JB/T 5000.15-2007 PDF English
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JB/T 5000.15-2007: Heavy mechanical general techniques and standards - Part 8: Forging---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/JBT5000.15-2007
JB
MECHANICAL INDUSTRY STANDARD
ICS 25.120.20
H 90
Registration number. 21709-2007
Replacing JB/T 5000.15-1998
Heavy mechanical general techniques and standards -
Part 15.Non-destructive inspection of forged steel
Issued on. AUGUST 28, 2007
Implemented on. FEBRUARY 01, 2008
Issued by. National Development and Reform Commission of PRC
Table of Contents
Foreword... 4
1 Scope... 6
2 Normative references... 6
3 Terms and definitions... 7
4 General requirements... 8
5 Ultrasonic testing and its quality grade... 9
6 Magnetic-powder testing and its quality grade... 17
7 Penetration testing and its quality grades... 31
Appendix A (Normative) Transverse-wave testing method and quality
acceptance requirements for forging steel... 41
Foreword
JB/T 5000 “Heavy mechanical general techniques and standards” is divided
into 15 parts.
- Part 1.Check of product;
- Part 2.Oxygen cutting workpiece;
- Part 3.Standards welding;
- Part 4.Iron casting;
- Part 5.Non-ferrous casting;
- Part 6.Steel castings;
- Part 7.Repair welding for steel castings;
- Part 8.Forging;
- Part 9.Cutting;
- Part 10.Assembly;
- Part 11.Attached piping;
- Part 12.Paint;
- Part 13.Packing;
- Part 14.Non-destructive inspection of cast steel;
- Part 15.Non-destructive inspection of forged steel.
This Part is Part 15 of JB/T 5000.
This Part replaces JB/T 5000.15-1998 “Heavy mechanical general techniques
and standards - Part 15.Non-destructive inspection of forged steel”.
As compared to JB/T 5000.15-1998, the main changes are as follows.
- REVISE the classification and definition of defect’s signals;
- REVISE the defect’s quality grades, record limits, acceptance limits.
Appendix A of this Part is normative.
This Part was proposed by the China Machinery Industry Federation.
This Part shall be under the jurisdiction of the Mechanical Industry Metallurgical
Equipment Standardization Technical Committee.
Drafting organization of this Part. China No. Heavy Machinery Group
Corporation.
The main drafters of this Part. Fan Lvhui, Zhao Xiaohui, Chen Chong.
This Part replaces the standard previously issued as follows.
- JB/T 5000.15-1998.
Heavy mechanical general techniques and standards -
Part 15.Non-destructive inspection of forged steel
1 Scope
This Part of the JB/T 5000 specifies the ultrasonic, magnetic-powder and
penetration testing methods and quality grades of forged steel.
This Part applies to non-destructive testing of forged steel for heavy machinery.
Non-destructive testing methods as specified in this Part may involve
hazardous materials, operations and equipment, so the non-destructive testing
personnel shall comply with relevant safety and health regulations.
The method, location, quality grade of the non-destructive testing of forgings
shall be indicated in the forging’s drawings, technical documents and technical
conditions of the ordering.
2 Normative references
The provisions in following documents become the provisions of this Part
through reference in this Part of JB/T 5000.For the dated references, the
subsequent amendments (excluding corrections) or revisions do not apply to
this Part; however, parties who reach an agreement based on this Part are
encouraged to study if the latest versions of these documents are applicable.
For undated references, the latest version of the referenced document applies.
GB/T 5097 Indirect assessment method for black light source (GB/T 5097-
1985, eqv 3059.1974)
GB/T 11259 Standard practice for fabrication and control of steel reference
blocks used in ultrasonic inspection (GB/T 11259-1999, eqv ASTM
E428.1992)
JB/T 8290 Magnetic-powder flaw detectors
JB/T 9214 Test methods for evaluating performance of A-mode ultrasonic
flaw detection using pulse echo technique
JB/T 9216 Methods for controlling the quality of liquid penetrant materials
JB/T 10061 Commonly used specification for A-mode ultrasonic flaw
detector using pulse echo technique
JB/T 10062 Testing methods for performance of probes used in ultrasonic
flaw detection
3 Terms and definitions
The following terms and definitions apply to this Part.
