CN111195807B - A method of making an internal crack defect test plate for non-destructive testing teaching - Google Patents
A method of making an internal crack defect test plate for non-destructive testing teaching Download PDFInfo
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Abstract
一种无损探伤教学用内部裂纹缺陷试板的制作方法，利用焊接过程中的焊缝冷裂纹产生机理，采用高拘束试板对接方式，利用高碳当量焊材进行常温施焊，辅以焊后施加强制快冷措施，放置24小时，即可制作出满足设计裂纹位置、深度和长度的焊缝内部裂纹，然后拆卸夹具及试板点固，对非设计裂纹区域打底焊接，再对缺陷试板填充及盖面焊接，最后进行焊缝表面清理，完成试板制作；本发明所制作出的焊缝内部裂纹不同于常用的探伤标准试板中的人工缺陷，其裂纹缺陷真实，方法可行，可用于超声等无损探伤，对无损探伤人员培训及考核，增强其对裂纹缺陷探伤信号的认识具有重要意义；本发明具有定位灵活准确、契合实际教学培训的需求和应用范围广的优点。
A method for making an internal crack defect test plate for non-destructive testing teaching, using the cold crack generation mechanism of the weld during the welding process, using a high-restraint test plate butting method, using high carbon equivalent welding consumables for normal temperature welding, supplemented by post-weld welding Forced quick cooling measures are applied and placed for 24 hours to produce internal cracks in the weld that meet the design crack position, depth and length, then dismantle the fixture and the test plate to fix it, weld the non-design crack area at the bottom, and then test the defects. Plate filling and cover welding, and finally the surface of the weld is cleaned to complete the production of the test plate; the internal cracks of the welded seam produced by the present invention are different from the artificial defects in the commonly used standard test plates for flaw detection, the crack defects are real, and the method is feasible. It can be used for non-destructive testing such as ultrasound, and is of great significance to the training and assessment of non-destructive testing personnel and enhancing their understanding of crack defect detection signals.
Description
Technical Field
The invention belongs to the technical field of nondestructive inspection of metal materials, and relates to a method for manufacturing a crack defect test plate for teaching or nondestructive inspection training, in particular to a method for manufacturing an internal crack defect test plate for nondestructive inspection teaching.
Background
Nondestructive testing is a new comprehensive application technology subject, which is a subject for measuring and evaluating various defects inside or on the surface of a substance on the premise of not damaging or damaging an inspected object; the common defect test plate is a necessary test piece in the processes of nondestructive inspection teaching, personnel training, examination and the like; the welding joint is a non-uniform body of chemical components, is a key part influencing the quality and the use safety of a product, and is also a're-disaster area' of defects in the structure of the product; therefore, effective detection of defects in welded joints is a necessary guarantee to ensure product quality and operational safety; among the defects of cracks, unfused, incomplete penetration, air holes, slag inclusion and the like of a welding joint, the crack defect is always the focus of attention in nondestructive testing work; the crack defect detection and evaluation can not accurately know the crack defect detection information; therefore, the manufacture of the real crack defect test plate has important engineering significance for finding and judging cracks in nondestructive flaw detection.
