Ministry of Defence

Defence Standard 01-10

Issue 1 Publication Date 25 August 2000

Ferrous Armour
Welding Consumables (Tests)
 AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

REVISION NOTE

This Defence Standard has been based on the requirements of RARDE 1056 and RARDE
1079. It has been revised and updated to reflect current technical requirements, restructured in
content and layout to Defence Standard 00-00 (Part 2) and incorporated into the Group 23
series of Defence Standards relating to vehicles and their equipment.

HISTORICAL RECORD

FVRDE Specification 2008

RARDE Specification 1079 dated 19 October 1956
RARDE Specification 1056 dated 15 September 1966
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CONTENT

Description Page

Content 1
Preface 2
Main Text 3

SECTION 1 GENERAL REQUIREMNTS

1 Scope 3
2 WARNING 3
3 Related Documents 3
4 Definitions 4

SECTION 2 TECHNICAL REQUIREMENTS

5 Validation 6
6 Certification 7
7 Consumable Requirements 7
8 Resistance to cracking 8
9 Resistance to Ballistic Attack 9
10 Packing and Marking 11

Table A Chemical Composition 7

Figure 1 Casting Repair Test Plate 10

Figure A.1 Rigid Butt Test Jig 15
Figure A.2 Test Jig Details 16
Figure A.3 Test Plates 17
Figure A.4 Weld Sections 18
Figure B.1 Swinden Test Piece 20
Figure C.1 Modified Reeve Test Assembly 23

Annex A Procedure for the R.D. Rigid Butt Joint Test 12

Annex B Procedure for the Swinden Tied Tee Test 19
Annex C Procedure for the Reeve Fillet Weld Test as Modified 21
For Heavy Armour

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PREFACE

Ferrous Armour Welding Consumables (Tests)

a. This Defence Standard specifies the requirements for Ferrous Armour Welding
Consumables.

b. This Defence Standard has been produced on behalf of the Standardization Advisory
Group (SAG) by the Corrosion Prevention and Metallic Materials Standards Production Group
(E3).

c. This Defence standard has been agreed by the authorities concerned with its use and is
intended to be used whenever relevant in all future designs, contracts, orders etc and whenever
practicable by amendment to those already in existence. If any difficulty arises which prevents
application of the Defence Standard, the Directorate of Standardization shall be informed so that
a remedy may be sought.

d. Any enquiries regarding this Defence Standard in relation to an invitation to tender or/a
contract in which it is invoked are to be addressed to the responsible technical or supervising
authority named in the invitation to tender or contract.

e. Compliance with this Defence Standard shall not in itself relieve any person from any
legal obligations placed upon them.

f. This Defence Standard has been devised solely for the use of the Ministry of Defence
(MOD) and its contractors in the execution of contracts for the MOD. To the extent permitted by
law, the MOD hereby excludes all liability whatsoever and howsoever arising (including, but
without limitation, liability resulting from negligence) for any loss or damage however caused
when the standard is used for any other purpose.

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TEXT

Ferrous Armour Welding Consumable (Tests)

SECTION 1 GENERAL REQUIREMENTS

1 SCOPE

1.1 This standard states the requirements for arc welding consumables for the welding of
ferrous armour and the procedure for demonstrating their acceptability. It includes a
requirement for manufacturers to validate consumables, prior to their use in production, by a
mixture of weld, cut and ballistic testing.

1.2 The tests specified within this standard may also be used to establish the weldability of
ferrous armours.

1.3 The requirements for the welding of ferrous armour are to be found in Def Stan 03-34.

2 WARNING

The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and
European laws regarding Health & Safety at Work, without exemption. All Defence Standards
either directly or indirectly invoke the use of processes and procedures that could be injurious
to health if adequate precautions are not taken. Defence Standards or their use in no way
absolves users from complying with statutory and legal requirements relating to Health &
Safety at Work.

3 RELATED DOCUMENTS

3.1 The publications shown below are referred to in the text of this standard. Publications are
grouped and listed in alpha numeric order.

