Ministry of Defence

Defence Standard 02-824 (NES 824)

Issue 1 Publication Date 01 April 2000

Copper Nickel Chromium Sand

Castings And Ingots
Part 1
Production Requirements

Incorporating NES 824 Category 2

Issue 3 Publication Date July 1993

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) 824 Part 1 Issue 3 dated July 1993.

Signature and Date

Ministry of Defence

Naval Engineering Standard

NES 824

Part 1

Issue 3 (Reformatted)

COPPER NICKEL CHROMIUM

SAND CASTINGS AND INGOTS
PART 1
PRODUCTION REQUIREMENTS

July 1993

This NES Supersedes

NES 824 PART 1 ISSUE 2

Record of Amendments
AMDT

INSERTED BY

INCORPORATED

INCORPORATED

INCORPORATED

4
5
6
7
8
9
10

DATE

NAVAL ENGINEERING STANDARD 824

COPPER NICKEL CHROMIUM SAND CASTINGS
AND INGOTS
PART 1
ISSUE 3 (REFORMATTED)
PRODUCTION REQUIREMENTS

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 824
Part 1
Issue 3 (Reformatted)

SCOPE
1.

This Naval Engineering Standard (NES) specifies the requirements for the manufacture,
inspection and testing of sand castings and ingots in Copper Nickel Chromium.

2.

It includes the Physical Characteristics, Mechanical Properties and Quality Assurance

documentation requirements together with Acceptance Standards, Defect rectification and
Packaging and Identification requirements.

iii

NES 824
Part 1
Issue 3 (Reformatted)

iv

NES 824
Part 1
Issue 3 (Reformatted)

FOREWORD
Sponsorship
1.

This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Director Naval Architecture (DNA), Section NA 115.

2.

This NES comprises:

a.

Part 1: Production Requirements

b.

Part 2: Production Methods.

3.

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

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

4.

Any user of this NES either in the MOD or in Industry may propose an amendment to it.
Proposals for amendments which are:
a.

not directly applicable to a particular contract are to be made to the Sponsor of the NES;

b.

directly applicable to a particular contract are to be dealt with using existing procedures
or as specified in the contract.

5.

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

6.

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

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
intervals.

8.

This NES has been reissued to reflect changes in technical requirements.

Conditions of Release
General
9.

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.

10.

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.

11.

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

NES 824
Part 1
Issue 3 (Reformatted)

MOD Tender or Contract Process

12.

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.

13.

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

14.

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
15.

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.

16.

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.

17.

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

Health and Safety

Warning
18.

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 824
Part 1
Issue 3 (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
vi
vi
vi
vi

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

vii

SECTION

1.
1.1
1.2
1.3
1.4

PHYSICAL CHARACTERISTICS . . . . . . . . . . . . .
Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quality of Material . . . . . . . . . . . . . . . . . . . . . . . . . . .
Composition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 1.1 CHEMICAL COMPOSITION . . . . . .
TABLE 1.2 TARGET LEVELS FOR IMPURITIES

1.1
1.1
1.1
1.1
1.1
1.2
1.2

SECTION

2.

HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

SECTION

3.

MECHANICAL PROPERTIES . . . . . . . . . . . . . . . .
TABLE 3.1 MECHANICAL PROPERTIES . . . . .

3.1
3.1

SECTION

4.

CLASSIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

SECTION

5.
5.1
5.2

QUALITY ASSURANCE DOCUMENTATION . . .

Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1
5.1
5.1

SECTION

6.
6.1
6.1.1
6.1.2
6.2
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6

TEST METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-destructive Tests . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensional Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
VisualOptical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Eddy Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiographic Examination of Non-designated
Regions on a Sample Basis . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.2
6.2

6.2.7

vii

6.2
6.2

NES 824
Part 1
Issue 3 (Reformatted)

SECTION

7.
7.1
7.1.1
7.1.2
7.2
7.2.1
7.2.2

ACCEPTANCE STANDARDS . . . . . . . . . . . . . . . . .
Destructive Examination Standards . . . . . . . . . . . . .
Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Non-destructive Examination Standards . . . . . . . . .
VisualOptical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Liquid Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7.1 LINEAR . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7.2 COMPLEX . . . . . . . . . . . . . . . . . . . . .
Eddy Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7.3 THROUGH-THICKNESS DEFECTS
Radiography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1
7.1
7.1
7.1
7.1
7.1
7.1
7.2
7.2
7.3
7.3
7.3
7.3
8.1
8.1
8.1
8.1
8.1

8.3.4
8.3.5

DEFECTS AND RECTIFICATION OF DEFECTS

Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Defects . . . . . . . . . . . . . . . . . . . . . . . .
Blending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weld Repair Definition and Concessionary
Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Dimensional Defects by Weld
Deposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rectification of Surface and Sub-surface Defects
by Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Limitations on Individual Repairs . . . . . . . . . . . . . .
Limits on Weld Repairs . . . . . . . . . . . . . . . . . . . . . . .

8.2
8.2
8.2

SECTION

9.
9.1
9.2

IDENTIFICATION OF INGOTS AND CASTINGS

Ingots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Castings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1
9.1
9.1

SECTION

10.

PACKAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1

ANNEX

A.

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

A.1

ANNEX

B.

DEFINITIONS AND ABBREVIATIONS . . . . . . . .

B.1

ANNEX

C.

PROCUREMENT CHECK LIST . . . . . . . . . . . . . . .

C.1

7.2.3
7.2.4
7.2.5
SECTION

8.
8.1
8.2
8.2.1
8.3
8.3.1
8.3.2
8.3.3

viii

8.1
8.2

NES 824
Part 1
Issue 3 (Reformatted)

1.

PHYSICAL CHARACTERISTICS

1.1

Ingots
a.

Ingots for casting stocks are to be cast from virgin metals and master alloys as
follows:
(1)

Nickelto the chemical composition requirements of BS 375 Grade

R99.95A or R99.95B but with carbon content less than 0.010%;

(2)

Copperto BS 6017 designation CUCATH1;

(3)

Manganese99.9% minimum purity electrolytic manganese flake;

(4)

Iron99.9% minimum purity electrolytic iron;

(5)

Siliconhigh purity lump silicon (0.3% iron maximum);

(6)

Chromium99.5% minimum purity electrolytic or thermic chromium.

NOTE:
(7)

Titaniumpure titanium in sponge or other solid form, high purity

copper titanium master alloy or high purity nickel titanium master alloy;

(8)

Zirconiumhigh purity copper zirconium master alloy or high purity

nickel zirconium master alloy.

NOTE:

1.2

With the exception of minor additions of readily oxidizable elements to

compensate for losses during re-melting, only ingots, virgin metals and the
manufacturers own approved scrap (see Annex B.) may be used to produce
castings.

Quality of Material
a.

No finishing additions such as magnesium or calcium are to be made. No further

additions are to be made to a cast after the final analytical sample has been
taken.

NOTE:

1.4

Where copper titanium or copper zirconium master alloys are used the
copper used in the preparation of these alloys is to be high purity
electrolytic copper.

Castings
a.

1.3

Where thermic chromium is used the aluminium content is to be less than

0.08%;

Contamination by carbon pick-up can be substantially reduced by using

rammed basic linings for electric furnaces and using an alumina wash on
ladles. Silicon carbide and graphite crucibles are not recommended.
Attention is drawn to NES 824 Part 2.

Composition
a.

The chemical composition of castings is given in TABLE 1.1. The chemical

composition of ingots is to be agreed between the ingot manufacturer and the
purchaser to ensure that due allowance is made for impurity pick-up during the
casting processes.

