Designation: E 192 – 04

Standard Reference Radiographs of

Investment Steel Castings for Aerospace Applications1
This standard is issued under the fixed designation E 192; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

This standard has been approved for use by agencies of the Department of Defense.

1. Scope responsibility of the user of this standard to establish appro-

1.1 The reference radiographs provided in the adjunct to this priate safety and health practices and determine the applica-
standard illustrate various types and degrees of discontinuities bility of regulatory limitations prior to use.
occurring in thin-wall steel investment castings.2 Use of this 2. Referenced Documents
standard for the specification or grading of castings requires
procurement of the adjunct reference radiographs which illus- 2.1 ASTM Standards: 3
trate the discontinuity types and severity levels. They are E 94 Guide for Radiographic Examination
intended to provide the following: E 1025 Practice for Design, Manufacture, and Material
1.1.1 A guide enabling recognition of thin-wall steel casting Grouping Classification of Hole-Type Image Quality Indi-
discontinuities and their differentiation both as to type and cators (IQI) Used for Radiology
degree through radiographic examination. E 1316 Terminology for Nondestructive Examinations
1.1.2 Example radiographic illustrations of discontinuities 2.2 ASTM Adjuncts:
and a nomenclature for reference in acceptance standards, Reference Radiographs of Investment Steel Castings for
specifications and drawings. Aerospace Applications4
1.2 Two illustration categories are covered as follows: 3. Terminology
1.2.1 Graded—Six common discontinuity types each illus-
trated in eight degrees of progressively increasing severity. 3.1 Definitions—Definitions of terms used in this standard
1.2.2 Ungraded—Twelve single illustrations of additional may be found in Terminology E 1316, Section D.
discontinuity types and of patterns and imperfections not 3.2 The terms relating to discontinuities present in these
generally regarded as discontinuities. reference radiographs are described based upon radiographic
1.3 The reference radiographs were developed for casting appearance. The terms “darker” and “lighter” as used in this
sections up to 1 in. [25.4 mm] in thickness. standard refer to the optical density of a radiographic film.
1.4 This document may be used where there is no other Where other radiographic imaging media are used, these terms
applicable document existing or for other material thicknesses should be understood to refer to areas of greater or lesser
for which it is found to be applicable and for which agreement radiologic transmission, respectively.
has been reached between the purchaser and manufacturer. 3.2.1 Gas:
3.2.1.1 gas holes—round or elongated, smooth edged dark
NOTE 1—The set of reference radiographs, produced with X-rays in the spots, occurring individually, in clusters, or distributed ran-
range from 130 to 250 kVp, consist of 16 plates (81⁄2 by 11 in. [216 by 279 domly throughout the casting.
mm]) in a 93⁄4 by 111⁄2-in. [248 by 292-mm] ring binder.
3.2.2 Shrinkage:
1.5 The values stated in inch-pound units are to be regarded 3.2.2.1 shrinkage cavity— an area with distinct jagged
as the standard. boundaries.
1.6 This standard does not purport to address all of the 3.2.2.2 shrinkage, sponge—an area, lacy in texture, with a
safety concerns, if any, associated with its use. It is the very diffuse outline.

1
These reference radiographs are under the jurisdiction of ASTM Committee
E07 on Nondestructive Testing and are the direct responsibility of Subcommittee
E07.02 on Reference Radiographs.
3
Current edition approved May 1, 2004. Published May 2004. Originally For referenced ASTM standards, visit the ASTM website, www.astm.org, or
approved in 1962. Last previous edition approved in 1995 as E 192 - 95 (1999). contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
2
The reference radiographs are considered to be applicable to all thin-wall steel Standards volume information, refer to the standard’s Document Summary page on
castings, requiring close tolerances. Such castings generally include those made by the ASTM website.
4
the lost wax, frozen mercury, ceramicast or shell mold processes. Available from ASTM Headquarters, Order RRE0192.

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959, United States.

