4.2.1 The manufacturer is to prepare deposited test assemblies using the WAAM process for
each deposition position (PA, PC, PE, PF, PG according to ISO 6947) for which the
manufacturer recommends.
4.2.2 A test programme for the consumables is to be devised by the manufacturer and shall
include:
The test assemblies are to be prepared under the supervision of the LR Surveyor and
using samples selected by him. The Surveyor will witness all subsequent tests. Where
more than one size of consumable is to be certified, the test programme is to
include test assemblies prepared using both the minimum and maximum consumable
sizes.
4.2.3 During the production of test assemblies, the manufacturer is to record the
depositing conditions used. These conditions include but are not limited to current,
voltage, travel speed, preheating, interpass, post-heating temperatures, deposition
path and direction of travel.
4.2.4 Test specimens are to be prepared from the test assemblies. The exact size of the
test assembly is left to the discretion of the manufacturer; however, it should be
of sufficient size to facilitate the preparation of all agreed test specimens
including any re-tests.
4.2.5 Provision is made for standard tests, i.e. those tests which apply to all types of
consumables, and specially considered tests, i.e. those tests which are dependent
upon material type and application.
4.2.6 Standard tests include but are not limited to:
- Non-destructive examination (NDE) is to include:
- Visual examination
- Surface crack detection (either magnetic particle or liquid
penetrant testing)
- Volumetric inspection (either radiographic or ultrasonic
inspection)
Location and when to perform NDE are to be specially considered and
is dependent upon the intended application, material type, and
manufacturing parameters. In the case of heat treatment being applied to
the assembly, the performance of NDE is after heat treatment is
complete. Assessment of results is to be per ISO 5817 Level B.
- Deposited chemistry The chemical analysis of the deposited metal is to
include the content of all significant alloying elements as specified by the
manufacturer.
- Tensile tests Test specimens are to be orientated at zero and ninety
degrees. Depending upon the intended application, material type and
manufacturing parameters, consideration will be given to through-thickness
testing. The specimens are to be a circular cross-section type and of
standard size, as detailed in ISO 6892-1 or another recognised standard as
appropriate. Testing is to be completed at ambient temperature. Yield
strength (ReH), tensile strength (Rm),
Elongation (As) and Reduction in Area (RA) are to
be reported.
- Microstructure examination Microstructure examination is to be completed
dependent upon alloy type. Results are to be presented in the form of a
report which gives representative photographs, details of the etchants used,
and a description of the microstructure shown.
4.2.7 Tests subject to special consideration depending upon the material type and the
intended application include but are not limited to:
- Toughness test, (Impact Test, CTOD, etc.) Toughness tests including Charpy
Impact Test and CTOD are to be carried out at a temperature indicative of
the intended application and will be specially considered.
- Hardness - Hardness tests are to follow a recognised technique such as
Vickers or Brinell. The extent of testing is to be agreed and will depend
upon the intended application. The recommended distance between indents is
1.0 mm, but the distance between them should not be less than the minimum
specified in the testing standard.
- Fatigue assessment Fatigue testing may be necessary to determine if the
material is capable of carrying the fatigue load expected during a
particular application. Depending on the type of the service load, one or
more fatigue strengths including axial fatigue strength, bending fatigue
strength and torsional fatigue strength should be determined by fatigue
testing. Depending on the fatigue assessment requirement, the objective of
the fatigue testing could be to determine one of the following: the fatigue
life at a specified stress amplitude, the fatigue strength at a specified
life or a full Wφhler or S-N curve. Fatigue tests should be completed and
data are to be analysed by following a recognised code or standard.
- Corrosion For certain specific applications, it may be necessary to
demonstrate that the consumable is not susceptible to corrosion resulting
from precipitation of deleterious phases. The type of corrosion test will be
material dependent. Typical examples include an intergranular corrosion test
for austenitic stainless steel and a pitting corrosion test for duplex
stainless steels.
- Ferrite measurement When applicable, ferrite content may be determined by
physical or metallographic means. The particular method used should be
included when reporting results. Location of measurements is to be specially
considered.
4.2.8 All testing is to be undertaken following recognised International/National
Standards, e.g. ISO, ASTM, etc.
4.2.9 Upon completion all test results will be submitted to LR for review and
assessment for certification.