1.1

NES 824
Part 1
Issue 3 (Reformatted)

ELEMENT

Per Cent by Weight

Not less than

Nickel

Not more than

29.00

32.00

Chromium

1.6

2.0

Iron

0.5

1.0

Manganese

0.5

1.0

Silicone

0.20

0.40

Zirconium

0.05

0.15

Titanium

0.03

0.15

Copper

REMAINDER

IMPURITIES
Lead

0.005

Phosphorus

0.005

Bismuth

0.001

Sulphur

0.005

Carbon

0.020

Cobalt

0.050

Boron

0.001

TOTAL IMPURITIES

0.070

TABLE 1.1 CHEMICAL COMPOSITION

b.

Weldability is adversely affected by impurities at the grain boundaries of the as

cast material. In order to increase the probability of producing castings which
are easy to weld it is recommended that target levels for impurities shown in
TABLE 1.2 are not exceeded.

c.

It is important that the carbon content be kept to an absolute minimum.

Per Cent by weight
Not more than
0.0015

IMPURITY
Lead
Bismuth

0.0005

Sulphur

0.0030

Carbon

0.006

Selenium

0.0005

Tellurium

0.0005

Arsenic

0.0010

Zinc

0.0030
TABLE 1.2 TARGET LEVELS FOR IMPURITIES

1.2

NES 824
Part 1
Issue 3 (Reformatted)

2.

HEAT TREATMENT
a.

After removal of feeders and running systems by approved methods such as

sawing or abrasive wheel cutting, but before any surface grinding, the castings
and mechanical test bars are to be Stress Relieved according to the schedule
set out in Clause 2.b. Further stress relieving treatments are mandatory on weld
repaired castings. Refer to Clauses 8.3.1a.8.3.5c. weld repair definition and
concessionary requirements.

b.

The Stress Relief treatment is to be carried out in a furnace validated in

accordance with NES 746 and is to consist of heating the casting at a maximum
rate of 200 C/hour, to 450500 C and held at this temperature for 1
hour/25mm section thickness (2 hours minimum) and air cooled. Where oil fired
or gas furnaces are used the sulphur content of the furnace atmosphere is to be
less than 0.005 grams/metre 3. Heat treatment of test pieces may NOT be carried
out separately from the castings they represent.

2.1

NES 824
Part 1
Issue 3 (Reformatted)

2.2

NES 824
Part 1
Issue 3 (Reformatted)

3.

MECHANICAL PROPERTIES
a.

At room temperature the mechanical properties of test pieces heat treated in

accordance with Clauses 2.a. and 2.b. and mechanically tested as specified in
Clause 6.1.2a. are to be as detailed in TABLE 3.1.
Elongation on 5.65 S o
Gauge Length

Tensile Strength

0.2% Proof Stress

N/mm 2

N/mm 2

Minimum 480

Minimum 300

Minimum 18

TABLE 3.1 MECHANICAL PROPERTIES

3.1

NES 824
Part 1
Issue 3 (Reformatted)

3.2

NES 824
Part 1
Issue 3 (Reformatted)

4.

CLASSIFICATION
a.

The classification of castings is as defined in NES 863.

4.1

NES 824
Part 1
Issue 3 (Reformatted)

4.2

NES 824
Part 1
Issue 3 (Reformatted)

5.

QUALITY ASSURANCE DOCUMENTATION

5.1

Ingots
a.

5.2

Each consignment of ingots is to be accompanied by Quality Assurance

Documentation providing the results of the melt control analysis and the results
of analysis of a sample piece taken from an ingot within the batch.

Castings
a.

Each consignment of castings is to be accompanied by Quality Assurance

Documentation giving the actual results of the tests required in Section 6.,
together with a Certificate of Compliance with the acceptance standards
detailed in Section 7.

b.

Test bars are required to be retained by the foundry for a minimum period of
6 months following completion of all testing and scrutiny (if so desired by the
acceptance authority) of their results.

5.1

NES 824
Part 1
Issue 3 (Reformatted)

5.2

NES 824
Part 1
Issue 3 (Reformatted)

6.

TEST METHODS

6.1

Destructive Tests

6.1.1

Analysis
a.

