Used in USNRC-RDT standards

Designation: A 388/A 388M – 05

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Standard Practice for

Ultrasonic Examination of Heavy Steel Forgings1
This standard is issued under the fixed designation A 388/A 388M; 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.

1. Scope* E 317 Practice for Evaluating Performance Characteristics

1.1 This practice2 covers the examination procedures for the of Ultrasonic Pulse-Echo Examination Instruments and
contact, pulse-echo ultrasonic examination of heavy steel Systems Without the Use of Electronic Measurement
forgings by the straight and angle-beam techniques. The Instruments
straight beam techniques include utilization of the DGS (Dis- E 428 Practice for Fabrication and Control of Steel Refer-
tance Gain-Size) method. See Appendix X3. ence Blocks Used in Ultrasonic Inspection
1.2 This practice is to be used whenever the inquiry, E 1065 Guide for Evaluating Characteristics of Ultrasonic
contract, order, or specification states that forgings are to be Search Units
subject to ultrasonic examination in accordance with Practice 2.2 ANSI Standard:
A 388/A 388M. B 46.1 Surface Texture4
1.3 The values stated in either SI units or inch-pound units 2.3 Other Document:
are to be regarded separately as standard. The values stated in Recommended Practice for Nondestructive Personnel Quali-
each system may not be exact equivalents; therefore, each fication and Certification SNT-TC-1A, (1988 or later)5
system shall be used independently of the other. Combining 3. Terminology
values from the two systems may result in non-conformance
with the standard. 3.1 Definitions:
1.4 This specification and the applicable material specifica- 3.1.1 individual indications—single indications showing a
tions are expressed in both inch-pound units and SI units. decrease in amplitude as the search unit is moved in any
However, unless the order specifies the applicable “M” speci- direction from the position of maximum amplitude and which
fication designation [SI units], the material shall be furnished are too small to be considered traveling or planar.
to inch-pound units. 3.1.2 indication levels (clusters)—five or more indications
1.5 This standard does not purport to address all of the in a volume representing a 2-in. [50-mm] or smaller cube in the
safety concerns, if any, associated with its use. It is the forging.
responsibility of the user of this standard to establish appro- 3.1.3 planar indications—indications shall be considered
priate safety and health practices and determine the applica- continuous over a plane if they have a major axis greater than
bility of regulatory limitations prior to use. 1 in. [25 mm] or twice the major dimension of the transducer,
whichever is greater, and do not travel.
2. Referenced Documents 3.1.4 traveling indications—inductions whose leading edge
2.1 ASTM Standards: 3 moves a distance equivalent to 1 in. [25 mm] or more of metal
A 469/A 469M Specification for Vacuum-Treated Steel depth with movement of the transducer over the surface of the
Forgings for Generator Rotors forging.
A 745/A 745M Practice for Ultrasonic Examination of Aus-
4. Ordering Information
tenitic Steel Forgings
4.1 When this practice is to be applied to an inquiry,
contract, or order, the purchaser shall so state and shall also
1
This practice is under the jurisdiction of ASTM Committee A01 on Steel, furnish the following information:
Stainless Steel and Related Alloys and is the direct responsibility of Subcommittee 4.1.1 Designation number (including year date),
A01.06 on Steel Forgings and Billets.
4.1.2 Method of establishing the sensitivity in accordance
Current edition approved Sept. 1, 2005. Published September 2005. Originally
approved in 1955. Last previous edition approved in 2004 as A 388/A 388M – 04. with 8.2.2 and 8.3.3 (Vee- or rectangular-notch),
2
For ASME Boiler and Pressure Vessel Code applications see related Specifi-
cation SA-388/SA-388M in Section II of that Code.
3 4
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Available from American National Standards Institute (ANSI), 25 W. 43rd St.,
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM 4th Floor, New York, NY 10036.
5
Standards volume information, refer to the standard’s Document Summary page on Available from the American Society for Nondestructive Testing, 1711 Arlin-
the ASTM website. gate Ln., P.O. Box 28518, Columbus, OH 43228–0518.

*A Summary of Changes section appears at the end of this standard.

