CN114113321A - Gas turbine compressor impeller root groove phased array ultrasonic detection system and method - Google Patents
Gas turbine compressor impeller root groove phased array ultrasonic detection system and method Download PDFInfo
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Abstract
The invention discloses a phased array ultrasonic detection system and a phased array ultrasonic detection method for a gas turbine compressor impeller blade root groove, wherein the system comprises a phased array ultrasonic probe, a detection tool, a comparison test block and a phased array ultrasonic detector, and the method comprises the following steps: s1: processing reference blocks with equal proportion and same or similar materials; s2: carrying out TCG calibration; s3: finding the highest reflection echo of the defect of the reference block; s4: determining a defect judgment reference; s5: and carrying out actual detection on the leaf root groove to be detected. By designing the special phased array ultrasonic probe, the detection tool and the comparison test block, the invention realizes the effective simulation of the blade root groove crack of the compressor impeller and the accurate positioning of the phased array ultrasonic probe and the defect position in the defect detection; the acute angle of the blade root groove of the compressor impeller is scanned by utilizing the ultrasonic primary wave and secondary wave technology, so that the defects of different positions and trends are comprehensively detected.
Description
Technical Field
The invention belongs to the field of ultrasonic detection, and particularly relates to a phased array ultrasonic detection system and method for a gas turbine compressor impeller blade root groove.
Background
The gas turbine compressor moving blade is a main component of a gas compressor for applying work to gas at the inlet of the gas turbine, and is used as a comprehensive action of bearing loads such as centrifugal stress, airflow impact force, vibration stress and the like during the operation of a rotating machine. The compressor moving blade and the compressor rotor are matched through the compressor impeller root groove, the key of transmitting the compressor rotor torque to the compressor moving blade is that the compressor impeller root groove not only bears the same or larger load action, but also has worse working environment due to the existence of corrosion, fretting wear and the like, and the detection of the health state of the compressor impeller root groove is particularly important for ensuring the safe and stable operation of the gas turbine.
In the starting and stopping process of the gas turbine, the stress at the acute angle between the front end (upstream side) and the rear end (downstream side) of the blade root groove of the compressor impeller is maximum, and after a certain number of starting and stopping cycles, cracks may appear at the acute angle at the bottom of the blade root groove of the compressor impeller.
As the crack propagates, it may cause the stiffness of the rim of the impeller between the root grooves to decrease, thereby causing the loosening of the compressor moving blades. In addition, the variation of the blade root holding rigidity may affect the frequency response of the compressor moving blade, and finally cause high-cycle fatigue damage such as impeller blade root slot abrasion, blade crack and the like. The radial expansion of the crack along the front and rear surfaces of the rim may further cause the fracture of the compressor impeller, thereby causing major accidents of the unit.
Disclosure of Invention
The technical problem to be solved by the invention is to provide a phased array ultrasonic detection system and method for a gas turbine compressor impeller root groove, which are used for carrying out in-situ phased array ultrasonic detection on a weak area of the compressor impeller root groove, finding out possible defects such as cracks in advance and the like, and ensuring the operation safety of a gas turbine unit.
The invention is realized by adopting the following technical scheme:
a phased array ultrasonic detection system for a gas turbine compressor impeller blade root groove comprises a phased array ultrasonic probe, a detection tool, a comparison test block and a phased array ultrasonic detector;
the phased array ultrasonic probe comprises a shell, a back lining, an electrode lead, a wafer, a matching layer and a wedge block; the shell is provided with a corresponding signal transmission interface, and the electric signal generated by the phased array ultrasonic probe is transmitted to the phased array ultrasonic detector through a cable; the back lining is in direct contact with the back surface of the wafer, can absorb high-amplitude ultrasonic waves emitted to the back surface of the wafer and reflected by a workpiece, has a vibration stopping effect on the wafer, reduces the width of an ultrasonic pulse signal and improves the axial resolution; the electrode lead is led out from the back of each array element of the wafer and is collected to a signal transmission interface on the shell; the wafer consists of a plurality of array elements, and each array element can independently excite and receive ultrasonic waves; the matching layer is in direct contact with the wafer and is used as a medium for transmitting the ultrasonic waves emitted by the wafer into the wedge block; the wedge block is connected with the probe shell, a coupling agent is filled between the upper surface of the wedge block and the matching layer and is in direct contact with the upper surface of the wedge block, and the lower surface of the wedge block is in direct contact with the root groove to be detected through the coupling agent;
the detection tool stably fixes the phased array ultrasonic probe on the upper surface of the to-be-detected blade root groove reference block, can realize stable coupling and continuous scanning of the phased array ultrasonic probe on the surface of the to-be-detected blade root groove, and can accurately measure and record the position and the swing angle of the phased array ultrasonic probe;
the overall dimension of the reference block is completely the same as that of the blade root groove to be detected, and artificial defects with different lengths, depths, shapes and trends are processed at the parts where the defects are easy to appear, so that the reference block is used for simulating various defect forms which are easy to appear in the blade root groove.
