1

Ministry of Defence Defence Standard 02-304 Part 4
Issue 2 Publication Date 12 September 2002
Shafting Systems and Propulsors
Part 4 Requirements for Repair of Main Propulsion Shafting
Category 2
AMENDMENTS ISSUED SINCE PUBLICATION AMD NO DATE OF ISSUE TEXT AFFECTED SIGNATURE & DATE
Revision Note This Issue of this Standard has been prepared to incorporate changes to text and presentation. The technical content has been updated in line with current practice. Historical Record Def Stan 02-304 Part 4 Issue 1 NES 304 Part 4, Issue 1 1 April 2000 1 December 1990
DEFENCE STANDARD 02304 SHAFTING SYSTEMS AND PROPULSORS PART 4 ISSUE 2 REQUIREMENTS FOR REPAIR OF MAIN PROPULSION SHAFTING
This Defence Standard is authorized for use in MOD contracts by the Defence Procurement Agency and the Defence Logistics Organisation
Published by: Defence Procurement Agency, An Executive Agency of The Ministry of Defence, UK Defence Standardization, Kentigern House, 65 Brown Street, Glasgow, G2 8EX. 1
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)
SCOPE 1. Defence Standard (Def Stan) 02304 Part 4 specifies the requirements for: a. b. c. 2. 3. Assessment of the rectification and repairs necessary to restore distorted, worn or corroded main propulsion shafts, couplings and sleeves to a serviceable condition; Performance of such treatment and repairs; Post-repair treatment and inspection. Shaft materials include carbon steel, stainless steel and non-ferrous alloys.
Individual requirements or limitations relating to shafts for specific vessels are included. Rectification and repair techniques considered include: a. b. c. d. e. f. Grinding; Machining; Welding; Metal spraying; Straightening; Plastic coating.
4. 5.
Post-repair operations include heat treatment, surface treatment and inspection. Acceptance standards are defined. The requirement to raise and maintain a repair history document for each main propulsion shaft is stated.
FOREWORD Sponsorship 1. 2. 3. This Defence Standard is sponsored by the Defence Logistics Organisation (DLO), Ministry of Defence (MOD). It is to be applied as required by any DLO contract for Main Propulsion Shafting Auxiliaries. The complete Def Stan 02304:
Shafting Systems and Propulsors, comprises:
Part 1: Design Requirements for Main Propulsion Shafting; Part 2: Design Requirements for Main Propulsion Shafting Auxiliaries; Part 3: Manufacturing and Detail Design Requirements for Propulsors; Part 4: Requirements for Repair of Main Propulsion Shafting; Part 5: Requirements for the Handling, Maintenance and Repair of Propellers for HM Surface Ships. 2
4.
Any user of this 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 Page 1, and those directly applicable to a particular contract are to be dealt with using existing departmental procedures. If it is found to be unsuitable for any particular requirement, MOD is to be informed in writing of the circumstances. No alteration is to be made to this standard except by the issue of an authorized amendment. Unless otherwise stated, reference in this Def Stan to approval, approved, authorized and similar terms means by the MOD in writing. Any significant amendments that may be made to this 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. This standard has been reissued because of technical update. Conditions of Release General
5. 6. 7. 8. 9.
10.
This standard 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 standard is used for any other purpose. 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. The Crown reserves the right to amend or modify the contents of this standard without consulting or informing any holder. MOD Tender or Contract Process 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. When this 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. When Defence Standards are incorporated into MOD contracts, users are responsible for their correct application and for complying with contractual and any other statutory requirements. Compliance with a Defence Standard does not of itself confer immunity from legal obligations. Categories of Defence Standards The Category of this Def Stan 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: 3
11.
12.
13.
14.
15.
16.
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. Related Documents 17. In the tender and procurement processes the related documents listed in each section and Annex A can be obtained as follows: a. British Standards British Standards Institution, 389 Chiswick High Road, London, W4 4AL. Defence Procurement Agency, An Executive Agency of The Ministry of Defence, UK Defence Standardization, Kentigern House, 65 Brown Street, Glasgow, G2 8EX. Tender or Contract Sponsor to advise.
b.
Defence Standards,
c. 18.
Other documents
All applications to Ministry Establishments for related documents are to quote the relevant MOD Invitation to Tender or Contract number and date, together with the sponsoring Directorate and the Tender or Contract Sponsor. Prime Contractors are responsible for supplying their subcontractors with relevant documentation, including specifications, standards and drawings. Health and Safety Warning
19.
20.
This standard may call for the use of processes, substances and/or procedures that may be injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way absolves either the supplier or the user from statutory obligations relating to health and safety at any stage of manufacture or use. Where attention is drawn to hazards, those quoted may not necessarily be exhaustive. This standard has been written, and is to be used, taking into account the policy stipulated in JSP 430 MOD Ship Safety Management System Handbook. Additional Information (There is no relevant information included)
21.
CONTENTS Page No TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Sponsorship ............................................................... 2 Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Categories of Defence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SECTION SECTION SECTION 1. 2. 3. 3.1 3.1.1 3.1.2 3.1.3 3.2 3.2.1 3.2.2 3.2.3 Figure 3.1 Figure 3.2 3.2.4 3.2.5 Table 3.1 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.3 3.3.1 3.3.2 3.3.3 3.3.4 3.3.4.1 3.3.5 Table 3.2 3.3.6 3.3.7 PERFORMANCE SPECIFICATION . . . . . . . . . . . . . . . . . . . 9 NATIONAL/INTERNATIONAL REGULATIONS . . . . . . . . 9 MILITARY STANDARDS/REQUIREMENTS . . . . . . . . . . . . 9 Preliminary Inspection and Defect Removal . . . . . . . . . . . . . 9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Defect Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Bore Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assessment of Repairs Required . . . . . . . . . . . . . . . . . . . . . . . 10 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Limitations on Repair by Grinding or Machining . . . . . . . . 11 Outboard Shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Requirements for Blending Isolated Defects . . . . . . . . . . . . . 12 Profile Requirements for Repair of Limited Areas by Local Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inboard Shafting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bearing Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Limiting Depth of Metal Removal on Outboard Shafts without Subsequent Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Non-ferrous and Stainless Steel Shafting . . . . . . . . . . . . . . . . 14 Limitations on Repair by Welding . . . . . . . . . . . . . . . . . . . . . 14 Limitations on Repair by Thermal Spraying . . . . . . . . . . . . 14 Coupling Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Straightening of Shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Location and Measurement of Eccentricity . . . . . . . . . . . . . . 15 Selection of Straightening Method . . . . . . . . . . . . . . . . . . . . . 16 Thermal Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Temperature Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Carbon and Low Alloy Steel Shafts . . . . . . . . . . . . . . . . . . . . 17 Recommended Temperature Ranges for Thermal Straightening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Stainless Steel and Non-ferrous Alloy Shafts . . . . . . . . . . . . . 18 Mechanical Straightening (all materials) . . . . . . . . . . . . . . . . 18 5
3.3.8 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 Figure 3.3 3.6.7 3.6.8 3.6.9 3.6.9.1 3.6.10 3.6.11 Table 3.3 3.6.12 Table 3.4 3.6.13 Table 3.5 3.6.14 3.6.15 3.6.16 3.6.17 3.6.18 3.6.19 Figure 3.4 3.7 3.7.1 3.7.2 3.7.2.1 3.7.2.2 3.7.2.3 3.7.2.4 3.7.2.5 3.7.3 3.7.3.1 3.7.3.2 3.7.3.3
Page No Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Repair by Grinding and/or Machining . . . . . . . . . . . . . . . . 19 Shaft Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Tail Shaft Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Shaft Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Shaft Sleeve Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Repair by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Welding Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Welding Procedure Specification . . . . . . . . . . . . . . . . . . . . . 22 Approval Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Organization Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 22 Welding Procedure Qualification . . . . . . . . . . . . . . . . . . . . . 23 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Welding Consumables Approval . . . . . . . . . . . . . . . . . . . . . . 24 Qualification of Automatic Welding Equipment . . . . . . . . . 24 Weld Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Local Repairs by Manual Welding . . . . . . . . . . . . . . . . . . 24 Excavation for Manual Weld Repairs (Cross Section) . . . . 25 Machining for Major Repairs . . . . . . . . . . . . . . . . . . . . . . . . 25 Preparation of Welding Consumables . . . . . . . . . . . . . . . . . 25 Production Welding Requirements . . . . . . . . . . . . . . . . . . . . 25 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Starts and Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Shaft Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Shaft Distortion Limits for Automatic Welding Process . . 27 Preheat and Interpass Temperature Control . . . . . . . . . . . . 27 Preheat and Interpass Temperatures . . . . . . . . . . . . . . . . . . 28 Heat Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Heat Input Limits for Shaft Weld Repair . . . . . . . . . . . . . . 29 Post-heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Interpass Weld Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Post-weld Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Post-weld Dressing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Post-weld Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Repair of Weld Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Local Weld Repairs Under Cladding . . . . . . . . . . . . . . . . . . 30 Thermal Spray Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 31 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Qualification of Spray Coating Procedures . . . . . . . . . . . . . 31 Qualification of Automatic Spray Coating Equipment . . . 32 Qualification of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Organization Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 32 Repair Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Repair Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Preparation for Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Spraying Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 6
3.7.3.4 3.7.3.5 3.7.3.6 3.7.3.7 3.7.3.8 3.7.3.9 3.7.3.10 3.7.3.11 3.7.4 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 3.9 3.9.1 3.9.2 3.9.3 3.9.4 3.9.5 3.9.6 3.9.7 3.10 3.11 3.12 SECTION SECTION ANNEX ANNEX ANNEX ANNEX 4. 5. A. B. C. D. Figure D.1 Figure D.2 Figure D.3 Figure D.4 Figure D.5 Figure D.6 Figure D.7
Page No Gas Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Powder Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Automatic and Semi-automatic Processes . . . . . . . . . . . . . . 33 Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Mechanical Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Intermediate Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Sealing of Sprayed Coatings . . . . . . . . . . . . . . . . . . . . . . . . . 34 Surface Finishing of Sealed Coatings . . . . . . . . . . . . . . . . . . 35 Inspection of Sealed Coating . . . . . . . . . . . . . . . . . . . . . . . . . 35 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Heating Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Local Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Temperature Control and Indication . . . . . . . . . . . . . . . . . . 36 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Final Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Visual Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Non-destructive Examination . . . . . . . . . . . . . . . . . . . . . . . . 38 Straightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Surface Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Preservation and Protection . . . . . . . . . . . . . . . . . . . . . . . . . 39 Repair History Document . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Electrochemical Metallization . . . . . . . . . . . . . . . . . . . . . . . . 40 DESIGN REQUIREMENTS/GUIDANCE . . . . . . . . . . . . . . 40 CORPORATE KNOWLEDGE AND EXPERIENCE . . . . . 40 RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 ABBREVIATIONS AND DEFINITIONS . . . . . . . . . . . . . . . 42 PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . . . . . . . . 44 WELDING QUALIFICATION TESTS . . . . . . . . . . . . . . . . . Qualification Test Plate: MMA and MMIG . . . . . . . . . . . . . Qualification Test Plate: MTIG . . . . . . . . . . . . . . . . . . . . . . . . Qualification Test Assembly: Automatic Welding . . . . . . . . . Test Plate Assembled in Welding Jig . . . . . . . . . . . . . . . . . . . Preparation of Destructive Examination Test Pieces: MMA, MMIG, MTIG Qualification . . . . . . . . . . . . . . . . . . . . Location of Hardness Traverses . . . . . . . . . . . . . . . . . . . . . . . Chemical Analysis Sampling of Weld Overlay . . . . . . . . . . . 7 45 45 45 46 46 48 49 50
Page No ANNEX E. Figure E.1 Figure E.2 F. Table F.1 Figure F.1 Figure F.2 Figure F.3 Figure F.4 SPRAY DEPOSITION QUALIFICATION TESTS . . . . . . . 50 Spray Deposition Qualification Test Piece . . . . . . . . . . . . . . . 51 Extraction of Test Specimens . . . . . . . . . . . . . . . . . . . . . . . . . . 52 ULTRASONIC EXAMINATION OF WELDS AND WELD CLADDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . Probe Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ultrasonic Reference Piece for Examination of Qualification Test Pieces for Manual Weld Repairs using Matching Fillers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ultrasonic Reference Piece for Examination of Qualification Test Pieces for Manual Weld Repair using Dissimilar Metal Filler . . . . . . . . . . . . . . . . . . . . . . . . . . Ultrasonic Reference Piece for Examination of Shafts Repaired with Matching Fillers . . . . . . . . . . . . . . . . . . . . . . . Ultrasonic Reference Piece for Examination of Shafts Repaired with Dissimilar Metal Filler . . . . . . . . . . . . . . . . . . 52 53 54 54 55 55
ANNEX
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) 1. PERFORMANCE SPECIFICATION This Defence Standard contains no Performance Specification information. 2. NATIONAL/INTERNATIONAL REGULATIONS This Defence Standard contains no National/International Regulations information. 3. MILITARY STANDARDS/REQUIREMENTS Related Documents: BS ISO 10012 Part 2; BS 970; BS 1134; BS 2872; BS 3076; DEF STAN 02304 Part 1; DEF STAN 02729 Parts 2 and 4; DEF STAN 02747; DEF STAN 02769; DEF STAN 02773; DEF STAN 02828; DEF STAN 02830 Part 1; DEF STAN 02833 Part 2; DEF STAN 02848 Part 1; NAVSHIPS 0900-038-6010;see also Annex A. 3.1 3.1.1 Preliminary Inspection and Defect Removal Inspection a. Preliminary inspection of the shaft is to be performed for local defects, which are then to be removed by mechanical means before assessment of the defect area, as detailed in Clause 3.2 for further rectification. All inspections are to be carried out by the Contractor in the presence of an Authorised Representative of the Project Manager (PM) or Equipment Support Manager (ESM). Where the shaft has a protective covering, e.g. epoxy resin bandage, this is to be visually inspected for perforations or damage and all defective areas marked or plotted. Swelling of a protective coating can result from corrosion of the underlying metal surface and such areas are therefore to be meticulously examined. Any defective areas of protective covering are to be removed and the underlying shaft areas cleaned to facilitate inspection. Alternatively, to obviate the need for subsequent local repair of the coating, the entire coating may be removed and replaced after all repair operations are completed. All exposed areas of the shaft are to be inspected visually, by either magnetic particle or dye penetrant techniques and by ultrasonic test. Defective areas are to be marked or plotted. After inspection and any necessary repairs, the protective covering is to be restored in accordance with Clause 3.10. Non-destructive Examination (NDE) is to be in accordance with the requirements and limitations of Clauses 3.9.3a to 3.9.3f . Defects to be plotted are to include: (1) (2) Cracks; Pitting and corrosion; 9
b.
c.
d.
e.
f. g. h.
(3) i.
Wear.
Areas of steel shafts which show circumferential grooving or chain pitting, often caused by electrochemical corrosion adjacent to non-ferrous fittings, are to be subjected to magnetic particle examination and other suitable NDE. If adjacent to gunmetal liners, these may be cut back up to 25 mm to facilitate such examination. Where there is significant general corrosion on uncoated lengths of shaft, sufficient to reduce the effectiveness of visual or NDE, the shaft surface is to be cleaned by light machining before completing inspection. The maximum permissible depth of the clean-up cut is 0.75 mm.
j.
3.1.2
Defect Removal a. Where defects are detected e.g. cracks or corrosion, the extent of which are not clearly defined, the surface areas containing defects are to be dressed, by grinding or machining, to remove the defects to assess the minimum repair to be carried out in accordance with Clause 3.2. Where the extent of the defect, e.g. grooving or other areas of wear, is clearly defined, assessment may be carried out without prior dressing. Removal of excess metal, e.g. for weld preparation, is not required at this stage. Magnetic particle or dye penetrant examination, in accordance with Def Stan 02729 Parts 2 and 4, is to be used to confirm the complete removal of defects. Wire brushes are to be of carbon steel or stainless steel, and free from dirt, rust and grease. Carbon steel brushes are to be used only on carbon and low alloy steel and must not come into contact with other metals. Stainless steel brushes may be used to clean any metal, but each brush is to be identified for use on only one metal and is not to be used on other metals. Grinding wheels are to be rubber or resin-bonded aluminium oxide or silicon carbide. Each wheel is to be clearly identified for use on only one metal and is not to be used on other metals. Files, burrs and deburring tools are to be of tungsten carbide and are to be thoroughly cleaned before each use, to prevent contamination by differing metals.
b. c.
d.
e. 3.1.3
Bore Inspection a. The bore of each hollow shaft is to be visually examined for corrosion or any other obvious defects. Rectification is to be in accordance with Clause 3.4.3a .
3.2 3.2.1
Assessment of Repairs Required General a. An examination is to be made of grooves and other areas of wear, together with those areas from which defects have been excavated, in order to assess the minimum repair work required to produce a serviceable shaft or sleeve which will meet the relevant acceptance standards in Clause 3.9. Selection of the most technically suitable and economic process for each repair is to be based upon: 10
b.
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) (1) (2) (3) (4) (5) c. The size and location of the area to be repaired; The technical limitations of other processes; The shaft material; The repair facilities available; Relative costs of other processes.
The processes to be used for repair are normally to be selected from: (1) (2) (3) (4) (5) Blending; Machining; Welding; Metal or ceramic spraying, see Clause 3.2.9b . Additionally, for certain limited applications as described in Clause 3.12, Electrochemical Metallization may be used.
d. e.
Where appropriate to a specific repair, a combination of the processes in Clause 3.2.1c is permissible. Repairs by bath electroplating are not permitted. However, where no alternative is available, any proposal to undertake such repairs is to be forwarded to DLO, MPS 212, for consideration. Wherever possible and within the limitations contained in Clauses 3.2.2a to 3.2.3g , complete repair is to be effected by local grinding or machining. In any repair procedures, the use of grinding wheels, burrs, etc., is to be subject to the limitations of Clauses 3.1.2b to 3.1.2d . Repair by welding is to be subject to the limitations detailed in Clauses 3.2.8a to 3.2.8d . In the assessment of any proposed repair by spray deposition, information contained in Def Stan 02828 on processes and equipment, together with limitations on their use and design considerations relevant to shafts are to be taken into consideration. Mandatory requirements of Def Stan 02828 are to apply to shaft repair.
f. g. h. i.
3.2.2
