CN116381052B - Probe parameter determination method for TOFD detection of inner surface defect of outer cylinder - Google Patents
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Abstract
The invention provides a method for determining probe parameters for detecting defects on the inner surface of an outer cylinder by TOFD, which adopts CIVA simulation technology to carry out TOFD detection process simulation research on outer cylinder model test blocks with different wall thicknesses for simulating defects, and can simulate and analyze sound field distribution rules and defect signal feedback conditions in different parameter states of a workpiece by adopting different probes and detection process parameters according to the structural characteristics, typical defects and distribution forms of the workpiece so as to determine optimal detection process parameters and probe parameter configuration suitable for detecting different defects.
Description
Technical Field
The invention relates to an ultrasonic detection technology, in particular to a probe parameter determination method for detecting defects of the inner surface of an outer cylinder by TOFD.
Background
In the prior art, the outer cylinder of the wind tunnel low-temperature liquid nitrogen storage tank is easy to generate defects such as corrosion pits and cracks after long-time use, and because a large amount of liquid nitrogen stored in the outer cylinder cannot be subjected to can opening detection during daily detection, the inner surface of the outer cylinder needs to be detected by using a TOFD detection technology, and after the existence of defect harm is determined, the liquid nitrogen is discharged to be subjected to can opening maintenance. However, the outer cylinder is more in variety and different in wall thickness, so that it is difficult to directly determine which probe is used for detection reasonably, if the probe is not reasonably selected, the defect detection omission condition of the inner surface of the outer cylinder can occur, and safety accidents such as liquid nitrogen leakage and explosion can be caused.
Therefore, there is a strong need for a scientific and accurate method for selecting the probe parameter configuration most suitable for detection for different wall thicknesses of the outer cylinder, which is a disadvantage of the prior art.
Disclosure of Invention
The invention aims to provide a technical scheme of a probe parameter determination method for detecting defects on the inner surface of an outer cylinder by TOFD, which adopts CIVA simulation technology to carry out TOFD detection process simulation research on outer cylinder model test blocks with different wall thicknesses and simulated defects, can simulate and analyze sound field distribution rules and defect signal feedback conditions in different parameter states of a workpiece by adopting different probes and detection process parameters according to the structural characteristics, typical defects and distribution forms of the workpiece, and determines optimal detection process parameters and probe parameter configuration suitable for detecting different defects, thereby providing necessary basis and guidance for design and selection of test blocks, wedges and probes and detection process optimization and detection cost reduction.
The scheme is realized by the following technical measures:
a method for determining probe parameters for detecting defects on the inner surface of an outer cylinder by TOFD (time of flight diffraction) comprises the following steps:
a. establishing a CIVA structure model of a defect-free sound field simulation test block according to the wall thickness size range of the outer cylinder to be detected;
b. establishing a CIVA structure model of the defect response simulation test block according to the wall thickness size range of the outer cylinder to be tested;
c. selecting different probes to perform sound field simulation on a defect-free sound field simulation test block, summarizing according to simulation results to obtain a rule that TOFD sound field energy distribution changes along with probe parameters, and preliminarily determining probe parameter configuration adapting to the wall thickness size range of the outer cylinder; and performing defect response simulation and simulation result analysis on the defect response simulation test block by adopting the adaptive probe parameter configuration to obtain upper tip diffraction echo amplitude values of different probes on defects.
d. And c, selecting the probe with the highest upper tip diffraction echo amplitude as the finally determined probe parameter configuration according to the upper tip diffraction echo amplitude of the different probe pairs defect obtained in the step c.
As a preferred embodiment of the present invention: in the step a, aiming at the range of the wall thickness of the outer cylinder, a plurality of defect-free sound field simulation test blocks with equal wall thickness intervals are established, the maximum size of each test block is larger than that of the outer cylinder, and the minimum size of each test block is consistent with that of the outer cylinder.
As a preferred embodiment of the present invention: in the step b, the established CIVA structural model of the defect response simulation test block is mainly divided into two types:
one class is: a plurality of defect response simulation test blocks with the same wall thickness and different defect sizes;
the other group is as follows: the defect sizes are the same, the wall thickness ranges are consistent with those of the outer cylinder, and the wall thickness intervals are equal to the defect response simulation test blocks;
the defect types of the two types of defect response simulation test blocks comprise two defects of simulated cracks and simulated corrosion pits.
