Founding - Ultrasonic examination - Part 2: Steel castings for highly stressed components

This part of this standard specifies the requirements for the ultrasonic testing of spheroidal graphite cast iron castings and the methods for determining internal discontinuities by the pulse echo technique. NOTE: The transmission technique should be used in exceptional cases only, for instance thick-walled spheroidal graphite cast iron castings, since it has insufficient detection sensitivity for the discontinuities typically found in such castings.

Gießereiwesen - Ultraschallprüfung - Teil 2: Stahlgussstücke für hoch beanspruchte Bauteile

Dieser Teil dieser norm legt die Anforderungen an die Ulstraschallprüfung von Gußstücken aus Gußeisen mit Kugelgraphit und die Verfahren zur Bestimmung innerer Fehler mit dem Impuls-Echo-Verfahren fest. AMERKUNG; Die Durchschallungstechnik sollte nur ausnahmesweise, z.B. für dickwandige Gußstücke aus Gußeisen mit Kugelgraphit, eingesetzt werden, da die Nachweisempfindlichkeit für die gußtypischen Fehlerausbildungen hierbei ungenügend sind.

Fonderie - Contrôle par ultrasons - Partie 2: Pieces moulées en acier pour composants fortement sollicités

Cette partie de la présente norme spécifie les prescriptions relatives au contrôle par ultrasons des pieces moulées en fonte a graphite sphéroidal, ainsi que les méthodes pour la détermination des discontinuités internes par la technique de contrôle par échos. NOTE: Il convient d'utiliser la technique de transmission uniquement dans des cas exceptionnels, par exemple pour des pieces moulées en fonte a graphite sphéroidal a paroi discontinuités que l'on trouve généralement dans ces pieces moulées.

Livarstvo – Ultrazvočna preiskava – 2. del: Jekleni ulitki za močno obremenjene sestavne dele

General Information

Status
Published
Publication Date
31-Oct-2003
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
01-Nov-2003
Due Date
01-Nov-2003
Completion Date
01-Nov-2003

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Gießereiwesen - Ultraschallprüfung - Teil 2: Stahlgussstücke für hoch beanspruchte BauteileFonderie - Contrôle par ultrasons - Partie 2: Pieces moulées en acier pour composants fortement sollicitésFounding - Ultrasonic examination - Part 2: Steel castings for highly stressed components77.140.80Železni in jekleni ulitkiIron and steel castings77.040.20Neporušitveno preskušanje kovinNon-destructive testing of metalsICS:Ta slovenski standard je istoveten z:EN 12680-2:2003SIST EN 12680-2:2003en01-november-2003SIST EN 12680-2:2003SLOVENSKI
STANDARD



SIST EN 12680-2:2003



EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 12680-2January 2003ICS 77.040.20English versionFounding - Ultrasonic examination - Part 2: Steel castings forhighly stressed componentsFonderie - Contrôle par ultrasons - Partie 2: Piècesmoulées en acier pour composants fortement sollicitésGießereiwesen - Ultraschallprüfung - Teil 2:Stahlgussstücke für hoch beanspruchte BauteileThis European Standard was approved by CEN on 21 November 2002.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the Management Centre or to any CEN member.This European Standard exists in three official versions (English, French, German). A version in any other language made by translationunder the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the officialversions.CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,Hungary, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and UnitedKingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2003 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 12680-2:2003 ESIST EN 12680-2:2003



EN 12680-2:2003 (E)2ContentspageForeword.31Scope.42Normative references.43Terms and definitions.44Requirements.54.1Order information.54.2Extent of examination.64.3Maximum permissible size of discontinuities.64.4Personnel qualification.64.5Wall section zones.64.6Severity levels.75Examination.75.1Principles.75.2Material.75.3Equipment, coupling medium, sensitivity and resolution of detection.85.4Preparation of casting surfaces for testing.85.5Examination procedure.95.6Examination report.12Annex A (normative)
Resolution of detection of the instrument/probe combination.20Annex B (informative)
Sound-beam diameters.21Annex C (informative)
Types of indications.23Bibliography.35SIST EN 12680-2:2003



