802-8999910 AM Welding Requirements PPD 2024.10.03_final.pdf

802-8999910

REVISION 0

PROJECT PECULIAR DOCUMENT

REQUIREMENTS FOR USING EXISTING

NAVSEA S9074-AQ-GIB-010/248 WELDING

PROCEDURES FOR INSTALLATION WELDING OF

PARTS PRODUCED VIA METAL ADDITIVE

MANUFACTURING

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE.

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

03 OCTOBER 2024

RECORD OF REVISIONS-1/(RECORD OF REVISIONS-2 Blank)

RECORD OF REVISIONS

REVISION

NO. DATE TITLE OR BRIEF DESCRIPTION/PREPARING ACTIVITY

0 03 OCT

Initial issue.

FOREWORD-1

FOREWORD

This document contains requirements for assessing the presumed S-Groups of additive manufacturing (AM) base materials. The S-Group verification testing required by this document has been selected to demonstrate that the heat-affected zone of the AM material does not exhibit deleterious behavior when test assemblies or prototypical mock-ups are welded under limited restraint. This behavior is extended to assert that existing welding procedures and personnel are acceptable for welding of AM parts.

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TABLE OF CONTENTS

Chapter/Paragraph Page

Chapter 1 Scope ......................................................................................................................................... 1-1 1-1 Introduction. ................................................................................................................................. 1-1 1-2 Engineering Intent. ....................................................................................................................... 1-1 1-3 Requirements and Guidance. ....................................................................................................... 1-1 1-4 Other NAVSEA Additive Manufacturing Qualification Standards. ............................................ 1-2

Chapter 2 References ................................................................................................................................. 2-1 2-1 Required References. ................................................................................................................... 2-1

2-1.1 Government Documents. .................................................................................................... 2-1 2-1.1.1 Defense Standardization Program Documents. ......................................................... 2-1 2-1.1.2 Other Government Publications. ............................................................................... 2-1

2-1.2 Non-Government Documents. ............................................................................................ 2-1 2-2 Background References. .............................................................................................................. 2-2 2-3 Order of Precedence. .................................................................................................................... 2-2

Chapter 3 Definitions ................................................................................................................................. 3-1 3-1 Introduction. ................................................................................................................................. 3-1 3-2 Definitions. ................................................................................................................................... 3-1

Chapter 4 General Requirements ............................................................................................................... 4-1 4-1 Scope. ........................................................................................................................................... 4-1 4-2 General Requirements. ................................................................................................................. 4-1

4-2.1 Responsibility. .................................................................................................................... 4-1 4-2.2 Welding Qualification Requirements. ................................................................................ 4-1

4-2.2.1 Workmanship Qualification. ..................................................................................... 4-1 4-2.2.2 Welding Process. ....................................................................................................... 4-1 4-2.2.3 Welding Filler Materials. .......................................................................................... 4-1

4-2.3 Nondestructive Testing Qualification Requirements. ......................................................... 4-1 4-2.3.1 Visual Inspection. ...................................................................................................... 4-1 4-2.3.2 Radiographic Testing. ............................................................................................... 4-1

4-2.4 Destructive Testing Requirements. ..................................................................................... 4-1 4-3 Records. ........................................................................................................................................ 4-1

4-3.1 Certification Data Package. ................................................................................................ 4-1 4-3.2 Nondestructive Test Reports. ............................................................................................. 4-2 4-3.3 Destructive Test Reports. ................................................................................................... 4-2 4-3.4 Records Retention. .............................................................................................................. 4-2

Chapter 5 Testing Requirements ................................................................................................................ 5-1 5-1 Scope. ........................................................................................................................................... 5-1 5-2 General Requirements. ................................................................................................................. 5-1

5-2.1 Testing Frequency and Requirements. ............................................................................... 5-1 ii

Chapter/Paragraph Page

5-2.1.1 S-Groups Not Listed. ................................................................................................ 5-1 5-2.1.2 Reasons for Re-Performing S-Group Verification Testing. ...................................... 5-1

5-2.2 Exceptions. ......................................................................................................................... 5-1 5-2.2.1 Welding of AM Parts Where Welding Procedure Qualification is Not Required. ... 5-1 5-2.2.2 Welding of AM Parts for Low-Risk Applications. ................................................... 5-1

5-2.3 S-Group Verification Testing Requirements for AM Parts Requiring Post-Weld Heat Treatment. ..................................................................................................................................... 5-1 5-2.4 Test Assembly Retest and Rejection Requirements. .......................................................... 5-1

5-2.4.1 S-Group Verification Test Assembly Retests. .......................................................... 5-1 5-2.4.2 Maximum Number of Retests Permitted. .................................................................. 5-2 5-2.4.3 Additional Retests with NAVSEA Approval. ........................................................... 5-2 5-2.4.4 Rejection of AM Materials Following S-Group Verification Testing. ..................... 5-2

5-2.5 S-Group Verification Test Assembly Repair Welding. ...................................................... 5-2 5-3 S-Group Verification Testing Requirements. ............................................................................... 5-2

5-3.1 S-Group Verification Test Assembly Welding Requirements. .......................................... 5-2 5-3.1.1 Preheat and Interpass Temperature Requirements. ................................................... 5-2 5-3.1.2 Heat Input Requirements........................................................................................... 5-2 5-3.1.3 Welding Procedure Selection. ................................................................................... 5-3

