IVECO NON−DESTRUCTIVE TESTS

Radiographic examination −
15−0161
Standard Defect classification − Callouts on drawing − Page 1/13
Methodology − Equipment Date 01.09.2010
All rights reserved. This standard must not be reproduced or in any way utilized by other parties without the written consent of IVECO

The present IVECO STD. corresponds in its contents to FIAT Standard 50161
Supervisor: IVECO STD. 19-0201
Manager: IVECO STD. 19-0201

1 PURPOSE

To specify a non−destructive test method through radiographic examination for the detection of de-
fects on semifinished and finished parts.

2 FIELD OF APPLICATION

Test procedure described in this Standard applies to semifinished or finished parts made of whatever
metallic material.

3 DEFECT EVALUATION

3.1 Definitions

See IVECO STD. 15−0160.

3.2 Evaluation

In the case of aluminum or magnesium alloy castings, defects are classified as follows:
− Defects subject to propagation (cracks, cold shuts, hot cracks, etc.).
− Isolated or single defects (shrinkages, inclusions, etc.) with lower stress concentration.
− Scattered defects (microshrinkages, shrinkage porosity or sponge, hot cracks, etc.).
HANDLING ON INTERLEAF

To evaluate aluminum or magnesium alloy casting defects see IVECO STD. 18−1402 and IVECO
STD. 18−1310 for iron castings.

Edition Date Description of modifications Group

1 24.02.2003 New.
2 01.09.2010 Supervisor, Manager and Standards Quoted updated.

TMD

IN CASO
ANYDIHARD
STAMPA LA IN
COPY COPIA
YOURÈ POSSESSION
DA RITENERSISHOULD
NON CONTROLLATA, PERTANTO,
BE CONSIDERED È NECESSARIO
NOT UP-TO-DATE. VERIFICARE
SEE L'AGGIORNAMENTO
RELEVAT WEB NELL'APPOSITO
SITE FOR UP-TO-DATE SITO WEB
DOCUMENT

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3.3 Defects subject to propagation

These discontinuities shall be considered as basis for rejection regardless of their location and size.

3.4 Isolated or single defects

The evaluation of the isolated or single defects shall be made by comparing the defect size which
appears on the radiograph with those of the reference radiographs (see IVECO STD. 18−1402).

Defects larger than those of the above reference standard radiographs shall be considered cause
for rejection. Two or more isolated defects can be accepted provided they are smaller than those
of the reference standard and more than 25 mm apart.

Two or more isolated defects contained in a 25 mm sided−square can be accepted if the sum of their
areas does not exceed the area of the defect on the reference standard radiograph.

3.5 Scattered defects

They shall be rated according to the seriousness of their radiographic appearance by comparison
with the reference radiograph (see IVECO STD. 18−1402).

Defects worse than the reference radiograph shall be considered cause for rejection.

4 CALLOUT ON DRAWINGS

The drawing or Specification of the component for which the radiographic inspection is requested
shall give the following indication:

“Radiographic examination according to IVECO STD. 15−0161”.

Moreover, the following information necessary to clearly identify the required part quality level shall
be included:
− Class of importance according to IVECO STD. 18−1402;
− Category identifying the component quality according to the acceptability standards.

This information shall be agreed between the stock Manufacturer and the User.

5 MARKING

5.1 Marking of stocks and/or inspected part

Each part inspected shall be permanently marked with serial numbers or letters proving that the test
was carried out: such numbers/letters will also identify and relate the part with the corresponding
radiographs or test Report.

Upon inspection, the “X” symbol shall be added on each acceptable part.

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5.2 Marking methods

Parts which conform to radiographic inspection requirements shall be marked in a manner and loca-
tion harmless to the part and which preclude removal by subsequent processing.

When so required on the Specification or drawing, part identification shall also be obtained by punch-
ing.

If part construction, finish or service requirements preclude the use of punching, identification may
be accomplished by dyeing and tagging.

5.3 Locating test area

If necessary and practicable, location markers whose images will appear on the film shall be placed
on the surface of the part in order that orientation of the film may be established and any defects
appearing on the film precisely located.