EN 12680-2:2003 (E)3ForewordThis document (EN 12680-2:2003) has been prepared by Technical Committee CEN/TC 190 "Foundry Technol-ogy", the secretariat of which is held by DIN.This European Standard shall be given the status of a national standard, either by publication of an identical text orby endorsement, at the latest by July 2003, and conflicting national standards shall be withdrawn at the latest byJuly 2003.Within its programme of work, Technical Committee CEN/TC 190 requested CEN/TC 190/WG 4.10 "Inner defects"to prepare the following standard:EN 12680-2, Founding — Ultrasonic examination — Part 2: Steel castings for highly stressed components.This is one of three European Standards for ultrasonic examination. The other standards are:EN 12680-1, Founding — Ultrasonic examination — Part 1: Steel castings for general purposes.EN 12680-3, Founding — Ultrasonic examination — Part 3: Spheroidal graphite cast iron castings.Annex A is normative. Annexes B and C are informative.According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following coun-tries are bound to implement this European Standard: Austria, Belgium, Czech Republic, Denmark, Finland,France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Malta, Netherlands, Norway, Portugal, Spain, Swe-den, Switzerland and the United Kingdom.SIST EN 12680-2:2003



EN 12680-2:2003 (E)41 ScopeThis European Standard specifies the requirements for the ultrasonic examination of steel castings (with ferriticstructure) for highly stressed components and the methods for determining internal discontinuities by the pulseecho technique.This European Standard applies to the ultrasonic examination of steel castings which have usually received a grainrefining heat treatment and which have wall thicknesses up to and including 600 mm.For greater wall thicknesses, special agreements apply with respect to test procedure and recording levels.This European Standard does not apply to austenitic steels and joint welds.2 Normative referencesThis European Standard incorporates by dated or undated reference, provisions from other publications. Thesenormative references are cited at the appropriate places in the text, and the publications are listed hereafter. Fordated references, subsequent amendments to or revisions of any of these publications apply to this EuropeanStandard only when incorporated in it by amendment or revision. For undated references the latest edition of thepublication referred to applies (including amendments).EN 583-1, Non-destructive testing — Ultrasonic examination — Part 1: General principles.EN 583-2, Non-destructive testing — Ultrasonic examination — Part 2: Sensitivity and range setting.EN 583-5:2000, Non-destructive testing — Ultrasonic examination — Part 5: Characterization and sizing of discon-tinuities.EN 12223, Non-destructive testing — Ultrasonic examination — Specification for calibration block No. 1.EN 12668-1, Non-destructive testing — Characterization and verification of ultrasonic examination equipment —Part 1: Instruments.EN 12668-2, Non-destructive testing — Characterization and verification of ultrasonic examination equipment —Part 2: Probes.EN 12668-3, Non-destructive testing — Characterization and verification of ultrasonic examination equipment —Part 3: Combined equipment.EN 27963, Welds in steel — Calibration block No. 2 for ultrasonic examination of welds (ISO 7963:1985).3 Terms and definitionsFor the purposes of this European Standard, the following terms and definitions apply.NOTEOther terms and definitions used in this European Standard are given in EN 583-1, EN 583-2, EN 583-5 andEN 1330-4.3.1reference discontinuity echo sizesmallest indication to be recorded during the assessment phase of an ultrasonic examination, usually expressed asan equivalent flat-bottomed hole diameter3.2point discontinuitydiscontinuity, the dimensions of which are smaller than or equal to the sound-beam diameterSIST EN 12680-2:2003



EN 12680-2:2003 (E)5NOTEDimensions in this standard relate to length, width and/or dimension in through-wall direction.3.3complex discontinuitydiscontinuity, the dimensions of which are larger than the sound-beam diameterNOTEDimensions in this standard relate to length, width and/or dimension in through-wall direction.3.4planar discontinuitydiscontinuity having two measurable dimensions3.5volumetric discontinuitydiscontinuity having three measurable dimensions3.6special rim zoneouter rim zone part with special requirements (for e.g. machined surfaces, higher stresses, sealing surfaces)3.7production weldingany welding carried out during manufacturing before final delivery to the purchaser3.7.1joint weldingproduction welding used to assemble components together to obtain an integral unit3.7.2finishing weldingproduction welding carried out in order to ensure the agreed quality of the casting4 Requirements4.1 Order informationThe following information shall be available at the time of enquiry and order (see also EN 583-1):¾ the areas of the casting and the number or percentage of castings to which the ultrasonic examination require-ments apply;¾ the severity level to be applied to the various zones or areas of the casting;¾ requirements for a written examination procedure;¾ whether there are any additional requirements for the examination procedure, see also 5.5.1.SIST EN 12680-2:2003



