WO2020250379A1 - 超音波探傷方法、超音波探傷装置、鋼材の製造設備列、鋼材の製造方法、及び鋼材の品質保証方法 - Google Patents
超音波探傷方法、超音波探傷装置、鋼材の製造設備列、鋼材の製造方法、及び鋼材の品質保証方法 Download PDFInfo
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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
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/50—Processing the detected response signal, e.g. electronic circuits specially adapted therefor using auto-correlation techniques or cross-correlation techniques
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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
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/48—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by amplitude comparison
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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
- 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
- G01N29/043—Analysing solids in the interior, e.g. by shear waves
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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
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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
- G01N29/11—Analysing solids by measuring attenuation of acoustic waves
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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
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/225—Supports, positioning or alignment in moving situation
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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
- G01N29/22—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
- 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
- G01N29/275—Arrangements for orientation or scanning by relative movement of the head and the sensor by moving both the sensor and the material
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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
- G01N29/34—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor
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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
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/449—Statistical methods not provided for in G01N29/4409, e.g. averaging, smoothing and interpolation
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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
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
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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
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
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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
- G01N2291/04—Wave modes and trajectories
- G01N2291/044—Internal reflections (echoes), e.g. on walls or defects
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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
- G01N2291/262—Linear objects
- G01N2291/2626—Wires, bars, rods
Definitions
- the present invention relates to an ultrasonic flaw detection method, an ultrasonic flaw detector, a steel material manufacturing equipment line, a steel material manufacturing method, and a steel material quality assurance method.
- Internal defects in the round bar may be the starting point of cracking when manufacturing mechanical parts made from the round bar, which reduces the strength and life of the mechanical parts after manufacturing. For this reason, it has been conventionally practiced to ultrasonically detect the inside of a round bar and evaluate the internal defects of the round bar.
- a single vertical and oblique array probe is moved relatively along the circumferential and axial directions of the round bar, or in the circumferential direction.
- a plurality of array probes are arranged in the wheel, and the round bar pair is moved in the axial direction to detect the entire surface of the round bar body.
- Patent Document 1 a defect signal is received while scanning an ultrasonic probe, and an aperture synthesis process is performed by setting a delay time according to the reception position for a plurality of received defect signals. A method for improving the detectability and resolution of defects by using a small-diameter ultrasonic probe is described.
- the defect detection ability can be improved by controlling the timing of exciting each vibrating element and changing the depth and direction in which the ultrasonic beam is focused.
- Patent Document 2 the ultrasonic beams are focused in the circumferential direction by simultaneously exciting the vibrating elements and adding a delay time to the received signals of each vibrating element on the computer to synthesize them. A method that enables high-speed flaw detection is described.
- the direction in which the probe is arranged is the case where an unfocused probe is used.
- the detectability is low, and when a focusing probe is used, the beam is concentrated on the central axis of the probe, so that the detectability is low at the position between the probe and the probe.
- a method of arranging the probes in a staggered pattern is conceivable, but when the local water immersion method is used, the range in which coupling is required becomes wider, so that air bubbles are more likely to be mixed.
- the focal point can be scanned on the computer in the circumferential direction, and a vibrating element that focuses in the axial direction in order to obtain high detectability uniformly in the axial direction of the round bar is provided.
- a vibrating element that focuses in the axial direction in order to obtain high detectability uniformly in the axial direction of the round bar is provided.
- the present invention has been made in view of the above problems, and provides an ultrasonic flaw detection method and an ultrasonic flaw detector capable of performing ultrasonic flaw detection with high detectability and resolution in the entire range inside the inspection material at high speed. There is. Another object of the present invention is to provide a steel material manufacturing facility line and a steel material manufacturing method capable of producing a steel material with a high yield. Furthermore, another object of the present invention is to provide a quality assurance method for a steel material capable of providing a high quality steel material.
- the ultrasonic flaw detection method transmits an ultrasonic signal from an ultrasonic probe to an inspection material and is reflected inside the inspection material. It is an ultrasonic flaw detection method that inspects the inside of the inspection material by receiving the sound sound signal as a defect signal in the ultrasonic probe, and changes the positional relationship between the inspection material and the ultrasonic probe. In addition, in the receiving step of receiving a plurality of defect signals in one or more vibrating elements provided in the ultrasonic probe and the positional relationship between the inspection material and the vibrating element, the sound received from the defects.
- the S / N ratio change rate of the defect signal is calculated by adding and averaging the received sound pressure ratio at each vibrating element position, and the above. It is characterized by including a step of determining a composite waveform group having an S / N ratio change rate of a predetermined value or more as a defect signal waveform used in the aperture synthesis process.
- the determination step is the angle formed by the central axis of the vibrating element and the ultrasonic propagation path within two orthogonal cross sections of the vibrating element. It is characterized by including a step of calculating the received sound pressure ratio by calculating the received sound pressure ratio based on the directivity angle and using the two calculated received sound pressure ratios.
- the determination step calculates an ultrasonic propagation path and an incident point satisfying Snell's law on one cross section of the vibrating element, and the cross section thereof. It is characterized by including a step of determining the delay time in the ultrasonic propagation path by calculating the position of the incident point and the ultrasonic propagation path satisfying Snell's law for the orthogonal planes.
