Ultrasonic assessment of shrinkage type discontinuities

This investigation into ultrasonic internal discontinuities is intended to demonstrate typical examples of internal 'shrinkage' type discontinuities and its connection with the casting suitability, integrity and reliability in service. This type of discontinuity can be misinterpreted by ultrasonic technicians and can lead to the rejection of castings unnecessarily, due to the mis-characterization of fine shrinkage - discrete porosity. The samples for this investigation were taken from thirty ton heavy section ductile iron mill flange castings, manufactured by Graham Campbell Ferrum International. The sampled area was of discontinuities that were recorded for sizing on an area due to loss of back wall echo, but had acceptable reflectivity. A comparative sample was taken adjacent to the area of discrete porosity. The discontinuities found by this investigation are of a 'spongy' type, gaseous in appearance and are surrounded by acoustically sound material. All discontinuities discussed in this paper are centrally located in the through thickness of the casting. The porous nature of this type of discontinuity consisting of approximately 80-90% metal has its own residual strength, as indicated by the proof stress results which reveal a residual strength of up to 50-60% of that of the unaffected area of the casting. The affected areas are elliptical in shape and vary in density and through thickness throughout.