ASTM E428-08(2013)
(Practice)Standard Practice for Fabrication and Control of Metal, Other than Aluminum, Reference Blocks Used in Ultrasonic Testing (Withdrawn 2019)
Standard Practice for Fabrication and Control of Metal, Other than Aluminum, Reference Blocks Used in Ultrasonic Testing (Withdrawn 2019)
SIGNIFICANCE AND USE
5.1 Reference blocks fabricated in accordance with this practice will exhibit specific area-amplitude and distance-amplitude relationships only with an immersion test at 5 MHz using the search unit, test instrument and test parameters described in this practice. Comparison test at other frequencies or with uncalibrated instruments will not necessarily give the same relationships shown in this practice. See Reference (1) for area-amplitude limitations at other frequencies and transducer diameters. Also see Reference (2) for cautions regarding use of standard blocks for test standardizations.
SCOPE
1.1 This practice covers a procedure for fabrication and control of metal alloy reference blocks used in ultrasonic examination that have a flat-surface sound entry, are cylindrical in shape, and contain flat-bottom holes (FBH) which may be used for checking the performance of ultrasonic examination instrumentation and search units and for standardization and control of ultrasonic examination of metal alloy products. The reference blocks described are suitable for use with either the direct-contact method or immersion pulse-echo ultrasonic methods.Note 1—Use of flat-surface reference blocks may not be suitable for cylindrical materials (3)2.
1.2 While this procedure is basically designed for the fabrication and control of carbon and alloy steel blocks to be used in conjunction with the examination of these materials, the fabrication and control procedures may also be suitable for the preparation of blocks for other types of materials such as nickel-base alloys, certain types of aluminum alloys, and so forth. Additional procedures and controls may be required when fabricating reference blocks from other than carbon or alloy steel material. This practice shall in no way preclude the specification or addition of any supplemented requirements as deemed necessary for the specific application. This practice, however, must not be confused with, nor does it supersede Practice E127, specifically governing the fabrication and evaluation of 7075-T6 aluminum alloy ultrasonic standard reference blocks.Note 2—Practice E127 and Guide E1158 also describe procedures for selecting material, fabricating blocks, and checking response. Unlike this practice, Practice E127 has requirements for evaluation relative to a specified standard target.
1.3 The values stated in inch-pound units are to be regarded as standard. The values given in parentheses are mathematical conversions to SI units that are provided for information only and are not considered standard.
1.4 This standard does not purport to address all of the safety problems, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.
WITHDRAWN RATIONALE
This practice covers a procedure for fabrication and control of metal alloy reference blocks used in ultrasonic examination that have a flat-surface sound entry, are cylindrical in shape, and contain flat-bottom holes (FBH) which may be used for checking the performance of ultrasonic examination instrumentation and search units and for standardization and control of ultrasonic examination of metal alloy products. The reference blocks described are suitable for use with either the direct-contact method or immersion pulse-echo ultrasonic methods.
Formerly under the jurisdiction of Committee E07 on Nondestructive Testing, this practice was withdrawn in December 2019 and replaced by Practice E127 on the Fabrication and Control of Flat Bottomed Hole Ultrasonic Standard Reference Blocks.1
General Information
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Standards Content (Sample)
NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.
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Designation: E428 − 08 (Reapproved 2013)
Standard Practice for
Fabrication and Control of Metal, Other than Aluminum,
Reference Blocks Used in Ultrasonic Testing
This standard is issued under the fixed designation E428; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision.Anumber in parentheses indicates the year of last reapproval.A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.
1. Scope 1.3 Thevaluesstatedininch-poundunitsaretoberegarded
as standard. The values given in parentheses are mathematical
1.1 This practice covers a procedure for fabrication and
conversions to SI units that are provided for information only
control of metal alloy reference blocks used in ultrasonic
and are not considered standard.
examinationthathaveaflat-surfacesoundentry,arecylindrical
1.4 This standard does not purport to address all of the
in shape, and contain flat-bottom holes (FBH) which may be
safety problems, if any, associated with its use. It is the
used for checking the performance of ultrasonic examination
responsibility of the user of this standard to establish appro-
instrumentation and search units and for standardization and
priate safety and health practices and determine the applica-
control of ultrasonic examination of metal alloy products. The
bility of regulatory limitations prior to use.
reference blocks described are suitable for use with either the
direct-contact method or immersion pulse-echo ultrasonic
2. Referenced Documents
methods.