- the determination step when the vibrating element is rectangular, the determination step utilizes the following equations (1), (2) and (3). It is characterized by including a step of calculating the received sound pressure ratios R1 and R2 using the directional angles ⁇ 1 and ⁇ 2 of the ultrasonic signals in two orthogonal cross sections.
- the parameter m in the following equation (3) is a coefficient determined by the directivity angles ⁇ 1 and ⁇ 2 and the width of the vibrating element.
- the ultrasonic flaw detector transmits an ultrasonic signal from the ultrasonic probe to the inspection material and is reflected inside the inspection material.
- An ultrasonic flaw detector that inspects the inside of the inspection material by receiving the sound sound signal as a defect signal in the ultrasonic probe, and changes the positional relationship between the inspection material and the ultrasonic probe. The sound received from the defect in each positional relationship between the inspection material and the vibrating element and the receiving means for receiving a plurality of defect signals in one or more vibrating elements provided in the ultrasonic probe.
- the steel material manufacturing equipment row according to the present invention inspects the manufacturing equipment for manufacturing the steel material and the inside of the steel material manufactured by the manufacturing equipment. It is characterized by comprising an ultrasonic flaw detector according to the above.
- the method for manufacturing a steel material according to the present invention is a steel material manufactured in the manufacturing step according to the manufacturing step for manufacturing the steel material and the ultrasonic flaw detection method according to the present invention. It is characterized by including a flaw detection step for detecting the inside of the.
- the quality assurance method for the steel material according to the present invention is obtained by a flaw detection step for detecting the inside of the steel material by the ultrasonic flaw detection method according to the present invention and the flaw detection step. It is characterized by including a quality assurance step of performing quality assurance of the steel material from the flaw detection results obtained.
- the entire range inside the inspection material is formed by aperture synthesis of signals received by one or more vibrating elements provided in the ultrasonic probe. It is possible to perform ultrasonic flaw detection with high detectability and resolution at high speed. Further, according to the steel material manufacturing equipment row and the steel material manufacturing method according to the present invention, the steel material can be manufactured with a high yield. Further, according to the steel material quality assurance method according to the present invention, it is possible to provide a high quality steel material.
- FIG. 1 is a schematic view showing the configuration of an ultrasonic flaw detector according to an embodiment of the present invention.
- FIG. 2 is a flowchart showing a flow of determining the aperture synthesis processing conditions according to the embodiment of the present invention.
- FIG. 3 is a schematic diagram for explaining an outline of the propagation path calculation process according to the embodiment of the present invention.
- FIG. 4 is a schematic diagram for explaining a configuration of an array probe for propagation path calculation processing according to an embodiment of the present invention.
- FIG. 5 is a schematic diagram for explaining the propagation path calculation process and the delay time calculation process in the circular bar body circumferential cross section according to the embodiment of the present invention.
- FIG. 1 is a schematic view showing the configuration of an ultrasonic flaw detector according to an embodiment of the present invention.
- FIG. 2 is a flowchart showing a flow of determining the aperture synthesis processing conditions according to the embodiment of the present invention.
- FIG. 3 is a schematic diagram for explaining an outline of the propagation path calculation process according to
- FIG. 6 is a schematic diagram for explaining a propagation path calculation process and a delay time calculation process in a round bar axial cross section according to an embodiment of the present invention.
- FIG. 7 is a schematic diagram for explaining the received sound pressure ratio calculation process and the optimum composite width calculation process in the circular bar body circumferential cross section according to the embodiment of the present invention.
- FIG. 8 is a schematic diagram for explaining a received sound pressure ratio calculation process and an optimum composite width calculation process in a round bar axial cross section according to an embodiment of the present invention.
- FIG. 9 is a diagram showing the result of simulating the relationship between the number of composite waveforms and the S / N ratio change rate when the signal processing according to the present invention is performed.
- FIG. 10 is a diagram showing the result of simulating the relationship between the number of composite waveforms and the S / N ratio change rate when signal processing is performed by the conventional method.
- the ultrasonic flaw detection device 1 ultrasonically detects a round bar RB manufactured by rolling a cast steel piece by an ultrasonic flaw detection method using a water immersion flaw detection method (hereinafter referred to as a water immersion method). It is a device.
- the ultrasonic flaw detector 1 includes an array probe 11 having a plurality of vibrating elements 111, a probe head 12, a gantry 13, a rotation drive device 14, a pulsar 15, a receiver 16, an A / D converter 17, a recording device 18, and a signal.
- the processing device 19 and the display device 20 are provided as main components.
- the ultrasonic flaw detector 1 transmits a plurality of defect signals to each of the plurality of vibrating elements 111 provided in the array probe 11 while changing the positional relationship between the inspection material and the array probe 11.
- a receiving means for receiving is provided.
- the receiver 16, the A / D converter 17, and the recording device 18 correspond to the receiving means.
- the ultrasonic flaw detector 1 has each vibration with respect to the received sound pressure at the vibrating element position where the received sound pressure from the defect is maximized in each positional relationship between the inspection material and the array probe 11.
