Materials and NDE

Book D

MQPS 4-3

Materials and Qualification Procedures for Ships

Procedure 4-3 Approval of a Works for the Manufacture of Stainless Steel Castings
including Propellers

Introduction

1.1

Application for approval

1.1.1

In order that consideration may be given to approval of a foundry for the manufacture of
stainless steel castings, the local Surveyors are to submit a report to Headquarters,
Materials and NDE Department, giving the information listed in Sections 2 and 3 together
with the results of approval tests carried out under their survey.

1.1.2

The names of approved foundries will appear in LR's List of Approved Manufacturers of
Materials, which is published on the intranet.

1.1.3

Approved foundries will be subject to periodic inspection (see Procedure 1-1).

1.2

Scope

1.2.1

The procedure applies to foundries manufacturing stainless steel castings, including

propellers and propeller blades, for use in constructions under LR survey.

1.3

Related Rules

1.3.1

LR's Rules and Regulations for the Classification of Ships (hereinafter referred to as the
Rules for Ships).

1.3.2

LR's Rules for the Manufacture, Testing and Certification of Materials (hereinafter referred
to as the Rules for Materials).

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

Information required for approval

2.1

Product details

2.1.1

The foundry is to provide the following product related details:

(a)

Name and address and brief

statement of background indicating
whether the works is new or long
established.

(b)

Types of castings and steel alloy

grades in general production.

(c)

Estimated total annual production of

finished castings.

(d)

Mass (as finished) and for propellers,

diameter of largest casting which can
be made.

(e)

Grades of steels for which approval is

required.

(f)

The specified chemical composition for

each grade to be approved.

2.2

Details of facilities and procedures

2.2.1

The foundry is to provide the following details of their facilities and procedures:

(a)

Details of number, type and capacity of

each melting furnace.

(b)

Details of charge materials and

melting practice.

(c)

Brief details of the system employed for

the control of chemical composition
including the method of chemical
analysis and, where applicable, details
of the standards used.

(d)

Types of moulding materials used.

(e)

Details of heat treatment furnaces

available, dimensions, type of fuel used
and facilities for temperature
measurement and control, including
details of the method for attaching
thermocouples to the castings.

(f)

Details of the facilities available and

general procedures used for the repair
of castings by welding. Welding
procedures will require to be qualified

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

(see Section 5).

(g)

Facilities available for mechanical

testing, chemical analysis,
metallographic and non-destructive
examination. This is to include
information regarding the name of the
manufacturer, type number or
description, serial number and
calibration status of all machines used
for tensile, impact and hardness
testing.

(h)

Details of the system used for the

identification of castings and
associated test material at all stages
of manufacture.

(i)

Details of the inspection and quality

control systems established in the
foundry. These are to include the name
and qualifications of the Quality
Manager and the number and
qualifications of staff employed on
inspection and quality control activities.
The lines of responsibility of the Quality
Manager and the Production Manager
are to be indicated, preferably in the
form of an organization chart showing
the senior management positions to
whom they report.

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

Approval test programme

3.1

Selection of material

3.1.1

Approval tests are to be carried out on at least three castings taken from different heats from current
production. Where appropriate, one of the castings selected for this purpose should be a
propeller with a diameter approaching the maximum which can be manufactured.
Approval will be limited to the types of steel in the castings submitted.

3.1.2

A minimum of one casting shall be at least 75% of the maximum weight for which approval
is required unless this weight exceeds 50 tonnes.

3.2

Selection of material

3.2.1

For each casting selected for approval tests, the foundry is to provide the following
information:

(a)

Sketch showing method of casting with

details of gating and feeding system
and the arrangements for the provision
of suitable mechanical test samples
(see 3.2.2).

(b)

Ladle analysis.

(c)

If applicable, details of heat

treatment.

3.2.2

The test samples are to be in accordance with Ch 4,1.6 of the Rules for Materials.

Approval tests

4.1

Tests, test samples and specimens

4.1.1

The location and dimensions of test samples, test specimens and mechanical testing
procedures are to be in accordance with the requirements of Ch 2 of the Rules for
Materials.

