VdEH
Ultrasonic testing of ferritic
abcd steel castings
1 Purpose and nature of the test
This sheet is concerned with the ultrasonic testing of ferritic
steel castings to determine internal flaws by the puls echo
technique.
2 Scope of application
This sheet applies to the testing of heat treated castings of
unalloyed and alloyed steel with wall thickness up to
600 mm. For greater thicknesses special agreements are
required with respect to test procedure and recording levels.
The ultrasonic testability requirements for castings and the
levels for recordable echo indications are subdivided into
test classes as per sections 9 and 10.6. They depend on
the planned locating of the castings and are to be stipulated
in the order as agreed upon by the parties involved. Devi-
ations can also be agreed upon.
3 Terms
The terms in this Steel Iron Test Sheet comply with the
stipulations made in DIN 54119 – Ultrasonic inspection
terms -.
4 Stipulations to be agreed upon prior to
testing
The following has be agreed upon on ordering:
- Extent of testing (see section 10.1)
- Test class (see section 10.6)
- Evaluation criteria (see section 13)
5 Requirements regarding the test personnel
The training and experience of the tester must be such that
he is able to perform correctly the tests in accordance with
the Steel Iron Test Sheet. The qualification of the tester
according to definite training guidelines established for
example by the „Deutsche Gesellschaft für zerstörungsfreie
Prüfung“ or „American Society for Nondestructive Testing“
(SNT-TC-1A) or works specification has to be proved to the
customer upon request.
The manufacturer has to designate a qualified test super-
visor.
6 Preparation of the castings to be tested
The test surfaces of the castings shall be such that impec-
cable coupling of the probes is possible.
This is attained if the surface quality corresponds at least to
the limits patterns 4 S 1 (for blasted surfaces) or 4 S 2 (for
ground surfaces) of the standard series CTIF-341-02.
Standard department No guarantee can be given inrespect of this translation. In all cases the latest German-language version of this
Stuttgart 17.07.2000
Winkler
form no. T607e – 09.99
July 1985
Steel Iron Test
Sheet 1922
3rd edition
7 Equipment
7.1 Requirements regarding the ultrasonic
equipment
The ultrasonic equipment to be used shall comply with the
state of engineering, i. e. it must have the following fea-
tures:
Time-base range of the least 20 mm to 2 m to be selected
uninterruptedly for longitudinal and shear waves in steel.
- Gain in steps of 2 dB over a range of at least
80 dB, adjustable with an accuracy of 1 dB.
- Linearity of sweep and vertical linearity better than
5 % of the time-base range or the screen height.
- Operable with probes of the nominal frequency of
1...6 MHz for the pulse echo technique with single
probes and TR probes.
7.2 Probes and test frequency to be used
Depending on the geometry of the casting and the type of
flaw to be detected, either straight beam or angle beam
probes are used or both types of probes for testing areas
close to the surface it is also possible to use TR straight or
angle beam probes.
The angles of incidence shall be between 35° and 70° for
oblique incidence. The nominal frequency shall be in the
range of 1...6 MHz.
7.3 Detection sensitivity
The detection sensitivity of the equipment shall at least
ensure the adjustment of the sensitivity required in section
10.4.
7.4 Couplant
The couplant shall be well able to wet the test surface and
ensure an adequate sound transmission.
The same couplant shall be used for the adjustment and all
subsequent testing work.
8 Adjustment of the test instrument
8.1 Adjustment of the distance
Using straight or angle beam probes, the distance is adju-
sted on the screen with the calibration block 1 as per
DIN 54120, calibration block 2 as per DIN 54122 or other
calibration blocks.
If necessary, the sound velocity difference between casting
and calibration block shall be taken into account.
When using straight beam probes, the distance shall be
adjusted on the casting itself.
8.2 Adjustment of the gain
The gain is adjusted by exposing a suitable reflector, for
example the opposite surface ot the casting or the circular
Page 1 of 7
SEP 1922 en.doc
standard shall be taken as authoritve.
Page 2 of 7 Steel Iron Test Sheet 1922
segments of the calibration blocks as per DIN 54120 or
DIN 54122 to ultrasonic waves.
The echo height in the depth range to be calculated is
characterized by giving the diameter of a circular reflector in
mm in accordance with the distance-gain-size (DGS)
method 1) 2).
9 Determining the ultrasonic testability
The ultrasonic testability characterizes the property of the
casting material to permit detection of a definite circular
reflector size with sufficient accuracy.
A secure verification conventionally signifies that the echo
height of the respective circular reflector, at the end of the
depht range to be evaluated, usually in the interval of the
first back wall echo in accordance with DGS diagrams 1), is
at least 8 dB above the noise level 3).
Such US (ultra sonic) testability is determined in indication
free areas which are characteristic for the wall thickness of
the casting and ensure a maximum echo height of the back
wall echo based upon their shape, e. g. walls with parallel
surfaces.
By convention a casting, to which this testing sheet applies,
shows sufficient US testability, if circular reflectors of at
least 3 mm diameter for class I and 6 mm diameter for