Limitations on Repair by Grinding or Machining a. Unless specifically permitted by Clauses 3.2.3a to 3.2.7b , or approval is given by the Technical Authority where repair is completed by metal removal without subsequent welding, the depth of metal removal is not to reduce any section below its minimum design thickness.
3.2.3
Outboard Shafting a. Single rounded defects may be removed and faired by local grinding, within the following limitations: 11
(1) (2) (3)
The maximum depth of excavation is to be 12 mm; The profile of any excavation is to conform to the limits of Figure 3.1; The separation of any two such excavations is to be at least 120 circumferentially and 200 mm axially.
Dimensions in mm
Figure 3.1 Requirements for Blending Isolated Defects b. Cavities formed by grinding as in Clause 3.2.3a are to be filled with epoxy resin paste prepared in accordance with Def Stan 02304 Part 1, before restoring the protective coating in accordance with Clause 3.10. Other areas containing minor defects may be locally ground within the following limitations: (1) (2) (3) The maximum depth of any excavation is not to exceed the limits in Table 3.1; The profile of any excavation is to conform with the limits of Figure 3.2; Locally ground areas are not to exceed 0.2 D measured axially or 0.1 D measured circumferentially, where D is the shaft diameter.
Dimensions in mm
c.
Figure 3.2 Profile Requirements for Repair of Limited Areas by Local Grinding d. Rounded defects which exceed the limitations for local grinding defined in Clauses 3.2.3a and 3.2.3c and all linear defects, e.g. cracks, grooves, lines of pitting, are to be removed by concentric machining of the shaft. 12
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) e. Where shafts are to be machined to remove shallow defects without subsequent weld repair, the depth of machining is not to exceed the limits in Table 3.1. When stepped bands are machined as in Clause 3.4.1b , this limitation applies to the total depth of the deepest band. Adjacent machined and/or blended areas are to be separated by not less than 50 mm, measured edge-to-edge. Rectification by machining and/or blending is not acceptable within 50 mm of bearings, glands, seals, tapers, couplings, sleeves, shoulders or keyways.
f. g. 3.2.4
Inboard Shafting a. The limiting depths in Table 3.1 apply to outboard lengths of shafts only. For inboard lengths, the limiting depths will be provided by DLO, MPS 212, after initial survey of the shaft.
3.2.5
Bearing Surfaces a. Areas of defects in way of bearing surfaces are to be reported to DLO, MPS 212, prior to any excavation or repair taking place.
Ship or Class Carrier Invincible Class HMS OCEAN Destroyers Type 42 Frigates Type 22 Type 23 Submarines Swiftsure Class Trafalgar Class Upholder Class Vanguard Class 5 5 5 5 6 5 6 5 3 Maximum Depth of Excavation (mm) Ship or Class Other Ships Fearless Class Hunt Class Island Class Castle Class Bird Class SurveyBoat Central Ocean Inshore HMS ENDURANCE 6 5 5 5 5 5 12 5 5 Maximum Depth of Excavation (mm)
Table 3.1 Limiting Depth of Metal Removal on Outboard Shafts without Subsequent Welding 3.2.6 Journals a. Defects on steel journals, or in way of stern glands, are to have the surface restored by machining where practicable. The depth of machining will be normally limited by considerations of bearing bush withdrawal but it is not permissible to reduce the journal diameter below that of the body of the shaft. 13
3.2.7
Non-ferrous and Stainless Steel Shafting a. These shafts may be machined down to nominal diameter in way of stern tubes and A-brackets, surface finish (0.8 m Ra BS 1134), but are not to be machined below nominal diameter. Defects on the outer diameter of shaft sleeves may be removed by circumferential machining in-situ provided that the residual diameter and thickness after machining conform with Def Stan 02304, Part 1.
b.
3.2.8
Limitations on Repair by Welding a. Weld repairs are to be performed by an auto/semi-automatic process preceded by concentric machining unless the following requirements are satisfied, in which case localized manual welding is permitted: (1) The total depth of metal removal required is not to exceed the limits in Table 3.1 increased by 3 mm. This limit is to include metal removal during any preliminary machining or dressing operations; The total length of local excavations measured along any circumference is not to exceed 1.25 D where D is the shaft diameter at that location; The total local weld repair area in any 200 mm length of shaft is not to exceed 20% of the shaft outer surface area over that length; In any 120 segment of shaft, the volume of weld metal, V, is not to exceed twice that in the similar diametrically opposed segment; Assume V = 0.6 Area maximum depth of excavation.
(2) (3) (4) (5) b.
Major weld repairs, e.g. incorporating machining of a circumferential band and automatic welding, are to conform to the following limitations: (1) The total depth of metal removal in the machined band, including all preliminary machining or dressing operations, is not to exceed the limitations of Table 3.1 increased by 3 mm; Additional local manual excavation in the machined band is permissible but the total depth of metal removal is then not to exceed the limitations of Table 3.1 increased by 5 mm.
(2)
c.
If excavation in accordance with Clause 3.2.8b has not completely removed all defects, no further excavation is to be performed without written approval of DLO, MPS 212, to whom a proposal for a special weld repair is to be submitted. Special weld repairs are to be subject to the limits agreed by MPS 212. Weld repairs on clad surfaces are not to extend the clad area more than 10 mm beyond its original limits.
d. 3.2.9
Limitations on Repair by Thermal Spraying a. Limitations on the application of thermal spray deposition contained in Def Stan 02828 are to be mandatory when this process is used for shaft repair. It is to be 14
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) particularly noted that a sprayed coating makes no contribution to the strength of a component and that the grooved finish required in machined preparation may adversely affect fatigue and shock resistance. b. Thermal spray deposition is not normally to be used for repairs in outboard bearing areas, unless prior authorization is received from MPS 212. It is acceptable only for the repair of inboard bearing sleeves, shaft ends, flanges and other areas where the restoration of dimensions is required, e.g. bulkhead glands, coupling tapers. All repairs to shafts by thermal spray deposition are to be performed on circumferential bands machined to a depth sufficient to remove all defects, but in no case to exceed the applicable limitations in Table 3.1 or in Clauses 3.2.2a to 3.2.7b . Where a proposed shaft repair would exceed the limits in Clause 3.2.9c , a special repair by spray deposition may be proposed, but a weld repair should also be considered as an alternative. For example, where a recess would exceed the limits of Table 3.1 excess depth to the limits of Clause 3.2.8b may be filled by welding. The welded area is then to be machined and spray coated.
c.
d.
3.2.10
Coupling Repair a. Integral coupling flanges are to be examined visually and by crack detection methods, with particular attention being paid to bolt holes. Defective areas are to be rectified wherever possible by machining provided that all relevant requirements of Def Stan 02304 Part 1 are satisfied. Loose couplings, including keyed and flanged couplings and muff couplings, coupling sleeves and shaft-reinforcing sleeves are to be visually examined for mechanical or corrosion damage. Defective areas may be rectified only by machining and only if this can be effected within all dimensional and surface finish requirements of Def Stan 02304 Part 1.
b.
3.3 3.3.1
Straightening of Shafts General a. The methods of straightening shafts described in Clause 3.3.2f are suitable for straightening shafts after repair or for preliminary straightening before repair. One of these methods is to be used unless an alternative is submitted in detail to the Equipment Project Manager (EPM) for approval. An Authorised Representative may be asked to witness any process. The Repairer is to record all details of straightening operations in the Repair History Document of each shaft, in accordance with Clause 3.11.
b. 3.3.2
Location and Measurement of Eccentricity a. Clauses 3.3.2b to 3.3.2f provide a detailed procedure for the location and measurement of shaft eccentricity. Any proposed alternative procedure is to be submitted to the EPM for approval before implementation. An Authorised Representative may be asked to witness any process. The shaft is to be mounted in a centre lathe or similar device with one end gripped in a four-jaw chuck and the other end supported in a steady. 15
b.
c. d. e.
Location stations are to be marked circumferentially at 300 mm centres. A dial gauge is to be set vertically below the centreline of the shaft to measure shaft eccentricity at each station as in Clause 3.3.2e . The shaft is to be rotated slowly and the indicator dial pointer displacement (M) between its extreme positions is to be recorded and the position of maximum eccentricity at each station is to be marked on the shaft. M = Total Indicator Reading (TIR) = 2 actual shaft eccentricity. This procedure is to be repeated at each station.
f.
The station with the greatest shaft eccentricity is to be identified and the eccentricity then measured at further stations at 100 mm and 200 mm on each side of this station. From these measurements, the location and degree of maximum eccentricity is to be marked on the shaft and recorded. The shaft may remain in the lathe for straightening, by thermal or mechanical methods as in Clauses 3.3.4.1d to 3.3.7f .
g. 3.3.3
Selection of Straightening Method a. If the measured eccentricity is outside the limits of Def Stan 02304 Part 1, straightening is to be carried out by one of the following methods, unless an alternative detailed procedure is submitted to the Technical Authority for approval: (1) (2) b. Thermal straightening using torches; Cold mechanical straightening.
Thermal straightening is normally preferred to cold mechanical straightening. The stresses imposed by the latter process can be dangerously high, particularly when shaft materials are of high yield strength. When cold mechanical straightening is proposed, a detailed procedure is to be submitted to the Technical Authority for approval before work is commenced. If welding has been performed on the shaft, approval of the Technical Authority is to be obtained before use of a procedure which requires heating of any part of a circumferential band which contains an area of weld metal.
c. d.
3.3.4 3.3.4.1
Thermal Straightening Temperature Measurement a. Shaft temperatures are to be monitored and recorded, during heating for thermal straightening, at sufficient points to ensure that the requirements of Table 3.2 for shaft temperature control are satisfied. The temperature record chart is to be included with the shaft documentation. Temperature sensors are to be calibrated thermocouples, resistance bulbs or other approved devices. Sensors are to be held in contact with the shaft surface by mechanical means or, in the case of thermocouples only, are to be spot welded to the shafts using approved equipment and procedures. They are to be located as close as practicable to the heated zone. 16
b.
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) c. d. 3.3.5 All temperature measurement equipment and systems are to be fully calibrated to meet the requirements of BS ISO 10012 Part 2 and traceable to National Standards. Thermocouple wires are to be insulated except at the hot junction and are to be routed in such a way that flames cannot impinge on them.
Carbon and Low Alloy Steel Shafts a. Clauses 3.3.5b to 3.3.5h provide a detailed procedure for straightening carbon and low alloy steel shafts by thermal methods. Any proposed alternative procedure is to be submitted to DLO for approval before implementation.
Material Specification Recommended Temperature Range C Min Steel Nickel Aluminium Bronze Nickel Copper (Monel K500 (1)) Ferralium Alloy 255 (1) * BS 970 En5K or Def Stan 02-848 Part 1, Class IIb Def Stan 02-833 Part 2 Def Stan 02-747 (DGS 348) BS 2872 CA104 BS 3076 Type NA18 300 300 Max 500 500
300 270
450* 350*
These temperatures are absolute maxima and must not be exceeded at any point. (1) Proprietary designation.
Table 3.2 Recommended Temperature Ranges for Thermal Straightening b. The shaft is to be set up in a lathe supported by steadies at the free end and on long shafts, at additional intermediate positions. The end of the shaft is to be free to move without restriction in order to accommodate thermal expansion during the straightening process. A dial indicator is to be located below the previously determined position of maximum eccentricity, (see Clause 3.3.2f ). The shaft is then to be rotated until the maximum eccentricity is at the top of the shaft. The dial indicator is to be adjusted so that the plunger is in contact with the shaft and the reading equal to the previously measured eccentricity. The plunger movement is to be checked to confirm that it can be depressed by a further amount equal to the above. The shaft is then to be locally heated by application of an oxy-gas torch with a large nozzle, adjusted to give a soft flame. This is to be applied to the top of the shaft, i.e. the point of maximum eccentricity, causing the shaft to rise locally and the indicator reading to increase. The maximum shaft surface temperature, measured as in Clauses 3.3.4.1a to 3.3.4.1c , is to be maintained within the range for the material as in Table 3.2. Torch movement is to be limited to the minimum necessary to prevent the maximum temperature in Table 3.2 being exceeded. Heating is to be continued until the shaft has risen by an amount equal to the eccentricity, i.e. when 17
c.
d.
the dial reading is reduced to zero. The shaft is then to be allowed to cool slowly to room temperature when the dial reading is again to be taken. e. Any reduction in eccentricity will be shown as an increase of the same amount in indicator reading on cooling, e.g. if the new reading equals twice the original, then the eccentricity at that location will have been completely removed. If the residual eccentricity exceeds the requirements of Clause 3.3.8b , the procedures of Clause 3.3.5d is to be repeated close to the same position until these requirements are satisfied. NOTE g. Reheating on exactly the same position may be ineffective.
f.
When the shaft straightness is locally acceptable to Clause 3.3.8a , the procedures of Clauses 3.3.2d to 3.3.2f are to be repeated to the minimum extent necessary to confirm the location and degree of the new point of maximum eccentricity. The procedures of Clauses 3.3.5d to 3.3.5f are then to be applied at that location. Successive points of maximum eccentricity are to be identified and treated in accordance with Clause 3.3.5f until the overall shaft straightness is within the standard of acceptance in Clause 3.3.8b .
h.
3.3.6
Stainless Steel and Non-ferrous Alloy Shafts a. For thermal straightening of stainless steel and non-ferrous alloy shafts, a suitable detailed procedure should be developed, to suit the particular alloy and shaft design. This procedure is to be submitted through the EPM for approval before implementation. An Authorised Representative may be asked to witness any process. In general, a similar procedure to that described in Clauses 3.3.5b to 3.3.5h may be applied to other alloys but subject to differences in temperature (see Table 3.2), area of heated zone and degree of deflection induced. For example, in the case of some types of Nickel Aluminium Bronze (Ni Al Br), it has been found effective to use the above procedure but with a moving flame, heating a zone of approximately 75 mm diameter. This alloy however requires a much larger induced deflection during heating, in the range five to ten times the local eccentricity, to restore straightness on cooling.
b.
c.
3.3.7
Mechanical Straightening (all materials) a. b. Mechanical straightening is to be performed only at normal temperature. The mechanical straightening procedure detailed in Clauses 3.3.7c to 3.3.7g is to be applied unless an alternative procedure has been submitted to the Technical Authority for approval. The shaft is to be set up in a lathe between two supports such that the point of maximum eccentricity, as previously determined in accordance with Clauses 3.3.2b to 3.3.2, is the lowest point. A hydraulic jack is to be positioned on the lathe bed immediately below this point and a dial gauge in contact with the shaft surface immediately above. Restraining clamps are to be used to fasten the shaft to the supports. 18
c.
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) d. With the restraining clamps securely fastened and the shaft fixed to prevent rotation, a small load is to be carefully applied at the jack. The load is to be increased very slowly and smoothly and the deflection measured by suitably located indicators. If, on release, the shaft eccentricity in that area is not within the acceptance limits of Clause 3.3.8a the loading cycle is to be repeated with increasing loads and deflections until that standard is attained. Care is to be exercised to prevent overstraightening, i.e. reversal of the original eccentricity of the shaft. When the shaft straightness is locally within the acceptance standard in Clause 3.3.8a , the procedures of Clauses 3.3.2d to 3.3.2f are to be repeated to the minimum extent necessary to confirm the location and degree of the new point of eccentricity. The procedures of Clauses 3.3.7c to 3.3.7e are then to be applied at that location. Successive points of maximum eccentricity are to be identified and treated in accordance with Clause 3.3.7f until the overall shaft straightness is within the limits of acceptance of Clause 3.3.8a .
e. f.
g.
3.3.8
Inspection a. b. The acceptance standard for straightness is to be in accordance with Def Stan 02304 Part 1. The straightened shaft is to be subjected to visual inspection and crack detection by liquid penetrant or magnetic particle examination in accordance with Clause 3.9. Inspection is to cover at least 300 mm either side of each zone heated during thermal straightening or, for mechanical straightening, the complete shaft surface between the outer most points supported or clamped, plus 300 mm minimum either side. Where thermal straightening has been applied, temperature records are to be inspected to confirm that the limitations of Table 3.2 have been observed in all heated zones.
c.
3.4 3.4.1
Repair by Grinding and/or Machining Shaft Repair a. When a repair is to be effected by local grinding, the excavation is to conform to the profile and dimensional requirements of Clause 3.2.3c , except for the repair of single rounded defects where the excavation is to be in accordance with Clause 3.2.3a . When a repair is to be effected by machining, the complete length between bearings is to be machined or a circumferential band of limited length parallel to the shaft axis containing the defective area is to be removed. The machined band is to be at least 50 mm wide. A stepped profile is permissible to minimize metal removal, provided that each step is at least 50 mm wide. The repair is to be completed by blending the sides and corners of the machined band in accordance with Figure 3.2. The depth of metal removed by machining is not to exceed the limits of Table 3.1. To ensure that any surface cracks are not obscured by machining marks, the surface finish of areas machined in accordance with Clause 3.4.1b is not to exceed 3.2 m Ra or in accordance with BS 1134. 19
b.
c. d.
e.
All areas machined and/or ground to remove surface defects are to be examined visually and by magnetic particle or dye penetrant technique. Each area examined is to include a 25 mm border around the rectification and is to meet the acceptance standards in Clause 3.9.2b . Magnetic particle examination is preferred for magnetic materials but is not applicable to non-magnetic materials. Where inspection reveals defects which are unacceptable to Clause 3.9.2b and cannot be rectified by further machining within the limitations of Clauses 3.4.1a to 3.4.1c , the shaft is to be reassessed in accordance with Clause 3.2 for repair by welding. The Repairer is to record details of all repairs in the Repair History Document of each shaft in accordance with Clause 3.11.
f.
g. 3.4.2
Tail Shaft Flanges a. Where corrosion or other defects are present beneath bronze collars on the outside diameter (od) or radii of tail shaft flanges, these defects are to be removed by machining to the minimum required depth. A modified collar of dimensions to suit the machined flange is then to be fitted. Details of such repairs are to be included in the shaft Repair History Document. (See Clause 3.4.1g ).
3.4.3
Shaft Bore a. Where inspection has revealed corrosion or other defects in the bore of a hollow shaft, this is to be cleaned by a honing operation. If this does not remove the defect or if an alternative method of dressing is proposed, details are to be provided to the Technical Authority.
3.4.4
Shaft Sleeve Repair a. b. Outer surfaces of shaft sleeves, which are machined as permitted by Clause 3.2.7b , are to have a surface finish of 0.8 m Ra or in accordance with BS 1134. Where refurbishment requires the replacement of a shaft sleeve, the requirements of def Stan 02304 Part 1, are to apply to dimensions and surface finish of both the shaft and the bore of the new sleeve.
3.5 3.5.1
