I

MILITARY
CASTINGS,

1.EEEE4
MIL-sTD-2175A 25 Auuust 1993 SUPERSEDING MIL-STD-2175 12 OCTOBER 19S4

STANDARD
CLASSIFICATION OF

AND INSPECTION

AREA NDTI AMSC - N/A DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

MIL-STD-2175A

FOREWORD
1. This mi1itary standard is approved for use by al1 Departments and Agencies of the Department of Defense.

2. Beneficial comments (recommendations, additions, and deletions) and any pertinent data which may be of use in improving this document should be addressed to: Commanding Officer, Naval Air Warfare Center A{rcraft Division Lakehurst, Systems Requirements Department, Code SR3, Lakehurst, NJ 08733-5100, by using the self:addressed Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter.

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MIL-STD-2175A

CONTENTS PARAGRAPH
1.

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;:1 1.2.1
1.2.2 1.3 1.3.1 1.3.2

SCOPE . . . . . . Purpose . . . . Applicabilicy . Casting methods Casting alloys Classification Classes . . . . Grades . . . .

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1 1 1 1 1 1 1 1 3 3 3 3 4 5 5 5 5 5 5 5 5 5 5 5 5 5 6 6 6 6 6 6 6 6 6 6 7 7 7 7 7 7 7 7

APPLICABLE DOCUMENTS . . . . . 2. Government documents . . . 2.1 Specifications and standards 2.1.1 Non-Government publications 2.2 Orderofprecedence . . . . 2.3 3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7

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3.8
3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22

DEFINITIONS . . . . . . . . . . . . . . . . . Alloy . . . . . . . . . . . . . . . . . . . . Casting . . . . . . . . . . . . . . . . . . . Chalet. . . . . . . . . . . . . . . . . . . Cold shut . . . . . . . . . . . . . . . . . . ~f:g;ctingagency . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . Diffraction . . . . . . . . . . . . . . . . . Discontinuity . . . . . . . . . . . . . . . . Foreign material . . . . . . . . . . . . . . Gas holes . . . . . . . . . . . . . . . . . . Gas porosity . . . . . . . . . . . . . . . . Hot tear . . . . . . . . . . . . . . . . . . Inclusions . . . . . . . . . . . . . . . . . Insert . . . . . . . . . . . . . . . . . . . Misruns . . . . . . . . . . . . . . . . . . . Penetrameter or image quality indlcater (IQI) Radiographic quality level . . . . . . . . . Segregation . . . . . . . . . . . . . . . . . Shrinkage . . . . . . . . . . . . . . . . . . . Shrinkage cavity Surface irregularities; I I u : : : n I u v u Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4. GENERAL REQUIREMENTS 4.1 Personnel qualificati~n. 1 : I 1 I R 4.2 Inspection sequence . . . . . . . . 4.3 Discontinuity removal . . . . . . . 4.4 Classification of castings . . . . 4.4.1 Determination of classes and grades 4.4.2 Class 1 casting requirements . . . 4.5 Inspection lot . . . . . . . . . .

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MIL-STD-2175A

CONTENTS PARAGRAPH
. . . . . . DETAIL REQUIREMENTS . . . . . . . . . . . . . 5. . . . . . . Outline of inspections . . . . . . . . . . 5.1 . . . . . . Visual inspection . . . . . . . . . . . . . 5.1.1 ion . . . . Magnetic Darticle and 1Iquid Penetrant insPec 5.1.2 Radiograph inspection . . . . . . . . . . . . . . . . . ic 5.1.3 . . . . . . . . . . . . . . . . 5.2 Sampling Visual insp;cti&jn l:... . . . . . . . . . . . . . 5.2.1 Magnetic particle and liquid penetrant inspection . . . . 5.2.2 Radiographi inspection . . . . . . . . . . . . . . . . . c 5.2.3 Inspection methods and acceptance criteria . . . . . . . Visual inspection . . . . . . . . . . . . . . . . . . . . :::.1 5.3.1.1 Surface roughness . . . . . . . . . . . . . . . . . . . . 5.3.1.2 Gate, riser,and parting line projections . . . . . . . 5.3.1.3 Surface pits and raised metal . . . . . . . . . . . . Magnetic particle and liquid penetrant inspection . . . . 5.3.2 5.3.2.1 Inspection method for ferromagnetic materials . . . . . . 5.3.2.2 Inspection method for nonferromagneticmaterials 5.3.2.3 Magnetic particle and liquid penetrant acceptance c~i~e~i~ Radiograph inspection . . . . . . . . . . . . . . . . . ic 5.3.3 5.3.3.1 Radiographic inspectionmethod . . . . . . . . . . . . . 5.3.3.2 Radiographic reference standards . . . . . . . . . . 5.3.3.3 Radiographic acceptance cci!eria . . . . . . . . . . . Reinspection 5.4 Reinspectionofrej~c~ed io~s : 1 R I n I 1 1 n j : ; : 1 5.4.1 Individual casting rejection . . . . . . . . . . . . . . 5.4.2 . . . . . . . . .

8 8 ; 8 8 8 8 8 8 8 9 9 9 9 9 9 10 10
10 10 10 10 10 11

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6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 TABLE 1. 2. 3. 4. 5.

