SPECIFICATION FOR CASTINGS, CARBON, LOW-

ALLOY, AND MARTENSITIC STAINLESS STEEL,

ULTRASONIC EXAMINATION THEREOF
SA-609 /SA-609M

(Identical with ASTM Specification A 609 /A 609M-91)

1. Scope establish appropriate safety and health practices and

determine the applicability of regulatory limitations
1.1 This practice covers the standards and procedures
prior to use.
for the pulse-echo ultrasonic examination of heat-treated
carbon, low-alloy, and martensitic stainless steel castings
by the longitudinal-beam technique.
2. Referenced Documents
1.2 This practice is to be used whenever the inquiry,
contract, order, or specification states that castings are 2.1 ASTM Standards:
to be subjected to ultrasonic examination in accordance A 217 /A 217M Specification for Steel Castings, Marten-
with Practice A 609 /A 609M. sitic Stainless and Alloy, for Pressure-Containing Parts,
Suitable for High-Temperature Service
1.3 This practice contains two procedures for ultra- E 94 Guide for Radiographic Testing
sonic inspection of carbon, low-alloy, and martensitic E 317 Practice for Evaluating Performance Characteris-
stainless steel castings, that is, Procedure A and Proce- tics of Ultrasonic Pulse-Echo Testing Systems Without
dure B. Procedure A is the original A 609 /A 609M the Use of Electronic Measurement Instruments
practice and requires calibration using a series of test
blocks containing flat bottomed holes. It also provides 2.2 Other Document:
supplementary requirements for angle beam testing. SNT-TC-1A Recommended Practice for Nondestructive
Procedure B requires calibration using a back wall Testing Personnel Qualification and Certification
reflection from a series of solid calibration blocks.
NOTE 1 — Ultrasonic examination and radiography are not directly
comparable. This examination technique is intended to complement 3. Ordering Information
Guide E 94 in the detection of discontinuities.
3.1 The inquiry and order should specify which
1.4 The values stated in either inch–pound units or procedure is to be used. If a procedure is not specified,
SI units are to be regarded separately as standard. Procedure A shall be used.
Within the text, the SI units are shown in brackets. The
3.2 Procedure A — Flat-Bottomed Hole Calibration
values stated in each system are not exact equivalents;
Procedure:
therefore, each system must be used independently of
the other. Combining values from the two systems may 3.2.1 When this practice is to be applied to an
result in nonconformance with this practice. inquiry, contract, or order, the purchaser shall furnish
the following information:
1.5 This standard does not purport to address all
of the safety problems, if any, associated with its use. 3.2.1.1 Quality levels for the entire casting or
It is the responsibility of the user of this standard to portions thereof,

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SA-609 /SA-609M 1998 SECTION II

3.2.1.2 Sections of castings requiring longitudi- 4.2.3 Other frequencies and sizes of search units
nal-beam examination, may be used for evaluating and pinpointing indications.

