As 2574-2000 Non-Destructive Testing - Ultrasonic Testing of Ferritic Steel Castings

AS 2574—2000

AS 2574

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Australian Standard™ Non-destructive testing—Ultrasonic testing of ferritic steel castings

This Australian Standard was prepared by Committee MT/7, Non-destructive Testing of Metals and Materials. It was approved on behalf of the Council of Standards Australia on 16 June 2000 and published on 6 November 2000.

The following interests are represented on Committee MT/7: Australasian Railway Association Australian Aerospace Non-Destructive Testing Committee Australian Industry Group Australian Institute for Non-Destructive Testing

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Australian Nuclear Science & Technology Organization Australian Pipeline Industry Association Bureau of Steel Manufacturers of Australia Industrial Research Limited, New Zealand Institution of Engineers, Australia National Association of Testing Authorities, Australia New Zealand Non-Destructive Testing Association Society of Automotive Engineers — Australasia Test Safe Australia Victorian WorkCover Authority Additional interests participating in the preparation of this Standard: Division of Telecommunications and Industrial Physics, CSIRO Foundries Testing Companies

Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about Standards can be found by visiting the Standards Australia web site at www.standards.com.au and looking up the relevant Standard in the on-line catalogue. Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Australian Standard, has a full listing of revisions and amendments published each month. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at [email protected], or write to the Chief Executive, Standards Australia International Ltd, GPO Box 5420, Sydney, NSW 2001.

This Standard was issued in draft form for comment as DR 98197.

AS 2574—2000

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Australian Standard™ Non-destructive testing— Ultrasonic testing of ferritic steel castings

Originated as AS 2574—1982. Second edition 2000.

COPYRIGHT © Standards Australia International All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Published by Standards Australia International Ltd GPO Box 5420, Sydney, NSW 2001, Australia ISBN 0 7337 3473 1

AS 2574—2000

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PREFACE This Standard was prepared by the Joint Standards Australia / Standards New Zealand Committee MT/7, Non-destructive Testing of Metals and Materials, to supersede AS 2574—1982, Non-destructive testing—Ultrasonic testing of steel castings and classification of quality. The objective of this revision is to upgrade the requirements for the A-scan ultrasonic testing of ferritic steel castings that are 15 mm or greater in thickness.

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During this revision, cognizance was taken of the following Standards: ASTM A 609-91

Practice for castings, carbon, low-alloy, and martensitic stainless steel, ultrasonic examination thereof.

BS 6208:1990

Ultrasonic testing of ferritic steel castings including quality levels.

Currently there are no International Standards (ISO) published on the subject. Statements expressed in mandatory terms in notes to tables and figures are deemed to be requirements of this Standard. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance.

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AS 2574—2000

CONTENTS Page FOREWORD ..............................................................................................................................5

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SECTION 1 SCOPE AND GENERAL 1.1 SCOPE AND APPLICATION .....................................................................................6 1.2 REFERENCED DOCUMENTS ...................................................................................6 1.3 DEFINITIONS .............................................................................................................7 1.4 QUALIFICATION OF PERSONNEL..........................................................................8 SECTION 2 EQUIPMENT AND CALIBRATION 2.1 GENERAL ...................................................................................................................9 2.2 PRESENTATION ........................................................................................................9 2.3 ASSESSMENT OF HORIZONTAL AND VERTICAL LINEARITY .........................9 2.4 GAIN CONTROL ........................................................................................................9 2.5 FREQUENCY RANGE................................................................................................9 2.6 PROBES ......................................................................................................................9 2.7 OVERALL SYSTEM GAIN ........................................................................................9 2.8 RESOLUTION...........................................................................................................10 2.9 COUPLANTS ............................................................................................................10 2.10 CALIBRATION BLOCKS.........................................................................................10 2.11 REFERENCE BLOCKS.............................................................................................10 SECTION 3 METHOD OF TEST 3.1 GENERAL .................................................................................................................11 3.2 PREPARATION OF TEST SURFACES....................................................................11 3.3 PREPARATION FOR TESTING...............................................................................11 3.4 DETERMINATION OF ATTENUATION AND SUITABILITY FOR ULTRASONIC TESTING ........................................................................................12 3.5 PROBES ....................................................................................................................12 3.6 METHOD...................................................................................................................12 SECTION 4 IDENTIFICATION AND SIZING OF DISCONTINUITIES 4.1 GENERAL .................................................................................................................15 4.2 ULTRASONIC RESPONSE TO DISCONTINUITIES—CHARACTERISTIC RESPONSE................................................................................................................15 4.3 SIZING OF DISCONTINUITIES ..............................................................................15 SECTION 5 APPLICATION ZONES AND ACCEPTANCE CRITERIA 5.1 GENERAL .................................................................................................................17 5.2 ZONES OF CASTING ...............................................................................................17 5.3 ACCEPTANCE CRITERIA.......................................................................................18 5.4 ACCEPTANCE CRITERIA FOR WELD REPAIRS .................................................18 SECTION 6 PRESENTATION OF TEST DATA 6.1 RECORD OF TEST ...................................................................................................21 6.2 TEST REPORT ..........................................................................................................21

