C08.0 Attachment 1.2 TM T9074-AA-GIB-010_1687.PDF

T9074-AA-GIB-010/1687

NAVSEA TECHNICAL PUBLICATION

THERMAL SPRAY PROCESSES FOR

NAVAL SHIP MACHINERY AND NONSKID APPLICATIONS

DISTRIBUTION STATEMENT A: APPROVED FOR PUBLIC RELEASE; DISTRIBUTION UNLIMITED

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

12 JUNE 2017

A

LIST OF EFFECTIVE PAGES

Dispose of superseded pages in accordance with applicable regulations.

Dates of issue for original and subsequent revisions:

Original …………………... 12 JUNE 2017

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 46, CONSISTING OF THE FOLLOWING:

Page No.

Title and A i-viii

1-1/(1-2 blank)

2-1 through 2-2

3-1 through 3-15/(3-16 blank)

4-1 through 4-10

5-1/(5-2 blank)

A-1 through A-2

TMDER

i

TABLE OF CONTENTS

Chapter/Paragraph/Title Page

Foreword ................................................................................................................................................................................... vii Chapter 1 Scope ................................................................................................................................................................................ 1-1

1.1 Scope. ................................................................................................................................................................................. 1-1

1.1.1 Thermal Spray Application Processes. ..................................................................................................................... 1-1

1.2 Application. ........................................................................................................................................................................ 1-1

1.2.1 Substrates. ................................................................................................................................................................. 1-1

1.2.1.1 Thermal Spray Nonskid Substrates. ...................................................................................................................... 1-1

Chapter 2 Applicable Documents ..................................................................................................................................................... 2-1

2.1 General. .............................................................................................................................................................................. 2-1

2.2 Government Documents. .................................................................................................................................................... 2-1

2.2.1 Specifications. .......................................................................................................................................................... 2-1

2.2.2 Other Government Documents. ................................................................................................................................ 2-1

2.3 Non-Government Publications. .......................................................................................................................................... 2-1

2.4 Order of Precedence. .......................................................................................................................................................... 2-2

Chapter 3 General Requirements ...................................................................................................................................................... 3-1

3.1 Quality Assurance System. ................................................................................................................................................. 3-1

3.1.1 Management. ............................................................................................................................................................ 3-1

3.1.2 Inspection System. .................................................................................................................................................... 3-1

3.1.3 Records. .................................................................................................................................................................... 3-1

3.1.4 Record Form. ............................................................................................................................................................ 3-1

3.1.5 Maintenance of Records. .......................................................................................................................................... 3-2

3.1.6 Noncompliance. ........................................................................................................................................................ 3-2

3.2 Qualification and Certification Requirements. ................................................................................................................... 3-2

3.2.1 Facility Certification Requirements. ......................................................................................................................... 3-2

3.2.1.1 Other Government and Commercial Activities. .................................................................................................... 3-2

3.2.2 Field Certification Requirements. ............................................................................................................................. 3-2

3.2.2.1 Thermal Spray Nonskid Process Validation. ......................................................................................................... 3-2

3.2.3 Quality Control Program. ......................................................................................................................................... 3-2

3.2.3.1 Naval Shipyards. .................................................................................................................................................... 3-2

3.2.3.2 Other Government and Commercial Activities. .................................................................................................... 3-2

3.2.3.3 Thermal Spray Procedure. ..................................................................................................................................... 3-2

3.2.3.4 Ships Intermediate Maintenance Activities (SIMAs) and Afloat IMAs. ............................................................... 3-2

3.2.3.5 Other Government and Commercial Activities. .................................................................................................... 3-2

3.3 Spraying Procedure Qualification. ...................................................................................................................................... 3-2

3.3.1 Spraying Procedures. ................................................................................................................................................ 3-2

3.3.1.1 Submittal for Approval. ......................................................................................................................................... 3-2

3.3.2 Procedure Qualification Testing. .............................................................................................................................. 3-3

3.3.3 Qualification Test Requirements. ............................................................................................................................. 3-3