2.1 ASTM Standards:
NOTE 1—Use of flat-surface reference blocks may not be suitable for
E127Practice for Fabricating and Checking Aluminum Al-
cylindrical materials (1) .
loy Ultrasonic Standard Reference Blocks
1.2 While this procedure is basically designed for the
E1158Guide for Material Selection and Fabrication of
fabrication and control of carbon and alloy steel blocks to be
Reference Blocks for the Pulsed Longitudinal Wave Ul-
used in conjunction with the examination of these materials,
trasonic Testing of Metal and Metal Alloy Production
the fabrication and control procedures may also be suitable for
Material
the preparation of blocks for other types of materials such as
E1316Terminology for Nondestructive Examinations
nickel-base alloys, certain types of aluminum alloys, and so
forth. Additional procedures and controls may be required
3. Terminology
when fabricating reference blocks from other than carbon or
alloy steel material. This practice shall in no way preclude the 3.1 Definitions—For definitions of terms used in this
specification or addition of any supplemented requirements as practice, see Terminology E1316.
deemed necessary for the specific application. This practice,
however, must not be confused with, nor does it supersede 4. Summary of Practice
Practice E127, specifically governing the fabrication and
4.1 This practice details a basic fabrication and control
evaluation of 7075-T6 aluminum alloy ultrasonic standard
procedure and defines the minimum requirements to be met in
reference blocks.
matching carbon and alloy steel reference blocks with the
material to be examined. Additional supplemental require-
NOTE 2—Practice E127 and Guide E1158 also describe procedures for
selecting material, fabricating blocks, and checking response. Unlike this ments may be needed when using this practice to fabricate
practice, Practice E127 has requirements for evaluation relative to a
reference blocks from other types of materials or with larger
specified standard target.
diameterholes.Thephysicalcharacteristicsoftheholemaybe
established by evaluating plastic replicas. It must be recog-
nized however that there are limitations on the size hole that
This practice is under the jurisdiction of ASTM Committee E07 on Nonde- may be replicated and evaluated.
structive Testing and is the direct responsibility of Subcommittee E07.06 on
Ultrasonic Method.
Current edition approved June 1, 2013. Published June 2013. Originally
approved in 1971. Last previous edition approved in 2008 as E428-08. DOI: For referenced ASTM standards, visit the ASTM website, www.astm.org, or
10.1520/E0428-08R13. contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Theboldfacenumbersinparenthesesrefertothelistofreferencesattheendof Standards volume information, refer to the standard’s Document Summary page on
this standard. the ASTM website.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E428 − 08 (2013)
5. Significance and Use changes usually yield readily discernible differences in acous-
tic response and restrict the applicability of reference blocks.
5.1 Reference blocks fabricated in accordance with this
practice will exhibit specific area-amplitude and distance-
7. Fabrication Procedure
amplitude relationships only with an immersion test at 5 MHz
7.1 Unless otherwise specified, select the blocks to be made
using the search unit, test instrument and test parameters
describedinthispractice.Comparisontestatotherfrequencies from those listed in Table 1. Block sets conforming to
customary commercial practice are grouped as follows:
or with uncalibrated instruments will not necessarily give the
same relationships shown in this practice. See Reference (2)
7.1.1 Distance-Amplitude Response (D/A),
for area-amplitude limitations at other frequencies and trans-
7.1.2 Area-Amplitude Response (A/A), and
ducer diameters.Also see Reference (3) for cautions regarding
7.1.3 Basic (selected from D/A and A/A groups).
use of standard blocks for test standardizations.
7.2 AllblocksaretobefabricatedinaccordancewithFig.1.
Dimension “A” (metal travel) and Dimension “D” (FBH
6. Material Selection
diameter) are given in Table 1; Dimension “E” (block length)
6.1 The material to be used for reference blocks should be is derived. The following machining sequence is recom-
similar in its acoustic attenuation to the material which is to be
mended:
examined. The grain size, heat treat condition, physical and
NOTE 3—This practice may be used to produce blocks with flat-bottom
chemical composition, surface finish, and manufacturing pro-
holes of a larger diameter than described. Utilization of larger flat-bottom
cedure (rolling, forging, and so forth) are variables to be
holes shall be by agreement of the using parties.
considered in matching acoustic responses.
