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IS 3038 (2006): Martensitic Stainless Steel and Alloy SteelCastings for Pressure Containing Parts Suitable for HighTemperature Service [MTD 14: Foundry]
IS 3038:2006
(ah7Ty7%-FT) ‘;
Indian Standard
MARTENSITIC STAINLESS STEEL AND ALLOY STEEL
CASTINGS FOR PRESSURE CONTAINING PARTS
SUITABLE FOR HIGH TEMPERATURE
SERVICE — SPECIFICATION
(’Fourth Revision )
ICS-77.140.80
0 BIS 2006
BUREAU OF lNDIAN STANDARDSMANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
ch/y 2006 Price Group 4
Foundry and Steel Casting Sectional Committee, MTD 14
FOREWORD
This Indian Standard (Fourth Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by theFoundry and Steel Casting Sectional Committee had been approved by the Metallurgical Engineering Division Council.
This standard was first published in 1965 and was subsequently revised in 1974, 1983 and 1992, While reviewing thestandard in the light of the experience gained during these years, the committee decided that the standard may befurther revised. In this revision, various clauses have been aligned with the recent standards on steel castings.
In this revision following modifications have been made:
a) Four new grades have been added in Table 1 and chemical composition of some of the grades have beenmodified; and
b) Table 2 and Table 3 have been modified.
Castings of martensitic stainless steel and alloy steel for valves, flanges, fittings and other.pressure containing parts andof quality generally suitable for assembly with other castings or wrought steel parts by fusion welding are covered bythis specification. It is not intended to imply that the steels specified in this standard possess equal degree of weldability.Therefore, it is the responsibility of the purchaser to establish for himself the suitable welding technique. Since thesegrades possess varying degrees of suitability for resistance to corrosion and high temperature service, it is also theresponsibility of the purchaser to determine which of the grades is suitable for the actual service requirement.
For the benefit of the purchaser, information regarding typical uses of different grades of alloy steel castings specifiedin the standard has been given in Annex A.
In the preparation of this standard, assistance has been derived from the following publications:
EN 1504:1976 ‘Specification for steel castings for pressure purposes’ issued by the British Standards Institution
ASTM A 217/A 2 17M-200 1 ‘Martensitic stainless steel and alloy steel castings for pressure containing partssuitable for high-temperature service’, issued by the American Society for Testing and Materials
For the purpose of deciding whether a particular requirement of this standard is complied with, the final value observedor calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS 2: 1960 ‘Rules forrounding off numerical values (revised)’. The number of significant places retained in the rounded off value should bethe same as that of the specified value in this standard.
IS 3038:2006
Indian Standard
MARTENSITIC STAINLESS STEEL AND ALLOY STEEL
CASTINGS FOR PRESSURE CONTAINING PARTS
SUITABLE FOR HIGH TEMPERATURE
SERVICE — SPECIFICATION
(Fourth Revision )
1 SCOPE
This standard covers the requirements for martensiticstainless steel and alloy steel castings for pressurecontaining parts suitable for high temperature service.
2 REFERENCES
The following standards contain provisions, which throughreference in this text, constitute provisions of this standard.At the time of publication, the editions indicated werevalid. All standards are subject to revision and parties toagreements based on this standard are encouraged toinvestigate the possibility of applying the most recenteditions of the standards indicated below:
IS No.
228
1599:1985
1608:20051S0 6892:1998
1757:1988
2595:1978
3658:1999
3703:2004
4897:1994
5530:1987
6601:1987
We
Methods for chemical analysis of steels(revised) (All parts)
Method for bend test (second revision)
Metallic materials — Tensile testing atambient temperature (third revision)
Methods for charpy impact test(V-notch) for metallic material (secondrevision)
Code of practice for radiographictesting (firsl revision)
Code of practice for liquid penetrantflaw detection (second revision)
Code of practice for magnetic particleflaw &tection (second revision)
Deviations on untoleranced dimensionsand mass of steel casting (third revzkion)
Recommendation for productionrectification and repair of steel castingsby metal arc welding process (secondrevision)
Permissible deviations in chemicalcomposition for product analysis of
IS No.
6907:1992
7666:1988
8800:1997
9565:1995
10724:1990
11732:1995
12938:1990
Title
steel castings (jlrst revision)
Steel castings — Methods of sampling(first revision)
Recommended procedure for ultrasonicexamination of ferritic castings ofcarbon and low alloy steel ~irsf
revision)
Technical delivery conditions for steelcastings (excluding investmentcastings) (fhird revision)
Acceptance standards for ultrasonicinspection of steel castings (secondrevision)
Acceptance standards for magneticparticle inspection of steel castings (firstrevision)
Acceptance standards for dye penetrantinspection of steel castings (firstrevision)
Acceptance standards for radiographicinspection of steel castings
3 TERMINOLOGY
For the purpose of this standard, the following definitionsshall apply.