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 A 388/A 388M – 05
4.1.2.1 The diameter and test metal distance of the flat- 7. Preparation of Forging for Ultrasonic Examination
bottom hole and the material of the reference block in 7.1 Unless otherwise specified in the order or contract, the
accordance with 8.2.2.2, forging shall be machined to provide cylindrical surfaces for
4.1.3 Quality level for the entire forging or portions thereof radial examination in the case of round forgings; the ends of
in accordance with 11.3, and the forgings shall be machined perpendicular to the axis of the
4.1.4 Any options in accordance with 1.4, 5.4, 5.5, 6.1, 7.1, forging for the axial examination. Faces of disk and rectangular
7.2, 8.1.11, 9.1, and 9.2. forgings shall be machined flat and parallel to one another.
5. Apparatus 7.2 The surface roughness of exterior finishes shall not
exceed 250 µin. [6 µm] unless otherwise shown on the forging
5.1 An ultrasonic, pulsed, reflection type of instrument shall drawing or stated in the order or the contract.
be used for this examination. The system shall have a mini- 7.3 The surfaces of the forging to be examined shall be free
mum capability for examining at frequencies from 1 to 5 MHz. of extraneous material such as loose scale, paint, dirt, and so
On examining austenitic stainless forgings the system shall forth.
have the capabilities for examining at frequencies down to 0.4
MHz. 8. Procedure
5.1.1 The ultrasonic instrument shall provide linear presen-
tation (within 5 %) for at least 75 % of the screen height 8.1 General:
(sweep line to top of screen). The 5 % linearity referred to is 8.1.1 As far as practicable, subject the entire volume of the
descriptive of the screen presentation of amplitude. Instrument forging to ultrasonic examination. Because of radii at change
linearity shall be verified in accordance with the intent of of sections and other local configurations, it may be impossible
Practice E 317. Any set of blocks processed in accordance with to examine some sections of a forging.
Practice E 317 or E 428 may be used to establish the specified 8.1.2 Perform the ultrasonic examination after heat treat-
65 % instrument linearity. ment for mechanical properties (exclusive of stress-relief
5.1.2 The electronic apparatus shall contain an attenuator treatments) but prior to drilling holes, cutting keyways, tapers,
(accurate over its useful range to 610 % (+1 dB) of the grooves, or machining sections to contour. If the configuration
amplitude ratio) which will allow measurement of indications of the forging required for the treatment for mechanical
beyond the linear range of the instrument. properties prohibits a subsequent complete examination of the
5.2 Search Units, having a transducer with a maximum forging, it shall be permissible to examine prior to treatment for
active area of 1 in.2 [650 mm2] with 3⁄4 in. [20 mm] minimum mechanical properties. In such cases, reexamine the forging
to 11⁄8 in. [30 mm] maximum dimensions shall be used for ultrasonically as completely as possible after heat treatment.
straight-beam scanning (see 8.2); and search units equipped 8.1.3 To ensure complete coverage of the forging volume,
from 1⁄2 by 1 in. [13 by 25 mm] to 1 by 1 in. [25 by 25 mm] index the search unit with at least 15 % overlap with each pass.
shall be used for angle-beam scanning (see 8.3). 8.1.4 For manual scanning, do not exceed a scanning rate of
5.2.1 Transducers shall be utilized at their rated frequencies. 6 in./s [150 mm/s].
5.2.2 Other search units may be used for evaluating and 8.1.5 For automated scanning, adjust scanning speed or
pinpointing indications. instrument repetition rate, or both, to permit detection of the
5.3 Couplants, having good wetting characteristics such as smallest discontinuities referenced in the specification and to
SAE No. 20 or No. 30 motor oil, glycerin, pine oil, or water allow the recording or signaling device to function. At no time
shall be used. Couplants may not be comparable to one another shall the scanning speed exceed the speed at which an
and the same couplant shall be used for calibration and acceptable calibration was made.
examination. 8.1.6 If possible, scan all sections of forgings in two
5.4 Reference Blocks, containing flat-bottom holes may be perpendicular directions.
used for calibration of equipment in accordance with 5.1.1 and 8.1.7 Scan disk forgings using a straight beam technique
may be used to establish recording levels for straight-beam from at least one flat face and radially from the circumference,
examination when so specified by the order or contract. whenever practicable.
5.5 DGS Scales, matched to the ultrasonic test unit and 8.1.8 Scan cylindrical sections and hollow forgings radially
transducer to be utilized, may be used to establish recording using a straight-beam technique. When practicable, also exam-
levels for straight beam examination, when so specified by the ine the forging in the axial direction.
order or contract. The DGS scale range must be selected to 8.1.9 In addition, examine hollow forgings by angle-beam
include the full thickness cross-section of the forging to be technique from the outside diameter surface as required in
examined. An example of a DGS overlay is found in Appendix 8.3.1.
X3. 8.1.10 In rechecking or reevaluation by manufacturer or
purchaser, use comparable equipment, search units, frequency,
6. Personnel Requirements and couplant.
6.1 Personnel performing the ultrasonic examinations to this 8.1.11 Forgings may be examined either stationary or while
practice shall be qualified and certified in accordance with a rotating in a lathe or on rollers. If not specified by the
written procedure conforming to Recommended Practice No. purchaser, either method may be used at the manufacturer’s
SNT-TC-1A (1988 or later) or another national standard that is option.
acceptable to both the purchaser and the supplier. 8.2 Straight-Beam Examination:

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 A 388/A 388M – 05
8.2.1 For straight-beam examination use a nominal 21⁄4- be directly read from the CRT screen. These flaw sizes are the
MHz search unit whenever practicable; however, 1 MHz is the equivalent flat bottom reflector that can be used as a reference
preferred frequency for coarse grained austenitic materials and point.
long testing distances. In many instances on examining coarse
NOTE 3—The above can be utilized on all solid forgings. Cylindrical
grained austenitic materials it may be necessary to use a hollow forgings, and drilled or bored forgings must be corrected to
frequency of 0.4 MHz. Other frequencies may be used if compensate for attenuation due to the central hole (see Appendix X4).
desirable for better resolution, penetrability, or detectability of
flaws. 8.2.3 Recalibration—Any change in the search unit, cou-
plant, instrument setting, or scanning speed from that used for
8.2.2 Establish the instrument sensitivity by either the
calibration shall require recalibration. Perform a calibration
reflection, reference-block technique, or DGS method (see
check at least once every 8 h shift. When a loss of 15 % or
Appendix X3 for an explanation of the DGS method).
greater in the gain level is indicated, reestablish the required
8.2.2.1 Back-Reflection Technique (Back-Reflection Cali- calibration and reexamine all of the material examined in the
bration Applicable to Forgings with Parallel Entry and Back preceding calibration period. When an increase of 15 % or
Surfaces)—With the attenuator set at an appropriate level, for greater in the gain level is indicated, reevaluate all recorded
example 5 to 1 or 14 dB, adjust the instrument controls to indications.
obtain a back reflection approximately 75 % of the full-screen
8.2.4 During the examination of the forging, monitor the
height from the opposite side of the forging. Scan the forging
back reflection for any significant reduction in amplitude.
at the maximum amplification setting of the attenuator (attenu-
Reduction in back-reflection amplitude may indicate not only
ator set at 1 to 1). Carry out the evaluation of discontinuities
the presence of a discontinuity but also poor coupling of the
with the gain control set at the reference level. Recalibration is
search unit with the surface of the forging, nonparallel back-
required for significant changes in section thickness or diam-
reflection surface, or local variations of attenuation in the
eter.
forging. Recheck any areas causing loss of back reflection.
NOTE 1—High sensitivity levels are not usually employed when in- 8.3 Angle-Beam Examination—Rings and Hollow Forgings:
specting austenitic steel forgings due to attendant high level of “noise” or 8.3.1 Perform the examination from the circumference of
“hash” caused by coarse grain structure. rings and hollow forgings that have an axial length greater than
8.2.2.2 Reference-Block Calibration—The test surface 2 in. [50 mm] and an outside to inside diameter ratio of less
roughness on the calibration standard shall be comparable to, than 2.0 to 1.
but no better than, the item to be examined. Adjust the 8.3.2 Use a 1 MHz, 45° angle-beam search unit unless
instrument controls to obtain the required signal amplitude thickness, OD/ID ratio, or other geometric configuration results
