_________________MW_

d LF

CHIA FP T>

No. _________

[JICL.I. C.3

ASSISTSIR(~ IREMNDTS C

C.~ I ~ FORW~UIN97M AIWE PELCNS.UEM emI

UrvIN V IftTIL&~Iu ;:A&CMIý=

U.S. ARMY TANK-AUTOMOTIVERESEARCH AND DEVELOPMENT COMMANDWarren, Michigan 48090

171C 02/0~

F.1

*1! TECHMICAL REM T NUIN 12256

OH ENT OF OUALITY ASSJRMCE TRAINING WAIAL7TO SISf I* ESTABLISHIM SDUUNESS REQUIRIEMETS

FOR ALUMIUM AND STEEL CASTINGS

BY

VALTER F. WULF AO IMELVIN V. PHVTILASALVATORE B. CATALAO AND DON MATICHUK

August 1978

AMWWi MATERIAL APPLICATION AND TENOLOGY FUNCTION

,;1 "U

to

ABSTRACT

"" I

Suaples of aluminum and steel casting flaws most comonly experiencedIn production were selected to be radiographed in order to developquantitative and descriptive picture images of various radiographicrferonce standards. Graphic illustrations of flaw size and flawdistribution for various radiographic reference standards were depictedby using radiographs and associated cross-sectional photo-macrographs.These graphic illustrations of radiographic levels of acceptance willprovie meaningful design criteria for establishing realisticstandards of acceptance for now material applications. This reportalso furnishes operational guidance to quality assurance andradiographic personnel in their normal on-the-Job duties.

I

•b•, • • • O0f'• ••

IT I OF C__m_ _

Abstract !

List of CM s A"l FPit" M

Introdwctiw 1

Object1Swmry 1

Conclusions 1

Test Meterials 2

Test Equipunt 2

Test Procedure 2

Itesults end DiscussioM 3

Distribution List

Form O 1473

1•.i I

LIST OF CHARTS AND FIGURES

STEEL CASTING FLAWS

FM i. 12, PrME V.1 Evaluation of Gas Pority In Cast Steel 5

2 Evaluation of Uas Pomsity in Cast Steel 6

3 Evaluation of Sand and Slag Inclusions in 7Cast Steel

4 Evaluation of Sand and Slag Inclusions in 8Cast Steel

SA Radiograplc Ingo of Dendritic Shrinkage 9in Cast Steel 2 Inchs Thick

58 Evaluation of pdritlic Shrinkage In Cast 10Steel 2 Inches Thick

6A Radiograohic Iuage of Internal Shrinkage 11In Cast Steel

68 Evaluation of Internal Shrinkage In Cast 12Steel

7A Radiograoic hIage of Dmndritic Shrinkage 13In Cost Steel 1-3/4 Inces Thick

7i Evaluation of Dendritic Shrinkage in Cast 14Steel 1-3/4 Inches Thick

8A Radiographic Impa of Dendritic Shrinkage 16In 2-1/2u Thickness of Steel

85 Nacrograph of Casting Cross-Section as- 16valig Severity and Location of ShrinkageCondition (Show• n Fig. BA)

SA Rdiographic Imagse of Dendritic Shrinkage 17In Cast Steel I Indce Thick

SO acrographs of Casting Cross-Sectons 18Revealiog Severity and Location o ShrinkageCondition (Shown in Fig SA)

10 Evaluation of Spo"e Shrinka• In Cast 19Steel 1-1/2 Inches Thick

i tii

IIA ft'gl € fSm• Srnage 20in Casitl1"12nceThc

Evaluation of = ge ShrIk age ist 21Steel 1-1/2 Thick

IZA Not Tear's 22

13 Evaluation of Hot Tear In Cast Steel 232-1/2 Imche Thick

13A Evaluation of Hot Tear In Cast Steel 242-1/2 Icem Thick

1iS Evaleatloa of Hot Tear Is Cast SW1l 252-1/2 inches Thick

ALUMINUM CASTING ELAWS

IA Waluation of Ga Holes in Cast Alu- 27

is Evaluation of Gas Holes in Cast Alu- 28minms

2A Evaluation of Gas Porosity-Round in 29Cast Aluminum

2B Evaluation of Gas Porosity-Round in 30Cast Aluminui

3A Evaluation of Gas Porosity-Rouad in 31Cast Aluinu

3B Evaluation of Gas Porosity-Round in 32

Cast Al,-minui

4A Evaluation of Gas Porouity-Round in 33i Gas t Alualum

S4B Evaluation of Gas Poroeity-RouvA in 34

Cast Aluninum

IIV

LIST OF CHARTS AND FIGURES(Continued)

SFIGURE NO. PAGE NO.

