ASTM A609/A609M-91(1997)

Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof

SCOPE
1.1 This practice covers the standards and procedures for the pulse-echo ultrasonic examination of heat-treated carbon, low-alloy, and martensitic stainless steel castings by the longitudinal-beam technique.
1.2 This practice is to be used whenever the inquiry, contract, order, or specification states that castings are to be subjected to ultrasonic examination in accordance with Practice A 609/A 609M.
1.3 This practice contains two procedures for ultrasonic inspection of carbon, low-alloy, and martensitic stainless steel castings; that is, Procedure A and Procedure B. Procedure A is the original A 609/A 609M practice and requires calibration using a series of test blocks containing flat bottomed holes. It also provides supplementary requirements for angle beam testing. Procedure B requires calibration using a back wall reflection from a series of solid calibration blocks.
Note 1—Ultrasonic examination and radiography are not directly comparable. This examination technique is intended to complement Guide E 94 in the detection of discontinuities.
1.4 The values stated in either inch-pound units or SI units are to be regarded separately as standard. Within the text, the SI units are shown in brackets. The values stated in each system are not exact equivalents; therefore, each system must be used independently of the other. Combining values from the two systems may result in nonconformance with this practice.
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 appropriate safety and health practices and determine the applicability of regulatory limitations prior to use.

General Information

• Status: Historical
• Publication Date: 14-Dec-1991
• Technical Committee: A01 - Steel, Stainless Steel and Related Alloys
• Drafting Committee: A01.18 - Castings

Relations

• Replaced By: ASTM A609/A609M-91(2002) - Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof
• Effective Date: 15-Dec-1991

Standards Content (Sample)

