CN112147223A - Method for detecting internal defects of casting blank - Google Patents
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- CN112147223A CN112147223A CN202011094550.6A CN202011094550A CN112147223A CN 112147223 A CN112147223 A CN 112147223A CN 202011094550 A CN202011094550 A CN 202011094550A CN 112147223 A CN112147223 A CN 112147223A
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- 239000002253 acid Substances 0.000 description 2
- 238000005530 etching Methods 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
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- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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- G01N29/34—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor
- G01N29/346—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor with amplitude characteristics, e.g. modulated signal
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- G01N29/34—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor
- G01N29/348—Generating the ultrasonic, sonic or infrasonic waves, e.g. electronic circuits specially adapted therefor with frequency characteristics, e.g. single frequency signals, chirp signals
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- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/449—Statistical methods not provided for in G01N29/4409, e.g. averaging, smoothing and interpolation
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/48—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by amplitude comparison
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- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
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Abstract
The invention relates to the technical field of casting blank defect detection, in particular to a method for detecting internal defects of a casting blank. The method comprises the following steps: attaching a probe of an ultrasonic flaw detector to a set position on the surface of a casting blank; respectively adjusting the ultrasonic frequency of the ultrasonic flaw detector and the basic amplitude of the primary bottom wave to be set frequency and set amplitude; calculating a sensitivity gain value at a set position; updating the sensitivity gain value at the set position to the sensitivity gain value at the central thickness of the casting blank; adjusting the sensitivity gain of the ultrasonic flaw detector to the updated sensitivity gain value at the set position; and scanning the interior of the casting blank to detect the internal defects of the casting blank. The invention adopts the ultrasonic flaw detection method to detect the internal defects of the casting blank, and adjusts the sensitivity gain of the ultrasonic flaw detector by using the sensitivity gain value at the central thickness of the casting blank, thereby inhibiting the influence of excessive grass-shaped waves on the accuracy of the detection result in the detection process and realizing the accurate detection of the internal defects of the casting blank.
Description
Technical Field
The invention relates to the technical field of casting blank defect detection, in particular to a method for detecting internal defects of a casting blank.
Background
The high-quality super-thick plate is mainly used for bridges, molds, large containers, hydroelectric engineering, ocean platforms and the like, and has strict requirements on the internal quality of the steel plate. However, the compression ratio of the extra-thick plate is limited during production, so that the requirement for the internal quality of the original cast slab is high. In the final stage of casting of the casting blank, due to the influence of volume shrinkage during the solidification of molten steel, the defects of gaps, air holes and the like are easy to appear in the casting blank, the center of the casting blank is loose, and the quality of the extra-thick plate is influenced.
According to the traditional evaluation of internal defects of casting blanks, the national standard GB/T226-2015 'steel macrostructure and defect acid etching inspection method' is adopted, two steel blanks are extracted according to smelting batches, and macrostructure and defect acid etching detection is carried out on a width section. The method is extracted according to batches, is limited to a cut section, has larger contingency and has low detection accuracy.
Therefore, how to improve the accuracy of detecting the internal defects of the casting blank is a technical problem which needs to be solved urgently at present.
Disclosure of Invention
The invention aims to provide a method for detecting internal defects of a casting blank, which is used for improving the accuracy of detection of the internal defects of the casting blank.
In order to achieve the above object, an embodiment of the present invention provides a method for detecting internal defects of a casting blank, including:
attaching a probe of an ultrasonic flaw detector to a set position on the surface of a casting blank;
adjusting the ultrasonic frequency of the ultrasonic flaw detector and the basic amplitude of the primary bottom wave to be set frequency and set amplitude respectively;
calculating a sensitivity gain value at the set position;
updating the sensitivity gain value at the set position to the sensitivity gain value at the central thickness of the casting blank;
adjusting the sensitivity gain of the ultrasonic flaw detector to the updated sensitivity gain value at the set position;
and scanning the interior of the casting blank so as to detect the internal defects of the casting blank.
