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2007 SECTION II, PART A SA-395

SPECIFICATION FOR FERRITIC DUCTILE IRON


PRESSURE-RETAINING CASTINGS FOR USE AT
ELEVATED TEMPERATURES
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SA-395

[Identical with ASTM Specification A 395-88 (Reapproved 1993)⑀1.]

1. Scope E 8 Test Methods of Tension Testing of Metallic Materials


1.1 This specification covers ductile iron castings for E 10 Test Method for Brinell Hardness of Metallic Mate-
pressure-retaining parts for use at elevated temperatures rials
(Note 1). E 30 Test Methods for Chemical Analysis of Steel, Cast
Iron, Open-Hearth Iron, and Wrought Iron
1.2 Valves, flanges, pipe fittings, pumps, and other E 59 Test Method of Sampling Steel and Iron for Determi-
piping components are generally manufactured in advance nation of Chemical Composition
and supplied from stock by the manufacturer, jobber, or E 186 Reference Radiographs for Heavy-Walled (2 to
dealer. 41⁄2 in. (51 to 114 mm)) Steel Castings
1.3 For supplemental casting requirements Specifica- E 280 Reference Radiographs for Heavy-Walled (41⁄2 to
tion A 834 may be utilized. 12 in. (114 to 305 mm)) Steel Castings
E 446 Reference Radiographs for Steel Castings up to 2 in.
1.4 The values stated within this specification are in
(51 mm) in Thickness
inch /pound units. A separate Specification A 395M is the
E 689 Reference Radiographs for Ductile Iron Castings
metric companion to this specification. The text in both is
identical. 2.2 Manufacturer’s Standardization Society of the
Valve and Fittings Industry Standard:
NOTE 1 — For service other than as specified in this section, reference
SP 25 (1964 edition) Standard Marking Systems for
should be made to Specification A 536 for Ductile Iron Castings.
Valves, Flanges, Pipe Fittings, and Unions

2. Referenced Documents
3. Ordering Information
2.1 ASTM Standards:
3.1 Orders for material under this specification shall
A 247 Test Method for Evaluating the Microstructure of
include the following applicable information:
Graphite in Iron Castings
A 370 Test Methods and Definitions for Mechanical Test- 3.1.1 Drawing, catalog number or part identifica-
ing of Steel Products tions,
A 395M Specification for Ferritic Ductile Iron Pressure- 3.1.2 Quantity (weight or number of pieces),
Retaining Castings for Use at Elevated Temperatures
3.1.3 ASTM designation and year of issue,
(Metric)
A 536 Specification for Ductile Iron Castings 3.1.4 Heat treating requirements (see 4.2.1),
A 732 /A 732M Specification for Castings, Investment, 3.1.5 Pressure test requirements (see 6.4.2),
Carbon and Low Alloy Steel for General Application, 3.1.6 Test samples from castings (see 9.1.1 and
and Cobalt Alloy for High Strength at Elevated Tempera- 10.1.1),
tures
A 834 Specification for Common Requirements for Iron 3.1.7 Test coupons size (see 9.2),
Castings for General Industrial Use 3.1.8 Metallographic option (see 10.1.1),

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SA-395 2007 SECTION II, PART A

3.1.9 Place of inspection (see 14.1), 6.2 Hardness:


3.1.10 Certification requirements (see 15.1), 6.2.1 The hardness of the castings and test specimens
shall be within the following limits:
3.1.11 Identification marking (see 16.2), and
HB, 3000 kgf load 143-187
3.1.12 Supplemental Requirements (see 1.3 and S1).
6.3 Microstructure:
6.3.1 The microstructure of the separately cast test
4. Materials and Manufacture coupon or the casting shall be essentially ferritic and con-
4.1 The melting method and the nodularizing practice tain no massive carbides, and have a minimum of 90%
shall be optional with the foundry. Type I and Type II Graphite as in Fig. 7 or Plate I of Test
Method A 247.
4.2 Except as provided in 4.2.1, all castings shall be
given a ferritizing heat treatment that produces essentially 6.4 Pressure Test Requirements:
a ferritic structure that contains no massive carbides. 6.4.1 Each pressure retaining casting shall be tested
4.2.1 When specified in the purchase order, castings after machining to the test pressure specified by the applica-
may be provided in an as cast condition provided they ble standard of ANSI, ASME Boiler and Pressure Vessel
comply with the requirements of 6.1 and 6.2.1. Code, or other pertinent code, and shall show no leaks.
4.2.2 Castings supplied in accordance with 4.2.1 may 6.4.2 Castings ordered under this specification not
be stress relieved by agreement between the manufacturer covered by ANSI standards and ASME Pressure Vessel
and purchaser. Code, and castings for special service applications, shall
be tested to such pressures as may be agreed upon by the
manufacturer and the purchaser.
5. Chemical Requirements 6.4.3 It is realized that the foundry may be unable
5.1 The casting shall conform to the following require- to perform the hydrostatic test prior to shipment, or that
ments for chemical composition (Note 2): the purchaser may wish to defer testing until additional
work or machining has been performed on the casting.
Total carbon, min,% 3.00 Castings ordered in the rough state for final machining
Silicon, max,% 2.50 by the purchaser may be tested hydrostatically prior to
Phosphorus, max,% 0.08
shipment by the manufacturer at pressures to be agreed
upon with the purchaser. However, the foundry is responsi-
5.1.1 The chemical analysis for total carbon shall be
ble for the satisfactory performance of the castings under
made on chilled cast pencil type specimens or from thin
the final hydrostatic test.
wafers approximately 1 / 32 in. thick cut from test coupons.
Drillings are not reliable because of the probable loss of
graphite.
7. Workmanship and Finish
5.1.2 For each reduction of 0.01% below the maxi- 7.1 The surface of the casting shall be examined visu-
mum specified phosphorus content, an increase of 0.08% ally and shall be free from adhering sand, scale, cracks,
silicon above the specified maximum will be permitted up and hot tears. Any other surface discontinuities shall meet
to a maximum of 2.75%. visual acceptance standards specified in the order.
NOTE 2 — Silicon contents above 2.75%, or phosphorus contents above
0.08% have a tendency to lower the impact resistance of the material. If
the carbon content is below 3.00%, excess cementite may form during 8. Repair
cooling and if this is not removed during heat treatment, the impact 8.1 Castings for valves, flanges, pipe fittings, pumps,
resistance of the material may be lowered.
and other piping components ordered under applicable
ANSI standards shall not be repaired by plugging, welding,
brazing, or impregnation.
6. Requirements
8.2 Castings not covered in 8.1 which leak on hydro-
6.1 Tensile: The ductile iron as represented by the test
static tests may be repaired by plugging, provided the
specimens shall conform to the following requirements for
following requirements are met:
tensile properties:
8.2.1 No welding or brazing is permitted.
Tensile strength, min, MPa 60 000 psi
Yield strength, min, MPa 40 000 psi 8.2.2 The diameter of the plug shall not exceed the
Elongation in % min, % 18 diameter of a standard 2 in. pipe plug.

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2007 SECTION II, PART A SA-395

8.2.3 The plugs, where practical, shall conform in 9.1.2 Test bars removed from castings shall conform
all dimensions to the standard ISO 3⁄8 plugs. In addition, to Fig. 5. The testing diameter shall be 1⁄2 in. if possible.
they shall have full thread engagement corresponding to Smaller diameters shall be utilized if necessary.
the thickness in the repaired section. Where a tapered plug
9.2 The test coupon size shall be as mutually agreed
is impractical because of the excess wall thickness in terms
upon between the manufacturer and purchaser. In the
of plug diameter and coincident thread engagement, other
absence of agreement, it shall be the option of the manufac-
types of plugs may be used provided both full engagement
turer.
and effective sealing against pressure are obtained. Where
possible, the ends of the plug should be ground smooth after 9.3 The test coupons shall be cast in molds made of
installation to conform to the inside and outside contours of suitable core sand having a minimum wall thickness of
the wall of the pressure vessel or pressure part. 11⁄2 in. for the 1⁄2 in., 1 in. sizes, and 3 in. for the 3 in.
8.2.4 The material from which the plug is manufac- size. The coupons shall be left in the mold until they have
tured shall conform in all respects to the materials specifi- changed to a black color (approximately 900°F or less).
cations which apply to the pressure vessel or pressure part. The keel block as shown in Fig. 1 or the modified keel
block produced from the mold shown in Fig. 4 may be
8.2.5 The area adjacent to the drilled hole shall be
substituted for the 1 in. block shown in Fig. 2.
examined by radiography, and shall meet the Level 3
acceptance requirements of Reference Radiographs E 689 9.4 When investment castings are made to this specifi-
and supporting Reference Radiographs E 446, E 186, or cation, the manufacturer may use test specimens cast to
E 280 as applicable and defined in accordance with Refer- size incorporated in the mold with the castings or separately
ence Radiographs E 689. cast to size using the same type of mold and the same
8.2.6 The thickness of any repaired section in relation thermal conditions that are used to produce the castings.
to the size of the plug used shall not be less than that given These test specimens shall be made to the dimensions
in Table 1. shown in Fig. 1 of Specification A 732 or Figs. 5 and 6
of Test Methods and Definitions A 370.
8.2.7 The minimum radius of repaired sections of
cylinders or cones in relation to the size of plug used shall 9.5 Separately cast test coupons shall be poured imme-
not be less than that given in Table 2. diately after the castings and shall represent the metal
8.2.8 A repaired area may consist of a maximum of treated with the nodularizing agent, and be identified with
three plugs with a spacing such that the ligaments between the castings they represent.
adjacent plugs shall not be less than listed in Table 3. Other 9.6 The manufacturer shall cast a sufficient number of
defective areas may also be repaired by plugging provided test coupons to provide for each ferritizing anneal. The
the minimum ligament between plugs in adjacent areas is test coupons shall be heat treated with the castings they
not less than twice the distance from the nearest plug, the represent. Sectioning of the test coupons prior to heat treat-
values for which are listed in Table 3. ing is not permitted.
8.3 Surface imperfections in castings other than valves, 9.7 The metallographic examination shall be made on
flanges, pipe fittings, pumps, and other piping components a test lug from the recommended test coupon shown in
may be repaired by plugging provided the depth of the Fig. 6 or from a casting. The test coupon shall represent
plug is not greater than 20% of the thickness of the casting the metal treated with the nodularizing agent.
section and the diameter of the plug is not greater than its
length. Repair of surface defects may not be done on pres-
sure containing portions of castings. The plug need not be 10. Number of Tests and Retests
threaded. The conditions of 8.2.1 and 8.2.4 shall also be 10.1 One tension test shall be made from sections cut
satisfied. from the test coupons (Fig. 3) for each ladle treated with
the nodularizing agent.
9. Test Coupon 10.1.1 Unless otherwise stated in the contract or
9.1 The separately cast test coupons from which the order for castings, a metallographic examination may be
tension test specimen is machined shall be cast to the size substituted for the tension test when separately cast test
and shape shown in Fig. 1, Fig. 2, or Fig. 4. Sectioning coupons are used. When the microstructure option is used,
procedure for removing test specimens from Y-blocks is a minimum of one tension test is required from each day’s
shown in Fig. 3. melt and for each heat treatment (see 10.2).
9.1.1 Test samples may be removed from castings 10.2 If any tension test specimen shows obvious
at locations designated on a drawing or as agreed to by defects, another from the same coupon, or from another
manufacturer and purchaser. coupon representing the same metal and the same anneal

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SA-395 2007 SECTION II, PART A

charge, may be tested. If an apparently sound test specimen 14. Inspection


fails to conform to this specification, castings may be re- 14.1 Unless otherwise specified in the contract or pur-
annealed and two retests made. If either retest fails to chase order, the manufacturer shall be responsible for car-
conform to this specification, the castings they represent rying out all the tests and inspection required by this
shall be rejected. specification.
14.2 The inspector representing the purchaser shall
have entry at all times, while work on the contract of the
11. Tension Test Specimen Preparation purchaser is being performed, to all parts of the manufactur-
11.1 The standard machined 1⁄2 in. round tension test er’s works which concern the manufacture of the material
specimen with 2 in. gauge length as shown in Fig. 5 shall ordered. The manufacturer shall afford the inspector all
be used except where the 1⁄2 in. Y-block test coupon is reasonable facilities to satisfy him that the material is being
required. In this case, either of the small size specimens, furnished in accordance with these specifications. Unless
0.375 or 0.250 in. round as shown in Fig. 5 shall be used. otherwise specified, all tests and inspection shall be made
at the place of manufacture or by an approved independent
laboratory prior to shipment, and shall be so conducted as
not to interfere unnecessarily with the operation of the
12. Test Methods
works.
12.1 Chemical analysis shall be made in accordance
with the following methods: Test Methods E 59 or E 30.
15. Certification
12.2 The chemical composition may also be determined
by spectrographic methods but should a dispute arise con- 15.1 When agreed upon in writing by the purchaser
cerning the chemical composition, the methods specified and the supplier, a certification shall be made on the basis
of acceptance of the material. This shall consist of a copy
in 12.1 shall be used as the umpire methods.
of the manufacturer’s test report or a statement by the
12.3 The yield strength shall be determined in accor- supplier accompanied by a copy of the test results, that
dance with Test Methods E 8 using one of the following the material has been sampled, tested, and inspected in
methods: accordance with the provisions of this specification. Each
certification so furnished shall be signed by an authorized
12.3.1 The 0.2% off-set method, or
agent of the supplier or manufacturer.
12.3.2 Extension under load method where the yield
strength may be determined as the stress producing an
elongation under load of 0.375%; that is, 0.0075 in. in a 16. Product Marking
gauge length of 2 in. 16.1 Casting for valves, flanges, pipe fittings, and
unions shall be marked for material identification in accor-
12.4 The hardness of the ductile iron as represented dance with paragraph 9.6 of the Standard Marking System
by the test specimens and castings shall be determined in for Valves, Flanges, Pipe Fittings, and Unions, SP-25.
accordance with Test Method E 10.
16.2 Castings other than valves, flanges, pipe fittings,
12.5 The percentage of each graphite type shall be and unions shall be identified subject to agreement by the
determined by manual counting, semi-automatic or auto- manufacturer and the purchaser.
matic image analysis methods. The sum of all graphite
types shall total to 100%. 16.3 Marking shall be in such a position as not to injure
the usefulness of the castings.

13. Records 17. Keywords


13.1 Records of the chemical composition, mechanical 17.1 casting; ductile iron; mechanical properties; pres-
properties, and metallographic examination, when applica- sure-retaining; pressure test; tensile strength; tension test-
ble, shall be systematically made and maintained. ing; yield strength

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2007 SECTION II, PART A SA-395

FIG. 1 KEEL BLOCK FOR TEST COUPONS

FIG. 2 Y-BLOCKS FOR TEST COUPONS


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SA-395 2007 SECTION II, PART A

FIG. 3 SECTIONING PROCEDURE FOR Y-BLOCKS

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2007 SECTION II, PART A SA-395

FIG. 4 MOLD FOR MODIFIED KEEL BLOCK

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SA-395 2007 SECTION II, PART A

FIG. 5 STANDARD 1 / 2 IN. ROUND TENSION TEST SPECIMEN WITH 2 IN. GAGE LENGTH AND EXAMPLES OF
SMALL SIZE SPECIMENS PROPORTIONAL TO THE STANDARD SPECIMEN
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FIG. 6 TEST COUPONS FOR MICROSCOPICAL EXAMINATION OF DUCTILE IRON

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2007 SECTION II, PART A SA-395

FIG. 7 SUGGESTED CLASSIFICATION OF GRAPHITE FORM IN DUCTILE CAST IRON


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TABLE 1 TABLE 2
MINIMUM THICKNESS OF REPAIRED SECTIONS MINIMUM RADIUS OF REPAIRED SECTIONS
Iron Pipe Size Plug, Minimum Thickness Repaired Minimum Radius of Cylinder
in. Section, in. Iron Pipe Size Plug, in. or Cone, in.
1 11 1 9
⁄8 ⁄32 ⁄8 ⁄16
1 7 1 11
⁄4 ⁄16 ⁄4 ⁄16
3
3
⁄8 1
⁄2 ⁄8 11⁄16
1
1
⁄2 21
⁄32 ⁄2 11⁄4
3 3 3
⁄4 ⁄4 ⁄4 2
1 13
⁄16 1 21⁄2
11⁄4 7
⁄8 11⁄4 4
11⁄2 15
⁄16 11⁄2 51⁄4
2 1 2 81⁄8

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SA-395 2007 SECTION II, PART A

TABLE 3
MINIMUM LIGAMENT BETWEEN PLUGSA,B

Nominal Plug Minimum Ligament Between Plugs, in.


1
Diameter, in. ⁄8, 1⁄4, 3⁄8 ⁄2, 1⁄4
1
1, 11⁄4 11⁄2, 2
1
⁄8, 1⁄4, 3⁄8 25⁄8 41⁄8 65⁄8 91⁄2
1
⁄2, 3⁄4 41⁄8 41⁄8 65⁄8 91⁄2
1, 11⁄4 65⁄8 65⁄8 65⁄8 91⁄2
11⁄2, 2 91⁄2 91⁄2 91⁄2 91⁄2
A
Based on efficiency of 80%.
B
Example: Assume three plugs are required for repair, one 1⁄8
in., one 3⁄8 in., and one 11⁄2 in. The minimum distance permitted is
as follows:
Ligament distance between 1⁄8 and 3⁄8 in. plugs is 25⁄8 in.
Ligament distance between 1⁄8 and 11⁄2 in. plugs is 91⁄2 in.
Ligament distance between 3⁄8 and 11⁄2 in. plugs is 91⁄2 in.

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2007 SECTION II, PART A SA-395

SUPPLEMENTARY REQUIREMENT

The following supplementary requirement shall not apply unless specified in the pur-
chase order.

S1. A microstructure test lug is to be cast attached to the casting at the location designated on the casting drawing.
The microstructure of the test lug shall be essentially ferrite and contain no massive carbides.

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