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Aluminium Alloy Casting Standards

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0% found this document useful (0 votes)
133 views9 pages

Aluminium Alloy Casting Standards

Uploaded by

matthewcastor88
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd

International Standard

INTERNATIONAL ORGANIZATION FOR [Link])I(LIYHAPOAHAR OPTAHM3AlJM fl0 CTAHAAPTM3ALWlM@ORGANlSATlON INTERNATIONALE DE NORMALISATION

Aluminium alloy castings produced by gravity, sand, or


chill casting, or by related processes - General conditions
for inspection and delivery
Pikes moulhes en alliages d’aluminium par gravitb, en sable ou en coquille ou par des pro&d& connexes - Conditions
g&&ales de contHe et de livraisoniTeh STANDARD PREVIEW
First edition - 1985-07-15 ([Link])
ISO 7722:1985
[Link]
369f7d061d59/iso-7722-1985

UDC 669.715-14 Ref. No. IS0 7722-1985 (E)


-13
Descriptors : aluminium, aluminium alloys, castings, delivery conditions, inspection, tests, macroscopic analysis.

Price based on 8 pages


Foreword
IS0 (the International Organization for Standardization) is a worldwide federation of
national standards bodies (IS0 member bodies). The work of preparing International
Standards is normally carried out through IS0 technical committees. Each member
body interested in a subject for which-a technical committee has been established has
the right to be represented on that committee. International organizations, govern-
mental and non-governmental, in liaison with ISO, also take part in the work.

Draft International Standards adopted by the technical committees are circulated to


the member bodies for approval before their acceptance as International Standards by
the IS0 Council. They are approved in accordance with IS0 procedures requiring at
least 75 % approval by the member bodies voting.
iTeh STANDARD PREVIEW
International Standard IS0 7722 was prepared by Technical Committee ISO/TC 79,
Light metals and their alloys. ([Link])
ISO 7722:1985
[Link]
369f7d061d59/iso-7722-1985

0 International Organization for Standardization, 1985

Printed in Switzerland
. INTERNATIONAL STANDARD IS0 77224985 (E)

Aluminium alloy castings produced by gravity, sand, or


chill casting, or by related processes - General conditions
for inspection and delivery

1 Scope and field of application If the level of control is not specified on ordering, the founder
shall apply the minimum level of control (Type 3).
This International Standard specifies the general conditions for
inspection and delivery of aluminium alloy gravity, sand, and The control level defines the nature of the tests (see table 1)
chill castings and aluminium alloy castings made by related and their minimum frequency (see 10.2.2, 10.2.6 and table 2).
processes. This choice will have an effect on the testing costs and the
selected level shall be clearly stated when bids are invited and
It specifies the conditions for ordering, and the conditions for confirmed when ordering.
producing, testing and accepting castings.

It applies to all aluminium alloy gravity castings, in particular 3.2 Type 1 control

defined in IS0 3522. iTeh STANDARDThis PREVIEW


those the chemical and mechanical properties of which are
control relates to castings where the internal soundness
and mechanical properties have to be verified. Internal sound-
([Link])
ness is the property of a metal which is free from faults such as
porosity, cavities or detrimental discontinuities with regard to
2 References intended use. The level of internal soundness shall be defined by
ISO 7722:1985common agreement between the founder and the purchaser, on
I SO 2092, Light metals and [Link]
their alloys - Code of designation pre-production castings for example.
based on chemical symbols. 369f7d061d59/iso-7722-1985
a) Metal control: chemical analysis of the bath and in
IS0 2378, Aluminium alloy chill castings - Reference test bar. some cases control of mechanical properties on separately
cast test pieces.
IS0 2379, Aluminium alloy sand castings - Reference test bar.
b) Castings control : shape and dimensions; internal
IS0 2859, Sampling procedures and tables for inspection by soundness verified by generally non-destructive tests;
attributes. mechanical properties of the castings are controlled either
on the castings themselves or on cast-on test pieces or cut
IS0 313414, Light metals and their alloys - Terms and defini- test pieces.
tions - Part 4: Castings.
c) Batch composition : the batch consists of castings :
IS0 3522, Cast aluminium alloys - Chemical composition and - of the same alloy;
mechanical properties.
- defined by the same drawing;
IS 0 6506, Metallic materials - Hardness test - Brinell test.
- issued from the same castl) and from the same
ISO 6892, Metallic materials - Tensile testing. charge of heat treatment.

