CN109100427B - Small-diameter tube base fillet weld phased array detection test block and use method thereof - Google Patents
Small-diameter tube base fillet weld phased array detection test block and use method thereof Download PDFInfo
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- CN109100427B CN109100427B CN201811033068.4A CN201811033068A CN109100427B CN 109100427 B CN109100427 B CN 109100427B CN 201811033068 A CN201811033068 A CN 201811033068A CN 109100427 B CN109100427 B CN 109100427B
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Abstract
The invention relates to an ultrasonic detection technology, in particular to a small-diameter tube base fillet weld phased array detection test block and a use method thereof. The test block comprises a coding debugging block, a left DAC verification block, a right DAC verification block, an angle gain correction block and a near field region defect comparison block; the left DAC verification block and the right DAC verification block are parts intercepted from the corner welding part of the tube seat of the small-diameter tube, the left DAC verification block and the right DAC verification block are symmetrically arranged, the upper ends of the left DAC verification block and the right DAC verification block are connected with the coding debugging block, the lower end of the left DAC verification block is welded with the right end of the angle gain correction block to obtain a left corner welding seam, and the lower end of the right DAC verification block is welded with the left end of the near field region defect comparison block to obtain a right corner welding seam; and a plurality of reflectors are arranged on the left DAC verification block, the right DAC verification block and the near field region defect comparison block.
Description
Technical Field
The invention relates to an ultrasonic detection technology, in particular to a small-diameter tube base fillet weld phased array detection test block and a use method thereof.
Background
The fillet weld of the tube seat has a complex structure and severe welding conditions, and the defects of air holes, slag inclusion, incomplete penetration, incomplete fusion, cracks and the like are easy to occur in the welding process; the stress is easy to be uneven in the operation process, and stress concentration is generated. Therefore, in the power station boiler inspection, the fillet weld of the tube seat is a common failure part and is also an important inspection and monitoring part.
The phased array detection technology adopts an electronic control mode and applies the electronic control mode to a plurality of wafers according to a specific focusing rule to realize deflection and focusing of sound beams and carry out real-time imaging on defects, thereby providing stronger detection capability than a single probe system for determining the shape, size and direction of the defects. Therefore, phased array ultrasonic detection is used as a leading edge detection technology and is more and more widely applied to the field of detection of the fillet weld of the tube seat. However, before phased array detection is performed, a test block is required to calibrate the performance of the instrument and the performance of the probe and the performance of the combined system, so that the test block is an important tool in phased array detection and directly influences the precision of a detection result.
At present, the angle gain correction is usually carried out by adopting an R50 or R100 semicircular test block; the sensitivity curve is manufactured by directly adopting a DL-1 or GS test block used by conventional ultrasonic waves, and a process verification test is usually carried out by adopting a self-made welding defect sample. The existing standard does not form a set of test block system special for the phased array, and some test blocks directly use conventional ultrasonic test blocks, so that the accuracy of the phased array detection result is directly influenced.
The prior art has the following defects:
(1) the existing domestic standard does not specify a test block specially used for determining the detection sensitivity of the small-diameter tube, the sensitivity is usually adjusted on a DL-1 or GS test block at present, direct waves are adopted to test transverse through holes with different depths to obtain a sensitivity curve, and primary reflected wave detection is mostly used in fillet weld detection, so that the detection is different from the echo characteristics of actual defects in fillet welds, and the detection is particularly obvious in thin-wall tube detection with the thickness of 4-8 mm.
(2) The phased array ultrasonic beam range is large, the sound field characteristics are complex, and the sound pressure characteristics of each point in the sound field range are different from theoretical values, so that process verification is needed before detection, and the sound beam coverage and sensitivity are confirmed to ensure that defects are not missed. The conventional simulation test block reflector is single in type, different in structural form from a real tube seat fillet weld and low in applicability.
(3) Before the phased array instrument is detected, angle gain correction is needed, and at present, an R50 semicircular standard test block is used for testing. The probe contact surface of the test block is a plane, a flat wedge needs to be replaced firstly, and then a corresponding curved wedge is replaced for detection after the calibration and adjustment are completed, so that the operation is complicated, and the modified instrument parameters can be adversely affected after the curved wedge is replaced.
(4) The phased array ultrasonic detection method and the conventional ultrasonic detection method have the same near field region, the sound pressure distribution of the near field region is uneven, when the region has defects, instruments often cannot accurately display the reflection energy characteristics of the defects, and the phased array ultrasonic detection method is particularly disadvantageous to the detection of the small-diameter thin-walled tube welded joint.