3.1 Cast (Melt) — The product of any of the following:
a)
b)
c)
One furnace heat,
One crucible heat, or
A number of furnace or crucible heats.of similarcomposition mixed in a ladle or tapped in separateladles and poured simultaneously for making acasting.
3.2 Batch — A group of castings of one grade of material,cast from the same melt and heat-treated together underidentical conditions.
1
1S3U.$U: Luutl
4 GRADES
This standard covers atotal of fourteen grades of steelcastings for pressure containing parts suitable for high
. temperature service.
5 SUPPLY OF MATERIALS
General requirements relating to supply of steel castingsshall be as laid down in IS 8800.
6 MANUFACTURE
The steel for the castings shall be made by electric arc orelectric induction or such other processes as may be agreedto between the purchaser and the manufacturer.
7 PARTIfXJLARS TO BE S-PECIFIED WHILEORDERING
For the benefit of the purchaser, particulars to be specifiedwhile ordering for steel castings to this specification aregiven in Annex B.
8 CHEMICAL COMPOSITION
8.1 The ladle analysis of steel when carried out either bythe method specified in IS 228 and its relevant parts orany other established instrumental/chemical methods shallbe as given in Table 1, In case of dispute the proceduregiven in IS 228 shall be the referee method. However,where the method is not given in IS 228, the referee methodshall be as agreed to between the purchaser and themanufacturer.
8.2 The manufacturer shall carry out analysis from asample of each melt of steel and shall supply a testcertificate of chemical analysis of the sample of steel foreach melt.
8.3 Product Analysis
If specified at the time of enquiry and order, the productanalysis may be carried out from a test piece or from acasting representing each melt. Drillings for analysis shallbe taken from not less than 6 mm beneath the cast surface,and in such a manner as not to impair the usefulness ofany casting selected. The permissible variation in productanalysis from the limits specified in Table 1 shall be asgiven in IS 6601.
8.4 Residual Elements
8.4.1 Elem~nts not specified in Table 1shall not ordinarilybe added to the steel and all reasonable precautions shallbe taken to prevent contamination from scrap, etc, to keepthem as low as practicable.
8.4,2 Table 2 specifies the limits for the elements notspecified in Table 1.
8.4.3 Analysis and reporting of the analysis in the testcertificate for the above residual elements shall be doneonly when so specified by the purchaser in the enquiryand order. However, the manufacturer shall ensure thatthe residual elements are within the limits specified.
9 WORKMANSHIP AND FINISH
9.1 The castings shall be accurately moulded inaccordance with the pattern or the working drawingssupplied by the purchaser with the addition of such letters,figures and marks as maybe specified.
9.2 The purchaser shall specifJ the tolerances on allimportant dimensions. On other dimensions, tolerancesspecified in IS 4897 shall apply.
10 FREEDOM FROM DEFECTS
10.1 All castings shall be free from defects that willadversely affect machining or utility of castings.
10.2 When necessary to remove risers or gates by flameor arc or a combination-thereof, or by-any other processinvolving intense heat, care shall be taken to make the cutat a suftlcient distance from the body of the castings so asto prevent any defect being introduced into the castingdue to local heating. Any such operation is preferablydone before final heat-treatment.
10.3 In the event of any casting proving defective fromfoundry causes in the course of preparation, machining orerection, such casting may be rejected notwithstanding anyprevious certification of satisfactory testing and/orinspection.
11 FETTLING AND DRESSING
All castings shall be properly fettled and dressed, and allsurfaces shall be thoroughly cleaned.
12 HEAT-TREATMENT
12.1 The castings shall be heat-treated in a properlyccmstructed furnace, having adequate means oftemperature control which shall permit the whole of thecastings being uniformly heated to the necessarytemperature. All castings shall be suitably heat-treated soas to attain the specified mechanical properties.
12.2 Unless otherwise specified in the enquiry and orderor agreed to between the purchaser and the manufacturer,all castings shall be supplied in the mormrdized andtempered condition. Grades 1, 2, 4 and 4A shall betempered at a temperature not less than 600”C. Grades 3,5, 5A, 6, 7 and 8 shall be tempered at a temperature notless than 675°C.
2
Table 1 Chemical Composition of Martensitic Stainless Steel and Alloy Steel Castingsfor Pressure Containing Parts Suitable for High Temperature Service
(Clauses 8.1,8 .3,8.4.1 and 8.4.2)
slNo.
