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Content
1.0 SCOPE ........................................................................................................................................................................................... 3

2.0 MATERIAL PROPERTIES ...................................................................................................................................................... 3

3.0 IDENTIFICATION ..................................................................................................................................................................... 3

4.0 REQUIREMENTS FOR NEW CASTING – FIRST ARTICLE ......................................................................................... 3

4.1 REQUIREMENTS FOR FIRST ARTICLE ........................................................................................................................... 3

5.0 INSPECTION REQUIREMENTS............................................................................................................................................ 4

5.1 CAST SURFACE APPEARANCE INSPECTION ................................................................................................................ 4

5.2 VISUAL INSPECTION REPORT (VT) .................................................................................................................................. 5

5.2.1 REQUIREMENTS FOR PERSONNEL ............................................................................................................................... 5

5.3 DIMENSIONAL INSPECTION (DM) ..................................................................................................................................... 5

5.3.1 EXAMINATION REPORT .................................................................................................................................................... 5

5.4 CAST SURFACE NDT INSPECTION .................................................................................................................................... 6

5.4.1 MAGNETIC PARTICLE INSPECTION (MPI) PROCEDURES AND ACCEPTANCE STANDARDS................. 6

5.4.1.1 EXAMINATION REPORT ................................................................................................................................................. 6

5.4.1.2 SURFACE REQUIREMENTS............................................................................................................................................ 6

5.4.1.3 REQUIREMENTS FOR PERSONNEL ............................................................................................................................ 7

5.4.1.4 METHOD ................................................................................................................................................................................ 7

5.4.1.5 MAGNETIC PARTICLE ACCEPTANCE CRITERIA ................................................................................................. 7

5.5 ULTRASONIC INSPECTION PROCEDURES .................................................................................................................... 8

5.5.1. PROCESS SPECIFICATION FOR THE ULTRASONIC EXAMINATION (UT) ..................................................... 8

5.5.2 EXAMINATION AREA:......................................................................................................................................................... 8

5.5.3 REQUIREMENTS FOR PERSONNEL ............................................................................................................................... 8

5.5.4 SURFACE REQUIREMENTS ............................................................................................................................................... 8

5.5.5 METHODS ................................................................................................................................................................................ 8

02 Change UT Method Calibration – Table 3 Oct/16 Chad R. Chad R.
01 First Edition Aug/16 Chad R. Chad R.

REV. REVISION / EMISSION DATE EXEC. APROV.

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5.5.5.1 CALIBRATION ..................................................................................................................................................................... 8

5.5.6 ACCEPTANCE CRITERIA ................................................................................................................................................... 9

5.5.7 EXAMINATION REPORT .................................................................................................................................................... 9

6.0 CASTING REPAIR ...................................................................................................................................................................10

6.1 REPAIRING OF DISCONTINUITIES .................................................................................................................................10

6.1.1 THERMAL PROCESS REPAIR .........................................................................................................................................10

6.1.2 MECHANICAL PROCESS REPAIR .................................................................................................................................10

6.1.3 CASTING WELD REPAIR .................................................................................................................................................10

6.1.3.1 DEFECTS REQUIRING WELD REPAIR .....................................................................................................................10

6.1.3.1.1 MINOR DEFECTS ..........................................................................................................................................................10

6.1.3.1.2 MAJOR DEFECTS ..........................................................................................................................................................11

6.1.3.1.3 STRESS RELIEF .............................................................................................................................................................11

7.0 MACHINE SURFACE(S) NDT INSPECTION....................................................................................................................12

7.1 VT ACCEPTANCE ...................................................................................................................................................................12

7.2 MPI ACCEPTANCE .................................................................................................................................................................13

8.0 SURFACE PREPARATION....................................................................................................................................................14

9.0 DATA BOOK..............................................................................................................................................................................14

9.1 DOCUMENTATION OF CASTINGS ...................................................................................................................................14

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1.0 SCOPE

This standard covers the inspection of castings used in mining crushers including first
piece and subsequent production castings.

