1、 Reference number ISO 4992-1:2006(E) ISO 2006INTERNATIONAL STANDARD ISO 4992-1 First edition 2006-02-15 Steel castings Ultrasonic examination Part 1: Steel castings for general purposes Pices moules en acier Contrle aux ultrasons Partie 1: Pices moules en acier pour usages gnraux ISO 4992-1:2006(E)
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5、06 All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from either ISO at the address below or ISOs member body in the cou
6、ntry of the requester. ISO copyright office Case postale 56 CH-1211 Geneva 20 Tel. + 41 22 749 01 11 Fax + 41 22 749 09 47 E-mail copyrightiso.org Web www.iso.org Published in Switzerland ii ISO 2006 All rights reservedISO 4992-1:2006(E) ISO 2006 All rights reserved iii Contents Page Foreword iv 1 S
7、cope . 1 2 Normative references . 1 3 Terms and definitions. 2 4 Requirements 2 4.1 Order information . 2 4.2 Extent of examination. 3 4.3 Maximum permissible size of discontinuities . 3 4.4 Personnel qualification 3 4.5 Wall-section zones 4 4.6 Severity levels. 4 5 Examination. 4 5.1 Principles. 4
8、5.2 Material 4 5.3 Equipment and coupling medium. 5 5.4 Preparation of casting surfaces for examination 5 5.5 Examination procedure 6 5.6 Examination report . 9 Annex A (informative) Sound-beam diameters . 16 Annex B (informative) Types of indications 18 Bibliography . 30 ISO 4992-1:2006(E) iv ISO 2
9、006 All rights reservedForeword ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing International Standards is normally carried out through ISO technical committees. Each member body interested in
10、a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the International Electrotechnical Commissi
11、on (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2. The main task of technical committees is to prepare International Standards. Draft International Standards adopted by the technical c
12、ommittees are circulated to the member bodies for voting. Publication as an International Standard requires approval by at least 75 % of the member bodies casting a vote. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. ISO shall n
13、ot be held responsible for identifying any or all such patent rights. ISO 4992-1 was prepared by Technical Committee ISO/TC 17, Steel, Subcommittee SC 11, Steel castings. ISO 4992 consists of the following parts, under the general title Steel castings Ultrasonic examination: Part 1: Steel castings f
14、or general purposes Part 2: Steel castings for highly stressed components INTERNATIONAL STANDARD ISO 4992-1:2006(E) ISO 2006 All rights reserved 1 Steel castings Ultrasonic examination Part 1: Steel castings for general purposes 1 Scope This part of ISO 4992 specifies the requirements for the ultras
15、onic examination of steel castings (with ferritic structure) for general purposes, and the methods for determining internal discontinuities by the pulse-echo technique. This part of ISO 4992 applies to the ultrasonic examination of steel castings which have usually received a grain-refining heat tre
16、atment and which have wall thicknesses up to and including 600 mm. For greater wall thicknesses, special agreements apply with respect to the test procedure and recording levels. This part of ISO 4992 does not apply to austenitic steels and joint welds. 2 Normative references The following reference
17、d documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. ISO 5577, Non-destructive testing Ultrasonic inspection Vocabulary ISO 7
18、963, Non-destructive testing Ultrasonic testing Specification for calibration block No. 2 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, Non-destructive testi
19、ng Ultrasonic examination Part 5: Characterization and sizing of discontinuities EN 1330-4, Non-destructive testing Terminology Part 4: Terms used in ultrasonic testing EN 12223, Non-destructive testing Ultrasonic examination Specification for calibration block No. 1 EN 12668-1, Non-destructive test
20、ing 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 e
21、xamination equipment Part 3: Combined equipment ISO 4992-1:2006(E) 2 ISO 2006 All rights reserved3 Terms and definitions For the purposes of this document, the terms and definitions given in ISO 5577, EN 583-1, EN 583-2, EN 583-5, and EN 1330-4, and the following, apply. 3.1 reference discontinuity
22、echo size smallest indication to be recorded during the assessment phase of an ultrasonic examination, usually expressed as an equivalent flat-bottomed hole diameter 3.2 point discontinuity discontinuity, the dimensions of which are smaller than or equal to the sound-beam width NOTE Dimensions in th
23、is part of ISO 4992 relate to length, width and/or dimension in the through-wall direction. 3.3 complex discontinuity discontinuity, the dimensions of which are larger than the sound-beam width NOTE Dimensions in this part of ISO 4992 relate to length, width and/or dimension in the through-wall dire
24、ction. 3.4 planar discontinuity discontinuity having two measurable dimensions 3.5 volumetric discontinuity discontinuity having three measurable dimensions 3.6 special rim zone outer rim-zone part with special requirements NOTE Examples of special requirements are machined surfaces, higher stresses
25、 and sealing surfaces. 3.7 production welding any welding carried out during manufacturing before final delivery to the purchaser 3.7.1 joint welding production welding used to assemble components together to obtain an integral unit 3.7.2 finishing welding production welding carried out in order to
26、ensure the agreed quality of the casting 4 Requirements 4.1 Order information The following information shall be available at the time of enquiry and order (see also EN 583-1): the areas of the casting and the number or percentage of castings to which the ultrasonic examination requirements apply (e
27、xamination volume, extent of examination); the severity level to be applied to the various zones or areas of the casting (acceptance criteria); ISO 4992-1:2006(E) ISO 2006 All rights reserved 3 requirements for a written examination procedure; whether there are any additional requirements for the ex
28、amination procedure, see also 5.5.1. 4.2 Extent of examination The casting shall be examined so that the agreed areas are totally covered (insofar as this is possible from the shape of the casting) by the use of the best applicable examination technique. For wall thicknesses greater than 600 mm, agr
