CN113567501A - Nondestructive testing method and device for weld penetration uniformity and cracks of tube plate plug - Google Patents
Nondestructive testing method and device for weld penetration uniformity and cracks of tube plate plug Download PDFInfo
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Abstract
The invention discloses a nondestructive testing method and a nondestructive testing device for weld penetration uniformity and cracks of a tube plate plug, wherein the method comprises the following steps: cleaning the surface of a pipe plate welding plug sample; measuring the center of the surface of the plug sample, marking, attaching a heating body with the diameter of 1/8-1/2 to the central area of the surface of the plug for heating, and covering the heating area; after heating, testing the temperature field of the surface of the plug sample, and if the temperature inside the welding seam and the temperature outside the welding seam are lower than the temperature of the area with the same diameter by a certain value, judging that the area is a welding seam with shallow penetration or a welding seam has cracks; the invention also discloses a test device for realizing the method; on the premise of not damaging a welding structure, the method can perform nondestructive detection on weld penetration uniformity and weld crack defects based on the principle that obvious temperature difference at two sides of the defects is caused by the obstruction of the defects on radial conduction heat flow at the center of the plug, and can provide a new effective method for quality evaluation of new products and the plug welded on the tube plate in service.
Description
Technical Field
The invention belongs to the technical field of material engineering, and particularly relates to a nondestructive testing method and device for weld penetration uniformity and cracks of a pipe plate plug.
Background
The tube plate type heat exchanger manufactured by the welding method is widely used in the fields of power generation, petrochemical industry, pharmacy and the like. The connection mode of the heat exchange tube and the tube plate has various forms such as expanded joint, welding, expanded welding composite and the like, the steam generator is one of core equipment of thermal power and nuclear power technologies and is a typical application representative of a welded tube plate heat exchanger, and the quality of a welded joint of the tube plate tube and the tube plate has important significance for the safe production of a power plant.
The pipe and the pipe plate welding joint are weak links of thermal power and nuclear power steam generators, the pipe is damaged due to long-term high-temperature steam corrosion, mechanical vibration and external abrasive wear, mixing of heat exchange media is finally caused, heat exchange efficiency is reduced, and huge risks of radioactive substance leakage exist for the nuclear power steam generators. Thus, once a pipe fails, it is common to seal off the inlet and outlet of the damaged pipe to short the failed pipe. The plugging mode mainly comprises various modes such as mechanical expansion connection plugging pipes, welding plugging pipes, expansion connection and welding composite plugging pipes, wherein the welding plugging pipes are newly developed high-reliability plugging pipe modes. However, the relative lack of corresponding detection technology is a bottleneck problem affecting the wide application and the after-service quality tracking. After welding and in-service plug quality detection need to be finished on site, the characteristics of weld reinforcement, appearance and the like can be detected by the existing method, but for defects of weld penetration, weld internal cracks and the like, due to site space limitation and tube plate position limitation, the existing commonly used means such as ray detection, eddy current detection and the like cannot be implemented. The method adopted at present usually adopts destructive detection means to detect and evaluate the defects in the optimization and solidification stages of the welding process, and finally obtains optimized process parameters. However, the method has the problems that the detection is not used and the use is not detected, so that the used plug has the risk of containing defects. Therefore, a nondestructive testing method suitable for the weld penetration uniformity/consistency and the weld cracks of the tube plate welding plug is urgently needed to be developed.
Disclosure of Invention
The invention aims to provide a nondestructive testing method and a nondestructive testing device for detecting and evaluating weld penetration uniformity and weld crack defects of a tube plate welding plug, aiming at solving the bottleneck problem that no nondestructive testing method for effectively detecting and evaluating the weld penetration uniformity and the weld crack defects of the tube plate welding plug exists at present.