3.2.1.3 Sections of castings requiring dual ele- 4.3 Reference Blocks:

ment examination,
4.3.1 Reference blocks containing flat-bottom holes
3.2.1.4 Sections of castings requiring supplemen- shall be used to establish test sensitivity in accordance
tary examination, using the angle-beam procedure de- with 8.2.
scribed in Supplementary Requirement S1 in order to 4.3.2 Reference blocks shall be made from cast
achieve more complete examination, and steels that give an acoustic response similar to the
castings being examined.
3.2.1.5 Any requirements additional to the provi-
sions of this practice. 4.3.3 The design of reference blocks shall be in
3.3 Procedure B: Back-Wall Reflection Calibration accordance with Fig. 1, and the basic set shall consist
Procedure — When this procedure is to be applied to of those blocks listed in Table 1. When section thick-
an inquiry, contract, or order, the purchaser shall desig- nesses over 15 in. [380 mm] are to be inspected, an
nate the quality levels for the entire casting or applicable additional block of the maximum test thickness shall
portions. be made to supplement the basic set.
4.3.4 Machined blocks with 3⁄32 in. [2.4 mm]
diameter flat-bottom holes at depths from the entry
PROCEDURE A — FLAT-BOTTOMED HOLE surface of 1⁄8 in. [3 mm], 1⁄2 in. [13 mm], or 1⁄2t and
CALIBRATION PROCEDURE 3⁄ in. [19 mm], or 3⁄ t (where t p thickness of the
4 4
block) shall be used to establish the DAC for the dual-
4. Apparatus
element search units (see Fig. 2).
4.1 Electronic Apparatus:
4.3.5 Each reference block shall be permanently
4.1.1 An ultrasonic, pulsed, reflection type of identified along the side of the block indicating the
instrument that is capable of generating, receiving, and material and the block identification.
amplifying frequencies of at least 1 to 5 MHz.
4.4 Couplant — A suitable couplant having good
4.1.2 The ultrasonic instrument shall provide linear wetting characteristics shall be used between the search
presentation (within 65%) for at least 75% of the unit and examination surface. The same couplant shall
screen height (sweep line to top of screen). Linearity be used for calibrations and examinations.
shall be determined in accordance with Practice E 317
or equivalent electronic means.
4.1.3 The electronic apparatus shall contain a signal 5. Personnel Requirements
attenuator or calibrated gain control that shall be accu- 5.1 The manufacturer shall be responsible for as-
rate over its useful range to 610% of the nominal signing qualified personnel to perform ultrasonic exami-
attenuation or gain ratio to allow measurement of signals nation in conformance with the requirements of this
beyond the linear range of the instrument. practice.
4.2 Search Units: 5.2 Personnel performing ultrasonic examinations in
4.2.1 Longitudinal Wave, internally grounded, accordance with this practice shall be familiar with the
having a 1⁄2 to 11⁄8 in. [13 to 28 mm] diameter or 1 following:
in. [25 mm] square piezo-electric elements. Based on 5.2.1 Ultrasonic terminology,
the signals-to-noise ratio of the response pattern of the
casting, a frequency in the range from 1 to 5 MHz 5.2.2 Instrument calibration,
shall be used. The background noise shall not exceed
5.2.3 Effect of transducer material, size, frequency,
25% of the distance amplitude correction curve (DAC).
and mode on test results,
Transducers shall be utilized at their rated frequencies.
5.2.4 Effect of material structure (grain size, clean-
4.2.2 Dual-Element, 5 MHz, 1⁄2 by 1 in. [13 by
liness, etc.) on test results,
25 mm], 12° included angle search units are recom-
mended for sections 1 in. [25 mm] and under. 5.2.5 Effect of test distance on test results,

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-609 /SA-609M

5.2.6 Effect of nonlinearity on test results, attenuator. This curve shall be referred to as the 100%
distance amplitude correction (DAC) curve. If the atten-
5.2.7 Effect of thickness and orientation of disconti-
uation of ultrasound in the casting thickness being
nuities on test results, and
examined is such that the system’s dynamic range is
5.2.8 Effect of surface roughness on test results. exceeded, segmented DAC curves are permitted.
5.3 A qualification record (see Note 2) of personnel 8.3 The casting examination surface will normally
considered suitable by the manufacturer to perform be rougher than that of the test blocks; consequently,
examinations in accordance with this practice shall be employ a transfer mechanism to provide approximate
available upon request. compensation. In order to accomplish this, first select
a region of the casting that has parallel walls and a
NOTE 2 — SNT-TC-1A, Ultrasonic Testing Method, provides a
recommended procedure for qualifying personnel. Other personnel surface condition representative of the rest of the casting
qualification requirement documents may be used when agreed upon as a transfer point. Next, select the test block whose
between the purchaser and the supplier. overall length, C (Fig. 1), most closely matches the
reflection amplitude through the block length. Place
the search unit on the casting at the transfer point and
6. Casting Conditions adjust the instrument gain until the back reflection
amplitude through the casting matches that through the
6.1 Castings shall receive at least an austenitizing
test block. Using this transfer technique, the examination
heat treatment before being ultrasonically examined.
sensitivity in the casting may be expected to be within
6.2 Test surfaces of castings shall be free of material 630% or less of that given by the test blocks.
that will interfere with the ultrasonic examination. They
may be as cast, blasted, ground, or machined. 8.4 Do not change those instrument controls and
the test frequency set during calibration, except the
6.3 The ultrasonic examination shall be conducted attenuator, or calibrated gain control, during acceptance
prior to machining that prevents an effective examina- examination of a given thickness of the casting. Make
tion of the casting. a periodic calibration during the inspection by checking
the amplitude of response from the 1⁄4-in.
(6.4-mm) diameter flat-bottom hole in the test block
7. Test Conditions utilized for the transfer.
7.1 To assure complete coverage of the specified NOTE 3 — The attenuator or calibrated gain control may be used
casting section, each pass of the search unit shall to change the signal amplitude during examination to permit small
amplitude signals to be more readily detected. Signal evaluation is
overlap by at least 10% of the width of the transducer. made by returning the attenuator or calibrated gain control to its
original setting.
7.2 The rate of scanning shall not exceed 6 in. /s
(150 mm /s). 8.5 During examination of areas of the casting having
7.3 The ultrasonic beam shall be introduced perpen- parallel walls, recheck areas showing 75% or greater
dicular to the examination surface. loss of back reflection to determine whether loss of
back reflection is due to poor contact, insufficient
couplant, misoriented discontinuity, etc. If the reason
for loss of back reflection is not evident, consider the
8. Procedure
area questionable and further investigate.
8.1 Adjust the instrument controls to position the
first back reflection for the thickness to be tested at
least one half of the distance across the cathode ray tube.
9. Report
8.2 Using the set of reference blocks spanning the 9.1 The manufacturer’s report of final ultrasonic
thickness of the casting being inspected, mark the flat- examination shall contain the following data and shall
bottom hole indication height for each of the applicable be furnished to the purchaser:
blocks on the cathode ray tube shield. Draw a curve
through these marks on the screen or on suitable graph 9.1.1 The total number, location, amplitude, and
paper. The maximum signal amplitude for the test area when possible to delineate boundaries by monitor-
blocks used shall peak at approximately three-fourths ing the movement of the center of the search unit of
of the screen height above the sweep by use of the all indications equal to or greater than 100% of the DAC,