As a preferred embodiment of the present invention: in the step c, sound field simulation parameters and unfilled response simulation parameters are required to be established before simulation;
the basic principle of parameter setting of sound field simulation is as follows: setting the sound beam intersection point of the transmitting probe and the receiving probe at the position of the detection area; ensuring that the ultrasonic beam completely covers the required detection area;
the sound field simulation parameters comprise probe parameters, detection parameters and calculation parameters;
the defect response simulation parameters comprise probe parameters, detection parameters, defect parameters and calculation parameters.
As a preferred embodiment of the present invention: in the step c, the steps of carrying out sound field simulation on the defect-free sound field simulation test block and preliminarily determining probe parameter configuration adapting to the wall thickness size range of the outer cylinder are as follows:
selecting a plurality of different probes, performing sound field simulation on a defect-free sound field simulation test block with the largest wall thickness, and acquiring a rule of sound field distribution change caused by probe frequency and probe diameter change when the sound beam angle is 45 degrees and the sound beam intersection point of the probe is arranged at the position where the bottom surface of the test block has defects; then simulating defect-free sound field simulation test blocks with different wall thicknesses respectively, and analyzing and obtaining corresponding probe parameters when the sound energy of the bottom surface position of each test block is highest;
and c2, selecting and obtaining the probe parameter configuration suitable for test blocks with different wall thicknesses based on the principle that the area of a focusing area with the wave amplitude larger than 90% formed at the intersection point of the sound beams by the probe is minimum and the detection signal-to-noise ratio and defect resolution are highest according to the rule that sound field simulation data and sound field energy distribution obtained in the step c1 change along with the probe parameters.
As a preferred embodiment of the present invention: in the step c, the step of performing defect response simulation on the defect response simulation test block comprises the following steps:
c31, simulation analysis of the response of the inner surface hazard defect:
c31-1, simulating defect response simulation test blocks with the same wall thickness and different simulated crack sizes:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c31-2, simulating defect response simulation test blocks with different wall thicknesses and same simulated crack size:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c32, simulation analysis of non-hazardous defect response of the inner surface:
c32-1, simulating defect response simulation test blocks with the same wall thickness and different simulated corrosion recess sizes:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c32-2, simulating defect response simulation test blocks with different wall thicknesses and same simulated corrosion recess sizes:
and performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect.
As a preferred embodiment of the present invention: in the step d, the finally determined probe parameter configuration needs to select the probe with the highest upper tip diffraction echo amplitude corresponding to different wall thicknesses of the outer cylinder.
As a preferred embodiment of the present invention: the parameters of the probe are configured as follows: when the emission angles are 45 degrees, the frequency and the diameter of the emission probe are equal.
The method has the advantages that according to the description of the scheme, as the TOFD detection process simulation research is carried out on the outer cylinder model test blocks with the simulated defects and different wall thicknesses by adopting the CIVA simulation technology in the scheme, according to the structural characteristics, typical defects and distribution forms of the workpiece, the sound field distribution rules and defect signal feedback conditions in different parameter states in the workpiece can be simulated and analyzed by adopting different probes and detection process parameters, the optimal detection process parameters and probe parameter configuration suitable for different defect detection are determined, and necessary basis and guidance are provided for the design and selection of the test blocks, wedge blocks and probes, the detection process optimization and the detection cost reduction.
It is seen that the present invention provides substantial features and improvements over the prior art, as well as significant advantages in its practice.
Detailed Description
All of the features disclosed in this specification, or all of the steps in a method or process disclosed, may be combined in any combination, except for mutually exclusive features and/or steps.
Any feature disclosed in this specification may be replaced by alternative features serving the same or equivalent purpose, unless expressly stated otherwise. That is, each feature is one example only of a generic series of equivalent or similar features, unless expressly stated otherwise.
The outer cylinder test parameters selected in this embodiment are:
ultrasonic response simulation analysis of internal surface hazard defects:
1-1, TOFD detection signal response intensity analysis of different crack size defects on a base material under the condition of the same wall thickness. For example, the signal response strength under the conditions of 52mm in wall thickness, 1mm in crack depth, 0.5mm in width, 1-10 mm in length (1 mm in interval) and the like is achieved.
1-2, TOFD signal response intensity analysis of different crack size defects on a weld joint under the condition of the same wall thickness. For example, the signal response strength under the conditions of 52mm in wall thickness, 1mm in crack depth, 0.5mm in width, 1-10 mm in length (1 mm in interval) and the like is achieved.
