Designation: E 155 – 00 An American National Standard

Standard Reference Radiographs for

Inspection of Aluminum and Magnesium Castings1
This standard is issued under the fixed designation E 155; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

These Reference Radiographs have been developed in cooperation with the Quality Control Committee and Aerospace Research and
Testing Committee of the Aerospace Industries Association.

This standard has been approved for use by agencies of the Department of Defense.

1. Scope E 142 Method for Controlling Quality of Radiographic

1.1 These reference radiographs illustrate the types and Testing3
degrees of discontinuities that may be found in aluminum-alloy E 505 Reference Radiographs for Inspection of Aluminum
and magnesium-alloy castings. The castings illustrated are in and Magnesium Die Casting2
thicknesses of 1⁄4 in. (6.35 mm) and 3⁄4 in. (19.1 mm). E 1316 Terminology for Nondestructive Examinations2
1.2 This document may be used where no other applicable 2.2 ASTM Adjuncts:4
document exists, for other material thicknesses for which it has Reference Radiographs for Inspection of Aluminum and
been found to be applicable and for which agreement has been Magnesium Castings:
reached between the purchaser and the manufacturer. Volume I, Aluminum and Magnesium Castings5
1.3 The values stated in inch-pound units are to be regarded Volume II, Magnesium Castings6
as the standard. 3. Terminology
1.4 This standard does not purport to address all of the
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safety concerns, if any, associated with its use. It is the 3.1 Definitions—Definitions of terms used in this standard
responsibility of the user of this standard to establish appro- may be found in Terminology E 1316.
priate safety and health practices and determine the applica- 3.2 Definitions of Terms Specific to This Standard:
bility of regulatory limitations prior to use. 3.2.1 The terms relating to discontinuities used in these
reference radiographs are described based upon radiographic
NOTE 1—Vol I: The set of reference radiographs consists of 13 plates appearance.
covering discontinuities in aluminum-alloy castings and 10 plates cover-
3.2.2 foreign materials—appear as isolated, irregular, or
ing discontinuities in magnesium-alloy castings. Each plate is held in an
81⁄2 by 11-in. (216 by 279-mm) cardboard frame and each plate illustrates elongated variations of film density, not corresponding to
eight grades of severity for the discontinuity in approximately a 2 by 2-in. variations in thickness of material, nor to cavities. They may be
(51 by 51-mm) area. The cardboard frames are contained in a 101⁄2by due to the presence of sand, slag, oxide or dross, or metal of
111⁄2-in. (267 by 292-mm) ring binder. different density.
Vol. II: The set of reference radiographs consists of four plates covering 3.2.3 gas holes—appear as round or elongated, smooth-
discontinuities in magnesium-alloy castings only. Each plate is held in an edged dark spots, occurring individually, in clusters, or distrib-
81⁄2 by 11-in. (216 by 279-mm) cardboard frame and illustrates eight
grades of severity for the discontinuity (with the exception of discrete
uted throughout the casting.
discontinuities, where only one example of each discontinuity is given). 3.2.4 gas porosity—represented by round or elongated dark
NOTE 2—Reference radiographs applicable to aluminum and magne- spots corresponding to minute voids usually distributed
sium die castings up to 1 in. (25 mm) in thickness are contained in through the entire casting.
Reference Radiographs E 505. 3.2.5 microshrinkage (feathery type)—microshrinkage hav-
ing an elongated appearance resembling feather-like streaks.
2. Referenced Documents
3.2.6 microshrinkage (sponge type)—microshrinkage hav-
2.1 ASTM Standards: ing a spongelike appearance, and more massive and equiaxed
E 94 Guide for Radiographic Examination2 than the feathery type.
3.2.7 reacted sand inclusions—appear on radiograph as
“spotty segregation,” that is, sharply defined round light areas,
1
These reference radiographs are under the jurisdiction of ASTM Committee
E07 on Nondestructive Testing and are the direct responsibility of Subcommittee 3
E07.02 on Reference Radiographs. Discontinued; see 1999 Annual Book of ASTM Standards, Vol 03.03. Replaced
Current edition approved Dec. 10, 2000. Published February 2001. Originally by Guide E 94.
4
published as E 155 – 60 T. Last previous edition E 155 – 95e2. Available from ASTM Headquarters.
5
2
Annual Book of ASTM Standards, Vol 03.03. Order RRE015501.
6
Order RRE015502.

