X-Ray Evaluation of Internal Ca$ting Defects

in Cast Steel Plstotr Componetrts 29Feb12

lssued/Approved by:
JA'-*-2r.,^
Matedals Maoager, Powertrain Systems - Heavy Duty

l. Scope aBd Application

To establish the Focass specification for X-ray inspection of intemal casting defects in cast steel
prston components.
This specification appli€s to piston component castings, piston weldmer*s and finish machined
pistons.

, References

MS-SI16 Cast Steel for Pistons - 4|401[iand 42CrMo4

ASTM E45 Methods for Determirilg the Inclusion Cortent ofSteels
ASTM E94 Standard Guide for Radiographic Examinarion
ASTM El92 Std. Referebce Radiographs oflnvestm€Ilt Steel Castings for Aerospace
Applications
ASTM E446 Reference Radiogmphs for Steel Castings Up to Z in- [5] r|rn] in Thickness
ASTM E1030 Standard Test Metfiod for Radiogmpbic Examination of Metajlic Castings
ASM Handbook Volumc 5. Cosring"
ASM Handbook Volume l'1, Nondestructive Eyaluation and gu.tlity Control

Basis for Us€

3.1. The rcference radiographs to be used witb ASTM 8192, Std. Referen€e Radiogq,hs of livestnent
Steel Castings.for Aerospace Applications ill\rshate the va.ious types and severity levels of
discontinuities occurring in thin-wall steel investment castings.

3.2, The reference radiographs were developed for casting sections up to 25.4 mm (1 itr,) in thickness.

3.3. The set ofieference radiographs, consist of 16 plates 216 by 279 mm (8 l/2 by I I ir,) that show
common discontinuity types each illustated in eight degrees ofprogressively iqcreasing severity.
The plates are held in a ring binder (See Appendix for typical radiographs showing Level 3
defects).

3.4. The referenca {adiographs a.e original radiographs and should be viewed using transmitted light.

3.5. Once a specific radiographic process and vendor have been qualified for a pisto[ product, they
must rcmain unchanged.
Any desired change to the radiography process or vendor must be approved by Fede.al-Mogul
Product Engineering.
 x-Ray Evaluation oflntarnal Casting Defects
in Cast Steel PistoD ComPonent! oale
I 29Feb12

4. DefDitions of X-Rey Itrdieations

radiog(aphic app%(ance
The defect types evalualed in this specification are desqibed below bassd on
when viewed using transmitted light-
clear spots'
4.1. Gas Holes: Gas holes appear as well defined round or elongated' smooth-edged
throughout the casting' They are
occurring individually, in clusters, or distibuted
caused by trapped air, mold gases or water vapor'

to minute
4.2. Gas Porosity: Gas porosity represented by round or irregular clear spots corresponding
' voids usualiy distributed through the entire castiog' The size of the holes valy witlr
thc gas conGnt ofthe metal atld the rate ofsolidification ofthe sectiofl'

orjagged clear
4.3- Shrinkage Cavity: Shrinkage cavities are represettedl'ydendritic,-Iilamerta4r'
" u."u" oiio"gular dimensions and indistinct outline' They a'e caused by an
insufficient supply ofmolten metal to feed the particular section'
lacy or honeycombed
4.4. Stlrinkage Porosity: Shrinkage porosity or sponge appears as a localized
metal
clearer atea. They are ilso caused by an insufficient supply ofmolten
during the soiidification process'
outline which tend
4.5. Cold Shuts: are represented by darkened areas ofvariable length and smooth
to be elongated and thin They occu' where the sfteams of molten metal have come
together;d have failed to weld together, so that the contact surfaces are oxidized'
Cold shuts may gene.ally be detected by vistlal examination'
dendritic when caused by
4.6. Cracks: are represented by darkened lin€s ofvariable width which arg
hot shortness, and ate more nearly linear, or straight, afld ofmore
constalt width when
originating from residual stressas in solid mstal'
They may be less or
Bar 4.7. Inclusions: are nonlnetallic materials in an otherwise solid metallic matrix'
mole dense than the matix alloy and will appear on the radiograph' respectively'
as

.1. darker or ligiter itdications'

I Inclusionsmayalsoconsistofnonnetallicoxides,whichappearontheradiogtaphas
inegular, dar{ blotches- These come from oxides (formed in the melt)
which have not
d the mold gates Careful
beei skimmed offprior to introduction ofthe melal into
melt duing
T} control of the melt (proper hold time in the ladle and skimming of the
pouring) will minimize or Fevent inclusions
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Figure 1
trive x-ray use the same
5
pi'on" tnill
.*'ff
" 1'3, :'::H,: !]"Jff "Tl**.

";#Ji""t1'iffi-f]fff;ri:#"'lli*s"u3*-"'tu'*"o'owestFatigue
[li,liliIJ;'1s1'1113;
',fn*:ll;:;;:::i'lJ;;a1'"'"'e""'1

VieY€ 3 & 4
Views f &Z
Bottolr CoEpotreEt
Views of Cast St€€l
Five X-ray
Figurc 2
 X-Rqy Evaluation of Interdal Castitrg Defects
s';ida---ir#dfrl
in Cast Ste€l Piston Components Dale 29Feb12
slup€rsedos lle1ll

6. Piston Inspection Zone Divisiotrs

piston design (see

6. I . This section defines the typicat irspection zone divisions for the monosteel
Figure l).

6.2. The zones shown in Figure 3 arc for reference on a typical Monosteel
pistol The tllr€e zones
may vary in size somewhat depending on specific piston geometty'

6.3. The surface ofthe piston is divided into three zones for the evaluation, see
Table l'

Figure 3 Moaosteel Pisto! with Casl Steel Bottotn - Z,one Divisio(s

Table1 Piston 7,one Deliritions

3.: Zo.te I Cdtcal: Fatigoe Factor < 2 0
LOne z Moderatelv Critical Fatigue Factor < 4.0
Zone 3 Non.Critic€l Fatigue Fac'tor? 4.Q

3.4.

.5. C
m
At
Prr

- "r . eqeral-Mogul
 X-Ray Evaluation of Int€nal Castfug Defects
P4e Sofo
Dgle 4Feb12

Appendix
Secti,oA 3.1: Typical Levgl 3 defectsasshoy4 in ISIMEI92, SId Refererce Radiographs of
s '
hn est neqt Steel Castirrgsfot AercsPqee APPlicatio .

Plate 3 118" Plate 3 3/8"

Plate 3 38" Dendriiic

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