. . . . . . . . . . . . . . NOTES Intended ~sej I...... . . . . . . . . Issue of DoDISS . . . . . . . . . . . . . . . Data requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sampling Cross reference. 1...... . . . . . . . . Radiographic quality grades for machined areas Producibility considerations . . . . . . Observational standards ...:: . . . . . . Ultrasonic Inspectionof thick castings . . . Subject term (keyword) listing . . . . . . . Changesfrom previous issue . . . . . . . . .

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12 12 12 :: 13 13 13 13 13 14 14

Sampling, radiographic inspection of class 2 castings, and magnetic particle and liquid penetrant inspectionof class 4 castings . . Sampling, radiographic inspection of class 3 castings . . . . . . Maximum allowable gate, riser; and parting line projections . . . Maximum permissible discontinuity size and distribution (in inches) for magnetic particle (MT) and 1iquid penetrant (PT) inspection . Notes portables 6through 14. . . . . . . . . . . . . . . . . . iv

15 15 15 16 18

MIL-STO-2175A CONTENTS
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@ Maximum permissible radiographic severity levels for discontinue ties in aluminum castings per ASTM E 155. . . . . . . . . . . . . . . . Maximum permissible radiographic severity levels for discontinue ties in magnesium castings per ASTM E 155 Maximum permissible radiographic severi~y.l&~l~ ~o~ di~c&~i~u~t~es in investment steel castings 1 in. wall or less per ASTM E 192 . . Maximum permissible radiographic severity levels for discontinue ties in heavy walled steel castings 2-4.5 in. per ASTM E 186 . . . . . Maximum permissible radiographic severity levels for discontinue ties in steel castfngs up to 2 in. in thickness per ASTM E 446. . . . . Maximum permissible radiographic severity levels for discontinue ties in heavy walled 4.5 - 12 in. steel castings per ASTN E 280 . . . . Maximum permissible radiographic severity levels for discontinuitles in high-strength copper-base and nickel-copperal10Y castings up to 2in. inthickness per ASTM E272 . . . . . . . . . . . . . . . . Maximum permissible radiographic severity levels for discontinue ties in high-strength copper-base and nickel-copperalIoy castings 2-6in. inthickness per ASTME 272 . . . . . . . . . . . . . . Maximum permissible radiographic severity levels for discontinue ties in tin bronze castings up to 2 in. in thickness per ASTM E 310 . . 19 20 21 22 23 24 25 26 27

6. 7. 8. 9. 10. 11. 12.

13. 14.

APPENOIX A TEST REPORT TECHNICAL CONTENT REQUIREMENTS . . . . . . . . . . . 28

MIL-STD-2175A SCOPE

1.

1.1 Purpose. The purpose of this mllitary standard 1s to prescribe the non-destructivetesting acceptance criteria for the inspectionof metal castings that are classified (see 1.3) in accordance with this standard. 1.2 Applicability. 1.2.1 Castinq methods. This standard is intended to apply to al1 casting methods except high pressure die castings (such as the ones covered by ASTM B 85, AluminumAl10Y Die Castings). 1.2.2 Castinq Alloys. This standard applies to casting alloys that fal1 under one of the alloy families covered in tables 6 through 14 of this standard. Al10YS that do not belong to any of the al10Y families covered in tables 6 through 14 may be inspected to this standard in accordancewith 5.3.3.2. 1.3 Classification. Castings that are inspected in accordancewith this standard are classified by classes and applicable grades. The class governs the frequency of inspection (see 6.4), while the grade controls the quality of the casting. 1.3.1 Classes follows: For design information only, castings are classified as

a. Class 1. A casting, the single failure of which would endanger the -f operating personnel, or cause the loss of a missile, aircraft, or other vehicle. b. Class 2. A casting, the single failure of which would result in a -cant operational penalty. In the case of missiles, aircraft, and other vehicles, this includes loss of major components, unintentionalrelease or inabi1ity to release armament stores, or failure of weapon instal1ation components. c. Class 3. Castings not included in Class 1 or Class 2 and having a -of safety of 200 percent or less. d. Class 4. Castings not included in Class 1 or Class 2 and having a -of safety greater than 200 percent. 1.3.2 -. Castings, or sections of a casting, shall be of grades A, 8, C or D as shown in Tables 6 through 14 for radiographic requirements,and table 4 for magnetic particle and 1iquid penetrant requirements. For design informationonly, definitions for the grades are shown below: a. Grade A - The highest quality grade of casting, or area of a casting, with minimum allowable discontinue ties and very difficult to produce except in local areas.

MIL-STD-2175A b. Grade B - The second highest quality grade of casting, or area of a casting, which allows slightly more discontinue ties than grade A, and difficult to produce, except in local areas. c. Grade C - A high quality grade of casting, or area of a casting, that can be consistently produced. d. Grade D - The lowest quality grade of a casting, or area of a casting, that is easily produced and is used primarily for low stress or noncriticalareas adjacent to the higher graded areas.