from the flat-bottom hole in the specified reference block. in failure to achieve calibration. Other frequencies may be used
Utilize the attenuator in order to set up on amplitudes larger if desirable for better resolution, penetrability, or detectability
than the vertical linearity of the instrument. In those cases, of flaws. For angle-beam inspection of hollow forgings up to
remove the attenuation prior to scanning the forging. 2.0 to 1 ratio, provide the transducer with a wedge or shoe that
will result in the beam mode and angle required by the size and
NOTE 2—When flat-surfaced reference block calibration is specified, shape of the cross section under examination.
adjust the amplitude of indication from the reference block or blocks to 8.3.3 Calibrate the instrument for the angle-beam examina-
compensate for examination surface curvature (an example is given in
Appendix X1).
tion to obtain an indication amplitude of approximately 75 %
full-screen height from a rectangular or a 60° V-notch on inside
8.2.2.3 DGS Calibration—Prior to use, verify that the DGS diameter (ID) in the axial direction and parallel to the axis of
overlay matches the transducer size and frequency. Accuracy the forging. A separate calibration standard may be used;
of the overlay can be verified by reference blocks and however, it shall have the same nominal composition, heat
procedures outlined in Practice E 317. Overlays are to be treatment, and thickness as the forging it represents. The test
serialized to match the ultrasonic transducer and pulse echo surface finish on the calibration standard shall be comparable
testing system that they are to be utilized with. but no better than the item to be examined. Where a group of
8.2.2.4 Choose the appropriate DGS scale for the cross- identical forgings is made, one of these forgings may be used
sectional thickness of the forging to be examined. Insert the as the separate calibration standard. Cut the ID notch depth to
overlay over the CRT screen, ensuring the DGS scale base line 3 % maximum of the thickness or 1⁄4 in. [6 mm], whichever is
coincides with the sweep line of the CRT screen. Place the smaller, and its length approximately 1 in. [25 mm]. Thickness
probe on the forging, adjust the gain to make the first back-wall is defined as the thickness of the forging to be examined at the
echo appear clearly on CRT screen. Using the Delay and time of examination. At the same instrument setting, obtain a
Sweep control, shift the screen pattern so that the leading edge reflection from a similar OD notch. Draw a line through the
of the initial pulse is on zero of the DGS scale and the peaks of the first reflections obtained from the ID and OD
back-wall echo is on the DGS scale value corresponding to the notches. This shall be the amplitude reference line. It is
thickness of the forging. Adjust the gain so the forging preferable to have the notches in excess metal or test metal
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back-wall echo matches the height of the DGS reference slope when possible. When the OD notch cannot be detected when
within 61 Db. Once adjusted, increase the gain by the Db examining the OD surface, perform the examination when
shown on the DGS scale for the reference slope. Instrument is practicable (some ID’s may be too small to permit examina-
now calibrated and flaw sizes that can be reliably detected can tion), as indicated above from both the OD and ID surfaces.