1-3, TOFD detection signal response intensity analysis of crack defects on base materials with different wall thicknesses under the condition of the same crack size. For example, the signal response strength under the conditions that the crack is 1mm deep, 0.5mm wide, 2mm long, 30 mm-52 mm thick (2 mm interval) and the like.
1-4, TOFD detection signal response intensity analysis of crack defects on welding lines with different wall thicknesses under the condition of the same crack size. For example, the signal response strength under the conditions that the crack is 1mm deep, 0.5mm wide, 2mm long, 30 mm-52 mm thick (2 mm interval) and the like.
Simulation analysis of the ultrasonic response of the non-hazardous defect on the inner surface:
2-1, TOFD detection signal response intensity analysis of different surface corrosion pit size defects on a base material under the condition of the same wall thickness. For example, the signal response strength under the conditions of 52mm of wall thickness, 1mm of corrosion pit depth, 1-10 mm of diameter (1 mm interval) and the like.
2-2, TOFD detection signal response intensity analysis of different surface corrosion pit size defects on the weld joint under the condition of the same wall thickness. For example, the signal response strength under the conditions of 52mm of wall thickness, 1mm of corrosion pit depth, 1-10 mm of diameter (1 mm interval) and the like.
2-3, TOFD detection signal response intensity analysis of the corrosion pits on the upper surfaces of the base materials with different wall thicknesses under the condition of the same surface corrosion pit size. For example, the signal response strength under the conditions of 1mm in depth, 2mm in diameter, 30-52 mm in wall thickness (2 mm in interval) and the like of the corrosion pit.
2-4, TOFD detection signal response intensity analysis of the corrosion pits on the upper surfaces of the welding lines with different wall thicknesses under the condition of the same surface corrosion pit size. For example, the signal response strength under the conditions of 1mm in depth, 2mm in diameter, 30-52 mm in wall thickness (2 mm in interval) and the like of the corrosion pit.
On the basis of regulations about test blocks and defect types, sizes, variation ranges thereof and the like in analysis simulation study contents, the ranges of three main parameters including probe frequency, probe diameter and sound beam angle used for TOFD detection of each test block defect are determined. Because the defects are all positioned at the bottom of the test block, the sound beam angle of 45 degrees is preferable, and the sound beam focus of the probe is arranged at the defect position of the bottom surface of the test block, the main detection parameter range of the TOFD method used by the simulation is shown in Table 1 based on the principle.
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The method comprises the following specific steps:
a. establishing a CIVA structural model of a defect-free sound field simulation test block:
since the wall thickness of the test block subjected to the sound field simulation in table 1 ranges from 30 to 52mm and the variation interval is 2mm, and since the distribution of sound field energy in the test block is mainly dependent on parameters such as the frequency of the probe generating the ultrasonic wave, the diameter of the probe, the angle of the sound beam, etc., the simulation model wall thickness is set to 60mm for better description of the sound field energy distribution in the test block with the wall thickness ranging from 30 to 52 mm. According to standard regulations, a sound beam angle of 45 degrees is optimized during TOFD sound field simulation, a probe sound beam intersection point is arranged at a defect position of the bottom surface of a test block (the sound beam intersection point is positioned at a 52mm position), and the rule analysis of the relation between the sound field energy distribution in a test block with the wall thickness of 60mm and the probe frequency and the probe diameter can cover the sound field distribution rule when the wall thickness is changed from 30mm to 52 mm.
Therefore, the maximum size of the wall thickness of the CIVA model for sound field simulation is 60×320×450mm according to the simulation content, and a plurality of CIVA models with wall thicknesses of 30-52 mm (changing at intervals of 2 mm) are simultaneously established.
b. Establishing a CIVA structural model of the defect response simulation test block:
according to the selected outer cylinder test parameters, the CIVA model of the defect response simulation test block can be unified into two series:
series one: model test blocks with defects of different sizes under the condition of the same wall thickness:
s1: the size is 60 x 320 x 450mm (thickness x width x length), the lower surface of the test block is carved with 10 artificial grooves with the depth of 1mm, the width of 0.5mm and the length of 1-10 mm (interval of 1 mm) for simulating crack defects (hazardous defects) with different sizes on the inner surface of the outer cylinder of the storage tank.