- a determination means is provided for calculating the ratio of the received sound pressure at the element position as the received sound pressure ratio and determining the composite waveform group in the aperture synthesis process at each vibrating element position of the inspection material based on the calculated received sound pressure ratio. ..
- the ultrasonic flaw detector 1 according to the present invention provides a delay time and a composite waveform group determined by the determining means with respect to the received waveforms in each of the plurality of vibrating elements 111 obtained by the plurality of transmissions and receptions. It is provided with an inspection means for inspecting the inside of the inspection material by performing an aperture synthesis process.
- the signal processing device 19 corresponds to the determination means and the inspection means.
- the array probe 11 is arranged at a predetermined distance from the round bar RB via water, which is a medium in the water immersion method, and during ultrasonic flaw detection, the array probe 11 is detected by a pulse signal output from the pulsar 15.
- a pulse signal output from the pulsar 15 By exciting each vibrating element 111 of the tentacle 11, an ultrasonic signal is transmitted to the round bar RB. Then, the ultrasonic signal (hereinafter referred to as a defect signal) propagated and reflected inside the round bar RB is received by the receiver 16 via the array probe 11.
- each vibrating element 111 provided in the array probe 11 is excited at the same time, and a plane wave is incident on the round bar RB.
- the excitation method of the array probe 11 in the present invention is not limited to simultaneous excitation, and the direction and focal length of ultrasonic waves may be changed and transmitted by shifting the excitation timing of each vibrating element 111.
- the probe head 12 includes an array probe 11 and is scanned in the axial direction of the round bar RB by moving on a gantry 13 arranged on the upper portion of the round bar RB.
- the probe head 12 is scanned while the round bar RB is rotated in the circumferential direction indicated by the arrow by the rotation driving device 14, and the defect signal is received by the receiver 16 to ultrasonically detect the entire volume of the round bar RB. be able to.
- the rotation speed of the rotation drive device 14 and the scanning speed of the probe head 12 are set so that the total volume of the round bar RB is not insufficient and ultrasonic flaw detection is performed.
- the analog defect signal received by the receiver 16 is converted into digital data by the A / D converter 17 while synchronizing with the pulse signal output from the pulsar 15, and stored in the recording device 18.
- the defect signal of the total product of the round bar RB is stored in the recording device 18.
- the stored defect signal is signal-processed by the signal processing device 19, and the signal processing result is displayed on the display device 20.
- the signal processing may be performed on the defective signal stored during ultrasonic flaw detection at any time, or may be performed after all the defective signals have been stored.
- the signal processing device 19 executes the determination of the aperture synthesis processing condition as one of the signal processing. In determining the aperture synthesis processing conditions, the signal processing device 19 determines the central axis of the vibrating element 111 and the ultrasonic propagation path within two orthogonal cross sections of each of the plurality of vibrating elements 111 provided in the array probe 11. The received sound pressure ratio of the defective signal is calculated based on the directional angle, which is the angle between the two, and the received sound pressure ratio is calculated by using the two calculated received sound pressure ratios. Then, the signal processing device 19 determines the optimum composite waveform group for each ultrasonic flaw detection range based on the calculated received sound pressure ratio. Further, the signal processing device 19 executes an aperture synthesis process as one of the signal processes. The signal processing device 19 performs aperture synthesis processing using a plurality of defect signals according to the determined composite waveform group. As a result, the inside of the round bar RB is inspected to detect internal defects, and the inside of the round bar RB is detected.
- the aperture synthesis process performed by a normal array probe is performed on the signal obtained by one transmission / reception.
- the optimum composite waveform group is set for each flaw detection range for the received waveform received by the array probe 11 while changing the position with respect to the inspection material, and the aperture synthesis process is performed.
- the aperture synthesis process can be performed with a wider aperture area, so that the focusing effect of the ultrasonic beam can be enhanced and the detectability can be improved.
- the ultrasonic flaw detection method according to the present embodiment includes three steps: (I) reception step, (II) determination step, and (III) inspection step. Further, each step is executed in the order of (I) reception step, then (II) determination step, (II) determination step, and (III) inspection step.
- each of the plurality of vibrating elements 111 provided in the array probe 11 receives a plurality of defect signals.
- a known method of receiving a defect signal by an ultrasonic probe can be used.
- the reception step can be realized by the operation of the receiver 16, the A / D converter 17, and the recording device 18 described above.
- the ratio of the received sound pressure in the above is calculated as the received sound pressure ratio, and based on the calculated received sound pressure ratio, the composite waveform group in the opening synthesis processing at each depth position of the inspection material is determined. Calculation of the composite waveform group at each depth position of the inspection material is the most important technique in the present invention. Therefore, the calculation method of the composite waveform group will be described in detail later.
- the delay time used for the aperture synthesis process is also calculated. Further, it is desirable that the synthesis width and the delay time are calculated for each defect depth by the determination step from the viewpoint of improving the detectability.
- a known method can be used for the calculation of the delay time as the aperture synthesis process. In the present embodiment, an example in which the propagation path of the transmitted ultrasonic signal in the inspection body is calculated and the delay time is determined based on the calculated propagation path will be described later.