3.3.3.1 Visual Examination Requirement. ......................................................................................................................... 3-3

3.3.3.2 Microscopic Examination. ..................................................................................................................................... 3-3 ii

Chapter/Paragraph/Title Page

3.3.3.3 Bend Test. .............................................................................................................................................................. 3-6

3.3.3.4 Bond Test ............................................................................................................................................................... 3-6

3.3.3.5 Non-Established Requirements. ............................................................................................................................. 3-6

3.3.4 Extent of Use of Qualified Spraying Procedure........................................................................................................ 3-6

3.3.4.1 Substrate Material. ................................................................................................................................................. 3-6

3.3.4.1.1 Substrate Material Groups. ................................................................................................................................. 3-6

3.3.4.2 Spray Procedure. .................................................................................................................................................... 3-6

3.3.4.3 Essential Elements. ................................................................................................................................................ 3-6

3.4 Personnel Training, Qualification, and Certification. ......................................................................................................... 3-6

3.4.1 General. .................................................................................................................................................................... 3-6

3.4.2 Training for Operators and Inspectors. ..................................................................................................................... 3-7

3.4.2.1 General................................................................................................................................................................... 3-7

3.4.2.2 Operators. .............................................................................................................................................................. 3-7

3.4.2.2.1 Organizations Performing Thermal Spray Nonskid Application. ....................................................................... 3-7

3.4.2.3 Operator Written Test. ........................................................................................................................................... 3-7

3.4.2.4 Vision Test Requirements. ..................................................................................................................................... 3-7

3.4.2.5 Inspector Training. ................................................................................................................................................. 3-7

3.4.2.6 Inspector Written Test. .......................................................................................................................................... 3-7

3.4.3 Operator Qualification Testing. ................................................................................................................................ 3-7

3.4.3.1 Operator Qualification Testing for Thermal Spray Nonskid Application by Arc Wire. ........................................ 3-8

3.4.4 Alternative Qualification Methods. .......................................................................................................................... 3-8

3.4.5 Qualification Test Examinations. ............................................................................................................................. 3-8

3.4.5.1 Visual Examination. .............................................................................................................................................. 3-8

3.4.5.2 Microscopic Examination. ..................................................................................................................................... 3-8

3.4.5.3 Bend Test Examination. ......................................................................................................................................... 3-8

3.4.5.4 Bond Test Examination. ........................................................................................................................................ 3-8

3.4.5.5 Limits of Certification. .......................................................................................................................................... 3-8

3.4.5.6 Maintenance of Certification. ................................................................................................................................ 3-8

3.4.5.6.1 Expiration. .......................................................................................................................................................... 3-8

3.4.5.6.2 Suspension. ......................................................................................................................................................... 3-8

3.4.5.6.3 Recertification..................................................................................................................................................... 3-8

3.4.6 Records for Operator Qualification. ......................................................................................................................... 3-8

3.5 Quality Control for Production Spraying. ........................................................................................................................... 3-8

3.5.1 In-Process Inspection. ............................................................................................................................................... 3-8

3.5.2 End Item Requirement. ............................................................................................................................................. 3-8

3.5.2.1 Inspection............................................................................................................................................................... 3-8

3.5.2.2 Test Specimens for Quality Control. ..................................................................................................................... 3-8

3.6 Testing Requirements for Procedure and Operator Qualification. ...................................................................................... 3-8

3.6.1 Preparation of Test Specimens. ................................................................................................................................ 3-9

3.6.1.1 Specimens for Microscopic Examination. ............................................................................................................. 3-9

3.6.1.2 Specimens for Visual and Bend Tests. .................................................................................................................. 3-9

3.6.1.3 Specimens for Bond Test. ...................................................................................................................................... 3-9 iii

Chapter/Paragraph/Title Page

3.6.2 Visual Examination. ................................................................................................................................................. 3-9

3.6.3 Microscopic Examination. ........................................................................................................................................ 3-9

3.6.4 Bend Test. ................................................................................................................................................................. 3-9