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SA-609 /SA-609M 1998 SECTION II

9.1.2 Questionable areas from 8.5 that, upon further amplitude of the indication is 100% of the DAC or where the back
reflection is reduced by 75%, using the center of the search unit as
investigation, are determined to be caused by discontinu- a reference point to establish the outline of the indication area.
ities,
NOTE 6 — In certain castings, because of very long metal path
9.1.3 The examination frequency, type of instru- distances or curvature of the examination surfaces, the surface area
ment, types of search units employed, couplant, manu- over which a given discontinuity is detected may be considerably
larger or smaller than the actual area of the discontinuity in the
facturer’s identifying numbers, purchaser’s order num- casting; in such cases, other criteria that incorporate a consideration
ber, and data and authorized signature, and of beam angles or beam spread must be used for realistic evaluation
of the discontinuity.
9.1.4 A sketch showing the physical outline of
the casting, including dimensions of all areas not in-
spected due to geometric configuration, with the location PROCEDURE B — BACK-WALL REFLECTION
and sizes of all indications in accordance with 9.1.1 CALIBRATION PROCEDURE
and 9.1.2.
11. Apparatus
11.1 Apparatus shall be kept on a regular six month
10. Acceptance Standards maintenance cycle during which, as a minimum require-
10.1 This practice is intended for application to ment, the vertical and horizontal linearities, sensitivity,
castings with a wide variety of sizes, shapes, composi- and resolution shall be established in accordance with
tions, melting processes, foundry practices, and applica- the requirements of Practice E 317.
tions. Therefore, it is impractical to specify an ultrasonic 11.2 Search Units — Ceramic element transducers
quality level that would be universally applicable to not exceeding 1.25 in. [82 mm] diameter or 1 in.2 [25
such a diversity of products. Ultrasonic acceptance or mm2] shall be used.
rejection criteria for individual castings should be based
on a realistic appraisal of service requirements and the 11.3 Search Units Facing — A soft urethane mem-
quality that can normally be obtained in production of brane or neoprene sheet, approximately 0.025 in. [0.64
the particular type of casting. mm] thick, may be used to improve coupling and
minimize transducer wear caused by casting surface
10.2 Acceptance quality levels shall be established roughness.
between the purchaser and the manufacturer on the
basis of one or more of the following criteria: 11.4 Calibration /Testing — The same system, in-
cluding the urethane membrane, used for calibration
10.2.1 No indication equal to or greater than the shall be used to inspect the casting.
DAC over an area specified for the applicable quality
level of Table 2. 11.5 Other Inspections — Other frequencies and
type search units may be used for obtaining additional
10.2.2 No reduction of back reflection of 75% or information and pinpointing of individual indications.
greater that has been determined to be caused by a
discontinuity over an area specified for the applicable 11.6 Couplant — A suitable liquid couplant, such
quality level of Table 2. as clean SAE 30 motor oil or similar commercial
ultrasonic couplant, shall be used to couple the search
10.2.3 Indications producing a continuous response unit to the test surface. Other couplants may be used
equal to or greater than the DAC with a dimension when agreed upon between the purchaser and supplier.
exceeding the maximum length shown for the applicable
quality level shall be unacceptable. 11.7 Reference Standards — Reference standards
in accordance with Fig. 3 shall be used to calibrate
10.2.4 Other criteria agreed upon between the the instrument for inspecting machined and cast surfaces.
purchaser and the manufacturer. Reference standards shall be flaw free and machined
10.3 Other means may be used to establish the within tolerances indicated.
validity of a rejection based on ultrasonic inspection.
NOTE 4 — The areas for the ultrasonic quality levels in Table 2 12. Ultrasonic Instrument
of Practice A 609 /A 609M refer to the surface area on the casting
over which a continuous indication exceeding the DAC is maintained. 12.1 Type — Pulsed ultrasonic reflection instrument
NOTE 5 — Areas are to be measured from dimensions of the capable of generating, receiving, and amplifying fre-
movement of the search unit by outlining locations where the quencies of 1 MHz to 5 MHz shall be used for testing.