- the S / N ratio change rate of the defective signal is calculated by adding and averaging the received sound pressure ratios at each vibrating element position, and the composite waveform so that the S / N ratio change rate becomes a predetermined value or more. It is preferable to determine the group as a defect signal waveform used in the aperture synthesis process.
- the aperture synthesis process is executed for the received waveforms in each of the plurality of vibrating elements 111 obtained by transmitting and receiving a plurality of times in the receiving step, using the delay time and the composite waveform group determined in the determination step.
- the inside of the inspection material is inspected based on the result of the aperture synthesis treatment.
- a known method can be used for the aperture synthesis treatment performed in the inspection step. In the present embodiment, an example in which a plurality of waveforms included in the composite waveform group determined by the determination step are added together over a delay time also determined by the determination step will be described later.
- the inside of the inspection material can be inspected and the inside of the inspection material can be known for flaw detection.
- the state inside the inspection material that can detect a flaw the presence / absence of a defect, the position of the defect, the size of the defect, etc. can be mentioned from the strength of the reflected signal from the defect, the reception time, and the like.
- the output method of the result of the obtained aperture synthesis process may be appropriately determined depending on the purpose of use of the result, etc., but is output in the form of a waveform or an image with respect to the position (width direction, rolling direction, depth, thickness, etc.). It is desirable because it has high visibility.
- the noise ratio (S / N ratio) to the defect signal is improved, so that the detectability can be improved.
- the operation of the signal processing device 19 when determining the aperture synthesis processing conditions, that is, the composite waveform group and the delay time in the determination step will be described.
- an example of a method of calculating the propagation path of the ultrasonic signal used for determining the delay time in the determination step will be described.
- the propagation path is a propagation path of the ultrasonic signal in the inspection body. If necessary, it may be a propagation path of the ultrasonic signal in the examination body and the medium.
- an example of a method for calculating the received sound pressure ratio used for determining the composite waveform group will also be described below.
- FIG. 2 is a flowchart showing the flow of determining the aperture synthesis processing conditions according to the embodiment of the present invention.
- the determination of the aperture synthesis processing condition is not only performed before ultrasonic flaw detection, but also ultrasonic flaw detection is started based on the value obtained during ultrasonic flaw detection such as the thickness measurement of the round bar RB by the ultrasonic signal. It may be done later.
- Aperture synthesis processing conditions are determined by the flaw detection condition input step (S1), the propagation path calculation step (S2), the delay time calculation step (S3), the received sound pressure ratio calculation step (S4), and the optimum synthesis width calculation step (S5). It is executed in the order of. In the following, each step when the round bar RB is used as an inspection body will be described in detail.
- the signal processing device 19 determines the dimensions of the round bar RB, the dimensions and arrangement intervals of the vibrating elements 111 provided in the array probe 11, the measurement pitch, and the positional relationship with the round bar RB.
- Acquire ultrasonic flaw detection conditions such as ultrasonic flaw detection range.
- the ultrasonic flaw detection condition may be acquired not only before the ultrasonic flaw detection but also during the ultrasonic flaw detection or after the ultrasonic flaw detection.
- the process of step S1 is completed, and the determination of the aperture synthesis processing conditions proceeds to the process of step S2.
- step S2 the signal processing device 19 uses the ultrasonic flaw detection conditions acquired in the process of step S1 to transfer each vibrating element 111 provided in the array probe 11 to the round bar RB according to Snell's law.
- the propagation path of the ultrasonic signal that is incident and passes through the assumed defect position is calculated (propagation path calculation process). The details of this propagation path calculation process will be described later.
- the process of step S2 is completed, and the determination of the aperture synthesis processing conditions proceeds to the process of step S3.
- step S3 the signal processing device 19 calculates the delay time at each reception position of the other plurality of defective signals with respect to the reference defective signal (delay time calculation process). The details of this delay time calculation process will be described later. As a result, the process of step S3 is completed, and the determination of the aperture synthesis processing conditions proceeds to the process of step S4.
- step S4 the signal processing device 19 calculates the received sound pressure ratio of the defective signal in the positional relationship between the round bar RB and each vibrating element 111 provided in the array probe 11 (received sound pressure ratio calculation). processing). The details of this received sound pressure ratio calculation process will be described later. As a result, the process of step S4 is completed, and the determination of the aperture synthesis processing conditions proceeds to the process of step S5.
- step S5 the signal processing device 19 determines the optimum composite waveform group in the aperture synthesis process at each depth position of the round bar RB based on the received sound pressure ratio calculated in the process of step S4. .. As a result, the process of step S5 is completed, and the determination of a series of aperture synthesis processing conditions is completed.
- the assumed defect position is determined by incident on the round bar RB from each vibrating element 111 of the array probe 11 while satisfying Snell's law.
- the delay time is determined by calculating the propagation path of the passing ultrasonic signal. That is, for each vibrating element 111 provided in the array probe 11, an ultrasonic propagation path and an incident point satisfying Snell's law are calculated on one cross section, and the position of the incident point and the position of the incident point and the plane orthogonal to the cross section are calculated.
