Professional Documents
Culture Documents
Approval of The Manufacturing Process of Metallic Materials: July 2019
Approval of The Manufacturing Process of Metallic Materials: July 2019
of Metallic Materials
July 2019
Rule Note
NR480 DT R04 E
NR 480
Approval of the Manufacturing
Process of Metallic Materials
SECTION 1 GENERAL
July 2019
Section 1 General
1 General 7
1.1 Scope
1.2 Request for approval
1.3 Preliminary information to be submitted
1.4 Approval test program
1.5 Certification
1.6 Renewal of approval
1.7 Reconsideration of the approval
1.8 Responsibilities of the manufacturer
1 General 9
1.1 Scope
1.2 Manufacturing process specification
1.3 Documents to be submitted for changing the approval conditions
1.4 Approval survey
1.5 Position of the test samples
1.6 Test specimens and testing procedure
1.7 Other tests
1.8 Results
2 Semi finished products for hull structural steel grades 11
2.1 Scope
2.2 Selection of the test product
2.3 Extent of the approval tests
2.4 Tests on semi finished products
3 Rolled products made in normal and higher strength steel for hull and
other structural applications 11
3.1 Scope
3.2 Selection of the test product
3.3 Extent of the approval tests
3.4 Tests on rolled products
3.5 Weldability tests
4 Rolled products made in hull structural steel for high heat input welding 13
4.1 Scope
4.2 Application of certification
4.3 Confirmation tests
4.4 Grade designation
5 Rolled products made in normal and higher strength corrosion resistant
steel for cargo oil tanks 15
5.1 Scope
5.2 Manufacturing process specification
5.3 Test program
5.4 Corrosion tests
SECTION 1 GENERAL
Symbols
d) Details of inspections and quality control facilities Manufacturers who have not produced the approved prod-
• How are materials and components identified at the ucts during the period between renewals will be required to
various manufacturing stages carry out approval tests or at the discretion of the Society,
• Equipment for chemical analysis, metallography, submit the results of production of similar products.
mechanical tests and relevant calibration procedures
• Equipment for non-destructive examinations 1.7 Reconsideration of the approval
• List of quality control procedures.
e) Approval(s) already granted by other Classification Soci- 1.7.1 During the period of validity, the approval may be
eties and relevant approval test reports as deemed useful. reconsidered in the following cases:
The approval tests are in general to be witnessed by the d) Changes brought by the Manufacturer, without prelimi-
Society’s surveyor at the manufacturer’s works. If the testing nary agreement of the Society, to the extent of the
facilities are not available at the manufacturer’s works, the approval defined at the time of the approval.
tests are to be carried out at recognised laboratories
accepted by the Society, and, witnessed by the Society’s sur-
veyor.
1.8 Responsibilities of the manufacturer
1.3 Documents to be submitted for changing • For plates having thickness greater than 40 mm,
the approval conditions when the capacity of the available testing machine
is insufficient to allow the use of test specimens of
1.3.1 The manufacturer has to submit to the Society the full thickness, multiple flat specimens, representing
documents required in [1.2] together with the request of collectively the full thickness, can be used. Alterna-
changing the approval conditions, in the case of the follow- tively two round specimens with the axis located at
ing a) through e): one quarter and at mid-thickness can be taken.
b) Impact test
a) Change of the manufacturing process (steel making, • For plates made from hot rolled strip one additional
casting, rolling and heat treatment) set of impact specimens is to be taken from the mid-
b) Change of the maximum thickness (dimension) dle of the strip constituting the coil
• For plates having thickness greater than 40 mm one
c) Change of the chemical composition, added element, additional set of impact specimens is to be taken
etc. with the axis located at mid-thickness
d) Subcontracting the rolling, heat treatment, etc. • In addition to the determination of the energy value
(Joule), the lateral expansion and the percentage
e) Use of the slabs, blooms and billets manufactured by
crystallinity are to be reported for each specimen.
other companies which are not approved.
c) Chemical composition
However, where the documents are duplicated by the ones
In general the content of the following elements is to be
at the previous approval for the same type of product, part
checked: C, Mn, Si, P, S, Ni, Cr, Mo, Al, N, Nb, V, Cu, As,
or all of the documents may be omitted except the approval
Sn, Ti and, for steel manufactured from electric or open-
test program.
hearth furnace, Sb and B. The material for the check anal-
ysis should be taken from the tensile test specimen. Both
1.4 Approval survey the ladle and product analysis are to be reported.
d) Sulphur prints
1.4.1 The approval tests are to be witnessed by the Sur-
Sulphur prints are to be taken from plate edges which
veyor at the manufacturer’s plant and the execution of the
are perpendicular to the axis of the ingot or slab.
plant inspection in operation may be required by the Sur-
veyor during the visit for the approval. They are to be approximately 600 mm long taken from
the centre of the edge selected, i.e. on the ingot centre-
If the testing facilities are not available at the works, the line, and are to include the full plate thickness.
tests are to be carried out at laboratories accepted by the
Society. e) Micrographic examination
The micrographs are to be representative of the full
thickness. For thick products in general at least three
1.5 Position of the test samples examinations are to be made at surface, one quarter and
mid-thickness of the product.
1.5.1 The test samples are to be taken, unless otherwise
All photomicrographs are to be taken at x100 magnifi-
agreed, from the product (plate, flat, section, bar) corre-
cation and where ferrite grain size exceeds ASTM 10,
sponding to the top of the ingot, or, in the case of continu-
additionally at x500 magnification. Where applicable,
ous casting, a random sample.
ferrite grain size should be determined for each photo-
The position of the samples to be taken in the length of the micrograph.
rolled product, and the direction of the test specimens with f) Drop weight test
respect to the final direction of rolling of the material are
indicated in the relevant table for the material. When required the test is to be performed in accor-
dance with ASTM E208. The Nil Ductility Transition
The position of the samples in the width of the product is to temperature (NDT) is to be determined and photographs
be in compliance with NR216 Materials and Welding, Ch 2, of the tested specimens are to be taken and enclosed
Sec 1, [1.8]. with the test report.
The test results are to be in accordance, where applicable,
1.6 Test specimens and testing procedure with the requirements specified for the different steel grades
in NR216 Materials and Welding, Ch 2, Sec 1.
1.6.1 The test specimens and testing procedures are to be
in accordance with NR216 Materials and Welding, Ch 1, 1.7 Other tests
Sec 2, unless agreed otherwise.
1.7.1 Additional tests such as CTOD test, large scale brittle
In particular the following applies:
fracture tests (Double Tension test, ESSO test, Deep Notch
a) Tensile test test, etc) or other tests may be required in the case of newly
developed type of steel, outside the scope of NR216 Materi-
• For plates made from hot rolled strip one additional
als and Welding, Ch 2, Sec 1, [2], or when deemed neces-
tensile specimen is to be taken from the middle of
sary by the Society.
the strip constituting the coil
1.8.1 All the results, which are to comply with the require- 2.4.1 Type of tests
ments of NR216 Materials and Welding, are evaluated for The tests to be carried out for the approval of the manufac-
the approval; depending on the results, particular limita- turing process of semi finished products are:
tions or testing conditions, as deemed appropriate, may be
• Chemical analysis. The analysis is to be complete and is
specified in the approval document.
to include micro-alloying elements
All the information required under [1.2], applicable to the • Sulphur prints.
products submitted to the tests, is to be collected by the
manufacturer and put in the technical documentation In addition, for initial approval and for any upgrade of the
which will include all the results of the tests and operation approval, the Society will require full tests indicated in this
records relevant to steel making, casting, rolling and heat section to be performed at rolling mill on the minimum
treatment of the test products. thickness semi finished product.
In case of multi-caster work, full tests on finished products
2 Semi finished products for hull shall be carried out for one caster and reduced tests (chemi-
cal analysis and sulphur print) for the others. The selection
structural steel grades of the caster shall be based on the technical characteristics
of the casters to be evaluated on case by case basis. Tests
2.1 Scope are to be performed at rolling mill on products manufac-
tured from the minimum thickness semi finished product.
2.1.1 This Article specifies the scheme for the approval of
the manufacturing process of semi finished products such as
ingots, slabs, blooms and billets for the hull structural steels.
3 Rolled products made in normal and
higher strength steel for hull and
other structural applications
2.2 Selection of the test product
2.2.1 For each grade of steel and for each manufacturing 3.1 Scope
process (e.g. steel making, casting, rolling and condition of
supply), one test product with the maximum thickness and 3.1.1 This Article gives the approval test program for the
one test product with the minimum thickness to be manufacture of normal and higher strength hull and struc-
approved are in general to be selected for each kind of tural steel products in groups A, B, D, E and AH32, DH32,
product (ingots, slabs, blooms/billets). EH32, FH32, AH36, DH36, EH36, FH36, AH40, DH40,
EH40 and FH40.