(5) Scanning frame encoder all need calibrate every day, and it gets certain length as the measuring basis to twine the volume with the tape on the pipeline during calibration, and is more troublesome during the operation to the tape produces easily to slide and leads to measuring inaccurate, influences the testing data.
(6) The angle gain correction, the sensitivity curve manufacturing and the process verification are all carried out on different test blocks, various test blocks are required to be prepared, and the field carrying is inconvenient.
Disclosure of Invention
In order to solve the problems, the invention provides the calibration test block specially used for the phased array detection of the fillet weld of the tube seat of the small-diameter tube, which has the advantages of reasonable structural design, complete functions and portability, solves the problem that the conventional test block has larger difference with the actual detection condition in the aspects of angle gain correction, sensitivity curve manufacture and process verification test, and improves the defect detection precision.
The technical scheme adopted by the invention is as follows:
a phased array detection test block for fillet weld of a tube seat of a small-diameter tube comprises a coding debugging block, a left DAC (digital-to-analog converter) verification block, a right DAC verification block, an angle gain correction block and a near field region defect comparison block; the left DAC verifying block and the right DAC verifying block are parts cut out from the corner welding part of the tube seat of the small-diameter tube,
the left DAC verification block and the right DAC verification block are symmetrically arranged, the upper ends of the left DAC verification block and the right DAC verification block are connected with the coding debugging block, the lower end of the left DAC verification block is welded with the right end of the angle gain correction block to obtain a left fillet weld, and the lower end of the right DAC verification block is welded with the left end of the near field region defect comparison block to obtain a right fillet weld;
and a plurality of reflectors are arranged on the left DAC verification block, the right DAC verification block and the near field region defect comparison block.
In the small-diameter pipe seat fillet weld phased array detection test block, the reflector on the left DAC verification block comprises a first transverse through hole, a first longitudinal through hole and a fourth rectangular groove with a rectangular section;
the first transverse through hole is formed in the upper portion of the left DAC verification block and transversely penetrates through the DAC verification block;
the first longitudinal through hole is formed in the right side of the left fillet weld, penetrates through the left fillet weld and is spatially vertical to the first transverse through hole;
the fourth rectangular groove is arranged along the outer circumferential direction of the left fillet weld.
In the small-diameter pipe seat fillet weld phased array detection test block, the reflector on the right DAC verification block comprises a first rectangular groove, a second rectangular groove, a third rectangular groove and a second longitudinal through hole;
the first rectangular groove, the second rectangular groove and the third rectangular groove are all arranged along the circumferential direction of the inner wall of the right DAC verification block and are arranged up and down;
and the second longitudinal through hole is arranged on the lower side of the right fillet weld, penetrates through the right fillet weld and is parallel to the first longitudinal through hole.
In the small-diameter pipe seat fillet weld phased array detection test block, the right side of the near field region defect comparison block is a comparison detection inclined plane, and the upper side of the near field region defect comparison block is a right detection surface;
the reflector on the contrast detection inclined plane comprises first to fourth contrast holes which are arranged at equal intervals, and the axes of the first to fourth contrast holes are parallel to each other and extend inwards perpendicular to the inclined plane.
In the small-diameter pipe base fillet weld phased array detection test block, the right detection surface is an arc surface, the curvature of the right detection surface is matched with that of the small-diameter pipe, and the included angle between the inclined surface and the plane where the detection surface is located is 55 degrees.
According to the small-diameter pipe base fillet weld phased array detection test block, the left side of the left DAC verification block is a correction detection surface, the upper surface of the left DAC verification block is a left detection surface, the correction detection surface is an arc surface and has a radius of 50mm, and the left detection surface is an arc surface and has a curvature matched with the small-diameter pipe.
In the small-diameter pipe base fillet weld phased array detection test block, the diameters of the first transverse through hole, the first longitudinal through hole and the second longitudinal through hole are all 2mm, the first longitudinal through hole is arranged at 1/3 of the vertical height of the right side of the left fillet weld, and the second longitudinal through hole is arranged at 1/3 of the transverse length of the lower side of the right fillet weld;
the diameters of the first to fourth comparison holes are all 2mm, and the vertical distances between the tail ends of the first to fourth comparison holes and the right detection surface are in an arithmetic progression gradually increasing.