3.6.4.1 Bend Test for Thermal Spray Nonskid Applications. ............................................................................................ 3-9

3.6.5 Bond Test. ................................................................................................................................................................ 3-9

3.6.5.1 Spraying. ................................................................................................................................................................ 3-9

3.6.5.2 Application. ........................................................................................................................................................... 3-9

Chapter 4 Detailed Requirements ..................................................................................................................................................... 4-1

4.1 Equipment. .......................................................................................................................................................................... 4-1

4.1.1 Spraying Systems. .................................................................................................................................................... 4-1

4.1.2 Abrasive Blasting Equipment. .................................................................................................................................. 4-1

4.1.2.1 Air Equipment. ...................................................................................................................................................... 4-1

4.1.3 Fixturing for Mechanical Positioning. ...................................................................................................................... 4-1

4.2 Performing Activity Facilities. ........................................................................................................................................... 4-1

4.2.1 Working Areas.......................................................................................................................................................... 4-1

4.2.1.1 Abrasive Blasting Areas. ....................................................................................................................................... 4-1

4.2.1.2 Thermal Spraying Areas. ....................................................................................................................................... 4-1

4.2.1.2.1 Enclosed Areas. .................................................................................................................................................. 4-1

4.2.1.2.2 Open Areas. ........................................................................................................................................................ 4-1

4.2.1.2.3 Thermal Spray Nonskid Areas. ........................................................................................................................... 4-1

4.2.2 Abrasive Blasting Equipment. .................................................................................................................................. 4-1

4.2.3 Thermal Spray Equipment. ....................................................................................................................................... 4-2

4.2.4 Protective Equipment. .............................................................................................................................................. 4-2

4.2.5 Fixturing for Mechanical Positioning. ...................................................................................................................... 4-2

4.3 Materials. ............................................................................................................................................................................ 4-2

4.3.1 Coating Materials. .................................................................................................................................................... 4-2

4.3.1.1 Coating Type. ........................................................................................................................................................ 4-2

4.3.1.2 Thermal Spray Wire and Powder. ......................................................................................................................... 4-2

4.3.1.3 Storage, Identification, and Separation of Wire and Powder. ................................................................................ 4-2

4.3.2 Thermal Spray Gases. ............................................................................................................................................... 4-2

4.3.2.1 For Flame Spraying. .............................................................................................................................................. 4-2

4.3.2.2 For Plasma Spraying. ............................................................................................................................................. 4-3

4.3.3 Abrasive Blasting Media. ......................................................................................................................................... 4-3

4.3.3.1 Requirements. ........................................................................................................................................................ 4-3

4.3.3.2 Restrictions. ........................................................................................................................................................... 4-3

4.3.4 Masking Materials. ................................................................................................................................................... 4-3

4.3.4.1 For Abrasive Blasting. ........................................................................................................................................... 4-3

4.3.4.2 For Thermal Spraying. ........................................................................................................................................... 4-3

4.3.4.3 Irregular Shapes. .................................................................................................................................................... 4-3

4.3.5 Sealants. .................................................................................................................................................................... 4-3

4.4 Process. ............................................................................................................................................................................... 4-3

4.4.1 Surface Condition. .................................................................................................................................................... 4-3 iv

Chapter/Paragraph/Title Page

4.4.1.1 Solvent Cleaning. ................................................................................................................................................... 4-3

4.4.1.1.1 Solvent Cleaning for Thermal Spray Nonskid Application. ............................................................................... 4-4

4.4.1.2 Heat Cleaning. ....................................................................................................................................................... 4-4

4.4.2 Machining for Surface Preparation in Non-Thermal Spray Nonskid Applications. ................................................. 4-4

4.4.2.1 Undercutting. ......................................................................................................................................................... 4-4

4.4.2.2 Threading or Grooving of Cylindrical Surfaces. ................................................................................................... 4-4

4.4.2.3 Shoulders. .............................................................................................................................................................. 4-4

4.4.2.3.1 Undercuts Near the End of the Shaft. ................................................................................................................. 4-4

