CN109959705A - Coated eddy current testing reference block and manufacturing method thereof - Google Patents
Coated eddy current testing reference block and manufacturing method thereof Download PDFInfo
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- CN109959705A CN109959705A CN201910329176.4A CN201910329176A CN109959705A CN 109959705 A CN109959705 A CN 109959705A CN 201910329176 A CN201910329176 A CN 201910329176A CN 109959705 A CN109959705 A CN 109959705A
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- 238000012360 testing method Methods 0.000 title claims abstract description 61
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 9
- 238000000576 coating method Methods 0.000 claims abstract description 29
- 239000011248 coating agent Substances 0.000 claims abstract description 28
- 239000000758 substrate Substances 0.000 claims abstract description 25
- 239000000463 material Substances 0.000 claims abstract description 22
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 15
- 239000000843 powder Substances 0.000 claims abstract description 15
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000000741 silica gel Substances 0.000 claims abstract description 13
- 229910002027 silica gel Inorganic materials 0.000 claims abstract description 13
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 239000011159 matrix material Substances 0.000 claims abstract description 10
- 238000010892 electric spark Methods 0.000 claims abstract description 9
- 239000011259 mixed solution Substances 0.000 claims abstract description 8
- 238000005507 spraying Methods 0.000 claims abstract description 8
- 238000001035 drying Methods 0.000 claims abstract description 7
- 238000012545 processing Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 8
- 239000012720 thermal barrier coating Substances 0.000 claims description 8
- 239000000919 ceramic Substances 0.000 claims description 4
- 238000003672 processing method Methods 0.000 claims description 3
- 239000002245 particle Substances 0.000 claims description 2
- 238000009760 electrical discharge machining Methods 0.000 claims 1
- 239000000203 mixture Substances 0.000 claims 1
- 238000001514 detection method Methods 0.000 abstract description 13
- 230000035945 sensitivity Effects 0.000 abstract description 9
- 238000009659 non-destructive testing Methods 0.000 abstract description 2
- 230000007547 defect Effects 0.000 description 4
- 239000000523 sample Substances 0.000 description 4
- 238000010998 test method Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000003064 anti-oxidating effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000003153 chemical reaction reagent Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N2001/2893—Preparing calibration standards
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- Chemical & Material Sciences (AREA)
- Analytical Chemistry (AREA)
- Physics & Mathematics (AREA)
- Health & Medical Sciences (AREA)
- Life Sciences & Earth Sciences (AREA)
- Biochemistry (AREA)
- General Health & Medical Sciences (AREA)
- General Physics & Mathematics (AREA)
- Immunology (AREA)
- Pathology (AREA)
- Electrochemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Investigating Or Analyzing Materials By The Use Of Magnetic Means (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
The invention discloses a coated eddy current test reference block and a manufacturing method thereof, belonging to the field of nondestructive testing. This eddy current test piece includes: the coating comprises a substrate, a coating and a plurality of rectangular grooves; the test block coating is sprayed on the surface of the matrix; the rectangular grooves are formed in the surface of the base body. The manufacturing method of the test block comprises the following steps: preparing a test block matrix; processing a plurality of rectangular grooves on the surface of the substrate by using electric sparks; filling the mixed solution of alumina powder and silica gel in the rectangular grooves until the rectangular grooves are filled flatly, and drying and roasting; and spraying a coating on the surface of the test block matrix. The invention can effectively simulate the size of the real crack of the detected piece; the test block for eddy current detection is basically consistent with the material, heat treatment state and surface state of the detected piece, and rectangular grooves with different sizes are formed in the test block, so that the test block can be effectively used for setting detection sensitivity and evaluating the size and the position of a crack.
Description
Technical Field
The invention belongs to the technical field of eddy current testing, and particularly relates to a coated eddy current testing reference block and a manufacturing method thereof.
Background
The high-temperature components of the aeroengine and the industrial gas turbine are made of high-temperature alloy with excellent high-temperature mechanical property and Oxidation and corrosion resistance, and the surfaces of the high-temperature components are sprayed with Thermal Barrier Coatings (TBCs) or Anti-Oxidation Coatings (AOC) so as to further improve the service temperature of the components and prolong the service life of the components. As the working environment of the high-temperature part is severe, cracks are easy to generate on the matrix in the service process, and the safe operation of the gas turbine is endangered. Therefore, nondestructive testing and evaluation of cracks in the substrate of high temperature components is essential to ensure safe and reliable operation of aircraft engines and industrial gas turbines.
