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Zawada NDT
Suppliers of instruments to test steel wire ropes in-situ, using magnetic, non-destructive method.
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Technical Discussions
kaushal jha
Engineering,
BHEL, India, Joined Feb 2014, 18

kaushal jha

Engineering,
BHEL,
India,
Joined Feb 2014
18
11:51 Feb-22-2014
casting Defect

Dear all,
i want to discuss problem regarding casting defect, in carbon steel casting material as per ASTM A216. we are doing UT and RT after the casting of the job. As per standard we are accepting the severity Level 2(ASTM A 609) in UT and upto Level 3 in RT(ASTM E 446).
But during machining of the same component, these defects are getting open out to the surface.

kindly suggest how to proceed in that case and what rework should be done???

kindly help plzz

 
 Reply 
 
Diego Martínez del Valle
Consultant,
Freelance, Spain, Joined May 2013, 197

Diego Martínez del Valle

Consultant,
Freelance,
Spain,
Joined May 2013
197
13:18 Feb-22-2014
Re: casting Defect
In Reply to kaushal jha at 11:51 Feb-22-2014 (Opening).

Kaushal

I understand that the indications shown by RT and UT are acceptable in accordance with the applicable levels and standards. Then and for defects found after machining; in my opinion, you should verify if these defects are acceptable according the applicable VT standard (Example: SSP-55). If they are not acceptable, they should be repaired in accordance with ASTM A 216

 
 Reply 
 
anjafo
NDT Inspector
Norway, Joined Aug 2009, 204

anjafo

NDT Inspector
Norway,
Joined Aug 2009
204
14:19 Feb-22-2014
Re: casting Defect
In Reply to Diego Martínez del Valle at 13:18 Feb-22-2014 .

improve cast quality and/or define more stringent acceptance criteria's for UT and RT, possibly only in the are to be machined?

 
 Reply 
 
Diego
Consultant,
Freelance, Spain, Joined May 2013, 197

Diego

Consultant,
Freelance,
Spain,
Joined May 2013
197
10:42 Feb-23-2014
Re: casting Defect
In Reply to anjafo at 14:19 Feb-22-2014 .

I do not understand your last question.
Why put more stringent acceptance criteria for UT and RT in this volume? if it will be removed later by machining.

 
 Reply 
 
S V Swamy
Engineering, - Material Testing Inspection & Quality Control
Retired from Nuclear Fuel Complex , India, Joined Feb 2001, 787

S V Swamy

Engineering, - Material Testing Inspection & Quality Control
Retired from Nuclear Fuel Complex ,
India,
Joined Feb 2001
787
13:21 Feb-23-2014
Re: casting Defect
In Reply to Diego at 10:42 Feb-23-2014 .

The idea of a tighter inspection standard is to ensure defect free material and avoid the opening up of the defects on machining. In a way saves time in repair of the opened up defects. However, solution of a general improvement of quality of the casting may be preferable. Economics and time involved will normally decide the most appropriate solution.

 
 Reply 
 
P V SASTRY
R & D, NDT tecniques metallurgy
TAKEN VRS FROM THE POSITION OF SR. DEPUTY GENERAL MANAGER BHEL CORPORATE R&D, India, Joined Jan 2003, 195

P V SASTRY

R & D, NDT tecniques metallurgy
TAKEN VRS FROM THE POSITION OF SR. DEPUTY GENERAL MANAGER BHEL CORPORATE R&D,
India,
Joined Jan 2003
195
16:09 Feb-24-2014
Re: casting Defect
In Reply to kaushal jha at 11:51 Feb-22-2014 (Opening).


1. When you are doing UT you will be knowing the depth of the defects. Even if the defects are acceptable as per the standard if they are falling within the machining depth
(+5 mm) they should be rejected.

2. It would have helped a little more if you had told what type of defects are opening up. Radiography ( LEVEL 3 ASTM E446) lists many type of defects.

The shrinkage ( C ) is usually a center line affair and normally does not open up in machining.( I am not going into the intricate details of the four types shrinkages and their combinations )

The cracks, tears, ( type D, E,)are never internal in this case ( 2" thickness casting) If they are present they will be from the surface and you should have detected them in Magnetic particle testing.

In any case irrespective of the level type D,E, F, defects are not acceptable. Mottling (G) is not usually a case in carbon steel castings.

That leaves the field to porosity/gas holes and inclusions.( A and B) You must be detecting one type or both types of the defects after machining and I agree detecting individual gas holes is difficult with UT.

3. In all cases any defect opening on the surface should be repaired irrespective of your acceptance standard. The repaired/welded area should be subjected to repeat NDT as per the original acceptance norms and passed.

As I mentioned in the beginning you should be taking care about the depth of defects in UT while accepting.

Good luck

P V SASTRY

1
 
 Reply 
 
kaushal jha
Engineering,
BHEL, India, Joined Feb 2014, 18

kaushal jha

Engineering,
BHEL,
India,
Joined Feb 2014
18
11:26 Feb-25-2014
Re: casting Defect
In Reply to P V SASTRY at 16:09 Feb-24-2014 .

Greeting to all
Thanks for giving me the valauable input.
As you said that in carbon steel casting, we have to do weld repair in defected area. After repair which method of NDT we should use and what will be the acceptnce criteria in that reason.

 
 Reply 
 
P V SASTRY
R & D, NDT tecniques metallurgy
TAKEN VRS FROM THE POSITION OF SR. DEPUTY GENERAL MANAGER BHEL CORPORATE R&D, India, Joined Jan 2003, 195

P V SASTRY

R & D, NDT tecniques metallurgy
TAKEN VRS FROM THE POSITION OF SR. DEPUTY GENERAL MANAGER BHEL CORPORATE R&D,
India,
Joined Jan 2003
195
12:26 Feb-25-2014
Re: casting Defect
In Reply to kaushal jha at 11:26 Feb-25-2014 .


After the repair the NDT methods to be used are same as you have used in the initial testing of casting and the acceptance criteria will also be same.

The above is the normal practice. But in the case of high integrity castings the welded area may require special attention.Discretion and judgement have to be used based on the type of weld defects observed.

But in your case the radio graphic acceptance criteria is Level 3 so it is not normally a high integrity casting so you can continue to use the same acceptance norms originally specified for the casting.

Good luck

P V SASTRY

 
 Reply 
 

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