The selection of the casts for the test product is to be based
on the typical chemical composition, with particular regard
to the specified CEQ or Pcm values and grain refining micro- 3.2 Selection of the test product
alloying additions.
3.2.1 For each grade of steel and for each manufacturing
process (e.g. steel making, casting, rolling and condition of
2.3 Extent of the approval tests supply), one test product with the maximum thickness
(dimension) to be approved is in general to be selected for
2.3.1 The extent of the test program is specified in [2.4]; it
each kind of product.
may be modified on the basis of the preliminary information
submitted by the manufacturer. In addition, for initial approval, the Society will require
selection of one test product of average thickness.
In particular a reduction of the indicated number of casts,
product thicknesses and grades to be tested or complete The selection of the casts for the test product is to be based
suppression of the approval tests may be accepted by the on the typical chemical composition, with particular regard
Society taking into account: to the specified CEQ or Pcm values and grain refining micro-
alloying additions.
a) Approval already granted by other Classification Societ-
ies and documentation of approval tests performed.
3.3 Extent of the approval tests
b) Grades of steel to be approved and availability of long
term statistic results of chemical properties and of 3.3.1 The extent of the test program is specified in [3.4] and
mechanical tests performed on rolled products. [3.5]; it may be modified on the basis of the preliminary
c) Change of the approval conditions. information submitted by the manufacturer.
On the other hand, an increase of the number of casts and In particular a reduction of the indicated number of casts,
thicknesses to be tested may be required in the case of steel plate thicknesses and grades to be tested or complete
newly developed types of steel or manufacturing processes. suppression of the approval tests may be accepted by the
Society taking into account:
Where the number of tests differs from those shown in
[2.4], the program is to be confirmed by the Society before a) Approval already granted by other Classification Societ-
the tests are carried out. ies and documentation of approval tests performed.
b) Grades of steel to be approved and availability of long In case of multi-source slabs or changing of slab manufac-
term statistic results of chemical and mechanical prop- turer, the rolled steel manufacturer is required to obtain the
erties. approval of the manufacturing process of rolled steels using
c) Approval for any grade of steel also covers approval for the slabs from each slab manufacturer and to conduct
any lower grade in the same strength level, provided approval tests in accordance with [3.4].
that the aim analysis, method of manufacture and con-
• The rolled steel manufacturer has already been
dition of supply are similar.
approved for the manufacturing process using other
d) For higher tensile steels, approval of one strength level semi finished products characterized by the same thick-
covers the approval of the strength level immediately ness, steel grade, grain refining and micro-alloying ele-
below, provided the steelmaking process, deoxidation ments, steelmaking and casting process
and fine grain practice, casting method and condition of
supply are the same. • The semi finished products manufacturer has been
approved for the complete manufacturing process with
e) Change of the approval conditions. the same conditions (steelmaking, casting, rolling and
f) Approval of the semi-finished products such as slabs, heat treatment) for the same steel types.
blooms and billets.
On the other hand, an increase of the number of casts and Where the number of tests differs from those shown in [3.4]
thicknesses to be tested may be required in the case of and [3.5], the program is to be confirmed by the Society
newly developed types of steel or manufacturing processes. before the tests are carried out.
3.4 Tests on rolled products A sketch of the weld joint depicting groove dimensions,
number of passes, hardness indentations should be attached
3.4.1 The tests to be carried out are indicated in Tab 1. to the test report together with photomacrographs of the
weld cross section.
The welding procedure should be as far as possible in Demonstration of conformance to the requirements of this
accordance with the normal welding practice used at the document approves a particular steel mill to manufacture
yards for the type of steel in question. grade of steel to the specific chemical composition range,
melting practice, and processing practice for which confor-
The welding parameters including consumables designation mance was established. The approval scheme does not
and diameter, pre-heating temperatures, interpass tempera- apply to qualification of welding procedures to be under-
tures, heat input, number of passes, etc. are to be reported. taken by the shipyards.
b) A set of 3 Charpy V-notch impact specimens transverse a) Outline of steel plate to be certified
to the weld with the notch located at the fusion line and • Grade
at a distance 2, 5 and minimum 20 mm from the fusion
line. The fusion boundary is to be identified by etching • Thickness range
the specimens with a suitable reagent. The test tempera- • Deoxydation practice
ture is to be the one prescribed for the testing of the
steel grade in question • Fine grain practice
• Aim range of chemical composition
c) Hardness tests HV 5 across the weldment. The indenta-
tions are to be made along a 1 mm transverse line • Aim maximum CEQ and Pcm
beneath the plate surface on both the face side and the
• Production statistics of mechanical properties tensile
root side of the weld as follows:
and Charpy V-notch impact test, if any.
• Fusion line
b) Manufacturing control points to prevent toughness dete-
• HAZ: at each 0,7 mm from fusion line into unaf- rioration in heat affected zone when welded with high
fected base material (6 to 7 minimum measurements heat input, relevant to chemical elements, steelmaking,
for each HAZ) casting, rolling, heat treatment, etc.
• The maximum hardness value should not be higher c) Welding control points to improve joint properties on
than 350 HV. strength and toughness, if any.
4.3 Confirmation tests 4.3.5 Examinations and tests for the test assembly
The test assembly is to be examined and tested in accor-
4.3.1 Range of certification dance with the following a) through h) unless otherwise
Range of certification for steel grades is to be the following agreed by the Society:
a) through e) unless otherwise agreed by the Society: a) Visual examination: Overall welded surface is to be uni-
a) Approval tests on the lowest and highest toughness lev- form and free from injurious defects such as cracks,
els cover the intermediate toughness level undercuts, overlaps, etc.
b) Approval tests on normal strength cover that strength b) Macroscopic test: One macroscopic photograph is to be
level only representative of transverse section of the welded joint
and is to show absence of cracks, lack of penetration,
c) For high tensile steels, approval tests on one strength lack of fusion and other injurious defects.
level cover strength level immediately below
c) Microscopic test: Along mid-thickness line across trans-
d) Tests may be carried out separately subject to the same verse section of the weld, one micrograph with x100
manufacturing process magnification is to be taken at each position of the weld
metal centreline, fusion line and at a distance 2, 5, 10
e) Certification and documentation of confirmation tests and minimum 20 mm from the fusion line. The test
performed by other Classification Societies may be result is provided for information purpose only.
accepted at the discretion of the Society.
d) Hardness test: Along two line across transverse weld
4.3.2 Weldability test program section 1 mm beneath plate surface on both face and
root side of the weld, indentations by HV5 are to be
Extent of the test program is specified in [4.3.5] but it may
made at weld metal centreline, fusion line and each
be modified according to the content of certification. In par-
0,7 mm from fusion line to unaffected base metal (mini-
ticular, additional test assemblies and/or test items may be
mum 6 to 7 measurements for each heat affected zone).
required in the case of newly developed type of steel, weld-
ing consumable and welding method, or when deemed The maximum hardness value should not be higher than
necessary by the Society. 350 HV.
Where the content of tests differs from those specified in e) Transverse tensile test: Two transverse (cross weld) ten-
[4.3.5], the program is to be confirmed by the Society sile specimens are to be taken from the test assembly.
before the tests are carried out. Test specimens and testing procedures are to comply
with the requirements of NR216 Materials and Welding,
4.3.3 Test plate Ch 1, Sec 2.
Test plate is to be manufactured by a process approved by The tensile strength is to be not less than the minimum
the Society in accordance with the requirements of [3]. required value for the grade of base metal.
For each manufacturing process route, two test plates with f) Bend test: Two transverse (cross weld) test specimens are
different thickness are to be selected. The thicker plate (t) to be taken from the test assembly and bent on a man-
and the thinner plate (less than or equal to t/2) are to be pro- drel with diameter of quadruple specimen thickness.
posed by the manufacturer. Bending angle is to at least 120°. Test specimens are to
comply with the requirements of NR216 Materials and
Small changes in manufacturing processing (e.g. within the Welding, Ch 1, Sec 2.
TMCP process) may be considered for acceptance without
testing, at the discretion of the Society. For plate thickness up to 20 mm, one face-bend and one
root-bend specimens or two side-bend specimens are to
4.3.4 Test assembly be taken.
One butt weld assembly welded with heat input over After testing, the test specimens shall not reveal any
50kJ/cm is to be generally prepared with the weld axis crack nor other open defect in any direction greater than
transverse to the plate rolling direction. 3 mm.