4.4.2.4 Masking. ................................................................................................................................................................ 4-4

4.4.2.5 Abrasive Blasting for Surface Preparation for Non-Thermal Spray Nonskid Applications. ................................. 4-4

4.4.2.6 Recycling Aluminum Oxide Grit for Non-Thermal Spray Nonskid Applications................................................. 4-4

4.4.3 Spraying. ................................................................................................................................................................... 4-4

4.4.3.1 Protection of Blasted Surface from Oxidation. ...................................................................................................... 4-4

4.4.3.2 Substrate Surface Temperature Requirements. ...................................................................................................... 4-5

4.4.3.3 Thermal Spray Application Area Cooling During Spraying. ................................................................................. 4-5

4.4.3.4 Thermal Spray Application Angle. ........................................................................................................................ 4-5

4.4.3.5 Thermal Spray Application Area Cooling Following Spraying............................................................................. 4-5

4.4.3.6 Application of Sealant. .......................................................................................................................................... 4-5

4.4.3.6.1 Application of Sealant in Thermal Spray Nonskid Application Areas. .............................................................. 4-5

4.4.4 Surface Finishing. ..................................................................................................................................................... 4-5

4.4.4.1 Thermal Spray on Machinery. ............................................................................................................................... 4-5

4.4.4.2 Thermal Spray Nonskid on Flight Decks. .............................................................................................................. 4-5

4.4.4.3 Quality of Finishing Process. ................................................................................................................................. 4-5

4.4.5 Safety Precautions. ................................................................................................................................................... 4-5

4.4.5.1 Safety Hazards. ...................................................................................................................................................... 4-6

4.4.5.2 Solvent Hazards. .................................................................................................................................................... 4-6

4.4.5.3 Pressurized Gas Hazards. ....................................................................................................................................... 4-6

4.4.5.4 Abrasive Blasting Hazards..................................................................................................................................... 4-6

4.4.5.5 Thermal Spray Gun Maintenance. ......................................................................................................................... 4-6

4.4.5.6 Dust Hazards. ......................................................................................................................................................... 4-6

4.4.5.7 Noise Hazards. ....................................................................................................................................................... 4-6

4.4.5.8 Electromagnetic Radiation Hazards. ...................................................................................................................... 4-6

4.4.5.9 Flame Hazards. ...................................................................................................................................................... 4-6

4.4.5.10 Personal Protective Equipment. ........................................................................................................................... 4-6

4.4.5.11 Do Not Work Alone. ............................................................................................................................................ 4-6

4.5 Thermal Spray Applications. .............................................................................................................................................. 4-6

4.5.1 General. .................................................................................................................................................................... 4-7

4.5.1.1 Intended Use. ......................................................................................................................................................... 4-7

4.5.1.2 Application Guidance. ........................................................................................................................................... 4-7

4.5.2 Approved Applications. ............................................................................................................................................ 4-8

4.5.2.1 Machinery. ............................................................................................................................................................. 4-8

4.5.2.1.1 Equipment. .......................................................................................................................................................... 4-9 v

Chapter/Paragraph/Title Page

4.5.2.2 Flight Deck Nonskid. ............................................................................................................................................. 4-9

4.5.2.2.1 Abrasive Blasting Surface Preparation Prior to Thermal Spray Nonskid Application. ...................................... 4-9

4.5.2.3 Proposed Applications. .......................................................................................................................................... 4-9

Chapter 5 Notes ................................................................................................................................................................................ 5-1

5.1 Intended Use. ...................................................................................................................................................................... 5-1

5.2 Acquisition Requirements. ................................................................................................................................................. 5-1

Appendix A List of Definitions ....................................................................................................................................................... A-1 A.1 List of Definitions. ............................................................................................................................................................ A-1 vi

