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ASNT

Con•inping Ed:uca•ion In Nondesl''ruc'live Tesl'ing.

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[ The American Society for Nondestructive Testing

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Materials and Processes for NDT Technology was editcrd by: Harry D. Moore Publication and review of this text was under the direction of the Personnel Training and Certification Committee of the American Society for Nondestructive Testing: George Wheeler, Chair (1976-80) Frank Sattler, Vice Chair (1976-79) Robert Anderson, Secretary (1976-79) F.C. Berry (1976-78) Chet Robards (1976-79) Carl Shaw (1976-82) Kermit Skeie (1976-J9r Robert Spinetti (1976-80)

Allen Whiting (1976-1979) Robert Brostrom (1978-81) Ward Rummel (1978-81) John Weiler (1978-81) Robert Baker (untenured) F.N. Moschini (untenured) Ed.Briggs (1979-82) Jack Spanner (1979-82)

Contributors: Donald R. Kibby Dr. Robert C. McMaster Dr. Vernon L. Stokes I

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ASNT Production Staff: Robert Anderson, Technical D~ector George Pherik9l D_irectcktif EduclUiOll Diana Nelson, Coordinator of Educ~tion Servict;,s • " e;..

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Copyright© 1981 by The American Society for Nondestructive Testing, Inc. AsNT is not responsible for the autpenticity or accuracy of information herein. Published opinions and statements do not necessarily reflect the opinion of ASNT. Products or services that are advertised or mentioned do not carry the endorsement or recommendation of ASNT. IRRSP, NDT Handbook, The NDT Technician and www.asnt.org are trademarks of The American Society for Nondestructive Testing, Inc. ACCP, ASNT, Level Ill Study~Guide, Materials Evaluation, Nondestructive Testing Handbook, Research in Nondestructive Evaluation and RNDE are registered trademarks of The American Society for Nondestructive Testing, Inc . ASNT exists to create a safer world by promoting the profession and technologies of nondestructive testing. ISBN-13: 978-0-931403-06-4 ISBN-10: 0-931403-06-5 Printed in the United States of America first printing 1981 second printing 12/87 third printing 05/88 fourth printing 10/89 fifth printing 12/91 sixth printing 01/94 seventh printi,ng 04/96 eighth printing 08/98 ninth printing 11/00 lOth printing 09/05 11th printing 10/07 12th printing 02/09 13th printing 04/11 14th printing 08/13

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Published by The American Society for Nondestru~tive Testing, inc .. 1711 Arlingate Lane PO Box 28518 Columbus, OH 43228-0518

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Table of Contents

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CHAPTER ,

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RELA:riQN OF: NDT :00 MANUFACTURING 1 NONDESTRUCTIVE TESTING: NDT Defini· tion.. RE~UIR,EMENTS FOR, NDT ·SUPER· • ~ISQRY PERSONNEL.. ;QUALIFICATION AND CERTlFICATION Qf :N.D~ LEVEL III TESTING PERSONNEL: Sourcesof,Technical Iqformation ·Available ' to . NDT · P~rsonnel. MANUFACTURING: MATERIAI:.S AND PROCESSES: Mate~al Failur~s. Purpose for Use of NDT. NDT IN FRACTURE CONTROL.

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INTRODUQTI,ON TO MANUFACTURING I 9 TECHNOLOGY History. INDUSTRIAL RELATIONSHIPS: Competition~ Industry. P~rsonnel. 'Nomenclature. SUBJECT MATTER: Materials. Processes. Economics. Order.

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,PROPERTIESOFMATERIALS 15 INTRODUCTION: Classes of Properties. Significance of Properties of Design. LOADING SYSTEMS AND MATERIAL FAILURE: Loading Systems. TESTING: The.Tensile Test. True Stress-True Strain. Compressfon Testing. Transverse Rupture Testing. Shear Testing. Fatigue Testing. Creep Testing. Notched Bar Testing. Bend Testing. Hardn~ss Testing. Fac· tor of Safety.