In the aspect of standard test plates for flaw detection, a large number of researches and specifications of standard test plates are carried out at home and abroad, and corresponding international, national and industrial standards are formed, such as the international standard test plate standard ISO2400-1972E, the steel weld manual ultrasonic flaw detection standard test plate standard GB/T11345-89, the mechanical industry standard test plate standard JB/T4730.1-4730.6-2005, the electric power industry standard test plate standard DL/T5048-95, the petroleum industry standard test plate standard Q/SY XQ7-2001, the nondestructive testing and ultrasonic testing test plate GB/T23905-. The standard test panels prescribed by these standards have two greatest features: (1) the defect is mostly manufactured in a manual mode, such as the mode of processing standard holes, steps and the like; (2) its function is mainly used to determine the performance of flaw detector, probe and system. However, there is a certain difference between the artificial defect and the actual defect in the standard test plate, and the limitation of the artificial defect manufacturing method makes it difficult for the inspector to recognize and distinguish the defect signal more deeply. Aiming at the problems of artificial defects in the standard test plate, a large amount of creative work is carried out by technical personnel; the invention patent with the publication number of CN101576450 discloses a method for manufacturing a surface welding crack test plate, which mainly increases the sensitivity of weld joint hot cracks by adding an S element in a weld joint and then manufactures the weld joint surface cracks by matching with a proper welding process. The invention patent with publication number CN102009280B discloses a welding electrode capable of generating welding cracks and a manufacturing method thereof, which also form cracks by improving the sensitivity of welding seams to heat cracks; the invention patents with the publication numbers of CN101576450 and CN102009280B both manufacture cracks by increasing the hot crack sensitivity of welding seams, and when the welding process parameters and the shape of a molten pool are not controlled properly, the target effect is difficult to achieve; patent publication No. CN105196002A made cracks by loading, but the cracks were different from actual cracks of the weld in authenticity; the patent with publication number CN107020440A discloses a method for manufacturing a crack defect test plate by manual welding, which utilizes the brittleness of a ball-milling cast iron welding seam to manufacture a manual crack in a local repair welding mode, and the position and the size of the crack are mainly controlled by grinding a groove with the depth of 2-3mm and the width of 3-5mm on a backing welding seam; however, the constraint stress of the groove with the size is very limited during repair welding, the crack generated in the repair welding mode is mainly dependent on the brittleness of a repair welding cast iron welding bead, and the effective effect cannot be achieved due to improper control of the welding process.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention aims to provide a method for manufacturing an internal crack defect test plate for nondestructive inspection teaching, which can randomly design a crack area on the test plate to manufacture a weld defect identical to an actual crack defect, deepens the recognition degree of students and inspectors on a defect detection signal, and has the advantages of flexible and accurate positioning, conformity with the requirements of actual teaching training and wide application range.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for manufacturing an internal crack defect test plate for nondestructive inspection teaching specifically comprises the following steps:
step one, selecting high carbon equivalent welding materials
Selecting a high carbon equivalent welding material with deposited metal carbon equivalent Ceq more than 0.46 percent according to the chemical components of the deposited metal of the welding rod and the following carbon equivalent formula: ceq ═ C + Mo/4+ Cr/5+ Mn/6+ V/14+ Si/24+ Ni/40 (%);
step two, preparation of defect test plate
Selecting a steel plate as a test plate 1; a double-sided V-shaped groove with a truncated edge is formed on the test plate 1;
step three, rigidly fixing the test board
Assembling and effectively fixing the test plate 1 with the processed grooves in a rigid fixing mode, and reserving gaps among the V-shaped grooves;
step four, crack manufacturing
Welding a high carbon equivalent welding bead 4 in a designed crack area between V-shaped grooves of the test plate 1 by using the selected welding rod in the step one, immediately and rapidly cooling the high carbon equivalent welding bead 4 after arc quenching, and placing for 24 hours to form a longitudinal welding crack 5 of the penetrable welding bead;
fifthly, loosening the rigid fixation and performing point-fixing welding on the test plate 1;
step six, backing welding of the non-designed crack area
Preheating the test plate 1, backing-welding the non-designed crack regions between the V-shaped grooves, polishing and removing point fixing welding beads by using an angle grinder when welding to a point fixing welding position, then carrying out backing-welding again, polishing the back surfaces of the backing-welded seams, and finishing the surfaces of the poorly-formed seams;
step seven, filling the defect test plate and welding the cover surface
After preheating the test plate 1, welding a filling weld bead 7 and a cover surface layer 8 on the test plate 1 by using a J427 welding rod with the diameter of 4.0 mm;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
The welding material selected in the first step comprises J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% or J107Cr welding rod with Ceq being 0.942%.
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as the steel plate of the test plate 1 in the second step; the angle A of the V-shaped groove is 45-60 degrees; the height H of the truncated edge is 3-5 mm.
The third step of rigid fixing comprises the step of clamping the test plate 1 by a rigid clamp 2 and a fastening bolt 3 arranged on the rigid clamp; the V-shaped groove gap width L of the test plate 1 is 2-4 mm.