6 ACCEPTABILITY PARAMETERS

6.1 Criteria

The acceptability criteria are usually specified in the general acceptance requirements of stocks.

6.2 Limits

The acceptability limits can be indicated on the drawing or on the IVECO STDs. of the component.

7 TEST PROCEDURE

7.1 Preparation of stocks and/or finished parts

7.1.1 Surfaces of the parts to be inspected shall be so prepared as to avoid conditions which might impair
the examination reliability.

7.1.2 Accessible surfaces of welds to be radiographed shall be prepared as necessary and in accordance
with the welding process Specification so that valley between beads, weld ripples and other surface
irregularities are blended to a degree such that the resulting radiographic contrast due to surface
condition shall not mask or be confused with that of any defect.

7.1.3 Moreover, the bead surface shall blend smoothly and gradually into the base metal surface.

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7.2 Radiographic technique

The following conditions shall be met in establishing an x−ray technique:

7.2.1 Use either a suitable method of blocking lateral radiation or section equalizing, or suitable lead filters
at the tube window of the X−ray machine, where necessary.

7.2.2 Use as low kilovoltage as practicable as a function of thickness and type of material.

7.2.3 Use a high contrast, fine−grained film.

7.2.4 Develop films in baths with temperature between 18 and 21 °C, except in automatic continuous
equipment designed for operation at higher temperatures.

7.3 Radiograph processing

Radiographs shall be free from handling defects and shall be properly processed.

7.3.1 Areas to be radiographed

Unless otherwise specified, areas subject to the principal static or dynamic loads, or combination
thereof, shall be radiographed. These areas shall be called out on drawing by Engineering.

7.3.2 Examination before and after machining

When specified, radiographic inspection shall be performed at a stage in the process of manufacture
or assembly at which harmful subsurface and internal discontinuities can be detected.

If radiography is permitted prior to machining and it indicates the possible presence of dubious de-
fects in highly stressed areas these shall be re−examined by radiography after machining.

7.3.3 Nonfilm radiographic technique

The use of nonfilm radiographic techniques is permitted provided the method used is sufficiently
sensitive to resolve the required quality level.

7.3.4 Placement of the penetrameter to measure contrast and definition

A penetrameter shall be placed upon the source side of the part to be radiographed (see point
8.1.10) in such a way that the penetrameter axis is as perpendicular as possible to the direction of
radiation.

In the inspection of irregular parts the penetrameter shall be placed on the area of the part farthest
from the film.

If a number of parts are simultaneously exposed, a single penetrameter placed upon the source side
of the part at the outer edge of the cone of radiation will suffice.

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Where it is impracticable to place the penetrameter on the part to be X−rayed the penetrameter may
be placed on the upper surface of a block of the same material, having the same radiographic ab-
sorptivity and approximately the same thickness as the part and located on the film at the outer edge
of the cone of radiation or in the most unsuitable area for x−ray examination.

One penetrameter shall represent an area within which radiographic densities do not vary by more
than −15 or +30 percent from the density adjacent to the penetrameter.

In the case such conditions are not met, proceed with other radiographs and suitable penetrameters.

7.3.5 Location of film

During exposure the film shall be as close to the surface of the part as practicable.

7.3.6 Focal distance

For any type of radiograph, the ratio of the distance of the source of radiation from the nearest sur-
face of the part to the distance of the film from the source surface shall be such that the image quality
required by this standard is met.

7.3.7 Re−radiographing

Whenever there is doubt as to the interpretation or clarity of a radiograph, the part shall again be
radiographed.

8 EQUIPMENT AND CONSUMABLES

8.1 Test equipment

8.1.1 X−ray machine

It shall supply a maximum peak voltage which can produce a radiation of such a wave length as to
pass through the entire thickness of the test piece while obtaining the radiographic contrast specified
herein.

The dimension of the X−ray source shall be as small as practicable compatibly with the machine
design characteristics. In any case the X−ray source dimensions shall permit the specified radio-
graphic image sharpness to be obtained.

8.1.2 Filters

They shall be made up of material capable of filtering high−energy radiation.

