normally recommended by the manufacturers of the
alloys. Recommended cold clearances are listed in Annexes E and F. Clearances for combinations and
sizes not listed in these Annexes are to be proved by qualifying the proposed brazing procedure as laid
down in clause 9.
Note: Radial clearances are quoted in the tables in Annexes E and F, whereas checking is normally and most
easily carried out by measuring the diametrical clearance with feeler gauges when the fitting and pipe are in contact
diametrically opposite the point at which the measurement is taken.
c) The maximum diametrical enlargement of pipes resulting from the use of pipe expanders or other
devices is not to exceed 0.5mm for pipes up to 50mm OD or 1% of the diameter for pipes over
50mm OD.
d) Pipes with tapered ends may be used only if the taper is insufficient to cause the clearances to be
outside the specified limits anywhere along the faying surfaces. To check for taper, the pipe may be
inserted about 3mm into the fitting and the clearance measured with feeler gauges, followed by a
second measurement with the pipe fully inserted.
e) Where clearances are excessive, brazing alloy may still enter the joint adequately due to gravity
provided that the joint orientation is suitable. Such joints are uneconomic, the joint strength is usually
lower than that of a similar capillary fed joint and they are to be avoided. If, nevertheless, a gravity-fed
brazed joint is proposed, it is to be qualified, together with the proposed brazing procedure, as laid down
in clause 9.
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6.7 Cleaning
a) Before brazing, the faying surface, the end face and the insert ring groove of the fitting, the brazing ring if
used, the outside of the pipe and the end of the pipe are to be cleaned to bright metal. The end of the
pipe is to be cleaned over a length equal to not less than twice the maximum depth of insertion of the
pipe into the fitting to allow for filleting and to avoid unnecessary degradation of the flux. The insert ring,
if fitted, is to be removed to facilitate cleaning of ring and groove. Any brazing rods to be used for face
feeding are also to be similarly cleaned.
b) Cleaning will generally involve the following processes although some commercial cleaning solutions
may provide satisfactory cleaning in one process:
1) Degrease with acetone, alcohol or other approved degreasing agent;
2) On fittings which are not copper plated for brazing, remove scale, oxides and other firmly adhering
contaminants by the use of abrasive cloth, stainless steel wire brushes or stainless steel wire wool.
Cleaning of copper plated fittings is limited to (1) and (3);
3) Finally wipe clean with lint-free wipers soaked in degreasing agent or dampened with water.
Note: Cleaned surfaces are not to be touched with bare hands and are not to be allowed to come into contact with
the skin or any other source of contamination. Natural body oils and acids transferred during contact with the skin will
seriously affect the quality of the brazed joint.
6.8 Fluxing
a) After cleaning, the faying surfaces are to be fluxed before brazing. If the surfaces are not fluxed within
eight hours of cleaning, they are to be re-cleaned as laid down above before fluxing.
b) Brazing flux is to be applied evenly to the faying surfaces in the form of a smooth stiff paste. If the joints
are not assembled immediately, the fluxed surfaces are to be protected so that the flux is neither
contaminated nor inadvertently removed. If the flux dries before the joint is assembled, the old flux is to
be removed and fresh flux applied.
c) If the joint is in a system or at a location where soaking and flushing cannot be used to clean the joint
after brazing, only sufficient flux to make a proper joint is to be applied. The flux is to be applied evenly
to the faying surfaces not more than five minutes before the joint is due to be assembled. Non-faying
surfaces are to be wiped clean either before or after assembly, depending on accessibility. Excess flux
is to be removed. During brazing, a nitrogen purge is required as described in Clause 6.11.
6.9 Assembly
a) To facilitate assembly and inspection, where the inside of a joint will not be accessible after brazing, a
reference mark is to be made on the outside of the pipe at a distance of 2L+10mm, say, from the end to
be brazed, where L is the socket depth or half of the sleeve length as shown in Figures 1 and 2. (The
figure of 10mm is only a suggestion and may be altered if required). The distance from the end of the
pipe to the reference mark is to be measured and recorded. The reference mark is to be located so that
it is clearly visible after brazing and may be used for measurement on final inspection. The method of
marking is to be such that the mark will not act as a stress raiser. In cases where the pipe bends too
close to the joint to allow the mark to be located as suggested above, it may be located closer to the
joint provided that it meets all of the other requirements.
b) When assembling a socket-type joint, the pipe end is to be inserted into the socket so that nowhere does
the distance between the end of the pipe and the bottom of the socket exceed the limits laid down in
Figure 1 or 2.
c) The radial clearance between the pipe and socket is to be within the limits laid down in Annex E and F,
or in an approved brazing procedure.
d) When assembling a sleeve-type joint, the pipe ends are to be inserted into the sleeve so that:
1) the pipes are located within the limits laid down in Figure 1 or 2;
2) nowhere does the distance between the ends of the pipes inside the sleeve exceed the limits laid
down in Figure 1 or 2.
11
e) The radial clearance between each pipe and the sleeve is to be within the limits laid down in Annexes E
and F, or in the approved brazing procedure to be used.
f) Before brazing, the pipe supports are to be checked to ensure that they are adequate and sufficiently
flexible to accommodate the expansion and contraction resulting from the heating and cooling. Supports
that are too rigid can impose excessive stresses on the pipes and joint during the brazing cycle.
6.10 Brazing of Valves
a) Before brazing connection to valves, the valves are to be dismantled if possible and all separable parts
removed, particularly soft seats, packings, seals etc, which are easily damaged by heat. Non-removable
items, (e.g. fixed valve seats, seat housings, integral threads etc) are to be protected from oxidation by
applying a film of flux or other protective medium.
b) Valves which are to be brazed while still assembled are to be kept as cool as possible, particularly the
bonnets. Before brazing, the valve is to be fully opened and then closed by a quarter of a turn. Gaskets,
‘O’ rings, seals and packings which could be damaged by the heat are to be removed. Controlled
heating and cooling techniques are to be used. Proprietary heat protective paste is to be used.
6.11 Nitrogen Purge
If the joint to be brazed is in a system or at a location where soaking and flushing cannot be used to clean
the joint after brazing, a nitrogen supply is to be connected to one end of the system and sufficient nitrogen
blown through the system to remove all the air. After the initial purge has removed the air, the nitrogen flow
is to be reduced until the nitrogen emerging from the discharge end can just be felt with the palm of the
hand. The purge is to be maintained during brazing and until the joint has cooled below 120°C. When the
purge is removed the ends of the system are to be sealed to maintain an inert atmosphere.
6.12 Tacking
If tacking is to be used, the brazing alloy used is to be the same as that in the insert ring or that to be used in
final assembly of face fed joints. Tacking is to be limited to the minimum required to maintain alignment. No
more than 4 tacks are to be used, evenly distributed around the joint. Heating is to be uniform to reduce the
possibility of cracking.
6.13 Heating
a) Brazing torches are to be oxy-fuel gas types. The sulphur content of any fuel gas used is not to exceed
0.009 gram per cubic metre. The flame is not to be applied directly to the brazing alloy or flux. Only the
outer envelope of the flame is to be applied. The inner cone of the flame is not to come into contact with
the assembly. The torch is to have sufficient capacity and the flame is to be adjusted to neutral or
slightly reducing.
b) Overheating is to be avoided. Fittings of gunmetal and phosphor bronze in particular are not to be
heated above 800°C. Heating and cooling rates are to be controlled to prevent cracking.
c) Temperatures may be measured with contact thermometers, or optical pyrometers.
d) Heat input is to be carefully controlled to ensure even distribution of heat around the joint.
e) Before brazing, large, thick walled fittings are to be preheated by raising the temperature slowly and
uniformly to 500°C in order to minimize thermal shock.
f) The temperature of the assembled pipes and fitting is to be raised uniformly to the brazing temperature
to optimize the capillary flow of the molten brazing alloy.
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6.14 Priming
Priming with flux of pre-inserted alloy joints is permitted, provided that all other requirements have been met.
Priming with brazing alloy is NOT permitted, as it will prevent any check of the brazing alloy flow round the
joint circumference.
6.15 Face Feeding
When the initial flow of the brazing alloy from the insert ring has been checked by the Inspector, it is
recommended that the joint should be face fed, while still hot, to complete the joint, make up for any
recession of the brazing metal on cooling, and ensure that a small circumferential fillet of alloy is present
when the joint has cooled.
Note: Large fillets are unnecessarily expensive and do not increase the joint strength.
6.16 Cooling
After completion of the joint, the assembly is to be allowed to cool in still air.
6.17 Marking of Joints
Where required, completed joints are to be marked to identify the brazer.
6.18 Heat Treatment after Brazing
Some materials are to be heat treated after brazing. These materials and the heat treatment required are
listed in Annex D.
6.19 Cleaning after Brazing
a) After cooling, all accessible surfaces are to be cleaned to remove scale and flux residues. Internal
surfaces are to be soaked for a minimum period of 12 hours in cold water, or for two hours in hot water
(at least 60°C). Subject to the approval of the Design Authority, some material combinations may be
cleaned by soaking in hot to boiling caustic soda solution (10% by weight) for at least one hour. For the
standard of cleanliness required for particular systems in submarines see Def Stan 02-341 Part 1.
b) Brazed joints made in situ are to be cleaned with water. The system is to be soaked for a period of at
least twelve hours, and flushed in accordance with the requirements for that system. Where soaking and
flushing is not permitted in a particular system, a nitrogen purge is used for brazing and the system is to
be filled with nitrogen and sealed as Clause 6.11.
6.20 Examination of Brazed Joints
After completion of the brazing, the newly brazed joints, together with any other brazed joints within 75mm of
a new joint are to be examined as laid down in clause 7 and are to meet the acceptance standards for
brazed joints in clause 8.
6.21 Repair of Joints
6.21.1 General
a) The brazing alloy used for repairs is to be the same as that originally used in brazing the joint.
b) Before starting any repair, the end face of the fitting adjacent to the faying surfaces and the adjacent
pipe surface are to be cleaned to bright metal and fluxed as laid down in clauses 6.7 and 6.8.
c) Repairs are not permitted if the joints have been exposed to fluids other than:
1) clean water;
2) approved cleaning solutions;
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3) nitrogen;
4) pure refrigerant.
d) If the joint has been exposed to refrigerant that cannot be guaranteed pure, the joint is not to be
repaired.
6.21.2 Repair Techniques

