SPECIFICATION FOR ULTRASONIC EXAMINATION

OF HEAVY STEEL FORGINGS

SA-388 /SA-388M

(Identical with ASTM Specification A 388 /A 388M-95.)

1. Scope A 745/A 745M Practice for Ultrasonic Examination of

1.1 This practice covers the examination procedures Austenitic Steel Forgings
for the contact, pulse-echo ultrasonic examination of E 317 Practice for Evaluating Performance Characteris-
heavy steel forgings by the straight and angle-beam tech- tics of Ultrasonic Pulse-Echo Testing Systems Without
niques. The straight beam techniques include utilization the Use of Electronic Measurement Instruments
of the DGS (Distance Gain-Size) method. See Appen- E 428 Practice for Fabrication and Control of Steel Refer-
dix X3. ence Blocks Used in Ultrasonic Inspection

1.2 This practice is to be used whenever the inquiry, 2.2 ANSI Standard:
contract, order, or specification states that forgings are B46.1 Surface Texture
to be subject to ultrasonic examination in accordance 2.3 Other Document:
with Practice A 388 /A 388M. Recommended Practice for Nondestructive Personnel
1.3 The values stated in either inch-pound or SI units Qualification and Certification SNT-TC-1A, Supple-
are to be regarded as the standard. Within the text, the ment C — Ultrasonic Testing
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 val- 3. Ordering Information
ues from the two systems may result in nonconformance 3.1 When this practice is to be applied to an inquiry,
with the specification. contract, or order, the purchaser shall so state and shall
also furnish the following information:
1.4 This specification and the applicable material
specifications are expressed in both inch-pound units and 3.1.1 Method of establishing the sensitivity in
SI units. However, unless the order specifies the applica- accordance with 7.2.2 and 7.3.3 (Vee or rectangular
ble “M” specification designation [SI units], the material notch),
shall be furnished to inch-pound units. 3.1.1.1 The diameter and test metal distance of
the flat-bottom hole and the material of the reference
1.5 This standard does not purport to address all of
block in accordance with 7.2.2.2,
the safety concerns, if any, associated with its use. It is
the responsibility of the user of this standard to establish 3.1.2 Quality level for the entire forging or portions
appropriate safety and health practices and determine thereof in accordance with 10.3, and
the applicability of regulatory limitations prior to use. 3.1.3 Any options in accordance with 6.1, 6.2, and
7.1.10.

2. Referenced Documents
2.1 ASTM Standards: 4. Apparatus
A 469 Specification for Vacuum-Treated Steel Forgings 4.1 An ultrasonic, pulsed, reflection type of instru-
for Generator Rotors ment shall be used for this examination. The system shall