The welding material strip used in the fourth step is any one of J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% or J107Cr with Ceq being 0.942%; the specification of the welding rod is 3.2mm in diameter, 4.0mm in diameter or 5.0mm in diameter; the welding current is 120-190A; the rapid cooling means includes water spraying or pouring liquid nitrogen.
In the fifth step, the welding rod for tack welding the test plate 1 is J427 with the diameter of 3.2 mm; the welding current is 110-140A, and the length of the point fixing welding bead is 8-15 mm.
In the sixth step, the preheating temperature of the test plate 1 is 200-300 ℃, the welding rod used for backing welding of the non-designed crack region is J427 with the diameter of 3.2mm, and the welding current is 110-140A.
The preheating temperature of the test plate 1 in the seventh step is 200-300 ℃; the welding rod adopted for welding the filling weld bead 7 and the cover surface layer 8 on the test plate 1 is J427 with the diameter of 4.0 mm; the welding current is 140-180A; ensuring the interlayer temperature not to be lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1.
And the welding of the high-carbon equivalent welding bead 4 is carried out at room temperature.
The invention adopts a high-restraint test plate butt joint mode, utilizes a high-carbon equivalent welding material to carry out normal-temperature welding, and is assisted with a measure of forced rapid cooling after welding to realize the manufacture of the test plate of the crack defect in the welding seam in a mode of generating an actual welding crack, so that the weld defect identical to the actual crack defect can be manufactured at a set position on the test plate, and the recognition degree of students and detection personnel on a defect detection signal is deepened; according to the prevention mechanism of welding cold cracks, the test plate is used against the welding cold cracks to promote the test plate to form actual welding cold joint cracks; when welding the high carbon equivalent welding material, cold cracks are usually prevented by combining the preheating and the restraint stress reduction; the sensitivity of the high-carbon equivalent welding material to cold cracks is utilized, and the weld bead cold cracks are positioned and generated by external reinforcing restraint and rapid cooling of defective weld beads, so that the method is one of the creative characteristics of the invention, and a similar welding crack defect manufacturing method report is not seen; the selection of the form of the groove of the test plate and the design of the position of the truncated edge are used for realizing the depth control of the welding crack and achieving the purpose of generating the crack at the set position and depth; after the completion of the crack bead, preheating and interlayer temperature control are performed to prevent the occurrence of weld defects in the non-design crack region. Compared with the standard test plate, the manufactured internal crack defect test plate has the following beneficial effects in terms of manufacturing method and effect:
(1) the actual welding method is adopted, the actual crack with the designed length and depth is manufactured at the designed position, and the actual weld defect is closer to the actual weld defect than a standard test plate;
(2) the detection signal of the manufactured crack defect test plate is the same as the real defect, so that the perceptual and rational understanding of a nondestructive detection technician on the actual defect is enhanced;
(3) the crack defect test plate manufactured by the invention can be used for nondestructive inspection methods such as ultrasonic inspection and the like, and the training, changing and evidence obtaining examination quality of nondestructive inspection personnel is improved;
in conclusion, the invention has the advantages of flexible and accurate positioning, and wide application range and conforms to the requirements of practical teaching and training.
Drawings
FIG. 1 is a schematic structural view of a groove of a defect test plate according to the present invention.
FIG. 2 is a schematic structural diagram of a defect test panel assembly and rigid fixing device according to the present invention.
Fig. 3 is a schematic view of surface cracks after rapid cooling of a high carbon equivalent weld bead in accordance with the present invention.
Fig. 4 is a schematic cross-sectional crack view of the high carbon equivalent weld bead of the present invention after rapid cooling.
FIG. 5 is a physical diagram of a crack in the present invention, wherein FIG. 5(a) is a physical diagram of a surface crack and FIG. 5(b) is a physical diagram of a cross-sectional crack.
FIG. 6 is a schematic view of the spot-bonding of a defect test panel according to the present invention.
FIG. 7 is a schematic cross-sectional view of the present invention after crack region filling and cap welding.
