SC431240802JT軸系鑄鍛件訂貨技術(shù)條件

1、CONTENTS1.Steel forgings1.1General 1.2Manufacture1.3Chemical composition1.4Heat treatment1.5Test material1.6Mechanical tests1.7Visual and non-destructive examination1.8Quality1.9Identification1.10Certification1.11Attached drawing2.Copper casting2.1General2.2Manufacture2.3Chemical composition2.4Heat

2、treatment2.5Test material2.6Mechanical tests2.7Inspection and non-destructive examination2.8Identification2.9Certification2.10Attached drawing1.Steel forgings1.1General1.1.1 The intermediate and propeller shafts to be made from high-quality carbon steel with tensile strength level of 560 N/mm2. One

3、piece of each shaft per ship, and one spare propeller shaft to be supplied per two ships by S/Y.The reaming bolts are to be made from alloy steels with tensile strength level of 880 N/mm2. Twenty-four pieces of forging per ship.The piston and body of hydraulic nut to be made from high-quality carbon

4、 steel with tensile strength level of 600 N/mm2. One piece of per ship.The stern tube seat and bearing seat to be made from high-quality carbon steel with tensile strength level of 400 N/mm2. One piece of per ship.1.2Manufacture1.2.1Forgings are to be made at works, which have been approved by BV. T

5、he steel is to be manufactured by the electric or one of the basic oxygen processes.1.2.2For components forged directly from ingots or from forged blooms or billets and in which the fibre deformation is mainly longitudinal the reduction ratio is not to be less than 3:1.1.2.3Where the length of any s

6、ection of a shaft forging is less than its diameter, the reduction ratio is to be not less than half that given in 1.2.2.1.3Chemical composition1.3.1All forgings are to be made from killed steels.1.3.2For forgings the chemical composition of ladle samples is to comply with the following overall limi

7、ts:Carbon0.60% max (for shafts and piston & hyd. nut)0.23% max (for stern tube seat & bearing seat)Silicon0.45% maxManganese0.30 - 1.60%Sulphur0.040% maxPhosphorus0.040% maxResidual elements:Copper0.30% maxChromium0.30% maxMolybdenum0.15% maxNickel0.40% maxTotal0.80% max Except where otherwise speci

8、fied, suitable grain refining elements such as aluminium, niobium or vanadium may be used at the discretion of the manufacturer. The content of such elements is to be reported in the ladle analysis.1.3.3The reaming bolts are to be made of alloy steel (30CrMo).1.4Heat treatment1.4.1At an appropriate

9、stage of manufacture, after completion of all hot working operations, forgings are to be suitably heat treatment to refine the grain structure and to obtain the required mechanical properties. 1.4.2If any straightening operation is performed after the final heat treatment, consideration should be gi

10、ven to a subsequent stress relieving heat treatment in order to avoid the possibility of harmful residual stresses.1.4.3The forgings are to be:a)Fully annealed, orb)Normalized, orc)Normalized and tempered, ord)Quenched and tempered.The tempering temperature to be not less than 550 oC.1.4.4The bolt f

11、orgings are to be quenched and tempered. The tempering temperature to be not less than 550 oC.1.5Test material15.1Specimens for mechanical tests are to be prepared as required by BV.15.2The test specimens of shaft are to be taken in the longitudinal direction but at the discretion of the manufacture

12、r and, if agreed by the Surveyor, alternative directions or positions recommended by BV may be used.15.3Test material, sufficient for the required tests and for possible re-test purposes, is to be provided with a cross-sectional area of not less than that part of the forging which it represents. Thi

13、s test material is to be integral with each forging.1.6Mechanical tests The mechanical properties of shaft forgings to be conform to the requirements given in the following tables:Steel forgingTensile strength Rm (N/mm2)min. Yield stressReH (N/mm2) min.ElongationA5 (%)min.Reduction of area Z (%) min