S2: the lower surface of the test block is drilled with a depth of 1mm and a diameter of 1-10 mm (1 mm apart) 10 artificial flat-bottomed holes with a size of 60-320-450 mm (thick-wide-long) are used for simulating corrosion pit defects (non-hazardous defects) with different sizes on the inner surface of the outer cylinder of the storage tank.
Series two: model test blocks with defects of the same size under different wall thickness sizes:
s3: the size is 30 x 200 x 100mm (thickness x width x length), the thickness of the test block is 30-52 mm (thickness change interval is 2 mm), the depth of the lower surface of the test block is 1mm, the width of the test block is 0.5mm, and the artificial groove with the length of 2mm simulates the crack defect (hazardous defect) on the inner surface of the outer cylinder of the storage tank.
S4: 30.200.100 mm (thickness.wide.length), the thickness of the test block is 30-52 mm (thickness change interval is 2 mm), the lower surface of the test block is drilled to have a depth of 1mm, and flat bottom holes with a diameter of 2mm simulate pit defects (non-hazardous defects) corroded on the inner surface of the outer cylinder of the storage tank.
c. Simulation parameter setting, sound field simulation and defect response simulation:
parameter setting for sound field simulation:
the basic principle of sound field simulation parameter setting is as follows: (1) setting the sound beam intersection point of the transmitting probe and the receiving probe at the position of the detection area; (2) ensuring that the ultrasonic beam completely covers the required detection area.
The sound field simulation parameters in this embodiment include probe parameters, detection parameters, calculation parameters, and the like, and specific parameter settings are shown in table 2.
。
Parameter setting for defect response simulation:
the defect response simulation parameters comprise probe parameters, detection parameters, defect parameters and calculation parameter settings, wherein the probe parameters and the detection parameter settings are shown in table 2, and the defect parameters and the calculation parameter settings are shown in table 3.
。
The size of the area is reasonably set, so that the operation precision and the operation speed can be ensured.
c1, simulating sound fields of defect-free sound field simulation test blocks:
when in diffraction time-lapse ultrasonic (TOFD) detection, a scanning device with a transmitting probe and a receiving probe is arranged on the outer surface of a test block, and the defect on the inner surface is positioned at the middle point of a connecting line of the two probes, the ultrasonic wave emitted by the transmitting probe propagates along the surface of a workpiece in the shortest path and is received by the receiving probe to form a straight-through wave, and the 45-degree ultrasonic wave emitted by the transmitting probe reaches the bottom surface of the workpiece and is received by the receiving probe to form a bottom wave after being reflected. When the bottom surface of the workpiece is defective, the sound waves diffract at the upper and lower tips of the defect, the diffraction waves are received by the receiving probe to form obvious upper and lower tip diffraction signals, and as the upper and lower tip diffraction signals have different propagation time in the workpiece, a defect diffraction signal image can be seen in a region above the bottom wave below the through wave in TOFD view scanning, if the defect is positioned at the bottom surface, obvious disturbance can be observed by the bottom wave at the position of the defect, and the size and the property of the defect existing at the position can be judged according to the signal image and the characteristics.
Based on the acoustic principle, selecting main simulation parameters in table 1, and setting the sound beam angle to be 45 degrees; the probe frequency is respectively 3MHz, 4MHz and 5MHz; the diameters of the probes are respectively 6mm, 9mm and 12mm, the sound beam intersection point of the transmitting probe and the receiving probe is arranged at the position of 52mm in depth, and sound field simulation is carried out on a sound field simulation test block model with the wall thickness of 60mm without defects, so that the law that the sound field energy distribution changes along with the parameters is obtained.
And then simulating each defect-free sound field simulation test block with the wall thickness of 30-52 mm (2 mm interval), and analyzing and giving out corresponding probe parameters when the sound wave energy of the bottom surface position of each test block is highest.
The specific acquisition process of the sound field energy distribution rule comprises the following steps:
(1) the sound field simulation is carried out on a 60mm defect-free sound field simulation test block model by adopting the combination that the sound beam angle is 45 degrees, the probe frequency is unchanged and the probe diameter is reduced, and the probe parameter configuration is shown in Table 4.
