A07. Ref_2.1-245-8627737G.pdf

A 53711 245 8627737 G

SIZE CAGE CODE ESWBS NAVSEA DRAWING NO REV.

DEPARTMENT OF THE NAVY

NAVAL SEA SYSTEMS COMMAND

WASHINGTON NAVY YARD, D.C. 20376-5160

NAVY PROPULSOR CASTING NICKEL-

ALUMINUM-BRONZE SPECIFICATION

NORFOLK NAVAL SHIPYARD DET.

NAVAL FOUNDRY AND

PROPELLER CENTER

PHILADELPHIA, PA 19112

PREPARED

CHECKED

APPROVED FOR NAVSEA 05P3

SCALE: FULL SHEET 1 OF 8

M. Crowley 10/29/21

T. G. Thayer 10/29/21

See Digital Signature

REVISIONS

SHEET REV DESCRIPTION DATE

APPROVED

A

CLARIFIED WELD PROCEDURE EQUIVALENCY IN NOTE 401.

CLARIFIED MACHINE GOUGE WELD CATEGORY IN NOTE 406.

CHANGED LOT TO APPLICABLE HEAT IN NOTE 601

C. MADDEN

2/12/2016

6-7

B

UPDATED NOTE 406 TO CLARIFY ABOUT SHIPYARDS

CLARIFIED NOTE 601

ADDED SUPPLEMENTAL REQUIREMENTS

C. MADDEN

7/10/2017

3-4 C

UPDATED NOTE 302 MECHANICAL REQUIREMENTS

UPDATED NOTE 303 REQUIREMENT, FIGURES AND

DIMENSIONS

C. MADDEN

11/02/2017

4-5

D

UPDATED NOTE 402 BASE METAL REQUIREMENT AND ADDED

NOTES 305, 403-405.

ADDED S4 & S5.

M. WELLS

1/23/2018

E

UPDATED TITLE

ADDED CENTRIFUGAL TO NOTE 101

UPDATED S4

M. WELLS

10/27/2019

F

UPDATED S1 TO PERMANENT COMPONENT INSTALLATION AND

ONE TIME APPROVAL

UPDATED S1.2 (THERMAL TRACES)

M. WELLS

8/20/2020

G

UPDATED NOTE 102 TO LATEST REVISION OF ASTM B824

UPDATED NOTE 402 TO INCLUDE PT METHOD CLARIFICATION

UPDATED NOTES 403 & 404 CONTINUAL VT USAGE IN VT

INSPECTED REGIONS

UPDATED AND MERGED NOTES S1 & S2 MOLD DESIGN

APPROVAL CLARIFICATION

UPDATE NOTE S4 0.060” MATERIAL EXCESS AND POST WELD

PT DEFFERAL

ADDED NOTE S6 TITANIUM ADDITION

SEE DIGITAL

SIGNATURE

NAVSEA 05P3 DIGITAL APPROVAL SIGNATURE

DISTRIBUTION STATEMENT A:

APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.

NFPC C1420 DIGITAL APPROVAL SIGNATURE

SCALE: FULL SHEET 2 OF 8

GENERAL NOTES

101. THE PURPOSE OF THIS DRAWING IS TO ESTABLISH REQUIREMENTS FOR NICKEL

ALUMINUM BRONZE SAND OR CENTRIFUGAL CASTINGS MADE OF UNS NO. C95800

ALLOY FOR USE IN NAVY PROPULSOR APPLICATIONS. CASTINGS SHALL BE AS-CAST

WITH NO TEMPER ANNEAL. WELD REPAIRS SHALL ALSO NOT REQUIRE TEMPER

ANNEAL.

102. MATERIAL FURNISHED UNDER THIS SPECIFICATION SHALL CONFORM TO THE

APPLICABLE REQUIREMENTS OF SECTIONS 9 TO 15 OF ASTM B824-17. WHERE THERE

IS CONFLICTING INFORMATION THIS SPECIFICATION TAKES PRECEDENCE OVER ASTM

B824-17.

