1、raising standards worldwideNO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBSI Standards PublicationBS 5L 101:2011Procedure for inspection,testing and acceptance ofaluminium-base andmagnesium-base ingots andcastingsPublishing and copyright informationThe BSI copyright notice di
2、splayed in this document indicates when the documentwas last issued. BSI 2011ISBN 978 0 580 70462 8ICS 49.025.20The following BSI references relate to the work on this standard:Committee reference ACE/61Draft for comment 10/30216241 DCPublication historyFirst published February 1950Second edition No
3、vember 1959Third edition March 1970Fourth edition December 1990Fifth (present) edition December 2011Amendments issued since publicationDate Text affectedBS 5L 101:2011 BRITISH STANDARDContentsForeword iiiSection 1: General 11 Scope 12 Normative references 13 Definitions 14 General 35 Information and
4、 requirements to be agreed and to be documented 36 Pre-production castings qualification of foundry technique 57 Manufacture of production castings 68 Re-qualification requirements 69 Heat treatment 710 Chemical composition 711 Dimensions and tolerances 712 Freedom from defects 813 Testing 814 Repai
5、r of castings 1215 Identification 1316 Protection against corrosion 1317 Certification 13Section 2: Approved ingots 1518 General 1519 Chemical composition 1520 Special requirements 15Section 3: Castings not subject to cut-up testing 1621 General 1622 Manufacture 1623 Chemical composition 1624 Mechan
6、ical testing 1625 Heat treated castings 1726 Retest procedure 17Section 4: Castings subject to cut-up testing 1827 General 1828 Manufacture 1829 Chemical composition 1830 Mechanical testing 1831 Heat treatment 1932 Retest procedure 19AnnexesAnnex A (normative) Procedure for the use and control of po
7、lymerquenchants 20Annex B (normative) Rules for application of values for chemical compositionand mechanical properties given in material specifications 21List of figuresFigure B.1 Forms of test samples A, B and C 22Figure B.2 Forms of test samples D and E 23Figure B.3 Forms of test sample F 24Figur
8、e B.4 Forms of test sample G 25Figure B.5 Forms of test sample H 26BRITISH STANDARD BS 5L 101:2011 BSI 2011 iList of tablesTable 1 Cast test sampling 9Table 2 Radiographic defect acceptance levels for aluminium alloy castings 11Table 3 Radiographic defect acceptance levels for magnesium alloycasting
9、s 12Summary of pagesThis document comprises a front cover, an inside front cover, pages i to iv,pages 1 to 26, an inside back cover and a back cover.BRITISH STANDARDBS 5L 101:2011ii BSI 2011ForewordPublishing informationThis British Standard is published by BSI and came into effect on 31 December201
10、1. It was prepared by Panel ACE/61/-/24, Light alloys, under the authority ofTechnical Committee ACE/61, Metallic materials for aerospace purposes. A list oforganizations represented on this committee can be obtained on request to itssecretary.SupersessionThis standard supersedes BS 4L 101:1990, whi
11、ch is withdrawn.Information about this documentThis standard is a full revision of BS L 101. The principal changes from theprevious edition are:Section 1:a) Definitions amended.b) Information to be supplied by purchaser added.c) Information to be agreed between manufacturer and purchaser added.d) Qu
12、alification of foundry technique requirements added.e) Impregnation requirements added.f) HIPping requirements added.g) Temperature control during heat treatment to BS M 54 replaced byAMS 2750.h) Re-qualification requirements added.i) Application of values requirements added.j) Tensile testing at am
13、bient temperature to BS A4-1.1 replaced byBS EN 2002-1.k) Hardness testing to BS A4-5 replaced by BS EN ISO 6506-1 andBS EN ISO 6508-1.l) Heat treatment temperature tolerances added.m) Penetrant flaw detection to BS M 39 replaced by EN 2006-16 andrequirements for penetrant sensitivity added.n) Radio
14、logical examination to BS M 34 replaced by BS 2002-21.o) Protection requirements amended.Section 3: Impregnation requirements deleted and transferred to Section 1.Appendix A: Re-identified as Annex B and reference to withdrawn BS 1957 replaced bydetails for rounding of values.Appendix B: Re-identifi
15、ed as Annex A and quenchant temperature requirementsamended.BRITISH STANDARD BS 5L 101:2011 BSI 2011 iiiHazard warningsWARNING. This British Standard calls for the use of substances and/orprocedures that can be injurious to health if adequate precautions are nottaken. It refers only to technical sui
16、tability and does not absolve the userfrom legal obligations relating to health and safety at any stage.Use of this documentIt has been assumed in the preparation of this British Standard that theexecution of its provisions will be entrusted to appropriately qualified andexperienced people, for whos
17、e use it has been produced.Presentational conventionsThe provisions of this standard are presented in roman (i.e. upright) type. Itsmethods are expressed either as a set of instructions or in sentences in whichthe principal auxiliary verb is “shall”.Commentary, explanation and general informative ma