- the delay time in the ultrasonic propagation path is determined by calculating the ultrasonic propagation path that satisfies Snell's law.
- FIG. 3 is a schematic diagram for explaining one aspect of the propagation path calculation process according to the embodiment of the present invention.
- FIG. 4 is an enlarged schematic view of the array probe 11.
- the delay in the reception time of the defect signal Sg2 from P d ) is defined as the delay time ⁇ T.
- the circumferential movement speed of the round bar RB is V1
- the axial movement speed of the array probe 11 is V2.
- the water distance portion is defined as w and the steel middle portion is defined as d (see FIG. 5).
- the water distance portion is Lw and the steel middle portion is Ls.
- the propagation path takes into consideration the refraction phenomenon according to Snell's law on the curved surface.
- FIG. 5 shows a schematic diagram showing a change in the propagation path of the round bar RB in the circumferential cross section
- FIG. 6 shows a schematic diagram showing the change in the propagation path in the axial cross section of the round bar RB.
- the rotational movement angle ⁇ between the vibrating element 111 at position P 03 and the vibrating element 111 at position P T5 is expressed by the following equation (5).
- the underwater portion of the ultrasonic propagation path from the vibrating element 111 at the position P T5 in the circumferential cross section of the round bar RB toward the defect D (position P d ) is Lw1
- the middle portion of the steel is Ls1.
- the ultrasonic propagation path follows Snell's law, so that the incident angle ⁇ w1 and the refraction angle ⁇ s1 satisfy the following equation (6).
- the incident point X1 existing on the circumference of the round bar under the condition of the formula (6) is determined by the focusing calculation.
- the height of the incident point X1 at this time from the bottom of the round bar RB is defined as P ⁇ .
- the amount of axial movement L between the vibrating element 111 at position P 03 and the vibrating element 111 at position P T5 is represented by the following equation (7).
- the underwater portion of the ultrasonic propagation path from the vibrating element 111 at the position P T5 in the axial cross section of the round bar RB to the defect D (position P d ) is Lw2
- the middle part of the steel is Ls2
- the incident point is Let it be X2.
- the height of the incident point X2 from the bottom of the round bar RB corresponds to the height P ⁇ of the incident point X1 from the bottom of the round bar RB determined by the circumferential cross section of the round bar RB.
- the incident angle ⁇ w2 and the refraction angle ⁇ s2 satisfy the following equation (8).
- the incident point X2 existing on the line segment AB under the condition of the equation (8) is determined by the focusing calculation.
- the propagation path lengths Lw and Ls shown in FIG. 3 are the following equations (9) and Ls, respectively. It is represented by (10).
- the delay time ⁇ T1 caused by the propagation path at the time of transmission is expressed by the following equation (11)
- the delay time ⁇ T2 caused by the propagation path at the time of reception is expressed by the following equation (12)
- ⁇ T is expressed by the following equation (13). Will be done.
- the defect signal can be detected with a high S / N ratio.
- the intensity of the defect signal in each vibrating element 111 of the array probe 11 changes according to the positional relationship between the vibrating element 111 and the internal defect. Specifically, in a long-distance sound field, when a defect exists on the central axis of the vibrating element 111, the intensity of the defect signal becomes the strongest, and the ultrasonic waves passing through the central axis of the vibrating element 111 and the internal defect The intensity of the defective signal decreases as the angle formed by the propagation path increases. In order to obtain a defect signal with a high S / N ratio by the aperture synthesis process, it is necessary to add a plurality of defect signals within the range where the defect signal has sufficient intensity, and when the defect signals with low intensity are added together. The effect of improving the S / N ratio is small.
- the ultrasonic signal output from the vibrating element 111 propagates while diffusing, the sound pressure distribution is formed to expand as the distance increases. At this time, if a defect exists in the sound pressure distribution, a defect signal having sufficient strength can be obtained. That is, the combined width (the number of defective signals to be added) with sufficient intensity changes depending on the sound pressure distribution of the ultrasonic signal and the moving position of the defect in the sound pressure distribution. Therefore, in order to obtain a defect signal having a high S / N ratio by the aperture synthesis process, it is necessary to appropriately set the composite waveform group based on the position of the internal defect and the flaw detection condition. Therefore, in the present embodiment, an appropriate composite waveform group is calculated for each depth position of the internal defect based on the received sound pressure ratio of the defect signal.
- the directivity angles ⁇ 1 and ⁇ 2 of the ultrasonic signal in two orthogonal cross sections that is, the directivity angles in the rotation direction at each position of the vibrating element 111.
- ⁇ 1 and the axial directivity angle ⁇ 2 the directivity angles in the rotation direction at each position of the vibrating element 111.
- FIG. 7 is a schematic view showing a circumferential directivity angle at each position of the vibrating element 111.
- ⁇ T is expressed by the following equation (14).
- the rotation angle ⁇ and the rotation angle ⁇ are represented by the following equations (15) and (16), respectively.
- the received sound pressure ratio R ⁇ mN uses the directivity angle ⁇ 1 and has the following equations (17), (18) and (19). Can be represented by.
- the parameter m in the equation (18) is a coefficient determined by the directivity angles ⁇ 1, ⁇ 2 and the probe width of the array probe 11.