5-3.2 Test Assembly Design Requirements. ................................................................................ 5-3 5-3.2.1 AM Base Material Heat Treatment Condition. ......................................................... 5-3 5-3.2.2 Test Assembly Thickness. ......................................................................................... 5-3 5-3.2.3 Test Assembly Arrangement (PBF). ......................................................................... 5-3 5-3.2.4 Test Assembly Arrangement (Wire DED). ............................................................... 5-3 5-3.2.5 Test Assembly Weld Joint Design. ........................................................................... 5-3 5-3.2.6 Test Assembly Weld Joint Preparation. .................................................................... 5-3

5-3.3 Special S-Group Verification Testing Requirements. ........................................................ 5-3 5-3.3.1 Tack Welds and Lock Welds. ................................................................................... 5-3 5-3.3.2 Fillet Welds. .............................................................................................................. 5-4 5-3.3.3 Piping Socket Welds. ................................................................................................ 5-4 5-3.3.4 Other Welds. ............................................................................................................. 5-4

5-4 Nondestructive and Destructive Testing Requirements. .............................................................. 5-4 5-4.1 Nondestructive Test Requirements. .................................................................................... 5-4

5-4.1.1 Nondestructive Test Acceptance Criteria. ................................................................. 5-4 5-4.2 Destructive Test Requirements. .......................................................................................... 5-4

5-4.2.1 Macro-Etch Examination. ......................................................................................... 5-4 5-4.2.2 Guided Bend Tests. ................................................................................................... 5-4 5-4.2.3 Tension Tests. ........................................................................................................... 5-4 5-4.2.4 Welded Extensions for Destructive Testing. ............................................................. 5-4 5-4.2.5 Preparation of Specimens for Destructive Testing. ................................................... 5-5

5-4.3 Destructive Test Acceptance Criteria. ................................................................................ 5-5 iii

Chapter/Paragraph Page

5-4.3.1 Macro-Etch Examination. ......................................................................................... 5-5 5-4.3.2 Guided Bend Tests. ................................................................................................... 5-5 5-4.3.3 Tension Tests. ........................................................................................................... 5-5

5-5 Evaluation of S-Group Verification TestING RESULTs. ............................................................ 5-5 5-5.1 Certification Data Package. ................................................................................................ 5-5 5-5.2 Certification Data Package Submittal. ................................................................................ 5-5 5-5.3 Certification Data Package Approval. ................................................................................ 5-5 5-5.4 Certification Data Package Transfer. .................................................................................. 5-6

Chapter 6 Tables and Figures .................................................................................................................... 6-1 Appendix A Supplemental Requirements for High-Risk Installations ..................................................... A-1

A-1 General. ...................................................................................................................................... A-1 A-1.1 General Requirements. ..................................................................................................... A-1 A-1.2 Test Assembly Requirements. .......................................................................................... A-1

A-1.2.1 Test Assembly Design Recommendation................................................................ A-1 A-1.2.2 Substitution of AM Shapes. .................................................................................... A-1 A-1.2.3 Additional Requirements for NAVSEA 08 Cognizant AM Parts. .......................... A-1

A-1.3 Test Assembly Welding and Testing. ............................................................................... A-1 A-1.3.1 Substitution of Face and Root Bend Tests. ............................................................. A-2

A-1.4 Piping Socket Welds. ........................................................................................................ A-2

LIST OF TABLES

Table Title Page

Table 6-1. Allowable Filler Materials ....................................................................................................... 6-1 Table 6-2. S-Group Verification Testing Requirements ........................................................................... 6-2 Table 6-3. Destructive Testing Requirements ........................................................................................... 6-3

LIST OF ILLUSTRATIONS

Figure Title Page

Figure 6-1. S-Group Verification Test Assembly ..................................................................................... 6-4 Figure 6-2. S-Group Verification Test Assembly Build Orientation ........................................................ 6-6

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CHAPTER 1

SCOPE

1-1 INTRODUCTION.

This document provides requirements for applying existing Naval Sea Systems Command (NAVSEA) welding requirements to AM parts manufactured using the powder bed fusion (PBF) and wire directed energy deposition (DED) processes. While this document is intended to be used with NAVSEA AM technical publications and AM material project peculiar documents (PPD), the requirements contained herein may also be used independently.

While analogous to conventional cast and wrought forms, AM produces base materials that have distinct microstructural characteristics. In some cases, these microstructures warrant supplemental testing to ensure that existing welding procedures produce acceptable weldments, with particular regard to evaluating the effect of welding on the soundness of the AM material’s heat-affected zone.

1-2 ENGINEERING INTENT.

This document provides the minimum requirements for classifying AM base materials in existing S-Groups from NAVSEA S9074-AQ-GIB-010/248, Requirements for Welding and Brazing Procedure and Performance Qualification. The requirements provided herein have been determined to be the most practicable at the time of writing and are based on the idea that base material grouping is historically performed by comparing the chemical composition and mechanical properties of a new alloy with previously grouped base materials. Most alloy types are easily grouped in this manner and, provided that they do not historically have metallurgical or welding-related concerns, are straightforward to classify as part of an existing S-Group in most cases.

For AM base materials where the alloy type is known to have weldability issues, or there are concerns for the effect of heat treatment, a relatively simple test of welding a standard test assembly under limited restraint is performed during the AM procedure qualification. If the weldability test is successful, the AM base material produced by the AM procedure qualification is then grouped in a go-forward manner with respect to future production. This approach was adopted using engineering judgement and the need to take on an acceptable amount of risk to support the planned rapid adoption of AM.