2.0 MATERIAL PROPERTIES

The casting drawing specifies the Metso material standard required for the casting. The
drawing may also note any deviations to the material standard. The supplier must confirm
chemical and mechanical properties meet requirements as specified by Metso material
standard. The material test reports must be submitted to Metso QA.

Hardness testing location, quantity and tensile test location are specified by drawing or
ITP. If the drawing does not contain hardness testing or test coupon location, the
supplier must contact prior to start of manufacturing Metso QA for instructions.

3.0 IDENTIFICATION

Castings delivered to Metso shall be marked according to the Metso Marking Instruction
for Castings. The location of identification markings is indicated on the drawings or in
Metso technical specification. The supplier must retain records that can be traceable to
individual casting to individual melting batch and its analysis.

4.0 REQUIREMENTS FOR NEW CASTING – FIRST ARTICLE

4.1 REQUIREMENTS FOR FIRST ARTICLE

Foundry is required to supply molding and process information such as locations of gates
and risers to Metso quality department prior to 1 st article piece production. Computer
mold solidification analysis should be performed within one month of initial order. A
report of the mold solidification analysis is not required, but the method and results
should be available for discussion upon request from Metso. If design changes are
required or suggested, the foundry is to initiate discussion with Metso Engineering and
QA department. Design changes must be approved by Metso and documented with
drawing revisions.

Lifting features may or may-not be included in the casting drawing. If the foundry adds
their own lifting features to the casting, it is their responsibility to appropriately size this
lifting feature. Lifting features must be removed if not shown on the finished machine
drawing.

Inspection of the First Article Production piece is termed FAI (First Article Inspection). FAI
requires that all cast dimensions generated, this includes but not limited to radii, draft
angle(s) and thicknesses, must be inspected to prove out the pattern and foundry
process. Casting tolerances are indicated on drawing or Inspection Test Plan (ITP).
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Additional NDT inspection may be required for FAI and it is the supplier’s responsibility to
make arrangements with Metso QA prior start of production to verify the inspection plan.

Whenever a new pattern is used, existing pattern is revised, or foundry process is

changed, the first part produced is considered a First Article Production piece. Metso QA
must be notified of these changes prior to production for quality surveillance.

5.0 INSPECTION REQUIREMENTS

5.1 CAST SURFACE APPEARANCE INSPECTION

Unless otherwise specified by drawing, the castings surface visual acceptance criteria are
defined in the Metso material standard specified for the casting. The acceptance criteria
are based on SCRATA specifications (surface comparator plates determined by the Steel
Casting Research and Trade Association).

Surface features General requirement (SCRATA)

Surface texture A3

Non- metallic inclusions B4

Gas porosity C3

Fusion discontinuities (laps and D3

cold shuts)

Expansion discontinuities (scabs) E1

Inserts F1

Surface finish- Thermal dressing G2

Surface finish- Mechanical H3

dressing

Welds J2

Table 1: Surface roughness acceptance requirements for general low-alloy steel casting
surfaces

Note: Supplier shall have in their possession the physical SCRATA comparator plates.
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5.2 VISUAL INSPECTION REPORT (VT)

The visual examination records shall contain at least the following information:

· the identification of the casting (item code and casting batch number)
· the designated category and specified level for each area examined
· the results of the examination with date and signature of examiner

5.2.1 REQUIREMENTS FOR PERSONNEL

The examination shall be carried out by sufficiently trained and experienced personnel. If
possible Quality personnel performing visual inspection shall be qualified and certified as
Level II in accordance with requirements of SNT-TC-1A or EN ISO 9712.

Visual examination shall be completed without the use of optical aids (not including
personal eyeglasses). The inspection area will be adequately illuminated to insure proper
evaluation of test surfaces. A minimum light intensity of 100 foot-candles (1000 Lx) is
required on the surface to be examined.

5.3 DIMENSIONAL INSPECTION (DM)

The manufactured part, after machining, must be dimensionally inspected by the supplier
to assure that is within the requirements and drawings. The main tolerances will be
shown in the drawing.