7.2.1 Machine all blocks to a uniform 32 rms finish and to
6.1.1 Thegeneralevaluationprocedureshallbetointroduce
the required dimensional tolerances.
a longitudinal pulse-echo beam into either side of the block on
7.2.2 Drill the test hole to the nominal ⁄4-in. (19.0-mm)
the axis to be used for determining metal-path distance. An
depth with a standard drill point.
immersionexaminationmethodusingcleanwaterasacouplant
7.2.3 Carefully prepare a flat-bottom drill or cutter with
or, a contact method using appropriate couplant (oil, glycerin,
cuttingedgessquareandflatwithin0.0005in.(0.013mm)and
and so forth) is satisfactory. The examination instruments,
perpendiculartoitslongitudinalaxis(flatness,squareness,etc.,
frequency, and search unit used in the evaluation of the raw
should be checked at a minimum of 60× magnification on an
material intended for the fabrication of the reference blocks
optical comparator).
shall be comparable to that used in the examination of the
7.2.4 Continue to drill as needed to remove all the conical
production material.
configuration of the bottom of the hole.
6.1.2 The material used for reference blocks shall be 100%
7.2.5 Remove drill, check cutting edge, regrind, if neces-
scanned while the examination system is adjusted to display,
sary.
wheneverpossible,anacousticnoiselevelfromthematerialof
7.2.6 Remove an additional 0.005 in. (0.13 mm) of material
20% of full-scale deflection (FSD). In cases of materials that
from the hole bottom.
are acoustically transparent to the extent that this requirement
7.2.7 Recheck cutting edges of the drill on the optical
cannot be satisfied, a readable acoustic noise level shall be
comparator, regrind, if necessary, and repeat 7.2.5 and 7.2.6.
displayed. The acoustic noise level from the material is not to
Careful attention must be given to the squareness of corners of
be confused with inherent electrical instrument noise often
the cutter, the slightest radius reduces the reflective area of the
observed when the system sensitivity is adjusted to its maxi-
hole bottom.
mum level range.
6.1.3 The material used for reference blocks shall be free of
8. Checking Physical Characteristics
discrete ultrasonic discontinuity indications greater than twice
the amplitude of the noise level displayed in accordance with 8.1 All dimensions of the reference blocks including the
the requirements of 6.1.2. diameter and perpendicularity of the examination hole may be
checked by normal quality control procedures for physical
6.1.4 Attenuation shall be checked by comparing multiple
measurements. The configuration, squareness, flatness, and
reflectionsfromthebacksurfaceofthetestblockmaterialwith
surfacefinishforholebottoms ⁄64in.(1.2mm)indiameterand
that of the material to be examined. With the amplitude from
larger may be checked by the following recommended tech-
thefirstbackreflectionadjustedto90%ofFSD,thesumofthe
nique for making and evaluating plastic replicas:
amplitude of the first three back reflections from both samples
shall compare within 625% or as required by the application. 8.1.1 Clean hole with a suitable oil-free noncorrosive sol-
vent and dry with a stream of dried and filtered air.
OnsamplesthataretohaveFBHssmallerthan ⁄64in.(1.2mm)
in diameter, the decay patterns shall compare within 610% or 8.1.2 Mix the replicating material in accordance with the
as required by the application. manufacturer’s instructions.
8.1.3 Force the material into the hole with a disposable
6.1.5 Lowering the examination frequency tends to mini-
medical syringe and needle of adequate size.
mize discernible differences in response. At 1.0 MHz, a large
group of materials may be acoustically penetrable with rela- 8.1.4 Fill the hole beginning at the bottom and gradually
tivelysimilarresultsandmaysatisfytherequirementsof6.1.4. moving outward making certain that no air pockets or bubbles
At frequencies such as 5.0 MHz and higher, microstructure remain in the hole.
E428 − 08 (2013)
TABLE 1 Standard Block Sizes and Recommended Block Sets
NOTE 1—Material to be as specified by the user.
NOTE 2—All dimensions and tolerances are to be in accordance with Fig. 1.
NOTE 3—1 in.=25.4 mm.
NOTE 4—Block sets shown are typical of established commercial practice: more or fewer blocks may be required for specific applications.