3.1
Single defect
The defect which has a spacing of more than 50 mm and an equivalent
diameter not less than the initially recorded equivalent.
3.2
A cluster of defects
There are five or more defect’s reflection signals simultaneously in the range
of the 50 mm sound-path of the screen’s scanning line; or five or more
defect’s reflection signals in the same depth on a 50 mm x 50 mm detection
surface.
3.3
Extended defect
The continuous echo height of the defect shall not be lower than the initially
recorded equivalent in at least one direction, the extended length shall be
greater than the maximum equivalent diameter allowed by the defect. The
extension of the extended defect is determined by the half-wave height
method (6 dB method). When determining the extension, it shall consider
the sound-field characteristics of the probe for correction.
4 General requirements
4.1 Principles of selection
4.1.1 The selection of testing method and quality acceptance level shall be
determined according to the specific use and type of forgings, meet the
requirements of the corresponding technical documents.
4.2 Documentation of testing
4.2.1 When forgings are tested in accordance with this Part, if necessary, it may
follow the provisions of this Part to establish a non-destructive testing
procedures which complies with the relevant specifications.
4.2.4 The performance of the instruments and equipment used for the testing
shall be periodically calibrated and have calibration records, which can only be
used after passing the calibration.
4.3 Testing personnel
4.3.1 Any person engaged in non-destructive testing shall hold the
corresponding qualification certificate issued by the relevant state department.
4.3.3 All personnel engaged in non-destructive testing must meet the following
requirements for vision in addition to good physical fitness.
4.3.3.1 Corrected visual acuity shall not be less than 5.0 (decimal record value
is 1.0) and be checked once a year.
5 Ultrasonic testing and its quality grade
5.1 Basis of testing
5.1.1 Relevant requirements for ultrasonic testing of forgings by the user or the
design and process department.
5.1.2 The method of establishing sensitivity, the selection of instruments and
equipment, the test of performance shall be consistent with the provisions in
this Part.
5.2 Instrument and equipment
5.3 Probe
5.3.1 Various probes shall be used at the calibrated frequency. In principle, it
uses the straight probes at 2 MHz ~ 2.5 MHz which have a wafer diameter 10
mm ~ 30 mm. The refraction angle of the angle beam probe shall be 35° ~ 70°,
the effective wafer area of the angle beam probe shall be 20 mm2 ~ 625 mm2.
5.3.2 The main beam of the probe shall have no obvious double peak, the
beam’s linear deflection shall be less than 2°.
5.3.3 It may replace it with other probes to assess defects and accurately locate
defects.
5.3.4 Probe’s performance test method is as specified in JB/T 10062.
5.4 Coupling agent
5.5 Test block
5.5.1 The test block shall be made of the same or approximate acoustic
properties as the workpiece being tested. When the material is tested by a
straight probe, there shall be no defects greater than the equivalent diameter of
the Φ2 mm flat-bottom hole.
5.5.5 In case of field testing, it may also use other types of equivalent test blocks.
5.6 Test of system’s combined performance
The test of the system’s combined performance is as specified in JB/T 9214.
5.7 Preparation of forgings before testing
5.7.1 Unless otherwise specified in the order, in case of radial testing of shaft
forgings, it shall machine a cylindrical surface. In case of axial testing, the both
end faces shall be machined into surfaces axially perpendicular to the forgings.
The surfaces of the pie-shaped and rectangular forgings shall be machined into
planes which are parallel to each other.
5.8 Testing procedures
5.8.1 General rules
5.8.1.1 Unless otherwise the testing cannot be performed due to the change of
sectional and local shape of the forgings due to chamfering, drilling, etc., it shall
carry out ultrasonic testing of the entire forging as much as possible.
5.8.1.4 It shall scan all the cross-sections of the forging as far as possible in
two mutually perpendicular directions.
5.8.1.5 For pie-shaped forgings, in addition to scanning from at least one plane,
it shall also carry out radial scanning from the circumferential surface as much
as possible.
5.8.1.6 For the testing of cylindrical solid or hollow forgings, in addition to the
radial scanning, it shall also carry out auxiliary scanning from the axial direction.