Above-mentioned minor diameter pipe tube seat fillet weld phased array detects test block, the perpendicular distance between the terminal of a contrast hole and the right side detection face is 2mm, the perpendicular distance between the terminal of No. two contrast holes and the right side detection face is 4mm, the perpendicular distance between the terminal of No. three contrast holes and the right side detection face is 6mm, the perpendicular distance between the terminal of No. four contrast holes and the right side detection face is 8 mm.
The small-diameter pipe base fillet weld phased array detection test block is characterized in that scales are arranged on the outer wall of the coding test block;
the opening height of the fourth rectangular groove is 1mm, the depth is 2mm,
the opening height of the first rectangular groove is 1mm, the depth of the first rectangular groove is 1mm,
the opening height of the second rectangular groove is 1mm, the depth is 3mm,
the opening height of the third rectangular groove is 1mm, the depth of the third rectangular groove is 2mm, and the horizontal position of the third rectangular groove corresponds to the lower side edge of the right fillet weld.
The use method of the small-diameter pipe seat fillet weld phased array detection test block comprises the following steps:
1) and (3) calibrating and debugging an encoder: installing a scanning frame with an encoder on the small-diameter pipe section, rotating the scanning frame to enable the encoder to walk for a certain length according to the scale display of the encoding debugging block, and then adjusting the parameters of a detection instrument to enable the display value of the detection instrument to be consistent with the actual distance traveled by the encoder, so as to finish the calibration of the encoder;
2) making a DAC (sensitivity) curve: placing the probe on the left DAC verification block, aligning the front end of the probe with the first longitudinal through hole, moving the probe back and forth to find the highest wave position of the first longitudinal through hole of the reflector, and recording the position point information by a detection instrument; then, the probe is placed on the right DAC verification block, the front end of the probe is aligned to the second longitudinal through hole, the probe is moved back and forth to find the highest wave position of the second longitudinal through hole of the reflector, and a detection instrument records the position point information; then two points are connected to generate a sensitivity curve;
3) and (3) verifying the fillet weld process of the tube seat: placing the probe on the pipe wall of the left DAC verification block, enabling the front end of the probe to face downwards to a left fillet weld, and observing whether an echo image of the first longitudinal through hole and the fourth rectangular groove can be clearly displayed on a screen of a detection instrument; then transferring to the tube wall of the right DAC verification block, and observing whether a screen of a detection instrument can clearly display an echo diagram of the third rectangular groove and the second longitudinal through hole; if the weld seam is clearly displayed, the process of the fillet weld of the tube seat is qualified;
4) angle gain correction of the detection instrument: the phased array probe is placed on the left detection surface of the angle gain correction block, the front end of the probe is aligned with the correction detection surface, and then the probe is moved back and forth to perform gain correction on the sound beams at all required angles one by one so that the sound beams at all angles meet the detection requirements;
5) and (3) defect comparison of a near field region: placing a phased array probe on a right detection surface of a near field region defect comparison block, enabling the front end of the probe to face a comparison detection inclined plane, moving the probe back and forth to measure the reflection characteristics of first to fourth comparison holes, and storing data in a detection instrument; and comparing the reflection characteristics of the defects found in the near field region and the first to fourth comparison holes to calculate the actual buried depth of the defects.
The invention has the beneficial effects that:
1. the multifunctional electric heating water heater is reasonable in design, multifunctional and convenient to use. The phased array instrument can be calibrated only by the test block under the condition of ensuring the instrument equipment to be qualified; the applicability is strong, and the placing type and inserting type tube seat fillet weld are both suitable.
2. The invention improves the condition that the conventional test block has larger difference with the actual detection condition in the aspects of angle gain correction, sensitivity curve manufacturing and process verification test.
3. The invention is provided with a group of rectangular grooves with different depths, thereby greatly improving the measurement precision of the incomplete penetration defect.
4. The invention provides a reflector arrangement form for near field region air hole defect comparison, and the defect detection precision of the region is improved.
5. The invention optimizes the semicircular test block, changes the detection surface into the arc surface, saves the process of frequently replacing the wedge block and improves the angle gain correction precision.
6. According to the invention, the graduated scale is processed at the end part of the test block, so that the process of binding and measuring a flexible rule is omitted, and the calibration precision of the encoder is improved.
