Ministry of Defence

Defence Standard 02-771 (NES 771)

Issue 1 Publication Date 01 April 2000

Requirements, Procedure And

Inspection For Weld Repair Of
Copper Alloy And Nickel Alloy Castings

Incorporating NES 771 Category 2

Issue 1 Publication Date July 1991

AMENDMENT RECORD
Amd No

Date

Text Affected

REVISION NOTE
This standard is raised to Issue 1 to update its content.
HISTORICAL RECORD
This standard supersedes the following:
Naval Engineering Standard (NES) 771 Issue 1 dated July 1991.

Signature and Date

Ministry of Defence

Naval Engineering Standard

NES 771

Issue 1 (Reformatted)

July 1991

REQUIREMENTS PROCEDURE AND INSPECTION

FOR WELD REPAIR OF COPPER ALLOY AND
NICKEL ALLOY CASTINGS

This NES Supersedes

DG SHIPS 9011

Record of Amendments
AMDT
1
2
3
4
5
6
7
8
9
10

INSERTED BY

DATE

NAVAL ENGINEERING STANDARD 771

ISSUE 1 (REFORMATTED)
REQUIREMENTS, PROCEDURE AND INSPECTION FOR
WELD REPAIR OF COPPER ALLOY AND
NICKEL ALLOY CASTINGS

The issue and use of this Standard

is authorized for use in MOD contracts
by MOD(PE) Sea Systems and
the Naval Support Command

ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Sea Systems, Foxhill, Bath BA1 5AB
i

ii

NES 771
Issue 1 (Reformatted)

SCOPE
1.

This NES specifies the minimum requirements, procedure and inspection standards for the
welding repair of castings in certain copper-based and nickel-based alloys.

iii

NES 771
Issue 1 (Reformatted)

iv

NES 771
Issue 1 (Reformatted)

FOREWORD
Sponsorship
1.

This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Director Naval Architecture (Submarines), (DNA(SM)), Section NA 133.

2.

It is to be applied as required to any Ministry of Defence contract for the Weld Repair of
Castings in certain Copper Alloys and Nickel Alloys.

3.

If it is found to be technically unsuitable for any particular requirement the Sponsor is to be

informed in writing of the circumstances with a copy to Director Naval Architecture (Surface
Ships), (DNA(SS)), Section NA 145.

4.

Any user of this NES either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract are to be
made to the Sponsor of the NES and those directly applicable to a particular contract are to
be dealt with using existing procedures or as specified in the contract.

5.

No alteration is to be made to this NES except by the issue of an authorized amendment.

6.

Unless otherwise stated, reference to this NES to approval, approved, authorized or similar
terms, means by the Ministry of Defence.

7.

Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical side line. Deletions will be indicated by 000 appearing at the end of the line
interval.

Conditions of Release
General
8.

This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.

9.

This document is Crown Copyright and the information herein may be subject to Crown or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.

10.

The Crown reserves the right to amend or modify the contents of this NES without consulting
or informing any holder.

MOD Tender or Contract Process

11.

This NES is the property of the Crown and unless otherwise authorized in writing by the MOD
must be returned on completion of the contract, or submission of the tender, in connection
with which it is issued.

12.

When this NES is used in connection with a MOD tender or contract, the user is to ensure that
he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made of

NES 771
Issue 1 (Reformatted)

the local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.
13.

When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.

Related Documents
14.

In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a.

British Standards

British Standards Institution,

389 Chiswick High Road,
London W4 4AL

b.

Defence Standards

Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX

c.

Naval Engineering Standards

CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP

d.

Other documents

Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

15.

All applications to Ministry Establishments for related documents are to quote the relevant
MOD Invitation to Tender or Contract Number and date, together with the sponsoring
Directorate and the Tender or Contract Sponsor.

16.

Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.

Health and Safety

Warning
17.

This NES may call for the use of processes, substances and/or procedures that may be injurious
to health if adequate precautions are not taken. It refers only to technical suitability and in
no way absolves either the supplier or the user from statutory obligations relating to health
and safety at any stage of manufacture or use. Where attention is drawn to hazards, those
quoted may not necessarily be exhaustive.

vi

NES 771
Issue 1 (Reformatted)

CONTENTS
Page No

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v
v
v
v
v
vi
vi
vi

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

SECTION

1.

MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

SECTION

2.
2.1
2.2
2.3

QUALIFICATION REQUIREMENTS . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding Procedure Records . . . . . . . . . . . . . . . . . . .
Welding Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.1 QUALIFICATION
PROCEDURESWELD PREPARATIONS . . . . . .
Welder Qualification . . . . . . . . . . . . . . . . . . . . . . . . .
Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Testing . . . . . . . . . . . . . . . . . . . . . . .
Destructive Testing . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.2 QUALIFICATION
PROCEDURESPOSITION OF TEST PIECES
IN 320 125 25mm AND 320 250 40mm
PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.3 QUALIFICATION
PROCEDURESTRANSVERSE TENSILE TEST
PIECES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.4 QUALIFICATION
PROCEDURESALL WELD METAL
TENSILE TEST PIECES . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.5 QUALIFICATION
PROCEDURESIDE BEND TEST PIECE . . . . . .
FIGURE 2.6 QUALIFICATION
PROCEDUREMACRO SECTION . . . . . . . . . . .
Acceptance Standards . . . . . . . . . . . . . . . . . . . . . . . .
Non-Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1
2.1
2.1
2.2

2.4
2.5
2.5.1
2.5.2

2.6
2.6.1
2.7
2.8

vii

2.4
2.5
2.5
2.5
2.6

2.7
2.8
2.9
2.10
2.11
2.12
2.12
2.12
2.12
2.13

NES 771
Issue 1 (Reformatted)

SECTION

3.
3.1
3.2
3.3
3.4

3.5
3.6

WELD REPAIR OF CASTING . . . . . . . . . . . . . . . .

Welding Limitations . . . . . . . . . . . . . . . . . . . . . . . . . .
General Welding Requirements . . . . . . . . . . . . . . . .
Approved Welding Processes . . . . . . . . . . . . . . . . . . .
Approved Welding Consumables . . . . . . . . . . . . . . .
TABLE 3.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 3.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Treatment of Weld Repairs . . . . . . . . . . . . . . .
Non-Destructive Examination . . . . . . . . . . . . . . . . . .

3.1
3.1
3.1
3.2
3.3
3.3
3.3
3.4
3.4

SECTION

4.

RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

ANNEX

A.

RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .

A.1

ANNEX

B.

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

B.1

ANNEX

C.

RECORD OF QUALIFICATION TEST OF

WELDING PROCEDURE TO NES 771 . . . . . . . . .

C.1

ANNEX

D.

WELD PROCEDURE SUMISSION FORM . . . . . .

D.1

ANNEX

E.

RECORD OF QUALIFICATION TEST OF

WELDER TO NES 771 . . . . . . . . . . . . . . . . . . . . . . .

E.1

ALPHABETICAL INDEX

viii

NES 771
Issue 1 (Reformatted)

1.

MATERIALS
a.

This NES relates to the weld repair of the following copper-based and
nickel-based alloy castings:
Nickel-copper alloy complying with BS 3071: NA1.
Nickel aluminium bronze (naval alloy) complying with NES 747 Parts 2
and 4 (unless used for propulsors).
Nickel aluminium bronze (commercial alloy) complying with NES 747
Part 3 (unless used for propulsors).
Gunmetal complying with NES 830 Part 1. (see also Clause 2.3c.).
Aluminium silicon bronze complying with NES 834 Part 3.

b.

The weld repair of the following copper-based and nickel-based alloy castings
is the subject of other NES:
Materials for propulsors (see NES 304 Part 5).
Nickel aluminium bronze (naval alloy) centrifugal castings complying
with NES 747 Part 1 (see NES 747 Part 1).
Nickel chromium molybdenum alloy 625 complying with NES 822 Parts 1
and 2 (see NES 823).
Copper nickel chromium complying with NES 824 Part 1 (see NES 825).

1.1

NES 771
Issue 1 (Reformatted)

1.2

NES 771
Issue 1 (Reformatted)

2.

QUALIFICATION REQUIREMENTS

2.1

General

2.2

a.

Weld repairs to castings cannot be subjected to destructive examination and, in

addition, non-destructive examination is often hindered by the casting
geometry. Thus, to ensure that weld repairs to castings are to a required
acceptance standard it is necessary to simulate the weld repair by welding test
plates which can then be subjected to rigorous destructive and non-destructive
examination. The validation of a welding procedure or welder by the production
of test pieces to a required acceptance standard is referred to as qualification.

b.

All welding is to be carried out using approved welding procedures in accordance

with this NES. Prior to production application, the contractor is to submit his
welding procedures and associated qualification data to an independent,
competent inspecting authority for approval. The inspecting authority is to be
proposed by the contractor and agreed by the contract sponsor or his
representative. It is permissible for the contract sponsor to nominate a
MOD(PE) representative (eg Principal Naval Overseer) to act as the inspecting
authority provided that personnel have sufficient expertise in the processes
being employed. Procedures are the contractors responsibility and approval by
the inspecting authority does not mitigate his responsibility for conformance
with contract requirements.

c.

The cost of conducting all qualification tests, including approvals, is to be borne

by the contractor. The contractor is to certify that the tests have been conducted
in accordance with the procedure to be qualified and is to arrange the witnessing
of tests to the satisfaction of the inspecting authority.

d.

