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ENGINEERING STANDARD

MATERIAL SPECIFICATION Date : 09 / 03 / 05


NO. WQS - 003A Sheet : 1 of 5

CARBON STEEL CASTINGS, IS : 1030, Grade 23 - 45

SCOPE :

This specification covers general requirements for Carbon Steel castings of moderate strength and

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weldable quality for general engineering purposes.

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REQUIREMENTS:

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The material shall meet all the requirements of IS : 1030, Gr. 23-45 except as modified herein.

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1. CHEMICAL COMPOSITION ( % )

Carbon 0 . 18 - 0 . 25 ga
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Manganese 0 . 50 - 0 . 75
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Silicon 0 . 20 - 0 . 80
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Phosphorus 0 . 05 max.
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Sulphur 0 . 05 max.
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Permissible total residual (traces) elements shall be 1% max. whereas the limit (%) of individual
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elements shall be as follows:


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Chromium 0 .4 max.
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Nickel 0 . 4 max.
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Molybdenum 0 . 2 max.
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Copper 0 . 3 max.
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Vanadium 0 . 3 max.

For each reduction of 0.01% C below the maximum of 0.25% specified, an increase of 0.04% Mn
above the maximum of 0.75% specified will be permitted upto a maximum of 1% Mn. i.e. Manganese
can be 1% if the Carbon is maintained at 0.19%.

To ensure weldability, the permissible Carbon Equivalent ( C. E. ) shall be 0.45 maximum, based on
the following equation.
Mn Cr + Mo Ni Cu
C. E. = C + ----- + --------------- + ----- + ---- < 0.45
6 10 20 40
ENGINEERING STANDARD

MATERIAL SPECIFICATION Date : 09 / 03 / 05


NO. WQS - 003A Sheet : 2 of 5

CARBON STEEL CASTINGS, IS : 1030, Grade 23 - 45

2. HEAT TREATMENT :

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Unless otherwise any heat treatment is specified on the drawing, castings shall be normalized or full
annealed.

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3. MECHANICAL PROPERTIES :

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Ultimate tensile strength 45 kgf / mm2, min.

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Yield strength 23 kgf / mm2, min.

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Elongation 22% min.

Reduction in area 31% min. ga


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Hardness 135 – 180 BHN, on the casting *
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Impact strength 2.5 kfg.m / cm2 at 200 to 300 C


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Angle of bend ( bend test ) 900 min., over a mandrel of 0 50mm.


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* The hardness shall be checked on the castings at places indicated by WIPRO. Even at the core, the
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hardness should not be less than 115 BHN. The mechanical properties specified above except hardness
shall be those of the test bars and not those of the castings.
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4. MICRO STRUCTURE:
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The microstructure of the castings should reveal ferrite and pearlite phases uniformly distributed and
should be free from harmful bandings. The banding thickness should not be usually more than
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0.025mm.
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a) Grain size:
The castings must have a fine grained structure. The grain size must be ASTM No. 5 to 8. Use of
limited amount of grain refiners such as Vanadium or Aluminium or Titanium as alloying element is
permitted.

b) Inclusion rating:
The inclusion rating when tested in accordance with IS : 4163 – 1967 shall not exceed grade 3A, 3B,
3C, 3D this series.
ENGINEERING STANDARD

MATERIAL SPECIFICATION Date : 09 / 03 / 05


NO. WQS - 003A Sheet : 3 of 5

CARBON STEEL CASTINGS, IS : 1030, Grade 23 - 45

5. INSPECTION OF CASTING:
WIPRO shall inspect the castings in accordance with the schedule WQS-011A.

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A. Visual Examination

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Casting surfaces shall be clean, dry and free from dirt and loose scales. Surfaces must be free from
cracks, shrinkage cavities, hot tears, weld repair defects, blow holes and pin hole porosities.

