Bsi bs en 01559 4 2015

BSI Standards PublicationFounding — Technical conditions of delivery Part 4: Additional requirements for aluminium alloy castings... ICS 77.150.10 Supersedes EN 1559-4:1999English Versio

BSI Standards Publication

Founding — Technical conditions of delivery

Part 4: Additional requirements for aluminium alloy castings

Committee NFE/35, Light metals and their alloys.

A list of organizations represented on this committee can be obtained on request to its secretary

This publication does not purport to include all the necessary provisions of a contract Users are responsible for its correct application

© The British Standards Institution 2015

Published by BSI Standards Limited 2015 ISBN 978 0 580 83651 0

ICS 77.150.10

Compliance with a British Standard cannot confer immunity from legal obligations.

This British Standard was published under the authority of the Standards Policy and Strategy Committee on 28 February 2015

Amendments/corrigenda issued since publication#

Date Text affected

ICS 77.150.10 Supersedes EN 1559-4:1999

English Version

Founding - Technical conditions of delivery - Part 4: Additional

requirements for aluminium alloy castings

Fonderie - Conditions techniques de fourniture - Partie 4:

Spécifications complémentaires pour les pièces moulées en

alliages d'aluminium

Gießereiwesen - Technische Lieferbedingungen - Teil 4: Zusätzliche Anforderungen an Gussstücke aus

Aluminiumlegierungen

This European Standard was approved by CEN on 26 December 2014

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,

Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M I T É E U R O P É E N D E N O R M A L I S A T I O N

E U R O P Ä I S C H E S K O M I T E E F Ü R N O R M U N G

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2015 CEN All rights of exploitation in any form and by any means reserved

worldwide for CEN national Members

Ref No EN 1559-4:2015 E

Contents Page

Foreword 3

Introduction 4

1 Scope 5

2 Normative references 5

3 Terms and definitions 5

4 Information to be supplied by the purchaser 6

4.1  Mandatory information 6

4.2 •• Optional information 6

4.3  Drawing, patterns and tools 6

4.4  Information on the mass 6

4.5  Preliminary sample 6

4.6 Initial sample 6

5  Designations 6

6  Manufacture 6

6.1  Manufacturing process 6

6.2 Welding operations 6

7 Requirements 7

7.1  General 7

7.2  Material 7

7.3 Casting 7

8  Inspection 9

8.1  General 9

8.2  Type of inspection documents and type of inspection 9

8.3 Test unit 9

8.4  Samples 9

8.5  Test procedures 9

8.6  Invalidation of test results 9

8.7  Retests 9

8.8  Sorting and reprocessing 9

9  Marking 9

10  Packaging and surface protection 9

11  Complaints 9

Annex A (informative) Procedure for the classification of excavation for finishing welding 10

Annex B (informative) Significant technical changes between this European Standard and the previous edition 12

Bibliography 13

Foreword

This document (EN 1559-4:2015) has been prepared by Technical Committee CEN/TC 132 “Aluminium and aluminium alloys”, the secretariat of which is held by AFNOR

This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by August 2015 and conflicting national standards shall be withdrawn at the latest by August 2015

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights

This document supersedes EN 1559-4:1999

Within its programme of work, Technical Committee CEN/TC 132 requested CEN/TC 132/WG 22 "Revision of

EN 1559-4:1999" to revise the following standard:

EN 1559-4, Founding — Technical conditions of delivery — Part 4: Additional requirements for aluminium alloy castings

Annex B provides details of significant technical changes between this European Standard and the previous edition

This European Standard is part of a series of standards which specify technical delivery conditions for castings The other standards in this series are:

EN 1559-1, Founding — Technical conditions of delivery — Part 1: General;

EN 1559-2, Founding — Technical conditions of delivery — Part 2: Additional requirements for steel castings;

EN 1559-3, Founding — Technical conditions of delivery — Part 3: Additional requirements for iron castings;

EN 1559-5, Founding — Technical conditions of delivery — Part 5: Additional requirements for magnesium alloy castings;