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 A 388/A 388M – 05
Utilize the ID notch when inspecting from the OD, and the OD 10.1.3 The designation (including year date) to which the
notch when inspecting from the ID. Curve wedges or shoes examination was performed as well as the frequency used,
may be used when necessary and practicable. method of setting sensitivity, type of instrument, surface finish,
8.3.4 Perform the examination by scanning over the entire couplant, and search unit employed; and
surface area circumferentially in both the clockwise and 10.1.4 The inspector’s name or identity and date the exami-
counter-clockwise directions from the OD surface. Examine nation was performed.
forgings, which cannot be examined axially using a straight
beam, in both axial directions with an angle-beam search unit. 11. Quality Levels
For axial scanning, use rectangular or 60° V-notches on the ID 11.1 This practice is intended for application to forgings,
and OD for the calibration. These notches shall be perpendicu- with a wide variety of sizes, shapes, compositions, melting
lar to the axis of the forging and the same dimensions as the processes, and applications. It is, therefore, impracticable to
axial notch. specify an ultrasonic quality level which would be universally
applicable to such a diversity of products. Ultrasonic accep-
9. Recording tance or rejection criteria for individual forgings should be
9.1 Straight-Beam Examination—Record the following in- based on a realistic appraisal of service requirements and the
dications as information for the purchaser. These recordable quality that can normally be obtained in the production of the
indications do not constitute a rejectable condition unless particular type forging.
negotiated as such in the purchase order or contract. 11.2 Heavy austenitic stainless steel forgings are more
9.1.1 For individual indications, report: difficult to penetrate ultrasonically than similar carbon or
9.1.1.1 In the back-reflection technique, individual indica- low-alloy steel forgings. The degree of attenuation normally
tions equal to or exceeding 10 % of a nominal back reflection increases with section size; and the noise level, generally or in
from an adjacent area free from indications, and isolated areas, may become too great to permit detection of
9.1.1.2 In the reference-block or DGS technique, indica- discrete indications. In most instances, this attenuation results
tions equal to or exceeding 100 % of the reference amplitude. from inherent coarse grained microstructure of these austenitic
9.1.2 For indications that are planar, traveling, or clustered, alloys. For these reasons, the methods and standards employed
determine the location of the edges and the major and minor for ultrasonically examining carbon and low-alloy steel forg-
axes using the half-amplitude (6dB drop) technique and report: ings may not be applicable to heavy austenitic steel forgings. In
9.1.2.1 The variation in depth or planar area, or both, of general, only straight beam inspecting using a back-reflection
traveling indications, reference standard is used. However, utilization of Practice
9.1.2.2 The length of major and minor axes of planar A 745/A 745M for austenitic steel forgings can be considered
indications, and if flat bottom hole reference standards or angle beam exami-
9.1.2.3 The volume occupied by indication levels and the nation of these grades are required.
amplitude range. 11.3 Acceptance quality levels shall be established between
9.2 Angle-Beam Examination—Record discontinuity indi- purchaser and manufacturer on the basis of one or more of the
cations equal to or exceeding 50 % of the indication from the following criteria.
reference line. When an amplitude reference line cannot be 11.3.1 Straight-Beam Examination:
generated, record discontinuity indications equal to or exceed- 11.3.1.1 No indications larger than some percentage of the
ing 50 % of the reference notch. These recordable indications reference back reflection.
do not constitute a rejectable condition unless negotiated as 11.3.1.2 No indications equal to or larger than the indication
such in the purchase order. received form the flat-bottom hole in a specific reference block
9.3 Report reduction in back reflection exceeding 50% of or blocks.
the original measured in increments of 10%. 11.3.1.3 No areas showing loss of back reflection larger than
9.4 When recording, corrections must be made for beam some percentage of the reference back reflection.
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divergence at the estimated flaw depth (See Guide E 1065). 11.3.1.4 No indications per 11.3.1.1 or 11.3.1.2 coupled
9.5 Report indication amplitudes in increments of 10%. with some loss of resultant back reflection per 11.3.1.3.
11.3.1.5 No indications exceeding the reference level speci-
10. Report fied in the DGS method
10.1 Report the following information: 11.3.2 Angle-Beam Examination—No indications exceed-
10.1.1 All recordable indications (see Section 9); ing a stated percentage of the reflection from a reference notch
10.1.2 For the purpose of reporting the locations of record- or of the amplitude reference line.
able indications, a sketch shall be prepared showing the 11.4 Intelligent application of ultrasonic quality levels in-
physical outline of the forging including dimensions of all volves an understanding of the effects of many parameters on
areas not inspected due to geometric configuration, the pur- examination results.
chaser’s drawing number, the purchaser’s order number, and
the manufacturer’s serial number, and the axial, radial, and 12. Keywords
circumferential distribution of recordable ultrasonic indica- 12.1 angle beam examination; back-reflection; DGS;
tions; reference-block; straight beam examination; ultrasonic