Dimensions of the test assembly are to be amply sufficient g) Impact test: Charpy V-notch impact specimens (three
to take all the required test specimens specified in [4.3.5]. specimens for one set) are to be taken within 2 mm
below plate surface on face side of the weld with the
The welding procedures should be as far as possible in notch perpendicular to the plate surface.
accordance with the normal practices applied at shipyards
for the test plate concerned. One set of the specimens transverse to the weld is to be
taken with the notch located at the fusion line and at
Welding process, welding position, welding consumable distance 2, 5 and minimum 20 mm from the fusion line.
(manufacturer, brand, grade, diameter and shield gas) and The fusion boundary is to be identified by etching the
welding parameters including bevel preparation, heat input, specimens with a suitable reagent. The test temperature
preheating temperatures, interpass temperatures, number of is to be the one prescribed for the testing of the steel
passes, etc. are to be reported. grade in question.
For steel plate with thickness greater than 50 mm or one 5.3 Test program
side welding for plate thickness greater than 20 mm,
one additional set of the specimens is to be taken from 5.3.1 General
the root side of the weld with the notch located at each The extent of approval is to be as per [3.3] with the addition
the same position as for the face side. of corrosion test plan.
The average impact energy at the specified test tempera-
ture is to comply with NR216 Materials and Welding, 5.3.2 Corrosion test plan
Ch 2, Sec 1, Tab 4 and Ch 2, Sec 1, Tab 7 depending on The corrosion test plan is to be submitted by the manufac-
the steel grade and thickness. turer for review. If the test program is found satisfactory by
the Society, it will be approved and returned to the manu-
h) Other test: Additional tests such as wide-width tensile facturer for acceptance prior to tests being carried out. Tests
test, HAZ tensile test, cold cracking tests (CTS, Cruci- that need to be witnessed by the Surveyor will be identified.
form, Implant, Tekken and Bead-on plate), CTOD or
other tests should be required at the discretion of the The number of test samples is to be in accordance with the
Society (see [4.3.2]). requirements of Appendix of the Annex to IMO MSC.289
(87) “Performance Standard for Alternative Means of Corro-
sion Protection for Cargo Oil Tanks of Crude Oil Tankers”.
4.4 Grade designation
The number of casts and test samples selected are to be suf-
4.4.1 Upon issuance of the certificate, the notation indicat- ficient to make it possible to confirm the validity of interac-
ing the value of heat input applied in the confirmation test tion effects and/or the control range (upper limit, lower
may be added to the grade designation on the test plate, e.g. limit) of the elements which are added or intentionally con-
“EH36-W300” (in the case of heat input 300kJ/cm applied). trolled, for improving the corrosion resistance. Where
The value of this notation is not to be less than 50 and every agreed, this may be supported with data submitted by the
10 added. manufacturer.
6.3 Extent of the approval tests On the other hand, an increase of the number of casts and
thicknesses to be tested may be required in the case of
6.3.1 The extent of the test program is specified in [6.4] and newly developed types of steel or manufacturing processes.
[6.5]. Each grade is to be tested. It may be modified on the Where the number of tests differs from those shown in [6.4]
basis of the preliminary information submitted by the manu- and [6.5], the program is to be confirmed by the Society
facturer. before the tests are carried out.
In particular a reduction of the indicated number of casts,
steel plate thicknesses and grades to be tested or complete 6.4 Tests on rolled products
suppression of the approval tests may be accepted by the
6.4.1 The tests to be carried out are indicated in Tab 2.
Society, taking into account:
a) Approval already granted by other Classification Societ- 6.4.2 For plates having thickness greater than 50 mm,
ies and documentation of approval tests performed charpy V-notch impact tests and Strain Aged charpy V-notch
impact tests are required from both the quarter and mid-
b) Grades of steel to be approved and availability of long thickness locations of the tests samples.
term statistic results of chemical and mechanical prop-
erties 6.5 Weldability tests
c) Change of the approval conditions
6.5.1 General
d) Approval of the semi-finished products such as slabs, Weldability tests are required for plates and are to be car-
blooms and billets. ried out on samples of the thickest plate.
Impact test (2) on strain EH36CAS, EH40CAS, EH47CAS Testing −20 −40 −60
aged specimens (4) Top - longitudinal temperature
for grades FH36CAS, FH40CAS (°C) −40 −60 −80
Complete analysis including micro
Chemical composition (5) Top
alloying elements
Sulphur prints Top
Micro examination Top
Grain size determination Top
Drop weight test (3) Top Determination of NDT
Only for grades with improved through
Through thickness tensile tests Top and bottom
thickness properties
Deep notch test or CTOD test
Brittle fracture initiation test Top
as per recognized standard
As per Appendix 1 ESSO test or alternative
Brittle crack arrest test Top - longitudinal
method (e.g. double tension test)
(1) Longitudinal direction for plates having width less than 600 mm.
(2) One set of 3 Charpy V-notch impact specimens is required for each impact test.
(3) Not required for plates having width less than 600 mm.
(4) Deformation 5% + 1 hour at 250°C.
(5) Besides product analysis, ladle analyses are required.
6.5.2 Preparation and welding of the test d) Brittle fracture initiation test across the weldment
assemblies
Deep notch test or CTOD test is to be carried out as per
The following tests are in general required: a recognized standard.
a) 1 butt weld test assembly welded with a heat input 6.5.4 Other tests
approximately 15 kJ/cm
Y-shape weld crack test is to be carried out.
b) 1 butt weld test assembly welded with a heat input
The test method is to be in accordance with recognized
approximately 50 kJ/cm.
standards such as KS B0870, JIS Z 3158, GB 4675.1 or ISO
The butt weld test assemblies are to be prepared with the 17642-2.
weld seam transverse to the plate rolling direction, so that
impact specimens will result in the longitudinal direction.
7 Rolled products made of extra high
The bevel preparation should be preferably 1/2V or K. strength steels for welded structure
The welding procedure should be as far as possible in
accordance with the normal welding practice used at the 7.1 Scope
yards for the type of steel in question.
7.1.1 This Article gives the approval test program for the
The welding parameters including consumables designation
manufacture of extra high strength steel products for welded
and diameter, pre-heating temperatures, interpass tempera-
structure made of grades A, B, D, E, F in the yield strength
tures, heat input, number of passes, etc. are to be reported.
groups 420, 460, 500, 550, 620, 690, 890 and 960.
6.5.3 Type of tests
7.2 Manufacturing process specification
From the test assemblies the following test specimens are to
be taken: 7.2.1 The following information is to be supplied by the
a) One cross weld tensile test manufacturer:
b) A set of 3 Charpy V-notch impact specimens transverse a) Type of products (plates, sections, bars and tubulars),
to the weld with the notch located at the fusion line and grades of steel, range of thickness, delivery condition
at a distance 2, 5 and minimum 20 mm from the fusion and aim material properties, as follows:
line. The fusion boundary is to be identified by etching • Range of chemical composition, aim analyses and
the specimens with a suitable reagent. associated control limits, including grain refining,
nitrogen binding, micro alloying and residual ele-
Charpy V-notch impact tests are to be taken at a position
ments, for the various grades of steel; if the range of
of ¼ thickness from the plate surface on the face side of
chemical composition depends on thickness and
the weld with the notch perpendicular to the plate sur-
supply condition, the different ranges are to be spec-
face.
ified, as appropriate.
One additional set of specimens is to be taken from the • In addition, where zirconium, calcium and rare
root side of the weld with the notch located at the same earth metals have been used during steelmaking for
position and at the same depth as for the face side. grain refinement and, or inclusion modification, the
The test temperature is to be the one prescribed for the contents of these elements shall be specified in the
testing of the steel grade in question. approved specification.
Additionally, at each location impacts tests are to be • Aim carbon equivalent CEQ according to IIW for-
carried out with appropriate temperature intervals to mula or CET formula and associated control limits.
properly define the full transition range. • Aim Pcm content and associated control limits.
c) Hardness tests HV 5 across the weldment. The indenta- • Production statistics of the chemical composition
tions are to be made along a 1 mm transverse line and mechanical properties (ReH , Rm , A5% and KV).
beneath the plate surface on both the face side and the The statistics are intended to demonstrate the capa-
root side of the weld as follows: bility to manufacture the steel products in accor-
dance with the requirements.