Repair by Welding General a. b. Repair by welding is to be subject to the limitations and requirements of Clauses 3.2.8a to 3.2.8d . Wherever practicable, the weld filler metal or consumable electrode is to produce a weld deposit of the same alloy type as the shaft or metal cladding which is to be repaired. Any proposal which would produce a dissimilar metal weld deposit is to be submitted to the Technical Authority for prior approval. Welding is to be carried out in the horizontal position wherever practicable, and by qualified personnel using approved equipment and working to approved procedures. Welding sequences are to be designed to minimize distortion. 20
c.
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) d. e. f. 3.5.2 Completed repairs are to be heat treated as required by Clause 3.8 and inspected as laid down in Clause 3.9. Care is to be taken at all times to avoid mechanical damage and stray arcing on shaft surfaces. The Repairer is to record all details of weld repair in the Repair History Document of each shaft in accordance with Clause 3.11.
Welding Processes a. Only the following welding processes are acceptable: (1) (2) (3) (4) (5) b. c. Manual Metal Arc (MMA); Tungsten Inert Gas (TIG) including Pulsed TIG (PTIG); Metal Inert Gas (MIG) including Pulsed MIG (PMIG); Submerged Arc Welding (SAW); Flux Cored Wire (FCAW).
Wherever practicable, fully automatic welding processes are preferred. The SAW process is to be used only with linear welding, i.e. where weld runs are parallel to the axis of the shaft, unless a proved procedure is approved by the Technical Authority. TIG and MIG processes are suitable for linear or spiral welding. The former mode is to be preferred wherever practicable in order to minimize distortion and produce optimum surface finish and concentricity. NOTE Semi-automatic TIG can be used for suitable repair welds of length down to 40 mm.
d.
Manual welding using MMA, TIG, FCAW or MIG processes is normally to be restricted to the local repair of areas which are too small for the use of automatic or semi-automatic processes. Any proposal to use manual welding where the latter processes are practicable is to be referred to the Technical Authority for approval and should be in accordance with Clause 3.2.8a .
3.5.3
Equipment a. Automatic welding equipment is to be qualified by practical tests in accordance with Clauses 3.6.4a and 3.6.4b and is to be regularly inspected and tested as part of an approved planned maintenance programme. Work handling equipment, used while welding to rotate the shaft or traverse the welding head, is to be under the control of the welder. Bronze or lead hammers are not to be used. Chain slings are not to be used. Slings made from hemp, nylon or wire (other than wire coated with lead or zinc) are to be used, the selection to be based on the weight of the shaft. Wire brushes, grinding wheels and other tools used for dressing purposes are to conform to the requirements of Clauses 3.1.2c to 3.1.2e . 21
b. c. d.
e.
3.5.4
Welding Procedure Specification a. A Welding Procedure Specification (WPS) is to be prepared, to this specification, for each weld repair defining the detailed course of action to be followed in welding. If necessary the Technical Authority to witness the tests. Each WPS is to contain the following information, where applicable to the weld concerned: (1) (2) (3) (4) (5) (6) (7) (8) (9) Welding process; Parent material specification, diameter and thickness (of hollow shafts); Sketch of preparation; Cleaning requirements; Welding position; Make, brand and type of welding consumables; Preheat and interpass temperature and methods of heating and control; Travel speed (mechanized welding), traverse and rotational; Approximate number, sequence and arrangement of runs and filler size(s);
b.
(10) Post-weld heat treatment temperature and methods of heating and control; (11) Shielding gas composition and flow rate; (12) Flux composition and type; (13) Type of electrical supply, voltage, polarity and current; (14) Pulse frequency and current; (15) Wire speed; (16) Weave technique. c. Any alteration in an approved WPS is to require a revised issue of the specification which is to be approved by the Technical Authority before production use. Requalification may be required by the PM/ESM.
3.5.5
Approval Requirements a. Before starting any repair welding, organizations working to this standard are to obtain approval from the Technical Authority for procedures, equipment and personnel. All welding is to be carried out in accordance with approved welding procedures. Any welding procedure passed by a Contractor to a subcontractor for use on an MOD contract is to be a MOD approved procedure. The subcontractor is to demonstrate to the satisfaction of the MOD Technical Authority his ability to work to the procedure before being used for repairs.
b.
3.6
Organization Responsibility a. Each Organization working to this standard is to carry out all necessary qualification tests at its own expense and is to provide adequate notice of each test to the Technical Authority so that the test may be witnessed. 22
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) b. When a test is intended to qualify simultaneously any combination of procedure, equipment and personnel, this must be clearly stated when notifying the Technical Authority and again when submitting details of approval tests. The Organization is to maintain records of all tests (including failures) and qualifications. Personnel qualification records are to be maintained for each welder currently employed and for ex-personnel until the PM/ESM Authorised Representative has approved of their disposal.
c.
3.6.1
Welding Procedure Qualification a. Each welding procedure is to be qualified by proving that acceptable sample welds can be produced on standard tests pieces. Before a weld procedure undergoes qualification testing, it is to be submitted to the Technical Authority for comment and to enable him to witness the tests. Test assemblies are to be prepared, examined and tested as described in Annex D. Test results and, if requested, the test pieces are to be submitted to the Technical Authority for approval. Any change in items (1) to (14), in Clause 3.5.4b , will normally require requalification of the procedure with the exception of the following: (1) Cumulative change in the gas flow rate of less than 25% from the qualification test level, or, for mixed gases, cumulative change of less than 25% in the content of a minor constituent. A minor constituent comprises less than 25% of the gas; Cumulative change of one-third or less in the diameter of electrode in MMA welding from the size used in the qualification test.
b.
c.
(2) 3.6.2
Qualification of Personnel a. Each welder is to be qualified by production of a test assembly prepared, examined and tested in accordance with Annex D. Test results and, if required, test pieces, are to be submitted to the Technical Authority for approval. A welder who has performed a satisfactory welding procedure qualification test is to be considered qualified for production welding using that procedure. Personnel currently qualified to meet the welding requirements of a recognized authority may, at the discretion of the Technical Authority, be granted exemptions in respect of welder qualification. The Technical Authority is to state clearly in writing the extent of any exemption granted. Requalification of welders and welding operators is required if: (1) The Technical Authority has reason to believe that the standard of workmanship of a particular welder or group of welders in production does not meet consistently the requirements of Clause 3.9; A period of six months has elapsed since the welder was last engaged on weld repair of shafts; A change is made to either of the following: 23
b. c.
d.
(2) (3)
(a) (b) 3.6.3
Welding procedure, to one for which he is not qualified; Shaft dimensions; from the range qualified by his existing welder qualification.
Welding Consumables Approval a. If the proposed consumable or combination of consumables specified in the welding procedure are not already approved by DPA, e.g. by inclusion in Def Stan 02769, they are to be tested and approved before use in production, using the qualification procedures laid down in Def Stan 02769. NOTE 1. Def Stan 02769 covers only matching filler materials plus associated gases and fluxes for use on carbon-manganese and low allow steels. 2. Consumables listed in Def Stan 02769 for welding B and BX quality steels over 12 mm thick are also approved for welding steels to Def Stan 02848 Part 1 in all thicknesses. 3. Nickel Chromium (Ni Cr) alloy to AWS A5.11 E Ni Cr M03 or AWS A5.14 ER Ni Cr M03 is the only non-ferrous filler material approved for repairs to ferrous shafting or Ni Cr alloy cladding.
3.6.4
Qualification of Automatic Welding Equipment a. Automatic welding equipment is to be qualified by test welds in accordance with an approved welding procedure or as part of a combined equipment/procedure qualification. The Organization is required to demonstrate that the machine-made welds can be constantly reproduced. The production welding procedure is to state the level and frequency of tests required to meet this requirement.
b.
3.6.5
Weld Preparation a. b. All weld preparations are to be in accordance with the limitations of Clauses 3.2.8a to 3.2.8d . Surfaces within 50 mm of the weld area are to be cleaned to bright metal and degreased.
3.6.6
Local Repairs by Manual Welding a. All excavations for manual weld repair are to be ground out in a boat-shaped depression with 15 min slopes leading in and out and in cross section as shown in Figure 3.3. The minimum length is to be 75 mm where permitted by Clauses 3.2.8a to 3.2.8d .
24
Figure 3.3 Excavation for Manual Weld Repairs (Cross Section) b. The surface of each excavation is to be inspected both visually and by either magnetic particle or dye penetrant methods. (see Clause 3.9). It is to be free from cracks, porosity and sharp discontinuities.
3.6.7
Machining for Major Repairs a. b. c. Where the shaft is machined to provide a true surface for welding, the total depth of machining is not to exceed the limits laid down in Clause 3.2.8b . Each length to be repaired by automatic or semi-automatic welding is to be machined cylindrically (i.e. not tapered) concentric with the shaft axis. After machining to the limits of Clause 3.2.8b (1), any defects remaining are to be locally excavated in accordance with Clauses 3.6.6a and 3.2.8b (2) and manually weld repaired, before remachining to match the existing machined surface and inspection in accordance with Clause 3.6.6. A similar procedure to Clause 3.6.7c may be adopted at shallower machined depths to excavate locally and repair isolated defects where this would economically reduce the amount of machining required.
d.
3.6.8
Preparation of Welding Consumables a. All electrode wires are to be free of moisture, dirt, grease and other contamination. MMA electrodes and fluxes for SAW are to be baked, dried and stored to manufacturers instructions.
3.6.9 3.6.9.1
Production Welding Requirements General a. Care is required to protect the parent metal outside the weld area from weld spatter and to prevent stray arc strikes. The latter are to be assessed as defects in accordance with Clause 3.2. 25
b. c.
Earth connections are to be securely attached to prevent arcing or abrasion. Welding is to be carried out, wherever practicable, in the downhand position with the shaft axis horizontal, using, for circumferential welding, a positioner or other device to rotate the shaft. The completed weld is to contain sufficient weld metal to ensure that the weld repair can be machined flush with the adjacent shaft surfaces. Each weld run is to be cleaned by wire brushing (see Clause 3.1.2c ) and inspected before starting the next pass. Doubtful areas are to be examined using an appropriate crack detection method in accordance with Clause 3.9. Defective areas and any undercut are to be removed by grinding, (see Clause 3.1.2d ). Stops and starts when using MMA are also to be removed by grinding. After automatic welding of a complete circumferential weld layer, subject to the requirements of Clauses 3.6.14a and 3.6.14b for post-heat of ferritic steel shaft, the weld metal may be machined to provide a true surface for welding the following layer and to assist NDE. Defects are to be removed by grinding, followed by local repair, if necessary, before automatic welding deposition of the following layer. Care is to be taken when using the manual TIG process, to avoid excessive heat input.
d. e.
f.
g. 3.6.10
Starts and Stops a. b. Starts and stops are to be staggered so that they are longitudinally separated by at least 20 mm, in any one layer or between consecutive layers. End craters and associated porosity are to be prevented in manual welding, e.g. by using the run back technique. The latter technique consists of delaying the electrode at the end of a weld run, allowing the electrode to dwell long enough to fill the crater and then welding in the reverse direction over the top of the run for a distance of 20 mm. The extra weld is then ground off, removing the final crater and any associated porosity. To prevent the same defects in automatic welding where equipment controls permit, one of the following techniques is to be applied: (1) (2) (3) d. Run back technique, as in Clause 3.6.10b ; Rotation and traverse, in spiral welding, stopped at the end of the run while the arc is maintained for a few seconds to fill the crater; Traverse stopped, in spiral welding, while rotation is continued, thereby depositing an additional bead.
c.
In all cases, the surplus metal is ground or machined off before the next layer is deposited.
3.6.11
Shaft Distortion a. When a shaft is set up for welding using a positioner or other similar device, the arrangement is to include dial indicators set to measure shaft distortion to within 0.025 mm. 26
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) b. Distortion can interfere with arc length control during automatic and semi-automatic welding and is to be minimized. If, during welding by such processes, shaft distortion develops in excess of the limits of Table 3.3, welding is to be stopped, the shaft straightened as in Clause 3.3 and measures taken to limit further distortion. Welding Process TIG MIG Submerged Arc NOTE Maximum Distortion TIR, mm (Note) 0.25 2.5 2.5
TIR = Total Indicator Reading = 2 shaft eccentricity.
Table 3.3 Shaft Distortion Limits for Automatic Welding Process c. In building up local areas, the weld is to be deposited in a sequence design to minimize shaft distortion. For example when such repair areas are diametrically opposed, or nearly so, the welds should be deposited in beads at least 75 mm long, alternate beads being laid on opposite sides of the shaft.
3.6.12
Preheat and Interpass Temperature Control a. b. c. Shafts are to be preheated before welding, in accordance with Table 3.4 . The preheat temperature is to be maintained until all welding is completed and, for steel shafts, for a further period as in Clause 3.6.14a . The minimum preheat temperature is to be maintained throughout a zone covering the weld area and extending a distance not less than 200 mm beyond the weld preparation. Preheat by electrical methods is preferred for all materials; flame heating is permitted only on carbon steels and only by neutral flame. Preheat temperature is to be measured in a sufficient number of positions to ensure that all of the material in the preheat zone, as defined in Clause 3.6.12c , has reached the minimum preheat temperature before welding is started. Temperatures may be measured by any of the following methods but contact thermometers or thermocouples are preferred where practicable: (1) (2) Contact Thermometers difficult to use on rotating work pieces; Thermocouple rotation is limited by the length of leads unless slip rings are used and so thermocouples are therefore normally unsuited to continuous spiral deposition; Infra-red Pyrometers for accurate readings, the shaft must be uncovered over a significant area. 27
d. e.
(3)
f.
Interpass temperature is defined as the temperature within the preheat zone, after completion of the first of any succeeding pass and immediately before commencing the next one. It is not to exceed the limits in Table 3.4. Material Steel Specification Def Stan 02848 Part 1 supersedes ADSPEC 1100 Class 11b and Interim Standard D/SSC/NA132/331/4/9 BS 970 En5K Pre-heat Temperature C 250 min Interpass Temperature C (max) 350
Nickel-Aluminium Def Stan 02833 Part 2 Bronze supersedes DGS 1043 and DGS 8452 Bronze HTA2 Gunmetal Gunmetal Ferralium Alloy Nickel-Copper NOTE 1. BS 3076 Grade NA 18 Def Stan 02830 Part 1 supersedes DGS 203 Def Stan 02830 Part 2/LG4
50 - 100
200
Ambient Ambient
150 (Note 1.) 200 (Note 2)
If the temperature of the shaft during welding rises above 305C measured at any point 25 mm from the weld area, welding is to be stopped until the temperature falls below 150C.
2. If the temperature of the shaft during welding rises above 400C measured at any point 25 mm from the weld area welding is to be stopped until the temperature falls below 200C. Table 3.4 Preheat and Interpass Temperatures 3.6.13 Heat Input a. Heat input during welding, calculated by the formula below, is to be maintained within the limits laid down in Table 3.5. Any proposal to use a heat input outside these limits is to be submitted to the Technical Authority together with the reasons for the proposal.
Heat input (kJ mm) + amps volts power factor 1000 welding speed (mm sec)
28
Machined Wall Thickness Before Welding mm Hollow Shafts below 40 40 to 64 over 64 Machined Diameter Before Welding mm Solid Shafts below 40 40 to 75 over 75
Heat Input kJ/mm 1.0 to 1.5 1.0 to 2.0 1.0 to 2.5
1.0 to 1.5 1.0 to 2.0 1.0 to 2.5
Table 3.5 Heat Input Limits for Shaft Weld Repair 3.6.14 Post-heat a. On completion of welding on steel shafts, other than stainless steels, or when welding is interrupted for a significant period, e.g. for inter run machining, minimum preheating temperature conditions as in Clauses 3.6.12a to 3.6.12e are to be maintained after welding has stopped for a period of not less than one hour per 50 mm wall thickness of a hollow shaft, or one hour per 50 mm diameter of a solid shaft, before the shaft is permitted to cool to room temperature. During post-heat and cooling, the shaft is to be slowly rotated.
b. 3.6.15
Interpass Weld Inspection a. On completion of each layer of weld metal, the weld surface is to be examined visually at 10 x magnification. Porosity, undercut, cracks and liner defects are to be ground out (see Clause 3.6.6a ) until shown by NDE to be completely removed. The excavation is to be filled with weld metal and examined for freedom from defects as above, or filled by the next layer of weld, if it can be shown that this will fill the excavation satisfactorily.
3.6.16
Post-weld Heat Treatment a. Where required by the WPS, the shaft is to be heat-treated after weld repair, in accordance with the requirements of Clause 3.8.
3.6.17
Post-weld Dressing a. Completed weld repairs are to be machined or ground flush with the adjacent surfaces. Surface finish is to meet the requirements of Clause 3.9.5a .
3.6.18
Post-weld Inspection a. All weld repairs are to be examined by magnetic particle or dye penetrant technique. Areas examined are to include a 25 mm border around each rectification and are to meet the acceptance standards in Clause 3.9.3 Magnetic Particle Examination is preferred for magnetic materials but is not applicable to non-magnetic materials. The inspection is to be repeated before and after heat treatment, whenever the latter is specified. Where distortion outside the acceptance limits of Def Stan 02304 Part 1 is measured, the shaft is to be straightened in accordance with Clause 3.3. 29
b.
c.
Inspection is to include ultrasonic testing in accordance with Annex F. The following are to be causes for rejection: (1) Any defect which gives a signal of over 80% FSD if: (a) or (b) (2) (3) It is a linear defect over 10 mm long; It is over 7 mm measured in two directions at 90 degrees;
Any defect which would be surface-breaking after final machining; Pores over 3 mm diameter.
d.
Any two pores, each over 1 mm diameter, separated by less than 1.25 times the diameter of the larger is to be assessed in accordance with Clause 3.6.18c (3), as a single rounded defect whose perimeter would enclose both.
3.6.19
Repair of Weld Cladding a. When repair of weld cladding does not require metal removal from the underlying shaft, welding is to be in accordance with all applicable clauses of this section, using filler metal of composition matching the cladding material. When local repairs are required to the parent shaft below areas of weld cladding, the cladding material is to be removed from around the parent material excavation to a sufficient distance to ensure that the filler matching the parent material is not deposited on the cladding material, (25 mm min if possible, see Figure 3.4). The parent metal excavation is then to be welded using matching filler to the level of the cladding interface. After dressing the weld bead flush, the repair is to be completed using filler metal matching the cladding material. Shafts which are clad or repaired with dissimilar metal fillers or which have had such previous repairs are not to be heat treated, (see Clause 3.8.1d ). Repairs are to be inspected by visual and non-destructive examination in accordance with the relevant requirements of Clauses 3.6.18a to 3.6.18c and of Clause 3.9.
b.
c. d.
Figure 3.4 Local Weld Repairs Under Cladding 30
