STORK: Stork Technimet, Inc. Testing + Product Evaluation + Fallure Analysis 2345 S. 170 Street Mr. Terry Schroeder New Berlin, Wisconsin 53151-2701 Masterdrive, Inc. USA North American Warehouse Telephone :(280) 760-044 W8622 Willis Ray Road Led jsoe Linge Whitewater, WI 53190-3800 Est, /Merelectcanet@stackcom Wetste —_awuechimstoam Report Report No. : 0108-02156-1 Date November 9, 2001 Subject: Material Specification for Gray and Ductile Iron Castings Dear Mr. Schroeder: As defined during our recent discussions and our meeting held on November 6, 2001, it was requested that a material specification be prepared for the sheaves, couplings and bushings manufactured from gray and ductile cast iron. It was stated that the gray iron parts should be manufactured from Class No. 30 Gray Iron, as this was similar to the Grade HT220 material defined in ISO 185, whereas the ductile iron parts should be made from Class 65-45-12 material. Based on our discussions, the material specification would reference standard ASTM specifications which would define the manufacturing controls required to produce the sheaves, couplings and bushings. In preparation of the specifications, the ISO 185, “Gray Cast Iron-Classification’, the ‘SAE J431, “Automotive Gray Iron Castings" and SAE J434, “Automotive Ductile (nodular) Iron Coatings” specifications were also referenced. If you have any questions concerning the material specifications, please call. Respectfully submitted, ct C Sow Craig C. Brown Metallurgical Engineering Manager nmb =, (SOMES 17028 cr ‘ehanteas — S0SEBSTORK: Stork Technimet, Inc. Testing Product Evaluation Failure Analysis 2345 S. 170th Street Mr. Terry Schroeder New Bern, Wisconsin 53151-2701 Masterdrive, Inc. North American Warehouse = (262) 782.6344 (00) 726-6365 (262) 782.3653 Stork [email protected] !watecnimetcom W8622 Wills Ray Road Whitewater, WI 53190-3800 Report No. 0108-02156-GI Spec. MATERIAL SPECIFICATION FOR GRAY IRON CASTINGS Craig C. Brown November 9, 2001 18s our policy to retain components and sample remnants for @ minimum of 30 days from the report date, after which time they may be lscarded. The data herein represents only the item(s) tested. This report shall not be reproduced, except in fl without prior permission of ‘Slork Technimet. Ee) SE ccc Page 1 of 5 PagesSTORI<’ : Stork Technimet, Inc. 1 SCOPE 1.1 This specification covers the manufacture of cast iron sheaves, bushings or similar parts. 1.2 The requirements of this specification are in addition to the requirements defined on the part drawing. In case of conflict between this specification and the part drawing, the requirements of the drawing take precedence. Il. REFERENCE DOCUMENTS 2.1. The following documents of issue in effect on the date of casting purchase form a part of this specification to the extent referenced in this material specification. Specification No. | Description ‘ASTM A 48* “Gray Iron Castings” ASTM A 247* “Evaluating the Microstructure of Graphite in Iron Castings” - “Steel Castings, Surface Acceptance Standards, Visual ASTM A 802 Senior “Common Requirements for Iron Castings for General eee Industrial Use” ASTMES “Tension Testing of Metallic Materials” ASTME 10 “Brinell Hardness of Metallic Materials” ASTM E 802" “Reference Radiographs for Gray Iron Castings up to 4-1/2 inches in Thickness” ASTME 1030" | “Radiographic Examination of Metallic Castings” “Included in appendix. lll. COMPOSITION 3.1. The chemical composition of the gray iron is subordinate to the mechanical properties, but the typical chemical composition of unalloyed iron should conform to the following ranges: Element Weight Percent Total Carbon 3.20-3.50 Silicon 4.90-2.30 Manganese. 0.60-0.90 Phosphorus 0.15 max. ‘Sulfur 0.45 max. ‘Approximate CE 3.94.2 CE=%C + 113% Si Report No. 0108-02156-GI Spec. November 9, 2001 Page 2 of 5 PagesSTORK” Stork Technimet, Inc. 3.2 3.3 3.4 3.5 Individual foundries may produce to narrower ranges than those shown in order to provide the specified material properties. Alloying elements such as chromium, copper, nickel, tin, molybdenum and other elements may be used to meet the mechanical properties and microstructure according to the section size of the casting. The modified chemical composition may also be agreed upon with the supplier. A lot of castings is defined in accordance with Section 10 of ASTM A 48. The chemical composition shall be determined by the supplier by analyzing samples produced at the time the castings are poured or from samples taken from castings. The sampling and methods for determining the composition shall be conducted in accordance with the requirements of ASTM A 834. IV. HEAT TREATMENT 44 42 The castings shall be in the as-cast condition unless a special heat treatment is specified by the part drawing or purchase order. In order to minimize distortion after machining of the parts in the as-cast condition, the castings may be stress relieved. V. MECHANICAL PROPERTIES. 51 5.2 5.3 54 5.5 Separately cast test blocks shall be used to qualify each production lot. The separately cast test blocks shall be manufactured and poured in accordance with Section 11 of ASTM A 48. As an option, the separately cast test blocks may be prepared in accordance with ISO 185, Section 6.1.1 The test blocks shall be subjected to the same thermal treatment as the castings they represent. Test specimens removed from the coupons must conform to the requirements of the Class No. 30 material as defined in Table 1 of ASTM A 48, The tension specimens shall be machined from the coupons at the designated locations and shall meet the dimensional requirements defined in ASTM A 48. Tension test specimens A, B and C shall be selected based on the critical section thickness of the castings that they qualify or as defined by the part drawings. The tension specimens may also be cut from castings to qualify each lot. The mechanical properties of the specimens cut from the castings shall meet the same requirements as the separately cast coupons. The tensile specimens shall be tested in accordance with ASTM E 8. The number of tests and retests shall be in accordance with Section 12 of ASTM A 48, Report No. 0108-02156-Gl Spec. November 9, 2007 Page 3 of 5 PagesSTORK” Stork Technimet, Inc. 5.6 5.7 5.8 Brinell hardness tests shall be conducted in accordance with ASTM E 10 at the location defined on the part drawing. After sufficient material has been removed from the casting surface to ensure a representative hardness reading, the parts shall have a Brinell hardness of 187 to 241. The material shall have a tensile to hardness ratio (t/h) minimum of 150 psi per kgf/mm? unless otherwise agreed upon with the purchaser, When requested by the purchaser, process capability studies shall be conducted to show that the hardness, tensile strength and tensile strength to hardness ratio requirements can be met. A minimum of 30 test specimens from separately cast test bars or from castings shall be used. The data should provide a Cpk value for each property, which must be 1.3 or larger. VI. QUALITY REQUIREMENTS 6.1 6.2 6.3 6A 6.5 Casting quality and inspection shall conform to the appropriate quality, workmanship and finish requirements of ASTM A 48 and A 834 and any other requirements specified on the part drawing or purchase order. Castings shall be free from shrinkage defects, hot tears, cracks, blow holes, porosity, foreign matter and other injurious discontinuities and must not disclose such defects during machining or subsequent testing. Casting surfaces shall be reasonably smooth and shall be free of scale and burned on sand. Runners, risers, fins, and other such cast-on pieces shall be removed and dressed down to blend with the normal profile of the casting surface. The surface discontinuities shall be evaluated in accordance with and meet the visual acceptance standards defined in ASTM A 802, Level 2. Magnetic particle inspection of prototype and pre-production castings, or production castings if required by the print, shall be conducted in accordance with ASTM A 834 supplementary requirement S1. This test method shall be used to qualify the manufacturing process prior to production release. Radiographic inspection of prototype and pre-production parts shall be in accordance with ASTM A 834 supplementary requirement $2. The radiographic evaluation shall be conducted in accordance with ASTM E 1030, E 802, E 446 and E 186. The acceptance criteria shall be defined on the part drawing. This test method shall be used to qualify the manufacturing process prior to production release. Any significant changes to the manufacturing process require requalification of the parts. As an alternative method of establishing internal soundness, representative castings may be destructively sectioned at multiple locations and the results submitted to Masterdrive Quality Department for approval. Casting dimensions shall meet the part drawing requirements. Report No. 0108-02156-Gl Spec. November 9, 2001 Page 4 of 5 PagesSTORK Stork Technimet, Inc. Vil. vill. Ix. 6.6 67 The microstructure of the castings shall be evaluated in accordance with ASTM ‘A 247 and shall consist of at least 80% Type A flake graphite with no more than 20% other types present. The flake size shall consist of greater than 80% size 3 orfiner. The matrix shall consist of ferrite and pearlite and the material shall not contain greater than 2% carbides or steadite. The microstructure should be uniform so as not to impact machinabilty The supplier shall afford Masterdrive Quality Department representatives all reasonable access to their facilities and the inspection, process, or test reports necessary to confirm that the material is being furnished in accordance with this specification and associated procurement requirements. REPAIR 7A Castings shall not be repaired by welding, brazing or peening without approval of Masterdrive, Inc. If specific permission is granted, any repair must be conducted in accordance with a qualified repair procedure and performed by qualified personnel. IDENTIFICATION 8.1 Unless otherwise specified, all castings shall be identified with a part number, ‘supplier identification (logo), and heat lot or date code. Additional requirements shall be in accordance with the part drawing and/or purchase order. The markings must be cast in raised letters unless otherwise noted on the drawing. CERTIFICATION 9.1 Acertificate stating that each lot has been sampled, tested and inspected in accordance with this specification shall be provided by the supplier. The certification must also include the chemical composition, tensile properties, hardness and tensile to hardness ratio for each lot of castings. When requested, the supplier shall furnish a certificate of microstructure. Report No. 0108-02156-GI Spec. November 9, 2007 Page 5 of 5 PagessToORK Stork Technimet, Inc. Testing Product Evaluation Analysis 2345 8. 170! Street New Beri, Wisconsin 63161-2704 Mr. Terry Schroeder Masterdrive, Inc. usa North American Warehouse Telephone: (262) 782-6344 W8622 Willis Ray Road Tate — Whitewater, WI 53190-3800 Eval Str tectmet@stocom Webste_wnmtecmtcom Report Report No. 0108-02156-DI Spec. MATERIAL SPECIFICATION FOR DUCTILE IRON CASTINGS Craig C. Brown November 9, 2001 Its our policy to retain components and sample remnants for @ minimum of 30 days from the report date, after which time they may be discarded. The data herein represen only the item(s) tested. This report shal not be reproduced, except in Tul, without prior permission of ‘Stork Technimet. Fae] 22 eens an Page 1 of 5 PagesSTORK 1. SCOPE 14 1.2 This specification covers the manufacture of cast iron bushings, couplings or similar parts. The requirements of this specification are in addition to the requirements defined on the part drawing. In case of conflict between this specification and the part drawing, the requirements of the drawing take precedence. ll. REFERENCE DOCUMENTS 24 The following documents of issue in effect on the date of casting purchase form a part of this specification to the extent referenced in this material specification. ‘Specification No. Description * “Evaluating the Microstructure of Graphite in ASTM A247" | tron Castings” ASTM A 536* “Ductile Iron Castings” ‘ASTM A834" __ | Common Requirements for Iron Castings for | *Steel Castings, Surface Acceptance ASTM A802" _| standards, Visual Examination” General Industrial Use” ASTME8 “Tension Testing of Metallic Materials” ‘ASTM E 10 “Brinell Hardness of Metallic Materials” ~ | ‘Reference Radiographs for Ductile Iron ASTME 689" | Cotings” » | "Radiographic Examination of Metallic ASTM E 1030° Castings” “included in appendix, lll. COMPOSITION 34 3.2 The chemical composition of the ductile iron is subordinate to the mechanical properties, but the typical chemical composition of unalloyed iron should conform to the following ranges: Element Weight Percent Total Carbon 3.20-4.10 Silicon 1.80-3.00 Manganese 0.10-1.00 Phosphorus 0.05 max. ‘Sulfur 0.02 max. Individual foundries may produce to narrower ranges than those shown in order to provide the specified material properties. The spheroidal graphite structure is produced by alloying the molten iron with small amounts of one or more elements such as magnesium or cerium, Report No. 0108-02156-DI Spec. November 9, 2007 Page 2 of 5 PagesSTORK” Stork Technimet, Inc. 3.3 3.4 3.5 A modified chemical composition may also be agreed upon with the supplier. A lot of castings is defined in accordance with ASTM A 834, Section 8. The chemical composition shall be determined by the supplier by analyzing samples produced at the time the castings are poured or from samples taken from castings. The sampling and methods for determining the composition shall be conducted in accordance with the requirements of ASTM A 834, Iv. HEAT TREATMENT 441 42 The castings shall be in the as-cast condition or may be given a normalize and temper to meet the requirements for Grade 65-45-12, unless a special heat treatment is specified on the part drawing or purchase order. In order to minimize distortion after machining of the parts in the as-cast condition, the castings may be stress relieved. V. MECHANICAL PROPERTIES 5.1 5.2 5.3 54 5.5 5.6 5.7 Separately cast test blocks shall be used to qualify each production lot. The separately cast Keel blocks or Y Blocks shall be manufactured and poured in accordance with ASTM A 536, Section 6. The size of the Y Block shall represent the section thickness of the castings unless otherwise approved. The test blocks shall be subjected to the same thermal treatment as the castings they represent. Test specimens removed from the coupons must conform to the requirements of the specified grade defined in Table 1 of ASTM A 536. The tension specimens shall be machined from the coupons at the designated locations and shall meet the dimensional requirements defined in ASTM A 536. The tension specimens may also be cut from castings to qualify each lot. The mechanical properties of the specimens cut from the castings shall meet the same requirements as the separately cast coupons. The tensile specimens shall be tested in accordance with ASTM E 8. The number of tests and retests shall be in accordance with ASTM A 36, Section 10. Brinell hardness tests shall be conducted in accordance with ASTM E 10 at the location defined on the part drawing. After sufficient material has been removed from the casting surface to ensure a representative hardness reading, the parts shall have a Brinell hardness of 156 to 217. When requested by the purchaser, process capability studies shall be conducted to show that the hardness, tensile strength, yield strength and percent elongation Report No. 0108-02156-DI Spec. November 9, 2007 Page 3 of 5 Pages _STORK? _ _ Stork Technimet, Inc. requirements can be met. A minimum of 30 test specimens from separately cast test coupons or form castings shall be used. The data should provide a Cpk value for each property, which must be 1.3 or larger. VI. QUALITY REQUIREMENTS 64 6.2 6.3 6.4 65 6.6 67 Casting quality and inspection shall conform to the appropriate quality requirements of ASTM A 536 and A 834 and any other requirements specified on the part drawing or purchase order. Castings shall be free from shrinkage defects, hot tears, cracks, blow holes, porosity, foreign matter and other injurious discontinuities and must not disclose such defects during machining or subsequent testing. Casting surfaces shall be reasonably smooth and shall be free of scale and burned on sand. Runners, risers, fins, and other such cast-on pieces shall be removed and dressed down to blend with the normal profile of the casting surface. The surface discontinuities shall be evaluated in accordance with and meet the visual acceptance standards defined in ASTM A 802, Level 2. Magnetic particle inspection of prototype and pre-production castings, or production castings if required by the print, shall be conducted in accordance with ASTM A 834 supplementary requirement S1. This test method shall be used to qualify the manufacturing process prior to production release. Radiographic inspection of prototype and pre-production parts shall be in accordance with ASTM A 834 supplementary requirement S2. The