Basic Set,
Metal Travel Distance/Amplitude, Area/Amplitude Set, 8 Total
10 Total
and Designator 19 in each set
Diameter of Flat-Bottom Holes ( ⁄64 in./1.6 mm) Dimension “D”
Nomi-
nal Dim. “A”
Desig. 3 5 8 3 5 8 1 2 3 4 5 6 7
MT
(in.) (in.) (mm)
0.063 0.0625 1.6 –0006 3 5 8 . . .
0.125 0.125 3.2 –0012 3 5 8 . 5 .
0.250 0.250 6.4 –0025 3 5 8 . 5 .
0.375 0.375 9.5 –0038 3 5 8 . . .
0.500 0.500 12.7 –0050 3 5 8 . 5 .
0.625 0.625 15.9 –0062 3 5 8 . . .
0.750 0.750 19.1 –0075 3 5 8 . . .
0.875 0.875 22.2 –0088 3 5 8 . . .
1.000 1.000 25.4 –0100 3 5 8 . . .
1.250 1.250 31.8 –0125 3 5 8 . . .
1.500 1.500 36.1 –0150 . . . . 5 .
1.750 1.750 44.5 –0175 3 5 8 . . .
2.000 2.000 50.8 –0200 . . . . . .
2.250 2.250 57.2 –0225 3 5 8 . . .
2.500 2.500 63.5 –0250 . . . . . .
2.750 2.750 69.9 –0275 . . . . . .
3.000 3.000 76.2 –0300 3 5 8 3 5 8 1 2 3 4 5 6 7
3.250 3.250 82.6 –0325 3 5 8 . . .
3.500 3.500 88.9 –0350 . . . . . .
3.750 3.750 95.3 –0375 3 5 8 . . .
4.000 4.000 101.6 –0400 . . . . . .
4.250 4.250 106.0 –0425 3 5 8 . . .
4.500 4.500 114.3 –0450 . . . . . .
4.750 4.750 120.7 -0475 3 5 8 . . .
5.000 5.000 127.0 –0500 . . . . . .
5.250 5.250 133.4 –0525 3 5 8 . . .
5.500 5.500 139.7 –0550 . . . . . .
5.750 5.750 146.1 –0575 . . . . . .
6.000 6.000 152.4 –0600 3 5 8 . 5 8
6.250 6.250 158.8 –0625
6.500 6.500 165.1 –0650
8.1.5 Insertasmallwire,pin,needle,orothersuitableobject flat-bottom holes shall be cleaned and temporarily plugged by
that will serve as a rigid core and facilitate removal of the
a press-fit TFE-fluorocarbon insert or sealed by some other
replica. suitable technique to ensure a leak-tight closure. It is recom-
8.1.6 After curing, the replica may be removed and exam-
mended that blocks fabricated as sets be compared with each
ined. The replica shall indicate that the hole bottom is flat
other to determine their relative ultrasonic-response character-
within 0.001 in. (0.03 mm)/ ⁄8 in. (3.2 mm) of diameter and
istics. This is particularly desirable in the cases of sets
roughness shall not be greater than 16 rms finish. For record 3
containing flat-bottom holes smaller than ⁄64in. (1.2 mm) in
purposes, the replica may be projected on a comparator screen
diameter that cannot be satisfactorily replicated.
and photographed as shown in Fig. 2.
9.2 Area/Amplitude Response Curves—An area/amplitude
9. Checking Ultrasonic Response Characteristics set may contain several blocks with same external dimensions
and distance from the entry surface to the selected FBHs of
9.1 All measurements of area-amplitude and distance-
varying sizes. An area/amplitude-response curve may be ob-
amplitude characteristics are to be made using a 5-MHz, ⁄8-in.
tained by adjusting the examination sensitivity to give a signal
(9.5-mm) flat transducer at a water path distance equal to the
withanamplitudeof30to40%ofFSDfromtheblocknearest
measured distance to the last near-field maximum (Y0+) and a
themiddleoftherangeofthereflectorsizes.Withoutchanging
previously linearity-calibrated test instrument. Reference
any examination parameters, the ultrasonic response from the
blocksthatexhibitsatisfactoryexternalphysicalcharacteristics
remaining blocks with both smaller and larger size reflectors
and proper configuration of the replicated hole shall be
are plotted on the response curve. A typical area/amplitude
subjected to additional examination to check their ultrasonic-
curve for a set of 4340 steel blocks is shown in Fig. 3. Any
response characteristics. If the ultrasonic-response characteris-
tics are to be established by immersion techniques, the drilled block that exhibits an erratic ultrasonic response and
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