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Chapter 074 Volume 1 Welding and Allied Processes S9086-CH-STM-010/CH-074R4 REVISION 4 NAVAL SHIPS’ TECHNICAL MANUAL CHAPTER 074 - VOLUME 1 WELDING AND ALLIED PROCESSES THIS CHAPTER SUPERSEDES CHAPTER 074 VOLUME 1, DATED 31 JULY 1998 DISTRIBUTION STATEMENT C: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR CONTRACTORS; ADMINISTRATIVE AND OPERATIONAL USE (31 JANUARY 1992). OTHER REQUESTS FOR THIS DOCUMENT WILL BE REFERRED TO THE NAVAL SEA SYSTEMS COMMAND (SEA-03M2). WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTED BY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C., SEC. 2751, ET SEQ.) OR EXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECT TO SEVERE CRIMINAL PENALTIES. DISSEMINATE IN ACCORDANCE WITH PROVISIONS OF OPNAVINST 5510.161, REFERENCE (JJ). DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLO- SURE OF CONTENTS OR RECONSTRUCTION OF THE DOCUMENT. PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND. 23 AUG 1999 TITLE-1 @@FIpgtype@@TITLE@@!FIpgtype@@ S9086-CH-STM-010/CH-074R4 Certification Sheet TITLE-2 S9086-CH-STM-010/CH-074R4 TABLE OF CONTENTS Chapter/Paragraph Page 074 VOLUME 1 WELDING AND ALLIED PROCESSES ...................... 74-1 SECTION 1 INTRODUCTION .................................... 74-1 074-1.1 GENERAL ......................................... 74-1 074-1.1.1 SCOPE. ...................................... 74-1 074-1.1.2 MANDATORY REFERENCING. ........................ 74-1 074-1.1.3 NUCLEAR AND COMBAT WEAPONS SYSTEMS. ............. 74-1 074-1.1.4 SHIP STRUCTURE AND SYSTEMS. ..................... 74-1 074-1.1.5 RESPONSIBILITY FOR COMPLIANCE. ................... 74-1 074-1.1.6 REQUIREMENTS. ................................ 74-1 074-1.2 WELD CATEGORIES ................................... 74-2 074-1.3 REFERENCE DOCUMENTS ............................... 74-2 074-1.3.1 GENERAL. .................................... 74-2 074-1.3.2 MANDATORY REFERENCE DOCUMENTS. ................. 74-5 074-1.3.3 GUIDANCE DOCUMENTS. .......................... 74-6 074-1.4 DEFINITIONS ....................................... 74-6 SECTION 2 QUALIFICATION REQUIREMENTS ........................ 74-7 074-2.1 INTRODUCTION ..................................... 74-7 074-2.2 WELDING, BRAZING, AND THERMAL SPRAYING PROCEDURE AND PERFORMANCE QUALIFICATIONS ........................ 74-7 074-2.2.1 INTRODUCTION. ................................ 74-7 074-2.2.2 MILITARY ACTIVITIES OTHER THAN SHIPYARDS. ........... 74-7 074-2.2.3 APPROVAL AGENCIES. ............................ 74-8 074-2.2.4 CIVILIAN PERFORMANCE QUALIFICATIONS. .............. 74-8 074-2.2.5 NONDESTRUCTIVE TESTING QUALIFICATIONS. ............ 74-8 074-2.2.6 MILITARY PERFORMANCE (WELDER) QUALIFICATION. ....... 74-8 074-2.2.6.1 Initial Qualification. ......................... 74-8 074-2.2.6.2 Specific Qualification. ........................ 74-8 074-2.2.6.3 Validation of Qualification. ..................... 74-8 074-2.2.6.4 Welding Navy Enlisted Classification Code Achievement. .... 74-8 074-2.2.7 NAVY ENLISTED CLASSIFICATION TEST REQUIREMENTS. ...... 74-9 074-2.2.7.1 Completion of Tests. ......................... 74-9 074-2.2.7.2 Welding Limitations. ........................ 