5.8.2 Sensitivity of testing
5.8.2.1 In principle, use the AVG method to determine the testing sensitivity. For
forgings which is limited by its geometry and whose testing thickness
approaches to the length of near-field, use the test block comparison method.
5.8.2.2 The testing sensitivity shall be based on the initially recorded equivalent
value, the reference wave height shall not be less than 40% of the full screen
height.
5.8.2.3 When assessing defects, it shall adjust the evaluation sensitivity in the
intact part of the forging.
5.8.2.4 Re-verification of testing sensitivity.
6 Magnetic-powder testing and its quality grade
6.1 Basis of testing
6.1.1 Relevant requirements of the user or design process department for the
magnetic-powder testing for forged steel.
6.1.2 Methods for establishing sensitivity, selection of instruments and
equipment, selection of magnetization methods, requirements for magnetic-
field’s strength shall be consistent with this Part.
6.2 Requirements of testing surface
6.2.1 The sensitivity of magnetic-powder testing is highly dependent on the
surface condition of the forged part being tested. If the irregular surface
condition affects the display or evaluation of the defect, the surface to be tested
must be treated by grinding, machining or other means.
6.2.3 The removal of foreign matter can be carried out by any method that does
not affect the magnetic-powder testing.
6.2.4 In order to test small defects, the roughness Ra of the surface of the
forging is generally not more than 6.3 μm.
6.2.5 Temperature of the testing surface. It shall be less than 300 °C in case of
dry method; it shall be less than 10 °C ~ 50 °C in case of wet method.
6.3 Testing period
6.3.1 Unless otherwise specified by the purchaser, the magnetic-powder
acceptance test shall be carried out after the final heat-treatment and finishing
of the forgings.
6.4 Equipment and magnetic-powder
6.4.1 Magnetic-powder testing equipment and special types of equipment must
meet the requirements of JB/T 8290.
6.4.3.4 Wet-powder method shall use kerosene or water as the dispersion
medium. When using water as a medium, it shall add appropriate rust inhibitors
and surfactants. The viscosity of the magnetic suspension shall be controlled
within 5000 Pa•s ~ 20000 Pa•s (25 °C).
6.4.3.5 The concentration of magnetic suspension shall be determined
according to the type, particle size, application method and time of the
magnetic-powder. Under normal circumstances, non-fluorescence. 10 g/L ~ 25
g/L. fluorescence. 1 g/L ~ 3 g/L, its dispersion medium shall not have
fluorescent properties.
6.5.1 Methods and materials
6.5.1.1 The ferromagnetic-powder used as the test medium may be either dry
or wet; it may be fluorescent or non-fluorescent.
6.7 Magnetic-field’s strength
6.7.1 The minimum magnetic-field’s strength used shall be able to show all
dissenting defects and distinguish them. The maximum magnetic-field’s
strength shall be just below the critical point at which the magnetic-powder
7 Penetration testing and its quality grades
7.1 Basis of testing
User or design process department’s requirements for penetration testing of
forged steel.
7.2 Requirements of testing surface
7.2.1 The surface of the testing area and the adjacent 25 mm shall be dry and
free of dirt, grease, cotton fiber, oxide scale, oil or other foreign matter which
7.3 Testing materials
7.3.1 Penetration testing materials generally include penetrants, emulsifiers,
cleaning agents, imaging agents.
7.3.2 The quality control of the penetration test material shall comply with the
requirements of JB/T 9216.
7.4 Control test block
7.4.1 The control test block is mainly used to test the performance of the testing
agent and the operation process.
7.4.2 The control test blocks are divided into aluminum-alloy test blocks and
chrome-plated test blocks.
7.4.3 Production of control test blocks.
7.5 Classification and selection of penetration testing methods
7.5.1 Classification and code of penetration testing methods
7.6 Operating procedures
7.6.1 Pre-cleaning
7.6.1.1 All areas to be tested must be pre-cleaned as required by 7.2 before
applying the penetrant.
7.6.1.2 Post-cleaning drying.
The cleaned workpieces shall be dried. Drying methods generally include
heating the workpiece in a drying oven, baking it using an infrared lamp, drying
it using hot compressed air, or drying it naturally at ambient temperature.
However, the temperature of the workpiece must not exceed 50 °C before
applying the penetrant.
