MAN B&W

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Connecting Rod Ident No.: 0741673-1

Forged Steel Connecting Rod

This document is valid for existing engine Quality Specification

types on order as of the date of this docu-
ment: 0741673-1.5

Engine types: February 2018

All two-stroke engine types
Info No: 391711

Structure No: 21-1426

Replaces:

Scope and Field of Application

This specification describes required quality in-
spection and acceptance criteria for production
of forged steel connecting rods.

Note! Requirements and/or specifications

stated on the relevant drawings must
be adhered to.

Document history
Date Designer  Checked AC Revision change Revision
1988-04-11 KNM 0
2011-03-30 GEL Z3 Updated to new layout 3
2013-12-19 LNU GEL Z3 Document restructured, zone definitions revised 4
2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany MAN Diesel & Turbo
Registered with the Danish Commerce and Companies Agency under CVR-no. 31611792 (referred to as “MAN Diesel & Turbo”). Teglholmsgade 41, 2450 Copenhagen SV, Denmark
This document is the property of MAN Diesel & Turbo and is to be treated as confidential by the party to whom it has been submitted by Phone +45 33 85 11 00
MAN Diesel & Turbo, and may not be disclosed to any third party without the specific prior written permission of MAN Diesel & Turbo. E-mail [email protected]
This document may be a translation of an original English language document. In case of any discrepancy between the original Web www.mandieselturbo.com
English language document and this translation, it is always the original English language document which shall prevail.
The original English language document may have been replaced by a later version, in which case only such later version shall be valid.
Quality Specification 0741673-1.5

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Contents Changes in this revision:

1. Introduction�����������������������������������������������������������������������������3 Requirements updated
2. References �����������������������������������������������������������������������������3 in connection with the
3. Material�����������������������������������������������������������������������������������3 new connecting rod with
4. Quality inspection�������������������������������������������������������������������3 flex hole design.
4.1. Minimum requirements for quality inspection 4
4.2. Ultrasonic testing 5
4.3. Magnetic particle testing 7
4.4. Penetrant testing 7
4.5. Positional check of the lubrication oil bore 7
5. Acceptance criteria�����������������������������������������������������������������8
5.1. Subsurface defects 8
5.2. Surface defects 10
6. Rectification of defects ������������������������������������������������������� 11
6.1. Grinding 12
6.2. Welding 13
7. Certification/identification��������������������������������������������������� 15

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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1. Introduction
All inspection/testing and documentation must comply with the rules of the Classification
Society(ies) involved.

Note! Requirements and/or specifications stated on the relevant drawings must be adhered to.

2. References
MAN B&W Production Specification:
No. 0742980-3; Marks and Stamps on Components for Two-stroke Diesel Engines.
No. 0742825-9; Connecting Rod - Rectification of Defects.

MAN B&W Standard:

EN602R: Ultrasonic examination of steel castings and forgings, Procedure (UT).
EN602U: Ultrasonic examination, General conditions (UT).
EN602S: Magnetic particle examination, Procedure (MT).

ISO 3452: Non-Destructive Testing - Penetrant Testing - General Principles.

3. Material
The material must be in accordance with the applicable drawings and MAN B&W Material Speci-
fication.

The conformity with the specified material must be documented to the satisfaction of the Clas-
sification Society(ies), including:
ƒƒ Chemical composition.
ƒƒ Mechanical properties.

4. Quality inspection
Chemical composition, tensile strength, yield strength and elongation must be determined in ac-
cordance with the description specified in subsection 4.1.
Ultrasonic testing (UT), magnetic particle testing (MT), penetrant testing (PT) and dimensional
inspection of the lubrication oil bore is to be carried out in accordance with the descriptions in
subsections 4.1, 4.2, 4.3, 4.4 and 4.5.

Acceptance criteria for the final machined connecting rod are specified in section 5.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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The connecting rod must be inspected at different stages during the production process. The
detailed planning of the quality inspection must be adapted to the type of connecting rod in ques-
tion and to the actual production process flow.

An inspection plan may look as shown below.

1. After forging:
ƒƒ Visual inspection.

2. After normalizing:
ƒƒ Chemical composition.
ƒƒ Mechanical properties.

3. After rough machining, before drilling of the central lubrication oil bore:
ƒƒ UT to reveal internal defects.

4. After rough machining and drilling of the central lubrication oil bore, before machining of
the flex-holes:
ƒƒ Positional check of the lubrication oil bore (connecting rods with flex hole design only).