NOTICE: This standard has either been superseded and replaced by a new version or
withdrawn. Contact ASTM International (www.astm.org) for the latest information.
Designation: A 609/A 609M – 91 (Reapproved 1997) An American National Standard
AMERICAN SOCIETY FOR TESTING AND MATERIALS
100 Barr Harbor Dr., West Conshohocken, PA 19428
Reprinted from the Annual Book of ASTM Standards. Copyright ASTM
Standard Practice for
Castings, Carbon, Low-Alloy, and Martensitic Stainless
Steel, Ultrasonic Examination Thereof
This standard is issued under the fixed designation A 609/A 609M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (e) indicates an editorial change since the last revision or reapproval.
1. Scope able for High-Temperature Service
E 94 Guide for Radiographic Testing
1.1 This practice covers the standards and procedures for
E 317 Practice for Evaluating Performance Characteristics
the pulse-echo ultrasonic examination of heat-treated carbon,
of Ultrasonic Pulse-Echo Testing Systems Without the Use
low-alloy, and martensitic stainless steel castings by the
of Electronic Measurement Instruments
longitudinal-beam technique.
2.2 Other Document:
1.2 This practice is to be used whenever the inquiry,
SNT-TC-1A Recommended Practice for Non-Destructive
contract, order, or specification states that castings are to be
Testing Personnel Qualification and Certification
subjected to ultrasonic examination in accordance with Prac-
tice A 609/A 609M.
3. Ordering Information
1.3 This practice contains two procedures for ultrasonic
3.1 The inquiry and order should specify which procedure is
inspection of carbon, low-alloy, and martensitic stainless steel
to be used. If a procedure is not specified, Procedure A shall be
castings, that is, Procedure A and Procedure B. Procedure A is
used.
the original A 609/A 609M practice and requires calibration
3.2 Procedure A—Flat-Bottomed Hole Calibration Proce-
using a series of test blocks containing flat bottomed holes. It
dure:
also provides supplementary requirements for angle beam
3.2.1 When this practice is to be applied to an inquiry,
testing. Procedure B requires calibration using a back wall
contract, or order, the purchaser shall furnish the following
reflection from a series of solid calibration blocks.
information:
NOTE 1—Ultrasonic examination and radiography are not directly
3.2.1.1 Quality levels for the entire casting or portions
comparable. This examination technique is intended to complement Guide
thereof,
E 94 in the detection of discontinuities.
3.2.1.2 Sections of castings requiring longitudinal-beam
1.4 The values stated in either inch-pound units or SI units
examination,
are to be regarded separately as standard. Within the text, the
3.2.1.3 Sections of castings requiring dual element exami-
SI units are shown in brackets. The values stated in each
nation,
system are not exact equivalents; therefore, each system must
3.2.1.4 Sections of castings requiring supplementary exami-
be used independently of the other. Combining values from the
nation, using the angle-beam procedure described in Supple-
two systems may result in nonconformance with this practice.
mentary Requirement S1 in order to achieve more complete
1.5 This standard does not purport to address all of the
examination, and
safety concerns, if any, associated with its use. It is the
3.2.1.5 Any requirements additional to the provisions of this
responsibility of the user of this standard to establish appro-
practice.
priate safety and health practices and determine the applica-
3.3 Procedure B: Back-Wall Reflection Calibration
bility of regulatory limitations prior to use.
Procedure—When this procedure is to be applied to an inquiry,
contract, or order, the purchaser shall designate the quality
2. Referenced Documents
levels for the entire casting or applicable portions.
2.1 ASTM Standards:
A 217/A217M Specification for Steel Castings, Martensitic PROCEDURE A—FLAT-BOTTOMED HOLE
CALIBRATION PROCEDURE
Stainless and Alloy, for Pressure-Containing Parts, Suit-
4. Apparatus
This practice is under the jurisdiction of ASTM Committee A-1 on Steel,
4.1 Electronic Apparatus:
Stainless Steel, and Related Alloysand is the direct responsibility of Subcommittee
A01.18on Castings.
Current edition approved Dec. 15, 1991. Published July 1992. Originally
published as A 609 – 70. Last previous edition A 609/A 609M – 90.
Annual Book of ASTM Standards, Vol 01.02.
For ASME Boiler and Pressure Vessel Code applications, see related Specifi-
Annual Book of ASTM Standards, Vol 03.03.
cation SA-609 of Section II of that Code.
Available from American Society for Nondestructive Testing, 914 Chicago
Ave., Evanston, IL 60202.
A 609/A 609M
4.1.1 An ultrasonic, pulsed, reflection type of instrument
that is capable of generating, receiving, and amplifying fre-
quencies of at least 1 to 5 MHz.