This approach does not encompass all available configurations and combinations of base materials, filler materials, weld processes, joint design, and other technical considerations across existing Navy welding requirements. As such, Appendix A specifies supplemental testing for components which may have significant adverse consequences if fabrication or repair welding were to encounter difficulties. This additional testing is required for all components under the cognizance of NAVSEA 08, and may be invoked by the purchasing activity where risk related to a specific AM part must be absolutely minimized.

The requirements contained in this document are intended to be executed by the AM supplier. With the understanding that not all AM suppliers have welding and nondestructive testing programs in conformance with NAVSEA requirements at this time, options have been provided to utilize commercial equivalent materials and standards. Additionally, while the tests herein are intended to be performed by the AM supplier, they may be performed by other capable activities, including the purchasing activity, to support fleet needs.

1-3 REQUIREMENTS AND GUIDANCE.

This document contains both mandatory requirements (indicated by the word “shall”), designed to serve as standards applicable to methods, materials, and inspection, and guidance information (indicated by either the word “should” or “may”). Guidance information is recommended but is not mandatory.

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1-4 OTHER NAVSEA ADDITIVE MANUFACTURING QUALIFICATION STANDARDS.

AM base material that has been qualified for welding in accordance with NAVSEA 250-1500-1, Welding Standard, may be utilized in lieu of performing the S-Group verification testing required by this document, provided the AM feedstock is allowed by NAVSEA 250-1500-1. Qualification evidence in accordance with NAVSEA 250-1500-1 may be submitted as part of the AM procedure qualification package by the AM supplier in lieu of the certification data package required by this document.

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CHAPTER 2

REFERENCES

2-1 REQUIRED REFERENCES.

2-1.1 GOVERNMENT DOCUMENTS.

2-1.1.1 Defense Standardization Program Documents.

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-C-24615 - Castings, Nickel-Chromium-Molybdenum-Columbium Alloy

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-22 - Welded Joint Design

MIL-STD-2035 - Nondestructive Testing Acceptance Criteria

(Copies of these documents are available online at https://quicksearch.dla.mil.)

2-1.1.2 Other Government Publications.

NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

S9074-AQ-GIB-010/248 - Requirements for Welding and Brazing Procedure and Performance Qualification

S9074-AR-GIB-010/278 - Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels

S9074-A2-GIB-010/AM-PBF - Requirements for Metal Powder Bed Fusion Additive Manufacturing

S9074-A4-GIB-010/AM-WIRE DED - Requirements for Metal Directed Energy Deposition Additive Manufacturing

T9074-AS-GIB-010/271 - Requirements for Nondestructive Testing Methods

250-1500-1 - Welding Standard

(Copies of these documents are available online via Model Based Product Support (MBPS) at https://mbps.navseaplm.navy.mil/Windchill/app/. To gain access to MBPS, obtain an account with National Help Desk Service Management (NHDSM) at https://nhdsm.navair.navy.mil (a valid CAC is required to access this website) and submit a SAAR-N Request. Refer questions, inquiries, or problems to

(888) 292-5919. These documents are available for ordering (hard copy) via the Naval Logistics Library (NLL) at https://nll.navsup.navy.mil. For questions regarding the NLL, contact the NLL Customer Service at nllhelpdesk@navy.mil, (866) 817-3130, or (215) 697-2626/DSN 442-2626.)

2-1.2 NON-GOVERNMENT DOCUMENTS.

AMERICAN WELDING SOCIETY (AWS) PUBLICATIONS

AWS A3.0M/A3.0 - Standard Welding Terms and Definitions

AWS B4.0 - Standard Methods for Mechanical Testing of Welds

(Copies of these documents are available online at www.aws.org.

ASTM INTERNATIONAL

ASTM E8/E8M - Standard Test Methods for Tension Testing of Metallic Materials https://quicksearch.dla.mil/ https://usg01.safelinks.protection.office365.us/?url=https%3A%2F%2Fmbps.navseaplm.navy.mil%2FWindchill%2Fapp%2F&data=05%7C01%7Crobert.a.alperstein.civ%40us.navy.mil%7C1b5617c00fa545a51dfb08dbb39e1d1f%7Ce3333e00c8774b87b6ad45e942de1750%7C0%7C0%7C638301263915890369%7CUnknown%7CTWFpbGZsb3d8eyJWIjoiMC4wLjAwMDAiLCJQIjoiV2luMzIiLCJBTiI6Ik1haWwiLCJXVCI6Mn0%3D%7C3000%7C%7C%7C&sdata=qr8QsyYAAuCXJF1xzayLRDw6FOtQeEXdxBufk6Ih3E8%3D&reserved=0 https://usg01.safelinks.protection.office365.us/?url=https%3A%2F%2Fnhdsm.navair.navy.mil%2F&data=05%7C01%7Crobert.a.alperstein.civ%40us.navy.mil%7C1b5617c00fa545a51dfb08dbb39e1d1f%7Ce3333e00c8774b87b6ad45e942de1750%7C0%7C0%7C638301263915890369%7CUnknown%7CTWFpbGZsb3d8eyJWIjoiMC4wLjAwMDAiLCJQIjoiV2luMzIiLCJBTiI6Ik1haWwiLCJXVCI6Mn0%3D%7C3000%7C%7C%7C&sdata=bVkiPxpGHZnHIMEIAW4XwBGlnsg2lOyPhJ3t%2ByQ0qHk%3D&reserved=0 https://nll.ahf.nmci.navy.mil/ mailto:nllhelpdesk@navy.mil file://peraton.com/FS/Programs/ALEXVA/ALX_Projects/Systech/Specs%20&%20Stds%20Processing%20-%20Elaine/SEA%2005P%20AM%20Specs%20-%20VC/PPDs/100S/www.aws.org