class II can be accurately verified (see table 1).
If the echo height of these smallest detectable circular
reflectors show less than 3 dB above the noise level at the
end of the depth range to be evaluated even if the proce-
dure is changed, for example by changing the test frequen-
cy, there is a reduced ultrasonis testability and the test
report has to state which circular reflector size as per DGS
diagram 1) would be resolved with a signal-to-noise distance
of the least 8 dB. In this case the further procedure has to
be agreed upon by the manufacturer and the customer.
Note: To determine the US testability of the casting to be
tested with perpendicular incidence the amplifier
threshold of the test equipment can be switched off
and the back wall echo be raised to an arbitrary
reference echo height then the gain is increased as
the DGS diagram, until the echo heights of the
3 mm diameter circular reflector of class I and the
6 mm diameter circular reflector of class II attain
the reference height. A further gain increase by
8 dB may raise the noise level no higher than the
reference echo height. If necessary, a reference
reflector may be used in a range without back wall
echo for determining the testability.
10 Performing the test
10.1 Extent of testing
The casting areas to be tested as agreed upon (see section
4) shall be examined to the fullest extent possible given the
shape of the casting and using the most favorable testing
procedure.
July 1985
10.2 General information on the test procedure
The choice of the direction of incidence and the suitable
probes (see also section 7.2) depend largely on the shape
of casting, the possible casting flaws and manufacturing
weld flaws. For the reason the manufacturer shall determine
the most favorable procedure. It is convenient to stipulate
the test procedure in testing instructions taking into conside-
ration areas which are critical for reasons of casting
practice. Manufacturing welds and all areas which are
endangered by cracks shall also be tested with angle beam
probes.
In test class I the casting areas to be tested (see sections 4
and 10.1) shall, if possible, be examined from both surfaces
using at least straight beam probes. Areas which are
accessible from one side only shall be tested with straight
beam probes and also with TR probes for detecting reflec-
tors close to the surface. An examination using TR probes
is sufficient for testing areas accessible from one side and
with wall thickness up to 60 mm. If the unilateral testing of
the casting indicates reflection points close to the probe,
probes with short-range resolution shall be used additio-
nally.
The customer has the obligation to point out to the manu-
facturer special requirements for the test procedure which
might result from the future use of the casting.
10.3 Scanning rate
For testing the scanning rate of the probe shall not exceed
10 cm/s. The paths shall be placed as close to each other
as to ensure an uninterrupted scanning of the complete
volume to be tested. This is usually attained if the paths
overlap by ¼ of the crystal diameter but depends in the
individual case on the type of probe used.
10.4 Test sensitivity
It is principally preferable to adjust the sensitivity ot the test
equipment (test sensitivity) on the casting itself. If this not
possible, adjusting or calibration blocks as per DIN 54120
or DIN 54122 shall be used. Transfer corrections are reqi-
red in these cases. The determination of the transfer
correction has to take into consideration not only the quality
of the coupling surface but also that of the opposite surface
because this influences the height of the back wall echo 4)
(used for the calibration).
For flaw detection, the gain shall be increased until the
noise level becomes visible on the screen (search sensi-
tivity).
___________________
1
) Krautkrämer, J.: Arch. Eisenhüttenwesen 30 (1959)
page 693/703. See also Steel Iron Delivery Specifica-
tions 072-69 annex 1.
2
) More details concerning the determination of the circular
reflector size are described in “Guidelines for the
Ultrasonic Examination of Weld Joints”, issued by the
German Society for Nondestructive Testing.
3
) Sum of noise and structural indications.
4
) The opposite surface has a quality sufficient for transfer
correction measurements if the surface is machi-ned or
compiles at least with pattern 4 S 1 or 4 S 2 of the
standard serias CTIF-341-02 when using straight beam
probes or pattern 4 S 1 or 3 S 2 of the standard serias
CTIF-341-02 when using angel beam probes.
 Steel Iron Test Sheet 1922
It has to be ensured that the echo heights of the circular
reflectors which are mentioned in section 9 and charac-
terize a sufficient ultrasonic testability are at least 2/5 of the
screen height at the end of the depth range to be evaluated.
If during testing the suspicion arises that the attenuation of
the back wall echo indication exceeds the permissible
value, the testing has to be performed with a locally
reduced test sensivity and the attenuation of the back wall
echo indication be determined quantitatively.
When adjusting the test sensitivity of angle beam probes it
has to be ensured that plane reflectors perpendicular to the
coupling surface and with echo heights below the recording
level of KSR 3 are indicated.
The adjustment of the test sensitivity has to be such that the
typical dynamic echo pattern of these reflectors (see Fig. 3)
is clearly visible on the screen.