Drawings
FIG. 1 is a perspective view of an embodiment of the present invention;
FIG. 2 is a perspective view of another embodiment of the present invention;
FIG. 3 is a schematic front view of an embodiment of the present invention;
FIG. 4 is a partial schematic view of an embodiment of the present invention;
FIG. 5 is a left side view of an embodiment of the present invention;
FIG. 6 is a schematic right-view of an embodiment of the present invention;
FIG. 7 is a schematic top view of an embodiment of the present invention.
In the figure: 1 is a coding debugging block, 2 is a left DAC verifying block, 3 is a right DAC verifying block, 4 is an angle gain correcting block, 5 is a near field region defect comparing block,
21 is a transverse through hole, 22 is a longitudinal through hole, 23 is a rectangular groove, 31 is a rectangular groove, 32 is a rectangular groove, 33 is a rectangular groove, 34 is a longitudinal through hole, 41 is a correction detection surface, 42 is a left detection surface, 51 is a comparison hole, 52 is a comparison hole, 53 is a comparison hole, 54 is a comparison hole and 55 is a right detection surface.
Detailed Description
The invention is further explained below with reference to the drawings.
A phased array detection test block for fillet weld of a tube seat of a small-diameter tube comprises a coding debugging block 1, a left DAC (digital-to-analog converter) verification block 2, a right DAC verification block 3, an angle gain correction block 4 and a near field region defect comparison block 5; the left DAC verification block 2 and the right DAC verification block 3 are parts cut at the corner welding part of the tube seat of the small-diameter tube, and the height of the coding debugging block 1 is 50mm in the embodiment;
the heights of the left DAC verification block 2 and the right DAC verification block 3 are 80mm, the left DAC verification block 2 and the right DAC verification block 3 are symmetrically arranged, the upper ends of the left DAC verification block 2 and the right DAC verification block 3 are connected with the coding debugging block 1, the lower end of the left DAC verification block 2 is welded with the right end of the angle gain correction block 4 to obtain a left fillet weld, and the lower end of the right DAC verification block 3 is welded with the left end of the near field region defect comparison block 5 to obtain a right fillet weld;
and a plurality of reflectors are arranged on the left DAC verification block 2, the right DAC verification block 3 and the near field region defect comparison block 5.
In the small-diameter pipe seat fillet weld phased array detection test block, the reflector on the left DAC verification block 2 comprises a first transverse through hole 21, a first longitudinal through hole 22 and a fourth rectangular groove 23 with a rectangular section;
the first transverse through hole 21 is formed in the upper portion of the left DAC verification block 2 and transversely penetrates through the DAC verification block 2;
the first longitudinal through hole 22 is formed in the right side of the left fillet weld, penetrates through the left fillet weld and is spatially vertical to the first transverse through hole 21;
the fourth rectangular groove 23 is provided along the outer circumferential direction of the left fillet weld.
In the small-diameter pipe seat fillet weld phased array detection test block, the reflector on the right DAC verification block 3 comprises a first rectangular groove 31, a second rectangular groove 32, a third rectangular groove 33 and a second longitudinal through hole 34;
the first rectangular groove 31, the second rectangular groove 32 and the third rectangular groove 33 are all arranged along the circumferential direction of the inner wall of the right DAC verification block 3 and are arranged up and down;
the second longitudinal through hole 34 is formed in the lower side of the right fillet weld, penetrates through the right fillet weld and is parallel to the first longitudinal through hole 22.
In the small-diameter pipe seat fillet weld phased array detection test block, the right side of the near field region defect comparison block 5 is a comparison detection inclined plane, and the upper surface is a right detection surface 55;
the reflector on the contrast detection inclined plane comprises first to fourth contrast holes 51, 52, 53 and 54 which are equidistantly arranged, and the axes of the first to fourth contrast holes 51, 52, 53 and 54 are parallel to each other and extend inwards perpendicular to the inclined plane.
In the small-diameter pipe base fillet weld phased array detection test block, the right detection surface 55 is an arc surface, the curvature of the right detection surface is matched with that of the small-diameter pipe, and the included angle between the inclined surface and the plane where the detection surface 55 is located is 55 degrees.
In the small-diameter pipe base fillet weld phased array detection test block, the left side of the left DAC verification block 2 is a correction detection surface 41, the upper surface of the left DAC verification block is a left detection surface 42, the correction detection surface 41 is an arc surface and has a radius of 50mm, and the left detection surface 42 is an arc surface and has a curvature matched with the small-diameter pipe.
