450-639768

Rev. 07.2004

POLYSIUS
Inspection instructions
for
steel castings in general
(e.g. hooks, guide pins and shackles for roller mills, thrust rollers for rotary kilns, etc.)

Polysius AG

Inspection instructions for

450-639768

steel castings in general

Rev. 07.2004

Contents

1.

1.

Scope

2.

Standards

3.

Materials

4.

Dimensions and tolerances

5.

Inspection

6.

Visual inspection

7.

Hardness measurement on the casting

8.

Non-destructive testing

9.

Elimination of defects

10.

Build-up welding

11.

Dimensional inspection and final inspection

12.

Marking

13.

Inspection reports of interim and final inspections

14.

Anti-corrosion protection

15.

Packing

16.

Reference standards

Scope
Unless any other written agreements are made, these instructions apply to all steel
castings in general manufactured for POLYSIUS AG and its subsidiaries.
These inspection instructions form an integral part of the relevant design drawings
and parts lists.
If the supplier has any reservations on grounds of casting or manufacturing methods, such reservations must be clarified with the purchaser in writing prior to the
order acknowledgement.
In the event of any deviations from the requirements specified herein, an agreement must be reached between purchaser and manufacturer regarding the procedures to be adopted.
Depending on the application, additional customer specifications may have to be
met as detailed in the relevant purchase order.
In principle the latest issue of these instructions applies.
Any print-out of these instructions is an uncontrolled copy.
Without the prior consent of POLYSIUS AG, any utilisation of the texts, even in
extract form, contravenes copyright law and makes the offender liable to prosecution. This also applies to reproduction, translations of all kinds, microfilming and
processing in electronic systems.

Page 1

Polysius AG

Inspection instructions for

450-639768

steel castings in general

2.

Rev. 07.2004

Standards
Provided it has been clarified with the purchaser in writing, national or international
standards which are equivalent to those specified in these instructions may be
used. (This is to be considered in each individual case.) In principle the latest issue of the relevant standard applies.

3.

Materials
The material quality to be used is specified in the respective parts list.
The material quality must be substantiated by the following test certifications:

Chemical analysis

Mechanical properties to be tested on test specimens cast in one with the actual casting. The thickness of the test specimens must correspond to the
maximum material thickness, however, the size of the test specimens is limited to a cross section of 100 x 150 mm.

Hardness test on the test specimen and the actual casting

Ultrasonic examination

Surface crack detection testing

Visual inspection

The mechanical properties must be confirmed by documenting the yield strength

ReH, the tensile strength Rm, the percentage elongation after fracture A5 and the
notch impact energy AV of a V-notch specimen. These values must be determined
for every molten batch.

4.

Dimensions and tolerances

4.1

Raw casting
ISO 8062 CT12 applies with regard to the tolerances for all dimensions.
For surfaces to be machined, additional machining allowances must be observed
to ensure that the workpiece can be machined to the surface quality and dimensions specified in the drawings and these instructions.

4.2

Machining
The dimensions and qualities given in the manufacturing drawings and piece lists
are binding for the manufacture.
For untoleranced dimensions, ISO 2768-m applies unless otherwise agreed. Here,
additional machining allowances must be observed to ensure that the workpiece
can be machined to the surface quality and dimensions specified in the drawing
and these instructions.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

5.

Rev. 07.2004

Inspection
The purchaser's inspectors as well as any additional third party inspectors must be
granted access to the manufacture at any time during normal working hours after
prior notification.
The purchaser reserves the right to witness the tests specified in these instructions. On this basis, the purchaser's quality control department must
be notified in due time of the individual inspection stages.
The supplier is obliged to provide all the equipment and tools, the valid drawings
and piece lists as well as all qualified personnel required for the inspection.
Indications in the unmachined or pre-machined state of the casting must be assessed such that the required quality grade is achieved in the finished state.

6.

Visual inspection
The casting must be subjected to thorough visual inspections from all sides both in
the unmachined or pre-machined state and after the finish-machining.
All unfinished casting surfaces must be assessed on the basis of reference specimens. They must conform to EN 1370, BNIF class 6 S 1 or SCRATA class S A 4.
Unmachined and pre-machined surfaces must be inspected for imperfections such
as gas pores, sand or slag inclusions, cracks, chill cracks, inserts and cold shuts.
In addition to the a.m. reference specimens, MSS, SP-55 (Manufacturers Standardisation Society, Standard Practice) can be used as reference basis.
The finished casting has to be inspected for surface damage and for its compliance with the drawing specifications (radii, surface finish).
Detected imperfections must be eliminated in accordance with section 9.
The anti-corrosion protection to be applied and the agreed packing shall also be
inspected. Castings with build-up welding shall be visually inspected for undercuts,
weld overfill and flatness.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

Rev. 07.2004

7.

