Section 2 Castings for valves, liners and bushes

2.1.1 This Section makes provision for copper alloy castings for valves, liners, bushes and other fittings intended for use in the construction of ships, other marine structures, machinery and pressure piping systems.

2.1.2 Castings are to be manufactured and tested in accordance with Chapters Ch 1 General Requirements and Ch 2 Testing Procedures for Metallic Materials, and also with the requirements given in this Section.

2.1.3 As an alternative to Ch 9, 2.1 Scope 2.1.2, castings which comply with National or proprietary specifications may be accepted provided that these specifications give reasonable equivalence to the requirements of this Section or alternatively are approved for a specific application. Generally, survey and certification are to be carried out in accordance with the requirements of Ch 1 General Requirements.

2.2.1 Castings are to be manufactured at foundries approved by LR.

2.3.1 All castings are to be free from surface or internal defects which would be prejudicial to their proper application in service.

2.4.1 The chemical composition is to comply with the requirements of a National or International Standard and, where appropriate, with the limits for the principal elements of the preferred alloys listed in Table 9.2.1 Chemical compositions of long freezing range alloys: principal elements only and Table 9.2.2 Chemical compositions of short freezing range alloys: principal elements only.

2.4.2 With the exception given in Ch 9, 2.4 Chemical composition 2.4.3, chemical analysis is required on each cast.

2.4.3 Where a cast is wholly prepared from ingots for which an analysis is already available, and provided that no significant alloy additions are made during melting, the ingot maker's certified analysis can be accepted subject to occasional check tests as requested by the Surveyor. The frequency of these check tests should, as a minimum, be one in every ten casts. If one of these check analyses fails to comply with the specification, checks are to be made on the previous and subsequent melts. If one or both of these further analyses is unsatisfactory, chemical analysis is to be carried out on all further melts until the Surveyor is satisfied that a return can be made to the use of occasional check tests.

2.5.1 Where required by the specification, castings may be supplied in either the `as-cast' or heat treated condition.

2.5.2 Where castings are supplied in a heat treated condition, the test samples are to be heat treated with the castings they represent prior to the preparation of the tensile test specimens.

2.6.1 Test material sufficient for the tests specified in Ch 9, 2.6 Test material 2.6.4 and for possible re-test purposes is to be provided for each cast of material.

2.6.2 The test material is to be separately cast into moulds made of the same material as that used for the castings they represent.

2.6.3 For the alloys listed in Table 9.2.1 Chemical compositions of long freezing range alloys: principal elements only, sand cast test bars are generally to be in accordance with Figure 9.2.1 Sand cast test bars for long freezing range alloys.

2.6.4 For the alloys listed in Table 9.2.2 Chemical compositions of short freezing range alloys: principal elements only, keel block type test samples are to be in accordance with Figure 9.1.1 Keel block type test sample.

2.6.5 If it is proposed to use any other form of test bar, this is to be agreed in advance with the Surveyor.

2.6.6 As an alternative, for liners and bushes, the test material may be taken from the ends of the castings.

2.7.1 A tensile test specimen is to be prepared from each test sample. The dimensions of the specimens are to comply with Figure 2.2.1 Test specimen dimensions for forgings and castings - I or Figure 2.2.2 Test specimen dimensions for forgings and castings - II and aluminum alloys in Chapter 2.

2.7.2 The results of all tests are to comply with the appropriate requirements given in Table 9.2.3 Mechanical properties of long freezing range alloys for acceptance purposes and Table 9.2.4 Mechanical properties of short freezing range alloys for acceptance purposes.

Table 9.2.3 Mechanical properties of long freezing range alloys for acceptance purposes

Alloy type	Designation	0,2% proof stress N/mm2 minimum (See Note 1)		Tensile strength N/mm2 minimum		Elongation on 5,65% minimum
		Sand	Centrifugal	Sand	Centrifugal	Sand	Centrifugal
Phosphor bronze	Cu Sn11 P	130	170	250	330	5	4
	Cu Sn12	140	150	260	280	7	5
Gunmetal	Cu Sn10 Zn2	130	130	270	250	13	5
Leaded gunmetal	Cu Sn5 Zn5 Pb5	90	110	200	250	13	13
	Cu Sn7 Zn2 Pb3	130	130	230	260	14	12
	Cu Sn7 Zn4 Pb7	120	120	230	260	15	12
	Cu Sn6 Zn4 Pb2	110	110	220	240	15	12
Leaded bronze	Cu Sn10 Pb10	80	110	180	220	8	6
	Cu Sn5 Pb9	60	90	160	200	7	6
	Cu Sn7 Pb15	80	90	170	200	8	7
	Cu Sn5 Pb20	70	80	150	170	5	6
Note 1. The 0,2% proof stress values are given for information purposes only and, unless otherwise agreed, are not required to be verified by test. Note 2. Castings may be supplied in the chill cast condition in which case the mechanical properties requirements are to be in accordance with a specification agreed by LR.