LIST OF ILLUSTRATIONS

Figure No. and Title Page

Figure 3-1. Wire Oxygen-Fuel Process and Parameter Record. .................................................................................................... 3-10 Figure 3-2. Wire Arc Spray Process and Parameter Record. ......................................................................................................... 3-11 Figure 3-3. Powder Oxygen-Fuel Spray Process and Parameter Record. ...................................................................................... 3-12 Figure 3-4. Plasma Spray Process and Parameter Record.............................................................................................................. 3-13 Figure 3-5. Oxide, Porosity Comparison Chart (× 200). ................................................................................................................ 3-14

LIST OF TABLES

Table No. and Title Page

Table 3-1. Thermal Spray Coating Properties. ................................................................................................................................. 3-4 Table 3-2. Required Training Time. ................................................................................................................................................ 3-7 Table 4-1. Recommended Spray Procedures. .................................................................................................................................. 4-7 Table 4-2. Spray Material Composition. .......................................................................................................................................... 4-8 vii

FOREWORD

This document is intended to define the certification, training, and qualification requirements for application of thermal spray coatings to repair or overhaul Naval ship machinery. The document also defines the certification, training, and qualification requirements for successful application of thermal spray nonskid. This document is organized as follows:

Chapter 1, Scope

Chapter 2, Applicable Documents

Chapter 3, General Requirements

Chapter 4, Detailed Requirements

Chapter 5, Notes

Appendix A, List of Definitions

TMDER INSTRUCTIONS

Ships, training activities, supply points, depots, Naval Shipyards and Supervisors of Shipbuilding are requested to arrange for the maximum practical use and evaluation of NAVSEA and SPAWAR technical manuals (TMs). All errors, omissions, discrepancies, and suggestions for improvement to NAVSEA and SPAWAR TMs shall be submitted as a Technical Manual Deficiency/Evaluation Report (TMDER). All feedback comments shall be thoroughly investigated and originators will be advised of action resulting there from.

The NAVSEA/SPAWAR Technical Manual Deficiency/Evaluation Report form, NAVSEA 4160/1 is included at the back of the

TM.

The following methods are available for generation and submission of TMDERs against unclassified TMs:

For those with a Technical Data Management Information System (TDMIS) account, the most expedient and preferred method of TMDER generation and submission is via the TDMIS website at: https://mercury.tdmis.navy.mil/.

For those without a TDMIS account, generate and submit TMDER via the Naval Systems Data Support Activity (NSDSA) website at: https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm. (TDMIS accounts may be requested at the NSDSA website at: https://nsdsa.nmci.navy.mil/, by submitting a Customer Service Request (CSR).)

When internet access is not available, submit TMDER via hardcopy to:

COMMANDER NAVAL SURFACE WARFARE CENTER

NAVAL SYSTEMS DATA SUPPORT ACTIVITY

4363 MISSILE WAY

ATTN: CODE 310 BLDG 1389 TMDERS

PORT HUENEME, CA 93043-4307

Additional copies of the TMDER form may also be downloaded from the Naval Systems Data Support Activity (NSDSA) website at: https://nsdsa.nmci.navy.mil/, by clicking on the blue tab labeled “Reference Docs/Forms”.

TMDERs against classified/restricted TMs (includes all NOFORN) must be submitted using the hardcopy method cited above.

Urgent priority TM deficiencies shall be reported by Naval message with transmission to Port Hueneme Division, Naval Surface Warfare Center (Code 310), Port Hueneme, CA. Local message handling procedures shall be used. The message shall identify each TM deficiency by TM identification number and title. This method shall be used in those instances where a TM deficiency constitutes an urgent problem, (i.e., involves a condition, which if not corrected, could result in injury to personnel, damage to the equipment, or jeopardy to the safety or success of the mission).

Complete instructions for TMDER generation and submission are detailed on the NSDSA website at:

https://nsdsa.nmci.navy.mil/, by clicking on the blue tab labeled “TMDER/ACN” and then clicking on the gray button labeled “TMDERs”.

https://mercury.tdmis.navy.mil/ https://mercury.tdmis.navy.mil/def_external/pubsearch.cfm https://nsdsa.nmci.navy.mil/ https://nsdsa.nmci.navy.mil/ https://nsdsa.nmci.navy.mil/ viii

SAFETY SUMMARY

Warnings appear throughout this manual. It is important that the significance of each be thoroughly understood by personnel using this manual. Their definitions are as follows:

WARNING – used to highlight a statement or some other notification about an operating or maintenance procedure, practice, or condition, that if not strictly observed could result in death, injury, or long-term health hazards.

