TECHNICAL DELIVERY CONDITION QA

OPEN DIE FORGING OF SPINDLE

1.0 Objective:

1.1. To obtain the good quality products by giving our requirements through the
technical data and standards

2.0 Scope:

  2.1. s.

3.0 Manufacturing method:

3.1 Open die forging of spindle at the temperature of 850°Celsius followed by the
heat treatment process (normalising or annealing) and then the material is need to
carburised at °Celsius followed by heat treatment (annealing or hardening) and machined
as final product.

4.0 Standards need to follow:

 ASTM A 388


5.0 Requirements:

5.1 Material: EN 353

5.2 Composition:

Element Wt %
C 0.2 max
Si 0.35 max
Mn 0.5-1.0
P 0.05 max
S 0.05 max
Ni 1.0-1.5
Cr 0.75-1.25
Mo 0.08-0.10

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5.3. Micro structure:

5.4. Hardness : 164-187 HBW

5.5. Non- destructive testing: Ultrasonic testing

5.5.1 Testing standard: ASTM A 388

5.5.2 Couplant : Water
5.5.3 Acceptance level 3 mm FBH
5.6 Visual inspection

5.6.1 Testing standard:

5.6.2 Acceptance level 3 mm FBH

5.7 Dimension inspection

5.7

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6. Slag inclusions.

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7. Sand drops.

8. Scab

9. Flashes 9. Rat tail

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10. Shrinkage 10. Shrinkage

11. Misrun

12. Cold shut 12. Cold shut

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13. Mismatch

14. Core shift.

15. Swell

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16. Surface roughness

17. Metal stripping

18. Distortion and Warpage

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WELD REPAIRING DEFECTS IN CASTINGS :

Weld cracks:

Cold crack (or) HIC

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In the casting bed, the following areas are the functional areas (also mentioned in
the figure).

i. Head stock,
ii. Tail stock mounting area
iii. Guide ways
iv. Lifting pads area
v. Bed lifting area
vi. Foundation pads

 Other areas are referred as Non-functional areas.

GUIDEWAYS
HEAD STOCK

TAILSTOCK MOUNTING AREA

LIFTING
PADS
AREA

FOUNDATION PADS

BED LIFTING AREA (FORKLIFT)

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VISUAL INSPECTION STANDARDS:

SURFACE TEXTURE - A1 SURFACE TEXTURE - A2

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SURFACE TEXTURE - A3 SURFACE TEXTURE - A4

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NON-METALLIC INCLUSIONS - B1 NON-METALLIC INCLUSIONS - B2

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NON-METALLIC INCLUSIONS - B3 NON-METALLIC INCLUSIONS - B4

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GAS POROSITY - C1 GAS POROSITY - C2

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GAS POROSITY - C3 GAS POROSITY - C4

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FUSION DISCONTINUITIES - D1 FUSION DISCONTINUITIES - D2

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FUSION DISCONTINUITIES - D5

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EXPANSION DISCONTINUITIES - E3 EXPANSION DISCONTINUITIES - E5

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INSERTS - F1 INSERTS - F3

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METAL REMOVAL MARKS - THERMAL METAL REMOVAL MARKS - THERMAL

DRESSING - G1 DRESSING - G2

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METAL REMOVAL MARKS (THERMAL METAL REMOVAL MARKS (THERMAL

DRESSING) - G3 DRESSING) - G5

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METAL REMOVAL MARKS (MECHANICAL METAL REMOVAL MARKS (MECHANICAL

DRESSING) - H1 DRESSING) - H3

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METAL REMOVAL MARKS (MECHANICAL METAL REMOVAL MARKS (MECHANICAL

DRESSING) - H4 DRESSING) - H5

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METAL REMOVAL MARKS (WELDS) - J1 METAL REMOVAL MARKS (WELDS) - J2

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METAL REMOVAL MARKS (WELDS) - J3 METAL REMOVAL MARKS (WELDS) - J5

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VISUAL INSPECTION STANDARDS:

SURFACE FEATURES LEVEL I LEVEL II LEVEL III LEVEL IV

Surface Texture A1 A2 A3 A4

Mon-metallic Inclusions B1 B2 B4 B5

Gas Porosity C1 C2 C3 C4

Fusion Discontinuities - D1 D2 D5

Expansion Discontinuities - - E3 E5

Inserts - - F1 F3

Metal Removal Marks

G1 G2 G3 G5
(Thermal Dressing)

Metal Removal Marks

H1 H3 H4 H5
(Mechanical Dressing)

Metal Removal Marks

J1 J2 J3 J5
(Welds)

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VISUAL INSPECTION STANDARDS:

A. Surface Texture - The natural surface of the casting after shot blasting and grinding.

B. Non-Metallic Inclusions - Non-metallic material trapped on the surface of castings.

C. Gas Porosity - Indications of gas holes on the casting surface.

D. Fusion Discontinuities - Surface irregularities giving a wrinkled appearance.

E. Expansion Discontinuities - Slightly raised surface irregularities.

F. Inserts - Indications of chaplets (sand core supports) or internal chills.

G. Metal Removal Marks (Thermal Dressing) - Surface remaining after using oxy-gas or
air- carbon arc processes for metal removal.

H. Metal Removal Marks (Mechanical Dressing) - Surface remaining after using a

mechanical means of dressing a cast surface or a previously thermally dressed surface.

J. Metal Removal Marks (Welds) - Indications of welds fully or partially removed by

thermal or mechanical dressing.

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NORMAL AND LOWER

HIGH SOUNDNESS AREA -
SOUNDNESS AREA -
TYPE ANOMALY NAME MACHINED AND AS-CAST
MACHINED SURFACES
SURFACES
ONLY

3.17mm diameter &

1.52mm diameter & 0.762mm
1.52mm deep, 12 holes
deep, 12 holes total, 3 holes
total, 3 holes on any 1
on any 100mm area
square mm areas.

I
GAS (BLOW HOLES) Any holes below
& 1.53mm diameter are
& Any holes below 0.762mm
ANOMALIES RESULTING
II not to be included in
FROM SAND AND SLAG diameter are not to be
the 12.
included in the 12 on as-cast
Depth in excess of 25%
surfaces
of section are
unsalvageable
No repairs allowed Repairs allowed
193 square mm area, 645 square mm area,
1.52mm deep, 3 per area 3.178 mm deep, 3
allowed, 50.8mm apart areas allowed, 50mm
minimum apart minimum
III SHRINKAGE
Any hole below 0.77mm Depth in excess of 25%
diameter is not to be included of section are
in the 12 on as-cast surfaces unsalvageable
No repairs allowed Repairs allowed

HOT TEAR CRACKS, COLD No indications or No indications or

IV
SHUT, CORE FIN VOIDS repairs allowed repairs allowed

1. Repairs in lower soundness areas allowed with approval of the Plant Quality Function
2. Centreline shrink or porosity in the gating area is allowed with approval of the Plant
Quality Function

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NDT TECHNIQUE – LIQUID PENETRANT TESTING:

Merits compared with visual inspection:

 Information about minute flaws are possible.

 Deep and narrow flaw can be inspected.

 Suitable for all type of surface flaws.

 Not much expensive (cheapest NDT technique).

Acceptance criterian
 Rounded Surface Flaw size less than 1.6 mm are accepted

 Linear flaw size less than 3 times of its smallest dimension are
accepted.

 More than 10 indications in 6 in² are unaccepted.

 Two indications placed apart with in 1.6 mm unaccepted.

 Rounded indications with max dimension in any one side

more than 4.8 mm are unaccepted
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Microstructural acceptance features of Grey iron casting:

Forms of graphite flakes according to the ISO 945

1. FORM A - uniform distribution, random orientation

2. FORM B - rosette grouping, random orientation
3. FORM C - super imposed flake size, random orientation
4. FORM D - interdendritic segregation, random orientation
5. FORM E - interdendritic segregation, preferred orientation

FORM A only acceptable

The microstructure should have 80%of form A and not more than 20% of the other forms of
graphite (B,C,D,E)

Following micrographs are showing the various forms of graphite,

FORMS:

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B C

D E

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DISTRIBUTION:

1 2

3 4

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5 6

7 8

Recommendation :

 Ideal graphite flake distribution should be 4 – 5.

