CN111862319B - Reconstruction method and system for weld joint microcrack morphology and expansion trend - Google Patents
Reconstruction method and system for weld joint microcrack morphology and expansion trend Download PDFInfo
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- CN111862319B CN111862319B CN202010757995.1A CN202010757995A CN111862319B CN 111862319 B CN111862319 B CN 111862319B CN 202010757995 A CN202010757995 A CN 202010757995A CN 111862319 B CN111862319 B CN 111862319B
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- 238000000034 method Methods 0.000 title claims abstract description 34
- 238000005498 polishing Methods 0.000 claims abstract description 38
- 238000003466 welding Methods 0.000 claims abstract description 19
- 238000000227 grinding Methods 0.000 claims abstract description 15
- 230000015572 biosynthetic process Effects 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 230000007246 mechanism Effects 0.000 claims description 5
- 238000012986 modification Methods 0.000 claims description 2
- 230000004048 modification Effects 0.000 claims description 2
- 238000012876 topography Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 description 7
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 3
- 229910052739 hydrogen Inorganic materials 0.000 description 3
- 239000001257 hydrogen Substances 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 238000011534 incubation Methods 0.000 description 2
- 238000005336 cracking Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000003745 diagnosis Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 238000003303 reheating Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
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Abstract
The invention relates to a reconstruction method and a reconstruction system of weld microcrack morphology and expansion trend, wherein the method specifically comprises the following steps: and transversely grinding and polishing the welding sample, then shooting metallographic pictures of the grinding and polishing surface, repeating the operation for a plurality of times to obtain a plurality of metallographic pictures, carrying out image processing on all the metallographic pictures, reconstructing a weld microcrack three-dimensional model according to all the metallographic pictures after the image processing, and obtaining the appearance and the expansion trend of the weld microcracks according to the model. Compared with the prior art, the method has the advantages of simplicity in operation, high precision and the like.
Description
Technical Field
The invention relates to the field of weld defect detection, in particular to a reconstruction method and a reconstruction system of weld microcrack morphology and expansion trend.
Background
Weld cracking is one of the most common serious defects in welds. Under the combined action of welding stress and other embrittlement factors, the binding force of metal atoms in local areas in the welded joint is destroyed, and a gap is generated by a new interface. It features sharp notches and a large aspect ratio. Cracks affect the safe use of the weld, a very dangerous process defect. Welding cracks occur not only during welding but also during a certain period of incubation and sometimes during reheating after welding.
How to prevent and detect weld cracks in welding engineering is a big problem, and in order to obtain the positions, the sizes, the forming reasons and the like of the cracks, industrial means such as ultrasonic and X-rays are adopted. However, due to the randomness of the crack growth of the welding seam, under the condition that the crack is relatively tiny, the conventional means usually generate missed judgment, only two-dimensional characteristics of the crack can be obtained, only partial information of the crack is often obtained, the crack growth trend and the crack growth direction cannot be obtained, and difficulty and even misjudgment can be brought to the analysis of the crack cause.
Disclosure of Invention
The invention aims to overcome the defects of the prior art and provide a reconstruction method and a reconstruction system for the shape and the expansion trend of weld microcracks, which are simple to operate and high in precision.
The aim of the invention can be achieved by the following technical scheme:
a reconstruction method of weld joint microcrack morphology and expansion trend specifically comprises the following steps:
and transversely polishing the welding sample, then shooting metallographic pictures of polished surfaces, repeating the operation for a plurality of times, wherein all polished surfaces are distributed at equal intervals, obtaining a plurality of metallographic pictures, performing image processing on all metallographic pictures, reconstructing a weld microcrack three-dimensional model according to all metallographic pictures after the image processing, and obtaining the appearance and the expansion trend of the weld microcracks according to the model.
Further, the image processing process specifically includes: performing binarization processing and position calibration on a metallographic picture, wherein the position calibration process specifically comprises the following steps: and calibrating the longitudinal coordinate of each metallographic picture and the two-dimensional coordinate of the weld microcrack on each metallographic picture.
