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This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles

for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.

Designation: E127 − 20

Standard Practice for


Fabrication and Control of Flat Bottomed Hole Ultrasonic
Standard Reference Blocks1
This standard is issued under the fixed designation E127; 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 (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.

1. Scope* priate safety, health, and environmental practices and deter-


1.1 This practice covers a procedure for fabrication and mine the applicability of regulatory limitations prior to use.
control of metal alloy reference blocks used in ultrasonic 1.10 This international standard was developed in accor-
examinations that contain flat bottom holes (FBH). dance with internationally recognized principles on standard-
1.2 These blocks may be used for checking the performance ization established in the Decision on Principles for the
of ultrasonic examination instrumentation and search units and Development of International Standards, Guides and Recom-
for standardization and control of ultrasonic examination of mendations issued by the World Trade Organization Technical
metal alloy products. Barriers to Trade (TBT) Committee.
1.3 The reference blocks described are suitable for use with 2. Referenced Documents
either the direct-contact method or immersion pulse-echo
ultrasonic methods. 2.1 ASTM Standards:2
1.4 Standard sets are described for flat surface sound entry; B107/B107M Specification for Magnesium-Alloy Extruded
the Basic set, Area-Amplitude set, and Distance Amplitude set. Bars, Rods, Profiles, Tubes, and Wire
B221 Specification for Aluminum and Aluminum-Alloy Ex-
1.5 The requirements for FBH fabrication may be applied to truded Bars, Rods, Wire, Profiles, and Tubes
round bar/billet reference standards and reference standards B241/B241M Specification for Aluminum and Aluminum-
fabricated from other product forms. Alloy Seamless Pipe and Seamless Extruded Tube
1.6 This practice does not specify reference reflector sizes E317 Practice for Evaluating Performance Characteristics of
or product rejection limits. It does describe fabrication prac- Ultrasonic Pulse-Echo Testing Instruments and Systems
tices and applied tolerances. In all cases of conflict between without the Use of Electronic Measurement Instruments
this practice and customer specifications, the customer speci- E428 Practice for Fabrication and Control of Metal, Other
fication shall prevail. than Aluminum, Reference Blocks Used in Ultrasonic
1.7 The values stated in inch-pound units are to be regarded Testing (Withdrawn 2019)3
as standard. The values given in parentheses are mathematical E1065 Practice for Evaluating Characteristics of Ultrasonic
conversions to SI units that are provided for information only Search Units
and are not considered standard. E1158 Guide for Material Selection and Fabrication of
Reference Blocks for the Pulsed Longitudinal Wave Ul-
1.8 This practice has incorporated the requirements of
trasonic Testing of Metal and Metal Alloy Production
Practice E428 and Guide E1158. Reference standards that were
Material (Withdrawn 2019)3
manufactured under Practice E428 and Guide E1158 comply
E1316 Terminology for Nondestructive Examinations
with the requirements of this practice.
E1324 Guide for Measuring Some Electronic Characteristics
1.9 This standard does not purport to address all of the of Ultrasonic Testing Instruments
safety concerns, if any, associated with its use. It is the E2375 Practice for Ultrasonic Testing of Wrought Products
responsibility of the user of this standard to establish appro-

1 2
This practice is under the jurisdiction of ASTM Committee E07 on Nonde- For referenced ASTM standards, visit the ASTM website, www.astm.org, or
structive Testing and is the direct responsibility of Subcommittee E07.06 on contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Ultrasonic Method. Standards volume information, refer to the standard’s Document Summary page on
Current edition approved Dec. 1, 2020. Published January 2021. Originally the ASTM website.
approved in 1958. Last previous edition approved in 2019 as E127 – 19ε1. DOI: 3
The last approved version of this historical standard is referenced on
10.1520/E0127-20. www.astm.org.

*A Summary of Changes section appears at the end of this standard


Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
E127 − 20
2.2 SAE Standards:4 obtain either a maximum number of back reflections from a
AMS 4928 Titanium Alloy Bars, Wire, Forgings, and Rings reference block or a maximum indication from its entry
6Al - 4V Annealed surface.
AMS 6409 Steel, Bars, Forgings, and Tubing 0.80Cr - 1.8Ni
- 0.25Mo (0.38 - 0.43C) (SAE 4340) Special Aircraft 3.2.1.1 Discussion—Angular error results when the entry
Quality Cleanliness, Normalized and Tempered surface, hole bottom, and back surface are not parallel to each
AMS 6415 Steel, Bars, Forgings, and Tubing 0.80Cr - 1.8Ni other.
- 0.25Mo (0.38 - 0.43C) (SAE 4340) 3.2.2 entry surface, n—the end of a reference block through
AMS 6484 Steel, Bars, Forgings, and Tubing 0.80Cr - 1.8Ni which ultrasonic energy must pass when reflections from the
- 0.25Mo (0.38 - 0.43C) (SAE 4340) Normalized and hole bottom are obtained.
Tempered 3.2.3 hole bottom, n—the flat reflecting surface in a refer-
QQ-A225/6 Aluminum Alloy, 2024, Bar, Rod, and Wire; ence block that is obtained by making the entire end of a drilled
Rolled, Drawn, or Cold Finished hole smooth and flat using best machining practices; the hole
QQ-A225/9 Aluminum Alloy 7075, Bar, Rod, Wire, and bottom is parallel to the entry surface of the block.
Special Shapes; Rolled, Drawn, or Cold Finished
3.2.4 hole size, n—the diameter of the hole in a reference
3. Terminology block that determines the area of the hole bottom.
3.1 Definitions—For definitions of terms not specific to this 3.2.5 metal distance, n—the distance in a reference block
practice, refer to Terminology E1316. from its entry surface to the hole bottom.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 angular error, n—the condition observed in ultrasonic 3.2.6 non-standard blocks, n—blocks fabricated from pro-
tests of reference blocks when the response from the hole duction material shapes, round and flat bar and billet, concave
bottom is not maximum while the search unit is positioned to surface standards, extruded, forged and additive manufactured
shapes.
4
Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,
3.2.7 standard block sets, n—flat entry surface blocks fab-
PA 15096, http://www.sae.org. ricated per Fig. 1.