103. UNLESS OTHERWISE SPECIFIED BY THE ORDERER THE UNIQUE HEAT

IDENTIFICATION NUMBER SHALL BE MARKED ON ALL CASTINGS.

CHEMICAL COMPOSITION

201. CHEMICAL COMPOSITION SHALL CONFORM TO THE REQUIREMENTS OF UNS NO.

C95800 LISTED IN TABLE 1 BELOW.

TABLE 1 - CHEMICAL REQUIREMENTS

CU AL FE* MN NI** SI PB SUM OF RESULTS

MIN. 79.0 8.5 3.5 0.8 4.0 99.5

MAX. 9.5 4.5 1.5 5.0 0.10 0.03

*IRON CONTENT SHALL NOT EXCEED THE NICKEL CONTENT

**NICKEL INCLUDES COBALT

202. THE COMPOSITION LIMITS DO NOT PRECLUDE THE PRESENCE OF OTHER

ELEMENTS. LIMITS MAY BE ESTABLISHED BY AGREEMENT BETWEEN MANUFACTURER

AND PURCHASER FOR THE UNNAMED ELEMENTS.

203. COPPER IS THE DIFFERENCE BETWEEN THE SUM OF RESULTS OF ALL ELEMENTS

DETERMINED AND 100%. WHEN ALL THE SPECIFICATION ELEMENTS ARE DETERMINED,

THE SUM OF RESULTS SHALL BE A MINIMUM OF 99.5%.

SCALE: FULL SHEET 3 OF 8

MECHANICAL PROPERTY REQUIREMENTS

301. THE MECHANICAL PROPERTIES SHALL BE DETERMINED FROM SEPARATELY CAST

TEST BAR CASTINGS.

302. MATERIAL FURNISHED UNDER THIS DRAWING SHALL CONFORM TO THE

MECHANICAL PROPERTIES STATED IN TABLE 2 SHOWN BELOW.

TABLE 2 - MECHANICAL REQUIREMENTS

TENSILE

STRENGTH

(KSI)

YIELD STRENGTH

0.5% EUL (KSI) ELONGATION (%)

MIN. 85 35 15

303. SEPARATELY CAST TEST BARS SHALL MEET THE PATTERN REQUIREMENTS AS

SHOWN IN FIGURES A AND B BELOW. THE MOLD MATERIAL SHALL BE SILICA SAND.

MINIMUM SAND THICKNESS AROUND THE MOLD CAVITY SHALL BE 1”. FIGURES A AND

B BELOW SHOW A SINGLE TEST BAR; MULTIPLE BARS MAY BE COMBINED IN A

SINGLE MOLD PROVIDED THE 1” MINIMUM SAND THICKNESS IS MET. THE ALLOWABLE

TOLERANCE ON ALL DIMENSIONS IS +/- 1/8”. TEST BAR DIMENSIONS SHALL

CONFORM TO FIGURE 8 OF ASTM E8/E8M FOR SMALL-SIZE SPECIMEN 3 WITH GAUGE

LENGTH FOUR TIMES THE DIAMETER (0.25” NOMINAL DIAMETER).

FIGURE A – TEST BAR PATTERN SIDE VIEW (SINGLE PATTERN)

SCALE: FULL SHEET 4 OF 8

304. ACCEPTANCE OR REJECTION SHALL BE BASED ON TENSILE STRENGTH, YIELD

STRENGTH, AND PERCENT ELONGATION. TENSILE STRENGTH AND YIELD STRENGTH

SHALL BE DETERMINED BY THE EXTENSION-UNDER-LOAD METHOD OF TEST METHODS

IN ASTM E8/E8M.

305. IN LIEU OF TEST BARS PER NOTE 303, STANDARD 0.5” NOMINAL DIAMETER

TEST BARS MAY BE POURED IAW ASTM B208, FIGURE 1 (A OR B).