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) 3.7 3.7.1 Thermal Spray Deposition General a. b. The Repairer is to record all details of repair by spray deposition in the Repair History Document of each shaft, in accordance with Clause 3.11. Unless otherwise required by this Def Stan, when such requirements are to have precedence, all mandatory requirements of Def Stan 02828 are also to apply to the repair of shafting by thermal deposition, including associated inspection and finishing operations. Additional requirements, specific to the repair of main propulsion shafting, are detailed in this Clause 3.7 which is to be read in conjunction with related clauses of Def Stan 02828. Fused coatings are not to be used in the repair of shafting. All sprayed coatings are to be sealed in accordance with Def Stan 02828. Repairs of shafting by thermal deposition are, wherever possible, to be by an automatic process in a fully circumferential mode. Thermal spraying is not permitted in way of the outboard and inboard bearing area or the torsion meters. Spraying methods and sequences are to be such as to minimize distortion. Care is to be taken at all times to avoid mechanical damage to shaft surfaces.
c. d. e.
f. g. 3.7.2 3.7.2.1
Qualification Requirements General a. Before starting any spray coating, organizations working to this Def Stan are to obtain approval from the Technical Authority for procedures, equipment and personnel. All spray coating is to be carried out in accordance with DPA approved written procedures. All thermal spray deposition procedures, operators and equipment are to be qualified by the production, inspection and testing of test pieces in accordance with Annex E and Def Stan 02828. All optional tests within the above are to be considered mandatory to satisfy the requirements of this standard. Any thermal spray deposition procedure passed by a Contractor to a subcontractor for use on a MOD contract is to be an DPA approved procedure. The subcontractor is to demonstrate to the satisfaction of the MOD Technical Authority his ability to work to the procedure before being used for repair. All spraying equipment, when used by qualified personnel working to approved procedures, is to be capable of consistently producing coatings to the required standards. Equipment is to be regularly inspected and tested as part of an approved planned maintenance programme. Personnel currently qualified to meet the spray coating requirements of a recognized authority may, at the discretion of the Technical Authority, be granted exemptions in respect of qualification. The Technical Authority is to state clearly in writing the extent of any exemption granted. 31
b.
c.
d.
e.
3.7.2.2
Qualification of Spray Coating Procedures a. b. A spray coating procedure document is to be prepared in accordance with Def Stan 02828 and submitted to the PM/ESM Authorised Representative for approval. The spray coating procedure is to be qualified by proving that acceptable sample coatings can be produced on standard test pieces. The test pieces are to be prepared and examined as in Annex E. The test results and, if requested, the test pieces are to be submitted to the Technical Authority for approval. The test results may be in the form of a laboratory report. Qualification of the procedure automatically qualifies the person who produced the test piece. Any alteration in a procedure is to be covered by a revised issue of the procedure approved by the Technical Authority before production use.
c. 3.7.2.3
Qualification of Automatic Spray Coating Equipment a. Automatic equipment is to be qualified by test coatings, sprayed in accordance with an approved spray coating procedure or as part of a combined equipment/procedure qualification. The Organization is required to demonstrate the reproducibility of machine-made coatings. The production procedure is to state the level and frequency of any additional inspections necessary to meet this requirement.
b.
3.7.2.4
Qualification of Personnel a. The Organization is responsible for qualifying each spray operator and for ensuring that he is capable of working strictly to approved spray coating procedures and of spraying under production conditions to the specified acceptance standards. Each spray operator is to be qualified by producing a sprayed sample, prepared, examined and tested in accordance with Annex E. A spray operator who carried out a satisfactory spray coating procedure qualification test is to be considered qualified for production spraying using that procedure. Requalification of a spray operator is required if: (1) (2) e. The Technical Authority has reason to believe that his workmanship is not consistently of the required standard; A period of six months has elapsed since the operator was last engaged on the type of work proposed.
b. c.
d.
Subject to the approval of the Technical Authority, requalification tests may be modified or waived for selected operators subject to full NDE of the first production item, or as otherwise specified by the Technical Authority via the PM/ESM.
3.7.2.5
Organization Responsibility a. Each Organization working to this Def Stan is to carry out all necessary qualification tests at its own expense. The Technical Authority is to be given adequate notice of each test so that the tests may be witnessed. 32
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) b. The Organization is to certify that tests are conducted in accordance with the preliminary, proposed or approved procedure. When a test is intended to qualify simultaneously any combination of procedure, equipment and personnel, this must be clearly stated when notifying the Technical Authority and again when submitting test results for approval. The Organization is to maintain records of all tests (including failures) and qualifications for a period specified in the contract. Personnel qualification records are to be maintained for each operator currently employed and for ex-personnel until the PM/ESM Authorised Representative has approved of their disposal.
c.
3.7.3 3.7.3.1
Repair Requirements Repair Samples a. For every repair, a repair sample is to be prepared. Wherever practicable, the sample is to be a representative length of shaft, identical in dimensions to the shaft being repaired. It is to be machined and sprayed in a manner identical to the actual repair. Where the above is not practicable, the form of the repair sample is to be agreed with the Technical Authority.
3.7.3.2
Preparation for Coating a. Preparation of areas of shafting to be spray coated is to be by machining in accordance with Clause 3.2.9c and with all applicable requirements of Def Stan 02828.
3.7.3.3
Spraying Position a. Spraying is to be carried out with the shaft axis horizontal.
3.7.3.4
Gas Spraying a. b. To minimize stress in the coating, the thickness of sprayed metal deposited in one pass is not to exceed 0.15 mm. Gas pressure regulators are to be calibrated at intervals of not more than six months to ensure that spray coating is to the standards required by this standard.
3.7.3.5
Powder Spraying a. Powder deposition processes are versatile and a wide range of metals can be sprayed due to the high efficiency of the process. Spraying of ceramic powders produces deposits which are unacceptable for shaft repairs. Powder is to be carried through the flame by a flow of gas independent of the burning gases. Gravity feeding of the powder externally to the nozzle is not acceptable.
b.
3.7.3.6
Automatic and Semi-automatic Processes a. When spraying by an automatic or semi-automatic process, the peripheral speed of the shaft and the traverse speed of the spray head is to be adjusted to suit the spraying rate. The following are suggested as a guide: 33
(1) (2)
S = 6.7 W
T+ D 56 W
Where:
S = W= T = D =
Shaft surface speed in metres per minute Spraying rate in kilograms per hour No of seconds required to traverse 1 mm Shaft diameter in mm
3.7.3.7
Distortion a. If, while spraying using an automatic or semi-automatic process, the shaft eccentricity at any point along the length of shaft to be sprayed exceeds 2 mm TIR, spraying is to be stopped, the reason for the excessive distortion determined and measures taken to limit any further distortion. The shaft is to be straightened in accordance with Clause 3.3 before continuing the spraying operation. In building up local areas, the coating is to be deposited in a sequence designed to minimize shaft distortion.
b. 3.7.3.8
Mechanical Drive a. The shaft is to be fixed in a positioner or between centres or in a suitable lathe and rotated mechanically. The drive is to be under the control of the spray coating operator. The traverse is to be mechanically driven and arranged so that the traverse speed can be suitably adjusted by the spray coating operator. The mechanical drives are to be stable, so that neither rotational speed nor traverse speed will vary more than 1% at any setting. Spraying is to be carried out using automatic or semi-automatic processes while the gun is traversing only in one direction. When the gun is returning, the shaft is to be protected by deflecting the gun or by other means. This procedure prevents uneven heating of the shaft.
b. c. d.
3.7.3.9
Intermediate Inspection a. Each bond coat or intermediate layer is to be visually inspected before deposition of the next layer to confirm that coverage is adequate, that there is no lifting or lack of adhesion, and that the surface finish is acceptable for subsequent deposition. If lifting or lack of adhesion is detected the coating is to be completely removed and the spray area reprepared and recoated.
b. 3.7.3.10
Sealing of Sprayed Coatings a. b. For all applications within the scope of this standard, sprayed coatings are to be sealed in accordance with Def Stan 02828. Care is necessary with some sealers to avoid inhalation of toxic fumes or contact with substances that can cause skin irritation. 34
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) c. Details of the sealer and the method of application are to be included in the spray deposition procedure submitted to the Technical Authority for approval. The procedure for application of the sealer is to state any hazards involved and list the precautions to be taken. If there are no hazards, the procedure is to state this. If the procedure does not cover hazards, the sealer is not to be used until full information is available. Sealers are to be applied while the coating is in the temperature range 25C to 35C. The first application is to be applied while the shaft is still warm from spraying but after initial inspection and crack detection. If resealing is required, e.g. after surface finishing, it is essential that all traces of coolant, grinding debris and other contaminants are removed before resealing the surface. Before applying the sealer, the shaft is to be gently warmed to a temperature of 25C to 35C. The sealer is then to be applied in accordance with the approved procedures.
d.
e.
3.7.3.11
Surface Finishing of Sealed Coatings a. Surface finishing is normally to be effected by grinding. Machining is to be used only when grinding is impracticable and only with tungsten carbide or diamond-tipped tools in good condition using very light cuts and slow feeds. Exposed edges of sprayed coatings are to be stoned or ground to a fine angle. The angle is to be just sufficient to ensure that no end pressure can be applied to the edge of the coating, e.g. by an abutting key or sleeve. After finishing by grinding or machining, the shaft is to be cleaned and resealed in accordance with Clauses 3.7.3.10d and 3.7.3.10e . Grinding of chrome oxide, ceramics and cermets is to be performed using resinoid-bonded diamond abrasive wheels. This type of wheel is also preferred for metal-sprayed coatings but silicon carbide wheels may alternatively be used.
b.
c. d.
3.7.4
Inspection of Sealed Coating a. Visual inspection is to confirm that sealing is complete with no unsealed or porous areas and without excess sealant on the surface. Surface appearance is to be uniform.
3.8 3.8.1
Heat Treatment General a. This section defines the requirements for post-repair heat treatment of carbonmanganese steel shafts, when this is specified in an approved repair procedure involving welding and/or straightening, with the aim of reducing internal stress and/or hardness. When heat treatment of shafts is specified, it is to be carried out in accordance with the specified requirements of the approved repair procedure. Heat treatment of shafts is to be applied subject to approval of the Technical Authority and only when specified in the drawing, specification or contract. 35
b. c.
d.
The following areas of shafts are not to be heat-treated except with specific approval in each case: (1) (2) (3) (4) Areas to which liners are fitted; Areas which have been weld-repaired using dissimilar metal fillers; Areas which have been weld-clad with dissimilar metal; or Areas which have been spray-coated.
Local heat treatment may be carried out at locations away from such areas, provided that the temperature of the shaft in any area which is not to be heat-treated is not permitted to exceed 300C. e. 3.8.2 Each shaft is to be adequately supported during heat treatment, to prevent the shaft from distorting or sagging under its own weight.
Heating Equipment a. Heat treatment is to be performed using gas-heated or electric ovens or by electric heating pads. Gas ovens are to be of a design which prevents flame impingement on the shaft or temperature-measuring equipment. Ovens and heating pads used for heat treatment are to be fitted with automatic controls which meet the requirements of Clauses 3.8.4a to 3.8.4e .
b. 3.8.3
Local Heat Treatment a. Repaired areas of shafts may be heat treated locally only by heating a complete circumferential band in which the repair is located centrally. The width of the heated band is to extend to a minimum axial distance equal to the shaft diameter D, on each side of the repaired area. Insulation is to be applied to ensure that the repaired and weld heat-affected zones are controllable within the requirements of Clauses 3.8.4f to 3.8.4h , and the temperature of the edges of the heated band during the soaking period is not less than 300C. Additionally, each adjacent length of shaft outside the heated area is to be insulated over a further minimum length equal to D, to prevent harmful thermal gradients.
3.8.4
Temperature Control and Indication a. Heat treatment is to be carried out under automatic control. Control equipment is to be capable of being programmed to: (1) (2) (3) b. Heat the shaft at a controlled rate until the whole of the heated length of the shaft is at the soaking temperature; Hold the shaft at the selected soaking temperature for the required length of time; Cool the shaft at a controlled rate until it is below the required discharge temperature.
Control equipment is to be capable of being programmed for different rates of heating and cooling. 36
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) c. Control equipment is to be capable of ensuring that no part of the shaft is heated to a temperature more than 10C above the selected soaking temperature during any part of the heat treatment cycle. Shaft temperatures are to be monitored and recorded, during heat treatment, using thermocouples spot-welded to the shaft, at sufficient points to ensure that the requirements for shaft temperature control have been met. The temperature record chart is to be included with the shaft documentation. Thermocouple wires are to be insulated except at the hot junction and are to be shielded from direct radiant heat. Shafts are to be heated slowly above 300C in order to prevent steep temperature gradients within the shaft. Above 300C the heating rate for hollow shafts is not to exceed 5000 _C per hour or 50C per hour, whichever is greater, where W mm is
W
d.
e. f.
the maximum thickness of the shaft wall in the heated zone. Similarly, for solid shafts, the heating rate is not to exceed 5000 C per hour or 50C per hour,
D
whichever is greater, where D mm is the maximum shaft diameter in the heated zone. g. Steel shafts are to be heated to a temperature within the range of 580C to 620C and held within that range for the specified soaking period. Soaking times are to be
D hours for solid shafts and W hours, for hollow shafts, respectively. 12 25
h.
After heat soaking, shafts are to be slowly cooled to 300C or below. Above
C per hour or 300C, the cooling rate for hollow shafts is not to exceed 6250
62.5 per hour, whichever is greater, and for solid shafts is not to exceed 6250 C
W
per hour or 62.5C per hour, whichever is greater. i. 3.8.5 Below 300C, shafts may be allowed to cool naturally in still air.
Finishing a. After heat treatment, shafts are to be cleaned to remove oxides and similar surface contamination. Surface marks resulting from attachment of temperature sensors or from any other cause are to be assessed and repaired, if required, as laid down in Clause 3.2.
3.8.6
Recording a. The Repairer is to record all details of heat treatment operations in the Repair History document of each shaft, in accordance with Clause 3.11.
3.9 3.9.1
Final Inspection General a. The requirements of this section are to be applied to final inspection after all repair and finishing operations and are additional to the requirements of other sections within the Def Stan, for pre-repair, inter-operation and post-repair inspection. 37
b.
All repairs are to conform to the limitations on location and dimensions contained in those clauses of Clauses 3.2 and 3.4 relevant to the type of defect and method of repair.
3.9.2
Visual Examination a. b. c. All shaft surfaces including repaired areas are to be visually examined. All surfaces are to be free from cracks, linear defects, visible porosity and weld undercut where relevant. All surfaces are to be free from oxides and damage marks.
3.9.3
Non-destructive Examination a. b. c. NDE methods are to be in accordance with Def Stan 02729. The repaired shaft is to be tested along its entire length in accordance with the methods of Def Stan 02304 Part 1, and to the acceptance standards. Any examination using an NDE technique is to be carried out by qualified personnel using approved equipment and working to a procedure approved in accordance with Def Stan 02729. The use of prods is prohibited when carrying out Magnetic Particle Examination, as these can cause prod arcing. When dye penetrant examination is used on weld repairs, the acceptance standard for rounded indications is to be in accordance with Def Stan 02773 for weld metal cladding. Ultrasonic examination is to conform to the requirements of Annex F.
d. e.
f. 3.9.4
Straightness a. The shaft is to be checked for straightness in accordance with the methods and acceptance standards of Def Stan 02304 Part 1.
3.9.5
Surface Finish a. The surface finish of each repair area after machining is to be measured and is to conform to the relevant drawing or BS 1134, with a maximum value of 3.2 m Ra.
3.9.6
Dimensions a. Dimensions of repaired shafts are to be checked as follows: (1) (2) (3) b. Diameters in the way of glands, seals, bearings and sleeves or other fitted items; Axial dimensions where these are important and may have altered due to repair or straightening; Keyways and shoulders in or near repairs.
Shaft dimensions are to be within the limits shown on the drawings for a new shaft of the same design, subject to the following exceptions: 38
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) (1) (2) (3) Surface areas restricted by blending or machining in accordance with Clause 3.4; Areas where a limited reduction in diameter is permitted, as detailed in Clauses 3.2.6a to 3.2.6b ; Keyways and shoulders in areas which have been spray-coated and are angled in accordance with Clause 3.7.3.11b to prevent end loads being transmitted to the coating.
3.9.7
Balancing a. On completion of all repair operations on a hollow shaft, the residual imbalance is to be in accordance with the requirements of Def Stan 02304 Part 1.
3.10
Preservation and Protection a. After all repairs have been completed all surface areas of shaft which have had protective coating wholly or partially removed, are to have this restored. Similarly, damaged coatings without any damage to the underlying shaft surface are to be restored. The Repairer is to record all details of coating repair and restoration in the Repair History Document of each shaft, in accordance with Clause 3.11. Restoration is to be in accordance with the general procedure in Def Stan 02304 Part 1, for the application and repair of the protective coating. Other than as permitted by Clause 3.10e , the coating material is to be glass reinforced epoxy resin in accordance with Def Stan 02304 Part 1. For in-situ repairs of coatings at low ambient temperatures down to 10C, the use of a glass-flake polyester resin system is permitted. Any proposed use of the polyester system requires prior approval from the Technical Authority. Full details of the properties and application procedures are to be obtained from the manufacturers, before making a proposal to the Technical Authority for use of the above system. Preservation and stowage of shafts, bores, tapers, etc., are to be in accordance with Def Stan 02304 Part 1.
b. c. d. e.
f.
g. 3.11
Repair History Document a. A Repair History Document is to be raised on first fitting of a new main propulsion shaft; it is to accompany the shaft throughout its service life and is to record all repair actions. Duplicate copies are to be forwarded to MPS 212 for records. Where any shaft to be overhauled has not been documented as above, then a Repair History Document is to be raised prior to overhaul and repair actions during that overhaul are to be recorded. A unique identification number, provided by DLO, MPS 212, is to be stamped on both ends of each new shaft using low stress stamps. If such identification is absent 39
b.
c.