(1)
O
ii)
iii)U
iv)
o
vi)
vii)
viii)
ix)
Constituent
(2)
carborr
Silicon
Manganese
Sulphur
Phosphorus
Chromium
Nickel
Molybdenum
Vanadium
Requiremerit, Percent ‘)
Grade1
(3)
0.18-0.25
0.60
1,20-1.60
0.045
0.040
●
�
—
Grade2
(4)
0.25
0.20-0.60
0.50-0.80
0.045
0.040
—
o.45-0.65
—
o M~imum, except where range is specified.
Grade3
(5)
0.10-0.15
0.20-0.45
0.40-0.70
0.030
0.030
0.30-0.50
—
o.40-0.60
0.22-0.30
Grade4
(6)
o.05-0.20
0.60
0.50-0.80
0.045
0.040
1.00-1.50
0.45-0.65
—
Grade4A
(7)
0.12-0.16
0.30-0.50
0.55-0,75
0.030
0.030
0.85-1.15
—
o.90-1.10
0.20-b.30
Grade5
(8)
0.15
0.20-0.45
0.40-0.70
0.030
0.030
2.00-2.50
—
o.90-1.20
Grade5A
(9)
o.05-0.18
0.60
0.40-0.70
0.045
0.040
2.00-2.50
—
o.90-1.20
—
Grade6
(lo)
0.20
0.75
0.40-0.70
0.045
0.040
4.00-6.50
—
o.45-0.65
—
Grade7
(Ii)
0.20
I.00
0.35-0.65
0.045
0.040
8.00-10.00
—
o.90-1.20
—
Grade8
(12)
0.15
I .50
1.00
0.040
0.040
11.50-14.00
—
—
Grade9
(13)
o.05-0.20
0.60
0.50-0.80
0.045
0.040
0.50-0.80
0.70-I.lo
o.45-0.65
Grade10
(14)
o.05-0.20
0.60
0.40-0.70
0.045
0.040
0.50-0.90
0.60-1.00
0.90-1.20
GradeII
(15)
o.15-0.21
0.30-0.60
0.50-0.80
0.015
0.020
I.oo-I.50
0.45-0.65
—
Grade12
(16)
0.08-0.12
0.20-0.50
0.30-0.60
0.010
0.030
8.00-9.50
—
0.85-1.05
0.18-0.25
~UIu
IS 3038:2006
Table 2 Residual Elements
(Clause 8.4.2)
,S1No. Grade (s) Constituent, Max, Percent Total
\Content
/---Cr(3)
Ni Mo Cu v w Sn(4) (5) (6) (7) (8) (9)
Zr “(lo)
Ti(11) (f’;)(1)
O
ii)
iii)
iv)
(2)
I
(13)
I .0
1.0
I.0
I.0
0,35 0.50 0.15 0.50 0.05 0.10 —
0.50 — 0.50 0.05 0.10 —
0.50 — 0.50 — 0.10 0.05
0.50 — 0.50 0.05 0,10 —
0.035 0.035 —
0.352
3, 4A, 5
4, 5A, 6
and 7
8
0.035 — —
0,025— —
— — — —
v)
vi)
vii)
viii)
I .00 0.50 0.50 0.05 0.1o — 0.65
0.60
1.0
—
—
—
—
—
—
—
—
9 and 10
11
12
— 0.50 — 0.10 —
0.50 — 0.35 0.03
0.40 — — — — —
— —
O,o1
— 0.04
12.3 The test pieces shall be heat-treated along with thecastings they represent.
13 MECHANICAL TESTS
13.1 The mechanical properties specified are those whichare to be obtained from test bars cast either separatelyfrom or attached to the castings to which they refer andheat-treated as given in 12. The test values so exhibited,therefore, represent the quality of steel from which thecastings have been poured; they do not neces-sarilyrepresent the properties of the castings themselves.
13.2 In the case of a special or large casting or in othercases, the purchaser may speciQ at the time of enquiryand order, that the test, bar be cast attached to the castingfrom which the mechanical tests are to be conducted. Thepurchaser shall show the size and location of such anattached test bar on the drawing, in the absence of whichthe manufacturer may use his discretion in this regard.
13.2.1 Such a test bar shall not be detached from.the castinguntil the heat-treatment of the casting is over and it hasbeen stamped by the purchaser.
13.3 The tensile test shall be carried out in accordancewith IS 1608. The relevant mechanical properties shall beas given in Table 3.