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 E 155
about 1 mm in diameter, and often with the rim lighter than the or jagged darkened area.
center. They are entrapped sand particles that underwent 3.2.10 shrinkage porosity or sponge (nonferrous alloys)—a
reaction with molten magnesium alloys containing zirconium localized lacy or honeycombed darkened area.
(Note 3).
3.2.8 segregations—appear as variations in film density 4. Significance and Use
which can be explained by segregation of elements of atomic 4.1 These radiographs are intended for reference only but
numbers different from that of the matrix. are so designed that acceptance standards, which may be
3.2.8.1 gravity segregation—appears white on radiograph developed for particular requirements, can be specified in
and may range from a mottling-type effect through white- terms of these radiographs. The illustrations are radiographs of
diffused spots blending with the matrix, to a cloud-like castings that were produced under conditions designed to
appearance in more severe cases. They are agglomerations of develop the discontinuities. The radiographs of the 1⁄4-in.
particles precipitated at temperatures above liquidus (Note 3). (6.35-mm) castings are intended to be used in the thickness
3.2.8.2 eutectic segregation—type of segregation is gener- range up to and including 1⁄2 in. (12.7 mm). The radiographs of
ally represented when a defect or discontinuity develops during the 3⁄4-in. (19.1-mm) castings are intended to be used in the
solidification and is fed with a near eutectic residual liquid rich thickness range of over 1⁄2 in. to and including 2 in. (51 mm).
with alloying elements that have a high X-ray attenuation. One The grouping and system of designations are based on consid-
exception to this enrichment as illustrated in Reference Radio- erations of the best practical means of making these reference
graphs E 155 is flow line (or eutectic depletion), where there is radiographs of the greatest possible value.
a local impoverishment of the alloying elements that have a 4.2 Film Deterioration—Radiographic films are subject to
high X-ray attenuation (Note 3). wear and tear from handling and use. The extent to which the
(1) eutectic segregation—microshrinkage type—type of seg- image deteriorates over time is a function of storage condi-
regation develops when a microshrinkage develops during tions, care in handling and amount of use. Reference radio-
solidification, and is fed with residual liquid rich in dense graph films are no exception and may exhibit a loss in image
alloying elements such as thorium. The area will show light on quality over time. The radiographs should therefore be peri-
a radiograph (Note 3). odically examined for signs of wear and tear, including
(2) eutectic segregation—pipe-shrink type—type of segre- scratches, abrasions, stains, and so forth. Any reference radio-
gation develops during solidification when a pipe shrink forms graphs which show signs of excessive wear and tear which
and is immediately filled with eutectic liquid rich in high X-ray could influence the interpretation and use of the radiographs
attenuation alloying elements. The area shows light on a should be replaced.
radiograph as a feathery or dendritic feature (Note 3). 5. Basis for Application
(3) eutectic segregation—hot-tear type—type of segrega-
tion develops during solidification when the hot tear that takes 5.1 The reference radiographs may be applied as acceptance
place is immediately filled with liquid rich in alloying elements standards tailored to the end use of the product. Application of
high in X-ray attenuation. The defect shows as white or light these reference radiographs as acceptance standards should be
irregular defined lines (Note 3). based on the intended use of the product and the following
(4) eutectic depletion—flow line—type of segregation devel- considerations (see Note 4).
ops when a section of a mold is filled by liquid and solidifies 5.1.1 An area of like size to that of the reference radiograph
at the front before liquid from another feed meets the solid shall be the unit area by which the production radiograph is
front. A portion of the solid front then partially melts; other- evaluated, and any such area shall meet the requirements as
wise, the discontinuity would be a cold shut. Solidification defined for acceptability.
begins after this remelt and the initial crystals are of high purity 5.1.2 Any combination or portion of these reference radio-
and contain fewer high-density alloying elements than the melt graphs may be used as is relevant to the particular application.
average. Since the metal is still flowing across these crystals, Different grades or acceptance limits may be specified for each
the composition ahead of this solidifying front is depleted. This discontinuity type. Furthermore, different grades may be speci-
depletion of the eutectic shows on the radiograph as a dark fied for different regions or zones of a component.
diffused line (Note 3). 5.1.3 Special considerations may be required where more
than one discontinuity type is present in the same area. Any
(5) oxide inclusions in magnesium alloys containing
modifications to the acceptance criteria required on the basis of
zirconium—show on a radiograph as well defined light area of
multiple discontinuity types must be specified.
irregular shape and size resembling a radiograph of a com-
5.1.4 Where the reference radiographs provide only an
pacted fine steel wool. It is composed of complex magnesium
ungraded illustration of a discontinuity, acceptance criteria
oxide film with high zirconium content, and, if present, rare
may be specified by referencing a maximum discontinuity size,
earths and thorium oxides also. It is often associated with
or percentage of the discontinuity size illustrated.
zirconium-rich particles.
5.1.5 Production radiographs containing porosity, gas or
NOTE 3—More detailed descriptions of these discontinuities can be inclusions may be rated by the overall condition with regard to
found in the article, “New Reference Radiographs for Magnesium Alloy size, number, and distribution. These factors should be consid-
Castings,” by B. Lagowski, published in the Journal of Testing and ered in balance.
Evaluation, Vol 2, No. 4, July 1974.
5.1.6 As a minimum the acceptance criteria should contain
3.2.9 shrinkage cavity—appears as a dendritic, filamentary, information addressing: zoning of the part (if applicable), the
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 E 155
acceptable severity level for each discontinuity type, and the TABLE 2 Reference Radiographs for Magnesium Castings—
specified area to which the reference radiographs are to be Volume II
applied. Applicable
Casting
Casting
Discontinuity Thickness,
NOTE 4—Caution should be exercised in specifying the acceptance Thickness,
in.A
criteria to be met in a casting. Casting design coupled with foundry in.A
practice should be considered. It is advisable to consult with the Eutectic segregation (discrete discontinui-
manufacturer/foundry before establishing the acceptance criteria to ensure ties)—pipeshrink, flow line, hot tears, oxide
the desired quality level can be achieved. inclusions
Reacted sand inclusion ⁄
14 all thicknesses
Eutectic segregation (microshrinkage type) ⁄
14 all thicknesses
6. Description Gravity segregation 1⁄4 all thicknesses
1⁄4 all thicknesses
6.1 The radiographs listed in Table 1 illustrate each type of
A
discontinuity in eight grades. The radiographs listed in Table 2 1 in. = 25.4 mm.
illustrate each type of discontinuity in eight grades, with the
exception of pipe shrink, flow line, hot tear and oxide inclu- approximately a 2 by 2-in. (51 by 51-mm) area. The radio-
sion, where a single ungraded illustration is given for each. graphic technique used is in agreement with Method E 142 and
Although eight grades of each discontinuity are shown (with Guide E 94, and produced a density of 2.0 to 2.25.
the above exceptions), a numerically smaller graded set of 6.2 The alloys used to reproduce the various discontinuities
discontinuities based on these reference radiographs could be were as listed in Table 3.
used for acceptance standards. Each grade is illustrated in NOTE 5—Misruns, core shift, cold shut, and surface irregularities are
not illustrated, as they are readily identifiable by surface inspection or by
other means of nondestructive testing.
TABLE 1 Reference Radiographs for Aluminum and Magnesium
Castings—Volume I 6.3 All of these references are original radiographs; they
Casting
Applicable should be viewed by transmitted light.
Casting
Discontinuity Thickness,
Thickness, 7. Keywords
in.A
in.A
7.1 aluminum; castings; discontinuities; magnesium; refer-
Aluminum-Alloy Castings
ence radiographs; x-ray
Gas holes ⁄
14 up to 1⁄2, incl
Gas holes ⁄
34 over 1⁄2 to 2, incl
Gas porosity (round) 1⁄4 up to 1⁄2, incl TABLE 3 Actual Alloys Used to Reproduce Discontinuities
Gas porosity (round) 3⁄4 over 1⁄2 to 2, incl
Discontinuity Alloy Used
Gas porosity (elongated) 1⁄4 up to 1⁄2, incl
Gas porosity (elongated) 3⁄4 over 1⁄2 to 2, incl Aluminum
Shrinkage cavity 1⁄4 All thicknesses
Gas holes 356
Shrinkage (sponge) 1⁄4 up to 1⁄2, incl
Gas porosity (round) 356
Shrinkage (sponge) 3⁄4 over 1⁄2 to 2, incl
Gas porosity (elongated) 195
Foreign material (less dense) 1⁄4 up to 1⁄2, incl
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Shrinkage cavity 356