CASTING REPAIR

401. ALL WELDING SHALL BE IN ACCORDANCE WITH S9074-AR-GIB-010A/278

EXCEPT AS MODIFIED BY THIS NOTE. ALL WELDERS AND WELD PROCEDURES SHALL

BE QUALIFIED IN ACCORDANCE WITH S9074-AQ-GIB-010/248. THIS SPECIFICATION

IS CHEMICALLY IDENTICAL TO MIL-B-24480A (BASE METAL GROUP S-36A PER

S9074-AR-GIB-010A/278). ANY WELD PROCEDURE QUALIFIED TO MIL-B-24480A MAY

BE USED FOR MATERIAL PRODUCED TO THIS SPECIFICATION.

402. SOUND BASE METAL IS DEFINED AS MEETING THE REQUIREMENTS OF MIL-STD-

2035A(SH), SECTION 7, CLASS 3, FINISHED MACHINE SURFACE CONDITION.

PARAGRAPHS 4.5 AND 7.5.4 AND TABLE IV DO NOT APPLY. LIQUID PENETRANT

INSPECTION (PT) SHALL BE IAW S9074-AS-GIB-010A/271, VISIBLE DYE (DEFINED

AS TYPE 2, PER S9074-AS-GIB010A/271 REVISION 1).

FIGURE B – TEST BAR PATTERN END VIEW (SINGLE PATTERN)

SCALE: FULL SHEET 5 OF 8

403. PRIOR TO WELDING ALL EXCAVATIONS SHALL BE PT INSPECTED AND PREPARED

TO SOUND BASE METAL AS DEFINED IN NOTE 402. IF THE PART SPECIFIC DRAWING

INSTRUCTS INITIAL INSPECTION OF AN AREA TO BE DONE BY VT, THE BASE METAL

OF EXCAVATIONS IN THAT AREA MAY ALSO BE INSPECTED BY VT AND SHALL MEET

THE CRITERIA OF SOUND BASE METAL AS DEFINED IN NOTE 402.

404. UNLESS OTHERWISE SPECIFIED IN THE PART SPECIFIC DRAWING, COMPLETED

WELD REPAIRS SHALL BE PT INSPECTED AND MEET THE SOUND BASE METAL

CRITERIA AS DEFINED IN NOTE 402. IF THE PART SPECIFIC DRAWING INSTRUCTS

INITIAL INSPECTION OF AN AREA TO BE DONE BY VT, COMPLETED WELD REPAIRS

IN THAT AREA MAY ALSO BE INSPECTED BY VT AND SHALL MEET THE CRITERIA

CALLED OUT IN THE PART SPECIFIC DRAWING.

405. IN ADDITION TO THE REQUIREMENTS OF NOTE 404, WHEN MORE THAN TWO

LAYERS OF WELD ARE NECESSARY TO WELD BUILD-UP OR TO REPAIR AN

EXCAVATION, EVERY THIRD LAYER SHALL BE PT INSPECTED AND MEET THE SOUND

BASE METAL CRITERIA AS DEFINED IN NOTE 402.

406. NO PEENING IS ALLOWED ON WELD METAL NOR BASE CASTING.

407. ONLY WELD FILLER WIRE IAW MIL-CUNIAL OF MIL-E-23765/3A IS

PERMITTED.

408. WELD REPAIR DEPTH SHALL BE DETERMINED FROM THE DESIGN SURFACE.

PRIOR TO COMPLETION OF MACHINING, THE DIMENSIONAL LIMITS FOR EACH

CATEGORY (MINOR, NOMINAL AND SPECIAL IAW S9074-AR-GIB-010A/278 SECTION

13) SHALL BE INCREASED BY THE AMOUNT OF LOCAL EXCESS MATERIAL REMAINING

ON THE CASTING. MACHINING GOUGES IN THE CASTING SHALL BE TREATED AS WELD

REPAIRS AND NOT WELD BUILD-UPS (S9074-AR-GIB-010A/278 SECTION 13).

409. MINOR AND NOMINAL WELD REPAIRS AS DEFINED ABOVE MAY BE MADE AT ANY

TIME DURING THE MANUFACTURING PROCESS WITHOUT APPROVAL. SPECIAL WELD

REPAIRS AT PUBLIC SHIPYARDS SHALL BE APPROVED BY THE NAVSEA AUTHORIZED

REPRESENTATIVE FOR INDIVIDUAL REPAIRS OF PROPULSORS PER S9074-AR-GIB-

010A/278 PRIOR TO WELDING. SPECIAL WELD REPAIRS AT NON-PUBLIC SHIPYARDS

REQUIRE NAVSEA 05P3 APPROVAL PRIOR TO WELDING.