FIG. 1 Standard Set Block Dimensions


E127 − 20
3.2.7.1 Discussion—Recommended Area Amplitude, Dis- determine the effect of variations in metal distance upon the
tance Amplitude, and Basic sets of these blocks are described ultrasonic response from detected discontinuities. Test sensi-
in Section 6. tivity standardizations and corrections for metal distance are
most reliable when made under the same conditions employed
4. Summary of Practice for the actual tests. For these purposes, reference blocks
4.1 Standard Sets (See 3.2.7) containing various combinations of hole size and metal dis-
4.1.1 These recommended sets are described in Section 6. tance are necessary.
Reference standard material is ultrasonically evaluated to 6.2 The following combinations or sets of blocks are rec-
ensure freedom from significant discontinuities and is then ommended:
precisely fabricated into cylindrical blocks of prescribed 6.2.1 Basic Set—The basic set consisting of ten reference
lengths. A single, flat-bottom hole of specific diameter is drilled blocks is listed in Table 1. Area-amplitude relations are
to a constant depth into the end of each block at its center, and obtained by intercomparison of blocks containing the 3 in.
the blocks are grouped into sets according to hole size and (76.2 mm) metal distance and 3⁄64 in., 5⁄64 in., and 8⁄64 in. (see
block length, or metal distance. Table 2 note) diameter holes, respectively. Distance-amplitude
4.1.2 Each block is checked ultrasonically using a calibrated relations are obtained by intercomparison of the blocks of
ultrasonic test system at a prescribed test frequency. Distance- various lengths which contain 5⁄64 in. diameter holes.
amplitude and area-amplitude characteristics are established
for sets of fabricated blocks using specific reflectors to provide NOTE 1—Direct conversion from inches to millimetres
(1 in. = 25.4 mm) gives hole size dimensions for which there are no
a standard response. Curves are plotted to establish the standard metric drills; however, Table 2 gives the nearest standard metric
interrelationship between the various blocks in the sets. drill size.
4.2 Non-Standard Blocks (See 3.2.6) 6.2.2 Area-Amplitude Set—The area-amplitude set consist-
4.2.1 Reference standard material is ultrasonically evalu- ing of eight ultrasonic standard reference blocks is listed in
ated to ensure freedom from significant discontinuities. The Table 3. Area-amplitude relationships are obtained by inter-
entry surface shall be free of surface discontinuities that would comparison of any three or more blocks with different flat
interfere with the sound beam. bottom-hole sizes at the same metal distance from front surface
4.2.2 Due to the variability of the end user test conditions, to hole bottom.
the curves plotting the interrelationship between the FBHs in 6.2.3 Distance-Amplitude Set—A distance-amplitude set
the standard are typically performed by the end user, not the may include any convenient number of the reference blocks
fabricator. shown in Table 4 and does not necessarily include all blocks
4.3 Selection of Material listed. A recommended distance-amplitude set contains at least
4.3.1 Section 7 of this standard contains guidance on the 12 blocks, and each set contains only one of the three hole sizes
selection and testing of material for ultrasonic reference shown in Table 4. Blocks comprising the 19 block distance-
standards. amplitude sets, which are customarily supplied commercially,
are indicated in Table 4. Increments of metal distance in each
5. Significance and Use of the three groups of blocks in the recommended set should be
5.1 Standard reference block sets per 4.1 fabricated in identical. Distance-amplitude relationships are obtained by
accordance with this practice will exhibit specific area- intercomparison of all blocks containing the same size hole.
amplitude and distance amplitude relationships only with an
immersion test at 5 MHz using the search unit, test instrument,
and test parameters described in this practice. Comparison tests TABLE 1 Dimensions and Identification of Reference Blocks in
at other frequencies or with uncalibrated instruments will not the Basic Set (see Fig. 1)
necessarily give the same relationships shown in this practice.
NOTE 1—Direct conversion from inches to millimeters
See Ref (1)5 for area-amplitude limitations at other frequencies
(1 in. = 25.4 mm) gives hole size dimensions for which there are no
and transducer diameters. Also see Ref (2) for cautions standard metric drills; however, Table 2 gives the nearest standard metric
regarding use of standard blocks for test standardizations. drill size.
5.2 Reference standards fabricated per 4.2 may utilize the Block
Hole Metal Overall
Diameter Distance Length
fabrication and verification techniques herein. Due to the Identi- (A) (B) (C)
variable nature of non-standard blocks, the details should be fication
Number ⁄
1 64 ths
in. mm in. mm
agreed upon in the ordering documents. in.
3-0300 3 3.000 76.2 3.750 95.2
6. Description of Various Recommended Sets 5-0012 5 0.125 3.2 0.875 22.2
5-0025 5 0.250 6.4 1.000 25.4
6.1 In ultrasonic testing of metals, a standard reference 5-0050 5 0.500 12.7 1.250 31.8
usually is necessary to establish a specified test sensitivity. A 5-0075 5 0.750 19.0 1.500 38.1
5-0150 5 1.500 38.1 2.250 57.2
standard ultrasonic reference also is required frequently to 5-0300 5 3.000 76.2 3.750 95.2
5-0600 5 6.000 152.4 6.750 171.4
8-0300 8 3.000 76.2 3.750 95.2
5
The boldface numbers in parentheses refer to a list of references at the end of 8-0600 8 6.000 152.4 6.750 171.4
this standard.