Hardness measurement on the casting

7.1

Scope of test
During the final acceptance inspection, representative hardness tests shall be
performed at various locations on the workpiece surface to document the hardness of the workpiece.
If repair welding has been performed, the hardness profile of at last one repair
weld has to be taken. Three measurements are required and the following data
must be protocolled:

base material

heat-affected zone (HAZ)

filler metal

heat-affected zone (HAZ)

base material

These measurements must be repeated and protocolled during the final inspection.
7.2

Adjustment of hardness testing apparatus

For the adjustment of the portable hardness testing apparatus, a test piece must
be prepared with the material of the castings to be supplied. The hardness values
of the test piece must be determined with a stationary, certified hardness testing
machine.

7.3

Preparation of unmachined or roughly premachined surfaces

With a grinding machine, the tested area is deepened as follows:

premachined surfaces:

2 mm

unmachined surfaces:

4 mm.

The size of the tested area must ensure the complete coupling of the measurement probe. The specified surface finish must be produced with a surface grinding
machine with a minimum coarseness of 80 grit.
7.4

Assessment
The distribution of the hardness values determined according to section 7.3 must
not exceed 8 % of the mean value of the measurements.
In repair weld areas, the maximum hardness of the weld material is 5 % above the
hardness value of the adjacent base material, and the minimum hardness of the
weld material is 15 % below the hardness value of the adjacent base material. In
the area of the heat-affected zone (HAZ), the hardness must not exceed the hardness value of the adjacent base material by more than 30 %.

7.5

Hardness measurement of build-up welding

The measurement area is excavated 2 mm with a grinding machine. The size of
the tested area must ensure the complete coupling of the measurement probe.
The specified surface finish must be produced with a surface grinding machine
with a minimum coarseness of 80 grit.
The hardness values of build-up welds must correspond to the requirements
specified in the parts lists.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

8.

Rev. 07.2004

Non-destructive testing
Qualification for testing
The personnel carrying out the test must have a certification according to EN 473
or an equivalent standard or a certification according to the specific regulations,
e.g. those of the German society for non-destructive testing (Deutsche Gesellschaft fr zerstrungsfreie Prfung) or the American Society for Nondestructive
Testing (SNT-TC-1A), or relevant company standards. On request of the purchaser, the supplier must present certifications of this qualification.

8.1.

Surface testing by magnetic particle inspection

8.1.1

Scope of test
Scope of test after pre-machining
The complete surface must be tested. For this, the surface areas must be prepared for testing without machining. Surfaces to be machined must be tested at an
allowance for cutting of approx. 2 -3 mm (Ra~12.5 mm).
Testing at this stage is to ensure that the dimensional requirements of the casting
can be achieved in case of later weld repair with subsequent stress-relieving.
In addition, all excavations and all areas requiring repair welding must be tested.
The entire surface must be tested after the final heat-treatment.

8.1.2

Test method
Magnetising must be by direct current saturation or, if burn marks on finishmachined surfaces are anticipated, a magnetising yoke. Only the wet process
(fluorescent or black-white) is acceptable.
In the case of direct current saturation, any remaining burn marks must be ground
out and re-tested with magnetising by a magnetising yoke.
The inspection must be performed from two different magnetising directions at
right angles (not < 50 and not > 130). This is to ensure that the magnetic field
lines cross any indication at least in one direction. A minimum holding time of 2
seconds is required.
The intensity of the tangential field strength must be within the range of 2000 6000 A/m. The purchaser's inspector is entitled to check this value with a tangential field intensity meter.
The indication reliability of the test equipment must be checked with respective
test indicators such as MTU or Berthold.

8.1.3

Surface preparation
The surface to be tested must be clean and free from oil or grease and must be
sand-blasted, ground or machined to ensure optimum conditions for the detection
of indications.
The surface roughness must correspond to EN 1370 of BNIF class 6 S 1 respectively SCRATA class S A 4.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

8.1.5

Rev. 07.2004

Acceptance criteria
For assessment, quality standard EN 1369 applies.
The differing indications are classified as follows:

non-linear indications

SM

linear indications

LM

indications in series

AM

An indication is regarded as linear when L (length) is 3 B (width).

Table 1
SM
length L [mm] 1) 2) 3)
2
total surface [mm ] 2) 3)

6
70

LM / AM
individual
accumulated
6
10
-

1.

L = largest acceptable indication

2.

A maximum of two (2) indications of the largest specified size is acceptable.

3.

The reference surface is 105 x 148 mm (DIN A6)

The figures according to EN 1369 annex B can be used for comparison.

The assessment of the indications found in the premachined state must ensure
that the specified quality grade is met in the finished state.
8.2

Surface testing by dye-penetration testing

8.2.1

Scope of test
If the results of the magnetic particle inspection in the area of an excavation are
not clear, a dye-penetration test must be performed.