The invention is realized by the following technical scheme:
a nondestructive testing method for weld penetration uniformity and cracks of a tube plate plug comprises the following steps:
1) cleaning the surface of a pipe plate welding plug sample to remove oxidation products and oil stain attachments on the surface, and preventing the influence of the surface temperature field evolution and measurement of the plug;
2) measuring and obtaining the center of the surface of the plug sample, marking the center, closely contacting and fixing a heating body with the diameter of 1/8-1/2 with the central area of the surface of the plug, heating the central area of the surface of the plug sample, and covering the surface with ceramic heat-insulating fibers;
3) heating for a preset time, taking out the ceramic thermal insulation fiber, testing a temperature field on the surface of the plug sample, and if the temperature inside the welding seam and the temperature outside the welding seam are lower than the temperature of a region with the same diameter by a certain value, judging that the region is a welding seam with shallow fusion depth or a welding seam has cracks;
the heat exchange can be carried out only by low-efficiency heat radiation by utilizing the characteristic that the heat conduction path outwards from the center of the plug along the diameter direction is reduced or partially blocked by the weld penetration depth and the crack defect, so that the temperature of the weld penetration depth or the crack defect close to the center side of the heat source is higher than that of other areas with the same radius, and the temperature of the weld penetration depth or the crack defect far away from the center side of the heat source is lower than that of other areas with the same radius, so that the semi-quantitative detection is carried out on the weld penetration depth uniformity and the crack defect.
Preferably, the heating body in step 2) heats the central area of the surface of the plug by using an electric heating rod for heat conduction heating or irradiation heating in the form of laser or xenon lamp.
Preferably, the heating body in the step 2) heats the plug to be not less than 150 ℃, so that the temperature difference caused by a shallow fusion depth and a crack defect can be detected, and the upper heating limit temperature is not higher than the temperature which can prevent the material structure and performance from changing.
Preferably, the heating preset time in the step 3) is between 1 and 15min, the higher the thermal conductivity between the plug and the weld material or the shorter the heating time is set as the set weld penetration depth is deeper, and the lower the thermal conductivity between the plug and the weld material or the longer the heating time is set as the set weld penetration depth is shallower.
Preferably, the test of the temperature field in the step 3) adopts a film thermocouple, a cloth mesh type thermocouple, an infrared thermometer or an infrared camera, the temperature resolution is not lower than 2 ℃, and the plane resolution is not lower than 0.2 ℃/mm.
Preferably, when the fusion depth or the crack defect is judged to be shallow in the step 3), the temperature difference between the two sides of the target area needs to be more than 5 ℃.
Preferably, the heat source temperature, the heating time and the material thermal conductivity of the material are combined, and the weld penetration and the defect size of different areas can be deduced by using the calculation result of the unsteady heat transfer relation of the point heat source semi-infinite area.
Preferably, the method is not only suitable for new products of the tube plate welding plugs, but also suitable for quality detection of in-service tube plate welding plugs.
The testing device for realizing the nondestructive testing method for the weld penetration uniformity and cracks of the tube plate plug comprises an automatic testing device three-point supporting framework 2, a magnetic fixing device 3 fixed at the bottom of the automatic testing device three-point supporting framework 2 and used for fixing with a welding plug testing sample piece 1, an XY two-dimensional moving platform 4 fixed at the inner side surface of the top of the automatic testing device three-point supporting framework 2, a horizontal rotating platform 5 fixed at the lower part of the XY two-dimensional moving platform 4, a first vertical direction slide rail 9 and a second vertical direction slide rail 10 fixed at two ends of the lower part of the horizontal rotating platform 5, an infrared camera 8 and a laser heating device 7 respectively fixed at the lower parts of the first vertical direction slide rail 9 and the second vertical direction slide rail 10, and two positioning cameras 6 fixed at the lower part of the horizontal rotating platform 5 and positioned between the first vertical direction slide rail 9 and the second vertical direction slide rail 10, the system comprises a data and electric power transfer interface 11 arranged on an automatic testing device three-point supporting framework 2, a process monitoring and control device 12 and a power supply 13, wherein the process monitoring and control device is connected with an XY two-dimensional moving platform 4, a horizontal rotating platform 5, a positioning camera 6, a laser heating device 7, an infrared camera 8, a first vertical direction slide rail 9 and a second vertical direction slide rail 10 through the data and electric power transfer interface 11.