MIL-STD-2 175A

2. APPLICABLE DOCUMENTS 2.1 Government documents. 2.1.1 Specificationsand standards. The following specifications and standards form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those 1isted in the issue of the Department of Defense Index of Standards and SDeclfications (0001SS) and supplement thereto, cited in the solIcitatlon ~see 6.2). SPECIFICATIONS MILITARY MIL-I-25135 STANDARDS MILITARY MIL-STD-41O NondestructiveTesting Personnel Qual and Certification Inspection, Radiographic Inspection, Liquid Penetrant cation Inspection Materials, Penetrants

MIL-STO-453 MIL-STD-6866

(Unless otherwise indicated, copies of mi1itary specificationsand standards are available from the DODSSP, Subscription Services Desk, 700 Robbins Avenue, Philadelphia, PA 19111-5094. ) 2.2 Non-Governmentpublications. The fol1owing documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of the documents which are DoD adopted are those listed in the issue of the DODISS cited in the solicitation. Unless otherwise specified, the issues of documents not listed in the DODISS are the issues of the documents cited in the solicitation (see 6.2). AMERICAN SCtIETY FOR TESTING AND MATERIALS (ASTM) ASTM E 155 ASTM E 186 Reference Radiographsfor Inspection of Aluminum and Magnesium Castings Reference Radiographsfor Heavy-wal led (2 to 4.5 in. (51 to 114 mm)) Steel Castings Reference Radiographsof Investment Steel Castings for Aerospace Applications Reference Radiographsfor High-StrengthCopper-Base and Nickel-Copper Al10Y Castings

ASTM E 192 ASTM E 272 -

MIL-STD-2175A

ASTM E 280 ASTM E 310 ASTM E 446 ASTM E 1255 ASTM E 1444-

Reference Radiographs for Heavy-wal 1ed (4.5 to 12 In. (114 to 305 mm)) Steel Castings Reference Radiographs for Tin Bronze Castings Reference Radiographs for Steel Castings Up To 2 in. (51 mm) in Thickness Radioscopic Real-Time Examination Magnetic Particle Exami nation

(Applicationfor copies should be addressed to the American Society for Testing and Materials, 1916 Race Street, Philadelphia,PA 19103-1187. ) (Non-governmentstandards and other publications are normal available 1y from the organizationsthat prepare or distribute the documents. These documents also may be avai1able in or through 1ibraries or other informational service s.) 2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedesapplicable laws and regulationsunless a specific exempt~on has been obtained.

MIL-STD-2175A 3. DEFINITIONS

3.1 ~. A metallic substance composed of two or more elements which possesses properties different from those of its constituents. 3.2 Casting. An object at or near finished shape obtained by fi11ing a mold with molten metal and allowing it to solidify. 3.3 Chaplet. Metal core support which is used in the mold cavity and which fuses into the casting. 3.4 Cold shut. An imperfect junction between two flows of metal in a mold caused by the surface of the streams of metal chl11lng too rapidly, or in effect, being chflled to the extent that fusfon does not occur. This discontinuitymay have the appearance of a crack or seam wfth snmth or rounded edges. 3.5 Contracting agency. A prfme contractor, subcontractor,or government agency procuring castfrigs. 3.6 Defect. A discontinuityor condition in a casting which exceeds allowable-s. Defects are, by definition, unacceptable. 3.7 Diffraction. A pattern of light or dark areas fn a casting radiograph,due to grafn structure, which is not detrimental to the casting. 3.8 Discontinuity. An fnterruption in the normal physf cal structure or configurationof a part such as cracks, Inclusions, and porosity, which may or may not affect the usefulnessof a part. 3.9 Foreiqn materials. Appear as fsolated, irregular,or elongated variationsof radiographic film densfty, correspondingto variations fn thicknessof materfal, or to cavftfes. They may be due to the presence of sand, slag, oxfde, dross, or metal of dffferent density. External forefgn materfal would, of course, be detected by visual inspection. In radiographic inspection,the dlsttnguf shfng factor between fnclusions and forefgn materfal is that the forefgn materfal fndfcatfons occur over a larger area while the inclusfon indications are singular indications of one fnclusfon. 3.10 Gas holes. Round or elongated, smcoth-edged voids occurring fndlvldually,fn clusters, or dfstrfbuted throughout the casting. They are general caused by trapped air or gases rejected from the metal during ly solidification. 3.11 Gas porosity. Mfnute vofds usually distributed throughout the entire casting. They are generally caused by trapped air or gases rejected from the metal durfng soledification. 3.12 Hot tear. Hot tears appear as ragged dark 1ines of variable width and with n~te 1ine of continuity. Hot tears may exfst in groups starting at a surface. They usually result from uneven coolfng associated with abrupt changes fn wal1 thfckness, and they are formed upon solidffication of the molten metal. 5