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E127 − 20
TABLE 2 Diameter of Flat-Bottom Holes in Inch-Pound Units and TABLE 4 Dimensions and Identification of Reference Blocks in
the Nearest Metric Drill Hole Diameter Distance-Amplitude Sets
NOTE 1—Ratio of the area of the nearest metric drill size to the area of Block Identifica- Metal Distance (B) Overall Length (C)
tion Number, 3-,
the inch-pound drill size is 1.016 throughout. in. mm in. mm
5-, and 8-A
Hole Diameter in Inch- Nearest Metric Drill
−0006B 0.0625 1.6 0.812 20.6
Pound Units, in. Size, mm
−0012B 0.125 3.2 0.875 22.2
1/64 0.40 −0025B 0.250 6.4 1.000 25.4
2/64 0.80 −0038B 0.375 9.5 1.125 28.6
3/64 1.20 −0050B 0.500 12.7 1.250 31.8
4/64 1.60 −0062B 0.625 15.9 1.375 34.9
5/64 2.00 −0075B 0.750 19.1 1.500 38.1
6/64 2.40 −0088B 0.875 22.2 1.625 41.3
7/64 2.80 −0100B 1.000 25.4 1.750 44.5
8/64 3.20 −0125B 1.250 31.8 2.000 50.8
−0150 1.500 38.1 2.250 57.2
−0175B 1.750 44.5 2.500 63.5
−0200 2.000 50.8 2.750 69.9
TABLE 3 Dimensions and Identification of Reference Blocks in −0225B 2.250 57.2 3.000 76.2
the Area-Amplitude Set (see Fig. 1) −0250 2.500 63.5 3.250 82.6
Hole Metal Overall −0275B 2.750 69.9 3.500 88.9
Block Diameter Distance Length −0300 3.000 76.2 3.750 95.3
Identi- (A) (B) (C) −0325B 3.250 82.6 4.000 101.6
fication −0350 3.500 88.9 4.250 108.0
Number ⁄
1 64 ths −0375B 3.750 95.3 4.500 114.3
in. mm in. mm
in. −0400 4.000 101.6 4.750 120.7
1-0300 1 3.000 76.2 3.750 95.3 −0425B 4.250 108.0 5.000 127.0
2-0300 2 3.000 76.2 3.750 95.3 −0450 4.500 114.3 5.250 133.4
3-0300 3 3.000 76.2 3.750 95.3 −0475B 4.750 120.7 5.500 139.7
4-0300 4 3.000 76.2 3.750 95.3 −0500 5.000 127.0 5.750 146.1
5-0300 5 3.000 76.2 3.750 95.3 −0525B 5.250 133.4 6.000 152.4
6-0300 6 3.000 76.2 3.750 95.3 −0550 5.500 139.7 6.250 158.8
7-0300 7 3.000 76.2 3.750 95.3 −0575B 5.750 146.1 6.500 165.1
8-0300 8 3.000 76.2 3.750 95.3 −0600 6.000 152.4 6.750 171.5
A
Hole diameters (A) 3⁄64, 5⁄64, and 8⁄64 in.
B
Blocks customarily included in commercial 19 block distance-amplitude sets.

6.3 If the blocks are to be used for immersion testing, they


should be suitably anodized or otherwise protected to enhance
TABLE 5 Recommended Reference Block Material
resistance to corrosion. Uncoated blocks shall be designated as
Material to be Tested Reference Material Typical Specification
Type 1; coated blocks shall be designated as Type 2. Aluminum 7075-T6 ASTM B221, ASTM
6.4 A number of important variables that affect the response B241/B241M, QQ-
A225/9
from reference blocks can be controlled during fabrication by --- 2024 ASTM B221, ASTM
accurate machining practices. The roughness of the entry B241/B241M, QQ-
A225/6
surface; the alignment of entry surface, hole bottom, and back Magnesium ZK60 ASTM B107/B107M
surface; and the surface condition of the hole bottom are the Titanium Ti-6Al-4V annealed AMS 4928
more important physical variables that must be controlled Low Alloy Steels 4340 annealed AMS 6484, AMS 6415,
AMS 6409
during the fabrication of reference blocks. The quality of
material used for blocks also is a factor.
6.5 Non-Standard Blocks—There are many different types reflectors, ultrasonically examine the reference block material
of reference blocks used in industry depending upon the size at the anticipated frequency and at a sensitivity that produces
and shape of the material to be examined. Some of the more an acoustic noise level of 20 % screen height. The entire block
common flat bottom hole (FBH) types are described in should be scanned from the surface which will be used for
Appendix X2. standardization. Any discrete indication that exceeds 40 %
7. Material Selection screen height should be cause to remove the material from
consideration as an ultrasonic reference block.
7.1 Recommended materials for standard block sets are 7.3.1 For materials with very low noise levels, this test may
listed in Table 5 (Practice E2375). be over-sensitive. Such materials may be ultrasonically exam-
7.2 For non-standard blocks, it is good practice to use a ined at a sensitivity that assures no signals will be present in the
sample removed from the production lot of material as the material that is more than half the response of the intended flat
reference block material. When this is not possible the refer- bottomed hole response. Suitable reference standards in acous-
ence block material should be of the same general shape and tically similar material will be required for standardization of
dimensions, surface finish, chemical composition, and micro- the test.
structure as the production material to be examined. 7.4 Methods for determining acoustic compatibility of ref-
7.3 To ensure that the material chosen is suitable for use as erence standards and material under test are typically defined
reference block material and is free of potentially interfering by the governing ultrasonic test specification.

