WO2009119539A1 - 超音波探傷方法及び装置 - Google Patents
超音波探傷方法及び装置 Download PDFInfo
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- WO2009119539A1 WO2009119539A1 PCT/JP2009/055743 JP2009055743W WO2009119539A1 WO 2009119539 A1 WO2009119539 A1 WO 2009119539A1 JP 2009055743 W JP2009055743 W JP 2009055743W WO 2009119539 A1 WO2009119539 A1 WO 2009119539A1
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- defect
- flaw detection
- maximum value
- ultrasonic probe
- width
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- 238000001514 detection method Methods 0.000 title claims abstract description 74
- 239000000463 material Substances 0.000 claims abstract description 63
- 239000000523 sample Substances 0.000 claims abstract description 60
- 238000005096 rolling process Methods 0.000 claims abstract description 48
- 238000012545 processing Methods 0.000 claims abstract description 41
- 239000002131 composite material Substances 0.000 claims abstract description 22
- 230000007547 defect Effects 0.000 claims description 166
- 238000007689 inspection Methods 0.000 claims description 33
- 230000015572 biosynthetic process Effects 0.000 claims description 23
- 238000003786 synthesis reaction Methods 0.000 claims description 23
- 238000004364 calculation method Methods 0.000 description 36
- 238000000034 method Methods 0.000 description 27
- 230000005540 biological transmission Effects 0.000 description 15
- 238000010586 diagram Methods 0.000 description 13
- 229910000831 Steel Inorganic materials 0.000 description 12
- 239000010959 steel Substances 0.000 description 12
- 239000000047 product Substances 0.000 description 6
- 238000003384 imaging method Methods 0.000 description 5
- 239000011159 matrix material Substances 0.000 description 3
- 238000007796 conventional method Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 230000001902 propagating effect Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000003129 oil well Substances 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- 230000008054 signal transmission Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
- G01N29/06—Visualisation of the interior, e.g. acoustic microscopy
- G01N29/0654—Imaging
- G01N29/069—Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/262—Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/265—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving the sensor relative to a stationary material
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/106—Number of transducers one or more transducer arrays
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/263—Surfaces
- G01N2291/2632—Surfaces flat
Definitions
- the present invention relates to an ultrasonic flaw detection method and apparatus that can easily and accurately measure the area of a defect extending in the rolling direction of a material to be inspected.
- the criterion for the pass / fail judgment is defined by, for example, the size of the defect to be detected.
- API standard 5CT which is one of steel pipe related standards for oil wells
- the area of the defect is It is specified that there must be no greater than 260 mm 2 (API Specification 5CT / ISO 11960).
- API Specification 5CT / ISO 11960 API Specification 5CT / ISO 11960.
- Non-Patent Document 1 As a conventional method for quantitatively calculating the area of a defect in ultrasonic flaw detection, Non-Patent Document 1 ("Ultrasonic Flaw Test III", 2001 edition, Japan Nondestructive Inspection Association, June 11, 2001) , P.57-58 and p.117-118), (A) A method for calculating the area of a defect using echo height, (B) A method is known in which the area of a defect is calculated based on a moving distance at which a defect echo appears by moving an ultrasonic probe. Patent Document 1 (Japanese Patent Application Laid-Open No. 2005-31061) discloses that (C) A method for calculating the area of a defect using an aperture synthesis process has been proposed. Hereinafter, these methods will be specifically described.
- bottom echo height P ⁇ is expressed by the following equation (2).
- the above equation (1) is an equation that is established when the surface of the defect is parallel to the transducer surface of the ultrasonic probe.
- the above calculation method is based on the premise that the surface of the defect is parallel to the transducer surface of the ultrasonic probe, and the maximum echo from the defect is received by the ultrasonic probe. Yes. Therefore, when the surface of the defect is inclined with respect to the transducer surface, it is difficult to receive the echo reflected by the defect with the ultrasonic probe, and there is a problem that the calculation accuracy is lowered. Further, the above calculation method cannot be applied when the size of the defect is larger than the effective width of the ultrasonic beam. For this reason, when the material to be inspected is a rolled material such as a steel pipe or a steel plate, it is necessary to use an ultrasonic probe having a large vibrator size for a planar defect extending in the rolling direction. is not.
