WO2019091029A1 - 铝合金焊接壳体焊缝的相控阵超声检测方法 - Google Patents
铝合金焊接壳体焊缝的相控阵超声检测方法 Download PDFInfo
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- WO2019091029A1 WO2019091029A1 PCT/CN2018/078110 CN2018078110W WO2019091029A1 WO 2019091029 A1 WO2019091029 A1 WO 2019091029A1 CN 2018078110 W CN2018078110 W CN 2018078110W WO 2019091029 A1 WO2019091029 A1 WO 2019091029A1
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- phased array
- aluminum alloy
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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
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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
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
Definitions
- the invention relates to the technical field of welding of aluminum alloy welded casings, in particular to the quality inspection technology of weld seams.
- the actual method of inspecting the weld is to place the work on a workbench that can control its movement, and the inspection worker holds a common ultrasonic instrument, and the inspection workman observes the dynamic waveform information through the display screen on the ultrasonic system, if found on it.
- the mark is marked there. Due to the long time of ordinary ultrasonic testing, the influence of human factors is large, and the use of the couplant remover is time consuming and laborious. For example, a 18-meter spiral welded pipe with a weld length of 40 meters and two ordinary ultrasonic sensors are tested at the same time, each requiring 90 minutes.
- Phased Array Ultrasonic Testing is a method of applying different time delays (or voltages) to each unit of an array probe when transmitting or receiving ultrasonic waves according to a set focusing law, and detecting the movement of the sound beam by beamforming.
- Ultrasonic inspection imaging technology for functions such as deflection and focusing.
- the phased array ultrasound host probe consists of 64 piezoelectric wafers. Each piezoelectric wafer forms a transmitting/receiving array element, and then under the excitation of the transmitting circuit, the phase difference formed by the phase relationship of each transmitting or receiving ultrasonic wave reaching a point in the object is changed by pulse delay to achieve the deflection of the beam. Focus to achieve detection.
- the ordinary phased array ultrasonic testing method can not achieve the intended purpose, and also causes missed or over-detected.
- the object of the present invention is to provide a phased array ultrasonic testing method for a weld of an aluminum alloy welded casing which is convenient, fast, accurate and convenient for later analysis.
- the invention adopts a phased array probe perpendicular to the weld seam and performs a linear scan along the straight pipe weld direction; the phased array probe is a phased array probe conforming to JB/T 11731.
- phased array probe The parameters of the phased array probe are shown in the following table:
- the present invention proposes a preferred detection scheme for selecting the parameters of the corresponding phased array probe according to the maximum thickness of the welded pipe to be inspected, which is convenient, fast and accurate, and is convenient for later analysis. purpose.
- phased array ultrasonic method of the present invention can be used to detect the workpiece.
- a 18-meter spiral welded pipe with a weld length of 40 meters can be completed by using the above phased array ultrasonic method of the present invention for one person for 30 minutes.
- phased array ultrasound is a sector scan, the influence of human factors is small, safe and environmentally friendly, high efficiency, high accuracy, and storable. This saves time and precision and ensures the quality of the product. Then, the defects found are re-examined by ordinary ultrasound and manual dissection.
- the detection efficiency can reach 3 to 5 times of ordinary ultrasonic detection and radiation detection; it can also cross-work, there is no specific requirement for environment and time; at the same time, all inspection records are digitally stored for easy traceability and preservation.
- the present invention uses two phased array probes for synchronous linear scanning, and two phased array probes are respectively disposed on the same side of the welded pipe weld, and on both sides of the straight pipe weld.
- the linear scanning speed is not more than 100 mm/s along the axis of the pipe. Improve the efficiency of testing and save time for testing.
- the speed of the straight scan is 1 to 2 m/min along the axial direction of the straight pipe. This not only ensures the work efficiency, but also obtains a stable data for analysis and judgment.
- the speed of the linear scanning is 1 to 2 m/min along the direction of the weld of the steel pipe. While ensuring work efficiency, a stable data can be obtained for analysis and judgment.
- the 10 ° C ⁇ 35 ° C water with pure, no bubbles and impurities is used as the coupling agent of the phased array probe. It is coupled with water and has no pollution to the environment. Under the water temperature of 10 °C ⁇ 35 °C, water transmits better to sound waves, and the obtained data is more accurate.