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12.2 Voltage — Line voltage shall be suitably 14.2.2 Casting Surfaces — Casting surfaces to
regulated by constant voltage equipment and metal be ultrasonically inspected shall be suitable for the
housing must be grounded to prevent electric shock. intended type and quality level (Tables 3 and 4) of
inspection as judged acceptable by a qualified individual
12.3 Linearity — The instrument must provide a as specified in 13.1.1.
linear presentation (within 65%) of at least 1.5 in.
[40 mm] sweep to peak (S /P). 14.2.3 Surface Condition — All surfaces to be
inspected shall be free of scale, machining or grinding
12.4 Calibrated Gain Control of Attenuator — The particles, excessive paint thickness, dirt, or other foreign
instrument shall contain a calibrated gain control or matter that may interfere with the inspection.
signal attenuator (accurate within 610%) which will
allow indications beyond the linear range of the instru- 14.3 Position of Casting — The casting shall be
ment to be measured. positioned such that the inspector has free access to
the back wall for the purpose of verifying change in
12.5 Time-Corrected Gain — The instrument shall contour.
be equipped to compensate for signal decay with dis-
tance. A method should be available to equalize signal
response at different depths.
15. Calibration
15.1 Calibration Blocks — Determine the thickness
13. Qualification of the material to be ultrasonically inspected. For
material thickness of 3 in. [75 mm] or less, use the
13.1 The requirements for pre-production qualification series of 3 blocks, 1⁄2, 2, 5 in. [13, 50, 125 mm] (Fig.
are as follows: 3, B dimension) for calibration. For a material thickness
13.1.1 Personnel — The personnel qualification greater than 3 in., use the series of 3 blocks, 2, 5, 10
requirements of SNT-TC-1A are applicable. Other per- in. [50, 125, 250 mm] (Fig. 3, B dimension) for
sonnel qualification requirement documents may be calibration.
used when agreed upon between the purchaser and the 15.2 Calibration of Search Units — For the thickness
supplier. Records of all personnel shall be available to of material to be inspected, as determined in 15.1, use
customers upon request. the following search units:
13.1.2 Equipment — The equipment shall be 15.2.1 For materials 3 in. [75 mm] or less in
capable of meeting the requirements in Section 12. thickness, use a 21⁄4 MHz, 1⁄2 in. [13 mm] diameter
search unit.
15.2.2 For material greater than 3 in. [75 mm] in
14. Preparation thickness, use a 21⁄4 MHz, 1 in. [25 mm] diameter
14.1 Time of Inspection — The final ultrasonic search unit.
acceptance inspection shall be performed after at least
15.3 Calibration Procedure:
an austenitizing heat treatment and preferably after
machining. In order to avoid time loss in production, 15.3.1 Set the frequency selector as required. Set
acceptance inspection of cast surfaces may be done prior the reject control in the “OFF” position.
to machining. Machined surfaces shall be acceptance
inspected as soon as possible after machining. Repair 15.3.2 Position the search unit on the entrant
welds may be inspected before the postweld heat surface of the block that completely encompasses the
treatment. metal thickness to be inspected (Fig. 3) and adjust the
sweep control such that the back reflection signal
14.2 Surface Finish: appears approximately, but not more than three-quarters
along the sweep line from the initial pulse signal.
14.2.1 Machined Surfaces — Machined surfaces
subject to ultrasonic inspection shall have a finish that 15.3.3 Position the search unit on the entrant
will produce an ultrasonic response equivalent to that surface of the smallest block of the series of 3 blocks
obtained from a 250 min. (6.3 mm) surface. The surface selected for calibration and adjust the gain until the
finish shall also permit adequate movement of search back reflection signal height (amplitude) is 1.5 in. [40
units along the surface. mm] sweep to peak (S /P). Draw a line on the cathode-