The eddy current detection technology is one of five conventional nondestructive detection technologies, is sensitive to crack defects on the surface or near surface of a detected workpiece, and is an effective method for detecting the cracks of a high-temperature component substrate. The eddy current test block is an important component of an eddy current test system and is an important tool for determining the sensitivity of eddy current test, measuring the effectiveness of eddy current and judging the property and the size of a defect. At present, test blocks for eddy current testing at home and abroad are all grooved and perforated by a processing method of electric sparks or laser on the surface to simulate natural defects. The reference block is suitable for checking and comparing the surface defects of the detected workpiece, and is not suitable for judging the eddy current detection sensitivity, the crack position and the size of the substrate of the coated high-temperature component.
Disclosure of Invention
The invention aims to provide a coated eddy current test reference block and a manufacturing method thereof, which are used for simulating the size of a real crack in a tested workpiece, adjusting the detection sensitivity of an eddy current detector, ensuring the accuracy of a detection result and judging and comparing the size and the position of the crack in the tested workpiece.
In order to achieve the purpose, the invention is realized by adopting the following technical scheme:
a coated eddy current test reference block comprises a substrate and a coating which are arranged from bottom to top in sequence; wherein,
the base body and the base body of the detected workpiece are consistent in material and heat treatment state; the coating is TBCs or AOCs, and the TBCs consist of a bonding layer and a ceramic layer double-layer structure; the material, the spraying process and the surface state of the coating are consistent with those of the workpiece to be detected; the coating is sprayed on the surface of the matrix; the surface of the base body is provided with a plurality of rectangular grooves.
The invention has the further improvement that the rectangular grooves are filled with mixed liquid of alumina powder and silica gel, and the volume ratio of the mixed liquid of alumina powder and silica gel is 1: 2-1: 5.
the invention is further improved in that the particle size of the alumina powder is less than or equal to 20 μm.
A further development of the invention is that the thickness of the matrix is 10. + -. 0.5 mm.
The invention has the further improvement that the widths of the rectangular grooves from the first rectangular groove to the seventh rectangular groove are 0.1 +/-0.02 mm, and the lengths are 20 +/-0.1 mm; the depths of the first rectangular groove to the fifth rectangular groove are respectively 0.1 +/-0.02 mm, 0.2 +/-0.02 mm, 0.5 +/-0.02 mm, 1 +/-0.02 mm and 2 +/-0.02 mm, and the depths of the sixth rectangular groove and the seventh rectangular groove are respectively 0.5 +/-0.02 mm.
The invention has the further improvement that the distance between the first rectangular groove and the fourth rectangular groove is 25 +/-0.5 mm from the edge of the test block, and the distance between the adjacent rectangular grooves is 25 +/-0.5 mm; the distance between the fourth rectangular groove and the fifth rectangular groove is 25 +/-0.5 mm, and the distance between the fifth rectangular groove and the edge of the test block is 25 +/-0.5 mm; the distance between the fifth rectangular groove and the seventh rectangular groove is 25 +/-0.5 mm, the sixth rectangular groove is connected with the edge of the test block, and the distance between the seventh rectangular groove and the edge of the test block is 5 +/-0.5 mm.
A manufacturing method of a coated eddy current testing reference block is based on the coated eddy current testing reference block and comprises the following steps:
the first step is as follows: preparing a test block matrix which is consistent with the material and the heat treatment state of the detected workpiece matrix;
the second step is that: processing a plurality of rectangular grooves on the surface of the substrate by an electric spark processing method;
the third step: filling the mixed solution of alumina powder and silica gel in the rectangular grooves, and drying;
the fourth step: repeating the third step until the rectangular groove is filled to be flat;
the fifth step: roasting for 2 hours at 800-900 ℃ in a high-temperature furnace;
and a sixth step: and spraying a coating on the surface of the substrate to obtain the eddy current test reference block with the coating.
The invention is further improved in that in the second step, a plurality of rectangular grooves are formed by adopting electric spark machining.
The further improvement of the invention is that in the third step, the thickness of the mixed liquid of the alumina powder and the silica gel filled in the rectangular groove each time is less than 0.1 mm.