It is recommendet to verify the sensitivity of angle beam
probes on real plane flaws (cracks with depth extension) or
on a component wall arranged perpendicular to the coupling
surface and infinite for the sound beam. This requires that
the probe bottom fits the casting shape.
Note: For flaw detection with simultaneous observation of
the back wall echo the use of equipment with
adjustable bach wall echo attenuation is recom-
mended.
The test sensitivity can differ considerably if the
surface quality changes locally. It is then essential
that the conditions for adjusting the search sensitivity
described in the second papagraph of this section
are observed.
For testing with TR straight beam probes the sensi-
tivity shall be adjusted on the casting in areas where
coupling and opposite surfaces are as parallel as
possible. If this is impossible adjusting blocks with
parallel surfaces or flat-bottom holes shall be used.
10.5 Consideration of different kinds of echo
indications
The following types of echo indications may occur during
the testing of castings:
a) Echo indications of flaws
b) Attentuations of the back wall echo which are not due
to the shape of casting or the coupling.
Table 1 Recording levels for the ultrasonic testing of casting of ferritic steel
Wall thickness
at the Test class I
reflector area
Diameter of the equivalent circular reflector
without with without
Measurable extension *)
mm mm mm
= 100 4 3
> 100 up to = 500 6 3
Weld ends 3 3
*) see section 12.1
July 1985 Page 3 of 7
Both types of echo indication which might occur separatly or
jointly have to be observed and evaluated.
The height of the echo indication is given as circular
reflector size 2), the attenuation of the back wall echo is
expressed in db as drop of the back wall echo height.
10.6 Recording levels and recording of
recordable echo indications
Unless otherwise stipulated all echo heights or back wall
echo attenuations reaching or exceeding the following
recording levels have to be recorded depending on the test
class.
Independent of the echo height the following indica-tions
are recordable:
a) Echo indications suggesting coherrent flaws of exten-
sive longitudinal or depth extension.
b) Echo indications suggesing casing defects in an unfa-
vorable location relative to the sound beam.
Depending on the echo height echo indications exceeding
the levels given in table 1 have to be recorded.
All locations where recordable reflectors have been found
must be marked and specified in the test report (section
14). The location of the reflection points can, if necessary,
be described by a grid, documented by a sketch or by
taking a picture.
11 Examination of recordable reflectors
The locations where recordable reflectors have been found
(see section 10.6) are to be examined more closely with
respect to type, form, size and location of the reflectors.
This can be achieved by a change of the ultrasonic test
technique (see sections 12.1 and 12.2), by x-raying,
grinding etc.
12 Procedure for determining the reflector size
Preliminary remarks:
Defined preconditions must be fulfilled (for exam-
ple, knowledge of the type of reflection point,
simple geometry of the reflection point, optimal
impingement of the sound beam on the reflector) in
order to permit the determination of the reflection
dimensions by ultrasonic testing with an accury
suffcient for technical applications. These require-
Recording levels
Test class II Test class I + II
Attenuation of the
with back wall echo
indication
mm mm dB
8 6 12
12 6 12
3 3 12
Page 4 of 7 Steel Iron Test Sheet 1922
ments are usually not met in the case of steel
castings. Large casting defects can appear as
serveral small recordable indications; the flaw
description can be improved by using additional
directions and angles of incidence. To simplify
and stand-ardize the procedure, the following
agreements are made.
12.1 Classification of the reflectors according
to their extension
12.1.1 Reflectors without measurable extension
Reflectors are called reflectors without measurable exten-
sion if their actual extension is less than or equal to the
diameter of the sound beam of the probe used at the
location of the reflector, as specified, for example in the
probe related data sheet or sonograms.
The sound beam diameter (6-dB-drop) as a fuction of the
sonic distance are specified in Fig. 1 for the generally
used probes or can be calculated with the following
equation:
λ⋅S D⋅S
DB(6dB) ≈ = (1)
D 4⋅N
where
DB (6dB) Sound beam diameter (6 dB drop)
? Wave lenght
D Crystal diameter
S Sonic distance
N Near field lenght (N ˜ D2/4?)
12.1.2 Reflectors with measurable extension
Reflectors are called reflectors with measurable exten-
sion if their actual dimension are greater than the sound
beam diameter of the probe used at the location of the
reflector.
12.2 Measuring the reflector dimension parallel
to the test surface
It is recommended to determine the reflector dimension if
possible with probes having a near field length which
agrees as far as possible with the sonic distance to the
reflector.
By shifting the probe on the test surface those points
have to be detected where the echo height
- of reflectors recordable according to table 1 has decres-
ased to 6 dB below the recording level,
- of reflectors according to section 10.6 a) and b) has
decreased by 6 dB below the echo height maximum
(half-value method)
The half-value method is applied analogously for attenu-
ations of the black wall echo. These points have to be
marked as accurately as possible (for example, probe