MIL-STD-21 75A 3.13 Inclusions. Inclusions are particles of foreign material such as sand or slag that are embedded in the cast metal. 3.14 Insert. A piece of steel used to localIy increase the rate of heat remval during soledification. It is also called an internal chill. 3.15 Misruns. A misrun is caused by a failure of the molten metal to on completely fill the mold. It appears the radiographas prominent darkened areas of variable dimensions with a definite and smooth outlinc. 3.16 Penetrameter or Image Quality Indicator (IQI). A strip of metal that is radiographical similar to the metal being tested, representing a ly percentageof object thickness and provided with a combinationof steps, holes or wires. Hhen placed in the path of X-rays or gamma rays, its image provides a check on the radiographic technique employed. 3.17 Radiographic quality level. The abi1ity of the radiographic procedure to demonstrate a certain IQI sensitivity based on the perception of the 101 holes or wires. 3.18 Segregation. A concentrationof alIoying elements in specific regions of the casting, usually the result of the primary crystallizationof one phase with the subsequent concentrationof other elements in the remaining liquid. 3.19 Shrinkaqe. The term shrinkage, as used in this standard, refers to a network of smal1 voids due to grain boundary soledificationphenomena. It is different than the larger and singular voids caused by soledification shrinkageon a large scale, as defined in 3.20 (shrinkagecavity). Shrinkage is usually categorized as either dendritic, filamentary, feathery, or sponge. It is usually below the surface but may extend to the surface. In radiographicinspection, depending on the category, shrinkagemay appear as dark irregular patches, as dark feathery streaks, or as a lacy or honeycombed darkened area with a diffuse outline. In penetrant inspection,dendritic shrinkage (sometImes called rniroshri c nkage), and sponge shrinkage, are often indistinguishable from each other and appear as a sponge-1 ike cluster of tlny pin holes or spotty irregular areas with feathery outlines. In magnetic particle inspection shrinkage may appear as a jagged area or irregular patch of magnetic particles. 3.20 Shrinkaqe cavity. Shrinkage cavities occur when insufficient feeding of a section results in a continuous cavity within the section. Shrinkage cavities appear on the radiograph as dark areas that are indistinctlyoutlined and have irregular dimensions. 3.21 Surface irregularities. In radiographic inspection, they are any images correspondingto an irregularityvisible on the surface. In visual inspectionthey are any interruptions,either positive (raiseal) negative or (depressed)from the normal cast surface. 3.22 Visual inspection. Inspection of casting surfaces to determine conformanceto the requirements for surface roughness, surface irregular ties, dimensions,or any visible surface discontinue ties. 6

MIL-STD-2175A

4.

GENERAL REQUIREMENTS

4.1 Personnel qualification. Personnel performing penetrant, magnetic particle or radiographic inspectionsas required by this standard shal1 be qualified and certified in accordance with MIL-STD-41O for the applicable method being used. 4.2 Insisection sequence. It is the responsi bi1ity of the contractor to perform appropriate inspectionsas necessary and in the proper sequence during processing to assure freedom from harmful discontinuities in the final product. The intent of inspections during processing is to detect flaws which would be detrimental to the final product at the earliest stage in processing so as to minlmize the cost of rejected or scrapped castirigs. The inspection sequence for 1iquid penetrant, magnetic particle, and radiographic inspections shal1 be as specified in ASTM-E-1444, MIL-STD-453, and MIL-STD-6866 or as otherwise specified by the design activity on the engineering drawing, applicable specification,or other contractual or engineering documentation. 4.3 Discontinuityremoval. If it is determined that rejectable discontinue ties shall subsequentlybe removed by machining on machining stock surfaces,or by blending on as-cast surfaces, then those discontinuitiesneed not be cause for rejection provided reinspection is performed after the material remaal to verify that the discontinuitywas removed, and the dimensional tolerance requirementsof the casting are satisfied. 4.4 Classificationof castinqs. 4.4.1 Determinationof classes and clrades. The design activity shall establish the class and grade(s) for eachcasting design (see 1.3). Sections of a casting may be of varying grades depending on the applied stresses to that portion of a casting. Particular attention should be given to areas that contain, or will eventually contain, stress risers after machining (such as sharp internal corners, holes, or notches). If the grade of casting is not indicatedon the drawing or other contractual document, grade C shal1 apply, except for class 4 castings, where grade D shal1 apply. 4.4.2 Class 1 castinq requirements. Al1 areas of class 1 castings shal1 be of a qualIty equivalent to, or better than,. grade C, except that al1 highly stressed areas of a class 1 casting shal1 be of a quality equivalent to, or better than, grade 8. 4.5 Inspection Lot. An inspection lot, for the purposes of visual, 1iquid penetrant, magnetic particle, and radiographic inspection shal1 be as defined in the casting (material) specification,engineering drawing, or purchase order. If not specified in any of the above documents, an inspection lot shall be defined as al1 castings of the same part number, of one al10Y, produced using the same processing parameters of the casting procedure, and submitted for inspection as a single group.

L.

MIL-STD-2175A 5. DETAIL REQUIREMENTS

5.1 Outline of inspections. 5.1.1 Visual inspection. Visual inspection shall be performed in accordance with, and evaluated to the acceptance criteria of 5.3.1. Sampling shall be in accordance with 5.2.1 (see 6.4). 5.1.2 Maqnetic particle and 1iquid penetrant inspection. Magnetic particle and 1iquid penetrant inspection shal1 be performed in accordance with, and evaluated to the acceptance criteria of 5.3;2. Sampling shal1 be in accordance with 5.2.2 (see 6.4): 5.1.3 Radiographic inspection. Radiographic inspection shal1 be performed in accordance with,and evalgated to the acceptance criteria of 5.3.3. Sampling shall be in accordance with 5.2.3 (see 6.4). 5.2 Sampling. 5.2.1 Visual inspection. Each casting shall be examined visually. 5.2.2 Magnetic particle and penetrant inspection. Each casting shall be subjected to either magnetic particleor penetrant inspection,as may be appropriate (see 5.3.2), except that class 4 castings shal1 be sample inspected in accordance with table 1, unless 100 percent inspection is required by the engineering drawing, cakting specificationor purchase order. 5.2.3 Radiographic inspection. Sampling inspection and inspection coverage shall be as indicated below: a. Class 1 casting; - Eath casting shall be completely examined. b. Class 2 casting: - Castings shal1 be selected in accordance with table 1 and completely exarni ned. c. Class 3 casting: - Castings shal1 be selected in accordance with table 2 and ccxnpletely examined. d. Class 4 castings - Radlographlc examination is not required unless otherwise specified in the casting drawing, specifi cation, contract, or purchase order. If radiographic examination is specified and no sampling i$ specified, table 11 shall apply. 5.3 Inspectionmethods and acceptance criteria.