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have a minimum capability for examining at frequencies Recommended Practice SNT-TC-1A or another national
from 1 to 5 MHz. On examining austenitic stainless forg- standard that is acceptable to both the purchaser and the
ings the system shall have the capabilities for examining supplier.
at frequencies down to 0.4 MHz.
4.1.1 The ultrasonic instrument shall provide linear
presentation (within 5%) for at least 75% of the screen 6. Preparation of Forging for Ultrasonic
height (sweep line to top of screen). The 5% linearity Examination
referred to is descriptive of the screen presentation of 6.1 Unless otherwise specified in the order or contract,
amplitude. Instrument linearity shall be verified in accor- the forging shall be machined to provide cylindrical sur-
dance with the intent of Practice E 317. Any set of blocks faces for radial examination in the case of round forgings;
processed in accordance with Practice E 317 or E 428 the ends of the forgings shall be machined perpendicular
may be used to establish the specified ±5% instrument to the axis of the forging for the axial examination. Faces
linearity. of disk and rectangular forgings shall be machined flat
4.1.2 The electronic apparatus shall contain an and parallel to one another.
attenuator (accurate over its useful range to ±10% (+1 dB)
6.2 The surface roughness of exterior finishes shall
of the amplitude ratio) which will allow measurement of
not exceed 250 ␮in. [6 ␮m] unless otherwise shown on
indications beyond the linear range of the instrument.
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] 6.3 The surfaces of the forging to be examined shall
minimum to 11⁄8 in. [30 mm] maximum dimensions shall be free of extraneous material such as loose scale, paint,
be used for straight-beam scanning (see 7.2); and search dirt, etc.
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). 7. Procedure
4.2.1 Transducers shall be utilized at their rated 7.1 General:
frequencies. 7.1.1 As far as practicable, subject the entire vol-
4.2.2 Other search units may be used for evaluating ume of the forging to ultrasonic examination. Because
and pinpointing indications. of radii at change of sections and other local configura-
tions, it may be impossible to examine some sections of
4.3 Couplants having good wetting characteristics
a forging.
such as SAE No. 20 or No. 30 motor oil, glycerin, pine
oil, or water shall be used. Couplants may not be compara- 7.1.2 Perform the ultrasonic examination after heat
ble to one another and the same couplant shall be used treatment for mechanical properties (exclusive of stress-
for calibration and examination. relief treatments) but prior to drilling holes, cutting key-
ways, tapers, grooves, or machining sections to contour.
4.4 Reference Blocks containing flat-bottom holes may
If the configuration of the forging required for the treat-
be used for calibration of equipment in accordance with
ment for mechanical properties prohibits a subsequent
4.1.1 and may be used to establish recording levels for
complete examination of the forging, it shall be permissi-
straight beam examination when so specified by the order
ble to examine prior to treatment for mechanical proper-
or contract.
ties. In such cases, reexamine the forging ultrasonically
4.5 DGS scales, matched to the ultrasonic test unit as completely as possible after heat treatment.
and transducer to be utilized, may be used to establish
7.1.3 To ensure complete coverage of the forging
recording levels for straight beam examination, when so
volume, index the search unit with at least 15% overlap
specified by the order or contract. The DGS scale range
with each pass.
must be selected to include the full thickness cross-section
of the forging to be examined. An example of a DGS 7.1.4 Do not exceed a scanning rate of 6 in. /s
overlay is found in Appendix X3. [150 mm /s].
7.1.5 If possible, scan all sections of forgings in
5. Personnel Requirements two perpendicular directions.
5.1 Personnel performing ultrasonic examinations in 7.1.6 Scan disk forgings using a straight beam tech-
accordance with this practice shall be qualified and certi- nique from at least one flat face and radially from the
fied in accordance with a written procedure conforming to circumference whenever practicable.