SA Evaluation of Gas Porosity-Elongated 35in Cast Aluminum

5B Evaluation of Gas Porosity-Elongated 36in Cast Aluminum

6A Evaluation of Gas Porosity-Elongated 37"in Cast Aluminum

6B Evaluation of Gas Porosity-Elongated 38in Cast Aluminum

7A Evaluation of Grain Boundary Shrinkage 39in High Strength Cast Aluminum

7B Evaluation of Grain Boundary Shrinkage 40in High Strength Cast Alumlitum

8 Evaluation of Cavity Type Shrinkage in 41Cast Aluminum

9 Evaluation of Cavity Type Shrinkagae in 42Cast Aluminum

0IA Evaluation of Sponge Shrinkage in Cast 43Aluminum

10B Evaluation of Sponge Shrinkage in Cast 44Aluminum

11A Evaluation of Sponge Shrinka_I in Cast 45Aluminum

11B Evaluation of Sponge Shrinkage in Cast 46Aluminum

12 Evaluation of Foreign Material in Cast 47Aluminum

13 Evaluation of Foreign Material in Cast 48Aluminum

,rv"

Il INTRODUCTION

Present soundness requireents for many military castings are beingspecified according to severity levels listed in v&rious specifications.Standards are selected on the basis of their numerical rating, or asspecified in a related specification without serious consideration ofthe type and degree of flaw permitted for each grade level. It wasoriginally Intended that reference radiographs be used to categorizedesignated standards according to the stress requirements of thecasting. With this procedure many castings are produced to a greatersoundness requirement than necessary; conversely, this procedure is toolenient for other highly critical castings and ultimately createsS~service problem.

iIn accordance with project authorization from U.S. Army Materials and

Mechanics Research Center, the task of compiling a flaw correlationII document was established under the Materials Testing Technology Program.

The effort was determined necessary to greatly assist the humanJudgment presently involved in designating casting soundness requirements.

OBJECT

The object of this task is to provide a document which illustratesflaw correlation with radiographic images to assist design engineersin the proper selection of casting soundness requirements.

iSU*AYE Typical flaw specimens of varying severity levels, presently encountered

in aluminum and steel castings, were selected from representative\ } components obtained from government and cmmercial sources. Flaw

severity levels were graded radiographically to existing militaryand ASTN reference standards and categorized according to castingsize ar.d thickness. Photo-macrographs of flaw cross-sections werecorrelated with radiographic images to illustrate the actual relation-ship of flaw size to the casting area under evaluation.

CONCLUSIONS

The completion of this document provides design engineers with flawcorrelation data which will assist in more accurately selectingradiographic soundness requirements on future castings. Thisdocument will also furnish operational guidance to quality assuranceand radiographic personnel In their normal on-the-Job duties.

,i i 1

TEST MATERIALS

1. Scrapped steel armor castings.

2. Scrapped aluminui castings of 355, 356 and special hi-strengthKaiser KO1 alloy.

3. Industrial x-ray film of various sizes, medium grain, fine grain,and extra-fine grain.

4. Comercial photographic copy film, size 4 x 5 inches.

5. Photographic projection print paper.

TEST EQUIP••,T

1. Industrial x-ray machine, I000KVP, 3NA capacity

2. Industrial x-ray machine, 250KVP, 1ONA capacity

3. Industrial x-ray machine, 140KVP, 24A capacity

4. Industrial x-ray machine, 25KVP, S5A capacity

5. Comercial 4 x 5 inch View camera

6. CoamercIal 4 x 5 condenser type photographic enlarger

7. Photographic reproduction printing equipment

8. Lithographic printing equipment

TEST PROCEDURE1. The procedure followed during the program was as follows:

it. Radiographic evaluation

b. Netallographic evalition

c. Selection of standards for flaw correlation

d. Reproduction of selected standards

2

2. Following Is a brief description of ech procedure:

a. Radiographic evaluation:

Radiography of approximately 20 each aluminum and steelarmor castings was performed in accordance with NIL-STD-453(1),dated 4 Septeiber 1963 (Radiographic Inspection). A minimamquality level of 2-1T, representing 1.4 percent sensitivitywas maintained for all exposures. Several x-ray machines anda variety of radiographic exposure techniques were employed.

b. Netallographic evaluation:

Cross-sections were extracted from the selected specimens ofmost flaw types for verification of radiographic evaluation.Photo-acrographs were made of typical flaw conditions forcorrelation with reference standards.

c. Selection of standards for flaw correlation:

Grading of standards for flaw correlation were based onexisting military and ASTH reference standards. Two levelsof severity and in some flaws special gross conditions wereselected to correlate the radiographic image with the flawcross-sectional area.

d. Reproduction of selected standards:

The original radiographs were photographically reproducedutilizing a conventional 4 x 5 inch view camera to copythe radiographic image as viewed with an eleven-tubeflourescent illuminator. Since photographic printingpapers do not have the latitude of x-ray film, projectionprints were made to allow the control necessary to obtainan authentic reproduction. Two methods of final reproductionwere used in this document. The aluminum standards werereproduced by the photographic method; however, due to theexceptionally high cost of photographic reproduction, thesteel standards were reproduced by the lithographic method.

RESLTS AND DISCUSSIONS

The lack of flaw correlation data has led to a questionable procedureof specifying radiographic soundness requirements according to severitylevels 1isted in specification without adequate radiographic andpictorial illustrations. The illustrated correlation data contained in

3

A II

Figures I through 13 will enable recognition of flaw sizes and distri-bution as comared to casting cross-sectional appearance and assist inestablishing more realistic standards of acceptance by design engineersand quality assurance personnel. This should ultimately result ingreater reliability of aluminum and steel armor castings.