In a possible embodiment, the adjusting the ultrasonic frequency and the primary bottom wave amplitude of the ultrasonic flaw detector to a set frequency and a set amplitude respectively includes:
if the average grain size of the crystal grains of the casting blank exceeds a set grain size, the value range of the set frequency is 0.5MHz to 1 MH;
and if the average grain size of the crystal grains of the casting blank does not exceed the set grain size, the value range of the set frequency is 2 MHz-2.5 MH.
In one possible embodiment, the calculating the sensitivity gain value at the set position includes:
calculating a sensitivity gain value delta at the set position by using a bottom wave formula1(ii) a Wherein the bottom wave formula is:
wherein λ is the wavelength of the ultrasonic wave of the set frequency, x1Is the thickness of the cast slab, D1The equivalent size of a reference flat bottom hole of the ultrasonic flaw detector is shown.
In a possible embodiment, the updating the sensitivity gain value at the set position to the sensitivity gain value at the center thickness of the cast slab includes:
calculating a sensitivity gain value delta at the center thickness of the casting blank2The specific calculation formula is as follows:
Δ2＝Δ1-12dB。
in a possible embodiment, the scanning the interior of the cast slab to detect the internal defects of the cast slab includes:
obtaining the amplitude h of the reflected wave of a defect1；
Calculating the amplitude h of the reflected wave of the certain defect1Difference Δ from current reference sensitivity Δ3The specific calculation formula is as follows:
Δ3＝|h1-Δ|；
calculating a defect equivalent size D of the certain defect2And defect depth x2The specific calculation formula is as follows:
in a possible embodiment, said calculating a defect equivalent size D of said certain defect2And defect depth x2Thereafter, the method further comprises:
any defect in all defects in the casting blank is equivalent to a defect sphere; wherein the diameter of the defect sphere is the defect equivalent size of any defect;
and calculating the accumulated defect volume corresponding to all the defects in the casting blank.
In a possible embodiment, after calculating the cumulative defect volume corresponding to all defects in the casting slab, the method further includes:
calculating an equivalent defect layer value E for evaluating the internal defects of the casting blank, wherein the specific calculation formula is as follows:
wherein V is the accumulated defect volume corresponding to all defects in the casting blank, and S is the detection area of the ultrasonic flaw detector;
and taking the maximum value in the defect depths of all defects in the casting blank as the maximum defect layer value for determining the pressing process of the casting blank.
In a possible embodiment, the set amplitude value ranges from 50% of the longitudinal range to 80% of the longitudinal range of the ultrasonic flaw detector.
Compared with the prior art, the invention has the following advantages and beneficial effects:
the invention adopts the ultrasonic flaw detection method to detect the internal defects of the casting blank, and adjusts the sensitivity gain of the ultrasonic flaw detector by using the sensitivity gain value at the central thickness of the casting blank, thereby inhibiting the influence of excessive grass-shaped waves on the accuracy of the detection result in the detection process and realizing the accurate detection of the internal defects of the casting blank.
Drawings
In order to more clearly illustrate the embodiments of the present specification or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present specification, and it is obvious for those skilled in the art that other drawings can be obtained according to the drawings without creative efforts.
Fig. 1 is a flowchart of a method for detecting internal defects of a casting blank according to an embodiment of the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be described clearly and completely with reference to the accompanying drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, rather than all embodiments, and all other embodiments obtained by those skilled in the art based on the embodiments of the present invention belong to the scope of protection of the embodiments of the present invention.
In the art, ultrasonic flaw detectors are commonly used to detect flaws within metals. The ultrasonic flaw detector transmits ultrasonic signals to the inside of the metal through the probe, receives the reflected ultrasonic signals, and detects the defects in the metal through waveform analysis. However, because the thickness of the casting blank is large, when the internal defect of the casting blank is detected by directly using the ultrasonic flaw detector, the low-frequency ultrasonic signal of the casting blank is interfered by the internal structure of the casting blank, so that a large amount of grass-shaped wave interference signals are carried in the reflected wave signal, which causes that the defect analysis cannot be accurately carried out on the signal, and therefore the ultrasonic flaw detector is not generally suitable for the defect detection of the casting blank in the field.