 High distribution number increases brittleness.

 Low distribution number decreases hardness and strength.

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COMPOSITION OF GREY IRON BY ASTM A 834 :

Element Weight Percent

Total carbon 3.2 -3.5
Silicon 1.9 – 2.3
Manganese 0.6 – 0.9
Phosphorus 0.15 max
Sulphur 0.15 max

Carbon Equivalent (app) 3.9 – 4.2

Formula for carbon equivalent, CE = %C + 1/3 % (Si + P)

GREY IRON CASTING, As per IS: 210

IS designation Compression Tensile strength(MPa) Brinell hardness

strength (MPa) (BHN)
FG 150 600 150 130 – 180
FG 200 750 200 160 – 220
FG 220 850 220 180 – 220
FG 260 900 260 180 – 230
FG 300 960 300 180 – 230
FG 350 1100 350 207 – 241
FG 400 - 400 207 - 270
Standard tensile test piece: As per ISO 210 : 2009

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Gauge Minimum Minimum Plain ends Screwed ends

diameter ‘D’ parallel radius ‘R’
D1 Lp D2 Ls
length Lc
20 55 25 23 65 25 30

All dimensions are in mm

Nature of Ferritic Pearlite austenitic martensitic Tempered

matrix martensitic
Hardness 110 - 140 160 - 220 140 - 160 350 - 450 260 - 350
(BHN)

Recommended heat treatment :

FG 150 - Normalizing and tempering
FG 260 - Full annealing
FG 350 - Partial annealing
FG 400 - Stress Relieving

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MICROSTRUCTURAL DEFECTS : (SEM image)

1) Widmansttaten graphite - due to presence of trace elements like lead ,bismuth,

antimony

2) Hydrogen Pin holes - presence of Al,Ti > 200ppm and moisture pick up

3) Nitrogen Pin holes - presence in resin, raw material and atmosphere contact

4) Slag inclusion - improper slag removal, skim bob failure.

5) Steadite structure – phosphide eutectic, P > 0.1% embrittlement occurs

1) Widmanstatten graphite structure :

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2) Hydrogen pin holes:

3) Nitrogen pin holes

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4)Slag inclusion

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5) Steadite structure

ACCEPTANCE CRITERIA FOR THE S.G IRON OR NODULAR IRON CASTINGS:

THE MICROGRAPH OF THE CASTING HAVING THE FOLLOWING SIZES OF THE

NODULES,

NODULE SIZE 3:
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 Magnification ×100, If diameter of circle = 120 mm

 Graphite size 3: 0.25 to < 0.5 mm

NODULE SIZE 4:

 Magnification ×100 ,If diameter of circle = 120 mm

 Graphite size 4: 0.12 to < 0.25 mm

NODULE SIZE 5:

 Magnification ×100, If diameter of circle = 120 mm

 Graphite size 5: 0.06 to < 0.12 mm

NODULE SIZE 6:

 Magnification ×100, If diameter of circle = 120 mm

 Graphite size 6: 0.3 to < 0.06 mm

NODULE SIZE 7:

 Magnification ×100, If diameter of circle = 120 mm

 Graphite size 7: 0.015 to < 0.03 mm

NODULE SIZE 8:

 Magnification ×100, If diameter of circle = 120 mm

 Graphite size 8: < 0.015 mm

Acceptance range :

Nodular size should be greater than size 3 by 80%

Strength & hardness increases with increase in nodular size,

Ideal nodular size for casting bed has to be 5 – 6.