Further, the reconstruction accuracy is adjusted by adjusting the distance between two adjacent polishing surfaces.
The reconstruction system for the appearance and the expansion trend of the weld microcracks comprises a sample grinding and polishing module, a metallographic shooting module, an image processing module and a three-dimensional reconstruction module;
the sample polishing module is used for transversely polishing a welded sample, a plurality of polishing surfaces with different longitudinal positions are obtained, all polishing surfaces are distributed at equal intervals, the sample polishing module can adjust reconstruction precision by adjusting the interval between two adjacent polishing surfaces, the metallographic photographing module photographs metallographic pictures of each polishing surface, the image processing module performs image processing on each metallographic picture, and the three-dimensional reconstruction module reconstructs a weld microcrack three-dimensional model according to all metallographic pictures subjected to image processing, and obtains the appearance and the expansion trend of the weld microcracks according to the model.
Further, the image processing process specifically includes: the image processing module carries out binarization processing on the metallographic picture and carries out position calibration, and the position calibration process specifically comprises the following steps: the image processing module is used for calibrating the longitudinal coordinates of each metallographic picture and the two-dimensional coordinates of the weld microcracks on each metallographic picture.
Compared with the prior art, the invention has the following beneficial effects:
(1) According to the invention, the transverse grinding and polishing are carried out on the welding sample, then the metallographic pictures of the grinding and polishing surface are shot, the operations are repeated for a plurality of times, a plurality of metallographic pictures are obtained, the image processing is carried out on all metallographic pictures, all metallographic pictures after the image processing are subjected to three-dimensional superposition, a weld microcrack three-dimensional model is reconstructed, and the shape and the expansion trend of the weld microcrack are obtained according to the model;
(2) The invention can adjust the reconstruction precision by adjusting the distance between two adjacent grinding and polishing surfaces, and has good flexibility.
Drawings
FIG. 1 is a schematic diagram of a reconstruction process of a weld microcrack three-dimensional model.
Detailed Description
The invention will now be described in detail with reference to the drawings and specific examples. The present embodiment is implemented on the premise of the technical scheme of the present invention, and a detailed implementation manner and a specific operation process are given, but the protection scope of the present invention is not limited to the following examples.
Example 1
A reconstruction method of weld joint microcrack morphology and expansion trend is shown in figure 1, specifically:
and transversely grinding and polishing the welding sample, then shooting metallographic pictures of the grinding and polishing surfaces, repeating the operation for a plurality of times, wherein all the grinding and polishing surfaces are distributed at equal intervals, the distance between two adjacent grinding and polishing surfaces is delta n, the reconstruction precision is adjusted by adjusting delta n, the smaller delta n is, the higher the precision is, a plurality of metallographic pictures are obtained, the image processing is carried out on all the metallographic pictures, a weld microcrack three-dimensional model is reconstructed according to all the metallographic pictures after the image processing, the shape and the expansion trend of the weld microcracks are obtained according to the model, and the full shape of the weld microcracks in three directions of length, width and height can be obtained according to the weld microcrack three-dimensional model and used for the failure analysis of the weld of the metal part.
The image processing process specifically comprises the following steps: performing binarization processing and position calibration on the metallographic picture, wherein the position calibration process specifically comprises the following steps: and calibrating the longitudinal coordinate of each metallographic picture and the two-dimensional coordinate of the weld microcrack on each metallographic picture.