Designation Title

BS 499 Welding Terms and Symbols

BS 2901: Part 2 Filler Rods and Wires for Gas-Shielded Arc Welding, Specification for
Stainless Steels.
BS EN 439 Welding Consumables. Shielding Gases for Arc Welding and Cutting.
BS EN 440 Welding Consumables. Wire Electrodes and Deposits for Gas Shielded
Metal-Arc Welding of Non Alloy and Fine Grain Steels. Classification.
BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc Welding
of Non Alloy and Fine Grain Steels. Classification.
BS EN 757 Welding Consumables - Covered Electrodes for Manual Metal Arc
Welding of High Strength Steels - Classification

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SECTION 1 GENERAL REQUIREMENTS

Designation Title

BS EN 758 Welding Consumables - Tubular Cored Electrodes for Metal Arc Welding
With and Without a Gas Shield of Non-Alloy and Fine Grain Steels -
Classification
BS EN 759 Welding Consumables - Technical Delivery Conditions for welding Filler
Metals - Type of Product, Dimensions, Tolerances and Marking
BS EN 1600 Welding Consumables - Covered Electrodes for Manual Metal Arc
Welding of Stainless and Heat Resisting Steels - Classification
BS EN 25817 Arc-welded Joints in Steel. Guidance on Quality Levels for Imperfections.
BS EN ISO 6947 Welds - Work Positions - Definitions of Angles of Slope and Rotation
Def Stan 01-9 Welding Consumables for Use on Ferrous Armour
Def Stan 03-34 Welding of Ferrous Armour
Def Stan 95-24/1 Steel Armour Plate (3mm to 160mm)
Def Stan 95-25/1 Armour Quality Castings
AWS A5.22 Flux Cored Corrosion Resisting Chromium and Chromium-Nickel Steel
Electrodes.

3.2 Reference in this Standard to any related document means in any invitation to tender or
contract the edition and all amendments current at the date of such tender or contract unless a
specific edition is indicated.

3.3 In consideration of 3.2 above, users shall be fully aware of the issue and amendment
status of all related documents, particularly when forming part of an invitation to tender or
contract.

3.4 DStan can advise regarding where related documents are obtained from. Requests for
such information can be made to the DStan Helpdesk. How to contact the helpdesk is shown on
the outside rear cover of Def Stans.

4 DEFINITIONS

4.1 For the purpose of this Defence Standard the definitions given in BS 499 apply together
with the following:

4.2 Manufacturer

This shall mean the person or persons, firm or firms, company or companies who have been
contracted to manufacture and supply welding consumables in accordance with this Standard.

4.3 Welding Consumable

The flux coated electrode or wire/shielding gas/flux combination used to make a weld.

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SECTION 1 GENERAL REQUIREMENTS

4.4 Welding Position

Shall be as defined in BS EN ISO 6947.

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SECTION 2 TECHNICAL REQUIREMENTS

5 VALIDATION

5.1 The validation of a welding consumable for use on armour material is carried out in two
stages, the first being referred to as "Tentative Acceptance", and the second as "Full Validation".

5.2 Tentative Acceptance

Is issued when a welding consumable has been shown to be compliant with the requirements of
this Standard and is capable of welding ferrous armour by the successful completion of the tests
given in this Standard, see clause 8. Tentative Acceptance permits the use of the consumable in
a single factory for a specific production trial which shall be agreed with the Technical and
Supervising Authority named in the contract.

5.3 Full Validation of Consumables for Welding Production Armour

This is granted to a consumable which, having gained Tentative Acceptance, has then
successfully completed an agreed production trial, as permitted by 5.2. The purpose of the trial is
to demonstrate that the consumable is capable of producing acceptable welds in a production
environment. The trial shall include various types and sizes of welds deposited in a number of
welding positions. Consumables for the repair of armour castings shall be validated as per 5.4.

5.3.1 Validation shall be based on Weld Procedure Approval Records, Welder Approvals
(for at least 3 welders) and production Non Destructive Examination (NDE) records (which can
be directly related to the consumable on trial) of at least 3 major fabrications. The NDE records
should include an examination of a major butt weld by either radiography or ultrasonics. Full
validation permits the unrestricted use of the consumable on work for which its class is specified
(See Def Stan 01-9).

