Astm A418
Astm A418
Astm A418
Designation: A418/A418M − 15
NOTE 1—Sensitivity multiplication factor such that a 10 % indication at the forging bore surface will be equivalent to a 1⁄8 in. [3 mm] diameter flat
bottom hole. Inspection frequency: 2.0 or 2.25 MHz. Material velocity: 2.30 × 105 in./s [5.85 × 105 cm/s].
FIG. 1 Bored Forgings
NOTE 1—Sensitivity multiplication factor such that a 10 % indication at the forging centerline surface will be equivalent to a 1⁄8 in. [3 mm] diameter
flat bottom hole. Inspection frequency: 2.0 or 2.25 MHz. Material velocity: 2.30 × 105 in./s [5.85 × 105 cm/s].
FIG. 2 Solid Forgings
the number, amplitude, or location of discontinuities, or a conical surfaces of the forging shall be replaced by stepped
combination thereof, which give rise to ultrasonic indications. surfaces in order to maintain the ultrasonic beam perpendicular
3.2 The acceptance criteria shall be clearly stated as order to the longitudinal axis. Such stepped surfaces shall be shown
requirements. on the forging drawing.
4. General Requirements 4.4 Forgings may be tested either stationary or while rotated
by means of a lathe or rollers. If not specified by the purchaser,
4.1 As far as possible, the entire volume of the forging shall either method may be used at the manufacturer’s option.
be subjected to ultrasonic inspection. Because of fillets at steps Scanning speed shall not exceed 6 in./s [15 cm/s].
and other local configurations, access to inspect some portions
of a forging may be limited. 4.5 To ensure complete coverage of the forging volume, the
4.2 The ultrasonic inspection shall be performed after final search unit shall be indexed no more than 75 % of the
heat treatment of the forging. In those cases in which wheels, transducer width with each pass of the search unit. Mechanized
slots, or similar features are machined into the forging before inspection of the rotating forging wherein the search unit is
heat treatment, the entire forging shall be inspected ultrasoni- mechanically controlled is an aid in meeting this requirement.
cally before such machining, and as completely as practicable 4.6 Frequencies of 1, 2.25, and 5 MHz may be used for
after the final heat treatment. accurately locating, determining orientation, and defining spe-
4.3 For overall scanning, the ultrasonic beam shall be cific discontinuities detected during overall scanning as de-
introduced radially. To conform with this requirement, external scribed in 4.4.
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A418/A418M − 15
FIG. 3 Conversion Factors to Be Used in Conjunction with Fig. 1 and Fig. 2 if a Change in the Reference Reflector Diameter is Required
4.7 Axial scanning, if required, shall be performed at that 6.1.2 The horizontal linearity shall be checked on a distance
frequency and transducer diameter which minimizes interfer- calibration bar using the multiple order technique (see Practice
ing ultrasonic reflections due to forging geometry and which E317). The horizontal linearity shall be 62 % of the metal
gives optimum resolution. (Axial tests are normally used as a path.
supplement to radial tests.) 6.1.3 If the rotor has a coupling or similar thin axial section
5. Personnel Requirements with parallel sides, the accuracy of the linearity shall be
checked by ultrasonically verifying the thickness of the cou-
5.1 Personnel performing the ultrasonic examinations to this
pling or axial section. If necessary, minor adjustments for
practice shall be qualified and certified in accordance with a
differences in the ultrasonic velocities between the calibration
written procedure conforming to Recommended Practice No.
SNT-TC-1A or another national standard that is acceptable to bar and the forging shall then be made.
both the purchaser and the supplier. 6.2 Amplifier—The amplifier and display shall provide lin-
ear response within 62 %, up to 100% of full screen height.
6. Pulsed Ultrasonic Reflection Equipment and
Accessories 6.2.1 Amplifier Calibration—An amplifier vertical linearity
check shall be made prior to performing the test by observing
6.1 Electronic Apparatus—A pulse-echo instrument permit-
a multiple order pattern from a calibration block using a 2.25
ting inspection frequencies of 1, 2.25, and 5 MHz is required.