3.3 Type 2 control


3 Control levels
This control relates to castings for which the internal sound-
ness and mechanical properties, although desirable, are not
3.1 General subjected to compulsory checks.

The intended use of the castings defines the minimum level of a) Metal control : chemical analysis of the bath and control
control to be prescribed by the customer, selected from the of mechanical properties on separately cast test pieces,
three categories defined in 3.2, 3.3 and 3.4. except in special cases referred to in note 6 of table 1.

1) The definition of “cast” shall be agreed upon between the founder and the customer, taking account of the production equipment of the foundry.

1
IS0 7722-1985 (El

b) Castings control : shape and dimensions; the internal c) quantity and plus or minus tolerance on the quantity of
soundness control by non-destructive tests and the control castings;
of mechanical properties on cast-on test pieces or cut test
pieces are left to the purchaser’s initiative. d) time and/or rate of delivery;

c) Batch composition: a batch is considered to be com- e) drawing of the casting with main dimensions and
posed of castings obtained from charges of approximately indication of special tolerances on these dimensions,
similar composition, provided that they have all been cast in compulsory indication of the support surfaces and bearing
less than 8 h and that the batch does not exceed 1 000 kg. components for the castings during machining and control
operations;
3.4 Type 3 control f) if the tools are to supplied by the purchaser, the enquiry
or order shall specify their design, condition, number and
This control relates to castings with no particular requirements. the controls to be carried out;
a) Castings control : appearance, shape and dimensions. g) conditions of manufacture or control of pre-production
castings, if required;
b) Batch composition : the batch can be defined by a
tonnage, a number of casting or a production period, by h) repair conditions (see [Link]);
agreement between the interested parties.
j) marking of castings.
The various properties to be controlled are given in table 1.

4.2.2 Definition of control level


4 Wording of enquiries and orders a) the control level, as defined in clause 3;

4.1 General iTeh STANDARD PREVIEW


b) standard, method, nature and frequency of the tests to
be carried out by the founder or by the purchaser:
Each consultation,
through drawings,
([Link])
enquiry or order shall convey, possibly
accompanying annexes or reference docu- - properties to be checked and values to be obtained;
ments, all the information the founder requires to show the - surface smoothers of the casting and areas to be
means and methods of manufacture and control suitable forISO 7722:1985
controlled;
[Link]
the quality level required for the product in question.
369f7d061d59/iso-7722-1985
- pressure tightness and test conditions;
This means that in addition to the actual definition of the
- verification of batch homogeneity;
product (drawing, material, administrative references, etc. 1
which is entirely his responsibility, in all cases the purchaser - mass and mass tolerances;
shall specify at the time of enquiry the control level (in ac-
cordance with clause 3) he has decided to achieve, depending - other tests to be carried out by the founder or by the
on the conditions of use of the castings and in particular the purchaser, whether or not they appear in this lnter-
non-destructive controls with their severity grades as defined national Standard;
in [Link].
c) any specially defined area on the casting, if there is one;
Moreover, if he intends to make these controls the responsi-
bility of the founder, he shall state this clearly. Should this not d) acceptance conditions and criteria;
be stipulated, the founder is only bound to verify the dimen-
e) any necessary references to consultation documents.
sions and appearance of the castings on receipt, this being in
addition to the current manufacture control.
4.2.3 Definition of acceptance
Whether or not the founder is contractually responsible for
carrying out the controls, the conditions and severity grades of a) the intervention of an organization or an agent, author-
these controls are defined by reference to national standards or ized by the purchaser or his representative, or checks
by agreement between the interested parties. carried out by the founder;