- test environment should not be carried out at locations that affect the normal operation of ultrasonic instruments and auxiliary electrical equipment, such as strong magnetic, vibration, high frequency, large dust, corrosive gases and noisy locations.
- the temperature and humidity of the working point should be controlled within the range allowed by the testing equipment, auxiliary electrical equipment and materials.
- the surface of the workpiece to be inspected is free from dust, impurities and pollutants, and the surface roughness is ⁇ Ra6.3.
- the control movement speed of this example is 80 mm/s.
- the shape and size of the weld profile, the corresponding standard calibration block and the comparison verification test block are selected for verification.
- Sensitivity adjustment The amplitude of the ⁇ 2 transverse through hole with a depth of 10 mm on the calibration test block is calibrated to 80%, and the sensitivity calibration is completed. This process uses the above coupling agent.
- TCG curve production select the TCG production module on the phased array ultrasound system, adjust the amplitude of the ⁇ 2 hole at the depth of 10mm to 80%, adjust the green line to the two red dotted boxes, click OK, add the next One point, adjust the amplitude of the ⁇ 2 transverse through hole at depth 20mm to 80%, and adjust the inner green line to the two red dotted lines. Add the first point, click OK, and the TCG curve is completed.
- the maximum depth of the transverse hole is greater than 2.2 times the thickness of the plate.
- the phased array probe is JB/T 11731 compliant.
- a phased array probe consists of an array of multiple wafers.
- phased array probe conforms to JB/T 11731, and the phased array probe consists of multiple wafers.
- the parameters of the phased array probe are shown in the following table:
- the wafer pitch refers to the distance between the same side or center of two adjacent wafers.
- the deflection direction aperture size refers to the size of a set of wafers used by each probe.
- the following is an example of longitudinal seam welding, and the maximum thickness of the straight pipe is 6 mm ⁇ T ⁇ 15 mm.
- Two phased array probes are used for synchronous linear scanning.
- the two phased array probes are respectively arranged on the same side of the straight pipe weld and on both sides of the weld.
- the time gain correction is to gain correction of the echoes of the same size reflector at different sound paths to achieve the same amplitude.
- the scan surface should be marked on the workpiece scan surface before the scan.
- the mark content includes at least the scan start point and the scan direction.
- Two phased array probes are used for synchronous linear scanning.
- the two phased array probes are respectively arranged on the same side of the steel pipe weld and on both sides of the steel pipe weld.
- the two phased array probe wafer arrays are oriented perpendicular to the probe's direction of movement or at a stable angle.
- the leading edge of the probe leaves a certain distance from the center of the weld and translates along the axis of the weld to obtain information on the weld within the coverage of the sound beam.
- the above coupling agent is continuously supplied by a water pump during the scanning process.
- the software should have at least A, S, B, and C display functions, and have the function of positioning, addressing, and analyzing defects on the scanned image.
- It can store and recall A, S, B, and C images, and can copy stored detection data to external storage space.
- the software should have the Focus Rule function A, CG calibration function, and TCG (or DAC) calibration function.
- the instrument should be capable of storing and resolving information about the relative position of each A-scan signal, such as the encoder position.
- the off-line analysis software should be able to view the key parameters of the test.
- the maximum amplitude of the defect does not exceed 100% of the full screen and is greater than 20%, the maximum length of the A-scan echo amplitude reduced by 6 dB at different angles of the defect is found as the length of the defect. If the maximum amplitude of the defect is less than 20% higher than 10%, then the defect is found at different angles. The A-scan echo amplitude is reduced to 10% to measure the defect indication length by the 10% absolute sensitivity method.
- the maximum amplitude of the defect exceeds 100% of the full screen, the maximum length of the defect at which the A-scan echo amplitude is reduced to 50% of the full screen is found as the length of the defect.
- Two defects adjacent in the length direction of the defect have a lengthwise spacing smaller than the smaller defect length and the distance between the two defects in the direction perpendicular to the length of the defect is less than 5 mm, and should be treated as a defect, and the sum of the two defect lengths is taken as Indicate the length (interval count). If the two defects are overlapped in the longitudinal direction projection, the distance between the left and right end points of the two defects projected in the longitudinal direction is taken as the indicated length.
- Defect identification marking the defect location of the inspected part
- the measurement of the weld defect is carried out using a tape measure, and the surface of the product is marked with information including the length, depth and grade of the defect.
- phased array ultrasonic testing speed is faster than other detection methods, such as 18 m workpiece, phased array ultrasonic testing takes 30 minutes, and ordinary ultrasonic testing takes 90 minutes.
