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Typically, when manufacturing UT calibration standards you want to simulate fabrication conditions as close to the fabrication condition of the actual component that will be subjected to ultrasonic examination. Grain size and pattern will affect attenuation for angle beam, more so than L-wave for UT. This will result in either over or under compensating establishment of DAC (distance amplitude correction) curves for the pre-drilled holes in the test block during calibration.
My question to you is how important is the UT exam? In other words, are you bound contractually to use ASTM A 609 for your specific application? Depending on the experience level of the UT operator you can do what you propose, if agreed upon between both parties or you know the exact type of defects or flaws that can occur in these components.
I want to caution you that the gain setting established by the forged test block will not be the same as for the cast component. This means that when you begin UT of the casting, you might start seeing noise caused by attenuation that may or may not affect your interpretation of results. If you are uncomfortable or believe the component is critical for an application, I would have the calibration blocks made from castings in accordance with the requirements of A 609.
One other option - have you considered radiographic testing (RT) or x-ray as a back-up in the event you can't obtain the necessary test blocks?
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A forged block is created through a manufacturing process that involves the shaping of the raw material using localized compressive forces. During the forging process a piece of raw material of the required material grade is compressed with a die till the desired shape of the block is achieved.
Forged blocks are often preferred to other options due to the inherent advantages that the forging process offers, including greater impact strength. The use of quality raw material, coupled with the added value steel gets from being forged, give this forged product high resistance and ductility, making it a better choice than castings or plate.
Open Die Block Forging
Open-die drop forging is the predominant method of block forging. In this process, a block of steel is heated to an extremely high temperature and then hammered onto a fixed anvil. The term "open-die" refers to the fact that the surfaces that come into contact with the block during the forging process do not completely surround it. This allows the block to be shaped into areas that are not in contact with the sides of the die. The dies used in open-die block forging are primarily flat, but some may have rounded or curved shapes, and different shapes can be used for specific purposes.
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Open-die block forging is capable of shaping metal blocks into various forms, such as discs, cylinders, hexagonal shapes, flat shapes, and others. The range of shapes that can be created depends on the design of the open die used in the forging process. Additionally, open-die forging is employed to enhance the strength of the metal by properly aligning its grain structure.
Closed Die Block Forging
Closed die block forging, or impression die forging, utilizes a metal die resembling a mold which fully encompasses a block of metal. This die is connected to an anvil, and the heated metal is then repeatedly struck in rapid succession, causing it to flow into the die and conform to its shape. After achieving the desired shape, most blocks are further refined into similar shapes, which may be more intricate, to optimize the design. A block undergoing closed die block forging may undergo this process multiple times until it attains its ultimate shape, with each subsequent die shape becoming progressively more intricate than the preceding one.
FCI manufactures forged blocks from a wide variety of material grades we carry in our raw material inventory on-site. The blocks can be produced in any size and shape to meet customers' specifications.
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