b) the conditions of intervention (on casting, on finished


4.2 Essential information castings, or as stated in the order specification);

4.2.1 Definition of the casting and wording of the order c) place of acceptance, if this cannot be carried out at the
founder’s works and, in some cases, the body responsible
a) designation or drawing number or casting number with for the tests for which the founder is not equipped (par-
an indication of the index where applicable; ticularly for chemical composition);

b) designation of the alloy and condition of the consign- d) batching and number of tests per batch; if these differ
ment; from the stipulations in 10.2.2;

2
IS0 77224985 (El

e) order stipulations, conditions of acceptance and control The founder may inform the purchaser of all the amendments
documents to be supplied (see clause 10); which have had to be added to the drawing, with a view to
obtaining sound castings. Close co-operation between the
(1) without acceptance purchaser, the founder and the pattern maker is strongly rec-
ommended.
(1.1) wi,thout statement or certificate;
(1.2) with statement of compliance with the order; The founder is not obliged to check the compliance of the
manufacture or control tools with the drawing submitted to
(1.3) with current manufacture control documents;
him, unless he has been directly responsible for producing the
(1.4) with specific control certificate for the tools; he is only obliged to do this if the purchaser has
castings supplied; stipulated this clearly in the order.
(2) with acceptance;
(2.1) with acceptance certificate; 7 Standard castings (mass production)
(2.2) with acceptance report.
7.1 General

Before starting to mass produce a new casting or amending an


5 Production and casting methods - Heat old casting, the purchaser shall ask the founder to submit “pre-
treatment production castings”. These shall be characteristic, for any
inspection or test carried out by the purchaser, in accordance
Unless otherwise stipulated, the production method (in par- with the contractual specifications, of all the properties of the
ticular the nature of the furnace charges), the casting method castings to be supplied by the founder to the purchaser, and
and the selection of the heat treatment cycle, if this is used, are shall enable founder and purchaser to co-operate as far as the
left to the founder, who shall supply the castings in accordance finalization of certain manufacturing details are concerned,
with the contractual stipulations. With this in mind, all draw-
iTeh STANDARD PREVIEW
ings, requirements or special information concerning internal
before starting mass production.

soundness, pressure tightness, basic tolerances and the


([Link])
7.2 Recommended
stability of the shapes, dimensions and appearance shall be procedure
communicated to the founder at the first consultation.
Unless otherwise specified, two stamped pre-production
ISO 7722:1985castings shall be submitted to the founder by the purchaser for
[Link]
acceptance. The latter shall subject the pre-production
6 Shape and dimensions - Drawings 369f7d061d59/iso-7722-1985
and castings, as soon as possible, to all useful tests and to sufficient
tools machining of the parts intended to be machined, to ensure that
the internal soundness of the castings is adequate for their
The shape and dimensions of the castings, taking into account intended use.
clearances, machining allowances and permissible dimensional
deviations without indication of tolerance are defined by the If the pre-production castings are considered “acceptable”
following : within the terms of the technical specifications, they shall be
stamped by the purchaser, who shall keep one and return the
- the tools, when these are submitted by the purchaser other to the founder. Acceptance of these pre-production
and the founder has not been made responsible for check- castings shall be recorded in an acceptance report.
ing them with regard to the drawings;
If the pre-production castings are “not acceptable”, they shall
- the drawing of the as-cast part, when the founder is be returned to the founder for finishing, with all the reasons for
directly responsible, either for designing or checking the rejection clearly stated within the terms of the technical
tools; specifications.
- the drawing of the as-cast part and, where applicable,
by the pre-production casting(s) accepted by the purchaser,
in the case of mass production. 8 Characteristics and control

In order to guide the founder in the selection of the appropriate 8.1 Basic conditions
casting method, the drawings shall state the special tolerances
and main dimensions affecting the determining dimensions, the The basic conditions determine the general delivery conditions
parts to be machined and the support and bearing elements of for aluminium or aluminium alloys castings.
the castings during machining and control operations.
8.1 .l Characteristics and inspection of castings
As far as possible, they shall state the clearance to be allowed
for or at least indicate in which direction it shall have to be
estimated with regard to the drawing - plus tolerance, minus [Link] Appearance
tolerance or plus/minus tolerance; in the absence of such infor-
mation, clearances shall be additional with regard to the The surface condition of castings which are ready for delivery
drawing. shall be examined visually without recourse to instruments.