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From the simulation results, it can be seen that: the sound beam angle is 45 degrees, the probe frequency is unchanged, when the probe diameter is reduced, the probe half-diffusion angle is increased, the-12 dB diffusion area at the intersection point of the two probes is gradually increased, the TOFD coverage area is increased, but the probe diameter is reduced to reduce the emitted sound energy, and the penetrability in metal is reduced, so that the overall detection signal-to-noise ratio is reduced.
In summary, under the premise of meeting the sound beam penetrability and coverage, the smaller the area (the amplitude is more than 90%) of a focusing area formed at the intersection point of the two probes is, the better the detection signal-to-noise ratio and the defect resolution is, and the area of the area with the amplitude more than 90% at the depth of 52mm of the wall thickness of each probe intersection point is respectively: 5MHz,6mm probe (8.6.9.1 mm) > 5MHz,12mm probe (5.8.5.6 mm) > 5MHz,9mm probe (5.5.4.8 mm).
(2) The sound field simulation is carried out on a 60mm defect-free sound field simulation test block model by adopting the combination that the sound beam angle is 45 degrees, the probe diameter is unchanged and the probe frequency is reduced, and the probe parameter configuration is shown in Table 5.
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From the simulation results, it can be seen that: the angle of the sound beam is 45 degrees, the diameter of the probe is unchanged, when the frequency of the probe is reduced, the semi-diffusion angle of the probe is increased, the-12 dB diffusion area at the intersection point of the probe is gradually increased, the TOFD coverage area is increased, the frequency of the probe is reduced, the wavelength is increased, the penetrability in metal is enhanced, but the longitudinal and transverse resolutions are reduced.
In summary, under the premise of meeting the sound beam penetrability and coverage, the smaller the area (the amplitude is more than 90%) of a focusing area formed at the intersection point of the probe, the better the detection signal-to-noise ratio and the defect resolution are, and the area of the area with the amplitude more than 90% at the depth of 52mm of the wall thickness of each probe intersection point is respectively: 3MHz,12mm probe (8.6X8.3mm) > 4MHz,12mm probe (6.8X6.6mm) > 5MHz,12mm probe (5.8X5.6mm).
(3) Rule summarization:
in view of the simulation results, for TOFD probes, the area of a focusing region at the intersection point of the two probes is important for detection process design, and the larger the area is, the larger the coverage of the sound beam in a test block is, but the signal-to-noise ratio is reduced as the coverage is increased; the smaller the area of the focusing area is, the better the transverse resolution in the test block is, so that the higher the detection signal-to-noise ratio is; the probe frequency is unchanged, the probe diameter is increased, and the penetrating force of the sound beam in the thickness direction of the test block is increased; the diameter of the probe is unchanged, the frequency of the probe is increased, the penetrating power of the sound beam in the thickness direction of the test block is reduced, the transverse resolution and the longitudinal resolution are increased, and the detection signal-to-noise ratio is increased.
The relationship between several main parameter indicators (coverage, penetration, signal to noise ratio, resolution, etc.) and probe frequency and probe diameter for TOFD measurements is shown in Table 6.
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c2, preliminarily determining probe parameters for inner surface defect TOFD detection adaptation:
according to the sound field simulation data obtained in the step c1 and the relation between the TOFD detection main parameter indexes, the probe frequency and the probe diameter in the table 6, after sound field simulation is carried out on a test block with the wall thickness of 30-52 mm (changing at intervals of 2 mm), the probe parameters suitable for TOFD detection of the inner surface defects can be preliminarily determined, and are shown in the table 7.
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When the wall thickness of the test block is 30mm, the probe 1 in Table 7 can be selected, and when the detection signal-to-noise ratio is reduced (less than 10 dB) as the wall thickness of the test block increases, the probe 2 and the probe 3 can be sequentially selected.
c3, performing defect response simulation:
c31, simulation analysis of the response of the inner surface hazard defect:
c31-1, simulating crack defect response simulation and result analysis of the variable-size inner surface of a test block with the wall thickness of 52 mm:
and c2, combining the adaptive probe parameters (table 7) determined in the step c2, and comprehensively referring to the probe parameter configurations in table 4 and table 5 to form the probe parameter configuration in table 8, and performing defect response simulation on the variable-size simulated cracks on the inner surface of the test block with the wall thickness of 52mm so as to further verify the sound field simulation result and the sound field distribution rule in the step c1, thereby obtaining the optimized detection process parameters through the simulation.
In the simulation, the upper tip diffraction echo amplitude of different probes for the same crack defect is compared under the same gain in the defect response simulation result, and the sound field simulation rule is combined to determine the more suitable probe configuration.