a) Repairs to improve the percentage bond, repair leaks, or to correct the alignment may be carried out by
re-heating the joint until the brazing alloy melts, rotating the fitting or pipe if required, followed by
addition of flux, face feeding of alloy and filleting as required.
b) No more than two attempts at repair are permitted on any one joint.
6.21.3 Examination
After completion of the repairs, all brazed joints within 75mm of a repair, together with the repaired joints, are
to be examined as laid down in clause 7 and are to meet the acceptance standards in clause 8.
6.21.4 Recording of Repairs

a) Each repair attempt is to be recorded, either by marking up the ship’s drawings or by marking the fitting
in accordance with the Contract Documents.
b) Where required, repaired joints may be marked also to identify the brazer carrying out the repair. The
method of marking is to be in accordance with the Contract Documents.
6.21.5 Heat Treatment of Repairs

Some materials are to be heat treated after repair. These materials and the heat treatment required are
listed in Annex D.
6.22 Re-use of Fittings
a) Fittings may be re-used, provided that the fittings are examined as laid down in clause 7.5 and meet the
acceptance standards in clause 8.6.
b) If necessary, the faying surfaces of the fitting and any insert ring grooves may be machined, provided
that the dimensions of the fitting after machining are still within the specific limits. Hand grinding is not
permitted.
c) Reference marks used for previous ultrasonic examinations need not be removed.
d) Brazing procedures for joints made with re-used fittings are to be the same as for joints made with new
fittings but, if required, insert rings may be slightly rounded on the outer corners to fit the insert grooves.
e) Re-used fittings are to be marked or records kept to show that they have been re-used. Where the
location and re-use of the fitting is to be recorded on the ship’s drawings, provided that the number of
previous heatings is also recorded, marking of the fitting may be omitted.
6.23 Re-use of Pipe
a) Pipes of materials other than 70/30 Copper-Nickel (Cu Ni), 90/10 Cu Ni and Aluminium-Nickel-Silicon
brass (Al-Ni-Si brass) may be re-used without formal inspection unless otherwise specified.
b) Pipes of 70/30 Cu Ni, 90/10 Cu Ni and Al-Ni-Si brass are to be inspected as laid down in clause 7.6.1
and are to meet the acceptance standards in clause 8.7.
c) Pipes to be re-used are to be prepared for re-use as laid down in clauses 6.6, 6.7 and 6.8.
d) Should pipe ends be oversize when the clearances are checked, the pipe OD may be reduced with
emery paper, used carefully to avoid causing ovality, provided that the pipe wall is not reduced below
the specified minimum thickness.
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7 Inspection and Test Requirements
7.1 General
a) The drawing or contract is to state the method and extent of any non-destructive examinations required,
and the acceptance standards.
b) Inspections are to be carried out in accordance with Def Stan 02-729.
c) The extent of examination and testing required on any brazed system is to be related to the ‘level’ of the
system. The level of each system or part of a system is to be stated in the contract or on the relevant
drawing which will specify also the required examinations and acceptance standards. The various
system levels are defined in clause 4.24.
d) Crack detection is to be carried out using dye penetrant examination techniques.
e) Dye penetrant and ultrasonic examinations are to be carried out by qualified personnel using approved
equipment and working to approved procedures.
7.2 Pre-Braze Inspections
7.2.1 Joint Components

a) Before brazing, each pipe and fitting is to be inspected to check that:
1) the materials of the pipe and fitting are as required by the drawing and the approved brazing
procedure;
2) the fittings have been correctly heat treated as laid down in Annex D;
3) fittings for 12mm OD pipe and over are suitable for ultrasonic examination after brazing and have
been ultrasonically examined as required by clause 7.2.2;
4) the distance from the end of each pipe to the reference mark, if required, has been accurately
measured and recorded;
5) when pipe and fitting are assembled, the joint clearances are within the limits laid down in Annexes E
and F, the drawing or approved brazing procedure for the materials and alloy combination being
used.
b) The faying surfaces of each pipe plus an adjacent pipe length of at least 10mm are to be examined using
dye penetrant. The surfaces are to meet the acceptance standards in clause 8.1.
c) The brazing alloy is to be checked to ensure that it meets the requirements of the drawing and the
brazing procedure
7.2.2 Ultrasonic Examination of Fittings before Brazing

7.2.2.1 General
a) Ultrasonic examination of brazed joints using external fittings is practicable only when pipes are 12mm
OD or over and used with fittings of wall thickness 1.5mm or over. When internal fittings are to be used,
the fitting is to be 12mm OD or over and the pipe wall is to be 1.5mm or over. The following clauses are
written to cover external fittings. Where internal fittings are to be used, the pipe wall is to be examined
before brazing instead of the fitting; the procedure is identical.
b) In order to obtain reliable results from ultrasonic examinations of brazed joints it is necessary to carry out
an ultrasonic examination of each fitting before brazing, in order to locate and record sub-surface
defects which could interfere with ultrasonic examinations after brazing.
15
7.2.2.2 Setting Up
a) The ultrasonic equipment is to be calibrated and qualified as laid down in Def Stan 02-729 Part 5.
b) Probes are to be combined double compressional wave of test frequency 5MHz. Where the material of
the fitting has a high attenuation factor, probe frequencies down to 2.5MHz may be used. Full probe
details are to be included in the ultrasonic examination report.
c) Focussed probes are to be preferred where material thickness permits.
d) All examinations are to be made using a couplant whose film integrity is to be maintained at all times.
e) The reject control is to be adjusted to the minimum setting consistent with a clean trace.
7.2.2.3 Search Sensitivity

The examination is to be carried out with the attenuator set to give 100% full scale deflection (FSD) for the
first back wall echo (BWE).
7.2.2.4 Examination
The search scan is to be along parallel lines separated by not more than 90% of the diameter of the probe
crystal, to ensure complete coverage of the faying surfaces.
7.2.2.5 Assessment
Any fitting containing defects which would interfere with the ultrasonic examination of the joint after brazing is
unacceptable and is to be rejected.
7.2.2.6 Report
The ultrasonic examination report is to be included with the paperwork for the fitting and form part of the
certification.
7.2.3 Gas
The certification of the gas to be used for torch brazing is to be checked to ensure that the sulphur content
does not exceed the limit laid down in clause 6.13.
7.2.4 Brazing Procedure