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SA-609 /SA-609M 1998 SECTION II

ray screen (CRT), parallel to the sweep line, through calibrated gains or attenuators. They require external
the peak of the 1.5 in. (S /P) amplitude. attenuators.

15.3.4 Position the search unit on the entrant

surface of the largest block of the series of 3 blocks
16. Scanning
selected for calibration, and adjust the distance ampli-
tude control to provide a back reflection signal height 16.1 Grid Pattern — The surface of the casting
of 1.5 in. [40 mm] (S /P). shall be laid out in a 12 by 12 in. [300 by 300 mm]
or any similar grid pattern for guidance in scanning.
15.3.5 Position the search unit on the entrant Grid numbers shall be stenciled on the casting for
surface of the intermediate calibration block of the record purposes and for grid area identity. The stenciled
series of 3 blocks being used for calibration and confirm grid number shall appear in the upper right hand corner
that the back reflection signal height is approximately of the grid. When grids are laid out on the casting
1.5 in. [40 mm] (S /P). If it is not, obtain the best surface and they encompass different quality levels,
compromise between this block and the largest block each specific area shall be evaluated in accordance
of the series of 3 blocks being used for calibration. with the requirements of the specific quality level
designated for that area.
15.3.6 Draw a line on the cathode ray tube screen
parallel to the sweep line at 0.5 in. [13 mm] (S /P) 16.2 Overlap — Scan over the surface allowing
amplitude. This will be the reference line for reporting 10% minimum overlap of the working diameters of
discontinuity amplitudes. the search unit.
15.3.7 For tests on machined surfaces, position 16.3 Inspection Requirements — All surfaces speci-
the search unit on a machined surface of casting where fied for ultrasonic (UT) shall be completely inspected
the walls are reasonably parallel and adjust the gain from both sides, whenever both sides are accessible.
of the instrument until the back reflection signal height The same search unit used for calibration shall be used
is 1.5 in. [40 mm] (S /P). Increase the inspection to inspect the casting.
sensitivity by a factor of three times (10 dB gain) with
the calibrated attenuator. Surfaces that do not meet the
requirements of 14.2.1 shall be inspected as specified 17. Additional Transducer Evaluation
in 15.3.8.
17.1 Additional information regarding any ultrasonic
15.3.8 For inspections on cast surfaces, position indication may be obtained through the use of other
the search unit on the casting to be inspected at a frequency, type, and size search unit.
location where the walls are reasonably parallel and
smooth (inside and outside diameter) and the surface
condition is representative of the surface being in- 18. Acceptance Criteria
spected. Adjust the gain of the instrument until the
18.1 Rejectable Conditions — The locations of all
back reflection signal height is 1.5 in. [40 mm] (S /P).
indications having amplitudes greater than the 0.5 in.
Increase the inspection sensitivity by a factor of six
[13 mm] line given in 15.3.6, when amplitude three
times (16 dB) by use of the calibrated control or
times (machined surfaces) or six times (cast surfaces)
attenuator. A significant change in surface finish requires
shall be marked on the casting surface. The boundary
a compensating adjustment to the gain.
limits of the indication shall be determined by marking
15.3.8.1 Rejectable indications on as-cast sur- a sufficient number of marks on the casting surfaces
faces may be reevaluated by surface preparation to 250 where the ultrasonic signal equals one half the reference
min. [6.3 mm] finish or better, and re-inspected in amplitude, 0.25 in. [6 mm]. To completely delineate
accordance with 15.3.7 of this practice. the indication, draw a line around the outer boundary
of the center of the number of marks to form the
15.3.8.2 It should be noted that some instruments indication area. Draw a rectangle or other regular shape
are equipped with decibel calibrated gain controls, in through the indication in order to form a polygon from
which case the decibel required to increase the sensitiv- which the area may be easily computed. It is not
ity must be added. Other instruments have decibel necessary that the ultrasonic signal exceed the amplitude
calibrated attenuators, in which case the required decibel reference line over the entire area. At some locations
must be removed. Still other instruments do not have within the limits of the indication, the signal may be

