No. 69 Guidelines For Non-Destructive Testing of Marine Steel Castings No. 69
No. 69 Guidelines For Non-Destructive Testing of Marine Steel Castings No. 69
No. 69 Guidelines For Non-Destructive Testing of Marine Steel Castings No. 69
69
3. Casting Condition
3.1 Heat Treatment
3.2 Surface Condition
4. Extent of Inspections
5. Inspection Procedures
5.1 Visual Inspections
5.2 Surface Inspections
5.3 Volumetric Inspections
6. Acceptance Criteria
6.1 Visual Inspection
6.2 Surface Inspection
6.3 Volumetric Inspection
7. Reporting
8. Rectification of Defects
Annex 1
Extent and methods of non-destructive testing to be applied to typical hull steel
castings.
1. General
No.
1.1.1 This document is intended to give general guidance on the extent, methods and
69 recommended quality levels applicable to the non-destructive testing (NDT), of marine
(cont) steel castings, except in those cases where alternative criteria have been otherwise
approved or specified.
1.1.2 Although no detailed guidelines are given for machinery components, the
requirements in these guidelines may apply correspondingly considering their
materials, kinds, shapes and stress conditions being subjected.
1.1.3 Castings intending to be examined by NDT methods are identified in Annex 1
to this document. The list of castings is not definitive. Criteria for the inspection of other
castings not listed in Annex 1 will be subject to agreement.
1.1.4 UR W8 or this Recommendation do not include every cast component type that
may be subject to Classification. In such cases where the particular component or type is
not included, appropriate national/international standards, or other Society requirements
may be applied, to determine the appropriate testing regime and defect acceptance
criteria.
1.1.5 These guidelines complement and reference the requirements of the following
UR’s - UR W8, UR W22, UR W29, UR A1 and UR W34, and contain general guidance
for the non-destructive testing methods, the extent of testing and the minimum
recommended quality levels that should be complied with unless otherwise approved or
specified.
1.1.7 Where intermediate inspections have been performed the manufacturer should
provide reports of the results upon the request of the Surveyor.
1.1.9 Where advanced ultrasonic testing methods are applied, e.g. PAUT or TOFD,
reference is made to UR W34, for general approach in adopting and application of these
advanced methods. Acceptance levels regarding accept/reject criteria are specified in
the applicable section in this Recommendation.
2.1.3 Personnel responsible for the NDT activity including approval of procedures
No. should be qualified and certified to Level III.
69 2.1.4 The NDT personnel’s certificates and competence should comprise all industrial
(cont) sectors and techniques being applied by the manufacturer or its subcontractors.
Certificates should be made available to the Society for verification, when requested.
2.1.5 The operator carrying out the NDT and interpreting indications, should, as a
minimum, be qualified and certified to Level II in the NDT method(s) concerned.
However, operators only undertaking the gathering of data using any NDT method and
not performing data interpretation or data analysis may be qualified and certified as
appropriate, at level I.
3. Casting Condition
3.2.1 Castings should be examined in the final delivery condition free from any
material such as scale, dirt, grease or paint that might affect the effectiveness of
the inspection. A thin coating of contrast paint is permissible when using magnetic
particle techniques. For surface inspection NDT methods, the surface quality should
be a minimum value of Ra ≤6.3 μm
3.2.2 Ultrasonic testing should be carried out after the castings have been
ground, machined or shot blasted to a suitable condition, with a minimum value
surface quality of Ra ≤12,5 μm. The surfaces of castings to be examined should be
such that adequate coupling can be established between the probe and the
casting and that excessive wear of the probe is avoided.
4. Extent of Inspections
(cont) - at positions where surplus metal has been removed by flame cutting, scarifying
or arc-air gouging.
4.1.3 Ultrasonic testing should be carried out in the zones indicated in Annex 1 and
also at the following locations:
- in way of all accessible fillets and at pronounced changes of section,
- in way of fabrication weld preparations for a distance of 50mm from the edge,
- in way of weld repairs where the original defect was detected by
ultrasonic testing.
- in way of riser positions,
- in way of machined areas particularly those subject to further machining such
as bolt hole positions.
4.1.4 In the case of castings such as rudder horns, which may have a large
surface area still untested after the above inspections have been applied, an
additional ultrasonic inspection of the untested areas should be made along
continuous perpendicular grid lines on nominal 225 mm centres, scanning from one
surface only.
5. Examination Procedures
5.1 Visual Inspection
5.1.1 Steel castings nominated for NDT should be subjected to a 100% visual
examination of all accessible surfaces by the manufacturer and made available to the
Surveyor. Viewing conditions at the inspected surfaces should be in accordance with
a nationally or internationally recognised standard. Unless otherwise agreed, the
visual and surface inspections should be carried out in the presence of the Surveyor.