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ASTM E23 - Standard Test Methods for Notched Bar Impact Testing of Metallic Materials

ISO/ASTM 52900 - Additive Manufacturing – General Principles – Fundamentals and Vocabulary

(Copies of these documents are available online at www.astm.org.)

2-2 BACKGROUND REFERENCES.

The following references are included for background information and may not be referenced in this document.

a. ASME Boiler and Pressure Vessel Code (BPVC)

b. MIL-STD-1689, Fabrication, Welding, and Inspection of Ships Structure

c. NAVSEA Letter 9070 Ser 05Z/191, of 22 May 2024, Guidance on Identification and Installation of Low Risk Additi05ve Manufactured Metal Components

d. NAVSEA Letter 9074 Ser 05P/050, of 01 Mar 2024, Project Peculiar Documents for Metal

Additive Manufacturing Material Specifications

e. NAVSEA Letter 9074 Ser 05P/218, of 18 Jul 2024, Project Peculiar Document for Directed

Energy Deposition Additively Manufactured Base Metals for Critical Applications:

Requirements for Gas Metal Arc Welding Additively Manufactured Pre-Forms for Low-Alloy Steel Applications

f. NAVSEA Letter 9074 Ser 05Z/223, of 08 May 2024, Guidance for Performing Non-Destructive Testing and Non-Destructive Testing Procedure Qualification in Support of Additive Manufacturing Efforts

g. T9074-AD-GIB-010/1688, Requirements for Fabrication, Welding, and Inspection of Submarine Structure

h. 802-8979757, Directed Energy Deposition Additively Manufactured Base Metals for Critical Applications: Requirements for Gas Metal Arc Welding Additively Manufactured Pre-Forms for Low-Alloy Steel Applications

i. 802-8979758, Austenitic Chromium-Nickel Stainless Steel, Corrosion-Resistant, Laser Powder Bed Fusion, Additively Manufactured

j. 802-8979759, Commercially Pure Titanium, Wire Arc, Directed Energy Deposition, Additively Manufactured

k. 802-8979760, Copper-Nickel (70-30), Wire Arc, Directed Energy Deposition, Additively Manufactured

l. 802-8979761, Copper-Nickel (70-30), Laser Powder Bed Fusion, Additively Manufactured

m. 802-8979762, Nickel Aluminum Bronze, Wire Arc, Directed Energy Deposition, Additively

Manufactured

n. 802-8985009, Austenitic Chromium-Nickel-Molybdenum Stainless Steel, Corrosion-Resistant, Directed Energy Deposition, Additively Manufactured

2-3 ORDER OF PRECEDENCE.

In the event of a conflict between the text of this document and the references cited herein, the conflict shall be reported to NAVSEA for adjudication.

https://www.astm.org/

3-1

CHAPTER 3

DEFINITIONS

3-1 INTRODUCTION.

Except as noted herein, welding nomenclature shall be as specified in NAVSEA S9074-AQ-GIB-010/248 or AWS A3.0M/A3.0, as applicable.

Except as noted herein, AM nomenclature shall be as specified in ISO/ASTM A52900.

3-2 DEFINITIONS.

a. AM Base Material. Base material produced via AM using the PBF or wire DED processes. This base material may take the form of AM parts, may be a shape or feature of an AM part designed specifically for subsequent testing (e.g., a prolongation on an existing AM build), or may be a dedicated test assembly.

b. AM Procedure Qualification. For the purposes of this document, the AM procedure qualification is either the PBF procedure specified in NAVSEA S9074-A2-GIB-010/AM-PBF, Requirements for Metal Powder Bed Fusion Additive Manufacturing, or the DED procedure specified in NAVSEA S9074-A4-GIB-010/AM-WIRE DED, Requirements for Metal Directed Energy Deposition Additive Manufacturing.

c. AM Supplier. The activity contracted to provide an AM part or a final assembly containing AM parts to the purchasing activity.

d. Approval (Approved). When the item under consideration requires acceptance by NAVSEA or its authorized representative. “Approval” or “approved,” as used herein, is granted by the NAVSEA authorized representative unless NAVSEA approval is specified.

e. Authorized Representative. For the purposes of this document, the authorized representative is the government representative designated in accordance with NAVSEA S9074-AQ-GIB-010/248.

f. Certification Statement. Where testing is required, the certification package shall include a written statement made by the responsible official of the AM supplier certifying that the tests and test results meet all requirements of this document and that the AM base material’s presumed S-Group has been validated as its actual S-Group for welding with procedures and personnel qualified in accordance with NAVSEA S9074-AQ-GIB-010/248.

g. Conventional Base Material. Material in a conventional product form (cast, wrought, forged, etc.) procured to an applicable military or commercial specification for installation via welding using procedures and personnel qualified in accordance with NAVSEA S9074-AQ-GIB-010/248.

h. High-Risk Installation. Installation or fabrication of an AM part which poses a significant risk to critical path for ship’s schedule or maintenance availability if welding issues arise. All AM parts under the cognizance of NAVSEA 08 are considered high-risk installations for the purposes of this document (see Appendix A).

i. Purchasing Activity. The activity purchasing an AM part intended to be welded using welding procedures and personnel qualified in accordance with NAVSEA S9074-AQ-GIB-010/248. It may be a commercial shipyard or their subcontractor(s), a government shipyard or repair activity, or other government agency. The purchasing activity is responsible for involving the appropriate NAVSEA technical stakeholders in decisions related to AM parts.

j. Material Condition. One of three general categories of post-processing following the build.