5. After final machining:

ƒƒ Visual inspection and dimensional inspection.
ƒƒ MT to reveal surface defects.

4.1. Minimum requirements for quality inspection

ƒƒ Chemical composition.
ƒƒ The following material testing must be carried out on 1 forged-on test piece.
ƒƒ Tensile strength.
ƒƒ Yield strength.
ƒƒ Elongation.
ƒƒ Brinell hardness.
ƒƒ Microstructure documentation (photos).
ƒƒ Visual examination (VT) after rough machining.
ƒƒ Ultrasonic testing (UT) after rough machining.
ƒƒ Magnetic particle testing (MT) after final machining.
ƒƒ Visual and dimensional inspection after final machining.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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4.2. Ultrasonic testing

Ultrasonic testing must be carried out according to MAN B&W Standards EN602R and EN602U.

The entire connecting rod must be inspected.

Special attention is required in the area equal to a sphere with a diameter of 200 mm and center
where the central lubrication oil bore meets the oil groove, see figure 1.

For the connecting rod with flex hole design, the area which requires special attention and has
additional requirements also covers the area around the flex-holes to a distance of 50 mm, see
figure 1.

Conventional connecting rods

Connecting rods with flex hole design

Figure 1: Area for which special attention is required during ultrasonic testing.

The main parameters of ultrasonic testing are as follows:

Instrument:
Analogue or digital ultrasonic flaw detector.
Example: General Electric Inspection Technologies (GE) USN 60 or Olympus Epoch 4 or equiva-
lent.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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Probe type:
d ≤ 25 mm:
4.0 - 5.0 MHz, double crystal, straight beam probe. Crystal diameter: 10 - 35 mm.
Example: MSEB4 or SEB4 from GE.

d > 25 mm:
2.0 - 5.0 MHz, single crystal, straight beam probe. Crystal diameter: 22 - 28 mm.
Example: B4S from GE.

d = depth measured from the closest surface.

Note! The connecting rod must be tested with both probe types.

Reference reflector:
Ø3 mm cylindrical reflectors (side drilled holes).

Reference block:
The reference block must be made of defect free material equivalent to the component being
tested.

Reference level:
The echoes from the reference reflectors give the reference level by using the Distance-Amplitude-
Correction method (DAC curves).

Transfer correction:
If the shape of the test piece differs from the shape of the reference block, transfer correction
must be applied.

Couplant:
The couplant used for the testing shall be the same as used for calibration.

Scanning level:
The scanning level must be acceptance level plus at least 10 dB.
For acceptance level see table 1.

Evaluation level:
The evaluation level is acceptance level minus 6 dB.
For acceptance level see table 1.

Reporting level:
= Evaluation level.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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4.3. Magnetic particle testing

Magnetic particle testing must be carried out on the final machined connecting rod in accordance
with MAN B&W Standard EN602S: Magnetic particle examination, Procedure - normal technique.

If the linear indications found by magnetic particle inspection are unclear, they must be evaluated
by liquid penetrant (PT) inspection in order to verify whether the indications can be characterised
as structural inhomogeneity or as regular cracks or porosities, see subsection 5.2.2.

4.4. Penetrant testing

The penetrant testing must be carried out in accordance with ISO 3452: Non-Destructive Testing
- Penetrant Testing - General Principles.

4.5. Positional check of the lubrication oil bore

This inspection is only required for the connecting rods with flex hole design and must be per-
formed before the machining of the flex-holes.

To confirm that the position of the lubrication oil bore is within its tolerance, the position at the
point where it meets the oil groove must be checked. The tolerance for the lubrication oil bore is
given on the drawing.
It is recommended to perform this check using a tool that is inserted into the lubrication oil bore,
see figure 2. Position, with reference to the sides of the connecting rod and the edges of the con-
tact faces to the crankpin bearing cap, must be checked and reported.

Tool

Insertion of tool

Figure 2: Positional check of the lubrication oil bore using a tool.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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5. Acceptance criteria
The finished connecting rod has to fulfil the acceptance criteria stated on the relevant drawings
and in subsections 5.1 and 5.2.

A group of defects should be considered as one single cluster if the distance between them is less
than (the largest dimension of) the largest defect in the cluster.
The size of the cluster is the diameter (= C) of the smallest circle/sphere, which is able to encase
the cluster. The cluster must be judged as one single defect with the defect length C.
Two such clusters shall never be judged as one single defect, even if the distance between them
is less than the diameter of the largest cluster.

