Additional information.docx

Additional information:

· Casting identification, including heat number and if applicable heat treatment lot number, drawing number, and serial number.

· Material identification by specification number and class or alloy.

· Provide copies of the inspection methods and results listed below:

· Visual test (DI-MISC-82386): VT shall be conducted on 100% of all accessible casting surfaces or areas which comprise the finished part. Gates, risers, test coupons, temporary test flanges, or similar extensions used as part of foundry procedure are excluded. Each casting is a Category 3I per table XV and shall be visually examined for conformance with specified dimensions and surface conditions (see table below). Identification markings shall be checked to assure accuracy.

Nonferrous casting VT acceptance criteria. 1/, 2/, 3/, 4/, 5/, 6/

2. Linear Indications (other than cracks and tears):

3. Non-Linear Indications:

1/ Criteria apply to cast, rough ground or machined surfaces, except for critical machined surfaces. Critical machined surfaces are O-ring surfaces, gasket surfaces and other sealing surfaces, seating surfaces, threaded surfaces and surfaces within ½" from intended welds. Critical machined surfaces shall be meet DWG 120-4326543 requirements.

2/ A linear indication is an indication in which the length is equal to or greater than three times the width. A nonlinear indication is an indication whose length is less than three times the width.

3/ T is the design casting thickness at the indication location. Indications, and excavations of indications not repair welded, shall not reduce casting thickness below the design thickness. Ground areas shall be smoothly blended.

4/ Linear indications with length less than or equal to 1/16" or 1/8T, whichever is less, and non-linear indications whose major dimension is less than or equal to 1/16" or 1/8T, whichever is less, do not require classification and are acceptable if acceptably separated (see Notes 8/ and 10/). Indications less than 0.015", regardless of proximity, do not require classification and are acceptable.

5/ This table is not applicable to high pressure die castings (e.g., ASTM B85). Criteria for high pressure die castings shall be proposed by the casting designer for approval by NAVSEA.

6/ Indications that are PT inspected and meet the acceptance criteria of Table XVI of S9074-AR-GIB-010/278 with Change A are acceptable.

7/ A cold shut is an imperfect junction between two flows of metal in a mold caused by the surface of the streams of metal chilling too rapidly, or in effect, being chilled to the extent that fusion does not occur. This discontinuity may have the appearance of a crack or seam with smooth or rounded edges.

8/ Longitudinally aligned linear indications shall be separated by 4D where D is the length of the longer indication. Non-aligned linear indications shall be separated by 2D. There shall be no more than 10 linear indications in any 6" x 6" area. Smaller areas shall be prorated.

9/ If minimum indication separation is less than required, then where the total indication lengths (i.e., including separation between indications) are less than the maximum permissible indication size, the indications shall be acceptable.

10/ Random individual non-linear indications shall be separated by 2D where D is the maximum dimension of the larger indication. There shall be no more than 4 non-linear indications in any 2" x 2" area. Smaller areas shall be prorated.

· Pressure (Hydrostatic) Test (DI-QC8C-82089): Pressure tests shall be applied to all pressure containing areas. Test requirements are shown below:

· Test pressure to be 200 psi

· Clean fresh water is to be the test medium

· Test duration is 30 minutes

· Acceptance criteria is no leakage or weeping allowed.

· Weld repair (DI-MISC-82386/DI-MISC-81356A): records shall include the following:

· A sketch showing the size (length, width, and depth) and location of all nominal and approved special repairs.

· Record of post weld heat treatment (when applicable).

· Record of weld repair inspection results.

· Completed repair welds shall be inspected by PT methods. The adjacent casting surface (1/2 inch from weld edges), shall be visually examined. The heat affected zone (3/16 inch from weld edges), shall be visually examined at a minimum of 5X magnification. Where the surfaces within 1 inch of weld edges are PT inspected inadvertently during the inspection of the weld deposit, suspect indications within the 1-inch area shall be noted; then the developer and penetrant shall be removed and suspect areas visually examined at 5X minimum magnification.

· PT Acceptance criteria: MIL-STD-2035 Class 2.

· Visual Inspection Acceptance Criteria (VT and 5XVT): Linear indications greater than 1/16 inch shall be cause for rejection by the visual examination specified herein.

· Weldability test (DI-MISC-82386): Records shall include:

· At least one test cast as shown in Fig. 1 shall be prepared for each lot of welding grade castings.

· The block shall be molded, gated, and risered in such a manner to produce a sound casting without defects that might interfere with welding or the interpretation of the results of the test.

· The groove in the test block shall be completely filled with weld deposit metal, using the manual metallic-arc process with 1⁄8-in. (12.7-mm) or 5⁄32-in. (3.97-mm) diameter copper nickel (70-30) coated electrodes conforming to classification AWSE CuNi of AWS Specification A5.6. The interpass temperature need not be controlled, unless it is to be controlled in fabrication.

· One 3⁄8-in. (9.52-mm) minimum thick bend coupon (see Fig. 2), shall be removed longitudinally from the center of the welded block by machining, sawing, abrasive cutting, or other suitable means. Cut surfaces and edges should be sanded smooth if necessary. The side bend specimen then shall be bent 180° in a guided bend jig around a mandrel 1-1⁄2 in. (38.1 mm) in diameter with the weld located at the center of the bend.

· Cracks or other open defects exceeding 1⁄8 in. (3.2 mm) measured in any direction in the fusion zone or heat-affected zone on the convex surface of the specimen after bending shall be cause for rejection. Cracks originating at weld-bead undercuts, at weld-slag inclusions, or at casting defects shall not be cause for rejection.

FIG. 1 Cast Block for Weldability Test

FIG. 2 Weldability Test Block image1.emf image2.emf