Fig. 8 is a schematic structural diagram of a completed defect test board according to the present invention.
Wherein: 1. testing a defect plate; 2, rigid clamp; 3 fastening the bolt; 4. a high carbon equivalent weld bead; 5. welding cracks; 6. fixing a welding bead; 7. filling a weld bead; 8. and covering layers.
Detailed Description
The present invention is described in further detail below with reference to the attached drawings.
A method for manufacturing an internal crack defect test plate for nondestructive inspection teaching specifically comprises the following steps:
step one, selecting high carbon equivalent welding materials
Selecting a high carbon equivalent welding material with deposited metal carbon equivalent Ceq more than 0.46 percent according to the chemical components of the deposited metal of the welding rod and the following carbon equivalent formula: ceq ═ C + Mo/4+ Cr/5+ Mn/6+ V/14+ Si/24+ Ni/40 (%);
step two, preparation of defect test plate
Referring to fig. 1, a steel plate is selected as a test plate 1; a double-sided V-shaped groove with a truncated edge is formed on the test plate 1;
step three, rigidly fixing the test board
Referring to fig. 1 and 2, the test plate 1 with the groove processed is assembled and effectively fixed in a rigid fixing mode, and a gap is reserved between the V-shaped grooves;
step four, crack manufacturing
Referring to fig. 3 to 5, the welding rod selected in the first step is adopted to weld the high carbon equivalent weld bead 4 in the designed crack area between the V-grooves of the test plate 1, and after arc quenching, the high carbon equivalent weld bead 4 is rapidly cooled and placed for 24 hours, so that the longitudinal weld crack 5 of the penetrating weld bead can appear;
step five, referring to fig. 2 and 6, loosening the rigid fixation and tack welding the test plate 1;
step six, backing welding of the non-designed crack area
Preheating the test plate 1, backing-welding the non-designed crack regions between the V-shaped grooves, polishing and removing point fixing welding beads by using an angle grinder when welding to a point fixing welding position, then carrying out backing-welding again, polishing the back surfaces of the backing-welded seams, and finishing the surfaces of the poorly-formed seams;
step seven, filling the defect test plate and welding the cover surface
Referring to fig. 7 and 8, after preheating the test plate 1, welding the test plate 1 with a filling weld bead 7 and a cover surface layer 8 by using a J427 welding rod with a diameter of 4.0 mm;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
The welding material selected in the first step comprises J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% or J107Cr welding rod with Ceq being 0.942%.
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as the steel plate of the test plate 1 in the second step; the angle A of the V-shaped groove is 45-60 degrees; the height H of the truncated edge is 3-5 mm.
The rigid fixing mode in the third step comprises the step of clamping the test plate 1 by a rigid clamp 2 and a fastening bolt 3 arranged on the rigid clamp; the V-shaped groove gap width L of the test plate 1 is 2-4 mm.
The welding material strip used in the fourth step is any one of J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% and J107Cr with Ceq being 0.942%; the specification of the welding rod is 3.2mm in diameter, 4.0mm in diameter or 5.0mm in diameter, the welding current is 190A, and the rapid cooling mode comprises water spraying or liquid nitrogen pouring.
In the fifth step, the welding rod adopted for the spot welding of the test plate 1 is J427 with the diameter of 3.2 mm; the welding current 110-.
In the sixth step, the preheating temperature of the test plate 1 is 200-300 ℃, the welding rod used for backing welding of the non-designed crack region is J427 with the diameter of 3.2mm, and the welding current is 110-140A.
The preheating temperature of the test plate 1 in the seventh step is 200-300 ℃; the welding rod adopted for welding the filling weld bead 7 and the cover surface layer 8 on the test plate 1 is J427 with the diameter of 4.0 mm; the welding current is 140-180A; ensuring the interlayer temperature not to be lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1.
And the welding of the high-carbon equivalent welding bead 4 is carried out at room temperature.