'I

4iF

ISTEEL CASTING FLAWS

Raigrpi imag of, ga:ooiy eeiylee hw oprswt

,_4-E 44 -- ra e

C t

,,¢

S~Radiographic image of gas porosity. Severity level shown compares withthe following:

ASTM-E-446 - Grade 2ASTM--E--186 -- Grade 2

MIL-R--11469 - Acceptance is based on pore size and casting thickness.Amount shown meets Std. 2 for 1", and Std. 1 for 2" thickness.

I .Macrograph of partial casting cross section showing normal location ofporosity near the surface. (unetched, actual size)

K , EVALUATION OF GAS POROSITY IN CAST STEEL

K -Figi

C,-oRadiographic~~~~~~~~~ img4fga ooit.Svri" ee hw oprswt

MLRadiogaphi img Accepancs bsdo poroiySe ertlel sizewnd comasten wthikes

Amount shown meets Std. 3 for 1", and Std. 2 for 2" thickness.

Macrograph of part.6'l caating cross section showing normal location ofporosity near -ih suI'facv. (unetched, actual size)

EVALUATION OF GAS POROSITY IN CAST STEEL

Fig. 2

II

RaigahcIaeoInlsosFSvrt ee hw oprswt

RaiogRaphic9 iAgepof ancebsdonlusions seirze leeaond cmarstwith

thickness. Amount shown meets Std. 2 for I", and Std. 1 for 2" thickness.

* Ma .rograph of partial casting cross section showing normal location of* Inclusions near the surface. (unetched, actual size)

EVALUATION OF SAND AND SLAG INCLUSIONS IN CAST STFIEL

Fig. 3

RaigahcIaeo.Icuin.Svrt wo hw oprswt

the folowng

Radiographiiae of princlustingconss sectrioyne showing normale woaithothenclusowng:a h ufc.(noceata ~*

ASTM-E18FIG 4 rd

SHRINKAGE -(DENDRITIC)

A'4w

RADIOGRAPHIC IMAGE OF DENDRITtC SHRINKAGE IN CAST STEEL2 INCHES THICK.

EVALUATION INCLUDED IN FIG, 5B.

Fig, 5A

EVALUATION OF FIG. 5ASeverity level of the shrinkage shown In Fig. 5A compares with the following:

ASTM-E--446 - Type CA - Grade 3ASTM.-E-186 - Type I - Grade 3MIL-R-11469 - Type B - Std 2

- I Macrograph of casting cross section AA, shown in Fig 5A, revealing severityand location of the shrinkagoi condition. (unetched, actual size)

EVALUATION OF DENDRITIC SHRINKAGE IN CAST STEEL 2 INCHES THICK

Fig. 5B

Fig. 6A

EVALUATION OF FIG. 6A

Severity level of shrinkage shown in Fig. 6A compares with the following:

SECT AA ASTM-E-446 - Fails to meet any gradeSEC AA ASTM-E-186 - Not applicable, too thin

CAVITY MIL-R-11469 - Std. 5 Ouge as gas)

SECTBB CCASTM-E-446 - Type CA - grade 3SEC BB& C ?ASTM-E-186 Not applicable, too thin

DENDRITICMIL-R-11469 -Type C - Std. 2

SECTION AA

fSECTION BB SECTION-CC

Marcographs of casting cross sections, shown in Fig 6A, revealing severity andand location of shrinkage conditioni. (unietched, actual size)

EVALUATION OF INTERNAL SHRINKAGE IN CAST STEEL

AL Fig. 6812

'44

RADIOGRAPHIC IMAGE OF DENDRITIC SHRINKAGE IN CAST STEEL13/ INCHES THICK. EVALUATION IS SHOWN IN FIG. 7B.

Fig. 7A

S 1...13

EVALUATION OF FIG. 7A

Severity level of shrinkage shown in Fig. 7A compares with the following:

ASTM-E---46 - Type CB - Grade 5- ASTM-E-186 - Not applicable, too thin

MIL-R--11469 - Type C -Std. 3

Macrograph of casting cross section - AA, shown In Fig 7A, revealing severityj ~ and location of the shrinkage condition. (unetchod, actual size)

EVALUATION OF DENDRITIC SHRINKAGE IN CAST STEEL13/ INCHES THICK.

Fig. 47B

7' -~ ___

Aý

ASM E18 ye t. 4r~

M I:: 169 Tp -SdFig 8A

k,

Fig. 8B

,t A

, i pmmqm

I VA

RADIOGRAPHIC IMAGE OF DENDRITIC SHRINKAGE I N CAST STEEL

2 INCHES THICK. EVALUATION SHOWN IN FIG. 9B.

Fig. 9A

17i

EVALUATION OF FIG. 9ASeverity level of shrinkage shown in Fig. 9A compares with the following:

ASTM-E-446 - Exceeds Grade CB-5IASTM-E-186 - T~ype 2 - Grade 5MIL-R-11469 - Type C - Std. 4

L24 *4.