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 E 192 – 04
3.2.2.3 shrinkage, dendritic—a distribution of very fine TABLE 1 Range of Illustration
lines or small elongated cavities that may vary in darkness and Illustration
are usually unconnected. Plate Thick- Applicable Casting
Illustrations
ness, in. Thickness, in. [mm]
3.2.2.4 shrinkage, filamentary—usually a continuous struc- [mm]
ture of connected lines or branches of variable length, width Graded:
and darkness, or occasionally, a network. Gas holes ⁄ [3.2]
18 ⁄ [6.4] and under
14

3.2.3 Heterogeneities: Gas holes ⁄ [9.5]

38 Over 1⁄4 to 1⁄2 [6.4 to 12.7], incl
Gas holes 3⁄4 [19] Over 1⁄2 to 1 [12.7 to 25.4], incl
3.2.3.1 foreign material less dense—irregularly shaped in-
dications darker than the adjacent material, but lighter than gas Shrinkage cavity 34 ⁄ [19] All thicknesses
holes of similar magnitude.
Shrinkage, sponge ⁄ [3.2]
18 ⁄ [6.4] and under
14
3.2.3.2 foreign material more dense—irregularly shaped Shrinkage, sponge ⁄ [9.5]
38 Over 1⁄4 to 1⁄2 [6.4 to 12.7], incl
indications lighter than the adjacent material. Shrinkage, sponge 3⁄4 [19] Over 1⁄2 to 1 [12.7 to 25.4], incl
3.2.4 Discrete Discontinuities:
Shrinkage, dendritic ⁄ [3.2]
18 ⁄ [6.4] and under
14
3.2.4.1 hot tears—ragged dark lines of variable width and Shrinkage, dendritic ⁄ [9.5]
38 Over 1⁄4 to 1⁄2 [6.4 to 12.7], incl
numerous branches. They have no definite lines of continuity Shrinkage, dendritic 3⁄4 [19] Over 1⁄2 to 1 [12.7 to 25.4], incl
and may exist in groups. They may originate internally or at the
Shrinkage, filamentary 34 ⁄ [19] All thicknesses
surface.
3.2.4.2 cold cracks— straight or jagged lines usually con- Foreign material, less dense ⁄ [3.2]
18 ⁄ [6.4] and under
14

tinuous throughout their length. Cold cracks generally appear Foreign material, less dense ⁄ [9.5]
38 Over 1⁄4 to 1⁄2 [6.4 to 12.7], incl
Foreign material, less dense 3⁄4 [19] Over 1⁄2 to 1 [12.7 to 25.4], incl
singly. They start at the surface.
3.2.4.3 cold shut—a distinct dark line or band of variable Ungraded:
length and definite smooth outline. Discrete Discontinuities:
Foreign material, more
3.2.4.4 misruns—prominent dark areas of variable dimen- dense ⁄
38 [9.5]
sions with a definite smooth outline. Hot tear ⁄
38 [9.5]
3.2.4.5 core shift—a variation in wall thickness. Cold crack ⁄
38 [9.5]
Cold shut 3⁄8 [9.5]
3.2.5 defective mold, is illustrated by such common defects Misrun 3⁄8 [9.5]
as mold crack, mold ridge, rattail, scab, and fin. These Core shift 3⁄8 [9.5]
conditions appear as areas or lines of different darkness than Defective Mold:
Mold buckle, positive ⁄
38 [9.5]
the adjacent material. Illustrations of the defect include: Mold buckle, negative ⁄
38 [9.5]
3.2.5.1 mold buckle, positive—a lightened irregularly Mold ridge ⁄
38 [9.5]
shaped area lightest near the center and gradually increasing in Excess metal in cracked 3⁄8 [9.5]
core
darkness away from the center. Diffraction pattern:
3.2.5.2 mold buckle, negative—a darkened irregularly Columnar 38 ⁄ [9.5]
shaped area darkest near the center and gradually getting Mottled 38 ⁄ [9.5]

lighter away from the center.