It is not permissible for the contractor to have the test weldments performed by
another organization. It is permissible however to subcontract any or all of the
work on the preparation of test specimens from the completed weldment and
the performance of non-destructive and mechanical tests, provided that the
contractor accepts responsibility for the results of such work.

e.

The approval of welding procedures by an independent inspecting authority is

also to be applied in principle to subcontracted work.

f.

All welding procedures and welders employed for weld repairs to castings are to
be subject to previous qualification.

g.

Qualification of a welding procedure or welder is limited to a particular type of

weld repair as defined in Clause 2.3c.

h.

Welding procedures and welders may be qualified simultaneously.

Welding Procedure Records

a.

Copies of all approved welding procedures and associated qualification data are
to be forwarded to DNA(SM), Section NA 133 for record purposes.

2.1

NES 771
Issue 1 (Reformatted)

2.3

Welding Procedure
a.

All welding is to be carried out by processes in accordance with Clause 3.3a., is

to use consumables in accordance with Clause 3.4a. and is subject to general
requirements in accordance with Clauses 3.1a. to 3.1o.

b.

Written welding procedures are to be prepared embodying the relevant

information from this NES and are to include all details necessary to produce
welds in accordance with this NES. The written welding procedures are to
include the following:
(1)

Parent material identity.

(2)

Dimensions of test plate used for qualification and type of repair being
qualified.

(3)

Operations carried out prior to welding as follows:

Heat treatment where applicable.

(b)

Sketch of weld preparation.

(c)

NDE and acceptance standard.

(4)

Welding process or combination of welding processes.

(5)

Welding process parameters as follows:

(6)

c.

(a)

(a)

Welding position (Flat Position welding is preferred).

(b)

Welding consumables, identity and specification.

(c)

Shielding gas composition and flow rate.

(d)

Welding characteristics including voltage, amperage and polarity.

(e)

Pre-heat and inter-run temperatures.

(f)

Inter-run cleaning procedures.

(g)

Deposition sequence.

Operations carried out subsequent to welding as follows:

(a)

Heat treatment where applicable.

(b)

NDE and acceptance standards.

Welding procedures are to be qualified using cast test plates as follows:

(1)

Dimensional rectification or repair of defects having excavated depths of

not more than 10mm.
A restrained test plate of minimum size 320mm 125mm 25mm thick
with an excavated groove the length of the plate in accordance with
FIGURE 2.1 is to be welded.

(2)

Repair of defects having excavated depths greater than 10mm.

A restrained test plate of minimum size 320mm 250mm 40mm thick
with an excavated groove the length of the plate in accordance with
FIGURE 2.1 is to be welded.

2.2

NES 771
Issue 1 (Reformatted)

(3)

Repair simulation
It is not possible to adequately simulate all weld repairs by test plates in
accordance with (1) or (2). In certain circumstances, such as restricted
access or casting geometries resulting in unusual restraint or heat
dissipation, the inspecting authority may rule that plates to (1) or (2) are
inappropriate for qualification purposes. In such instances it is necessary
to simulate the repair using a test plate machined to reproduce the actual
casting wall thickness and repair to be undertaken. The test plate is to
embody as far as possible all essential features regarding access, restraint
and heat dissipation and is subject to approval by the inspecting authority.
A special instance of plates to (1) or (2) being inappropriate for
qualification is the weld repair of gunmetal to NES 830 Part 1. This
material has limited weldability being prone to cracking in the parent
metal when multi-run welding is carried out. For this reason only minor
weld repairs are allowable (excavation depth not to exceed 5mm); plates
to (1) or (2) are inappropriate and simulation of the repair is required.

d.

To ensure that cast-in defects are identified before welding and do not in
themselves subsequently cause rejection of the test weld, test plates are to be
subject to NDE prior to welding. The NDE is to consist of visual and liquid
penetrant examination for all materials and radiography, or where appropriate
ultrasonics, for all materials other than gunmetal to NES 830 Part 1.

e.

Subject to qualification in accordance with both non-destructive and

destructive acceptance standards defined in Clauses 2.6.1a. and 2.7a. the
written welding procedure complete with test results is to be submitted to the
inspecting authority for approval. The weld procedure and test results are to be
recorded in a form similar to that shown in Annex C. or BS 4870 and are to be
accompanied by a weld procedure submission of the form indicated in Annex D.

f.

Qualified welding procedures are transferable from one organization to

another, including contractors to subcontrators, providing the organization
using the procedure can demonstrate it can work to that procedure to the
satisfaction of MOD(PE).

g.

Re-qualification is required if changes are made to a qualified welding

procedure. All such changes are to be submitted to the inspection authority for
approval.