13.4 If specified in the enquiry and order the impact testshall be carried out in accordance with IS 1757 and thevalues obtained shall conform to the requirements givenin Table 3.
13.5 Bend Test
Bend test pieces shall be of suitable length, convenientfor the machine on which they will be bent and shall haveeither a diameter of 25 mm or rectangular section of25 x 20 mm. The edges of the rectangular test piece shallbe rounded to a radius of not more than 1.5 mm and thetest shall be made by bending the test piece over the thinnersection in accordance with IS 1599.
14 NON-DESTRUCTIVE TESTS
14.1 Non-destructive testing shall be applied if sospecified in the.enquiry and the order. Under this heading,the tests are grouped which aim at revealing defects thatcannot be revealed by a simple visual examination, suchas dye penetrant, magnetic particle, ultrasonic,X-radiographic, or gamma-radiographic inspection; alsoincluded under this heading are tests on the surfacecondition by visual or visual-tactile examination. Thepurchaser shall speci@ in the enquiry and order:
a)
b)
c)
-d)
e)
The type of non-destructive testing which he intendsto carry out or to have carried out;
The area or areas of the casting to which these testsapply, and the type of discontinuity, where relevant
Whether all, or what proportion, of the castings areto be tested;
The severity level defining the acceptability ornon-acceptability of defects which maybe revealed;and
Whether the manufacturer is or is not contractuallyresponsible for carrying out the tests.
4
Table 3 Mechanical Properties of Martensitic Stainless Steel and Alloy Steel Castingsfor Pressure Containing Parts Suitable for High Temperature Service
(Clauses 13.3 and 13.4)
S1No. Characteristics Requirement
/Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade Grade
(;)540”
320
2(4) (:)
450-620 510”
240 i95
4A(:) (7)
485-655 5901’
275 440
5 3A 7 9 10 12(8) (9) $3) (11) (1!2) (13) (14) (1:) (16)
510’) 485-655 620-795 620-795 620-795 485-655 685-655 550-725 585-760
310 275 415 415 450 275 275 345 415
(1) (2)
i) Tensile streirgth, MPa
ii) Yield stress or 0.2 percent,proof stress, MPa, &fin
iii) Elongation, percent,Min GL 5.65 ~
16 22 17 18 15 17 18 17 17 17 18 18 17 i7
— 35 35 35 30 35 35 45 45iv) Reduction of area,b percent, Min
35 — 35
v) Charpy V-notch impactvalue, J, Mitr (see Note)
20
90”
50
— 20 25 25 — — — —
vi) Bend test angle of bend,Min (see Note)
. 90” — 90” 90° — — — — — —
vii) Diameter of maridrel, inm — 50 — 50 50 — — — — — —
NOTE — Either bend test or impact test may be specified. When no requirement is specified by the purchaser, the criterion is at manufacturer’s option.
“ Minimum.
IS 3038:2006
14.2 Unless otherwise agreed upon, whennon-destrr,tctivetesting is to be done, the castings shall be examined asfollows:
. a) ultrasonic examination as per IS 7666;
b) magnetic particle examination as per IS 3703;
c) dye penetrant examination as per IS 3658; and
d) radiographic examination as per IS 2595.
NOTE — In case of austenitic grades, ultrasonic inspection andmagnetic particle inspection may not ordinarily be feasible.
1
14.3 Unless otherwise agreed upon the following shall bethe acceptable standards:
a) IS 9565 for ultrasonic inspection,
b) 1S 10724 for magnetic particle inspection,
c) IS 11732 for dye penetrant inspection, and
d) IS 12938:1990 for radiographic .inspection.
NOTE — In case of austenitic grades, ultrasonic inspection andmagnetic particle inspection may not ordinarily be feasible.
15 REPAIR OF CASTINGS
15.1 Unless otherwise specified by the purchaser in theenquiry and order, castings may be rectified by welding.All repairs by welding shall be carried out in accordancewith the procedure laid down in IS 5.530, If castings havebeen subjected to non-destructive testing or hydraulictesting by agreement between the purchaser and themanufacturer, the castings shall be re-examined in the areaof repair following any recti~ing operation performed onthe castings.
15,2 To form the basis of an agreement between thepurchaser and the supplier in this respect, where relevant,the following classification shall apply concerning theextent of repair:
a) Weld repair involving a depth not exceeding20 percent of wall thickness or 25 mm, whicheveris lower, shall be termed as a minor repair.
b) Any weld repair exceeding the above shall betermed as a major repair. Further, any single repairhaving an area exceeding250 mm square for everymillimetre of wall thickness shall also be deemedto be a major repair, regardless of the considerationsmentioned in (a) above.