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The defect echo amplitude values of the defect response simulation performed by the probe parameter configuration in the table are shown in table 9.
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Simulation result analysis:
(1) the upper tip diffraction echo amplitude of each probe is sequentially from high to low: 5M-9, 5M-12, 3M-6, 5M-6, 3M-9, 3M-12. As the defect response simulation does not consider the grain size and attenuation influence of the material, in actual detection, when the wall thickness is larger than 50mm, the half-diffusion angle of the probe with the probe diameter of 6mm is large, the attenuation caused by the half-diffusion angle is also increased sharply, and meanwhile, the acoustic energy emitted by the smaller probe diameter is also smaller. If the influence is considered, 5M-6 and 3M-6 probes can be not considered in detecting defects on the inner surface of the test block with the wall thickness of 52 mm; it is known from sound field simulation that for 5M-9 and 5M-12, the two probes are not much different in defect wave amplitude, and the beam coverage of the probe with the diameter of 9mm is far larger than that of the probe with the diameter of 12mm for the bottom surface.
(2) When the defect length is 3mm, the defect display can not be basically seen by a probe with the frequency of 3MHz from a defect simulation view, and the main reason is that the detection capability of small defects mainly depends on the probe frequency under the premise of considering the grain size and attenuation influence of materials, and when the defect is larger than 3mm, the echo amplitude differentiation of each probe is obvious.
(3) Based on comprehensive consideration of material attenuation, sound wave penetrating power, beam coverage, detection resolution and signal-to-noise ratio, for detecting cracks on the inner surface of a test block with the wall thickness of 52mm, a probe with a lower frequency such as 3M-9 can be selected for detection when the signal-to-noise ratio is reduced (less than 10 dB) for detecting defects with smaller sizes.
c31-2, simulating crack defect response simulation of sizing of the bottom surface of a test block with the wall thickness of 30-52 mm (2 mm interval):
using the probe parameters given in table 7, a defect response simulation was performed on simulated crack defects with a wall thickness of 30-52 mm (varying at 2mm intervals) and an inner surface size of 1 x 0.5 x 2mm, and the tip diffraction echo amplitudes on the defects were compared to further verify the sound field simulation results, and the bottom defect response simulation results of each wall thickness test block and the corresponding optimal probe parameter configuration are shown in table 10.
。
c32, simulation analysis of non-hazardous defect response of the inner surface:
c32-1, simulating defect response simulation and result analysis of corrosion pits with variable size on the inner surface of a test block with the wall thickness of 52 mm:
and c2, combining the adaptive probe parameters (table 7) determined in the step c2, and comprehensively referring to the probe parameter configurations in table 4 and table 5 to form probe parameter configurations in table 11, and performing defect response simulation on the variable-size simulated corrosion pits on the inner surface of the test block with the wall thickness of 52mm by using each probe parameter configuration in table 11 so as to further verify the sound field simulation result and the sound field distribution rule in the step c1, thereby obtaining optimized detection process parameters through the simulation. In the simulation, the proper probe configuration is determined by comparing the peak diffraction echo amplitude values of different probes on the same crack defect and combining with a sound field simulation rule mainly through the defect response simulation result under the same gain.
。
The defect echo amplitude values for performing defect response simulation by configuring the parameters of each probe in the table are shown in table 12.
。
Simulation result analysis:
from comparison of the diffraction echo amplitude results of the upper end points of simulated corrosion pits of different diameters in Table 12, it can be seen that:
(1) the echo amplitude of each probe is sequentially from high to low: 5M-9, 5M-12, 5M-6, 3M-9, 3M-6, 3M-12. As the defect response simulation does not consider the grain size and attenuation influence of the material, in actual detection, when the wall thickness is larger than 50mm, the half-diffusion angle of the probe with the probe diameter of 6mm is large, the attenuation caused by the half-diffusion angle is also increased sharply, and meanwhile, the acoustic energy emitted by the smaller probe diameter is also smaller. If the influence is considered, 5M-6 and 3M-6 probes can be not considered in detecting defects on the inner surface of the test block with the wall thickness of 52 mm; it is known from sound field simulation that for 5M-9 and 5M-12, the two probes are not much different in defect wave amplitude, and the beam coverage of the probe with the diameter of 9mm is far larger than that of the probe with the diameter of 12mm for the bottom surface.