The brazing procedure is to be checked to ensure that only approved procedures are used for production.
7.3 Inspections during Brazing for Joints using Insert Rings
After the alloy insert ring has been melted and capillary flow has taken place, the joint is to be inspected
before any face feeding is permitted, in order to check that adequate capillary flow has occurred. The joint is
to meet the acceptance standards for capillary flow in clause 8.2.
7.4 Inspection of Completed Joints
7.4.1 Visual Examination of Brazed Joints

a) After brazing or repair each joint is to be inspected for:
1) evidence of brazing alloy at the face of the fitting;
2) correct depth of insertion and correct clearance between the end of each pipe and the bottom of its
socket in socket-type fittings, or between the ends of the pipes in sleeve-type fittings;
Note: When the inside of the joint is inaccessible, the insertion depth and clearances can be checked by measuring
the distance from the face of the fitting to the reference mark placed on the pipe before assembly;
3) Correct alignment to drawing.
b) Each joint is to meet the acceptance standards in clauses 8.3 and 8.4. In multi-socket fittings, each joint
is to be similarly re-examined after completion of the last brazing operation on the fitting.
16
c) After completion or repair of a joint, every other brazed joint within 75mm is to be similarly re-examined.
7.4.2 Ultrasonic Examination of Brazed Joints

7.4.2.1 General
a) The extent of ultrasonic examination required is to be stated in the contract or drawing. When the
requirement is not stated, the extent of ultrasonic examinations is to be as follows:
Level 1 systems 100%;

Level 2 systems 100%;
Level 3 systems 10% minimum;
Level 4 systems Nil.
b) Where part of a system has a different level from the rest, the two parts are to be treated as separate
systems for the purpose of deciding the extent of ultrasonic examination.
Note: Ultrasonic examination of brazed joints is feasible only when the pipe is 12mm OD or over and the wall
thickness of the fitting is 1.5mm or over. All fittings for use with pipes of 12mm OD or over are to be suitable for ultrasonic
examination as laid down in Clause 7.2.2.1.
7.4.2.2 Method, Search Sensitivity and Calibration

a) To be in accordance with Def Stan 02-729 Part 5.
b) The average percentage bond is to be calculated for each joint and this is to meet the acceptance
standards in clause 8.5.
7.4.2.3 Examination of Joints with External Hexagonal Configuration

Each of the six sides is to be examined and the average percentage bond calculated. The percentage bond
is to meet the acceptance standards for hexagonal fittings in clause 8.5.2.
7.4.3 Radiographic Examination of Brazed Joints

When radiographic examination of joints is specified in the drawing or contract as a check of fit-up, unless
otherwise specified, a minimum of 2% of the joints are to be radiographed by qualified personnel using
procedures approved in accordance with Def Stan 02-729 Part 1.
7.4.4 Hydraulic Testing

a) Hydraulic testing of brazed pipe systems is to be carried out in accordance with pressures given in the
relevant system Defence Standard or Contract Documents.
b) All leaks are to be repaired.
7.5 Inspection of Used Fittings Salvaged for Re-use
7.5.1 Inspection before Re-use

a) Each used fitting is to be inspected to check that:
1) sufficient of the old brazing alloy has been removed to meet the acceptance standards in clause 8;
2) the dimensions meet the acceptance standards in clause 8.6.1;
3) the fitting has not been heated more than twice before, for brazing or repairing. If there are no
markings on the fitting, the drawings are to be checked for the information.
b) The fitting is to be inspected using dye penetrant examination and is to meet the acceptance standards
in clause 8.6.2.
c) The fitting is also to be fully inspected as specified for pre-braze inspections in clause 7.2.
17
7.5.2 Inspection after Brazing
Each re-used fitting is to be inspected to check that the fitting has been marked to show the additional
brazing operation due to its re-use. Where approval has been obtained to record the re-use on the ship’s
drawings, these are to be inspected to check that the location and re-use have been recorded and that the
total number of previous re-heats is also recorded.
7.6 Inspection of Used Pipe Salvaged for Re-use
7.6.1 Inspection before Re-use

Before re-use, the ends of used pipes of 70/30 Cu Ni, 90/10 Cu Ni and Al-Ni-Si brass are to be inspected
using dye penetrant examination over a minimum length P, where P is equal to the socket depth plus 50mm.
The areas inspected are to meet the acceptance standards in clause 8.7. This inspection may be omitted for
pipes of other materials.
7.7 Inspection of Qualification Test Pieces
7.7.1 General
Qualification test pieces are to be examined and tested as laid down in clauses 7.7.2 to 7.8 and are to meet
the acceptance standards for qualification test pieces in clause 8.
7.7.2 Pre-Braze Inspection

Before brazing, qualification test pieces are to be inspected as stated in clause 7.2.1.
7.7.3 Inspection during Brazing for Joints with Insert Rings

After the insert ring has melted and capillary flow has taken place, each joint is to be inspected before any
face feeding is permitted, in order to check that adequate capillary flow has occurred.
Notes:
1) Face feeding is not permitted during qualification tests using automatic brazing on joints with insert rings
unless face feeding would always be possible under production conditions.
2) Repairs to test pieces are not permitted
7.7.4 Visual Examination of Completed Test Pieces

After completion, qualification test pieces are to be inspected as stated in clause 7.4.1.
7.7.5 Bond Assessment

The bond in qualification test pieces is to be assessed either by ultrasonic examination or by peel tests as
laid down in clauses 7.7.6 or 7.7.7. Ultrasonic examinations are not feasible on pipes below 12mm OD and
for these pipes, peel tests are to be carried out.
7.7.6 Ultrasonic Examination

When ultrasonic examination is specified, every test piece produced for a particular qualification is to be
examined as stated in clauses 7.4.2.1 and 7.4.2.2.
7.7.7 Peel Tests

a) Peel tests are to be carried out using one of the two methods described below:
1) Method 1. Mechanical Peel Test:
i) Peel test specimens are to be as shown in Figure 4. When the pipe is 51mm OD or larger, the
test specimens are to be 40mm wide, measured round the OD of the pipe outside the joint.
When the pipe is less than 51mm OD, each test specimen is to be a 90° segment of the test
piece;
18
ii) The specimens are to be separated along the line of the brazing alloy by peeling the filling
material from the pipe or vice versa. To facilitate separation, the test specimen may be heated
to 550°C or, after removing the fillet of alloy from the face of the fitting, the specimen may be
cooled with dry ice or liquid nitrogen. The total area of defects, unbrazed areas and flux
inclusions is to be measured and recorded.
2) Method 2. Peel Test by Machining.
i) The fitting is to be parted off just clear of the end of the pipe. The test specimen is then to be
prepared by machining the OD until the wall of the fitting remaining is 0.2mm to 0.3mm thick.
Then with the tube set true in a lathe the fitting wall is to be turned down carefully, taking
successive cuts of 0.01mm - 0.05mm. After each cut the surface is to be inspected carefully for
‘bubbling’ of the metal surface caused by separation of the fitting from the brazing alloy or by
separation of the brazing alloy from the pipe. All areas of separation are to be plotted on one
scale plan, together with areas of flux inclusions and other defects. Continue machining until all
of the brazing alloy has been removed;
ii) The total unfused area is to be taken as the sum of the areas plotted on the scale plan, with
any overlapping areas counted only once.
b) The percentage bond is to be calculated for each joint as follows:
1) Method 1. Mechanical Peel Test:

For each joint, calculate the total area of faying surface of the fitting in the two test
specimens (F). Calculate also the total defective area in the two test specimens (A):
F-A
Then percentage bond = 100
F
The percentage area examined (E) is to be calculated as follows:
F
E= 100
Total area of faying surface of socket
2) Method 2. Peel Test by Machining.