.15.3 Carbon Equivalent
Unless otherwise specified in the enquiry and order, orotherwise agreed to, the carbon equivalent C.E. for thepurpose of guidance in determination of the pre and postweld treatment applicable to carbon and low alloy steelsshall be computed as follows:
Mn + Cr+Mo+VC.E. = C+—
+lQi+Cu
6 5 15
NOTE — In case of high alloy steels for formula for computing.Carbon equivalent shall be subject to agreement betweenthe parties,
16 HYDRAULIC TEST
16.1 When so specified by the purchaser in the enquirymd order, a hydraulic test shall be carried out; the details]f the test shall be agreed to between the purchaser and:hemanufacturer.
16.2 The castings shall not be peened, plugged orImpregnated, to stop leakages. However, unless otherwise
;pecifled at the time of enquiry and order, rectificationmd upgradation of a casting by welding may be carriedJut in accordance with the approved procedures as laid~own in the relevant clause of the standard.
17 METHOD OF SAMPLING
rhe method of sampling steel castings for the pqose of;hemical analysis and mechanical tests including re-testshall be in accordance with IS 6907.
18 MARKING
18.-1 Each casting shall be legibly -marked with tirefollowing:
a)
b)
c)
number of identification mark by which it ispossible to trace the melt and the heat-treatmentbatch from which it was made;
manufacturer’s initials or trade-mark; and
other identification marks in accordance with anyagreement between the purchaser and themanufacturer.
NOTE — It is recommended that a minimum of markings be used.
18:2 By agreement between the purchaser and themanufacturer, castings complying with the requirementsof this standard may, afler inspection, be legibly markedwith an acceptance mark.
18.3 BIS Certification Mtwking
The castings may also be marked with the Standard Mark.
18.3.1 The use of the Standard Mark is governed by theprovisions of the Bureau of Indian Standards Act, 1986
and the Rules and Regulations made thereunder. Thedetails wfanditions under-which the Iicence for the weof Standard Mark may be granted to manufacturers orproducers, may be obtained from the Bureau of IndianStandards.
6
IS 3038:2006
CastingDesignation
Grade 1
Grade 2
Grade 3
Grade 4
Grade 4A
ANNEX A( Foreword)
TYPICAL APPLICATIONS OF VARIOUS GRADES OF CASTINGS
Use CastingDesignation
General purpose constructional alloy Grade 5particularly for pressure castings operatingup to about 400”C.
Steam turbine castings and other Grade 5Aapplication at temperature of about 450”C.
Steam tucbine castings for applications at Grade 6temperature of about 540”C.
Moderate creep resistance castings forvalves and pressure vessels for thepetroleum industry at temperature of about Grade 7 and520°C. Grade 8
Steam turbine castings for applicationinvolving relatively severe stresses attemperature of about 550”C.
Use
Steam turbine castings for applicationinvolving relatively severe stress attemperature of about 580”C.
Castings for creep resistance applicationat temperature of about 580°C.
Castings for general engineering, chemicaland petroleum industries, suitable forapplication involving creep resistance attemperature up to about 600”C.
Castings for general engineering,chemical and petroleum industries,suitable for application involving creepresistance at temperature up to about650”C.
ANNEX B( Clause 7 )
INFORMATION TO BE SUPPLIED BY THE PURCHASER
B-1 BASIS FOR ORDER c)
While placing an order for the purchase of steel castings d)covered by this standard, the purchaser should specie thefollowing:
a)
b)
Material specification;e)
Drawing or reference number of the pattern (if f)supplied by the purchaser), along with a copy ofthe drawing; g)
Optional/additional tests required, if any;
Whether the castings are to be inspected and testedin the presence of the purchaser’s representative;
Condition ofdelivety;
Any special requirement; and
Test report.
7
Bureau of Indian Standards
BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promoteharmonious development of the activities of standardization, marking and quality certification of goods andattending to connected matters in the country.
,
Copyright
BIS has the copyright of all its publications. No part of these publications may be reproduced in any formwithout the prior permission in writing of BIS. This does not preclude the free use, in the course of implementingthe standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating tocopyright be addressed to the Director (Publications), BIS.
Review of Indian Standards
Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewedperiodically; a standard along with amendments is reaffired when such review indicates that no changes areneeded; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standardsshould ascertain that they are in-possession of the latest amendments or edition by referring to the latest issue of‘BIS Catalogue’ and ‘Standards: Monthly Additions’.
This Indian Standard has been developed ffom Dot: No. MTD 14 (4577).
Amendments Issued Since Publication
Amend No. Date of Issue Text Affected
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