Attachment_(1)_DDG_Propeller_Shaft_Standard_SOW_10-31-17_with_GFM_sleeves.docx

Enclosures:

(1) Supplementary Split Sleeve Data and Instructions (FWD Sleeve)

(2) Supplementary Split Sleeve Data and Instructions (AFT Sleeve)

(3) Application of Sherwin Williams’ Nova-Plate UHS Primer High Solids Epoxy Paint

Government Provided Material (GFM):

(1) One (1) DDG 51 Class Propeller Shaft FWD Sleeve (NSN 2010-01-633-6992) ( DWG 243-6220431, P/N DMSH1/SH006-02)

(2) One (1) DDG 51 Class Propeller Shaft AFT Sleeve (NSN 2010-01-633-2143) ( DWG 243-6220431, P/N DMSH1/SH006-03)

A. Complete Pre-Repair in accordance with S9243-AW-TRS-011/SHAFT.

B. Prep for weld repair by machining as necessary up to 19 linear feet (entire shaft circumference).

C. NDT all prepped areas prior to welding in accordance with NAVSEA Tech. Pub. S9074-AR-GIB-010/278 and/or NAVSEA Tech. Pub. T9074-AS-GIB-010/271 as required by MIL-STD-2191.

D. Weld repair all prepped areas in accordance with NAVSEA Tech. Pub. S9074-AQ-GIB-010/248 as required by MIL-STD-2191 up to 1 pass of 19 linear feet (entire shaft circumference) and up to an additional 6 linear feet (entire shaft circumference) of multilayer passes.

E. NDT weld repair areas, in accordance with NAVSEA Tech. Pub. S9074-AR-GIB-010/278 and/or NAVSEA Tech. Pub. T9074-AS-GIB-010/271 as required by MIL-STD-2191. Additional NDT will be required for multiple weld passes.

F. Stress relieve all welded areas in accordance with MIL-STD-2191.

G. Cold roll AFT sleeve fit area in accordance with MIL-STD-2191 if weld repaired or if temperature exceeds 475 degree F during weld repair and subsequent stress relief of adjacent areas.

H. Recheck concentricity after stress relieving; straighten if necessary in accordance with MIL-STD-2191.

I. Final machine welded areas to design specifications in accordance with the applicable shaft detail drawing.

J. Machine/handwork as necessary not to exceed 32 man-hours and $500 in material to remove defects on other shaft surfaces in accordance with S9243-AW-TRS-011/SHAFT.

K. Inspect shaft as required by S9243-AW-TRS-011/SHAFT prior to sleeve installation including MT, UT, hardness readings, dimensional, and concentricity.

L. Purchase backing strips for sleeves. FWD and AFT sleeves will be provided as GFM.

M. Split, prep machine and inspect sleeves prior to installation.

N. Install sleeves and weld in place in accordance with S9243-AW-TRS-011/SHAFT including the use of strain gages to monitor stress during welding.

O. Final machine sleeves to print specifications and inspect including dimensions, concentricity and PT.

P. Enclosures (1) and (2) shall be completed and submitted with the final repair report.

Q. Skim cut the FWD flange vertical mating and non-mating faces within tolerances and surface finishes to remove defects maintaining tolerance in way of aligning spigot fits and counter bores.

R. Shot peen FWD flange fillet if weld repaired – or –if fillet temperature exceeds 475 degrees F during weld repair and subsequent stress relief of adjacent areas – or – if there is no evidence of prior shot peen. Peening shall be in accordance with MIL-S-13165C and/or MIL-R-81841. When peening is conducted in accordance with MIL-S-13165C, the peening gun shall not be manually manipulated, but shall comply with the requirements stated in Paragraph 3.2.1 of subject document. Peening shot media shall conform to SAE AMS 2431/1E. The peening intensity shall be 0.012 to 0.016 A with a nominal shot size of 0.033 inches. The peening shall include the entire curvature of the fillet and the entire circumference, thereby achieving 100% coverage.

