1、 Part 2: Rules for Materials and Welding Aluminum and Fiber Reinforced Plastics (FRP) Chapters 5-6) RULES FOR MATERIALS AND WELDING 2013 PART 2 ALUMINUM and FIBER REINFORCED PLASTICS (FRP) (CHAPTERS 5-6) American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Cop
2、yright 2012 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA ii ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 Rule Change Notice (2013) Rule Change Notice (2013) The effective date of each technical change since 1993 is shown
3、in parentheses at the end of the subsection/paragraph titles within the text of each Part. Unless a particular date and month are shown, the years in parentheses refer to the following effective dates: (2000) and after 1 January 2000 (and subsequent years) (1996) 9 May 1996 (1999) 12 May 1999 (1995)
4、 15 May 1995 (1998) 13 May 1998 (1994) 9 May 1994 (1997) 19 May 1997 (1993) 11 May 1993 Listing by Effective Dates of Changes from the 2006 Rules Notice No. 1 (effective on 1 January 2007), Notice No. 2 (effective on 1 January 2008), Notice No. 3 (effective on 1 January 2009), Notice No. 4 (effectiv
5、e on 1 January 2010), Notice No. 5 (effective on 1 January 2011), and Notice No. 6 (effective on 1 January 2012) to the 2006 Rules, which are incorporated in the 2013 Rules, are summarized below. EFFECTIVE DATE 1 January 2007 shown as (1 January 2007) (based on the contract date for new construction
6、 between builder and Owner) Part/Para. No. Title/Subject Status/Remarks 2-5-A1/Figure 9 Test No. 2 Guided Bend Test for Root Bend and Face Bend (Plate or Pipe) To allow bend test specimens to be machined down to 3/8” as clarified in AWS D1.2, AWS B4.0, ASME Section IX, and this PRC. (Incorporates No
7、tice No. 1) EFFECTIVE DATE 1 January 2008 shown as (1 January 2008) (based on the contract date for new construction between builder and Owner) Part/Para. No. Title/Subject Status/Remarks 2-5-8/5.3.1 Drift Expansion Tests To add one more acceptance criteria based on current ABS practice. (Incorporat
8、es Notice No. 2) EFFECTIVE DATE 1 January 2009 shown as (1 January 2009) (based on the contract date for new construction between builder and Owner) Part/Para. No. Title/Subject Status/Remarks 2-5-A2/Table 1 Consumable Grades and Base Materials for the Approval Test Drift Expansion Tests To incorpor
9、ate Rev. 1 of IACS UR W26. (Incorporates Notice No. 3) 2-5-A2/Table 3 Requirements for the Transverse Tensile and Bend Tests To incorporate Rev. 1 of IACS UR W26. (Incorporates Notice No. 3) ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 iii EFFECTIVE DATE 1 Ja
10、nuary 2010 shown as (1 January 2010) (based on the contract date for new construction between builder and Owner) Part/Para. No. Title/Subject Status/Remarks 2-5-5/Table 1 Mechanical Property Limits of Non-Heat-Treatable Sheet and Plate Aluminum Alloys To reflect changes to ASTM B 928. To allow use o
11、f 5d gauge length as permitted in ASTM B 26, B 209 one is to be forwarded to the purchaser, three are to be retained for the use of ABS. Before the mill certificates or shipping statements are distributed Part 2 Rules for Materials and Welding Aluminum and Fiber Reinforced Plastics (FRP) Chapter 5 M
12、aterials for Hull Construction Aluminum Section 1 General 2-5-1 ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 9 by the local ABS office, the manufacturer is to furnish the Surveyor with a certificate stating that the material has been sampled, tested and inspe
13、cted in accordance with these Rules and that it has met the requirements. The following form of certificate will be accepted if printed on each mill sheet or shipping statement with the name of the firm and initialed by the authorized representative of the manufacturer: “We hereby certify that the m
14、aterial described herein has been made to the applicable specifications of alloy _; temper _, and the required samples tested in accordance with the requirements of _ (The American Bureau of Shipping Rules or state other specification) in the presence of a Surveyor from the American Bureau of Shippi
15、ng with satisfactory results.” At the request of manufacturers, consideration may be given to modifications to the form of certificate, provided it correspondingly indicates compliance with the requirements of these Rules to no less degree than indicated in the foregoing statement. 5.3 Other Certifi
16、cates Where an aluminum alloy ingot is not produced in the plant where it is rolled, extruded or forged, a certified report is to be supplied to the Surveyor stating the name of the manufacturer, the alloy, ingot or manufacturing and inspection lot identification numbers and certification that the a
17、lloy meets the required chemical composition limits. 5.5 Dual Certification Dual certification of aluminum alloys is permitted only when alloy designations involved meet the specified chemical composition and specified minimum mechanical property requirements; provided they have the same ANSI temper