MHz transducer (see Practice E317). The first back reflection
The accuracy of discontinuity amplitude analysis using this
shall be set at 100 % of full screen height. The higher order
practice involves a knowledge of the true operating frequency
of the complete inspection system. One of the best ways to back reflections, 10 % and higher in amplitude, shall also be
obtain the desired accuracy is by use of a tuned pulser and positioned on the screen and their amplitudes noted. The first
narrow band amplifier of known frequency response, with back reflection shall be reduced to 50 % and then 25 % of full
either a broadband transducer, or a narrow-band tuned trans- screen height. The amplitudes of the higher order back reflec-
ducer of known and matching frequency. tions shall be noted at each step. The vertical linearity will be
6.1.1 Apparatus Qualification and Calibration—Basic considered acceptable if the signal heights of the higher order
qualification of the ultrasonic test instrument shall be per- reflections decrease in proportion to the decrease set for the
formed at intervals not to exceed 12 months or whenever first back reflection. The maximum acceptable error for the
maintenance is performed that affects the equipment function. decrease of the higher order reflections is the greater of 65 %
The date of the last calibration and the date of the next required of the expected back reflection height or 62 % of full screen
calibration shall be displayed on the test equipment. height.
15 in. [380 mm] or greater in diameter and bored sections 8.1.8 For indications in heavy sections, if the 0.5-in. [10-
having wall thicknesses of 7.5 in. [190 mm] or greater. mm] diameter transducer can be satisfactorily calibrated for the
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A418/A418M − 15
section, evaluate all indications located within the first 6 in. display none of the characteristics defined in 9.1.3.2 through
[150 mm] from the test surface using the 0.5 in. [10-mm] 9.1.3.4. Normal indications shall be reported individually.
diameter transducer, regardless of the transducer used to locate 9.1.3.2 Traveling indications are indications whose leading
the indication during the primary scan and regardless of the edge moves a distance equivalent to 1 in. [25 mm] or more of
scan method employed during the primary scan (shaft rotating metal depth with movement of the transducer over the surface
or hand scan). of the forging. The variation in radial depth and planar area of
8.2 Supplementary Tests: traveling indications shall be determined and reported.
9.1.3.3 Planar indications shall be considered continuous
8.2.1 Special Radial Tests—Test at additional frequencies
over a plane if they have a major axis greater than 1 in. [25
may be used for accurately locating and determining the
mm]. Their minor axes shall be reported when measurable in
orientation of each recordable indication and for evaluating the
accordance with 8.1.7.2. In recording these flaw
minimum reflecting area of each large indication.
characteristics, corrections must be made for beam divergence
8.2.2 Axial Tests—When required, scan the flat surfaces at the estimated flaw depth.
normal to the forging axis. Establish the sensitivity level and 9.1.3.4 Indication levels are group indications 10 % (5⁄32 in.
recordable standards for the axial tests by agreement between [4 mm]) or larger of 100 % full screen height at the prescribed
purchaser and supplier (see 4.7). high sensitivity showing continuously on the screen as the
transducer is moved over the area tested.
9. Report 9.1.4 When required, recordable indications shall be ex-
9.1 The manufacturer’s report of final ultrasonic inspection pressed as minimum reflecting areas as follows:
shall contain the following data, and shall be furnished to the
purchaser: solid forgings:A F 5 A R 3SD a
L
2
3
P
10
(1)
9.1.1 Each diameter shall be numbered on a sketch starting
with rotor diameter No. 1 at the stenciled end. When an entire
rotor is tested, a complete sketch showing the diameters shall
bored forgings:A F 5 A R 3 SD Œa
L
2
3
P
10
b
d
(2)
be submitted with the test results. When a portion of the rotor where:
is tested, a sketch of the portion of the rotor tested shall be
AF = minimum reflecting area of discontinuity,
submitted. When no recordable indications are found, a sketch AR = reflecting area of reference (0.012 in.2 [8 mm2]),
is not required. a = distance to discontinuity, in. (or mm),
9.1.2 Recordable indications as described in 8.1.5 shall be L = distance to bore or centerline of solid forgings, in. (or
located on the sketch (see 8.1.1) (1) radially with respect to the mm), and
centerline or bore surface, (2) axially with respect to the P = discontinuity reflection amplitude (percent of sweep-
stenciled end of the forging, and (3) circumferentially with the to-peak CRT segment at the prescribed high-sensitivity
center point of the serial number which shall be used as 12 level).
o’clock. The accuracy of the indication characterization shall b = bore diameter
be sufficient to permit the relocation and reproduction of the d = forging cylinder diameter.
data. 9.1.5 Observable loss of bore or back reflection at the
9.1.3 Unless specified otherwise, the supplier shall report scanning sensitivity.
recordable indications as described in 8.1.5 as percentages of 9.1.6 Couplant.