3
Ison22-1985 E)

Such defects as incipient cavities, cracks, etc., are likely to be 8.8.2 Properties and examination I or
considered determining factors, depending on the require- the al mf
ments of the order.
[Link] Chemical composition
Unless otherwise specified in the order, the castings shall be
carefully deburred by any appropriate means. Runners, risers The limits of the chemical composition of the aluminium alloys
and feeder heads shall be sheared off in order not to impede are fixed, individually, by reference to a standard (for example :
machining or impair casting appearance after mechanical IS0 3522, table 1) or to a specification accepted by the in-
finishing. Unless otherwise stated, the castings shall be terested parties.
delivered as-cast.
Sampling for chemical tests shall be carried out on samples
The first consultation and the order shall convey all necessary taken either separately from a metal mould with metal from the
information for avoiding disputes; in particular in the case of same cast (more thorough method) or from cast-on test blocks
castings to be subsequently protected or decorated, e.g. by for this purpose (subject to a segregation risk).
anodizing, it is recommended that, whenever possible, a range
of samples be used which presents all the characteristic For the spectral analysis of castings or test blocks, it is strongly
aspects, whether these are permitted or not. advised that they be re-melted for the subsequent chilling of an
adequate test piece and every precaution shall then be taken to
preserve the initial composition of the alloy.
. If the castings do not have the correct appearance, the accept-
ing agent may require that light material removal be carried out
in those parts where such an operation is acknowledged to be [Link] Tensile test - Separately cast test pieces
possible. Material removal shall naturally be in accordance with
the dimensional tolerance requirements. The order shall define, bY reference to a standard or a specific
specification sheet :
When the presence of cracks is suspected, a liquid penetrant
examination may be required and this shall be stated in an ad- - the shape and dimensions of the test pieces for tensi le
iTeh STANDARD
ditional clause or technical specifications. PREVIEW
testing;
- the characteristics to
Non-determining defects, ([Link])
which appear after the castings have IS0 2378 and IS0 2379).
be obtained (for example:

been put into use and which result in an appearance which


does not comply with the order, may be repaired in accordance ISO 7722:1985 These test pieces shall be cast at the same time and with the
with the conditions stated in [Link], subject to agreement be- same metal as that used for the batch casti ngs.
tween the interested parties.
[Link]
369f7d061d59/iso-7722-1985
For heat-treated casti rigs, separately cast test pieces shall be
hea t-treated with I the bate :h of castings to which they relate.
8.1 .1.2 Checking the dimensions
There shall be a sufficient number of test pieces for carrying out
the standard tests and the additional tests specified in 10.2.6
If gauges are used for the checking, the purchaser shall send
and 10.2.7.
these gauges and drawings of them to the founder, as soon as
the foundry tools are started; if the gauges are to be used by
the founder, they shall be submitted to him for the casting [Link] Hardness test
inspection and an agreement shall be drawn up for the cali-
bration of these tools. A hardness test may be carried out on the heads of separately
cast tensile test pieces, in accordance with the stipulations of
The castings shall be controlled in delivery condition and the IS0 6566.
checks carried out, principally, at the reference temperature of
20 + 5 OC. The dimensions of the as-cast parts and the ma- 8.2.3 Properties and examination of castings
chined parts shall be measured, depending on the size and
dimensions, using instruments which can give the required ac- [Link] Physical properties
curacy.
[Link].1 Roughness
For mass production, the controls shall be carried out on
castings selected is accordance with the rules and sampling
The method for measuring or assessing by comparison the re-
tables given in IS0 2859.
quired values and the places in question shall be stated at the
first consultation.