5.4 Full Validation of Consumables for the Repair of Armour Castings

Consumables for the repair of Armour Castings shall attain full validation upon satisfactory
completion of the test given in clause 9.

5.5 Material and Information to be provided by the Manufacturer

5.5.1 The manufacturer shall provide the following information when submitting a brand of
consumable for validation.

A) Tentative Acceptance: The manufacturing organisation and site of manufacture; the

classification and property requirements; welding data sheets, including welding parameters and
fume information; welded test plates (as required by clause 8) with a full weld history, including
Heat Input values for each weld run and Run Out Ratios (if appropriate), which have been
witnessed by a Second or Third Party.

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SECTION 2 TECHNICAL REQUIREMENTS

B) Full Validation: A statement of acceptability from the fabricator conducting the agreed
Production Trial which is supported by the records given in 5.3.

5.6 Once Full Validation has been granted, no change in the constituents of the consumable
or method or site of manufacture shall be made without the agreement of the Technical and
Supervising Authority who may require further tests to be performed.

6 CERTIFICATION

Consumable manufacturers shall provide a Certificate of Conformity for all consumables

supplied to this Standard stating that all elements of the Standard have been complied with and
that all tests have been satisfactorily completed. A clear distinction must be made between
Tentatively Accepted and Fully Validated consumables.

7. CONSUMABLE REQUIREMENTS

7.1 Consumables shall be manufactured and classified in accordance with BS 2901, BS

EN 440, BS EN 499, BS EN 757, BS EN 758, BS EN 1600 or AWS A5.22 as appropriate.
Shielding gases, when required, shall be in accordance with BS EN 439.

7.2 Consumables for Classes 1 to 3 of Def Stan 01-9 shall deposit metal of the following
composition (i.e. it shall have a designation of: 20.10.3).

Table A: Chemical Composition

Element Wt %

Carbon 0.08 max

Silicon 1.2 max
Manganese 0.5 – 2.5
Phosphorus 0.030 max
Sulphur 0.025 max
Chromium 18.5 – 21.0
Nickel 9.0 - 11.0
Molybdenum 2.0 - 3.5

7.2.1 The deposit shall have a minimum tensile strength of 620 MPa.

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SECTION 2 TECHNICAL REQUIREMENTS

7.3 Consumables for Classes 4 and 5 of Def Stan 01-9 shall deposit weld metal having the
following mechanical properties:

Tensile Strength = 510 MPa minimum

Yield strength = 420 MPa minimum
Impact = 47 J minimum @ -30°C Charpy V-notch

7.4 Consumables for Class 6 of Def Stan 01-9 are for specific applications which shall be
defined in the list of validated consumables. Consumables for the repair of ferrous armour
castings shall comply with the requirements of clauses 8 and 9.

7.5 For Tentative Acceptance, the consumables shall comply with clause 8 at both the
maximum and minimum heat inputs recommended by the manufacturer (e.g. the highest current
and slowest travel speed and the lowest current and fastest travel speed). The maximum
permitted weave for covered electrodes shall be three times the core wire diameter.

7.6 When this Standard is used for testing armour material, the requirements of clause 8
shall be met when the plate is welded with fully validated class 1 and class 4 consumables at the
maximum heat input recommended by the consumable supplier.

8 RESISTANCE TO CRACKING

8.1 Welding consumables shall be satisfactory with regard to the freedom from cracking of
joints welded under restraint as determined by the tests required in clauses 8.2 and 8.3.
Consumables for Class 6 may require additional tests which shall be specified at the time of
initial application.

8.2 For Armour Thicknesses up to and including 14 mm:

8.2.1 All welding consumables shall be submitted to the following tests.

8.2.2 The R.D. Rigid Butt Joint Test

This test shall be carried out in accordance with the procedure specified in Annex A, in order to
determine the resistance to cracking in the junction or heat affected zone of the armour.

