Ministry of Defence

Defence Standard 02-830 Part 2

Issue 2 Publication Date 19 August 2002

Requirements for Gunmetal Ingots and

Castings

Part 2

Continuously Cast

Category 3
 AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO DATE OF TEXT AFFECTED SIGNATURE &

ISSUE 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

DG Ships 285
NES 830 Pt 1 Issue 1 Nov 87
NES 830 Pt 1 Issue 2 Jul 94
Def Stan 02-830 Pt 1 Issue 1 Apr 00
 DEFENCE STANDARD 02–830

REQUIREMENTS FOR GUNMETAL INGOTS AND CASTINGS

PART 2 ISSUE 2

CONTINUOUSLY CAST

This Defence Standard is

authorized for use in MOD contracts
by the Defence Procurement Agency and
the Defence Logistics Organization

Published by:

UK Defence Standardization
Defence Procurement Agency
An Executive Agency of The Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown Street
Glasgow G2 8EX

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DEF STAN 02–830 PART 2 / ISSUE 2
(NES 830)

SCOPE
1. Part 2 of this Defence Standard defines the requirements for the manufacture, inspection and
testing of continuously cast gunmetal to BS EN 1982 in grades CC491K and CC492K that are
normally classified as a Class III material in accordance with DEF STAN 02-863 unless
otherwise stated in the Contract.

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 DEF STAN 02–830 PART 2 / ISSUE 2
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FOREWORD
Sponsorship
a. This Defence Standard (DEF STAN) is sponsored by the Defence Procurement Agency (DPA),
Ministry of Defence (MOD).
b. The complete Standard comprises:
Requirements for Gunmetal Ingots and Castings
Part 1: Gunmetal Ingots and Class III Sand Castings
Part 2: Continuously Cast
c. 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 shall be
made to the publishing authority identified on Page (i), and those directly applicable to a
particular contract shall be dealt with using contract procedures.
d. If it is found to be unsuitable for any particular requirement MOD shall be informed in writing
of the circumstances.
e. No alteration shall be made to this Standard except by the issue of an authorized amendment.
f. Unless otherwise stated, reference in this Standard to approval, approved, authorized and
similar terms, means by the MOD in writing.
g. 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.
h. This Standard has been reissued to reflect changes in Departmental Nomenclature due to the
MOD reorganization and the changes to technical requirements.
Conditions of Release
General
i. 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 Defence Standard
is used for any other purpose.
j. This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It shall not be released, reproduced or published without written
permission of the MOD.
k. The Crown reserves the right to amend or modify the contents of this Defence Standard
without consulting or informing any holder.
MOD Tender or Contract Process
l. This Standard is the property of the Crown. Unless otherwise authorized in writing by the
MOD shall be returned on completion of the contract, or submission of the tender, in
connection with which it is issued.
m. When this Standard is used in connection with a MOD tender or contract, the user shall 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.
n. When Defence Standards are incorporated into MOD contracts, users are responsible for their
correct application and for complying with contractual and other statutory requirements.
Compliance with a Defence Standard does not of itself confer immunity from legal obligations.

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Categories of Standard
o. The Category of this Standard has been determined using the following criteria:
a. Category 1. If not applied may have a Critical affect on the following:
Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
b. Category 2. If not applied may have a Significant affect on the following:
Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through life costs and support.
c. Category 3. If not applied may have a Minor affect on the following:
MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.
Related Documents
p. In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a. British Standards British Standards Institution,
389 Chiswick High Road,
London, W4 4AL
b. Defence Standards Defence Procurement Agency
An Executive Agency of the Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown Street
Glasgow, G2 8EX.
c. Other documents Tender or Contract Sponsor to advise.
q. All applications to the MOD for related documents shall quote the relevant MOD Invitation
to Tender or Contract number and date, together with the sponsoring Directorate and the
Tender or Contract Sponsor.
r. The Form Facsimiles shown in this Defence Standard are not to be copied since they are only
replicas for information purposes and will be subject to change by the form Sponsor to reflect
current MOD policy.
s. Prime Contractors shall be responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
Health and Safety
Warning
t. This Standard may call for the use of processes, substances and/or procedures that are
injurious to health if adequate precautions are not taken. It refers only to technical suitability
and in no way absolves either the supplier or the user from statutory obligations relating to
health and safety at any stage of manufacture or use. Where attention is drawn to hazards,
those quoted may not necessarily be exhaustive.
u. This Standard has been written and shall be used taking into account the policy stipulated in
JSP 430: MOD Ship Safety Management System Handbook.
Additional Information
v. (There is no relevant information included.)

