ASTM A609/A609M-91(2002)
(Practice)Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof
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.
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Designation: A 609/A 609M – 91 (Reapproved 2002)
Standard Practice for
Castings, Carbon, Low-Alloy, and Martensitic Stainless
Steel, Ultrasonic Examination Thereof
ThisstandardisissuedunderthefixeddesignationA609/A609M;thenumberimmediatelyfollowingthedesignationindicatestheyear
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 (e) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.
1. Scope A217/A217M Specification for Steel Castings, Martensitic
2 Stainless and Alloy, for Pressure-Containing Parts, Suit-
1.1 This practice covers the standards and procedures for
able for High-Temperature Service
the pulse-echo ultrasonic examination of heat-treated carbon,
E94 Guide for Radiographic Examination
low-alloy, and martensitic stainless steel castings by the
E317 Practice for Evaluating Performance Characteristics
longitudinal-beam technique.
of Ultrasonic Pulse-Echo Examination Instruments and
1.2 This practice is to be used whenever the inquiry,
Systems Without the Use of Electronic Measurement
contract, order, or specification states that castings are to be
Instruments
subjected to ultrasonic examination in accordance with Prac-
2.2 Other Document:
tice A609/A609M.
SNT-TC-1A Recommended Practice for Non-Destructive
1.3 This practice contains two procedures for ultrasonic
Testing Personnel Qualification and Certification
inspection of carbon, low-alloy, and martensitic stainless steel
castings; that is, ProcedureAand Procedure B. ProcedureAis
3. Ordering Information
the original A609/A609M practice and requires calibration
3.1 Theinquiryandordershouldspecifywhichprocedureis
using a series of test blocks containing flat bottomed holes. It
tobeused.Ifaprocedureisnotspecified,ProcedureAshallbe
also provides supplementary requirements for angle beam
used.
testing. Procedure B requires calibration using a back wall
3.2 Procedure A—Flat-Bottomed Hole Calibration Proce-
reflection from a series of solid calibration blocks.
dure:
NOTE 1—Ultrasonic examination and radiography are not directly
3.2.1 When this practice is to be applied to an inquiry,
comparable.ThisexaminationtechniqueisintendedtocomplementGuide
contract, or order, the purchaser shall furnish the following
E94 in the detection of discontinuities.
information:
1.4 The values stated in either inch-pound units or SI units
3.2.1.1 Quality levels for the entire casting or portions
are to be regarded separately as standard. Within the text, the
thereof,
SI units are shown in brackets. The values stated in each
3.2.1.2 Sections of castings requiring longitudinal-beam
system are not exact equivalents; therefore, each system must
examination,
beusedindependentlyoftheother.Combiningvaluesfromthe
3.2.1.3 Sections of castings requiring dual element exami-
two systems may result in nonconformance with this practice.
nation,
1.5 This standard does not purport to address all of the
3.2.1.4 Sectionsofcastingsrequiringsupplementaryexami-
safety concerns, if any, associated with its use. It is the
nation, using the angle-beam procedure described in Supple-
responsibility of the user of this standard to establish appro-
mentary Requirement S1 in order to achieve more complete
priate safety and health practices and determine the applica-
examination, and
bility of regulatory limitations prior to use.
3.2.1.5 Anyrequirementsadditionaltotheprovisionsofthis
practice.
2. Referenced Documents
3.3 Procedure B: Back-Wall Reflection Calibration
2.1 ASTM Standards:
Procedure—Whenthisprocedureistobeappliedtoaninquiry,
contract, or order, the purchaser shall designate the quality
levels for the entire casting or applicable portions.
This practice is under the jurisdiction of ASTM Committee A01 on Steel,
Stainless Steel and RelatedAlloys and is the direct responsibility of Subcommittee
A01.18 on Castings.
Current edition approved March 10, 2002. Published July 1992. Originally Annual Book of ASTM Standards, Vol 01.02.
published as A609–70. Last previous edition A609/A609M–90. Annual Book of ASTM Standards, Vol 03.03.
2 5
For ASME Boiler and Pressure Vessel Code applications, see related Specifi- Available fromAmerican Society for Nondestructive Testing, P.O. Box 28518,
cation SA-609 of Section II of that Code. 1711 Arlingate Ln., Columbus, OH 43228-0518.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.
A 609/A 609M – 91 (2002)
PROCEDURE A—FLAT-BOTTOMED HOLE
CALIBRATION PROCEDURE
4. Apparatus
4.1 Electronic Apparatus:
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
accordancewithPracticeE317orequivalentelectronicmeans.
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
toallowmeasurementofsignalsbeyondthelinearrangeofthe
instrument.