• Fusion line
b) Steelmaking
• HAZ: at each 0,7 mm from fusion line into unaf-
fected base material (6 to 7 minimum measurements • Steelmaking process and capacity of furnace(s) or
for each HAZ) converter(s)
• The maximum hardness value should not be higher • Raw material used
than 350 HV. • Deoxidation, grain refining, nitrogen binding and
A sketch of the weld joint depicting groove dimensions, alloying practice
number of passes, hardness indentations should be • Desulphurisation, dehydrogenation, sulphide treat-
attached to the test report together with photomacro- ment, ladle refining and vacuum degassing installa-
graphs of the weld cross section. tions, if any.
c) Casting methods: ingot or continuous casting 7.3 Selection of the test product
In the case of continuous casting, information relevant
to type of casting machine, teeming practice, methods 7.3.1 For each grade of steel and for each manufacturing
to prevent re-oxidation, inclusions and segregation con- process (e.g. steel making, casting, rolling and condition of
trol, presence of electromagnetic stirring, soft reduction, supply), one test product with the maximum thickness
etc., is to be provided as appropriate (dimension) to be approved is in general to be selected for
• Casting/solidification cooling rate control each kind of product.
• Ingot or slab size and weight In addition, for initial approval, the Society will require
• Ingot or slab treatment: scarfing and discarding pro- selection of one test product of representative thickness.
cedures.
The selection of the casts for the test product is to be based
d) Reheating and rolling
on the typical chemical composition, with particular regard
• Type of furnace and treatment parameters to the specified CEQ, CET or Pcm values and grain refining
• Rolling: reduction ratio of ingot/slab/bloom/billet to micro-alloying additions.
finished product, rolling and finishing temperatures
for each grade/thickness combination
7.4 Extent of the approval tests
• Descaling treatment during rolling
• Capacity of the rolling stands. 7.4.1 The extent of the test program is specified in [7.5] and
e) Heat treatment [7.6]; it may be modified on the basis of the preliminary
• Type of furnaces, heat treatment parameters for information submitted by the manufacturer.
products to be approved
In particular a reduction of the indicated number of casts,
• Accuracy and calibration of temperature control steel plate thicknesses and grades to be tested or complete
devices suppression of the approval tests may be accepted by the
• The method used to determine austenization tem- Society taking into account:
perature, re-crystallisation temperature and Ar3 tem-
perature a) Approval already granted by other Classification Societ-
ies and documentation of approval tests performed
• Description of quenching and tempering process, if
applicable. b) Grades of steel to be approved and availability of long
f) Programmed rolling term statistic results of chemical and mechanical prop-
erties
For products delivered in the normalised rolling (NR) or
thermo-mechanical rolling (TM) condition, the follow- c) Change of the approval conditions
ing additional information on the programmed rolling
schedules is to be given: d) Approval of the semi-finished products such as slabs,
• Description of the rolling process blooms and billets.
• Austenization temperature, re-crystallization tem- On the other hand, an increase of the number of casts and
perature and Ar3 temperature and the methods used thicknesses to be tested may be required in the case of
to determine them newly developed types of steel or manufacturing processes.
• Control standards for typical rolling parameters used
for the different thickness and grades of steel (tem- In case of multi-source slabs or changing of slab manufac-
perature and thickness at the beginning and at the turer, the rolled steel manufacturer is required to obtain the
end of the passes, interval between passes, reduc- approval of the manufacturing process of rolled steels using
tion ratio, temperature range and cooling speed of the slabs from each slab manufacturer and to conduct
accelerated cooling, if any) and relevant method of approval tests in accordance with [7.5] and [7.6].
control
• The rolled steel manufacturer has already been
• Calibration of the control equipment. approved for the manufacturing process using other
g) Recommendations for working and welding in particu- semi-finished products characterized by the same thick-
lar for products delivered in the NR or TM condition ness, steel grade, grain refining and micro-alloying ele-
• Cold and hot working recommendations if needed ments, steelmaking and casting process.
in addition to the normal practice used in the ship- • The semi-finished products manufacturer has been
yards and workshops approved for the complete manufacturing process with
• Minimum and maximum heat input and recom- the same conditions (steelmaking, casting, rolling and
mended pre-heat/interpass temperature. heat treatment) for the same steel types.
h) Where any part of the manufacturing process is assigned
to other companies or other manufacturing plants, addi- 7.4.2 Where the number of tests differs from those shown
tional information required by the Society is to be in [7.5] and [7.6], the program is to be confirmed by the
included. Society before the tests are carried out.
7.5 Tests on rolled products 7.6.2 Butt weld test for steel strength levels 420 to
500 N/mm²
7.5.1 The tests to be carried out are indicated in Tab 3. Testing on higher grades can cover the lower strength and
toughness grades.
7.5.2 Additional tests such as stress relieved tensile test (for
TM steels), cold cracking tests (CTS, cruciform, implant, The following butt weld tests are required:
Tekken, bead on plate), CTOD test on parent plate, large
scale brittle fracture tests (Double Tension test, ESSO test, a) 1 butt weld test assembly welded with the heat input
Deep Notch test) or other tests may be required when 15 ± 2kJ/cm is to be tested as-welded
deemed necessary by the Society. b) 1 butt weld test assembly welded with the heat input
50 ± 5kJ/cm for N/NR and TM steels and 35 ± 3,5kJ/cm
7.6 Weldability tests for QT steels is to be tested as-welded
Option: steels intended to be designated as steels for high b) Steels delivered in QT condition shall be heat treated for
heat input welding are to be tested with 1 butt weld test a minimum time of 1 hour per 25 mm thickness (but not
assembly in the as-welded condition and 1 butt weld test less than 30 minutes and needs not be more than 150
assembly in the post weld heat treated (PWHT) condition, minutes) at a maximum holding temperature of 550°C
both welded with the maximum heat input being approved. with the maximum holding temperature of at least 30°C
below the previous tempering temperature, unless oth-
7.6.3 Butt weld test for steel strength levels 550 to erwise approved at the time of approval
960 N/mm²
Approval tests on the highest toughness grade cover c) For all delivery condition, heating and cooling above
approval for any lower grade in the same strength level, 300°C shall be carried out in a controlled manner in
provided that the aim analysis, method of manufacture and order to heat/cool the material uniformly. The cooling
condition of supply are similar. rate from the maximum holding temperature to 300°C
shall not be slower than 55°C/hr.
The following butt weld tests are required:
a) 1 butt weld test assembly welded with the heat input 7.6.7 Type of tests
10 ± 2kJ/cm is to be tested as-welded
From the test assemblies the following test specimens are to
b) 1 butt weld test assembly welded with the maximum be taken:
heat input as proposed by the manufacturer is to be
tested as-welded. The approved maximum heat input a) One cross weld tensile test. One full thickness test sam-
shall be stated on the manufacturer approval certificate. ple or sub-sized samples cover the full thickness cross
Option: If the manufacturer requests to include the approval section.
for post weld heat treated (PWHT) condition, 1 additional
b) A set of 3 Charpy V-notch impact specimens transverse
butt weld test assembly welded with a maximum heat input
to the weld with the notch located at the fusion line and
proposed by the manufacturer for the approval same as test
at a distance 2, 5 and minimum 20 mm from the fusion
assembly b) is to be post-weld heat treated (PWHT) prior to
testing. Postweld heat treatment procedure is specified in line. The fusion boundary is to be identified by etching
[7.6.6]. the specimens with a suitable reagent.
1 - 2 mm a 1 - 2 mm a
CTOD test
specimen
CTOD test
specimen
GCHAZ GCHAZ
a) b)
a) For plate thickness ≤50mm, CTOD test specimen is to be sampled in full thickness.
b) For plate thickness >50mm, subsidiary test specimen with thickness of maximum 50mm in subsurface area is to be sampled.
d) Brittle fracture initiation test across the weldment. 8 Rolled products for boilers and
CTOD tests are to be carried out for butt weld test pressure vessels
assembly specified in [7.6.2] b) and [7.6.3] b) in accor-
dance with EN ISO 15653 or other recognized standard. 8.1 Scope
• The specimen geometry (B=W) is permitted for plate 8.1.1 This Article gives the approval test program for the
thickness up to 50mm. For plate thicker than 50mm, manufacture of carbon manganese steel products made of
subsidiary specimen geometry (50x50mm) is permit- grades (360HA, 360HB, 360HD, 410HA, 410HB, 410HD,
ted, which is to be taken 50mm in depth through 460HB, 460HD, 510HB, 510HD) and low alloy steel grades
thickness from the subsurface and 50mm in width. (0,3Mo - 1Cr0,5Mo - 2,25Cr1Mo) for boilers and pressure
vessels.
See Fig 1 for more details.
• The specimens shall be notched in through thickness 8.2 Selection of the test product
direction
8.2.1 For each grade of steel and for each manufacturing
• Grain-coarsened HAZ (GCHAZ) shall be targeted for process (e.g. steel making, casting, rolling and condition of
the sampling position of the crack tip supply), two products (one per cast) from two different casts
representing average and maximum thickness (dimension)
• The test specimens shall be in as-welded and post- to be approved are in general to be selected for each kind of
weld heat treated, if applicable product.
• Three tests shall be performed at -10°C on each butt An additional product from another cast is to be tested for
weld test assembly. grades intended for application at elevated temperatures
(boilers).