Calculate the total area of faying surface in the socket (F):
F-A
Percentage bond = 100
F
where A is the total unfused area determined earlier.
19
Notes:
2. For test pieces brazed in the horizontal position, AA is to be the horizontal axis.
3. For pipes below 51 OD, peel test specimens are to be 90o segments.
4. For pipes over 75 OD, all test specimens for one brazing position may be taken from the same joint,
provided that the specimens are taken from the correct positions as shown.
Figure 4 – Mechanical Peel Test Specimens and Reduced Section Tensile Test Specimens
20
Figure 5 – Full Section Tensile Test
8 Acceptance Standards for Brazed Pipe Joints
8.1 Faying Surfaces of Pipes
All faying surfaces and adjacent areas of pipe are to be inspected using dye penetrant and are to be free
from cracks, linear defects and similar faults.
8.2 Faces of Joints using Insert Rings – Before Face Feeding
Capillary flow of alloy from the melted insert ring is acceptable when, before any face feeding of alloy has
taken place, alloy can be seen at the face of the fitting, extending round at least 75% of the circumference of
the joint.
8.3 Faces of Joints after Face Feeding
The joint face is acceptable when a small fillet of alloy is visible round the whole of the circumference of the
joint.
21
8.4 Joint Geometry
a) In joints using socket-type fittings, the depth of insertion of each pipe into its socket is to be such that the
clearance between the end of the pipe and the bottom of the socket does not exceed the limit specified
in the drawing or in Figure 1 or Figure 2.
b) In joints using sleeve-type fittings, the depth of insertion of each pipe into the sleeve and the clearance
between the end of the pipes are to be within the limits specified in the drawing or in Figure 1 or
Figure 2.
c) The alignment of the pipes and joints is to be as shown on the drawing.
8.5 Ultrasonic Examination of Brazed Joints
8.5.1 General Fittings

The average bond of new joints is not to be less than 50%. Joints which have been ‘in service’ and on
inspection are found to have an average bond of 40% or greater are acceptable for further service. For
Submarines refer to Annex H.
8.5.2 Special Fittings

a) Table 1 acceptance standards may be used for fittings which are not suitable for full ultrasonic
examination of the faying surfaces and for the use of which special approval has been obtained from the
Design Authority.
b) Fittings with cylindrical exterior surfaces which are too small to allow examination of all of the faying
surfaces are to meet the acceptance levels in Table 1. Where the area available for examination lies
between the values quoted in the table, use the lower area figure in the table (which will require a higher
acceptance standard).
c) For fittings with hexagonal exterior surfaces the average bond for the joint is to be not less than 80%.
Table 1 – Bond Acceptance Standards
Percentages of faying
Acceptable % Bond
surfaces examined
50 80
60 75
70 70
80 65
90 55
100 50
8.6 Fittings Salvaged for Re-use
8.6.1 Visual/Dimensional Examination

a) The fittings are to be clean and free from brazing alloy, except that traces of alloy remaining in the
corners of the insert ring groove may be allowed to remain.
b) The dimensions of the fitting are to be within the limits laid down in the drawings, except that a small
increase in the interior diameter of the faying surfaces is acceptable provided that it does not require an
unacceptable degree of enlargement of the pipe to provide the correct clearances for brazing (see
clause 6.6.3). The radius of the internal corners of the insert ring groove is to be not less than 0.4mm.
22
8.6.2 Dye Penetrant Examination
The fitting is to be free from cracks, linear defects and similar faults.
8.7 Pipe Salvaged for Re-use
The pipe ends and adjacent areas are to be free from cracks, linear defects and similar faults.
8.8 Qualification Test Pieces
8.8.1 Faces of Joints using Insert Rings, before Face Feeding

Capillary flow of alloy from the melted insert ring is acceptable when, before any face feeding of alloy has
taken place, alloy can be seen at the face of the fitting, extending round at least 75% of the circumference of
the joint and any gap in the brazing alloy around the circumference is less than 10% of the circumference.
8.8.2 Ultrasonic Examination

The average percentage bond for any joint is to be not less than 70%. For Submarines refer to Annex H.
8.8.3 Peel Tests

a) When mechanical peel tests are used, the percentage bond for any joint is to be not less than stated in
Table 2. Where the percentage area examined falls between the figures listed in the table, use the
acceptance standard for the next lower figure of percentage area examined.
b) When peel tests are carried out by machining, the percentage bond for any joint is to be not less
than 70%.
Table 2 – Minimum Acceptance Standards for

Percentage Bond in Peel Tests
Percentage Area Minimum Average

Examined Bond
% %
50 80
40 90
30 or less 100
8.8.4 Tensile Tests

a) If the failure occurs in the brazing alloy, the stress in the pipe at failure is to be not less than the
minimum ultimate tensile stress for the annealed pipe.
b) If the pipe or fitting fractures, then the stress in the fractured material at failure is to be not less than 90%
of the minimum ultimate tensile stress for annealed material.
9 Qualification
9.1 General
a) Manufacturers working to this Defence Standard are to establish and maintain control of procedures,
equipment and personnel which form part of production, repair, inspection, or required safety
precautions. Equipment, essential processing environments, procedures and personnel qualifications
are to be subject to approval or certification.
b) Manual brazing equipment will not normally require qualification tests. Automatic/Mechanical brazing
equipment is to be qualified by practical qualification tests as detailed in clause 9.4.
23
c) All brazing equipment, when used by qualified personnel working to approved procedures, is to be
capable of consistently producing joints to the required standards. Equipment is to be regularly
inspected and tested as part of an approved planned maintenance programme.
d) Brazers will normally qualify by producing test pieces that meet the specified Acceptance Standards as
laid down in clause 9.5.
e) A brazing procedure is qualified by proving that acceptable sample joints can be produced on standard
test pieces, using the procedure. The test pieces are to be prepared, examined and tested as described
in clause 9.7. The test results and, if requested, test pieces and test specimens are to be submitted for
verification by the Examining Body. Qualification of the procedure automatically qualifies the person who
brazed the test piece and the equipment used for the test.
f) Manufacturers may be exempted from procedure qualification tests if, during the previous three years,
brazed pipe joints similar to those covered by this Standard have been successfully brazed to an
acceptable quality.
g) The same test piece may be used for qualification of brazers, procedures and equipment.
9.2 Responsibilities of the Manufacturer
a) Each manufacturer working to this Defence Standard is to carry out all necessary qualification tests at its
own expense.
b) The manufacturer is to certify that tests are conducted in accordance with the preliminary, proposed or
approved brazing procedure. When a test is intended to qualify simultaneously any combination of
procedure, equipment and personnel, this must be clearly stated when submitting details to the
Examining Body for approval.
c) The manufacturer is to keep up-to-date records of qualifications. The records are to include details of all
tests carried out including failures as well as passes. The records are to include at least the following
information:
1) Brazer identification;
2) Date of test and result;
3) Procedure;
4) All test reports;
5) Letter or other signed form of approval.
d) Records for personnel qualifications are to be retained until the person leaves the manufacturer.
e) Records for procedure and equipment qualifications are to be retained in accordance with the Contract
Documents.
9.3 Qualification of Brazing Alloys, Fluxes and Combinations thereof
a) Brazing alloys, fluxes and combinations of these approved for brazing to this Standard are listed in
Annex C.
b) If the proposed alloy / flux combination specified in the brazing procedure is not already approved, it is to
be tested and approved before use in production. In certain cases long term corrosion tests may be
necessary.
9.4 Qualification of Automatic/Mechanical Brazing Equipment
a) Automatic or mechanical brazing equipment is to be qualified by test brazes in accordance with an