The testing device is implemented according to the following testing steps: firstly, removing attachments such as oxides, organic matters and the like on the surfaces of plugs 1-3 and nearby areas in a welding plug test sample 1 by adopting a mechanical polishing and organic solvent cleaning method, and ensuring that the center parts of the plugs are smooth; fixing a testing device on the surface of a welding plug testing sample 1 through a magnetic fixing device 3; secondly, starting a testing device, driving two positioning cameras 6 which are not parallel to each other by a process monitoring and controlling device 12, measuring the geometric center of the plug to be tested by an image method, and obtaining the plane coordinate of the plug to be tested; the XY two-dimensional moving platform 4 and the horizontal rotating platform 5 are driven by the process monitoring and controlling device 12 to enable the laser heating device 7 to be aligned to the geometric center of the plane of the plugs 1-3; heating the center of the surface of the plug 1-3 with the diameter being between 1/8-1/2 of the plug by using laser or a heating rod in a mode of focusing by using laser or driving the second vertical slide rail 10, and covering the surface by using a ceramic heat-insulating fiber blanket; and finally, after heating for a certain time, taking out the ceramic thermal insulation fiber, driving the XY two-dimensional moving platform 4 and the horizontal rotating platform 5 through the process monitoring and control device 12 to enable the infrared camera 8 to be aligned to the geometric center of the plane of the plugs 1-3, testing the temperature field on the surface of the welding plug test sample 1 under a reasonable view field by driving the first vertical direction slide rail 9, and judging that the weld penetration is shallow or the weld has cracks when the temperature in the welding seam and the outside of the welding seam is lower than a certain value of the temperature of the area with the same diameter.
Compared with the prior art, the invention has the following advantages:
1) the quality of the plug is not affected in the testing process, the testing equipment is small in size, and the hardware requirement is simple.
2) The testing time of a single plug is short.
3) Semi-quantitative results of defect size can be obtained by theoretical calculations.
Drawings
FIG. 1 is a typical apparatus for nondestructive testing of weld penetration uniformity and cracks in a tube plate plug weld; in the figure, 1-welding plug test sample pieces (1-1 tube plate, 1-2 tubes, 1-3 plugs and 1-4 welding seams), 2-an automatic test device three-point support framework, 3-a magnetic fixing device, a 4-XY two-dimensional moving platform, 5-a horizontal rotating platform, 6-a positioning camera, 7-a laser heating device, 8-an infrared camera, 9-a first vertical direction slide rail, 10-a second vertical direction slide rail, 11-a data and power transfer interface, 12-a process monitoring and control device and 13-a power supply.
Detailed Description
The present invention will now be described in further detail with reference to the following detailed description and accompanying drawings of which, by way of illustration and not limitation, the invention is described.
FIG. 1 is a diagram of a device for realizing the nondestructive testing method of the weld penetration uniformity and cracks of the tube plate plug, which comprises an automatic testing device three-point supporting framework 2, a magnetic fixing device 3 fixed at the bottom of the automatic testing device three-point supporting framework 2 and used for fixing with a welding plug testing sample piece 1, an XY two-dimensional moving platform 4 fixed at the inner side surface of the top of the automatic testing device three-point supporting framework 2, a horizontal rotating platform 5 fixed at the lower part of the XY two-dimensional moving platform 4, a first vertical direction slide rail 9 and a second vertical direction slide rail 10 fixed at two ends of the lower part of the horizontal rotating platform 5, an infrared camera 8 and a laser heating device 7 respectively fixed at the lower parts of the first vertical direction slide rail 9 and the second vertical direction slide rail 10, and two positioning cameras 6 fixed at the lower part of the horizontal rotating platform 5 and positioned between the first vertical direction slide rail 9 and the second vertical direction slide rail 10, the system comprises a data and electric power transfer interface 11 arranged on an automatic testing device three-point supporting framework 2, a process monitoring and control device 12 and a power supply 13, wherein the process monitoring and control device is connected with an XY two-dimensional moving platform 4, a horizontal rotating platform 5, a positioning camera 6, a laser heating device 7, an infrared camera 8, a first vertical direction slide rail 9 and a second vertical direction slide rail 10 through the data and electric power transfer interface 11.