The invention has the following beneficial technical effects:
1. the invention can effectively simulate the size of the real crack of the detected workpiece;
2. the eddy current test reference block base body with the coating is basically consistent with the material and the heat treatment state of the detected piece, and the material, the spraying process and the surface state of the coating are basically consistent with the detected piece;
3. the surface of the test block coating is smooth, and the influence on the eddy current detection result is small;
4. rectangular grooves with different sizes are engraved on the reference block with the coating, and the reference block can be effectively used for setting detection sensitivity and evaluating the size and the position of a crack;
5. the alumina powder and the silica gel are common materials or reagents, and can be conveniently obtained by a person skilled in the art.
Drawings
FIG. 1 is a schematic structural diagram of a coated eddy current test reference block according to the present invention.
In the figure: 1-substrate, 2-coating, 3-9-first rectangular groove to seventh rectangular groove.
Detailed Description
The invention is further described below with reference to the accompanying drawings.
Example 1
As shown in fig. 1, a coated reference block for eddy current testing, comprising: the substrate 1, the coating 2 and the first to seventh rectangular grooves 3-9; the rectangular groove is arranged on the surface of the base body 1.
The embodiment can be specifically realized as follows:
1) selecting a base material of the eddy current testing reference block according to the base material of the detected workpiece, and requiring that the base material grade and the heat treatment state of the eddy current testing reference block are consistent with the detected part of the detected workpiece;
2) processing first to seventh rectangular grooves 3-9 on the surface of the substrate 1 by using electric sparks;
3) filling the mixed solution of alumina powder and silica gel in the first to seventh rectangular grooves 3-9, and drying;
4) repeating the step 3) until the first rectangular groove to the seventh rectangular groove are filled to be flat by 3-9 parts;
5) roasting at 830 +/-10 ℃ in a high-temperature furnace for 2 hours;
6) the surface of the substrate 1 is sprayed with a coating 2(TBCs), the thickness of the bonding layer is 0.15 +/-0.05 mm, and the thickness of the ceramic layer is 0.35 +/-0.05 mm.
The eddy current test procedure using the reference block was as follows:
1) connecting an eddy current probe and starting an eddy current instrument;
2) debugging the sensitivity of the instrument on a reference block;
3) detecting the detected piece;
4) evaluating cracks in the detected piece by means of a reference block;
5) after the detection is finished, the eddy current instrument is calibrated by using the comparison test block, if the eddy current instrument is unchanged, the detected piece can be checked, and if the eddy current instrument is changed, the detected piece is required to be detected again;
6) the vortex finder was turned off.
Example 2
As shown in fig. 1, a coated reference block for eddy current testing, comprising: the substrate 1, the coating 2 and the first to seventh rectangular grooves 3-9; the rectangular groove is arranged on the surface of the base body 1.
The embodiment can be specifically realized as follows:
1) selecting a base material of the eddy current testing reference block according to the base material of the detected workpiece, and requiring that the base material grade and the heat treatment state of the eddy current testing reference block are consistent with the detected part of the detected workpiece;
2) processing first to seventh rectangular grooves 3-9 on the surface of the substrate 1 by using electric sparks;
3) filling the mixed solution of alumina powder and silica gel in the first to seventh rectangular grooves 3-9, and drying;
4) repeating the step 3) until the first rectangular groove to the seventh rectangular groove are filled to be flat by 3-9 parts;
5) roasting for 2 hours at 870 +/-10 ℃ in a high-temperature furnace;
6) the surface of the substrate 1 is sprayed with coating 2(TBCs), the thickness of the bonding layer is 0.2 +/-0.05 mm, and the thickness of the ceramic layer is 0.5 +/-0.05 mm.
The eddy current test procedure using the reference block was as follows:
1) connecting an eddy current probe and starting an eddy current instrument;
2) debugging the sensitivity of the instrument on a reference block;
3) detecting the detected piece;
4) evaluating cracks in the detected piece by means of a reference block;
5) after the detection is finished, the eddy current instrument is calibrated by using the comparison test block, if the eddy current instrument is unchanged, the detected piece can be checked, and if the eddy current instrument is changed, the detected piece is required to be detected again;
6) the vortex finder was turned off.
