ASTM A503 A503M-2001(2006) Standard Specification for Ultrasonic Examination of Forged Crankshafts《锻制大型曲轴的超声波检验》.pdf

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1、Designation: A 503/A 503M 01 (Reapproved 2006)Standard Specification forUltrasonic Examination of Forged Crankshafts1This standard is issued under the fixed designationA 503/A 503M; the number immediately following the designation indicates the yearof original adoption or, in the case of revision, t

2、he 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.1. Scope1.1 This is an acceptance specification for the ultrasonicinspection of forged steel crankshafts having main b

3、earingjournals or crankpins 4 in. 100 mm or larger in diameter.1.2 This specification covers the testing equipment requiredand the test procedure to be followed, and it defines the criticaland noncritical areas and limits of acceptance.1.3 This specification is intended to cover both continuousgrain

4、 flow (CGF) crankshafts for medium and high speeddiesel engines as well as solid (slab) forged crankshafts forother applications.1.4 The values stated in either inch-pound units or SI(metric) units are to be regarded separately as the standard.Within the text and tables, the SI units are shown in br

5、ackets.The values stated in each system shall be used independently ofthe other. Combining values from the two systems may resultin nonconformance with the specification.1.5 Unless the order specifies the applicable “M” specifica-tion designation, the inch-pound units shall be used.1.6 This standard

6、 does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.2. Referenced Documents2.1 ASTM

7、Standards:2A 388/A 388M Practice for Ultrasonic Examination ofHeavy Steel ForgingsE 428 Practice for Fabrication and Control of Metal, Otherthan Aluminum Reference, Blocks Used in UltrasonicExamination2.2 American National Standard:3ANSI B46.1, Surface Texture3. Terminology3.1 Definitions:3.1.1 cont

8、inuous grain flow crankshaftsproduced by aprocess in which the solidification centerline of the originalingot or starting stock is maintained through the main bearings,webs, crankpins, and flanges of the finished crankshaft, usuallyby means of closed die forging.3.1.2 solid (slab) forged crankshafts

9、made from open dieforgings such that the grain flow in the webs is essentiallyparallel to the major axis of the forging and the crankpins areoffset from the forging centerline by machining. They may beset in the correct orientation by a hot twisting operation.4. Ordering Information4.1 It is necessa

10、ry that the crankshaft be identified as beingeither continuous grain flow or solid (slab) forged.4.2 Unless otherwise specified by means of supplementaryordering information, the test methods and acceptance criteriafor the appropriate crankshaft type shall be used.5. Apparatus and Personnel Requirem

11、ents5.1 The apparatus and personnel requirements shall be inaccordance with Practice A 388/A 388M. For standardizationpurposes, it is recommended that final acceptance be based onthe use of 25 MHz transducers.6. Critical Sections6.1 The division of a crankshaft into three volumetric zones,as shown i

12、n Fig. 1 and Fig. 2, for the purpose of ultrasonicexamination evaluation is applicable to both solid (slab) forgedand continuous grain flow crankshafts.1This specification is under the jurisdiction of ASTM Committee A01 on Steel,Stainless Steel and Related Alloys and is the direct responsibility of

13、SubcommitteeA01.06 on Steel Forgings and Billets.Current edition approved March 1, 2006. Published April 2006. Originallyapproved in 1964. Last previous edition approved in 2001 as A 503/A 503M 01(2001)e1.2For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer S

14、ervice at serviceastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.3Available from American National Standards Institute, 11 W. 42nd St., 13thFloor, New York, NY 10036.1Copyright ASTM International, 100 Barr Harbor Drive, P

15、O Box C700, West Conshohocken, PA 19428-2959, United States.6.2 The major critical sections shown as Zone 1 in Fig. 1include the heavily loaded areas of the crankpins, webs, andmain bearings.6.3 The minor critical sections shown as Zone 2 in Fig. 1include the balance of the surface areas of the main

16、 bearing andcrankpin journals and adjacent fillets, flanges, and gear fitareas.6.4 The balance of the crankshaft as shown in Fig. 1,including the remaining sections of the webs, is included inZone 3.7. Calibration of Ultrasonic Equipment on Crankshaft7.1 For solid (slab) forged crankshafts, the sens