4.2 Search Units:
4.2.1 Longitudinal Wave,internallygrounded,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
NOTE 1—Opposite ends of reference block shall be flat and parallel
from1to5MHzshallbeused.Thebackgroundnoiseshallnot
within 0.001 in. [0.025 mm].
NOTE 2—Bottom of flat-bottom hole shall be flat within 0.002-in.
exceed 25% of the distance amplitude correction curve
[0.051 mm] and the finished diameter shall be ⁄4 + 0.002 in. [6.4 +
(DAC).Transducers shall be utilized at their rated frequencies.
0.050].
4.2.2 Dual-Element,5-MHz,½by1-in.[13by25-mm],12°
NOTE 3—Hole shall be straight and perpendicular to entry surface
includedanglesearchunitsarerecommendedforsections1in.
within 0°, 30 min and located within ⁄32 in. [0.80 mm] of longitudinal
[25 mm] and under.
axis.
4.2.3 Other frequencies and sizes of search units may be 1 1
NOTE 4—Counter bore shall be ⁄2 in. [15.0 mm] diameter by ⁄8 in. [5
used for evaluating and pinpointing indications. mm] deep.
FIG. 1 Ultrasonic Standard Reference Block
4.3 Reference Blocks:
4.3.1 Referenceblockscontainingflat-bottomholesshallbe
TABLE 1 Dimensions and Identification of Reference Blocks in
used to establish test sensitivity in accordance with 8.2.
the Basic Set (See Fig. 1)
4.3.2 Reference blocks shall be made from cast steels that
Metal Overall Width or Block
give an acoustic response similar to the castings being exam-
Hole Diameter
Distance Length Diameter Identifi-
ined. in ⁄64 ths, in.
A
(B),in. (C),in. (D), min, cation
[mm]
4.3.3 The design of reference blocks shall be in accordance [mm] [mm] in. [mm] Number
withFig.1,andthebasicsetshallconsistofthoseblockslisted
16 [6.4] 1 [25] 1 ⁄4 [45] 2 [50] 16-0100
16 [6.4] 2 [50] 2 ⁄4 [70] 2 [50] 16-0200
inTable 1.When section thicknesses over 15 in. [380-mm] are
16 [6.4] 3 [75] 3 ⁄4 [95] 2 [50] 16-0300
to be inspected, an additional block of the maximum test
16 [6.4] 6 [150] 6 ⁄4 [170] 3 [75] 16-0600
thickness shall be made to supplement the basic set. 3
16 [6.4] 10 [255] 10 ⁄4 [275] 4 [100] 16-1000
3 B
16 [6.4] B B + ⁄4 [B + 20] 5 [125] 16-B00
4.3.4 Machined blocks with ⁄32-in. [2.4-mm] diameter flat-
1 A
bottom holes at depths from the entry surface of ⁄8 in. [3 mm], Tolerance 6 ⁄8 in. [3 mm].
B
Additional supplemental blocks for testing thickness greater than 10 in. [250
1 1 3 3
⁄2 in. [13 mm], or ⁄2 t and ⁄4 in. [19 mm], or ⁄4 t (where t =
mm], see 4.3.3.
thickness of the block) shall be used to establish the DAC for
the dual-element search units (see Fig. 2).
4.3.5 Each reference block shall be permanently identified
5.2 Personnel performing ultrasonic examinations in accor-
alongthesideoftheblockindicatingthematerialandtheblock
dance with this practice shall be familiar with the following:
identification.
5.2.1 Ultrasonic terminology,
4.4 Couplant—A suitable couplant having good wetting
5.2.2 Instrument calibration,
characteristics shall be used between the search unit and
5.2.3 Effect of transducer material, size, frequency, and
examination surface. The same couplant shall be used for
mode on test results,
calibrations and examinations.
5.2.4 Effect of material structure (grain size, cleanliness,
etc.) on test results,
5. Personnel Requirements
5.2.5 Effect of test distance on test results,
5.1 The manufacturer shall be responsible for assigning 5.2.6 Effect of nonlinearity on test results,
qualified personnel to perform ultrasonic examination in con- 5.2.7 Effect of thickness and orientation of discontinuities
formance with the requirements of this practice. on test results, and
A 609/A 609M – 91 (2002)
NOTE 1—Entrant surface shall be 250 µin. [6.3 µm] or finer.
