PRC-6504 Rev D

Process Specification for Ultrasonic

Inspection of Wrought Metals

Engineering Directorate
Structural Engineering Division

February 2010

National Aeronautics and

Space Administration
Lyndon B. Johnson Space Center
Houston, Texas

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Page 1 of 12

PRC-6504 Rev D

Process Specification for Ultrasonic

Inspection of Wrought Metals

Prepared by:

Signature on file
Ajay M. Koshti,
Materials and Processes
Branch/ES4

2/16/10
Date

Signature on file
______________________
Norman P. Ruffino,
Materials and Processes
Branch/ES4

2/16/10

Reviewed by:

Signature on file
David M. Stanley,
Materials and Processes
Branch/ES4

2/18/10
Date

Approved by:

Signature on file
Bradley S. Files,
Chief, Materials and
Processes Branch/ES4

2/18/10
Date

Reviewed by:

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Date

PRC-6504 Rev D

REVISIONS
VERSION
Baseline

CHANGES

DATE

Original version

7/26/99

Reviewed document per QMS requirements. Updated

division name, organization codes, and document
numbers.

12/19/02

Replaced references to MIL-STD-2154 with AMS-STD2154. (MIL-STD-2154 was canceled on November 15,
2004.)

1/14/05

Added NASA-STD-5009 and NASA-STD-5019

9/25/06

Revised 4.0 References, Training and Certification of

02/16/10

Personnel

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PRC-6504 Rev D
1.0

SCOPE

This process specification establishes the minimum requirements for ultrasonic

inspection of wrought metals and wrought metal components.

2.0

APPLICABILITY

This specification is applicable to in-process, final, and in-service ultrasonic

inspections to detect discontinuities in wrought metals and components made
from wrought metals with a cross section thickness of 0.250 inch or greater. This
specification is not applicable to non-metals, composites, welds, and castings.

3.0

USAGE

This specification shall be invoked by including an inspection note on the

applicable engineering drawing or by reference in a Process Specification, Task
Performance Sheet, Discrepancy Report/Material Review Record or other
appropriate document. The engineering drawing or referencing document shall
specify the applicable ultrasonic acceptance class. When there are different
acceptance classes for different areas on a component, the drawing shall be
zoned with the acceptance class identified for each zone. If the number of
components to be inspected and the amount of coverage of each component are
not specified, all components shall be examined and shall receive 100 percent
ultrasonic coverage.
The standard ultrasonic inspection note for flight hardware and critical ground
equipment is given in Figure 1.

PERFORM ULTRASONIC INSPECTION PER JSC PRC-6504,

CLASS A.
Figure 1.
3.1

CLASSES

The ultrasonic acceptance class shall be specified in the inspection note or

referencing document on the basis of the following:
a.

Single discontinuities Any discontinuity producing an indication greater

than the response from a reference flat-bottom hole or equivalent notch at
the estimated discontinuity depth of the size given in Table 1 is not
acceptable.
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PRC-6504 Rev D

b.

Multiple discontinuities Multiple discontinuities producing indications

greater than the response from a reference flat-bottom hole or equivalent
notch at the estimated discontinuity depth of the size given in Table 1 are
not acceptable if the centers of any two of these discontinuities are less
than 1 inch apart. Not applicable to Class C.

c.

Linear discontinuities Any discontinuity longer than the length given in

Table 1 with an indication greater than the response from a reference flatbottom hole or equivalent notch at the estimated discontinuity depth of the
size given in Table 1 is not acceptable. Not applicable to Class C. For
flight hardware, linear discontinuities are not acceptable regardless of
length.

d.

Loss of back reflection Loss of back reflection greater than the percent
given in Table 1, when compared to a non-defective material in a similar
part, is not acceptable when this loss of back reflection is accompanied by
an increase in noise signal (at least double the normal background noise
signal) between the front and back surface. The loss of back reflection is
applicable only to the straight beam tests.

e.

Noise Noise that exceeds the level given in Table 1 is not acceptable,
except for reforging stock.

Titanium For Class AAA inspection of titanium, the minimum linear

discontinuity length shall be 1/8 inch and the minimum response shall be
same as that from 2/64 inch diameter flat bottom hole. For Class AA
inspection of titanium, the minimum linear discontinuity length shall be 1/4
inch and the minimum response shall be same as that from 2/64 inch
diameter flat bottom hole.
Note:
The ultrasonic acceptance class for flight hardware shall be at
least Class A.
f.