radiographic evaluation shall be conducted in accordance with ASTM E 1030, E 689, E 446 and E 186. The acceptance criteria shall be defined on the part drawing. This test method shall be used to qualify the manufacturing process prior to production release. Any significant changes to the manufacturing process require requalification of the parts. As an alternative method of establishing internal soundness, representative castings may be destructively sectioned at multiple locations and the results submitted to Masterdrive Quality Department for approval. Casting dimensions shall meet the part drawing requirements. The microstructure of the castings shall be evaluated in accordance with ASTM A 247 and shall consist of at least 85% spheroidal graphite conforming to Type | and II. The nodule count shall be greater than 150/mm? in all sections less than 2". The matrix shall consist of ferrite or ferrite and pearlite and the material shall not contain greater than 2% carbides or steadite. The microstructure should be uniform so as not to impact machinability. The supplier shall afford Masterdrive Quality Department representatives all reasonable access to their facilities and the inspection, process, or test reports necessary to confirm that the material is being furnished in accordance with this specification and associated procurement requirements. Report No. 0108-02156-DI Spec. November 9, 2001 Page 4 of 5 PagesSTORK Stork Technimet, Inc. Vil. REPAIR 7.4 Castings shall not be repaired by welding, brazing or peening without approval of Masterdrive. If specific permission is granted, any repair must be conducted in accordance with a qualified repair procedure and performed by qualified personnel. Vill. IDENTIFICATION 8.1 Unless otherwise specified, all castings shall be identified with a part number, supplier identification (logo), and heat lot or date code. Additional requirements shall be in accordance with the part drawing and/or purchase order. The markings must be cast in raised letters unless otherwise noted on the drawing. IX. CERTIFICATION 9.1 Accertificate stating that each lot has been sampled, tested and inspected in accordance with this specification shall be provided by the supplier. The certification must also include the chemical composition, tensile properties and hardness for each lot of castings. When requested, the supplier shall furnish a certificate of microstructure. Report No. 0108-02156-DI Spec. November 9, 2007 Page 5 of § Pagesi Designation: A 48 - 94a‘ apn om Sl oak ASTM ai Sagi ATH Standard Specification for Gray Iron Castings" “his snared nderthe fed eigaation A; the munberinmailyfloing the desinato indict the year of igi ‘eye sdopon of in theese feiss psn (9 nee ner at eso. Ananbernpreateses indents be Yu ast appeal Arapemesist ge ic the lt revlon or eappval ‘hs standart has bon approved forse by egret of the Deparment of Defoe. Tis specication plas Federal Speco core, {© Nore Nowe | war aed eerily ia Soper 9, Scope LLL This specification covers gray iron castings intended for general engineering use where tensile strength is a major consideration. Castings are classified onthe basis of the tensile strength of the iron in separately cast test bars. LICL This specification subordinates chemical composition to tensile strength, 1.2 Castings produced to this specification are graded on the basis of minimum tensile strength obtained in special test ‘coupons designed to standardize cooling rate. The tensile strength developed in certain casting sections may vary from test coupon values (eee X1.2). 1.3 The values stated in inch-pound units are to be regarded fas the standard, The values given in parentheses are for information only. Nort |The text ofthis standard reference oles nd footnote which provide explanatory materia. These notes and fomotes (excusing those fn tables and figures) shall not be considered st oqsicements ofthe andar, 2. Referenced Documents 2.1 ASTM Standards: ‘A644 Terminology Relating to Tron Castings? E8 Test Methods for Tension Testing of Metalic Materials? 22. Military Standard: MIL-STD-129 Marking for Shipment and Storage! 23. Federal Standart! Federal Standard No, ‘Agencies)* 123 Marking for Shipment (Civil 3. ‘Terminology 3.1. Definitions 3.1.1 Definitions for many terms common to gray iron "Ti pcan i adr he juin f ASTM Cove Ao ton Casings an ithe die responsiblity of Subcomminze AOKOI oa Gay Ion Cosa ‘Cactcéion approved July 15,194, Published Sepenber 198. rial pulsed as 4806, Lat previous eon A 4894. "anual Boo of ATH Sonia, a 1.02 2 dnl Book of ASTM Sander, ol 03. + hb om Stndartatin Damen Order De, Bl 4 Stn D, 700 ‘Robbins Ave, Pidepin, PA 1911-094, ts NPODS. castings are found in Terminology A 644. 4, Classification 4.1 Castings ordered and produced in accordance with this specification are clasified into a numberof grades based on the properties of separately cast test bars (Table 1). Each class is designated by a number followed by a letter The number indicates the minimum tensile strength of the separately cast test bar, and the letter indicates the size of the test bar. ‘Examples of proper designations are as follows: Gray Iron Castings, ASTM Specification A 48, Class 30B. Gray Iron Castings, ASTM Specification A 48, Class 40C. 8. Ordering Information ‘1 Ordets for material to this specification shall include the following information: 5.1 ASTM designation mumber and year of issue, 5.1.2 Class of iron required (see 4.1 and Table 1), 5.13 The size of the separately cast test bar (letter classification—A, B, C, or S) that best represents th thickness of the controlling section ofthe casting (see Table 2), 5.1.4 The tension test specimen (B or C) to be machined from test bar C (see 13.3, Table 3, and Fig. 1), ‘5 The tension test specimen to be machined from test bar $ (see 13.4, Table 3, and Fig. 1), 5.1.6 Lot size (see Section 10), 5.17 Special requirements (see Section 6), 5.1.8 Saving tested specimens or unbroken test bars (see 15), and 5.1.9 Special preparation for delivery (see Section 19) 6, Special Requirements 6.1 When agreed upon in writing between the manufacturer and the purchaser, it may be necessary for the castings to meet special requirements as to hardness, chemical composition, ‘microstructure, pressure tightness, radiographic soundness, dimensions, surface finish, etc. 17. Tensile Requirements 7.1 Test bars representing castings conforming to ths speci- fication shall meet the requirements for tensile strength as ‘described in Table 1.Qh Aas Strength of Gray Cast rons B ‘Ban Norn Tat Bar ‘lee, We aA 88 2.4 Neze 12005) Ne206 20 (08) Ne 208 Bans No.254, 254173 88 224 ho 258 12005) Ne 356 20 (803) e258 Bans Na.20A, 30200 0.98 224 hone 12605) Nea0e 20 (803) Ne308 Basse Naas 3524 088 224 Noasa $305) Nease 20,608) noass Bans Nason 006) as 2) Ne a08 209) Aewe 206608) heaos eens a 45 45010 ase 22.4) Nes 8 ‘Szrans) hease 206608) hades Bess a 504 04s) a8 2.4) No. 508 szans) hee 20 eu) Ness Bess a 554 507) ase 24) Nessa zens) Ns 556 20 (08) Ne 558 Bonet No goa soar) 98 22.4 Noes 12005) Nooo zo (en) Nees Bos s* “a amersanseastbaS shale a agreed pon behven te manuBOTer nd te pochase Specie TABLE? Separately Cast Test Bars for Use Wh st Bor and Correlation Has Not Been Established Between the the Casting Trees fe Wala the Contating Sect of te Cong. (rn) der 25 (6) = n2st0080 (61 12) a O51 t 1.00 (131025) e 11261050) rar (5) 8, Dimensional Requirements 8.1 The castings shall conform to the dimensions or draw- ings furnished by the purchaser, or, there are no drawings, to the dimensions predicted by the patter equipment supplied by the purchaser. 9. Workmanship and Winish 9.1 The surface ofthe cating shall be fice of adhering sand, scale, cracks, and hot tears, as determined by visual examing tion. 9.2 No repairing by plugging or welding of any kind shall be permitted unless written permission is granted by the purchaser, 10. Sampling 10.1 A Lot shall consist of one of the following: 10.1.1 All the metal poured from a single heating in a batch type melting furnace. 10.1.2 All the metal from two or more batch type melting furnaces poured into a single ladle or a single casting. 10.13 All the metal poured from a continuous melting furnace for a given period of time between changes in charge, processing conditions, or aim-for chemistry or 4, whichever is the shorter period 1013.1 The purchaser may agree to extend the 4-h time period to 8 h if the manufacturer can demonstrate sufficient process control to warrant such an extension. AL, Cast Test Bars 11.1 Test bars shall be separate castings poured from the same lot as the castings they represent and shall have dimen- sions as shown in Table 3. Allowance may be made for seasonable pattern draft within th tolerances shown in Table 3 ‘Test bars A, B, and C are all standard test bars in the form of simple cylinders. Test bar Sis special and is intended for use where the standard bars are not satisfactory. 