ARTICLE 23

ULTRASONIC STANDARDS

A03

SA-388/SA-388M.2 Standard Practice for Ultrasonic Examination of Heavy Steel Forgings . . . . . . . . . . . . .

[ASTM A 388/A
388M-95 (R2001)]

379

SA-435/SA-435M
[ASTM A 435/A
435M-90 (1996)]

Standard Specification for Straight-Beam Ultrasonic Examination of Steel Plates . . . .

387

SA-577/SA-577M
[ASTM A 577/A
577M-90 (1996)]

Standard Specification for Ultrasonic Angle-Beam Examination of Steel Plates. . . . . .

389

SA-578/SA-578M
(ASTM A 578/A
578M-96)

Standard Specification for Straight-Beam Ultrasonic Examination of

Plain and Clad Steel Plates for Special Applications . . . . . . . . . . . . . . . . . . . . . . . . . . .

392

SA-609/SA-609M
[ASTM A 609/A
609M-91 (1997)]

Standard Practice for Castings, Carbon, Low-Alloy, and Martensitic

Stainless Steel, Ultrasonic Examination Thereof. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

398

SA-745/SA-745M
(ASTM A 745/A
745M-94)

Standard Practice for Ultrasonic Examination of Austenitic Steel Forgings. . . . . . . . . .

409

SB-548
(ASTM B 548-90)

Standard Method for Ultrasonic Inspection of Aluminum-Alloy Plate

for Pressure Vessels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

415

SE-114.2
[ASTM E 114-95
(R2001)]

Standard Practice for Ultrasonic Pulse-Echo Straight-Beam

Examination by the Contact Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

421

SE-213
(ASTM E 213-98)

Standard Practice for Ultrasonic Examination of Metal Pipe and Tubing . . . . . . . . . . .

426

SE-273
(ASTM E 273-93)

Standard Practice for Ultrasonic Examination of Longitudinal Welded

Pipe and Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

432

377

SE-797.2
[ASTM E 797-95
(R2001)]

Standard Practice for Measuring Thickness by Manual Ultrasonic

Pulse-Echo Contact Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

378

436

SPECIFICATION FOR ULTRASONIC

EXAMINATION OF HEAVY
STEEL FORGINGS
SA-388/SA-388M.2
[Identical with ASTM Specification A 388 /A 388M-95 (R2001)1]

1.

Scope

2.

1.1 This practice covers the examination procedures

for the contact, pulse-echo ultrasonic examination of
heavy steel forgings by the straight- and angle-beam
techniques. The straight beam techniques include utilization of the DGS (Distance Gain Size) method. See
Appendix X3.

Referenced Documents

2.1 ASTM Standards:

A 469 Specification for Vacuum-Treated Steel Forgings
for Generator Rotors
A 745/A 745M Practice for Ultrasonic Examination of
Austenitic Steel Forgings
E 317 Practice for Evaluating Performance Characteristics of Ultrasonic Pulse-Echo Testing Systems Without
the Use of Electronic Measurement Instruments
E 428 Practice for Fabrication and Control of Steel Reference Blocks Used in Ultrasonic Inspection

1.2 This practice is to be used whenever the inquiry,

contract, order, or specification states that forgings are
to be subject to ultrasonic examination in accordance
with Practice A 388/A 388M.

2.2 ANSI Standard:

B46.1 Surface Texture

1.3 The values stated in either inch-pound or SI

units are to be regarded as the standard. Within the
text, the SI units are shown in brackets. The values stated
in each system are not exact equivalents; therefore,
each system must be used independently of the other.
Combining values from the two systems may result in
nonconformance with the specification.

2.3 Other Document:

Recommended Practice for Nondestructive Personnel
Qualification and Certification SNT-TC-1A, Supplement C Ultrasonic Testing

1.4 This specification and the applicable material

specifications are expressed in both inch-pound units
and SI units. However, unless the order specifies the
applicable M specification designation (SI units), the
material shall be furnished to inch-pound units.

3.1 When this practice is to be applied to an inquiry,

contract, or order, the purchaser shall so state and shall
also furnish the following information:

1.5 This standard does not purport to address all

of the safety concerns, if any, associated with its use.
It is the responsibility of the user of this standard to
establish appropriate safety and health practices and
determine the applicability of regulatory limitations
prior to use.