8.2 Special conditions


[Link].2 Macroscopic examination

8.2.1 Applications The macroscopic examination shows any porosity or cavities


and, after the appropriate metallographic etching, the grain
The special conditions required by the purchaser shall only dimensions.
be applied if they have been stated in the enquiry and the
order. The order shall specify the areas to be examined.

4
IsOT122-1985 E)

[Link].3 Microscopic examination The technique of crack impregnation shall be agreed on and the
order shall state the time at which crack impregnation shall be
The microscopic examination makes it possible to define the carried out and, for each casting section to be examined, the
alloy structure accurately, i.e. to determine qualitatively the type of discontinuity to be taken into account and the severity
nature, shape and distribution of the components as well as the grade.
size of the grains and the properties of the dendrites.

The order shall state the areas to be examined and stipulate an [Link].4 ‘Pressure tightness
agreement on the reference microscopic examinations and the
The pressure tightness requirements,‘which shall be met by the
standards of acceptance, which shall be agreed between the
castings, shall be stated in the enquiry or on the attached draw-
purchaser and the founder.
ings: roughing down stage of the casting, nature of the fluid,
temperature, test pressure, method of pressurization (internal
[Link].4 Mass and mass tolerances or external), duration of pressure application, permissible fluid
leakage rate. 1)
The masses shall be assessed at the first consultation and
shown on the accompanying drawings. NOTE - The safety of the staff carrying out these tests shall be
carefully supervised, in particular during tests under gas pressure.
Where necessary, the mass tolerances shall be finally agreed on
once the first castings have been made. [Link] Mechanical properties

[Link] Non-destructive controls [Link].1 Tensile test - Test pieces adjoining or taken from
the castings

[Link].1 General The tensile tests shall be carried out in accordance with
IS0 6892.
This concept covers all the controls, the aim of which is to
iTeh STANDARD PREVIEW
check the internal soundness of the castings, by detecting For level 1 and in accordance with an agreement between the
defects which are not visible by simple visual examination, such interested parties, the test pieces of suitable dimensions may
([Link])
as radiography, impregnation tests, ultrasonic testing; also be adjoining the castings themselves or taken from the cast-
ings.
,
included under this heading are surface condition examination
by visual means or using viso-tactile comparison specimens.
ISO 7722:1985In such cases:
[Link]
Applying the principle stated in 8.2.1, the purchaser shall -
369f7d061d59/iso-7722-1985 their location and dimensions shall be agreed between
specify in his enquiry, in accordance with the standards:
the founder and the purchaser;
- the nature of the non-destructive controls he intends to - their characteristics may be different from those ob-
carry out or have carried out; tained with separately cast test pieces and shall be agreed
between the founder and the purchaser.
- the part(s) of the casting submitted to these controls;
- the severity grades for assessing the detrimental or [Link].2 Hardness test
otherwise nature of any defects which may be revealed.
Hardness measurements shall be carried out on castings in
Whether or not the founder is contractually responsible for locations agreed between the interested parties, in accordance
carrying out these controls, the conditions and severity grades with the provisions of IS0 6506.
shall be defined by reference to standards, or otherwise by
This measurement may have the purpose of checking:
agreement between the interested parties.
- either the hardness itself as a property, particularly in
[Link].2 Radiography or radioscopy the case of heat treated alloys;
- or the homogeneity of the batches.
If a radiographic or radioscopic examination is specified in the
order, it shall state the areas to be examined. It is essential that
[Link] Defect repair
the acceptance limits be defined with respect to a standard
record or to reference radiographs. The purpose of defect repair is to restore to the castings the
qualities required on the order, if any of these qualities are im-
[Link].3 Crack impregnation paired by the defects. Repair is not, however, meant to be an
operation which simply hides defects. The normal deburring
Crack impregnation with dyes reveals any discontinuities which operations and the preparation of the support and bearing
open at the surface. elements are not considered to be repairs.

