Materials and Qualification Procedures for Ships

Materials and Qualification Procedures for Ships

Procedure 7-1

Approval of a Foundry for the Manufacture of Iron Castings

1 Introduction

1.1 Application for approval

1.1.1 In order that consideration may be given to approval of a foundry for the manufacture of iron

castings, the local Surveyors are to submit a report to Materials and NDE Department, giving

the information listed in Sections 2 and 3 and the results of approval tests carried out under

their survey.

1.1.2 The names of approved works will appear in LR's List of Approved Manufacturers of Iron

Castings which is published on the intranet.

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

1.2 Scope

1.2.1 The procedure applies to the manufacture of general types of castings in flake (grey) or

spheroidal graphite (nodular) iron. The castings include valve bodies, cylinder liners, etc.

1.2.2 Additional tests are required for iron castings for crankshafts (see Procedure 7-2).

1.3 Related Rules

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

Rules for Ships).

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

as the Rules for Materials).

Materials and NDE Book F MQPS 7-1

ABCD© Lloyd’s Register 2002. All rights reserved Rev. 1

2 Information required for approval

2.1 Product details

2.1.1 The manufacturer is to provide the following product related details:

(a) Name and address and brief

statement of background indicating

whether the works is new or long

established.

(b) Types of castings and grades of

iron in general production.

(c) Mass (as dressed) of the largest

casting which can be made for each type of iron for which approval is

required.

(d) Estimated total annual production of

finished castings.

(e) Types of castings and grades of

iron for which approval is required.

2.2 Details of facilities and procedures

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

(a) Number and type of cupolas and other

melting furnaces including maximum

capacity of each unit.

(b) Details of raw materials used in iron

production.

(c) For spheroidal or nodular graphite

irons, details of the inoculation

practice, including the metal

temperature and maximum time

interval between inoculation and end

of pouring, and any control procedures

based on on-line metallographic

testing.

(d) Types of moulding materials used.

(e) Where applicable, details of

furnaces used for heat treatment

including dimensions, type of fuel used

and facilities for temperature

measurement and control.

(f) Facilities available for mechanical

Materials and NDE Book F MQPS 7-1

ABCD© Lloyd’s Register 2002. All rights reserved Rev. 1

testing, chemical analysis,

metallographic and non-destructive

examinations. This is to include

information regarding the name of the

manufacturer, type number or

description, serial number and

calibration status of all machines used

for tensile, impact and hardness

testing.

(g) Details of the system used for the

identification of castings and

associated test material at all stages

of manufacture.

(h) Details of the inspection and quality

control systems established in the

works. These are to include the name

and qualifications of the Quality

Manager and the number and

qualifications of staff employed on

inspection and quality control. The lines

of responsibility of the Quality Manager

and the Production Manager are to be

indicated, preferably in the form of an

organization chart showing the senior

management positions to whom they

report.

Materials and NDE Book F MQPS 7-1

ABCD© Lloyd’s Register 2002. All rights reserved Rev. 1

3 Approval test programme

3.1 Selection of material

3.1.1 Approval tests are to be carried out on at least three castings, taken from current production

If approval is required for both flake and spheroidal cast irons, two castings of each material

type should be tested.These are to be from different charges and be reasonably

representative of the dimensions for which approval is requested.

3.1.2 A minimum of one casting shall be at least 75% of the maximum weight for which approval is

required unless this weight exceeds 50 tonnes.

3.1.3 The test samples are to be taken towards the end of the pouring of the castings.

3.2 Specific product approval information

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

information:

(a) Chemical composition of ladle samples.

(b) Sketch showing method of casting with

details of the gating and feeding

systems.

(c) Where applicable, details of heat

treatment.

(d) Applicable specification.

Materials and NDE Book F MQPS 7-1

ABCD© Lloyd’s Register 2002. All rights reserved Rev. 1

4 Approval tests

4.1 Tests, test samples and specimens

4.1.1 The dimensions of separately cast test samples, dimensions of test specimens and

mechanical testing procedures are to be in accordance with Ch 2 and Ch 7 of the Rules for

Materials.

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

approval tests:

(a) Visual examination in the dressed and,

where applicable, machined condition.

(b) Where applicable, a hydraulic

pressure test.

(c) Mechanical tests are to be taken in

accordance with the requirements of

the applicable specification and in all

cases are to include at least one tensile

test specimen.

(d) Hardness tests are to be carried out at

various positions on the castings and

compared with the hardness value of

the corresponding tensile test

specimen.

(e) Representative photomicrographs ,etched and unetched,

at x100 magnification prepared from

the separately cast test samples.

(f) One typical casting is to be tested for

internal soundness either by breaking

up with a hammer or falling weight or

by sectioning by sawing. Photographs

of the casting and of the surfaces of the

fractured or sawn sections are to be

included in the report. Where possible

a casting which has been rejected for

dimensional inaccuracies or for other

reasons should be used for this

purpose. Alternatively, suitable

volumetric non- destructive

examination may be used.

(g)