8.2.3 The Swinden Tied Tee Test.

This test shall be carried out in accordance with the procedure specified in Annex B, in order to
determine the resistance to weld metal cracking.

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SECTION 2 TECHNICAL REQUIREMENTS

8.3 For Armour Thicknesses over 14 mm:

8.3.1 All welding consumables shall be submitted to the following test in addition to those
specified in 8.2.

8.3.2 The Modified Reeve test

This test shall be carried out in accordance with the procedure specified in Annex C, in order to
determine the resistance to cracking in the junction or heat affected zone of the armour.

9 RESISTANCE TO BALLISTIC ATTACK

9.1 Consumables for the repair of ferrous armour castings shall be approved when they have
been demonstrated not to degrade the ballistic properties of the parent casting. The test is based
on the "protection limit" assessment of the base Def Stan 95-25 plate.

9.2 The test piece shall consist of 2 areas of weld metal in a test plate, produced to the
requirements of Def Stan 95-25, as specified in Fig 1.

9.3 The recesses B and C shall be filled with weld metal in the PA position (see BS EN ISO
6947) using the highest heat input recommended by the manufacturer and shall have minimal
reinforcement. A minimum preheat of 100°C may be applied. Weld runs in each layer shall be in
alternate directions and each layer shall be at 90° to the previous one.

9.4 Upon completion of welding, no post weld heat treatment is permitted.

9.5 There shall be no dressing of the weld caps or the parent plate.

9.6 Upon completion of welding, the test plate shall be submitted to a suitable test range for
ballistic assessment to the requirements of Def Stan 95-25. Area A shall be used for the
assessment of the plate protection limit.

9.7 A comparative assessment shall be made against Area B, i.e. the welded area shall be the
target face. If the results match or exceed the results of Area A, the consumable shall be
approved for external repairs.

9.8 A second comparative assessment shall be made against the back of Area C, i.e. the
welded area shall be the target back face. If the results match or exceed the results of Area A, the
consumable shall be validated for internal repairs.

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SECTION 2 TECHNICAL REQUIREMENTS

Note 1 : Area A shall be gridded with white paint in 100 mm squares and shall have the
actual plate thickness painted in the centre of each.
Note 2 : Matching tolerances are + 1mm : all others are as Def-Stan 95-25. All machined
radii shall be 12 mm.
Note 3 : After welding, area B shall be gridded in 100 mm squares with white paint.
Note 4 : The back of area C shall be gridded in 100 mm squares with white paint.
Note 5 : All dimensions are in millimetres. Tolerances are +8% and –2%.

Fig 1: Casting Repair Test Plate

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SECTION 2 TECHNICAL REQUIREMENTS

10 PACKING AND MARKING

10.1 Consumables shall be packed in accordance with the requirements of the contract or
order. The use of contaminated packaging may render the whole consignment liable to rejection.
The packaging shall be suitable for maintaining the properties of the consumables for a
minimum period of five years in the unopened condition.

10.2 It is the Manufacturer's responsibility to mark the packaging in accordance with BS EN

759 and any legal requirements. In addition, the containers shall be both legibly and durably
marked with the following details:

Description viz.: Ferrous Armour Welding electrodes (or wire)

Defence Standard viz.: Def Stan 01-10
Contract or order number:
Distinctive lot and/or batch number:
Brand of electrode:
Electrode Class in Def Stan 01-9
Recommended current and voltage range:
Size of electrode/diameter of wire:
Quantity of contents:
Date of manufacture:
Manufacturer's initials or recognised Trade Mark:

and any other markings called for in the contract or order.

10.3 The lot or batch number on the package shall be such that the consumables can be traced
back to the ingredients and mixes employed in their manufacture.

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ANNEX A

PROCEDURE FOR THE R.D RIGID BUTT TEST

A.1 DESCRIPTION OF TEST

A.1.1 The R.D. rigid butt joint test is essentially a self restrained butt weld between two
plates butting closely together at each end of a specially prepared vee. The degree of restraint is
governed by the width of the test plates which have been standardized at 150 mm. The two
plates are prevented from angular distortion by being firmly held down to a baseplate jig. The
test establishes the susceptibility of the consumable to induce cold cracking due to the build up
of residual stresses. A general view of the test set up ready for welding is shown in Fig A.1,
dimensioned drawings being given in Fig A.2.