14、.Average impact energy (J)at +20oC min. Brinell hardness HB V-notch U-notchLTLTLTLTIntermediate & propeller shaft 5602802014402725152517160-200Reaming bolts880670139402727182620255-305Hydraulic nut body & piston6003001813402718122015175-215Stern tube seat & bearing seat4002002619503532183020110-150

15、L: LongitudinalT: Transverse1.6.1Where more than one tensile test is taken from a forging, the variation in tensile strength is not to exceed 70 N/mm2 (for shafts, stern tube seat and bearing seat), 100 N/mm2 (for reaming bolts and hydraulic nut body & piston).1.7Visual and non-destructive examinati

16、on1.7.1Before acceptance, all forgings are to be presented to surveyor for visual examination. Where applicable, this is to include the examination of internal surfaces and bores.1.7.2Forgings are to be examined in the condition for final delivery. Surfaces are to be clean and free from dirt, grease

17、, paint, etc. Black forgings are to be suitably descaled by either shotblasting or flame descaling methods.1.7.3Ultrasonic examination is to be carried out after the forgings have been machined to a condition suitable for this type of examination and after the final heat treatment. The test results

18、are to be to the Surveyor satisfaction.1.7.4Magnetic particle or dye penetrant testing is to be carried out on the forgings.1.7.5Unless otherwise agreed, the accuracy and verification of dimensions are the responsibility of the manufacturer. 1.8 Quality All forgings are to be free from surface or in

19、ternal defects, which be prejudicial to their proper application in service. 1.9IdentificationForgings are to be clearly marked by the manufacturer in at least one place with the particulars detailed in the appropriate specific requirements. The following details are to be shown on all forgings, whi

20、ch have been accepted:a)Identification number, cast number or other marking which will enable the full history of the forging to be traced.b)BV or BVs Register and the abbreviated name of BVs local office.c)Personal stamp of Surveyor responsible for inspection.d)Test pressure, where applicable.e) Da

21、te of final inspection.1.10CertificationThe manufacturer is to provide the Surveyor with a written statement giving the following particulars for each forging or batch of forgings, which has been accepted:a)Purchasers name and order number.b)Description of forgings and steel quality.c)Identification

22、 number.d)Steelmaking process, cast number and chemical analysis of ladle samples.e) General details of heat treatment.f) Results of mechanical tests.g) Test pressure, where applicable.1.11Attached drawings1.11.1Intermediate shaft:Notes:1)The outline sizes (thick line) indicated on the drawing to be

23、 sizes after rough machining.2)Number: 13) Weight: 8764 kg1.11.2Propeller shaft:Notes:1)The outline sizes (thick line) indicated on the drawing to be sizes after rough machining.2)Number: 13) Weight: 10830 kg 1.11.3Reaming bolt (I):Notes:1)The outline sizes (thick line) indicated on the drawing to b

24、e sizes after rough machining.2) Number: 243) Weight: 17 kg1.11.4Reaming bolt (II): Notes:1) The outline sizes (thick line) indicated on the drawing to be sizes after rough machining.2) Number: 243) Weight: 19 kg1.11.5 Hydraulic nut body:Notes:1)The outline sizes (thick line) indicated on the drawin

25、g to be sizes after rough machining.2) Number: 13) Weight: 892 kg1.11.6 Hydraulic nut piston:Notes:1) The outline sizes (thick line) indicated on the drawing to be sizes after rough machining.2) Number: 13) Weight: 104 kg1.11.7 Stern tube seat:Notes:1)The outline sizes (thick line) indicated on the

26、drawing to be sizes after rough machining.2)Number: 13)Weight: 500 kg1.11.8 Bearing seat:Notes:1)The outline sizes (thick line) indicated on the drawing to be sizes after rough machining.2)Number: 13) Weight: 2600 kg2.Copper casting2.1General The fair water cap is to be made from copper alloys with

27、tensile strength level of 590 N/mm2. One piece for per ship.2.2ManufactureAll castings are to be manufactured at foundries approved by BV.2.3Chemical compositionThe chemical composition of samples from each cast is to comply with the requirements given in the following table (%):Alloy designationCuS