*A

SETO ASCIO BSCINC

Macrogvaphr,~~~~~~~~~~*t* ofcsigcosscios hw nFg Arvaigsvrt

and ocaton o shrnkag conitio. (uetchd, a tua:ieFig 9

'AA

Radiographic image of sponge shrinkage in 1%" steel. Severity level showncompares with the following7

ASTM-E-446 - Type CC, Grade 4ASTM-E-186 - Not applicable, too thinMIL-R--11469 - Type D - Std. 3

Macrograph ofcasting cross section-AA showing severity and location ofshrikagecondition. (unetched, actual size)

EVALUATION OF SPONGE SHRINKAGE IN CAST STEEL 11/ INCHES THICK.

Fig. 10

I ~IV'1 ; ° 4 " °

4.4

: r , -1

RADIOGRAPHIC IMAGE OF SPONGE SHRINKAGE IN CAST STEEL 11/2 INCHESTHICK. EVALUATION INCLUDED IN FIG. 11B.

Fig. 11AI;s

I EVALUATION OF FIG. 11ASeverity level of the shrinkage shown in Fig. I A compares with the following.ASTM-E-446 - Type CC -Grade 5

t ~ASTM-E-186 - Not applicable, too thinMIL-R-11469 - Type D - Std. 3

Macrograph of casting cross section AA, shown In Fig. I1 A, revealing severityand location of the shritikage condition. (unetched, actual size)

EVALUATION OF SPONGE SHRINKAGE IN CAST STEEL 1½ INCHES TFCK.

Fig. 11iB

II

tt

Radim ahefa3 hot tears in aoesb t r te ' tik(adiation wa oeprle ihtetangl Se ve200)

evaluation shown In Fig. 12B.

Fig. 12A

EVALUATION OF FIG. 12A

Severity level of the tear shown In Fig. 12A compares with the following.

ASTM-E-446 - Not applicable, too thickASTM-E-186 - Level 4MIL-R-11469 - Std. 4

1-4 '6

Macrograph of casting crors section AA, shown in Fig. 12A, revealing sevierityand location of the tear. (unetched, actual sizce)

EVALUATION OF HOT TEAR IN CAST STEEL 21/ INCHES TH!CK.

Fig. 12B

23WEI

Radiograph of a 5" hot tear in cast steel 216 Inches thick. Severity level isas follows:

ASTM-E-446 - Not applicable, too thickASTM-E-186 - Level 5MIL-R--11468 - Std. 5

EVALUATION OF HOT TEAR IN CAST STEEL 21,' INCHES THICK.

Fig. 13A

-nil

'..2

Macrograph of casting section AA shown in Fig. 13A, revealing cross sectionalextent of the tear. (unetched, actual size)

EVALUATION OF HOT TEAR IN CAST STEEL 21/2 INCHES THICK.

Fig. 13B

425

ALUMINUM CASTING FLAWS

This edition of the report is updated to includa 22 figures-actual photographs- of the various alumlnum casting flaws understudy. The pictures will permit engineers and technicians togot a realistic perceptiou for material integrity and flawclassification in these thickness ranges of aluminum.

26

GAS HOLES

Actual Size Rdiogrph - Material Thiclmess 5/16"Meets 3td. 4 of ASTN 19-155

4 hMscmgraph ot Cross Seotlon AA Exposing the Flaw1 A~l Nagiftoatlon- UAetahed

UVALUATION OP OAS li(,&3 IN CAST ALUNMINJ

Fgur IA

GAS HOLES

Actual Size Radiograph M ater'ial Thickniess 5/16"Meets Std. 7 or ASTM E-155

Macrograph of Cross Section AA Exposing the FlawUX MAgnificatiort- Vkietched

EVALUATION 0F OAS NOWE IN CAST1 ALWIInm3

- i GAS POROSITY-ROUND

"* -r . ....,, *

Actual Sit* Radiograph - Material Thickness 1/4&"Nets Std. 9 ot ASTH B-15

Nicz o-Radloaraph of a .025" Thick Specimen Adjacentto Cross Section AA Shoving a Single Laer View of thePorous Condition at lOX Magnification.

'VALUATION OF GA uau PORtD'Wi -wOVOi I1N CAS ALrUnaW_

ftguro 2A

GAS POROSITY - ROUND

Macrograph of Cross Section AA (Fig.2A)Showirig

StdI. 2 Porosity at 4X Magnification. Unetched

Micrograph or Cross Sovotion AA (Fig.2A) Showing thePorous Condition at 10OX Magnification - Kellers Etch.

IVALUATION OF OAS POROSITY-ROUND fIN CAST ALUMINUM

II Figure 2B

GAS POROSITY - ROUND

Actual Size Radiograph - Material Thickness 3/8"Meets St. 4 of ASTM E-155

Micoro-Radiograph of a .025" Thick Specimen Adjacent toCross Seotion)AA Showing a Single Layer View of the PorousCondition at lOX Magnification.

EVALUATION OF GAS POROSITY-ROUND IN CAST ALUMIM

Figure 3A

GAS POROSITY -ROUND

4

H acrograph of Cross Section AA (Fig.3A) Showing Std.4Porosity at 4IX Magnif'ication - Urietched.

lipJe~

Micrograph of Cross Section AA (Fig.3A) Showing thePorous Condition at 10OX Magnification - Kellers Etch.