410. ALL WELD REPAIRS, INCLUDING MINOR WELD REPAIRS, SHALL BE RECORDED

AND INCLUDE THE FOLLOWING:

A. A SKETCH, DRAWING OR PICTURE SHOWING THE DIMENSIONS DEPTH AND

LOCATIONS

B. WELD REPAIR INSPECTION RESULTS

C. CASTING IDENTIFICATION NUMBER

SCALE: FULL SHEET 6 OF 8

D. WELD REPAIR PROCEDURE IDENTIFICATION NUMBER

E. WELDER IDENTIFICATION

F. INSPECTOR IDENTIFICATION

411. CASTINGS SHALL NOT BE IMPREGNATED.

QUALITY ASSURANCE

501. UNLESS OTHERWISE SPECIFIED, THE MANUFACTURER IS RESPONSIBLE FOR

PERFORMANCE OF ALL INSPECTIONS AND TEST REQUIREMENTS SPECIFIED. THE

MANUFACTURER MAY USE ITS OWN OR ANY OTHER SUITABLE FACILITIES FOR THE

PERFORMANCE OF THE INSPECTION AND TEST REQUIREMENTS UNLESS DISAPPROVED

BY THE PURCHASER AT THE TIME THE ORDER IS PLACED. THE PURCHASER SHALL

HAVE THE RIGHT TO PERFORM ANY OF THE INSPECTIONS OR TESTS SET FORTH WHEN

SUCH INSPECTION AND TESTS ARE DEEMED NECESSARY TO ENSURE THAT THE

MATERIAL CONFORMS TO PRESCRIBED REQUIREMENTS.

CERTIFICATION

601. THE PURCHASER SHALL BE FURNISHED CERTIFICATION THAT SAMPLES

REPRESENTING EACH APPLICABLE HEAT HAVE BEEN TESTED AND INSPECTED AS

DIRECTED IN THIS SPECIFICATION AND REQUIREMENTS HAVE BEEN MET. THIS

CERTIFICATION SHALL INCLUDE ACTUAL CHEMICAL AND MECHANICAL TEST RESULTS.

SCALE: FULL SHEET 7 OF 8

SUPPLEMENTARY REQUIREMENTS

THE FOLLOWING SUPPLEMENTARY REQUIREMENTS SHALL APPLY ONLY WHEN SPECIFIED BY THE

PURCHASER IN THE DRAWING OR CONTRACT.

S1. MOLD DESIGN DOCUMENTATION & CASTING PROCESS APPROVAL.

VENDOR SHALL SUBMIT TO NAVSEA 05P3 FOR NAVSEA 05P3 APPROVAL THE

FOLLOWING INFORMATION PRIOR TO MOLD HEATING. MOLD DESIGN APPROVAL IS

ONLY FOR ONE CASTING UNLESS EXPLICITLY STATED. SUBSEQUENT CASTINGS MADE

TO THE SAME DESIGN MUST BE RE-APPROVED FOR UNLIMITED PRODUCTION:

1. DOCUMENTATION OF THE PLANNED MOLDING AND POURING OF THE CASTING IN

ACCORDANCE WITH LATEST REVISION OF NAVSEA DRAWING 810-7642133.

2. RESULTS OF CASTING SIMULATIONS OF THE PROPOSED MOLD DESIGN ALONG

WITH RATIONALE AS TO WHY THE CASTING SIMULATIONS REPRESENT THE

ACTUAL POUR IN ACCORDANCE WITH LATEST REVISION OF NAVSEA DRAWING

810-7642133. THERMAL TRACES FROM LIQUIDUS TO SOLIDUS AT APPROPRIATE

POINTS SHALL TO BE INCLUDED IN THE EVALUATION. JUSTIFICATION SHALL

BE PROVIDED USING EVALUATION RESULTS OF SIMILAR SIZED CASTINGS

RECENTLY COMPLETED, INCLUDING A COMPARISON OF THE ACTUAL CASTING

QUALITY VS THE PREDICTED CASTING QUALITY, AND THE RATIONALE FOR

CHANGES FROM PAST PRACTICES.