The invention has the further improvement that the detection tool is fixed on the upper surface of the reference test block of the blade root groove of the compressor impeller in a magnet or mechanical fixing mode, and does not have obvious relative displacement with the upper surface of the reference test block in the detection process.
The invention is further improved in that the parts of the reference block which are easy to have defects are sharp angles at the front end and the rear end.
The phased array ultrasonic detector is further improved in that the phased array ultrasonic detector is connected with the phased array ultrasonic probe through a cable, and the phased array ultrasonic detector at least has 64 channels, so that the pulse voltage and the pulse width can be adjusted.
A phased array ultrasonic detection method for a gas turbine compressor impeller blade root groove is based on the phased array ultrasonic detection system for the gas turbine compressor impeller blade root groove, and comprises the following steps:
s1: processing defects with different sizes, shapes and trends at acute angles of the leaf root groove reference test blocks made of the same material or similar materials according to the size, shape and material processing proportion of the leaf root groove to be detected;
s2: connecting a phased array ultrasonic probe with a phased array ultrasonic detector, setting pulse voltage, pulse width and focusing rule, and carrying out TCG calibration on a standard test block;
s3: fixing a phased array ultrasonic probe on the upper surface of a reference block through a detection tool, transmitting ultrasonic waves to carry out sector scanning on the acute angle position of a leaf root groove reference block, finding out the highest reflection echo by moving the phased array ultrasonic probe, and if the set defect reflection echo cannot be clearly distinguished, adjusting pulse voltage, pulse width and focusing rule until the clear distinguishing of the defect reflection echo is realized;
s4: after finding out the reflection echoes of the defects on the reference block, integrating the images and waveform display of S scanning and A scanning, enabling the reflection echoes to be displayed more clearly by adjusting the gain and scanning range of the phased array ultrasonic detector, and taking the images and waveforms of the S scanning and A scanning as the reference for judging the defects;
s5: fixing a phased array ultrasonic probe on the upper surface of a blade root groove to be detected through a detection tool, scanning through the detection tool, and judging that the detected part has no crack if a reflection echo at an acute angle of the blade root groove does not exceed a reference; and if the reflection echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
The invention is further improved in that the defect size at the acute angle of the reference block is set according to the allowable minimum size defect, the shape and the trend of the defect are set by statistically finding the defect and analyzing the structure and the stress condition of the root groove.
The invention is further improved in that the sharp angle of the blade root groove is detected by adopting primary waves and secondary waves.
The invention has the further improvement that the focusing mode of the ultrasonic wave adopts depth focusing, and the focusing position is near the depth position at the acute angle of the blade root groove.
The invention has at least the following beneficial technical effects:
according to the phased array ultrasonic detection system for the blade root groove of the compressor impeller of the gas turbine, the special phased array ultrasonic probe, the detection tool and the comparison test block are designed, so that effective simulation of the blade root groove crack of the compressor impeller and accurate positioning of the phased array ultrasonic probe and the defect position in detection are realized, and a reliable and complete phased array ultrasonic detection system is provided for field in-situ detection of the blade root groove crack of the compressor impeller.