Use of filters is recommended for voltages higher than 250 kV.

8.1.3 Screens

They shall be used when it is necessary either to absorb high−energy radiation or filter out scattered
radiation.

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8.1.3.1 Lead Screens to be used in cassette

Front and back screens shall be 0.1 to 0.15 mm and 0.2 to 0.25 mm thick, respectively.
They shall be used for voltages higher than 150 kV.

8.1.3.2 Lead screens incorporated In the film

The two screens are 0.05 mm thick. They can be used for voltages ranging from 120 to 150 kV.

8.1.3.3 Fluorescent screens

They are permitted only in particular cases and upon approval of Testing Labs.

8.1.4 Darkroom

It shall be suitably ventilated and maintained at a constant temperature (about 18 °C).

External lighting shall be prevented from entering the darkroom.

Darkroom shall be divided into two compartments: the dry side and the wet side.

8.1.4.1 Dry side

It includes tables for the assembly of cassettes and developing hangers’ shelves or cabinets for stor-
ing sensitive material, filters, cassettes, etc. The dry side shall be located as far as possible from
the wet side.

8.1.4.2 Wet side

It includes the processing means such as: developer, stop and fixing baths in thermostatic tanks.

8.1.5 Safe illumination

The film is particularly sensitive to the blue radiations and the blue component of the white light.

It is thus necessary to provide the darkroom with a number of green−yellow safety lamps located
at not less than 1 m from the workbench.

8.1.6 Developing thermostatic facilities

They can be either manually or automatically operated provided they meet the quality requirements
specified herein.

8.1.7 Negatoscopes

Their luminous intensity shall allow examination of radiographs of density up to D = 3 when mea-
sured with luminous spot densitometers.

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8.1.8 Adiactinic lamps

Adiactinic lamp color, candlepower and distance from the workbench shall be such as to produce
a maximum haze on the film of 0.3 density (intended as the log. 10 of the ratio of the incident−light
intensity, expressed in lux, and the transmitted light intensity).

8.1.9 Developing hangers

They shall be made of stainless steel and their configuration shall not cause irregularities during use.

8.1.10 Penetrameters

Penetrameters are image−quality indicators and they are used to evaluate the quality level of the
radiograph through determination of radiographic contrast and sharpness.

They shall be made from material having the same or approximately the same radiation absorption
of the material of the part being inspected. Thus, it is necessary that the Radiographic Laboratory
have available a complete set of penetrameters suitable for every thickness requirement for each
type of material to be inspected (e.g. aluminum alloy, etc.). ASTM E 142−type rectangular penetra-
meters are normally used although DIN 54109−EN 462 wire−type penetrameters are permitted.

8.1.10.1 Rectangular penetrameters (according to ASTM E 142)

They consist of a plaque (Figure 1) and a shim (Figure 2). The plaque has a known T thickness equal
to 2% of the shim S thickness which, to a certain degree, represents the thickness of the piece to
be radiographed.

The plaque permits useful information on radiographic contrast and definition to be obtained.

Dimensions in mm
j 4T j 1T j 2T G
B + 0.1

N + 0.1

F C + 0.1 M + 0.1 S + 0.1

D + 0.1
T + 10% = 2% of S
E + 0.1
A + 0.1
FIGURE 2

FIGURE 1

8.1.10.1.1 Identification of penetrameters and shim

a) Plaque identification
− Each plaque shall be identified with the chemical symbol of the constituent material and
a number indicating the S thickness (expressed in mm) of the shim which shall be matched
with the plaque. The symbol shall be made of lead and it shall be securely attached to the
plaque (see Figure 1).
In Table I the relevant symbols of commonest use materials are shown.

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b) Shim identification
− To identify the shim it is sufficient to mark the symbol of the constituent material and the
S thickness (mm) with an electric pen or other suitable means.
The symbols of the more commonly used materials are shown in Table I.