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-609 /SA-609M

less than the reference line, but nevertheless still present 18.3.6 Repair welds of castings shall meet the
such that it may be judged as a continuous, signal quality level designated for that particular area of the
indication. Rejectable conditions are as follows and casting.
when any of the conditions listed below are found, the
18.3.7 Any location that has a 75% or greater
indications shall be removed and repair welded to the
loss in back reflection and exceeds the area of the
applicable process specification.
applicable quality level, and whose indication ampli-
18.2 Linear Indications — A linear indication is tudes may or may not exceed the 0.5 in. [13 mm]
defined as one having a length equal to or greater than rejection line, shall be rejected unless the reason for
three times its width. An amplitude of 1⁄2 in. [13 mm], the loss in back reflection can be resolved as not being
such as would result from tears or stringer type slag caused by an indication. If gain is added and back
inclusion, shall be removed. echo is achieved without indication percent amplitude
exceeding the 0.5 in. [13 mm] rejection line, the area
18.3 Non-Linear Indications:
should be accepted.
18.3.1 Isolated Indications — Isolated indications
shall not exceed the limits of the quality level designated
by the customer’s purchase order listed in Table 3. An 19. Records
isolated indication may be defined as one for which
19.1 Stenciling — Each casting shall be permanently
the distance between it and an adjacent indication is
stenciled to locate inspection zones or grid pattern for
greater than the longest dimension of the larger of the
ease in locating areas where rejectable indications were
adjacent indications.
observed.
18.3.2 Clustered Indications — Clustered indica- 19.2 Sketch — A report showing the exact depth
tions shall be defined as two or more indications that and surface location in relation to the stencil numbers
are confined in a 1 in. [25 mm] cube. Clustered shall be made for each rejectable indicator found during
indications shall not exceed the limits of the quality each inspection.
level designated by the customer purchase order in
Table 4. Where the distance between indications is less 19.2.1 The sketch shall also include, but not be
than the lowest dimension of the largest indication in limited to, the following:
the group, the cluster shall be repair welded. 19.2.1.1 Part identification numbers,
18.3.3 The distance between two clusters must be
19.2.1.2 Purchase order numbers,
greater than the lowest dimension of the largest indica-
tion in either cluster. If they are not, the cluster having 19.2.1.3 Type and size of supplemental transduc-
the largest single indication shall be removed. ers used,
18.3.4 All indications, regardless of their surface 19.2.1.4 Name of inspector, and
areas as indicated by transducer movement on the
casting surface and regardless of the quality level 19.2.1.5 Date of inspection.
required, shall not have a through wall distance greater
than 1⁄3T, where T is the wall thickness in the area
containing the indication. 20. Product Marking
18.3.5 Repair welding of cluster-type indications 20.1 Any rejectable areas (those indications exceeding
need only be the extent necessary to meet the applicable the limits of Section 19) shall be marked on the casting
quality level for that particular area. All other types as the inspection progresses. The point of marking shall
of rejectable indications shall be completely removed. be the center of the search unit.

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SA-609 /SA-609M 1998 SECTION II

FIG. 1 ULTRASONIC STANDARD REFERENCE BLOCK

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-609 /SA-609M

FIG. 2 ULTRASONIC STANDARD REFERENCE BLOCK FOR DUAL-SEARCH UNIT CALIBRATION

FIG. 3 CALIBRATION BLOCKS

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SA-609 /SA-609M 1998 SECTION II

FIG. 4 BASIC CALIBRATION BLOCK FOR ANGLE BEAM EXAMINATION

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-609 /SA-609M

TABLE 1
DIMENSIONS AND IDENTIFICATION OF REFERENCE BLOCKS IN THE BASIC SET
(SEE FIG. 1)

Metal Overall Width or

Hole Diameter Distance Length Diameter Block
in 1⁄64ths, in. (B), in.A (C), in.A (D), min, Identification
[mm] [mm] [mm] in. [mm] Number

16 [0.70] 1 [25] 13⁄4 [45] 2 [50] 16-0100

16 [0.70] 2 [50] 23⁄4 [70] 2 [50] 16-0200
16 [0.70] 3 [75] 33⁄4 [95] 2 [50] 16-0300
16 [0.70] 6 [150] 63⁄4 [170] 3 [75] 16-0600
16 [0.70] 10 [255] 103⁄4 [275] 4 [100] 16-1000
16 [0.70] B B + 3⁄4 5 [125] 16-B00B
[B + 20]
A Tolerance 6 1⁄8 in. [3 mm].
B Additional supplemental blocks for testing thickness greater than 10 in. [250 mm], see 4.3.3.