from a shaft at overhaul, DLO, MPS 212 are to be requested to provide the required number. d. The Repair History Document is to include the following information as minimum: (1) (2) (3) (4) (5) (6) (7) (8) (9) 3.12 Shaft identification number; Material(s); Service history (ships, dates); Overhaul history (dates, inspection methods, repair methods, dimensional inspection charts); Location and method of all repairs, e.g. welding, metal spraying, electrochemical deposition; Details of welding repairs (welding procedure, welder identification, consumables); Details of metal spraying (spray procedure, operator consumables); Thermal records of all local and complete heat treatments (temperatures, times, locations of heated zones); Coating history (local repairs, complete recoatings).
Electrochemical Metallization a. b. Prior to the use of electrochemical metallization for any application, approval must be given by DPA. General information and requirements specified for applications of selective electrochemical metallization (Contact Electroplating) in US Naval Ships are contained in NAVSHIPS 0900-038-6010.
4.
DESIGN REQUIREMENTS/GUIDANCE This Defence Standard contains no Design Requirements/Guidance information.
5.
CORPORATE KNOWLEDGE AND EXPERIENCE This Defence Standard contains no Corporate Knowledge and Experience information.
40
ANNEX A. RELATED DOCUMENTS A1. The following documents and publications are referred to in this Defence Standard: BS ISO 10012 BS 499 BS 709 BS 970 BS 1134 BS 2872 BS 3076 BS 4870 JSP 430 Quality Assurance requirements for measuring equipment: Part 2: Guidelines for control of measuring process. Welding terms and symbols: Part 1: Welding, brazing and thermal cutting glossary. Methods of testing fusion welded joints and weld metal in steel. Wrought steels in the form of blooms, billets bars and forgings. Method for the assessment of surface texture. Copper and copper alloys. Forging stock and forgings. Specification for nickel and nickel alloys bar. Approval testing of welding procedures. MOD Ship Safety Management System Handbook: Volume 1: Policy and Guidance on MOD Ship and Equipment Safety Management. Shafting Systems and Propulsors: Part 1: Design Requirements for Main Propulsion Shafting. Requirements for Non-destructive Examination Methods: Part 2: Magnetic Particle; Part 4: Liquid Penetrant; Part 5: Ultrasonic. Requirements for Nickel Aluminium Bronze Castings and Ingots. Approval System for Welding Consumables for Structural Steels. Minimum Acceptance Standards for Welds in HM Surface Ships and Submarines. Thermal Spray Deposition of Metals and Ceramics for Engineering Purposes. Requirements for Gunmetal Ingots and Castings: Part 1: Gunmetal Ingots and Class III Gunmetal Castings; Part 2: Continuously Cast. Requirements for Nickel Aluminium Bronze: Part 2: Forgings, Forging Stock, Rods and Sections. Requirements for Carbon Manganese and Low Alloy Steel Forgings: Part 1: Carbon Manganese Steel Forgings. 41
Def Stan 02304 (NES 304) Def Stan 02729 (NES 729)
Def Stan 02747 (NES 747) Def Stan 02769 (NES 769) Def Stan 02773 (NES 773) Def Stan 02828 (NES 828) Def Stan 02830 (NES 830) Def Stan 02833 (NES 833) Def Stan 02848 (NES 848)
NAVSHIPS 0900-038-6010 AWS A5.11 AWS A5.14 D/SSC/NA132/331/4/ 9 DGS 203 DGS 1043 (DGS 8452)
Deposition of metals by contact (brush on method) electroplating. Nickel and nickel alloy covered welding electrodes. Nickel and nickel alloy bare welding rods and electrodes. Carbonmanganese steel forgings, forging stock and bar. Gunmetal Ingots and Castings. Nickel Aluminium Bronze Forging Stock, Rods and Sections.
ANNEX B. ABBREVIATIONS AND DEFINITIONS B1. For the purpose of this Defence Standard the following abbreviations (and definitions) apply. BS BWE DGS DLO DPA EN EPM ESM FCAW FSD HAZ ISO JSP m mm MIG MMA MMIG MOD MTIG NDE NES Ni Al Br British Standard(s) (as the context requires) Back Wall Echo Director General Ships Defence Logistics Organisation Defence Procurement Agency European Committees for Standardisation Equipment Project Manager Equipment Support Manager Flux Cored Wire Full Scale Deflection Heat Affected Zone International Standards Organisation Joint Service Publication(s) (as the context requires) metre millimetre Metal Inert Gas Manual Metal Arc Manual Metal Inert Gas Ministry of Defence Manual Tungsten Inert Gas Nondestructive Examination Naval Engineering Standard(s) (as the context requires) Nickel Aluminium Bronze 42
Ni Cr od PM PMIG PTIG SAW TIG TIR V WPS
Nickel Chromium outside diameter Project Manager Pulsed Metal Inert Gas Pulsed Tungsten Inert Gas Submerged Arc Welding Tungsten Inert Gas Total Indicator Reading Volume of Weld Metal Welding Procedure Specification
B2. For the purpose of this Defence Standard the following definitions apply: Automatic Welding Welding in which all the welding parameters are controlled and may be automatically varied during welding by mechanical and/or electronic means to maintain the required welding conditions. Shaping and smoothing or fairing depressions to remove sharp corners and other stress-promoting features. Mechanical straightening without heating the shaft. Materials used up during welding or spray deposition, e.g. wire, electrodes, gases, cord. Mechanical straightening of a shaft heated to a temperature at which the strength of the shaft material is reduced. Shafting forward of the aft-most inboard coupling. Deposition of successive weld runs in straight parallel lines such that the weld deposits form a continuous solid layer. Repair to a limited area not extending around the full circumference of a shaft. Shafting which transmits power from the main engine or gearbox output flange to the propulsor, and transmits thrust from the propulsor to the hull via the thrust block. Repair extending around the full circumference of a shaft. The Company, or part of a Company, responsible for execution of the required repairs. Shafting aft of the aft-most inboard coupling. A low viscosity liquid applied to porous coatings, which solidifies within the pores to form a seal. 43
Blending Cold Straightening Consumables Hot Straightening
Inboard Shafting Linear Welding or Deposition
Local Repair Main Propulsion Shafting
Major Repair Organization Outboard Shafting Sealant
Semi-automatic Welding
Welding in which some of the welding parameters are automatically controlled, but manual guidance is necessary. Abraded by hand using an abrasive stone block.
Stoned
Terms related to welding, unless otherwise stated in this Defence Standard, conform to the definitions in BS 499 Part 1.
ANNEX C. PROCUREMENT CHECK LIST C1. No relevant information included.
44
ANNEX D. WELDING QUALIFICATION TESTS D1. General a. Clauses D1. to D8. apply to all weld repair procedures using matching filler metals. Clause D9. contains the requirements for qualification for weld overlay cladding with dissimilar filler metals and for weld repair of such overlays.
D2. Test Assemblies a. b. For any weld procedure, the same test assembly design is to be used for qualification of welder, weld procedure and equipment, either separately or in combination. MMA and MMIG welding for local repairs is to be qualified by preparation and test of a plate as illustrated in Figure D1. MTIG welding is to be qualified by a similar test plate with a weld groove as Figure D2.
250 min
All dimensions in mm
300 min
30_ to 40_
22 40 R10
Figure D1 Qualification Test Plate: MMA and MMIG
45
60_
6 min 20 min R3
Figure D2 Qualification Test Plate: MTIG c. Qualification tests for welding by automatic MIG or SAW processes are to be performed on a length of hollow shaft or other similar cylindrical material prepared as in Figure D3.
500 min 50 min 371/2_
300 dia approx
25
R10 All dimensions in mm
a. General Arrangement
b. Weld preparation detail
Figure D3 Qualification Test Assembly: Automatic Welding d. e. a. The material of the test assembly is to be as detailed in the weld procedure or from the same material group as defined in BS 4870:1981. Test assemblies for weld overlay cladding are to be as detailed in Clauses D9.a. to D9.c. The weld is to be completed in accordance with the weld procedure specification, while the test piece is fully restrained, e.g. as shown in Figure D4 for plate welding.
Minimum three clamps per side
D3. Welding
Test Piece Base - Length 400 min
75 min
350 min Figure D4 Test Plate Assembled in Welding Jig 46
D4. Post-Weld Heat Treatment a. Post-weld heat treatment is to be applied, if required, by the weld procedure specification.
D5. Non-destructive Examination a. b. Visual inspection and crack detection are to be carried out in accordance with Clause 3.9. Ultrasonic testing is to be performed in accordance with Annex F. Weld procedure and welder qualification tests are to be radiographically examined in accordance with def Stan 02729 and to the Class 1 acceptance standards of Def Stan 02773.
47
D6. Tensile and Bend Tests a. Test pieces for manual welding qualification are to be prepared by machining and grinding, in accordance with the plan in Figure D5. Additionally, for automatic welding qualification, a circumferential all-weld metal test piece is to be prepared from the test assembly in NO TAG. Further detailed dimensions together with methods of preparation and test are to be in accordance with BS 709:1983.
20 min 10 10
37
37
20 20 20 min Bend and Tensile t 25 Macro and Hardness t t = 25 mm for MMA, MMIG and Auto Processes. = 8 mm for MTIG process. All dimensions in mm Machined flush
Figure D5 Preparation of Destructive Examination Test Pieces: MMA, MMIG, MTIG Qualification 48
b. c.
Welds are to be ground flush with the parent material surface before removal of test pieces. Transverse tensile tests are to be performed on full weld thickness test pieces. The measured ultimate tensile stress and elongation are to conform to the requirements of the shaft material specification. Two face bend tests are to be performed on MTIG test plates qualification of all other welding processes is to include two transverse bend tests. The weld and HAZ are to be contained within the bent portion of each bend-test piece. The test piece is to be bent through a minimum angle of 90 around a former of 4t, where t is the thickness of the test piece. After bending, any open defect exceeding 3 mm measured in any direction is to be cause for non-acceptance. Cracking at corners of the bent area is however to be acceptable unless clearly related to pre-welding defects.
d. e.
D7. Hardness Tests a. Vickers hardness tests, 10 kg load, are to be performed on a cross-section, in accordance with BS 709 and Figure D6. Traverses are to be made 2 mm below the test piece surface and across the weld 2 mm from the root. At least three indentations are to be made in the weld metal and in the parent metal on each side plus one indentation per mm in each HAZ.
Indentations spaced as Clause D7.
Figure D6 Location of Hardness Traverses b. Hardness values in parent material, HAZ or weld metal are not to exceed the maximum limit of the shaft material specification. If this is not specified, the maximum hardness within the HAZ is not to exceed the maximum measured hardness in the parent material by more than 50 Hv 10.
D8. Macro-Examination a. Both cross-sections of each macro-examination test piece are to be prepared to a fine emery finish, etched with a suitable reagent and examined under 10 magnification. No cracks are acceptable and other defects are to conform to the acceptance limits for radiographic examination of Class 1 non-piping welds in Def Stan 02773. Photomacrographs of all faces examined are to be included in the qualification test report.
D9. Weld Overlay Cladding a. Qualification of an automatic weld overlay cladding procedure is to be performed on a cylindrical test piece of 150 mm od minimum. The test piece is to be solid or have a wall thickness of at least 50 mm. 49
b.
The use of weld overlay cladding for local repair of shaft material or of existing cladding by manual welding is to be qualified by a test deposit 25 mm 100 mm on a rectangular plate 50 mm 125 mm minimum. In all cases, the deposit thickness is to be at least equal to the required minimum overlay thickness of new cladding or the original overlay thickness of cladding to be repaired. Weld deposits are to be machined and examined visually and by liquid penetrant testing in accordance with Clause 3.9. Ultrasonic testing is to be applied in accordance with Annex E. Four transverse macrosections, at 90 intervals on cylindrical test specimens and at 25 mm intervals on plate, are to be prepared and examined in accordance with Clause D8. No lack of fusion between overlay and base material is to be accepted. Chemical analysis samples are to be taken from metal removed during machining at levels in accordance with Figure D7. Chemical composition of the deposit is to be in accordance with the consumables manufacturers specification. Additionally the iron content of the nickelchromium overlay on a steel shaft is not to exceed 10%.
Chemical Analysis Sample
c. d. e.
f.
5 max Weld overlay
Min production thickness
Base Metal
Figure D7 Chemical Analysis Sampling of Weld Overlay
ANNEX E. SPRAY DEPOSITION QUALIFICATION TESTS E1. Test Assemblies a. For qualification of procedures, operators or equipment, a cylindrical test piece is to be prepared as shown in Figure E1. Grit blasting is to be preceded by machine-grooving or threading where this is a requirement of the spray coating procedure. Grooved or threaded test pieces are to be spray-coated to a depth of 0.25 mm to 0.50 mm above tooth profile - sufficient to allow the test piece to be machined or ground back to the correct diameter after spraying.
b.
E2. Records a. A record is to be kept of any repairs required during the test. 50
E3. Test Requirements a. b. Destructive and visual examinations of qualification test pieces and production test samples are to be carried out as described below. Test specimens are to be prepared from qualification test pieces or production test samples as shown in Figure E2.
E4. Visual Examination a. Test specimen C is to be visually examined, with the aid of magnifiers if required, to determine the quality of the surface after grit blasting. The surface profile of the grit blasted (unsprayed) surface is to be within the specified limits.
E5. Bend Tests a. Two bend tests are to be carried out around a former of radius 6 mm with the coated surface in tension using test specimens A and B. The coating is to show no lack of adhesion after bending. Surface cracking is to be expected and is acceptable.
E6. Micro-sections a. A micro-section is to be prepared from test specimen D and a photomicrograph produced at a magnification of 200. NOTE b. Care is necessary to avoid adhesion failure and cracking during micro-preparation.
The micro-section is to be examined under suitable magnification against the following requirements: (1). Unfused globules are not to exceed 5% of the cross-sectional area; (2). Lack of bonding is unacceptable; (3). Cracks are unacceptable.
Carbon Steel Tube 75 mm od 10 SWG 1. 10 mm border masked at each end before grit blasting. 2. 30 x 40 area masked after grit blasting before spraying. 3. Tube ends to be machined square.
Figure E1 Spray Deposition Qualification Test Piece 51
Cut test specimen from this ring
Test specimen C - includes masked patch
Figure E2 Extraction of Test Specimens
ANNEX F. ULTRASONIC EXAMINATION OF WELDS AND WELD CLADDING F1. General a. Ultrasonic examination is to be performed using an approved procedure, in accordance with all requirements of Def Stan 02729 Part 5, unless otherwise specified in this Annex, in which case the latter is to apply. The surface is to be free from scale, rust, weld spatter and other foreign matter and from surface irregularities. If necessary, the surface is to be machined to provide a surface suitable for ultrasonic examination. All ultrasonic examinations are to be carried out by qualified personnel using approved equipment and working to approved procedures. 52
b.
c.
F2.
Equipment a. b. All equipment is to meet the requirements of Def Stan 02729 Part 5. Standard probes are to be used where possible in accordance with the requirements in Table F1. Weld Material Frequency MHz Steel Nickel Chromium Nickel Aluminium Bronze Nickel Copper Stainless Steel 4 to 6 (Note 2.) 2 to 5 2 to 6 (Note 2.) 2 to 5 (Note 2.) 2 to 6 (Note 2.) Probe Details (Note 1.) Round Crystal max dia mm 16 (Note 3.) 10 (Note 3.) 16 max (Note 3.) 16 max (Note 3.) 16 max (Note 3.) Rectangular Crystal max area sq mm 260 100 260 max (Note 1.) 260 max (Note 2.) 260 max (Note 3.)
NOTE 1. All probes are to be fitted with double crystals. 2. For evaluation of defects less than 2 mm below the surface, special 12 MHz probes may be used. 3. Where access is difficult, miniature probes may be used but the probe details are to be included in the examination report. Table F1 Probe Requirements F3. Calibration a. A suitable reference piece for each type of examination to be undertaken, is to be prepared. Approved designs are shown in Figure F1 to Figure F4. Other proposed designs are to be submitted to the Technical Authority for approval. Ultrasonic reference pieces are to be examined before use to ensure that there is no defect in the piece which would affect its use as a reference. Such examination is to include ultrasonic test, crack detection and, where appropriate, radiography. The reject control is to be adjusted to the minimum setting consistent with a clean trace. (This is not to be readjusted unless the equipment is subsequently recalibrated as described below). The time base is to be set to a suitable scale, e.g. 1 division = 1 mm. The search sensitivity is to be set as follows: (1). The probe is to be located on the selected reference piece, using a couplant, over a hole whose depth below the surface is equal to the average depth of the weld to be examined. The probe location is to be adjusted to obtain the maximum signal from the target hole; (2). The attenuator is then to be adjusted until a display of 20% of Full Scale Deflection (FSD) is obtained. The indicated attenuator figure is to be recorded. This setting is to be used for the initial search scan. 53
b.
c. d. e.
Preparation: 1. 2. Material: carbon or carbonmaganese steel. Minimum finished width30 mm. Drill holes, flat bottomed, 3 mm dia, depths below the top surface as shown.
Figure F1 Ultrasonic Reference Piece for Examination of Qualification Test Pieces for Manual Weld Repairs using Matching Fillers
Weld - Cladding of dissimilar metal filler
Base Material: 1. Carbon or carbonmanganese steel min finished width - 30 mm. Preparation: 1. Machine Base 2. Deposit cladding where shown 3. Drill holes, flat bottomed, 3 mm dia, in centres of flat areas to depths shown. 4. Machine bar to give correct thickness of cladding above holes (3 mm, 6 mm, 12 mm and 18 mm respectively).
Figure F2 Ultrasonic Reference Piece for Examination of Qualification Test Pieces for Manual Weld Repair using Dissimilar Metal Filler
54
Preparation: 1. Material: carbonmaganese steel. 2. Radius R is also that of the shaft to be examined. 3. Drill four flat-bottomed holes radially as shown.
Figure F3 Ultrasonic Reference Piece for Examination of Shafts Repaired with Matching Fillers
Weld - Cladding of dissimilar metal filler
Base Material: 1. Carbon or carbon-manganese steel. Preparation: 1. Machine Base. 2. Deposit cladding where shown. 3. Drill 3 mm dia, holes flat bottomed as shown. 4. Machine piece to suitable size.
Figure F4 Ultrasonic Reference Piece for Examination of Shafts Repaired with Dissimilar Metal Filler 55
F4.
Method a. b. c. During scanning, the probe is to be moved at a uniform speed consistent with effective examination and signal recognition. This speed is to be determined during calibration. All manually deposited welds are to be examined on scan lines separated by not more than 80% of the crystal diameter. Welds deposited using automatic or semi-automatic welding equipment are to be examined on scan lines normal to the direction of welding and separated by 50 mm except: (1). Near shoulders, internal corners and similar discontinuities; (2). Near the edge of the area of weld deposition. NOTE In these areas, scan lines within 50 mm of the shoulder, edge, etc., are to be separated by not more than 80% of the crystal diameter, to ensure complete cover.
F5.
Examination a. The surface area of the weld is to be scanned and all indications recorded where the signal amplitude exceeds 20% FSD. When a clear Back Wall Echo (BWE) is present, indications which are not accompanied by attenuation of the BWE or which are accompanied by an increase in BWE are to be ignored, see Clause 3.6.18a . If the first BWE is attenuated to 20% FSD or below with no defect indication and this cannot be attributed to the geometry of the part being examined, the surface and the couplant are to be checked. If the coupling is satisfactory, the attenuation is attributable to micro-porosity. Each recorded defect is to be evaluated, with the search sensitivity adjusted to 20% FSD, for a target hole in the reference bar whose depth below the surface is closest to the depth of the defect. The size of each defect is to be determined using the 6 dB drop technique.
b.
c.
F6.
Evaluation Recorded defects are to be assessed in accordance with Clause 3.6.18.
56
DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4) ALPHABETICAL INDEX (Note: Page numbers are given)
A
Adspec 1100, 24 Approval requirements
automatic welding equipment, 24 organization responsibility, 22, 23 spray procedures, equipment, personnel, 31 weld procedures, equipment, personnel, 22 welding consumables, 24
Defect removal, 10, 29 Definitions, 42, 43 Dimensions, final inspection, 38 Dissimilar metal welds, 20, 30 Distortion
in spray deposition, 34 in welding, limitation of, 27 in welding, measurement, 26
Arcing, 21, 25, 26 Assessment of repairs, 10 Automatic welding, 21