A.1.2 The main base plate is made from 25 mm thick alloy steel with a minimum yield
strength of 750 MPa. The intermediate backing plate is of the same material and has a grooved
copper strip in a recess to prevent the root of the test weld fusing onto the backing plate, i.e. the
copper strip is not a backing bar for the test weld. The restraining bars are of 25 mm x 50 mm
alloy steel, with a minimum yield strength of 500 MPa, shaped at each end to drop over 25 mm
diameter steel studs and held down by 25 mm diameter nuts.

A.2 PREPARATION

A.2.1 Two 14 mm thick ferrous armour test plates to Def Stan 95-24 shall be prepared by
cutting a 300 mm square plate into two pieces nominally 300 mm x 150 mm with the long side
transverse to the main rolling direction. A 30° bevel shall be machined on part of one of the long
sides of each plate to give an included angle of 60° when the two bevelled sides are butted
together. The abutting faces shall be finished such that when set up, the plate ends shall be in
intimate contact and a root gap of 1.0 ± 0.25 mm is formed in the groove. The corners at the end
of the bevels shall be smooth and round: a slope of 45° has been found to provide a reasonable
surface for arc striking. The sharp feather edge of the bevels shall be "broken" by light filing but
care shall be taken to avoid the formation of any appreciable root face, i.e. the root face shall be
less than 1 mm. Two 150 mm wide plates prepared for assembly are shown in Fig A.3a.

A.2.2 After the plates have been prepared, they shall be set in the jig with paper (total
thickness 0.165 mm to 0.178 mm) between them and the loose backing plate; this paper to be set
back clear of the root gap for approximately 13mm each side. The purpose of the paper is to
prevent too rapid heat transference from the test plates into the jig. The assembly bolts shall be
tightened to ensure that the test plates are abutting tightly and then the restraining bar nuts shall
be tightened fully. The assembly bolts may then be slackened off. Care shall be taken in setting
up to ensure that the groove in the copper strip is immediately beneath the joint in the test plates.
A mark as shown in Fig A.1 is a useful aid.

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ANNEX A

A.3 PROCEDURE

A.3.1 The temperature of the whole test piece, welding jig, and room in which the work is
carried out shall not be less than 15°C, nor more than 26°C. Further, the ambient temperature
shall not fall below 15°C prior to sectioning. The test plates shall be welded in the PA position.

A.3.2 After appropriate cleaning the vee shall be filled in four layers with the layers being
deposited in alternate directions. All the runs in a layer shall be in the same direction with a
minimum interval between runs. The following consumable sizes have been found to produce
satisfactory welds: electrodes - 4 mm root and 5 mm fill; wire - 1.2 mm.

A.3.3 A time interval of five minutes shall be maintained between layers, and all traces of
slag shall be thoroughly removed after the first minute.

A.3.4 Care shall be taken to prevent excessive penetration on the first run, though lack of
fusion is equally to be guarded against, (the optimal parameters, to achieve the required weld
profile, may be used for the root run only, the rest of the weld shall be made with the required
parameters, see 6.5). On all runs care shall be taken to ensure that deep penetration is not made
into the parent plate. Care shall be taken on the last run to obtain correct fusion of the top edges,
since it is undesirable to have either overlap or traces of a notch. The reinforcement of the weld
should be of the order of 0.8 mm to 1.5 mm above the plate and be of uniform appearance and
smooth contour. A record shall be kept of the Heat Input and of the Run-Out Ratio (the ratio of
deposited weld metal to the length of covered electrode used) applicable to each layer.

A.3.5 On completion of welding, the assembly shall be covered and left in still air (protected
from draughts) for 24 hours. At the end of this time, the test plate shall be removed from the jig.
The test plate shall then be left in still air for a further 5 days. If after this period, there are no
obvious cracks, the weld shall be examined by either Magnetic Particle or Dye Penetrant
Inspection (by suitably qualified personnel). If there are no cracks, the weldment shall be
removed by lubricated sawing approximately 45 mm from the weld centreline on both sides of
the weld (see Fig A.3b). Cross sections shall be taken at distances of 35 mm, 75 mm, and
115 mm from the start of the root run (see Fig A.3c).