5.1. Subsurface defects

All defects less than or equal to evaluation level, see section 4.2, are to be ignored.

Any defect above the evaluation level must be further investigated and maximized.

The connecting rod is divided into 2 Quality Classes, see figure 3:

Quality Class A:
ƒƒ The area equal to a sphere with a diameter of 200 mm and center where the lubrication oil
bore meets the oil groove.
ƒƒ Additionally for the connecting rod with flex hole design: The first 50 mm surrounding the
flex-holes.

Quality Class B:
ƒƒ Remaining connecting rod.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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Conventional connecting rods

Connecting rods with flex hole design

Quality Class A
Quality Class B

Figure 3: Definition of Quality Classes.

Table 1: Max. acceptable equivalent reflector size (acceptance level).

Quality Class A B
d ≤ 25 mm Ø3 mm SDH -9 dB Ø3 mm SDH -6 dB
d > 25 mm Ø3 mm SDH -6 dB Ø3 mm SDH +0 dB
d = depth measured from the closest surface.
SDH = Side Drilled Hole.

Table 2: Max. acceptable length for defects with echo amplitude bigger than evaluation level
and less than acceptance level.

Defect depth d ≤ 25 mm d > 25 mm

Max. length of a single defect 10 mm 25 mm
For any 200 mm, in any direction, the total length
40 mm 80 mm
of defects must not exceed

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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5.2. Surface defects

The connecting rod is divided into 4 inspection zones, see figure 4:
ƒƒ Zone 1: Connecting rod with flex hole design only: All faces inside the flex-holes.
ƒƒ Zone 2: Rod area and transition to bearing heads.
ƒƒ Zone 3: Bearing heads.
ƒƒ Zone 4: Bearing bores and contact faces.

In general the surfaces must appear free from defects.

Zone 1
Zone 2
Zone 3
Zone 4

Figure 4: Zone definition.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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5.2.1. Definition of linear and non-linear indications

The following definition is used to distinguish between linear and non-linear indications:
ƒƒ Linear indication: An indication with a length at least three times the width.
ƒƒ Non-linear indication: Any other indication.

Note! Cracks are linear defects, which are not allowed.

5.2.2. Definition of structural inhomogeneity

1. The indication is visible on the surface.
2. The indication is linear.
3. The indication can be detected with MT.
4. The indication cannot be detected with PT.

Note! Always carry out penetrant testing very carefully. In case of doubt (e.g. if only part of the
indication can be detected with PT) the indication must be judged as an ordinary linear
defect and not as a structural inhomogeneity.

5.2.3. Acceptance criteria

All indications less than 1 mm are to be ignored. However, no visual cracks can be accepted.

Table 3: Acceptance criteria for surface defects.

Zone 1 2 3 4
Max. length of a single linear defect 1.0 mm 1.5 mm 1.5 mm 3 mm
Max. length of a single non-linear defect / struc-
1.5 mm 3 mm 5 mm 10 mm
tural inhomogeneity
Max. length of a single structural inhomogeneity
aligned longitudinal within ± 15º of the connecting 1.5 mm 5 mm - -
rod axis
For any 200 mm, in any direction, the total length
1.5 mm 15 mm 25 mm 35 mm
of defects must not exceed

6. Rectification of defects
Rectification of defects by grinding/machining must always be considered first as an alternative
to welding.

Note! Repair welding of recurrent (systematic) defects, which can be traced back to an incor-
rect forging technique, is not acceptable.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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6.1. Grinding
Unacceptable defects may be removed by grinding, but the finished connecting rod has to fulfil
the following acceptance level.

All transition roundings must appear smoothly rounded, see figure 5, polished and defect free.
There’s an exception for this rule on the bearing bores and contact faces (Zone 4), see section 6.1.1.
The surface roughness of the ground area must, as a minimum, fulfil the specifications for the finish
machined connecting rod, see applicable MAN B&W drawing.

Ground areas in Zone 2 must have an elliptical shape with a smooth bottom radius. The major axis
of the resulting ellipse must be parallel to the longitudinal axis of the connecting rod.

Grinding out in the transition roundings in Zone 2 is to be carried out in such a way, that the grind-
ing extends over a large area so that no local indentation occurs.