- phased array ultrasonic testing is less affected by artificial factors, while ordinary ultrasonic testing and X-ray testing are greatly affected by the level of artificial defects.
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Abstract
铝合金焊接壳体焊缝的相控阵超声检测方法，涉及铝合金焊接壳体的焊接技术领域，特别是对焊缝的质量检测技术。采用相控阵探头垂直于焊缝，沿直管焊缝方向进行直线扫查。本发明提出了一种根据被检的焊管的最大厚度进行选择相应相控阵探头的各参数的优选检测方案，达到的方便、快速、准确，还方便后期分析的目的。
Description
本发明涉及铝合金焊接壳体的焊接技术领域，特别是对焊缝的质量检测技术。
在工业化生产中，将材料通过纵缝、环缝或螺旋缝焊接形成设计需要的管材后，需要及时对管材的焊缝进行超声波无损检测，对于达到符合质量要求的才能进入下一工序，而如经检查不符合质量要求的则必须返工。
目前实际检查焊缝的方法是：将工作放置于可控制其运动的工作台上，检测工则手持普通超声仪，检测工目不转睛地通过超声仪上的显示屏观察动态波形信息，如发现其上反映出了非正常(即不符合质量要求)的信息时，则在管材的该处作记号。由于普通超声检测时间长，人为因素影响大，使用的耦合剂清除时费时费力。比如，1根18米螺线焊管，焊缝长度达40米，普通超声2个人同时进行检测，每人需要90分钟。由于普通超声是锯齿形扫查，人为因素导致的漏检风险非常大，并且波形不可存储，不能进行后期再次分析。另外，因普通超声仪或X-Ray检测受缺陷在焊缝位置的影响，有些缺陷无法检出而被漏检。
相控阵超声检测(简称PAUT)，是一种依据设定的聚焦法则对阵列探头各个单元在发射或者接收超声波时施加不同的时间延迟(或电压)，通过波束形成实现检测声束的移动、偏转和聚焦等功能的超声 检测成像技术。
相控阵超声主机探头由64个压电晶片组成。每个压电晶片形成一个发射/接收阵元，然后在发射电路的激励下通过脉冲延迟，改变各个发射或者接收超声波到达物体内某点的相位关系所形成相位差，来达到对波束的偏转与聚焦，从而实现检测。
但是，由于现实生产过程中铝合金焊接壳体的厚度不同，因此，采用普通的相控阵超声检测方法则不能达到预期目的，同样也会造成漏检或过检。
发明内容
本发明目的是提出一种方便、快速、准确，还方便后期分析的铝合金焊接壳体焊缝的相控阵超声检测方法。
本发明采用相控阵探头垂直于焊缝，沿直管焊缝方向进行直线扫查；所述相控阵探头为符合JB/T 11731的相控阵探头。
相控阵探头的各参数见下表：
经反复研究、论证、对比，本发明提出了一种根据被检的焊管的最大厚度进行选择相应相控阵探头的各参数的优选检测方案，达到的 方便、快速、准确，还方便后期分析的目的。
实际应用中，可先利用本发明的以上相控阵超声方法对工件进行检测。比如，1根18米螺线焊管，焊缝长度达40米，采用本发明的以上相控阵超声方法1人30分钟即可完成。由于相控阵超声是扇形扫查，人为因素影响小，安全环保，效率高，准确率高，且可存储。这样既省时又精确，确保产品焊接质量。然后，对发现的缺陷再用普通超声和人工剖开的方法进行复检。
本发明的优势：
1、无电离辐射，使用水作为耦合剂，对人体和环境无害，是一种绿色的检测方法。
2、对未熔合和裂纹等面积缺陷比较敏感，相对于普通超声检测、射线检测，缺陷检出率更高。
3、检测效率可达普通超声检测、射线检测的3～5倍；还能交叉作业，对环境、时间没有特定的要求；同时，所有检测记录数字化存储，便于追溯和保存。
进一步地，本发明采用两只相控阵探头进行同步直线扫查，两只相控阵探头分别布置在焊管焊缝的同一面，且在直管焊缝的两侧。选用类似一维线扫描的机理，这样只需扫查一次可同时获得焊缝两侧扫描的数据。
经研究，相对于不同的铝合金壳体的不同焊缝，直线扫查的速度不同：
所述焊缝为纵缝时，所述直线扫查的速度为沿管道轴线方向不大 于100mm/s。提高了检测的工作效率，节省了检测的时间。