For steel strength level 690N/mm² and above, dehydro- The selection of the casts for the test product is to be based
genation of as-welded test pieces may be carried out by on the typical chemical composition, with particular regard
a low temperature heat treatment, prior to CTOD test- to the specified CEQ or Pcm values and grain refining micro-
ing. Heat treatment conditions of 200°C for 4h are rec- alloying additions.
ommended, and the exact parameters shall be notified
with the CTOD test results. 8.3 Extent of the approval tests
e) Y-shape weld crack test (Hydrogen crack test) is to be 8.3.1 The extent of the test program is specified in [8.4] and
carried out. [8.5]; it may be modified on the basis of the preliminary
information submitted by the manufacturer.
The test method is to be in accordance with recognized
standards such as KS B0870, JIS Z 3158, GB/T4675.1 or In particular a reduction of the indicated number of casts,
steel plate thicknesses and grades to be tested or complete
ISO 17642-2.
suppression of the approval tests may be accepted by the
Minimum preheat temperature is to be determined and Society taking into account:
the relationship of minimum preheat temperature with a) Approval already granted by other Classification Societ-
thickness is to be derived. ies and documentation of approval tests performed.
b) Grades of steel to be approved and availability of long On the other hand, an increase of the number of casts and
term statistic results of chemical and mechanical prop- thicknesses to be tested may be required in the case of
erties. newly developed types of steel or manufacturing processes.
c) Approval for any grade of steel also covers approval for Where the number of tests differs from those shown in [8.4]
any lower grade in the same strength level, provided and [8.5], the program is to be confirmed by the Society
that the aim analysis, method of manufacture and con- before the tests are carried out.
dition of supply are similar.
8.4 Tests on rolled products
d) Approval of one yield strength level covers the approval
of the yield strength level immediately below, provided
8.4.1 The tests to be carried out are indicated in Tab 4.
the steelmaking process, deoxidation and fine grain
practice, casting method and condition of supply are
the same. 8.5 Weldability tests
8.5.2 Preparation and welding of the test assemblies 9 Rolled products made in ferritic steels
The following tests are in general required: for low temperature applications
a) 1 butt weld test assembly welded with a heat input
equal to the minimum heat input recommended by the 9.1 Scope
steelmaker
b) 1 butt weld test assembly welded with a heat input 9.1.1 This Article gives the approval test program for the
equal to the maximum heat input recommended by the manufacture of ferritic steel products for low temperature
steelmaker. applications including carbon manganese steels grade LE or
LF in the tensile strength groups 410, 460, 510 and 550 and
The butt weld test assemblies are to be prepared with the
nickel steels grade 1,5Ni - 3,5Ni - 5,0Ni and 9,0Ni.
weld seam parallel to the plate rolling direction, so that
impact specimens will result in the transverse direction.
9.2 Selection of the test product
The bevel preparation should be preferably 1/2V or K
depending on the thickness. 9.2.1 For each grade of steel and for each manufacturing
The welding procedure should be as far as possible in process (e.g. steel making, casting, rolling and condition of
accordance with the normal welding practice used at the supply), two products (one per cast) from two different casts
manufacturing shop for the type of steel in question. representing average and maximum thickness (dimension)
to be approved are in general to be selected for each kind of
The welding parameters including consumables brand
product.
name, designation and diameter, pre-heating temperatures,
interpass temperatures, heat input, number of passes, etc. The selection of the casts for the test product is to be based
are to be reported. on the typical chemical composition, with particular regard
to the specified CEQ or Pcm values and grain refining micro-
8.5.3 Type of tests alloying additions.
From the test assemblies the following test specimens are to
be taken: 9.3 Extent of the approval tests
a) One cross weld tensile test
9.3.1 The extent of the test program is specified in [9.4] and
b) A set of 3 Charpy V-notch impact specimens transverse [9.5]; it may be modified on the basis of the preliminary
to the weld with the notch located at the fusion line and information submitted by the manufacturer.
at a distance 2, 5 and minimum 20 mm from the fusion In particular a reduction of the indicated number of casts,
line. The fusion boundary is to be identified by etching steel plate thicknesses and grades to be tested or complete
the specimens with a suitable reagent. The test tempera- suppression of the approval tests may be accepted by the
ture is to be the one prescribed for the testing of the Society taking into account:
steel grade in question. The minimum average impact
energy shall exceed 27 J for carbon-manganese steels a) Approval already granted by other Classification Societ-
and 31 J for low alloy steels. ies and documentation of approval tests performed.
c) Hardness tests HV 5 across the weldment. The indenta- b) Grades of steel to be approved and availability of long
tions are to be made along a 1 mm transverse line term statistic results of chemical and mechanical prop-
beneath the plate surface on both the face side and the erties.
root side of the weld as follows: c) Approval for any grade of steel also covers approval for
• Weld metal, at each 2 mm any lower grade in the same strength level, provided
• Fusion line that the aim analysis, method of manufacture and con-
dition of supply are similar.
• HAZ: at each 0,5 mm from fusion line into unaf-
fected base material d) Approval of one yield strength level covers the approval
of the yield strength level immediately below, provided
• The maximum hardness value should not be higher
the steelmaking process, deoxidation and fine grain
than 320 HV.
practice, casting method and condition of supply are
A sketch of the weld joint depicting groove dimensions, the same.
number of passes, hardness indentations should be attached
e) Change of the approval conditions.
to the test report together with photomacrographs of the
weld cross section. f) Approval of the semi-finished products such as slabs,
blooms and billets.
Where a stress relieving treatment is required, cross weld
tensile and Charpy V-notch impact tests are to be repeated On the other hand, an increase of the number of casts and
in the stress relieved conditions. thicknesses to be tested may be required in the case of
newly developed types of steel or manufacturing processes.
8.5.4 Other tests
Where the number of tests differs from those shown in [9.4]
Additional tests such as cold cracking tests (CTS, cruciform, and [9.5], the program is to be confirmed by the Society
implant, Tekken, bead on plate), CTOD, or other tests may before the tests are carried out.
be required when deemed necessary by the Society.
9.4 Tests on rolled products The bevel preparation should be preferably 1/2V or K
depending on the thickness.
9.4.1 The tests to be carried out are indicated in Tab 5.
The welding procedure should be as far as possible in
accordance with the normal welding practice used at the
yards for the type of steel in question.
9.5 Weldability tests
The welding parameters including consumables brand
9.5.1 General name, designation and diameter, pre-heating temperatures,
Weldability tests are required for plates and are to be car- interpass temperatures, heat input, number of passes, etc.
ried out on samples of the thickest plate. are to be reported.
a) 1 butt weld test assembly welded with a heat input a) One cross weld tensile test
equal to the minimum heat input recommended by the
steelmaker b) A set of 3 Charpy V-notch impact specimens transverse
to the weld with the notch located at the fusion line and
b) 1 butt weld test assembly welded with a heat input at a distance 1, 3, 5, 7 and minimum 20 mm from the
equal to the maximum heat input recommended by the
fusion line. The fusion boundary is to be identified by
steelmaker.
etching the specimens with a suitable reagent. The test
The butt weld test assemblies are to be prepared with the temperature is to be the one prescribed for the testing of
weld seam parallel to the plate rolling direction, so that the steel grade in question. The minimum average
impact specimens will result in the transverse direction. impact energy shall exceed 27 J
The welding parameters including consumables brand 11 Round bars for anchor chain cables
name, designation and diameter, pre-heating temperatures,
interpass temperatures, heat input, number of passes, etc.
are to be reported. 11.1 Scope
From the test assemblies the following test specimens are to
be taken: 11.1.1 This Article gives the approval test program for the
manufacture of round bars made of steel grade Q1, Q2 or
a) One cross weld tensile test. Q3 used for the manufacture of anchor chain cables.
b) Two sets of 3 Charpy V-notch impact specimens trans-
verse to the weld with the notch located at the fusion 11.2 Selection of the test product
line and at a distance 1, 3, 5, 7 and minimum 20 mm
from the fusion line. The fusion boundary is to be identi-
fied by etching the specimens with a suitable reagent. 11.2.1 For each grade of steel and for each manufacturing
The test temperature is 0°C and −20°C. The minimum process (e.g. steel making, casting, rolling and condition of
average impact energy shall exceed 27 J. supply), two products (one per cast) from two different casts
representing maximum diameter to be approved are in gen-
c) Hardness tests HV 5 across the weldment. The indenta-
eral to be selected for each kind of product.
tions are to be made along a 1mm transverse line
beneath the plate surface on both the face side and the The bars are to be heat treated in a way to simulate the heat
root side of the weld as follows: treatment made during the manufacture of the anchor chain
• Weld metal, at each 2 mm cable.