The phased array ultrasonic detection method for the blade root groove of the gas turbine compressor impeller provided by the invention has the advantages that the acute angle of the blade root groove of the compressor impeller is scanned by utilizing the ultrasonic primary wave and secondary wave technology, so that the defects of different positions and trends are comprehensively detected; the method combines S scanning and A scanning, and realizes accurate detection of the position and the trend of the defect by adjusting the pulse width, the pulse voltage and the focusing rule and accurately determining the position and the direction of the phased array ultrasonic probe.
Drawings
FIG. 1 is a schematic diagram of a gas turbine compressor impeller root groove phased array ultrasonic detection system and method of the present invention.
Description of reference numerals:
1-phased array ultrasonic probe, 101-shell, 102-backing, 103-electrode lead, 104-wafer, 105-matching layer, 106-wedge, 2-detection tool, 3-comparison block, 301-comparison block upper surface, 302-acute angle, 4-phased array ultrasonic detector, 5-ultrasonic wave, 501-primary wave and 502-secondary wave.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
Referring to fig. 1, the phased array ultrasonic detection system for the blade root slot of the gas turbine compressor impeller provided by the invention comprises a phased array ultrasonic probe 1, a detection tool 2, a reference block 3 and a phased array ultrasonic detector 4.
The phased array ultrasonic probe 1 includes a housing 101, a backing 102, electrode leads 103, a wafer 104, a matching layer 105, and a wedge 106; the shell 101 is provided with a corresponding signal transmission interface, and an electric signal generated by the phased array ultrasonic probe 1 can be transmitted to the phased array ultrasonic detector 4 through a cable; the back lining 102 is directly contacted with the back surface of the wafer 104, can absorb high-amplitude ultrasonic waves emitted by the wafer 104 to the back surface and reflected by a workpiece, has a vibration stopping effect on the wafer, reduces the width of an ultrasonic pulse signal and improves the axial resolution; the electrode lead 103 is led out from the back of each array element of the wafer 104 and is collected to a signal transmission interface on the shell 101; the wafer 104 is composed of a plurality of array elements, each array element can independently excite and receive ultrasonic waves, and the array element is the most core part in the phased array ultrasonic probe 1; the matching layer 105 is in direct contact with the wafer 104 and mediates the ultrasonic waves emitted by the wafer 104 into the wedge 106; the wedge 106 is connected with the probe shell 101 through a screw, the upper surface of the wedge is filled with coupling agent and directly contacts with the matching layer 105, and the lower surface of the wedge is directly contacted with a root groove to be detected through the coupling agent.
The detection tool 2 stably fixes the phased array ultrasonic probe 1 on the upper surface 301 of the leaf root groove contrast test block to be detected, can realize stable coupling and continuous scanning of the phased array ultrasonic probe 1 on the surface of the leaf root groove to be detected, and can accurately measure and record the position and the swing angle of the phased array ultrasonic probe 1.
The overall dimension of the reference block 3 is completely the same as that of the blade root groove to be detected, artificial defects with different lengths, depths, shapes and trends are processed at the parts where the defects are easy to appear, and various defect forms which are easy to appear in the blade root groove are simulated.
The detection tool 2 is fixed on the upper surface 301 of the reference test block of the blade root groove of the compressor impeller in a magnet or mechanical fixing mode and the like, and does not generate obvious relative displacement with the upper surface 301 of the reference test block in the detection process.
The reference block 3 is prone to defects, which are generally acute angles 302 between the front end and the rear end.
The phased array ultrasonic detector 4 is connected with the phased array ultrasonic probe 1 through a cable, and the phased array ultrasonic detector 4 at least has 64 channels, so that the pulse voltage and the pulse width can be adjusted.
A phased array ultrasonic detection method for a gas turbine compressor impeller blade root groove comprises the following steps:
s1: and processing defects with different sizes, shapes and trends at acute angles 302 of the leaf root groove reference test block 3 made of the same material or similar materials according to the equal proportion of the size, the shape and the material processing of the leaf root groove to be detected.
S2: the phased array ultrasonic probe 1 is connected with the phased array ultrasonic detector 4, pulse voltage, pulse width, focusing rule and the like are set, and TCG calibration is carried out on a standard test block.
