gol hes he nt kn ecu oskios than a copy wo ey for frouse 7 ‘SMS Schioemann-Siemag AG. fo tO DIN retrace set 3) November 1985 (December 1984) Ultrasonic testing of forgings and forged | ron-steet steel bars from ~100 mm diameter a or edge length Edition 1 ee a2 Se os 26 = & 8 g 1. Principle and Purpose of the Test Specification This test specification deals with the ultrasonic testing of forgings and forged steel bars (hereinafter designated "forging") in general use, peferably for detecting internal defects using the impulse and echo technique. The ultrasonic test enables data to be collected on the position, size, extent and frequency of reflectors. For forgings subject to acceptance criteria, this test specification serves as a guideline for establishing the scope of testing to be carried out (see section 6.2) an¢ the acceptance limits (see sections 6.§ and 6.6). Tt deseribes the test process and the conditions to be observed with regard to the test system, the quality of the workpiece being tested and the classification of the test results. 2. Field of Application This test specification applies to the testing of suitably designed, machined or unmachined, untreated and heat-treated forgings, preferably of unalloyed or alloyed steel (see section 6.1). For forgings on which higher demands are nade, SEP 0000"is applicable. If the test is being carried out on non-transfornable steels, the testability may be impaired by acoustic decay and other factors. In such cases, the achievable recistration and acceptance limits should be stated in order to asseas testability. If testing iz not practicable, another method of proceeding should be agreed with the customer or his representative. 3. Classification Depending on the scope of testing. forgings are classified in four groups (see section 6.2), and depending on the size and length ef indication acceptable, into five categories or classes (see sections 6.4 and 5.5, table 1). The acceptable frequency of indications iz also divided into five frequency classes (se section 6.4.3). 4. Preparation of the Forgings For testing, rough forgings should be simple in form or dynamically balanced (see DIN 54126 part 1, section 6). Test surfaces and other surfaces to be used for reflection should be sufficiently even to allow adequate probe-to-specinen contact. A smooth even surface which is free of loose scale may be suitable for testing provided that adequate contact can be achieved. Should it be necessary to machine the surface, an approximate average roughness of <20 ym to DIN 4762 should be aimed at In the case of steels which have not been heat-treated, it should be engured that the acoustic decay of the workpieces allows the agreed acceptance linit (or registration limit) to be detected. Ii transformable steel is being used, the forging may be treated to reduce the acoustic decay, ‘The surface and structural condition required for efficient detection of defects must, if necessary, be adapted to the machining and heat treatment and allow the indication of defects of the agreed size and category (table 1). “in preporation Continued on page 2 - 6Page 2 SEP_ 1921 5. Test system 5.1 Test Equipment ‘The ultrasonic testing device should function on the impulse and echo principle, and possess an amplification regulator calibrated in decibels (4B) which allows echo conditions to be measured with an accuracy of + 248. The amplifier should not show amplifica~ tion threshold or saturaticn!! in the field of senstivity of the unit in use. It should be possible to adjust the test unit to the setting yrange required for the test. Deviations from linearity of up to 2S of the setting range are permitted. 5.2 Probes ‘The nominal frequency of the probe should be adapted to the size of the circular disk reflector to be detected, to the length of the sound wave path and to the acoustic decay of the workpiece. In general, testing is done at between 1 and 4 Miz; however, other frequencies may be used provided that the acceptance limit values fixed in section 6.5 are detectable. As a rule, vertical probes are used. In addition, other types of Probes such as transmitter-receiver (SE) probes or angular probes may be used for example to locate reflectors close to the surface, to improve the resolution of indications in inaccessible areas of the forging, as well as with hollow bodies or for special types of defects. This applies especially te groups 3 and 4 (see section 6.2). For the analysis of indications of circular disk reflector size, a distance-amplification (AVG) diagran for every type of contact should be familiar. 5.3 Monitoring the Test systea For basic principles, see DIN 54 126 part 1. For equipment setting and monitoring of the fuctions both of equipment and probes, test specimen 1 (DIN 54120?) should be available. For monitoring the test system, test piece 2 (DIN 54 1227) or other suitable test specimen with reference reflectors may be used. 5.4 Contact Medium ‘me contact agent (see DIN 54 126 part 1, section 5.6) must wet the surface of the workpiece thoroughly. Appropriate for this purpose are water (preferably with additive for increasing viscosity). oils, and pastes. The same agent should be used for setting the test system and for all subsequent test work. If chined forgings are being tested, the contact agent should not give rise to corrosion. If necessary, the test surface should be cleaned or éxied following testing. Conduct of the Test 6.1 Timing of the 7 Preliminary testing should be carried out as soon as possible in order that a decision can be taken as to the testability and useability of the forging. In general, acceptance testing is carried out when as few contours as possible are present on the forging, but following the heat treatment essential for the material characteristics, or at another agreed stage early in the systes, ‘see DIN 54125 - Allgeneine Regeln zur Profung nit Ultraschall - Teil 1 - Anforderungen ax die Prifeysten - sovie Teil 2- Durchfunrung der Prifung. DIN 54120 - KentotikorDer und seine Verwendung 244 Juste rong und Kentolle von Ultaschal-Impule-Echo: Ger DIN 54122 - KontotkSrper 2 und seins Verwoncung aur JustoSEP_1921 Page 3 6.2 Scope of Testing Depending on the demands being made on the forging, the scope of testing can be divided into four sub groups. Areas which are subequently removed by machining do not require testing. Test Group 2: ‘Testing with vertical probes on one or several paths’ (maximum width 50 mm) on the outer surface, over the entire length of the Surface lines, with disks, algo on the front surface. in general, the central area of the cross section are covered caka ¢ Bare Hollow bodies. and rings One test path in axis Girection ‘One path on front surface and one circumference surtace 4 aviat test paths in axis direction Test Group 2 ‘Testing with vertical probes on two or several paths (maxinun width 80 mm), on disks with grid on front surface, over the entire length ef the surface or circumference lines. The central area of the cross section and a wider part of the volume are + 8 @ 2334 Examples: == Bars. Disks Two test paths in axis direc at 90° to one another Two or more paths on the cir- cumerential surface, grid at 200 mm clearance on front Holiow bodies and rings More tran four axlal test paths in axis direction surface. ‘Test Group 3: ‘test using vertical probes from two directions vertical to one another on the outer accessible surface. The greatest possible volune of the forging should be covered. To evaluate the indications, other types of probes way be used. Examples Bars At least half the circumference over the entire lengin, axiat testing of one front surface should be agreed sepa- rately Disk A least half the circumference ‘surface and one entire front surface, Hollow bodies and rings Entire outer circumference surface and one front surface Test Group 4 In the case of special test requirements, testing of the entire accessible volune. The scope of testing, the use of several probe types, test angles and angles of penetration should in general be arranged between manufacturer and customer or specified by customer. Note: In the case of special test requirements, SEP 0000" may be referred to . #1 preparation