5.3.1 EXAMINATION REPORT

The dimensional inspection records shall contain at least the following information:

· The identification of the component (PO, item code and drawing number);
· The information of main dimensions according to the drawing or defined inspection
plan.
· The record must inform, at least, the drawing dimension, the tolerance expected
and real dimension after manufacturing
· The record must contain the rejected dimensions and the action plan or Metso
plan for rework.
· In case of rejection, a new report is required after completion of repair(s)
· The name, title, date of inspection and signature of inspector;

Note: Supplier is responsible for inspection and recorded data for all features generated.
If supplier subcontracts any operation specified in Metso drawings or standards, Metso’s
Quality and Procurement department must be notified and supplier must indicate sub-
supplier and operation subcontracted. This does not relieve or mitigate Metso’s supplier
of their responsibility under purchase order requirements.
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5.4 CAST SURFACE NDT INSPECTION

5.4.1 MAGNETIC PARTICLE INSPECTION (MPI) PROCEDURES AND ACCEPTANCE

STANDARDS

This procedure defines the minimum requirements and acceptance criteria for magnetic
particle inspection used for detection of surface discontinuities on the castings (as casting
surface, rough machined surfaces and final machined surfaces).

Unless otherwise specified, magnetic particle testing shall be performed after the
completion of operations that could cause surface or near surface defects. Such
operations include, but are not limited to, heat treating, welding, grinding, straightening
and machining. Magnetic particle testing shall be done of 100% of castings and 100% of
casting surface.

5.4.1.1 EXAMINATION REPORT

The magnetic particle inspection records shall contain at least the following information:

· Characteristic data of the examined casting (Serial Number, Material or drawing

number, Purchase Order and line item and condition of casting) IE; After Stress
relief
· Report shall reference this specification;
· Type of examination equipment used;
· Magnetization technique including parameters used in examination;
· Detection media used and contrast aid paint is used;
· Surface preparation and lighting conditions;
· Information on all characteristic features of discontinuities to be recorded and the
description of their position (sketch or photograph), including the defects observed;
· In case of rejection, a new report after repair;
· The name, qualification and signature of inspector;
· Date of inspection and signature of inspector;

5.4.1.2 SURFACE REQUIREMENTS

Surface should be dry and free of dirt, oil, grease, loose rust, loose scale, sand/slag,
machining marks or any other contaminants or conditions that might restrict the particle
movement or interfere with the efficiency of the inspection. Grit blast as-cast surfaces and
hand dress areas where grit blast cannot reach Surface texture must be at least:
SCRATA – A3.
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5.4.1.3 REQUIREMENTS FOR PERSONNEL

Personnel performing magnetic particle testing shall be qualified and certified as a

minimum, Level II in accordance with the requirements of SNT-TC-1A or EN ISO
9712:2012. Supplier shall be responsible to assure compliance with the requirements of
this procedure and validity of the inspection equipment used.
The inspection area will be adequately illuminated to insure proper evaluation of test
surfaces. A minimum light intensity of 100 foot-candles (1000 Lx) is required on the
surface to be examined.

5.4.1.4 METHOD

MPI procedure per ASTM E709 WET method, prods can be used for as casting or rough
machined surface. If prods are used, remove all arc marks from surfaces that will not be
machined by grinding and blending, MPI arc mark grind outs with yokes. Final machined
surfaces shall be done by yoke.

5.4.1.5 MAGNETIC PARTICLE ACCEPTANCE CRITERIA

Unless otherwise specified on ITP, purchase order or drawing the following requirements
shall apply.

Foundry must mark all defects to be excavated. The defect map is required prior to
approval of the welding repair. Linear and non-linear discontinuities (cracks and pores)
should be evaluated by ASTM A903 – Level II.

Unless otherwise specified on ITP, purchase order and drawing the following
requirements shall apply and shall be evaluated according ASTM E125 with the following
acceptance criteria:

TYPE II (Shrinkage) Degree 1

TYPE III (Inclusions) Degree 1
TYPE IV (Chill and chaplets) Not acceptable
TYPE VI (Welds) Not acceptable on as cast surfaces
*All weld repair must be ground
except for Degree 1,2 and 3 when on
a surface that will be machined
TYPE VII (False indications) Degree 2 and 3 are acceptable
Degree 1 and 4 are not acceptable
unless on a surface that will be
machined
TYPE VIII (Magnetic anomalies) Degree 1 and 3 are acceptable

Table 2: MPI acceptance criteria

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5.5 ULTRASONIC INSPECTION PROCEDURES

5.5.1. PROCESS SPECIFICATION FOR THE ULTRASONIC EXAMINATION (UT)

The determination of internal discontinuities of the steel castings shall be inspected by

ultrasonic examination according to ASTM E317 and ASTM A609.

5.5.2 EXAMINATION AREA:

Areas to be inspected by ultrasonic testing shall be defined by drawing and / or ITP.

5.5.3 REQUIREMENTS FOR PERSONNEL

Personnel performing ultrasonic testing shall be qualified and certified as a minimum,

Level II according to ASNT SNT-TC-1A or EN ISO 9712:2012. Supplier shall be
responsible to assure compliance with the requirements of this procedure and validity of
the inspection equipment used.

5.5.4 SURFACE REQUIREMENTS

Surface should be dry and free of dirt, oil, grease, loose rust, loose scale, sand/slag,
machining marks or any other contaminants or conditions that might interfere with the
efficiency of the inspection.

All geometric irregularities, such as notches or steps must be removed. Radii to be

blended into adjacent surfaces. Surface texture must be at least: SCRATA – A3 or
otherwise specified on drawing.

5.5.5 METHODS

Examination must be performed per ASTM E317 and ASTM A609, unless otherwise
specified in the ITP. Examination shall include 3 test methods: Longitudinal element, Dual
element and Angle beam.

5.5.5.1 CALIBRATION

Probe Type Standard Method Angle

Longitudinal Element ASTM A609 Procedure A – Flat Bottomed Hole 0°
Dual Element ASTM A609 Procedure A – Flat Bottomed Hole 0°
Angle Beam ASTM A609 Calibration block per Fig. S1.1 of 60° and 70°
ASTM A609 for 50-100 [2.00-4.00] inclusive
nominal production thickness.

Table 3: Ultrasonic Probe Calibration

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Note: For angle beam the casting shall be scanned both ways in two perpendicular
directions.

5.5.6 ACCEPTANCE CRITERIA

The acceptable quality levels for critical areas specified in Metso drawings or ITP and for
all other areas are defined in Table 3. Any discontinuity exceeding one of the criteria
shall be considered as unacceptable.

Examination Method Critical Areas Other Areas - Quality Level ASTM A609 Table

The quality level as defined on ITP or 1/3 wall thickness

Longitudinal Drawing must be according to ASTM Inner Center Outer
Table 2
A609 Table 2 2 3 2

The quality level as defined on ITP or

Level 2 within 50mm [2.00”] of surface
Dual Element Drawing must be according to ASTM Table 2
Critical Areas: Level 1 within 50mm [2.00”] of surface
A609 Table 2

The quality level as defined on ITP or

Angle Beam Drawing must be according to ASTM Level 2 within 50mm [2.00”] of surface Table 2
A609 Table 2

Table 4: The limits of acceptance for discontinuities in ultrasonic testing

5.5.7 EXAMINATION REPORT

The UT examination report shall contain at least the following information:

· Reference to ASTM A609

· Characteristic data of the examined casting (Serial Number, Material or drawing
number, Purchase Order and line item and condition of casting) IE; After Stress
relief
· Report shall reference this specification
· Extent of examination
· Type of examination equipment used
· Probes used
· Probe angle
· The examination technique with reference to the examination area;
· Calibration method
· Information on all characteristic features of discontinuities to be recorded (e.g.
backwall echo reduction, position and dimension in through-wall direction, length,
area and flat-bottomed hole diameter) and the description of their position (sketch
or photograph)
· The name, qualification and signature of inspector
· The date of inspection and signature inspector
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6.0 CASTING REPAIR

Foundry to mark all defects to be excavated. An excavation and weld map of all “minor”
and “major defect(s) is required to be submitted.