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CONTENTS
Page No
TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Categories of Naval Defence Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Additional Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SECTION 1. PERFORMANCE SPECIFICATION . . . . . . . . . . . 7

1.1 Physical Characteristics . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 1.1 Mechanical Properties . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3 Manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.1 Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.1.1 Chemical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.1.2 Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5.1.3 Test Pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.2 Non-Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.2.1 Dimensional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.5.2.2 Visual-Optical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.6 Defects and Rectification of Defects . . . . . . . . . . . . . 8
1.6.1 Rectification of Surface Defects by Blending . . . . . 8

SECTION 2. NATIONAL/INTERNATIONAL REGULATIONS 8

SECTION 3. MILITARY STANDARDS/REQUIREMENTS . . . . 8

3.1 Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1 Destructive Examination Standards . . . . . . . . . . . . . 8
3.1.1.1 Chemical Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1.1.2 Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 Non-destructive Examination Standards . . . . . . . . . 9
3.1.2.1 Dimensional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2.2 Visual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Quality Assurance Documentation . . . . . . . . . . . . . . 9
3.3 Identification of Continuously Cast Material . . . . . 9
3.4 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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SECTION 4. DESIGN REQUIREMENTS/GUIDANCE . . . . . . . 10

SECTION 5. CORPORATE EXPERIENCE & KNOWLEDGE . 10

5.1 History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.2 Typical Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Joining Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.4 Remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

ANNEX A RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . . 11

ANNEX B DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

ANNEX C PROCUREMENT CHECK LIST . . . . . . . . . . . . . . . 13

ALPHABETICAL INDEX ........................................... 14

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 DEF STAN 02–830 PART 2 / ISSUE 2
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1. PERFORMANCE SPECIFICATION
Related Documents: BS EN 1982; BS EN 10002–1; DEF STAN 02–863; see also
Annex A.
1.1 Physical Characteristics
a. Continuously cast material to this Standard shall conform to the chemical
compositions of alloys CC491K or CC492K of specification BS EN 1982.
1.2 Mechanical Properties
a. At room temperature the mechanical properties from the tensile tests pieces
specified in Clause 1.5.1.2a. shall be as detailed in Table 1.1. Values of proof
stress are given for information only.
Elongation On
5.65S oGauge
Tensile Strength 0.2% Proof
(N/mm2) Stress (N/mm2)
Length (%)
CC491K
250
100
13
CC492K
270
130
12

Table 1.1 – Mechanical Properties

1.3 Manufacture
a. The material shall be manufactured by the continuously cast process and shall
be in the form of solid or hollowsectioned rods or cylinders.
b. The tolerance on the crosssectional dimensions for solid rod and sections shall
be ±0.5 mm.
c. Unless stated otherwise in the Contract the tolerances on the hollowsectioned
rods and cylinders shall be ±0.5 mm on the outside diameter and +0 -0.5 mm
on the internal diameter.
d. The tolerance on lengths of all rods and cylinders shall be no greater than
±5mm for lengths less than 2 m and ±10 mm for lengths over 2 m or as stated in
the Contract.
1.4 Classification
a. The classification of castings shall be as defined in DEF STAN 02-863.
1.5 Test Methods
1.5.1 Destructive Tests

1.5.1.1 Chemical Analysis

a. A full chemical analysis shall be taken from each cast for noncontinuous
melting. For continuous casting, analysis shall be made corresponding to each
melt poured during the length of the cast.
1.5.1.2 Mechanical Tests

a. Tensile tests shall be carried out in accordance with BS EN 10002-1. Three test
bars are required from each cast and shall be taken from the actual casting; two
of the test bars shall be held in reserve for any retests.

