CN113720908A - Ultrasonic detection method and process determination method for rail vehicle resistance spot welding - Google Patents
Ultrasonic detection method and process determination method for rail vehicle resistance spot welding Download PDFInfo
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- CN113720908A CN113720908A CN202110905114.0A CN202110905114A CN113720908A CN 113720908 A CN113720908 A CN 113720908A CN 202110905114 A CN202110905114 A CN 202110905114A CN 113720908 A CN113720908 A CN 113720908A
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- 238000001514 detection method Methods 0.000 title claims abstract description 72
- 238000000034 method Methods 0.000 title claims abstract description 59
- 238000003466 welding Methods 0.000 title claims abstract description 59
- 238000012360 testing method Methods 0.000 claims abstract description 70
- 239000000523 sample Substances 0.000 claims abstract description 42
- 230000007547 defect Effects 0.000 claims abstract description 35
- 239000002893 slag Substances 0.000 claims description 6
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 238000007689 inspection Methods 0.000 claims description 2
- 239000013078 crystal Substances 0.000 abstract description 4
- 238000005516 engineering process Methods 0.000 abstract description 4
- 230000000694 effects Effects 0.000 abstract description 3
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- 230000004927 fusion Effects 0.000 description 3
- 239000006247 magnetic powder Substances 0.000 description 2
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- 230000035515 penetration Effects 0.000 description 2
- 230000035945 sensitivity Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 229910000679 solder Inorganic materials 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
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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
- 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
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/0289—Internal structure, e.g. defects, grain size, texture
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
- G01N2291/2672—Spot welding
Abstract
The invention discloses an ultrasonic detection method for resistance spot welding of a railway vehicle and a process determination method, and aims to solve the problems of incomplete detection and poor detection effect in the existing detection technology. Which comprises the following steps: selecting weld defect test blocks with different weld defects; respectively carrying out an orthogonal test of resistance spot welding ultrasonic detection on the selected weld defect test block according to a pre-designed orthogonal test scheme; analyzing the orthogonal test result to determine the optimal resistance spot welding ultrasonic detection process; through selecting 2 kinds of probe K values, 2 kinds of probe frequency to combine 2 kinds of scanning modes to test, select for use the twin-crystal probe frequency to be 4Hz, the probe K value is 3, under the test condition of zigzag scanning mode, detected out including rosin joint, crackle, gas pocket, not fusing and press from both sides common welding defect of sediment, and formulated new detection mode with this, solved current detection technology, detected incompletely, the not good problem of detection effect.
Description
Technical Field
The invention relates to an ultrasonic detection method and a process determination method for resistance spot welding of a railway vehicle.
Background
Resistance spot welding is a main welding method in the manufacturing process of stainless steel railway passenger cars, and the quality of the resistance spot welding has important influence on the safety of car body structures.
The on-site conventional weld joint nondestructive detection method comprises ray inspection, magnetic powder detection, eddy current detection and penetration detection. Magnetic powder, eddy current and penetration detection technologies are generally used for detecting surface defects of workpieces; the sensitivity of ray detection to crack defect detection is seriously influenced by the defect direction and the workpiece thickness, and the joint quality cannot be accurately evaluated; the ultrasonic detection method can accurately obtain the position of the defect according to the geometrical position relation between the sound wave propagation path and the defect, and has the advantages of low cost, high efficiency and the like.
Therefore, the design of an ultrasonic detection method for the resistance spot welding of the railway vehicle and a process determination method are urgently needed.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provides an ultrasonic detection method for resistance spot welding of a railway vehicle and a process determination method, which can improve the precision and efficiency of ultrasonic detection of resistance spot welding and reduce the detection cost.
In order to achieve the above purpose/to solve the above technical problems, the present invention is realized by adopting the following technical scheme:
a rail vehicle resistance spot welding ultrasonic detection process determination method comprises the following steps:
selecting weld defect test blocks with different weld defects;
respectively carrying out an orthogonal test of resistance spot welding ultrasonic detection on the selected weld defect test block according to a pre-designed orthogonal test scheme;
and analyzing the orthogonal test result to determine the optimal resistance spot welding ultrasonic detection process.
Preferably, the weld defect test block comprises an upper test block and a lower test block, and the upper test block and the lower test block are partially welded in an overlapping manner.
Preferably, the thickness of the upper test block is 2mm, the thickness of the lower test block is 3mm, the width and the length of the two test blocks are the same, both are 40mm and 110mm, and the length of the overlapping part is 40 mm.
Preferably, the equipment for manufacturing the weld defects comprises a medium-frequency inverter type direct current spot welding machine.
Preferably, the weld defects include cold joint, cracks, blowholes, unfused, and slag inclusions.