11.2 The test bars shall be cast in dried, baked, or chemi- cally bonded molds made mainly of an aggregate of siliceous sand with appropriate binders. The average grain size of the sand shall approximate that of the sand in which the castings sare poured. Molds for the test bars shall be approximately at oom temperature witen poured. More than one test bar may be cast in a single mold, but each bar in the mold shall be surrounded by a thickness of sand which is not less than the iameter of the bar. A suitable design for a mold is shown in Fig. 2. [Nore 2—Theintat of thse provisions is as flows: to roibit the casting of test bars in molds of metal, grapite, zcon, light-weight ‘sggregates, or other materials which woul significantly aft he tensile strength ofthe io to probit contol of tensile stength ofthe et bare ‘by manipulation of the grin sizeof the sand; and to rohit the easing of text bare in mols prebested substantially above room tempest, 11.3 Test bars that ae intended to represent castings that are cooled in the mold to less than 900°F (480°C), before shakeout, shall be cooled in their molds toa temperature less than 900°F (480° C). They then may be cooled in sill air to room temperature. 11.4 ‘Test bars thatare intended to represent casings thet are hotter than 900°F (480° C), when shaken out of their molds, shall be cooled as described in 11.3 or (by agreement between, the manufacturer and the purchaser) may be shaken out of their ‘molds at approximately the same temperature as the castings ‘they represent 11S When castings are stress-elieved, annealed, or other- wise heat-treated, test bars shall receive the same thermal treatment and shall be treated adjacent to the castings they represent.Qh A 48 TABLE 3. Diameters and Lengths of Cast Test Bare ‘Acca Diamant) Length ne) Test Bar onal ‘imam Tamim Ron Mima (tom) | Mam (9) = ee x 085 2.4) oa aa Taree ‘50 (135 “301155 a $20 008) Goo) ia, 80118) 8.0130) &, 20 08} +80 (403) 201683), 70 (17) 100258) "id aearsans oat ba hall eas agaed upon byt maroc onde prea a | Jc Ros Tio Tat Tn Tek Tension Tent Dimension, frm) Specimen Spearman 8 Spoaimen © GLangh of paral min a0 79), 075.40) 1256, Dime Ais 2 0010 750 = ons 125 does (a7 2025) (gas =4) (G17 = 0050) ‘AR ofa, in 125) 108) 2060 ‘Leng of recat acon, min vasa) raga) een ‘Coveraterge, mie 209) 49) 4 (160) {Golamstr of end teten appro ‘wean tet) taun Ectongh of shut, in 48) % @ amet of hotsor ve ie hes Me ins ie (ese9 gas, geo) Lang of ane sation "opioralio heli on eing machine WWresi0d, rok Gale sal ot bo ess an dnanson F FIG, 1 Tonsion-Test Spacimens 12, Number of Tests and Retests 12.1 The tension test shall be conducted in accordance with ‘Test Method E 8. 122 One tension test shall be performed on each lot and shall conform to the tensile requirements specified 12.3 If the results of a valid test fail to conform to the requirements ofthis specification, two retests shall be made. If either retest fails to meet the specification requirements, the castings represented by these test specimens shall be rejected. A valid test is one wherein the specimen has been properly prepared and appears to be sound and on which the approved ‘est procedure has been followed. 124 Ifsuficient separately cast test pieces are not available, the manufacturer shall have the option of removing a test specimen from a location of representative casting, as agreed ‘upon between the manufacturer and purchaser. 125 If the frst test results indicate that a heat treatment is needed to meet the test requirements, the entire lot of castings and the representative test specimens shall be heat treated together. Testing shall proceed in accordance with 12.1-123. 126 If, ater testing, a test specimen shows evidence of a defect, the results of the test may be invalidated and another made on a specimen from the same Tot. 13. ‘Tension Test Specimens 131 For test Bar A, the tension-test specimen A, as shown in Fig. 1, shall be machined concentric with the axis of the test ba. 13.2 For test Bar B, the tension test specimen B, as shown in Fig. 1, shall be machined concentric with the axis ofthe test bar, 133 For test Bar C, tension test specimens B or C, as shown, in Fig. 1, shall be machined concentric with the axis of the test ‘ar. Unless the size ofthe tension tet specimen to be machined from test bar C is specified in writing by the purchaser, the pve fas ASTM Henguarers 4 Onde PON 1750802122 2 Ones PON 1750800222 * er ON 1750800822 1 3, Terminology 3.1 Definitions —Foe definitions of terms used in this docu- ment, see Terminology F 1316, Section D. 4, Significance and Use 4.1 These reference rediograp, along with the referenced applicable steel casting standards (Reference Radiographs E186 and E446), are supplied as a means of establishing categories and severity levels of common intemal discontinuity types in gray iron castings subjected to radiographic examin tion, They may be used in accordance with contractual speci- fications as agreed upon between purchaser and supplies “42 The use of this standard is not intended to be restricted to the specific energy level or to the absolute thickness limits that ae contained in this standard title. The tite is intended to be descriptive and not restrictive. This document may be used, where there is no other applicable document, for other energy levels or thicknesses, or both, for which it is found to be applicable and for which agreement has been reached between ‘purchaser and supplier 5, Method of Preparation 5.1 The original radiographs used to prepare the accompa- ying roference radiographs were produced on high contrast fine-grain film by the respective use of radiation energies stated in LL.1-1.13. The radiographs were made with a penetrameter sensitivity a8 determined by ASTM penetrameters (see Guide E94) of 2-27. The reproductions have been prepared to an HAD density from 2.00 to 2.25 and they have retained substantially the contrast ofthe original radiographs. 5.2 Film Deterioration—Radiographic films are subject to ‘wear and tear from handling and use. The extent to which the image deteriorates over time is a function of storage condi- tions, care in handling and amount of use. Reference radio- ‘graph films are no exception and may exhibit a loss in image ‘quality over time. The radiographs should therefore be peri- codically examined for signs of wear and tear, including soratches, abrasions stains, and so forth. Any reference radio- ‘graphs which show signs of excessive wear and tear which ‘ould influence the interpretation and use of the radiographs should be replaced. 6, Determination of Radiographic Classification 6.1 For purposes of evaluation of castings, @ determination@p E802 ‘must be made of the radiographic clasifcation to be assigned to individual castings or specific areas of castings. The deter- rmination of the applicable radiographic-severty classification shall be based on an evaluation of the casting applications, design, and service requirements. In these evaluations, consid- rations shall be given to such factors as pressure, temperature, section thickness, applicable design safety factor, vibration, shock, resistance to cortosion, involvement of penetrating zadiations or radiation products, and involvement of dangerous ‘Bases or liquids. [Nore 1—The radiographic definition ofthe defect llusated will vary sccorlng tothe energy levels ofthe sources employed in the adiography. 17. Classification Specifications 71 The applicable radiographic severity level should be esignated for each discontinuity type by the contracting ‘agency in formal specifications or drawings and in the specific ‘contract or order. For castings, the level should be indepen- dently specified for each discontinuity type, since they have been shown to affect strength properties differently. For ex- ample, in the same casting severity level 2 might be specified for shrinkage Type 3 and severity level 4 for gas porosity Type 1, The specifications, drawings, contact, or order should also ‘designate the sampling plan forthe castings to be radiographed and the extent and quality level of the radiographic coverage. 