5.2.2 For magnetic particle testing, attention is to be paid to the contact between the
casting and the clamping devices of stationary magnetisation benches in order to avoid
local overheating or burning damage in its surface. Prods should not be permitted on
finished machined items. Note that the use of solid copper at the prod tips must be
avoided due to the risk of copper contamination into the casting. The pole of the
magnets should have close contact with the component.
5.3.2 In some cases, due to the shape, nature, complexity of casting, or defect type
or orientation, there may be a need for radiographic testing. In such cases,
radiographic testing may be carried out on the basis of prior agreement with the
Classification Society. Where radiographic testing is to be applied, national or
international standards for both the testing method, and the quality or severity level to be
applied, should be agreed with the Classification Society.
Guidance on standards:
ASTM E446 – 15
ASTM E186 – 15 (2019) e1
ASTM E280 – 15 (2019) e1
ISO 4993:2015
A suitable quality level for marine castings would normally be severity level 2 or 3 (of
the above standards), depending on the location zone and type of casting. Other
severity levels may be applied, and should be agreed with the Classification Society
5.3.3 Only those areas shown in the agreed inspection plan should be tested,
however, the inspections may reveal indications that require further evaluation or an
extension of testing. In such cases, this should be agreed with the Classification
Society. The plan should include those locations nominated in section 4.2.3 together
with the scanning zones identified for the relevant casting in Annex 1.
5.3.5 The backwall echo obtained on parallel sections should be used to monitor
variations in probe coupling and material attenuation. Any reduction in the amplitude
of the back wall echo due to material properties should be corrected. Attenuation in
excess of 30dB/m could be indicative of an unsatisfactory annealing heat treatment
and may render the effectiveness of the testing as unsuitable. In such cases of
excessive attenuation, this should be investigated, and suitable mitigation measures
carried out for effective ultrasonic testing to continue, where possible.
5.3.6 Machined surfaces, especially those in the vicinity of riser locations and in
No. the bores of stern boss castings, should also be subject to a near surface
69 (approximately 25mm) scan using a twin crystal 0o probe.
(cont) Additional scans on machined surfaces are of particular importance in cases where
boltholes are to be drilled or where surplus material such as ‘padding’ has been
removed by machining thus moving the scanning surface closer to possible areas of
shrinkage.
5.3.7 In the examinations of those zones nominated for ultrasonic examination the
reference sensitivity for the 0° probe should be established against a 6mm reflector.
Sensitivity can be calibrated either against 6mm diameter flat bottomed hole(s) in a
reference block (or series of blocks) corresponding to the thickness of the casting
provided that a transfer correction is made, using the DAC (distance-amplitude-
correction) method, or by using the DGS (distance-gain-size) method.
5.3.8 The reference sensitivity of angle probes (where required for testing)
should be established against an appropriate 6mm reflector (e.g. reference
reflectors angled perpendicular to the sound beam) for the DAC method, or
equivalent using the DGS method.
5.3.9 The DGS diagrams issued by a probe manufacturer identify the difference in
dB between the amplitude of a back wall echo and that expected from a 6mm
diameter disk reflector. By adding this difference to the sensitivity level initially set by
adjusting a back wall echo to a reference height e.g. 80%, the amended reference
level will be representative of a 6mm diameter disk reflector. Similar calculations can
be used for evaluation purposes to establish the difference in dB between a back wall
reflector and disk reflectors of other diameters such as 12 or 15 mm.
6. Acceptance Criteria
6.1 Visual Inspection
6.1.1 All castings should be free of cracks, crack-like indications, hot tears, cold
shuts or other detrimental indications. Thickness of the remains of sprues or risers
should be within the casting dimensional tolerance.
6.2.2 For the purpose of evaluating indications, the surface should be divided into
reference band length of 150 mm for level MT1/PT1 and into reference areas of
22500mm2 for level MT2/PT2. The band length and/or area should be taken in the most
unfavourable location relative to the indications being evaluated.
6.2.3 The following quality levels recommended for magnetic particle testing
(MT) and/or penetrant testing (PT) are;
Level MT1/PT1 - fabrication weld preparation and weld repairs.
Level MT2/PT2 - other locations nominated for surface inspection in Annex 1.
The allowable numbers and sizes of indications in the reference band length and/or
area are given in Table 1. The required quality level should be shown on the
manufacturer’s inspection plan. Cracks and hot tears should not be accepted.
No.