approved, preliminary or proposed brazing procedure.
24
b) The manufacturer is required to demonstrate the reproducibility of machine brazed joints. The production
brazing procedure is to state the level and frequency of any additional inspections necessary to meet
this requirement.
c) To qualify automatic equipment, a minimum of two test pieces are to be brazed, one in a vertical position
and one in a horizontal position, as shown in Figure 6 or Figure 7.
d) A successful qualification test using pipe of wall thickness ‘t’ will qualify the equipment for brazing pipes
with a range of wall thicknesses defined in Table 4.
9.5 Qualification of Brazers
a) The manufacturer is responsible for qualifying each brazer and for ensuring that he or she is capable of
working strictly to brazing procedures and of brazing under production conditions to the specified
acceptance standards. Brazer qualification shall be carried out in accordance with BS EN 13133 and the
requirements of this Defence Standard.
b) A brazer will be qualified by producing acceptable sample brazed test pieces using an approved brazing
procedure. The procedure is to include the inspection requirements and acceptance standards. The test
pieces are to be examined and tested as described clause 9.7.
c) To qualify a brazer a minimum of two test pieces are to be brazed, one in a vertical position and one in a
horizontal position, as shown in Figure 6 or Figure 7. The test pieces are to be fixed so that the pipes
cannot rotate once brazing has started.
d) For normal qualification of brazers, the test piece arrangement shown in Figure 6 is to be used, but if the
brazer is required to be qualified for brazing where access is restricted, then the test piece arrangement
shown in Figure 7 is to be used.
Notes:
1) Access is defined as ‘restricted’ when a panel or other surface passes within 150mm of the joint, the surface
extending for 70° or more around the joint and obstructing the access for the torch or brazing rod.
2) A typical case of restricted access occurs when a joint is required in a pipe run close to an inside corner. This
condition is used in qualification tests for brazing with restricted access, see Figure 7.
e) A successful qualification test using pipe of wall thickness ‘t’ will qualify the brazer for brazing pipes with
a range of wall thicknesses defined in Table 4.
9.5.1 Retests
Retests of brazers will be permitted in accordance with BS EN 13133.
9.5.2 Requalification
a) Requalification of brazers is required if:
1) the Approving / Certification Authority has reason to believe that the production workmanship is not
consistently of the required standard;
2) a period of six months has elapsed since the brazer was last engaged on this work.
b) In exceptional circumstances, qualification or requalification tests may be modified or waived for selected
brazers subject to full non-destructive examination of the first production braze.
25
Notes:
1. H is to be not less than 150mm. It is necessary to check that the dimension H is
sufficient for any tensile tests required.
2. Test pieces to be fixed to prevent rotation.
Figure 6 – Qualification Test Piece
26
Notes:
2. To be read in conjunction with Figure 6.
Figure 7 – Qualification Test Arrangements for Restricted Access
9.6 Qualification of Brazing Procedures
a) The brazing procedure is to contain the necessary information on the required process variables as
defined in BS EN 13134.
b) In addition, required non-destructive examinations and acceptance standards and any destructive tests
(normally only in qualification procedures) and acceptance standards should be stated, either within the
brazing procedure, or on associated information sheets.
c) The brazing procedure will be qualified in accordance with BS EN 13134 by carrying out appropriate
brazing procedure tests as required by BS EN 13134 and this Defence Standard which shall be verified
by an Examiner or Examining Body.
9.6.1 Changes in Brazing Procedures

a) Any alteration in a brazing procedure is to be covered by an authorized change to the procedure issued
in writing.
27
b) Any change in brazing procedure process variables (see clause 9.6a) will normally require a new
procedure and qualification of the new procedure and personnel except:
1) in brazing procedures, changes of pipe wall thickness within the range already qualified;
2) changes in consumables where the new consumable is supplied to the same specification as the
original;
3) changes in fuel gas;
4) changes in frequency or source of high frequency current for induction brazing;
5) changes in fit-up clearances which do not allow the clearances to exceed the limits laid down in
Annexes E and F;
6) changes affecting only the reference marks.
9.6.2 Requalification
Following a change to a brazing procedure, requalification is not required prior to use of the procedure,
provided that:
1) the approved conditions are unchanged;

2) the brazing equipment is producing acceptable joints;
3) requalification is not required for any other reason.
9.7 Requirements for Qualification Tests
For qualification testing, a minimum of two test pieces are to be brazed, one in a vertical position and one in
a horizontal position, as shown in Figure 6. The test pieces are to be fixed so that the pipes cannot rotate
once brazing has started.
The same test piece is used for qualification of brazers, procedures and equipment.
9.7.1 Qualification of Test Pieces

a) To ensure that sufficient test specimens can be produced to meet the examination requirements in
clauses 7 and 9.7.4, it is often necessary to braze more than one test piece in each position. The actual
number of test pieces to be brazed in each position will depend on the size of pipe selected for the test
pieces. Table 3 gives some guidance on the probable minimum numbers required. The exact
requirements will depend on the method of preparation of the test specimens and are to be decided by
the manufacturer before the tests commence.
b) These requirements are to be read in conjunction with clause 6. In addition to the requirements
described below, the requirements of clause 6 are to be met, omitting any requirement of clause 6 which
is not compatible with the requirements of this clause.
c) Repair of test pieces is not permitted.
d) Supplementary face feeding and filleting are not permitted in qualification tests using automatic brazing
systems unless face feeding would always be possible under production conditions.
e) In qualification tests for manual brazing using fittings with alloy insert rings, supplementary face feeding
and filleting are permitted only after an inspection of the joint has shown that the braze resulting from the
melting of the insert rings meets the appropriate acceptance standards in clause 8.
28
Table 3 – Probable Numbers of Test Pieces required for
each Position (Horizontal and Vertical)
Test Pieces required for

Tests for each position No. of Test Pieces to be
Pipe Brazed in each position
OD A B or C
Tensile Mechanical Machined Tests Tests Tests
Tests Peel Tests Peel Tests A+B A+C A + UT
75 max 2 1 1 3 3 2
Over 75
1 1 1 2 2 1
to 110
One Test Piece can provide
Over 110 1 1 1
all of the test specimens
Note: Peel tests are not required if the brazed joints are ultrasonically (UT) examined before the
destructive tests.
9.7.2 Range of Qualification

Successful qualification of a procedure using pipe of wall thickness ‘t’ will qualify the brazer, the equipment
and the brazing procedure for use with a range of pipe wall thicknesses defined in Table 4. The qualification
covers pipe of any diameter.
Table 4 – Extent of Qualification
Wall thickness 't' of pipe Range of pipe wall thickness

brazed in Test Piece covered by qualification
Up to and including 9mm 0 to 2t
Over 9mm to 18mm inclusive 9mm to 2t
Over 18mm 18mm to 2t
9.7.3 Examination of Completed Test Pieces

After brazing, the test piece is to be heat treated, if required, in accordance with Annex D, as specified in the
brazing procedure and then examined as laid down below.
Examinations are to be carried out as required in clause 7.7. Inspection and testing are to be fully detailed in
the qualification brazing procedure or in associated procedures called up in the brazing procedure.
9.7.4 Additional Tests required only for Qualification of Procedures

a) For qualification of procedures, two tensile tests are to be carried out on test specimens from both the
horizontal and vertical brazing positions (four tests in all).
b) Tensile test specimens are to be full section as shown in Figure 5 when the Pipe is less than 75mm OD.
When the pipe is 75mm OD or larger, reduced section tensile test specimens are to be prepared as
shown in Figure 4.
c) The load at failure and the location of the break are to be recorded for each tensile test.
d) The extent of the qualification obtained by a test is to be as shown in Table 4.
29
Annex A
Procurement Check List
Notes:
1. This Check List is to ensure that certain aspects of this Defence Standard are consulted
when preparing a procurement specification 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.
3. Each item is to be marked either:
9 = included
NA = not applicable
Check Clause
Check 9 or NA
No. No.
1 Requirements for recording repair of fittings 6.21.4a
2 method of marking for repaired fittings 6.21.4b
3 Method and extent of non-destructive examinations 7.1a
4 System Level to be stated 7.1c
5 Extent of ultrasonic examination 7.4.2.1
6 Radiographic examination 7.4.3
7 Hydraulic test pressure requirements 7.4.4
8 Record keeping 9.2a
30
Annex B
Coefficients of Linear Thermal Expansion for
Materials Included in Annexes C to F
B.1 The coefficients of linear thermal expansion of materials included in Annexes C to F are shown in
Table B.1.
Table B.1 – Coefficient of Linear Thermal Expansion of Materials
Coefficient of Linear
Material
Specification or Standard Thermal Expansion
(see Note 4)
mm per mm per °C
Copper – 0.0000195 (1)
70/30 Cu-Ni Def Stan 02-878 0.00001 (2)
90/10 Cu-Ni Def Stan 02-878 0.0000171 (2)
Ni-Cu BS 3072 to 3076-NA 13 0.0000168 (1)
Al-Ni-Si Brass Def Stan 02-878 0.0000195 (1)
Al Brass BS EN 12451 CW702R(3) 0.0000185 (2)
Al-Si Bronze Def Stan 02-834 Part 3 0.0000194 (1)
Phosphor Bronze BS EN 12163 CW451K 0.0000180 (2)
Naval Brass BS EN 12163 CW712R(3) 0.0000212 (2)
Gunmetal (88/10/2) – 0.0000182 (2)
Notes
1. Average coefficient over range 0-700°C.
2. Average coefficient over range 0-300°C.
3. Unqualified data. Temperature range not known.
4. Cu = Copper Al = Aluminium
Ni = Nickel Si = Silicon
B.2 Clearances in Annex E Table E.1, Table E.2 and Annex F Table F.2 are based on the coefficients of
expansion quoted in Table B.1. Coefficients covered by Note 1 in Table B.1 may be regarded as reliable and
the clearances listed in later tables may be used without reservation. Clearances not based on coefficients
covered by Note 1 are to be checked by qualification of the procedure before use in production. The
qualification is to include at least one test piece with clearances at the upper limit of the proposed range and
at least one test piece with clearances at the lower limit of the proposed range.
B.3 Other materials may be acceptable but the correct data is to be determined for each material before
use. Each proposed procedure is to be qualified, including the requirements of clause B.2.
31
Annex C
Fluxes and Brazing Alloys
C.1 Table C.1 and Table C.2 list brazing alloys and fluxes approved for use with the material combinations
shown. (Material combinations including Al-Ni-Si Brass are covered in Annex F).
C.2 Orders for the purchase of brazing alloys are to specify that the composition and supply are to be in
accordance with BS EN ISO 17672 unless otherwise approved by the Design Authority.
C.3 For plating of fittings, see Annex F.
Table C.1 – Brazing Alloys
Melting Range
Material Combination
Specification Short Code (approximate) °C
Pipe Fitting Solidus Liquidus
70/30 Cupro-Nickel
or
90/10 Cupro-Nickel
or
Copper Nickel-Copper
or or
70/30 Phosphor Bronze
BS EN ISO
Cupro-Nickel or AG 103 630 660
17672
or Gunmetal
90/10 or
Cupro-Nickel Naval Brass
or
Copper
or
Aluminium Brass
Table C.2 – Fluxes
Material Combination Working Range