17、itivity of theinstrument shall be adjusted so that the thickness to beexamined will give a full-scale back reflection. Such calibra-tions shall be done in an area free of interfering indications.7.2 For CGF crankshafts, 80 % of the full-scale backreflection is used when evaluating indications in acc

18、ordancewith Fig. 3.8. Procedure8.1 The crankshaft should be examined after heat treatment,but before machining geometric features such as chamfers andoil holes that could interfere with ultrasonic examination.8.2 Unless otherwise specified by the purchase order, thescanned surfaces shall have a maxi

19、mum surface roughness of250 in. 6.35 m.8.3 The crankshaft shall be scanned as shown in Fig. 2.9. Acceptance Criteria9.1 Acceptance Zones:9.1.1 For acceptance purposes, the crankshaft shall bedivided into three zones as shown in Fig. 1.9.1.2 Because of crankshaft geometry, particularly for CGFcranksh

20、afts, the ultrasonic examination shall be carried out tothe maximum extent possible.9.2 Solid Forged Crankshafts:9.2.1 In Zone 1, indications equal to or greater than 20 % ofthe back reflection as established in 7.1 shall be cause forrejection.9.2.2 Indications in Zone 2 equal to or greater than 50

21、% ofthe back reflection shall be cause for rejection.FIG. 1 Crankshaft UT Acceptance ZonesFIG. 2 Scanning DirectionsFIG. 3 Distance to Indication as Percentage of Cross-sectionA 503/A 503M 01 (2006)29.2.3 Indications in Zone 3 equal to or greater than 100 % ofthe back reflection shall be cause for r

22、ejection.9.2.4 Loss of back reflection in excess of 50 % in any zone,and not caused by geometric configuration, shall be recorded interms of size and location. Normally this condition shall because for rejection, but it may be referred to the purchaser fordisposition.9.3 Continuous Grain Flow Cranks

23、hafts (CGF):9.3.1 Ultrasonic indications detected in CGF crankshaftsshall be evaluated in accordance with Fig. 3. Indications thatexceed the appropriate zone curve are cause for rejection.9.3.2 Loss of back reflection in excess of 50 % in any zone,and not attributable to geometric configuration shal

24、l be re-corded in terms of percentage loss and location. Normally thiscondition shall be cause for rejection, but it may be referred tothe purchaser for disposition.10. Keywords10.1 contact method; continuous grain flow; crankshafts;forged steel; slab forged; ultrasonic examinationSUPPLEMENTARY REQU

25、IREMENTSThe following supplementary requirements shall apply only when specified by the purchaser in theinquiry or order. Details of these supplementary requirements shall be agreed upon by themanufacturer and the purchaser.S1. Ultrasonic Testing: Reference Block CalibrationS1.1 A distance amplitude

26、 correction (DAC) curve shall beused to provide compensation for signal attenuation.S1.1.1 Two or more reference specimens of incrementallengths shall be used to establish the DAC curve.S1.1.2 The reference blocks shall be manufactured in accor-dance with Practice E 428.S1.1.3 The DAC is established

27、 by placing the search unit onthe reference block with the shortest distance to the test holeand adjusting the gain control to secure a signal response of100 % full screen. The signal peak is marked on the screen.The procedure is repeated for succeeding greater test distanceswithout altering the gai

28、n. The DAC curve is established byconnecting adjoining peaks with a straight line.S1.1.4 The basis for rejection shall be agreed upon betweenthe purchaser and manufacturer.S2. DGS ScalesS2.1 DGS scales similar to those described in PracticeA 388/A 388M shall be used in the examination of either soli

29、d(slab) forged or CGF crankshafts.S2.2 The acceptance curves shall be agreed upon betweenthe purchaser and manufacturer.ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are express

30、ly advised that determination of the validity of any such patent rights, and the riskof infringement of such rights, are entirely their own responsibility.This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years andif not revised,

31、either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standardsand should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of theresponsible technical committee, which you may att

32、end. If you feel that your comments have not received a fair hearing you shouldmake your views known to the ASTM Committee on Standards, at the address shown below.This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the aboveaddress or at 610-832-9585 (phone), 610-832-9555 (fax), or serviceastm.org (e-mail); or through the ASTM website(www.astm.org).A 503/A 503M 01 (2006)3