Example 1
Step one, selecting high carbon equivalent welding materials
Selecting a J607R welding rod with Ceq being 0.461%, wherein the diameter of the welding rod is 3.2 mm;
step two, preparation of defect test plate
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as a test plate 1; opening a double-sided V-shaped groove with a truncated edge on the test plate 1 according to the designed crack depth, wherein the angle A of the V-shaped groove is 45 degrees; the height H of the truncated edge is 3 mm;
step three, rigidly fixing the defect test plate
Assembling the test plate 1 with the processed groove by using a rigid clamp 2 and a fastening bolt 3, wherein the gap width L of the groove is 2mm, and screwing the fastening bolt 3 after assembling to ensure effective rigid fixation of the test plate 1;
step four, crack manufacturing
Adopting a J607R welding rod with the Ceq of 0.461 percent and the diameter of 3.2mm to weld the high carbon equivalent welding bead 4 in the designed crack area between the V-shaped grooves of the test plate 1, wherein the welding current is 120A, and immediately cooling the high carbon equivalent welding bead 4 in a water spraying mode and placing for 24 hours after arc quenching so as to generate a penetrating welding bead longitudinal welding crack 5;
step five, disassembling the clamp and spot welding the defect test plate
Loosening the fastening bolt 3, and performing tack welding on the test plate 1 by adopting a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 110A, and the length of a tack welding bead 6 is 8 mm;
step six, backing welding of the non-designed crack area
Preheating a test plate 1 at 200 ℃, and then backing-welding a non-designed crack region between V-shaped grooves by using a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 110A; when the welding is carried out to the position of the point fixing welding bead 6, the point fixing welding bead 6 is polished and removed by an angle grinder, and then bottoming welding is carried out again; grinding the back of the bottoming weld joint, and finishing the surface of the poorly formed weld joint;
step seven, filling the defect test plate and welding the cover surface
Preheating a test plate 1 at 200 ℃, and then welding a filling weld bead 7 and a cover surface layer 8 on the test plate 1 by using a J427 welding rod with the diameter of 4.0mm, wherein the welding current is 140A, and the interlayer temperature is not lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
Example 2
Step one, selecting high carbon equivalent welding materials
Selecting a J857CrNi welding rod with Ceq being 0.708%, wherein the diameter of the welding rod is 3.2 mm;
step two, preparation of defect test plate
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as a test plate 1; according to the design crack depth, a double-sided V-shaped groove with a truncated edge is formed on the test plate 1, and the angle A of the V-shaped groove is 50 degrees; the height H of the truncated edge is 4 mm;
step three, rigidly fixing the test board
Assembling the test plate 1 with the processed V-shaped groove by using a rigid clamp 2 and a fastening bolt 3, wherein the gap width L of the V-shaped groove is 3mm, and screwing the fastening bolt 3 after assembling to ensure effective rigid fixation of the test plate 1;
step four, crack manufacturing
Adopting a J857CrNi welding rod with the Ceq of 0.708 percent and the diameter of 3.2mm to weld a high-carbon equivalent welding bead 4 in a designed crack area between V-shaped grooves of the test plate 1, wherein the welding current is 140A, immediately spraying water to the high-carbon equivalent welding bead 4 after arc quenching, rapidly cooling and placing for 24 hours to obtain a longitudinal crack 5 of a penetrable welding bead;
step five, disassembling the clamp and spot welding the defect test plate
Loosening the fastening bolt 3, and adopting a J427 welding rod with the diameter of 3.2mm to perform point fixing welding on the test plate 1, wherein the welding current is 130A, and the length of a point fixing welding bead is 10 mm;
step six, backing welding of the non-designed crack area
Preheating a test plate 1 at 250 ℃, and then backing-welding a non-designed crack region between V-shaped grooves by using a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 130A; when the welding is carried out to the point fixing welding position, the point fixing welding bead 6 is polished by an angle grinder and then rebating welding is carried out; grinding the back of the bottoming weld joint, and finishing the surface of the poorly formed weld joint;
step seven, filling the defect test plate and welding the cover surface