Flux Type
Pipe Fitting °C
70/30 Cupro-Nickel
or
BS EN 1045 –
90/10 Cupro-Nickel 550 – 800
FH10
or
Copper Nickel-Copper
or Phosphor Bronze
70/30 or
Cupro-Nickel Gunmetal
or BS EN 1045 –
or 550 - 800
90/10 FH10
Naval Brass
Cupro-Nickel or
Copper
BS EN 1045 –
Aluminium Brass 500 – 800
FH11
32
Annex D
Heat Treatment
D.1 Fittings
Before brazing, all wrought fittings are to be fully annealed and cast fittings are to be stress relieved. When
necessary, heat treatment is to be carried out as indicated in Table D.1.
D.2 Tubing
D.2.1 Before Brazing

a) Cupro-Nickel tubing is to be delivered in the fully annealed condition (Reference Def Stan 02-878 for
90/10 Cu-Ni and 70/30 Cu-Ni).
b) Al-Ni-Si Brass Tubing is to be delivered in the solution treated and precipitation hardened condition
(Reference Def Stan 02-878).
D.2.2 After Brazing

After brazing Al-Ni-Si Brass tubing, a post-braze heat treatment (PBHT) is to be carried out by raising the
temperature of the relevant area to 500°C ± 25°C for one hour followed by slow cooling in still air. PBHT can
be accomplished either by local heat treatment for example by using resistance or induction equipment or by
heat treatment in a furnace. Although PBHT of the complete pipe length will not have an adverse effect on
the pipe material, it is necessary to heat treat the pipe only up to 300mm from the braze.
D.2.3 Furnace Treatment

Where heat treatment is carried out in a furnace, the sulphur content of the atmosphere is not to exceed
0.23g per cubic metre.
Table D.1 – Heat Treatment of Fittings
Preferred Soak
Materials Hardness after Temperature Soak Time
Treatment °C
Wrought materials 70/30 Cu-Ni 85-95 HV
to be annealed 800-850 10 mins
90/10 Cu-Ni 105 max
Nickel-Copper 140 HV max 870-980 10 mins
Phosphor Bronze 5-85 HV 500-700 10 mins

Cast materials to Gunmetal – 350 30 mins
be stress relieved
Phosphor Bronze – 350 30 mins
Al-Si Bronze – 500 30 mins

Notes:
1. Heat slowly and uniformly to the stated temperature.
2. Cool slowly in still air to below 250oC. Below 250oC water quenching may be used to accelerate
cooling.
33
Annex E
Clearances for Capillary Brazed Joints
(excluding material combinations with Al-Ni-Si Brass which are covered in Annex F)
E.1 The radial clearance at room temperature between a round pipe and a fitting is to be within the limits
specified in Tables E.1 and E.2.
E.2 The cold clearances listed in the tables are calculated to produce, at the brazing temperature, radial
clearances of 0.05 to 0.13mm - the limits specified by the manufacturers - for the brazing alloys listed in
Annex C. The calculated clearances are based on the coefficients of expansion listed in Annex B. Where
these coefficients are not average coefficients over 0 to 700°C the proposed clearances are to be checked
by qualification of the procedure before use in production. The qualification is to include at least one test
piece with clearances at the upper limit of the proposed range of clearances and at least one test piece with
clearances at the lower limit of the proposed range.
E.3 Before using brazing alloys other than those listed in Annex C, the clearance required at the brazing
temperature is to be checked. Where this clearance or the brazing temperature, differs from that specified for
the alloys listed in Annex C, the cold clearances are to be calculated and proved by qualification of the
proposed procedure, including the additional check for each end of the proposed range of clearances as
specified above.
E.4 When the pipe and fitting are of the same material, the clearance will remain constant from room
temperature to brazing temperature as long as there is no temperature difference between the fitting and the
pipe.
E.5 Where the minimum clearance shown in the tables is negligible or ‘0.00’, the pipe is to be enlarged so
that it can be assembled to the fitting cold without hammering and without undue force.
E.6 For the calculations, room temperature has been taken as 15°C.
34
Table E.1 – Radial Clearances at Room Temperature

for Pipes used with Internal Fittings
Cold Clearances (Radial)

Outer Material Inner Material Pipes Pipes Pipes Pipes
– Pipe – Fitting Pipes up Above 20 Above 40 Above 60 Above 80
to 20 ID up to 40 up to 60 up to 80 up to 100
ID ID ID ID
Cupro-Nickel* 0.05 to 0.05 to 0.05 to 0.05 to 0.05 to
70/30 0.13 0.13 0.13 0.13 0.13
90/10 0.13 0.13 0.13 0.14 0.13
0.05 to 0.05 to 0.05 to 0.05 to 0.06 to
Nickel Copper
Cupro-Nickel* 0.13 0.13 0.13 0.13 0.13
70/30 Aluminium* 0.06 to 0.07 to 0.08 to 0.09 to 0.10 to
Brass 0.13 0.14 0.16 0.17 0.18
Phosphor* 0.05 to 0.06 to 0.07 to 0.08 to 0.09 to
Bronze 0.13 0.14 0.15 0.16 0.17
0.06 to 0.07 to 0.08 to 0.09 to 0.10 to
Gunmetal*
0.13 0.14 0.15 0.16 0.17
70/30 0.13 0.13 0.12 0.12 0.12
90/10 0.13 0.13 0.13 0.13 0.13
0.05 to 0.05 to 0.05 to 0.05 to 0.04 to
Nickel Copper
Cupro-Nickel* 0.13 0.13 0.13 0.12 0.12
Brass 0.13 0.14 0.15 0.16 0.17
Bronze 0.13 0.13 0.14 0.15 0.15
0.05 to 0.06 to 0.07 to 0.07 to 0.08 to
Gunmetal*
0.13 0.14 0.14 0.15 0.16
0.06 to 0.07 to 0.08 to 0.09 to 0.10 to
Naval Brass*
0.13 0.14 0.15 0.16 0.17
70/30 0.12 0.10 0.08 0.07 0.05
90/10 0.12 0.11 0.09 0.08 0.06
0.04 to 0.03 to 0.02 to 0.00 to 0.00 to
Nickel Copper
0.12 0.10 0.09 0.07 0.05
Copper
Aluminium* 0.06 to 0.04 to 0.04 to 0.03 to 0.02 to
Brass 0.13 0.12 0.11 0.11 0.10
Bronze 0.12 0.12 0.11 0.10 0.09
0.05 to 0.04 to 0.03 to 0.02 to 0.02 to
Gunmetal*
0.13 0.12 0.11 0.10 0.09
0.05 to 0.05 to 0.05 to 0.05 to 0.05 to
Copper
0.13 0.13 0.13 0.13 0.13
* See Annex B. before using data Dimensions in mm
35
Table E.2 – Radial Clearances at Room Temperature

for Pipes used with External Fittings
Cold Clearances (Radial)