- the received sound pressure ratio R may be determined by using the result of an experiment or a physical analysis using the finite element method or the like. ..
- the received sound pressure ratio R may be obtained by multiplying the above equation (14) by the reflection directivity function of the defect.
- the composite width is calculated using the received sound pressure ratio R calculated by the above procedure.
- the formula (17) is the same as the formula (1), in which "R1" in the above formula (1) is replaced with "R ⁇ mN ".
- FIG. 8 is a schematic view showing an axial directivity angle at each position of the vibrating element 111. Similar to FIG. 7, the vibrating element 111 at the reference time to the position (reference vibration element) and P 11, the position of the N-th resonator element 111 as P 12 from the reference time from the reference vibration element when the elapsed sampling time ⁇ T Let P 13 be the position of the Nth vibrating element 111 from the reference vibrating element when m ⁇ T has elapsed from the reference time.
- the axial movement amount L1 and the axial movement amount L are represented by the following equations (20) and (21), respectively.
- the received sound pressure ratio RLmN uses the directivity angle ⁇ 2 and has the following equations (18), (19) and (22). Can be represented by.
- the received sound pressure ratio R may be determined by using the result of an experiment or a physical analysis using the finite element method or the like. ..
- the received sound pressure ratio R may be obtained by multiplying the above equation (14) by the reflection directivity function of the defect.
- the composite width is calculated using the received sound pressure ratio R calculated by the above procedure.
- the formula (22) is the same as the formula (2), in which "R2" in the above formula (2) is replaced with " RLmN ".
- the position of each vibrating element 111 and the received sound pressure ratio at each time are calculated, and the array arranged in descending order is RA (x).
- the received sound pressure ratio S after aperture synthesis when the elements 1 to X of RA are added is expressed by the following equation (24).
- the S / N ratio improvement coefficient E after aperture synthesis with respect to the aperture synthesis S / N at the reference assumed defect position F is calculated by the following equation (25). expressed.
- the S / N of the defect signal can be maximized by setting the composite width N max at which E is maximized by the above equation (24) and performing aperture synthesis. Further, the S / N of the defect signal can be sufficiently improved by determining the N max satisfying the above-mentioned equation (25) and performing the aperture synthesis process.
- each vibrating element 111 of the array probe 11 is simultaneously excited, it is assumed that the transmitted wave is a plane wave, and only the reception directivity of the vibrating element 111 is considered.
- the ultrasonic flaw detection method and the ultrasonic flaw detector 1 according to the present invention not only when the transmitted wave is a plane wave as described above, but also the excitation timing of the vibrating element 111 is controlled to control a specific directivity and focal length. It is also possible to use a transmitted wave having a distance. In this case, it is desirable to calculate the received sound pressure ratio in consideration of the directivity and distance characteristics of the transmitted wave.
- signals received by one or more vibrating elements 111 provided in the array probe 11 are aperture-synthesized by aperture synthesis.
- Ultrasonic flaw detection with high detectability and resolution can be performed at high speed in the entire range inside the inspection material.
- an ultrasonic probe having one or more vibrating elements can be used.
- the present invention is similarly effective when one ultrasonic probe having one vibrating element is used, or when a plurality of ultrasonic probes having one vibrating element are used.
- the type of ultrasonic probe to be used may be appropriately selected in consideration of the performance, dimensions, inspection material condition, flaw detection environment condition (space availability, etc.) of the ultrasonic probe. ..
- Example 2 The excellent results of the ultrasonic flaw detection method according to the present invention will be described in Examples.
- the focusing effect of the ultrasonic beam when the method described in Patent Document 1, the method described in Patent Document 2, and the method of the present invention is used is improved by the S / N ratio change rate, that is, the aperture synthesis treatment.
- the comparison was made according to the S / N ratio.
- FIG. 9 is a diagram showing an example of a change in the relationship between the number of composite waveforms and the S / N ratio change rate of the defective signal due to the difference in the composite width.
- a defect located at an internal depth of 170 mm of a round bar steel having a diameter of ⁇ 175 mm has a frequency of 5 MHz, a width of a vibrating element in the circumferential direction: 12 mm, and a width of a vibrating element in the axial direction: 1. 8 mm, vibrating element spacing: 0.2 mm, number of vibrating elements: 61, repetition frequency: 1 kHz, round bar rotation speed: 1100 mm / s, axial scanning speed: 240 mm / s.
- FIG. 10 shows a defect located at an internal depth of 170 mm of a round bar steel having a diameter of ⁇ 175 mm, with a frequency of 5 MHz, a circumferential vibrating element width of 1.8 mm, an axial vibrating element width of 12 mm, and a vibrating element.
- Interval 0.2 mm
- number of vibrating elements 121
- flaw detection with an array probe and synthesis when the received waveform obtained by each vibrating element of the array probe is aperture-combined only in the circumferential direction. This is the result of calculating the relationship between the number of waveforms and the rate of change of the defect signal S / N ratio.
- the vibrating elements of the array probe are arranged side by side in the circumferential direction, which is the result of simulating the method described in Patent Document 2.