Preheating a test plate 1 at 250 ℃, and then welding a filling weld bead 7 and a cover surface layer 8 on the test plate 1 by using a J427 welding rod with the diameter of 4.0mm, wherein the welding current is 160A, and the interlayer temperature is not lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
Example 3
Step one, selecting high carbon equivalent welding materials
Selecting a J107Cr welding rod with Ceq being 0.942%, wherein the diameter of the welding rod is 4.0 mm;
step two, preparation of defect test plate
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as a test plate 1; according to the designed crack depth, a double-sided V-shaped groove with a truncated edge is formed on the test plate 1, and the angle A of the V-shaped groove is 60 degrees; the height H of the truncated edge is 5 mm;
step three, rigidly fixing the defect test plate
Assembling the test plate 1 with the processed V-shaped groove by using a rigid clamp 2 and a fastening bolt 3, wherein the groove gap L is 4mm, and screwing the fastening bolt 3 after assembling to ensure effective rigid fixation of the test plate 1;
step four, crack manufacturing
Adopting a J107Cr welding rod with the Ceq of 0.942% and the diameter of 4.0mm to weld the high carbon equivalent welding bead 4 in the designed crack area between the V-shaped grooves of the test plate 1, wherein the welding current is 160A, and immediately after arc quenching, rapidly cooling the high carbon equivalent welding bead 4 in a water spraying mode and placing for 24 hours to form a longitudinal welding crack 5 of the penetrating welding bead;
step five, disassembling the clamp and spot welding the defect test plate
Loosening the fastening bolt 3, and adopting a J427 welding rod with the diameter of 3.2mm to perform tack welding on the test plate 1, wherein the welding current is 140A, and the length of a tack welding bead 6 is 12 mm;
step six, backing welding of the non-designed crack area
Preheating a test plate 1 at 300 ℃, and then backing-welding a non-designed crack region between V-shaped grooves by using a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 140A; when the welding is carried out to the position of the point fixing welding bead 6, the point fixing welding bead 6 is polished and removed by an angle grinder, and then bottoming welding is carried out again; grinding the back of the bottoming weld joint, and finishing the surface of the poorly formed weld joint;
step seven, filling the defect test plate and welding the cover surface
Preheating a test plate 1 at 300 ℃, and then welding a filling weld bead 7 and a cover surface layer 8 on the test plate 1 by using a J427 welding rod with the diameter of 4.0mm, wherein the welding current is 180A, and the interlayer temperature is not lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
Example 4
Step one, selecting high carbon equivalent welding materials
Selecting a J107Cr welding rod with Ceq being 0.942%, wherein the diameter of the welding rod is 4.0 mm;
step two, preparation of defect test plate
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as a test plate 1; according to the designed crack depth, a double-sided V-shaped groove with a truncated edge is formed on the test plate 1, and the angle A of the V-shaped groove is 60 degrees; the height H of the truncated edge is 5 mm;
step three, rigidly fixing the defect test plate
Assembling the test plate 1 with the processed V-shaped groove by using a rigid clamp 2 and a fastening bolt 3, wherein the groove gap L is 4mm, and screwing the fastening bolt 3 after assembling to ensure effective rigid fixation of the test plate 1;
step four, crack manufacturing
Adopting a J107Cr welding rod with the Ceq being 0.942% and the diameter being 5.0mm to weld the high carbon equivalent welding bead 4 in the designed crack area between the V-shaped grooves of the test plate 1, wherein the welding current is 190A, and immediately after arc quenching, rapidly cooling the high carbon equivalent welding bead 4 in a water spraying mode and placing for 24 hours to form a longitudinal welding crack 5 of the penetrating welding bead;
step five, disassembling the clamp and spot welding the defect test plate
Loosening the fastening bolt 3, and adopting a J427 welding rod with the diameter of 3.2mm to perform tack welding on the test plate 1, wherein the welding current is 140A, and the length of a tack welding bead 6 is 12 mm;
step six, backing welding of the non-designed crack area
Preheating a test plate 1 at 300 ℃, and then backing-welding a non-designed crack region between V-shaped grooves by using a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 140A; when the welding is carried out to the position of the point fixing welding bead 6, the point fixing welding bead 6 is polished and removed by an angle grinder, and then bottoming welding is carried out again; grinding the back of the bottoming weld joint, and finishing the surface of the poorly formed weld joint;