AS 2574—2000

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Page APPENDICES A PURCHASING GUIDELINES.....................................................................................23 B FACTORS INFLUENCING PROBE SELECTION......................................................24 C METHODS FOR THE DETERMINATION OF ATTENUATION AND TRANSFER LOSS..............................................................................................25 D SELECTION OF BEAM ANGLE FOR HOLLOW CASTINGS ..................................28 E COMPENSATION FOR CONVEX CURVATURE .....................................................29 F GUIDANCE ON THE NATURE OF DISCONTINUITIES, THEIR LOCATION AND IDENTIFICATION ........................................................................31 G PROCEDURES FOR THE SIZING OF DISCONTINUITIES .....................................50 H THE USE OF REFLECTIVITY DIAGRAMS..............................................................57 I EXAMPLES OF THE APPLICATION OF EVALUATION SENSITIVITY LEVELS TO CASTING ZONES..................................................................................59

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AS 2574—2000

FOREWORD The detection and the location of discontinuities in steel castings are facilitated if a grainrefining heat treatment and appropriate test surface preparation have been carried out.

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Where an adequate grain refining heat treatment has not been carried out, it is difficult to make a direct comparison of the ultrasonic response from a casting with that of a distanceamplitude curve (DAC) produced from standard fine-grained reference blocks, or to use recognized distance-gain-size (DGS) principles. In this case, alternative blocks, or sections of the casting itself, should be used to establish the test sensitivity. Ultrasonic testing of castings is carried out using compression wave (normal) probes, and shear wave (angle) probes where the geometry of the casting limits the effectiveness of normal probes. Indicated discontinuity sizes should not be taken as absolute in any assessment of serviceability of the casting. Ultrasonic testing can only produce an indication of the response of a discontinuity to ultrasound. The sizing techniques described in this Standard can, in some circumstances, underestimate the true size of small discontinuities.

AS 2574—2000

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STANDARDS AUSTRALIA Australian Standard Non-destructive testing—Ultrasonic testing of ferritic steel castings

S E CT I ON

1

S COP E

AND

GE NE RAL

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1.1 SCOPE AND APPLICATION This Standard sets out methods for the ultrasonic testing of specified areas of heat-treated ferritic steel castings that are 15 mm or greater in thickness, using A-scan presentation. It employs three evaluation sensitivity levels and divides the casting wall thickness into zones. NOTES: 1 Advice and recommendations on information to be supplied by the purchaser at the time of enquiry and order are contained in the purchasing guidelines set out in Appendix A. 2 This Standard does not apply to the testing of austenitic steel castings, unless by agreement, because such castings have a columnar structure which is not amenable to grain refining by heat treatment. 3 The level of evaluation of discontinuities is normally specified in relevant product Standards or is determined by agreement between the contracting parties after due consideration of the size, configuration and the service requirements of the casting. 4 Steel deposited during repair welding is deemed to be part of the casting. 5 This Standard does not include methods for the ultrasonic immersion testing of castings.

Procedures described in this Standard enable the test operator to determine the location, size, shape and often, the identification of discontinuities in all specified zones of heattreated steel castings. To enable the accurate sizing of discontinuities, castings should be machined or ground to provide optimum probe contact. For unmachined castings it is necessary that some form of surface preparation be carried out. The recording requirements and the acceptance criteria, as specified in Sections 3 and 5 respectively, may not apply to complicated castings where heavy indentations or shapes are to be produced by machining, e.g. gear teeth or splines, because the zone parameters (see Section 5) cannot be rigidly applied. NOTE: In such cases the recording/acceptance criteria is subject to negotiation between the purchaser and the supplier.

Although the methods outlined in this Standard are intended to be applied to heat-treated castings, they may be used on non heat-treated castings, by agreement, provided that it is recognized that some types of discontinuity may be difficult to detect in structures that have not been grain refined. In this case, an acceptance standard cannot be applied. For non heattreated castings, where direct comparison with standard fine grained calibration blocks, or the use of recognized distance-gain-size (DGS) principles, is not appropriate, alternative blocks, or sections of the casting itself, should be used to evaluate discontinuities. 1.2 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1929

Non-destructive testing—Glossary of terms

2083

Calibration blocks and their methods of use in ultrasonic testing

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AS 2574-2000, Non-destructive testing - Ultrasonic testing of ferritic steel castings

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