EN 12680-2:2003 (E)64.2 Extent of examinationThe casting shall be examined so that the agreed areas are totally covered (insofar as this is possible from theshape of the casting) by the use of the best applicable examination technique.For wall thicknesses greater than 600 mm, agreement shall be made between the parties concerned on the testprocedure and also on the recording and acceptance levels.4.3 Maximum permissible size of discontinuities4.3.1 GeneralThe purchaser shall specify the acceptance level according to the required severity level for planar and volumetricdiscontinuities within each zone and in each specified area of the casting.The wall section shall be divided into zones as shown in Figure 1. These sections relate to the sizes of castingsready for assembly (finish machined).4.3.2 Indications without measurable dimensionsIn special rim zones and at weld preparation ends, indications without measurable dimensions are limited to amaximum number of indications.These indications shall not exceed the limits given in Table 1.4.3.3 Indications with measurable dimensions4.3.3.1 Planar discontinuitiesPlanar discontinuities shall not exceed the limits given in Figure 2.The area of indication with measurable length but with non-measurable dimension in through-wall direction shall becalculated according to the formula given in Figure 2.The sizing of small planar discontinuities, as given in Figure 2, becomes more difficult with increasing beam-pathlength and sound-beam diameter. As a guide, these sizings are normally applied to a rim zone of 30 mm. It makesthe use of probes with focussed beams such as twin-crystal probes necessary.4.3.3.2 Volumetric discontinuitiesVolumetric discontinuities shall not exceed the sizes given in Figure 3 for rim zone and Figure 4 for core zone. Indi-cations with measurable dimensions are not permissible in severity level 1. The area of an indication with measur-able length but non-measurable width shall be calculated in accordance with the formula given in Figures 3 and 4.4.4 Personnel qualificationIt is assumed that ultrasonic examination is performed by qualified and capable personnel. In order to prove thisqualification, it is recommended to certify personnel in accordance with EN 473.4.5 Wall section zonesThe wall section shall be divided into zones as shown in Figure 1. These sections relate to the dimensions of thecasting ready for assembly (finish machined).SIST EN 12680-2:2003



EN 12680-2:2003 (E)74.6 Severity levelsIf the purchaser specifies different severity levels in different areas of the same casting, all of these areas shall beclearly identified on the purchaser's drawing and shall include:¾ all necessary dimensions for accurate location of zones;¾ the full extent of all weld preparations and the thickness of any special rim zone.Severity level 1 is only applied to weld preparations and special rim zones.Unless other requirements have been agreed by the time of acceptance of the order, for finishing welds, the re-quirements for the parent metal shall apply.5 Examination5.1 PrinciplesThe principles of ultrasonic examination given in EN 583-1, EN 583-2 and EN 583-5 shall apply.5.2 MaterialThe suitability of material for ultrasonic examination is assessed by comparison with the echo height of a referencereflector (usually the first backwall echo) and the noise signal. This assessment shall be carried out on selectedcasting areas which are representative of the surface finish and of the total thickness range. The assessment areasshall have parallel surfaces.The reference echo height according to Table 2 shall be at least 6 dB above the noise signal.If the echo height of this smallest detectable flat-bottomed or equivalent side-drilled hole diameter at the end of thetest range to be assessed is less than 6 dB above the grass level, then the ultrasonic testability is reduced. In thiscase, the flat-bottomed or side-drilled hole diameter which can be detected with a signal-noise ratio of at least 6 dBshall be noted in the test report and the additional procedure shall be agreed between the manufacturer and thepurchaser.NOTEFor the definition of an adequate flat-bottomed hole size, the distance gain size system (DGS) or a test block ofidentical material, heat treatment condition and section thickness containing flat-bottomed holes with a diameter according toTable 2 or equivalent side-drilled holes, can be used. The following formula is used for converting the flat-bottomed hole di-ameter into the side-drilled hole diameter:sDD´´=2FBHQl4935,4(1)whereDQis the side-drilled hole diameter in millimetres;DFBHis the flat-bottomed hole diameter in millimetres;lis the wave length in millimetres;sis the path length in millimetres.The formula is applicable for DQ ³ 2 l and s ³ 5 ´ near-field length and is only defined for single element probes.SIST EN 12680-2:2003