end craters, 26 equipment qualification, 24
Dressing, post-welds, 29 Dye penetrant examination, acceptance stan dard, 38
E
Earth connections, 26 Eccentricity, location and measurement, 15, 16 Electrochemical metallization , US Navy, 40 Electroplating, bath, 11 End craters, prevention, 26 Equipment
automatic welding, 21 heat treatment, 36 work handling, 21
B
B quality steel, weld consumables, 24 Balancing, 39 Blending, definition, 43 Bore honing, 20
inspection, 10
Burrs, 10 BX quality steel, welding consumables, 24
C
Carbon, low alloy steels, thermal straighten ing, 17, 18 Chemical analysis, 45 Cladding, weld, repair of, 30 Collars, tail shaft flanges, 20 Consumables, weld, definition, 43 Corrosion,
electrochemical, 10 general, 10
F
Files, 10 Filler metal, cladding, 30 Final inspection, 37 Fumes, toxic, sealants, 34 Fused coatings, sprayed, 31
H
Hammers, bronze/lead, 21 Hazards, spray coating, sealing,, 35 Heat input, MTIG, limitation, 28 Heat treatment
Coupling Repair, 15
D
Defect acceptance, 38, 52 Defect plotting, 9
equipment, 36 finishing after, 37 in weld qualification tests, 45 limitations, 36
57