18、 designations in order to avoid any differences that may arise in welding and marine corrosion characteristics of the alloys with differing temper designations. 5.7 Electronic Certification System (2011) An electronic certification system may be used to issue certified mill test reports, which may b
19、e electronically signed and stamped by an attending Surveyor, subject to the following conditions. All relevant information regarding the customer order, including the electronic certification request, is to be provided to the attending Surveyor by the manufacturer. Procedures are to be established
20、to control handling and distribution of certified mill test reports among the manufacturer, ABS, and the purchaser. In order to implement the electronic certification system, the manufacturer is to be under mandatory ABS-QA program. 7 Identification Markings 7.1 Marine Grades Aluminum alloys with ab
21、ility to resist intergranular and exfoliation forms of corrosion when in direct contact with seawater or when used in marine environment conditions shall be treated as marine grades. Aluminum alloys with magnesium content greater than or equal to 3% are prone to these forms of corrosion and shall be
22、 tested, inspected and certified in accordance with ASTM B928 specification by the manufacturer. The acceptance criteria for corrosion tests (ASTM G66 and G67) are to follow ABS Rule requirements. The test results shall be reported on the mill certificates and are to be verified by the Surveyor. The
23、 alloy grade shall be suffixed with the letters “MG” while marking as indicated in 2-5-1/7.3. 7.3 Material Identification (2011) All materials which have been sampled, tested and have successfully passed the requirements and have been approved by the Surveyor are to be clearly ink marked or stamped
24、with the manufacturers name or trademark and material identification on each finished sheet, plate, shape, bar, rod casing or forging to signify that the material has satisfactorily complied with the tests prescribed. The material identification is to include: Part 2 Rules for Materials and Welding
25、Aluminum and Fiber Reinforced Plastics (FRP) Chapter 5 Materials for Hull Construction Aluminum Section 1 General 2-5-1 10 ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 i) The initials AB ii) The aluminum alloy designation according to the Aluminum Association
26、 iii) The temper designation according to the Aluminum Association iv) The manufacturers batch number v) The letter “MG” is to be added after the grade and temper designation only if the material has been corrosion tested as per requirements of Section 2-5-6 of these Rules and ASTM B928. Example: AB
27、/5083 H321 MG 7.5 Stenciled Material In special cases, when approved, strapped or secured lifts or bundles of light sheet, plates, shapes, bars, rods or tubes of comparatively small size may be marked or stenciled on only the top piece or the marking may be shown on the tag attached to each lift or
28、bundle. ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 11 PART Section 2: Standard Test Methods 2 CHAPTER 5 Materials for Hull Construction Aluminum SECTION 2 Standard Test Methods 1 General (2011) The latest issue of the following test methods or specification
29、s or their equivalents are considered acceptable: 1.1 Chemical Analysis The chemical analyses are to be carried out in accordance with ASTM E34 or ASTM E716 or ASTM E1251 or equivalent, as may be appropriate to a specific alloy under testing and consideration for certification. The sampling practice
30、 for chemical analyses is to be carried out as indicated in 2-5-3/3 and may follow a recognized standard to the extent as may be modified or stated in this document. 1.3 Tension Testing Refer to 2-5-5 for requirements for test specimens. Alternative Standards ASTM E 8/8M or ASTM B557/557M or equival
31、ent may be used. 1.5 Shear Testing Shear tests are to be carried out in accordance with ASTM B769 or ASTM B565 or equivalent. 1.7 Hardness Testing* Hardness tests, if applicable, are to be carried out in accordance with ASTM E18 or equivalent. 1.9 Electrical Conductivity Testing* Electrical Conducti
32、vity tests, if applicable, are to be carried out in accordance with ASTM E1004 or equivalent. * Note: Hardness and Electrical Conductivity testing are reference only for evaluation of alloys and tempers of heat treatable aluminum products. 12 ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REI
33、NFORCED PLASTICS (FRP) .2013 PART Section 3: Chemical Composition 2 CHAPTER 5 Materials for Hull Construction Aluminum SECTION 3 Chemical Composition 1 General The chemical composition of each cast is to be determined by the aluminum manufacturer and is to conform to the applicable requirements of t