- (B) A method of calculating the area of the defect by moving the ultrasonic probe and the moving distance at which the defect echo appears.
- the ultrasonic probe is moved.
- the range in which the defect echo falls from the maximum echo height to a predetermined level while moving, or the range in which the echo height appears above the predetermined height regardless of the maximum echo height The method of measuring as is known.
- the length of the defect can be measured with relatively high accuracy by selecting an ultrasonic probe having a transducer having a size smaller than the length of the defect to be measured. Therefore, for a planar defect or the like extending in the rolling direction in a rolled material such as a steel pipe or a steel plate, the defect size (defect length) in the rolling direction can be measured with relatively high accuracy by the above method.
- the precondition of the above method that the size of the defect is larger than the effective width of the ultrasonic beam is satisfied. It becomes difficult to make. This is because if the size of the vibrator is reduced, the ultrasonic beam is expanded, and if the size of the vibrator is increased, the oscillating ultrasonic beam itself is widened.
- an ultrasonic probe having a transducer width of 3.5 mm and 0.7 mm is moved in the width direction of the defect at a position 10 mm away from the defect (depth).
- An example of the result of measuring the echo height by placing an ultrasonic probe on the surface of the inspection object having a defect at a position of 10 mm and moving it in the width direction of the defect) is shown.
- the width distribution of the echo height has a gentle shape due to the large effective width of the ultrasonic beam. Yes.
- the defect width measured by each ultrasonic probe is 6.3 mm and 2.8 mm, which is larger than the actual defect width (1 mm). Indicates the value.
- the above method was able to measure the defect length with a relatively high accuracy with respect to a planar defect extending in the rolling direction and having a narrow width in the direction orthogonal to the rolling direction.
- the defect width is measured to be larger than the actual width. That is, in the above method, the defect area is excessively calculated. As a result, even products that are not originally defective may be determined to be defective, and the yield may be reduced.
- Patent Document 1 discloses an inspection based on data collected by performing ultrasonic flaw detection using a group of transducers arranged in a matrix.
- a method for automatically calculating the area of a defect by generating three-dimensional imaging data inside a material and processing the three-dimensional imaging data is disclosed. Specifically, when automatically calculating the area of the defect from the three-dimensional imaging data, the three-dimensional imaging data is seen through in the direction of each axis of the orthogonal coordinate system, and the data having the maximum value is projected onto the plane. Then, in the projected plane, the area of the defect is calculated by counting the number of meshes having a value equal to or greater than a predetermined threshold value.
- the resolution of the aperture synthesis processing image obtained by aperture synthesis processing depends on the arrangement pitch of the transducers and the size of the aperture.
- the size of the aperture corresponds to the overall size of the transducer group that receives an echo during aperture synthesis processing (the overall size of the transducer group arranged in the direction in which aperture synthesis processing is performed). It is known that the resolution increases as the arrangement pitch of the transducers decreases and the size of the opening (the overall size of the transducer group) increases.
- the defect when calculating the area of the defect in the rolled material, the defect is long in the rolling direction and short in the direction orthogonal to the rolling direction. Therefore, in order to increase the calculation accuracy of the defect area, the direction orthogonal to the rolling direction. Therefore, it is necessary to measure the defect dimension with high accuracy.
- the resolution in the rolling direction becomes higher than necessary, while the size of the opening is small in the direction perpendicular to the rolling direction. Therefore, the resolution is lowered and the area that can be measured at a time is narrowed.
- the present invention has been made to solve the above-described problems of the prior art, and provides an ultrasonic flaw detection method and apparatus that can easily and accurately measure the area of a defect extending in the rolling direction of a material to be inspected.
- the task is to do.
- the present inventors have conducted intensive studies. As a result, the defect size (defect length) in the rolling direction is moved in the same manner as in the prior art described above (B) by moving the ultrasonic probe. The method of calculating the defect area according to the moving distance at which the defect echo appears was considered to be sufficient. Then, by combining this method with a method capable of measuring the defect dimension (defect width) in the direction orthogonal to the rolling direction with high accuracy, it was considered that the area of the defect could be measured with high accuracy and simply.