TABLE 2
REJECTION LEVEL
NOTE 1 — The areas in the table refer to the surface area on the casting over which a continuous indication
exceeding the amplitude reference line or a continuous loss of back reflection of 75% or greater is maintained.
NOTE 2 — Areas shall be measured from the center of the search unit.
NOTE 3 — In certain castings, because of very long test distances or curvature of the test surface, the
casting surface area over which a given discontinuity is detected may be considerably larger or smaller than
the actual area of the discontinuity in the casting; in such cases a graphic plot that incorporates a consideration
of beam spread should be used for realistic evaluation of the discontinuity.

Area, in.2
[cm2]
Ultrasonic Testing (see 10.2.1 and Length, max,
Quality Level 10.2.2) in. [mm]
1 0.8 [5] 1.5 [40]
2 1.5 [20] 2.2 [55]
3 3 [20] 3.0 [75]
4 5 [30] 3.9 [100]
5 8 [50] 4.8 [120]
6 12 [80] 6.0 [150]
7 16 [100] 6.9 [175]

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SA-609 /SA-609M 1998 SECTION II

TABLE 3
ACCEPTANCE CRITERIA FOR SINGLE ISOLATED INDICATIONS
NOTES:
(1) The area measured by movement of the center of the transducer over the casting surface.
(2) O p outer wall 1⁄3, or inner wall 1⁄3.
C p mid wall 1⁄3.
E p entire wall.

Maximum Non-Linear Position of

Quality Level Indication, Area, in.2 [cm2] Indication
1 0 E
2 1 [6] E
3 1 [6] O
2 [13] C
4 3 [19] E
5 3 [19] O
5 [32] C
6 5 [32] E
7 5 [32] O
7 [45] C
8 7 [45] E
9 7 [45] O
9 [58] C
10 9 [58] E
11 9 [58] O
11 [71] C

TABLE 4
ACCEPTANCE CRITERIA FOR CLUSTERED INDICATIONS

Minimum Area in
Cumulative Area Which Indications
of Indications, Must be Dispersed,
Quality Level in.2 [cm2]A,B in.2 [cm2]C
1 0 0
2–3 2 [13] 36 [232]
4–5 4 [26] 36 [232]
6–7 6 [39] 36 [232]
8–9 8 [52] 36 [232]
10–11 10 [64] 36 [232]
A Regardless of wall location, that is midwall 1⁄3, innermost 1⁄3, or outermost 1⁄3.
B Each indication that equals or exceeds the 0.5 in. [18 mm] reference line shall be traced to the position
where the indication is equal to 0.25 in. [6 mm]. The area of the location, for the purpose of this evaluation,
shall be considered the area that is confined within the outline established by the center of the transducer
during tracing of the flaw as required. Whenever no discernible surface tracing is possible, each indication
which equals or exceeds the 0.5 in. reference amplitude shall be considered 0.15 in.2 [1 cm2] (three times
the area of the 1⁄4 diameter [6 mm] flat bottomed hole to compensate for reflectivity degradation of natural
flaw) for the cumulative area estimates.
C The indications within a cluster with the cumulative areas traced shall be dispersed in a minimum surface

area of the casting equal to 36 in.2 [230 cm2]. If the cumulative areas traced are confined with a smaller
area of distribution, the area shall be repair welded to the extent necessary to meet the applicable quality level.

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-609 /SA-609M

TABLE 5
DIMENSIONS OF CALIBRATION BLOCKS FOR ANGLE-BEAM EXAMINATION
NOTE 1 — For each increase in thickness of 2 in. [50 mm], or a fraction thereof, the hole diameter shall
increase 1⁄16 in. [1.6 mm].
NOTE 2 — For block sizes over 3 in. [75 mm] in thickness, T, the distance from the hole to the end of
the block shall be 1⁄2 T, min, to prevent coincident reflections from the hole and the corner. Block fabricated
with a 2 in. [50 mm] minimum dimension need not be modified if the corner and hole indications can be
easily resolved.