- the maximum S / N ratio change rate: 17.4 dB is obtained with the number of composite waveforms: 97 waveforms
- the maximum S / N ratio is obtained with the composite waveform: 1512 waveforms.
- a ratio change rate of 28.3 dB can be obtained.
- the ultrasonic beam can be focused not only in the circumferential direction of the round bar but also in the axial direction of the round bar, the sensitivity is improved by 10 dB or more as compared with the conventional method, and its effectiveness is confirmed. did it. Furthermore, it was also confirmed that the S / N ratio change rate can be maximized by appropriately selecting the synthetic waveform group according to the present invention.
- the present invention may be applied as an inspection device constituting a row of steel material manufacturing equipment, and the inside of the steel material manufactured by the manufacturing device may be inspected and flaw detected by the ultrasonic flaw detector according to the present invention.
- the present invention may be applied as an inspection step included in a method for manufacturing a steel material, and the inside of the steel material manufactured in the manufacturing step may be inspected and flawed.
- the flaw detection step defects inside the steel material are detected based on the results of the aperture synthesis treatment in the inspection step, and results regarding the presence / absence of defects, defect positions, defect sizes, etc. are obtained. According to such a steel material manufacturing facility line and a steel material manufacturing method, the steel material can be manufactured with a high yield.
- the present invention may be applied to a method for quality assurance of a steel material, and the quality of the steel material may be guaranteed by inspecting and detecting the inside of the steel material.
- the inside of the steel material can be detected by the flaw detection step, and the quality of the steel material can be guaranteed from the flaw detection result obtained in the flaw detection step.
- the flaw detection step defects inside the steel material are detected based on the results of the aperture synthesis treatment in the inspection step, and results regarding the presence / absence of defects, defect positions, defect sizes, etc. are obtained.
- the subsequent quality assurance step based on the results related to the presence or absence of defects, the position of defects, and the size of defects obtained by the flaw detection step, it is determined whether or not the manufactured steel material meets the predetermined criteria, and the quality of the steel material is determined. Guarantee. According to such a quality assurance method for steel materials, high quality steel materials can be provided. As described above, other embodiments, examples, operational techniques, and the like made by those skilled in the art based on the present embodiment are all included in the scope of the present invention.
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Abstract
Description
本発明の実施形態である超音波探傷装置の構成について、図1を参照して説明する。超音波探傷装置1は、水浸探傷法(以下、水浸法と表記)を利用した超音波探傷方法によって、鋳造された鋼片を圧延して製造された丸棒体RBを超音波探傷する装置である。この超音波探傷装置1は、複数の振動素子111を有するアレイ探触子11、プローブヘッド12、架台13、回転駆動装置14、パルサ15、レシーバ16、A/Dコンバータ17、記録装置18、信号処理装置19、及び表示装置20を主な構成要素として備えている。
次に、本実施形態に係る超音波探傷方法について説明する。本実施形態に係る超音波探傷方法は、(I)受信ステップ、(II)決定ステップ、及び(III)検査ステップの3つのステップを含む。また、各ステップは、(I)受信ステップの次に(II)決定ステップ、(II)決定ステップの次に(III)検査ステップの順に実行される。