center in case of straight beam probes, probe index in
case of angle beam probes).
The measururable extension of the reflector is deter-
mined by connecting the marked points. If permitted by
the test piece geometry the boundary points of the
reflectors determined with angle beam probes are projec-
ted onto the test surface using the projection distances.
The extreme values of the distances between the marked
points shall be entered into Fig. 1 for the measured sonic
distance to the reflector. If the measured distance bet-
ween the extreme values is below or on the curve for the
July 1985
Sound beam diameter of the used probe or if the distance
is less than or equal to the sound beam diameter calcu-
lated with equation (1) for the measured sonic distance,
the reflector is defined as “reflector without measurable
extension“. If the distance lies above the curve or the
value calculated with equation (1), the measured dimen-
sion has to be recorded.
12.3 Measuring the reflector dimensions per-
pendicular to the test surface
It is recommended to use probes which have a sound
beam diameter as small as possible in the region of the
reflector (focal point of focussing probes or use of the
natural focus of TR angle beam probes).
Depending on the type of reflectory, the reflector dimen-
sions perpendicular to the test surface can be measured
by
- Perpendicular incidence from two opposite sides
(Fig. 2) or
- Oblique incidence.
In case of oblique incidence, the depth extension of plane
reflectors is determined by the difference of the sonic
distances, measured on the reflector edges.
The following procedure has been applied successfully
for estimating the depth extension of indications close to
the surface up to a depth of about 50 mm.
Using a TR angle beam probe (with roof angle, trans-
verse waves) the maximum echo of the depth dynamics
of the reflector to be measured is brought to 100 %
screen height. By shifting the probe perpendicular to the
reflector, those points are to be located where the echo
height has decreased to 10 % of the screen height. The
depth extension is calculated from the sonic distance S1
and S2 and the angle of incidence (Fig. 3).
13 Evaluation of echo indications
The customer and the manufacturer have to agree on
stipulations for the evaluation of echo indications in
respect of their admissiblity. Reference can be made to
existing standards (for example, DIN 1690 part 2).
14 Test report
The test report must contain the following data:
a) Characteristic data of the test piece.
b) Extent of test
c) Type of test equipment used.
d) Type of probes and test method used indicating the
relevant time-base range.
e) All data required for characterizing the sensitivity
calibration.
f) Information on ultrasonic testability.
g) Description of the location of reflectors causing
recordable echo indications (for example sketch or
photo) and indication of all characteristic features, for
example circular reflector sizes, back wall echo
attenuation, depth position and depth extension,
length and area (other agreements on extent of
indication description can be made for test class II).
h) Data of test and name of tester.
 Steel Iron Test Sheet 1922
Standards and other documents referred to
DIN 1690 part 2
Technical delivery for castings of metallic materials;
classification of the quality of steel castings on the basis
of nondestructive tests.
DIN 54119
Non-destructive testing; Ultrasonic inspection; terms
DIN 54120
Non-destructive testing; calibration block 1 and its use for
the adjustment and control of ultrasonic echo eqipment.
DIN 54122
Non-destructive testing; reference block 2 and its use for
the adjustment and control of ultrasonic echo equipment.
Stahl-Eisen-Lieferbedindungen 072
Ultrasonic tested heavy plate; technical delivery specifica-
tions. (Obtainable from: Verlag-Stahleisen mbH Postfach
105164 D-40042 Düsseldorf)
CTIF-341-02
Caractérisation d´état de surface de pièces en acier
moulé; Recommandation Technique du Bureau de
Normalisation des Industries de la Fonderie. (Obtainable
from: Editions Techniques des Industries de la Fonderie,
12 avenue Raphael, F-75016 Paris)
SNT-TC-1A
Personnel Qualification and Certification in Non-destruc-
tive Testing (Obtainable from: ASNT American Soc. for
Nondestructive Testing, 1711 Arlington Lane, P O Box
28518, Columbus, OH 43228-0518, USA)
July 1985 Page 5 of 7
Guidelines ultra sonic examination of weld joints
(Obtainable from: Deutsche Gesellschaft für zerstörungs-
freie Prüfung e. V., Motardstraße 54, D-13629 Berlin)
Previous edition:
SEP 1922: 8.75, 6.77
Modifications:
Compared with the edition 6.77 the following modi-
fications were made:
a) Extension of the scope of application to castings with
wall thickness up to 600 mm.
b) Modification of the recording levels for castings with
wall thickness between 100 mm and 150 mm.
c) Stipulation of the requirements for the test personnel.
d) Stipulation of the surface quality requirements.
e) Revision and amendmenrt of the pragraph dealing
with the equipment, adjustment of the test instru-
ment, determination of the ultrasonic testability and
performance of the test.
f) Inclusion of regulations regarding to procedure for
determining the size of reflectors.
g) Reference to DIN 1690 part 2 for evaluating echo
indications.
h) Modification of part of the requirements regarding the
content of the test report.
i) Adaptation of terms to DIN 54119.
 Crystal Near
Near field
fieldlength for
lenght for
Page 6 of 7