The invention discloses a nondestructive testing method for weld penetration uniformity and cracks of a welding plug, which is implemented by the following steps:
firstly, removing attachments such as oxides, organic matters and the like on the surface of the plug 1-3 and in the nearby area by adopting a mechanical polishing and organic solvent cleaning method, and ensuring that the central part of the plug is flat and has the roughness not higher than Ra 4.5 mu m; the automatic testing device shown in fig. 1 is fixed on the surface of a welding plug test sample 1 through a magnetic fixing device 3. Secondly, the automatic detection device is started, the process monitoring and control device 12 drives the two positioning cameras 6 which are not parallel to each other to determine the geometric center of the plug to be detected by an image method, and the plane coordinate of the plug to be detected is obtained. The XY two-dimensional moving platform 4 and the horizontal rotating platform 5 are driven by the process monitoring and controlling device 12 to enable the laser heating device 7 to be aligned to the geometric center of the plane of the plugs 1-3. The center of the surface of the plug 1-3 with the diameter being between the diameters 1/8-1/2 of the plug is heated by laser or a heating rod in a mode of focusing by laser or driving the second vertical slide rail 10, and the surface is covered by a ceramic heat-insulating fiber blanket. And finally, after heating for a certain time, taking out the ceramic thermal insulation fiber, driving the XY two-dimensional moving platform 4 and the horizontal rotating platform 5 through the process monitoring and control device 12 to enable the infrared camera 8 to be aligned to the geometric center of the plane of the plugs 1-3, testing the temperature field on the surface of the welding plug test sample 1 under a reasonable view field by driving the first vertical direction slide rail 9, and judging that the weld penetration is shallow or the weld has cracks when the temperature in the welding seam and the outside of the welding seam is lower than a certain value of the temperature of the area with the same diameter.
The specific embodiment is as follows:
example 1: the specific embodiment is as follows:
example 1: an Incolly 800H alloy pipe with the outer diameter of 19mm and the wall thickness of 3mm and a TIG welding joint made of an Incolly 800H alloy pipe plate with the thickness of 200mm are selected, and the Incolly 800H plug with the diameter of 12.85mm is selected to plug the pipe by adopting a TIG welding method. After plugging, the welding plug test sample 1 shown in fig. 1 is obtained by machining. Firstly, removing attachments such as oxides, organic matters and the like on the surface of the plug 1-3 and in the nearby area by using an angle grinder polishing and acetone cleaning method, and ensuring that the central part of the plug is flat and has roughness not higher than Ra 4.5 mu m; next, the automatic testing apparatus shown in fig. 1 is fixed to the surface of the welding plug test sample 1 by the magnetic fixing device 3. Secondly, the automatic detection device is started, the process monitoring and control device 12 drives the two positioning cameras 6 which are not parallel to each other to determine the geometric center of the plug to be detected by an image method, and the plane coordinate of the plug to be detected is obtained. The XY two-dimensional moving platform 4 and the horizontal rotating platform 5 are driven by the process monitoring and controlling device 12 to enable the laser heating device 7 to be aligned to the geometric center of the plane of the plugs 1-3. The center of the surface of the plug 1-3 with the diameter being between the diameters 1/8-1/2 of the plug is heated by laser or a heating rod in a mode of focusing or driving the second vertical slide rail 10 by laser, the heating temperature is set to 450 ℃ by adjusting the laser power, and the surface is covered by a ceramic heat-insulating fiber blanket. And finally, after heating for 3.5 minutes, taking out the ceramic thermal insulation fiber, driving the XY two-dimensional moving platform 4 and the horizontal rotating platform 5 through the process monitoring and control device 12 to enable the infrared camera 8 to be aligned to the geometric center of the plane of the plugs 1-3, testing the temperature field on the surface of the sample in a reasonable visual field by driving the first vertical direction slide rail 9, and judging that the weld penetration is shallow or the weld has cracks when the temperature in the weld and the outer side of the weld is lower than a certain value of the temperature in the same diameter region. The method comprises the steps of testing 3 samples under different welding parameters totally, wherein no welding crack is found in any of the 3 samples, strip-shaped areas which are parallel to an annular welding seam and have the temperature difference between 15 ℃ and 29 ℃ and the length of 8.2mm exist on two sides of the welding seam in 1 sample, judging the strip-shaped areas as the defects of the weld penetration depth, dissecting and observing the samples subjected to nondestructive testing by adopting a destructive metallographic method, wherein the observation result is consistent with the nondestructive testing result, no defect is found in any of the 2 samples, the strip-shaped areas exist in the 1 sample, and the length testing result is 7.4 mm.