- the transducers are arranged so that the arrangement direction of the transducers coincides with the direction orthogonal to the rolling direction of the material to be inspected.
- the arrangement pitch of the transducers of the one-dimensional array type ultrasonic probe is about 0.6 mm, for example, in the one-dimensional array type ultrasonic probe having 256 transducers, the size of the opening is about 153 mm, which is sufficient for the defect width. Further, it has been conceived that the defect length can be easily measured based on the distribution in the rolling direction of the flaw detection signal when the ultrasonic probe is moved in the rolling direction.
- the present invention has been completed based on the findings of the inventors. That is, in the ultrasonic flaw detection method according to the present invention, the step of disposing a one-dimensional array type ultrasonic probe in which a plurality of transducers are arranged in a direction orthogonal to the rolling direction of the material to be inspected facing the material to be inspected. And a step of relatively moving the ultrasonic probe in the rolling direction of the material to be inspected, and calculating an area of a defect existing in the material to be inspected based on a flaw detection signal output from the ultrasonic probe. Steps.
- the step of calculating the defect area includes the following first to sixth steps.
- First step Flaw detection is performed on each cross section of the material to be inspected in a direction facing the ultrasonic probe by performing aperture synthesis processing on the flaw detection signal output from the ultrasonic probe. An aperture composite image of the signal is generated.
- Second step The maximum value of the flaw detection signal in the facing direction is extracted from the aperture composite image, and the maximum value distribution of the flaw detection signal in the arrangement direction of the transducers is generated.
- Third step Based on the maximum value distribution of the flaw detection signal in the arrangement direction of the transducers, both end portions in the width direction of the defect in each cross section of the inspection object are calculated, and between the calculated both end portions Based on the distance, the width of the defect in each cross section of the inspection object is calculated.
- Fourth step generating a maximum value distribution of flaw detection signals in the rolling direction from a maximum value distribution of flaw detection signals in the arrangement direction of the vibrators in a plurality of cross sections of the material to be inspected.
- Fifth step The length of the defect is calculated based on the maximum value distribution of the flaw detection signal in the rolling direction generated in the fourth step.
- Sixth step The area of the defect is calculated based on the length of the defect calculated in the fifth step and the width of the defect in each cross section calculated in the third step.
- the width of the defect (the dimension in the direction perpendicular to the rolling direction) in each cross section of the inspection object in the direction facing the ultrasonic probe is measured with high accuracy. Is possible. And the length of a defect (dimension of a rolling direction) is simply measurable by the 4th step and the 5th step. Therefore, the defect area can be easily measured with high accuracy by the sixth step.
- the “maximum value of the flaw detection signal” in the present invention means the maximum value of the flaw detection signal having a positive polarity and the minimum value of the flaw detection signal having a negative polarity (that is, the absolute value of the flaw detection signal having a negative polarity). Means the maximum value).
- the present invention is a primary arrangement in which a plurality of vibrators are arranged in a direction perpendicular to the rolling direction, which is disposed to face the material to be inspected, relatively moves in the rolling direction of the material to be inspected.
- An original array-type ultrasonic probe, and signal processing means for calculating an area of a defect present in the inspection object based on a flaw detection signal output from the ultrasonic probe, and the signal processing means Also provided is an ultrasonic flaw detector characterized by executing the first to sixth steps.
- the area of a defect extending in the rolling direction of a material to be inspected can be easily measured with high accuracy.
- FIG. 1 is an explanatory diagram for explaining a conventional defect area calculation method.
- FIG. 2 is a schematic diagram showing a schematic configuration of an ultrasonic flaw detector according to an embodiment of the present invention.
- FIG. 2A is a block diagram showing the overall configuration
- FIG. 2B is a perspective view for explaining the arrangement of the one-dimensional array type ultrasonic probe.
- FIG. 3 is an explanatory diagram for explaining the aperture synthesis processing performed by the aperture synthesis processing unit shown in FIG.
- FIG. 4 is an explanatory diagram for explaining a transmission / reception pattern of the ultrasonic probe shown in FIG.
- FIG. 5 is an explanatory diagram for explaining processing performed by the width direction profile calculation unit and the defect both end calculation unit illustrated in FIG. 2.