Preferably, the design method of the orthogonal test scheme comprises:
determining the size of a probe wafer, and taking the K value of the probe, the frequency of the probe and a scanning mode as influence factors;
simultaneously selecting 2 probe K values A, B, 2 probe frequencies C, D and 2 scanning modes E, F to generate an orthogonal test table as shown in the following table:
preferably, the probe wafer size selected is 6mm x 6mm, the probe K value A, B is 2.5 and 3, respectively, the probe frequency C, D is 4Hz and 5Hz, respectively, and the scanning mode E, F is a transverse scan and a zig-zag scan, respectively.
A rail vehicle resistance spot welding ultrasonic detection method, the method comprising:
carrying out ultrasonic detection on the resistance spot welding by adopting a predetermined optimal ultrasonic detection process for the resistance spot welding;
wherein, the optimal resistance spot welding ultrasonic detection process is determined by adopting the method.
Preferably, the detection parameters of the optimal resistance spot welding ultrasonic detection process are as follows: the size of the probe wafer is 6mm multiplied by 6mm, the K value of the probe is 3, the frequency of the double-crystal probe is 4MHz, and the scanning mode is sawtooth.
Compared with the prior art, the invention has the following beneficial effects:
according to the method for determining the ultrasonic detection process of the resistance spot welding of the rail vehicle, the orthogonal test of the ultrasonic detection of the resistance spot welding is respectively carried out on the selected welding seam defect test block according to the pre-designed orthogonal test scheme, and the optimal ultrasonic detection process of the resistance spot welding is determined by analyzing the orthogonal test result, so that the problem that the sensitivity of the ray detection process to the defects of the resistance spot welding cracks of the vehicle body of the urban rail vehicle is influenced by the defect position and the workpiece thickness can be solved, and the accuracy and the efficiency of the ultrasonic detection of the resistance spot welding can be improved and the detection cost can be reduced by adopting the optimal ultrasonic detection process of the resistance spot welding determined by the method;
2 probe K values and 2 probe frequencies are selected through designing an orthogonal test, and the test is carried out by combining 2 scanning modes, and finally under the test conditions that the bicrystal probe frequency is selected to be 4Hz, the probe K value is 3 and the zigzag scanning mode is adopted, common welding defects including insufficient solder joints, cracks, air holes, incomplete fusion and slag inclusion are detected, so that the problems that the detection result is incomplete, the detection efficiency is low and the detection precision is low in the existing detection technology are solved.
Drawings
FIG. 1 is a schematic structural diagram of a weld defect test block provided in an embodiment of the present invention;
in the figure: 1. and (3) loading a test block: 2. the test block is shown below.
Detailed Description
The invention is further described below with reference to the accompanying drawings. The following examples are only for illustrating the technical solutions of the present invention more clearly, and the protection scope of the present invention is not limited thereby.
The first embodiment is as follows:
the embodiment of the invention provides a method for determining a rail vehicle resistance spot welding ultrasonic detection process, which comprises the following steps of:
the method comprises the following steps: selecting weld defect test blocks with different weld defects;
step two: respectively carrying out an orthogonal test of resistance spot welding ultrasonic detection on the selected weld defect test block according to a pre-designed orthogonal test scheme;
step three: and analyzing the orthogonal test result to determine the optimal resistance spot welding ultrasonic detection process.
As shown in fig. 1, the weld defect test block comprises an upper test block 1 and a lower test block 2, the upper test block and the lower test block are arranged in an overlapping mode, the thicknesses of the upper test block and the lower test block are d2=2mm and d1=3mm respectively, the widths and the lengths of the two test blocks are the same, both the widths and the lengths are 40mm and 110mm, and the length of an overlapping portion is 40 mm.
The artificial defects of the resistance spot welding mainly comprise cold joint, cracks, air holes, incomplete fusion and slag inclusion, and a medium-frequency inverter type direct current spot welding machine is selected as welding equipment in the orthogonal test of the embodiment.
The design method of the test block orthogonal test scheme comprises the following steps:
determining the size of a probe wafer, and taking the K value of the probe, the frequency of the probe and a scanning mode as influence factors;
simultaneously selecting 2 probe K values A, B, 2 probe frequencies C, D and 2 scanning modes E, F to generate an orthogonal test table shown in Table 1:
table 1:
in the table: a. B2.5 and 3 respectively, C, D4 Hz and 5Hz respectively, E, F transverse scan and zigzag scan respectively. In an embodiment of the invention, the probe wafer size is selected to be 6mm by 6 mm.
As shown in Table 2, the results of the ultrasonic testing of resistance spot welding according to the orthogonal test protocol shown in Table 1 are:
table 2:
as can be seen from table 2: the detection method corresponding to test number 4 can comprehensively detect 5 weld defects including cold joint, cracks, air holes, unfused and slag inclusion, and the detection result is most comprehensive, so that test number 4 is determined as the optimal resistance spot welding ultrasonic detection process, and the corresponding probe parameters are as follows: the frequency of the double-crystal probe is 4Hz, the K value of the probe is 3, and the scanning mode is zigzag scanning.
