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1、BRITISH STANDARD AEROSPACE SERIES BS HC 100:1972 Incorporating Amendment Nos. 1, 2 and 3 Inspection and testing procedure for iron, nickel, copper, cobalt and refractory metal base alloy castings UDC 629.7:669.15 + 669.245 + 669.35 + 669.255:669.018.45 14:620 Licensed Copy: London South Bank Univers
2、ity, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS HC 100:1972 This British Standard, having been approved by the Aerospace Industry Standards Committee was published under the authority of the Executive Board of the Institution on 31 July 1972 BSI 0
3、2-2000 The following BSI references relate to the work on this standard: Committee reference ACE/60 Draft for comment 70/35359 ISBN 0 580 07344 0 Foreword This British Standard covers the general inspection and testing requirements for iron, nickel, copper, cobalt and refractory metal base alloy cas
4、tings. The procedure defined is primarily for use in conjunction with related material specifications in the HC series of British Standards and the Ministry of Defence DTD series. It may also be used in conjunction with firms own casting specifications. In this standard wherever agreement between th
5、e manufacturer and the purchaser is required, the onus is on the purchaser to obtain the concurrence of the parent design firm to such agreement; if such concurrence is mandatory the word “purchaser” is marked with an asterisk (*). This standard makes reference to the latest issues of the following
6、British Standards: BS A4, Test pieces and test methods for metallic materials for aircraft. BS 240, Method of Brinell hardness test Part 1: Testing of metals. BS 427, Method for Vickers hardness test Part 1: Testing of metals. BS 891, Method for Rockwell hardness test Part 1: Testing of metals. A Br
7、itish Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a fr
8、ont cover, an inside front cover, pages i and ii, pages 1 to 13 and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Amendments issued since publication Amd. No.Date of
9、 issueComments 3064December 1979 6133May 1990 6574March 1991Indicated by a sideline in the margin Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS HC 100:1972 BSI 02-2000i Contents Page ForewordInside front c
10、over 1General requirements1 1.1Foundry approval1 1.2Definitions1 1.3Control of material1 1.4Chemical composition1 1.5Heat treatment temperatures2 1.6Mechanical tests2 1.7Methods of testing2 1.8Freedom from defects2 1.9Tolerances3 1.10 Rectification of defects in castings3 1.11 Foundry technique3 1.1
11、2 Cut-up or break-up tests3 1.13 Identification3 1.14 Final marking3 2Re-melting stock4 2.1Manufacture4 2.2Analytical requirements4 2.3Provision, selection and preparation of test samples4 2.4Mechanical properties4 2.5Test certificate4 3Precision castings4 3.1Manufacture4 3.2Analytical requirements5
12、 3.3Condition5 3.4Provision, selection and preparation of test samples5 3.5Acceptance tests6 3.6Mechanical properties6 3.7Hardness6 3.8Depth of case8 3.9Intercrystalline corrosion8 3.10 Test certificate8 4Sand castings8 4.1Manufacture8 4.2Analytical requirements8 4.3Condition8 4.4Provision, selectio
13、n and preparation of test samples8 4.5Acceptance tests10 4.6Mechanical properties10 4.7Hardness11 4.8Depth of case11 4.9Intercrystalline corrosion11 4.10 Test certificate11 5Centrifugal castings11 5.1Manufacture11 5.2Analytical requirements11 5.3Condition11 Licensed Copy: London South Bank Universit
14、y, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS HC 100:1972 ii BSI 02-2000 Page 5.4Provision, selection and preparation of test samples12 5.5Acceptance tests12 5.6Mechanical properties12 5.7Hardness13 5.8Intercrystalline corrosion13 5.9Test certific
15、ate13 Figure 1 Test samples for precision castings7 Figure 2 Test samples for sand castings9 Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS HC 100:1972 BSI 02-20001 1 General requirements 1.1 Foundry approv
16、al 1.1.1 At the initiative of the Design Authority, foundries producing castings for critical applications shall be required to demonstrate their ability to produce castings of a high standard of uniformity of properties, in addition to the basic quality assurance requirements. 1.1.2 To obtain appro
17、val against this requirement, the foundry shall produce evidence of the uniformity of mechanical properties and shall nominate a metallurgist to be responsible for process and metallurgical control, to the satisfaction of the Design and Quality Assurance Authorities. 1.2 Definitions For the purposes
18、 of this British Standard the following definitions apply: 1.2.1 batch unless otherwise agreed by the Quality Assurance Authority, either: a) castings of similar dimensions, (see Note 1), produced from the same melt and, if heat treated, heat treated together; or b) precision castings of similar dim
19、ensions (see Note 2), poured from a melt made up of re-melt stock or re-melt stock plus the same amount of alloying additions (see 3.1.1 1), 3.1.1 2) and 3.1.2) and, if heat treated, heat treated together. NOTE 1For centrifugal castings, similar dimensions only apply to the cross section dimension,
20、i.e. length can be ignored. NOTE 2If mechanical test samples are cut from actual castings, a batch comprises castings to the same pattern. Castings to the left-hand and right-hand version of any pattern are considered as being to the same pattern. 1.2.2 cast the product of a single furnace charge, o
21、r more than one furnace charge mixed prior to pouring, used to produce re-melting stock 1.2.3 centrifugal castings castings made by a process involving centrifugal casting in either metal dies or sand moulds rotating about the major axis of the casting 1.2.4 melt the product of a single furnace char
22、ge, or more than one furnace charge mixed prior to pouring, used to produce castings 1.2.5 precision castings those products produced by an investment process, the Shaw process or any similar process as agreed by the Quality Assurance Authority 1.2.6 re-melting stock metal, supplied in cast or wroug
23、ht form, the chemical composition of which has been established by analysis NOTEThis is also known as “master melt” in connection with investment castings. 1.2.7 sand castings castings made by a process involving the moulding of a re-usable pattern with a suitably bonded sand (but excluding those ma
24、de by the centrifugal process) 1.2.8 vacuum melting the practice of melting and casting under vacuum 1.2.9 quality assurance authority the authority stated in the contract or the accredited representative of that authority 1.2.10 design authority the organization responsible for the detailed design
25、of matriel and which has the responsibility for certifying designs and/or for sealing drawings and specifications 1.3 Control of material 1.3.1 All raw materials, including scrap, used directly for the production of melts shall be carefully stored to prevent mixing and contamination with harmful mat
26、erials. 1.3.2 The method of melting employed for the production of re-melting stock and castings shall be as required by the material specification or as required by the Approved Metallurgist and recorded in the foundry technique. 1.4 Chemical composition 1.4.1 The chemical composition of re-melt st
27、ock and castings shall comply with the requirements of the material specification. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS HC 100:1972 2 BSI 02-2000 1.4.2 Elements not quoted in the material specific
28、ation shall not be intentionally added to the alloy without the agreement of the purchaser, except for the purpose of finishing the heat; reasonable precautions shall be taken to prevent their inclusion during manufacture. For special applications the purchaser, by agreement with the manufacturer, m
29、ay set a limit to the amount of one or more such elements and may require the amount of such elements to be stated on the certificate of analysis. NOTECare is to be taken to prevent contamination of the metal from preceding casts or melts of different composition melted in the same furnace. 1.4.3 No
30、 further additions shall be made to a cast or melt after the final analytical sample has been selected. 1.5 Heat treatment temperatures If a temperature with a tolerance is stated in a material specification, order or drawing, that temperature shall be mandatory, if a temperature range is stated, a
31、temperature within that range shall be selected to give the required properties. 1.6 Mechanical tests 1.6.1 Tensile, stress rupture, creep strain and impact tests. Except as provided for in 1.6.2 all test samples shall be machined in the finally heat treated condition to the dimensions of the approp
32、riate largest size of proportional round test piece shown in BS A4 that can be prepared from the test samples. An impact test shall comprise a minimum of two notches. 1.6.2 Alternatively to 1.6.1, except for cast to size test pieces, mechanical test samples, for which the specified minimum tensile s
33、trength is 1 300 N/mm2 or greater, shall be machined to test piece size plus, if required, a grinding allowance, and heat treated in that size or, in the case of maraging or precipitation hardening materials, the test sample shall be machined to test piece size plus, if required, a grinding allowanc
34、e after solution treatment. 1.6.3 Bend test. Bend test samples shall be machined to the largest practicable round test piece, subject to a maximum diameter of 10 mm, that can be prepared from the test sample. Alternatively, the bend test may be carried out on the full section of the test sample subj