• Fusion line
• HAZ: at each 0,5 mm from fusion line into unaf- 11.3 Extent of the approval tests
fected base material.
d) Determination of ferrite content (aim at 30% - 60%) in 11.3.1 The extent of the test program is specified in [11.4];
base metal heat affected zone and for information in it may be modified on the basis of the preliminary informa-
weld metal. tion submitted by the manufacturer.
Full clad plate, one from each end of the clad As per NR216 Materials and Welding, Ch 2, Sec 1
Bend tests for clad plates
plate
12.3.1 Two clad plates are to be selected from current pro- 13.2.1 In addition to the information mentioned in [1.2],
duction representing the average and the maximum thick- the following information is to be supplied:
ness to be approved. a) Maximum thickness and steel grades with delivery con-
ditions for which approval is requested
12.4 Extent of the approval tests b) Details about process modifications to obtain the prop-
erties (inclusion shape control, low sulphur...)
12.4.1 The extent of the test program is specified in [12.5];
c) Ultrasonic examination procedures and acceptance cri-
it may be modified on the basis of the preliminary informa-
teria.
tion submitted by the manufacturer.
Where the number of tests differs from those shown in 13.3 Selection of the test product
[12.5], the program is to be confirmed by the Society before
the tests are carried out. 13.3.1 One plate representative of maximum thickness to
be approved is to be selected.
12.5 Tests on clad plate
13.4 Extent of the approval tests
12.5.1 The tests to be carried out are indicated in Tab 9.
13.4.1 The extent of the test program is specified in [13.5];
it may be modified on the basis of the preliminary informa-
13 Plates with specified through tion submitted by the manufacturer.
thickness properties Where the number of tests differs from those shown in
[13.5], the program is to be confirmed by the Society before
the tests are carried out.
13.1 Scope
13.1.1 This Article gives the approval test program for the 13.5 Tests on plates
manufacture of plates with specified through thickness
13.5.1 The tests to be carried out are indicated in Tab 10.
properties.
c) Approval for any grade of steel also covers approval for For each product, all the relevant tests required in NR216
any lower grade in the same strength level, provided Materials and Welding, Ch 2, Sec 2 are to be performed in
that the method of manufacture and condition of supply addition to the following tests (1)
are similar. Chemical
From product sample Complete analysis
composition
d) Approval for a strength level may cover approval for
lower strength levels provided that the type of steel and Microexamina-
Magnification 100
the conditions of supply are the same. tion
Where the number of tests differs from those shown in Segregation Sulphur print;
[1.7], the program is to be confirmed by the Society before examination other tests than
the tests are carried out. Sulphur prints for
Cross-sectional area segregation exam-
1.6.3 Sampling and position of test specimens ination may be
agreed with the
The test samples are to be taken in accordance with NR216 Society
Materials and Welding, Ch 2, Sec 2.
Dimensional
The test specimens and testing procedures are to be, as a examination
rule, in accordance with NR216 Materials and Welding, (1) When non-destructive examination is required by NR
Ch 1, Sec 2. 216, NDT report is to be provided and shall include:
reference to a testing standard and procedure, extent of
1.7 Approval tests testing, rejection/acceptance criteria and statement for
results of examination, identification and signature of
1.7.1 The tests to be carried out are indicated in Tab 1. qualified NDT operator
• Frequency of calibration
1.3 Manufacturing process specification
• Length of untested ends, if applicable
1.3.1 The following manufacturing process information
• Sensitivity to detect internal, external defects
and relevant documentation are to be submitted together
with the request for approval and in addition to general • Acceptance, rejection criteria
information as detailed in Sec 1, [1.3].
• Operators qualification according to international
a) Manufacture of the steel and semi-finished products standard.
• Steelmaking process and capacity of furnace(s) or
converter(s), raw material used, deoxidation and
alloying practice, vacuum degassing, casting
1.4 Documents to be submitted for
method(s) changing the approval conditions
• Semi-finished products: weight and size range
1.4.1 The manufacturer has to submit to the Society the doc-
• List of semi-finished products suppliers. uments required in [1.3] together with the request of chang-
ing the approval conditions, in the case of change of the
b) Description of the manufacturing process approval conditions (e.g. dimension range, steel grades, etc.).
• Forming operations
However, where the documents are duplicated by the ones
• Weld joint type, welding procedure specification at the previous approval for the same type of product, part
and supporting welding procedure approval report, or all of the documents may be omitted except the approval
welding equipment. test program.
1.5 Approval survey d) Approval for a strength level may cover approval for
lower strength levels provided that the type of steel and
1.5.1 The approval tests are to be witnessed by the Sur- the conditions of supply are the same.
veyor at the manufacturer’s plant and the execution of the Where the number of tests differs from those shown in [1.7],
plant inspection in operation may be required by the Sur- the program is to be confirmed by the Society before the
veyor during the visit for the approval. tests are carried out.
If the testing facilities are not available at the works, the
tests are to be carried out at laboratories accepted by the 1.6.3 Sampling and position of test specimens
Society.
The test samples are to be taken in accordance with NR216
Materials and Welding, Ch 2, Sec 2.
1.6 Approval test program
The test specimens and testing procedures are to be, as a
rule, in accordance with NR216 Materials and Welding,
1.6.1 Selection of the test product
Ch 1, Sec 2.
For each grade of steel, each manufacturing process and
each condition of supply, two test products originating from
different heats and representing the average and the maxi- 1.7 Approval tests
mum dimensions to be approved are in general to be
selected. 1.7.1 The tests to be carried out are indicated in Tab 1.
1.6 Approval test program 1.6.3 Sampling and position of test specimens
1.6.1 Selection of test product The test samples are to be taken in accordance with NR216
The selected test products shall be representative of the type Materials and Welding, Ch 2, Sec 3 for the type of steel
and weight range for which approval is requested. forging involved.
The approval may be requested for the following type of
The test specimens and testing procedures are to be, as a
steel:
rule, in accordance with NR216 Materials and Welding,
• Carbon steels
Ch 1, Sec 2.
• Carbon-manganese steels
• Low-alloy steels
• Alloy steels 1.7 Approval tests
• Stainless steels.
1.7.1 The tests to be carried out are indicated in Tab 1.
When the approval is applied for one type of steel, two forg-
ings, from two different casts, representative of the range of
forgings to be approved are to be tested. When the approval 1.7.2 Results and records
is applied for carbon, carbon-manganese, low-alloy and All the results, which are to comply with the requirements
alloy steels, it may be reduced to one cast only per each of NR 216 Materials and Welding and approved material
type of steel.
specification, are evaluated for the approval; depending on
1.6.2 Extent of the approval tests the results, particular limitations or testing conditions, as
The extent of the test program is specified in [1.7]; it may be deemed appropriate, may be specified in the approval doc-
modified on the basis of the preliminary information sub- ument.
mitted by the manufacturer.
In particular a reduction of the indicated number of prod- All the information required under [1.3] is to be collected
ucts and grades to be tested or complete suppression of the by the manufacturer and put in the technical documenta-
approval tests may be accepted by the Society taking into tion which will include all the results of the tests and opera-
account: tion records relevant to steelmaking, casting, hot forgings
a) Approval already granted by other Classification Societ- operations with total reduction ratio, and, heat treatment of
ies and documentation of approval tests performed. each tested product.
b) Grades of steel to be approved and availability of long
term statistic results of chemical and mechanical prop- When steel is cast in a mill other than where the steel forg-
erties. ings are manufactured, the steelmaker’s certificate stating
Where the number of tests differs from those shown in the manufacturing process, the grade of steel, the cast num-
[1.7], the program is to be confirmed by the Society before ber and the relevant ladle analysis is to be provided for each
the tests are carried out. tested product.
1.6.2 Extent of the approval tests The test specimens and testing procedures are to be, as a
The extent of the test program is specified in [1.7]; it may be rule, in accordance with NR216 Materials and Welding,
modified on the basis of the preliminary information sub- Ch 1, Sec 2.
mitted by the manufacturer.
In particular a reduction of the indicated number of prod- 1.7 Approval tests
ucts and grades to be tested or complete suppression of the
approval tests may be accepted by the Society taking into 1.7.1 The tests to be carried out are indicated in Tab 1.
account:
a) Approval already granted by other Classification Societ- 1.7.2 Results and records
ies and documentation of approval tests performed.
All the results, which are to comply with the requirements
b) Grades of steel to be approved and availability of long of NR 216 Materials and Welding and approved material
term statistic results of chemical and mechanical prop- specification, are evaluated for the approval; depending on
erties. the results, particular limitations or testing conditions, as
Where the number of tests differs from those shown in deemed appropriate, may be specified in the approval doc-
[1.7], the program is to be confirmed by the Society before ument.
the tests are carried out.