5.3.1 Visual inspection. Each casting shall be 100% visually inspected. Visual inspection should be performed in areas with an ambient 1ighti range ng of no less than 75 foot-candl es. Castings shal1 be free of foreign material s,and shal1 not contain any cracks, hot tears, CO1d shuts, and negative core seams (also called parting line below flush). In addition, visual inspectionsshall be performed to determine conformance to the criteria specifiedon the engineering drawing, specification,or agreed upon observationalstandards (see 6.8). 8

MIL-STD-21 75A 5.3.1.1 Surface rouqhness. Dimensions and surface roughness shall conform to the engineering drawing requirements. Surface roughness requirementsspecified on the engineering drawing (for example 63 Ra) do not preclude the presence of acceptable 1iquid penetrant or magnetic particle indications. Visual and tactile comparison with cormnercially available observational standards may be used to determine conformance to surface roughness requirements. 5.3.1.2 Gate, riser, and partinq line projections. If allowance limits for gate, riser, or parting 1ine projections are not specified on the engineering drawing or casting (material) specifi cation, then the maximum 1imit for gates, risers and parting 1ines shall be in accordance WIth table 3. 5.3.1.3 Surface pits and raised metal. Allowable surface pits and raised metal (also called positive metal), other than gates, risers and parting lines, that are not specificallycontrolled by the engineering drawing or agreed upon observational standards shal1 be allowed as specified below: a. For sand castings, surface pits are acceptable if they have smooth rounded contours and do not cause the casting to fall outside the dimensional requirementsof the engineering drawing. Raised metal that has a jagged or irregular surface, or which causes the casting to fall outside of the dimensional requirementsof the engineering drawing, shal1 be removed or blended to conform to the dimensional and surface roughness requirements of the engineering drawing. For investment and permanent mold castings, random raised metal shal1 be limited to a height of 0.015-0.030 inch by 0.125 by 0.125 inch and no more than one per square inch. Random surface pits shal1 be limited to 0.030-0.060 inch in diameter and 0.030 inch in depth and no more than one per square inch. Smaller surface pits or raised metal may be present at random provided they do not interfere with the function of the part.

b.

5.3.2 Maqnetic particle and 1iauid penetrant inspection. 5.3.2.1 Inspection method for ferromagneticmaterials. Class 1, 2 and 3 castings and sample castings of class 4 ferromagneticmaterials shall be magnetic particle inspected. Magnetic particle inspection shal1 be in accordance with ASTM E 1444. If necessary, and when approved by the contractingagency, 1iquid penetrant inspectionsmay be performed 1n ~ieu of magnetic particle inspection on ferromagneticmaterials if their size or complex shape prohibits adequate inspection with magnetic particle inspection. The surface quality of the castings shall conform to 5.3.2.3. Al1 precipitationhardening stainless steels shal1 be penetrant 1nspected in accordance with 5.3.2.2. (due to the possibility of delta ferrite stringers), unless otherwise prohibited by the contracting agency. 5.3.2.2 Inspection method for nonferromaqneticmaterials. Class 1, 2 and 3 castings and sample castings of class 4 nonferromagneticmaterial shall be penetrant inspected in accordance with MIL-STD-6866. The design activity shal1 specify, on the engineering drawing or other applicable documents, the 9

MIL-STD-2175A

sensitivity level of the penetrant materials to be used in accordance with the classificationof MIL-I-25135. If no sensitivity ievel is specified, the inspectionfaci1ity shal1 determine the appropriate :ensitivlty level for the inspection procedure in accordance w!th MIL-STD-6866, or the company process specification. The surface quality of the castings shal1 conform to 5.3.2.3. Penetrant materials which exhibit excessive fluorescent background which could mask or obscure relevant discontinui ties on the as-cast surface shal1 not be used. 5.3.2.3 Magnetic Darticle and 1iquid tsenetrant acceptance criteria. If the design activity does not specifythelr own magnetic particle or liquid penetrant acceptance crdteria on the engineering drawing, then the surface quality of each grade designation shal1 conform to table 4. 5.3.3 Radiographic instsection. 5.3.3.1 Radiographic inspectionmethod. Radiographic inspection shall be in accordance with MIL-STD-453: The use of nonfilm radiographic techniques (radioscopy)is permitted, provided the method used is sufficientlysensitive to resolve the required radiographicquality level. Radioscopic inspection shal1 be in accordance with ASTM E 1255. However, prior approval shalI be obtained from the contractingagency on the detailed inspection,evaluation and quality control procedures. 5.3.3.2 Radiographic reference standards. Radiographic standards shalI be as required in ASTME 155; ASTM El86, ASTM E 192, ASTM E 272, ASTM E 280, ASTM E 310 and ASTM E 446. For al10Y types where reference radiographs are specificallycovered, the reference radiograph shal1be of the same al10Y family as the casting. For alloys not specifical included in the alloy lY family covered by the ASTM reference radiographic standards, the design activity shal1 either select an ASTM standard representativeof the quality required, or develop their ownradiograph c standards containing detai1s comparable to an ASTM standard. 5.3.3.3 Radiographic acceptance criteria. The design activity shall specify on the drawing other document the radiographic grade(s) for classes or 1, 2 and 3 castings designs. The design activity may specify radiographic grade(s) for class 4 casting designs. Either the castings, or areas of the castings, shal1 be in accordance with the requirements for the applicable grades of tables 6 through 14 of this standard. 5.4 Reinspection.