8, Procedure for Evaluation 8.1 Compace radiographs ofthe casting submited for evalu- ation with the zeference radiographs applicable to the section thickness and the source used ‘82 When a particular class or severity is ealled for and the radiograph being evaluated is equal to or better than the reference, indicate the cating as radiogrephicelly acceptable. If the radiograph shows a discontinuity of greater severity than the reference radiograph, the casting shall be rejected, 83 When two or more types of discontinuities are present in ‘he same radiograph, the predominating ones if unacceptable, shall govern without regard to the other types of dscontini- ties. 84 When two or more categories of discontinuities are present to an extent equal othe maximum permissible level, as ‘shown inthe pertinent standards for each category, then that part ofthe casting shall bo judged unacceptable until stistac- torly epated, if permissible 8.5 In general, there i no limit with regard to the extent of scooptable discontinuities ina casting, provided that no 5 by Tin. (127 by 178-mm) area throughout the casting contains discontinuities that exceed those indicated on the minimum acceptable refecence radiographs ‘86 Where the reference image consists of a collection of Aiscontinuites, as inthe case of porosity, for example, accept ability may be based on the aggregate sizeof te discontinui- ties present on both the reference radiograph and the object radiograph, the maximum defect size present, the spacing between discantinuitos, or a combination of these or other criteria. These exter must be determined based upon the particular application o part under consideration and must be specified by agreement between the purchaser and supplier 9. Keywords 9.1 castings; discontinuities; gamma ray; gray iron; refer- cence radiographs; X-ray “th Amarcan Soc for Teng nd Mas ito ro postion respecting th vat of an pat igs ssrted in conection wih any tm manson nis standard User of isn are express ased at teria of eval ay auch Datet da ond eh ining of auch a, are oneeta om responsi. ‘Ths stander i subi revision a any int he respons tein! commits and st bo aomad every fe yer and ‘reatensed eer remproved rman. Your comment arf aero osion of is sacra aoa ada lint shoul bo aafonsod © ASTM Headutar Your commas nil ecto cartuconseaion af mesg of responsible ‘Sbncal conte, wich ou may ston yo al hat your conmans avert recived a boing ou shoud mae our wo now tte ASTI Gorn on Standards, be aeess shown baw. ‘is standard copyighed by ASTM, 100 Bar Harbor Dive, PO Box 6700, West Conshahackan, PA 1848-269, Und Sits, India! rope fara or maple copies) of bis Sandard may bs hated by contacting ASTM atte above ads o” a (10-8220585 (phone) 10822-688(), srrcaGasin og (oma or rough the AST websie (wasn afy Designation: E 1030-95 Standard Test Method for Radiographic Examination of Metallic Castings* “This sada ised under th fed esgaonB 103; he stn inmeay flowing the dexgnton nets te yee of ‘ia loon oa theese fein yn les revise, A sambern preteen nae the Ya of ast epptva A ‘Spersipt plon () atcts a tr hags sine telat evison or eapyovl L. Scope 11 This test method? provides uniform procedure for radiographic examination of metallic castings using radio- graphic film as the recording medium. 1.2 Due to the many complex geometries and part configu- rations inherent with cast products, it is necessary to recognize potential limitations associated with obtaining complete radio- ‘graphic coverage on castings. Radiography of areas where ‘geometry or part configuration does not allow achievement of ‘complete coverage with practical radiographic methods shall bbe subject to mutual agreements between purchaser and supplier. The use of alternative nondestructive methods for areas that are nat conducive to practical radiography shall also be specifically agreed upon between purchaser and supplier. 113 The radiographic method is highly sensitive to volumet- ric discontinuities that displace a detectable volume af cast ‘material. Discoatinuities that do not displace an appreciable volume of material, however, such as cracks ot other planar- type indications, may not be detected with radiography unless the radiation beam is coincidentally aligned with the planar crientation of the discontinuity. In view of this limitation, it ‘may be considered appropriate to use the radiographic method in conjunction with additional nondestructive methods that rmaintain reliable detection capabilities for these types of discontinuities. The use of additional methods shal be specif- cally agreed upon between the purchaser and supplier. 114. The values stated in inch-pound units are to be regarded as standard. 1.5. This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appro- priate safety and health practices and determine the applica- bility of regulatory limitations prior to use. 2, Referenced Documents 2.1 ASTM Standards: Ths wot method is ander te juinision of ASTM Commitee 6-7 08 Nonderrucve Teng ands the det responsi of StbcommiteeB7.01 oe Radlogy Qc sl Gam) Meta ‘Cureton approved Sept 10 1995, Publhed November 1985, rill pita mB 103084, Last pesos eon B1030~ 91. For ASME Bote sd fru Vestel Cate spplcaans see reed Test Metiot SE1050 i Soin If tat Coe E94 Guide for Radiographic Testing? 31 Miied x Coating Quality of Radiographic Tests E155 Reference Radiographs for Inspction of Aluminum ‘and Magnesium Castings E 186 Reference Radiographs for Heavy-Walled (2 to 4¥A- ‘in, (51 to 14mm) Steel Castings? E 192 Reference Radiographs of Investment Steel Castings ‘for Aerospace Applications? E272 Reference Radiographs for High-Strength Copper- ‘Base and Nickel-Copper Alloy Castings? E280 Reference Radiographs for Heavy-Walled (4¥4 to 12-in, (114 to 305-mm)) Steel Castings? E310 Reference Radiographs for Tin Bronze Castings? E446 Reference Radiographs for Steel Castings Up to 2 in. (S1 mm) in Thickness? E505 Reference Radiographs for Inspection of Aluminum ‘and Magnesium Die Castings? 543 Practice for Evaluating Agencies that Perform Non- destructive Testing? E689 Reference Radiographs for Ductile Iron Castings? E746 Test Method for Determining Relative Image Quality ‘Response of Industral Radiographic Film? E747 Practice for Design, Manufacture and Material ‘Grouping Classification of Wire Image Quality Indicators (1QN Used for Radiology? 802 Reference Radiographs for Gray Iron Castings Up to 414 in, (114 mm) in Thickness? E999 Guide for Controlling the Quality of Industrial Ra- diographic Film Processing? E1025 Practice for Design, Manufacture, and Material (Grouping Classification of Hole-Type Image Quality Indi- ‘ators (IQN) Used for Radiology? E1254 Guide for Storage of Radiographs and Unexposed Industrial Radiographic Film? E1316 Terminology for Nondestructive Examinations? 22 ASNT/ANSI Standards: Recommended Practice No, SNT-TC-1A “Personnel Quali fication and Certification in Nondestructive Testing™ * dame Book ef AST Standart Xl 0.03 * Artble om the Ameen Seca fr Nooletsve Tess, (ASNT), 171 Angst Psa, PO. Bex 2851, Calm, OF 322qh € 1030 CP-189 Qualification and Certification of Nondestructive Testing Personnel 23. Military Standard: ‘MIL-STD-410 Nondestructive Testing Personnel Qualifica- tion and Certification? 3. Terminology 3.1 Defintions—Foe definitions of terms used in this test method, see Terminology E 1316. 4, Significance and Use 4.1 The requirements expressed in this test method are intended to control the quality ofthe radiographic images, to produce satisfactory end consistent results, and are not in- fended for controlling the acceptability or quality of materials or products, ‘5. Basis of Application 5.1 The following items shall be agreed upon by the purchaser and supplier: S.L.l Nondestructive Testing Agency Evaluation—If speci- fied in the contractual agreement, nondestructive testing (NDT) agencies shall be qualified and evaluated in accordance with Practice E543. The applicable version of Practice E $43 shall be specified in the contractual agreement. ‘S.L.2 Personnel Qualifcation—NDT personnel shall be (qualified in accordance with a netionelly recognized NDT personnel qualification practice or standard such as ANSI/ ASNT-CP-189, SNT-TC-1A, MIL-STD-410 or a similar docu- ‘ment, The practice or standard used and its applicable revision shall be specified in the contractual agreement between the using partis. 5.1.3 Reguirements—General requirements (see 8.1, 82, 85, and 8.7.4) shall be specified. 