4.1.2 The ultrasonic instrument shall provide linear presen-
tation (within 65 %) for at least 75 % of the screen height
(sweep line to top of screen). Linearity shall be determined in
accordance with Practice E 317 or equivalent electronic means.
4.1.3 The electronic apparatus shall contain a signal attenu-
ator or calibrated gain control that shall be accurate over its
useful range to 610 % of the nominal attenuation or gain ratio
to allow measurement of signals beyond the linear range of the
instrument.
4.2 Search Units:
4.2.1 Longitudinal Wave, internally grounded, havinga½to
1! in. [13 to 28 mm] diameter or 1-in. [25-mm] square
piezo-electric elements. Based on the signals-to-noise ratio of
the response pattern of the casting, a frequency in the range
from 1 to 5 MHz shall be used. The background noise shall not
exceed 25 % of the distance amplitude correction curve
(DAC). Transducers shall be utilized at their rated frequencies.
4.2.2 Dual-Element, 5-MHz, ½ by 1-in. [13 by 25-mm], 12°
included angle search units are recommended for sections 1 in.
NOTE 1—Opposite ends of reference block shall be flat and parallel
[25 mm] and under.
within 0.001 in. [0.025 mm].
4.2.3 Other frequencies and sizes of search units may be
NOTE 2—Bottom of flat-bottom hole shall be flat within 0.002-in.
used for evaluating and pinpointing indications. 1
[0.051 mm] and the finished diameter shall be ⁄4 + 0.002 in. [6.4 + 0.050].
4.3 Reference Blocks:
NOTE 3—Hole shall be straight and perpendicular to entry surface
within 0°, 30 min and located within ⁄32 in. [0.80 mm] of longitudinal
4.3.1 Reference blocks containing flat-bottom holes shall be
axis.
used to establish test sensitivity in accordance with 8.2.
1 1
NOTE 4—Counter bore shall be ⁄2 in. [15.0 mm] diameter by ⁄8 in. [5
4.3.2 Reference blocks shall be made from cast steels that
mm] deep.
give an acoustic response similar to the castings being exam-
FIG. 1 Ultrasonic Standard Reference Block
ined.
4.3.3 The design of reference blocks shall be in accordance
TABLE 1 Dimensions and Identification of Reference Blocks in
with Fig. 1, and the basic set shall consist of those blocks listed
the Basic Set (See Fig. 1)
in Table 1. When section thicknesses over 15 in. [380-mm] are
to be inspected, an additional block of the maximum test
Metal Overall Width or Block
Hole Diameter
Distance Length Diameter Identifi-
thickness shall be made to supplement the basic set.
in ⁄64ths, in.
A
(B), in. (C), in. (D), min, cation
4.3.4 Machined blocks with ⁄32-in. [2.4-mm] diameter flat- [mm]
[mm] [mm] in. [mm] Number
bottom holes at depths from the entry surface of ⁄8 in. [3 mm],
16 [6.4] 1 [25] 1 ⁄4 [45] 2 [50] 16-0100
1 1 3 3
⁄2 in. [13 mm], or ⁄2t and ⁄4 in. [19 mm], or ⁄4t (where t 5 3
16 [6.4] 2 [50] 2 ⁄4 [70] 2 [50] 16-0200
thickness of the block) shall be used to establish the DAC for 16 [6.4] 3 [75] 3 ⁄4 [95] 2 [50] 16-0300
16 [6.4] 6 [150] 6 ⁄4 [170] 3 [75] 16-0600
the dual-element search units (see Fig. 2).
16 [6.4] 10 [255] 10 ⁄4 [275] 4 [100] 16-1000
4.3.5 Each reference block shall be permanently identified 3 B
16 [6.4] B B + ⁄4 [B + 20] 5 [125] 16-B00
along the side of the block indicating the material and the block
A
Tolerance 6 ⁄8 in. [3 mm].
B
identification.
Additional supplemental blocks for testing thickness greater than 10 in. [250
mm], see 4.3.3.
4.4 Couplant—A suitable couplant having good wetting
characteristics shall be used between the search unit and
5.2.4 Effect of material structure (grain size, cleanliness,
examination surface. The same couplant shall be used for
etc.) on test results,
calibrations and examinations.
5.2.5 Effect of test distance on test results,
5. Personnel Requirements
5.2.6 Effect of nonlinearity on test results,
5.2.7 Effect of thickness and orientation of discontinuities
5.1 The manufacturer shall be responsible for assigning
on test results, and
qualified personnel to perform ultrasonic examination in con-
5.2.8 Effect of surface roughness on test results.
formance with the requirements of this practice.
5.3 A qualification record (see Note 2) of personnel consid-
5.2 Personnel performing ultrasonic examinations in accor-
ered suitable by the manufacturer to perform examinations in
dance with this practice shall be familiar with the following:
accordance with this practice shall be available upon request.
5.2.1 Ultrasonic terminology,
5.2.2 Instrument calibration,
NOTE 2—SNT-TC-1A, Ultrasonic Testing Method, provides a recom-
5.2.3 Effect of transducer material, size, frequency, and
mended procedure for qualifying personnel. Other personnel qualification
mode on test results, requirement documents may by used when agreed upon between the
A 609/A 609M
NOTE 1—Entrant surface shall be 250 μin. [6.3 μm] or finer.
NOTE 2— The ⁄32-in. [2.4 mm] flat-bottom hole must be flat within 0.002 in. [0.05 mm]. Diameter must be within +0.005 in. [0.13 mm] of the required