(1) As-Built. The absence of a heat treatment. For the purposes of this document, application of post-processing techniques near room temperature (e.g., machining) are still considered to be in the as-built condition.

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(2) Heat Treated Within PPD Requirements. Post-build heat treatment in accordance with NAVSEA Letter 9074 Ser 05P/050 of 01 Mar 2024.

(3) Heat Treated Outside PPD Requirements. Post-build heat treatment not in accordance with NAVSEA Letter 9074 Ser 05P/050 of 01 Mar 2024. This specifically includes heat treatment in accordance with NAVSEA S9074-AR-GIB-010/278, Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels, excluding presumed group S-1 materials.

k. Presumed S-Group. The S-Group to which an AM base material is presumed to be interchangeable based on similar chemical composition and mechanical properties. This assumption is made based on chemical composition and mechanical properties testing during AM procedure qualification, or as prescribed by the applicable AM material specification.

l. S-Group (S-Number). A designation used to group base materials for procedure and performance qualification in accordance with NAVSEA S9074-AQ-GIB-010/248. The designation of a specific base metal’s S-Group is typically based on its chemical composition and mechanical properties. The S-Group is analogous to AWS M-Numbers and American Society of Mechanical Engineers (ASME) P-Numbers.

m. S-Group Verification Testing. Testing performed in accordance with the requirements of this document to evaluate AM base materials for classification as part of an existing S-Group. The purpose of this testing is to validate that the AM base material performs like conventional product forms when welded using procedures and personnel qualified in accordance with NAVSEA

S9074-AQ-GIB-010/248.

4-1

CHAPTER 4

GENERAL REQUIREMENTS

4-1 SCOPE.

This chapter addresses the general requirements for S-Group verification testing of PBF and wire DED AM base materials.

4-2 GENERAL REQUIREMENTS.

4-2.1 RESPONSIBILITY. When this document is specified, the AM supplier (or its subcontractors) shall perform the required tests identified herein to determine if the presumed S-Group of an AM base material is its actual S-Group for the purposes of NAVSEA S9074-AQ-GIB-010/248.

4-2.2 WELDING QUALIFICATION REQUIREMENTS. Welding procedures and welders (or welding operators) shall be qualified in accordance with NAVSEA S9074-AQ-GIB-010/248 for the presumed S- Group of the AM base material. Where qualification in accordance with NAVSEA S9074-AQ-GIB-010/248 is not practicable, welding procedures and welders (or welding operators) qualified in accordance with AWS, ASME Boiler and Pressure Vessel Code (BPVC), or other commercial standards may be used.

4-2.2.1 Workmanship Qualification. Welders (or welding operators) need not be trained on welder workmanship in accordance with NAVSEA S9074-AQ-GIB-010/248 when commercial standards are used for welding of S-Group verification test assemblies.

4-2.2.2 Welding Process. Shielded Metal Arc Welding (SMAW) or Gas Tungsten Arc Welding (GTAW) processes shall be used to the maximum extent practicable for performing S-Group verification testing when no welding process is specified.

4-2.2.3 Welding Filler Materials. Welding filler material shall be as specified in table 6-1, unless otherwise approved by NAVSEA.

4-2.3 NONDESTRUCTIVE TESTING QUALIFICATION REQUIREMENTS. Nondestructive testing procedures, equipment, and personnel shall be qualified in accordance with NAVSEA T9074-AS-GIB-010/271, Requirements for Nondestructive Testing Methods, as modified by current NAVSEA AM nondestructive testing guidance (e.g., NAVSEA Letter 9074 Ser 05Z/223 of 08 May 2024).

Where qualification in accordance with NAVSEA T9074-AS-GIB-010/271 is not practicable, nondestructive testing procedures, equipment, and personnel qualified in accordance with AWS, ASME, American Society for Nondestructive Testing (ASNT), or other commercial standards may be used.

4-2.3.1 Visual Inspection. Visual inspection (VT) shall be accomplished prior to any magnetic particle testing (MT) or liquid penetrant testing (PT) when MT or PT is a required inspection.

4-2.3.2 Radiographic Testing. Radiographic testing (RT) may be performed before or after VT and MT or PT, at the discretion of the AM supplier.

4-2.4 DESTRUCTIVE TESTING REQUIREMENTS. Destructive testing shall be in accordance with applicable AWS or ASTM standards, as modified by this document.

4-3 RECORDS.

4-3.1 CERTIFICATION DATA PACKAGE. At a minimum, the certification data package shall contain the following items:

a. Certification data package number, revision, and date.

b. The AM supplier’s name.