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B. Dimensional Inspection

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Sample castings shall be inspected for general conformance to the drawing. Specified minimum
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machining allowances must be positively provided on the casting. Error in the position of a particular
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section is permissible only upto a level at which some machining allowance will be still present though
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the positional error has reduced the machining allowance at tsome places.
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Unspecified tolerances on the dimensions shall be as per IS : 4897 – 1976. After the initial
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dimensional inspection, if the quality of the casting is acceptable in all respects, a minimum of 10% of
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the castings shall be subjected to marking by Wipro to see the distribution of machining allowances.
The same may be proof machined or fully machined. Castings with insufficient machining allowances
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and with visual defects on the machined surfaces which would affect the serviceability of the part shall
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not be accepted.
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C. Soundness Inspection
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a) Magnetic particle inspection:


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The casting supplier is advised to carry out magnetic particle testing on the entire casting for initial
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sample qualification and periodic quality audit for subsequent supplies.

b) Radiographic inspection:
The casting shall be of Radiographic quality. All sample castings which are newly developed or which
are supplied from a new vendor source shall be subjected to radiographic inspection to detect shrinkage
defects, cracks, slag inclusions, sand inclusions and weld repair defects, etc. Also periodic checks for
subsequent supplies will be made at WIPRO’S discretion. The internal soundness of castings must
meet the following reference radiograph standards (ASTM E446 for the thickness upto 2” and ASTM
E186 for thickness of 2” to 4.5”) unless otherwise specified on the casting drawing.
ENGINEERING STANDARD

MATERIAL SPECIFICATION Date : 09 / 03 / 05


NO. WQS - 003A Sheet : 4 of 5

CARBON STEEL CASTINGS, IS : 1030, Grade 23 - 45

Type of defect ( discontinuity ) Acceptable severity level


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Porosity Class II or better

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Inclusion Class III or better

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Shrinkage Class III or better

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Cracks, hot tears None

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Unfused chaplets None

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Unfused internal chills None
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The above defects are accepted within the permissible levels if they are isolated. i.e., when two or
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more types of defects are present in the same 5” x 7” radiograph to the extent of maximum acceptance
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level, the casting shall be judged unacceptable. Cluster porosity is not permitted.
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Repair welding: Minor welding repair involving a depth not exceeding 20% of the wall thickness or
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25mm whichever is lower can be done on the casting to rectify surface imperfections or discontinuities
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of severity levels of Class III or better. Welding procedures shall be in accordance with IS : 5530 –
1969. The welding rod used for the repair must be compatible with the material being welded and
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preheating to 1500 to 2000 C must be done on the area to be welded. Whenever weld repair is done,
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casting must be re-heat treated in the same manner as it is specified for a good casting in order to make
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the welded zone machinable and to avoid stresses due to welding.


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D. Chemical analysis
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The chemistry of the product shall be checked by WIPRO on one casting for every heat / lot.

E. Mechanical testing
a) Tensile test shall be done in accordance with IS : 1608 – 1972. However, a minimum gauge
diameter of 14mm is recommended to achieve better test results.
b) Hardness shall be checked on the casting.
c) Impact test as per IS: 1757 – 1973 and bend test as per IS: 1599 – 1974 shall be carried out for
castings which are newly developed by any vendor. Periodic checks may be done for the purpose
of quality audit.
ENGINEERING STANDARD

MATERIAL SPECIFICATION Date : 09 / 03 / 05


NO. WQS - 003A Sheet : 5 of 5

CARBON STEEL CASTINGS, IS : 1030, Grade 23 - 45

F. Study of microstructure

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This shall be done by WIPRO on one number sample casting for each heat / lot

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6. SUPPLY CONDITIONS:

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The technical delivery conditions for the castings shall be in accordance with IS : 8800 – 1996. Some

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specific points to be noted are:

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a) A test bar with heat number duly punched on it must be supplied along with the casting for each
heat of the
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casting.
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b) Castings must be shot blast to give a clean surface.


c) Castings shall be legibly marked with the heat number and vendor code number.
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7. CERTIFICATION:
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The casting manufacturer must provide test certificates for chemical composition and mechanical
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properties
( UTS, YS, Elongation and hardness) for each heat. The castings must be dispatched along with the
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test certificates.
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8. MATERIAL REJECTION:
Material which reveals injurious defects subsequent to its acceptance, at any stage of manufacture at
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WIPRO, or at any stage during functioning of the final product leading to a failure of the equipment,
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shall be rejected and sent back to the supplier for the equipment, shall be rejected and sent back to the
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supplier for getting replacement for the same. Necessary corrective action must be taken immediately
to avoid any such defect in future supplies.

Prepared by : Date of revision : 90.03.05


Date of previous issue : 90.01.25

QUALITY ASSURANCE – WIPRO LIMITED, BANGALORE – 560 058.