図2を参照して、決定ステップにおいて開口合成処理条件、即ち、合成波形群及び遅延時間を決定する際の信号処理装置19の動作について説明する。加えて、決定ステップにおいて、遅延時間の決定に用いる、超音波信号の伝搬経路を算出する方法の例について説明する。ここで、伝搬経路とは、検査体中における超音波信号の伝搬経路である。必要に応じて、検査体中と媒質中とにおける超音波信号の伝搬経路としてもよい。また、以下では、合成波形群の決定に用いる受信音圧比を算出する方法の例についても説明する。
次に、図3から図6を参照して、ステップS2の伝搬経路算出処理及びステップS3の遅延時間算出処理について詳しく説明する。
次に、図7及び図8を参照して、図2に示すステップS4の受信音圧比算出処理及びステップS5の最適合成幅算出処理について詳しく説明する。
本発明に係る超音波探傷方法の優れた結果を実施例で説明する。本実施例では、特許文献1に記載の手法、特許文献2に記載の手法及び本発明手法を用いた場合の超音波ビームの集束効果を、S/N比変化率、つまり開口合成処理によって改善されるS/N比によって比較した。
11 アレイ探触子
111 振動素子
12 プローブヘッド
13 架台
14 回転駆動装置
15 パルサ
16 レシーバ
17 A/Dコンバータ
18 記録装置
19 信号処理装置
20 表示装置
RB 丸棒体
Claims (9)
- 超音波探触子から検査材に超音波信号を送信し、前記検査材の内部で反射された超音波信号を欠陥信号として前記超音波探触子において受信することによって、前記検査材の内部を検査する超音波探傷方法であって、
前記検査材と前記超音波探触子との位置関係を変化させながら、前記超音波探触子に備えられた一つ以上の振動素子において複数の欠陥信号を受信する受信ステップと、
前記検査材と前記振動素子との各位置関係において、欠陥からの受信音圧が最大となる振動素子位置での受信音圧に対する、各振動素子位置での受信音圧の比を受信音圧比として算出し、算出された前記受信音圧比に基づいて、前記検査材の各振動素子位置での開口合成処理における合成波形群を決定する決定ステップと、
複数回の送受信によって得られた前記振動素子における受信波形に対して、前記決定ステップで決定した合成波形群と、前記複数の欠陥信号の遅延時間とを用いて、開口合成処理を実行することによって前記検査材の内部を検査する検査ステップと、
を含むことを特徴とする超音波探傷方法。 - 前記決定ステップは、各振動素子位置における前記受信音圧比を加算平均することによって欠陥信号のS/N比変化率を算出し、前記S/N比変化率が所定値以上となるような合成波形群を、開口合成処理に用いる欠陥信号波形として決定するステップを含むことを特徴とする請求項1に記載の超音波探傷方法。
- 前記決定ステップは、前記振動素子について、二つの直交する断面内で前記振動素子の中心軸と超音波伝搬経路とのなす角である指向角に基づき前記受信音圧比を算出し、算出された二つの前記受信音圧比を用いることにより、受信音圧比を算出するステップを含むことを特徴とする請求項1または請求項2に記載の超音波探傷方法。
- 前記決定ステップは、前記振動素子について、一つの断面上でスネルの法則を満たす超音波伝搬経路及び入射点を算出し、前記断面に直交する面について前記入射点の位置及びスネルの法則を満たす超音波伝搬経路を算出することにより、超音波伝搬経路における前記遅延時間を決定するステップを含むことを特徴とする請求項1から請求項3のいずれか一項に記載の超音波探傷方法。
- 超音波探触子から検査材に超音波信号を送信し、前記検査材の内部で反射された超音波信号を欠陥信号として前記超音波探触子において受信することによって、前記検査材の内部を検査する超音波探傷装置であって、
前記検査材と前記超音波探触子との位置関係を変化させながら、前記超音波探触子に備えられた一つ以上の振動素子において複数の欠陥信号を受信する受信手段と、
前記検査材と前記振動素子との各位置関係において、欠陥からの受信音圧が最大となる振動素子位置での受信音圧に対する、各振動素子位置での受信音圧の比を受信音圧比として算出し、算出された前記受信音圧比に基づいて、前記検査材の各振動素子位置での開口合成処理における合成波形群を決定する決定手段と、
複数回の送受信によって得られた前記振動素子における受信波形に対して、前記決定手段で決定された合成波形群と、前記複数の欠陥信号の遅延時間とを用いて、開口合成処理を実行することによって前記検査材の内部を検査する検査手段と、
を備えることを特徴とする超音波探傷装置。 - 鋼材を製造する製造装置と、
前記製造装置によって製造された前記鋼材の内部を検査する請求項6に記載の超音波探傷装置と、
を備えることを特徴とする鋼材の製造設備列。 - 鋼材を製造する製造ステップと、
請求項1から請求項5のいずれか一項に記載の超音波探傷方法によって、前記製造ステップにおいて製造された鋼材の内部を探傷する探傷ステップと、
を含むことを特徴とする鋼材の製造方法。 - 請求項1から請求項5のいずれか一項に記載の超音波探傷方法によって、鋼材の内部を探傷する探傷ステップと、
前記探傷ステップによって得られた探傷結果から前記鋼材の品質保証を行う品質保証ステップと、
を含むことを特徴とする鋼材の品質保証方法。
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CN201980097177.9A CN113994204B (zh) | 2019-06-13 | 2019-06-13 | 超声波探伤方法、超声波探伤装置、以及钢材的制造方法 |
KR1020217039767A KR20220004195A (ko) | 2019-06-13 | 2019-06-13 | 초음파 탐상 방법, 초음파 탐상 장치, 강재의 제조 설비열, 강재의 제조 방법, 및 강재의 품질 보증 방법 |
EP19932974.9A EP3985388A4 (en) | 2019-06-13 | 2019-06-13 | ULTRASONIC DEFECT DETECTION METHOD, ULTRASONIC DEFECT DETECTION DEVICE, STEEL MATERIAL MANUFACTURING EQUIPMENT LINE, STEEL MATERIAL MANUFACTURING METHOD AND STEEL MATERIAL QUALITY ASSURANCE METHOD |
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CN113607813A (zh) * | 2021-07-30 | 2021-11-05 | 南昌航空大学 | 激光焊t型焊缝缺陷的超声自动检测装置及其定量方法 |
CN113607813B (zh) * | 2021-07-30 | 2023-08-18 | 南昌航空大学 | 激光焊t型焊缝缺陷的超声自动检测装置及其定量方法 |
CN117147693A (zh) * | 2023-10-09 | 2023-12-01 | 西南交通大学 | 一种基于声弹性耦合的无砟道床与路基层间缺陷检测方法 |
CN117147693B (zh) * | 2023-10-09 | 2024-04-09 | 西南交通大学 | 一种基于声弹性耦合的无砟道床与路基层间缺陷检测方法 |
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CN113994204A (zh) | 2022-01-28 |
KR20220004195A (ko) | 2022-01-11 |
EP3985388A4 (en) | 2022-05-25 |
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