All the information required under [1.3] is to be collected
1.6.3 Sampling and position of test specimens by the manufacturer and put in the technical documenta-
The test samples and the test specimens are to be taken in tion which will include all the results of the tests and opera-
accordance with NR216 Materials and Welding, Ch 2, Sec 4 tion records relevant to steelmaking, casting, and, heat
for the type of steel casting involved. treatment of each tested product.
1.8.1 The extent of the test program is specified in [1.9]; it 1.10.1 General
may be modified on the basis of the preliminary information Weldability tests are required for plates and are to be car-
submitted by the manufacturer. ried out on samples of plate (average and maximum thick-
ness) for alloys newly developed or newly manufactured.
In particular a reduction of the indicated number of heats,
dimensions and grades to be tested may be accepted by the 1.10.2 Preparation and welding of the test assemblies
Society taking into account: One butt weld is to be prepared for each thickness tested.
a) Approval already granted by other Classification Societ- The welding procedure should be as far as possible in
ies and documentation of approval tests performed. accordance with the normal welding practice used at the
yards for the type of aluminium alloy in question.
b) Grades of aluminium alloys to be approved and avail-
The welding parameters including consumables designation
ability of long term statistic results of chemical and
and diameter, heat input, number of passes, etc. are to be
mechanical properties.
reported.
When long term statistic results are available for following
1.10.3 Type of tests
alloys, approval tests may be reduced to routine tests as per
NR216 Materials and Welding, Ch 3, Sec 2: The relevant tests required in NR216 Materials and Weld-
• Series 5000 alloys: ing, Ch 5, Sec 4, [6] are to be performed with the following
tests in addition:
5083 - 5086 - 5052 - 5154A - 5454 - 5754 in temper
• Corrosion tests on as welded samples and welded sam-
state 0 - H111 - H112 - H116 - H321 - H32 - H22 - H34
ples artificially aged at 100°C during 7 days: ASTM G66
- H24 - H36 - H26
(ASSET test) and ASTM G67 (NAMLT test)
• Series 6000 alloys: These tests are to be repeated with the surface of the
6005A - 6106 - 6061 - 6082 - 6060 in temper state T4 - samples slightly machined (about 10% of original thick-
T5 - T6. ness material removed)
• Stress corrosion tests in marine atmosphere such as
On the other hand, an increase of the number of heats and bending tests with a yield stress on the tension side up
thicknesses to be tested may be required in the case of to 90% of heat affected zone yield strength performed
newly developed types of aluminium alloys or manufactur- on as welded samples and welded samples artificially
ing processes. aged at 100°C during 7 days
These tests are to be repeated with the surface of the
Where the number of tests differs from those shown in [1.9],
samples slightly machined (about 10% of original thick-
the program is to be confirmed by the Society before the
ness material removed).
tests are carried out.
1.10.4 Other tests
1.9 Tests on base material Additional tests such as fatigue tests may be required in the
case of newly developed type of aluminium alloys outside
1.9.1 The tests to be carried out are indicated in Tab 1. the scope of the NR216 Materials and Welding, or when
deemed necessary by the Society.
1.10.5 Results and records tion which will include all the results of the tests and opera-
All the results, which are to comply with the requirements tion records relevant to alloy making, casting, and, heat
of NR 216 Materials and Welding and approved material treatment of each tested product.
specification, are evaluated for the approval; depending on
the results, particular limitations or testing conditions, as When the aluminium alloys are cast in a work other than
deemed appropriate, may be specified in the approval doc- where they are manufactured into finished products, the
ument. work’s certificate stating the manufacturing process, the
All the information required under [1.2] is to be collected grade of aluminium alloy, the cast number and the relevant
by the manufacturer and put in the technical documenta- ladle analysis is to be provided for each tested product.
1.1 Scope 1.4.1 The approval tests are to be witnessed by the Sur-
veyor at the manufacturer’s plant and the execution of the
plant inspection in operation may be required by the Sur-
1.1.1 This Section gives the scheme for the approval of the veyor during the visit for the approval.
manufacturing process of explosion bonded alumin-
ium/steel transition joints for ships. If the testing facilities are not available at the works, the
tests are to be carried out at laboratories accepted by the
Society.
1.2 Manufacturing process specification
1.2.1 The following information is to be supplied by the 1.5 Selection of the test product
manufacturer:
1.5.1 For each type of joint to be approved, enough mate-
a) Manufacturer’s specification which is to contain follow- rial is to be selected from current production to perform the
ing information: approval tests.
• Aluminium grades and steel grades used for the
manufacture of the joints 1.6 Extent of the approval tests
• Dimensions of the joints and thickness of the various
layers 1.6.1 The extent of the test program is specified in [1.7]; it
may be modified on the basis of the preliminary information
• Guaranteed mechanical properties of the joints. submitted by the manufacturer. In particular a reduction of
the approval test program may be accepted by the Society
b) Description of the manufacturing process including taking into account:
inspection points
c) Non destructive tests procedures a) Approval already granted by other Classification Societ-
ies and documentation of approval tests performed
d) Recommendations for fitting, welding, cutting...
b) Type of joints to be approved and availability of statistic
Where any part of the manufacturing process is assigned to results of mechanical properties.
other companies or other manufacturing plants, additional
information required by the Society is to be included. On the other hand, an increase of the number of tests may
be required in the case of newly developed type of joints.
1.3 Documents to be submitted for Where the number of tests differs from those shown in [1.7],
changing the approval conditions the program is to be confirmed by the Society before the
tests are carried out.
1.3.1 The manufacturer has to submit to the Society the
documents required in [1.2] together with the request of 1.7 Approval tests
changing the approval conditions, in case of the following:
a) Change of the manufacturing process 1.7.1 The tests to be carried out are indicated in Tab 1.
1 Anchor chain cables and accessories d) Description of quality control during production with
inspection points
for ships
e) Procedures or instructions for:
1.1 Scope • heat treatment and associated control
• non destructive tests of finished links
1.1.1 This Section gives the scheme for the approval of the
manufacturing process of flash butt-welded or cast anchor • type, extent and acceptance criteria.
chain cables for ships and associated cast or forged acces- Where any part of the manufacturing process is assigned to
sories (end link, enlarged link, anchor shackle, joining other companies or other manufacturing plants, additional
shackle, Kenter shackle and swivel). information required by the Society is to be included.
The approval scheme for other manufacturing process is
subjected to case by case consideration. 1.2.3 Forged accessories
The following information is to be supplied by the manufac-
1.2 Manufacturing process specification turer:
a) Steel grade specification, size range and drawing of
1.2.1 Flash butt-welded chain cables each type of accessory
The following information is to be supplied by the manufac-
b) Raw materials (ingots, round bars...) suppliers name &
turer:
address
a) Steel grade specification for round bars and name and
c) Description of forging process
address of suppliers
b) Size range to be approved and drawing of common d) Heat treatment furnaces, type, equipment for tempera-
chain link (including stud details for studlink chains) ture monitoring and its calibration
c) Description of the manufacturing process with details e) Description of quality control during production from
about: raw materials to finished products with inspection
points
• welding machines
f) Procedures or instructions for:
• heat treatment furnaces, type, equipment for tem-
perature monitoring and its calibration. • heat treatment and associated control
d) Description of quality control during production from • non destructive tests of finished products
raw materials to finished products with inspection • type, extent and acceptance criteria.
points
Where any part of the manufacturing process is assigned to
e) Procedures or instructions for: other companies or other manufacturing plants, additional
• heat treatment and associated control information required by the Society is to be included.
• non destructive tests of weld joint and finished links
1.2.4 Cast accessories
• type, extent and criteria
The following information is to be supplied by the manufac-
• non destructive tests of stud weld, as applicable. turer:
Where any part of the manufacturing process is assigned to a) Steel grade specification, size range and drawing of
other companies or other manufacturing plants, additional each accessory
information required by the Society is to be included.
b) Description of steelmaking and casting process
1.2.2 Cast chain cables c) Heat treatment furnaces, type, equipment for tempera-
The following information is to be supplied by the manufac- ture monitoring and its calibration
turer:
d) Description of quality control during production
a) Steel grade specification, size range and drawing of
common chain link e) Procedures or instructions for:
b) Description of steelmaking and casting process • heat treatment and associated control
c) Heat treatment furnaces, type, equipment for tempera- • non destructive tests of finished products
ture monitoring and its calibration • type, extent and criteria.
Where any part of the manufacturing process is assigned to Where the number of tests differs from those shown in [1.7],
other companies or other manufacturing plants, additional the program is to be confirmed by the Society before the
information required by the Society is to be included. tests are carried out.