local, 36 post-repair requirements, 35 post-weld, 29 recording, 37 temperature control/indication, 36, 37
Manual welding, processes, 21 MIG process, 21
N
NDE methods
final inspection, 38 weld qualification tests, 45
I
Identification number, 39 Inboard shafting, definition, 43 Inspection,
balancing, 39 defect standards, 38, 52 dimensions, 38 final, 37 liquid penetrant, 38 magnetic particle, 38 methods, NDE, 38 post-weld, 29, 30 post-weld, ultrasonic, 30 preliminary inspection, 9 repair, location and dimensions, 38 spraying, final, 35 spraying, intermediate, 34 straightness, 38 surface finish, 38 ultrasonic, 38, 52 visual, 38 weld interpass, 29
Non-ferrous alloys, thermal straightening, 18
O
Organisation, definition, 43 Organization responsibility,
spray deposition, 33 weld qualification, 22, 23
Outboard shafting, definition, 43 Overstraightening, 19
P
Personnel, welding, qualification of, 23 Pitting, chains of, 9 Porosity, acceptance in welds, 30 Post-heat, welding, 29 Post-repair operations, 2 Powder spraying, 33 Preheat, welding, 27 Preservation and Protection
glass flake polyester coating, 39 glass reinforced epoxy coating, 39
Interpass temperature control, 28
L
Linear welding, processes, 21 Linear welding, deposition, definition, 43 Liners, gunmetal, 10 Liquid penetrant examination, 38 Local grinding/machining, 11 Local repair, definition, 43
Production welding, 25, 26, 27 Protective cover, 9
Q
Qualification, combination, 23 Qualification,
automatic welding equipment, 24 records, 23 spray procedures, 32, 50 welding personnel, 23 welding procedures, 23
M
Machining, repair by, 19 Macro-examination, 45 Magnetic particle examination, 20, 38 Main propulsion shafting, definition, 43 Maintenance, planned, 31 Major repair, definition, 43
R
Records,
heat treatment, 37
58