18、terial is presented insmaller italic type, and does not constitute a normative element.Contractual and legal considerationsThis publication does not purport to include all the necessary provisions of acontract. Users are responsible for its correct application.Compliance with a British Standard cann
19、ot confer immunity from legalobligations.BRITISH STANDARDBS 5L 101:2011iv BSI 2011Section 1: General1 ScopeThis British Standard specifies a procedure for the inspection and testing ofaluminium alloy and magnesium alloy ingots and castings to be used foraerospace purposes and other critical applicat
20、ions.2 Normative referencesThe following referenced documents are indispensable for the application ofthis document. For dated references, only the edition cited applies. For undatedreferences, the latest edition of the referenced document (including anyamendments) applies.BS EN 2002-1, Metallic mat
21、erials Test methods Part 1: Tensile testing atambient temperatureBS EN ISO 3452-2, Non-destructive testing Penetrant testing Part 2: Testing ofpenetrant materialsBS EN ISO 6506-1, Metallic materials Brinell hardness test Part 1: Test methodBS EN ISO 6508-1, Metallic materials Rockwell hardness test
22、Part 1: Testmethod (scales A, B, C, D, E, F, G, H, K, N, T)EN 2002-16, Metallic materials Test methods Part 16: Non-destructive testing Penetrant testing1)EN 2002-21, Metallic materials Test methods Part 21: Radiographic testing ofcastings1)AMS 2750, PyrometryASTM E155, Standard reference radiograph
23、s for inspection of aluminium andmagnesium castings3 DefinitionsFor the purposes of this British Standard the following definitions apply.3.1 alloying additionsmaterials in elemental or alloy form for use in making up melts from a virginmetal base3.2 approved ingotingot which has been proved to conf
24、orm to the chemical composition specifiedin the material specification3.3 approved scrapscrap which arises from the founders own production from approved materialand which is segregated and identified. It may include headers, runners andheavy fettling scrap, but excludes all small particles1)Publish
25、ed as ASD Prestandard at the date of publication of this standard.BRITISH STANDARD BS 5L 101:2011 BSI 2011 13.4 batchingots for remelting or castings, each of which is:a) of the same form and of the same nominal dimensions or of the samedrawing number; andb) from the same cast for ingots or from the
26、 same melt for castings; andc) from the same heat treatment charge.3.5 cast (term used for ingots)metal taken from the same furnace or from the same ladle or from severalfurnaces and mixed in the same furnace or in the same ladle before pouringwhere a continuous melting process is used, a cast may b
27、e defined as metaltaken from the furnace before the next following charge3.6 designated areahighly stressed or otherwise important region of a casting, the location of whichis determined by the Design Authority and stated on the drawing or associateddocuments3.7 design authorityorganization responsi
28、ble for the detailed design of materiel and which has theresponsibility of certifying and/or sealing drawings and specificationsNOTE The Design Authority may not be the purchaser3.8 melt (term used for castings)metal taken from the same furnace or from the same ladle, or from severalfurnaces and mix
29、ed in the same furnace or in the same ladle before pouring3.9 permanent mould castingcasting made by introducing molten metal by gravity or pressure into a metalmould3.10 precision castingcasting made by any of the following processes or any similar process:a) investment, including ceramic shell, an
30、d block mould;b) ceramic piece moulding, e.g. Shaw;c) resin shell mould;d) plaster.3.11 purchaserbody which purchases the products from a founderNOTE The purchaser may not be the Design Authority3.12 quality assurance authoritybody responsible for authorizing the founder or supplier to issue certifi
31、cation,when to certify means to attest as meeting a standard3.13 sand castingcasting made by a process involving the moulding of a pattern with a suitablybonded sandBRITISH STANDARDBS 5L 101:20112 BSI 20113.14 undesignated arearegions within a casting which have not been designated3.15 virgin metalp
32、ure aluminium or magnesium with impurity levels such that they will conformto the material specification for which its use is intended4 GeneralThis standard details the basic requirements for the inspection and testing ofBritish Standard Aerospace L series cast aluminium base and magnesium basealloy
33、s.In addition to the definitive requirements, this standard also requires the itemsdetailed in Clause 5 to be documented. For compliance with this standard, boththe definitive requirements and the documented items have to be satisfied.If the purchaser wishes to specify an inspection, testing or acce