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E127 − 20
8. Fabrication Procedure the blocks shown in to Figs. X2.2-X2.5. A pilot hole is used to
8.1 Standard sets per 4.1 shall be fabricated to the dimen- locate and position the FBH thus eliminating the milling of the
sions of Fig. 1 and Table 6. steps. This allows the bar circumference to remain for support
during standardization which is much more representative to
8.2 The following machining sequence is recommended: production material. This method also results in an added
8.2.1 Machine all blocks to a uniform entry surface finish advantage for mechanical examination of rotating material by
and to the required dimensional tolerances. allowing signals from the reference block to be more easily
8.2.2 Drill the test hole to the nominal depth with a standard evaluated dynamically as the block is moved at the maximum
drill point. scanning rate.
8.2.3 Carefully prepare a flat-bottom drill or cutter with
8.4.1 The method is simply to use a larger pilot drill to
cutting edges square and flat within 0.0005 in. (0.013 mm) and
produce a hole to within a short distance of the depth of the
perpendicular to its longitudinal axis (flatness, squareness, etc.,
should be checked at a minimum of 60× magnification on an FBH. The body and bottoming drills for the FBH are then
optical comparator). successively mounted in a holder of the same diameter as the
8.2.4 Continue to drill as needed to remove all the conical pilot drill for the final drilling and flattening operations. This
configuration of the bottom of the hole helps to ensure that the flat bottom of the final hole will be
8.2.5 Remove drill, check cutting edge, regrind, if neces- parallel to a tangent of the top surface at a point immediately
sary. above the hole. This is due to the increased stiffness of the pilot
8.2.6 Remove an additional 0.005 in. (0.13 mm) of material drill and the holder being much greater than that of the smaller
from the hole bottom. final drills. That prevents skewing of the final holes that could
8.2.7 Recheck cutting edges of the drill on the optical result from deep drilling of a small hole due to excess drilling
comparator, regrind, if necessary, and repeat 8.2.5 and 8.2.6. speed or pressure or to grain anomalies or small hardness
Careful attention must be given to the squareness of corners of variations in the material that might deflect smaller drills if
the cutter; the slightest radius reduces the reflective area of the used for the total distance.
hole bottom. 8.4.2 The size of a typical pilot hole used for this purpose is
8.2.8 Typical Block Identification: 0.375 in. (9.53 mm). The pilot hole is typically drilled to within
approximately 0.50 in. (12.7 mm) of the final desired FBH
7075 = Typical alloy designation, depth. After the FBH is drilled, cleaned, and verified the
5 = Hole size in 1⁄64 in. increments, and entrance to the pilot hole must be sealed to prevent the entry of
0150 = 1.50 in. metal travel in 00.00 in. couplant or other foreign material.
8.3 Non-standard Blocks, fabricated from production 8.4.3 Fig. X2.1 shows cross sectional views of FBHs placed
shapes, bar/billet standards, curved surface standards, etc. will in a round bar by this method.
use the fabrication methods of 8.2 and the tolerances defined in 8.4.4 For standardization of a system for examination of
Table 6 as far as is practical. Surface finish on bar and billet cylindrical material, the bottom of the FBH fabricated in
standards is typically the finish supplied on the bar or as accordance with this procedure at any depth in the material
specified by the customer. For blocks such as concave stan- may be used for “static” standardization (that is, with no
dards where the surface is fabricated, the surface finish relative motion between standard and search unit). “Dynamic”
tolerance of Table 6 may be applicable. Metal distance is standardization is performed with rotary and translational
typically defined by governing Ultrasonic Method Specifica- motion between standard and search unit at the maximum
tions or as specified by the customer. speeds to be used for the final examination. In this case, the
8.4 Counterbore Method for Deep Flat Bottomed Holes— instrument alarm gate may be set to be activated by the signal
This describes a method for fabricating deep FBHs that can be from any FBH drilled to a depth of less than a radius of the
simpler, faster, and less expensive than those used to fabricate material while not responding to signals from the sides of the

TABLE 6 Fabrication Tolerances for Standard Set Blocks


Parameter Dimension Tolerance Dimension Metric (mm) Tolerance Metric (mm)
A. FBH Diameter Per Table 1, Table 3 ±0.0005 in. Per Table 1, Table 3 ±0,0127
B. Metal Distance Per Table 1, Table 3, Table 4 ±0.015 in. Per Table 1, Table 3, Table 4 ±0,381
C. Overall Length Per Table 1, Table 3, Table 4 ±0.005 in. Per Table 1, Table 3, Table 4 ±0,127
D. Hole Depth 0.75 in. ±0.005 in. 19,05 ±0,127
E. Block Diameter 2.0 in. ±0.020 in. 50,8 ±0,508
Block Diameter >6 in. TMD 2.5 in. ±0.030 in. 63,5 ±0,762
F. End Face Flatness Within 0.0005 in. --- Within 0,0127 ---
G. Parallelism Within 0.001 in. --- Within 0,0254 ---
H. FBH Perpendicularity Within 20 minutes --- Within 20 minutes ---
I. Hole Bottom Flatness 0.001 in. Per 0.125 in. 0.0254 Per 3,175
J. Centered Within 0.010 in. --- Within 0,254 ---
K. Counterbore 0.25 in. x 0.063 in. --- 6,35 x 1,6 ---
L. Block ID Size 0.12 in. min height 3,048 min height
M. Block ID Location 0.25 in. min from top 6,35 min from top
N. Entry Surface Finish 32 µinch max 0,8 µmeter max
Other Surface Finish 63 µinch nominal 1,6 µmeter nominal