EN 12680-2:2003 (E)85.3 Equipment, coupling medium, sensitivity and resolution of detection5.3.1 Ultrasonic instrumentThe ultrasonic instrument shall meet the requirements given in EN 12668-1 and shall have the following character-istics:¾ range setting, from at least 10 mm to 2 m continuously selectable, for longitudinal and transverse wavestransmitted in steel;¾ gain, adjustable in 2 dB maximum steps over a range of at least 80 dB with a measuring accuracy of 1 dB;¾ time-base and vertical linearities less than 5 % of the adjustment range of the screen;¾ suitability at least for nominal frequencies from 1 MHz up to and including 6 MHz in pulse-echo technique withsingle-crystal and twin-crystal probes.5.3.2 Probes and transducer frequenciesThe probes and transducer frequencies shall be as given in EN 12668-2 and EN 12668-3 with the following excep-tions:¾ nominal frequencies shall be in the range 1 MHz to 6 MHz;¾ for oblique incidence, angle probes with angles between 35° and 70° shall be used.NOTENormal or angle probes can be used for the examination of steel castings for highly stressed components. The typeof probe used depends on the geometry of the casting and the type of discontinuity to be detected.For examining zones close to the surface, twin-crystal probes (normal or angle) should be preferred.5.3.3 Checking the ultrasonic examination equipmentThe ultrasonic examination equipment shall be checked regularly by the operator according to EN 12668-3.5.3.4 Coupling mediumA coupling medium in accordance with EN 583-1 shall be used. The coupling medium shall wet the examinationarea to ensure satisfactory sound transmission. The same coupling medium shall be used for calibration and allsubsequent examination operations.NOTEThe sound transmission can be checked by ensuring one or more stable backwall echoes in areas with parallelsurfaces.5.3.5 Sensitivity and resolution of detectionThe detection sensitivity of the instrument shall allow at least the setting of the sensitivity in accordance with therequirements of 5.5.2.The resolution of detection of the instrument/probe combination shall meet the requirements of annex A.5.4 Preparation of casting surfaces for testingFor the preparation of casting surfaces for examination see EN 583-1.The casting surfaces to be examined shall be such that satisfactory coupling with the probe can be achieved.SIST EN 12680-2:2003



EN 12680-2:2003 (E)9In the case of single-crystal probes, satisfactory coupling can be achieved if the condition of the surfaces to be ex-amined corresponds at least to the limit comparator 4 S1 or 4 S2 according to EN 1370.The roughness of any machined surface to be examined shall be Ra £ 12,5 For special techniques, higher surface qualities such as 2 S1, 2 S2 (see EN 1370) and Ra £ 6,3 s-sary.5.5 Examination procedure5.5.1 GeneralBecause the choice of both the direction of incidence and suitable probes largely depends on the shape of thecasting or on the possible casting discontinuities or on the possible discontinuities from finishing welding, the appli-cable examination procedure shall be specified by the manufacturer of the casting. In special cases, specificagreements can be made.If possible, the areas to be tested shall be examined from both sides. When testing from one side only, short-rangeresolving probes shall be used additionally for the detection of discontinuities close to the surface. Testing withtwin-crystal probes is only adequate for wall thicknesses up to 50 mm.Additionally, when not otherwise agreed between the purchaser and the manufacturer, for all castings, twin-crystalnormal and/or angle probes shall be used to examine the following areas up to a depth of 50 mm:¾ critical areas, e.g. fillets, changes in cross-section, areas with external chills;¾ finishing welds;¾ weld preparation areas as specified in the order;¾ special rim zones, as specified in the order, critical for the performance of the casting.Finishing welds which are deeper than 50 mm shall be subject to supplementary examination with other suitableangle probes.For angle probes with angles over 60°, the sound beam path shall not exceed 150 mm.Complete coverage of all areas specified for examination shall be conducted by carrying out systematically over-lapping scans.The scanning rate shall not exceed 150 mm/s.5.5.2 Range settingRange setting shall be carried out in accordance with EN 583-2 on the screen of the test instrument using normalor angle probes in accordance with one of the three options given below:¾ with the calibration block in accordance with No. 1 EN 12223 or No. 2 in accordance with EN 27963;¾ with an alternative calibration block made in a material exhibiting similar acoustic properties to those of thematerial to be examined;¾ on the casting itself when using normal probes. In this case, the casting to be tested shall have parallel sur-faces, the distance between which shall be measured.SIST EN 12680-2:2003



EN 12680-2:2003 (E)105.5.3 Sensitivity setting5.5.3.1 GeneralSensitivity setting shall be carried out after range setting (see 5.5.2) in accordance with EN 583-2. One of the fol-lowing two techniques shall be used:¾ Distance-amplitude correction curve technique (DAC)The distance-amplitude correction curve technique makes use of the echo-heights of a series of identical re-flectors (flat-bottomed holes FBH or side-drilled holes SDH), each reflector having a different sound-beampath.NOTEA frequency of 2 MHz and a diameter of 6 mm for the flat-bottomed holes are most commonly used.¾ Distance gain size technique (DGS)The distance gain size technique makes use of a series of theoretically derived curves which link the sound-beam path, the apparatus gain and the diameter of a disc-shaped reflector which is perpendicular to the beamaxis.5.5.3.2 Transfer correctionTransfer correction shall be determined according to EN 583-2.When calibration blocks are used, transfer correction can be necessary. When determining the transfer correction,consideration shall be given not only to the quality of the coupling surface but also to that of th
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