3.1.4 Procedure Requirements (eee 9.1, 9.1.1, 93, and 9.7.0) shall be specified 3.1.5 Records—Record retention (see 12.1) shall be speci- fed, 6. Apparatus 6. Radiation Sources: G11 X Radiation Sources—Seletion of appropiate Xray voltage and curent levels is dependent upon variables regard- ing the specimen being examined (material type and thickness) and economically permissible exposure time. The suitability of these Xray parameters shall be demonstrated by atainment of sequired peneameter (0) sensitivity and compliance with all other requirements stipulated herein, Guide E94 contains provisions concerning exposure calculations and charts forthe tse of Xray sours. 6.12 Gamma Radiation Sources—Isotope sources, when used, shall be capable of demonstating the required radio- ‘raphic sensitiv. 62 Film Holders and Cassettes—Film holders and cassotes sill be lighttight and shall be bended propery to reduce the * Avalube lm Staariaon Dacunents Orde Desk, lg 4 Sesion D, 700 Robins Ave, Paladin, PA 1911-5086, At NPODS. hood that they may be damaged. They may be flexible vinyl, plastic, or any durable material; or, they may be made from metallie materials. In the event that light leaks into the film holder and produces images on the film extending into the area of interes, the film shall be rejected. If the film holder exhibits light leaks, it shall be repaired before reuse or discarded. Film holders and cassettes should be routinely examined to minimize the likelihood of light leaks. 63 Intensifying Screens: 63.1 Lead:Foil Sereens: 63.1.1 Intensifying screens of the lead-oil type are gener- ally used forall production radiography. Lead-fol soreens shall be of the same approximate area dimensions as the flm being used and they shall be in direct contact with the film during exposure, 63.1.2 For X-ray voltages between 200 KV and 1 MeV, ‘front and rear sereen thicknesses shall be a minimum of 0.005 in, (0.127 mm) thick. Below 200 KV, front screen thicknesses ‘up to 0.005 in, and rear screen thicknesses of atleast 0.005 in, should be used if they improve radiographic quality. For isotope and high-voltage X-radiography (greater than 1 MeV) increased thicknesses may be appropriate for improvements in zadiographi quality and should be used accordingly. Interme- diate screens (between muliloaded film) may be used if desired, 63.1.3 Sheet lead, with or without backing, used for screens should be visually examined for dust, dic, oxidation, cracking or creasing, foreign material or other condition that could ender undesirable nonrelevant images on the film. 63.2 Fluorescent or Fluorometallic Screens: 63.2.1 Fluorescent or luorametallic screen may be used. However, they must be capable of demonstrating the required penetrameter [QD sensitivity. 63.2.2 Sereen Care—All screens should be handled care- fully to avoid dents, scratches, grease, or dist on active surfaces, Sereens that render false indications on radiographs shall be discarded or reworked to eliminate the artifact 64 Filters—Filters shall be used whenever the contrast reductions caused by low-energy scattered radiation or the cextent of undereut and edge burn-off occurring on production radiographs is of significant magnitude so as to cause failure to. ‘meet the quality level or radiographic coverage requirements stipulated by the job order or contract (see Guide E 94). 65 Masking—Masking material may be used, as necessary, to help reduce image degradation due to undercutting (see Guide E94) 6.6 Penetrameters (IO)—Unless otherwise specified by the applicable job order or contract, only those penetrameters that comply with the design and identification requirements speci- fied in Practice E747 or Practice E 1025 shall be used. 61 Shims and Separate Blocks—Shims or separate blocks ‘made of the same or radiographically similar materials (as defined in Method E 142) may be used to facilitate penetram- ter positioning, There is no restriction on shim or separate block thickness provided the penetrameter and area-of-interest density tolerance requirements of 9.7.6.2 are met. 68 Radiographic Location and Identification Markers— Lead numbers and leters are used to designate the part numberi) E1030 and location number, The size and thickness of the markers shall depend on the ability of the radiographic technique to ‘image the markers on the radiograph. As a general rule, rmarkers Ye in, (1.58 mm) thick will suffice for most low ‘energy (less than 1 MeV) X-ray and Iridium-192 radiography; for higher energy radiography it may be necessary to use markers that are 4 in. (3.17 mm) or more thick. (69 Radiographic Density Measurement Apparatus—Either fa transmission densitometer or a step-wedge comparison film shall be used for judging film density requirements. Step wedge comparison films or densitometer calibration, or both, shall be verified by comparison with a calibrated step-wedge film traceable to the National Institute of Standards and ‘Technology. 7, Reagents and Materials 7. Films—Definte rules on selection of films cannot be ssven since choice depends on such factors as the required radiographic quality level and the maximum economically ‘permissible exposure time. In any case, the films selected must ‘be capable of demonstrating the required penetrameter (IQ1) sensitivity. [Nore I—Test Method B46 provides a method for detemsining the relative image quality responte of adustral radiographic fm and may be ‘wed a the basis far fil selection, 8, Requirements 8.1 Procedure Requirement—Unless otherwise specified by the applicable job order or contract, radiographic examination shall be performed in accordance with a written procedure. Specific requirements regarding the preparation and approval fof writen procedures shall be dictated by a purchaser and supplier agreement. The procedure details should include at least those items stipulated in Appendix XI. In addition, @ radiographic standard shooting sketch (RSS), Fig. X1.1, shall ‘be prepared similar fo that shown in Appendix X1 and shall be available for review during interpretation of the film. 8.2 Radiographic Coverage—Unless otherwise specified by ‘a purchaser and supplier agreement, the extent of radiographic coverage shall be the maximum’ practical volume of the casting. Areas that requie radiography shall be designated as illustrated in Figs. X1.2 and X1.3 of Appendix X1. When the shape or configuration ofthe casting is such that radiography is ‘impractical, these areas shall be so designated on drawings or sketches that accompany the radiographs. Examples of casting ‘geometries and configurations that may be considered imprac- tical to radiograph are illustrated in Appendix X2. 83 Radiographic Film Quality—All radiographs shall be ‘ree of mechanical, chemical, handling,related, or other blem- ishes which could mask or be confused with the image of any discontinuity in the area of interest on the radiograph. If any doubt exists as to the true nature of an indication exhibited by the film, the radiograph shall be retaken or rejected. 84 Radiographic Quality Level—The applicable job order for contract shall dictate the requirements for radiographic ‘quality level. (See Practice E1025 or Practice E747 for ‘Buidance in selection of quality level.) 8.5 Acceptance Level—Radiographic acceptance levels and associated severity levels shall be stipulated by the applicable ‘contract, job order, drawing, or other purchaser and supplier agreement, 8.6 Radiographic Density Limitations—Radiographic den- sity inthe azea of interest shall be within 1. to 4.0 for eitier single or superimposed viewing, 87 Film Handling: 8.7.1 Darkroom Facilities—Darkzoom facilities should be kept clean and as dust-feee as practical. Safelights should be ‘those recammended by film manufacturers forthe radiographic materials used and should be positioned in accordance with the ‘manufacturer's recommendations. All darkroom equipment ‘and matecials should be capable of producing radiographs that are suitable for interpretation. 8.7.2 Film Processing—Radiographic film processing shall be controlled in aecotdance with Guide E 999. 8.73 Film Viewing Facilties—Viewing facilites shall pro- vide subdued background lighting of an intensity that will not cause troublesome reflections, shadows, or glare on the radio- ‘raph, The viewing light shall be of sufficient intensity to review densities up to 4.0 and be appropriately controlled so thatthe optimum intensity for single or superimposed viewing of radiographs may be selected. 8.7.4 Storage of Radiographs —When storage is required by ‘the applicable jab order or contract, the radiographs should be stored in an area with sufcient” environmental control to preclude image deterioration or other damage. The radiograph storage duration and location after casting delivery shall be as agreed upon between purchaser and supplier. (See Guide E 1254 for storage information.) 