S. Shot peen AFT flange fillet if weld repaired – or –if fillet temperature exceeds 475 degrees F during weld repair and subsequent stress relief of adjacent areas – or – if there is no evidence of prior shot peen. Peening shall be in accordance with MIL-S-13165C. The peening gun shall not be manually manipulated, but shall comply with the requirements stated in Paragraph 3.2.1 of subject document. Peening shot media shall conform to SAE AMS 2431/7. The peening intensity shall be 0.008 to 0.012 A with a nominal shot size of 0.033 inches. The peening shall include the entire curvature of the fillet and the entire circumference, thereby achieving 100% coverage.

T. Brush hone the shaft bore as necessary.

U. Restore AFT flange bolt and dowel pin holes to design specifications in accordance with the applicable shaft detail drawing.

V. The shaft body area between the FWD and AFT sleeves shall receive the glass-reinforced plastic (GRP) covering system as detailed in MIL-STD-2199 Change Notice 1 dtd. 05 October 1993 with the exception that surface prep shall be via abrasive blasting only. Chemical (solvent) cleaning is not an allowable/acceptable method of surface prep.

W. The shaft journal area FWD of the FWD coupling cover sleeve, including the flange fillet, non-mating face, and O.D., shall be preserved/painted as detailed in Enclosure (3). Do not paint the mating face, bolt holes, or bolt hole washer faces. If Nova-Plate primer is not able to be applied due to availability or procedure development, Mare Island paint (MIL-DTL-24441/29B, Type 4) or Euronavy paint, as currently approved for use on CG-47 and DDG-51 Classes, shall be applied in accordance with OEM application procedures.

X. If Nova-Plate primer is applied, once primer has cured, perform low voltage discontinuity (holiday) test in accordance with ASTM D5162-08, using low voltage wet sponge test equipment.

Y. Die stamp FWD end of shaft to note NSN, UT inspection, stress relieve temperature, and shot peening after repairs and inspection.

Z. Final inspect for customer acceptance.

AA. Package and Preserve in accordance with MIL-DTL-2845E and International Standards for Phytosanitary Measures (ISPM) No. 15, "Regulation of Wood Packaging Material in International Trade."

AB. Upon approval of all CDRLs, shaft repair vendor shall arrange for transportation via a MIL-DTL-2845E compliant trailer (including required permits) to the closest of the following two locations:

a) DODAAC SW3126

DLA DISTRIBUTION CHEATHAM

CHEATHAM ANNEX

1 C STREET

WILLIAMSBURG, VA 23185

M/F: NAVSEA CSP-EAST

ATTN: NAVSUP WSS MATREP (John Leonard)

PH: 757-887-7113

b) DODAAC SW3215

DEFENSE DISTRIBUTION DEPOT (DDBC-EOR)

YERMO ANNEX, BLDG 401 (WEST END)

MARINE CORPS LOGISTICS BASE

BARSTOW, CA 92311-5049

M/F: NAVSEA CSP-WEST

ATTN: EARNEST GARRETT/MATREP

PH: 760-577-6940

*NOTE: While skim cutting/hand working the shaft body between the FWD and AFT sleeve areas, remove the minimum amount of metal required to clear/blend existing defects while maintaining design diameter.

Contract Data Requirements List (CDRLs):

(A001) CONTRACTOR’S PROGRESS, STATUS AND MANAGEMENT REPORT

(A004) REQUEST FOR DEPARTURE FROM SPECIFICATIONS

(A005) VISUAL PRESERVATION INSPECTION (VPI)

(A006) PRE-REPAIR INSPECTION REPORT

(A009) MAGNETIC PARTICLE (MT) INSPECTION REPORT/RESULTS

(A010) LIQUID PENETRANT (PT) INSPECTION REPORT/RESULTS

(A011) ULTRASONIC TEST (UT) INSPECTION REPORT/RESULTS

(A012) FINAL REPAIR REPORT

(A014) CERTIFICATION DATA REPORT

DDG 51 CLASS PROPELLER SHAFT

NSN 2S 2010-01-468-8692 P2

Repair Statement of Work (SOW)

NOTE: Measurement stations B and D are not required for sleeves less than 36” in length.

NOTE: At least 24 hours before taking measurements, place the sleeve in close proximity to the shaft to ensure that both are at the same temperature and that both shaft and sleeve are between 60°F - 80°F.

