Chapter 2 Page 68

Section 6

Fittings and Pressed Parts, Bolts and Nuts

II - Part 1 GL 2009

5.4 Where no heat treatment is performed following machining and the starting material is in the final heat treated condition, testing of the starting material with regard to demonstrating mechanical properties shall suffice. In this case steel bars from the same heat and with the same diameter and heat treatment are to be grouped into test batches of 5000 kg maximum. The performance of the tensile and notched bar impact tests require one set of test specimens to be taken from each test batch. 5.5 Where machining is followed by heat treatment, testing shall be performed in the same way as on the corresponding formed bolts as per 5.2. 5.6 The surface finish, dimensions and compliance with tolerances shall be verified by the Surveyor on at least 20 bolts and on at least 10 bolts in the case of batch sizes of 200. The manufacturer shall supply the gauges and callipers necessary for this purpose. 5.7 The uniformity of the delivery is to be demonstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 bolts from each test batch are to be tested, and at least 10 bolts in the case of quantities 200. The results of the test are to be submitted to the Surveyor. 5.8 For bolts calculated for elevated temperature application on the basis of their high-temperature mechanical characteristics, the 0,2 % or 1 % proof stress shall be proved by a high-temerature tensile test performed on one specimen from each batch. The test shall be performed at the temperature which approximates most closely to the level of the operating temperature, rounded off to the nearest 50 C. The test may be dispensed with in the case of bolts to recognized standards, the high-temperature mechanical properties of which are regarded as proven. 6. 6.1 Testing of nuts Chemical composition

1,06d (1,04d) d

(1:100)

d Test mandrel for 6% expansion (1.06 d) or 4% expansion (1.04 d) of the nut d = m = nominal thread diameter nominal depth of nut force

The chemical composition shall satisfy the stipulations according to Section 3, B., Table 3.2 and the relevant standards or specifications respectively. 6.2 Nuts with nominal thread diameters of up to and including 39 mm are to be subjected to the expansion test using a mandrel with a 1:100 taper, see Fig. 6.2. Before testing, the nuts are to be drilled out to the thread outside diameter. The expansion shall be at least 6 % for nuts with a depth of 0,8 nominal thread diameter d (at least 4 % for nuts with a depth of 0,5 to < 0,8 d). The numbers of test specimens shown in Table 6.4 are applicable, but for quantities of 200 at least 2 nuts shall be tested. 6.3 Nuts with nominal thread diameters > 39 mm are to be subjected to testing of the starting material as specified in 5.2 rather than the expansion test.

1,5 m

1,2 m

hardened

1,1d Test arrangement

Fig. 6.2 Expansion testing of nuts

II - Part 1 GL 2009

Section 6

Fittings and Pressed Parts, Bolts and Nuts

Chapter 2 Page 69

6.4 The uniformity of the delivery is to be demonstrated by the manufacturer by means of hardness tests. For this purpose, at least 20 nuts from each test batch are to be tested, and at least 10 nuts in the case of quantities 200. The results of the test are to be submitted by the Surveyor. 6.5 The surface finish, dimensions and compliance with tolerances shall be verified by the Surveyor in the same way as described in 5.6. 7. Proof of chemical composition

9.

Retests

9.1 Where one of the test specimens required for carrying out testing of mechanical properties does not satisfy the specified conditions, two additional test specimens or test sets of each are to be taken which shall satisfy the requirements. If these test samples also fail to meet the requirements, the test batch shall be regarded as unacceptable. The manufacturer may, however, heat treat the batch again and present it for retesting. If, however, these test specimens still fail to meet the requirements, the test batch shall be rejected for once and for all. 9.2 Where one of the test specimens required for carrying out hardness testing, non-destructive testing to check for surface defects, or for carrying out a dimensional check fails to meet the requirements, a further random sample of 20 specimens (or 10 specimens in the case of batch sizes of 200) shall be taken of which all the test specimens shall satisfy the requirements. Otherwise the entire test batch shall be regarded as unacceptable. For the hardness test, the manufacturer may present this batch for retesting once he has carried out a further heat treatment. If these test specimens still fail to satisfy the requirements, the entire batch shall be rejected for once and for all. 10. Marking

7.1 For each delivery, the manufacturer shall provide the surveyor with a certificate giving the results of the chemical analysis, heat numbers, dimensions and the as-delivered condition of the starting material processed by him. The name of the steel producer shall also be indicated in the certificate. 7.2 Alloy steel bolts and nuts shall be subjected by the manufacturer to appropriate tests for use of the correct material. 8. Non-destructive tests

The manufacturer shall apply a suitable method of crack detection to the following bolts: turbine casing bolts bolts in main steam lines with temperatures > 350 C propeller blade fixing bolts

10.1 Bolts and nuts are to be marked with the manufacturer's symbol and with the strength category or the steel grade, as well as with the heat number in the case of bolts of M52 size and above. Bolts of M52 size and above are to be individually marked with the GL stamp, which in all other cases is to be applied to the packing label. 10.2 Steel bars over 25 mm in diameter for the machining of bolts and nuts are to be marked at one end with the manufacturer's symbol, the steel grade and the GL stamp, and alloy steel bars are to be additionally marked with the heat number. Where the diameter of the steel bars is 25 mm or less, it is sufficient to apply the corresponding markings to the label attached to the bundle of bars.

and, for diesel engines with cylinder diameters > 400 mm, the following bolts: main bearing bolts connecting rod bolts cross-head bearing bolts cylinder cover bolts