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1.5.1.3 Test Pieces

a. All test pieces shall be permanently marked with the cast number.
b. To ensure representative results all machined test pieces require a surface
finish 0.8
m Ra or better.
c. Unless authorized by the Project Manager all test pieces shall be retained for a
period of two months after completion of the contract or delivery of the
material.
1.5.2 Non-Destructive Tests
1.5.2.1 Dimensional
a. All products shall be fully dimensionally checked to ensure that they comply
with DEF STAN 02-863. Rods and cylinders shall be gauged and sizes
recorded.
1.5.2.2 Visual-Optical
a. All cast surfaces shall be 100% visually inspected, assisted where necessary by
the use of x5 magnification optics. All imperfections shall be identified and
recorded.
1.6 Defects and Rectification of Defects
a. Defects discovered during machining may be cause for rejection of any rod,
section or cylinder notwithstanding that the item had been previously certified
as conforming to this Standard.
b. Minor surface defects shall be acceptable, provided that they are not on the
finished machined surface.
c. Rectification of defects by welding shall not be permitted.
1.6.1 Rectification of Surface Defects by Blending
a. Unacceptable surface defects on the finish machined surface may be blended
out by an approved process, providing the resulting depression does not reduce
the contract drawing section thickness by more than 5 mm for section thickness
over 50 mm, or 10% of section thicknesses up to and including 50 mm. The
depression sides and ends shall be smoothly blended out by a minimum radius
of three times the maximum depth of blending and the edge formed with the
surface is also to be faired smooth. The total area subjected to blending,
including the area affected by the fairing, is not to exceed 20% of any
nondesignated region.

2. NATIONAL/INTERNATIONAL REGULATIONS
(No relevant information included)
3. MILITARY STANDARDS/REQUIREMENTS
Related Documents: BS EN 1982, see also Annex A.
3.1 Acceptance Standards
3.1.1 Destructive Examination Standards
3.1.1.1 Chemical Analysis
a. Each chemical analysis shall conform with the requirements of alloy CC491K or
CC492K of BS EN 1982 as appropriate.

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3.1.1.2 Mechanical Tests

a. Each test result shall conform with the relevant section of Table 1.1 of this
Standard. If any of the original test pieces fail to meet the test requirements,
two further samples may be tested if the manufacturer so desires. If the
manufacturer elects not to test further samples or if any of the retests fail to
meet the properties specified in Table 1.1, the material represented by the test
pieces shall be rejected.
3.1.2 Non-destructive Examination Standards
3.1.2.1 Dimensional
a. All rods, sections and cylinders shall be dimensionally within the tolerances
stated in Clauses 1.3b., 1.3c. and 1.3d. or as stated in the Contract.
3.1.2.2 Visual
a. The finished surface of the product, either `as cast' or finish machined, shall be
free from cracks, tears, laps, burrs, seams, slivers or scale. A light coating of
oxidation scale is acceptable on the `ascast' surface.
3.2 Quality Assurance Documentation
a. Each consignment of material shall be supplied with a Certificate of
Conformity. This shall provide:
(1) cast numbers;
(2) composition and mechanical test certificate numbers.
Actual test certificates shall be retained by the manufacturer.
3.3 Identification of Continuously Cast Material
a. For identification purposes, all material shall be legibly marked by the
manufacturer with the following particulars applied by self adhesive tape or
indelible ink:
(1) the cast number together with DEF STAN 02-830 CC491K-CC or DEF
STAN 02-830 CC492K-CC;
(2) Contract number;
(3) ships' numbers or additional markings as may be required by the
Contract.
b. The indelible ink shall not have a deleterious effect during subsequent hot
working.
3.4 Packaging
a. Except where otherwise stated in the Contract, rods, section and cylinders shall
be packaged in accordance with the manufacturer's normal trade practice and
shall ensure that no damage occurs during transit.
b. Each package shall carry a label marked with the following additional
identification details:
(1) NATO Stock No when applicable;
(2) Description;
(3) Quantity;
(4) Contract Number.

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4. DESIGN REQUIREMENTS/GUIDANCE
(No relevant information included)

5. CORPORATE EXPERIENCE & KNOWLEDGE

5.1 History

a. In the early 1960's Naval Construction Research Establishment (NCRE)

conducted shock tests on a number of Gunmetal hull valves of the type fitted in
conventional submarines (Ref. D/SSC/NA113/850/18/2)

b. A 4¼ inch standard right angled hull valve failed by complete fracture of the
neck. Two similar valves that were tested both showed damage at low shock
levels.

c. The low shock shock factor levels resulted in Nickel Aluminium Bronze (NAB)
replacing Gunmetal for submarine hull valves and all first level systems.
Gunmetal sand castings are now only Class III castings and for surface
applications only

5.2 Typical Uses

a. General purpose casting such as low pressure valves, pipe fittings, oil line
fittings and pump castings. This is the most widely used grade of Gunmetal
where pressure tightness is required. Normally used for Class III castings only.