2.3

NES 771
Issue 1 (Reformatted)

FIGURE 2.1 QUALIFICATION PROCEDURESWELD PREPARATIONS

2.4

NES 771
Issue 1 (Reformatted)

2.4

Welder Qualification
a.

Each welder is to be qualified to meet the appropriate acceptance standard

using the approved welding procedures. No welder is to be employed on work
requiring an acceptance standard beyond his proven capabilities.

b.

The contractor is responsible for ensuring that each welder is capable of

working strictly to the welding procedures under production conditions to the
relevant acceptance standards. The contractor is to ensure that welders
maintain the required standard by checking their work through normal
production non-destructive testing.

c.

Where a welder is unable consistently to meet the acceptance standards or fails

to work in accordance with the approved procedure, he is not to be employed on
MOD(PE) work. Re-establishment of the welder qualification is subject to
acceptance by MOD(PE).

d.

Welder qualification test assemblies are to be chosen from those detailed in

Clauses 2.3c. and 2.3d.

e.

Qualification of a welder is acceptable if the visual, dye penetrant and

radiographic examinations meet the requirements of Clause 2.6.1a. and the side
bend test and macro specimen tests meet the requirements of Clause 2.7a. The
test results are to be recorded in a form similar to that shown in Annex E.

f.

Re-qualification of welders is required if:

(1)

the QAR has reason to doubt that the standard of workmanship in

production meets the requirements of this NES;

or
(2)

g.

a period of six months has elapsed since the welder was last engaged on
welding the material to the acceptance standards required using the
approved welding procedure.

Weld procedures and welders may be qualified simultaneously.

2.5

Test Methods

2.5.1

Non-Destructive Testing
a.

All non-destructive examination is to be carried out using methods in

accordance with NES 729.

b.

Non-destructive examination of test pieces is to be carried out subsequent to

any specified post-weld heat treatment.

c.

Test pieces in gunmetal to NES 830 Part 1 are subject to visual and liquid
penetrant examination. For the other materials covered by this NES test pieces
are, in addition to visual and dye penetrant examination, subject to
radiographic or, where appropriate, ultrasonic examination.

2.5

NES 771
Issue 1 (Reformatted)

2.5.2

Destructive Testing
a.

b.

Subject to satisfactory NDE and acceptance the following destructive tests are
to be carried out in accordance with EN 10 0021 and BS 4206 as appropriate:
(1)

Transverse tensile tests (see FIGURE 2.2 and FIGURE 2.3).

(2)

All weld metal tensile test (see FIGURE 2.2 and FIGURE 2.4).

(3)

Side bend test (see FIGURE 2.2 and FIGURE 2.5).

(4)

Examination of etched macro-sections at 10 magnification (see

FIGURE 2.2 and FIGURE 2.6).

For gunmetal to NES 830 Part 1, examination of etched macro section

at 10 magnification (see FIGURE 2.6) is the only destructive test
requirement.

2.6

NES 771
Issue 1 (Reformatted)

FIGURE 2.2 QUALIFICATION PROCEDURESPOSITION OF TEST PIECES

IN 320 125 25mm AND 320 250 40mm PLATES

2.7

NES 771
Issue 1 (Reformatted)

FIGURE 2.3 QUALIFICATION PROCEDURESTRANSVERSE TENSILE TEST PIECES

2.8

NES 771
Issue 1 (Reformatted)

FIGURE 2.4 QUALIFICATION PROCEDURESALL WELD METAL TENSILE TEST PIECES

2.9

NES 771
Issue 1 (Reformatted)

FIGURE 2.5 QUALIFICATION PROCEDURESIDE BEND TEST PIECE

2.10

NES 771
Issue 1 (Reformatted)

FIGURE 2.6 QUALIFICATION PROCEDUREMACRO SECTION

2.11

NES 771
Issue 1 (Reformatted)

2.6

Acceptance Standards

2.6.1

Non-Destructive Tests
a.

2.7

The acceptance standards for test pieces in gunmetal to NES 830 Part 1 are to
be as for non-designated areas in accordance with NES 745 Part 1. For other
materials the acceptance standards for test pieces are to be as for critical test
regions complying with NES 745 Part 1.

Destructive Tests
a.

Mechanical test specimens in accordance with Clause 2.5.2a. are to show the
following minimum properties shown in TABLE 2.1:
(1)

(2)

The maximum crack length that is acceptable in side bend test specimens
after bending is:
(a)

1mm in any longitudinal direction.

(b)

3mm in any transverse direction.