9, Procedure 9. Time of Examination—Unless otherwise spevitied by ‘the applicable job order or contract, radiography may be performed prior to heat treatment and in the as-cast, rough- ‘machined, or finished.machined condition. 9.1.1 Penetrametér (101) Selection—Unless otherwise specified in the applicable job order or contract, penetrameter (LQU) selection shall be based on the following: ifthe thickness tobe radiographed exceeds the design thickness of the finished ‘piece, the penetrameter (IQ) size shall be based on a thickness Which does not exceed the design thickness of the finished piece by mare than 20% or ¥4 in. (6.35 mm), whichever is greater. In no case shall the penetrameter (IQ) size be based on. 8 thickness greater than the thickness to be radiographed. 9.2 Surface Preparation—The casting surfaces shall be prepared as necessary to remove any conditions that could mask of be confused with internal casting discontinuities. 9.3 Source-to-Film Distance—Unless otherwise specified in the applicable job order or contract, geometric unsharpness (Ue) shall not be greater than one percent ofthe maximum part thickness being interpreted on the radiograph, or 0.070 in. (8 zum), whichever is less. Geometric unsharpness values shall be determined as specified in Guide E 94. ‘94 Direction of Radiation—The direction of radiation shalt bbe govemed by the geometry of the casting and the radio sraphic coverage and quality requirements stipulated by the applicable job order & contract. Whenever practicable, place {he central beam ofthe radiation perpendicular tothe surface of ‘the film. Appendix X2 provides examples of preferred sourceGh) E 1030 and film orientations and examples of casting geometries and configurations on which radiography is impractical or very dificult. 95 Back Scattered Radiation Protection: 9.5.1 Back Scattered Radiation—(secondary radiation ema- nating ffom surfaces behind the film, that is, was, floors, et.) serves to reduce radiographic contrast and may produce undesirable effects on radiographic quality. A Vein. (3.17 min) lead sheet placed behind the film generally furnishes adequate protection against back-scattered radiation. 9.5.2 To detect back-scattered radiation, position a lead {etter “B" (approximately 4 in, (3.17 mm) thick by in, (12.7 ‘mim high) on the rear side of the film holder. Ifa light image ower density) of the lead letter “B” appears on the radio- _graph, it indicates that more back-scatter protection is neces- sary, The appearance of a dark image of the lead letter “B” should be disregarded unless the dark image could mask or be confused with rejectable casting defects 9.6 Penetrameter 101) Placement—Place all penetrameters (QI) being zadiographed on the source side of the casting. ‘Place penetrameters (IQI's) in the radiographic area of interes, unless the use of a shim or separate block is necessary, as specified in 9.7.6, 9.7 Number of Penetrameters (101's) 9.7.1 One penetameter (IQD shall represent an area within which radiographic densities do not vary more than +30% to~ 15 % fiom the density measured through the body of the penetrameter (IQ). 9.7.2 When the film density varies more than ~ 15% to + 30%, two penetrameters (IQI’s) used as follows will be acceptable: if one penetrameter (IQN) shows acceptable sensi- tivity representing the most dense portion of the exposure, and the second penetrameter (IQ) shows acceptable sensitivity representing the least dense portion of the exposure, then these ‘vo penetrameters (IQI's) shall qualify the exposure location within these densities, provided the density requirements stipulated in 8.6 are met 9.7.3 For cylindrical or fat castings where more than one film holder is used for an exposure, at least one penetrameter (LQD image shall appear on each radiograph. For cylindrical shapes, where a panoramic type source of radiation is paced in the center of the cylinder and @ complete or partial circumtfer- ence is radiographed using at least four overlapped film holders, at least three penetrameters (IQls) shall be used. On ‘partial circumference exposures, a penetrameter (IQ) shall be placed at ezch end of the length of the image to be evaluated fon the radiograph with the intermediate penetrameters (IQIs) placed et equal divisions of the length covered. For full circumferential coverage, three penetrameters ([QIs) spaced 120° apart shall be used, even when using a single length of roll film. 9.1.4 When an array of individual castings in a circle is radiographed, the requirements of 9.7.1 or 9.72, or both shall prevail for each casting. 9.1.5 If the required penetrameter (IQl) sensitivity does not show on any one film in a multiple film technique (see 9.11), Dut does show in composite (Superimposed) film viewing, interpretation shall be permitted only by composite film viewing for the respective area 9.1.6 When itis not practicable to place the penetrameters) (4Q{) on the casting, a shim or separate block eanforming tothe requirements of 6.7 may be used. 9.7.6.1 The penetremeter (1) shall be no closer the film than the souree side ofthat part of the casting being radio- ‘graphed in the curent view. 9.7.6.2 The radiographic density measured adjacent to the penetameter (QH) through the body ofthe shim or separate biock shall not exceed the density measured in the area of interest by more than 15 %, The density may be lighter than the area of interest density, provided acceptable quality level is ‘obiained and the density requirements of 8.6 are met. 9.2.63 The shim or separate block shall be placed at the comer of the film holder or close to that part of the area of interest that is furthest from the central beam. This isthe worst case position fom a beam angle standpoint that a discontinuity would be in 9.1.64 The shim or separate block dimensions shal exceed the penetrameter (QD dimensions such that the outline of at least three sides of the pencirameter (QI) image shall be visible on the radiograph 9.1.7 Film Side Penetrameter (102)—In the case where the penetrameter (IQH) cannot be physically placed an the source side and the use of a separate block technique isnot practical, penetrameters (IQs) placed on the-flm side may be used. The applicable job order or contact shall dictate the requirements for film side radiographic quality level (see 8.4. 938 Location Markers—The radiographic image ofthe 10- cation markers for the coordination ofthe casting with the film shall appear on the film, without interfering with the interpre tation, in such an arrangement thet itis evident that the required coverage was obtained. These marker positions shall ‘be marked onthe casting and tho postion of the markers shall be maintained on the part during the complete radiographic cycle. The RSS shall show all marker locations. 99. Radiographic Identfeation—A system of postive iden- tifcation of the film shall be provided. As a minimum, the ‘allowing shall appear on the radiograph: the name or symbol ‘ofthe inspecting laboratory, the dat, the cating identification number, and whether i isa original or subsequent exposure, 9.10 Subsequent Exposure Identfication—All repair radio- sraphs afte the original (intl) shall have an inspection status designation that indicates the reason. Subsequent radiographs ‘made by reason of a reputed area shall be identified with the letter “R” followed by the respective repair eyce (hat is, R-L for the first repair, R-2 forthe second rept, et.) Subsequent radiographs that are necessary as a result of additonal surface preparation should be identified by the leters “REG.” 9.11 Multiple Film Téchnigues—Two or more fms of equal or dffezent speeds in the same casette are allowed, provided presaibed quality lovel and density sequirements are met (8 9.72 and 9.75) 9:12 Radiographic Techniques: 9.12.1 Single Wall Technique—Except as provided in 9.12.2, radiography shall be performed using a technique in which’ the radiation passes through only one wall. 9.12.2 Double Wall Technigque—For castings with an inside4h E 1030 iametae of 4 in, or les, a technique may be used in which the radiation passes through both walls and both walls are viewed for acceptance on the same film. An adequate number of ‘exposures shall be taken to ensure that required coverage has ‘been obtained. '9.13 Safety—Radiographic procedures shall comply with applicable city, state, and federal regulations 10, Radiograph Evaluation 10.1 Film Quality—Verify that the radiograph meets the quality requirements specified in 83, 84, 8.6, 9.5.2 and 9. 