4.1.2

The following tests and examinations are to be carried out on each casting submitted for
approval tests:

(a)

Visual examination before and after

final machining.

(b)

Dye penetrant or magnetic particle

testing as appropriate of all surfaces
after final machining.

(c)

Ultrasonic or radiographic
examination, where appropriate,
particularly in way of the blade roots on
propellers.

(d)

Tensile tests.

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

(e)

Charpy V-notch impact tests at

+20C, 0C, -20C and -40C. (-196C only for austenitic steel)
Three specimens are to be tested at
each temperature and both the energy
absorbed and the percentage
crystallinity are to be reported.

(f)

Chemical analysis of the casting.

(g)

Intercrystalline corrosion tests

in accordance with
Ch 3.7.6 of the Rules for Materials.

(h)

Representative
photomicrographs at x100
magnification. For duplex stainless
steels this should also include a ferrite
count.

Repair procedures

5.1

Welding repairs

5.1.1

Welding procedures are to be provided for each type and grade of casting material for
which approval is required.

5.1.2

Each welding procedure is to include, as a minimum, the following information:

(a)

Welding equipment.

(b)

Welding process.

(c)

Parent metal.

(d)

Welding consumables.

(e)

Type of joint and preparation of

the edges to be welded as well
as backings.

(f)

Thickness of the parent metal.

(g)

Welding position.

(h)

Welding sequence (number and

order of metal depositions).

(j)

Welding parameters: amperage

and voltage, welding speed.

(k)

Pre-heating and post weld heat

treatment.

(l)

Heat input and interpass

temperature.

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

5.1.3

The welding procedure, endorsed by the Surveyor, is to be submitted with the information
required by Section 3. It should be noted that all repairs made to castings during
manufacture are to be in accordance with the requirements of Ch 4 of the Rules for
Materials.

5.1.4

All welders and welding procedures are to be qualified in accordance with a recognized
National or International Standard.

5.1.5

As an alternative to 5.1.4, a welder may be approved on the basis of past experience

provided that qualification tests acceptable to the Surveyor are undertaken satisfactorily
for each type and grade of material (see also Procedure 0-2).

5.1.6

The material to be used in qualification tests is to be cast and of a size suitable to ensure
a reasonable heat distribution and equivalence to practical use.

5.1.7

All tests and examinations are to be made after any specified heat treatment has been
carried out. Where no heat treatment is specified, as may be the case with austenitic or
duplex stainless steels, the weld test sample is to be subjected to a stress relief heat
treatment prior to testing.

5.1.8

Tests and examinations on the welded assembly are to include the following:

(a)

Two cross-weld tensile tests. The

tensile strengths of the specimens are
not to be less than those of the parent
material.

(b)

Two root bend and two face bend tests

in accordance with Ch 11.8 of the
Rules for Materials the
specimens after test are to be included
in the report.

(c)

Where the Rules require the cast

material to be impact tested, then
impact tests should be taken from the
weld centreline and heat affected
zone and exhibit properties
equivalent to that specified for the cast
material.

(d)

A hardness survey through the

weld, heat affected zone and
parent metal, see Fig. 4-3.5.1.

(e)

Two macrographs showing the weld,

heat affected zone and parent metal
and photomicrographs at x100
magnification showing the
microstructures of these three regions.

(f)

For duplex stainless steels a ferrite

count should be included and the
material should be free of deleterious
sigma, chi and laves phases.

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1

Materials and NDE

Book D

MQPS 4-3

Validity of approval certificate

6.1

Duration

6.1.1

The initial approval certificate will have a validity of three years.

6.1.2

For the validity to be extended for a further three years the Surveyors should undertake a
periodic inspection in accordance with Procedure 1-1.

,5

h 2 mm

mm

S
HAZ

GCHAZ

Weld metal

Parent metal

4607/14

Fig. 4-3.5.1
Example showing positions of the indentations for hardness testing in the weld, heat
affected zone and parent metal of a butt weld

!"#$

Lloyds Register 2002. All rights reserved

Rev. 1