In addition to the normal melt control analysis, a full analysis for chemical
composition is to be made from a sample piece taken from each cast for ingots
and for castings.

NOTE:
6.1.2

Mechanical Tests
a.

Tensile tests in accordance with BS EN 10002 are to be carried out on test bars
which are to be cast in accordance with BS 1400: Appendix E, Figure 2, from the
same cast as the castings they represent, and be heat treated in accordance with
Clauses 2.a. and 2.b.

NOTE:

6.2

6.2.2

Reference diagrams according to NES 863 are to be provided by the purchaser

for all Class I and Class II castings to show Critical Test Regions and Test
Regions which are to be subjected to non-destructive testing (NDI).

Dimensional Check
a.

All castings are to be fully dimensionally checked, where practicable, to ensure

that drawing requirements are met, in accordance with NES 863. Depending on
accessibility, thickness measurements may be made by direct measurements,
dial caliper gauges or ultrasonics.

b.

Ultrasonic thickness readings, regardless of accessibility to mechanical

measurements, are to be carried out in Critical Test Regions and is to be in
accordance with NES 729 Part 5. The Critical Test Regions are to be surveyed
for compliance with maximum/minimum wall thickness.

c.

It is recommended that the ultrasonic equipment is calibrated on a known

thickness of the castings being inspected or the time base is set up on a steel
block and readings converted via a calibration curve for NES 824 specification
CuNiCr. (Velocity of sound in NES 824 CuNiCr is nominally 5200 ms1).

VisualOptical
a.

6.2.3

It is advisable to cast three test bars to represent each cast to enable

re-testing if necessary to meet the acceptable standard detailed in Clause
7.1.2a.

Non-destructive Tests
a.

6.2.1

The analysis is to be made using analytical standards which are available

from NA 115, Foxhill, Bath.

Where possible, all castings are to be 100% visually inspected, assisted where
necessary, by the use of X5 magnification optics. All imperfections are to be
identified and recorded.

Liquid Penetrant
a.

It is recommended that a 100% liquid penetrant examination, in accordance

with NES 729 Part 4, is carried out on all Class I and Class II castings before any
machining operations are commenced to prevent nugatory work.

b.

A 1.00% liquid penetrant inspection is to be undertaken on all surfaces of Class

I and Class II castings with the surfaces examined in their finished condition.

6.1

NES 824
Part 1
Issue 3 (Reformatted)

6.2.4

6.2.5

Eddy Current
a.

It is recommended that a 100% eddy current surface and sub-surface

examination, using approved procedures in accordance with NES 729 Part 3, is
carried out on all Class I and Class II castings before any machining operations
are commenced to prevent nugatory work.

b.

A 100% surface and sub-surface eddy current examination is to be undertaken

on all surfaces of Class I and Class II castings with the surfaces examined in
their finished condition.

c.

The eddy current inspection is to be carried out in accordance with the

MOD(PE) approved inspection procedures.

Radiography
a.

6.2.6

Radiographic Examination of Non-designated Regions on a Sample Basis

a.

6.2.7

Critical Test Regions and Test Regions are to be subjected to 100% radiographic
examination in accordance with NES 729 Part 1. All sub-surface imperfections
are to be identified for subsequent assessment in accordance with the
acceptance standards.

ln certain circumstances examination by Radiography on a sample basis may

be specified by the contract or drawings to establish that a satisfactory general
quality of product is being supplied. Typical examples are:
(1)

sample positions on non-test areas of large Class II and Class III castings;

(2)

batch supply of Class III castings.

Pressure Tests
a.

When stated in the Contract the castings are to be subjected to the specified
water pressure test for a minimum period of 15 minutes. Certain castings may
require longer periods of pressure testing; when necessary, this will be specified
in the Contract.

6.2

NES 824
Part 1
Issue 3 (Reformatted)

7.

ACCEPTANCE STANDARDS

7.1

Destructive Examination Standards

7.1.1

Analysis
a.