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3
NODULE SIZE: 3

0.25 To <0.50 mm

Magnification ×100

If dia of circle = 120 mm

NODULE SIZE:4

0.12TO<0.25 mm

Magnification ×100

If dia of circle = 120 mm

NODULE SIZE:5

0.06 TO <0.12 mm

Magnification ×100

If dia of circle = 120 mm

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NODULE SIZE:6 6

0.03 TO <0.06 mm

Magnification ×100

If dia of circle = 120 mm

NODULE SIZE:7

0.015 TO <0.03 mm

Magnification ×100

If dia of circle = 120 mm

NODULE SIZE:8

<.015 mm

Magnification ×100

If dia of circle = 120 mm

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Composition for SG iron by ASTM A 834 :

Elements Composition

Total carbon 3.2 – 4.1

Silicon 1.8 – 3

Manganese 0.1 – 1.0

Phosphorus 0.05 max

Sulphur 0.02 max

Nodule count and Phase fraction :

 Nodular count should be greater than 150/mm² in all section less than 2”.

 Matrix shall consist of ferrite or ferrite & pearlite.

 Material shall not contain greater than 2% of carbides and steadite.

The graphite nodule count nF is determined by using the planimetric method. Nodules are particles normally
classified as form VI or V (or even form IV).

nF is the number of particles per unit surface area of the sample;

N is the number of nodules counted;

A is the magnified area;

F is the linear magnification factor.

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Different Grade of S.G IRON as per A536 - 09

Recommended Heat treatment:
Grade Tensile Hardness(BHN) Elongation(%)
strength(MPa)

800 – 2 800 245 – 335 2

700 – 2 700 225 – 305 2

600 – 3 600 190 – 270 3

500 – 7 500 170 – 230 7

450 – 10 450 160 – 210 10

400 – 15 400 130 – 180 15

400 – 18 400 130 - 180 18

400 – 18 Grade - Full Ferritizing annealing

800 – 2 Grade - Quenching and tempering

600 – 3 Grade - Normalizing and tempering

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NDT INSPECTION:

ULTRASONIC TESTING OF CASTING BEDS:

Defect free casting Defective casting

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Flaw indication of ultrasonic testing:

 Small defect echo signal in between the FWP and BWP signal
 No Indication of BWP Signal
 Both defect echo and BWP is missing.

Note : FWP – front wall peak.

BWP – back wall peak.

Maximum thickness of cast iron inspection:

Challenges for cast iron inspection by UT :

 High noise and attenution – coarser grain size

 More scattering of sound waves

Remedial measures:
 Prefer Low frequency waves

 Use lager diameter probes.

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X – ray radiography testing:

Challenges of casting bed inspection by RT(radiographic testing):

o Sharpness of the image is affected, if thickness > 9 inch.

o Complex shaped components are difficult to inspect, because of overlap

of image.

o location and depth of flaw are tedious to estimate

Remedial measures:

o Portable Film radiography technique can be used, to eliminate thickness

issues and can be used for functional parts alone.

o Gamma ray testing can also be preferred, because of shorter wavelength.

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Metallurgical Design Acceptance for Casting bed:

1. Compensate the shrinkage of the solidified molten metal by making patterns of slightly
oversize.

2. In sand casting, it is more economical and accurate if the parting line is on a flat plane.
Contoured parting lines are not economical. Further, some degree of taper, or draft is
recommended to provide to the pattern for its easy removal.

3. In sand casting, it is recommended to attach the raiser near to the heavier section. The
thinnest sections are farthest from the raiser and solidify first and then the solidification
proceeds toward the direction of raiser i.e. towards the heavier section.

4. Sharp corners in a casting design cause uneven cooling and lead to formation of hot spots in
the final cast structure. Moreover sharp corner in a casting structure acts as a stress
raiser. Rounding the corner decreases the severity of the hot spot and lessens the stress
concentration.

5. Abrupt changes in sections should be avoided. Fillets and tapers are preferable to sharp steps

6. The interior walls and sections are recommended to be 20% thinner than the outside
members to reduce the thermal and residual stresses, and metallurgical changes.

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