TABLE I − Material composition of plaques and shims

Symbol Material
Al Aluminum and aluminum alloys
Mg Magnesium and magnesium alloys
Fe Ferrous materials
Cu Copper and copper alloys
Ti Titanium

8.1.10.1.2 Sets of penetrameters

For each type of material Testing Labs shall have a suitable set of penetrameters and shims avail-
able to radiograph all the thickness range covered on drawings.

Normally, the sets of penetrameters according to ASTM E 142 meet this requirement.

8.1.10.1.3 Radiograph quality level requirements

The three quality levels tabulated below can be adopted on the basis of the number of holes (one,
two or three) visible in the developed image − see Table II.

TABLE II − Radiograph Quality Levels

Radiograph quality Minimum perceptible hole Equivalent

levels size sensitivity
(%)
1 1T 1.4
2 2T 2
3 4T 2.8

Usually, quality level 2 is used. Should quality levels 1 or 3 be used, the drawing or product specifica-
tion shall indicate these levels.

8.1.10.2 Wire penetrameters (according to DIN 54109)

They consist of a set of parallel metal wires contained in a low−absorption envelope (see Figure 3).

The wires permit useful information on radiographic contrast and sharpness to be obtained.

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8.1.10.2.1 Construction and identification of wire penetrameters

Wire−type penetrameters shall be made up of metal wires having the diameters shown in Table III.

1
The wire diameters decrease approximately in geometric progression with the quotient 10Ǹ .
10

This progression corresponds to the rounded off series of standard numbers Ra 10 to IVECO STD.
10−1008.

Each penetrameter consists of 7 wires arranged parallel and at a distance of 5 mm with respect
to each other. Wire length shall be 50 mm or 25 mm as shown in Table IV.

The penetrameter (see Figure 3) shall be marked for identification with the following information:
− DIN symbol according to DIN 31;
− Number 62 (indicates the year of introduction of the new wire penetrameters);
− Material symbol (e.g. FE);
− Number of the thickest wire (1 or 6 or 10);
− ISO symbol;
− Number of the thinnest wire (7 or 12 or 16).

Dimensions in mm

≈5
6x≈5
50

= ≈ 30

FIGURE 3

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TABLE III

Wire diameters Wire

Permissible identification
tolerance number
mm mm K
3.20 1
2.50 ± 0.03 2
2.00 3
1.60 4
1.25 5
1.00 ± 0.02 6
0.80 7
0.63 8
0.50 9
0.40 10
0.32 11
± 0.01
0.25 12
0.20 13
0.16 14
0.125 15
± 0.005
0.100 16
K This number is also the identification number of the BZ radio-
graph according to DIN 54109.

8.1.10.2.2 Sets of penetrameters

Table IV gives the code numbers, length and material composition of the wires of the penetrameters
to DIN 54109 used for some groups of materials to be inspected. In case the wire metal composi-
tions of the penetrameters used to inspect other groups of materials differ from those in Table IV,
penetrameters shall be made accordingly.

TABLE IV − Sets of penetrameters for some groups of materials

Groups of
Wire identification number Wire length Wire
Designation materials to
to Table III in mm materials
be inspected
DIN FE 1/7 1 2 3 4 5 6 7 50
Non− Ferrous
DIN FE 6/12 6 7 8 9 10 11 12 50 or 25
alloyed steel materials
DIN FE 10/16 10 11 12 13 14 15 16 50 or 25
DIN CU 1/7 1 2 3 4 5 6 7 50
Copper and
DIN CU 6/12 6 7 8 9 10 11 12 50 Copper
its alloys
DIN CU 10/16 10 11 12 13 14 15 16 50 or 25
DIN AL 1/7 1 2 3 4 5 6 7 50 Aluminum
DIN AL 6/12 6 7 8 9 10 11 12 50 Aluminum and
DIN AL 10/16 10 11 12 13 14 15 16 50 or 25 its alloys

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8.1.10.2.3 Radiographic quality level requirements

a) Identification number of the radiographic quality level

The radiographic quality level number (abbreviated by the letters BZ) represents the radiographic
quality level adopted.