5.4.1 Reinspectionof re.lected lots. When an inspection lot is rejected on the basis of a samjling plan, regardless of the inspectionmethod, it may be resubmitted for 100 percent inspection and defective castings removed from the lot per 5.4.2. For lots of class 2 and class 3 castings which were rejected in a radiographic inspection sampling plan, each part shal1 be completely examined upon reinspection,whereas for class 4 castings, only the areas where the rejectable di$contingi ties were found need to be inspected.

10

MIL-STD-21 75A

5.4.2 Individual castinq rejection. Individual casting rejection shall aPPIY in those instances where al1 castings in the lot are inspected and any individualcasting is found defective in visual, penetrant, magnetic particle, or radiographic inspection. Only the defective casting needs to be rejected, and individual castings meeting the requirements of this standard may be accepted.

11

MIL-STD-2175A 6. NOTES

(This section contains guidance informationof a general or explanatory nature that may be helpful, but is not mandatory) 6.1 Intended use. This standard prescribes acceptance criteria for surface inspectionsand radiographic inspectionsapplied to metal castings. This standard is not intended to apply to high pressure die castings. Acceptance criteria for die castings may be based on standards and guidelines developed by the American Society for Testing and Materials. (ASTM), and the North American Die Casting Association (formerly the American Die Casting Institute (ADCI)). Examples are ASTM E 505 and ADCI Q, E, and M series standards. 6.2 Issue of DoDISS. 14henthis standard is used in acquisition, the issue of the DoDISS to be appl~cable to this solicitationmust be cited in the solicitation. 6.3 Data requirements. The following Oata Item Descriptions (DIDs) must be listed,as applicab~e, on the Contract Data Requirements List (DD Form 1423) when this standard is applied in a contract, in order to obtain the data, except where DOO FAR Supplement ?7 .475-1 exempts the requirement for a DD Form 1423. Suggested Reference Paragraph DID Number 010 Title Tailoring Appendix A DI-MISC-80653 Test Reports Use contractor format 6.4 Sampling. The following is included as a quick check to aid in identifyingthe sampling requirement: Specified herein for the different inspectionmethods as they apply to each class: a. Class 1. For castings classified as class 1, all castings in the lot are inspected by the methods specified in this standard. b. . Class 2 For castings classified as class 2, all castings in the lot are inspected by the methods s~ecified in this standard, except for radiographic inspection, in wh~ch case the castings are sampled per table 1. c. Class 3. For castings classified as class 3, all castings in the lot are inspected by the methods specified in this standard, except for radiographic inspection, in which case the castings are sampled per table 2. d. . Class 4 For castings classified as class 4, all castings in the lot are inspected by visual inspection, while castings are sampled in accordance with table 1 for penetrant or magnetic particle inspection. Radiographicexamination is not required unless specified on the engineering drawing, specification, contract, or purchase order.

12

MI L-STD-2 175A

6.5 Cross reference. The class of castings defined in paragraph 1.3 corresponds to those deffned in MIL-C-6021H as shown below:

MIL-C-6021H designation Class 1 Class 2 Class 3 Class 4

MIL-C-6021G designation Class 1, Class 1A Class 1, Class lB Class 2, Class 2A Class 2, Class 2B