the 100 % full screen height at the prescribed gain level, along 9.1.7 Type of instrument, manual or automated scanning,
with the distances to the discontinuity and to the bore or inspection frequency, and type transducers employed for the
centerline (solid forgings) and shall be identified as normal, inspection.
traveling, continuous, or indication level, or a combination 9.1.8 Inspector’s name or identity and date of test.
thereof. When flaw size estimates are required, these data shall
be used for calculations as indicated in 8.1.5 and as limited by 10. Keywords
X1.4 of Appendix X1. 10.1 generator material; nondestructive tests; rotors,
9.1.3.1 Normal indications are single indications that show turbine, or generator; steel forgings; steel forgings—alloy;
a normal decrease in amplitude as the search unit is moved in turbine materials; ultrasonic examination; ultrasonic examina-
any direction from the position of maximum amplitude and tion method
The following supplementary requirements apply when specified by the purchaser in the contract or
order.
S1. Forging Rotation During Examination S4. Use of Dual Element Transducers
S1.1 Forgings shall be rotated during testing by means of a S4.1 Dual-element transducers shall be used to axially
lathe or rollers. Scanning speed shall not exceed 6 in./s [15 inspect those regions of a forging containing a bore to ensure
cm/s]. coverage of areas in the near field of the single element
S2. Enhanced Inspection Coverage transducers used for axial scanning.
S2.1 The search unit shall be indexed approximately 50 % of S4.2 Dual-element transducers shall be used to inspect areas
the transducer width with each pass of the search unit. The near the back-wall of solid regions of forgings where indica-
search unit shall be held by a suitable fixture attached to the tions caused by noise exceed the reporting requirements shown
tool post of the lathe and traversed mechanically for scanning in 8.1.5.
of the rotating forging. See 8.1.6 for recommended forging
rotation speeds. S5. Surface Finish
S2.2 Hand-held transducer testing is only permitted in those
areas where the transducer holder interferes with the inspection S5.1 The surface finish shall not exceed 125 µin. [3.17 µm]
coverage. where the definition for surface finish is as per Specification
A788/A788M.
S3. Axial UT of the Entire Diameter
S3.1 The shape of the forging during axial UT shall be such
as to permit inspection of the entire outside diameter of the part
that will be machined from it.
APPENDIX
(Nonmandatory Information)
X1.1 Theoretical formulas relating properties, such as dis- λ = wavelength of sound used for inspection.
continuity area, distance, and echo amplitude, may be derived
at various levels of complexity. Detailed descriptions of such X1.2 Using the procedure described in the main body of this
methods of analysis may be found in standard texts on standard, the echo from a forging back wall or bore is set at
acoustics or ultrasonics, and will not be given here. The 100 % of (linear) screen height, and sensitivity is then adjusted
method used in deriving the curves of Fig. 1, Fig. 2, and Fig. by a multiplying factor M such that the theoretical echo
amplitude from a disk reflector of given area A at the forging
3 uses the spherical-wave approximation to describe the
centerline or bore surface would be 10 % of screen height, that
behavior of the sound field, with analytical techniques analo-
is, multiplying factor (M) times the echo from the small disk
gous to those of geometric optics. The resulting relations
reflector (A) would equal 10 % of the echo from opposite
between theoretical echo amplitudes are as follows:
surfaces of solid cylinders or from bore surfaces of bored
echo from small disk reflector 2dA cylinders. These multiplying factors would be:
5
echo from large plane or solid cylinder a 2 λ
S DS D
10 a 2λ dλ
Œ
Solid cylinder:M 5 5
echo from small disk reflector ~ d 2 b ! A d 100 2dA 80A
5
a2λ
where:
echo from cylindrical bore b
Bored cylinder:M 5
~d 2 b!λ
40A
Œ b
d
a = distance to disk reflector (flat-bottom hole), X1.3 The curves given in Fig. 1 and Fig. 2 have been
b = bore diameter, calculated from these formulas, using a reference disk-reflector
d = forging cylinder diameter, of 0.125-in. [3-mm] diameter, and values of sound velocity and
A = area of disk reflector, and
frequency typical for steel forging inspection to define the
SUMMARY OF CHANGES
Committee A01 has identified the location of selected changes to this standard since the last issue
(A418/A418M–10) that may impact the use of this standard. (Approved May 1, 2015.)
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