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 A 388/A 388M – 05

SUPPLEMENTARY REQUIREMENTS

The following supplementary requirements shall apply only when specified by the purchaser in the
inquiry, contract, or order. Details shall be agreed upon by the manufacturer and the purchaser.

S1. Reporting Criteria 2. 1⁄8 in. [3 mm] FBH for thicknesses of 1.5-6 in. [40-150 mm]
inclusive
S1.1 Reference block calibration shall be performed using 3. 1⁄4 in. [6 mm] FBH for thicknesses over 6 in. [150 mm]
at least three holes, spaced to approximate minimum, mean,
and maximum thickness as tested, and shall be used to generate S1.2 Reporting criteria include:
a distance amplitude correction (DAC) curve. The following 1. All indications exceeding the DAC curve
hole sizes apply: 2. Two or more indications separated by 1⁄2 in. [12 mm] or less

1. 1⁄16 in. [1.5 mm] flat bottom holes (FBH) for thicknesses less
than 1.5 in. [40 mm]

APPENDIXES

(Nonmandatory Information)

X1. TYPICAL TUNING LEVEL COMPENSATION FOR THE EFFECTS OF FORGING CURVATURE

X1.1 The curve (Fig. X1.1) was determined for the follow-
ing test conditions:
Material nickel-molybdenum-vanadium alloy steel
(Specification A 469/A 469M, Class 4)
Instrument Type UR Reflectoscope
Search unit 1 ⁄8-in. [30-mm] diameter quartz
1

Frequency 21⁄4 MHz

Reference block ASTM No. 3-0600 (aluminum)
Reflection area of refer- 0.010 in.2 [6.5 mm2] in nickel-molybdenum-vana-
ence curve dium alloy steel
Surface finish 250 µin. [6 µm], max, roughness

X1.2 To utilize curve, adjust reflectoscope sensitivity to

obtain indicated ultrasonic response on ASTM No. 3-0600

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reference block for each diameter as shown. A response of 1 in.
[25 mm] sweep-to-peak is used for flat surfaces. Use attenuator
to obtain desired amplitude, but do testing at 1 to 1 setting.

FIG. X1.1 Typical Compensation Curve for Effects of Forging

Curvature

X2. INDICATION AMPLITUDE COMPENSATION FOR TEST DISTANCE VARIATIONS

X2.1 The curve (Fig. X2.1) has been determined for the Reference block ASTM No. 3-0600 (aluminum)
following test conditions: Reflection area of refer- 0.010 in.2 [65 mm2] in nickel-molybdenum-vana-
ence curve dium alloy steel
Material nickel-molybdenum-vanadium alloy steel Surface finish 250 µin. max, roughness
(Specification A 469/A 469M, Class 4)
Instrument Type UR Reflectoscope
Search unit 11⁄8-in. [30-mm] diameter quartz X2.2 To utilize curve, establish amplitude from ASTM
Frequency 21⁄4 MHz reference block to coincide with values from Appendix X1.
Couplant No. 20 oil

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FIG. X2.1 Typical Distance-Amplitude Correction Curve

X3. BACKGROUND INFORMATION ON THE DGS METHODS

FIG. X3.1 Example of DGS Overlay

X3.1 The DGS method was developed to determine flaw on the CRT screen. The back reflection of the part must be
sizes by comparison to a back-wall echo produced on the part established and suitable gain added. Flaw echo indications that
to be ultrasonically tested. The derivation of DGS curves is appear can be sized via the flaw size curves on the overlay. The
extensively covered and can be found in standard texts on overlay also defines the transducers and material it works in
ultrasonic testing, and will not be covered here. The distance or conjunction with, and the series of curves that are matched to
thickness of the forging to be tested must be accurately defined the overlay scales.

X4. COMPENSATION FOR CENTER HOLE ATTENUATION ON CYLINDRICAL BORED OR HOLLOW FORGINGS
UTILIZING THE DGS METHOD

X4.1 The hole in a cylindrical bored forging causes sound X4.1.1 Determine the correction value in dB from the
scatter. In these cases, a correction is required which depends Nomogram (Fig. X4.1). With the gain-dB control, proceed as
on the wall thickness and bore diameter. described in 8.2.2.4 reducing the flaw detector gain by the
correction value determined.
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 A 388/A 388M – 05

NOTE—Metric units are presented in this figure to be consistent with DGS scales presently available. Conversion to English units would also be
acceptable.
FIG. X4.1 The Influence of a Central Bore on the Backwall Echo Amplitude of Cylindrical or Plane Parallel Forgings

SUMMARY OF CHANGES

Committee A01 has identified the location of the following changes since A 388/A 388M–03 that may impact
the use of this standard.

(1) Revised 10.1.4.

Committee A01 has identified the location of the following changes since A 388/A 388M – 04 that may impact the use of this
standard.

(1) Added Section 3, clarified Section 9. (2) Combined X4.1.1, X4.1.2, and X4.1.3.

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 A 388/A 388M – 05

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