7.6.2 Applying penetrant
JB/T 5000.15-2007
JB
MECHANICAL INDUSTRY STANDARD
ICS 25.120.20
H 90
Registration number. 21709-2007
Replacing JB/T 5000.15-1998
Heavy mechanical general techniques and standards -
Part 15.Non-destructive inspection of forged steel
Issued on. AUGUST 28, 2007
Implemented on. FEBRUARY 01, 2008
Issued by. National Development and Reform Commission of PRC
Table of Contents
Foreword... 4
1 Scope... 6
2 Normative references... 6
3 Terms and definitions... 7
4 General requirements... 8
5 Ultrasonic testing and its quality grade... 9
6 Magnetic-powder testing and its quality grade... 17
7 Penetration testing and its quality grades... 31
Appendix A (Normative) Transverse-wave testing method and quality
acceptance requirements for forging steel... 41
Foreword
JB/T 5000 “Heavy mechanical general techniques and standards” is divided
into 15 parts.
- Part 1.Check of product;
- Part 2.Oxygen cutting workpiece;
- Part 3.Standards welding;
- Part 4.Iron casting;
- Part 5.Non-ferrous casting;
- Part 6.Steel castings;
- Part 7.Repair welding for steel castings;
- Part 8.Forging;
- Part 9.Cutting;
- Part 10.Assembly;
- Part 11.Attached piping;
- Part 12.Paint;
- Part 13.Packing;
- Part 14.Non-destructive inspection of cast steel;
- Part 15.Non-destructive inspection of forged steel.
This Part is Part 15 of JB/T 5000.
This Part replaces JB/T 5000.15-1998 “Heavy mechanical general techniques
and standards - Part 15.Non-destructive inspection of forged steel”.
As compared to JB/T 5000.15-1998, the main changes are as follows.
- REVISE the classification and definition of defect’s signals;
- REVISE the defect’s quality grades, record limits, acceptance limits.
Appendix A of this Part is normative.
This Part was proposed by the China Machinery Industry Federation.
This Part shall be under the jurisdiction of the Mechanical Industry Metallurgical
Equipment Standardization Technical Committee.
Drafting organization of this Part. China No. Heavy Machinery Group
Corporation.
The main drafters of this Part. Fan Lvhui, Zhao Xiaohui, Chen Chong.
This Part replaces the standard previously issued as follows.
- JB/T 5000.15-1998.
Heavy mechanical general techniques and standards -
Part 15.Non-destructive inspection of forged steel
1 Scope
This Part of the JB/T 5000 specifies the ultrasonic, magnetic-powder and
penetration testing methods and quality grades of forged steel.
This Part applies to non-destructive testing of forged steel for heavy machinery.
Non-destructive testing methods as specified in this Part may involve
hazardous materials, operations and equipment, so the non-destructive testing
personnel shall comply with relevant safety and health regulations.
The method, location, quality grade of the non-destructive testing of forgings
shall be indicated in the forging’s drawings, technical documents and technical
conditions of the ordering.
2 Normative references
The provisions in following documents become the provisions of this Part
through reference in this Part of JB/T 5000.For the dated references, the
subsequent amendments (excluding corrections) or revisions do not apply to
this Part; however, parties who reach an agreement based on this Part are
encouraged to study if the latest versions of these documents are applicable.
For undated references, the latest version of the referenced document applies.
GB/T 5097 Indirect assessment method for black light source (GB/T 5097-
1985, eqv 3059.1974)
GB/T 11259 Standard practice for fabrication and control of steel reference
blocks used in ultrasonic inspection (GB/T 11259-1999, eqv ASTM
E428.1992)
JB/T 8290 Magnetic-powder flaw detectors
JB/T 9214 Test methods for evaluating performance of A-mode ultrasonic
flaw detection using pulse echo technique
JB/T 9216 Methods for controlling the quality of liquid penetrant materials
JB/T 10061 Commonly used specification for A-mode ultrasonic flaw
detector using pulse echo technique
JB/T 10062 Testing methods for performance of probes used in ultrasonic
flaw detection
3 Terms and definitions
The following terms and definitions apply to this Part.