6.6 Radfoarafshf quality grades for mathfned areas. Castfngs that have c been found acceotabl Der the ASTM radtoaraDhfc standards often times have e fnternal dfscontlnuftfes(such as shrfnk~gej porosfty, and inclusions) exposed after machfnfng. One way to help alleviate thfs problem fs to quantify (fn terms of size) the ASTM reference radiographic discontfnuf tfes so that thefr size on the surface may be approxf mated. Once thls has been done, the engineer or designer should be able to determine if the dfscontinui ties allowed in the radiographicgrade wi11 be permfssfble on the surface. If they are not permissible, then the area that fs machined should be zoned to a more strfngent radiographic grade. 6.7 Producibilftv considerations. The class assigned to the casting should reDresent a realistic value for the functional requirements.do not assign a class 1 castfng for a class 2 functfon. Castfng design coupled wfth foundry practfce can make overly severe soundness requirements impractical for a manufacturer to satisfy. Caution should be exercised in specifying the grade of maximum permissfble radiographicdfscontinufty level and surface qualfty requirements to be met in a casting. 6.8 Observational standards. Observational standards for visual inspectionmay include sample castings wfth known discontinuitfes. Assistance with the vfsual inspection criteria for steel castings may be obtafned by reference to ASTM A 802 and MSS SP-55. MSS SP-55 contaf reference ns photographs that i11ustrate varfous types and degrees of surface discontfnuf tfes, uhfle ASTM A 802 contafns plates that model actual dfscontfnuitiesand surface roughness. The ful1 titles of ASTM A 802 and MSS SP-55 are shown below: a. ASTf4A 802 Steel Castfngs, Surface Acceptance Standards, Vfsual Examinat fen (Copf may be obtafned from the ASTM address given fn es sectfon 2) b. MSS 5P-55 Qualfty Standard for Steel Castfngs for Valves, Flanges, and Ffttings and other Pfpfng Components (Visual Method) (Copfes may be obtafned from the Manufacturers Standardizatf Society of the on Valve and Ffttfngs Industry, 127 Park Street, N.E., Vienna, VA 22180 6.9 Ultrasonic inspectionof thick castinqs. Class 1 and Class 2 castf ngs having a section thickness of 4.50 iriches and greater should also be inspected by U1trasoni methods due to the loss of radiographic sensftivity in c the thicker sectfons. It should be noted that U1trasonic examfnatfon and radiography are not directly comparable. Therefore, the design activity would 13

, /----

MIL-STD-21 75A need to specify, on the engineering drawing, the appropriate document for ultrasonic inspection along with the appropriate quaiify level of acceptance criteria contained within that document. One document that could be specified is: a. ASTM A 609 Castings, Carbon, Low-Alloy, and Martensitic Stainless Steel, Ultrasonic Examination Thereof 6.10 Subject term (key word) listinq. Liquid penetrant testing Nondestructive esting t Magnetic particle testing Radiographictesting 6.11 Chanqes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extensivenessof the changes. Custodians: Army - MR Navy - AS Air Force - 11 Review activities: Army - AR, EA, MI Navy - SH, OS Air Force - 70, 71, 80, 82, 84, 99 OLA - IS User activities: Army - ME

Preparing activity: Navy - AS (Project No. NDTI-0131 )

14

MIL-STD-21 75A TABLE 1. Sampling, radiographic inspection of class 2 castinqs, and maqnetic particle and Iiauid penetrant inspectionof class 4 castinqs. Lot size [/ , 2-5 6-8 9-11 12-15 16-20 21-26 Al1 : 7 21-36 37-51 52-82 83-162 163-971 I 972 and over 1? 12 13 .Sample size ~f Lot size Samp1e size

I I

;;

I I

~1 See 4.5 for lot definition. ~1 Acceptance number is O.

TA8LE 2.

Samplinq, radioqra~hic inspectionof Class 3 Castings.

Lot size ~1 2-4 5-6 7-11 12-17

Sample size ~1 Al1 4 2

Lot size 18-27 28-48 49 and over

Sample size 7 8 9

~/ ~)

See 4.5 for lot definition. Acceptance number is O.

Table 3. Maximum alIowable gate, riser, and partinq 1ine projections. Casting weight lb. up to 10 over 10 thru 25 over 25 thru 50 over 50 Nonmachined surface (in.)
.031

Machined surface (in.)

.047 .062 .125

.062 .094 .188

15.

r.

MIL-STD-21 75A TABLE 5. Notes for tables 6 through 14.

(1) An area of like size to the reference radiograph shall be the unit area by which the production radiograph is evaluated. If the production radiograph shows a discontinuity that is equal to or better than the severity level of the reference radiograph, the casting shal1 be acceptable. If the production radiograph shows a discontinuityof greater severity than the reference radiograph, the casting shal1 be rejected. (2) When two or more types of discontinue ties are present (in an area equal to the reference radiograph c plate area) to an extent equal to the maximum permissible severity levei for each type, the casting shall be rejected. (3) Numbers in the tables are ASTM radiograph c plate numbers for a Particular type and severity of discontinuity. A low number indicates fewer, smaller discontinue ties while a higher number indicates more numerous, larger discontinue ties. (4) The smallest resolvable indication size, below which indications are considered non-interpretable,:hal1 be 0.015 inches. (5) Gas holes, sand spot:, and inclusions allowed by these tables (even those smaller than the maximimallowable size) shall be cause for rejection when closen than twice their maximum dimension to an edge. Exceptions to this note based on the class and grade of the casting are shown belOU: ~1 Class 1 No exceptions from note 5.

Class,2 No exceptions from note 5 for Grade A and Grade B areas, or other areas that are specified critical or highly stressed. Otherwise, the note 5di scontinuitiesare acceptable if they are separated from the edge bya distance, equal to, or greater than, the discontinyi tys max~mum dimension. Class 3 Gas holes, sand spots? and inclusions,of the maximum size allowed by these tables, shal1 be cause for rejection if they are closer than one diameter of their maximum dimension to an edge. This doe: not apply to gas holes, sand spots, and inclusions smalle~ than the maximum allowable size. Edge of part discontinuities are acceptable if they are not crack-like, 1inear,or round with protruding 1inear indications.