当所述焊缝为螺旋焊缝时，所述直线扫查的速度为沿直管轴线方向1～2m/min。这样既保证了工作效率的同时，可以得到一个稳定的数据，便于分析判断。
而当所述焊缝为环缝时，所述直线扫查的速度为沿钢管焊缝方向1～2m/min。既保证了工作效率的同时，可以得到一个稳定的数据，便于分析判断。
扫查时采用纯净、无气泡和杂质的10℃～35℃水为相控阵探头的耦合剂。用水耦合，对环境无污染，在10℃～35℃水温条件下水对声波传输的更好，取得的数据更精准。
一、检测前期处理：
1、场地：
检测环境不应在影响超声波仪器和辅助电气设备正常工作的地点进行，诸如强磁、震动、高频、灰尘大、有腐蚀性气体及噪声大的地点进行。
2、温度及湿度：
工作点的温度及湿度应控制在检测仪器、辅助电气设备及材料所允许的范围内。
3、为了探头的移动和耦合，对被检工件表面进行无灰尘、杂质、污染物处理，表面粗糙度≤Ra6.3。
将工件置于一可控制等速、沿直管轴向运动的控制台上。本例的 控制运动速度为80mm/s。
二、检测用主机：
使用奥林巴斯(OLYMPUS)OmniScan MX2相控阵超声仪；仪器的数据采集和扫查装置移动同步，具备存储和分辨功能。
三、耦合剂：
使用纯净、无气泡和杂质的10℃～35℃水。
四、扫查步骤：
根据工件厚度、焊缝剖口形状和尺寸，选用相应的标准校准试块和对比验证试块进行校验。
1、灵敏度调校：将在校准试块上深度为10mm的φ2横通孔的波幅校准到80％，完成灵敏度校准。该过程选用以上耦合剂。
2、TCG曲线制作：选择相控阵超声仪上TCG制作模块，把在深度10mm处的φ2孔的波幅调节到80％，将绿色的线调节到两条红色虚线框内，点击确定，添加下一点，把深度20mm处的φ2横通孔波幅调到80％，将其内绿色的线调节到两条红色虚线框内，类似添加第一个点，点击确定，TCG曲线制作完毕。横通孔最高深度要大于板厚的2.2倍。
3、探头选择：
相控阵探头符合JB/T 11731。相控阵探头由多个晶片组成阵列。
选用的相控阵探头符合JB/T 11731，相控阵探头由多个晶片组成阵列；相控阵探头的各参数见下表：
上表中，晶片间距是指：两个相邻晶片的同侧边或者中心之间的距离。
偏转方向孔径尺寸是指各个探头所用一组晶片的尺寸大小。
以下以纵缝焊，且直管的最大厚度6mm≤T＜15mm为例进行检测分析。
选用两只相控阵探头进行同步直线扫查，两只相控阵探头分别布置在直管焊缝的同一面，且在焊缝的两侧。
4、补偿：按照产品质量保障体系要求加6dB补偿进行测量，点击相控阵超声仪上UT按键进行设置，选择高级，点击参考dB，点击增益+6，完成对增益的设置。
时间增益修正是对不同声程处相同尺寸反射体的回波进行增益修正，使之达到相同幅值。
5、扫查面准备：
扫查前应在工件扫查面上予以标记，标记内容至少包含扫查起始点和扫查方向。
6、操作步骤：
采用两只相控阵探头进行同步直线扫查，两只相控阵探头分别布置在钢管焊缝的同一面，且在钢管焊缝的两侧。两只相控阵探头晶片 阵列方向与探头移动方向垂直或成稳定的某一角度。
探头前沿离开焊缝中心一定距离，沿焊缝轴线方向平移，以获得声束覆盖范围内焊缝的信息。
扫查过程中通过水泵连续供以上述耦合剂。
扫查至超过起始点后，即停止扫查，并按保存按键。
7、测量：
将仪器中的存储卡存储到电脑上，使用OmniPC-4.4R3软件打开，结合仪器中的B型显示、C型显示、S型显示及A扫描显示，对缺陷的位置、幅度、长度进行测量。
OmniPC-4.4R3软件说明：
软件至少应有A、S,B、C型显示的功能，且具有在扫描图像上对缺陷定位、定址及分析功能。
能够存储、调出A、S、B、C图像，并能将存储的检测数据复制到外部存储空间中。
软件应具有聚焦法则计打功能A、CG校准功能，以及TCG(或DAC)校准功能。
仪器应能存储和分辨各A扫描信号之间相对位置的信息，如编码器位置。
离线分析软件中应能对检测时关键参数设甡进行查看。
8、缺陷长度的确定：
若缺陷最高波幅未超过满屏100％且大于20％，则以此幅度为基准，找到此缺陷不同角度A扫描回波幅度降低6dB的最大长度作为该 缺陷的长度。若缺陷最高波幅小于20％高于10％，则找到此缺陷不同角度A扫描回波幅度降低到10％，以用10％绝对灵敏度法测量缺陷指示长度。