The invention hopes to realize accurate detection of the internal defects of the casting blank by using the ultrasonic flaw detector through the following scheme.
The present embodiment provides a method for detecting internal defects of a casting blank, please refer to fig. 1, where fig. 1 is a flowchart of the method embodiment, and specifically includes steps 11 to 16.
And 11, attaching a probe of the ultrasonic flaw detector to a set position on the surface of the casting blank.
Specifically, the ultrasonic flaw detector can set a detection range, and the attachment position of the probe determines the detection range. In the present example, the detection range of the ultrasonic flaw detector is set to a region of the entire width of the cast slab centered on the set position × 200 mm.
And 12, respectively adjusting the ultrasonic frequency of the ultrasonic flaw detector and the basic amplitude of the primary bottom wave to be set frequency and set amplitude.
Specifically, the ultrasonic frequency of the ultrasonic flaw detector can be set by the frequency selection knob of the ultrasonic flaw detector, and the basic amplitude of the primary bottom wave can be adjusted by the emission intensity knob and the suppression knob of the ultrasonic flaw detector.
Specifically, if the average grain size of the crystal grains of the casting blank exceeds a set grain size, the value range of the set frequency is 0.5MHz to 1 MH; and if the average grain size of the crystal grains of the casting blank does not exceed the set grain size, the value range of the set frequency is 2 MHz-2.5 MH.
Specifically, the range of the set amplitude is from 50% of the longitudinal range of the ultrasonic flaw detector to 80% of the longitudinal range. The unit of amplitude and sensitivity is dB.
And step 13, calculating a sensitivity gain value at the set position.
Here, a scheme for calculating a sensitivity gain value at a set position is given, specifically:
step 21, calculating the sensitivity gain value delta at the set position by using the bottom wave formula1(ii) a Wherein the bottom wave formula is:
wherein λ is the wavelength of the ultrasonic wave of the set frequency, x1Is the thickness of the cast slab, D1The equivalent size of a reference flat bottom hole of the ultrasonic flaw detector is shown.
And step 14, updating the sensitivity gain value at the set position to the sensitivity gain value at the center thickness of the casting blank.
Specifically, since the sensitivity gain value at the set position is directly used as the sensitivity gain value of the ultrasonic flaw detector, a large number of grass-shaped wave interference signals appear in the reflected waveform diagram, after a large number of experiments, the inventor of the present invention finds that the amplitude height of the grass-shaped wave interference signals can be effectively suppressed by adjusting the sensitivity gain of the ultrasonic flaw detector to the sensitivity gain value at the central thickness of the casting blank, and further eliminates the interference of the grass-shaped waves on defect analysis.
The method for calculating the sensitivity gain value at the central thickness of the casting blank comprises the following steps:
step 31, calculating a sensitivity gain value delta at the central thickness of the casting blank2The specific calculation formula is as follows:
Δ2＝Δ1-12dB。
and step 15, adjusting the sensitivity gain of the ultrasonic flaw detector to the updated sensitivity gain value at the set position.
Specifically, the sensitivity gain of the ultrasonic flaw detector can be adjusted by the sensitivity gain knob of the ultrasonic flaw detector.
And step 16, scanning the interior of the casting blank so as to detect the internal defects of the casting blank.
The internal defect scanning detection scheme for the casting blank is provided, and specifically comprises the following steps:
step 41, obtaining the amplitude h of the reflected wave of a certain defect1。
Specifically, according to the reflection oscillogram, the reflected wave representing a single defect inside the casting blank can be easily distinguished, and the amplitude height (i.e. wave height) of the reflected wave can be known through reading.
Step 42, calculating the amplitude h of the reflected wave of the certain defect1Difference Δ from current reference sensitivity Δ3The specific calculation formula is as follows:
Δ3＝|h1-Δ|。
specifically, the current reference sensitivity is the sum of the reference sensitivity before the sensitivity gain of the ultrasonic flaw detector is adjusted and the sensitivity gain value at the center thickness of the cast slab.
