25 NOU "82 16:04 VON ABE KRAFTU. KW/PTOI SEITE 210 July 1985 STAHL-EISEN- PRUEFBLATT/ Ultrasonic testing of ferritic steel castings STEEL TRON TEST SHEET 1922 3rd Edition 1. Aim and manner of testing This sheet deals with the ultrasonic testing of ferritic steel castings for determining internal flaws as per the echo method. 2. Scope Thig sheet holds good for the testing of heat-treated unalloyed and alloyed ferritic steel castings with wall thicknesses of upto 60 mm, In the case of larger thicknesses special agreements relating to the method of testing and the registration levels are to be concluded, The requirements governing the suitability of the castings for ultrasonic testing end the limits for echo displays that need to be recorded are subdivided into test classes as per Sections 9 and 18.6. They are based on the envisaged stressing of the castings and are to be stipulated in the order after agreement between those concerned. Deviations can be agreed upon. 3. Terminology The terms for ultrasonic testing used in this steel iron test sheet correspond to the stipulations of DIN 54119 ~ Ultrasonic testing; terms. 4. Agreement to be concluded prior to the testing To be agreed upon while placing an order are: -- Scope of testing (see Section 10.1) -- Test class (see Section 19.8) Evaluation criteria (see Section 13) 5. Qualifications of the test personnel After training and accumulating experience, the testing personne! must be in a position to carry out tests properly in accordance with this steel-iron test sheet. The qualifications of the testing personnel as per specific training guidelines such as the Deutschen Gesellschaft25 Nov "821 VON @EB KRAFTUL KU/PTOX kaa fuer serstoerungsfreie Pruefung or the American Society for Non- destructive Testing (SNT-TC-1A) or even as per factory guidelines should be communicated to the client on request. SEITE @11 SEP 1922 The manufacturer has to nominate a qualified testing committee. 6. Preparation of the castings to be tested The test surface of the castings must be conditioned in such a manner that a trouble-free coupling of probes is possible. This is attained when the surface finish corresponds to the reference specimens 4 § 1 (in the case of blasted surfaces) or 4S 2 (in the case of ground surfaces) of the standard series CTIF-341-02. 7. Testing system 7.1 Specifications for the ultrasonic testing device The ultrasonic testing devices to be used mist correspond to the state of the art; this means they should possess the following features: =- Adjustment range (time-base renge) of at least 20 mm to 2 m infinitely variable for the longitudinal end transverse waves in steel. == Amplification in steps or Z @B over 4 cunye uf at least 68 dB and adjustable with a precision of 1 dB. -- Linearity of the time-base deflection (sweep) and a vertical linearity better than 5% of the adjustment renge or the height of the visual display screen. -- Usable with probes with a rated frequency of 1 to 6 MH2 for the echo method employing single probes and TR probes. 7.2 Probes and test frequency to be employed Depending on the geometry of the casting and the type of flaw to be detected, straight beam or angle beam probes or both are used for testing. For testing of regions lying next to the surface TR straight beam probes or TR angle beam probes are used. For inclined scanning an angle of incidence lying between 35 deg. - 76 deg. should be used. The rated frequency should lie in the range of 1 to 6 Miz.25 NOU '82 16:06 VON ABB KRAFTU. KU/PTOI SEITE o12 12] 23 / SEP 1922 7.3 Sensitivity of detection The sensitivity of detection of the testing system should guarantee the setting for the sensitivity of testing required as per Section 18.4. 7.4 Coupling medium The coupling medium should moisten the test surface well and guarantee an adequate transmission of. sound. The same coupling medium should be used for the adjustment and all euheequent tasting activities. 8. Setting of the testing device 8.1 Adjustment of the distance The adjustment on the visual display screen of the test device is carried out using straight beam or angle beam probes and the calibration block 1 as per DIN 54129, the calibration block 2 as per DIN 54122 or other adjusting blocks. Here the difference between the velocity of sound in the casting and in the calibration block is to be taken into account if necessary. When using normal (straight beam) probes the adjustment of the distance is to be carried out on the casting itself. 8.2 Adjustment of the amplification The adjustment of the amplificetion takes place through acoustic irradiation of s suitable reflector, e.g, the opposite surface of the casting or circular segments of calibration blocks as per DIN 54120 or DIN 54122. The display height in the depth range to be evaluated is characterised by the stipulation of the djgneter ofa diso shaped reflector in mm according to the DGS method : 1) Krautkreemer, J.: Arch. Eisenhuettenwes. 