Nominal Production Basic Calibration Hole Diameter

Material Thickness Block Thickness (d), in 1.002 Minimum Depth
(t), in. [mm] (T), in. [mm] [mm 6 0.05] (D), in. [mm]

Up to 1 [25] incl 1 [25] or t 3⁄ [2.4] 11⁄2 [40]

32
Over 1 to 2 [25–50] 2 [50] or t 1⁄ [3.2] 11⁄2 [40]
8
Over 2 to 4 [50–100] 4 [100] or t 3⁄ 11⁄2
16 [4.8] [40]
Over 4 to 6 [100–150] 6 [150] or t 1⁄ [6.3] 11⁄2 [40]
4
Over 6 to 8 [150–200] 8 [200] or t 5⁄ 11⁄2
16 [7.9] [40]
Over 8 to 10 [200–250] 10 [250] or t 3⁄ [9.5] 11⁄2 [40]
8
Over 10 [250] t See Note 1 11⁄2 [40]

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SA-609 /SA-609M 1998 SECTION II

SUPPLEMENTARY REQUIREMENTS

The following supplementary requirement shall be applied only when agreed upon
between the purchaser and the supplier to achieve an effective examination of a
critical casting area that cannot be effectively examined using a longitudinal beam
as a result of casting design or possible discontinuity orientation.

S1. Angle Beam Examination of Steel Castings S1.2.3 Do not use basic calibration blocks with
as cast surface equivalent to SCRATA Comparator A3
S1.1 Equipment:
to examine castings with surface rougher than SCRATA
S1.1.1 Examination Instrument — Examination Comparator A3. Use a machined calibration block for
shall be conducted with an ultrasonic, pulsed-reflection machined surfaces.
type of system generating frequencies of at least 0.4 S1.2.4 The search unit and all instrument control
to 5 MHz. Properties of the electronic apparatus shall settings remain unchanged except the attenuator or
be the same as those specified in 4.1. calibrated gain control.
S1.1.2 Search Units — Angle-beam search units S1.2.4.1 The attenuator or calibrated gain control
shall produce an angle beam in steel in the range from may be used to change the signal amplitude during
30 to 75° inclusive, measured to the perpendicular of examination to permit small amplitude signals to be
the entry surface of the casting being examined. It is more readily detected. Signal evaluation is made by
preferred that search units shall have frequency of 0.4 returning the attenuator or calibrated gain control to
to 5 MHz. its original setting.
S1.1.3 Calibration Blocks — A set of blocks, as S1.3 Data Reporting — The supplier’s report of final
shown in Fig. 4, with as cast surface equivalent to ultrasonic examination shall contain the following data:
SCRATA Comparator A3 and of a thickness comparable S1.3.1 The total number, location, amplitude, and
to the sections being examined with side-drilled holes area of all indications equal to or greater than 100%
at 1⁄4t, 1⁄2t, and 3⁄4t (where t p thickness of the block) of the distance amplitude curve.
shall be used to establish an amplitude reference line
(ARL). S1.3.2 The examination frequency, type of instru-
ment, type, and size of search units employed, couplant,
S1.2 Calibration of Equipment: transfer method, examination operator, supplier’s identi-
fying numbers, purchase order number, date, and author-
S1.2.1 Construct the distance amplitude correction
ized signature.
curve by utilizing the responses from the side-drilled
holes in the basic calibration block for angle beam S1.3.3 A sketch showing the physical outline of
examination as shown in Fig. 4 and Table 5. the casting, including dimensions of all areas not exam-
ined due to geometric configuration, with the location
S1.2.1.1 Resolve and mark the amplitudes of of all indications in accordance with S1.3.1.
the 1⁄4t and 1⁄2t side-drilled holes from the same surface.
The side-drilled hole used for the 1⁄4t amplitude may S1.4 Acceptance Standards — Acceptance quality
be used to establish the 3⁄4t amplitude from the opposite levels shall be established between the purchaser and
surface or a separate hole may be used. the manufacturer on the basis of one or more of the
following criteria:
S1.2.1.2 Connect the 1⁄4t, 1⁄2t, and 3⁄4t amplitudes S1.4.1 No indication equal to or greater than the
to establish the applicable DAC. DAC over an area specified for the applicable quality
level of Table 2.
S1.2.2 The basic calibration blocks shall be made
of material that is acoustically similar to the casting S1.4.2 Other criteria agreed upon between the
being examined. purchaser and the manufacturer.

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