34、he alloys listed in 2-5-3/Table 1 or 2-5-3/Table 2 or such other requirements as may be specially approved. 3 Sampling A control sample for chemical analysis is to be taken before starting to pour and one additional sample is to be taken during the pouring of each group of ingots poured simultaneous
35、ly from the same source of molten metal. If not analyzed during pouring samples, it may be taken from semi-finished or finished products. When samples are taken from finished or semi-finished products, one sample is to represent each 1800 kg (4000 lb), or fraction thereof, of each alloy in an inspec
36、tion lot. The manufacturers declared analysis will be subject to occasional checks if required by the Surveyor. Product analysis may be required where the final product chemistry is not well represented by the analysis from the cast. When the aluminum alloys are not cast in the same works in which t
37、hey are manufactured into semi- finished products, a certificate issued by the works is to be provided to the Surveyor which indicates the reference numbers and chemical composition of the heats. 5 Definition of an Inspection Lot An inspection lot is defined as: For non-heat treated tempers, an iden
38、tifiable quantity of material of the same mill form, alloy, temper, section and size submitted for an inspection at one time before shipment. And for heat treated temper an identifiable quantity of material of the same mill form, alloy, temper, section and size traceable to a heat treated lot or lot
39、s and submitted for inspection at one time before shipment. Mill forms: sheet and plate, all material of the same thickness is considered to be of the same size. Part 2 Rules for Materials and Welding Aluminum and Fiber Reinforced Plastics (FRP) Chapter 5 Materials for Hull Construction Aluminum Sec
40、tion 3 Chemical Composition 2-5-3 ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 13 TABLE 1 Chemical Composition Limits of Wrought Aluminum Alloys (2013) Limits are in weight percent. Single value represents maximum limit, unless shown as a range or indicated a
41、s a minimum. Others (1)Alloy Silicon Iron Copper Manganese Magnesium Chromium Zinc Titanium Each Total Aluminum 5052 0.25 0.40 0.10 0.10 2.2-2.8 0.15-0.35 0.10 0.05 0.15 Remainder 5059 0.45 0.50 0.25 0.60-1.2 5.0-6.0 0.25 0.40-0.90 0.20 0.05 (5)0.15 (5)Remainder 5083 0.40 0.40 0.10 0.40-1.0 4.0-4.9
42、0.05-0.25 0.25 0.15 0.05 0.15 Remainder 5086 0.40 0.50 0.10 0.20-0.7 3.5-4.5 0.05-0.25 0.25 0.15 0.05 0.15 Remainder 5383 0.25 0.25 0.20 0.70-1.0 4.0-5.2 0.25 0.4 0.15 0.05 (4)0.15 (4)Remainder 5454 0.25 0.40 0.10 0.50-1.0 2.4-3.0 0.05-0.20 0.25 0.20 0.05 0.15 Remainder 5456 0.25 0.40 0.10 0.50-1.0
43、4.7-5.5 0.05-0.20 0.25 0.20 0.05 0.15 Remainder 5754 0.40 0.40 0.10 0.50 (2)2.6-3.6 0.30 (2)0.20 0.15 0.05 0.15 Remainder 6005A 0.50-0.9 0.35 0.30 0.50 (3) 0.4-0.7 0.30 (3) 0.20 0.10 0.05 0.15 Remainder 6061 0.40-0.8 0.70 0.15-0.40 0.15 0.8-1.2 0.04-0.35 0.25 0.15 0.05 0.15 Remainder 6063 0.20-0.6 0
44、.35 0.10 0.10 0.45-0.9 0.10 0.10 0.10 0.05 0.15 Remainder 6082 0.70-1.3 0.50 0.10 0.40-1.0 0.6-1.2 0.25 0.20 0.10 0.05 0.15 Remainder Notes: 1 (2011) The term Others includes any other element(s) for which no specific limit is shown in the above table. Other element(s), if added intentionally or ana
45、lyzed by the alloy producer or specified by the purchaser, are to be reported and not to exceed the limit as given in the Others column. 2 Mn + Cr : 0.10 0.60 3 Mn + Cr : 0.12 0.50 4 Zr: maximum 0.20. The total for other elements does not include Zirconium. 5 Zr: 0.05-0.25. The total for other eleme
46、nts does not include Zirconium. TABLE 2 Chemical Composition Limits of Cast Aluminum Alloys AA Aluminum Association Limits are in weight percent. Single value represents maximum limit, unless shown as a range or indicated as a minimum. AA Silicon Iron Copper Manganese Magnesium Zinc Titanium Others
47、Aluminum Each Total 356.0 6.57.5 0.6 (1)0.25 0.35(1)0.200.45 0.35 0.25 0.05 0.15 Remainder A356.0 6.57.5 0.20 0.20 0.10 0.200.45 0.10 0.20 0.05 0.15 Remainder 357.0 6.57.5 0.15 0.05 0.03 0.450.6 0.05 0.20 0.05 0.15 Remainder Note: 1 If the iron content exceeds 0.45%, manganese content shall not be l
48、ess than one half of the iron. 14 ABSRULES FOR MATERIALS AND WELDING ALUMINUM AND FIBER REINFORCED PLASTICS (FRP) .2013 PART Section 4: Heat Treatment 2 C HAPTER 5 Materials for Hull Construction Aluminum SECTION 4 Heat Treatment Alloys 6005A, 6061 and 6082 products are to be suitably heat treated t
49、o develop the mechanical properties specified in 2-5-5/Tables 2, 4, 5 and 6 for the various tempers. Alternative heat treatments will be specially considered. T4 Solution heat treated and then naturally aged. T451 For sheet and plate that are stress relieved by stretching after solution heat treatment. T4511 For extruded bars, rods or shapes that are stress relieved by stretching after solution heat treatment. T5 Cooled from an elevated temperature shaping process and then artificially a
