Fig.

12 Ti-6Al-6V-2Sn -β forged billet illustrating macroscopic appearance of β flecks that appear as dark
spots. Etched with 8 mL HF, 10 mL HF, 82 mL H2O, then 18 g/L (2.4 oz/gal.) of NH4HF2 in H2O. Less than 1×

Unsealed center conditions are associated with insufficient ingot reduction. These are more prevalent in the larger stock
sizes (>230 mm, or 9 in., in diameter) and are normally removed by adequate croppage at the mill. Clean voids describe a
condition that can be associated with unsatisfactory sealing of porosity elsewhere in the ingot or through center porosity
formed during ingot reduction.

Nondestructive Inspection. Ultrasonic inspection is the most definitive and practical method of inspecting titanium
alloy forgings. Inspection techniques are normally tailored to the rejection level indicated in the specifications and to the
physical condition of the material being inspected. Surface conditions usually must be ideal, grain size must be fine, and
structural conditions must be controlled. Most airframe or similar static parts are inspected with equipment settings based
on a No. 3 flat-bottom-hole standard. For the examination of critical rotating forgings for aircraft gas-turbine engines, it is
not uncommon to inspect to the equivalent of a No. 1 flat-bottom-hole standard. Experience with these highly critical
forgings, which in service rotate at high speed in the presence of extreme temperature and pressure, has indicated that
small voids can initiate cracks and have caused catastrophic failures.

For satisfactory ultrasonic inspection of forgings to these stringent requirements, special techniques and equipment are
usually required. Specially designed ultrasonic electronic equipment is used with focused or otherwise unique
transducers. Also required are an immersion tank with rotating devices, automatic small incremental indexing devices,
and automatic alarms for signal level. Special reference blocks are required, along with the usual flat-bottom-hole
reference blocks. The correct indexing increment must be established, the linear alignment of the ultrasonic unit must be
verified, and calibration checks must be made. All information must be recorded and retained for future reference.

Nondestructive Inspection of Forgings

Visual Inspection

Despite the many sophisticated inspection methods available, unaided visual inspection is still important and is often the
sole method of inspecting forgings used for common hardware items. Under proper lighting conditions, the trained eye
can detect several types of surface imperfections, including certain laps, folds, and seams. Visual inspection is often used
first, then questionable forgings are further examined by macroetching and inspection with macrophotography or some
type of nondestructive method.

The only equipment necessary for visual inspection is a bench on which to place the forging and suitable cranes or hoists
for forgings that are too heavy to lift by hand. Good and well-controlled lighting conditions are essential. Optical aids
such as magnifying glasses that can magnify up to about ten diameters are often used to increase the effectiveness of
visual inspection.

Nondestructive Inspection of Forgings

Magnetic Particle Inspection

Magnetic particle inspection is useful for detecting surface imperfections as well as certain subsurface imperfections that
are within approximately 3 mm ( in.) of the surfaces in forgings of steel, some grades of stainless steel, and other
ferromagnetic metals. Magnetic particle inspection can be used with fluorescent particles and ultraviolet light. Detailed
information is available in the article "Magnetic Particle Inspection" in this Volume.

The advantages of magnetic particle inspection include the following: