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Designation: E 505 – 96 An American National Standard
Standard Reference Radiographs for
Inspection of Aluminum and Magnesium Die Castings1
This standard is issued under the fixed designation E 505; 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
1.1 These reference radiographs illustrate the categories and
severity levels of discontinuities that may occur in aluminum- alloy and magnesium-alloy die castings. They are intended to
provide:
1.1.1 A guide enabling recognition of discontinuities and
their differentiation both as to type and severity level through
radiographic examination.
1.1.2 Example radiographic illustrations of discontinuities
and a nomenclature for reference in acceptance standards,
specifications, and drawings.
1.1.3 The values stated in inch-pounds are to be regarded as
standard.
NOTE 1—The set of reference radiographs consists of five 81⁄2 by 11-in.
cardboard frames containing radiographs covering discontinuities in
aluminum and magnesium alloy die castings. The first four frames each
contain two sets of four graded levels of increasing severity, while the last
frame contains two ungraded radiographs. The 5 frames are contained in
a 101⁄2 by 111⁄2-in. ring binder.
NOTE 2—Reference radiographs applicable to aluminum and magne- sium castings up to 2 in. (50 mm) in thickness are contained in ASTM
Reference Radiographs E 155, for Inspection of Aluminum and Magne- sium Castings, Volumes I and II.
1.2 Two kinds of illustration categories are covered as
follows:
1.2.1 Graded—Three discontinuity categories for alumi- num die castings and three discontinuity categories for mag- nesium die castings, each illustrated in four levels of progres- sively increasing severity. Category A discontinuities are
illustrated for aluminum and magnesium die castings having
thicknesses of 1⁄8 in. (3.2 mm) and 5⁄8 in. (15.9 mm); Category
B discontinuities are illustrated for 1⁄8-in. thick aluminum and
magnesium die castings; and Category C discontinuities are
illustrated for 5⁄8-in. thick aluminum and magnesium die
castings.
1.2.2 Ungraded—One illustration of one discontinuity for
0.20-in. (5.1-mm) thickness aluminum die casting; and one
illustration of one discontinuity for 1⁄8-in. (3.2-mm) thickness
magnesium die casting.
1.3 This document may be used for other materials, thick- nesses, or with other energy levels for which it has been found
to be applicable and agreement has been reached between the
purchaser and manufacturer.
1.4 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the
responsibility of the user of this standard to establish appro- priate safety and health practices and determine the applica- bility of regulatory limitations prior to use.
2. Referenced Documents
2.1 ASTM Standards:
E 94 Guide for Radiographic Testing2
E 142 Test Method for Controlling Quality of Radiographic
Testing2
E 1316 Terminology for Nondestructive Examinations2
2.2 ASTM Adjuncts:
Reference Radiographs for Inspection of Aluminum and
Magnesium Die Castings3
3. Terminology
3.1 Definitions—For definitions of terms used in this docu- ment, see Terminology E 1316.
4. Appearance of Radiographic Indications
4.1 The following descriptions are for use in discontinuity
identification and classification. These descriptions apply to
these reference radiographs only.
4.1.1 Category A (Porosity)—Round or elongated, smooth- edged dark spots occurring individually distributed or in
clusters.
4.1.2 Category B (Cold Fill)—A distinct darkened line or
band of variable length and definite smooth outline, usually
continuous or interconnected.
4.1.3 Category C (Shrinkage)—Filamentary or jagged dark- ened areas, usually continuous or interconnected.
4.1.4 Category D (Foreign Material)—Isolated irregular
variation in film density, either lighter or darker than surround- ing areas. They may indicate the inclusion of oxide or dross or
metallic compounds of different density. Illustration shows a
more dense material.
5. Significance and Use
5.1 These radiographs are so designed that acceptance
1 These reference radiographs are under the jurisdiction of ASTM Committee
E-7 on Nondestructive Testing.
Current edition approved Feb. 10, 1996. Published April 1996. Originally
published as E 505 – 74. Last previous edition E 505 – 91.
2 Annual Book of ASTM Standards, Vol 03.03. 3 Available from ASTM Headquarters. Order PCN 17-505050-22.
1
Copyright © ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.
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standards, which may be developed for particular require- ments, can be specified in terms of these radiographs. The
radiographs are of castings that were produced under condi- tions designed to produce the discontinuities. These reference
radiographs are intended to be used for casting thickness
ranges in accordance with Table 1.
5.2 The radiographic illustrations listed in Table 1 illustrate
three types of discontinuities in four severity levels. Two
ungraded illustrations have been included to establish the
radiographic appearance of foreign material.
5.3 These reference radiographs were produced in accor- dance with Guide E 94 and Test Method E 142. All of the
references are original radiographs.
5.4 Film Deterioration—Radiographic films are subject to
wear and tear from handling and use. The extent to which the
image deteriorates over time is a function of storage condi- tions, care in handling and amount of use. Reference radio- graph films are no exception and may exhibit a loss in image
quality over time. The radiographs should therefore be peri- odically examined for signs of wear and tear, including
scratches, abrasions, stains, and so forth. Any reference radio- graphs which show signs of excessive wear and tear which
could influence the interpretation and use of the radiographs
should be replaced.
6. Basis for Application
6.1 These reference radiographs may be applied as accep- tance standards tailored to the end use of the product. Appli- cation of these reference radiographs as acceptance standards
should be based on the intended use of the product and the
following considerations (see Note 3):
6.1.1 Unless otherwise specified, discontinuities of equal or
lesser severity than that in the specified reference radiograph
are acceptable in any specified unit area of the casting. The size
of the unit area should be specified in the acceptance criteria.
Discontinuities more severe than those in the specified refer- ence radiograph shall be considered rejectable.
6.1.2 Any combination or portion of these reference radio- graphs may be used as is relevant to the particular application.
Different grades or acceptance limits may be specified for each
discontinuity type. Further, different grades may be specified
for various regions or zones of the component.
6.1.3 Special consideration may be required where more
than one discontinuity type is present in the same area. Any
modification of the acceptance criteria required on the basis of
multiple discontinuity types must be specified.
6.1.4 Where the reference radiograph contains multiple
discontinuities, as in that case of gas holes, acceptance may be
based upon the aggregate area of the discontinuities, the
maximum discontinuity size in the reference radiograph, the
spacing between discontinuities, or a combination of these or
other criteria, or both.
6.1.5 As a minimum the acceptance criteria should contain
information addressing; zoning of the part (if applicable),
acceptance severity level for each discontinuity type, and the
specific area to which the reference radiographs are to be
applied.
NOTE 3—Caution should be exercised in specifying the acceptance
criteria to be met in the casting. Casting design coupled with foundry
practice should be considered. It is advisable to consult with the
manufacturer or foundry before establishing the acceptance criteria to
ensure the desired quality level can be achieved.
7. Keywords
7.1 aluminum; die castings; discontinuities; magnesium;
reference radiographs; X-ray
TABLE 1 Reference Radiographs for Aluminum and Magnesium Die Castings
Discontinuity Plate Thickness,
in. (mm)
Applicable Casting
Thickness,
in. (mm)
Aluminum Die Castings
Category A (Porosity) 1⁄8 (3.2) up to 3⁄8 (9.5), incl
Category A (Porosity) 5⁄8 (15.9) over 3⁄8 to 1 (9.5 to 25.4),
incl
Category B (Cold fill) 1⁄8 (3.2) up to 3⁄8 (9.5), incl
Category C (Shrinkage) 5⁄8 (15.9) over 3⁄8 to 1 (9.5 to 25.4),
incl
Category D (Foreign
material)
0.200 (5.08) up to 1 (25.4), incl
Magnesium Die Castings
Category A (Porosity) 1⁄8 (3.2) up to 3⁄8 (9.5), incl
Category A (Porosity) 5⁄8 (15.9) over 3⁄8 to 1 (9.5 to 25.4),
incl
Category B (Cold fill) 1⁄8 (3.2) up to 3⁄8 (9.5), incl
Category C (Shrinkage) 5⁄8 (15.9) over 3⁄8 to 1 (9.5 to 25.4),
incl
Category D (Foreign
material)
1⁄8(3.2) up to 1 (25.4), incl
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