In the small-diameter pipe seat fillet weld phased array detection test block, the diameters of the first transverse through hole 21, the first longitudinal through hole 22 and the second longitudinal through hole 34 are all 2 mm; the vertical distance between the first transverse through hole 21 and the lower end face of the coding debugging block 1 is 30mm, the first longitudinal through hole 22 is arranged at 1/3 of the vertical height of the right side of the left fillet weld, and the second longitudinal through hole 34 is arranged at 1/3 of the transverse length of the lower side of the right fillet weld;
the diameters of the first to fourth comparison holes 51, 52, 53 and 54 are all 2mm, and the vertical distances between the tail ends of the first to fourth comparison holes 51, 52, 53 and 54 and the right detection surface 55 are in an arithmetic progression with gradually increasing equal difference.
Above-mentioned minor diameter tube seat fillet weld phased array detects test block, the perpendicular distance between the terminal of a contrast hole 51 and the right detection face 55 is 2mm, the perpendicular distance between the terminal of No. two contrast holes 52 and the right detection face 55 is 4mm, the perpendicular distance between the terminal of No. three contrast holes 53 and the right detection face 55 is 6mm, the perpendicular distance between the terminal of No. four contrast holes 54 and the right detection face 55 is 8 mm.
The small-diameter pipe base fillet weld phased array detection test block is characterized in that scales are arranged on the outer wall of the coding and debugging block 1;
the opening height of the fourth rectangular groove 23 is 1mm, the depth is 2mm,
the opening height of the first rectangular groove 31 is 1mm, the depth of the first rectangular groove is 1mm, and the vertical distance between the first rectangular groove and the lower end face of the coding debugging block 1 is 50 mm;
the opening height of the second rectangular groove 32 is 1mm, the depth of the second rectangular groove is 3mm, and the vertical distance between the second rectangular groove and the first rectangular groove 31 is 40 mm;
the opening height of No. three rectangular channel 33 is 1mm, the degree of depth is 2mm, the horizontal position of No. three rectangular channel 33 is corresponding to the lower side of right fillet weld and is No. three rectangular channel 33 and No. two rectangular channel 32's vertical distance is 20 mm.
The using method of the test block comprises the following 1) to 5) contents:
1) and (3) calibrating and debugging the encoder by using the encoding debugging block 1: the scanning frame with the encoder is installed on the small-diameter pipe section, the scanning frame is rotated, the encoder is made to walk for a certain length according to the scale display of the encoding debugging block 1, then the parameters of the detecting instrument are adjusted to make the display value of the detecting instrument consistent with the actual distance traveled by the encoder, the calibration of the encoder is completed, the operation is convenient and fast, and the calibration precision is high.
2) Preparing a DAC sensitivity curve: placing the probe on the left DAC verification block 2, aligning the front end of the probe with the first longitudinal through hole 22, moving the probe back and forth to find the highest wave position of the first longitudinal through hole 22 of the reflector, and recording the position point information by a detection instrument; then, the probe is placed on the right DAC verification block 3, the front end of the probe is aligned to the second longitudinal through hole 34, the probe is moved back and forth to find the highest wave position of the second longitudinal through hole 34 of the reflector, and a detection instrument records the position point information; then, the two points are connected to generate a sensitivity curve.
The range of the phased array sound beam is larger than that of the conventional ultrasonic sound beam, and the first longitudinal through hole 22 and the second longitudinal through hole 34 are separately arranged to avoid mutual interference of echo waves of the reflectors. And the first longitudinal through hole 22 and the second longitudinal through hole 34 are arranged on the DAC verification block 3 with curvature, the sensitivity curve made by the method is closer to the real detection situation, and the detection precision is improved. The first longitudinal through hole 22 is arranged on the near-probe side of the left fillet weld in the vertical direction, the second longitudinal through hole 34 is arranged on the far-probe side of the right fillet weld in the horizontal direction, and the two positions are respectively close to the maximum value and the minimum value of the sensitivity of the primary reflected wave, so that for the phased array detection of the fillet weld of the tube seat, the sensitivity curve can be made by the first longitudinal through hole 22 and the second longitudinal through hole 34 to meet the detection requirement, and the phased array detection method is more efficient and more accurate than DL-1 and GS test blocks.
3) Carrying out process verification: placing the probe on the pipe wall of the left DAC verification block 2, enabling the front end of the probe to face downwards to a left fillet weld, and observing whether an echo image of the first longitudinal through hole 22 and the fourth rectangular groove 23 can be clearly displayed on a screen of a detection instrument; then transferring to the tube wall of the right DAC verification block 3, and observing whether the screen of the detection instrument can clearly display an echo diagram of the third rectangular groove 33 and the second longitudinal through hole 34; if the weld seam is clearly displayed, the process of the fillet weld of the tube seat is qualified.