A.4 SECTIONING, EXAMINATION AND ASSESSMENT

A.4.1 Three sections shall be removed and the surfaces ground and polished for
micro-examination, and lettered for reference as follows:

Section 35 mm from start of first run - A

Section 75 mm from start of first run - B
Section 115 mm from start of first run - C

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ANNEX A

A.4.2 Each section shall be examined visually and at a magnification of not less than 50X. A
section is acceptable if the imperfections are within the specified limits of level B in
BS EN 25817, except for excess weld metal when level C shall apply. If it is considered that an
unacceptable imperfection is due to faulty welding technique, the test shall be discounted and a
repeat test made.

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ANNEX A

Fig A.1 R.D. Rigid Butt Test Jig

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ANNEX A

Fig A.2 Test Jig Details

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ANNEX A

Fig A.3a Prepared test plates

Fig A.3b Removed weldment Fig A.3c Cross-sections

Fig A.3 Test Plates

ANNEX A

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Fig A.4 Weld Sections

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ANNEX B

PROCEDURE FOR THE SWINDEN TIED TEE TEST

B.1 DESCRIPTION OF TEST AND PREPARATION

B.1.1 The test piece illustrated in Fig B.1 is in the form of a small tee joint with a bar welded
on the back of the main member in order to increase the rigidity.

B.1.2 The leg and baseplates of the tee are formed of 14 mm thick ferrous armour plate to
Def Stan 95-24. The test piece is 150 mm long, the horizontal base being 90 mm wide while the
vertical leg, which is finally tacked in position along the centre line of the horizontal plate, is 100
mm high. A piece of 25 mm square mild steel bar is welded to the horizontal plate by means of
two 6 mm fillet welds (A & B in Fig B.1).

B.1.3 All scale shall be removed from the vicinity of the welds. The lower edge of the
vertical plate is ground so as to make as close a fit as possible with the horizontal plate, the
maximum gap permissible being 0.13 mm. The vertical plate is clamped firmly in position,
tacked at each end and the clamping then removed.

B.2 Procedure

B.2.1 The temperature of the test piece immediately prior to the deposition of the first test
weld shall not be less than 15°C nor more than 26°C.

B.2.2 The two test welds shall be made in the PA position with a maximum interval of 12
seconds between the breaking of the arc on the completion of run 1 and the re-striking of the arc
for run 2. During this interval the test piece shall be turned and tilted in the opposite direction so
that run 2 is commenced opposite the crater of run 1 and proceeds in the opposite direction. A
new covered electrode shall be used for the second run.

B.2.2.1 A record shall be kept of the Heat Input and Run Out Ratio (the ratio of deposited weld
metal to the length of covered electrode used) applicable to each run.

B.2.3 It is emphasised that the time interval is most critical and shall be complied with.

B.2.4 The size of the test welds is important and care should be taken to ensure that a
uniform equal leg length of 8.5 mm ± 0.5 mm is achieved. (When covered electrodes are being
tested, a 5.0 mm electrode should be used whenever possible).

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DEF STAN 01-10/1

ANNEX B

B.3 SECTIONING, EXAMINATION AND ASSESSMENT

B.3.1 Three sections shall be removed and the surfaces ground and polished for
micro-examination, and lettered for reference as follows:

Section 25 mm from start of first run - A

Section 65 mm from start of first run - B
Section 100 mm from start of first run - C

B.3.2 Each section shall be examined visually and at a magnification of not less than 50X. A
section is acceptable if the imperfections are within the specified limits of level B in BS EN
25817, except for excessive convexity and excess throat thickness for which level C shall
apply. Penetration into the parent plate shall be no more than 2.5 mm. If it is considered that an
unacceptable imperfection is due to faulty welding technique, the test shall be discounted and a
repeat test made.