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7.1.7 Scan cylindrical sections and hollow forgings NOTE 2 — When flat-surfaced reference block calibration is specified,
by angle-beam technique. When practicable, also exam- adjust the amplitude of indication from the reference block or blocks
to compensate for examination surface curvature (an example is given
ine the forging in the axial direction. in Appendix X1).
7.1.8 In addition, examine hollow forgings by 7.2.2.3 DGS Calibration — Prior to use, verify
angle-beam technique from the outside diameter surface that the DGS overlay matches the transducer size and
as required in 7.3.1. frequency. Accuracy of the overlay can be verified by
7.1.9 In rechecking or reevaluation by manufac- reference blocks and procedures outlined in Practice E
turer or purchaser use comparable equipment, search 317. Overlays are to be serialized to match the ultrasonic
units, frequency, and couplant. transducer and pulse echo testing system that they are to
be utilized with.
7.1.10 Forgings may be examined either stationary 7.2.2.4 Choose the appropriate DGS scale for the
or while rotating in a lathe or on rollers. If not specified cross-sectional thickness of the forging to be examined.
by the purchaser, either method may be used at the manu- Insert the overlay over the CRT screen, ensuring the DGS
facturer’s option. scale base line coincides with the sweep line of the CRT
7.2 Straight-Beam Examination: screen. Place the probe on the forging, adjust the gain to
make the first backwall echo appear clearly on CRT
7.2.1 For straight-beam examination use a nominal
screen. Using the Delay and Sweep control, shift the
21⁄4 MHz search unit whenever practicable; however,
screen pattern so that the leading edge of the initial pulse
1 MHz is the preferred frequency for coarse grained
is on zero of the DGS scale and the backwall echo is on
austenitic materials and long testing distances. In many
the DGS scale value corresponding to the thickness of
instances on examining coarse grained austenitic materi-
the forging. Adjust the gain so the forging backwall echo
als it may be necessary to use a frequency of 0.4 MHz.
matches the height of the DGS reference slope within ±1
Other frequencies may be used if desirable for better
Db. Once adjusted, increase the gain by the Db shown
resolution, penetrability, or detectability of flaws. on the DGS scale for the reference slope. Instrument is
7.2.2 Establish the instrument sensitivity by either now calibrated and flaw sizes that can be reliably detected
the reflection, reference-block technique, or DGS method can be directly read from the CRT screen. These flaw
(see Appendix X3 for an explanation of the DGS method). sizes are the equivalent flat bottom reflector that can be
used as a reference point.
7.2.2.1 Back-Reflection Technique (Back-Reflec-
tion Calibration Applicable to Forgings with Parallel NOTE 3 — The above can be utilized on all solid forgings. Cylindrical
Entry and Back Surfaces) — With the attenuator set at hollow forgings, and drilled or bored forgings must be corrected to
compensate for attenuation due to the central hole (see Appendix X4).
an appropriate level, for example 5 to 1 or 14 dB, adjust
the instrument controls to obtain a back reflection approx- 7.2.3 Recalibration — Any change in the search
imately 75% of the full-screen height from the opposite unit, couplant, instrument setting, or scanning speed from
side of the forging. Scan the forging at the maximum that used for calibration shall require recalibration. Per-
form a calibration check at least once every 8 h shift.
amplification setting of the attenuator (attenuator set at
When a loss of 15% or greater in the gain level is indi-
1 to 1). Carry out the evaluation of discontinuities with
cated, reestablish the required calibration and reexamine
the gain control set at the reference level. Recalibration
all of the material examined in the preceding calibration
is required for significant changes in section thickness or
period. When an increase of 15% or greater in the gain
diameter.
level is indicated, reevaluate all recorded indications.
NOTE 1 — High sensitivity levels are not usually employed when 7.2.4 During the examination of the forging, moni-
inspecting austenitic steel forgings due to attendant high level of “noise” tor the back reflection for any significant reduction in
or “hash” caused by coarse grain structure. amplitude. Reduction in back-reflection amplitude may
7.2.2.2 Reference-Block Calibration — The test indicate not only the presence of a discontinuity but also
surface roughness on the calibration standard shall be poor coupling of the search unit with the surface of the
comparable to but no better than the item to be examined. forging, nonparallel back-reflection surface, or local vari-
Adjust the instrument controls to obtain the required sig- ations of attenuation in the forging. Recheck any areas
nal amplitude from the flat-bottom hole in the specified causing loss of back reflection.
reference block. Utilize the attenuator in order to set up 7.3 Angle-Beam Examination — Rings and Hollow
on amplitudes larger than the vertical linearity of the Forgings:
instrument. In those cases, remove the attenuation prior 7.3.1 Perform the examination from the circumfer-
to scanning the forging. ence of rings and hollow forgings that have an axial

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 SA-388 /SA-388M 2004 SECTION II