5.3 Joining Methods

a. Soft soldering is the recommended joining method. Silver brazing should give
satisfactory results where restraint is absent. The welding of CC491K alloy with
Shielded Metal Arc Welding (SMAW) and Gas Metal Arc Welding (GMAW)
processes is only possible with specialist techniques.

5.4 Remarks

a. This alloy is inferior to the 87-7-3-3 Gunmetal for castings subject to sliding
friction without oil lubrication. The material is hot-short. This material
supersedes BS 1400 LG2.

b. See also BR3008 Chapter 1 data sheet NF4-04.

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 DEF STAN 02–830 PART 2 / ISSUE 2
(NES 830)

ANNEX A.
A.
RELATED DOCUMENTS
A1. The following documents and publications are referred to in this Standard:
BS EN 1982 Copper Alloy Ingots and Copper Alloy and High Conductivity
Copper Castings
BS EN 10002-1 Tensile Testing of Metallic Materials
Part 1: Method of Test at Ambient Temperature
JSP 430 Ship Safety Management System Handbook
DEF STAN 02-863 Requirements for the Classification, Dimensions, Tolerances and
(NES 863) General Standards of Acceptance for Copper and Nickel Alloy
Castings
BR 3008 Materials and Processes (Mechanical Engineering)

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ANNEX B.
B.
DEFINITIONS
B1. For the purpose of this Standard the following definitions apply:
Cast A cast is:
a. the product of one furnace melt; or
b. the product of one crucible melt; or
c. the product of a number of furnace or crucible melts where
such are aggregated and mixed prior to sampling; or
d. in continuous casting, the product from a number of
consecutive melts of the same alloy through a die.
Certificate of This is supplied with material of which traceability during
Conformity manufacturing is required and is issued on the basis of the
required tests having been carried out on the casts from which
the material supplied has been taken.
Contractor The Firm, Company, Organization or Establishment working
within the scope of this Standard.
Project Manager The Section within the Defence Procurement Agency or Defence
Logistics Organisation, acting on behalf of the Secretary of State
for Defence. The Project Manager should be specified in the
Contract, but where not known by the contractor, enquiries are to
be forwarded to Defence Procurement Agency Section STGMT
Abbey Wood, Bristol. For sub-contractors, the Project Manager
may be the Prime Contractor.
S0 The crosssectional area of the gauge length in a tensile test piece,
before testing, as detailed in BS EN 10002

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 DEF STAN 02–830 PART 2 / ISSUE 2
(NES 830)

ANNEX C.
C.
PROCUREMENT CHECK LIST
Notes:
C.1 This Check List is to ensure that certain aspects of this Standard are consulted
when preparing a procurement specification for a particular application.
C.2 Clauses where a preference for an option is to be used or where specific data is
to be added are included in the Check List.
C.3 Each item is to be marked either:

= included
NA = not applicable
CHECK
CHECK CLAUSE No
or NA
No
1 Composition to be specified; either CC491K or 1.1a.
CC492K
2 Alternative period for retaining test pieces to be 1.5.1.3c.
specified?
3 Are there special dimensional tolerance 3.1.2.1a.
requirements?
4 Are there special packaging requirements? 3.4a.

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ALPHABETICAL INDEX O
(Note: Page numbers are given)
Oxidation scale, 9

B
P
Blending, 8
Proof stress, 7

C
R
Certificate of Conformity, 9
Retests, 7, 9
Chemical composition, 7
Contract number, 9
Cracks, 9 S
Seams, 9
F Slivers, 9

Finished surface, 9
T
H Tears, 9
Hollow-section, 7 Tensile Strength, 7
Hot working, 9 Tensile tests, 7
Tolerance,7, 9

I
Imperfections, 8 W
Indelible ink, 9 Welding, 8

14
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/69/02/830 Pt 2.

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.