Table 9.2.4 Mechanical properties of short freezing range alloys for acceptance purposes

Alloy type	Designation	0,2% proof stress N/mm2 minimum		Tensile strength N/mm2 minimum		Elongation on 5,65% minimum
		Sand	Centrifugal	Sand	Centrifugal	Sand	Centrifugal
Copper 30% Nickel	Cu Ni30 Fe1 Mn1	120	120	340	340	18	18
	Cu Ni30 Fe1 Mn1 Nb Si	230	–	440	–	18	–
	Cu Ni30 Cr2 Fe Mn Si	250	–	440	–	18	–
Copper 10% Nickel	Cu Ni10 Fe1 Mn1	120	100	280	280	20	25
Aluminium Bronze	Cu Al10 Fe5 Ni5	250	280	600	650	13	13
	Cu Al11 Fe6 Ni6	320	380	680	750	5	5

2.8.1 All castings are to be cleaned and adequately prepared for inspection. Before acceptance, all castings are to be presented to the Surveyor for visual examination. This is to include the examination of internal surfaces, where applicable.

2.8.2 For valves and other pressure components, dye penetrant inspection is required and the Surveyor is to witness the tests. Unless otherwise agreed, the acceptance criteria to be applied are to meet the requirements of Table 9.2.5 Visual and surface NDE acceptance criteria for valves and pressure components, or equivalent.

2.8.3 The accuracy and verification of dimensions are the responsibility of the manufacturer. However, the report on dimensional inspection is to be presented to the Surveyor who may request to witness confirmatory measurements.

2.9.1 Subject to the prior approval of the Surveyor, castings containing local porosity may be rectified by impregnation with a suitable plastic filler provided that the extent of the porosity is such that it does not adversely affect the strength of the casting.

2.9.2 Proposals to repair a defective casting by welding are to be submitted to the Surveyor before this work is commenced. The Surveyor is to be satisfied that the number, position and size of the defects are such that the castings can be efficiently repaired.

2.9.3 Where approval is given for the repair by welding, complete elimination of the defects is to be proven by adequate non-destructive testing.

Figure 9.2.1 Sand cast test bars for long freezing range alloys

2.9.4 All welding is to be in accordance with an approved and qualified weld procedure and carried out by a qualified welder.

2.9.5 A statement and/or sketch detailing the extent and position of all weld repairs is to be prepared by the manufacturer as a permanent record. These records are to be available for review by the Surveyor, and copies of individual records are to be supplied to the Surveyor on request.

2.9.6 The alloys listed in Table 9.2.1 Chemical compositions of long freezing range alloys: principal elements only are not satisfactory for repair by welding which is generally not permitted. Weld repairs may, however, be considered in special circumstances provided that a suitable procedure, with proof of previous satisfactory repairs is submitted to the Surveyor.

2.9.7 The welding during manufacture of liners is not permitted in any alloy containing more than 0,5 per cent lead.

2.10.1 Where required by the relevant Rules, castings are to be pressure tested before final acceptance. Unless otherwise agreed, these tests are to be carried out in the presence of the Surveyors and are to be to their satisfaction.

2.11.1 The manufacturer is to adopt a system of identification as per the requirements of Ch 1, 4.8 Identification of materials, which will enable all finished castings to be traced to the original cast and the Surveyor is to be given full facilities for tracing the castings when required.

2.11.2 Before acceptance, all castings which have been tested and inspected with satisfactory results are to be clearly marked by the manufacturer with the following details:

1. Identification number, cast number or other markings which will enable the full history of the casting to be traced.

2. LR or Clasifications Register and the abbreviated name of LR's local office.

3. Personal stamp of the Surveyor responsible for inspection.

4. Test pressure, where applicable.

5. Date of final inspection.

2.11.3 Where small castings are manufactured in large numbers, modified arrangements for identification may be specially agreed with the Surveyor.

2.12.1 A LR certificate is to be issued, see Ch 1, 3.1 General.

2.12.2 The manufacturer is to provide the Surveyor with the following particulars for each casting or batch of castings which has been accepted:

1. Purchaser's name and order number.

2. Description of castings and alloy grade.

3. Identification number.

4. Ingot or cast analysis.

5. Full details of heat treatment, where applicable.

6. Mechanical test results.

7. Test pressure, where applicable.

2.12.3 In addition to Ch 9, 2.12 Certification of materials 2.12.2, the manufacturer is to provide, where applicable, a statement and/or sketch detailing the extent and position of all weld repairs made to each casting.