7.1.2

Each chemical analysis, determined in accordance with Clause 6.1.1a., is to

conform to TABLE 1.1.

Mechanical Tests
a.

The mechanical properties determined in accordance with Clause 6.1.2a. are to

conform to TABLE 3.1. Should an original test bar fail to meet the
requirements, two further test bars from the same cast are to be tested; both
results are to conform to the requirements of TABLE 3.1.

7.2

Non-destructive Examination Standards

7.2.1

VisualOptical
a.

7.2.2

On visual-optical inspection (Clause 6.2.2a.) the finished condition of all

surfaces is to be clean and free from linear defects in excess of the limits of
Clause 7.2.2a. The surface finish is to meet the standard specified in the
Contract Documents and drawings.

Liquid Penetrant
a.

Indications of chain-like porosity and surface oxide inclusions in linear

formations are to be evaluated as follows:
(1)

The permissible length of any single indication is not to exceed the

finished drawing wall thickness (t) mm. On flanges t is to be taken as the
flange thickness.

(2)

The length of a defect is defined as the maximum size of the major axis of
the defect.

(3)

All discontinuities less than 0.1t in length can be ignored for assessment
purposes, except when a discontinuity, found by eddy current inspection,
has a variable amplitude response, when its total length is to be assessed
by its maximum response.

(4)

Adjacent discontinuities are to be assessed to determine if they should be

regarded as being a single, larger discontinuity by the following means:
(a)

The lengths of the two discontinuities are to be averaged and then

if the distance between the two discontinuities is greater than the
average length of the discontinuities they can be considered
independent.

(b)

If the distance between discontinuities is equal to or less than the

average length of the discontinuities then they are to be considered
as one discontinuity, the size of which is taken to be the overall
length or the major axis of the discontinuities including the distance
between them.

(c)

The composite discontinuity is acceptable provided its length is less

than or equal to t mm.

(d)

The composite discontinuity is to be assessed to determine if any

further discontinuities are interacting with it using the same
procedure.

7.1

NES 824
Part 1
Issue 3 (Reformatted)

Examples are given in FIGURE 7.1 and FIGURE 7.2.

FIGURE 7.1 LINEAR

FIGURE 7.2 COMPLEX

b.

Indications arising from porosity and surface oxide inclusions in non-linear

formations are to be assessed as follows:
(1)

Pinpoint porosity (any circular bleed out of less than 0.5mm diameter) is
acceptable except in areas where sealing of a housing against a running
shaft is required, eg pump glands, propeller shaft seals etc, and in flexible
couplings where they are not acceptable.

(2)

Bleed-outs larger than pinpoint and other non-linear defects are

acceptable provided that:
(a)

the maximum size of any indication does not exceed 5mm diameter
bleed-out;

AND
(b)
NOTE:

c.

the sum of the diameters of all indications in any area of 70 70mm

does not exceed 24mm.

The indications identified in Clause 7.2.2b.(1) and (2) are acceptable

provided that the immediate area of the castings is acceptable when
examined for sub-surface defects.

Where removal of unacceptable defects revealed by dye penetrant examination

on wetted surfaces reduces the wall thickness below that permitted by the
contract/NES 863, it is to be the cause for rejection.

7.2

NES 824
Part 1
Issue 3 (Reformatted)

d.
7.2.3

Defects revealed by liquid penetrant examination of the sealing faces may be

weld repaired in accordance with Clause 8.3.1a.

Eddy Current
a.

Oxide inclusions/discontinuities identified by surface eddy current examination

are not acceptable in sealing areas; however these may be recovered by weld
repair in accordance with Clause 8.3.1a. Other areas are to be evaluated in
accordance with Clause 7.2.2a.

b.

Oxide indusions/discontinuities identified by sub-surface eddy current

examination at a maximum depth of 10mm below each surface are to be noted
and recorded with single indications recorded as being a discontinuity with the
diameter of the probe. Larger, continuous discontinuities are to have their
positions plotted. The discontinuities are then to be evaluated in accordance
with Clause 7.2.2a.

c.