3.1.1.1 The diameter and test metal distance of

the flat-bottom hole and the material of the reference
block in accordance with 7.2.2.2,

3.

Ordering Information

3.1.1 Method of establishing the sensitivity in

accordance with 7.2.2 and 7.3.3 (Vee or rectangular
notch),

3.1.2 Quality level for the entire forging or portions

thereof in accordance with 10.3, and
379

A03

SA-388/SA-388M.2

2001 SECTION V

3.1.3 Any options in accordance with 6.1, 6.2,

and 7.1.10.

4.

recording levels for straight-beam examination, when

so specified by the order or contract. The DGS scale
range must be selected to include the full thickness
cross-section of the forging to be examined. An example
of a DGS overlay is found in Appendix X3.

Apparatus

4.1 An ultrasonic, pulsed, reflection type of instrument

shall be used for this examination. The system shall
have a minimum capability for examining at frequencies
from 1 to 5 MHz. On examining austenitic stainless
forgings the system shall have the capabilities for
examining at frequencies down to 0.4 MHz.

5.

Personnel Requirements

5.1 Personnel performing the ultrasonic examinations

to this practice shall be qualified and certified in
accordance with a written procedure conforming to
Recommended Practice No. SNT-TC-1A or another
national standard that is acceptable to both the purchaser
and the supplier.

4.1.1 The ultrasonic instrument shall provide linear

presentation (within 5%) for at least 75% of the screen
height (sweep line to top of screen). The 5% linearity
referred to is descriptive of the screen presentation
of amplitude. Instrument linearity shall be verified in
accordance with the intent of Practice E 317. Any set
of blocks processed in accordance with Practice E 317
or E 428 may be used to establish the specified
5% instrument linearity.

6.

Preparation of Forging for Ultrasonic

Examination

6.1 Unless otherwise specified in the order or contract,

the forging shall be machined to provide cylindrical
surfaces for radial examination in the case of round
forgings; the ends of the forgings shall be machined
perpendicular to the axis of the forging for the axial
examination. Faces of disk and rectangular forgings
shall be machined flat and parallel to one another.

4.1.2 The electronic apparatus shall contain an

attenuator [accurate over its useful range to 10% (
1 dB) of the amplitude ratio] which will allow measurement of indications beyond the linear range of the
instrument.

6.2 The surface roughness of exterior finishes shall

not exceed 250 in. [6 m] unless otherwise shown
on the forging drawing or stated in the order or the
contract.

4.2 Search Units having a transducer with a maximum

active area of 1 in.2 [650 mm2] with 3 / 4 in. [20 mm]
minimum to 11 / 8 in. [30 mm] maximum dimensions
shall be used for straight-beam scanning (see 7.2); and
search units equipped from 1 / 2 by 1 in. [13 by 25
mm] to 1 by 1 in. [25 by 25 mm] shall be used for
angle-beam scanning (see 7.3).

6.3 The surfaces of the forging to be examined shall

be free of extraneous material such as loose scale,
paint, dirt, etc.

4.2.1 Transducers shall be utilized at their rated

frequencies.

7.

4.2.2 Other search units may be used for evaluating

and pinpointing indications.

Procedure
7.1 General:

7.1.1 As far as practicable, subject the entire

volume of the forging to ultrasonic examination. Because of radii at change of sections and other local
configurations, it may be impossible to examine some
sections of a forging.

4.3 Couplants having good wetting characteristics

such as SAE No. 20 or No. 30 motor oil, glycerin,
pine oil, or water shall be used. Couplants may not
be comparable to one another and the same couplant
shall be used for calibration and examination.

7.1.2 Perform the ultrasonic examination after heat

treatment for mechanical properties (exclusive of stressrelief treatments) but prior to drilling holes, cutting
keyways, tapers, grooves, or machining sections to
contour. If the configuration of the forging required
for the treatment for mechanical properties prohibits a
subsequent complete examination of the forging, it
shall be permissible to examine prior to treatment for

4.4 Reference Blocks containing flat-bottom holes

may be used for calibration of equipment in accordance
with 4.1.1 and may be used to establish recording
levels for straight-beam examination when so specified
by the order or contract.
4.5 DGS scales, matched to the ultrasonic test unit
and transducer to be utilized, may be used to establish
380

ARTICLE 23 ULTRASONIC STANDARDS

mechanical properties. In such cases, reexamine the

forging ultrasonically as completely as possible after
heat treatment.