The macro-specimen is to be rejected if cracks, hot tears or lack of fusion

are visible in the weld or heat affected zone. Cracks originating at casting
defects in the parent material are to be recorded but are not to be cause
for rejection.
Transverse
( )
Tensile Test (1)

Material

All Weld Metal

Tensile Test

Side
Bend
Be
d
Angle (2)
(3)

UTS
N/mm 2

UTS
N/mm 2

Elongation
%

430

460

25

120

620

620

12

35

Nickel aluminium
bronze (commercial
alloy) to NES 747
Part 3

620

620

12

35

Aluminium silicon
bronze to NES 834
Part 3

460

540

12

120

Nickel-copper alloy
to BS 3071:NA1
Nickel aluminium
bronze (naval alloy)
to NES 747 Parts 2
and 4

TABLE 2.1
NOTES

1.

Elongation and position of fracture to be recorded.

2.

Angle at which first indication of cracking occurs to be recorded.

3.

The side bend test is to be accomplished through the angle

indicated over a 4t diameter mandrel, where t = thickness
of test specimen.

2.12

NES 771
Issue 1 (Reformatted)

2.8

Retests
a.

In the event of test pieces failing to meet the acceptance standards the retest
procedure is to be as follows:
(1)

Where the test piece fails to meet the non-destructive examination test
requirements a further test piece is to be made and tested. Failure of this
further test piece to fully meet the non-destructive and destructive test
acceptance standards is to result in the rejection of the welding procedure
or welder.

(2)

Where a test piece fails to meet the destructive examination test

requirements two further test pieces are to be made and tested. Failure of
either of these further test pieces to fully meet the non-destructive and
destructive test acceptance standards is to result in the rejection of the
welding procedure or welder.

2.13

NES 771
Issue 1 (Reformatted)

2.14

NES 771
Issue 1 (Reformatted)

3.

WELD REPAIR OF CASTING

3.1

Welding Limitations
a.

The extent of weld repair undertaken is to be the minimum required to enable

the casting to meet the relevant acceptance standards. Weld repair for cosmetic
reasons is prohibited and, wherever possible, surface defects are to be rectified
by blending in accordance with Section 9 of NES 745 Part 1.

b.

Mandatory limitations on allowable excavation and subsequent weld repair are

specified in Section 9 of NES 745 Part 1. When repairs are required which are
more extensive then a concession may be submitted for approval by the Design
Authority. Concessions submitted for consideration are to include:

c.

3.2

(1)

Full details of the proposed method of repair including the welding

procedure(s) to be used.

(2)

Sketches of the proposed repair indicating the position, nature, extent and
depth of defects, design wall thickness of the area and thickness of the
parent material remaining.

Weld repair of castings is only to be carried out using welding procedures and
welders which have been qualified using test plates in accordance with
Clause 2.3c. and approved by MOD(PE) as being appropriate to the type of
repair being undertaken.

General Welding Requirements

a.

Defects are to be removed by machining, pneumatic chipping and/or grinding.

Excavation of defects is to commence in sound material at the ends of the defects
and proceed from each end towards the centre.

b.

When excavating defects in preparation for weld repair the objective is to

produce a rectangular or boat shaped excavation of uniform depth to facilitate
full access and correct manipulation of the electrode or filler wire. Excavations
are to have sloping side walls and be rounded at the base.

c.

To ensure that any defects remaining after excavation are identified and do not
in themselves subsequently cause rejection of the weld, all excavated areas are
to be subject to NDE prior to welding. This NDE is to consist of visual and dye
penetrant examination for all excavated areas and in addition it is mandatory
to carry out radiographic or, where appropriate, ultrasonic examination of
excavated areas in test regions and critical test regions.

d.

Care is to be taken to ensure the complete removal of all contaminants resulting

from non-destructive examination prior to deposition of weld metal.

e.

Pre-heat is required for the following materials:

Nickel aluminium bronze (naval and commercial alloys) complying with
NES 747 Parts 2 to 4.
Gunmetal complying with NES 830 Part 1.
Aluminium silicon bronze complying with NES 834 Part 3.

f.

Pre-heat temperatures are to be measured in accordance with Clause 3.1o. and

are to be within the range 50 to 100 C, unless specified otherwise by the
consumables manufacturer.

3.1

NES 771
Issue 1 (Reformatted)

3.3

g.

As far as is practicable all welding is to be done in the flat position.

h.

Weaving increases the heat input during weld repair which is undesirable.
Stringer bead deposits are to be made at all times with a weld bead width not
exceeding three times the electrode or wire diameter.

i.

Stop/start porosity or deep end craters are to be minimized by use of the run
back technique. This technique is a means of avoiding porosity and crater
cracking which can be caused by the abrupt withdrawal of the welding arc at
the end of a weld run. This technique consists of delaying the consumable at the
weld end to fill the crater and then welding back along the top of the previously
deposited weld for a short distance, thus facilitating the withdrawal of the arc
from superfluous weld metal which is subsequently removed.

j.