Class 4

~1

The term edge refers to the outer boundary of the radiographic image of the casting. This interpretationneed only be made in the standard exposures (view:) defined by the approved radiograph c technique. Additional radiographic exposures, to determine the distance from the surface of each gas hole, sand spot, or inclusion in other orientations, are not required.

18

MIL-STO-21 75A

TABLE 6. Maximum permissible radiographic severity levels for discontinuities in aluminum castings per ASTM E 155. ~/, ~/, ~/

Grade A Discontinuity Inch 1/4 314

Grade B
Inch 14 3/4

Grade C Inch 1/4 3/4

Grade D Inch /4 314

Gas holes None 11 22 55 Gas porosity (round) None 71 33 Gas porosity (elongated) None 34 5 Shrinkage cavity None 1 NA 2/ 2 NA 21 3 NA~ Shrinkage (sponge) None 1 T 2 4 2 Foreign material (less dense material) None 1 1 4 4 22 Foreign material (mere dense material) None 11 21 43 Cracks ~/ None None None None Cold shuts ~/ None None None None Surface irregularty j/ Not to e) ed drawing toleran~e Core shift ~/ Not to exceed drawing tolerance

No reference radiograph c plates available. use the 1/4 inch reference radiographic PIate thickness with a severity level 2 units greater than the one shown for the 1/4 inch column. ASTM E 155 Volume I reference radiographic plates. For feature thicknesses greater than two inches, the 3/4 inch reference radiograph plates may be used. ic See table 5 for additional notes that apply to this table.
Not avai I able,

19

MIL-STD-2175A TABLE 7. Maximum permissible radiographic severitv levels for discontinue ties in maqnesium castinqsperASTM E 155. ~/, ~/, ~/ !,

Grade A Discontinuity Gas holes Microshri nkage (feathery) Microshrinkage(sponge) Foreign material (less dens( material) Foreign material (mor~ dens[ material ) Cracks ]/ Cold shuts ~/ Surface irregularity~/ Core shift 1/ Reacted sand inclusions Gravity segregation Eutectic segregation (a) Microshri nkage type (b) Pipe shrink type Inch 114 314 None None None None

Grade B Inch 114 314 11 11 11 22

Grade C Inch 1/4 314 32 44 34 33

Grade D Inch 1/4 314 44 77 78 44

33 11 None 22 None None None None None None None None I Not tO c :eed drawlg tolera ce Not to e :eed draw 9 tolera :e THICKNES~ AP~LIC m 6 4 3 1 4 2 1 3 None None 4 None 5 None 6 1/3 of iizeon plate :wi the ce size on plate same as size on plate Any length ~1

(c) Hot tear type

None

same as size on plate 1/3 of size on plate same as size on plate

same as size on plate 112 of size on plate wice the size on plate

Oxide Inclusions

None

Eutectic depletlon - Flow line

None

~/ ~/ ~/ ~/ ~/

No reference radiographicplates available. No other types of d~scont~nuitiesare allowed to be contained with it in an area of 1ike size to the reference radiographic plate. ASTM E 155 Volume Iand 11 reference radiograph numbers. For feature sizes greater than 2 inches, the 3/4 inch reference radiographic plates may be used. See table 5 for additional notes that apply to this table.

20

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MIL-STD-2175A

APPENDIX A TEST REPORT TECHNICAL CONTENT REQUIREMENTS 10.

SCOPE

10.1 g. This appendix covers the technical content requirements that shal1 be includedon data records when required by the contract or order. This appendfx is mandatory only when data item description 01-MISC-80653 is cited on the DO Form 14.23. 20. APPLICABLE DOCUMENTS This section is not applicable to this appendix. 30. REPORTS

30.1 Data records. When required by the contract or purchase order the data record shall consist of the f~llowing; a) The certificate of conformance for each lot. b) The radiograph(s)of the casting. 30.2 Certificateof conformance. The certificate of conformance for each lot Inspected shall consl$t.of the-following information: a) The casting part number and heat or lot number. a) For rejected castirigs,the reasons for rejection. b) T& date of inspection. c) The inspectors identificationand certification level. d) A statement that the lot of castings have been accepted in conformance with the requirements of MIL-STD-21 75. e) The number of ca;t!ngs inspected in each lot, and the number rejected.

28

STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL

letter should given. be ofthis ormmustcomplete f blocks ,5,6, 7. 4 and 2. Thesubmitter 3. The preparing activity must provide a reply within 30 days from receipt of the form. NOTE: Thisform may not be used to request copies of documents, nor to reqUeSt WaiVerEt i; dahfication of requirements on current contracts. Comments submitted on this form do not constitute or imply authorization to waive any . . ~ortion of the referenced document(s) or to amend contractual requirements.
1. OOCUMENT :i~icomti~iti~;cff~ .,<;..* ,,.,..<,. -,.,.,, :,;,. , , ,..:,.:,,...,: . :,,:,., ?,,.:,..,.,..% . 00 CUMENT TITLE NUMaLR 2. OOCUMENT OATE (YVMMDDJ

CASTINGS,
HATUREOF CHANGE (Menti&

CLASSIFICATION
num&fati

AND

INSPECTION
rewrite, il@ble.

OF
AHtcheflrJ ficrbasneeded.J .,.

paragraph

im/udepropo$ed

I
, F.fASONFOR RECOMMtNOATION

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