JOHN DEERE WATERLOO

STANDARD
APPROVED FOR SUPPLIER DISTRIBUTION
JDT17015

RADIOGRAPHIC INSPECTION OF IRON CASTINGS

1. SCOPE

1.1 This standard deals with the radiographic inspection and quality requirements for the internal soundness

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of iron and steel castings. The documents and methods to be followed in the radiographic inspection of
castings by x-rays or gamma rays are referenced.

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1.2 The standard also defines indication types, severity levels, and inspection procedures. All castings shall
be free from gross or coarse defects. Casting surfaces shall be smooth, free of burned in sand, fins, gates,
cold shuts, cracks, hot tears, and the like. This standard applies to all iron and steel castings whether
referenced on the individual part drawing or not.

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1.3 The processes described in this standard may involve hazardous materials, operations, and equipment.
This standard does not purport to address any of the safety issues associated with its use. It is the
responsibility of the user to establish appropriate safety, health, and environmental practices and to
determine the applicability of any regulatory limitations.

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2. TEST METHODS, QUALITY LEVEL, AND EQUIVALENT SENSITIVITY
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2.1 Radiographic Test Methods and Quality Level

ASTM E1742 establishes the basic parameters for the application and control of the radiographic examination
method and ASTM E94 is a guide to radiographic examination. ASTM E1030 establishes a standard test
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method for the radiographic examination of metallic castings. The quality level required for the subject
radiographs shall be at least 2% (2-2T) as called out in ASTM E 94 and ASTM E1742 unless otherwise
specified. The penetrameter shall be placed on the source side of the casting radiographed.
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2.2 Qualifications of Radiographic Test Personnel

Radiographs will be set-up and taken by individuals that have attained at least a level 2 status as
outlined in ASNT SNT-TC-1A. Radiographs will be interpreted by a level 3 technician or a level 2 technician
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who is under the supervision of a level 3. Any other circumstances must have prior approval from John
Deere.

2.3 Back Scatter Determination

As a check on back scatter radiation, a lead symbol "B" with minimum dimensions of approximately 13mm
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length x 6mm width x 2mm thick shall be attached to the back of each film holder. If the image of "B" appears
on the radiograph, then protection from back scattering is not sufficient and the radiograph is not acceptable
and screens, lead backing, or other appropriate measures shall be implemented on subsequent exposures to
reduce back scatter. See ASTM E1742 for more information.

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STANDARD
APPROVED FOR SUPPLIER DISTRIBUTION
JDT17015

3. INDICATION CATEGORIES AND SEVERITY LEVELS

3.1 Reference Radiographs

The internal soundness and other characteristics shall be reported to and compared to reference radiographs
found in the appropriate standard (see ASTM E446 for steel, ASTM E689 for ductile iron, and ASTM E 802

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for gray iron). Indication category drawings are for illustration purposes only. The indication category and
severity level shall be reported for each radiograph. If no indications are identified, then the radiograph will be

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reported as sound. Permissible levels of indications are established and agreed to during a DPAR or
PPAP.

3.2 Indication Category "A": Gas Porosity

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This indication category is characterized by essentially spherical holes. The indication severity level shall be
reported for each radiograph. Castings shall be free from an indication of this type. If indications are
present, then John Deere shall disposition the casting based on severity level and location of the

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indications.
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The depictions shown above are for illustrative purposes only.

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STANDARD
APPROVED FOR SUPPLIER DISTRIBUTION
JDT17015

3.3 Indication Category "B": Sand Holes

This indication type is characterized by irregular shaped holes. The indication severity level shall be reported
for each radiograph. Castings shall be free from an indication of this type. If indications are present, then
John Deere shall disposition the casting based on severity level and location.

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The depictions shown above are for illustrative purposes only.

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STANDARD
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JDT17015

3.4 Indication Category "C": Shrinkage (Types CA and CC)

This indication type is characterized by an area of very small, irregular shaped holes. The indication severity

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level shall be reported for each radiograph. Castings shall be free from an indication of this type. If
indications are present, then John Deere will disposition a casting based on severity level and

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location of indication.

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The depictions shown above are for illustrative purposes only.

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STANDARD
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JDT17015

3.5 Indication Category "C": Shrinkage (Types CB and CD)

This indication type is characterized by dendritic shaped holes or cracks. The indication severity level shall be
reported for each radiograph. Castings shall be free from any defect of this type. If indications are present,
then John Deere will disposition the casting based on severity level and location of indication.

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The depictions shown above are for illustrative purposes only.

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 JOHN DEERE WATERLOO
STANDARD
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JDT17015

3.6 Indication Category "D": Cracks and Cold Shuts

This indication category is characterized below. Indications of this type shall always be reported for each
radiograph. This indication category is not permitted by John Deere.

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The depictions shown above are for illustrative purposes only.

3.7 Indication Category "E": Hot Tear

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This indication category is characterized below. Indications of this type shall always be reported for each
radiograph. This indication category is not permitted by John Deere.
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STANDARD
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JDT17015

The depictions shown above are for illustrative purposes only.

3.8 Indication Category "F": Unfused Chaplet

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This indication type is characterized by a circular crack and is illustrated below. Indications of this type shall
always be reported for each radiograph. This indication category is not permitted by John Deere.

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The depictions shown above are for illustrative purposes only.

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4. GENERAL SURFACE REQUIREMENTS

Surface condition requirements may be defined in several documents that include but are not limited to JDM
B11, JDM B15, RES10570, RWS 1330.01, or other unit standards. See the drawing notes for documents that
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apply to a particular component.