6.1 REPAIRING OF DISCONTINUITIES

6.1.1 THERMAL PROCESS REPAIR

If it was necessary to remove defects by thermal removal process the general surface
requirements for finish surface of the cavity shall be: G2 (SCRATA).

6.1.2 MECHANICAL PROCESS REPAIR

If it was necessary to remove defects by mechanical dressing process the general

surface requirements finish surface of the cavity shall be: H3 (SCRATA).

Small surface defects not meeting acceptable standards shall be corrected by grinding
and/or rotary filing, providing that drawing tolerances are maintained.

6.1.3 CASTING WELD REPAIR

When weld repair is required, welding procedures (WPS / PQR) and welder qualification
(WPQR) shall be done in accordance to ASTM A488 or equivalent. The supplier shall
submit their welding procedure for Metso for review and approve during first article phase
or change in material requirements. Weld maps are required for all weld areas.

All repaired areas shall be examined by UT and MT in ground condition prior to stress
relief and after stress relief. Acceptance levels used shall be as per original as-cast
requirements. Welding zone and heat affected zone hardness shall be measured and it
shall not vary outside the hardness range specified in the Metso Material Specification.

Welds shall be ground to blend with the adjacent surfaces and welded regions shall be
inspected visually (all surfaces: J2, SCRATA) and with ultrasonic and magnetic particle
testing as described in section 5.4 and 5.3.1 of this standard.

6.1.3.1 DEFECTS REQUIRING WELD REPAIR

6.1.3.1.1 MINOR DEFECTS

Welds are considered as minor when the depth of the cavity prepared for welding does
not exceed 20% of the wall thickness or maximum 1 inch (25mm) of depth or the weld
surface area is less than 10 square inches (65 cm²).
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Preheat per requirements of welding procedure specification (WPS) and procedure

qualification record (PQR) approved by Metso.

Note: Minor defects are subjected to be reclassified to Major, if quantity and depth are
determined by Metso QA or Engineering to be profuse in a 12 square inch (93 cm²) area
or in areas specified by drawing as “Critical”.

6.1.3.1.2 MAJOR DEFECTS

Welds repair are considered major when the depth of the cavity prepared for welding
exceeds 20% of the wall thickness or greater than 1 inch (25mm) depth or the weld
surface area is equal to or greater than10 square inches (65 cm²).

Preheat per requirements of welding procedure specification (WPS) and procedure

qualification record (PQR) approved by Metso

The supplier must submit excavation map to Metso for review prior to start of weld repair
for approval. All excavations must be verified by MPI (Magnetic Particle Inspection) or LP
(Liquid Penetrant Test) to assure no indications are present.

Map of weld repairs to be reported in foundry certification. Report shall to include

hardness values of weld zone, heat affect zone and parent material adjacent to weld
repair area.

Weld repairs of “Major defects” shall be followed with the whole casting receiving a stress
relief cycle as per paragraph 6.1.3.1.3.

6.1.3.1.3 STRESS RELIEF

Stress relief will consist by placing the casting in a suitable furnace and heating uniformly
to 1050°F (566°C) minimum to 1150°F (621°C) maximum temperature. If casting is
tempered maximum stress relief temperature should be 50°F (28°C) below actual
tempering temperature. Castings are to be held at temperature one hour per inch
(25.4mm) of metal thickness, or twelve hours maximum.

Heating and cooling rates shall be uniform. Rate of temperature change shall not exceed
400°F divided by the thickness in inches of the heaviest section of rough casting.
[Example: 400 / 8.0-inch thickness = 50° per hour change]

Heat treatment records shall be submitted for review and approval

Heat treatment records shall contain the follow information

· Start and ending time
· Temperature
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· Duration hours
· Date(s)
· Furnace number
· Company information
· Casting Serial number
· Part number
· PO and Line item number

NOTE: Metso must be notified prior to repair of any indications that exceeds NDT
requirements including visual that are detected after stress relief.

7.0 MACHINE SURFACE(S) NDT INSPECTION

100% of all machined surfaces shall be inspected visually and with MPI.

7.1 VT ACCEPTANCE

Unless noted otherwise per drawing and /or ITP the visual acceptance must be according
table 5.

Quality Classes Abbreviation Surface Areas

Quality Level 1 QT Sealing surfaces*
Quality Level 1 Q1 Critical Surface Areas**
Quality Level 2 Q2 Other Surface Areas

Table 5: Quality classes for machined surfaces

*) Sealing surface areas shall be defined by drawing and / or ITP

**) Critical surface areas shall be defined be drawing and / or ITP
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Acceptance criteria for different quality classes is in accordance Table 6 below:

Quality Application Acceptable Sizes

Classes
QT Limited only to certain No defects are allowed which are detectable with
critical areas of component visual inspection
which may act as a sliding
or sealing surface(s).
Q1 Spherical defects or 0.06” [1.5 mm] maximum allowed diameter of
shortage of material defect;
0.06” [1.5 mm] maximum allowed depth;
2 ea. is maximum amount of defects allowed in
area of 9 square inches [225 cm²];
No linear indications;

Q2 Spherical defects or 0.118” [3 mm] maximum allowed diameter of

shortage of material defect;
0.118” [3 mm] maximum allowed depth;
4 ea. is maximum amount of defects allowed in
area of 9 square inches [225 cm²];
No linear indications;

Table 6: Quality classes and acceptable sizes

Repair actions shall be specified by, and / or approved by Metso’s Engineering

or Quality department. Repair actions will involve either welding repair or opening and
smoothing the defect edges, depending on the defect type, size, orientation and location.

7.2 MPI ACCEPTANCE

Unless noted otherwise per drawing and /or ITP.

Critical areas as specified per drawing and / or ITP shall have the following acceptance
criteria:

Linear and non-linear discontinuities (cracks and pores) shall be evaluated by ASTM
A903 – Level I.

Weld repaired areas shall have the following acceptance criteria: Linear and non-linear
discontinuities (cracks and pores) shall be evaluated by ASTM A903 – Level I. No
undercut, porosity or slag inclusions are allowed.
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All remaining machined surfaces shall have the following acceptance criteria: Linear and
non-linear discontinuities (cracks and pores) shall be evaluated by ASTM A903 – Level II.

All weld repairs that are completed on final machined surface shall be blended flush with
adjacent surface no high spots or low spots are allowed. Weld repair area will be buffed
by hand to maintain similar appearance as adjacent machined surfaces. Surface finish
shall meet drawing requirements.

8.0 SURFACE PREPARATION

All surfaces that will be painted shall be prepared by shot/grit/sand blasting. Machined
surfaces shall be protected from grit blasting and paint overspray. Requirements for
painting and surface protection are given in Metso surface preparation, cleaning and
painting standard 03-01-01 or Metso drawings or Purchase order.

9.0 DATA BOOK

9.1 DOCUMENTATION OF CASTINGS

All documentation and certifications must be in the English.

Documentation shall be done according to EN 10204:2004. Documentation should be

approved by a quality control person, completely independent from the production.

All documents shall include a traceable Metso part number, PO and line item number.
Examination results shall be recorded to supplier´s examination report forms and all
reports required according to the Metso’s Technical specification/drawings shall be
submitted to Metso upon requested.

Casting documentation shall be provided according to scope of Metso inspection and

must include:

· Metso’s Compliance Certificate

· Chemical composition
· Heat treatment charts (i.e. Normalizing, Tempering and Stress Relief)
· Mechanical properties
· Visual inspection record for all areas
· Defect and Excavation map
· UT reports
· MPI reports
· Dimensional report for all dimensions
· PT report if MPI is not applicable
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· Identification report and photos

· Surface Preparation and Painting Report
· Machining Surface Preparation and Packaging Report and photos

Deviations from the described scope and frequency of testing needs to be agreed
separately with Metso.

Metso control can be carried out at vendors site by Metso quality persons.