- FIG. 2 is a schematic diagram showing a schematic configuration of an ultrasonic flaw detector according to an embodiment of the present invention.
- FIG. 2A is a block diagram showing the overall configuration
- FIG. 2B is a perspective view for explaining the arrangement of the one-dimensional
- FIG. 5A shows an example of an aperture synthesized image generated by the aperture synthesis processing unit.
- FIG. 5B shows the intensity distribution of the flaw detection signal along the line AA shown in FIG.
- FIG. 5C shows a width direction profile generated by the width direction profile calculation unit for the aperture composite image shown in FIG.
- FIG. 5D is a diagram illustrating a method in which the defect both-ends calculation unit calculates both ends in the width direction of the defect based on the width-direction profile shown in FIG.
- FIG. 6 shows an example of the length direction profile generated by the length direction profile calculation unit shown in FIG.
- FIG. 7 is an explanatory diagram for explaining processing performed by the defect area calculation unit shown in FIG.
- FIG. 8 shows an example of the result of calculating the defect width in the embodiment of the present invention.
- FIG. 2 is a schematic diagram showing a schematic configuration of the ultrasonic flaw detector according to the present embodiment.
- FIG. 2A is a block diagram showing the overall configuration
- FIG. 2B is a perspective view for explaining the arrangement of the one-dimensional array type ultrasonic probe.
- the ultrasonic flaw detector 100 according to the present embodiment includes a one-dimensional array type ultrasonic probe 1 and a material to be inspected based on a flaw detection signal output from the ultrasonic probe 1.
- signal processing means 2 for calculating the area of the defect F existing in M.
- the ultrasonic probe 1 is disposed so as to face the material M to be inspected, relatively moves in the rolling direction of the material M to be inspected, and a plurality of transducers 11 are arranged in a direction perpendicular to the rolling direction.
- the signal processing means 2 includes a switching circuit 2A, a pulser 2B, a receiver 2C, an amplifier 2D, an A / D converter 2E, a waveform memory 2F, an aperture synthesis processing unit 2G, a transmission / reception pattern control unit 2H, a width direction profile calculation unit 2I, a defect Both end calculator 2J, length direction profile calculator 2K, position detector 2L, and defect area calculator 2M are provided.
- the switching circuit 2A is connected to each transducer 11 of the ultrasonic probe 1.
- the switching circuit 2A selects the transmission transducer 11 and the reception transducer 11 in accordance with a predetermined transmission / reception pattern transmitted from the transmission / reception pattern control unit 2H, and couples them with the pulser 2B and the receiver 2C.
- the pulsar 2B applies a transmission signal to the selected transducer 11 for transmission.
- the ultrasonic wave oscillated from the transmitting transducer 11 propagates through the material to be inspected M, is reflected by the surface of the material to be inspected M and the defect F, and is selected by the selected transducer for receiving 11.
- the received flaw detection signal is converted into digital data via the receiver 2C, the amplifier 2D, and the A / D converter 2E, and is recorded in the waveform memory 2F.
- the aperture synthesis processing unit 2G performs aperture synthesis processing on the flaw detection signal recorded in the waveform memory 2F.
- information of the ultrasonic probe 1 and the inspection material M for example, the positional relationship between the ultrasonic probe 1 and the inspection material M, the flaw detection frequency of the ultrasonic probe 1, the inspection material M and The sound velocity in the contact medium, the outer diameter when the material M to be inspected is a tube, and the transmission / reception pattern stored in the transmission / reception pattern control unit 2H are used.
- FIG. 3 is an explanatory diagram illustrating the aperture synthesis process performed by the aperture synthesis processing unit 2G.
- the coordinate space of the cross-section M1 (see FIG. 2) of the material M to be inspected in the direction facing the ultrasonic probe 1 is divided into meshes.
- the value of the flaw detection signal recorded in the waveform memory 2F is acquired and input to each mesh.
- the transmission transducer 11 of interest (vibrator P in FIG. 3) and reception.
- the vibrator 11 for use (the vibrators Ra and Rb in FIG. 3) is determined.