3.2.6 Diffraction Pattern:
TABLE 2 Alloys Used
3.2.6.1 columnar—few or many lines or arrays of linear
Illustration Alloy
indications that are both darker and lighter than the surround-
ing area. Gas holes, 1⁄8 in. [3.2 mm], 3⁄8 in. [9.5 mm], and 3⁄4 4330
in. [19 mm]
3.2.6.2 mottled—indistinct areas of darker and lighter im- Foreign material less dense, 1⁄8 in. [3.2 mm], 3⁄8 in. [9.5 4330
ages. mm] and 3⁄4 in. [19 mm]
Shrinkage cavity, 3⁄4 in. [19 mm] 4330
4. Description Shrinkage, sponge, 1⁄8 in. [3.2 mm] AMS 5355A
Shrinkage, sponge, 3⁄8 in. [9.5 mm] and 3⁄4 in. [19 mm] 4330
4.1 The range of radiographic illustrations is given in Table Shrinkage, dendritic, 1⁄8 in. [3.2 mm], 3⁄8 in. [9.5 mm], and 4330
3⁄4 in. [19 mm]
1. The graded discontinuities are illustrated in eight grades.
Shrinkage, filamentary, 3⁄4 in. [19 mm] 4330
These grades range from that discernible at a 2-1T quality level Foreign material more dense 4330
or better to that evident of poor workmanship and commonly Cold shut ACI HK
rejectable in commercial practice.5 The ungraded illustrations Hot tear 4330
Cold crack 4330
have been included to establish the appearance of the radio- Misrun 4330
graphic indications they represent in thin-wall steel castings. Core shift 4330
The alloys used are listed in Table 2. Mold buckle, positive AMS 5382B
Mold buckle, negative AMS 5360A
Mold ridge AMS 5382B
Excess metal in cracked core ACI CF-8M
5
Each grade of a given discontinuity type is contained in an individual Diffraction pattern, columnar ACI HK
approximate 2 by 23⁄4-in. [51 by 70-mm] machined casting block. These blocks were Diffraction pattern, mottled ACI HK
inserted in steel keeper plates with radiographic characteristics equivalent to the
casting blocks. The assembled plates were then radiographed to obtain the various
gradations shown.

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 E 192 – 04
4.2 The ASTM penetrameters included on each graded plate 5.1.5 Where the reference radiograph contains multiple
were used for contrast and resolution control only, and in discontinuities, as in the case of gas holes, acceptance may be
accordance with Practice E 1025. All of the references are based upon the aggregate size of the discontinuities, maximum
original radiographs. The radiographic technique used was in discontinuity size in the reference radiograph, the spacing
accordance with Guide E 94 and produced a density of from between discontinuities, or a combination of these and/or other
2.00 to 2.25. criteria.
5.1.6 As a minimum the acceptance criteria should contain
5. Basis for Application information addressing; zoning of the part (if applicable), the
5.1 The reference radiographs may be applied as acceptance maximum acceptable severity level for each discontinuity type,
standards in a variety of ways tailored to the specific applica- and the specified area that the reference radiograph is to be
tion. Application of these reference radiographs as acceptance applied.
standards should be based on the intended use of the product NOTE 2—Caution should be exercised in specifying the grade of
and the following considerations (see Note 2): discontinuity to be met in a casting. Casting design coupled with foundry
practice should be considered. It is advisable to consult with the
5.1.1 The discontinuities in the specified reference radio-
manufacturer/foundry before establishing the acceptance criteria to ensure
graph are acceptable in the specified unit area of the casting the desired quality level can be achieved.
being examined. The size of this unit area should be specified
in the acceptance criteria. 5.2 Film Deterioration—Radiographic films are subject to
wear and tear from handling and use. The extent to which the
5.1.2 Any combination or portion of these radiographs may
image deteriorates over time is a function of storage condi-
be used as is relevant to the particular application. Different
tions, care in handling and amount of use. Reference radio-
grades or acceptance limits may be specified for each discon-
graph films are no exception and may exhibit a loss in image
tinuity type. Furthermore, different grades may be specified for
quality over time. The radiographs should therefore be peri-
different regions or zones of a component.
odically examined for signs of wear and tear, including
5.1.3 Special considerations may be required where more scratches, abrasions, stains, and so forth. Any reference radio-
than one discontinuity type are present in the same area. Any graphs which show signs of excessive wear and tear which
modifications to the acceptance criteria required on the basis of could influence the interpretation and use of the radiographs
multiple discontinuity types must be specified. should be replaced.
5.1.4 Where the reference radiographs provide only an
ungraded illustration of a discontinuity, an acceptance level 6. Keywords
may be specified by referencing a maximum discontinuity size, 6.1 aerospace; discontinuities; investment castings; refer-
or a percentage of the discontinuity size illustrated. ence radiographs; steel; x-ray

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