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pilot or FBH drills as they enter the beam from the search unit. 9.1.4 Fill the hole beginning at the bottom and gradually
For C-scan standardization, all FBH depths can be gated at moving outward making certain that no air pockets or bubbles
once, the pilot holes show up separate from the FBH indica- remain in the hole.
tions. 9.1.5 Insert a small wire, pin, needle, or other suitable object
8.5 Diffusion Bonding Method—The diffusion bonding tech- that will serve as a rigid core and facilitate removal of the
nique offers an alternative method of reference block manu- replica.
facture. With this method, it is possible to fabricate reference 9.1.6 After curing, the replica may be removed and exam-
blocks containing flat disc-shaped ultrasonic reflectors instead ined. The replica shall indicate that the hole diameter and hole
of FBHs. In many cases, this permits the examination of the bottom flatness are within Table 6 tolerances and hole bottom
reference block from more than one direction, thus enhancing roughness shall not be greater than 16 µinch Ra finish. For
the utility of the block. record purposes, the replica may be projected on a comparator
8.5.1 A typical example is shown in Fig. X2.6 in Appendix screen and photographed as shown in Fig. 2, or other equiva-
X2. A diffusion-bonded reference block for small diameter lent techniques.
rounds could be fabricated as shown. A section is removed
10. Procedure for Assessing Ultrasonic Characteristics of
from one of the round bars to be examined. The bar section is
Blocks
split lengthwise and both split surfaces are carefully ground.
An end mill of the desired diameter is used to mill a shallow 10.1 For standard block sets, all measurements of area/
(typically 1⁄2 the hole diameter in depth) FBH in one of the split amplitude and distance amplitude characteristics are to be
sections. The sections are then bonded back together using the made using a 5 MHz, 3⁄8 in. (9.5 mm) flat transducer at a water
diffusion bonding process. (The application of heat and pres- path distance equal to the measured distance to the last
sure on the two sections for a period of time results in a sound near-field maximum (Y0+) and a calibrated test instrument.
diffusion bond which is indistinguishable ultrasonically from The transducer shall be characterized according to Practice
the normal structure.) (See Note 2.) The result is a reference E1065. Reference blocks that exhibit satisfactory external
standard that can be examined from either of two sides. physical characteristics and proper configuration of the hole
shall be subjected to additional examination to check their
NOTE 2—The time, temperature, and pressure requirements for a
diffusion bond are both material and configuration dependent and there-
ultrasonic response characteristics. If the ultrasonic-response
fore are beyond the scope of this practice. The American Welding Society characteristics are to be established by immersion techniques,
can furnish information on the subject. the drilled flat-bottom holes shall be cleaned and temporarily
8.5.2 With developed skills, all of the reference blocks plugged or sealed by some other suitable technique to ensure a
shown in Figs. X2.1-X2.5 along with many more types can be leak-tight closure. It is recommended that blocks fabricated as
successfully fabricated using the diffusion bonding technique. sets be compared with each other to determine their relative
8.5.3 Replication of the disc-shaped reflector in diffusion ultrasonic-response characteristics. This is particularly desir-
bonded reference blocks is not possible. An alternative method able in the cases of sets containing flat-bottom holes smaller
of determining whether the reflector has been distorted by the than 3⁄64 in. (1.2 mm) in diameter that cannot be satisfactorily
bonding process is to fabricate a second block under identical replicated.
conditions for destructive examination at the conclusion of the 10.2 Area/Amplitude Response Curves—An area/amplitude
process. set may contain several blocks with same external dimensions
and distance from the entry surface to the selected FBHs of
9. Checking Physical Characteristics varying sizes. An area/amplitude-response curve may be ob-
9.1 All dimensions of the reference blocks including the tained by recoding the gain setting required to set each block
diameter and perpendicularity of the examination hole may be response to a set full screen height reference level (choosing a
checked by normal quality control procedures for physical set value in the range of 50 % to 90 % is recommended).
measurements. The configuration, squareness, flatness, and Relative area on the X axis is the block number squared (a #8
surface finish for hole bottoms 3⁄64 in. (1.2 mm) in diameter and block is plotted as 64 relative area units.) The Relative Area X
larger may be checked by the following recommended tech- axis is plotted on a logarithmic scale. A typical area/amplitude
nique for making and evaluating plastic replicas: curve for a set of blocks is shown in Fig. 3. Any block that
9.1.1 Clean hole with a suitable oil-free noncorrosive sol- exhibits an erratic ultrasonic response and does not fall within
vent and dry with a stream of dried and filtered air. the apparent normal area/amplitude-response curve is consid-
9.1.2 Mix the replicating material in accordance with the ered unsatisfactory and shall not be used. Modification of the
manufacturer’s instructions. FBH to meet the required ultrasonic response is not an
9.1.3 Force the material into the hole with a disposable acceptable procedure. Area/amplitude responses between dif-
medical syringe and needle of adequate size. ferent FBH sizes are calculated by the formula

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FIG. 2 Shadow-Graph (20× Magnification) of ⁄ in. (6.4 mm) Diameter Flat-Bottom Hole Replica as Viewed on 62.5× Optical Comparator
16 64

with Commercial Viewing Screen (Reduced 1⁄2)

FIG. 3 Area Amplitude Response Plot

dB=20*LOG(A1⁄A2) where A1 and A2 are the areas of the flat 10.3 Distance Amplitude Response Curves—A distance/
bottomed holes. See S1 for additional ordering options. amplitude set may contain a number of blocks with identical

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E127 − 20
dimensions and hole sizes but with varying distances from the should be detailed in contract documents. End users may use
entry surface to the FBHs. A distance/amplitude-response the techniques above to gauge the non-standard block re-
curve may be obtained by adjusting and recording the gain sponse.
setting in dB which gives a response at a set full screen height
reference level (choosing a set value in the range of 50 % to 10.6 See Appendix X1 for alternate amplitude based plot-
90 % is recommended). A typical distance/amplitude curve for ting techniques.
a set of 15 blocks is shown in Fig. 4. Any block that exhibits
an erratic ultrasonic response and does not fall within the 11. Block Identification and Finish
apparent normal distance/amplitude-response curve should be 11.1 Reference blocks exhibiting acceptable physical di-
considered unsatisfactory and shall not be used. Under no mensions and ultrasonic-response characteristics may be sub-
circumstances may the FBH be altered to change the ultrasonic mitted to the following procedures for identification and
response characteristics of the reference block. application of protective finish:
NOTE 3—Because of the resolution obtainable with 5 MHz transducers, 11.1.1 Identification—Each block must be permanently
blocks with metal distances of less than 0.500 in. (12.7 mm) may not be marked (metal stamping or engraving required) with the
able to be checked in accordance with this recommended practice. See S2 material AISI alloy or grade, or both, size of the examination
for additional ordering options.
hole in 1⁄64 in. (0.4 mm) increments and distance in inches from
10.4 Basic Set—The 3-0300, 5-0300, and 8-0300 blocks the entry surface to the FBH. For example, the identification of
may be plotted as an area amplitude set. The 5-#### blocks 4340-5-0300 signifies an AISI 4340 steel reference block with
may be plotted as a distance amplitude set. The 8-0600 block a 5⁄64 in. (2.0 mm) diameter FBH at a 3 in. (76 mm) distance
response may be compared to response of the 5-0600 block. from the examination surface. Serial numbers shall be trace-
10.5 Non-Standard Blocks are typically not plotted by the able to the certification and block response curves. For non-
fabricator due to the variabilities of probe styles that will be standard blocks, the identification shall be specified by the
used during test. Any testing to be performed by the fabricator customer.