Claims (10)
1. A nondestructive testing method for weld penetration uniformity and cracks of a tube plate plug is characterized by comprising the following steps:
1) cleaning the surface of a pipe plate welding plug sample to remove oxidation products and oil stain attachments on the surface, and preventing the influence of the surface temperature field evolution and measurement of the plug;
2) measuring and obtaining the center of the surface of the plug sample, marking the center, closely contacting and fixing a heating body with the diameter of 1/8-1/2 with the central area of the surface of the plug, heating the central area of the surface of the plug sample, and covering the surface with ceramic heat-insulating fibers;
3) heating for a preset time, taking out the ceramic thermal insulation fiber, testing a temperature field on the surface of the plug sample, and if the temperature inside the welding seam and the temperature outside the welding seam are lower than the temperature of a region with the same diameter by a certain value, judging that the region is a welding seam with shallow fusion depth or a welding seam has cracks;
the heat exchange can be carried out only by low-efficiency heat radiation by utilizing the characteristic that the heat conduction path outwards from the center of the plug along the diameter direction is reduced or partially blocked by the weld penetration depth and the crack defect, so that the temperature of the weld penetration depth or the crack defect close to the center side of the heat source is higher than that of other areas with the same radius, and the temperature of the weld penetration depth or the crack defect far away from the center side of the heat source is lower than that of other areas with the same radius, so that the semi-quantitative detection is carried out on the weld penetration depth uniformity and the crack defect.
2. The nondestructive testing method for the weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the heating of the heating body in the step 2) on the central area of the surface of the plug is electric heating rod heat conduction heating or irradiation heating in the form of laser or xenon lamp.
3. The nondestructive testing method for the weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the heating body in the step 2) heats the plug at a temperature of not less than 150 ℃ so that the temperature difference caused by shallow penetration and crack defects can be detected, and the upper heating limit temperature is not higher than the temperature at which the material structure and performance are not changed.
4. The nondestructive testing method for the weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the heating preset time in the step 3) is 1-15min, the higher the thermal conductivity between the plug and the weld material is, or the shorter the heating time is set for the set weld penetration depth, the lower the thermal conductivity between the plug and the weld material is, or the longer the heating time is set for the set weld penetration depth.
5. The nondestructive testing method for the weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the test of the temperature field in the step 3) adopts a thin film thermocouple, a mesh-type thermocouple, an infrared thermometer or an infrared camera, the temperature resolution is not lower than 2 ℃, and the plane resolution is not lower than 0.2 ℃/mm.
6. The nondestructive testing method for weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the temperature difference between two sides of the target area needs to be greater than 5 ℃ when the weld penetration is shallow or the crack defect is judged in step 3).
7. The nondestructive testing method for weld penetration uniformity and cracks of the pipe plate plug according to claim 1, wherein the weld penetration and defect sizes of different areas can be deduced by combining the heat source temperature, heating time and material thermal conductivity of the material and calculating the result by using the unsteady heat transfer relationship of the point heat source in the semi-infinite area.
8. The nondestructive testing method for the weld penetration uniformity and cracks of the tube plate plug according to claim 1, characterized in that the method is not only suitable for new tube plate welding plugs, but also suitable for quality detection of in-service tube plate welding plugs.