Inter-run cleaning is to be carried out using a bronze wire brush which has not
been used on any other material.

k.

Inter-run grinding, when necessary, is to be carried out with rubber/resin

bonded alumina or silicon carbide grinding wheels or with tungsten carbide
burrs.

l.

In multi-run welds the interpass temperature, defined as the temperature of

the weld and adjacent parent metal immediately prior to the application of the
next run, is to be measured in accordance with Clause 3.1o. This measurement
is to be carried out on the surface of the parent material at a point within 75mm
ahead of the weld start and within 25 mm from the edge of the adjacent weld
run on the side from which welding will be performed.

m.

Interpass temperatures are not to exceed 200 C.

n.

In multi-run welds the weld metal is to be deposited in such a manner that the
final weld run consists of weld metal to weld metal.

o.

Pre-heat and interpass temperature is to be determined by contact pyrometers

or thermocouples; the use of other methods such as temperature indicating
crayons or paints is prohibited.

Approved Welding Processes

a.

Subject to satisfactory welding procedure and welder qualification tests,

welding is to be carried out by one of, or a combination of, the following
processes: TIG, MIG or pulsed MIG. In addition the use of the MMA process is
permissible for the weld repair of non-designated areas of castings in
nickel-copper complying with BS 3071: NA1 and in gunmetal complying with
NES 830 Part 1.

3.2

NES 771
Issue 1 (Reformatted)

3.4

Approved Welding Consumables

a.

Approved consumables are detailed in the following Tables; the use of these
materials is not however mandatory and alternative consumables may be
submitted to DNA(SM)/NA 133 for approval.
Parent Material

Approved Consumables
TIG/MIG/Pulsed MIG

Supplier of
Approved
Consumables

Nickel-copper alloy to
BS 3071:NA1

Monel FM 60

Greengrove Welding
Wires Ltd
Stratford-upon-Avon

Nickel aluminium bronze

(naval and commercial
alloys) to NES 747
P t 2 tto 4
Parts

Bostrand AT 246

Murex Welding
Products Ltd
Waltham Cross

Stubs A 3444

Stubs Welding Ltd

Warrington

Gunmetal to
NES 830 Part 1
Aluminium silicon bronze
to NES 834 Part 3.

Stubs A 320

Stubs Welding Ltd

Warrington
Delta (Manganese
Bronze) Ltd, Ipswich

Delta Alloy W 23
TABLE 3.1

Parent Material

Approved Consumables
MMA

Supplier of
Approved
Consumables

Nickel-copper to
BS 3071:NA1

Monel 190

Greengrove Welding
Wires Ltd
Stratford-upon-Avon

Gunmetal to
NES 830 Part 1

Stubs 320

Stubs Welding Ltd

Warrington

TABLE 3.2
b.

All approved welding consumables are to be positively and readily identifiable.

c.

All welding consumables are to be stored in a dry clean atmosphere, in the

packaging as delivered by the manufacturer, and are, where appropriate, to be
baked immediately prior to use in accordance with the manufacturers
instructions.

d.

Covered electrodes which have been exposed to the atmosphere for a period in
excess of two hours are to be re-dried for a minimum period of two hours before
use or in accordance with the manufacturers instructions. Electrodes which
have their coating chipped or other wise damaged, or have exceeded their
recommended shelf life, are not to be used.

e.

A cleanliness check of filler material is to be made before MIG or TIG welding

commences by feeding the wire or rod through a piece of lint-free cloth. If
contamination is evident, degreasing is to be undertaken by wiping with acetone
using a lint-free cloth.

f.

Shielding gas for use with the MIG and TIG welding process is to be welding
quality argon of 99.95% minimum purity. Requests to use other gas mixtures
are to be forwarded to DNA(SM), Section NA 133 for approval.

3.3

NES 771
Issue 1 (Reformatted)

3.5

Heat Treatment of Weld Repairs

a.

Castings in nickel aluminium bronze which have been weld repaired are
required to be subsequently heat treated. In such instances the required heat
treatments are detailed in the relevant material specifications:
Nickel aluminium bronze (naval alloy) to NES 747 Part 2.
Nickel aluminium bronze (naval alloy) to NES 747 Part 4.

b.

3.6

Any proposals for post-weld stress-relief heat treatment of aluminium silicon

bronze to NES 834 Part 3 are to be referred to the Design Authority or
DNA(SM), Section NA 133 for approval.

Non-Destructive Examination
a.

Non-destructive examination of weld repairs is to be carried out subsequent to

grinding or machining the weld surfaces to the required profile and, where
specified, heat treatment.

b.

All non-destructive examination is to be carried out using methods in

accordance with NES 729.

c.

All weld repairs are subject to visual and dye penetrant inspection.

d.