- the ultrasonic wave propagation path WI from the transmitting transducer P to the target mesh and the ultrasonic wave propagation paths WRa and WRb from the target mesh to the receiving transducers Ra and Rb are determined.
- the propagation paths WI, WRa, and WRb are determined based on the positional relationship between the transducers P, Ra, and Rb and the material to be inspected M, the sound velocity in the contact medium and the material to be inspected M, and the like.
- Snell's law is the propagation path connecting the incident point or exit point of the ultrasonic wave to the inspection object M and the propagation path connecting the incident point or exit point of the ultrasonic wave to the inspection object M and the target mesh.
- a signal value corresponding to the time (Ta) for propagating through the propagation paths WI and WRa is acquired and input to the target mesh.
- a signal value corresponding to the time (Tb) for propagating through the propagation paths WI and WRb is acquired and input to the same target mesh. (to add).
- the value of the flaw detection signal input to the target mesh is determined. Then, by performing this process on all the meshes, an aperture composite image of the cross section M1 is generated. Since the ultrasonic probe 1 relatively moves in the rolling direction of the inspection material M, an aperture composite image is generated for a plurality of cross sections of the inspection material M. Specifically, a plurality of cross sections associated with the relative positions of the ultrasonic probe 1 and the inspection object M detected by the position detector 2L (for example, cross sections for each predetermined relative movement amount) are opened. A composite image is generated.
- a transducer group (a part or all of the transducers 11 constituting the ultrasonic probe 1) to be driven as the transmission transducer 11 and the reception transducer 11 is selected. Then, by sequentially switching the transmitting transducer 11 and the receiving transducer 11 in the selected transducer group, one aperture composite image can be obtained for a cross section of one material M to be inspected. Further, as shown in FIG. 4B, a plurality of aperture composite images can be obtained for the same cross section by switching the transducer group to be selected in the same cross section and performing the same processing (however, the final Specifically, the values of the meshes of the plurality of aperture composite images are added to form one aperture composite image).
- the width direction profile calculation unit 2I performs the ultrasonic probe 1 and the inspection object M with respect to the combined aperture image of each cross section of the inspection object M generated by the aperture synthesis processing unit 2G as described above.
- the maximum value of the flaw detection signal in the opposite direction is extracted, and the maximum value distribution of the flaw detection signal in the arrangement direction of the transducers 11 (width direction of the defect F) (hereinafter referred to as “width” as appropriate).
- the defect both-ends calculation part 2J calculates the both ends of the width direction of the defect F in each cross section of the inspection object M based on the width direction profile generated by the width direction profile calculation part 2I, and the calculated both ends Based on the distance between the parts, the width of the defect F in each cross section of the inspection object M is calculated.
- FIG. 5 is an explanatory diagram for explaining processing performed by the width direction profile calculation unit 2I and the defect both-ends calculation unit 2J.
- FIG. 5A shows an example of an aperture synthesized image generated by the aperture synthesis processing unit 2G.
- FIG. 5B shows the intensity distribution of the flaw detection signal along the line AA shown in FIG.
- FIG. 5C shows a width direction profile generated by the width direction profile calculation unit 2I for the aperture composite image shown in FIG.
- FIG. 5D is a diagram for explaining a method in which the defect both-ends calculation unit 2J calculates both ends in the width direction of the defect F based on the width direction profile shown in FIG.
- the width direction profile calculation unit 2I outputs the value of the flaw detection signal input to the mesh at each position in the width direction (arrangement direction of the transducers 11) with respect to the aperture composite image shown in FIG. Are sequentially read along the opposing direction of the ultrasonic probe 1 and the material M to be inspected, and the maximum value is extracted and plotted at each position in the width direction. For example, at the position in the width direction of the line AA in FIG. 5A, the value of the flaw detection signal input to each mesh along the line AA is sequentially read, and the maximum value A ′ is extracted and plotted at the position in the width direction. To do. At this time, the width direction profile calculation unit 2I also stores the coordinates (width direction position, depth direction position) of the mesh to which the extracted maximum value is input.
- the width direction profile which is the maximum value distribution of the flaw detection signals in the width direction of the defect F (arrangement direction of the transducers 11). Is generated.