And determining main cracks of the welding seam according to the three-dimensional model of the welding seam microcrack, and observing the characteristics of the main cracks, which is a precondition step for analyzing the reasons of the cracks of the welding fracture. The reasons for forming the weld cracks are various, the reasons are not only related to poor control of the welding process, but also related to the service working condition of the weld, the cracks related to the welding process are generated in the welding engineering, a certain incubation period is also provided, and the cracks can be divided into four types of hot cracks, cold cracks, reheat cracks and lamellar tearing according to the conditions of crack formation, wherein the hot cracks can be further divided into crystallization cracks, liquefaction cracks and polygonal cracks according to the characteristics of the forming process, and the cold cracks can be further divided into quenching cracks, hydrogen-induced delay cracks and deformation cracks according to the main causes. Cracks related to service conditions of the welding seam can be divided into fatigue cracks under alternating load, creep cracks under combined action of stress and temperature, cracks generated in the loading process in an inert medium, stress corrosion cracks under combined action of stress and chemical medium and hydrogen induced cracks caused after hydrogen enters. The forming process and mechanism of each type of crack are different, the appearance features and the expansion trends of different cracks are different, the stress corrosion crack shows a dead dendritic feature, and the fatigue crack is accompanied by the features of a sliding band, inclusions, extrusion ridges and the like due to different fatigue mechanisms.
To obtain all the characteristics of the crack, it is not enough to obtain only two-dimensional information of the weld, and a three-dimensional model needs to be built. Cracks are surface defects in the material, and are characterized by two dimensions of length and width, and are divided into three basic states of open cracks, sliding cracks and tearing cracks. However, in the actual member, the cracks in the actual crack body are a combination of two or more basic states due to the complexity of the applied stress, and branch cracks in different directions exist around one main crack due to the randomness of the crack propagation direction, so that the cracks under the actual working condition basically have the characteristics of three dimensions of length, width and height. The recognition of the shape and the expansion trend of the weld microcracks is beneficial to the diagnosis of the weld failure reasons, and the weld crack failure analysis of the metal part specifically comprises the starting point of cracks, the positions of crack source areas, the number of the crack source areas, the sequence of a plurality of crack source areas, the expansion of the cracks, the crack expansion speed, the proportion of crack formation and crack expansion, the microscopic mechanism of crack formation and the like. The weld crack failure analysis can provide a basis for preventing the occurrence of fracture again and a direction for the establishment of corrective measures.
Example 2
The reconstruction system of the weld microcrack morphology and the expansion trend corresponding to the embodiment 1 comprises a sample grinding and polishing module, a metallographic shooting module, an image processing module and a three-dimensional reconstruction module;
the sample polishing module is used for transversely polishing a welded sample, obtaining a plurality of polishing surfaces with different longitudinal positions, all polishing surfaces are distributed at equal intervals, the sample polishing module can adjust reconstruction precision by adjusting the interval delta n between two adjacent polishing surfaces, the smaller delta n is, the higher the precision is, the metallographic shooting module shoots metallographic pictures of each polishing surface, the image processing module carries out image processing on each metallographic picture, the three-dimensional reconstruction module reconstructs a three-dimensional model of the weld microcrack according to all metallographic pictures subjected to the image processing, and the morphology and the expansion trend of the weld microcrack are obtained according to the model.
The image processing process specifically comprises the following steps: the image processing module carries out binarization processing on the metallographic pictures and carries out position calibration, and the position calibration process specifically comprises the following steps: the image processing module calibrates the longitudinal coordinate of each metallographic picture and the two-dimensional coordinate of the weld microcrack on each metallographic picture.
Embodiment 1 and embodiment 2 propose a reconstruction method and a reconstruction system of the appearance and the expansion trend of weld microcracks, a method of transversely grinding and polishing a defect sample and carrying out three-dimensional overlapping reconstruction on the metallographic phase of the defect sample is adopted to obtain the appearance of crack expansion and the three-dimensional growth trend, and the operation is simple and the precision is high.
The foregoing describes in detail preferred embodiments of the present invention. It should be understood that numerous modifications and variations can be made in accordance with the concepts of the invention by one of ordinary skill in the art without undue burden. Therefore, all technical solutions which can be obtained by logic analysis, reasoning or limited experiments based on the prior art by the person skilled in the art according to the inventive concept shall be within the scope of protection defined by the claims.