Tshaft __________°F Tsleeve __________°F Measure and record the shaft outside diameter in way of the sleeve (ODshaft).

0°-180°

45°-225°

90°-270°

135°-315°

AVERAGE

Measure and record the sleeve inside diameter prior to splitting into halves (IDsleeve). The average values should be within +/- 0.003” of the corresponding shaft OD average values at each station.

0°-180°

45°-225°

90°-270°

135°-315°

AVERAGE

Measure and record the average sleeve outside diameter (ODsleeve) in the rough turned condition prior to splitting into halves.

ODsleeve = _________

Enclosure (1)

SUPPLEMENTARY SPLIT SLEEVE DATA AND INSTRUCTIONS

(DDG-51 CLASS PROPELLER SHAFT – FWD SLEEVE)

Shaft S/N __________________________

Signature __________________________________ Date ______________

Machining of the weld joints shall be per DWG 803-2145807 (see excerpt above), with the following exceptions:

· To prevent weld burn-thru, as well as excessively thin welds in the way of GRP end preps, the backing strip thickness shall be 0.188” +0.000/-0.005”.

· To improve weld shrinkage, the 50° bevel angle in the weld joint detail (Detail 61-B) shall be changed to 60°.

· To ensure watertight integrity at the sleeve ends, the backing strip widths will be increased for the first 6” under the ends of the finished sleeve so as to reduce the fit-up gap to 0.022” +/-0.004”, which will result in a nominal shrink fit at the sleeve ends of 0.014”. For the remainder of the joint between the 6” ends, the fit-up gap shall be 0.032” +/-0.004”, which will result in a nominal shrink fit of 0.020”. The transition in backing strip width shall have a generous corner break so as not to create a sharp step.

Enclosure (1)

SUPPLEMENTARY SPLIT SLEEVE DATA AND INSTRUCTIONS

(DDG-51 CLASS PROPELLER SHAFT – FWD SLEEVE)

Measure and record the widths of the backing strips (Wstrip) and that of the respective slots (Wslot) prior to splitting the sleeve into halves.

WstripA

WslotA

WstripB

WslotB

Signature __________________________________ Date ________________

During welded installation of the sleeves, strain gages shall be installed to monitor the stress due to weld shrinkage as follows:

· A welding procedure prepared by a welding engineer and approved by NAVSEA is required.

· Strain gages shall be located along the weld joints (both sides) and 90° from the weld joints along the length of the sleeve. The distance between the gages and the weld joints shall be sufficient to prevent gage damage, de-bonding, or false readings.

· All strain gages will measure uniaxial strain around the circumference of the sleeve, so as to indicate the measured shrink fit.

· The prior joint modifications require placement of strain gages within 3” of the sleeve ends and additional gages in between shall coincide with the dimensional measurement stations along the length of the sleeve to monitor the stress in areas of design and modified fit-up.

· The sleeves shall be accurately aligned and securely clamped to the shaft and appropriately grounded prior to welding. In no case shall the sleeve be welded to the shaft.

· Peening of welds shall only be accomplished as required to remove excessive stress, while optimizing residual stress within the allowable limits. Repair activities are cautioned against premature peening of welds in an effort to limit the in-process stress below the 16 ksi limit, as this typically leads to insufficient shrink fit in the final condition. Based on a modulus of elasticity of 21 x 106 psi, the threshold strain limit after final welding would be 762 x 10-6 in/in.

· Every weld layer will be subject to a liquid dye penetrant (PT) inspection with Class 2 acceptance criteria per MIL-STD-2035A(SH) in lieu of the RT requirements for M-1 Category A in S9074-AR-GIB-010/278. The final PT shall also use Class 2 acceptance criteria.

· After welding there shall be no gap between the sleeve groove and backing strip. If gaps remain, or if any of the strain gages indicate a shrink fit of less than 0.014”, a completed copy of this document shall be submitted for engineering evaluation prior to machining the sleeve.

Measure and record the final strain [e] values indicated by the strain gages.

e

After final welding, but prior to removing the runoff portion of the backing strips, measure and record the final widths of the backing strip by measuring the protruding portion of the backing strips immediately adjacent to the sleeve end at each end of each weld joint using dial calipers.