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PRC-6504 Rev D

Table 1. Ultrasonic Acceptance Classes

AAA

Single Discontinuity
Response
(Diameter, inch)
1/64 or 25% of 3/64

Multiple Discontinuity
Response
(Diameter, inch)
10% of 3/64

AA
A
B
C

3/64
5/64
8/64
8/64

2/64
3/64
5/64
Not Applicable

Class

Linear Discontinuity
(Length Response)

Loss of Back
Reflection

Noise Level

1/8 inch 10% of

3/64
1/2 inch 2/64
1 inch 3/64
1 inch 5/64
Not Applicable

50%

10% of 3/64

50%
50%
50%
50%

Alarm Level
Alarm Level
Alarm Level
Alarm Level

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PRC-6504 Rev D

3.2

INSPECTION SEQUENCE

The stage in the manufacturing process where ultrasonic inspection is performed

should be specified on the engineering drawing or in the referencing document.
3.3

DISCONTIUITY ORIENTATION

Unless otherwise specified on the engineering drawing or in the referencing

document, ultrasonic inspections shall be performed to detect discontinuities in
all orientations. The designer may limit the inspection to the detection of
discontinuities with specific orientations by indicating the relevant orientations on
the engineering drawing. The designer and fracture analyst should determine
the adequacy of inspections that are limited to specific discontinuity orientations.
3.4

SPECIAL NDE OF FRACTURE CRITICAL COMPONENTS

When implementation of fracture control requirements necessitates Special

Nondestructive Evaluation (NDE) of a fracture critical component, the
requirement for Special NDE shall appear in the inspection note as shown in
Figure 2. When Special NDE is required, the specific inspection procedure and
inspector shall be qualified in accordance with Section 7.0.

PERFORM ULTRASONIC INSPECTION PER JSC PRC-6504,

CLASS A. SPECIAL NDE QUALIFICATION REQUIRED.
Figure 2.

4.0

REFERENCES

The following specifications, standards, and handbooks form a part of this

document to the extent specified herein. All documents listed are assumed to be
the current revision unless a specific revision is listed. In the case of conflict
between this specification and the technical requirements cited in other
referenced documents, the requirements of this document take precedence.

ASTM E 2375

Standard Practice for Ultrasonic Evaluation of

Wrought Products

ASTM B 594

Standard Practice for Ultrasonic Inspection of

Aluminum-Alloy Wrought Products
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PRC-6504 Rev D
AMS-STD-2154

Process for Ultrasonic Inspection of, Wrought Metals

ASTM E 114

Standard Practice for Ultrasonic Pulse-echo Straight

Beam Examination by Contact Method

ASTM E 214

Standard Practice for Immersed Ultrasonic Testing by

the Reflection Method Using Pulsed Longitudinal
Waves

ASTM E 213

Standard Practice for Ultrasonic Examination of Metal

Pipes and Tubing

ASTM E 587

Standard Practice for Ultrasonic Angle Beam

Examination by Contact Method

ASTM E 127

Fabricating and Checking Aluminum Alloy Ultrasonic

Standard Reference Blocks

ASTM E 428

Standard Practice for Fabrication and Control of

Metal, Other than Aluminum, Reference Blocks Used
in Ultrasonic Testing

ASTM E 317

Standard Practice for Evaluating Performance

Characteristics of Pulse-echo Examination
Instruments and Systems without the Use of
Electronic Measurement Instruments

ASTM E 2192

Standard Guide for Planer Flaw Height Sizing by

Ultrasonics

ASTM E 1065

Standard Guide for Evaluating Characteristics of

Ultrasonic Search Units

ASTM E 1316

Standard Terminology for Nondestructive

Examinations

NASA-STD-5009

Nondestructive Evaluation Requirements for Fracture

Critical Metallic Components

NAS 410

NAS Certification & Qualification of Nondestructive

Test Personnel

NASA-STD-5003

Fracture Control Requirements for Payloads Using

the Space Shuttle

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PRC-6504 Rev D

NASA-STD-5019

Fracture Control Requirements for Spaceflight

Hardware

SNT-TC-1A

Personnel
Qualification
Nondestructive Testing

SOP-009.86

Written Practice for Certification and Qualification of

Nondestructive Personnel

SSP 30558

Fracture Control Requirements for Space Station

and

Certification

in

The following references were used to develop this process specification:

SOP-007.1

Preparation and Revision of Process Specifications

(PRCs)

JSC 8500

Engineering Drawing System Requirements

5.0

MATERIAL REQUIREMENTS

Couplant and test block materials shall be in accordance with AMS-STD-2154.