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THE NATURE OF MATERIALS AND SOLID STATE CHANGES IN METALS 31 The Effect of. Energy on the Atom. Metallic Structure. Solidification. Grain Size. SOLID STATE CHANGES IN METALS: Work Hardening. Plastic Deformation. Cold Work. RECRYSTALLIZATION: Recovery. Recrystallization. Grain Growth. AGE HARDENING. ALLOTROPIC CHANGES. HEAT TREATMENT OF s:rEEL: Approximate Equilibrium Heat-Treatment Processes. Austenitization. Annealing. Normalizing. Spheroidizing. Hardening of Steel. Temperi,ng. CORROSION: Direct Chemical Action. ElectrolY,tic (Electrochell)i~l) R:eac;;tiq,n.•Corrosi,.oq .:Rate Dependent on Several Factors. Types of Corrosion. Corrosion Protection.

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MENT: Cupola. Crucible Furnaces. Pot Furnaces. Reverberatory Furnaces. Electric Arc Furnaces. Induction Furnaces. FOUNDRY MECHANIZATION. 9

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FERROUSMETALS 45 Choosing Metals and Alloys. Ferrous Raw Materials. CAST IRONS. STEEL: Wrought Iron. Steel Making. Plain Carbon Steel. Alloy Steels. Low Alloy Structural Steels. Low Alloy AISI Steels. Stainless Steels. Tool and Die Steels. Cast Steels. MATERIAL IDENTIFICATION SYSTEMS.

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NONFERROUS METALS AND PLASTICS 57 ALUMINUM ALLOYS: Generhl ·Pi-'operties. Wrought Aluminum Alloys. Prope~ty Changes. 11 • Cast Alun:ilnum Alloys. COPPER ALLOYS: General Metallizing. Vacuum Metallizing. Hot Dip Plating. Electroplating. CHEMICAL CO,NVERSIONS: Anodizing. Chromate Coatings. Phosphate Coatings. Chemical Oxide Coatings.

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Index

INSPECTION 183 INSPECTION PROCEDURES: Organization of Inspection. Quantity of Inspection. Process Control Charts. PRINCIPLES OF MEASUREMENT: Dimensional References. Tolerances. Sources of Measurement Variation. :Basis for Measurement. INSPECTION EQUIPMENT: Micrometer Caliper. Other Adjustable Tools. Indicating Gages and Comparators. Fixed Gages. Surface Finish. Surface Finish Measurement. Surface Specification. 199

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r l. Preface

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This book has been compiled as a reference and source of general information concerning manufacturing for use by personnel involved in designing, using, or evaluating nondestructive testing of products and structures. The text material has been kept as general as pos,, sible to still retain technical value but broad enough to ,. include all phases of manufacturing industry and most of the materials used. The depth of treatment has intentionally been kept low in order that NDT personnel without a great amount of formal education might gain an interest and develop understanding of the material. However, the techniques of NDT are not included in the coverage. It is intended that persons using this text be already informed regarding that subject or acquire the necessary knowledge from other more specialized sources. Wherever practical, though, throughout the· book mention is made of certain NDT methods that might be suitable for the kinds of defects under consideration. Some of the limitations of the methods are also indicated in some applications. One of the essential needs for satisfactory use of NDT is recognition of its limitations; knowledge of the source of defects and the materials in which they are found is an aid in determin· ing the validity of any test and its evaluation. Appreciation is hereby expressed: to Grid Incorporated for giving permission to use large portions of Manufacturing: Materials and Processes by Harry D. Moore and Donald R. Kibbey, 1975,

to Vernon L. Stokes for providing many of the illustrations used and copy which served as a guide for some of the text material, to Robert T. Anderson, Technical Director, ASNT, and George L. Pherigo, Director of Education, ASNT, for their invaluable assistance in selecting and or• ganizing the material and for supplying the majority of the NDT tie-ins scattered throughout the text, and to Diana Nelson, Coordinator of Educational Services, ASNT, for her aid in editing the text material. H. Don Moore 1979

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Relation of NOT to Manufacturing

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Qi NONDESTRUCTIVE TESTING

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Nondestructive testing is a fundamental and essen-· tial tool for control of quality of engineering materials, manufacturing processes, t:eliability of pr