34、ptance procedurefor any property of any product, which differs from that specified in thisstandard, this shall be agreed between the purchaser and the manufacturer andshall be fully documented on the order, drawing or inspection schedule,provided that the purchaser is also the quality assurance auth
35、ority. If thepurchaser is not also the quality assurance authority, deviations from therequirements of this standard shall only be agreed and documented afterwritten approval has been obtained from the quality assurance authority.5 Information and requirements to be agreed andto be documented5.1 Inf
36、ormation to be supplied by the purchaserThe following information to be supplied by the purchaser, which is specified inthe clauses referred to, shall be fully documented on the order, drawing orinspection schedule, on which the number of this British Standard shall also begiven.Both the definitive
37、requirements specified throughout the standard and thefollowing documented items shall be satisfied before a claim of compliance withthe standard2)can be made and verified.a) General:1) the number of the material specification with which this standard is tobe used;2) all details relating to pre-prod
38、uction castings in order to optimize andqualify the method of manufacture and mould configuration and todemonstrate that the requirements of the Design Authority can be met(see 6.1);3) the heat treatment required if different from that specified in thematerial specification (see 9.1);4) radiological
39、 examination technique (see 13.7.1);2)Marking a British Standard identifier (e.g. BS 2L 169:2002) on or in relation to aproduct represents a manufacturers declaration of conformity, i.e. a claim by or onbehalf of the manufacturer that the product meets the requirements of the standard.The accuracy o
40、f the claim is solely the claimants responsibility. Such a declaration isnot to be confused with third-party certification of conformity.BRITISH STANDARD BS 5L 101:2011 BSI 2011 35) the radiological acceptance standard if other than level B (see 13.7.3);6) all details relating to any special protect
41、ive treatment (see Clause 16);b) Castings not subject to cut-up testing:1) if one test sample per casting is required (see 24.1.4);c) Castings subject to cut-up testing:1) the method of obtaining the test samples (see 30.1.1)5.2 Items to be agreed between the founder and the purchaserThe following i
42、tems to be agreed between the contracting parties, which arespecified in the clauses referred to, shall be fully documented.Both the definitive requirements specified throughout the standard and thefollowing documented items shall be satisfied before a claim of compliance withthe standard3)can be ma
43、de and verified.a) if weld repair is permitted in order to consistently produce castings fullycompliant with drawing requirements (see 6.3);b) if correction of distortion is permitted (see 7.2);c) if impregnation is permitted (see 7.3);d) if Hot Isostatic Pressing (HIPping) is permitted (see 7.4);e)
44、 method of temperature control if other than AMS 2750 (see 9.2);f) if the use of polyalkylene glycol is permitted as a quenchant (see 9.4);g) if non-standard test pieces cut from castings, cast integrally with castings orgated to castings are permitted (see 13.2.2);h) if non-standard separately cast
45、 test-pieces are permitted (see 13.2.3);i) if flaw detection using non-fluorescent penetrants is permitted (see 13.6.1);j) standards of acceptance for other than cracks or crack-like defects(see 13.6.4);k) if weld repair of series production castings is permitted (see 14.1);l) any special requiremen
46、ts for approved ingots (see Clause 20);m) if it is permissible to relax the frequency of chemical compositiondetermination (see 23.2);n) if it is permissible to use one test sample to represent a series of melts madefrom one cast of approved ingot (see 24.1.2);o) if it permissible, for re-test purpo
47、ses, to submit one or more representativecastings to cut-up test (see 26.1 3);p) for re-test purposes, the form, size and location of the test pieces and theminimum mechanical test values to be obtained (see 26.1 3);q) if it is permissible for the number of test pieces machined from each castingto b
48、e less than that machined from the pre-production approval casting(s)during routine cut-up testing (see 30.1.2);3)Marking a British Standard identifier (e.g. BS 2L 169:2002) on or in relation to aproduct represents a manufacturers declaration of conformity, i.e. a claim by or onbehalf of the manufac
49、turer that the product meets the requirements of the standard.The accuracy of the claim is solely the claimants responsibility. Such a declaration isnot to be confused with third-party certification of conformity.BRITISH STANDARDBS 5L 101:20114 BSI 20116 Pre-production castings qualification of foundrytechnique6.1 Prior to commencing series production of a design, pre-production castingsshall be produced in order to optimize and qualify the method of manufactureand mould configuration and to demonstrate that the
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