6.0

PROCESS REQUIREMENTS

6.1

GENERAL

Ultrasonic inspections shall be performed in accordance with AMS-STD-2154

except as modified by this specification.
6.2

WRITTEN PROCEDURES

A detailed written procedure shall be prepared for each part to be inspected. The
procedure shall meet the requirements of this specification and shall ensure the
consistency and reproducibility of the inspection at the required sensitivity level.
General procedures covering a variety of different parts may be used provided
they meet the requirements of this procedure and clearly apply to the parts to be
inspected. When general procedures are used, a written part specific technique
shall be prepared. At a minimum, the part specific procedure or the general
procedure and part specific technique shall cover all of the information required
by ASTM-E-2375.

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PRC-6504 Rev D
For work performed at JSC facilities, written procedures should consist of
Detailed Process Instructions (DPIs) selected for use from the DPI-6504-XX
series of work instructions.
6.3

SCAN PLAN

Unless otherwise specified on the engineering drawing or in the referencing

document, scan plans shall be designed to detect discontinuities in all
orientations. The scan plan shall specify the surfaces from which inspections are
to be performed, the ultrasonic beam paths, the scan paths, and the scanning
index.
6.4

FRACTURE CRITICAL COMPONENTS

Ultrasonic inspections of fracture critical components shall be performed in

accordance with the process requirements in NASA-STD-5009.
The
requirements NASA-STD-5009 not otherwise covered in this specification are
included in the following:
a.

Surface finishes shall be 125 RMS or better;

b.

Inspections shall be performed with the ultrasonic beam direction as close

to perpendicular to the relevant discontinuity orientation as possible;

c.

The inspection surfaces shall not be coated; and

d.

The component shall not be loaded in compression.

When Special NDE is specified by the engineering drawing or referencing

document, the inspection procedure and inspector shall be qualified in
accordance with Section 7.0.

7.0

SPECIAL NDE QUALIFICATION

Use of Special NDE in accordance with NASA-STD-5009, NASA-STD-5003,

SSP 30558 or NASA-STD-5019 requires formal demonstration of the capability
to detect flaws at least as small as the initial crack size for the specific
component to a 90/95 detection reliability. Each procedure, procedure
application, and operator must demonstrate the required capability. Requests for
Special NDE qualification shall be directed to the JSC Materials and Processes
Branch (ES4).
8.0

DEVIATIONS AND WAIVERS

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PRC-6504 Rev D
Any deviations or waivers regarding the use of this process specification shall be
requested in writing. This request shall be directed to the JSC Materials and
Processes Branch (ES4) with the appropriate justification and rationale. A
written response will be provided upon such a request.
9.0

TRAINING AND CERTIFICATION OF PERSONNEL

Personnel performing radiographic inspections of Class I, II, IIIW and GSE shall
be qualified and certified in accordance with NAS 410. Personnel performing
ultrasonic inspections of Class III, STE/D, mockups, and testing equipment shall
be qualified and certified in accordance with either NAS 410 or SNT-TC-1A.
Personnel making accept/reject decisions shall be certified to at least Level II.
Personnel performing inspections on fracture critical components shall, at a
minimum, be certified to Level II.
For work performed at JSC facilities, the NAS 410 requirements may be satisfied
by the training and certification of personnel using SOP-0009.86.

10.0

DEFINITIONS

90/95

Flaw Detection
Capability:
Discontinuity

It is an estimate of flaw detection reliability. It can be

estimated by the Probability of Detection (POD) analysis of
experimental flaw detection data. It implies 90% POD with
minimum 95% confidence.
A flaw size with high flaw detection reliability (e.g. 90/95)
An intentional or unintentional interruption in the physical
structure or configuration of a material or component that
may be detectable by nondestructive testing; a flaw.
Discontinuities are not necessarily rejectable.

Final Inspection

The final inspection performed for the acceptance of the

component.

Fracture Critical
Component

Classification which assumes that fracture or failure of the

component resulting from the occurrence of a crack will
result in a catastrophic hazard. Fracture critical components
will be identified as such on the engineering drawing.

Indication

Evidence of a discontinuity that requires interpretation to

determine its significance.

In-Process

Inspections that occur during manufacturing before a

component is in final form.
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PRC-6504 Rev D
In-Service

Inspections performed on components that are in use or

storage.

Special NDE

A fracture control term denoting nondestructive inspection

process with specified personnel, procedures, and
equipment with a demonstrated capability to reliably (90/95)
detect the specified flaw size that is smaller than those
normally detected by the Standard NDE procedures.

Wrought Metals

Wrought metals include forging stock, forgings, rolled billet

or plate, extruded or rolled bars, and extruded or rolled
shapes.

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