Specifically, the unit of the amplitude and the sensitivity of the reflected wave is dB.
Step 43, calculating the defect equivalent size D of the certain defect2And defect depth x2The specific calculation formula is as follows:
specifically, the depth of the defect refers to the depth distance from the defect to the surface of the cast slab. By repeating the steps 41 to 43, the defect equivalent size and the defect depth corresponding to all the defects can be obtained by scanning.
In order to evaluate the internal defects of the casting blank more intuitively, the invention also provides a scheme for evaluating the internal defects of the casting blank by utilizing the accumulated defect volume, which specifically comprises the following steps:
step 51, any defect in all defects in the casting blank is equivalent to a defect sphere; wherein the diameter of the defect sphere is the defect equivalent size of any defect.
And step 52, calculating the accumulated defect volume corresponding to all the defects in the casting blank.
The defects are equivalent to spheres, the existence condition of the internal defects of the casting blank can be judged by accumulating the defect volume, and the production and the processing after guidance are facilitated.
In order to evaluate the internal defects of the casting blank more comprehensively, the invention also provides a scheme for evaluating the internal defects of the casting blank by utilizing the equivalent defect layer numerical value and the maximum defect layer numerical value, which specifically comprises the following steps:
step 61, calculating an equivalent defect layer value E for evaluating the internal defects of the casting blank, wherein the specific calculation formula is as follows:
and V is the accumulated defect volume corresponding to all defects in the casting blank, and S is the detection area of the ultrasonic flaw detector.
Specifically, the equivalent defect layer value is used for evaluating the integral average defect depth and reflecting the integral condition of the internal quality of the whole casting blank.
And step 62, taking the maximum value of the defect depths of all defects in the casting blank as the maximum defect layer value for determining the laminating process of the casting blank.
Specifically, the maximum defect layer number value indicates the maximum size of the defect in the depth direction, and can be used as a quantitative index of which lamination process is adopted, so as to design a process for laminating various size defects.
The following application cases are given here:
a continuous casting billet with the thickness of 400mm in a certain steel mill is subjected to regional ultrasonic flaw detection by adopting a 1MHz low-frequency longitudinal wave straight probe, the specific detection region is a region with the length of 200mm and the width of the full width of the casting billet, the reference sensitivity is adjusted according to FBH5, the sensitivity gain value is calculated to be 36dB according to a bottom wave formula, the final sensitivity gain is set to be 24dB (namely 36dB-12dB), then the probe is placed on the casting billet, the bottom wave is adjusted to 50% for 1 time for scanning, and the defect value is recorded. Finally, by analysis, the defect equivalent size was at most 9.95mm, the defect equivalent size was 5-6mm for 32 spots, and the cumulative defect volume was 17.001cm3The equivalent average defect layer number was 0.0425mm, and the maximum defect layer number was 9.95 mm.
The technical scheme provided by the embodiment of the invention at least has the following technical effects or advantages:
according to the embodiment of the invention, the internal defects of the casting blank are detected by adopting an ultrasonic flaw detection method, the sensitivity gain of the ultrasonic flaw detector is adjusted by using the sensitivity gain value at the central thickness of the casting blank, the influence of excessive grass-shaped waves on the accuracy of the detection result in the detection process is inhibited, and the accurate detection of the internal defects of the casting blank is realized.
While preferred embodiments of the present invention have been described, additional variations and modifications in those embodiments may occur to those skilled in the art once they learn of the basic inventive concepts. Therefore, it is intended that the appended claims be interpreted as including preferred embodiments and all such alterations and modifications as fall within the scope of the invention.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (8)
1. A method for detecting internal defects of a casting blank is characterized by comprising the following steps:
attaching a probe of an ultrasonic flaw detector to a set position on the surface of a casting blank;
adjusting the ultrasonic frequency of the ultrasonic flaw detector and the basic amplitude of the primary bottom wave to be set frequency and set amplitude respectively;
calculating a sensitivity gain value at the set position;
updating the sensitivity gain value at the set position to the sensitivity gain value at the central thickness of the casting blank;
adjusting the sensitivity gain of the ultrasonic flaw detector to the updated sensitivity gain value at the set position;
and scanning the interior of the casting blank so as to detect the internal defects of the casting blank.