EVALUATION OF GAS POROSITY-ROUND IN CAST ALUMINUM

KIM Figure 3B

GAS POROSITY- ROUND

Actual Size Radiograph- Material Thickniess 1/4"

U Av

IJ.

Micro-Radiograph of a .025" Thick Specimen Adjacent toCross Section AA Showin~g a Single Layer View or the PorousCondition at lox Magnif'icationi.

EVALUTION OF GAS POROSITY-.ROUND IN CAST ALUMINUM

Figure 4A

GAS POROSITY - ROUND 'toI

aI 0 A.,

Macrograph of' Cross Section AA (Fig.4A) ShowingStd.6 Porosity at 4X Magnification -Unetched

100

4 4

'A#

Micrograph of' Cross Section AA (Fig.l4A) Showingthe Porous Condition at 10OX Ma~gnification-Kellers Etch.

EVALUATION )F GAS POROSITY-ROUND IN CAST ALUMINUM

Figure 4B

I] GAS POROSITY - LONGATED

IJI

7:kicro-Hadiograph of a .027" Thick Specimen Adjacentto Cro e Sctioan AA Showing a Single Layrer View of the Porous

CritoZ nat loX Magnification.L

VALUATIONM OPGS0NM1NATDI ATAUD

Figure 5A

GAS POROSITY - ELONGATED

44~

; A

Micrograph of Cross Section AA (Fig.5A) Showingth

Porous Condition at 10OX Magnirication-Kellers Etch,

EVALUATION OF GAS POROSITY-ELONGATED IN CAST ALUMINUM

Figure 5B

GAS POROSITY - ELONGATED

'04 v A 'II'e ,'

f jI ~

Actual Size Radiograph -Material Thickness 1/2"Meets Std.6 of' ASTM E-155

.13

*1v

Micro-Radiograph of' a .020" Thick Specimen Adjacentto Cross Section AA Showing a Single Layer View of' thePorous Condition at lOX Magnification.

EVALUATI0tT OF' GAS POROSITY-ELONOATED IN CAST ALUM4INUM

Figure 6A -

GAS POROSITY -ELONGATED

~ AA

Micrograph of Cross Section AA (Fig.6A) Showingth

Porous Condition at ).OOX Magnification-Kellers E~tch.

EVALUATION OF GAS POROSITY-ELoONGATED IN ChST ALUM4INUM'

Figure 6B

.- L

GRAIN BOUNDARY SHRINKAGE

Actual Size Radiograph -Material Thicknelss 3/8"This Condition is not included in ASTM E-15 It

Appears Similar to, and Compares with Std.4 of Gas Pqr-ooity-Elongated.

Micro-Radiograph of a .030"1 Thick Specimen AdjacentIt to Cross Section AA Showing a Single Layer View or the

Shrinkage Condition at lOX Magnification.

EVALUJATION OF GRAIN BOUNDARY SHRINKAGE XIN HIGHSTRENGTH CAST ALUMNUM0LIII Figure 7A

GRAIN BOUNDARY SHRINKAGE

9 7.

Maorograph of Cross Section AA (Fig.A). No

Evidence of the Shrink Condition Is Visible at 4X

Magitfioation Unetched.

4I• -X, • 9 ,, . . :• )A \th., P , 9 I• ,, '. .

AN~

Micrograph of Cross Section AA (FIS.7A) Shoving the

Shrink Condition at lOOX Magnification - Keller. Etch.

EVALUATION 01 GRtAIN BOUNDARY SHIRINKAGE IN HIGH

STdRDIUfl CAST ALUMNDUM.

•~ ~ ~ ~ ~ Fgr 7kk B '• ."•,''•''& :.

SHRINKAGE - CAVITY

Aotual Site Radiograph - Material Thickneass 1/4"Meeto Std.3 of ASTM E-155

Maorograph of Cross Section AA Exposing the Flaw-4X agni•i•cation - Unetohed. Small Pores are Gas Porosity.

EVALUATION JP CAVITY TYPE SHRINKAOE IN CAST ALUMINUI

Figure 8

SHRINKAGE - CAVITY

Actual Size Rtadiograph -Material Thickness 1/4"

Meets Std.? or ASTI4 E-155

Kt

M4acrograph or Cross Section AA Exposing the Flaw- 4iX

Msgnif Ioation - Unetohel. Small Pores are Gas Porosity.

FLi~ EVALUATION OF CAVITY TYPE SHRINKAGE IN CAST ALUMNDM

SHRINKAGE SPONGE

Actual Size Radiograph -Material Thickness 7/811Meets Std.L4 of ASTM E-155

Micro-Radiograph of a .023" Thick Specimen Adjacentto Cross Section AA Showing a Single Layer View of theShrinkage Condition at lox Magnification.

EVALUATION OF SPONGE SHRINKAGE IN CAST ALUMINUM

Figure 10A

SHRINKAGE - SPONGE

Macrograph of Cross Section AA (Fig.lOA) ShowingStd. 4~ Shrinkage at 4X Magnification - Unetched.