(2) When the diameter of the corroded pit is smaller than 3mm, the probe with the frequency of 3MHz can not be seen from a defect simulation view basically for displaying defects, and the main reason is that the detection capability of small defects mainly depends on the frequency of the probe under the premise of considering the grain size of materials and the influence of attenuation, and when the defect is larger than 3mm, the echo amplitude differentiation of each probe is obvious.
(3) Based on comprehensive consideration of material attenuation, sound wave penetrating power, beam coverage, detection resolution and signal-to-noise ratio, for detecting cracks on the inner surface of a test block with the wall thickness of 52mm, a probe with a lower frequency such as 3M-9 can be selected for detection when the signal-to-noise ratio is reduced (less than 10 dB) for detecting defects with smaller sizes.
c32-2, simulating corrosion pit defect response simulation of sizing of the inner surface of a test block with the wall thickness of 30-52 mm (2 mm interval):
the probe parameters given in table 7 were used to simulate defect response of a simulated corrosion pit defect having a wall thickness of 30-52 mm (varying at 2mm intervals) and a size of 1 x 2mm in the inner surface of the block, and the sound pressure reduction values of the defect echoes were compared to further verify the sound field simulation results, and the bottom defect response simulation results of each wall thickness block and the corresponding optimal probe parameter configuration are shown in table 13.
。
d. Determining final probe parameter configuration and detection process:
from the simulation data and conclusions of step c, the following probe parameter configuration and inspection process was developed, as listed in table 14.
。
In the embodiment, TOFD detection process simulation research is carried out on the low-temperature liquid nitrogen storage tank outer barrel member with typical defects by adopting CIVA simulation technology, a CIVA simulation model for TOFD detection of the low-temperature liquid nitrogen storage tank outer barrel test block is established, and according to the detection and simulation research purpose requirements and the third section of nondestructive detection of NB/T47013.3-2015: the relevant regulations of ultrasonic detection standards determine the probe frequency, probe diameter and sound beam angle range, and main parameters affecting the detection result are obtained through sound field simulation and defect response simulation calculation: the relation among the probe frequency, the probe diameter, the sound beam angle and the energy distribution of the sound field in the test block, and relatively optimized detection parameters are given, and the simulation also obtains the following conclusion:
(1) the contact TOFD method is a relatively effective method for detecting the crack defects on the inner surface of the outer cylinder of the low-temperature liquid nitrogen storage tank by utilizing the principle that the propagation time of the diffraction sound waves at the upper end point and the lower end point of the defects is different, and is a relatively effective method for corroding pit defects on the inner surface of the outer cylinder of the low-temperature liquid nitrogen storage tank;
(2) for the defect of the inner surface of the outer cylinder of the low-temperature liquid nitrogen storage tank, because the depth of the defect is shallow and the length is short, a probe with a recommended higher frequency is preferentially used for actual detection so as to ensure enough detection resolution and sensitivity, and when the detection signal-to-noise ratio is reduced, probes with the recommended lower frequency can be sequentially selected;
(3) the simulation does not consider the influence of the grain size and attenuation of the material on detection, and the probe can be flexibly selected according to the rule between the probe parameter and the sound field energy distribution during actual detection, so that the detection sensitivity and the signal to noise ratio can meet the requirements, and the requirements of detecting various defects on the inner surface of the outer cylinder of the low-temperature liquid nitrogen storage tank can be met.
The invention is not limited to the specific embodiments described above. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification, as well as to any novel one, or any novel combination, of the steps of the method or process disclosed.