Inner Material Outer Material Pipes up Pipes Pipes Pipes Pipes
– Pipe – Fitting to Above 20 Above 40 Above 60 Above 80
20 up to 40 up to 60 up to 80 up to 100
OD OD OD OD OD
70/30 0.13 0.13 0.13 0.13 0.13
90/10 0.13 0.13 0.12 0.12 0.12
0.05 to 0.05 to 0.05 to 0.05 to 0.05 to
Nickel Copper
Cupro-Nickel* 0.13 0.13 0.13 0.13 0.13
Brass 0.12 0.11 0.10 0.09 0.08
Bronze 0.13 0.12 0.11 0.10 0.09
0.06 to 0.05 to 0.04 to 0.03 to 0.02 to
Gunmetal*
0.13 0.12 0.11 0.10 0.09
70/30 0.13 0.13 0.13 0.14 0.14
90/10 0.13 0.13 0.13 0.13 0.13
0.05 to 0.05 to 0.05 to 0.06 to 0.06 to
Nickel Copper
Cupro-Nickel* 0.13 0.13 0.13 0.13 0.14
Brass 0.13 0.12 0.11 0.10 0.09
Bronze 0.13 0.12 0.12 0.11 0.10
0.05 to 0.04 to 0.03 to 0.03 to 0.02 to
Gunmetal*
0.13 0.12 0.11 0.11 0.10
0.05 to 0.04 to 0.03 to 0.01 to 0.00 to
Naval Brass*
0.13 0.11 0.10 0.09 0.08
70/30 0.14 0.15 0.17 0.19 0.21
90/10 0.14 0.15 0.16 0.18 0.19
0.06 to 0.07 to 0.09 to 0.11 to 0.13 to
Nickel Copper
0.14 0.15 0.17 0.19 0.20
Copper
Aluminium* 0.05 to 0.06 to 0.07 to 0.07 to 0.08 to
Brass 0.13 0.14 0.14 0.15 0.16
Bronze 0.13 0.14 0.15 0.16 0.17
0.05 to 0.06 to 0.07 to 0.08 to 0.09 to
Gunmetal*
0.13 0.14 0.15 0.16 0.16
0.05 to 0.05 to 0.05 to 0.05 to 0.05 to
Copper
0.13 0.13 0.13 0.13 0.13
* See Annex B. before using data Dimensions in mm
36
Annex F
Consumables and Clearances for Aluminium Nickel Silicon Brass (Al-Ni-Si Brass)
Piping used with Aluminium Silicon Bronze (Al-Si Bronze) Fittings
F.1 Brazing Alloys to European standards are listed in Table F.1, and fluxes in Table F.2. Although those
listed provide acceptable mechanical properties for pipe joints, they have not been fully evaluated for long
term corrosion resistance.
F.2 The radial clearance at room temperature between a round pipe and a fitting is to be within the limits
specified in Table F.1.
F.3 The cold clearances listed in the tables are calculated to produce, at the brazing temperature, radial
clearances of 0.05 to 0.13mm - the limits specified by the manufacturers, for the brazing alloys listed in
Table F.1. The calculated clearances are based on the coefficients of expansion listed in Annex B.
Note: Before using brazing alloys other than those listed in Table F.1, the clearance required at the brazing
temperature is to be checked. The same clearance will be required at room temperature.
F.4 For these calculations, room temperature has been taken as 15°C.
F.5 Plating of Fittings
a) The faying surfaces of fittings may be copper plated to provide a barrier layer to facilitate brazing to
Al-Ni-Si brass pipe.
b) In some literature a plating thickness of 0.005mm is recommended. A plating thickness of 0.05mm on

Al-Si bronze fittings has been used successfully and this has allowed the use of general purpose fluxes
complying with BS EN 1045 – FH10, in conjunction with brazing alloy to BS EN ISO 17672 – AG 103.
Table F.1 – Brazing Alloys for use with

Al-Si Bronze Fittings and Al-Ni-Si Brass Pipes
Consumable Radial Cold Clearance

Melting Range between Al-Ni-Si Brass Pipe
BS EN ISO 17672 °C and Al-Si Bronze Fittings
Brazing Alloy (mm)
Classification
B-Ag55ZnCuSn-630/660 AG103 630-660 0.05 to 0.13
B-Ag60CuZn-695/730 AG 202 695-730 0.07 to 0.20
Notes:
The brazing alloys listed above (used with the flux listed in Table F.2) provide acceptable mechanical properties
for pipe joints but long term corrosion resistance etc have not been fully evaluated.
Because the difference in the coefficient of thermal linear expansion for the two materials (Al-Ni-Si Brass / Al-Si
Bronze) is insignificant, the cold clearances required are the same as the hot clearances specified by the
manufacturer of the brazing alloy.
37
Table F.2 – Brazing Flux for use with
Al-Si Bronze Fittings and Al-Ni-Si Brass Pipes
Melting Range
BS EN 1045 Classification
°C
FH11 500-800
Notes:
The brazing flux listed above (used with the alloys listed in Table F.1)
provide acceptable mechanical properties for pipe joints but long term
corrosion resistance etc have not been fully evaluated.
Table F.3 – Clearances (Radial) at Room Temperature (Al-Ni-Si Brass Piping with Al-Si Bronze
Fittings) for Proprietary Brazing alloys that have historically been used
Radial
Brazing Melting BS EN ISO
Clearances at
Alloy Name Manufacturer Range 17672
Room
°C Classification
Temperature
M25T Thessco Ltd 630-660 0.05 to 0.12 AG103
M13 Thessco Ltd 690-770 0.05 to 0.20 –

Johnson Matthey
Silverflo 55 630-660 0.05 to 0.13 AG 103
Metals Ltd
Johnson Matthey
Silverflo 60 695-730 0.07 to 0.20 AG 202
Metals Ltd
Johnson Matthey
Silverflo 43 690-775 0.10 to 0.20 –
Metals Ltd
38
Annex G
Health Protection and Safety Precautions
G.1 General
a) The high temperature of brazing operations will generate harmful fumes and gases derived from the
brazing consumables, base materials and any coatings or surface contamination present. Necessary
controls should be put in place to ensure that personnel are protected from the hazards associated with
brazing. Guidance is given in the Health and Safety Executive (HSE) publication:
COSHH essentials for welding, hot work and allied processes WL8 - Oxy-gas welding and brazing
b) In each brazing procedure, attention is to be drawn to the conditions likely to produce health hazards
during brazing operations.
G.2 Cadmium Exposure

a) When heated, brazing alloys containing cadmium, and cadmium plating on base metals, may give rise to
cadmium oxide fumes, the inhalation of which can result in acutely harmful effects.
b) Only cadmium-free brazing alloys are to be used and are to be selected from the lists in Annexes C
and F.
c) All operations on cadmium plated items are to be undertaken with effective local exhaust ventilation
adjacent to the joint being brazed. Exhausted air is to be filtered so that the concentration of cadmium at
outlets within enclosed work areas is less than that stated in Table G.1. Where it is not possible to
ensure that personal exposures are kept below the relevant Maximum Exposure Limits (MELs) by
engineering and process control measures alone, then suitable and adequate Respiratory Protective
Equipment (RPE) should be worn. Guidance is given in the Health and Safety Executive (HSE)
publication:
HSE Information Sheet; Engineering Sheet No 31 - Cadmium in silver soldering or brazing
While most of the metallic elements used in silver solders have been assigned occupational exposure
limits, those alloys containing cadmium are likely to present the most significant health risks.
Table G.1 – Occupational Exposure Limits of the Metallic Elements used in Silver Soldering
Element 8 Hour TWA Short Term 15 minutes