74-9 074-2.2.8 COURSE A-701-0025, BASIC WELDING. .................. 74-9 074-2.2.9 COURSE A-701-0026, NEC 4954, GENERAL MAINTENANCE WELDER. ......................................... 74-9 074-2.2.9.1 Minimum Requirements. ...................... 74-9 074-2.2.9.2 Weld Categories. ........................... 74-10 i S9086-CH-STM-010/CH-074R4 TABLE OF CONTENTS - Continued Chapter/Paragraph Page 074-2.2.10 COURSE A-701-0027, NEC 4955, NON-NUCLEAR WELDER. ...... 74-11 074-2.2.11 EXTENT OF QUALIFICATION. ........................ 74-12 074-2.3 UNDERWATER WELDING AND NDT QUALIFICATION .............. 74-12 074-2.4 MILITARY RECORDS .................................. 74-12 074-2.4.1 QUALIFICATION TEST RECORDS. ...................... 74-12 074-2.4.2 VISION TEST RECORDS. ........................... 74-12 074-2.4.3 PERSONNEL SERVICE RECORD ENTRIES. ................. 74-13 074-2.4.4 QUALIFICATION MAINTENANCE. ...................... 74-13 074-2.4.5 RENEWAL OF QUALIFICATIONS. ...................... 74-13 074-2.4.6 EQUIPMENT QUALIFICATION. ........................ 74-13 SECTION 3 QUALITY ASSURANCE ................................ 74-13 074-3.1 INTRODUCTION ..................................... 74-13 074-3.2 MATERIALS REQUIREMENTS AND CERTIFICATION ............... 74-13 074-3.3 WELDING MATERIAL CONTROL ........................... 74-14 074-3.4 INSPECTION AND RECORDS ............................. 74-14 074-3.4.1 CATEGORY A AND C WELDS. ........................ 74-14 074-3.4.2 CATEGORY B WELDS. ............................. 74-14 074-3.4.3 EMERGENCY WELDS. ............................. 74-14 074-3.4.4 CATEGORY D WELDS. ............................. 74-15 074-3.4.5 Category E and F welds. ............................. 74-15 SECTION 4 WELDING AND BRAZING REQUIREMENTS ................... 74-15 074-4.1 INTRODUCTION ..................................... 74-15 074-4.2 GENERAL REQUIREMENTS .............................. 74-15 074-4.3 WELDING IN WAY OF WETTED SURFACES .................... 74-15 074-4.4 TEMPERATURE-INDICATING CRAYONS ...................... 74-16 074-4.5 BIMETALLIC BOND ................................... 74-16 074-4.6 WELD DEPOSITS ..................................... 74-16 074-4.7 OXYFUEL GAS CUTTING ............................... 74-16 074-4.8 HOT OR COLD FORMING OF CASTINGS ...................... 74-16 074-4.9 PREPARATION OF FULL PENETRATION DOUBLE BEVEL WELD JOINT DESIGNS ........................................ 74-17 ii S9086-CH-STM-010/CH-074R4 TABLE OF CONTENTS - Continued Chapter/Paragraph Page 074-4.10 REDUCED SOCKET DEPTH .............................. 74-17 074-4.11 REDUCED COUNTERBORE DEPTH ......................... 74-17 074-4.12 BRAZING ......................................... 74-17 074-4.13 ALLIED PROCESSES .................................. 74-17 074-4.13.1 RESISTANCE WELDING. ............................ 74-17 074-4.13.2 METALLIZING. ................................. 74-18 074-4.13.3 ELECTROPLATING. ............................... 74-18 074-4.13.3.1 Selective Electroplating. ....................... 74-18 074-4.13.3.2 Shaft Electroplating. ......................... 74-18 SECTION 5 STRAY CURRENT PROTECTION .......................... 74-18 074-5.1 UNDERWATER CORROSION .............................. 