1.3 Documents to be submitted for 1.6.2 Flash butt welded chain cable
changing the approval conditions Each grade and type of chain is to be tested.
1.3.1 The manufacturer has to submit to the Society the Approval for studlink chain cable of any grade may cover
documents required in [1.2] together with the request of approval for studless chain cable of same diameter provided
changing the approval conditions, in case of the following: that the method of manufacture and condition of supply are
similar.
a) Change of the manufacturing process
Approval for common links may cover approval for
b) Change of the range of approval (maximum diameter,
enlarged link and end link up to tested diameter provided
steel grade...).
that the method of manufacture and condition of supply are
However, where the documents are duplicated by the ones similar.
at the previous approval for the same type of product, part
or all of the documents may be omitted except the approval 1.6.3 Cast chain cable
test program.
Each grade and type of chain is to be tested.
Approval for studlink chain cable of any grade may cover
1.4 Approval survey approval for studless chain cable of same diameter provided
1.4.1 The approval tests are to be witnessed by the Sur- that the method of manufacture and condition of supply are
veyor at the manufacturer’s plant and the execution of the similar.
plant inspection in operation may be required by the Sur- Approval for common links may cover approval for
veyor during the visit for the approval. enlarged link and end link up to tested diameter provided
If the testing facilities are not available at the works, the that the method of manufacture and condition of supply are
tests are to be carried out at laboratories accepted by the similar.
Society.
1.6.4 Forged or cast accessories
1.5 Selection of the test product Each type of manufacturing process is to tested.
For a type of accessory, approval for any grade of steel may
1.5.1 Flash butt welded chain cable cover approval for lower strength grades provided that the
One chain length with suitable number of links for the steel type, method of manufacture and condition of supply
approval tests is to be selected as follows: are similar.
• Maximum diameter to be approved Each type of accessory is to be tested. However approval for
• The length is to be heat treated using current production anchor shackle may cover approval for joining shackle up
equipment and procedures. to the same diameter provided that the method of manufac-
ture and condition of supply are the same.
1.5.2 Cast chain cable
One chain length with suitable number of links for approval
tests is to be selected as follows:
1.7 Approval tests and documentation
• Maximum diameter to be approved 1.7.1 Approval tests for flash butt welded chain
• The length is to be heat treated using current production cables
equipment and procedures. In addition to test reports, documentation relative to the
manufacturing process parameters of the length tested is to
1.5.3 Forged or cast accessories
be supplied and is to include:
Suitable quantity of each type of accessories is to be
selected as follows: • Heating and hot bending of round bars
• Maximum diameter to be approved • Welding parameters
• The items are to be heat treated using current produc- • Stud insertion and all information about stud welding,
tion equipment and procedures. as applicable
• Heat treatment.
1.6 Extent of the approval tests
The tests to be carried out are indicated in Tab 1.
1.6.1 The extent of the test program is specified in [1.7]; it
may be modified on the basis of the preliminary information 1.7.2 Approval tests for cast chain cables
submitted by the manufacturer. In particular a reduction of
the approval test program may be accepted by the Society The tests to be carried out are indicated in Tab 2.
taking into account approval already granted by other Clas-
sification Societies and documentation of approval tests 1.7.3 Approval tests for cast or forged accessories
performed. The tests to be carried out are indicated in Tab 3.
1.7.4 Results and records tion which will include all the results of the tests and opera-
All the results, which are to comply with the requirements tion records relevant to alloy making, casting, and, heat
of NR 216 Materials and Welding and approved material treatment of each tested product.
specification, are evaluated for the approval; depending on
the results, particular limitations or testing conditions, as When steel is cast in a work other than where the ship
deemed appropriate, may be specified in the approval doc- chain cables and/or accessories are manufactured, the
ument. steelmaker’s certificate stating the manufacturing process,
All the information required under [1.2] is to be collected the grade of steel, the cast number and the relevant ladle
by the manufacturer and put in the technical documenta- analysis is to be provided for each tested product
Symbols
σ = load / WS tS
Rolling
1 ESSO test method direction
500 mm
1.1 Scope
1.2 Purpose
29 mm
1.2.1 The purpose of this test is to encourage the perfor- 500 mm and above
mance of a standard test for assessment of brittle crack
arrest toughness with temperature gradient and to obtain
the corresponding brittle crack arrest toughness value Kca. Thicknesses are original thicknesses.
LS
LR
LP
1.4 Test equipment 1.6.2 Cooling and heating may be implemented from one
side on the side opposite the side on which the thermocou-
1.4.1 The test equipment to be used is to consist of pin load ple is fitted, or from both sides.
type hydraulic test equipment capable of tensile tests.
1.6.3 The temperature gradient is to be controlled in the
1.4.2 The distance between the pins is to be not less than range of 0,25°C/mm to 0,35°C/mm in the range of width
2000 mm. The distance between pins refers to the distance
from 0,3 WS to 0,7 WS at the central part of the test speci-
between the centres of the pin diameters.
men.
1.4.3 Drop weight type or air gun type impact equipment
may be used for the impact energy required for generating 1.6.4 When the specific temperature gradient is reached,
brittle cracks. the temperature is to be maintained for more than 10 min-
utes, after which the specified test load may then be
1.4.4 The wedge is to have an angle greater than the upper applied.
notch of the test specimen, and an opening force is to be
applied on the notch. 1.6.5 After maintaining the test load for at least 30 seconds,
a brittle crack is to be generated by impact. The standard
1.5 Test preparation impact energy is taken as 20 to 60 J per 1 mm plate thick-
ness. If the brittle crack initiation characteristics of the base
1.5.1 The test piece is to be fixed directly to the pin load jig metal are high, and it is difficult to generate a brittle crack,
or by means of weld joint through the tab plate. The overall the impact energy may be increased to the upper limit of
length of the test specimen and tab plate is to be not less 120 J per 1 mm plate thickness.
than 3 WS.
The thickness and width of the tab plate are to be such that: 1.6.6 Loading is stopped when the initiation, propagation,
and arrest of crack have been confirmed. Normal tempera-
0,8 tS ≤ tR ≤ 1,5 tS
ture is restored, and if necessary, the ligament is broken by
WS ≤ WR ≤ 2 WS gas cutting and forcibly the specimen is broken by using the
testing machine. Or, after the ductile crack has been propa-
If the tab plate has a thickness tR smaller than the thickness gated to an adequate length with the testing machine, the
tS of the test specimen, the reflection of stress wave is to be ligament is broken by gas cutting.
on the safer side for the assessment; therefore, considering
the actual circumstances for conducting the test, the lower
1.6.7 After forcing the fracture, photos of the fractured sur-
limit of thickness is taken as 0,8 tS.
face and the propagation route are to be taken, and the
1.5.2 Thermocouples are to be fitted at 50 mm pitch on the crack length is to be measured.
notch extension line of the test specimen.
1.7 Test results
1.5.3 If the brittle crack is estimated to deviate from its pre-
sumed course, thermocouples are to be fitted at two points
separated by 100 mm on the line of load from the notch 1.7.1 The distance from the top of the test specimen includ-
extension line at the centre of width of the test specimen. ing the notch to the maximum length in the plate thickness
direction of the arrested crack tip is to be measured. If the
1.5.4 If dynamic measurements are necessary, strain gauges crack surface deviates from the surface normal to the line of
and crack gauges are to be fitted at specific locations. load of the test specimen, the projected length on the sur-
face normal to the line of load is to be measured. In this
1.5.5 The test specimen is to be fixed to the testing case, if the trace of brittle crack arrest is clearly visible on
machine together with the tab plate after welding and the the fractured surface, the first crack arrest position is taken
pin load jig. as the arrest crack position.
1.8 Report 1.8.3 From effective test results measured at more than
3 points, the linear approximation equation is to be deter-
1.8.1 The following items are to be reported: mined on the Arrhenius plot, and Kca at the desired temper-
• testing machine specifications; testing machine capac- ature is to be calculated. In this case, data should exist on
ity, distance LP between pins both sides, that is, the high temperature and low tempera-
• load jig dimensions; tab plate thickness tR , tab plate ture sides around the assessed temperature.
width WR, test specimen length including tab plate
Figure 3 : Necessary conditions
(LS + 2 LR)
of arrest crack position
• test specimen dimensions; plate thickness tS , test speci-
men width WS and length LS
• test conditions; preload stress, test stress, temperature
distribution (figure or table) impact energy 0,3Ws
60°
• test results; crack arrest length aa , temperature gradient
at arrest position, brittle crack arrest toughness value Kca 0,7Ws
• dynamic measurement results (if measurement is carried
out); crack growth rate, strain change
• test specimen photos; fracture route, fractured surface.