- the coordinates of the mesh in which the generated width direction profile and the extracted maximum value are input are input to the defect both end calculation unit 2J.
- the defect both end calculation unit 2J has a range where the width direction profile (FIG. 5C) generated by the width direction profile calculation unit 2I is reduced by a predetermined dB from the maximum value Mn, or the maximum flaw detection signal. A range where the value exceeds a preset threshold value is calculated. In the example shown in FIG. 5C, a range W that is 6 dB lower than the maximum value Mn is calculated. Then, as shown in FIG. 5D, the defect both-ends calculation unit 2J reads the coordinates of the mesh to which the maximum values corresponding to both ends of the calculated range W are input, and both ends ELn of the defect F, The coordinates of ERn are used. Then, the distance between both ends ELn and ERn of the defect is calculated, and this is defined as the width of the defect F.
- the width of the defect F in each cross section of the inspection object M is calculated.
- the length direction profile calculation unit 2K is obtained from the width direction profiles in a plurality of cross sections of the inspection object M associated with the relative positions of the ultrasonic probe 1 and the inspection object M detected by the position detector 2L.
- a maximum value distribution of flaw detection signals in the rolling direction (length direction of the defect F) (hereinafter referred to as “length direction profile” as appropriate) is generated. Specifically, by plotting the maximum value Mn (see FIG. 5) of the width direction profile in each cross section at the position in the length direction (rolling direction) of the material M to be rolled corresponding to each cross section, FIG. A length direction profile as shown in FIG.
- the length direction profile calculation unit 2K calculates the length of the defect F based on the generated length direction profile. Specifically, a range where the maximum value of the length direction profile is reduced by a predetermined dB or a range where the maximum value Mn of the flaw detection signal exceeds a preset threshold is calculated as the length of the defect F.
- the defect area calculation unit 2M calculates the area of the defect F based on the length of the defect F calculated by the length direction profile calculation unit 2K and the width of the defect F in each cross section calculated by the defect both-ends calculation unit 2J. . Specifically, as shown in FIG. 7, the width Wn of the defect F calculated for the cross section within the range corresponding to the length of the defect F, and the distance in the rolling direction (the length direction of the defect F) between the cross sections.
- the area of the defect F is calculated by performing a product-sum operation with ⁇ L within a range corresponding to the length of the defect F.
- the area of the defect F extending in the rolling direction of the inspection material M can be measured with high accuracy and simply.
- FIG. Went A flaw detection test using the ultrasonic flaw detection apparatus according to the present invention schematically shown in FIG. Went.
- the one-dimensional array type ultrasonic probe has a flaw detection frequency of 5 MHz, a transducer arrangement pitch of 0.5 mm, a number of transducers of 64, and a transducer length in the direction orthogonal to the arrangement direction of 6 mm.
- the aperture composite image was generated every time the ultrasonic probe and the material to be inspected were relatively moved by 1 mm.
- FIG. 5A is an example of an aperture composite image obtained by this example.
- the aperture composite image is obtained by transmitting ultrasonic waves with any one transducer, receiving them with 64 transducers, and sequentially switching the transmitting transducer from the first transducer to the 64th transducer. It is a thing.
- a width direction profile shown in FIG. 5C is generated for the aperture composite image, and both end portions in the width direction of the defect are calculated as shown in FIG. From the distance, the width of the defect in each cross section of the flat plate was calculated.
- the defect width calculated for the aperture composite image in FIG. 5A was 3.2 mm. Although it is calculated to be slightly narrower than the actual defect width of 3.6 mm, it can be said that it can be calculated with high accuracy.
- FIG. 6 is a length direction profile obtained by this example. A range where the maximum value of the length direction profile was reduced by 6 dB was calculated as the defect length. The calculated defect length is 23 mm, and although it is calculated a little longer than the actual defect length of 20 mm, it can be said that the defect can be calculated accurately.
- the product sum operation of the width of the defect calculated about the cross section within the range corresponding to the length of the defect and the distance (1 mm) in the rolling direction (the length direction of the defect) between each cross section is calculated as the length of the defect.
- the area of the defect was calculated by carrying out within the range corresponding to.
- the calculated defect area was 81 mm 2 , and it was found that measurement was possible with an error of about + 13% compared to the actual defect area of 72 mm 2 .