28、nZnPbNiFeAlMngrade Cu377 820.11.00.033.06.02.06.07.0 11.00.5 4.02.4Heat treatment2.4.1At the option of the manufacturer, castings may be supplied in the “as cast” or heat treated condition.2.4.2 If any welds are made in the casting, stress relief heat treatment is required in order to minimize the r

29、esidual stresses.2.5Test material2.5.1The test samples are to be of the keel block type, generally in accordance with the dimensions recommended by BV and are to be cast in moulds made of the same type of material as that used for the castings.2.5.2The method and procedures for the identification of

30、 the test specimens, and the castings they represent, are to be agreed with the Surveyor. The identification marks are to be transferred and maintained during the preparation of test specimens.2.6Mechanical testsThe results of these tests are to comply with the following requirements:Alloy designati

31、on0.2% proof stress minimumN/mm2Tensile strength minimumN/mm2 Elongation on 5.65So %minimumGrade Cu3245590162.7Inspection and non-destructive examination2.7.1 All finished castings are to be subjected to a comprehensive visual examination by the surveyor, including internal surfaces such as the bore

32、 and bolt holes. 2.7.2The accuracy and verification of dimensions are responsibility of the manufacturer. However, the report on dimensional inspection is to be presented to the Surveyor who may require checks to be made in his presence.2.8IdentificationBefore acceptance, all castings, which have be

33、en tested and inspected with satisfactory results are to be clearly marked by manufacturer with the following details:a)Identification mark which will enable the full history of the item to be traced.b)Alloy grade.c)BV or BVs Register and the abbreviated name of BVs local office.d)Personal stamp of

34、Surveyor responsible for the final inspection.e)Date of final inspection.2.9CertificationThe manufacturer is to provide the Surveyor with a written statement giving the following particulars for each casting, which has been accepted:a)Purchasers name and order number.b)Description of castings.c)Allo

35、y designation and/or trade name.d)Identification number of castingse)Cast identification number.f)Details of heat treatment, where applicable.2.10Attached drawing:Fairing capNotes:1)The outline sizes indicated on the drawing to be sizes after machining.2)Number: 13)Weight: 450 kg目錄1.鍛鋼件1.1總則1.2制造1.3

36、化學成分1.4熱處理1.5試驗材料1.6機械性能試驗1.7目測及無損檢測1.8質(zhì)量1.9標記1.10合格證書1.11附圖2.鑄銅件2.1總則2.2制造2.3化學成分2.4熱處理2.5試驗材料2.6機械性能試驗2.7目測及無損檢測2.8標記2.9合格證書2.10附圖1. 鍛鋼件1.1總則1.1.1中間軸和螺旋槳軸由優(yōu)質(zhì)碳素鋼制造，其抗拉強度為560 N/mm2。每船各一件，每兩條船由船廠提供一件備用螺旋槳軸。 鉸制孔螺栓由合金鋼制造，其抗拉強度為880 N/mm2。每船二十四件。液壓螺母的本體和活塞由優(yōu)質(zhì)碳素鋼制造，其抗拉強度為600 N/mm2。每船各一件。尾管座和軸承座由優(yōu)質(zhì)碳素鋼制造，其抗

37、拉強度為400 N/mm2。每船各一件。1.2 制造1.2.1 鍛件應在BV認可的工廠內(nèi)制造?？刹捎秒姞t或堿性氧吹法冶煉。1.2.2 若鍛件直接由鋼錠或由大鋼錠或由方坯鍛制，如其纖維變形主要呈縱向時，其鍛造比應不小于3:1。1.2.3 當鍛件任一截面的長度小于其直徑時，其鍛造比不小于中的一半。 1.3 化學成分1.3.1 所有的鍛鋼件應采用鎮(zhèn)靜鋼制造。1.3.2 鍛鋼件的桶樣化學成分應符合如下規(guī)定： C最大 0.60% (軸、液壓螺母的本體和活塞)最大 0.23% (尾管座和軸承座) Si最大 0.45% Mn0.30-1.60% S最大0.04% P最大0.04% 殘余元素:Cu最大 0.3