35、ect to a diameter or minor sectional dimension of 10 mm maximum. 1.7 Methods of testing 1.7.1 Mechanical tests. The test pieces shall be tested in accordance with the requirements of BS A4. 1.7.2 Hardness tests. Hardness tests shall be carried out in accordance with the requirements of BS 240, Part
36、1, using an F/D2 ratio of 10 for copper and copper based alloys and 30 for all other alloys, unless otherwise stated in the material specification, or BS 427, Part 1, or BS 891, Part 1, as required by the material specification. 1.7.3 Depth of case tests. The depth of case of test samples shall be d
37、etermined by fracturing, metallographic examination, taper grinding and hardness testing, or other examination to the satisfaction of the Inspector. 1.7.4 Intercrystalline corrosion test 1.7.4.1 If required by the material specification a bend test piece, prepared in accordance with the requirements
38、 of 1.6.3, shall be sensitized for 30 min at 650 10 C and cooled in air. It shall then be immersed either: 1) for 72 h in a boiling solution having the following composition: 111 g of copper sulphate crystals (CuSO45H2O) 98 g of concentrated sulphuric acid (s.g. 1.84) made up to one litre with disti
39、lled water; or 2) for 24 h in a boiling solution of the composition given in 1) to which 50 g of copper turnings or filings are added before the test, and the test piece shall be in contact with this copper. The test solution may be used only once. Precautions shall be taken during boiling to preven
40、t concentration by evaporation. 1.7.4.2 If required by the material specification, a bend test piece, prepared in accordance with the requirements of 1.6.3, shall be tested in accordance with the requirements of 1.7.4.1, except that the sensitizing treatment shall be omitted. 1.8 Freedom from defect
41、s 1.8.1 Re-melting stock shall be free from rust, scale, slag, grease, paint and other foreign matter. 1.8.2 Vacuum re-melting stock shall be capable of producing vacuum melts which are essentially free from dross or foreign matter on the melt surface, if required, a standard shall be agreed between
42、 the manufacturer and the purchaser. 1.8.3 All castings shall be suitably fettled, dressed and cleaned for surface inspection purposes. 1.8.4 Each casting shall be examined for surface defects by a non-destructive method to the satisfaction of the Quality Assurance Authority. Flaw detection shall be
43、 carried out by the founder unless otherwise agreed by the purchaser. Any casting subsequently subjected to heat treatment or to a proof loading test shall be re-examined. Licensed Copy: London South Bank University, London South Bank University, Sat Dec 09 02:53:23 GMT+00:00 2006, Uncontrolled Copy
44、, (c) BSI BS HC 100:1972 BSI 02-20003 1.8.5 Castings shall be radiologically examined to the satisfaction of the Quality Assurance Authority. 1.8.6 The standard of acceptance for defects shall be agreed between the founder and the purchaser*. 1.8.7 Notwithstanding previous acceptance as complying wi
45、th the requirements of this specification any re-melting stock or casting that is later found to contain harmful defects may be rejected. 1.9 Tolerances 1.9.1 Re-melting stock. Re-melting stock shall comply with the agreed dimensional and weight tolerance stated on the order or drawing. 1.9.2 Castin
46、gs 1.9.2.1 The casting tolerances shall be as agreed between the purchaser and the founder, and stated on the drawing. The casting shall be capable of being machined, when required, to the finished dimensions without leaving evidence of the cast surface. 1.9.2.2 Drawings shall indicate the datum poi
47、nts to be used for machining or jigging and, unless otherwise between the purchaser and the founder, samples for pattern approval shall be supplied. 1.10 Rectification of defects in castings 1.10.1 Rectification of defects by welding shall be carried out only with the prior consent of the founders a
48、pproved metallurgist and of the purchaser*. Such rectification shall be subject to the conditions laid down by the Quality Assurance Authority and, unless otherwise agreed between the founder and the purchaser*, shall be followed by the appropriate heat treatment and non-destructive testing. 1.10.2
49、Correction of distortion shall be carried out only by agreement with the founders approved metallurgist. He shall be responsible for specifying the conditions under which such correction is to be carried out, subject to any special provisions required by the design authority, and shall ensure that the specified procedures are followed. If re-heat treatment is required the castings shall be subsequently tested in accordance with the requirements of the material specification. Finally, the castings shall be submitted to flaw detection. 1.11 Foundry technique. A sa
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