1) If the castings are intended to contain a fluid and where absolute pressure tightness is not required, the order mayspecify, for example, a
permissible fluid leakage volume during pressure application.

5
1s0 77224985 (El

When no characteristic casting internal soundness is required, 10 Acceptance


the founder is the only judge of and is responsible for the
occasion and selection of the method of repair from those
10.1 General
listed below, unless there is any specific agreement in the
order. If however, the founder feels that the defect is such that
it is likely to affect the solidity of the casting, he shall inform the 10.1.1 When no receipt IS required, castings may be
purchaser. delivered :

When a characteristic internal soundness is required, no repair a) without statement or certificate;


may be carried out without the client’s authorization and his
agreement on the repair method as well as means of inspecting b) with a statement of compliance with the order : a docu-
this operation. ment in which the founder states that the castings supplied
comply to the requirement of the order, without details of
The repair may consist, depending on the circumstances, of any test results;
carrying out, in accordance with the rules of the art, either a
filler metal by means of a suitable welding method or an oper- c) with a current production inspection report: a docu-
ation to position a threaded stud or machined element. If the ment in which the founder states that the castings supplied
casting has been subjected to heat treatment before welding comply with the requirements of the order and in which he
repair, this heat treatment shall be restarted, unless otherwise gives the results of current production inspection tests on
specified by the purchaser. products from the same production process as the delivery,
but not necessarily relating to the castings delivered;
To prevent leaks in castings which should be pressure tight, it is
possible, but only with the written agreement of the purchaser, d) with a test report which specifically covers the castings
to have recourse to impregnation; then the casting shall be supplied: a document which contains the results of all the
subjected to the pressure test after the impregnation process prescribed tests and which states that they apply to the
has been completed. castings supplied.

iTeh STANDARD
The impregnation method and chosen products shall be sub-
mitted beforehand for the approval of the purchaser and shall
PREVIEW
10.1.2 When receipt of delivery is to be acknowledged, this

use of the castings treated in this way.


([Link])
under no circumstances adversely affect the manufacture or
shall be stated in the enquiry so that is included explicitly in the
contract with details of the corresponding manufacture and in-
spection costs and related items. Depending on the circum-
ISO 7722:1985
stances, the documents to be supplied are as follows:
9 Marking of the castings[Link]
a) certificate of acceptance: document signed
369f7d061d59/iso-7722-1985 by the
If the castings are to be marked , this shall be specified in the receiving agent appointed by the purchaser 11, containing
order. the results of all the tests prescribed for the batch in
question;
The order shall also state, by reference to the as-cast casting
drawing, the position, designation and methods used to pro- b) acceptance report: when the acceptance certificate
duce these markings. is signed by special agreement by the founder and the
If this information is not given and the dimensions of the purchaser, or his representative*), it is called an acceptance
castings and their conditions of use permit it, each casting shall report.
be stamped in hollow or in relief (in principle when out of the
foundry) with the following markings, preferably in the follow- 10.1.3 Final acceptance shall take place at the foundry when
ing order : the acceptance certificate or report is submitted, subject to
a) designation of the alloy (unless otherwise agreed in ac- those controls which may only be carried out later on the
cordance with IS0 2092); purchaser’s premises within the time stipulated by the order.

b) mark of the founder;


10.1.4 In the event of a dispute concerning the results ob-
.
c) mark or number of the tool (In accordance with the tained by the purchaser, an arbitration test shall be carried out
drawing or order specification); in a laboratory approved by the interested parties.

d) year of manufacture (if required);


10.2 Acceptance procedure
e) any other information (cast number or individual
number for example) if required, as agreed previously
between the interested parties. 10.2.1 Place of acceptance

If nothing is specified in the order, the founder may, if he The samp e selection, preparation of test pieces and the tests
wishes, stamp his mark on the casting. stipulated in the order shall be carried out at the foundry.