S3: the phased array ultrasonic probe 1 is fixed on the upper surface 301 of a reference block through the detection tool 2, ultrasonic waves 5 are emitted to conduct sector scanning on the acute angle 302 of the leaf root groove reference block, and the highest reflection echo is found by moving the phased array ultrasonic probe 1. If the set defect reflection echo cannot be clearly distinguished, the clear distinguishing of the defect reflection echo can be realized by adjusting the pulse voltage, the pulse width, the focusing rule and the like.
S4: after the reflection echoes of the defects are found out on the reference block 3, the images and waveform display of the S scanning and the A scanning are integrated, the reflection echoes are displayed clearly by adjusting the gain, the scanning range and the like of the phased array ultrasonic detector 4, and the images and waveforms of the S scanning and the A scanning at the moment are used as the reference for judging the defects.
S5: fixing a phased array ultrasonic probe 1 on the upper surface of a blade root groove to be detected through a detection tool 2, scanning through the detection tool 2, and judging that the detected part has no crack if a reflection echo at an acute angle of the blade root groove does not exceed a reference; and if the reflection echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
The defect size at the acute angle 302 of the reference block is set according to the allowable minimum size defect, and the shape and the trend of the defect are set by counting the defects found and analyzing the structure and the stress condition of the root groove.
The sharp corner 302 of the root groove can be detected by using a primary wave 501 and a secondary wave 502.
The focusing mode of the ultrasonic wave 5 adopts depth focusing, and the focusing position is near the depth position 302 at the acute angle of the blade root groove.
The invention is further illustrated:
the phased array ultrasonic probe 1 is stably coupled on the upper surface 301 of the reference block through the detection tool 2 and is aligned to the acute angle 302 of the compressor impeller blade root groove reference block. The phased array ultrasonic detector 4 emits pulse current to excite the phased array ultrasonic probe 1 to generate ultrasonic waves 5, the excitation sequence of each array element of the phased array probe wafer 104 is controlled to control the sound beam deflection angle, the defects of the acute angle 302 can be scanned by primary waves 501 and secondary waves 502, the phased array ultrasonic probe 1 is moved to find the highest echo of the defective primary waves 501 and secondary waves 502, and the highest echo serves as the phased array ultrasonic detection sensitivity.
The method comprises the steps of coupling a phase control array ultrasonic probe 1 on the upper surface of a blade root groove of a gas turbine compressor impeller to be detected through a detection tool 2, detecting the blade root groove of the gas turbine compressor impeller in service according to a set sensitivity standard, if a reflected echo is found, evaluating whether the blade root groove is cracked according to the sensitivity standard, and displaying and determining the position, the trend and the like of the crack through A scanning and S scanning.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and are intended to enable one skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (8)
1. A phased array ultrasonic detection system for a gas turbine compressor impeller blade root groove is characterized by comprising a phased array ultrasonic probe (1), a detection tool (2), a reference block (3) and a phased array ultrasonic detector (4);
a phased array ultrasound probe (1) includes a case (101), a backing (102), electrode leads (103), a wafer (104), a matching layer (105), and a wedge (106); wherein, the shell (101) is provided with a corresponding signal transmission interface, and the electric signal generated by the phased array ultrasonic probe (1) is transmitted to the phased array ultrasonic detector (4) through a cable; the back lining (102) is in direct contact with the back surface of the wafer (104), can absorb high-amplitude ultrasonic waves emitted by the wafer (104) to the back surface and reflected by a workpiece, and has a vibration stopping effect on the wafer, so that the width of an ultrasonic pulse signal is reduced, and the axial resolution is improved; the electrode lead (103) is led out from the back of each array element of the wafer (104) and is converged to a signal transmission interface on the shell (101); the wafer (104) is composed of a plurality of array elements, and each array element can independently excite and receive ultrasonic waves; the matching layer (105) is in direct contact with the wafer (104) and serves as a medium for transmitting ultrasonic waves emitted by the wafer (104) into the wedge (106); the wedge block (106) is connected with the probe shell (101), a coupling agent is filled between the upper surface of the wedge block (106) and the matching layer (105) and is in direct contact with the upper surface of the wedge block, and the lower surface of the wedge block is in direct contact with the root groove to be detected through the coupling agent;
the detection tool (2) stably fixes the phased array ultrasonic probe (1) on the upper surface (301) of the to-be-detected blade root groove reference block, can realize stable coupling and continuous scanning of the phased array ultrasonic probe (1) on the surface of the to-be-detected blade root groove, and can accurately measure and record the position and the swing angle of the phased array ultrasonic probe (1);
the overall dimension of the reference block (3) is completely the same as that of the root groove to be detected, and artificial defects with different lengths, depths, shapes and trends are processed at the parts where the defects are easy to appear, so that the reference block is used for simulating various defect forms which are easy to appear in the root groove.