GENERAL SAFETY PRECAUTIONS

The following are general safety precautions that are not related to any specific procedure and therefore do not appear elsewhere in this manual. These are recommended precautions that personnel must undergo and apply during all phases of operation.

Should situations arise that are not covered in these safety precautions, the Commanding Officer or other authority will issue orders as necessary to cover the situation.

KEEP AWAY FROM LIVE CIRCUITS

Operational and maintenance personnel must observe all safety regulations. Do not replace components or make adjustments inside equipment with the power turned on. Under certain conditions, dangerous potentials may exist even after power is removed due to charges retained by internal capacitors. To avoid bodily injury, always remove power and discharge a circuit by grounding before touching it.

DO NOT SERVICE OR ADJUST ALONE

Under no circumstances should any person reach inside any cabinet for the purpose of servicing or adjusting the equipment except in the presence of someone who is capable of rendering first aid.

RESUSCITATION

Personnel working with or near high voltages should be familiar with modern methods of resuscitation.

1-1/(1-2 blank)

CHAPTER 1

SCOPE

1.1 SCOPE.

This manual covers thermal spray processes for repair and corrosion protection of naval ship machinery, and for application of thermal spray nonskid. Thermal spraying of aluminum for corrosion protection was historically covered under MIL-STD-2138, but this standard was cancelled on February 19, 2009. This manual does not apply to primary and secondary systems of nuclear ships. Included are requirements for the qualification of thermal spray procedures and operators, requirements and guidance for use of thermal spray material and equipment, quality assurance requirements, and descriptions of applicable qualification tests.

1.1.1 Thermal Spray Application Processes. The thermal spray processes covered by this manual are:

a. wire spraying of consumable coating material using oxygen-fuel gas, or using two consumable electrodes in an electric arc system,

b. powder spraying, using oxygen-fuel gas or plasma arc, and

c. powder spraying with high-velocity oxygen-fuel gas.

1.2 APPLICATION.

Thermal spray coatings shall be used only for applications specifically permitted herein (see 4.5.2) or for which prior approval has been obtained from the Naval Sea Systems Command (NAVSEA).

1.2.1 Substrates. Requirements of this manual pertain only to the thermal spray coatings applied to ferrous and non-ferrous metal substrates.

1.2.1.1 Thermal Spray Nonskid Substrates. In the case of thermal spray nonskid application, requirements of this manual pertain only to the thermal spray coatings applied to ferrous metal substrates.

2-1

CHAPTER 2

APPLICABLE DOCUMENTS

2.1 GENERAL.

The documents listed in this section are specified in chapters 3 or 4 of this manual. This section does not include documents cited in other sections of this manual or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in chapters 3 or 4 of this manual, whether or not they are listed.

2.2 GOVERNMENT DOCUMENTS.

2.2.1 Specifications. The following specifications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

BB-A-106 - Acetylene, Technical, Dissolved

BB-A-1034 - Compressed Air, Breathing

BB-H-886 - Hydrogen

BB-H-1168 - Helium, Technical

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-A-18455 - Argon, Technical

MIL-PRF-32577 - Coating System, Nonskid, Metallic Thermal Spray Application

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

2.2.2 Other Government Documents. The following other Government documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

CODE OF FEDERAL REGULATIONS (CFR)

29 CFR 1910.107 - Spray Finishing Using Flammable and Combustible Materials

(Copies of this document are available online at www.ecfr.gov.)