NOTE 2—The ⁄32-in.[2.4mm]flat-bottomholemustbeflatwithin0.002in.[0.05mm].Diametermustbewithin+0.005in.[0.13mm]oftherequired
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
5.2.8 Effect of surface roughness on test results. 8.2 Using the set of reference blocks spanning the thickness
5.3 Aqualification record (see Note 2) of personnel consid- of the casting being inspected, mark the flat-bottom hole
ered suitable by the manufacturer to perform examinations in indication height for each of the applicable blocks on the
accordance with this practice shall be available upon request. cathode ray tube shield. Draw a curve through these marks on
the screen or on suitable graph paper. The maximum signal
NOTE 2—SNT-TC-1A, Ultrasonic Testing Method, provides a recom-
amplitude for the test blocks used shall peak at approximately
mended procedure for qualifying personnel. Other personnel qualification
three-fourthsofthescreenheightabovethesweepbyuseofthe
requirement documents may by used when agreed upon between the
purchaser and the supplier.
attenuator.Thiscurveshallbereferredtoasthe100%distance
amplitude correction (DAC) curve. If the attenuation of ultra-
6. Casting Conditions
sound in the casting thickness being examined is such that the
6.1 Castings shall receive at least an austenitizing heat
system’s dynamic range is exceeded, segmented DAC curves
treatment before being ultrasonically examined.
are permitted.
6.2 Test surfaces of castings shall be free of material that
8.3 The casting examination surface will normally be
will interfere with the ultrasonic examination. They may be as
rougher than that of the test blocks; consequently, employ a
cast, blasted, ground, or machined.
transfer mechanism to provide approximate compensation. In
6.3 The ultrasonic examination shall be conducted prior to
order to accomplish this, first select a region of the casting that
machining that prevents an effective examination of the cast-
has parallel walls and a surface condition representative of the
ing.
restofthecastingasatransferpoint.Next,selectthetestblock
whose overall length, C (Fig. 1), most closely matches the
7. Test Conditions
reflection amplitude through the block length. Place the search
7.1 To assure complete coverage of the specified casting
unit on the casting at the transfer point and adjust the
section, each pass of the search unit shall overlap by at least
instrument gain until the back reflection amplitude through the
10% of the width of the transducer.
casting matches that through the test block. Using this transfer
7.2 Therateofscanningshallnotexceed6in./s[150mm/s].
technique, the examination sensitivity in the casting may be
7.3 The ultrasonic beam shall be introduced perpendicular
expected to be within 630% or less of that given by the test
to the examination surface.
blocks.
8. Procedure
8.4 Do not change those instrument controls and the test
8.1 Adjust the instrument controls to position the first back frequency set during calibration, except the attenuator, or
reflection for the thickness to be tested at least one half of the calibrated gain control, during acceptance examination of a
distance across the cathode ray tube. given thickness of the casting. Make a periodic calibration
A 609/A 609M – 91 (2002)
TABLE 2 Rejection Level
during the inspection by checking the amplitude of response
from the ⁄4-in. [6.4-mm] diameter flat-bottom hole in the test
NOTE 1—The areas in the table refer to the surface area on the casting
block utilized for the transfer.
overwhichacontinuousindicationexceedingtheamplitudereferenceline
or a continuous loss of back reflection of 75% or greater is maintained.
NOTE 3—The attenuator or calibrated gain control may be used to
NOTE 2— Areas shall be measured from the center of the search unit.
changethesignalamplitudeduringexaminationtopermitsmallamplitude
NOTE 3—In certain castings, because of very long test distances or
signalstobemorereadilydetected.Signalevaluationismadebyreturning
curvature of the test surface, the casting surface area over which a given
the attenuator or calibrated gain control to its original setting.
discontinuity is detected may be considerably larger or smaller than the
8.5 During examination of areas of the casting having
actual area of the discontinuity in the casting; in such cases a graphic plot
parallel walls, recheck areas showing 75% or greater loss of that incorporates a consideration of beam spread should be used for
realistic evaluation of the discontinuity.
back reflection to determine whether loss of back reflection is
2 2
due to poor contact, insufficient couplant, misoriented discon- Area, in. [cm ]
Ultrasonic Testing Length, max,
(see 10.2.1 and
tinuity, etc. If the reason for loss of back reflection is not Quality Level in. [mm]
10.2.2)
evident, consider the area questionable and further investigate.
1 0.8 [5] 1.5 [40]
2 1.5 [10] 2.2 [55]
9. Report
3 3 [20] 3.0 [75]
9.1 The manufacturer’s report of final ultrasonic examina- 4 5 [30] 3.9 [100]
5 8 [50] 4.8 [120]
tion shall contain the following data and shall be furnished to
6 12 [80] 6.0 [150]
the purchaser:
7 16 [100] 6.9 [175]
9.1.1 The total number, location, amplitude, and area when
possible to delineate boundaries by m
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