2. The phased array ultrasonic detection system for the blade root groove of the compressor impeller of the gas turbine as claimed in claim 1, wherein the detection tool (2) is fixed on the upper surface (301) of the comparison test block of the blade root groove of the compressor impeller in a magnet or mechanical fixing mode, and does not have obvious relative displacement with the upper surface (301) of the comparison test block in the detection process.
3. The phased array ultrasonic testing system for the root groove of the blade of the compressor impeller of the gas turbine as claimed in claim 1, wherein the parts of the reference block (3) prone to defects are acute angles (302) at the front end and the rear end.
4. The phased array ultrasonic detection system for the blade root slot of the gas turbine compressor impeller according to claim 1, wherein the phased array ultrasonic detector (4) is connected with the phased array ultrasonic probe (1) through a cable, and at least 64 channels are provided for the phased array ultrasonic detector (4) so as to adjust pulse voltage and pulse width.
5. A phased array ultrasonic detection method for a blade root groove of a compressor impeller of a gas turbine, which is based on the phased array ultrasonic detection system for the blade root groove of the compressor impeller of the gas turbine of any one of claims 1 to 4, and comprises the following steps:
s1: processing defects with different sizes, shapes and trends at acute angles (302) of the leaf root groove reference test block according to the size, shape and material processing proportion of the leaf root groove to be detected and the reference test block (3) made of the same material or similar materials;
s2: connecting a phased array ultrasonic probe (1) with a phased array ultrasonic detector (4), setting pulse voltage, pulse width and focusing rule, and carrying out TCG calibration on a standard test block;
s3: fixing a phased array ultrasonic probe (1) on the upper surface (301) of a comparison test block through a detection tool (2), transmitting ultrasonic waves (5) to carry out sector scanning on the acute angle (302) of a leaf root groove comparison test block, finding the highest reflection echo through moving the phased array ultrasonic probe (1), if the set defect reflection echo cannot be clearly distinguished, and adjusting pulse voltage, pulse width and focusing rule until the clear distinguishing of the defect reflection echo is realized;
s4: after the reflection echoes of the defects are found out on the reference block (3), images and waveforms of S scanning and A scanning are displayed comprehensively, the reflection echoes are displayed clearly by adjusting the gain and the scanning range of the phased array ultrasonic detector (4), and the images and waveforms of the S scanning and the A scanning at the moment are used as the reference for judging the defects;
s5: fixing a phased array ultrasonic probe (1) on the upper surface of a blade root groove to be detected through a detection tool (2), scanning through the detection tool (2), and judging that the detected part has no crack if a reflection echo at an acute angle of the blade root groove does not exceed a reference; and if the reflection echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
6. The phased array ultrasonic testing method for the blade root groove of the gas turbine compressor impeller according to claim 5, characterized in that the defect size at the acute angle (302) of the reference block is set according to the allowable minimum size defect, and the shape and the trend of the defect are set by counting the defects found and analyzing the structure and the stress condition of the blade root groove.
7. The phased array ultrasonic testing method for the blade root groove of the gas turbine compressor impeller according to claim 5, characterized in that the acute angle (302) of the blade root groove is detected by using a primary wave (501) and a secondary wave (502).
8. The phased array ultrasonic testing method for the blade root groove of the gas turbine compressor impeller according to claim 5, characterized in that the ultrasonic waves (5) are focused in a depth focusing mode, and the focusing position is near the depth position of an acute angle (302) of the blade root groove.
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