length greater than 2 in. [50 mm] and an outside to inside 8. Recording
diameter ratio of less than 2.0 to 1. 8.1 Straight-Beam Examination — Record the follow-
ing indications as information for the purchaser. These
7.3.2 Use a 1 MHz, 45° angle-beam search unit recordable indications do not constitute a rejectable con-
unless thickness, OD /ID ratio, or other geometric con- dition unless negotiated as such in the purchase order.
figuration results in failure to achieve calibration. Other 8.1.1 In the back-reflection technique, individual
frequencies may be used if desirable for better resolution, indications equal to or exceeding 10% of the back reflec-
penetrability, or detectability of flaws. For angle-beam tion from an adjacent area free from indications; in the
inspection of hollow forgings up to 2.0 to 1 ratio, provide reference-block or DGS technique, indications equal to
the transducer with a wedge or shoe that will result in or exceeding 100% of the reference amplitude.
the beam mode and angle required by the size and shape
of the cross section under examination. 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
7.3.3 Calibrate the instrument for the angle-beam
extent of such an indication shall be accurately measured
examination to obtain an indication amplitude of approxi-
along with variations in amplitudes of reflections.
mately 75% full-screen height from a rectangular or a
60° V-notch on inside diameter (ID) in the axial direction 8.1.2.1 Planar indications shall be considered
and parallel to the axis of the forging. A separate calibra- continuous over a plane if they have a major axis greater
tion standard may be used; however, it shall have the than 1 in. [25 mm]. In recording these indications correc-
same nominal composition, heat treatment, and thickness tions must be made for beam divergence at the estimated
as the forging it represents. The test surface finish on the flaw depth.
calibration standard shall be comparable but no better 8.1.3 In the back-reflection technique, discontinuity
than the item to be examined. Where a group of identical indications equal to or exceeding 5% of the back reflec-
forgings is made, one of these forgings may be used as tion. In the reference-block technique, indications equal
the separate calibration standard. Cut the ID notch depth to or exceeding 50% of the reference amplitude providing
to 3% maximum of the thickness or 1⁄4 in. [6 mm], which- that they travel, are continuous, or appear as clusters.
ever is smaller, and its length approximately 1 in. 8.1.3.1 Traveling indications are herein defined
[25 mm]. Thickness is defined as the thickness of the as indications whose leading edge moves a distance
forging to be examined at the time of examination. At equivalent to 1 in. [25 mm] or more of metal depth with
the same instrument setting, obtain a reflection from a movement of the search unit over the surface of the
similar OD notch. Draw a line through the peaks of the forging.
first reflections obtained from the ID and OD notches.
This shall be the amplitude reference line. It is preferable 8.1.3.2 A cluster of indications is defined as five
to have the notches in excess metal or test metal when or more indications located in a volume representing a
possible. When the OD notch cannot be detected when 2 in. [50 mm] or smaller cube in the forging.
examining the OD surface, perform the examination when 8.1.4 Reduction in back reflection exceeding 20%
practicable (some ID’s may be too small to permit exami- of the original measured in increments of 10%.
nation), as indicated above from both the OD and ID 8.1.5 Amplitudes of recordable indications in incre-
surfaces. Utilize the ID notch when inspecting from the ments of 10%.
OD, and the OD notch when inspecting from the ID.
Curve wedges or shoes may be used when necessary and 8.2 Angle-Beam Examination — Record discontinuity
practicable. indications equal to or exceeding 50% of the indication
from the reference line. When an amplitude reference
line cannot be generated, record discontinuity indications
7.3.4 Perform the examination by scanning over the
equal to or exceeding 50% of the reference notch. These
entire surface area circumferentially in both the clockwise
recordable indications do not constitute a rejectable con-
and counter-clockwise directions from the OD surface.
dition unless negotiated as such in the purchase order.
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 rectangu-
9. Report
lar or 60° V-notches on the ID and OD for the calibration.
These notches shall be perpendicular to the axis of the 9.1 Report the following information:
forging and the same dimensions as the axial notch. 9.1.1 All recordable indications (see Section 8).

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 PART A — FERROUS MATERIAL SPECIFICATIONS SA-388 /SA-388M

9.1.2 For the purpose of reporting the locations of microstructure of these austenitic alloys. For these rea-
recordable indications, a sketch shall be prepared showing sons, the methods and standards employed for ultrasoni-
the physical outline of the forging including dimensions cally examining carbon and low-alloy steel forgings may
of all areas not inspected due to geometric configuration, not be applicable to heavy austenitic steel forgings. In
the purchaser’s drawing number, the purchaser’s order general, only straight beam inspecting using a back-
number, and the manufacturer’s serial number, and the reflection reference standard is used. However, utilization
axial, radial, and circumferential distribution of rec- of Practice A 745/A 745M for austenitic steel forgings
ordable ultrasonic indications. can be considered if flat bottom hole reference standards
9.1.3 The specification to which the examination or angle beam examination of these grades are required.
was performed as well as the frequency used, method 10.3 Acceptance quality levels shall be established
of setting sensitivity, type of instrument, surface finish, between purchaser and manufacturer on the basis of one
couplant, and search unit employed. or more of the following criteria.
9.1.4 The inspector’s signature and date examina- 10.3.1 Straight-Beam Examination:
tion performed. 10.3.1.1 No indications larger than some percent-
age of the reference back reflection.
10. Quality Levels 10.3.1.2 No indications equal to or larger than
10.1 This practice is intended for application to forg- the indication received from the flat-bottom hole in a
ings, with a wide variety of sizes, shapes, compositions, specific reference block or blocks.
melting processes, and applications. It is, therefore, 10.3.1.3 No areas showing loss of back reflection
impracticable to specify an ultrasonic quality level which larger than some percentage of the reference back
would be universally applicable to such a diversity of reflection.
products. Ultrasonic acceptance or rejection criteria for 10.3.1.4 No indications per 10.3.1.1 or 10.3.1.2
individual forgings should be based on a realistic coupled with some loss of resultant back reflection per
appraisal of service requirements and the quality that can 10.3.1.3.
normally be obtained in the production of the particular
type forging. 10.3.1.5 No indications exceeding the reference
level specified in the DGS method.
10.2 Heavy austenitic stainless steel forgings are more
10.3.2 Angle-Beam Examination — No indications
difficult to penetrate ultrasonically than similar carbon
exceeding a stated percentage of the reflection from a
or low-alloy steel forgings. The degree of attenuation
reference notch or of the amplitude reference line.
normally increases with section size; and the noise level,
generally or in isolated areas, may become too great to 10.4 Intelligent application of ultrasonic quality levels
permit detection of discrete indications. In most instances, involves an understanding of the effects of many parame-
this attenuation results from inherent coarse grained ters on examination results.