Weld repairs to test regions and critical test regions are subject to radiographic
or, where appropriate, ultrasonic inspection.

e.

When required by the Contract, pressure testing of castings is to be carried out

subsequent to any necessary weld repair.

f.

The acceptance standards for weld repairs are to be in accordance with

NES 745 Part 1.

g.

If after three attempts a weld repair fails to meet the acceptance standards the
Design Authority is to be consulted before proceeding further.

3.4

NES 771
Issue 1 (Reformatted)

4.

RECORDS
a.

The contractor is to be responsible for maintaining records of all welding carried

out within the scope of this NES. Records are to be kept as specified in the
contract of each individual weld repair and are to include:
(1)

Cast number and material.

(2)

Accurate sketch showing location of weld repair, depth of excavation and

classification of area.

(3)

Weld procedure qualification.

(4)

Welder qualification.

(5)

Heat treatment where specified.

(6)

NDE and acceptance standards.

(7)

Weld history when previous unsuccessful attempts at weld repair have

been made.

4.1

NES 771
Issue 1 (Reformatted)

4.2

NES 771
Issue 1 (Reformatted)

ANNEX A.
RELATED DOCUMENTS
A.1

The following documents and publications are referred to in this NES:

See Clause
EN 10 0021

Tensile testing of metallic materials

BS 499

Welding terms and symbols:

BS 3071

Part 1: Glossary for welding, brazing and

thermal cutting
Nickel-copper alloy castings

BS 4206
BS 4870

Methods of testing fusion welds in copper

and copper alloys
Approval testing of welding procedures

*NES 304

Shafting Systems and Propulsors:

NES 729
NES 745

NES 747

NES 822

NES 823
NES 824

2.5.2a.
B.1B.2
1.a., 3.3a.,
3.4a.
2.5.2a.
2.3e.

Part 5: Requirements for Inspection,

Welding and Weld Repair of Propulsors
Requirements for Non-destructive
Examination Methods, Parts 15 inclusive
Classification, Inspection Requirements and
Acceptance Standards of Steel and
Copper-based Alloy Castings,

1.b.

Part 1: Copper Alloy and Nickel Alloy

Castings
Requirements for Nickel Aluminium Bronze
Castings and Ingots:
Part 1: Nickel Aluminium Bronze (Naval
Alloy) Centrifugal Castings and Ingots
Part 2: Nickel Aluminium Bronze Naval
Alloy) Sand Castings and Ingots

2.6.1a., 3.1a.,
3.1b., 3.6f.

Part 3: Nickel Aluminium Bronze

(Commercial Alloy) Sand Castings and
Ingots

1.a., 2.7a.,
3.1e., 3.4a.

Part 4: Nickel Aluminium Bronze (Naval

Alloy) Sand Castings with Welding
Restricted to the Non-wetted Surface (Class
I and Class II Castings only)

1.a., 2.7a.,
3.1e., 3.4a.,
3.5a.

2.5.1a., 3.6b.

1.b.
1.a., 2.7a.,
3.1e., 3.4a.,
3.5a.

Requirements for Nickel Chromium

Molybdenum Niobium Alloy 625:
Part 1: Centrifugal Castings

1.b.

Part 2: Sand Castings and Ingots

1.b.

Requirements for the Welding of Cast

1.b.
Alloy 625
Copper Nickel Chromium Sand Castings and
Ingots:
Part 1: Production Requirements
1.b.

A.1

ANNEX A.

NES 771
Issue 1 (Reformatted)

NES 825
NES 830

NES 834

Requirements for the Welding of High

Strength Chromium Cupro-Nickel Castings
Requirements for Gunmetal Ingots and
Castings:
Part 1: Gunmetal Sand Castings and Ingots,
Ingots
Class III Castings only

1.b.

Requirements for Aluminium Silicon

Bronze:
Part 3: Ingots and Castings

1.a., 2.7a.,
3.1e., 3.4a.,
3.5b.

*In course of preparation.

ANNEX A.

A.2

1.a., 2.3c.,
2.3d., 2.5.1c.,
2 5 2b
2.5.2b.,
2.6.1a., 3.1e.,
3.3a., 3.4a.

NES 771
Issue 1 (Reformatted)

ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1

B.2

For the purpose of this NES the following definitions apply:

Acceptance Authority

The Design Authority for the system concerned.

Contractor

The Firm, Company, Organization,

Establishment or HM Naval Base working
within the scope of this NES.

Design Authority

The relevant Section of the Sea Systems

Controllerate responsible for the systems
concerned.

Inspecting Authority

An independent Company or Organization

employed with the agreement of MOD(PE) to
oversee and approve Weld Procedures on behalf
of DNA(SM), Section NA 133.