2. The method for detecting internal defects of a casting blank according to claim 1, wherein the adjusting the ultrasonic frequency and the primary bottom wave amplitude of the ultrasonic flaw detector to a set frequency and a set amplitude, respectively, comprises:
if the average grain size of the crystal grains of the casting blank exceeds a set grain size, the value range of the set frequency is 0.5MHz to 1 MH;
and if the average grain size of the crystal grains of the casting blank does not exceed the set grain size, the value range of the set frequency is 2 MHz-2.5 MH.
3. The method for detecting internal defects of a casting slab according to claim 1, wherein the calculating of the sensitivity gain value at the set position includes:
calculating a sensitivity gain value delta at the set position by using a bottom wave formula1(ii) a Wherein the bottom wave formula is:
wherein λ is the wavelength of the ultrasonic wave of the set frequency, x1Is the thickness of the cast slab, D1The equivalent size of a reference flat bottom hole of the ultrasonic flaw detector is shown.
4. The method for detecting internal defects of a cast slab according to claim 3, wherein the updating the sensitivity gain value at the set position to the sensitivity gain value at the center thickness of the cast slab includes:
calculating a sensitivity gain value delta at the center thickness of the casting blank2The specific calculation formula is as follows:
Δ2＝Δ1-12dB。
5. the method for detecting internal defects of a cast slab according to claim 4, wherein the scanning the interior of the cast slab to detect the internal defects of the cast slab comprises:
obtaining the amplitude h of the reflected wave of a defect1；
Calculating the amplitude h of the reflected wave of the certain defect1Difference Δ from current reference sensitivity Δ3The specific calculation formula is as follows:
Δ3＝|h1-Δ|；
calculating a defect equivalent size D of the certain defect2And defect depth x2Tool for measuringThe formula for the calculation of volume is:
6. the method according to claim 5, wherein the defect equivalent size D of the defect is calculated2And defect depth x2Thereafter, the method further comprises:
any defect in all defects in the casting blank is equivalent to a defect sphere; wherein the diameter of the defect sphere is the defect equivalent size of any defect;
and calculating the accumulated defect volume corresponding to all the defects in the casting blank.
7. The method for detecting internal defects of a cast slab according to claim 6, wherein after the step of calculating the cumulative defect volume corresponding to all defects in the interior of the cast slab, the method further comprises:
calculating an equivalent defect layer value E for evaluating the internal defects of the casting blank, wherein the specific calculation formula is as follows:
wherein V is the accumulated defect volume corresponding to all defects in the casting blank, and S is the detection area of the ultrasonic flaw detector;
and taking the maximum value in the defect depths of all defects in the casting blank as the maximum defect layer value for determining the pressing process of the casting blank.
8. The method for detecting the internal defect of the casting blank according to any one of claims 1 to 7, wherein the set amplitude value ranges from 50% of a longitudinal range to 80% of the longitudinal range of the ultrasonic flaw detector.
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Cited By (2)
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| CN114088817A (en) * | 2021-10-28 | 2022-02-25 | 扬州大学 | Deep learning flat ceramic membrane ultrasonic defect detection method based on deep features |
| CN115753995A (en) * | 2022-11-28 | 2023-03-07 | 安徽鑫科铜业有限公司 | Strip billet internal defect detection device and detection method thereof |
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| CN114088817A (en) * | 2021-10-28 | 2022-02-25 | 扬州大学 | Deep learning flat ceramic membrane ultrasonic defect detection method based on deep features |
| CN114088817B (en) * | 2021-10-28 | 2023-10-24 | 扬州大学 | Deep learning flat ceramic membrane ultrasonic defect detection method based on deep features |
| CN115753995A (en) * | 2022-11-28 | 2023-03-07 | 安徽鑫科铜业有限公司 | Strip billet internal defect detection device and detection method thereof |
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