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APPENDICES

(Nonmandatory Information)
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X1. TYPICAL TUNING LEVEL X2.2 To utilize curve, establish amplitude from
COMPENSATION FOR THE EFFECTS OF ASTM reference block to coincide with values from
FORGING CURVATURE Appendix X1.
X1.1 The curve (Fig. X1.1) was determined for the
following test conditions:
X3. BACKGROUND INFORMATION ON THE
Material nickel-molybdenum-vanadium alloy steel DGS METHODS
(Specification A 469, Class 4)
Instrument Type UR Reflectoscope X3.1 The DGS method was developed to determine
Search unit 11⁄8 in. [30 mm] diameter quartz flaw sizes by comparison to a back wall echo produced
Frequency 21⁄4 MHz on the part to be ultrasonic tested. The derivation of DGS
Reference block ASTM No. 3-0600 (aluminum) curves is extensively covered and can be found in standard
Reflection area of ref- 0.010 in.2 [6.5 mm2] in nickel-molybde- texts on ultrasonic testing, and will not be covered here.
erence curve num-vanadium alloy steel
Surface finish 250 ␮in. [6 ␮m], max, roughness
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
X1.2 To utilize curve, adjust reflectoscope sensitivity be established and suitable gain added. Flaw echo indica-
to obtain indicated ultrasonic response on ASTM No. 3- tions that appear can be sized via the flaw size curves
0600 reference block for each diameter as shown. A (C) on the overlay. Item (D) depicts the transducers that
response of 1 in. [25 mm] sweep-to-peak is used for flat the overlay works in conjunction with and (E) depicts
surfaces. Use attenuator to obtain desired amplitude, but the series of curves that the overlay scales are matched to.
do testing at 1 to 1 setting.

X4. COMPENSATION FOR CENTER HOLE

X2. INDICATION AMPLITUDE ATTENUATION ON CYLINDRICAL
COMPENSATION FOR TEST DISTANCE BORED OR HOLLOW FORGINGS
VARIATIONS UTILIZING THE DGS METHOD
X2.1 The curve (Fig. X2.1) has been determined for X4.1 The hole in a cylindrical bored forging causes
the following test conditions: sound scatter. In these cases, a correction is required
Material nickel-molybdenum-vanadium alloy steel
which depends on the wall thickness and bore diameter.
(Specification A 469, Class 4) X4.1.1 Determine the correction value in dB from
Instrument Type UR Reflectoscope the Nomogram (Fig. X4.1).
Search unit 11⁄8 in. [30 mm] diameter quartz
Frequency 21⁄4 MHz X4.1.2 Proceed as described in 7.2.2.3.
Couplant No. 20 oil
X4.1.3 With the GAIN-dB control, reduce the flaw
Reference block ASTM No. 3-0600 (aluminum)
Reflection area of ref- 0.010 in.2 [6.5 mm2] in nickel-molybde- detector gain by the correction value determined as per
erence curve num-vanadium alloy steel the Nomogram (Fig. X4.2). Thus, the flaw detector gain
Surface finish 250 ␮in. [6 ␮m], max, roughness is accurately adjusted.

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PART A — FERROUS MATERIAL SPECIFICATIONS SA-388 /SA-388M

FIG. X1.1 TYPICAL COMPENSATION CURVE FOR FIG. X2.1 TYPICAL DISTANCE-AMPLITUDE
EFFECTS OF FORGING CURVATURE CORRECTION CURVE

FIG. X4.1 EXAMPLE OF DGS OVERLAY

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FIG. X4.2 THE INFLUENCE OF A CENTRAL BORE ON THE

BACKWALL ECHO AMPLITUDE OF CYLINDRICAL OR
PLANE PARALLEL FORGINGS

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