4-2

c. Identification of the AM procedure used to manufacture the S-Group verification test assemblies and/or prototypical mock-up, including machine make, model and serial number, and feedstock.

d. Actual chemical composition and mechanical properties of the AM base material (e.g., applicable test reports from the AM procedure).

e. Material specification of the AM base material (e.g., NAVSEA PPD or applicable commercial specification).

f. Presumed S-Group for the AM base material.

g. The specific heat or lot number, or equivalent identification, of the AM base material used for all testing.

h. The heat treatment condition of the AM base material (see 3-2.j).

i. The welding procedure used.

j. Welder/welding operator (name and employee number).

k. Filler material used for welding test assemblies, including filler material conformance test certificates.

l. Nondestructive test results and acceptance criteria.

m. Destructive test results and acceptance criteria.

n. Certified nondestructive and destructive test reports for all tests/inspections performed, including photomacrographs of the macro-etch cross-sections (see 5-4.3.1).

o. Guided bend test mandrel radius, if not reported in the destructive test report (see 5-4.2.2).

p. Heat treatment records, if applicable.

q. Repair welding data, if applicable (see 5-2.5.e).

r. The failed retest technical data package in accordance with 5-2.4.2, if applicable.

s. The failed second retest technical data package in accordance with 5-2.4.3, if applicable.

t. If elevated S-Group verification testing was performed in lieu of the S-Group verification testing requirements of Chapter 5 (see Appendix A).

u. Results of the required evaluation (see 5-5), as applicable.

v. A certification statement in accordance with 3-2f.

4-3.2 NONDESTRUCTIVE TEST REPORTS. Nondestructive test reports shall, at a minimum, contain the information required by NAVSEA T9074-AS-GIB-010/271, regardless of whether the nondestructive testing procedure used is qualified in accordance with NAVSEA T9074-AS-GIB-010/271 or not.

4-3.3 DESTRUCTIVE TEST REPORTS. Destructive test reports shall, at a minimum, contain the information required by the applicable AWS or ASTM standard invoked for the testing.

4-3.4 RECORDS RETENTION. Records shall be retained in accordance with NAVSEA S9074-A2-GIB-010/AM-PBF or NAVSEA S9074-A4-GIB-010/AM-WIRE DED, as applicable.

5-1

CHAPTER 5

TESTING REQUIREMENTS

5-1 SCOPE.

This chapter addresses the specific requirements for validating that existing NAVSEA welding procedures in accordance with NAVSEA T9074-AQ-GIB-010/248 are acceptable for use on AM base material.

5-2 GENERAL REQUIREMENTS.

5-2.1 TESTING FREQUENCY AND REQUIREMENTS. S-Group verification testing shall be performed when specified in table 6-2. S-Group verification testing shall be completed during AM procedure qualification and approved prior to production welding of part(s) manufactured using the same AM procedure. For cases where AM procedure qualification has already been completed, S-Group verification shall be completed separately.

5-2.1.1 S-Groups Not Listed. The requirements of this document may be used for S-Group verification testing of S-Groups not listed in table 6-2. A description of the proposed tests shall be submitted to NAVSEA for approval prior to conducting S-Group verification testing.

5-2.1.2 Reasons for Re-Performing S-Group Verification Testing. When the associated AM procedure requires Level I or Level II requalification in accordance with NAVSEA S9074-A2-GIB-010/AM-PBF or NAVSEA S9074-A4-GIB-010/AM-WIRE DED, as applicable, S-Group verification testing shall be re-performed in accordance with this document.

5-2.2 EXCEPTIONS. S-Group verification testing is not required for the following applications, or when otherwise approved by NAVSEA. Where S-Group verification testing is not required, the AM base material may be treated as if its presumed S-Group were its actual S-Group, and a certification data package (see 4- 3.1) is not required.

5-2.2.1 Welding of AM Parts Where Welding Procedure Qualification is Not Required. S-Group verification testing is not required for welding of AM parts where welding procedure qualification is not required by the applicable fabrication standard (e.g., “minor structure” welding).

5-2.2.2 Welding of AM Parts for Low-Risk Applications. S-Group verification testing is not required for low-risk AM parts when AM procedure qualification is not required.

5-2.3 S-GROUP VERIFICATION TESTING REQUIREMENTS FOR AM PARTS REQUIRING

POST-WELD HEAT TREATMENT. Where post-weld heat treatment is required for the AM part, NAVSEA shall be contacted for guidance.

5-2.4 TEST ASSEMBLY RETEST AND REJECTION REQUIREMENTS.

5-2.4.1 S-Group Verification Test Assembly Retests. If an S-Group verification test assembly fails to meet the applicable acceptance criteria of this document, it may still be considered part of its presumed S-Group if retested under the following conditions:

a. An S-Group verification test assembly that fails to meet nondestructive testing acceptance criteria may be repair welded as specified in 5-2.5 and retested in accordance with this chapter.

b. An S-Group verification test assembly that fails to meet nondestructive testing or macro-etch acceptance criteria may be retested. The retest shall consist of one new S-Group verification test assembly for each S-Group verification test assembly that failed to meet nondestructive testing or macro-etch acceptance criteria. The new S-Group verification test assembly shall pass all required nondestructive and destructive testing.

c. An S-Group verification test assembly that fails to meet destructive testing acceptance criteria may be retested. The retest shall consist of two new S-Group verification test assemblies for each

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S-Group verification test assembly that failed to meet destructive testing acceptance criteria.