A

Micrograph of Cross Section AA (Fig.1oA) Showing theShrinkage Condition at iQOX Magnification - Kellere Etch.

6 EVALUATION OF SPONGE SHRINKAGE IN CAST ALUMINUM

Figure 1OB

SHRINKAGE SPONGE

Actual Size Radiograph - MaeilTicnI /6Meete Std.7' of ASTM E-155

Micro-Radiograph of a .025"1 Thick Specimen

Adjacent to Cr085 Section AA Showing a Single

Layer View or the Shrinkise Condition at IOX

Ma~gnif'icationl.

EVALUATION OF' SPONGE SMU~NMEQ IN CAST ALUMINUM

Figure 11A

SHRINKAGE -SPONGE

,, I- .

IMacrograph of Cross Section AA (Fig.11A) ShowingStd. 7 Shrinklage at 4IX Plagniiication -Unetched.

g,<

Miorograph or Cross Seation AA (Plg.12A) Showing theShrinkage Con4ition at 1001 MAignirloation - Kellers Etch.

EVALUATION OF SPONGE SHRInKAG IN CAST ALUMINUm

Figure 11B

FOREIGN MATERIAL -LESS DENSE

Actual Size Radiograph - Material Thickniess 5/16"1Meets Std. 7 of ASTM E-155"

Macrograph of Cr080 Section AA Exposing the Flaw44X Magnification -Unetched

Macrograph of Cross Section BB Exposing the Flaw4X Magnification - Unetched

EVALUATION OF FOREIGN MATERIAL IN CKhST ALUMINUM

Figure 12

-. ---- - ---

FOREIGN MATERIAL- LESS DENSE

I ~Actual Size Radiopraph - Mlaterial Thickn~ess /8Mleets Std. 8 or ANNK 3-155

Ab1

*V4

vik

'I crZogwe~a% of Cross Section~ AA Uposing the Piew*2 agnitlation - nbetched

NVALUAION OF FORIZON KATNUALI IN CAST ALtNMZ1KL

NO. OFAUDRESSEE COPIES

CommanderV U. S. Arpiy Arawumnt Copw~nd

ATTN: DRSAR-Q, Mr. J. Obren1I)RSAP.-QAE, Mr. D. Spears1DRSAR-PPW..IR, Mr. 9t 44e1

Rock Islands IL 01201CommanderRock Island ArsenalATTN: SARRI-R, Mr. W. Kisnor1

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Watervliet, NY 12189

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Dover. NJ 07801

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SARFA-K3300, Mr. 6. NorwitzI ~SARFA-K-4000, Mr. It. SokolQwski 1SARFA-QAA-Qj Kr. I. 64rr

Philadelphia, PA 1131

CommanderEdgewood ArsenalATTN: Mr. W. E. Montanary, C., Prograp Division 1L i ~SAREA-PAT!4, Dr. W. J. Maurits1Aberdeen Proving (iroun4w MP 21Q05

49

wp,.

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DRXDO-EDE, Mr. Benjamin F. Willis 12800 Powder Hill RoadAdelphi, MD 20783

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DRSAV-LE, Mr. J. T. Conroy IP. 0. Box 209St. Louis, MO 63166

ComawnderU.S. Army Test & Evaluation CommandATTN: DRSTE-TA.- _

URSTE-TO-P, Mr. A. Baldridge1ORSTE-ME, Mr. S. Wise

Aberdeen Proving Ground, MD 21005

50

NO. OFADDRESSEE COPIES

CummanderAberdeen Proving GroundATTN: STEAP-MT-M 1

STEAP-NT-G, Mr. R. L. Huddlestoi 1Aberdeen Proving Ground, Ij 21005

CommanderDugway Proving GroundATTN: STEDP-PCOugway, UT 84622

CommanderJefferson Proving Ground

ATTN: STEJP-TDMadison, IN 47250Commander

U.S. Army Tropic Test CenterATTN: STETC-TD-T, DraWer $42Fort Clayton, CZ

CommanderU.S. Army White Sands Missile 4"ATTN: STEWS-TE-PMWhite Sands Missile RAnge, NN MW

CommanderYuma Proving GroundATTN: STEYP-HP, Mr. tuiYuma, AZ 85364

CommanderU.S. Army Troop Support CommasdATTN: DRSTS-Q4300 Goodfellow BoulevardSt. Louis, MO 63120

CommanderU.S. Army Mobility Equipmtnt Research, A•Nlv1ol% ,t COuuundATTN: DRXFB-QA, Mr. J. K. Mauzy 1

DRXFt-E4, Mr. S. Levlw 1DRXFO-RI4, Mri. E. Vork 1

Fort Belvoir, VA 22060

,'; ComunanderU.S. Army Natick R&D Comand

', )ATTNi: DiRXNH-EM, Mr. S. Werkomki 1DRXNt4-GE, Mr. 14. Budnick

Kansas StreetiNatick, 14A 01762 5

NO. OFADDRESSEE COPIES

O irectorArmy Materials and Mechanics Research CenterATTH: DRX04R-CT 1

DRXMR-1I, Mr. G. A. Darcy 1DRXI41-RA, Mr. F. Valente 1DRXMR-EM, Mr. T. UeSisto 1DRXMR-X, Dr. E. S. Wright 1ORXMR-PP, 14r. J. O'Connor 1