Example 3
As shown in fig. 1, a coated reference block for eddy current testing, comprising: the substrate 1, the coating 2 and the first to seventh rectangular grooves 3-9; the rectangular groove is arranged on the surface of the base body 1.
The embodiment can be specifically realized as follows:
1) selecting a base material of the eddy current testing reference block according to the base material of the detected workpiece, and requiring that the base material grade and the heat treatment state of the eddy current testing reference block are consistent with the detected part of the detected workpiece;
2) processing first to seventh rectangular grooves 3-9 on the surface of the substrate 1 by using electric sparks;
3) filling the mixed solution of alumina powder and silica gel in the first to seventh rectangular grooves 3-9, and drying;
4) repeating the step 3) until the first rectangular groove to the seventh rectangular groove are filled to be flat by 3-9 parts;
5) roasting at 830 +/-10 ℃ in a high-temperature furnace for 2 hours;
6) and spraying a coating 2(AOC) on the surface of the substrate 1, wherein the thickness of the AOC is 0.35 +/-0.05 mm.
The eddy current test procedure using the reference block was as follows:
1) connecting an eddy current probe and starting an eddy current instrument;
2) debugging the sensitivity of the instrument on a reference block;
3) detecting the detected piece;
4) evaluating cracks in the detected piece by means of a reference block;
5) after the detection is finished, the eddy current instrument is calibrated by using the comparison test block, if the eddy current instrument is unchanged, the detected piece can be checked, and if the eddy current instrument is changed, the detected piece is required to be detected again;
6) the vortex finder was turned off.
Example 4
As shown in fig. 1, a coated reference block for eddy current testing, comprising: the substrate 1, the coating 2 and the first to seventh rectangular grooves 3-9; the rectangular groove is arranged on the surface of the base body 1.
The embodiment can be specifically realized as follows:
1) selecting a base material of the eddy current testing reference block according to the base material of the detected workpiece, and requiring that the base material grade and the heat treatment state of the eddy current testing reference block are consistent with the detected part of the detected workpiece;
2) processing first to seventh rectangular grooves 3-9 on the surface of the substrate 1 by using electric sparks;
3) filling the mixed solution of alumina powder and silica gel in the first to seventh rectangular grooves 3-9, and drying;
4) repeating the step 3) until the first rectangular groove to the seventh rectangular groove are filled to be flat by 3-9 parts;
5) roasting for 2 hours at 870 +/-10 ℃ in a high-temperature furnace;
6) and spraying a coating 2(AOC) on the surface of the substrate 1, wherein the thickness of the AOC is 0.45 +/-0.05 mm.
The eddy current test procedure using the reference block was as follows:
1) connecting an eddy current probe and starting an eddy current instrument;
2) debugging the sensitivity of the instrument on a reference block;
3) detecting the detected piece;
4) evaluating cracks in the detected piece by means of a reference block;
5) after the detection is finished, the eddy current instrument is calibrated by using the comparison test block, if the eddy current instrument is unchanged, the detected piece can be checked, and if the eddy current instrument is changed, the detected piece is required to be detected again;
6) the vortex finder was turned off.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and are intended to enable one skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (9)
1. A coated eddy current testing reference block is characterized by comprising a base body (1) and a coating (2) which are sequentially arranged from bottom to top; wherein,
the base body (1) is consistent with the base body material and the heat treatment state of the detected workpiece; the coating (2) is TBCs or AOCs, and the TBCs consist of a bonding layer and a ceramic layer double-layer structure; the material, the spraying process and the surface state of the coating (2) are consistent with those of the workpiece to be detected; the coating (2) is sprayed on the surface of the substrate (1); the surface of the base body (1) is provided with a plurality of rectangular grooves.
2. The coated eddy current testing reference block according to claim 1, wherein the rectangular grooves are filled with a mixture of alumina powder and silica gel at a volume ratio of 1: 2-1: 5.
3. the coated eddy current test reference block according to claim 2, wherein the particle size of the alumina powder is 20 μm or less.
4. A coated eddy current test reference block according to claim 1, wherein the thickness of the substrate (1) is 10 ± 0.5 mm.