38、0%Cr最大 0.30%Mo最大 0.15%Ni最大 0.40%總計最大 0.80% 除非另有規(guī)定，制造廠可自行決定添加如鋁，鈮或釩等細化晶粒元素。這些元素的含量應在桶樣分析報告中注明。1.3.3 鉸制孔螺栓由30CrMo合金鋼制造。1.4熱處理1.4.1 鍛鋼件完成全部熱加工后，在適當?shù)闹圃祀A段，進行相應的熱處理，以便細化晶粒組織并獲得所要求的機械性能。 1.4.2 如鍛鋼件經(jīng)最終熱處理以后又進行了矯直，則應再次進行熱處理，以消除有害的殘余應力。 1.4.3 鍛件應進行熱處理，方法如下： a) 完全退火；或 b) 正火；或 c) 正火和回火；或 d) 淬火和回火。回火溫度不得低于550 oC

39、。1.4.4 鉸制孔螺栓鍛件應進行淬火和回火處理，回火溫度不得低于550 oC。1.5試驗材料15.1試樣應按照BV的要求準備。15.2軸的試樣應沿縱向選取，但若驗船師同意，制造廠可自行采用BV推薦的方向和位置。15.3每一鍛件應提供足夠的試驗材料，以符合規(guī)定試驗和可能復試的需要，其截面尺寸應與所代表的鍛鋼件的那一部分截面相同，試驗材料和每一鍛件應為一整體。1.6機械性能試驗軸鍛件的機械性能應滿足如下要求：鋼鍛件抗拉強度Rm最小值(N/mm2)屈服強度ReH最小值(N/mm2)伸長率 A5(%)最小值截面收縮率(Z%)最小值平均沖擊功（J）在20oC 最小值布氏硬度HBV形切口試樣U形切口試樣

40、縱向橫向縱向橫向縱向橫向縱向橫向中間軸和螺旋槳軸5602802014402725152517160-200鉸制螺栓880670139402727182620255-305液壓螺母本體和活塞6003001813402718122015175-215尾管座和軸承座4002002619503532183020110-1501.6.1 當從一個鍛件上截取不止一個拉伸試件時，抗拉強度的差值不得超過70 N/mm2 （對軸、尾管座和軸承座），100 N/mm2 （對螺栓、液壓螺母本體和活塞）。1.7目檢和無損檢測1.7.1 在驗收時，所有鍛鋼件均應提交驗船師目檢。如需要，還應包括內(nèi)表面和鏜孔的檢驗。1.7

41、.2 鍛鋼件最后交貨時表面應保持清潔，沒有雜物，油脂，油漆等。粗鍛鋼件可用噴丸，火焰等方式去銹。1.7.3 鍛鋼件在機加工到適當階段和最終熱處理后，應進行超聲波檢測。檢測的結(jié)果應讓驗船師滿意。1.7.4 鍛鋼件應作磁粉探傷或著色試驗。1.7.5 除非另有協(xié)議，制造廠應負責和校核鍛鋼件的尺寸精度。 1.8 質(zhì)量 所有鍛件內(nèi)外表面不應存在影響正常工作的缺陷。1.9 標記 鍛鋼件制造廠對每一鍛鋼件或每批鍛鋼件，應至少在一個位置清晰地標上以下的標記：a) 標記號，爐罐號及供查閱此鍛鋼件制造過程的識別標記;b) BV或BVs Register和BV當?shù)剞k事處的縮寫名稱；c) 負責檢驗的驗船師印章d) 試驗壓力（如有時）；e) 最后檢驗日期。1.10合格證書 制造廠應對每一鍛鋼件或每批鍛鋼件提供包括下列內(nèi)容的合格證書：a) 訂貨方的名稱和合同號；b) 鍛鋼件和鋼的質(zhì)量說明；c) 標記號；d) 煉鋼過程，爐罐號及桶樣化學分析