SA-388/SA-388M.2

ator set at 1 to 1). Carry out the evaluation of discontinuities with the gain control set at the reference level.
Recalibration is required for significant changes in
section thickness or diameter.

7.1.3 To ensure complete coverage of the forging

volume, index the search unit with at least 15% overlap
with each pass.

NOTE 1 High sensitivity levels are not usually employed when

inspecting austenitic steel forgings, due to attendant high level of
noise or hash caused by coarse grain structure.

7.1.4 Do not exceed a scanning rate of 6 in. /s

[150 mm /s].

7.2.2.2 Reference-Block Calibration The test

surface roughness on the calibration standard shall be
comparable to but no better than the item to be examined. Adjust the instrument controls to obtain the required signal amplitude from the flat-bottom hole in
the specified reference block. Utilize the attenuator in
order to set up on amplitudes larger than the vertical
linearity of the instrument. In those cases, remove the
attenuation prior to scanning the forging.

7.1.5 If possible, scan all sections of forgings in

two perpendicular directions.
7.1.6 Scan disk forgings using a straight-beam
technique from at least one flat face and radially from
the circumference, whenever practicable.
7.1.7 Scan cylindrical sections and hollow forgings
by angle-beam technique. When practicable, also examine the forging in the axial direction.

NOTE 2 When flat-surfaced reference block calibration is specified,

adjust the amplitude of indication from the reference block or blocks
to compensate for examination surface curvature (an example is
given in Appendix X1).

7.1.8 In addition, examine hollow forgings by

angle-beam technique from the outside diameter surface
as required in 7.3.1.
7.1.9 In rechecking or reevaluation by manufacturer
or purchaser use comparable equipment, search units,
frequency, and couplant.

7.2.2.3 DGS Calibration Prior to use, verify

that the DGS overlay matches the transducer size and
frequency. Accuracy of the overlay can be verified by
reference blocks and procedures outlined in Practice E
317. Overlays are to be serialized to match the ultrasonic
transducer and pulse-echo testing system that they are
to be utilized with.

7.1.10 Forgings may be examined either stationary

or while rotating in a lathe or on rollers. If not specified
by the purchaser, either method may be used at the
manufacturers option.
7.2 Straight-Beam Examination:

7.2.2.4 Choose the appropriate DGS scale for the

cross-sectional thickness of the forging to be examined.
Insert the overlay over the CRT screen, ensuring the
DGS scale baseline coincides with the sweep line of
the CRT screen. Place the probe on the forging, adjust
the gain to make the first backwall echo appear clearly
on the CRT screen. Using the Delay and Sweep control,
shift the screen pattern so that the leading edge of the
initial pulse is on zero of the DGS scale and the
backwall echo is on the DGS scale value corresponding
to the thickness of the forging. Adjust the gain so the
forging backwall echo matches the height of the DGS
reference slope within 1 Db. Once adjusted, increase
the gain by the Db shown on the DGS scale for the
reference slope. Instrument is now calibrated and flaw
sizes that can be reliably detected can be directly read
from the CRT screen. These flaw sizes are the equivalent
flat bottom reflector that can be used as a reference point.

7.2.1 For straight-beam examination use a nominal

2 4-MHz search unit whenever practicable; however,
1 MHz is the preferred frequency for coarse grained
austenitic materials and long testing distances. In many
instances on examining coarse grained austenitic materials it may be necessary to use a frequency of 0.4
MHz. Other frequencies may be used if desirable for
better resolution, penetrability, or detectability of flaws.
1

7.2.2 Establish the instrument sensitivity by either

the reflection, reference-block technique, or DGS
method (see Appendix X3 for an explanation of the
DGS method).
7.2.2.1 Back-Reflection Technique (Back-Reflection Calibration Applicable to Forgings with Parallel
Entry and Back Surfaces) With the attenuator set
at an appropriate level, for example 5 to 1 or 14 dB,
adjust the instrument controls to obtain a back reflection
approximately 75% of the full-screen height from the
opposite side of the forging. Scan the forging at the
maximum amplification setting of the attenuator (attenu-

NOTE 3 The above can be utilized on all solid forgings. Cylindrical

hollow forgings and drilled or bored forgings must be corrected to
compensate for attenuation due to the central hole (see Appendix X4).