Example: APPEARENCE PER RWS 1330.01 CASTING STANDARD

CASTING REQUIREMENTS PER JDM B15
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5. INSPECTION FREQUENCY AND RECORD RETENTION

5.1 Radiographic Shooting Sketch (RSS)

Unless otherwise specified, the following information shall be documented in an RSS as the minimum

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STANDARD
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JDT17015

requirements for radiographic inspection procedures. The following information should be recorded and kept
on file for a minimum of five (5) years. See ASTM E 1030 for more information.
• Sensitivity level of radiograph and penetrameter type
• Radioisotope source and activity level (in curies)
• X-ray power and mA settings
• X-ray or gamma ray source to film distance
• Casting to film distance

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• Exposure time
• Film type used and density obtained in area interest

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• Sketch of x-ray source, casting and film location
• Type and location of screens or filters used

5.2 Experimental Parts

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These parts will be radiographically inspected as design and production process changes warrant. The need for
these inspections will be mutually agreed upon between the supplier and John Deere. These films need not be
retained unless designated by the appropriate John Deere personnel.

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5.3 Pilot and Durability Test Parts

The need for these inspections will be mutually agreed upon between the supplier and John Deere. These
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films shall be kept on file for a minimum of five (5) years.

5.4 First Piece Production Parts (ISIR)

Frequency: Cavities Per Mold Quantity

1 3 (3 molds)
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2 4 (each cavity of 2 molds)

3 or more each cavity of one mold
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X-ray inspection shall be done using the guidelines shown above for frequency. Any indications and the
corresponding severity levels shall be reported to John Deere for review and disposition. If
the indicated severity level is determined to be unacceptable, the parts are rejected and the supplier must
submit a written correction action plan designed to eliminate the non-conforming area(s). After the corrective
action has been implemented, new x-ray tests must be done before parts are submitted to John Deere. All
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radiographs which show indications of any severity level for first piece production castings must be sent to
John Deere for review and approval before shipment of parts. The acceptability of any indication present in
the radiographs shall be made by John Deere.

6. QUALITY ASSURANCE REQUIREMENTS FOR PURCHASED COMPONENTS

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6.1 The supplier shall pursue a program for continuous improvement with the goal of demonstration of
process control and process capability as outlined in the JDS G223. John Deere personnel may periodically
evaluate the program. Manufacturers shall be responsible to ensure that all parts shipped to John Deere
units meet all specifications. If problems are found, the supplier shall contact the appropriate John Deere
personnel. Parts not meeting specifications may not be used without an explicit and written deviation from

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STANDARD
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JDT17015

John Deere. All requests for deviations shall be made through appropriate John Deere personnel. Some
examples of what a request should contain include the following: the part number, the number of parts, what
is discrepant about the parts, information about the scope and location of the problem, and what corrective
action has been taken. Suppliers shall not ship parts that do not meet specification without an approved
deviation from John Deere.

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6.2 The material, drawing notes, and related standards shall be reviewed and approved in a Design, Process
and Assembly Review (DPAR) or Production Part Approval Process (PPAP) with John Deere personnel and
the supplier. Part conformance to drawing requirements and standards shall be documented in an Initial

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Sample Inspection Report (ISIR). Test standards, methods, and procedures shall be reviewed and agreed to
during the DPAR. The supplier shall develop a method to verify internal soundness of castings. This
procedure may include x-ray, ultrasonic, or sectioning or a combination of these inspection techniques. The
method developed must be reviewed and approved by John Deere.
6.3 Parts will be radiographically inspected if any of the following events occur:

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• John Deere requests the testing be done
• Design changes which may affect internal soundness (may require recertification)
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Supplier makes production process or parameter changes that could affect internal soundness. A
sampling procedure may be used with John Deere approval.
• Supplier process shows an out-of-control condition that may affect internal soundness. A sampling
procedure may be used with John Deere approval.
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All such occurrences and the inspection results shall be reported to John Deere. An alternate inspection
method may be used with prior approval from John Deere. Any casting or lot of castings not meeting
internal soundness levels shown in the approved first piece certification shall not be used without
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written engineering approval from John Deere.

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7. DRAWING NOTATION

Any area of a casting with quality requirements other than those outlined in this standard will be noted on the
part drawing.
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8. REPAIR WELDING

Repair welding is not permitted without prior approval by John Deere.

9. INDICATION VERIFICATION
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If any radiograph exhibits indications as outlined above, then that casting or castings shall be destructively
examined (sectioned). Photographs and a written report will be attached to the original radiograph to verify
the nature, severity, and location of the indications. If necessary, microspecimens may be required to
complete the report. All of the data must be submitted to John Deere for disposition of the castings.

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STANDARD
APPROVED FOR SUPPLIER DISTRIBUTION
JDT17015

10. REFERENCES

ASNT SNT-TC01A Recommended Practice for Personnel Qualification and Certification of Nondestructive
Testing Personnel

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ASTM E 94 Standard Guide for Radiographic Testing

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ASTM E 142 Standard Method for Controlling Quality of Radiographic Testing

ASTM E 446 Standard Reference Radiographs for Steel Castings up to

2 in. (51mm) in Thickness

ASTM E 689 Standard Reference Radiographs for Ductile Iron Castings

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ASTM E 746 Standard Test Method for Determining Relative Image Quality Response of Industrial
Radiographic Film Systems

ASTM E 802

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Standard Reference Radiographs for Gray Iron Castings up to 4.5 in. (115mm) in
Thickness
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ASTM E1030 Standard Test Method for Radiographic Examination of Metallic Castings

ASTM E1742 Standard Practice for Radiographic Examination

AFS “International Atlas of Casting Defects”, 1974

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JDM B11 General Requirements for Iron Castings (before 6/30/1994)

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JDM B15 General Requirements for Iron Castings (after 6/30/1994)

RES10570 F-1 General Rough Casting Inspection Standard

RWS 1330.01 John Deere Waterloo Works Appearance Standard

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JDS G-223 Supplier Quality Manual

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