qualification, 23, 33
Thermal Spray Deposition
Rectification repair techniques, 2, 11 Repair History, 15, 20, 21, 31, 37, 39
contents, 40 identification number, 39
Run-back technique, 26
S
SAW process, 21 Scope, 2 Sealant, definition, 43 Semi-automatic welding, TIG, 21 Sleeves,
replacement, 20 surface finish, 19
Slings, selection of, 21 Spiral welding

definition, 43 processes, 21
applications, 15 distortion, 34 fused coatings, 31 gas spraying, 33 hazards, 35 inspection, 34, 35 limitations, 15 mechanical drive, 34 position, 33 powder spraying, 33 preparation, 33 qualification, 31, 32, 33 qualification, equipment, 32 qualification, Organization responsibility, 32, 33 qualification, personnel, 32 qualification, procedures, 32, 50 qualification, requalification, 32 qualification, tests, 50 qualification, waiver, 32 repair samples, 33 sealing, 31, 34, 35 spraying speed, 33 surface finishing, 35 toxic fumes, 34 manual, 21 mode, 21 semi-automatic, 21
TIG process
Spray Deposition, Thermal, 31

NES 828 requirements, 31
Stainless steel, thermal straightening, 18 Starts and stops, 26 Stepped profile, machining of, 19 Stoned, definition, 43 Straightening of Shafts, 15
cold, definition, 43 hot, definition, 43 mechanical, 18, 19 methods, 16 thermal, 16, 17, 18, 19 thermal, carbon and low alloy steels, 17, 18 thermal, stainless steels and non-ferrous alloys, 18
Tools, deburring, 10 Total indicator reading (TIR), 16
U
Ultrasonic Inspection, 52
calibration, 52 equipment, 52 evaluation, 52 examination, 52 final inspection, 38 method, 52
Straightness, standard, 38 Surface finish, 19 Surface finish, final inspection, 38 Surface finishing, coatings, 35
V
Visual examination, 20, 38
W T
Tail shaft flanges, 20 Temperature records
heat treatment, 37 thermal straightening, 19
Weld cladding repair, 30 Weld cleaning, 24 Weld filler metal, 20 Weld preparation, 24, 25
cleaning of, 24
59

inspection of, 25 local excavation, 26 major repairs, 25 manual repairs, 24, 25 personnel qualification, 23 personnel qualification, exemption, 23 position, 20, 26 post-heat, 29 post-weld heat treatment, 35 pre-heat, 27 procedure specification, 22 procedure specification, alterations in, 22, 23 procedure specification, contents, 22 procedure specification, qualification, 23 procedure specification, requalification, 22, 23 qualification tests, 45 qualification tests, chemical analysis, 45 qualification tests, hardness tests, 45 qualification tests, macro-examination, 45 qualification tests, NDE, 45 qualification tests, post-weld heat treatment, 45 qualification tests, tensile and bend tests, 45 qualification tests, test assemblies, 45 qualification tests, welding of test assemblies, 45 qualififcation tests, weld overlay, 45 SAW process, 21 semi-automatic, TIG process, 21 spiral, process, 21 TIG process, 21
Weld repair, special, 14 Weld spatter, prevention, 25 Welding automatic, semi-automatic, 43

definition, 43
Welding, automatic, 21, 43
consumables, 43 consumables, approval, 24 consumables, b, bx, Adspec 1100, Ni-Cr alloy, 24 consumables, preparation of, 25 defect removal, 29 definition, 43 interpass temperature, 28 limitations, 14 limitations, automatic, 14 limitations, local/manual, 14 limitations, major, 14 limitations, semi-automatic, 14 manual processes, 21 MIG process, 21 MMA process, 21
Wire brushes, 10, 21
60
Inside Rear Cover
Crown Copyright 2002 Copying Only as Agreed with DStan
Defence Standards are Published by and Obtainable from: Defence Procurement Agency An Executive Agency of The Ministry of Defence UK Defence Standardization Kentigern House 65 Brown Street GLASGOW G2 8EX
DStan Helpdesk Tel 0141 224 2531/2 Fax 0141 224 2503 Internet e-mail enquiries@dstan.mod.uk
File Reference The DStan file reference relating to work on this standard is D/DStan/69/02/304/4. 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 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 is contained in Def Stan 00-00 Standards for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence Standards and Defence Specifications published annually 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 requested to notify the Directorate of Standardization (DStan) without delay in order that the matter may be investigated and appropriate action taken.

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Ministry of Defence Defence Standard 02-304 Part 4

Issue 2 Publication Date 12 September 2002

Shafting Systems and Propulsors

Part 4 Requirements for Repair of Main Propulsion Shafting

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

(1) (2) (3)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

(2) (3) (4) (5) b.

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

(a) (b) 3.6.3

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

TIR = Total Indicator Reading = 2 shaft eccentricity.

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

150 (Note 1.) 200 (Note 2)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Heat Input kJ/mm 1.0 to 1.5 1.0 to 2.0 1.0 to 2.5

1.0 to 1.5 1.0 to 2.0 1.0 to 2.5

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Figure 3.4 Local Weld Repairs Under Cladding 30

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DESIGN REQUIREMENTS/GUIDANCE This Defence Standard contains no Design Requirements/Guidance information.

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Ni Cr od PM PMIG PTIG SAW TIG TIR V WPS

Blending Cold Straightening Consumables Hot Straightening

Inboard Shafting Linear Welding or Deposition

Local Repair Main Propulsion Shafting

Major Repair Organization Outboard Shafting Sealant

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

ANNEX C. PROCUREMENT CHECK LIST C1. No relevant information included.

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Figure D1 Qualification Test Plate: MMA and MMIG

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

300 dia approx

R10 All dimensions in mm

b. Weld preparation detail

Test Piece Base - Length 400 min

350 min Figure D4 Test Plate Assembled in Welding Jig 46

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Indentations spaced as Clause D7.

DEF STAN 02304 Part 4/ Issue 2 (NES 304 Part 4)

Min production thickness