Through-casting defects are NOT permitted. Where material thickness

prevents through-casting measurement, then defects on opposite sides of a
section are deemed to be through-casting when less than or equal to
a + b
apart. See FIGURE 7.3.
2

FIGURE 7.3 THROUGH-THICKNESS DEFECTS

7.2.4

Radiography
a.

Cracks, hot tears or cold shuts are not acceptable in any area of the casting.
Internal porosity, sponginess and shrinkage are acceptable where:
(1)

the local reduction in wall thickness does not exceed 5% of the design wall
thickness in Critical Test Regions and 10% of the design wall thickness in
Test Regions;

and
(2)
b.

7.2.5

the total defective area does not exceed 10% of each Critical Test Region
and 20% of each Test Region containing the defect.

Where sample inspection is carried out in accordance with Clause 6.2.6a. the
cumulative local reduction in section thickness resulting from sub-surface
defects at any position is not to exceed 20% of the contract drawing section
thickness. The total defective area is not to exceed 20% of the total area of the
casting examined.

Pressure Tests
a.

Each casting is to show no evidence of leakage.

7.3

NES 824
Part 1
Issue 3 (Reformatted)

7.4

NES 824
Part 1
Issue 3 (Reformatted)

8.

DEFECTS AND RECTIFICATION OF DEFECTS

8.1

Defects
a.

Any casting may be rejected for defects when discovered during subsequent
machining, notwithstanding that the casting had been passed previously as
conforming to this NES.

8.2

Rectification of Defects

8.2.1

Blending
a.

Unacceptable surface defects may be blended out by an approved process

providing the resultant depression does not reduce the designed wall thickness
by more than 6mm or 10% whichever is the less. The depression is to be faired
out with a minimum radius equal to three times the maximum depth. The
remaining wall thickness in way of the depression is to be free from sub-surface
defects in Critical Test Regions and Test Regions. The total area subjected to
blending, including the fairing, is not to exceed 10% of the Critical Test Region
or 20% of the Test Region in which the defect is situated.

NOTE:

Blending out of surface defects is preferable to weld repair whenever

possible.

8.3

Weld Repair

8.3.1

Weld Repair Definition and Concessionary Requirements

a.

The rectification of surface defects by welding is not permitted on any seawater

wetted surface except for oxide inclusions on sealing faces (eg where in contact
with O seals) which see no flow; these may be repaired in accordance with
Clause 8.3.1d.

b.

Weld repair of surface (non-wetted area) and sub-surface defects may only be
carried out when, after removal of the defect, excavation does not penetrate to
within 10mm of the wetted surface and the depth of the weld metal will not
exceed 10mm.

c.

All permitted weld repairs are to be carried out in accordance with NES 825 and
are to be undertaken using MOD(PE) approved weld procedures and qualified
welders.

d.

The authority to proceed with weld repair is as follows:

(1)

NOTE:

(2)
NOTE:

Minor surface defects may be repaired within the limits of NES 824
without reference to MOD(PE).
Minor surface defects are defined as defects found on machined surfaces,
and are less than 3mm deep, with a maximum dimensional area of 5
5mm and will be repaired using a TIG process.
Minor functional repairs not affecting the Water Tight (WT) boundary,
eg flanges, are to be a Minor Concession as specified in the contract.
Minor concessions are limited to:
(a)

defects less than 3mm deep with a maximum dimensional area of 30

30mm when using a TIG processs.

OR
(b)

defects less than 10mm deep with a maximum dimensional area of

50 50mm when using a pulsed MIG process.

8.1

NES 824
Part 1
Issue 3 (Reformatted)

8.3.2

Major repairs falling outside the welding limits of NES 824 are not
to be referred to MOD as approval to proceed will not be given under any
circumstances.

Dimensional defects and machining errors may be rectified by weld deposition

subject to the following limits:
(1)

Weld deposition thickness is to be restricted to 20% of contract drawing

thickness from 12mm to 50mm and to 10mm above 50mm section
thickness.