Claims (6)
1. A method for determining probe parameters for detecting defects on the inner surface of an outer cylinder by TOFD is characterized by comprising the following steps: the method comprises the following steps:
a. establishing a CIVA structure model of a defect-free sound field simulation test block according to the wall thickness size range of the outer cylinder to be detected;
b. establishing a CIVA structure model of the defect response simulation test block according to the wall thickness size range of the outer cylinder to be tested;
c. selecting different probes to perform sound field simulation on a defect-free sound field simulation test block, summarizing according to simulation results to obtain a rule that TOFD sound field energy distribution changes along with probe parameters, and preliminarily determining probe parameter configuration adapting to the wall thickness size range of the outer cylinder; performing defect response simulation and simulation result analysis on the defect response simulation test block by adopting the adaptive probe parameter configuration to obtain upper tip diffraction echo amplitude values of different probes on defects;
d. c, according to the upper tip diffraction echo amplitude values of the defects of the different probe pairs obtained in the step c, selecting the probe with the highest upper tip diffraction echo amplitude value as the finally determined probe parameter configuration;
in the step c, the steps of performing sound field simulation on the defect-free sound field simulation test block and preliminarily determining probe parameter configuration adapting to the wall thickness size range of the outer cylinder are as follows:
selecting a plurality of different probes, performing sound field simulation on a defect-free sound field simulation test block with the largest wall thickness, and acquiring a rule of sound field distribution change caused by probe frequency and probe diameter change when the sound beam angle is 45 degrees and the sound beam intersection point of the probe is arranged at the position where the bottom surface of the test block has defects; then simulating defect-free sound field simulation test blocks with different wall thicknesses respectively, and analyzing and obtaining corresponding probe parameters when the sound energy of the bottom surface position of each test block is highest;
c2, selecting probe parameter configuration for adapting to test blocks with different wall thicknesses based on the principle that the smaller the area of a focusing area with the wave amplitude larger than 90% formed at the intersection point of sound beams by the probe is, the better the detection signal-to-noise ratio and defect resolution is;
in the step c, the step of performing defect response simulation on the defect response simulation test block is as follows:
c31, simulation analysis of the response of the inner surface hazard defect:
c31-1, simulating defect response simulation test blocks with the same wall thickness and different simulated crack sizes:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c31-2, simulating defect response simulation test blocks with different wall thicknesses and same simulated crack size:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c32, simulation analysis of non-hazardous defect response of the inner surface:
c32-1, simulating defect response simulation test blocks with the same wall thickness and different simulated corrosion recess sizes:
performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect;
c32-2, simulating defect response simulation test blocks with different wall thicknesses and same simulated corrosion recess sizes:
and performing defect response simulation by adopting the adaptive probe parameter configuration and the defect response simulation parameters obtained in the preamble step, and obtaining the upper tip diffraction echo amplitude of each probe aiming at each crack defect.
2. The method for determining the probe parameters for detecting the defects of the inner surface of the outer cylinder by TOFD according to claim 1, wherein the method comprises the following steps: in the step a, a plurality of defect-free sound field simulation test blocks with equal wall thickness intervals are established according to the range of the wall thickness of the outer cylinder, the maximum size of each test block is larger than that of the outer cylinder, and the minimum size of each test block is consistent with that of the outer cylinder.
3. The method for determining the probe parameters for detecting the defects of the inner surface of the outer cylinder by TOFD according to claim 1, wherein the method comprises the following steps: in the step b, the established CIVA structural model of the defect response simulation test block is mainly divided into two types:
one class is: a plurality of defect response simulation test blocks with the same wall thickness and different defect sizes;
the other group is as follows: the defect sizes are the same, the wall thickness ranges are consistent with those of the outer cylinder, and the wall thickness intervals are equal to the defect response simulation test blocks;
the defect types of the two types of defect response simulation test blocks comprise two defects of simulated cracks and simulated corrosion pits.
4. The method for determining the probe parameters for detecting the defects of the inner surface of the outer cylinder by TOFD according to claim 1, wherein the method comprises the following steps: in the step c, sound field simulation parameters and fault response simulation parameters need to be established before simulation;
the basic principle of parameter setting of sound field simulation is as follows: setting the sound beam intersection point of the transmitting probe and the receiving probe at the position of the detection area; ensuring that the ultrasonic beam completely covers the required detection area;
the sound field simulation parameters comprise probe parameters, detection parameters and calculation parameters;
the defect response simulation parameters comprise probe parameters, detection parameters, defect parameters and calculation parameters.
5. The method for determining the probe parameters for detecting the defects of the inner surface of the outer cylinder by TOFD according to claim 1, wherein the method comprises the following steps: in the step d, the finally determined probe parameter configuration needs to select the probe with the highest upper tip diffraction echo amplitude corresponding to different wall thicknesses of the outer cylinder.
6. The method for determining the probe parameters for detecting the defects of the inner surface of the outer cylinder by TOFD according to claim 1, wherein the method comprises the following steps: the probe is an ultrasonic emission probe; the parameters of the probe are configured as follows: and when the angles are 45 degrees, the frequency and the diameter of the transmitting probe are equal.
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