Both new S-Group verification test assemblies shall pass all required nondestructive and destructive testing.

5-2.4.2 Maximum Number of Retests Permitted. Only one retest cycle shall be permitted for AM base material undergoing S-Group verification testing without NAVSEA approval. Prior to performing the retest, the cause for failure shall be evaluated and the cause and action(s) taken on the subsequent S-Group verification test assembly to avoid this failure shall be documented.

5-2.4.3 Additional Retests with NAVSEA Approval. A second retest cycle shall require NAVSEA approval. A detailed technical data package detailing the tests performed, the assessed cause(s) of failure, proposed corrective actions, and any other technical rationale required to support adjudication of the failed S-Group verification testing shall be submitted to NAVSEA for approval.

5-2.4.4 Rejection of AM Materials Following S-Group Verification Testing. Any AM base material produced using an AM procedure that fails S-Group verification testing shall be rejected and shall not be used for production applications. AM base material produced using an AM procedure that has failed S-Group verification testing shall be quarantined, and NAVSEA shall be contacted for guidance.

5-2.5 S-GROUP VERIFICATION TEST ASSEMBLY REPAIR WELDING. Welded S-Group verification test assemblies that fail nondestructive testing may be repair welded in accordance with the following requirements.

a. The defects repaired are identified by the nondestructive testing required for S-Group verification test assembly and are not indicative of inadequate AM base material performance or unexpected metallurgical failure.

b. Repair welding is representative of repair welds that could be performed on production weldments.

c. Incomplete penetration and lack of fusion assessed to be the result of welder performance may be repaired. Cracks, except for crater cracks, shall not be repaired.

d. Only one repair welding cycle is permitted per S-Group verification test assembly.

e. Repair welding details are provided in the certification data package (see 4-3.1.q), to include the results of the nondestructive test(s) that failed to meet the requirements of this document, and the repair work performed to correct the condition (e.g., a description of the deficient condition, depth of repair, and any special repair techniques used).

5-3 S-GROUP VERIFICATION TESTING REQUIREMENTS.

5-3.1 S-GROUP VERIFICATION TEST ASSEMBLY WELDING REQUIREMENTS.

5-3.1.1 Preheat and Interpass Temperature Requirements. Minimum preheat and maximum interpass temperature requirements shall be in accordance with the applicable fabrication standard for the presumed S-Group. For AM base materials with presumed S-Groups that do not have minimum preheat or maximum interpass temperatures specified in the applicable fabrication standard, minimum preheat and maximum interpass temperature requirements shall be as qualified in the welding procedure, unless otherwise approved by NAVSEA. For AM base materials with presumed S-Groups where the applicable fabrication standards invoke different minimum preheat and maximum interpass temperatures, any applicable minimum preheat and maximum interpass temperature may be used to complete S-Group verification testing. A change between minimum preheat and maximum interpass temperatures invoked by different fabrication standards is not a reason to re-perform S-Group verification testing.

5-3.1.2 Heat Input Requirements. Welding of S-Group verification test assemblies shall involve the maximum practicable heat input and maximum preheat/interpass temperatures permitted by good welding practice and the applicable welding procedure, in order to produce the lowest possible cooling rate.

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5-3.1.3 Welding Procedure Selection. The welding procedure for S-Group verification testing shall be selected based on the presumed S-Group of the AM base material.

5-3.2 TEST ASSEMBLY DESIGN REQUIREMENTS. S-Group verification testing shall be performed using the figure 6-1 S-Group verification test assembly.

5-3.2.1 AM Base Material Heat Treatment Condition. S-Group verification testing shall be performed on the AM base material in the same heat treatment condition in which it will be welded in production (see 3-2.j). When multiple heat treatment conditions for the same AM part(s) are used in production, S-Group verification testing shall be performed on AM base material in each heat treatment condition to be used in production.

5-3.2.2 Test Assembly Thickness. The S-Group verification test assembly thickness shall be a minimum of ½ inch for PBF AM base material and shall be a minimum of ¾ inch for wire DED AM base material, unless otherwise approved by NAVSEA.

5-3.2.3 Test Assembly Arrangement (PBF). The S-Group verification test assembly shall consist of two PBF AM base material specimens. One side (Side A) shall be manufactured such that the PBF build orientation is perpendicular to the long axis (e.g., the weld axis) of the S-Group verification test assembly.

The other side (Side B) shall be manufactured such that the PBF build orientation is inclined not less than 45 degrees from the long axis of the S-Group verification test assembly, and preferentially parallel to the long axis of the S-Group verification test assembly.

5-3.2.4 Test Assembly Arrangement (Wire DED). The S-Group verification test assembly shall consist of two wire DED AM base material specimens. One side (Side A) shall be manufactured such that the wire DED build orientation is perpendicular to the long axis (e.g., the weld axis) of the S-Group verification test assembly. The other side (Side B) shall be manufactured such that the wire DED build orientation is parallel to the long axis of the S-Group verification test assembly.

5-3.2.5 Test Assembly Weld Joint Design. The S-Group verification test assembly weld joint design shall be a B1V.1, as specified in MIL-STD-22. The backing bar may be conventional or AM base material of the same presumed S-Group as the S-Group verification test assembly to be welded. The S-Group verification test assembly shall be clamped or fixed to prevent movement during welding.