3.1
Single defect
The defect which has a spacing of more than 50 mm and an equivalent
diameter not less than the initially recorded equivalent.
3.2
A cluster of defects
There are five or more defect’s reflection signals simultaneously in the range
of the 50 mm sound-path of the screen’s scanning line; or five or more
defect’s reflection signals in the same depth on a 50 mm x 50 mm detection
surface.
3.3
Extended defect
The continuous echo height of the defect shall not be lower than the initially
recorded equivalent in at least one direction, the extended length shall be
greater than the maximum equivalent diameter allowed by the defect. The
extension of the extended defect is determined by the half-wave height
method (6 dB method). When determining the extension, it shall consider
the sound-field characteristics of the probe for correction.
4 General requirements
4.1 Principles of selection
4.1.1 The selection of testing method and quality acceptance level shall be
determined according to the specific use and type of forgings, meet the
requirements of the corresponding technical documents.
4.2 Documentation of testing
4.2.1 When forgings are tested in accordance with this Part, if necessary, it may
follow the provisions of this Part to establish a non-destructive testing
procedures which complies with the relevant specifications.
4.2.4 The performance of the instruments and equipment used for the testing
shall be periodically calibrated and have calibration records, which can only be
used after passing the calibration.
4.3 Testing personnel
4.3.1 Any person engaged in non-destructive testing shall hold the
corresponding qualification certificate issued by the relevant state department.
4.3.3 All personnel engaged in non-destructive testing must meet the following
requirements for vision in addition to good physical fitness.
4.3.3.1 Corrected visual acuity shall not be less than 5.0 (decimal record value
is 1.0) and be checked once a year.
5 Ultrasonic testing and its quality grade
5.1 Basis of testing
5.1.1 Relevant requirements for ultrasonic testing of forgings by the user or the
design and process department.
5.1.2 The method of establishing sensitivity, the selection of instruments and
equipment, the test of performance shall be consistent with the provisions in
this Part.
5.2 Instrument and equipment
5.3 Probe
5.3.1 Various probes shall be used at the calibrated frequency. In principle, it
uses the straight probes at 2 MHz ~ 2.5 MHz which have a wafer diameter 10
mm ~ 30 mm. The refraction angle of the angle beam probe shall be 35° ~ 70°,
the effective wafer area of the angle beam probe shall be 20 mm2 ~ 625 mm2.
5.3.2 The main beam of the probe shall have no obvious double peak, the
beam’s linear deflection shall be less than 2°.
5.3.3 It may replace it with other probes to assess defects and accurately locate
defects.
5.3.4 Probe’s performance test method is as specified in JB/T 10062.
5.4 Coupling agent
5.5 Test block
5.5.1 The test block shall be made of the same or approximate acoustic
properties as the workpiece being tested. When the material is tested by a
straight probe, there shall be no defects greater than the equivalent diameter of
the Φ2 mm flat-bottom hole.
5.5.5 In case of field testing, it may also use other types of equivalent test blocks.
5.6 Test of system’s combined performance
The test of the system’s combined performance is as specified in JB/T 9214.
5.7 Preparation of forgings before testing
5.7.1 Unless otherwise specified in the order, in case of radial testing of shaft
forgings, it shall machine a cylindrical surface. In case of axial testing, the both
end faces shall be machined into surfaces axially perpendicular to the forgings.
The surfaces of the pie-shaped and rectangular forgings shall be machined into
planes which are parallel to each other.
5.8 Testing procedures
5.8.1 General rules
5.8.1.1 Unless otherwise the testing cannot be performed due to the change of
sectional and local shape of the forgings due to chamfering, drilling, etc., it shall
carry out ultrasonic testing of the entire forging as much as possible.
5.8.1.4 It shall scan all the cross-sections of the forging as far as possible in
two mutually perpendicular directions.
5.8.1.5 For pie-shaped forgings, in addition to scanning from at least one plane,
it shall also carry out radial scanning from the circumferential surface as much
as possible.
5.8.1.6 For the testing of cylindrical solid or hollow forgings, in addition to the
radial scanning, it shall also carry out auxiliary scanning from the axial direction.
5.8.2 Sensitivity of testing
5.8.2.1 In principle, use the AVG method to determine the testing sensitivity. For
forgings which is limited by its geometry and whose testing thickness
approaches to the length of near-field, use the test block comparison method.