FIG. 4 Distance Amplitude Response Plot

8
E127 − 20
11.1.2 Protective Finish—After plugging of the FBHs per 14. Technical Precaution
Section 13, a protective coating may be applied to the exterior
14.1 When Practice E127-type reference blocks are used for
surfaces of reference blocks fabricated from corrodible-type
transfer or penetration comparisons, caution is recommended.
materials. However, the coating must not significantly affect
Back wall reflection amplitude measurements may be influ-
the physical dimensions or ultrasonic-response characteristics
enced by sidewall reinforcement or edge-to-center differences
of the blocks. Generally, nickel plating to a maximum thick-
in metallurgical structure. Practice E127-type blocks were
ness of 0.0008 in. (0.020 mm) is an acceptable coating for
carbon and alloy steel blocks and anodizing is acceptable for designed primarily for flat bottomed hole amplitude response
aluminum blocks which are to be used in a corrosive environ- comparisons in flat surface material of 2 in. width or greater.
ment. Recent work has suggested that a more appropriate use is in
determining comparisons and consistency of characteristics of
12. Additional and Equivalent Blocks instruments and transducers (see Ref (2)). Practice E317 and
12.1 Additional blocks can be used, where advantageous, to Guide E1324 are examples of specifications which utilize the
supplement the recommended sets. If additional blocks are standard reference block sets. Caution must be exercised when
fabricated, their ultrasonic response should conform to the using these blocks for other purposes.
area-amplitude and distance-amplitude interrelationships de- 14.2 The physical and ultrasonic characteristics of the block
fined by the curves in Fig. 3 and Fig. 4. sets measured in Section 10 represent the dimensions and
12.2 Blocks that do not meet the ultrasonic response re- ultrasonic response at the time of manufacture. Factors such as
quirements given in Section 10 are not considered equivalent to use in corrosive environments (immersion use) and leakage or
the ASTM E127 Ultrasonic Standard Reference Blocks. If they damage to hole plugs, etc., can cause changes to ultrasonic
meet all other requirements, and if a correction curve or table response over time.
is furnished with these blocks so that their amplitude response 14.2.1 Re-verification of ultrasonic response on a periodic
can be corrected to give a response equivalent to the require- basis is recommended; the re-verification period should be
ments of this recommended practice, they may be considered determined by severity of conditions in which they are used
ASTM-type reference blocks. and criticality of the inspections. Re-verification of the overall
12.3 Excessive wear and use may require the occasional block physical condition (obvious corrosion or damage that
introduction of a newly-fabricated block into an existing set. may interfere with the ultrasonic response) may be necessary at
These replacement blocks must align (fit in) with Fig. 3 and periodic intervals; however, this does not include the physical
Fig. 4, or both. characteristics of the FBH.

13. Plugging Procedure 15. Report


13.1 Reference blocks that have met the requirements for
15.1 Report the following information:
physical dimensions and ultrasonic response and have been
properly identified may be plugged in accordance with the 15.2 Equipment Used:
following recommended procedure: 15.2.1 Instrument: manufacturer, model and serial numbers.
13.1.1 Clean the examination hole with a noncorrosive 15.2.2 Search unit: diameter, frequency, and serial number.
solvent and dry with a stream of filtered and dried air.
13.1.2 Insert a press-fitted plug (same alloy as reference 15.3 Area/Amplitude Block Sets:
block) in the counterbore opening as shown in Fig. 1. 15.3.1 Numerical response values obtained by procedure
13.1.3 Seal the opening by peening the edges of the plug to 10.2.
move the metal outward against the sides of the counterbore. 15.3.2 Provide data plot in accordance with Fig. 3.
13.1.4 Grind as needed to blend the back surface and plug to
the required tolerances shown in Table 6. 15.4 Distance/Amplitude Block Sets:
13.2 An optional plugging method that may be used on 15.4.1 Numerical response values obtained by procedure
reference blocks fabricated from non-corrodible alloys is as 10.3.
follows (also typically applied to non-standard blocks of all 15.4.2 Provide data plot in accordance with Fig. 4.
alloys): 15.5 Basic Sets:
13.2.1 Clean the examination hole as described in 13.1.1. 15.5.1 For 3-0300, 5-0300, and 8-0300, follow 10.2.
13.2.2 Insert a 1⁄8 in. (3.2 mm) long press-fitted phenolic or
TFE-fluorocarbon plug to 1⁄2 the hole length. 15.5.2 For all other blocks, follow 10.3 for applicable metal
13.2.3 Fill the remainder of the hole with silicone rubber distances.
compound or suitable epoxy sealant.
13.2.4 Blend the plug to the back surface as needed. The 16. Keywords
machined counterbore may be omitted if this plugging tech- 16.1 aluminum reference blocks; area-amplitude reference
nique is used. An adequate air gap must be maintained at the blocks; distance-amplitude reference blocks; nondestructive
hole bottom. testing; standard reference blocks; ultrasonic reference blocks

9
E127 − 20
SUPPLEMENTARY REQUIREMENTS

The following supplementary requirements shall apply only when specified by the purchaser in the
inquiry, contract, or order. Details shall be agreed upon by the manufacturer and the purchaser.

S1. Area Amplitude Acceptance Criteria reference level than it should on a dB plot or gives an
S1.1 When specified on ordering documents, the block amplitude response equivalent to 3 dB higher than the normal
responses shall fall within +2, -3 dB relative to an ideal curve. curve on an amplitude plot.
The ideal curve is plotted by calculating the gain difference
between the #8 block relative area and each flat bottomed hole S2. Distance Amplitude Acceptance Criteria
number relative area. The same offset gain is applied to each S2.1 When specified on ordering documents, the block
point to align the ideal curve with block set data. Error bars are responses shall fall within +2 dB, -3 dB relative to a best fit
applied as +2 dB, -3 dB ideal values. Actual gain values at curve. If error bars are not included on the plot, block values
reference for each block shall be recorded in a table or as shall be empirically verified to be within tolerance. Reference
call-outs on the plot and included in the certification. Reference Fig. S2.1.
Fig. S1.1. The rational for this tolerance is that when using a block set
The rational for this tolerance is that when using a block set for future production testing:
for future production testing: (1) +2 dB would result in a production test that was 2 dB
(1) +2 dB would result in a production test that was 2 dB under sensitive. The point requires 2 dB lower gain to get to
under sensitive. The point requires 2 dB lower gain to get to reference level than it should on a dB plot or gives an
reference level than it should on a dB plot or gives an amplitude response equivalent to 2 dB lower than the normal
amplitude response equivalent to 2 dB lower than the normal curve on an amplitude plot.
curve on an amplitude plot. (2) -3 dB would result in a production test that was 3 dB
(2) -3 dB would result in a production test that was 3 dB over sensitive. The point requires 3 dB higher gain to get to
over sensitive. The point requires 3 dB higher gain to get to reference level than it should on a dB plot or gives an

FIG. S1.1 Area Amplitude Response Plot with +2 dB, -3 dB Error Bars

10
E127 − 20

FIG. S2.1 Distance Amplitude Response Plot with +2 dB, -3 dB Error Bars

amplitude response equivalent to 3 dB higher than the normal curve on an amplitude plot.