5-3.2.6 Test Assembly Weld Joint Preparation. S-Group verification test assemblies shall be machined or ground to sound metal prior to fit-up for welding for a minimum of 1 inch from the expected weld area.

Such machining or grinding shall not reduce the test assembly thickness below that specified in 5-3.2.2.

All features such as support structures, surface irregularities resulting from the AM process, or other conditions that may interfere with welding or nondestructive and destructive testing shall be removed.

Contaminants and deleterious materials (e.g., paint, oil, grease, moisture, cutting or machining fluids, mill scale, slag, oxides) that may interfere with a sound weld shall be removed for a minimum of ½ inch from the expected weld area.

5-3.3 SPECIAL S-GROUP VERIFICATION TESTING REQUIREMENTS. This section addresses S-Group verification testing requirements for special applications such as lock welds and tack welds, fillet welds, piping socket welds, and other weld joint configurations. Welding shall be as specified in 5-2 and 5-3. S-Group verification test assembly design, inspection requirements, and acceptance criteria shall be as described in this section.

5-3.3.1 Tack Welds and Lock Welds. S-Group verification testing for tack welds and lock welds shall be a prototypical mock-up of the production application. A partial mock-up representative of the thickness and orientation of the AM base material to be welded plus an additional 1 inch (approximately) of AM base material in each direction around the weldment is considered an acceptable test assembly. The S-Group verification test assembly shall be subjected to VT and PT, as specified in 5-4.1. A macro-etch cross-section transverse to the weld shall be prepared in accordance with 5-4.2.1 and examined in accordance with 5-

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4.3.1. In lieu of performing a prototypical mock-up, an S-Group verification test in accordance with the requirements of this chapter may be used to qualify tack welds and lock welds.

5-3.3.2 Fillet Welds. Fillet welds shall be tested in accordance with the S-Group verification testing requirements specified in this chapter, unless otherwise approved by NAVSEA.

5-3.3.3 Piping Socket Welds. Piping socket welds shall be tested in accordance with the S-Group verification testing requirements specified in this chapter, unless otherwise approved by NAVSEA.

5-3.3.4 Other Welds. Other configurations shall be as approved by NAVSEA.

5-4 NONDESTRUCTIVE AND DESTRUCTIVE TESTING REQUIREMENTS.

5-4.1 NONDESTRUCTIVE TEST REQUIREMENTS. S-Group verification test assemblies shall be nondestructively tested as follows.

a. Prior to welding, the weld joint preparation and adjacent ½ inch of AM base material shall be subjected to VT and either MT or PT (as applicable).

b. Following completion of welding, the entire weld joint and adjacent ½ inch of AM base material shall be subjected to VT, MT, or PT (as applicable).

c. RT is not required unless specified by the NAVSEA authorized representative or otherwise required by this document for high-risk installations (see Appendix A). When RT is required, it shall be 360-degree (or 100 percent) RT inspection of the weld.

d. For butt welded test assemblies, indications within 1 inch from each end of the test assembly may be disregarded unless the area will be included within a destructive test specimen. This allowance does not apply to pipe-type test assemblies.

5-4.1.1 Nondestructive Test Acceptance Criteria. Unless otherwise approved by NAVSEA, acceptance standards for all nondestructive testing required by this document shall be based on the class I nondestructive test acceptance criteria of MIL-STD-2035, as modified by the applicable AM nondestructive test acceptance criteria provided by NAVSEA (e.g., NAVSEA Letter 9074 Ser 05Z/223 of 08 May 2024).

5-4.2 DESTRUCTIVE TEST REQUIREMENTS. Destructive testing shall be in accordance with table 6-3 and this section.

5-4.2.1 Macro-Etch Examination. Macro-etch cross-sections shall be prepared and etched in accordance with good metallographic practice. Macro-etch cross-sections shall be examined at a minimum magnification of 10x.

5-4.2.2 Guided Bend Tests. Guided bend tests shall be in accordance with AWS B4.0. For AM base materials with 20 percent or lower minimum elongation requirements, elongation for determining bend radius shall be selected based on the applicable AM material specification. For AM base materials with a minimum elongation greater than 20 percent, bend testing radius determination shall be performed using 20 percent elongation. Guided bend test mandrel radius shall be reported (see 4-3.1.o).

5-4.2.3 Tension Tests. Transverse tension testing shall be in accordance with ASTM E8/E8M. Tension test specimen geometry shall accommodate the weld metal and the AM base material heat-affected zone within the gauge length. Ultimate tensile strength, elongation, reduction in area, and yield strength (0.2 or

0.5 percent, as applicable to the material specification) shall be reported.

5-4.2.4 Welded Extensions for Destructive Testing. Prolongations or extensions may be welded to destructive test specimens using any metallurgically compatible base material and any suitable filler materials, welding procedures, welded joint designs, and welders (or welding operators) to facilitate destructive testing if the destructive test specimens identified in this document do not satisfy length requirements for available destructive testing equipment. Welding of prolongations or extensions should take place before any required machining or surface preparation of the destructive test specimens. These

5-5 welds shall not adversely affect the results of destructive testing, but otherwise do not have any acceptance criteria or requirements. Destructive test specimens with welded prolongations or extensions shall be specifically identified as such in destructive test reports.

5-4.2.5 Preparation of Specimens for Destructive Testing. Care shall be taken during machining of specimens for destructive testing to prevent reduction of specimen thickness below that specified in 5-3.2.2.

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