diameter. Hole axis must be perpendicular to the block and within an angle of 0°, 30 min.
NOTE 3—Hole shall be plugged following checking for ultrasonic response.
in. [mm] in. [mm]
1 1
⁄8 [3] 1 ⁄4 [32]
1 1
⁄4 [6] 1 ⁄2 [38]
1 3
⁄2 [13] 1 ⁄4 [44]
⁄4 [19.0] 2 [50]
1 [25] 10 [254]
FIG. 2 Ultrasonic Standard Reference Block for Dual-Search Unit Calibration
purchaser and the supplier.
the screen or on suitable graph paper. The maximum signal
amplitude for the test blocks used shall peak at approximately
6. Casting Conditions
three-fourths of the screen height above the sweep by use of the
6.1 Castings shall receive at least an austenitizing heat
attenuator. This curve shall be referred to as the 100 % distance
treatment before being ultrasonically examined.
amplitude correction (DAC) curve. If the attenuation of ultra-
6.2 Test surfaces of castings shall be free of material that
sound in the casting thickness being examined is such that the
will interfere with the ultrasonic examination. They may be as
system’s dynamic range is exceeded, segmented DAC curves
cast, blasted, ground, or machined.
are permitted.
6.3 The ultrasonic examination shall be conducted prior to
8.3 The casting examination surface will normally be
machining that prevents an effective examination of the cast-
rougher than that of the test blocks; consequently, employ a
ing.
transfer mechanism to provide approximate compensation. In
order to accomplish this, first select a region of the casting that
7. Test Conditions
has parallel walls and a surface condition representative of the
7.1 To assure complete coverage of the specified casting
rest of the casting as a transfer point. Next, select the test block
section, each pass of the search unit shall overlap by at least
whose overall length, C (Fig. 1), most closely matches the
10 % of the width of the transducer.
reflection amplitude through the block length. Place the search
7.2 The rate of scanning shall not exceed 6 in./s [150 mm/s].
unit on the casting at the transfer point and adjust the
7.3 The ultrasonic beam shall be introduced perpendicular
instrument gain until the back reflection amplitude through the
to the examination surface.
casting matches that through the test block. Using this transfer
technique, the examination sensitivity in the casting may be
8. Procedure
expected to be within 630 % or less of that given by the test
8.1 Adjust the instrument controls to position the first back
blocks.
reflection for the thickness to be tested at least one half of the
8.4 Do not change those instrument controls and the test
distance across the cathode ray tube.
frequency set during calibration, except the attenuator, or
8.2 Using the set of reference blocks spanning the thickness
of the casting being inspected, mark the flat-bottom hole calibrated gain control, during acceptance examination of a
indication height for each of the applicable blocks on the given thickness of the casting. Make a periodic calibration
cathode ray tube shield. Draw a curve through these marks on during the inspection by checking the amplitude of response
A 609/A 609M
TABLE 2 Rejection Level
from the ⁄4-in. [6.4-mm] diameter flat-bottom hole in the test
block utilized for the transfer.
NOTE 1—The areas in the table refer to the surface area on the casting
over which a continuous indication exceeding the amplitude reference line
NOTE 3—The attenuator or calibrated gain control may be used to
or a continuous loss of back reflection of 75 % or greater is maintained.
change the signal amplitude during examination to permit small amplitude
NOTE 2— Areas shall be measured from the center of the search unit.
signals to be more readily detected. Signal evaluation is made by returning
NOTE 3—In certain castings, because of very long test distances or
the attenuator or calibrated gain control to its original setting.
curvature of the test surface, the casting surface area over which a given
8.5 During examination of areas of the casting having
discontinuity is detected may be considerably larger or smaller than the
parallel walls, recheck areas showing 75 % or greater loss of
actual area of the discontinuity in the casting; in such cases a graphic plot
back reflection to determine whether loss of back reflection is
that incorporates a consideration of beam spread should be used for
realistic evaluation of the discontinuity.
due to poor contact, insufficient couplant, misoriented discon-
tinuity, etc. If the reason for loss of back reflection is not
2 2
Area, in. [cm ]
evident, consider the area questionable and further investigate.
Ultrasonic Testing Length, max,
(see 10.2.1 and
Quality Level in. [mm]
10.2.2)
9. Report
1 0.8 [5] 1.5 [40]
9.1 The manufacturer’s report of final ultrasonic examina-
2 1.5 [10] 2.2 [55]
tion shall contain the following data and shall be furnished to
3 3 [20] 3.0 [75
...