APPENDIXES

(Nonmandatory Information)

X1. ALTERNATE AMPLITUDE PLOTTING TECHNIQUES

INTRODUCTION

Plotting of standard block sets by Amplitude vs. Metal Path or Area may be used to fulfill the
documentation of Section 10. Amplitude plots may be useful in the continuity of monitoring existing
sets or other customer needs.

X1.1 All measurements of area-amplitude and distance- tics are to be established by immersion techniques, the drilled
amplitude characteristics are to be made using a 5 MHz, 3⁄8 in. flat-bottom holes shall be cleaned and temporarily plugged by
(9.5 mm) flat transducer at a water path distance equal to the a press-fit TFE-fluorocarbon insert or sealed by some other
measured distance to the last near-field maximum (Y0+) and a suitable technique to ensure a leak-tight closure. It is recom-
previously linearity-calibrated test instrument. Reference mended that blocks fabricated as sets be compared with each
blocks that exhibit satisfactory external physical characteristics other to determine their relative ultrasonic-response character-
and proper configuration of the replicated hole shall be istics. This is particularly desirable in the cases of sets
subjected to additional examination to check their ultrasonic- containing flat-bottom holes smaller than 3⁄64 in. (1.2 mm) in
response characteristics. If the ultrasonic-response characteris- diameter that cannot be satisfactorily replicated.

11
E127 − 20
X1.2 Area/Amplitude Response Curves—An area/amplitude ⁄ of the distance range. Without changing any test parameters,
14

set may contain several blocks with same external dimensions the ultrasonic response from the remaining blocks with both
and distance from the entry surface to the selected FBHs of shorter and longer distances are plotted on the response curve.
varying sizes. An area/amplitude-response curve may be ob- A typical distance/amplitude curve for a set of Type AISI 4340
tained by adjusting the examination sensitivity to give a signal steel blocks is shown in Fig. X1.2. Any block that exhibits an
with an amplitude of 30 to 40 % of FSD from the block nearest erratic ultrasonic response and does not fall within the apparent
the middle of the range of the reflector sizes. Without changing normal distance/amplitude-response curve should be consid-
any examination parameters, the ultrasonic response from the ered unsatisfactory and shall not be used. Under no circum-
remaining blocks with both smaller and larger size reflectors stances may the FBH be altered to change the ultrasonic-
are plotted on the response curve. A typical area/amplitude response characteristics of the reference block.
curve for a set of 4340 steel blocks is shown in Fig. X1.1. Any
block that exhibits an erratic ultrasonic response and does not X1.4 Area/amplitude and distance/amplitude response
fall within the apparent normal area/amplitude-response curve curves are greatly affected by variations in the configuration of
is considered unsatisfactory and shall not be used. Modification the beam of the search unit, by the near field/far field
of the FBH to meet the required ultrasonic response is not an characteristics and by the horizontal and vertical linearity
acceptable procedure. responses of the test instrument. Therefore, consideration
should be given to the operating characteristics of the search
X1.3 Distance/Amplitude Response Curves—A distance/ unit and instrument (generally available from the equipment
amplitude set may contain a number of blocks with identical manufacturer) when evaluating the response curves from the
dimensions and hole sizes but with varying distances from the reference blocks.
entry surface to the FBHs. A distance/amplitude-response
curve may be obtained by adjusting the test sensitivity to give X1.5 As shown in Fig. X1.1 and Fig. X1.2, a gain increase
a signal with an amplitude of 70 to 80 % of FSD from a block may be used to provide more accurate details for blocks with
with a distance from the entry surface to the FBH in the lower responses of less than about 20 % of full scale.

FIG. X1.1 Typical Area Amplitude Ultrasonic Response Curve

12
E127 − 20

NOTE 1—Because of the resolution obtainable with 5 MHz transducers specified in 10.1, blocks with metal distances of less than 0.500 in. (12.7 mm)
may not be able to be checked in accordance with this recommended practice.
FIG. X1.2 Typical Distance-Amplitude Ultrasonic Response Curve

X2. TYPICAL NON-STANDARD BLOCK CONFIGURATIONS

X2.1 See Fig. X2.1, Fig. X2.2, Fig. X2.3, Fig. X2.4, Fig.
X2.5, and Fig. X2.6 for typical non-standard block
configurations.

NOTE 1—All holes are the same diameter.


FIG. X2.1 Typical Distance-Amplitude Reference Block Configuration for the Ultrasonic Testing of Large Metal and Metal Alloy Round
Bars of from 1 to 10 in. (25.4 to 254.0 mm) Diameter and Larger Capable of Dynamic Rotation for Standardization

13
E127 − 20

NOTE 1—All holes are the same diameter.


FIG. X2.2 Typical Distance-Amplitude Reference Block Configuration for the Ultrasonic Testing of Large Convex Surface Forgings

NOTE 1—Holes are of different diameters.


FIG. X2.3 Typical Area-Amplitude Reference Block for Use in Verifying Linearity on Round Bar Inspection Systems

NOTE 1—All holes are the same diameter.


FIG. X2.4 Typical Distance-Amplitude Reference Block for the Ultrasonic Testing of Large Square or Rectangular Bars Greater than 1 in.
(25.4 mm)

NOTE 1—Holes are of different diameters.


FIG. X2.5 Typical Area-Amplitude Reference Block for Use in Verifying Linearity on Bar Inspection Systems

14
E127 − 20

NOTE 1—The finish and fitup of the mating surfaces strongly influence the success of the bond.
FIG. X2.6 Typical Example of a Diffusion Bonded Reference Block for Small Diameter Round Bars