5.8.2.2 The testing sensitivity shall be based on the initially recorded equivalent
value, the reference wave height shall not be less than 40% of the full screen
height.
5.8.2.3 When assessing defects, it shall adjust the evaluation sensitivity in the
intact part of the forging.
5.8.2.4 Re-verification of testing sensitivity.
6 Magnetic-powder testing and its quality grade
6.1 Basis of testing
6.1.1 Relevant requirements of the user or design process department for the
magnetic-powder testing for forged steel.
6.1.2 Methods for establishing sensitivity, selection of instruments and
equipment, selection of magnetization methods, requirements for magnetic-
field’s strength shall be consistent with this Part.
6.2 Requirements of testing surface
6.2.1 The sensitivity of magnetic-powder testing is highly dependent on the
surface condition of the forged part being tested. If the irregular surface
condition affects the display or evaluation of the defect, the surface to be tested
must be treated by grinding, machining or other means.
6.2.3 The removal of foreign matter can be carried out by any method that does
not affect the magnetic-powder testing.
6.2.4 In order to test small defects, the roughness Ra of the surface of the
forging is generally not more than 6.3 μm.
6.2.5 Temperature of the testing surface. It shall be less than 300 °C in case of
dry method; it shall be less than 10 °C ~ 50 °C in case of wet method.
6.3 Testing period
6.3.1 Unless otherwise specified by the purchaser, the magnetic-powder
acceptance test shall be carried out after the final heat-treatment and finishing
of the forgings.
6.4 Equipment and magnetic-powder
6.4.1 Magnetic-powder testing equipment and special types of equipment must
meet the requirements of JB/T 8290.
6.4.3.4 Wet-powder method shall use kerosene or water as the dispersion
medium. When using water as a medium, it shall add appropriate rust inhibitors
and surfactants. The viscosity of the magnetic suspension shall be controlled
within 5000 Pa•s ~ 20000 Pa•s (25 °C).
6.4.3.5 The concentration of magnetic suspension shall be determined
according to the type, particle size, application method and time of the
magnetic-powder. Under normal circumstances, non-fluorescence. 10 g/L ~ 25
g/L. fluorescence. 1 g/L ~ 3 g/L, its dispersion medium shall not have
fluorescent properties.
6.5.1 Methods and materials
6.5.1.1 The ferromagnetic-powder used as the test medium may be either dry
or wet; it may be fluorescent or non-fluorescent.
6.7 Magnetic-field’s strength
6.7.1 The minimum magnetic-field’s strength used shall be able to show all
dissenting defects and distinguish them. The maximum magnetic-field’s
strength shall be just below the critical point at which the magnetic-powder
7 Penetration testing and its quality grades
7.1 Basis of testing
User or design process department’s requirements for penetration testing of
forged steel.
7.2 Requirements of testing surface
7.2.1 The surface of the testing area and the adjacent 25 mm shall be dry and
free of dirt, grease, cotton fiber, oxide scale, oil or other foreign matter which
7.3 Testing materials
7.3.1 Penetration testing materials generally include penetrants, emulsifiers,
cleaning agents, imaging agents.
7.3.2 The quality control of the penetration test material shall comply with the
requirements of JB/T 9216.
7.4 Control test block
7.4.1 The control test block is mainly used to test the performance of the testing
agent and the operation process.
7.4.2 The control test blocks are divided into aluminum-alloy test blocks and
chrome-plated test blocks.
7.4.3 Production of control test blocks.
7.5 Classification and selection of penetration testing methods
7.5.1 Classification and code of penetration testing methods
7.6 Operating procedures
7.6.1 Pre-cleaning
7.6.1.1 All areas to be tested must be pre-cleaned as required by 7.2 before
applying the penetrant.
7.6.1.2 Post-cleaning drying.
The cleaned workpieces shall be dried. Drying methods generally include
heating the workpiece in a drying oven, baking it using an infrared lamp, drying
it using hot compressed air, or drying it naturally at ambient temperature.
However, the temperature of the workpiece must not exceed 50 °C before
applying the penetrant.
7.6.2 Applying penetrant
......
Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al.
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