Foreign material (less dense) 3⁄4 over 1⁄2 to 2, incl
Shrinkage (sponge) 356
Foreign material (more dense) 1⁄4 up to 1⁄2, incl
Foreign material (less dense) 356
Foreign material (more dense) 3⁄4 over 1⁄2 to 2, incl
Foreign material (more dense) 356
Magnesium-Alloy Castings
Magnesium
Gas holes ⁄
14 up to 1⁄2, incl
Gas holes ZK51A
Gas holes 3⁄4 over 1⁄2 to 2, incl
Eutectic segregation and flow line EZ33A
Microshrinkage (feathery) 1⁄4 up to 1⁄2, incl
Gravity segregation ZK91
Microshrinkage (feathery) 3⁄4 over 1⁄2 to 2, incl
Microshrinkage (feathery) AZ91C
Microshrinkage (sponge) 1⁄4 up to 1⁄2, incl
Microshrinkage (sponge) AZ91C
Microshrinkage (sponge) 3⁄4 over 1⁄2 to 2, incl
Foreign material (less dense) AZ91C
Foreign material (less dense) 1⁄4 up to 1⁄2, incl
Foreign material (more dense) AZ91C
Foreign material (less dense) 3⁄4 over 1⁄2 to 2, incl
Reacted sand inclusions HK31A
Foreign material (more dense) 1⁄4 up to 1⁄2, incl
Oxide inclusion in magnesium HZ11
Foreign material (more dense) 3⁄4 over 1⁄2 to 2, incl
alloys containing zirconium
A
1 in. = 25.4 mm.

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 E 155
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