EN 1559-6, Founding — Technical conditions of delivery — Part 6: Additional requirements for zinc alloy castings

According to the CEN-CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom

Introduction

In order to assist manufacturers and purchasers to prepare proper contractual arrangements and prevent misunderstandings, CEN/TC 190 "Foundry Technology" approved the preparation of a series of standards covering technical delivery conditions These have been prepared as separate parts

This European Standard covers the additional technical delivery conditions for aluminium alloy casting

materials and has the same structure as EN 1559-1 "Founding - Technical conditions of delivery – Part 1: General"

This European Standard cannot be used alone for compiling a specification for ordering and supplying aluminium alloy castings, but as a complement to EN 1559-1

The structure of this standard is as follows:

 clauses and sub clauses preceded by  indicate no additional conditions to EN 1559-1;

 clauses and sub clauses marked with a single dot • indicate that conditions shall be agreed at the time of enquiry and order;

 clauses and sub clauses marked with two dots •• indicate that conditions can be agreed at the time of enquiry and order (optional);

 clauses and sub clauses without a symbol are mandatory;

 clauses and sub clauses preceded by  are supplementary to those in EN 1559-1;

 clauses and sub clauses preceded by  completely replace those in EN 1559-1

1 Scope

This European Standard specifies the additional technical delivery conditions for aluminium alloy castings unless other conditions have been agreed at the time of enquiry and order

This European Standard retains the same structure and numbering system as used in EN 1559-1 and repeats the numbering of clauses and sub-clauses even if nothing extra or different has been added It also indicates items specific to aluminium alloy castings under existing or new headings

2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 1371-1, Founding — Liquid penetrant testing — Part 1: Sand, gravity die and low pressure die castings

EN 1559-1, Founding — Technical conditions of delivery — Part 1: General

EN 1706, Aluminium and aluminium alloys — Castings — Chemical composition and mechanical properties

EN 12681, Founding — Radiographic examination

3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN 1559-1, in the applicable material standard and the following apply

3.1

 excavation

cavity produced by the removal of cast material prior to subsequent welding (or other finishing methods)

4.1  Mandatory information

4.2 •• Optional information

4.3  Drawing, patterns and tools

4.4  Information on the mass

4.5  Preliminary sample

4.6 Initial sample

 If required, a minimum of two initial samples shall be supplied to the purchaser for approval If these initial samples are accepted, one shall be retained by the purchaser and one returned to the manufacturer marked as "approved"

Supplementary initial samples (one for metallurgical and the other for dimensional purposes) should be retained either by the manufacturer or by the purchaser

NOTE Testing of initial samples by the manufacturer can be agreed

5  Designations

6  Manufacture

6.1  Manufacturing process

6.2 Welding operations

6.2.1  General

6.2.2 Production welding

Production welding is permitted, unless otherwise agreed at the enquiry and order stage For railway applications, production welding has to be agreed separately (see EN 15085-2)

 Actions to finish castings or eliminate casting imperfections may include the use of a filler metal deposited by a suitable welding process or the insertion of a machined piece secured by welding The manufacturer's and purchaser's attention is drawn to the need for approved procedures and suitably qualified welders (see EN ISO 15614-4, for finishing welding)

After preparing the casting for finishing welding, the excavation can be classified in accordance with the procedure given in Annex A

6.2.2.1 

6.2.2.2 

6.2.2.4 

6.2.2.5 

6.2.2.6 

7 Requirements

7.1  General

7.2  Material

7.2.1  Chemical composition

NOTE Metal is usually taken for optical emission spectrometry analysis at the time the castings are made,

in the form of a chill cast disc (see EN 14361)

7.2.2  Mechanical properties

7.2.3  Other properties

7.2.4  Additional requirements

The manufacturer shall examine the results of any treatment of the melt carried out during the melting process by using appropriate methods

7.3 Casting

7.3.1  Chemical composition

For chemical composition of aluminium alloy castings, refer to the appropriate table in EN 1706

7.3.2  Mechanical properties

7.3.3 Outer and inner conditions (non-destructive testing)

 Liquid penetrant examination shall be carried out in accordance with EN 1371-1

 Radiographic inspection shall be carried out in accordance with EN 12681

 Where applicable, unacceptable external and internal discontinuities shall be eliminated by production welding (see 6.2.2) or other agreed methods.