381

SA-388/SA-388M.2

2001 SECTION V

7.2.3 Recalibration Any change in the search

unit, couplant, instrument setting, or scanning speed
from that used for calibration shall require recalibration.
Perform a calibration check at least once every 8 h
shift. When a loss of 15% or greater in the gain level
is indicated, reestablish the required calibration and
reexamine all of the material examined in the preceding
calibration period. When an increase of 15% or greater
in the gain level is indicated, reevaluate all recorded
indications.

setting, obtain a reflection from a similar OD notch.

Draw a line through the peaks of the first reflections
obtained from the ID and OD notches. This shall be
the amplitude reference line. It is preferable to have
the notches in excess metal or test metal when possible.
When the OD notch cannot be detected when examining
the OD surface, perform the examination when practicable (some IDs may be too small to permit examination)
as indicated above from both the OD and ID surfaces.
Utilize the ID notch when inspecting from the OD,
and the OD notch when inspecting from the ID. Curve
wedges or shoes may be used when necessary and
practicable.

7.2.4 During the examination of the forging, monitor the back reflection for any significant reduction in
amplitude. Reduction in back-reflection amplitude may
indicate not only the presence of a discontinuity but
also poor coupling of the search unit with the surface
of the forging, nonparallel back-reflection surface, or
local variations of attenuation in the forging. Recheck
any areas causing loss of back reflection.

7.3.4 Perform the examination by scanning over

the entire surface area circumferentially in both the
clockwise and counter-clockwise directions from the OD
surface. Examine forgings, which cannot be examined
axially using a straight beam, in both axial directions
with an angle-beam search unit. For axial scanning,
use rectangular or 60 V-notches on the ID and OD
for the calibration. These notches shall be perpendicular
to the axis of the forging and the same dimensions as
the axial notch.

7.3 Angle-Beam Examination Rings and Hollow

Forgings:
7.3.1 Perform the examination from the circumference of rings and hollow forgings that have an axial
length greater than 2 in. [50 mm] and an outside to
inside diameter ratio of less than 2.0 to 1.

8.

7.3.2 Use a 1 MHz, 45 angle-beam search unit

unless thickness, OD /ID ratio, or other geometric configuration results in failure to achieve calibration. Other
frequencies may be used if desirable for better resolution, penetrability, or detectability of flaws. For anglebeam inspection of hollow forgings up to 2.0 to 1
ratio, provide the transducer with a wedge or shoe that
will result in the beam mode and angle required by the
size and shape of the cross section under examination.

Recording

8.1 Straight-Beam Examination Record the following indications as information for the purchaser. These
recordable indications do not constitute a rejectable
condition unless negotiated as such in the purchase
order.
8.1.1 In the back-reflection technique, individual
indications equal to or exceeding 10% of the back
reflection from an adjacent area free from indications;
in the reference-block or DGS technique, indications
equal to or exceeding 100% of the reference amplitude.

7.3.3 Calibrate the instrument for the angle-beam

examination to obtain an indication amplitude of approximately 75% full-screen height from a rectangular or
a 60 V-notch on inside diameter (ID) in the axial
direction and parallel to the axis of the forging. A
separate calibration standard may be used; however, it
shall have the same nominal composition, heat treatment, and thickness as the forging it represents. The
test surface finish on the calibration standard shall be
comparable but no better than the item to be examined.
Where a group of identical forgings is made, one of
these forgings may be used as the separate calibration
standard. Cut the ID notch depth to 3% maximum of
the thickness or 1 / 4 in. [6 mm], whichever is smaller,
and its length approximately 1 in. [25 mm]. Thickness
is defined as the thickness of the forging to be examined
at the time of examination. At the same instrument