(WstripA)final

(WstripB)final

Prior to machining the sleeve, measure and record any gaps remaining after final installation, where GAPfinal for a particular sleeve end is the sum total of combined gaps remaining in both joints at that end, as determined by inspection with wire, cut-down feeler gages, etc.

GAPfinal

Upon completion of welding, and to ensure watertight integrity, the ends of the weld joints shall be ground after final machining to remove metal burrs that may have been forced into gaps remaining around the ends of the backing strips. Grinding is to be a minimum of 0.03” deep and is to include the outline of the backing strip to the maximum extent possible without damaging the shaft surface. Incidental damage to the shaft must be evaluated for acceptability, faired smooth, and be subject to either MT or PT per NAVSEA Technical Publication T9074-AS-GIB-010/271.

Following grinding, repeat measurements and record any gaps remaining after final machining, where GAPmachined for a particular sleeve end is the sum total of combined gaps remaining in both joints at that end, as determined by inspection with wire, cut-down feeler gages, etc.

GAPmachined

Enclosure (1)

SUPPLEMENTARY SPLIT SLEEVE DATA AND INSTRUCTIONS

(DDG-51 CLASS PROPELLER SHAFT – FWD SLEEVE)

Following grinding, the ends of the weld joints and the entire periphery of the sleeve ends and backing strip ends shall be sealed with a wicking grade thread sealant (Loctite 290 or equivalent) followed by a bead of polysulfide.

NOTE: Measurement stations B and D are not required for sleeves less than 36” in length.

NOTE: At least 24 hours before taking measurements, place the sleeve in close proximity to the shaft to ensure that both are at the same temperature and that both shaft and sleeve are between 60°F - 80°F.

Tshaft __________°F Tsleeve __________°F Measure and record the shaft outside diameter in way of the sleeve (ODshaft).

0°-180°

45°-225°

90°-270°

135°-315°

AVERAGE

Measure and record the sleeve inside diameter prior to splitting into halves (IDsleeve). The average values should be within +/- 0.003” of the corresponding shaft OD average values at each station.

0°-180°

45°-225°

90°-270°

135°-315°

AVERAGE

Measure and record the average sleeve outside diameter (ODsleeve) in the rough turned condition prior to splitting into halves.

ODsleeve = _________

Enclosure (2)

SUPPLEMENTARY SPLIT SLEEVE DATA AND INSTRUCTIONS

(DDG-51 CLASS PROPELLER SHAFT – AFT SLEEVE)

Signature __________________________________ Date ______________

Machining of the weld joints shall be per DWG 803-2145807 (see excerpt above), with the following exceptions:

· To prevent weld burn-thru, as well as excessively thin welds in the way of GRP end preps, the backing strip thickness shall be 0.188” +0.000/-0.005”.

· To improve weld shrinkage, the 50° bevel angle in the weld joint detail (Detail 61-B) shall be changed to 60°.

· To ensure watertight integrity at the sleeve ends, the backing strip widths will be increased for the first 6” under the ends of the finished sleeve so as to reduce the fit-up gap to 0.022” +/-0.004”, which will result in a nominal shrink fit at the sleeve ends of 0.014”. For the remainder of the joint between the 6” ends, the fit-up gap shall be 0.032” +/-0.004”, which will result in a nominal shrink fit of 0.020”. The transition in backing strip width shall have a generous corner break so as not to create a sharp step.

Measure and record the widths of the backing strips (Wstrip) and that of the respective slots (Wslot) prior to splitting the sleeve into halves.

WstripA

WslotA

WstripB

WslotB

During welded installation of the sleeves, strain gages shall be installed to monitor the stress due to weld shrinkage as follows:

· A welding procedure prepared by a welding engineer and approved by NAVSEA is required.

· Strain gages shall be located along the weld joints (both sides) and 90° from the weld joints along the length of the sleeve. The distance between the gages and the weld joints shall be sufficient to prevent gage damage, de-bonding, or false readings.

· All strain gages will measure uniaxial strain around the circumference of the sleeve, so as to indicate the measured shrink fit.