- FIG. 8 shows widths processed to different depths in a flat plate using the ultrasonic flaw detector according to the present embodiment.
- variety of the flat bottom hole of mm and 1.0 mm is shown.
- the width of the defect can be calculated with high accuracy regardless of the depth position of the defect (flat bottom hole).
- the area of the flat bottom groove (inclined by 10 ° with respect to the horizontal direction of the flat plate, width of 3.6 mm, length of 20 mm) provided in the flat plate is calculated as a defect. did.
- the same defect area as described above was calculated using a normal ultrasonic probe. Specifically, the ultrasonic probe is moved in the length direction and width direction of the defect, and the length and width of the defect are calculated based on the moving distance at which the defect echo appears, thereby calculating the area of the defect. (Equivalent to (B) of the prior art described above). The results are shown in Table 1.
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Abstract
Description
(A)エコー高さを利用して欠陥の面積を算出する方法、
(B)超音波探触子を移動させ、欠陥エコーが出現する移動距離によって、欠陥の面積を算出する方法
が知られている。
また、特許文献1(日本国特開2005-31061号公報)には、
(C)開口合成処理を用いて欠陥の面積を算出する方法
が提案されている。
以下、これらの方法について具体的に説明する。
欠陥の大きさが超音波ビームの有効広さよりも小さい場合、欠陥の面積とエコー高さが比例する関係を利用して、欠陥の面積を算出することができる。
上記の式(1)より、欠陥エコー高さPRは、欠陥の面積であるπd2/4に比例することが分かる。
欠陥の大きさが超音波ビームの有効広さよりも大きい場合、超音波探触子を移動させながら、欠陥エコーが最大のエコー高さから所定のレベルまで低下する範囲、或いは、最大エコー高さとは関係なくエコー高さが所定の高さ以上で出現する範囲を、欠陥の指示長さとして測定する方法が知られている。この方法によれば、測定対象となる欠陥の長さよりも小さい寸法の振動子を有する超音波探触子を選択することで、欠陥の長さを比較的精度良く測定することができる。従って、鋼管や鋼板などの圧延材における、圧延方向に延びる面状の欠陥等については、上記の方法により圧延方向の欠陥寸法(欠陥長さ)を比較的精度良く測定可能である。
一方、特許文献1には、マトリックス状に配置された振動子群を用いて超音波探傷を行うことにより収集したデータに基づき、被検査材内部の3次元画像化データを生成し、この3次元画像化データを処理することによって、欠陥の面積を自動計算する方法が開示されている。具体的には、3次元画像化データから欠陥の面積を自動計算する際に、3次元画像化データを直交座標系の各軸方向に透視して、最大値を有するデータを平面に投影する。そして、投影した平面において、予め決められたしきい値以上の値を有するメッシュの数をカウントすることにより、欠陥の面積が計算される。この方法では、3次元画像化データを生成する際に開口合成技術を適用することによって、高解像度で欠陥を表示することを可能としている。しかしながら、この方法を圧延材の面状欠陥等へ適用する際には、算出効率及び算出精度の面で問題がある。以下、具体的に説明する。
(1)第1ステップ:前記超音波探触子から出力される探傷信号に対して開口合成処理を施すことにより、前記超音波探触子に対向する方向の被検査材の各断面について、探傷信号の開口合成像を生成する。