若缺陷最高幅度超过满屏100％，则找到此缺陷不同角度A扫描回波幅度降低到满屏50％时的最大长度作为此缺陷的长度。
沿缺陷长度方向相邻的两缺陷，其长度方向间距小于其中较小的缺陷长度且两缺陷在与缺陷长度相垂直方向的间距小于5mm，应作为一条缺陷处理，以两缺陷长度之和作为其指示长度(间距计入)。如果两缺陷在长度方向投影有重叠，则以两缺陷在长度方向上投影的左、右端点间距距离作为其指示长度。
9、缺陷标识：对被检件缺陷位置进行标识；
按照评定的记录对焊缝缺陷部位使用皮尺进行测量确认，并在产品表面做好标记，信息包括缺陷长度、深度及等级。
10、判定：被检件焊缝质量要求符合客户技术要求。
焊接接头不允许存在裂纹、未熔合和未焊透等缺陷；
波幅在10％以下的缺陷均评为Ⅰ级；
焊接接头质量分级按照下表2的规定进行判定，如按照Ⅰ级标准控制：
11、对比结果：
利用相控阵超声对工件进行检测共发现缺陷41个，其中15个为Ⅰ级，26个为Ⅲ级。
15个Ⅰ级缺陷：
而利用普通超声抽检了5个，其中3个为Ⅰ级缺陷，2个未发现。利用人工剖开抽检了1个缺陷。
26个Ⅲ级缺陷：
而利用普通超声抽检了16个，其中11个为Ⅲ级，5个未发现。
利用人工剖开抽检了8个，均发现了缺陷。
相控阵超声检测速度比其它检测手段快，如18米工件，相控阵超声检测需30分钟，普通超声检测则需90分钟。
同时，经研究还发现相控阵超声检测受人工因素影响小，而普通超声检测和X射线检测受人工缺陷判定水平影响较大。
通过检测验证对比，不仅初步掌握了相控阵超声检测的方法，同 时也深深地感到与传统的X射线检测和普通超声检测相比，无论是准确率，还是检测速度等方面都有着较大的优势，应该说将其应用到实际的检测当中，必将全面提升产品焊接质量。
Claims (6)
- 铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：采用相控阵探头垂直于焊缝，沿直管焊缝方向进行直线扫查；所述相控阵探头符合JB/T 11731，相控阵探头由多个晶片组成阵列。
- 根据权利要求1所述铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：采用两只相控阵探头进行同步直线扫查，两只相控阵探头分别布置在直管焊缝的同一面，且在直管焊缝的两侧。
- 根据权利要求1或2所述铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：所述焊缝为纵缝时，所述直线扫查的速度为铝合金焊接壳体轴线方向不大于100mm/s。
- 根据权利要求1或2所述铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：所述焊缝为螺旋焊缝时，所述直线扫查的速度为沿螺旋焊管轴线方向1～2m/min。
- 根据权利要求1或2所述铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：所述焊缝为环缝时，所述直线扫查的速度为沿外壳焊缝方向1～2m/min。
- 根据权利要求1或2所述铝合金焊接壳体焊缝的相控阵超声检测方法，其特征在于：扫查时采用纯净、无气泡和杂质的10℃～35℃水为相控阵探头的耦合剂。
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| CN104849349A (zh) * | 2015-05-18 | 2015-08-19 | 田国良 | 采用相控阵超声组合技术检测薄壁小径管焊缝的方法 |
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| CN104849349A (zh) * | 2015-05-18 | 2015-08-19 | 田国良 | 采用相控阵超声组合技术检测薄壁小径管焊缝的方法 |
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