It corresponds to the wire number, shown in Table III, of the thinnest wire distinguishable on the
radiograph after placement of the penetrameter on the farthest end of the part on the source side.
When evaluating the radiographic quality level the penetrameter image shall be completely visible
and no area shall be obscured or screened during exposure.

Generally, wires shall be considered detected when they are visible for the whole length.

If the length of the zone to be inspected is shorter than the length of the wires it will be sufficient
to detect the wire included in the area subject to inspection.

When inspecting welding beads the above condition is met even though the wire is not visible for
the whole length due to bead unevenness or internal discontinuities.

b) Categories of image quality

DIN Standard 54109, Part 2, gives two categories of image quality: Class I and Class II.

They have a different number identifying the quality (see point 8.1.10.2.3 a) to be achieved in a ra-
diograph with respect to the thickness of a given test piece.

Class II is normally used while Class I shall be adopted exceptionally.

The latter class involves each time the selection of the equipment and technique to be used; conse-
quently, it shall be indicated on the drawing or part Specification.

8.2 Films

8.2.1 Films shall be non−flammable and of high−contrast and fine−grain type. Moreover, contrast, sharp-
ness and speed characteristics shall meet the radiographic quality requirements specified herein.

Film shall also withstand abrasion, pressure prints, rubbing action and mechanical stress in general.

8.2.2 Film handling

Films shall be handled with care by holding them at the edges to avoid possible marks and/or kinks.

8.2.3 Film development requirements

Development time and temperature of photosensitive material shall be those recommended by the
film Manufacturer or those indicated in the qualification certificate of the product.

These parameters shall be constant and no photographic processing expedients shall be used to
compensate for possible exposure errors.

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8.2.4 Identification

Each radiograph shall bear a serial number or a code letter of the radiographic: inspection made on
the part to which it refers.

8.2.5 Storage

8.2.5.1 Storage of unexposed films

It should be noted that even the films stored adequately can fog due to cosmic radiations.
It is therefore necessary to conform to the expiration dates shown on the film original boxes.

The boxes shall never be placed horizontally one upon another in a damp place or stored at tempera-
tures higher than those recommended by the film Manufacturer.

The unexposed films shall be stored well away from X−rays or gamma−rays. Films which shall be
used within short time can be stored in the darkroom.

8.2.5.2 Filing of radiographs

Radiographs of parts of class of importance 1 shall be kept on file for at least 5 years while radio-
graphs of parts of class of importance 2 and 3 shall be kept available for at least 2 years.

9 EQUIPMENT EFFICIENCY AND MAINTENANCE

9.1 Equipment intended for a continuous service of not less than 8 hours shall be inspected at least once
a week.

9.2 A form shall be maintained at the equipment site on which the inspections shall be recorded at the
time they are performed along with the date of inspection.

10 PROTECTION AGAINST X−RAYS

It shall be checked every year using permanent quantimeters by SEPIN.

11 WORK CONDITIONS

Radiographic techniques and standards shall comply with the requirements specified herein.

The premises and equipment shall present no hazard to the safety of personnel or property.

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12 PERSONNEL

Personnel shall be quite trained.

Personnel qualification shall be 1st−2nd level according to ASNT−SNT−TC1A or similar provided
that recognized by IVECO S.p.A.
Inspection report shall be issued by 2nd or 3rd level certified personnel.

13 AUTHORIZATION

The Laboratory or Dept. responsible for the radiographic inspection shall have all the required autho-
rizations and shall strictly meet all regulations and provisions set by Law, in particular the following:
− Legge della Repubblica Italiana n° 1860 − 31/12/1962 (Peaceful use of nuclear energy) (G.U.
n° 27 30/1/1963).
− Decreto del Presidente della Repubblica Italiana n° 185 − 13/2/1964 (Equipment Safety require-
ments and protection of the operating personnel and the general public against ionizing radiation
effects resulting from peaceful use of nuclear energy) (Supplement to G.U. n° 95 16/4/1964);
Decrees and regulations issued later.

QUOTED STANDARDS

IVECO STD.: 10−1008, 15−0160, 18−1402, 18−1310, 19−0201.

DIN: 31, 54109.

ASTM: E 142.

EN: 462.

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