VENDOR SHALL SUBMIT TO NAVSEA 05P3 THE FOLLOWING INFORMATION, IF

APPLICABLE, WITHIN 60 DAYS AFTER THE POUR IS COMPLETE:

1. DOCUMENTATION OF THE ACTUAL AS-BUILT MOLD AND ACTUAL POURING

CONDITIONS.

S2. N/A

SCALE: FULL SHEET 8 OF 8

S3. EXTRACTED MECHANICAL SAMPLES

MECHANICAL TEST SAMPLES SHALL BE TAKEN FROM THE LOCATION DESIGNATED ON

THE PART DRAWING (OR LOCATION SPECIFIED BY THE PURCHASER) AND MEET THE

FOLLOWING MINIMUM REQUIREMENTS:

TABLE 3 – EXTRACTED SAMPLE MECHANICAL REQUIREMENTS

TENSILE

STRENGTH

(KSI)

YIELD STRENGTH

0.5% EUL (KSI) ELONGATION (%)

MIN. 60 24 10

S4. SURFACE INSPECTION PRIOR TO FINAL MACHINING

PRIOR TO FINAL MACHINING (DEFINED AS AT LEAST 0.060” MATERIAL EXCESS

ABOVE NET), ALL SURFACES SHALL MEET PT REQUIREMENTS OF SOUND BASE METAL

PER NOTE 402. WELD REPAIR OF ANY SOUND BASE METAL GRINDOUTS MAY BE

DEFFERED UNTIL AFTER FINAL MACHINING AT THE OPTION OF THE MANUFACTURER.

PT OF WELD REPAIRS MADE PRIOR TO FINAL MACHINING MAY BE DFFERED UNTIL

AFTER FINAL MACHINING AT THE OPTION OF THE MANUFACTURER. PT OF EVERY

THIRD LAYER OF WELD PER NOTE 405 STILL APPLIES. FIXTURING DATUMS MAY BE

FINISH MACHINED WITHOUT THIS PT INSPECTION PROVIDED THOSE SURFACES ARE

PT INSPECTED TO THE PART SPECIFIC DRAWING REQUIREMENTS PRIOR TO ANY

OTHER MACHINING.

S5. FIRST ARTICLE INSPECTION

THE FIRST CASTING AFTER MOLD DESIGN APPROVAL SHALL UNDERGO DESTRUCTIVE

TESTING. A CUTTING PLAN SHALL BE REVIEWED AND APPROVED BY NAVSEA 05P3.

AT A MINIMUM THE CUTTING PLAN SHALL SPECIFY CUTS AT LOCATIONS WITH THE

HIGHEST PROCLIVITY OF SHRINKAGE BASED ON CASTING SIMULATION SOFTWARE

RESULTS AND AT MAJOR ATTACHMENT HOLE LOCATIONS. ALL CUT SURFACES SHALL

BE LIQUID PENETRANT INSPECTED AND EVALUATED IAW SOUND BASE METAL

REQUIREMENTS PER NOTE 402.

ONCE THE DESIGN IS APPROVED, ANY SIGNIFICANT MOLD DESIGN CHANGE (AS

DETERMINED BY NAVSEA 05P3) WILL REQUIRE A NEW DESTRUCTIVE FIRST ARTICLE

TEST. THE VENDOR MAY SUBMIT FOR NAVSEA 05P3 APPROVAL A JUSTIFICATION WHY

DESTRUCTIVE TESTING IS NOT REQUIRED. AN ALTERNATE PLAN SUCH AS SPLITTING

RISERS AND COMPARING TO SIMULATION RESULTS MAY ALSO BE SUBMITTED FOR

NAVSEA 05P3 APPROVAL.

S6. COPPER TITANIUM MASTER ALLOY SHALL BE ADDED TO ACHIEVE A NOMINAL

0.048% TITANIUM BY WEIGHT.