9. The testing device for realizing the nondestructive testing method for the weld penetration uniformity and cracks of the pipe plate plug in any one of claims 1 to 8 is characterized by comprising an automatic testing device three-point supporting framework (2), a magnetic fixing device (3) fixed at the bottom of the automatic testing device three-point supporting framework (2) and used for fixing a welding plug testing sample piece (1), an XY two-dimensional moving platform (4) fixed on the inner side surface of the top of the automatic testing device three-point supporting framework (2), a horizontal rotating platform (5) fixed at the lower part of the XY two-dimensional moving platform (4), a first vertical direction slide rail (9) and a second vertical direction slide rail (10) fixed at the two ends of the lower part of the horizontal rotating platform (5), and an infrared camera (8) and a laser heating device (7) respectively fixed at the lower parts of the first vertical direction slide rail (9) and the second vertical direction slide rail (10), fix two location cameras (6) in horizontal rotation platform (5) lower part and be located between first vertical direction slide rail (9) and the vertical direction slide rail of second (10), data and electric power transfer interface (11) of setting on automatic testing arrangement three point support skeleton (2), through process monitoring and controlling means (12) and power (13) that data and electric power transfer interface (11) and XY two-dimensional moving platform (4), horizontal rotation platform (5), location camera (6), laser heating device (7), infrared camera (8), first vertical direction slide rail (9) and the vertical direction slide rail of second (10) are connected.
10. The test device of claim 9, wherein the following test steps are performed: firstly, removing attachments such as oxides, organic matters and the like on the surface of a plug (1-3) and a nearby area in a welding plug test sample 1 by adopting a mechanical polishing and organic solvent cleaning method, and ensuring that the center part of the plug is flat; fixing a testing device on the surface of a welding plug testing sample piece (1) through a magnetic fixing device (3); secondly, starting a testing device, driving two positioning cameras (6) which are not parallel to each other by a process monitoring and controlling device (12), measuring the geometric center of the plug to be tested by an image method, and obtaining the plane coordinate of the plug to be tested; the XY two-dimensional moving platform (4) and the horizontal rotating platform (5) are driven by the process monitoring and controlling device (12) to enable the laser heating device (7) to be aligned to the geometric center of the plane of the plug (1-3); heating the center of the surface of the plug (1-3) with the diameter being between 1/8-1/2 of the plug by using laser or a heating rod in a mode of focusing by using laser or driving a second vertical slide rail (10), and covering the surface by using a ceramic heat-insulating fiber blanket; and finally, after heating for a certain time, taking out the ceramic thermal insulation fiber, driving an XY two-dimensional moving platform (4) and a horizontal rotating platform (5) through a process monitoring and control device (12) to enable an infrared camera (8) to be aligned to the geometric center of the plane of the plug (1-3), testing the temperature field on the surface of the welding plug test sample piece (1) under a reasonable view field by driving a first vertical direction slide rail (9), and judging that the weld penetration is shallow or the weld has cracks when an area with the temperature lower than a certain value of the temperature of the area with the same diameter appears inside and outside the weld.
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114002391A (en) * | 2021-11-22 | 2022-02-01 | 江苏科技大学 | Method and device for evaluating welding filler material solidification crack sensitivity |
| CN114034272A (en) * | 2021-11-02 | 2022-02-11 | 广东博盈特焊技术股份有限公司 | Method for measuring and calculating weld penetration depth |
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2021
- 2021-09-03 CN CN202111035536.3A patent/CN113567501A/en active Pending
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114034272A (en) * | 2021-11-02 | 2022-02-11 | 广东博盈特焊技术股份有限公司 | Method for measuring and calculating weld penetration depth |
| CN114034272B (en) * | 2021-11-02 | 2024-05-24 | 广东博盈特焊技术股份有限公司 | Method for measuring and calculating weld penetration of build-up welding |
| CN114002391A (en) * | 2021-11-22 | 2022-02-01 | 江苏科技大学 | Method and device for evaluating welding filler material solidification crack sensitivity |
| CN114002391B (en) * | 2021-11-22 | 2024-03-26 | 江苏科技大学 | Method and device for evaluating solidification crack sensitivity of welding filling material |
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Address after: 6 fuxingmennei street, Xicheng District, Beijing 100031 Applicant after: HUANENG GROUP TECHNOLOGY INNOVATION CENTER Co.,Ltd. Applicant after: Xi'an Thermal Power Research Institute Co.,Ltd. Address before: 710032 No. 136 Xingqing Road, Beilin District, Xi'an City, Shaanxi Province Applicant before: Xi'an Thermal Power Research Institute Co.,Ltd. Applicant before: HUANENG GROUP TECHNOLOGY INNOVATION CENTER Co.,Ltd. |