step seven, filling the defect test plate and welding the cover surface
Preheating a test plate 1 at 300 ℃, and then welding a filling weld bead 7 and a cover surface layer 8 on the test plate 1 by using a J427 welding rod with the diameter of 4.0mm, wherein the welding current is 180A, and the interlayer temperature is not lower than 200 ℃ in the welding process; when the test board 1 is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board 1;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
The invention is realized based on the following principles:
in the field of welding, in order to evaluate the sensitivity of steel materials to welding cold cracks, a plurality of indirect or direct crack sensitivity evaluation methods are established, a carbon equivalent calculation formula recommended by the Japanese society for welding (JIS) is Ceq ═ C + Mo/4+ Cr/5+ Mn/6+ V/14+ Si/24+ Ni/40 (%), and when the carbon equivalent Ceq calculated based on the chemical components of steel is more than 0.46%, the steel has certain cold crack sensitivity, and preheating is necessary to avoid the generation of cracks; on the basis of the principle of the indirect or direct crack sensitivity evaluation method, the method is carried out in a mode of butt joint of rigidly fixed high-constraint test plates, welding materials with high carbon equivalent are used for welding the designed defect position at normal temperature, the welded test plates are quickly cooled and placed for 24 hours, then the longitudinal welding crack with penetration of a weld bead can appear, then a clamp is disassembled and the defect test plates are fixed, the bottom welding is carried out on the non-designed crack area, then the defect test plates are filled and the cover surfaces are welded, and finally the surface of the weld joint is cleaned, so that the manufacture is completed.
Claims (10)
1. A method for manufacturing an internal crack defect test plate for nondestructive inspection teaching is characterized by comprising the following steps: the method specifically comprises the following steps:
step one, selecting high carbon equivalent welding materials
Selecting a high carbon equivalent welding material with deposited metal carbon equivalent Ceq more than 0.46 percent according to the chemical components of the deposited metal of the welding rod and the following carbon equivalent formula: ceq ═ C + Mo/4+ Cr/5+ Mn/6+ V/14+ Si/24+ Ni/40 (%);
step two, preparation of defect test plate
Selecting a steel plate as a test plate (1); a double-sided V-shaped groove with a truncated edge is formed on the test plate (1);
step three, rigidly fixing the test board
Assembling the test plate (1) with the processed V-shaped grooves in a rigid fixing mode and effectively fixing the test plate, wherein gaps are reserved among the V-shaped grooves;
step four, crack manufacturing
Welding high carbon equivalent welding beads (4) in the designed crack areas among the V-shaped grooves of the test plate (1) by adopting the selected welding rods in the step one, immediately and rapidly cooling the high carbon equivalent welding beads (4) after arc quenching and placing for 24 hours to form longitudinal welding cracks (5) of the penetrating welding beads;
fifthly, loosening the rigid fixation and performing point-fixing welding on the test plate (1);
step six, backing welding of the non-designed crack area
Preheating a test plate (1), backing-welding a non-designed crack area between V-shaped grooves, polishing and removing a point-fixing weld bead by using an angle grinder when welding to a point-fixing welding position, then carrying out backing-welding again, polishing the back of the backing-welding seam, and finishing the surface of the poorly-formed weld seam;
step seven, filling the defect test plate and welding the cover surface
After preheating the test plate (1), welding a filling weld bead (7) and a cover surface layer (8) on the test plate (1) by adopting a J427 welding rod with the diameter of 4.0 mm;
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
2. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: the welding material selected in the first step comprises J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% or J107Cr welding rod with Ceq being 0.942%.
3. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as the steel plate of the test plate (1) in the second step; the angle A of the V-shaped groove is 45-60 degrees; the height H of the truncated edge is 3-5 mm.
4. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: the third step of rigid fixing comprises the step of clamping the test plate (1) by a rigid clamp (2) and a fastening bolt (3) arranged on the rigid clamp; the V-shaped groove gap width L of the test plate (1) is 2-4 mm.
5. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: the welding material strip used in the fourth step is any one of J607R with Ceq being 0.461%, J857CrNi with Ceq being 0.708% or J107Cr with Ceq being 0.942%; the specification of the welding rod is 3.2mm in diameter, 4.0mm in diameter or 5.0mm in diameter; the welding current is 120-190A; the rapid cooling means includes water spraying or pouring liquid nitrogen.
6. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: fifthly, welding rods adopted for spot welding the test plate (1) are J427 with the diameter of 3.2 mm; the welding current 110-.
7. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: in the sixth step, the preheating temperature of the test plate (1) is 200-.
8. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: the preheating temperature of the test plate (1) in the seventh step is 200-300 ℃; the welding rod adopted for welding the filling welding bead (7) and the cover surface layer (8) on the test plate (1) is J427 with the diameter of 4.0 mm; the welding current is 140-180A; ensuring the interlayer temperature not to be lower than 200 ℃ in the welding process; when the test board (1) is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board (1).
9. The method for manufacturing the internal crack defect test board for the non-destructive inspection teaching of claim 1, wherein the method comprises the following steps: the method specifically comprises the following steps:
step one, selecting high carbon equivalent welding materials
Selecting a J857CrNi welding rod with Ceq being 0.708%, wherein the diameter of the welding rod is 3.2 mm;
step two, preparation of defect test plate
Selecting a low-carbon steel plate with the length of 300mm, the width of 150mm and the thickness of 30mm as a test plate (1); according to the design crack depth, a double-sided V-shaped groove with a truncated edge is formed on the test plate (1), the angle A range of the V-shaped groove is 50 degrees, and the height H of the truncated edge is 4 mm;
step three, rigidly fixing the test board
Assembling the test plate (1) with the processed V-shaped groove by using a rigid clamp (2) and a fastening bolt (3), wherein the gap width L of the V-shaped groove is 3mm, and screwing the fastening bolt (3) after assembling to ensure effective rigid fixation of the test plate (1);
step four, crack manufacturing
Adopting a J857CrNi welding rod with the Ceq of 0.708 percent and the diameter of 3.2mm to weld a high-carbon equivalent welding bead (4) in a designed crack area between V-shaped grooves of a test plate (1), wherein the welding current is 140A, immediately spraying water to the high-carbon equivalent welding bead (4) after arc quenching, rapidly cooling and placing for 24 hours, and then generating a longitudinal crack (5) of a penetrating welding bead;
step five, disassembling the clamp and spot welding the defect test plate
Loosening the fastening bolt (3), and adopting a J427 welding rod with the diameter of 3.2mm to perform tack welding on the test plate (1), wherein the welding current is 130A, and the length of a tack welding bead is 10 mm;
step six, backing welding of the non-designed crack area
Preheating the test plate (1) at 250 ℃, and then backing-welding the non-designed crack region between the V-shaped grooves by using a J427 welding rod with the diameter of 3.2mm, wherein the welding current is 130A; when the welding is carried out to the point fixing welding position, the point fixing welding bead (6) is polished and removed by an angle grinder, and then bottoming welding is carried out again; grinding the back of the bottoming weld joint, and finishing the surface of the poorly formed weld joint;
step seven, filling the defect test plate and welding the cover surface
Preheating a test plate (1) at 250 ℃, and then welding a filling weld bead (7) and a cover surface layer (8) on the test plate (1) by using a J427 welding rod with the diameter of 4.0mm, wherein the welding current is 160A, and the interlayer temperature is not lower than 200 ℃ in the welding process; when the test board (1) is filled and the cover surface is welded, a front surface and a back surface are welded alternately to ensure the flatness of the test board (1);
and eighthly, cleaning the surface of the welding seam after the step is finished, and finishing the manufacture of the internal crack defect test plate after the cleaning is finished.
10. The method for manufacturing an internal crack defect test plate for non-destructive inspection teaching according to claim 1 or 9, wherein: and the welding of the high-carbon equivalent welding bead (4) is carried out at room temperature.
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