Claims (6)
1. A reconstruction method of weld joint microcrack morphology and expansion trend is characterized by comprising the following steps:
performing transverse grinding and polishing on a welding sample, then shooting metallographic pictures of a grinding and polishing surface, repeating the operations for a plurality of times to obtain a plurality of metallographic pictures, performing image processing on all metallographic pictures, reconstructing a weld microcrack three-dimensional model according to all metallographic pictures after the image processing, obtaining a weld microcrack morphology and a propagation trend according to the model, performing metal part weld crack failure analysis based on the weld microcrack morphology and the propagation trend, and formulating modification measures, wherein the metal part weld crack failure analysis comprises starting points of cracks, positions of crack source areas, the number of the crack source areas, sequence of the plurality of crack source areas, crack propagation speed, proportion of crack formation and crack propagation and microscopic mechanism of crack formation,
the image processing process specifically comprises the following steps: performing binarization processing and position calibration on a metallographic picture, wherein the position calibration process specifically comprises the following steps: and calibrating the longitudinal coordinate of each metallographic picture and the two-dimensional coordinate of the weld microcrack on each metallographic picture.
2. The method for reconstructing the morphology and the expansion trend of the weld microcracks according to claim 1, wherein the reconstruction accuracy is adjusted by adjusting the distance between two adjacent grinding and polishing surfaces.
3. The method for reconstructing the morphology and the expansion trend of the weld microcracks according to claim 1, wherein all the polishing surfaces are distributed at equal intervals.
4. A reconstruction system for weld microcrack morphology and propagation trend, comprising:
the sample polishing module is used for transversely polishing the welding sample to obtain a plurality of polishing surfaces with different longitudinal positions;
the metallographic shooting module is used for shooting metallographic pictures of each polished surface;
the image processing module is used for carrying out image processing on each metallographic picture;
the three-dimensional reconstruction module is used for reconstructing a weld microcrack three-dimensional model according to all metallographic pictures subjected to image processing;
obtaining the shape and the expansion trend of the weld joint microcrack according to the model, carrying out crack failure analysis of the weld joint of the metal part based on the shape and the expansion trend of the weld joint microcrack, and formulating a rectifying and modifying measure, wherein the crack failure analysis of the weld joint of the metal part comprises starting points of cracks, positions of crack source areas, the number of the crack source areas, sequence of a plurality of crack source areas, crack expansion speed, proportion of crack formation and crack expansion and microscopic mechanism of crack formation,
the image processing process specifically comprises the following steps: the image processing module carries out binarization processing on the metallographic picture and carries out position calibration, and the position calibration process specifically comprises the following steps: the image processing module is used for calibrating the longitudinal coordinates of each metallographic picture and the two-dimensional coordinates of the weld microcracks on each metallographic picture.
5. The reconstruction system for the morphology and the expansion trend of the weld microcracks of claim 4, wherein the sample polishing module adjusts the reconstruction accuracy by adjusting the distance between two adjacent polishing surfaces.
6. The weld microcrack topography and propagation trend reconstruction system of claim 4 wherein all of the polishing surfaces are equally spaced.
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| CN113192070B (en) * | 2021-06-30 | 2021-09-10 | 深圳市超准视觉科技有限公司 | Weld image processing method and system based on computer vision |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106093037A (en) * | 2016-06-06 | 2016-11-09 | 南京航空航天大学 | Use the method that side successively polishing etch obtains fragile material cracks can spread three-dimensional appearance |
| CN108802049A (en) * | 2018-06-19 | 2018-11-13 | 上海大学 | Demarcate the method and its application of joint for resistance spot welding central defect |
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Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN106093037A (en) * | 2016-06-06 | 2016-11-09 | 南京航空航天大学 | Use the method that side successively polishing etch obtains fragile material cracks can spread three-dimensional appearance |
| CN108802049A (en) * | 2018-06-19 | 2018-11-13 | 上海大学 | Demarcate the method and its application of joint for resistance spot welding central defect |
Non-Patent Citations (3)
| Title |
|---|
| TC4钛合金微束等离子弧焊接接头疲劳性能研究;邹慧;雷娟娟;孙宇博;王志平;;焊接技术(11);全文 * |
| 金属断口宏观形貌三维重构研究;于斌;靳庆臣;刘志栋;;兵器材料科学与工程(03);全文 * |
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