Cadmium (and Cadmium Oxide) 0.025mg/m³ 0.05mg/m³
Copper 0.2mg/m³ –
Manganese 1mg/m³ 3mg/m³
Nickel 0.5mg/m³ –
Phosphorus 10mg/m³ –
Silicon (total dust) 0.1mg/m³ –
Tin 2mg/m³ 4mg/m³
Zinc (oxide fume) 5mg/m³ 10mg/m³
39
Annex H
Acceptance Standards for the Ultrasonic Inspection
of Brazed Joints in Submarines
H.1 Scope
a) The text of Annex H is reproduced from, and supersedes, Specification DPT 1306, Issue 3
b) The purpose of this specification is to define the acceptance standards for the ultrasonic inspection of
brazed joints in Submarines only.
H.2 Applicability
a) All brazed joints of Submarines which are subject to ultrasonic inspection both during manufacture and
subsequent periodic in-service inspection as may be specified in the Ship's hull surveillance documents,
maintenance schedules, etc.
b) This Annex is to be used in conjunction with the main body of this Defence Standard.
H.3 Acceptance Standard for all Material Combinations except Gunmetal
H.3.1 Submarines under construction

All brazed joints are to have a bond of 50% or greater when assessed in accordance with the requirements
of Def Stan 02-729 Part 5.
Note: This includes fittings which have been unbrazed and approved for re-use. See Note ‡.
H.3.2 Submarines in Refit

a) All new brazed joints are to comply with the requirements of clause H.3.1. See Note ‡.
b) Joints which have been "in service" and on inspection are found to have a bond of 40% or greater when
assessed in accordance with Def Stan 02-729 Part 5 are acceptable for further service. See Note ‡.
c) Joints with less than 40% bond are unacceptable for further service and are to be replaced by new joints
complying with the requirements of clause H.3.1 (i.e. 50% minimum bond). See Note ‡.
H.3.3 Operational Submarines

a) New joints are to comply with the requirements of clause H.3.1.
b) "In service" joints with a bond of 40% or more are to comply with the requirements of clause H.3.2b. See
Note ‡.
c) In-service joints with less than 40% bond but not less than 30% bond when assessed in accordance with
the requirements of Def Stan 02-729 Part 5 are acceptable for continued service provided that these
joints are re-examined at each base maintenance period to ensure that the bond has not fallen below
30%. See Note ‡.
d) Joints with less than 30% bond are unacceptable for further service and are to be replaced by new joints
complying with the requirements of clause H.3.1. See Note ‡.
Note: Clause 8.5.1 of this Defence Standard applies for partially examined joints.
40
H.4 Acceptance Standard for Gunmetal Fittings
Due to the variable grain size of gunmetal, ultrasonic penetration of this material may be impaired thus
reducing the ability to determine the percentage bond of a joint. This degree of impairment generally
increases with the number of heats applied until ultrasonic penetration is virtually impossible. Such joints are
classified "Non Ultrasonically Penetrable" (NUP).
H.4.1 Submarines in Refit

a) All new brazed joints are to have a bond of 50% or greater when assessed in accordance with the
requirements of clause 7.4.2.2 of this Defence Standard.
Note 1. This includes fittings which have been unbrazed and approved for re-use.
Note 2. Each gunmetal fitting shall be checked for ultrasonic penetration before assembly to the pipework and shall
be rejected if there is any appreciable degree of impairment.
b) Joints which have been "in service" and on inspection are found to have a bond of 40% or greater when
assessed in accordance with the requirements of clause 7.4.2.2 of this Defence Standard are acceptable
for further service.
c) Joints with less than 40% bond are unacceptable for further service and are to be replaced by new joints
in accordance with the requirements of clause H.4.1a.
d) All joints classified as NUP are to be replaced.
H.4.2 Operational Submarines

a) All new joints are to comply with the requirements of clause H.4.1a.
b) "In service" joints with a bond of 40% or more are to comply with the requirements of clause H.4.1b.
c) In-service joints with less than 40% bond but not less than 30% bond when assessed in accordance with
the requirements of clause 7.4.2.2 of this Defence Standard are acceptable for continued service
provided that these joints are re-examined at each base maintenance period to ensure that the bond has
not fallen below 30%.
d) Joints with less than 30% bond are unacceptable for further service and are to be replaced by new joints
in accordance with the requirements of clause H.4.1a.
e) Joints classified NUP are normally to be replaced.
f) Where exceptionally the work involved in replacing a brazed joint classified NUP is such that acceptance
under concession may be justified, the application for concession should be made to the Design
Authority and should include:
1) Joint history sheet detailing - Results of ultrasonic examination, time in-service, number of re-heats,
whether joint has been face fed to achieve leak tightness etc.
2) Evidence of satisfactory pressure test.
3) Results of a careful visual examination for brazing defects such as - overheating, poor fillet of brazing
alloy between pipe and fitting etc.
4) Results of dye penetrant examination for signs of cracking of the fitting and adjacent pipework.
H.4.3 Recording Procedure
To be in accordance with the main body of this Defence Standard.
41
©Crown Copyright 2012
Copying Only as Agreed with DStan
Defence Standards are published by and obtainable from:
Defence Equipment and Support
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
DStan Helpdesk
Tel: +44 (0) 141 224 2531/2
Fax: +44 (0) 141 224 2503
Internet e-mail: enquiries@dstan.mod.uk
File Reference
The DStan file reference relating to work on this standard is D/DStan/69/02/743/5.
Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards

Defence Standards are revised as necessary by an up issue or amendment. It is important that users
of Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk,
updated weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is encouraged
to notify UK Defence Standardization (DStan) without delay in order that the matter may be
investigated and appropriate action taken. Sponsors and authors shall refer to Def Stan 00-00 part 2
before proceeding with any standards work.

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Ministry of Defence

Defence Standard 02-743 Part 5

Figure 1 – Joints using Alloy Insert Rings................................................................................................6

Table 1 – Bond Acceptance Standards .................................................................................................. 22

Amd No Date Text Affected Signature and Date

This standard is raised to Issue 2 to update its content.

This standard supersedes the following:

2. The complete Def Stan 02-743 Pipe Manipulation comprises:

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

MOD Tender of Contract Process

Categories of Naval Defence Standard

a) Category 1. If not applied may have a Critical affect on the following:

b) Category 2. If not applied may have a Significant affect on the following:

c) Category 3. If not applied may have a Minor affect on the following:

a) British Standards British Standards Institution,

Health and Safety

Pipe Manipulation: Part 5 – Brazing

BS 499 Welding terms and symbols

BS 3072 Nickel and nickel alloys: sheet and plate

BS 3073 Nickel and nickel alloys: strip

BS 3074 Nickel and nickel alloys: seamless tube

BS 3075 Specification for Nickel and Nickel alloys: wire

BS 3076 Specification for Nickel and Nickel alloys: bar

BS EN 12163 Copper and copper alloys. Rod for general purposes

BS EN 13133 Brazing. Brazer approval

BS EN 13134 Brazing. Procedure approval

BS EN ISO 17672 Brazing – Filler Metals

Def Stan 02-729 Requirements for Non-Destructive Examination Methods

Def Stan 02-834 Requirements for Aluminium Silicon Bronze

BR 3013 Admiralty Pipework Standard

JSP430 MOD Ship Safety Management System Handbook

4 Terms and Definitions

f) Further guidance on brazed joint design is given in BS EN 14324.

5.2 Joint Design

b) A realistic ‘rule of thumb’ is:

Figure 1 – Joints using Alloy Insert Rings

Figure 2 – Face Feed Joints

Note: For flange and pipe materials and for

Figure 3 – Brazed Flange Joints

5.2.3 Design to Facilitate Ultrasonic Examination

Note: Ultrasonic examination of a brazed joint is practicable only when the:

5.3 Heat Treatment

5.4 Brazing Alloys and Fluxes

b) Whenever practicable, brazing is to be carried out in the workshop.

6.2 Brazing Processes

a) Brazing may be carried out by one of the following processes:

1) Manual torch brazing;

6.3 Brazing Alloys and Fluxes

a) The following types of fitting may be used:

1) Socket and sleeve types as shown in Figure 1 and Figure 2;

6.6 Preparation of Pipes

6.10 Brazing of Valves

6.11 Nitrogen Purge

c) Temperatures may be measured with contact thermometers, or optical pyrometers.

6.15 Face Feeding

6.17 Marking of Joints

Where required, completed joints are to be marked to identify the brazer.

6.18 Heat Treatment after Brazing

6.19 Cleaning after Brazing

6.20 Examination of Brazed Joints

6.21 Repair of Joints

6.21.2 Repair Techniques

6.21.4 Recording of Repairs

6.21.5 Heat Treatment of Repairs