30 (1959) pages 693/703. See also Steel-Iron Conditions of Delivery @72-69 Supplementary Sheet 1. Details about the procedure for determining the disc shaped reflector size are accordingly described in the “Guidelines for the ultrasonic testing of weld seams” published by the German Society for Non-destructive Methods of Testing.25 NOU 'S2 16:07 ON ABB KRAFTU. KU/PTOL 13/24 9. Determination of the suitability for ultrasonic testing SEITE aig SEP 1922 The suitability for ultrasonic testing characterises the property of a casting material to render possible with adequate reliability the detection of a disc shaped reflector of a specific size. AS per agreement a reliable detection is understood to be the echo height of the concerned disc shaped reflector at the end of the depth range to be evaluated, and normally at # distance equal to the first back wall echo as por the PGS diagrams ), which lies at least 8 dB above the noise background . The suitability for ultrasonic testing is determined at locations without a display, which are indicative of the wall thickness of the casting and, because of their shape, guarantee the largest possible display height of the back wall echo, for example walls with parallel surfaces. According to agreement it holds good for castings for which this test wheet is used, that en adequate suitability for ultrasonic testing xists if disc shaped reflectors of 3 mm diameter of test class 1 and 6 mm diameter of test class II (see table 1) can be detected with adequate reliability. If the echo height of the smallest disc shaped reflector to be detected at the end of the depth range under evaluation is less than 8 aB above the noise background even when the method is eltered, ¢.2. by changing the test frequency, then a reduced suitability for ultrasonic testing is said to exist. To be noted in the test report jg thus the size of the disc shaped reflector as per the rau which can be still detected at a signal to noise background ratio of et least 6 4B. In this case the further procedure is to be decided between the manufacturer and the client. Note: For the determination of the suitability of castings for ultrasonic testing using perpendicular probing, one can for example proceed in such a manner that with the amplifier threshold of the testing device shut-off the back wall echo is brought to an arbitrary reference height. Subsequently the gain as per the DGS diagram is to be raised so high thet the echo height of the disc shaped reflector of 3 mm diameter of test class I and of 6 mmdiamster of test class II reach the reference height. Upon raising the amplification (gain) further by 8 dB the noise level may at the very most reach the reference height. If necessary a reference reflector can be used in areas without a back wall echo for determining the suitability for testing. 3) Sum of noise display and microstructure display.25 NOU 'S2 16:88 VON. ABB KRAFTW. KW/PTOI SEITE @14 ay [27 SEP 1922 . 19. Execution of the test 10.1 Scope of testing The casting regions to be tested as per agreement (see Section 4) should bo investigated in such a manner that the entire volume is covered so long as this is possible using the most favourable method of testing. 1®.2 General remarks on the testing procedure The selection of the direction of incidence and suitable probes (see also Section 7.2} is to a large extent dependent on the shape of the casting, the possible casting defects and the possible flaws in production welds. Accordingly the most desirable method shall be determined by the manufacturer. It is advantageous to fix the testing procedure through testing instructions keeping in mind the areas critical from the casting point of view. Production welds as well as areas endangered by cracks during manufacture are to be additionally ested with angle-beam probes. For test class I the regions to be examined for the casting (see Sections 4 and 1.1) are to be at least tested with straight beam probes, possibly starting from both surfaces. Areas accessible only from one side sre to be tested with straight beam probes and for registering reflectors lying near the surface also with TR probes. Testing with TR probes is sufficient for areas with wall thicknesses of upto 6@ um end accessible only from one side. If during the one side testing of castings indications of reflection points lying close to the probe are obtained, then near field resolution probes are to be used. In case special requirements relating to the testing procedure arise due to the intended use of the castings, then it is the duty of the customer to point this out to the manufacturer. 1.3 Scanning velocity the velocity of the probe should not exceed 10 om/s while testing. The scan paths are to be selected so close to one another such that a complete scanning of the volume to be tested iv vusured, In gonoral this is possible with an overlap of approx. one-fourth of the diameter of the transducer and in any one case depends on the type of probe. 18.4 Sensitivity of testing Basically the setting of the sensitivity of the testing system (sensitivity of testing) is to be preferably carried out at the casting. If thie is not possible, then the use of adjusting or calibration blocks es per DIN 54120 or 54122 is to be made. | Transfer correction, apart from the quality of the coupling surface, the surface finish of the opposite curface is to he also considered