69 Table 1 Allowable number and size of indications in a reference band length/area
Linear 41) 3
1)
Aligned 4 3
area Linear 6 5
Aligned 6 5
6.3.1 Acceptance criteria for ultrasonic testing are identified in Table 2 as UT1 and
UT2. As stated in 4.2.1 the quality levels applicable to the zones to be examined
should be identified on an inspection plan. The following quality levels are nominated
for the castings identified in Annex 1.
- fillet radii to a depth of 50mm and within distance of 50mm from the radius end,
- castings subject to cyclic bending stresses e.g. rudder horn, rudder castings
and rudder stocks - the outer one third of thickness in the zones nominated
for volumetric inspection by Annex 1,
- positions outside locations nominated for level UT1 inspection where feeders
and gates have been removed.
69 6.3.2 For near surface testing (to an approximate depth of 25 mm) twin crystal 0o
(normal beam) probe should be used, plus a 0o probe (usually single crystal beyond a
(cont) depth of 25 mm) for the remaining volume.
6.3.3 Ultrasonic acceptance criteria for other casting areas not nominated in Annex
1 should be subject to special consideration based on the anticipated stress levels and
the type, size and position of the discontinuity.
6.3.4 Table 2 describes the acceptance criteria for both methods of applied
sensitivity (DGS and DAC)
6.3.5 DGS and DAC methods may be used for determining sensitivity. The DAC
method for normal beam probes may be based on a 6.0mm diameter reflector or flat
bottomed hole (FBH). A DAC curve should be produced using reference blocks
containing 6.0mm FBH reflectors over a range representative of the inspection
thickness, after adjustment for transfer and attenuation losses,
6.3.6 For quality level UT 1, any discontinuity producing a signal amplitude in excess
of the 6.0 mm DAC curve is unacceptable.
6.3.7 For quality level UT2, the sensitivity may be based on actual size FBH (of 12mm
and 15 mm) or based on equivalent 6mm FBH, and the sensitivity adjusted to obtain
equivalent amplitudes, as described in 6.3.8.
6.3.8 For use of FBH of 6mm for setting sensitivity, adjustment of signal amplitudes
(measured in dB above 6mm DAC) can be determined for 12mm and 15mm FBH
reflectors: to be DAC + 12dB and DAC + 16dB (plus any compensation for transfer and
attenuation losses). This is illustrated in Figure 1. The increase in dB to the indicated
levels represent the equivalent FBH sizes (for 12 mm and 15mm), and their respective
corresponding ultrasonic response amplitudes.
Figure 1 DAC curve produced from 6.0mm FBH reflector and DAC curves
adjusted to represent equivalent 12.0mm and 15.0mm FBH reflectors.
69 The bottom curve (DAC) represents a sensitivity based on 6mm FBH, and the two
(cont) additional curves (DAC + 12 and DAC + 16dB) above this represent the equivalent
sensitivities converted for larger FBH’s (12mm and 15mm).
When scanning using these curves, and applying Table 2 acceptance criteria, for UT2,
any indication below DAC +12mm should be disregarded, and any indication above DAC
+16mm should be rejected.
Any indication between these two curves should be evaluated according to its size, as
per Table 2.
Table 2 Ultrasonic Acceptance Criteria for steel castings – Using DGS or DAC
system
UT1 >6 0 0
UT2 12-15 5 50
>15 0 0
Notes:
1) DGS: distance-gain size.
2) DAC: Distance Amplitude Correction
3) The corresponding DAC level to each of the FBH reflectors is at 100% DAC
4) grouped in an area measuring 300 x 300 mm
5) measured on the scanning surface
6) the measured indication is regarded as the longest dimension, as measured in the
scanning process
6.3.9 The maximum number of indications to be registered and the maximum length
of indications permissible for quality level 2 (as stated in Table 2) apply to normal probes.
6.3.11 Any signal between 12 + 15 curve should be evaluated for length of defect,
and referred to table 2 for acceptance
7. Reporting
No. 7.1 General
(10) Test standards used. including reference to the appropriate tables for
acceptance purposes
(11) Results, including documentation regarding the repair and testing history (as
appropriate);
8. Rectification of Defects
No. 8.1 Indications that exceed the requirements of Table 1 and Table 2, should be
69 classed as defects, and should be repaired or rejected as appropriate, according to
Classification Society Rules.
(cont)
8.2 Generally it may be permissible to remove shallow indications by light grinding,
however, all repairs should be undertaken in accordance with Classification Society
Rules.
8.3 Complete removal of the defect should be proved by magnetic particle testing or
penetrant testing, as appropriate.
8.4 Castings which are repaired should be examined by the same method as
at initial inspection, as well as by any additional methods as requested by the
Surveyor.
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