5. The coated eddy current test reference block according to claim 1, wherein the width of the rectangular grooves from the first rectangular groove to the seventh rectangular groove (3-9) is 0.1 ± 0.02mm, and the length is 20 ± 0.1 mm; the depths of the first rectangular groove to the fifth rectangular groove (3-7) are respectively 0.1 +/-0.02 mm, 0.2 +/-0.02 mm, 0.5 +/-0.02 mm, 1 +/-0.02 mm and 2 +/-0.02 mm, and the depths of the sixth rectangular groove (8) and the seventh rectangular groove (9) are respectively 0.5 +/-0.02 mm.
6. The coated eddy current test reference block according to claim 5, wherein the first to fourth rectangular grooves (3-6) are spaced 25 ± 0.5mm from the block edge, and the interval between adjacent rectangular grooves is 25 ± 0.5 mm; the distance between the fourth rectangular groove (6) and the fifth rectangular groove (7) is 25 +/-0.5 mm, and the distance between the fifth rectangular groove (7) and the edge of the test block is 25 +/-0.5 mm; the distance between the fifth rectangular groove (7) and the seventh rectangular groove (9) is 25 +/-0.5 mm, the sixth rectangular groove (8) is connected with the edge of the test block, and the distance between the seventh rectangular groove (9) and the edge of the test block is 5 +/-0.5 mm.
7. A method for manufacturing a coated eddy current test reference block, which is based on the coated eddy current test reference block of any one of claims 1 to 6, comprising the steps of:
the first step is as follows: preparing a test block matrix (1) consistent with the material and the heat treatment state of the matrix of the detected workpiece;
the second step is that: processing a plurality of rectangular grooves on the surface of the substrate (1) by an electric spark processing method;
the third step: filling the mixed solution of alumina powder and silica gel in the rectangular grooves, and drying;
the fourth step: repeating the third step until the rectangular groove is filled to be flat;
the fifth step: roasting for 2 hours at 800-900 ℃ in a high-temperature furnace;
and a sixth step: and (3) spraying a coating (2) on the surface of the substrate (1) to obtain the coated eddy current testing reference block.
8. The method of claim 7, wherein the second step is performed by electrical discharge machining of the rectangular grooves.
9. The method for manufacturing the coated eddy current testing reference block according to claim 7, wherein in the third step, the thickness of the mixed solution of alumina powder and silica gel filled in the rectangular groove each time is less than 0.1 mm.
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
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CN110231398A (en) * | 2019-07-16 | 2019-09-13 | 山东电力工业锅炉压力容器检验中心有限公司 | A kind of simulating test pieces for lead sealing Defect With Eddy Current Testing and preparation method thereof and application |
CN112051325A (en) * | 2020-09-29 | 2020-12-08 | 西安热工研究院有限公司 | Test block for eddy current testing of coated welding joint array |
CN112051327A (en) * | 2020-09-29 | 2020-12-08 | 西安热工研究院有限公司 | Method for identifying cracks of welded joint under tungsten carbide coating based on array eddy current |
CN112345634A (en) * | 2020-11-20 | 2021-02-09 | 西安热工研究院有限公司 | Eddy current detection system and method for cracks of coated turbine blade matrix of heavy-duty gas turbine |
CN113155952A (en) * | 2021-03-26 | 2021-07-23 | 中国飞机强度研究所 | Test block for testing internal crack capability of eddy current detection multilayer structure and application method thereof |
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Cited By (6)
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CN110231398A (en) * | 2019-07-16 | 2019-09-13 | 山东电力工业锅炉压力容器检验中心有限公司 | A kind of simulating test pieces for lead sealing Defect With Eddy Current Testing and preparation method thereof and application |
CN110231398B (en) * | 2019-07-16 | 2023-01-31 | 山东电力工业锅炉压力容器检验中心有限公司 | Simulation test block for detecting defects of lead-sealed eddy current test and manufacturing method and application thereof |
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CN112051327A (en) * | 2020-09-29 | 2020-12-08 | 西安热工研究院有限公司 | Method for identifying cracks of welded joint under tungsten carbide coating based on array eddy current |
CN112345634A (en) * | 2020-11-20 | 2021-02-09 | 西安热工研究院有限公司 | Eddy current detection system and method for cracks of coated turbine blade matrix of heavy-duty gas turbine |
CN113155952A (en) * | 2021-03-26 | 2021-07-23 | 中国飞机强度研究所 | Test block for testing internal crack capability of eddy current detection multilayer structure and application method thereof |
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