8.1.2 An indication that is continuous on the same

plane regardless of amplitude, and found over an area
larger than twice the diameter of the search unit. The
extent of such an indication shall be accurately measured
along with variations in amplitudes of reflections.
8.1.2.1 Planar indications shall be considered
continuous over a plane if they have a major axis
greater than 1 in. [25 mm]. In recording these indications, corrections must be made for beam divergence
at the estimated flaw depth.
8.1.3 In the back-reflection technique, discontinuity
indications equal to or exceeding 5% of the back
reflection. In the reference-block technique, indications
382

ARTICLE 23 ULTRASONIC STANDARDS

SA-388/SA-388M.2

equal to or exceeding 50% of the reference amplitude

providing that they travel, are continuous, or appear
as clusters.

ual forgings should be based on a realistic appraisal of service requirements and the quality that can normally be
obtained in the production of the particular type forging.

8.1.3.1 Traveling indications are herein defined

as indications whose leading edge moves a distance
equivalent to 1 in. [25 mm] or more of metal depth
with movement of the search unit over the surface of
the forging.

10.2 Heavy austenitic stainless steel forgings are more

difficult to penetrate ultrasonically than similar carbon or
low-alloy steel forgings. The degree of attenuation normally increases with section size; and the noise level, generally or in isolated areas, may become too great to permit
detection of discrete indications. In most instances, this
attenuation results from inherent coarse grained microstructure of these austenitic alloys. For these reasons, the
methods and standards employed for ultrasonically examining carbon and low-alloy steel forgings may not be applicable to heavy austenitic steel forgings. In general, only
straight-beam inspecting using a back-reflection reference
standard is used. However, utilization of Practice A 745/
A 745M for austenitic steel forgings can be considered if
flat-bottom hole reference standards or angle-beam examination of these grades are required.

8.1.3.2 A cluster of indications is defined as

five or more indications located in a volume representing
a 2-in. [50-mm] or smaller cube in the forging.
8.1.4 Reduction in back reflection exceeding 20%
of the original measured in increments of 10%.
8.1.5 Amplitudes of recordable indications in increments of 10%.
8.2 Angle-Beam Examination Record discontinuity
indications equal to or exceeding 50% of the indication
from the reference line. When an amplitude reference line
cannot be generated, record discontinuity indications equal
to or exceeding 50% of the reference notch. These recordable indications do not constitute a rejectable condition
unless negotiated as such in the purchase order.
9.

10.3 Acceptance quality levels shall be established

between purchaser and manufacturer on the basis of
one or more of the following criteria.
10.3.1 Straight-Beam Examination:
10.3.1.1 No indications larger than some percentage of the reference back reflection.

Report
9.1 Report the following information:

10.3.1.2 No indications equal to or larger than

the indication received from the flat-bottom hole in a
specific reference block or blocks.

9.1.1 All recordable indications (see Section 8).

9.1.2 For the purpose of reporting the locations
of recordable indications, a sketch shall be prepared
showing the physical outline of the forging including
dimensions of all areas not inspected due to geometric
configuration, the purchasers drawing number, the purchasers order number, and the manufacturers serial
number, and the axial, radial, and circumferential distribution of recordable ultrasonic indications.

10.3.1.3 No areas showing loss of back reflection

larger than some percentage of the reference back
reflection.
10.3.1.4 No indications per 10.3.1.1 or 10.3.1.2
coupled with some loss of resultant back reflection per
10.3.1.3.

9.1.3 The specification to which the examination

was performed as well as the frequency used, method
of setting sensitivity, type of instrument, surface finish,
couplant, and search unit employed.

10.3.1.5 No indications exceeding the reference

level specified in the DGS method.
10.3.2 Angle-Beam Examination No indications
exceeding a stated percentage of the reflection from a
reference notch or of the amplitude reference line.

9.1.4 The inspectors signature and date examination performed.

10.

10.4 Intelligent application of ultrasonic quality levels

involves an understanding of the effects of many parameters on examination results.

Quality Levels

10.1 This practice is intended for application to forgings, with a wide variety of sizes, shapes, compositions,
melting processes, and applications. It is, therefore, impracticable to specify an ultrasonic quality level which
would be universally applicable to such a diversity of products. Ultrasonic acceptance or rejection criteria for individ-

11.