· The prior joint modifications require placement of strain gages within 3” of the sleeve ends and additional gages in between shall coincide with the dimensional measurement stations along the length of the sleeve to monitor the stress in areas of design and modified fit-up.

· The sleeves shall be accurately aligned and securely clamped to the shaft and appropriately grounded prior to welding. In no case shall the sleeve be welded to the shaft.

· Peening of welds shall only be accomplished as required to remove excessive stress, while optimizing residual stress within the allowable limits. Repair activities are cautioned against premature peening of welds in an effort to limit the in-process stress below the 16 ksi limit, as this typically leads to insufficient shrink fit in the final condition. Based on a modulus of elasticity of 21 x 106 psi, the threshold strain limit after final welding would be 762 x 10-6 in/in.

· Every weld layer will be subject to a liquid dye penetrant (PT) inspection with Class 2 acceptance criteria per MIL-STD-2035A(SH) in lieu of the RT requirements for M-1 Category A in S9074-AR-GIB-010/278. The final PT shall also use Class 2 acceptance criteria.

· After welding there shall be no gap between the sleeve groove and backing strip. If gaps remain, or if any of the strain gages indicate a shrink fit of less than 0.014”, a completed copy of this document shall be submitted for engineering evaluation prior to machining the sleeve.

Measure and record the final strain [e] values indicated by the strain gages.

e

After final welding, but prior to removing the runoff portion of the backing strips, measure and record the final widths of the backing strip by measuring the protruding portion of the backing strips immediately adjacent to the sleeve end at each end of each weld joint using dial calipers.

(WstripA)final

(WstripB)final

Prior to machining the sleeve, measure and record any gaps remaining after final installation, where GAPfinal for a particular sleeve end is the sum total of combined gaps remaining in both joints at that end, as determined by inspection with wire, cut-down feeler gages, etc.

GAPfinal

Upon completion of welding, and to ensure watertight integrity, the ends of the weld joints shall be ground after final machining to remove metal burrs that may have been forced into gaps remaining around the ends of the backing strips. Grinding is to be a minimum of 0.03” deep and is to include the outline of the backing strip to the maximum extent possible without damaging the shaft surface. Incidental damage to the shaft must be evaluated for acceptability, faired smooth, and be subject to either MT or PT per NAVSEA Technical Publication T9074-AS-GIB-010/271.

Following grinding, repeat measurements and record any gaps remaining after final machining, where GAPmachined for a particular sleeve end is the sum total of combined gaps remaining in both joints at that end, as determined by inspection with wire, cut-down feeler gages, etc.

GAPmachined

Following grinding, the ends of the weld joints and the entire periphery of the sleeve ends and backing strip ends shall be sealed with a wicking grade thread sealant (Loctite 290 or equivalent) followed by a bead of polysulfide.

ENCLOSURE (3)

APPLICATION OF SHERWIN WILLIAMS'

NOVA-PLATE UHS PRIMER HIGH SOLIDS EPOXY PAINT

Perform a visual inspection to verify all surfaces to be blasted are free of hydrocarbons, and other contaminants such as sea salts, loose rust, mud, and marine growth, which could become imbedded in the surface to be prepared.

2.4.3 Where doubt exists as to the adequacy of surface cleanliness prior to surface preparation, inspect the surface using a UV light (approx. 60 A) to detect hydrocarbons on the surface. The ultraviolet light will not allow the proper detection of hydrocarbons on the surface if the surface being inspected is exposed to day or artificial light. For proper UV light hydrocarbon detection, lights must be off for interior spaces, and the inspection must be conducted during darkness for surfaces exposed to sunlight. Take appropriate safety measures to prevent worker hazards in the darkened space. When hydrocarbons are present, the hydrocarbons will fluoresce as bright green, lime green, or blue/violet on the surface.

CAUTION

UV lights that contain mercury are prohibited from use in mercury exclusion areas.

WARNING

NEVER add thinner to any high solids paint.

5.2 CHECKPOINT (Single Coat):

5.2.1 (Holiday Inspection): Perform a visual inspection of primer for holidays.

5.2.2 (Dry Film Thickness): Perform dry film thickness measurements and record. Verify compliance with Reference 1.2.

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