After removal of defects, the ground out area must undergo a magnetic particle test (MT) or pen-
etrant test (PT) to secure that no defects have been hidden during the grinding operation.

Table 4: Acceptance criteria for ground out defects.

Zone 1 2 and 3 4
Max. depth of grinding No grinding 3 mm 3 mm
Max. length of single defect to be removed No grinding - ≤ 1.5 x t
For any 200 mm, in any direction, the total
No grinding - 50 mm
length of ground out areas must not exceed
t = bearing shell thickness.

Handling of surface defects exceeding the above stated acceptance criteria are to be determined
individually from case to case.

Smooth Smooth
R R

R≥3×H

Figure 5: Recommended geometry of ground out area.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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6.1.1. Grinding on bearing bores and contact faces

On the bearing bores and contact faces, the extent of the ground out area must be minimized
while retaining a smooth bottom radius.

In the area at the distance of t, t = bearing shell thickness, to the edges and oil groove, rectification
by grinding is not allowed, see figure 6.

Figure 6: Area where grinding is not allowed on bearing bores.

6.2. Welding
Rectification of defects by grinding/machining should always be considered first as an alternative
to welding.

Rectification by welding must only take place when done in accordance with MAN B&W Production
Specification No. 0742825-9; Connecting Rod - Rectification of Defects.

Note! Rectification by welding in the flex-holes (Zone 1) and/or on the rod area and transition
to bearing heads (Zone 2) is not allowed.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

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Weld rectification should not be necessary during normal production. It is therefore very important
that the cause of the defect is found in every case. Repair welding of recurrent (systematic) defects,
which can be traced back to an improper forging technique, is not acceptable.

Defects caused by improper forging technique and practise may not be rectified and such a con-
necting rod must be rejected. If a defect or a cluster of defects exceeds the following dimensions,
it should also be considered as improper forging technique and rectification by welding is not
acceptable.

The max. allowable dimensions of the ground out area, which is made in order to rectify a defect
by welding, is as follows:
ƒƒ Depth: 10% of actual external diameter at the location of defect.
ƒƒ Length: 20% of actual external diameter at the location of defect, max 100 mm.

6.2.1. Subsurface defects in welds

Linear (planar) indications are not acceptable.

Scattered non-linear (volumetric) indications are acceptable, provided they do not exceed the
limits stated in table 5.

The weld must be scanned with both a normal probe and an angle probe, the angle probe must
be used to scan perpendicular to the sides of the weld groove.

Probe type:
ƒƒ 4 MHz normal probe and
ƒƒ 4 MHz angle probe where the ultrasonic beam hit perpendicular to the groove sides.

Table 5: Acceptance criteria inside welded area and the adjacent 15 mm.

Defect depth Entire weld

Max. acceptable equivalent reflector size Ø3 mm SDH -9 dB
Max. length of single defect 10 mm
For any 200 mm, in any direction, the total length
of defects must not exceed more than 7 % of the
40 mm
largest dimension of the welded area or the fol-
lowing length
SDH = Side Drilled Hole.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod
Quality Specification 0741673-1.5

Page 15 of 15

6.2.2. Surface defects on welds

Linear indications in weld material and surrounding Heat Affected Zone (HAZ) are not acceptable.

Scattered non-linear indications are acceptable, provided they do not exceed the limits stated in
table 6.

Table 6: Acceptance criteria for surface defects on welded areas and the adjacent 15 mm.

Zone 3 4
Max. length of single non-linear defect 3 mm 7 mm
For any 200 mm, in any direction, the total length
of defects must not exceed more than 7 % of the
15 mm 25 mm
largest dimension of the welded area or the fol-
lowing length

7. Certification/identification
Certificates from the classification society(ies) concerned, must be in accordance with their rules
and the requirements stipulated or referred to in this procedure, i.e. documenting the material
properties, the results of non-destructive tests, etc.

Each connecting rod must be marked with the supplier’s name, classification societies mark
and identification marks according to the Classification Societies rules, for the location of marks/
stamps, see figure 7.

For additional information regarding marks/stamps, see MAN B&W Production Specification No.
0742980-3; Marks and Stamps on Components for Two-stroke Diesel Engines.

Marking to be performed here

Figure 7: Location of marks/stamps.

Date Designer  Checked AC Revision change Revision

2018-02-13 LNU NWRA Z3 Requirements updated in connection with the new flex-hole-type 5

Copyright © 2018 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0741673–1. Forged Steel Connecting Rod