2.3 NON-GOVERNMENT PUBLICATIONS.

The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL (ASTM)

ASTM C633 - Standard Test Method for Adhesion or Cohesion Strength of Thermal Spray Coatings

ASTM D4285 - Standard Test Method for Indicating Oil or Water in Compressed Air

ASTM D4417 - Standard Test Methods for Field Measurement of Surface Profile of Blast Cleaned Steel

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

AMERICAN WELDING SOCIETY (AWS)

AWS A3.0M/A3.0 - Standard Welding Terms and Definitions; Including Terms for Adhesive Bonding, Brazing, Soldering, Thermal Cutting, and Thermal Spraying http://quicksearch.dla.mil/ http://www.ecfr.gov/ http://www.astm.org/

2-2

AWS C2.19/C2.19M - Specification for the Application of Thermal Spray Coatings to Machine Elements for OEM and Repair

AWS C2.21M/C2.21 - Specification for Thermal Spray Equipment Acceptance Inspection

AWS C2.25/C2.25M - Specification for Thermal Spray Feedstock – Wire and Rods

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

COMPRESSED GAS ASSOCIATION (CGA)

CGA G-4 - Oxygen

(Copies of this document are available online at www.cganet.com.)

SAE INTERNATIONAL

SAE AMS 2447 - Coating, Thermal Spray, High Velocity Oxygen/Fuel Process

(Copies of this document are available online at www.sae.org.)

SOCIETY FOR PROTECTIVE COATINGS (SSPC)

SSPC-SP 1 - Solvent Cleaning

SSPC-SP 5/NACE No. 1 - White Metal Blast Cleaning

SSPC-QP 6 - Standard Procedure for Evaluating the Qualifications of Contractors, Thermal Spray Contractor Qualification

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

2.4 ORDER OF PRECEDENCE.

Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

http://www.aws.org/ http://www.cganet.com/ http://www.sae.org/ http://www.sspc.org/

3-1

CHAPTER 3

GENERAL REQUIREMENTS

3.1 QUALITY ASSURANCE SYSTEM.

A written quality assurance system shall be implemented and maintained, which assures that the requirements of this manual and the functions of the thermal sprayed coatings are met (see 3.3).

3.1.1 Management. Effective management for quality of thermal spray of machinery components shall be clearly prescribed by written procedures. Written procedures shall be prepared, which assign responsibility and provide accountability for performing work and inspection. Personnel performing quality functions shall have sufficient, well-defined responsibility, authority, and the organizational freedom to identify and evaluate problems and to initiate, recommend, or provide solutions.

Management shall review the status and adequacy of the quality program through semi-annual documented audits.

3.1.2 Inspection System. The performing activity shall maintain an inspection system adequate to assure NAVSEA or authorized agent that all of the requirements of this manual have been met. Written procedures shall be prepared to assign responsibility and provide accountability for performing work and inspection. Personnel performing acceptance inspections shall be trained and qualified for the work they are to perform. Records of such training shall be maintained.

3.1.3 Records. Unless otherwise specified herein, written records shall be prepared and maintained for each sprayed component (see 3.1.4). The records shall include at least the following information:

a. Identification of spraying activity.

b. Specific identification of component and system (such as no. 1 fire pump main).

c. Component drawing or part number.

d. Component material (Military, ASTM, or other specification).

e. Job order or work number.

f. Cleaning method and method of base metal preparation (abrasive blasting, threading).

g. Sketch showing area to be sprayed, undercut depth and length, shoulders, masking locations.

h. Reason for spraying.

i. Spray procedure identification (and revision).

j. Bond and finish coat material - generic type and manufacturer’s identification.

k. As-sprayed coating thickness (bond and finish).

l. Final coating thickness.

m. Method of surface finishing (grinding, machining).

n. If ground, state grinding wheel and surface finish.

o. Sealant material and sequence of application.

p. Date sprayed.

q. Sprayer’s identification.

r. Inspection procedure and results.

s. Inspection personnel identification.

3.1.4 Record Form. A record form shall be prepared prior to commencement of the operation it covers. Operations shall be recorded prior to the commencement of the next operation. Each item on the record form shall be signed and dated by the operator, except for those checkpoints designated for verification by the inspectors. When a specific item on the record form is not applicable, the letters “N.A.” shall be entered. Prior to acceptance, all items on the record forms shall be marked as specified (see 3.1.3).