Mr. M. Cheney 1Watertown, MA 02172

P14, Selected AmmunitlonPicatinny ArsenalDover, NJ 07801

P14, Aircraft Survivability EquipmentU.S. Arny Aviation Systems CommandSt. Louis, MO 63166

PM, CH-47 Modernization ProgramU.S. Army Aviation Systems CommandSt. Louis, MO 63166 1

PH, COBRAU.S. Army Aviation Systems CommndSt. Louis, MO 63166 1

PM, Iranian Aircraft ProgramU.S. Army Aviation Systems CommandSt. Louis, MO 63166

PM, Heavy Lift HelicopterU.S. ArnLy Aviation Systems ConmandSt. Louis, MO 63166

PM, Army Tactical Conmmunications SystemsU.S. Army Electronics CommandFt. Monmouth, NJ 07703

P14, Anrmy Tactical Data SystemsU.S. Army Electronics CommandFt. Monmouth, NJ 07703

PM, Mortar/Artillery Locating RadarsU.S. Army Electronics CommandFt. Monmouth, NJ 07703

•u L: 52

O. OF'AIJURESSEE COPIES

PM, Multi-Service Comunications Systems.U.S. Amy Electronics CowandFt. Monmouth. NJ 07703

PH, Navigation Control SystemsU.S. Army Electronics ComnandBuilding 2525Ft. Monmouth, NJ 077031

PM, Remotely Monitored Battlefield Sensor SystemU.S. Army Electronics CommandFt. Ionmouth, NJ 07703

P14, DragonU.S. Army Hissile ConuuandRedstone Arsenal, AL 35809

PM, HawkU.S. Army Missile CommandRedstone Arsenal, AL 35809

PM, HELLFIRE Missile SystemU.S. Army Missile CommandRedstone Arsenal, AL 35809

PM, LANCEU.S. Army Missile CrnandRedstone Arsenal, AL 35809

P14, PershingU.S. Army Missile CommandRedstone Arsenal, AL 35809

PM, Precision Laser UesignatorsU.S. Army Missile CommandRedstone Arsenal, AL 35809

PH, 2.75" Rocket SystemU.S. Army Missile ComandRedstone Arsencl, AL 358•9

P1t, TOWU.S. Army Missile CoimmandRedstone Arsenal, AL 35809

53

NO. OFADDRESSEE COP I S

Wi~. 1-1/4 Ton Commercial Truck SystemsU.S Army Tank-Automotive Materiel Readiness ComandM4MP, Bldg. 2Warren, Michigan 48090

P14, FANECCFt. Belvoir, VA 22060

PH,, Heavy Equipment TransporterU.S. Army Tank-Automotive Material Rediness CommndWarren, Michigan 48090

P14, 1460 Tank Development28150 DequindreWarren, MI 48092 1

P(4, Advanced Attack HelicopterU.S. AriLy Aviation SystemsCwSt. Louts, 140 63166 1

P4, Hechanized Infantry Combat VehicleU.S. Amy Tank-Automtive Materiel Rediness Command28150 DequindreWarren, NI 48092 1

PM4, Mobile Electric Power7500 Backlick RoadSpringfield, VA 22150 1

P14, Munitions Production BaseModernization and ExpansionPicatinny ArsenaliiDover, NJ 078011

P14, PATRIOTU.S. Amy Missile CommnndRedstone Arsenal, AL 35809

P4, Satellite CommunicationsFt. Monmouth, NJ 07703

t PM, SANGATTN: AMCPM-NG 1

f 5001 Eisenhower AvenueAlexandria, VA 22333 1

PM, Training DevicesNaval Training Equipment CenterOrlando, FL 32813 1

54

I NO. OF

ADDRESSEE COPIES

PF, Utility Tactical Transport Aircreft SysteU.S. Army Aviation Systems CmaundSt. Louis, NO 63166 1

Rio, X-l Tank System28150 DequindreW4rren. t41 48092 1

P14, StingerU.S. Army Missile CommandRedstone Arsenal, AL 35809

P$PRt Advanced Scout HelicopterU.S. Amy Aviation Syste.s a mlSt. Louis. 140 63166

F't, Special Electronic I4issiom Ainrtft (S3NA) btmwielRsdinessU.S. Army Aviaition Systems Coss4dSt. Louise M0 631661

P14, Single Channel Ground and Atrjibuw !.do $mAdseU.S. Army Electronics ComWFt. Monmouth, NJ 07703IN. Signal Intelligence/Dectmatic 1kWfat" (S|GIRT/1W)

Materiel ReadinessU.S. Army Electronics ComandFt. Monmouth, NJ 07703

P1, High Energy Laser SystemU.S. Army Missile CommandRedstone Arsenals AL 35809 I