BIBLIOGRAPHY

(1) Anon., “Ultrasonic Measurement Services,” NIST Calibration Ser- the Calibration of ASTM E127—Type Ultrasonic Reference
vices Users Guide 1989. Ed., J. Simmons, NIST Special Publication Blocks,” National Bureau of Standards Technical Note 924, Note
250, 1989, pp 40–45. 1976.
(2) Beck, K.H., “Limitations to the use of Reference Blocks for Periodic (12) Cline, C. W., and Morgan, J. B., “Standardization in Ultrasonic
and Preinspection Calibration of Ultrasonic Inspection Instruments Testing,” Nondestructive Testing, Vol 23, July–August, p 23.
and Systems,” Materials Evaluation, Vol. 57, No. 3, March 1999. (13) Eitzen, D. G., et al., “Improved Ultrasonic Standard Reference
(3) Warchol, M. F., and Warchol, L. V., “E127 Reference Standards,” 40th Blocks,” National Bureau of Standards Report NBSIR 75-685, 1975.
Review of Progress in Quantitative Nondestructive Evaluation, 2015, (14) Panian, F. C., and Van Valkenburg, H. E., “Development of ASTM
pp. 1717–1728. Standard Reference Blocks for Ultrasonic Inspection,” Proceedings,
(4) Anon. (ASTM E07.06), “ASTM Research Report on E127 Annex,” American Society for Testing and Materials, Vol 59, 1959, pp
ASTM Research Report RR:E07-1000. 1237–1260.
(5) Blessing, G. V., “An Assessment of Ultrasonic Reference Block (15) Posakony, G. J., “Performance Differences in Quartz Ultrasonic
Calibration Methodology,” National Bureau of Standards Report Search Units,” Ultrasonic Materials Characterization, H. Berger
NBSIR 83-2710, 1983. and M. Linzer, eds., Proceedings of the First International Sympo-
(6) Blessing, G. V., and Eitzen, D. G.,“ Variables Affecting Ultrasonic sium on Ultrasonic Materials Characterization, NBS, Gaithersburg,
Reference Block Calibration,” 1982 Paper Summaries, ASNT Na- MD, June 7–9, 1978, National Bureau of Standards Special Publi-
tional Spring Conference, March 22–25, 1982, Boston, MA, pp. cation 596, 1980, pp 595–603.
287–291. (16) Slotwinski, J. A., and Blessing, G. V., “NIST Calibration of ASTM
(7) Blessing, G. V., and Eitzen, D. G., “Ultrasonic Artifact Calibration E127–Type Ultrasonic Reference Blocks,” NIST Report NISTIR
Methodology,” Offıce of Nondestructive Evaluation Technical 5430, U.S. Dept. of Commerce Technology Administration, NIST,
Activities, 1985, Edited by G. Birnbaum, National Bureau of Stan- Gaithersburg, MD, May 1994.
dards Report NBSIR 85-3187, 185. (17) Sushinsky, G. F., Eitzen, D. G., and Chwirut, D. J., “Improved
(8) Burley, C. E., “Calibration Blocks for Ultrasonic Testing,” Nonde- Ultrasonic Standard Reference Blocks,” National Bureau of Stan-
structive Testing—A Review, Edited by Harold Berger, ASTM, STP dards Report NBSIR 76-984, 1976.
624, 1977, pp 146–158. (18) Ginzel, E., and James, S., “Variables to Consider in the Fabrication
(9) Chwirut, D. J., “Recent Improvements to the ASTM-type Ultrasonic of Ultrasonic Reference Blocks,” The e-Journal of Nondestructive
Reference Block System,” National Bureau of Standards Report, Testing, Vol. 19, No. 5, 2014.
NBSIR 79-1742, 1979. (19) Beck, K. H., “Problems Using Flat Reference Blocks for Calibrating
(10) Chwirut, D. J., and Boswell, G. D.,“ The Evaluation of Search Units Ultrasonic Systems for Testing Cylindrical Material,” Material
Used for Ultrasonic Reference Block Calibrations,” National Bureau Evaluation, ASNT, Vol 62, No. 4, April 2004, pp. 427–429.
of Standards Report NBSIR 78-1454, 1978. (20) Beck, K. H., “Ultrasonic Area-Amplitude Linearity Limitations,”
(11) Chwirut, D. J., Sushinsky, G. F., and Eitzen, D. G., “Procedures for Materials Evaluation, ASNT, Vol 50, No. 8, August 1992.

15
E127 − 20
EXPLANATORY NOTES

NOTE 1—Read Ref (3). Mark Warchol inherited Fred Panion’s work on through the original work done by Fred Panion, there were attempts to use
the development of E127 a few years after Fred’s untimely passing. other frequencies, that is, 10 MHz and 15 MHz, but they were unsuccess-
Several anomalies were noted in the use of the standard and later attempts ful (amplitude response varied widely). This was due to the bandwidth and
to adhere to the requirement. After 20 years of investigation the points are: center frequencies of the transducers used.
(1) NIST has abandoned the certification/recertification of E127 stan- NOTE 3—Additionally, the differing grain structure mentioned in item 4
dards because of the problems of adhering to the E127 standard. It is greatly affects the response. This was not realized at the time of the early
rumored that the “standard set” still exists, but we have been unable to work and how this influenced the amplitude response. The combination of
confirm this. all three of these effects is why the “required response curves” were
(2) The transducer plays a part in the ability to match the curve. The changed and eventually removed from E127. Experiments on material
frequency and the bandwidth of the transducer greatly effects the curve made from various diameters of rod stock and plate stock have shown that
that is generated. (Note: a quartz transducer will not give the same results the distance amplitude response varies drastically from the original “rolled
as a PbMn.) round rod” standard blocks.
(3) The ultrasonic instruments used (which were state of the art at the
time) were nonlinear, suffered from inconsistent bandwidth, had gain NOTE 4—These finding are repeatable and currently used in R&D work
instabilities, as well as other issues. for grain sizing by measuring response variations in amplitude and
(4) The metal used for the original standard sets is not available today. frequency.
This is in Ref (3). The original material was “rolled round rod” and is no NOTE 5—The E127 standards were primarily developed for plate and
longer produced. The material used today is extrude rod. The two large cross section extrusions and forgings when the grain flow is parallel
processes yield drastically different grain structures as evidenced in the to the inspection surface. The authors of Ref (3) have performed extensive
plat presented in the paper. This is the major player in the shift of the work in verifying that the E127 standards work well for plate material but
response curve. are compromised when the grain structure of the part under test becomes
NOTE 2—Referencing items 2 and 3 from the list above—while digging oblique with reference to the sound travel direction.

SUMMARY OF CHANGES

Committee E07 has identified the location of selected changes to this standard since the last issue
(E127 – 19ε1) that may impact the use of this standard.

(1) Updated 14.2. (2) Added 14.2.1.

ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
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make your views known to the ASTM Committee on Standards, at the address shown below.

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16

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