What each test can and cannot tell you

A robust inspection and test plan uses each method where its evidence is meaningful. Adding more tests without defining acceptance does not automatically improve quality.

PMI requirements for alloy verification

State whether PMI applies to each flange, a sampling plan or selected heats. Define the instrument method, required elements, calibration checks, marking after acceptance and reporting. X-ray fluorescence is widely used for alloy sorting but has limitations for light elements such as carbon; another method may be needed when the project requires those measurements.

PMI results should be linked to the flange marking and heat number. A result that simply says “pass” without measured elements, instrument identification or item traceability provides limited audit value.

UT coverage and acceptance

Ultrasonic examination of wrought products requires a written procedure, qualified personnel, suitable calibration references and defined scanning coverage. ASTM E2375 provides a practice for UT of wrought products, but the purchase order or engineering document must identify the acceptance class or alternate criteria.

Flange geometry can create dead zones and complex reflections around hubs, bores and changes in section. The procedure should address accessible surfaces, scan directions, sensitivity, reportable indications and any areas that cannot be fully examined.

Hardness plan and report review

Specify the hardness scale, instrument, surface preparation, test locations, number of readings and acceptance range. Portable hardness results can be sensitive to surface condition, part support, curvature and operator technique. Conversion between scales should only be used when permitted by the governing requirement.

• Confirm report number, PO item, flange ID and heat number
• Check procedure and personnel qualification references
• Review calibration blocks and instrument status
• Verify coverage, locations and actual values, not only “accepted”
• Confirm acceptance criteria and disposition of any nonconformance
• Ensure retests or re-heat treatment are fully documented