(2)

The area of weld deposition in Critical Test Regions and Test Regions is
to be restricted to 10% of the surface area of the region, not including
flange thicknesses and webs, subject to any other limitations.

(3)

The area of weld deposition in non-designated regions is to be restricted

to 20% of the surface area of the region, not including flange thicknesses
and webs, subject to any other limitations.

(4)

Weld build-up exceeding the tolerance on the contract drawing section

thickness is to be a reason for rejection.

Unacceptable surface and sub-surface defects which cannot be blended out

within the limitations of Clause 8.2.1a. may be repaired by welding subject to
the limits of Clause 8.3.2a. (2), (3) and (4).

Limitations on Individual Repairs

a.

8.3.5

(4)

Rectification of Surface and Sub-surface Defects by Welding

a.

8.3.4

Major repairs affecting WT boundary with an acceptable risk of

success will be a Major Concession as specified in the contract.
Contractors will need to be aware of the possibility of marginal cases
drifting into the next category resulting in nugatory work and
expenditure.

Rectification of Dimensional Defects by Weld Deposition

a.

8.3.3

(3)

Any individual repair in Critical Test Regions is not to exceed 5% of the test area
containing the defect. In Test Regions any individual repairs are not to exceed
10% of the test area containing the defect.

Limits on Weld Repairs

a.

The total area of weld repairs from all causes, eg dimensional correction, surface
and sub-surface defects is to be within the following limits:
(1)

The total weld repair area of Class I and Class II castings is not to exceed
10% of the surface area of the casting, excluding flange thicknesses and
webs.

(2)

The total weld repair area of Class III castings is not to exceed 20% of the
surface area of the casting, excluding flange thicknesses and webs.

b.

After all weld repairs have been completed the casting is to be re-heat treated
in accordance with Clause 2.b.

c.

After welding the welded area must be liquid penetrant tested (Clause 6.2.3a.),
eddy current tested (Clauses 6.2.4a. and 6.2.4c.) and be re-radiographed
(Clause 6.2.5a.). The requirements of Section 7. must be met.

8.2

NES 824
Part 1
Issue 3 (Reformatted)

9.

IDENTIFICATION OF INGOTS AND CASTINGS

9.1

Ingots
a.

9.2

Each ingot is to be marked with legend CU NI CR to NES 824 and a unique

cast number stamped or embossed in easily discernible letters. The unique cast
number is to positively identify the ingot to its quality assurance
documentation.

Castings
a.

b.

Each casting is to be clearly identifiable during manufacture and to be

permanently marked for identification during service life with the following
details:
(1)

pattern numbers or ships identity number;

(2)

the legend NES 824 in raised lettering not more than 15mm high in a
non-machined area;

(3)

class of casting, ie CI, CII, CIII. (See NES 863.);

(4)

the legend Copper Nickel Chromium or CU NI CR;

(5)

the unique number which will relate the casting to its Quality Assurance
Documentation;

(6)

all castings are required to be identified with H as a prefix to the unique

number (referred to in (5) above) on being heat treated;

(7)

all castings are required to have the letter A as an additional prefix to the
unique number for weld repaired castings.

An example of the required identification for each casting is shown below:

HA12345X/NES824/CI/CU NI CR/25.12.88

c.

The markings detailed in Clauses 9.2a. and 9.2b. except 9.2a.(2) are to be
stamped, engraved or vibro-etched in the positions indicated on the drawing.
Markings are to be as conspicuous as the nature of the casting allows and
provision is to be made for transferring identification markings during
manufacture so that traceability is maintained throughout the service life of a
casting. The markings are not to be made on the highly stressed regions, eg
Critical Test Regions of the casting. Where castings are marked using stamps,
round nose stamps are to be used. The location of stamping/marking positions
for highly stressed castings are to be shown on the drawing. Stamping/marking
of the periphery of flanges is acceptable.

d.