1) This agent may, for all or some of the operations and by mutual agreement, be a member of the inspection staff at the foundry.
2) Not on the foundry staff.

6
Is0 77224985 E)

10.2.2 Batching 10.2.5 Marking the samples and the test pieces

The size of the batches depends on the inspection level (see The test pieces shall, in principle, be cast in the presence of the
clause 3). accepting agent, on the understanding, however, that the
casting operations can, under no circumstances, be delayed by
his absence.
10.2.3 Submission for acceptance
The samples shall be selected by the accepting agen t 1); like the
Submission for acceptance, sample selection and the ac- test pieces, they shall be stamped in his presence.
ceptance tests which may be carried out on the spot, shall be
carried out in the foundry. While the test pieces are being prepared, if the stamp marks
have to be removed or displaced, such operations may only be
The founder shall inform the purchaser in due time of the date carried out in the presence of the accepting agent.
of submission for acceptance.
10.2.6 Number of tests per batch
This note shall state the number of castings submitted from
each cast, as well as the relevant order references; it con- Unless otherwise stated in the order, the number of tests per
stitutes a certificate stating that the prescribed manufacturing batch, and also the number of castings to be selected for the
conditions have been complied with and that the individual tests, are as stated in tables 2 and 3.
tests, if required, have been carried out.
10.2.7 Check tests
The representative, who has been given free access to the
place where the castings are stored, shall call there on the day If the test results are unsatisfactory and the user agrees to this,
stipulated in the written invitation or within 5 days of that, fail- two additional tests shall be carried out for each inadequate
ing which, in order to avoid disturbing the production cycle, the test.
founder may carry out the acceptance test himself and submit
the acceptance report to the purchaser.
iTeh STANDARD The batch is considered to comply with the requirements,
PREVIEW
when the two check tests meet the minimum mechanical re-
quirements specified.
10.2.4 Checking of batch homogeneity ([Link])
For sand cast test pieces, if a machining fault is visible on the
The homogeneity of each of the batches is checked by hard- test piece, a single check test shall be carried out, subject to
ness measurements. This test shall be carried out on ISO 7722:1985 agreement
castings by the purchaser.
and positions agreed between [Link]
the interested parties.
369f7d061d59/iso-7722-1985It may, however, be rejected if a single check test gives un-
Unless otherwise agreed, the recorded hardness values shall satisfactory results.
not differ from each other by more than 20 Brine11 units;
moreover, they shall not be lower than those agreed by com- 10.2.8 Acceptance approval
parison with the measurements taken from the separately cast
tensile test piece heads. If all the conditions stipulated in the order, in accordance with
this International Standard, are met, the batch shall be
If the results of the hardness test carried out on the castings in considered to comply and shall be accepted by the purchaser,
accordance with the percentages given in table 3 differ by more subject to controls which may only take place later on the
than 20 Brine11 units, the test shall be carried out on all the purchaser’s premises within the time interval stipulated in the
castings in the batch in question. order.

1) This agent may, for all or some of the operations and by mutual agreement, be a member of the inspection personnel at the foundry.

Common questions

Powered by AI

Heat treatment procedures significantly impact the mechanical properties and structural integrity of castings by altering their microstructure. The selection of these procedures involves considerations of the casting's alloy composition, desired hardness, tensile strength, and ductility . Factors such as furnace type, cycle duration, and temperature gradients must be carefully controlled. The procedures are typically left to the expertise of the founder unless otherwise specified, to optimize the castings for specific industrial applications and conditions . Thorough documentation and communication during the initial consultation ensure that the desired properties are achieved .

Ensuring batch homogeneity is challenging due to inherent variations in casting processes and material properties. Strategies include consistent process controls, uniform material handling, and regular hardness testing across batches . Inconsistencies in test results, such as variations exceeding 20 Brinell units, can lead to batch rejection or necessitate additional testing, thereby impacting production timelines and costs . Setting clear standards for test variance and employing rigorous sampling protocols can help mitigate these challenges and enhance the reliability of casting quality .