Keywords

11.1 angle beam examination; back-reflection; DGS;

reference-block; straight beam examination; ultrasonic
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SA-388/SA-388M.2

2001 SECTION V

APPENDIXES
(Nonmandatory Information)

X1. TYPICAL TUNING LEVEL

COMPENSATION FOR THE EFFECTS OF
FORGING CURVATURE

X2.2 To utilize curve, establish amplitude from

ASTM reference block to coincide with values from
Appendix X1.

X1.1 The curve (Fig. X1.1) was determined for the

following test conditions:
Material

X3. BACKGROUND INFORMATION ON THE

DGS METHODS

Nickel-molybdenum-vanadium alloy
steel (Specification A 469, Class 4)
Type UR Reflectoscope
11 / 8 in. [30 mm] diameter quartz
21 / 4 MHz
ASTM No. 3-0600 (aluminum)
0.010 in.2 [6.5 mm2] in nickel-molybdenum-vanadium alloy steel
250 in. [6 m] max. roughness

X1.2 To utilize curve, adjust reflectoscope sensitivity

to obtain indicated ultrasonic response on ASTM No.
3-0600 reference block for each diameter as shown. A
response of 1 in. [25 mm] sweep-to-peak is used for
flat surfaces. Use attenuator to obtain desired amplitude,
but do testing at 1 to 1 setting.

X3.1 The DGS method was developed to determine

flaw sizes by comparison to a back wall echo produced
on the part to be ultrasonic tested. The derivation of
DGS curves is extensively covered and can be found
in standard texts on ultrasonic testing, and will not be
covered here. The distance or thickness of the forging
(A) to be tested, as noted on the overlay, must be
accurately defined on the CRT screen. The back reflection (B) of the part must be established and suitable
gain added. Flaw echo indications that appear can be
sized via the flaw size curves (C) on the overlay. Item
(D) depicts the transducers that the overlay works in
conjunction with and (E) depicts the series of curves
that the overlay scales are matched to.

X2. INDICATION AMPLITUDE

COMPENSATION FOR TEST DISTANCE
VARIATIONS

X4. COMPENSATION FOR CENTER HOLE

ATTENUATION ON CYLINDRICAL
BORED OR HOLLOW FORGINGS
UTILIZING THE DGS METHOD

Instrument
Search unit
Frequency
Reference block
Reflection area of
reference curve
Surface finish

X4.1 The hole in a cylindrical bored forging causes

sound scatter. In these cases, a correction is required
which depends on the wall thickness and bore diameter.

X2.1 The curve (Fig. X2.1) has been determined for

the following test conditions:
Material
Instrument
Search unit
Frequency
Couplant
Reference block
Reflection area of
reference curve
Surface finish

Nickel-molybdenum-vanadium alloy
steel (Specification A 469, Class 4)
Type UR Reflectoscope
11 / 8 in. [30 mm] diameter quartz
21 / 4 MHz
No. 20 oil
ASTM No. 3-0600 (aluminum)
0.010 in.2 [6.5 mm2] in nickel-molybdenum-vanadium alloy steel
250 in. max. roughness

X4.1.1 Determine the correction value in dB from

the Nomogram (Fig. X4.1).
X4.1.2 Proceed as described in 7.2.2.3.
X4.1.3 With the GAIN-dB control, reduce the flaw
detector gain by the correction value determined as
per the Nomogram (Fig. X4.2). Thus, the flaw detector
gain is accurately adjusted.

384

ARTICLE 23 ULTRASONIC STANDARDS

SA-388/SA-388M.2

FIG. X2.1 TYPICAL DISTANCEAMPLITUDE

CORRECTION CURVE

FIG. X1.1 TYPICAL COMPENSATION CURVE FOR

EFFECTS OF FORGING CURVATURE

FIG. X4.1 EXAMPLE OF DGS OVERLAY

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SA-388/SA-388M.2

2001 SECTION V

FIG. X4.2 THE INFLUENCE OF A CENTRAL BORE ON THE BACKWALL ECHO AMPLITUDE OF CYLINDRICAL
OR PLANE PARALLEL FORGINGS

386