8.2.2

Test method
After the application of the penetrant, 10 to 20 minutes must be allowed for penetration. After the removal of the surplus penetration fluid, the developer can be applied. Since the colour in the developer spreads rapidly, observation of the distribution must be made immediately after the application. The comparison with the
inspection criteria must be made within 10 to 20 minutes. The dye-penetration
tests must be performed in accordance with the instructions of the testing media
manufacturer.

8.2.3

Surface preparation
The surface to be tested must be clean and free from oil or grease and must be
sand-blasted, ground or machined to ensure optimum conditions for the detection
of indications.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

8.2.4

Rev. 07.2004

Acceptance criteria
On a reference area of 105 x 148 mm (DIN A6), the maximum acceptable number
of non-linear indications is six (6). The smallest recordable indication is 0.5 mm.
The largest acceptable indication is 1 mm.
Linear indications and indications in series are unacceptable.

8.3.

Ultrasonic examination

8.3.1

Scope of test and test procedure

- All sections with premachined surfaces,
- all sections critical with regard to geometry and casting technique,
- all areas with repair welding must be tested.

8.3.2

Calibration of the ultrasonic test equipment

The testing is performed to the Distance-Gain-Size (DSG) method. For calibration,
standard reference blocks according to EN 12223 can be used.
The use of special calibration blocks which in material composition and heat
treatment correspond with the workpiece is acceptable. With the use of normal
probes, the calibration can also be performed on the workpiece itself. The height
of an echo indication is set by the indication of an equivalent flaw size (EFS) in
mm. To determine the equivalent flaw size, DGS-Diagrams as well as DGS-Scales
can be used. For the calibration of the ultrasonic test equipment, the transfer correction and the sound attenuation may have to be taken into account.

8.3.3

Requirements for the workpiece and test equipment

The properties of the test surface must be such that a proper coupling of the test
probes used is ensured. The ultrasonic test is to be performed by the ImpulseEcho-Method with vertical test probes. The use of a testing frequency of 2 MHz
and an oscillating probe diameter of approx. 25 mm is preferred. Testing frequencies of 1 and 4 MHz are also acceptable. The different registration levels must be
clearly perceptible on the screen.
The workpiece can be subjected to the test providing that the equivalent flaw sizes
(EFS) specified in table 1 reach an echo height of at least 6 dB above noise level
at the end of the test range.
Table 1: Equivalent flaw sizes (EFS)
Material thickness

EFS [mm ]

[mm]

up to 200
up to 300

2
3

If these conditions cannot be met, the manufacturer must contact the purchaser
and reach an agreement on further procedures.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

8.3.4

Rev. 07.2004

Assessment of ultrasonic indications for acceptance or registration

For better assessment, indications may have to be subjected to additional tests,
for example with SE- or angle probes. The purchaser is entitled to participate in
these tests after previous agreement.
The following indications must be recorded:

Backwall echo attenuations which are not due to the geometry of the casting
or the different coupling (according to Fig. 2).

All echo indications with measurable extension clearly detectable above the
noise level (according to Figure 2). These are echo indications with an actual
extension larger than the sound beam diameter of the probe used for the test.

Echo indications without measurable extension (according to table 2).

These are echo indications with an actual extension smaller than or equal to
the sound beam diameter of the probe used for the test, as to be seen e.g.
from test-probe-specific data sheets or sonograms.

Table 2: Limits for acceptance and registration

Maximum acceptable
equivalent flaw size [mm ]
6

Smallest value to be
registered
[mm ]
4

Recordable indication area in cm2

50
18
40

16
14

30

12
10
8

20

6
4

10

2
0

1/4
Distance between indication and
workpiece surface respectively
back wall

1/2 S =

Largest acceptable indication area in cm2

Fig. 2: Limits for registration and acceptance of ultrasonic indications in

tests with normal test probes

thickness of
workpiece in the
tested area

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

Rev. 07.2004

Backwall echo attenuations above 12 dB must be registered when the indicated areas exceed the acceptable limits specified in Fig. 2.

Intermediate echoes must be recorded when they have a measurable expansion exceeding the limits indicated in Figures 2 and 3.

The maximum acceptable depth extension is 5 % of the actual wall thickness

of the workpiece in the tested area.

Two indications separated by a distance of less than 2 cm are to be considered as an individual indication.

When an indication has a measurable extension in only one direction (length),

the indicated area A to be considered is A = 0.3 x measured length.

Recordable indication area in cm2

3
1
0,8

0,6
1

0,4
0,2
0

1/4
Distance between indication and
workpiece surface respectively
back wall

1/2 S =

Largest acceptable indication area in cm2

Fig. 3: Limits for registration and acceptance of ultrasonic indications with

measurable depth extension (area indication) in tests with angle test probes

thickness of
workpiece in the
tested area

Areas with backwall echo attenuations above 12 dB and areas indicated by intermediate echoes are unacceptable when they exceed the limits specified in Figures
2 and 3. Size, type and depth of all ultrasonic indications exceeding the registration limits must be recorded. Before the completion of the ultrasonic testing and
the assessment of the results, the casting may not be released for further machining.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

Rev. 07.2004

9.