74-18 074-5.2 CURRENT FLOW ..................................... 74-18 074-5.3 WELDING EQUIPMENT REQUIREMENTS ...................... 74-19 074-5.4 GROUNDING CONNECTIONS ............................. 74-19 074-5.4.1 CABLE LUGS. .................................. 74-19 074-5.4.2 CABLE SIZE. ................................... 74-19 074-5.4.3 RESISTANCE. .................................. 74-22 074-5.5 WELDING UNIT ARRANGEMENTS .......................... 74-23 074-5.6 SPECIAL PRECAUTIONS ................................ 74-35 074-5.6.1 GENERAL. .................................... 74-35 074-5.6.2 WELDING CURRENT. ............................. 74-35 074-5.6.3 SPLITTING GROUND RETURN CABLES. .................. 74-35 074-5.6.4 RESISTANCE CHECKS. ............................. 74-35 074-5.6.5 LOCATION OF GROUND RETURN CABLES. ................ 74-35 SECTION 6 SURFACE SHIP HULL STRUCTURE ........................ 74-35 074-6.1 HULL MATERIAL REPLACEMENT .......................... 74-35 074-6.1.1 GENERAL. .................................... 74-35 074-6.1.2 HY-80 AND HY-100 STEEL. .......................... 74-36 074-6.1.3 ALUMINUM ALLOY 6061-T6. ......................... 74-36 074-6.2 STEEL SONAR DOMES ................................. 74-36 074-6.3 REPAIR OF MECHANICAL FASTENERS ....................... 74-36 074-6.4 DUCTILE METAL OVERLAY TO ARREST CRACKS IN SHIP PLATES ..... 74-37 iii S9086-CH-STM-010/CH-074R4 TABLE OF CONTENTS - Continued Chapter/Paragraph Page 074-6.5 WELDING CORRODED PLATE SURFACES AND WELDS ............. 74-38 074-6.5.1 GENERAL. .................................... 74-38 074-6.5.2 ABRASIVE BLASTING. ............................ 74-39 074-6.5.3 CORRODED PLATE. .............................. 74-39 074-6.5.4 ISOLATED PITS. ................................. 74-39 074-6.5.5 CORRODED WELDS. .............................. 74-39 074-6.6 ALUMINUM DECKHOUSE REPAIR .......................... 74-39 074-6.7 CLOSURE PATCHES FOR TEMPORARY OPENINGS AND ACCESSES ..... 74-40 074-6.7.1 GENERAL. .................................... 74-40 074-6.7.2 NEW ACCESS HOLES. ............................. 74-40 074-6.7.3 CLOSURE PATCHES ON PREVIOUSLY MADE JOINTS. ......... 74-43 074-6.7.4 WELDING REQUIREMENTS FOR PATCHES AND CLOSURE PLATES. ......................................... 74-44 074-6.7.5 PROXIMITY REQUIREMENTS. ........................ 74-44 074-6.7.6 CLOSURE PATCHES ON MECHANICALLY FASTENED JOINTS. .... 74-45 074-6.8 MECHANICAL FASTENER REQUIREMENTS .................... 74-45 074-6.9 UNDERWATER WELDING ............................... 74-46 074-6.9.1 SCOPE. ...................................... 74-46 074-6.9.2 DEFINITION. ................................... 74-46 074-6.9.2.1 Customer. ............................... 74-46 074-6.9.2.2 Dry Chamber Welding. ....................... 74-46 074-6.9.2.3 Underwater Welding. ........................ 74-46 074-6.9.3 GENERAL. .................................... 74-46 074-6.9.4 SAFETY REQUIREMENTS. .......................... 74-48 074-6.9.4.1 General. ................................ 74-48 074-6.9.4.2 Dry Chamber Support Requirements. ............... 74-48 074-6.9.4.3 Explosive
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