29、eement shall be made between the parties concerned on the examination procedure and also on the recording and acceptance levels. 4.3 Maximum permissible size of discontinuities 4.3.1 Limits of acceptance for planar discontinuities mainly orientated perpendicular to the surface The limits of acceptan
30、ce for planar discontinuities are given in Figure 1. Indications with measurable dimensions are not permissible as severity level 1. The largest dimension in the through-wall direction shall not exceed 10 % of wall thickness, except indications with a measurable length u 10 mm. Such indications shal
31、l not exceed a dimension in the through-wall direction of 25 % of wall thickness or 20 mm. The greatest distance between indications, as a criterion for evaluation as a single indication or indication area perpendicular or lateral to the surface, shall be 10 mm. For an area with a measurable length
32、and non-measurable dimension in the through-wall direction, this non-measurable dimension shall be taken as 3 mm and the area shall be calculated as follows: A = 3 L (1) where A is the area of indication, in square millimetres; 3 is the width taken, in millimetres; L is the measurable length, in mil
33、limetres. 4.3.2 Limits of acceptance for volumetric discontinuities The limits of acceptance for volumetric discontinuities are given in Table 1. Any discontinuity exceeding one of the criteria shall be considered as unacceptable. 4.3.3 Maximum permissible discontinuities in the case of radiographic
34、 examination of the casting carried out as a supplement to ultrasonic examination Unless otherwise agreed by the time of enquiry and order, when, after conducting the radiographic and the ultrasonic examination in combination, it has been demonstrated that a discontinuity is situated in the core zon
35、e, this additional information makes the discontinuity acceptable at one level less severe, e.g. severity level 3 instead of 2 for radiographic examination, see EN 1559-2. 4.4 Personnel qualification It is assumed that ultrasonic examination is performed by qualified and capable personnel. In order
36、to prove this qualification, it is recommended to certify personnel according to ISO 9712 or EN 473. ISO 4992-1:2006(E) 4 ISO 2006 All rights reserved4.5 Wall-section zones The wall section shall be divided into zones as shown in Figure 2. These sections relate to the dimensions of the casting ready
37、 for assembly (finish machined). 4.6 Severity levels If the purchaser specifies different severity levels in different areas of the same casting, all of these areas shall be clearly identified on the purchasers drawing and shall include: all necessary dimensions for accurate location of zones; the f
38、ull 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 requirements for the parent metal sh
39、all apply. 5 Examination 5.1 Principles The principles of ultrasonic examination given in EN 583-1, EN 583-2 and EN 583-5 shall apply. 5.2 Material The suitability of material for ultrasonic examination is assessed by comparison with the echo height of a reference reflector (usually the first backwa
40、ll echo) and the noise signal. This assessment shall be carried out on selected casting areas which are representative of the surface finish and of the total thickness range. The assessment areas shall have parallel surfaces. The reference echo height according to Table 2 shall be at least 6 dB abov
41、e the noise signal. If the echo height of this smallest detectable flat-bottomed or equivalent side-drilled hole diameter at the end of the test range to be assessed is less than 6 dB above the grass level, then the ultrasonic testability is reduced. In this case, the flat-bottomed or side-drilled h
42、ole diameter which can be detected with a signal-noise ratio of at least 6 dB shall be noted in the test report, and the additional procedure shall be agreed between the manufacturer and the purchaser. NOTE For the definition of an adequate flat-bottomed hole size, the distance gain size system (DGS
43、) or a test block of identical material, heat treatment condition and section thickness containing flat-bottomed holes with a diameter according to Table 2 or equivalent side-drilled holes, can be used. The following formula is used for converting the flat- bottomed hole diameter into the side-drill
44、ed hole diameter: 2 4 FBH Q 4,935 D D s = (2) where D Qis the side-drilled hole diameter, in millimetres; D FBHis the flat-bottomed hole diameter, in millimetres; is the wave length, in millimetres; s is the path length, in millimetres. ISO 4992-1:2006(E) ISO 2006 All rights reserved 5 The formula i
45、s applicable for D QW 2 and s W 5 near-field length and is only defined for single element probes. 5.3 Equipment and coupling medium 5.3.1 Ultrasonic instrument The ultrasonic instrument shall meet the requirements given in EN 12668-1 and shall have the following characteristics: range setting, from
46、 at least 10 mm to 2 m continuously selectable, for longitudinal and transverse waves transmitted in steel; gain, adjustable in 2 dB maximum steps over a range of at least 80 dB with a measuring accuracy of 1 dB; time-base and vertical linearities less than 5 % of the adjustment range of the screen;
47、 suitability, at least for nominal frequencies from 1 MHz up to and including 5 MHz, in the pulse-echo technique with single-crystal and twin-crystal probes. 5.3.2 Probes and transducer frequencies The probes and transducer frequencies shall be as given in EN 12668-2 and EN 12668-3 with the followin
48、g exceptions: nominal frequencies shall be in the range 1 MHz to 5 MHz; for oblique incidence, angle probes with angles between 35 and 70 shall be used. NOTE Normal or angle probes can be used for the examination of steel castings. The type of probe used depends on the geometry of the casting and th
49、e 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 equipment The ultrasonic examination equipment shall be checked regularly by the operator in accordance with EN 12668-3. 5.3.4 Coupling medium A coupling medium in accordance with EN 583-1 shall be used. The coupling medium shall wet the examination area to ensure
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