P1. KUWAITU.S. Amy Missile ComandRedstone Arsenal, AL 35809 1

P4, US ROLANDU.S. Army Missile Co mmand

Redstone Arsenal, AL 35809

P14, VIPERU.S. Army hissile CommandRadstonte Ar al, AL 35809

"55

NO. OFADDRESSEE COPIES

P14, Istproved TOW Vehicle (ITV)U.S. Army Tank-Automotive RID.CommandWavrren, MI 48090

PH, 1460 Tank Production28150 DequindreWarren, HI 48092 1

PH. Amphibians and WatercraftU.S. Amy Troop Support Command5300 Goodfellow BoulevardSt. Louis, MO 63120

PH, Army Container Oriented Distribution SystemU.S. Army Material Development & Readiness Command5001 Eisenhower AvenueAlexandria, VA 22333 1

P14, Chemical Demilitarization and Installation RestorationAberdeen Proving Ground, 140 21010 1

PH, DCS (Army) Communications SystemsFt. Monmouth, NJ '07703

PH, Nuclear MunitionsPicatinny ArsenalDover, NJ 07801 1

P14, Automatic Test Support SystemsU.S. Artay Electronic CommandFt. Monmouth, NJ 07703 1

PH, FIREFINDERU.S. Army Electronics CosmandFt. Monmouth, NJ 07703

PM, H113/H113Al Fatmly c Vehicle ReadinessU.S. Army Tank-Automotive Materiel Readiness ConinandMAMP, Bldg. 2Warren, NI 48090 1

PM, SMOKEAberdeen Proving Ground, N4 21005 1

PH, Army Gun Air Defense SystemsU.S. Army Armaent CommandRock Island, IL 61201 1

j 56

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NO. OF

ADDRESSEE COPIES

PH, Cannon Artillery Wapons SystemsPicatinny ArsenalDover, NJ 07801 1

P14. HIlOE2 8" HowitzerU.S. Army Armament ComandRock Island, IL 61201 1

PH* Safeguard MunitionsPicatinny ArsenalDover, NJ 07801

Defense Documentation CenterATTN: DIC-TC 12Cameron Station5010 Duke StreetAlexandria, VA 22314

SECURITY CLASSIFICATIOWi OF TRHI PACE (Whom Doda Xntev,.VREPORT DOCUMENTATION PAGE READ INSTRUCTIONS

1_EFORE COMPLETING FORM

m7REPORU MUMNER ."OVT ACCELSSION NO. 3• RE1CIPINT'S CATALOG NUMkERV p

122564. TITLE fd WaMbdItJ S. TYPK Oa REPORT a PERIOD COVKRED

Developmnt of (PUalit' Assurance Training Hanuolto Assist in Estblishing Soundness Rquiremmt _

for Aluminum and'Steel Castinis 6,. PERFoMINo ORG.-IPORT NU+,,k

7.AUTHOR(@) S.CONTRACT 0R MUM1119(a

Walter F. Wulf and Melvin V. PhytilaSalvatore B. Catalano and Don Natichuk

9. PERFORMING ORGANIATION NAME AND AODRESSII I6PROGRAM EI•MCHT, PROJKCT, TASK

U.S. Army T~nk-Automotive Research & Development AREA A WORK UNIT NUMiERS

CommandWarren, Michigan 48090

It. CONTROLLING OFFICE NAME AND ADDRESS It. R"PORr DATEAugust 1978

"I&, NUM9, OE PAGES59-14. iONITORING AGtNCY NAME A AOORiKS(I/ @UI(eorent fiom Ccfla~in.g OluIf7 ile .IC EURITY CLAii. (oef thts'

7epoo

UnclassifiedSCHEDULE

111t DISTRIBUTION STATEMENT (of iAla X"p•4

kpp~rer)"d i>'nr r~b"Wl rolcauo;di•utributi on un-Lmitad.

17. DISTRINUTION STATEMENT (ei Ohs abtractl oIareo4 In 01#0g 20. IO 0li0jjI Ite Repeot)

4 I 14. SUPPLEMENTARY NOTES

:Is. KEY WORDS (Ce"Obwh an feovor side If RaeSvllJ• OW Ideity& 6 by "AWh u6j)

30. AWITMACI (Ca.,Iiau an, reverse did@ It "69..awr and IdaleItfy by 6104A mm&.")Samples of aluminum and steel casting flaws most comonly experienced in

production were selected to be radiographed in order to develop quantitativeand descriptive picture images of various radiographic reference standards.Graphic illustrations of flaw size and flaw distribution for various radio-graphic reference standards were depicted by using radiographs and associatedcross-sectional photo-mcrographs. These graphic illustrations of radiographiclevels of acceptance will provide meaningful design criteria for establishing

-(continued on reverse)"DD F 1473 EDITION OF INOV e6il ObSOLEtE UNCLASSIFIED

58 1ECURITY CLASSIIFICATION OF THIS PAGE (Whom Vale Kn1o.0)

Izoo M�y.�L(cos�Istasd)

v.alIs�1c stap�ar4s of accept�snp for �sterial applications, Thisreport also fv�n1shp operatiqmal gut .��ual1ty as tanc� andrbdtgre�h1c persemasi in their normal on-the-,�ob duties.

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