Fig B.1 Swinden Tied Tee Test Piece

ANNEX C

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ANNEX C

PROCEDURE FOR THE REEVE FILLET WELD TEST AS MODIFIED FOR HEAVY
ARMOUR

C.1 DESCRIPTION OF TEST

C.1.1 The Reeve test consists of a lap fillet weld between two plates restrained by welds
anchoring one plate to the other and by bolts clamping both plates to a heavier and more rigid
baseplate.

C.1.2 The assembly is illustrated in Fig C.1 from which it will be seen that the permanent
baseplate consists of a 75 mm plate 460 mm by 460 mm drilled with six holes. The two 75 mm
thick test plates are cut to sizes of 255 mm x 175 mm and 150 mm x 125 mm respectively, and
drilled from the same jig as the baseplate. The main rolling direction of the test plate shall be
transverse to the test weld, i.e. the 175 mm and 150 mm sides.

C.2 PREPARATION

All scale shall be removed from the vicinity of welds and a good fit between the plates assured
(by grinding if necessary) such that any gap along the test joint shall not exceed 0.5 mm. The
test plates should be assembled on the jig and the nuts tightened. After preheating the assembly
to 100 - 150°C the 12 mm leg length anchor welds shall be deposited in the PA position by one
run in the sequence shown in the diagram; the rear weld first and then the two side welds from
the rear towards the test weld. The whole assembly shall then be allowed to cool to an ambient
room temperature of 15°C - 26°C and the nuts retightened.

C.3 PROCEDURE

C.3.1 With the assembly at 15°C - 26°C it should be positioned at 45° for the test weld to be
deposited in the PA position.

C.3.2 The 25 mm equal leg length fillet test weld shall be deposited in three stages.

C.3.3 The first stage shall be an 11 mm - 13 mm fillet weld deposited with a minimum
number of layers and runs per layer. The runs in each layer shall be in the same direction with a
minimum interval between runs. The direction of welding shall alternate between layers and
there shall be a minimum interval between layers. (8 mm and 10 mm diameter covered
electrodes should complete this stage in a single run).

C.3.4 The second stage shall be started after an interval of 5 minutes from the end of the first
in the opposite direction to the last layer. This stage will result in a 17 mm - 19 mm fillet weld,
with a minimum number of layers and runs per layer similar to the first stage. (8 mm and 10 mm
diameter covered electrodes should complete this stage in a single run).

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ANNEX C

C.3.5 The third stage shall be started after an interval of 5 minutes from the end of the second
in the opposite direction to the last layer. This stage will result in a 25 mm fillet weld, with a
minimum number of layers and runs per layer similar to the first stage. (8 mm and 10 mm
diameter covered electrodes should complete this stage in a single layer of two runs).

C.3.6 A record shall be kept of the Heat Input and Run Out Ratio (the ratio of deposited weld
metal to the length of covered electrode used) applicable to each layer.

C.3.7 After welding, the assembly shall be protected from draughts and allowed to cool to a
room temperature of not less than 15°C. Further, the ambient temperature shall not fall below
15°C prior to sectioning the test pieces. Twenty four hours after welding the test pieces shall be
unbolted and left for a further period of 5 days before being sectioned.

C.4 SECTIONING, EXAMINATION AND ASSESSMENT

C.4.1 Three sections shall be removed and the surfaces ground and polished for
micro-examination, and lettered for reference as follows:

Section 35 mm from mid-point on one side of first run -A

Section at mid-point of first run -B
Section 35 mm from mid-point on other side of first run -C

C.4.2 Each section shall be examined visually and at a magnification of not less than 50
diameters. A section is acceptable if the imperfections are within the specified limits of level B
in BS EN 25817, except for excessive convexity and excess throat thickness for which level C
shall apply. Penetration into the parent plate shall be no more than 4.0 mm. If it is considered
that an unacceptable imperfection is due to faulty welding technique, the test shall be discounted
and a repeat test made.

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 DEF STAN 01-10/1

ANNEX C

Fig. C.1 Modified Reeve Test Assembly

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