The reflectors of the left and right DAC validation blocks 2, 3 are provided with multiple functions: since the phased array device can not only display the waveform, but also have a powerful image display function, the first longitudinal through hole 22 and the second longitudinal through hole 34 can be used for manufacturing the sensitivity curve, and the reasonability of the detection process can be verified according to the imaging quality of the first longitudinal through hole and the second longitudinal through hole. The third rectangular groove 33 is a representation of incomplete penetration, and can be used together with the first rectangular groove 31 and the second rectangular groove 32 to compare and measure the incomplete penetration depth of the fillet weld of the tube seat, the depth of the first rectangular groove 31 is 1mm, the depth of the third rectangular groove 33 is 2mm, and the depth of the second rectangular groove 32 is 3mm, so that a depth sequence is just formed, and the actual depth value of the incomplete penetration defect can be obtained through actual measurement data comparison. Rectangular groove number four 23 is an unfused characterization that can be used as a reference for actual defect characterization.
4) Angle gain correction is carried out on the detection instrument: the phased array probe is placed on the left detection surface 42 of the angle gain correction block 4, the front end of the probe is aligned with the correction detection surface 41, and then the probe is moved back and forth to perform gain correction on the sound beams at all required angles one by one so that the sound beams at all angles meet the detection requirements.
Because the left detection surface 42 is designed to be a curved surface, the process of replacing the flat wedge block and the arc wedge block is omitted, the calibration error is reduced, and the detection precision is improved.
5) Near field region defect comparison block 5: placing the phased array probe on a right detection surface 55, enabling the front end of the probe to face a contrast detection inclined surface, moving the probe back and forth to measure the reflection characteristics of the first to fourth contrast holes 51, 52, 53 and 54, and storing data in a detection instrument; and comparing the reflection characteristics of the defects found in the near field region and the first to fourth comparison holes 51, 52, 53 and 54 to calculate the actual buried depth of the defects.
The right detection surface 55 is a circular arc surface, the curvature of the right detection surface is matched with that of the small-diameter tube, the coupling between the probe and the test block is good, and the test precision is improved. The center angle of a common small-diameter tube self-focusing phased array probe is 55 degrees, the included angle between the contrast detection inclined plane and the right detection plane 55 is 55 degrees, and the first to fourth contrast holes 51, 52, 53 and 54 of the reflector are arranged perpendicular to the contrast detection inclined plane, so that the axial line of a phased array sound beam can be perpendicular to the upper end faces of the first to fourth contrast holes 51, 52, 53 and 54, and the reflection characteristics of real pore defects can be simulated. The contrast reflector and the arrangement form thereof disclosed by the invention improve the detection precision of the near field region air hole defects.
The application discloses structural style and the design theory of a novel test block, according to the actual specification and the welding form of the detection object, refer to the content that the application discloses and can process corresponding special test block. The test block features and embodiments of the present application are described in conjunction with the drawings, but are not intended to limit the scope of the present application. It should be understood by those skilled in the art that various modifications and changes may be made without inventive work based on the technical solution of the present application and still be within the protective scope of the claims of the present application.
Claims (8)
1. The utility model provides a path pipe tube seat fillet weld phased array detects test block which characterized in that: the device comprises a coding debugging block (1), a left DAC (digital-to-analog converter) verification block (2), a right DAC verification block (3), an angle gain correction block (4) and a near field defect comparison block (5); the left DAC verification block (2) and the right DAC verification block (3) are parts cut at the corner welding part of the tube seat of the small-diameter tube,
the left DAC verification block and the right DAC verification block (2 and 3) are symmetrically arranged, the upper ends of the left DAC verification block and the right DAC verification block are connected with the coding debugging block (1), the lower end of the left DAC verification block (2) is welded with the right end of the angle gain correction block (4) to obtain a left fillet weld, and the lower end of the right DAC verification block (3) is welded with the left end of the near field region defect comparison block (5) to obtain a right fillet weld;
a plurality of reflectors are arranged on the left DAC verification block (2), the right DAC verification block (3) and the near field region defect comparison block (5);
the left side of the left DAC verification block (2) is a correction detection surface (41), the upper surface of the left DAC verification block is a left detection surface (42), the correction detection surface (41) is an arc surface and has a radius of 50mm, and the left detection surface (42) is an arc surface and has a curvature matched with the small diameter pipe;
the right side of the near field region defect comparison block (5) is a comparison detection inclined plane, and the upper side of the near field region defect comparison block is a right detection surface (55); the right detection surface (55) is an arc surface, the curvature of the right detection surface is matched with that of the small-diameter pipe, and the included angle between the inclined surface and the plane where the right detection surface (55) is located is 55 degrees.
2. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 1, wherein: the reflector on the left DAC verification block (2) comprises a first transverse through hole (21), a first longitudinal through hole (22) and a fourth rectangular groove (23) with a rectangular section;
the first transverse through hole (21) is formed in the upper portion of the left DAC verification block (2) and transversely penetrates through the DAC verification block (2);
the first longitudinal through hole (22) is arranged on the right side of the left fillet weld, penetrates through the left fillet weld and is spatially vertical to the first transverse through hole (21);
the fourth rectangular groove (23) is arranged along the outer circumferential direction of the left fillet weld.
3. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 2, wherein: the reflector on the right DAC verification block (3) comprises a first rectangular groove (31), a second rectangular groove (32), a third rectangular groove (33) and a second longitudinal through hole (34);
the first rectangular groove (31), the second rectangular groove (32) and the third rectangular groove (33) are all arranged along the circumferential direction of the inner wall of the right DAC verification block (3) and are arranged up and down;
and the second longitudinal through hole (34) is arranged at the lower side of the right fillet weld, penetrates through the right fillet weld and is parallel to the first longitudinal through hole (22).
4. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 3, wherein: the reflector on the contrast detection inclined plane comprises first to fourth contrast holes (51, 52, 53, 54) which are equidistantly arranged, and the axes of the first to fourth contrast holes (51, 52, 53, 54) are parallel to each other and extend inwards perpendicular to the inclined plane.
5. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 4, wherein: the diameters of the first transverse through hole (21), the first longitudinal through hole (22) and the second longitudinal through hole (34) are all 2mm, the first longitudinal through hole (22) is arranged at 1/3 of the vertical height of the right side of the left fillet weld, and the second longitudinal through hole (34) is arranged at 1/3 of the transverse length of the lower side of the right fillet weld;
the diameters of the first to fourth comparison holes (51, 52, 53, 54) are all 2mm, and the vertical distances between the tail ends of the first to fourth comparison holes (51, 52, 53, 54) and the right detection surface (55) are in an arithmetic progression with gradually increasing equal difference.
6. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 5, wherein: the perpendicular distance between the terminal of a contrast hole (51) and right side detection face (55) is 2mm, the perpendicular distance between the terminal of No. two contrast holes (52) and right side detection face (55) is 4mm, the perpendicular distance between the terminal of No. three contrast holes (53) and right side detection face (55) is 6mm, the perpendicular distance between the terminal of No. four contrast holes (54) and right side detection face (55) is 8 mm.
7. The phased array test block for detecting the fillet weld of the tube seat of the small-diameter tube according to claim 5, wherein: scales are arranged on the outer wall of the coding debugging block (1);
the opening height of the fourth rectangular groove (23) is 1mm, the depth is 2mm,
the opening height of the first rectangular groove (31) is 1mm, the depth is 1mm,
the opening height of the second rectangular groove (32) is 1mm, the depth is 3mm,
the opening height of No. three rectangular channel (33) is 1mm, the degree of depth is 2mm, the horizontal position of No. three rectangular channel (33) corresponds to the lower side of right fillet weld.