7.3.3.1 

7.3.3.2 

7.3.3.3 

7.3.3.4 

7.3.4.2  Fettling and finishing

7.3.4.3  In order to eliminate leaks in castings, it is possible with the approval of the purchaser, to use impregnation The impregnation medium and method, maximum permitted size of discontinuities and retest procedures shall be agreed between purchaser and manufacturer

7.3.4.4  In the case of as cast castings, it is recommended that the purchaser agrees with the manufacturer on the choice of any non-destructive testing and criteria to determine the acceptability of a subsequently machined surface Unless specifically agreed, discontinuities revealed

on the machined surface should not be regarded as a cause for rejection If the porosity on machined surfaces is to be assessed, manufacturer and purchaser should agree on the method to be used

7.3.5  Mass of the casting

7.3.6  Additional requirements regarding the conditions of the casting

7.3.6.1  Macrostructure

Where appropriate, a macroscopic examination of a suitably prepared and etched section shall be used to assess the grain size and/or structural discontinuities of a casting to agreed criteria Assessment is usually carried out with or without low magnification

7.3.6.2  Microstructure

Where appropriate, a microscopic examination of a suitably polished and etched section shall be used

to determine the metallurgical structure of a casting to agreed criteria Assessment is usually carried out at a high magnification and includes the nature, shape and distribution of the structural constituents

NOTE A cooling curve/thermal analysis carried out on a sample of liquid alloy before casting, can predict, to

a limited extent, the metallurgical structure to be expected in the casting

7.3.6.3  Density evaluation can be used to estimate the soundness of castings by weighting

in air and water to agreed criteria

8.1  General

8.2  Type of inspection documents and type of inspection

8.3 Test unit

8.3.1  Formation of test units

8.3.2  Size of test units

8.3.3 Inspection frequency

 When tests are requested, unless any agreement to the contrary has been made, one test per test unit shall be carried out For hardness testing, the inspection frequency shall be agreed between the manufacturer and the purchaser by the time of acceptance of the order

8.4  Samples

8.5  Test procedures

8.6  Invalidation of test results

8.7  Retests

8.7.1  General

8.7.2  Non-sequential tests (individual values)

8.7.2.1  Retest of chemical composition

If disagreement occurs between the manufacturer and the purchaser on the chemical composition of a test unit the manufacturer shall re-check the composition wherever possible on the original test piece

If disagreement persists, a referee analysis shall be carried out by a mutually acceptable laboratory

8.7.3  Sequential tests

8.8  Sorting and reprocessing

9  Marking

10  Packaging and surface protection

11  Complaints

Procedure for the classification of excavation for finishing welding

The procedure for the classification of excavations for finishing welding is as follows:

- measure the original wall thickness of the casting adjacent to the excavations;

- measure the depth and, if required, the projected area of the excavation;

- classify the excavation into class 1, 2 or 3 using the cavity depth, the original wall thickness of the casting adjacent to the excavation and Figure A.1;

- if the excavation is of class 3 (major) the manufacturer should obtain the purchaser's agreement to the method of correction and the inspection procedures to be followed;

- unless otherwise agreed, if the excavation is of class 1 (surface), the manufacturer should perform the correction work without consultation with the purchaser;

- unless otherwise agreed, if the excavation is of class 2 (minor), reference should be made to Figure A.2 using the projected area of the cavity This may reclassify the cavity due to its projected area as class 3: in these cases the manufacturer should obtain the purchaser's agreement to the method of correction and the inspection procedures to be projected If the excavation is still of class 2 then such consultation is not necessary

Key

X depth of excavation in millimetres

Y nominal casting wall thickness in millimetres

1 class 1: surface

2 class 2: minor

3 class 3: major

4 not relevant for finishing welding

5 dimensions out of class

Figure A.1 — Classification of surface, minor and major excavations depending on their depth