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Casting Quality and Inspection

The document discusses various inspection methods for cast components based on factors like material type, loading stresses, and required quality level. It recommends quality levels from 1-5 for different materials, with 1 being the highest inspection level. Common non-destructive testing methods mentioned include visual inspection, magnetic particle testing, liquid penetrant testing, ultrasonic testing, and x-ray radiography, with each method suited to detect different types of surface and internal defects. The document provides details on how each inspection method works and its advantages.

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210 views11 pages

Casting Quality and Inspection

The document discusses various inspection methods for cast components based on factors like material type, loading stresses, and required quality level. It recommends quality levels from 1-5 for different materials, with 1 being the highest inspection level. Common non-destructive testing methods mentioned include visual inspection, magnetic particle testing, liquid penetrant testing, ultrasonic testing, and x-ray radiography, with each method suited to detect different types of surface and internal defects. The document provides details on how each inspection method works and its advantages.

Uploaded by

isaac
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Quality of castings

Inspection methods and testing

1
Inspection methods for cast components
How to select proper inspection method?

• There is no such thing as sound casting


– Defects exist because
• Properties of cast materials (shringage etc.)
• Manufacturing process
• You have to know the quality level when inspecting castings

2
Factors which affect on the choice of the inspection
method

• Requirements of the component


– Loading, stresses
– risks
• Casting material
• Inspection level should be selected so that you first concider all the
requirements of the component

3
Inspection level

• Quality class
– In inspection standards the quality level is between 1 to 5
• Size of allowed casting defects go up when 1 => 5
• Costs go up when 5 => 1
• Inspection methos
– Some inspection methods are suotable only to certain materials
• Inspection frequency
– 100%/sampling
– proto, series deliveries

4
Recommendation for quality level
• Carbon steels
– Basic class 3
– If class 3 is not enough choose tempering steel
• Tempering steel
– Basic class 3
– Mechanically stressed areas class 2
– Extremely stressed areas class 1 (e.g. gearing)
• Stainless steels
– Basic class 4
• GJS
– Visual inspection
• GJL
– Visual inspection

5
Non-destructive testing, NDT of castings

• Visual inspection
• pintatarkastus
– magneettijauhetarkastus (MT)
– tunkeumanestetarkastus (PT)
• sisäinen eheys
– ultraäänitarkastus (UT)
– röntgentarkastus (RTG)

6
Visual inspection

• Simplest and fastest inspection method


• Most commonly employed
• Usually good to check surface defects
• Fails to identify internal defects

7
Magnetic particle inspection, MPI
• Most satisfactory method used to find
surface and sub surface defects
• Quick, cheap and very sensitive
• Can only be applied to ferrous metals like
normal steels and cast iron

8
Liquid penetrant test, LPI
• Surface preparation
• Penetrant application Laatuluokka 3
• Penetrant dwell
• Excess penetrant removal
• Developer application
• Indication development
• Inspection
• Clean surface

9
Ultrasonic testing, UT

• When there is a crack or hole in the wave path, part of


the energy will be reflected back from the flaw surface
and it is displayed on a screen
• From the signal, experienced inspector can get
information about the reflector location, size and
orientation

10
X-ray radiography, XXR
• X-ray technique is effective in locating cracs,
inclusions, porosity etc.
• X-ray can be used for inspection in all casting metals
• High costs
• Safety issues

11

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