8. The use method of the phased array test block for fillet weld of the tube socket of the small-diameter tube according to claim 7 is characterized by comprising the following steps:
1) and (3) calibrating and debugging an encoder: installing a scanning frame with an encoder on a small-diameter pipe section, rotating the scanning frame to enable the encoder to display and walk for a certain length according to the scale of the encoding debugging block (1), and then adjusting the parameters of a detection instrument to enable the display value of the detection instrument to be consistent with the actual distance traveled by the encoder, so as to finish the calibration of the encoder;
2) making a DAC (sensitivity) curve: placing the probe on the left DAC verification block (2), aligning the front end of the probe with the first longitudinal through hole (22), moving the probe back and forth to find the highest wave position of the first longitudinal through hole (22) of the reflector, and recording the position point information by a detection instrument; then, the probe is placed on the right DAC verification block (3), the front end of the probe is aligned to the second longitudinal through hole (34), the probe is moved back and forth to find the highest wave position of the second longitudinal through hole (34) of the reflector, and a detection instrument records the position point information; then two points are connected to generate a sensitivity curve;
3) and (3) verifying the fillet weld process of the tube seat: placing a probe on the pipe wall of the left DAC verification block (2), enabling the front end of the probe to face downwards to a left fillet weld, and observing whether a screen of a detection instrument can clearly display echo images of the first longitudinal through hole (22) and the fourth rectangular groove (23); then transferring to the tube wall of the right DAC verification block (3), and observing whether the screen of the detection instrument can clearly display an echo diagram of a third rectangular groove (33) and a second longitudinal through hole (34); if the weld seam is clearly displayed, the process of the fillet weld of the tube seat is qualified;
4) angle gain correction of the detection instrument: the phased array probe is placed on a left detection surface (42) of an angle gain correction block (4), the front end of the probe is aligned to a correction detection surface (41), and then the probe is moved back and forth to perform gain correction on sound beams at all required angles one by one so that the sound beams at all angles meet the detection requirements;
5) and (3) defect comparison of a near field region: the phased array probe is placed on a right detection surface (55) of a near field region defect comparison block (5), the front end of the probe faces a comparison detection inclined plane, the probe is moved back and forth to measure the reflection characteristics of first to fourth comparison holes (51, 52, 53 and 54), and data are stored in a detection instrument; and comparing the reflection characteristics of the defects found in the near field region and the first to fourth comparison holes (51, 52, 53 and 54) to calculate the actual buried depth of the defects.
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| CN109780453B (en) * | 2019-02-21 | 2024-05-14 | 北京隆盛泰科石油管科技有限公司 | Reference block for ultrasonic detection of oil and gas pipeline B-type sleeve fillet weld |
| CN110672043B (en) * | 2019-10-17 | 2024-05-03 | 中船澄西船舶修造有限公司 | Welding leg gauge |
| CN111537612B (en) * | 2020-05-26 | 2023-11-21 | 山东丰汇工程检测有限公司 | Phased array detection and assessment method for austenitic stainless steel small-diameter pipe welding joint |
| CN112305084A (en) * | 2020-11-26 | 2021-02-02 | 淮浙煤电有限责任公司凤台发电分公司 | Fillet weld detection process based on ultrasonic technology and test block |
| CN113433225A (en) * | 2021-07-30 | 2021-09-24 | 山东丰汇工程检测有限公司 | Phased array ultrasonic detection test block and detection method for stainless steel small-diameter pipe weld joint |
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| JP4055278B2 (en) * | 1999-01-22 | 2008-03-05 | 株式会社Ｉｈｉ | Method for manufacturing non-destructive test specimen and non-destructive test method |
| JP3723555B2 (en) * | 2003-05-09 | 2005-12-07 | 川田工業株式会社 | Ultrasonic inspection method for welds |
| US20090178465A1 (en) * | 2008-01-14 | 2009-07-16 | Ethridge Roger E | Acoustic transducer support frame and method |
| CN103293224B (en) * | 2013-05-08 | 2015-02-18 | 江苏法尔胜材料分析测试有限公司 | Ultrasonic phased array detection method of steel box beam U-rib angle welding seam |
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| CN109946387B (en) * | 2019-03-27 | 2024-02-27 | 东方电气集团东方锅炉股份有限公司 | Small-diameter pipe phased array ultrasonic detection reference block and detection and verification method using same |
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Effective date of registration: 20220130 Address after: 250200 No. 1996 Century Avenue, Zhangqiu District, Jinan City, Shandong Province Patentee after: SHANDONG MECHANICAL ENGINEERING TESTING Co. Address before: 250102 building a2-6, Hangu Jinggu, 7000 Jingshi East Road, high tech Zone, Jinan City, Shandong Province Patentee before: POWERCHINA SEPCO1 ELECTRIC POWER CONSTRUCTION Co.,Ltd. Patentee before: SHANDONG MECHANICAL ENGINEERING TESTING Co. |
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Application publication date: 20181228 Assignee: JINING LUKE TESTING EQUIPMENT Co.,Ltd. Assignor: SHANDONG MECHANICAL ENGINEERING TESTING Co. Contract record no.: X2024980000855 Denomination of invention: A phased array detection test block for small diameter pipe seat corner welds and its usage method Granted publication date: 20201106 License type: Common License Record date: 20240116 |
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