Where difficulty is being experienced in satisfactorily applying identification

symbols the problem is to be resolved by consulting the Acceptance
Authority/QAR.

9.1

NES 824
Part 1
Issue 3 (Reformatted)

9.2

NES 824
Part 1
Issue 3 (Reformatted)

10.

PACKAGING
a.

Except where otherwise stated in the contract, packaging is to be in accordance

with the contractors normal practice subject to the affixing of a trade warning
label and the addition of the following identification details on each package or
case:
(1)

description of castings;

(2)

quantity;

(3)

Contract No.

10.1

NES 824
Part 1
Issue 3 (Reformatted)

10.2

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX A.
RELATED DOCUMENTS
A.1

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

See Clause
BS EN 10002

Tensile testing of metallic materials

6.1.2a.

BS 375

Refined nickel

1.1a.

BS 1400

Copper alloy ingots and copper alloy and

high conductivity copper castings
Copper refinery shapes

6.1.2a.

BS 6017
NES 729

NES 746
NES 824

NES 825
NES 863

1.1a.

Requirements for non-destructive

examination methods
Part 1: Radiographic

6.2.5a.

Part 3: Eddy current

6.2.4a.

Part 4: Liquid penetrant

6.2.3a.

Part 5: Ultrasonic

6.2.1b.

Approval and control of heat treatment

furnaces
Copper nickel chromium sand castings and
ingots
Part 2: Guide to production methods

2.b.

Requirements for welding copper nickel

chromium sand castings
Requirements for the classification,
dimensions, tolerances and general
standards of acceptance for copper and
nickel alloy castings

8.3.1c.

A.1

1.3a.

4.a., 6.2a.
6.2.1a., 7.2.2c.,
9.2a.

ANNEX A.

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX A.

A.2

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX B.
DEFINITIONS AND ABBREVIATIONS
B.1

For the purpose of this NES the following definitions apply:

Acceptance Authority

The Acceptance Authority is as specified in the

Contract. Where this is not known by the contractor,
enquiries are to be forwarded to DNA Section
NA 115, Foxhill, Bath.

Approved Scrap

a.

derived from cast copper nickel chromium

foundry arisings, the composition of which
has been established with regard to the
complete range of both the alloying elements
and impurity elements

and
b.

segregated and identifiable to the satisfaction

of the MOD QAR/Acceptance Authority.

Cast

A cast is:
a.
the product of one furnace melt, or
b.
the product of one crucible melt, or
c.
the product of a number of furnace or crucible
melts where such are aggregated and mixed
prior to sampling.

Contractor

The firm, company, organization, establishment or

HM Naval Base working within the scope of this
NES.

Ingots

A mass of metal of proportions to suit the founders

requirements.
Those Ministry of Defence (PE) personnel engaged in
ensuring that the requirements of this standard are
being met.

Quality Assurance
Representative (QAR)

B.1

ANNEX B.

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX B.

B.2

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX C.
PROCUREMENT CHECK LIST
Notes:
1.

2.
3.

This Check List is to ensure that certain aspects of this Naval Engineering
Standard are consulted when preparing a Statement of Technical
Requirements for a particular application.
Clauses where a preference for an option is to be used or where specific data is
to be added are included in the Check List.
List
Each item is to be marked either
!

= included

NA

= not applicable

CHECK
CHECK
CLAUSE No
No
1
When stated in Contract Documents the
6.2.7a.
castings are to be subjected to the specified
water pressure test for a minimum period of 15
mins. Certain castings may require longer
periods of pressure testing. When necessary this
will be specified in Contract Documents.
2

Stipulate in contract the concession procedure.

Except where otherwise stated in accordance

10.a.
with the contractors normal practice subject to
conditions stipulated in this clause.

C.1

!or NA

8.3.1d.

ANNEX C.

NES 824
Part 1
Issue 3 (Reformatted)

ANNEX C.

C.2

Inside Rear Cover

 Crown Copyright 2000

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The DStan file reference relating to work on this standard is D/DStan/69/02/824.
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