(2)第2ステップ:前記開口合成像に対して前記対向方向についての探傷信号の最大値を抽出し、前記振動子の配列方向についての探傷信号の最大値分布を生成する。
(3)第3ステップ:前記振動子の配列方向についての探傷信号の最大値分布に基づき、被検査材の各断面における前記欠陥の幅方向の両端部を算出し、該算出した両端部間の距離により、被検査材の各断面における前記欠陥の幅を算出する。
(4)第4ステップ:被検査材の複数の断面における前記振動子の配列方向についての探傷信号の最大値分布から、前記圧延方向についての探傷信号の最大値分布を生成する。
(5)第5ステップ:前記第4ステップによって生成した前記圧延方向についての探傷信号の最大値分布に基づき、前記欠陥の長さを算出する。
(6)第6ステップ:前記第5ステップで算出した前記欠陥の長さと、前記第3ステップで算出した各断面における前記欠陥の幅とに基づき、前記欠陥の面積を算出する。
図2に示すように、本実施形態に係る超音波探傷装置100は、一次元アレイ型超音波探触子1と、超音波探触子1から出力される探傷信号に基づいて、被検査材Mに存在する欠陥Fの面積を算出する信号処理手段2とを備えている。
図5は、幅方向プロファイル演算部2I及び欠陥両端部演算部2Jが行う処理を説明するための説明図である。図5(a)は、開口合成処理部2Gによって生成された開口合成像の一例を示す。図5(b)は、図5(a)に示すAA線に沿った探傷信号の強度分布を示す。図5(c)は、図5(a)に示す開口合成像について幅方向プロファイル演算部2Iによって生成される幅方向プロファイルを示す。図5(d)は、図5(c)に示す幅方向プロファイルに基づき、欠陥両端部演算部2Jが欠陥Fの幅方向の両端部を算出する方法を説明する図である。
Claims (2)
- 被検査材の圧延方向に直交する方向に複数の振動子を配列した一次元アレイ型超音波探触子を被検査材に対向して配置するステップと、前記超音波探触子を被検査材の圧延方向に相対移動させるステップと、前記超音波探触子から出力される探傷信号に基づいて、被検査材に存在する欠陥の面積を算出するステップとを含み、
前記欠陥の面積を算出するステップは、
前記超音波探触子から出力される探傷信号に対して開口合成処理を施すことにより、前記超音波探触子に対向する方向の被検査材の各断面について、探傷信号の開口合成像を生成する第1ステップと、
前記開口合成像に対して前記対向方向についての探傷信号の最大値を抽出し、前記振動子の配列方向についての探傷信号の最大値分布を生成する第2ステップと、
前記振動子の配列方向についての探傷信号の最大値分布に基づき、被検査材の各断面における前記欠陥の幅方向の両端部を算出し、該算出した両端部間の距離により、被検査材の各断面における前記欠陥の幅を算出する第3ステップと、
被検査材の複数の断面における前記振動子の配列方向についての探傷信号の最大値分布から、前記圧延方向についての探傷信号の最大値分布を生成する第4ステップと、
前記第4ステップによって生成した前記圧延方向についての探傷信号の最大値分布に基づき、前記欠陥の長さを算出する第5ステップと、
前記第5ステップで算出した前記欠陥の長さと、前記第3ステップで算出した各断面における前記欠陥の幅とに基づき、前記欠陥の面積を算出する第6ステップとを含むことを特徴とする超音波探傷方法。 - 被検査材に対向して配置され、被検査材の圧延方向に相対移動し、該圧延方向に直交する方向に複数の振動子を配列した一次元アレイ型超音波探触子と、
前記超音波探触子から出力される探傷信号に基づいて、被検査材に存在する欠陥の面積を算出する信号処理手段とを備え、
前記信号処理手段は、
前記超音波探触子から出力される探傷信号に対して開口合成処理を施すことにより、前記超音波探触子に対向する方向の被検査材の各断面について、探傷信号の開口合成像を生成する第1ステップと、
前記開口合成像に対して前記対向方向についての探傷信号の最大値を抽出し、前記振動子の配列方向についての探傷信号の最大値分布を生成する第2ステップと、
前記振動子の配列方向についての探傷信号の最大値分布に基づき、被検査材の各断面における前記欠陥の幅方向の両端部を算出し、該算出した両端部間の距離により、被検査材の各断面における前記欠陥の幅を算出する第3ステップと、
被検査材の複数の断面における前記振動子の配列方向についての探傷信号の最大値分布から、前記圧延方向についての探傷信号の最大値分布を生成する第4ステップと、
前記第4ステップによって生成した前記圧延方向についての探傷信号の最大値分布に基づき、前記欠陥の長さを算出する第5ステップと、
前記第5ステップで算出した前記欠陥の長さと、前記第3ステップで算出した各断面における前記欠陥の幅とに基づき、前記欠陥の面積を算出する第6ステップとを実行することを特徴とする超音波探傷装置。
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