Quality Assurance
Representatives (QAR)

MOD(PE) personnel engaged in ensuring that

the requirements of this NES are being met.

Welding terms used in this NES, unless defined, comply with BS 499 Part 1.

B.1

ANNEX B.

NES 771
Issue 1 (Reformatted)

ANNEX B.

B.2

NES 771
Issue 1 (Reformatted)

ANNEX C.
RECORD OF QUALIFICATION TEST OF WELDING PROCEDURE TO NES 771

C.1

ANNEX C.

NES 771
Issue 1 (Reformatted)

(Organizations symbol or
logo)

Record of qualification
Test record No
test of welding procedure
to NES 771
1. Test results
State acceptable, non-acceptable (with reasons or give numerical results)
Non-destructive tests
Visual

Radiography

Penetrant

Ultrasonics

Destructive tests
Tensile

0.2% proof stress

(Units)

Tensile strength
(Units)

Radius of former

Side bend angle

Fracture location

Transverse Tensile
All weld Metal
Tensile
Bend

Angle at which
first indication of
cracking occurs

Side Bend Test

Examination of Macrosection

Additional test(s) and result(s), eg chemical analysis, micro-examination,

nick-break

The statements in this record are correct. The test welds were prepared,
welded and tested in accordance with the requirements of NES 771.
Manufacturers representative

Inspecting Authority

Position

Witnessed by

Date

ANNEX C.

Date

C.2

NES 771
Issue 1 (Reformatted)

ANNEX D.
WELD PROCEDURE SUMISSION FORM

See Page D2.

see Page D3.
see Page D2.

D.1

ANNEX D.

NES 771
Issue 1 (Reformatted)

WELD PROCEDURE SUBMISSION FORM (Duplicate)

Copy No

Inspecting Authority Comments of Destructive and Non-Destructive Testing

Inspecting Authority Comments on Acceptance/Rejection

Contd

ANNEX D.

D.2

NES 771
Issue 1 (Reformatted)

INSTRUCTIONS FOR HANDLING WELD PROCEDURE SUBMISSION FORM

D.1

Originator to complete stage 1 on both copies and forward to inspecting authority

with:
2 copies of weld procedure
2 copies of weld history
1 set of radiographs
2 copies of laboratory report
2 sets of photomacrographs

D.2

Inspecting authority to complete stage 2 and 3 as required. Copy 1 to be returned to

originator, with 1 set of supporting documents in D.1 above including any
radiographs, together with test certificates and photomacrographs. Copy 2 to be sent
to DNA(DM), NA 133 with 1 set of supporting documentation (eg radiographs)
including test certificates and photomacrographs.

D.3

The originator must not use the procedure in production until approved. Procedures
in use without an attached submission form are to be considered unapproved.

D.3

ANNEX D.

NES 771
Issue 1 (Reformatted)

ANNEX D.

D.4

NES 771
Issue 1 (Reformatted)

ANNEX E.
RECORD OF QUALIFICATION TEST OF WELDER TO NES 771

E.1

ANNEX E.

NES 771
Issue 1 (Reformatted)

ANNEX E.

E.2

NES 771
Issue 1 (Reformatted)

ALPHABETICAL INDEX

A
Acceptance standards, 2.6, 2.7, 3.4

B
Blending, 3.1

C
Cast test plates, 2.2, 2.3
Cast-in defects, 2.3, 2.7, 3.1
Cosmetic repair, 3.1

D
Definitions, B.1
Destructive test methods, 2.5

E
Excavation, 3.1

F
Flat position welding, 3.1

G
General welding requirements, 3.1, 3.2

H
Heat treatment of weld repairs, 3.4

M
Multi-run welds, 3.2

N
Non-destructive examination of weld repairs, 3.4
Non-destructive examination prior to welding, 2.3, 3.1
Non-destructive test methods, 2.5, 3.4

INDEX.1

INDEX

NES 771
Issue 1 (Reformatted)

P
Photomacrographs , D.1
Preheat, 3.1, 3.2
Pressure testing, 3.4

Q
Qualification requirements, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7

R
Records, 4.1
Requalification, 2.4
Retests, 2.7
Run back technique, 3.2

S
Shielding gas, 3.3
Side bend test, 2.5, 2.7
Stop/Start porosity, 3.2
Stringer bead deposits, 3.2

T
Tensile tests, 2.5, 2.7
Transfer of qualified welding procedures, 2.3

W
Weaving, 3.2
Weld repair of castings, 3.1, 3.2, 3.3, 3.4
Welder qualification, 2.4
Welding consumables, 3.3
Welding limitations, 3.1
Welding procedure, 2.2, 2.3, 2.4
Welding procedure records, 2.1
Welding processes, 3.2

INDEX

INDEX.2

Inside Rear Cover

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