Verification of mass and mass tolerances is crucial because it ensures that the casting meets specified requirements for both functionality and material use. Discrepancies in mass can affect the casting's performance, impacting balance, fitting, and overall structural integrity. It can be effectively managed by detailing mass specifications during initial consultations, employing precise weighing techniques, and establishing clear tolerance margins . Regular checks and early agreements on acceptable mass deviations enable consistent production standards and aid in minimizing material waste and ensuring compliance with design criteria .

Non-destructive testing (NDT) plays a critical role in ensuring the internal soundness and integrity of castings in industrial applications. By employing techniques like radiography and ultrasonic tests, NDT identifies defects not visible to the naked eye, thereby preventing failures in service. This form of testing allows for early detection of production issues, reducing the likelihood of costly rework and contributing to safety and reliability in critical applications such as aerospace and automotive industries . The specification of NDT methods and their frequency in process documentation amplifies the quality of the controls, minimizing risks and promoting effective quality assurance across the production cycle .

Voluntary non-destructive tests are typically chosen at the discretion of the purchaser and may target specific areas of concern without being part of mandatory compliance checks, offering additional assurance of quality beyond minimum requirements . Mandatory tests are required by standards or specifications and are crucial for ensuring that all castings meet baseline quality thresholds. The implications for product quality are significant; while mandatory tests ensure standard compliance, voluntary tests provide bespoke insights into specific casting aspects, potentially revealing issues not covered by standard checks. Both test types support thorough quality control and enhance confidence in the casting's performance and reliability .

Defining acceptance criteria poses challenges as it necessitates clear communication and agreement between purchasers and founders on quality and performance standards. If not thoroughly established, misunderstandings can lead to disputes over compliance and rejection of batches, affecting lead times and production costs . Additionally, variability in interpretation of criteria may result in inconsistent application of tests, impacting the objectivity of acceptance and leading to strained relationships. Establishing detailed criteria, as well as a framework for arbitration and control documents, can mitigate these risks by providing transparency and ensuring mutual understanding of expectations .

Macroscopic and microscopic examinations are complex due to the detailed analysis required to assess casting defects, alloy composition, and grain structures. Macroscopic examination highlights porosities and cavities, requiring specific etching and precise scrutiny, while microscopic examination provides detailed insights into alloy structures, dendritic properties, and fine defects . These processes contribute to quality control by detecting imperfections that could compromise casting integrity and performance. Early identification of such issues prevents downstream failures and supports the continuous improvement of casting quality and reliability .

Drawings and annexes play a fundamental role in the casting manufacturing process as they convey detailed specifications and requirements of the product to the founder. These documents provide essential information about the shape, dimensions, machining allowances, and permissible tolerances, ensuring the castings meet the design and functional criteria specified by the purchaser . They help the founder select appropriate manufacturing methods and tools and set up proper controls, directly affecting the quality and performance of the final product .

Specifying repair conditions in casting orders is crucial as it delineates acceptable remediation methods for detected defects, affecting the casting's durability and lifecycle. Clear repair protocols ensure that any corrective actions do not compromise the casting's integrity, performance, or safety standards . It also facilitates transparency and efficiency in addressing defects, thereby enhancing product reliability and decreasing downtime. Detailed stipulations regarding permissible repair techniques and testing aid in maintaining consistent quality across batches and extend the usable life of castings within the supply chain .

Specifying control levels in casting orders is crucial as it determines the scope and rigor of testing necessary to ensure the product meets the required quality standards. Control levels guide both the purchaser and the founder in establishing the necessary non-destructive controls, severity grades, and compliance with national standards, affecting both the production method and final acceptance of the casting . These levels ensure that the product is suitable for its intended use by setting explicit expectations for quality assurance procedures, thereby influencing production cycles and acceptance criteria .

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