dimension Longitudinal waves ¦ Transverse

waves
Longitudinal waves (L) Transverse waves (T)

1 MHz 2 MHz 4 MHz 5 MHz 2 MHz 4 MHz

mm
mm (approx.)

Ø5 2,11 4,22 -
Ø 10 4,22 8,0 15,6 -
Ø 24 22,7 45,0 88,0 115

8x9 10 20
20 x 22 75 150

1 1MHz / L Ø 10
2 2MHz / L Ø 10
3 1MHz / L Ø 24
4 2MHz / T 8 x 9

elliptical sound beam cross section is plotted.)

5 4MHz / L Ø 10
6 2MHz / L Ø 24
Steel Iron Test Sheet 1922

7 4MHz / T 8 x 9
8 2MHz / T 20 x 22
9 4MHz / L Ø 24
10 5MHz / L Ø 24
11 4MHz / T 20 x 22

Sound beam diameter DB (6 dB) in mm

July 1985

Sonic distance s in mm

Fig 1 Approximate values of the near field length and the sound beam diameter (6 dB) in the far field of single probes
as a function of sonic distance. (For curves 4, 7, 8 and 11 of angle beam probes the smaller of the two axes of the
 Steel Iron Test Sheet 1922 July 1985 Page 7 of 7

Fig 2 Measuring the depth extension with straight beam probes

depth extension t = d – (s1 + s2)

Echo height

a) Interrupted reflector

Echo height

b) Uninterrupted reflector

Fig 3 Measuring the depth extension of reflectors with measurable extension perpendicular to the test surface using
angle beam probes and characteristic forms of danymics: depth extension t = (s2 – s1) cos a