10.2 Film Evaluation—Determine the acceptance or rejec- tion ofthe casting by comparing the radiographic image tothe agreed upon acceptance criteria (se 8.5). LL, Reference Radiographs 111 Reference Radiographs E 155, E 186, E 192, E272, E280, E310, E446, E505, £689, and E802 are graded radiographic illustrations of ‘various casting discontinuities. ‘Those reference radiographs may be used to help establish acceptance criteria and may also be useful as radiographic interpretation training aids, 12. Report 121 The following radiographic records shall be main- tained as agreed upon between purchaser and supplier: 12.L1 Radiographic standard shooting sketch, 12,12 Weld repair documentation, 1213 Film, 12.1.4 Film interpretation record containing as a minimum: 12.1.4.1 Disposition of each radiograph (acceptable or re- Jeotable), 12,1.4.2 Izejectable, cause for rejection (shrink, gas, et.) 121.43 Surface indication verified by visual examination (mold, marks, ee), and 121.44 Signature ofthe film interpreter. 13, Precision and Bias 13.1 No statement has been made about either the precision or bias of this test method since the result merely states, whether there is conformance to the criteria for success specified in the procedure. 14. Keywords 14.1 castings; gamma-ray; nondestructive testing; radi sraphic; radiography; x-ray APPENDIXES (Nonmandatory Information) a {X1. RADIOGRAPHIC STANDARD SHOOTING SKETCH (RSS) ‘X11 The radiographic standard shooting sketch (RSS) ‘provides the radiographic operator and the radiographic inter- preter with pertinent information regarding the examination of 1 casting. The RSS is designed to standardize radiographic methodologies associated with casting inspection; it may also ‘provide e means of a purchaser and supplier agreement, prior +o initiation ofthe inspection on a production basis. The use of RSS is advantageous due to the meny configurations associ- ‘ated with castings and the corresponding variations in tech- niques for inspection of any particular one. The RSS provides ‘a map of location marker placement, directions for source and film arcangement, and instructions for all other parameters associated with radiography of a casting. This information serves to provide the most efficient method for controling the ‘quality and consistenoy of the resultant radiographic represen tations. ‘X12 The RSS usually consists of an instruction sheet and sketch(es) of the casting: the instruction sheet specifies the radiographic equipment, materials, and technique-acceptance parameters for each location; the sketch(es) illusrate(s) the location, orientation, and the Source and film arrangement for ceach location. Figs. XI.1-X1.3 of this appendix provide a typical instruction sheet and sketch sheets. As a minimum, the RSS should provide the following information, All spaces shall ‘oiled in unless not applicable; in those cass, the space shall be marked NA. X1.2.1 The instruction sheet should provide the fellowing: X12.1.1 Company preparing RSS and activity performing raiogcanby. XI2.1.2 Casting identitostion including: (o) Drawing number, (©) Casing identtication number, (@ Descriptive name (for example, pump casting, valve body, eto), (@) Matai ype and material specification, (@) Beat number, and @ Paver number. ‘X1.2.1.3 Surface condition at time of radiography (as cast, rough machined, inished machined). “12.14 Spaces for approve (8 applicable). 12.15 Radiographic Technique Parameters for Eack Lox (o) Radiographic loetion designation, Source spe and sie, (@ Finished thickness, (@ Thickness when rdiographed, (@) Penetameters, {Source to fim distance, @ Bim ype and quanti,4h & 1030 FIG. X14 Sample Radiographic Standard Shooting Sketch (RSS) () Fim size, @ Required penetrameter 1QN) quality level, @ Radiographic acceptance standard, and @) Applicable radiographic severity level. X1.2.2 The sketch(es) should provide the following: X12 Location marker placement X1.22.2 Location of foundry's identification pad or symbol on the casting. °X1.22.3 Designation of areas thet require radiography (as applicable). ‘XI.2.24 Designation of arcs that are considered impract- cal of very dificult o radiograph (see 1.2 and 8.2). X1.2.25 Radiographic source and fm arrangement and radiation beam direction foreach location. Nore XI1—The RSS should desigate the involved locaton and spl be tesigu fr hse oats i pica, or sso ofthe esting on which a continig sees of loaon re tobe radiopaphed ‘withthe same base source and fl arangemeat for each location. X1.23 Fig. X11 of this appendix provides a sample RSS that has been developed for a typical production application, and Figs, X1.2 and X13 provide sample RSS sketches that Ihave been developed for a typical production application. ‘X1.24 The RSS may not provide what is considered to be the most effective means of technique contol for all radio- ‘graphic activites, but, in any event, some means of technique standardization should be employed. As a general rue, it is a ‘beneficial practice forthe supplier to solicit purchaser approval of the radiographic methodology prior to pecforming produc- tion radiography. This genecally entails the demonstration of the adequacy of the methodology by submitting the proposed technique parameters and a corresponding set of pilot radio- graphs to the purchaser for review. Purchaser approval of the ‘technique shall be addressed in the applicable job order or contractfal Seem Pelee CAD sso Trea FEMS RSE OFS FSS NO cn ae FIG. X1.2 Samples of Radiographle Standard! Shooting Skotches (RSS) Views tlustrating Layout and Source and Film Placement@) E1030 TNs ae Pengo RES oS FIG. X1.3 Samples of Radiographic Standard Shooting Sketches (RSS) ‘Views ilustrating Layout and Extent of Coverage 1X2, PREFERRED SOURCE AND FILM ALIGNMENT FOR FLANGE RADIOGRAPHY AND EXAMPLES OF AREAS THAT ‘ARE CONSIDERED IMPRACTICAL TO RADIOGRAPH X2.1 Preferred Source and Film Alignment for Flange Radiography—The effective use of radiography for assessing ‘material soundness in casting areas where a flange joins a body is somewhat limited by the source and flm alignment that the _goometzio configuration of these areas require. The following figures desoribe source and film alignments that can be employed and discusses the limits and benefits of each.@h e 1030 ‘Nore 1—For general eplcation, this alignment provides the most effective compromise of quality radiography and maximum cbiable coverage, FIG. X21 Preferred Source and Film Alignment UNFLANGED PORT: cASTING B0DY /Rt COVERAGE NOT OBTAINED IN Tus AREA. hoe [Nore 1—Tis alignment provides a suitable altemative when other eating appendages (Doses, fanges, etc.) projet into the radiation path as thre in Fig: X22 when this alignment i sed, adional loess in coverage (a8 opposed to Fig. X21) should be expected and noted accordingly con the applicable RSS. FIG. X22 Permissible Source and Film Algnment when Fig. X2.1 Cannet Be Applied Due to Casting Geometrylb E1030 [Nore 1—This ligament is perisible if he sadition source energy snd fm multload capabilities are sufeient 9 afford compliance withthe technique requirements sipalated berein, This alignment wil generally sequze the use offer or masking to reduce the influence of radiation that undereuts the hiker aveas snd reduces overall radiographic quali. FIG, X23 Allowable Source Film Alignment a= Governed by Source Energy and Mult-Film Load Accoptable Density Latitude 1X3. EXAMPLES OF AREAS THAT ARE CONSIDERED TO BE IMPRACTICAL TO RADIOGRAPH. cees- involve the juncture of two casting sections. The following illustrations provide typical examples of such areas. XG.1 Certain casting geometry configuration are i sible for conventional source and film arrangements that will provide meaningful radiographic results. These areas generally ramen om Neen FIG, X31 Areas lnvolving Flangesqh € 1030 aemee pari mre emt ees 0 FIG. X3.2 Areas Involving Other Junctures ‘The Amarcan Soc for Teng and Malaria kas no poston pectin th vay of ay pangs etoredin connection wih any fam mordoned nis standard Uso of is land are express asad Wal delrmatia eval a 2 Date gts and kof nigamon of uch Hgts, re erly a respons ‘This anda sub oevon at any tine by he response teil commie and mus be reid ear ve yours and ‘fratronsad oor reapproved a wthoraun You comments ae ied aero reso is standard rasan andar Sd shold be adrosod fo ASTI Hosur. Your comments il cave call corso at a moan oe response teal come, yan Fo fl at a cas have hl cna fa gy sd a Yor This standard is copyrighted by ASTI 100 Bar Harbor Do, West Conshohockan, Pa 1428-260, Unted Sates Inia ‘epi (igo ratte cop) ef sandr may be cad by contacting ASTM a th abo adons oa 6108320585 (Dhone), 61-88-9555 (ay cr sonicadlsimery (ena) or hugh ne ASTI webs i/wnw asin.)