Elimination of defects

9.1

Unacceptable surface indications

Surface indications whose dimensions and frequency exceed the limits specified in
section 8.1 are not accepted. They can be eliminated by grinding.
Excavations must not exceed the following dimensions:

9.2

individual area:

50 mm

total area:

10 % of the assessed surface

depth:

0.1 x the material thickness of the assessed workpiece

Repair welding
Defects exceeding the dimensions specified in section 9.1 can be eliminated by
repair welding.
Repair welding will only be accepted at suitable materials. All repair welding must
be performed in accordance with a material-specific welding plan. The welding
plan must contain the following items:

sketch of defect

the type of weld preparation

welding method

filler metals (same classification as the base material)

qualifying certificates for the welding personnel

pre- and post-heat-treatment

After the stress relieving heat treatment, surface crack testing according to 8.1
must be performed.
If the above requirements have not been complied with, the purchaser reserves
the right to reject the castings.

10.

Build-up welding
Any build-up welding required at the castings must be performed in accordance
with a welding plan containing the following items:

welding method

pre-heat-treatment

welding material

seam thickness

The welding performance must be visually inspected to rule out undercuts, excess
weld metal and to ensure flatness.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

11.

Rev. 07.2004

Dimensional check and final inspection

Depending on the order specification (premachined workpiece or finish-machined
workpiece) a dimensional inspection of the base-size or finished-size has to be
performed. All specified and actual dimensions are to be entered in the dimensional protocol.
If the measurements of the material thicknesses with mechanical equipment prove
to be impractical, ultrasonic measuring methods can be used.

12.

Marking
Each casting must be marked with a stamp on the riser side. The stamp must
include the following information:

purchase order number / purchase order item

order no. of manufacturer

manufacturer's stamp

The stamped area must be highlighted with permanent red paint.

13.

Documentation of interim and final inspections

All results (actual and specified data) of the interim and final inspections must be
entered by a representative of the manufacturer into the protocols provided.
The entries have to be confirmed by the stamp and signature of the representatives of both the manufacturer and the purchaser.
All the inspection certificates specified in these instructions together with the test
and dimensional records must be submitted to the purchaser's inspector for the final inspection:

inspection certificate 3.1 (to EN 10204) of the used materials of ReH, Rm, A5
and Av for every molten batch,

inspection certificate 3.1 (to EN 10204) of chemical analysis for every molten
batch,

welding procedure in accordance with section 9,

record specifying the number and the locations and extensions of all performed repair welding,

heat treatment records including the heating and cooling curves of all furnace
treatments,

protocol with the results of the visual inspections performed according to section 6,

magnetic-particle-inspection test reports according to section 8,

dye-penetration test reports according to section 8,

ultrasonic examination test reports according to section 8,

location and contents of manufacturer's stamp,

dimensional protocol.

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Polysius AG

Inspection instructions for

450-639768

steel castings in general

Rev. 07.2004

14.

Anti-corrosion protection

14.1

Machined surfaces
All machined surfaces which on the basis of their eventual function or assembly
requirements cannot be permanently coated, are to be covered with a temporary
coating, e.g. TECTYL 506 or an equivalent product which has guaranteed protective properties for free storage of at least 8 months. The material must be sprayedon (not brushed on) with a coat thickness of 80 to 100 mm.

14.2

Other surfaces
All other surfaces are to be treated as specified in the piece list.

15.

Packing
Details concerning the packing are specified in the relevant packing instructions of
the purchaser.

16.

Reference standards

DIN EN 12223

Non-destructive testing - Ultrasonic examination - Specification for calibrating block No 1

DIN EN 473

Non destructive testing - Qualification and certification of

NTD personnel - General principles

DIN EN 1370

Founding: Surface roughness inspection by visual-tactile

comparators

DIN EN 1371

Founding, - liquid penetrant inspection - part 1: sand gravity

die and low-die castings

DIN EN 10204

Types of inspection documents

DIN EN 12680

Founding: Ultrasonic testing

DIN ISO 2768

General tolerances

DIN ISO 8062

Castings: System of dimensional tolerances and machining

allowance

DIN EN 1369

Magnetic Particle Testing

BNIF

Bureaux de Normalisation des Industries de la Fonderie

MSS, SP -55

Manufacturers Standardisation Society, Standard Practice

SCRATA

Comparators for the definition of surface quality of steel

castings

SNT-TC-1A

American Society for Nondestructive Testing

Page 12

Polysius AG