3-2

3.1.5 Maintenance of Records. The sprayed component record form shall be maintained by the performing activity and shall be available to NAVSEA upon request. Disposition of records shall be as agreed upon by the NAVSEA agent or the contractor.

The performing activity shall maintain records to be made available to NAVSEA or its authorized agent.

3.1.6 Noncompliance. In the event of noncompliance with the requirements of this manual, the applicable work covered by this manual shall be suspended until the performing activity has demonstrated that work deficiencies have been corrected.

3.2 QUALIFICATION AND CERTIFICATION REQUIREMENTS.

3.2.1 Facility Certification Requirements. Performing activities shall have thermal spray facilities that meet the requirements for working areas (see 4.2.1 through 4.2.5).

3.2.1.1 Other Government and Commercial Activities. Prior to contract award, activities shall submit a request to the Supervisor of Shipbuilding, Regional Maintenance Center, or NAVSEA designated organization, for certification of their thermal spray facility. The request shall contain written evidence that the facility meets requirements of this manual.

3.2.2 Field Certification Requirements. Performing activities completing shipboard thermal spray application shall have thermal spray procedures that meet the requirements for working areas (see 4.2.1 through 4.2.5), including operation of thermal spray robotic system, provided as Government-furnished equipment, for application.

3.2.2.1 Thermal Spray Nonskid Process Validation. Prior to contract award, performing activities intending to apply thermal spray nonskid shipboard shall qualify their thermal spray personnel and field application procedures on a mock flight deck constructed by NAVSEA. The performing activity shall demonstrate the successful application of a thermal spray nonskid coating using a thermal spray wire approved by NAVSEA, a thermal spray application robot furnished by NAVSEA, and with process oversight provided by NAVSEA (see 3.3.2).

3.2.3 Quality Control Program. Performing activities shall have a quality control program that addresses requirements for management (see 3.1.1, 3.1.2, 3.1.4, 3.1.5, 3.3, 3.4, and 4.3). In addition, each activity shall have a written audit plan and audit the thermal spray operation on a periodic basis.

3.2.3.1 Naval Shipyards. Prior to production work, naval shipyards shall submit a request to NAVSEA for certification of their quality control program for thermal spray. Thermal spray procedures shall be approved by NAVSEA.

3.2.3.2 Other Government and Commercial Activities. Prior to contract award, activities shall submit a request to the Supervisor of Shipbuilding, Regional Maintenance Center, or NAVSEA designated organization, for certification of their quality control program for thermal spray.

3.2.3.3 Thermal Spray Procedure. Thermal spray procedures shall meet the requirements specified in 3.3.

3.2.3.4 Ships Intermediate Maintenance Activities (SIMAs) and Afloat IMAs. Thermal spray procedures shall be approved by NAVSEA.

3.2.3.5 Other Government and Commercial Activities. Thermal spray procedures shall be approved by NAVSEA.

3.3 SPRAYING PROCEDURE QUALIFICATION.

Spraying procedure qualification shall include preparation of spraying procedure and procedure qualification test data (see 3.3.1.1).

3.3.1 Spraying Procedures. Performing activities shall prepare written spraying procedures and perform tests (see 3.3.3) as required to qualify these procedures. The procedures shall include the items listed on figures 3-1 through 3-4, and a listing of the sequence in which the various processes (such as blasting, inspections, and degreasing) are performed. An approved spray procedure may be used by a facility other than the developing facility. Each spray operator who will be using a previously qualified procedure shall be qualified on that procedure in accordance with 3.4.3.

3.3.1.1 Submittal for Approval. Prior to the utilization of the spraying procedure, the performing activity shall submit and obtain approval of the test qualification data from NAVSEA. Procedures shall be submitted with the supporting test qualification data. Data submitted shall not relieve the performing activity of responsibility for conformance with other requirements of this manual. Contractors shall be responsible for similar qualification of all sub-contractors.

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3.3.2 Procedure…