Example two:
the embodiment of the invention provides an ultrasonic detection method for resistance spot welding of a railway vehicle, which adopts a predetermined optimal ultrasonic detection process for resistance spot welding to carry out ultrasonic detection on the resistance spot welding.
The optimal resistance spot welding ultrasonic detection process can be determined by adopting the method described in the first embodiment.
In the embodiment of the invention, the detection parameters of the optimal resistance spot welding ultrasonic detection process are as follows: the size of the probe wafer is 6mm multiplied by 6mm, the K value of the probe is 3, the frequency of the double-crystal probe is 4MHz, and the scanning mode is sawtooth.
The detection method provided by the embodiment of the invention can be used for detecting common welding defects including cold joint, cracks, air holes, incomplete fusion and slag inclusion, and has the advantages of most comprehensive detection defects and best detection effect.
The above is only a preferred embodiment of the present invention, and it should be noted that, for those skilled in the art, several modifications and variations can be made without departing from the technical principle of the present invention, and these modifications and variations should also be regarded as the protection scope of the present invention.
Claims (9)
1. A rail vehicle resistance spot welding ultrasonic detection process determination method is characterized by comprising the following steps:
selecting weld defect test blocks with different weld defects;
respectively carrying out an orthogonal test of resistance spot welding ultrasonic detection on the selected weld defect test block according to a pre-designed orthogonal test scheme;
and analyzing the orthogonal test result to determine the optimal resistance spot welding ultrasonic detection process.
2. The rail vehicle resistance spot welding ultrasonic detection process determination method according to claim 1, wherein the weld defect test block comprises an upper test block and a lower test block, and the upper test block and the lower test block are partially overlapped and welded.
3. The method for determining the rail vehicle resistance spot welding ultrasonic detection process according to claim 2, wherein the upper test block has a thickness of 2mm, the lower test block has a thickness of 3mm, the two test blocks have the same width and length, are 40mm and 110mm respectively, and the overlapping part has a length of 40 mm.
4. The rail vehicle resistance spot welding ultrasonic detection process determining method according to claim 1, wherein the weld defect manufacturing equipment comprises a medium-frequency inverter type direct current spot welder.
5. The rail vehicle resistance spot welding ultrasonic detection process determination method according to any one of claims 1 to 4, wherein the weld defects include cold joint, cracks, blowholes, unfused and slag inclusion.
6. The rail vehicle resistance spot welding ultrasonic detection process determination method according to claim 1, wherein the design method of the orthogonal test scheme comprises:
determining the size of a probe wafer, and taking the K value of the probe, the frequency of the probe and a scanning mode as influence factors;
simultaneously selecting 2 probe K values A, B, 2 probe frequencies C, D and 2 scanning modes E, F to generate an orthogonal test table as shown in the following table:
7. the method for determining the ultrasonic testing process of the rail vehicle resistance spot welding according to claim 6, wherein the selected probe wafer size is 6mm x 6mm, the probe K value A, B is 2.5 and 3 respectively, the probe frequency C, D is 4Hz and 5Hz, and the scanning modes E, F are transverse scanning and zigzag scanning respectively.
8. An ultrasonic testing method for resistance spot welding of a rail vehicle, characterized by comprising:
carrying out ultrasonic detection on the resistance spot welding by adopting a predetermined optimal ultrasonic detection process for the resistance spot welding;
wherein the optimum resistance spot welding ultrasonic inspection process is determined using the method of any one of claims 1 to 7.
9. The ultrasonic rail vehicle resistance spot welding detection method according to claim 8,
the detection parameters of the optimal resistance spot welding ultrasonic detection process are as follows: the size of the probe wafer is 6mm multiplied by 6mm, the K value of the probe is 3, the frequency of the probe is 4MHz, and the scanning mode is zigzag.
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| CN202110905114.0A CN113720908A (en) | 2021-08-08 | 2021-08-08 | Ultrasonic detection method and process determination method for rail vehicle resistance spot welding |
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| CN202110905114.0A CN113720908A (en) | 2021-08-08 | 2021-08-08 | Ultrasonic detection method and process determination method for rail vehicle resistance spot welding |
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| CN101441198A (en) * | 2008-11-28 | 2009-05-27 | 中国航天空气动力技术研究院 | Ultrasonic wave detection method of wind tunnel body structure butt-jointed seam |
| CN108241023A (en) * | 2018-01-22 | 2018-07-03 | 北京北方车辆集团有限公司 | Armored vehicle car body weld seam multi-beam ultrasound examination technique and its determining method |
| CN111458406A (en) * | 2019-12-31 | 2020-07-28 | 南京晨光集团有限责任公司 | Ultrasonic detection method for austenitic stainless steel fillet weld |
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2021
- 2021-08-08 CN CN202110905114.0A patent/CN113720908A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101441198A (en) * | 2008-11-28 | 2009-05-27 | 中国航天空气动力技术研究院 | Ultrasonic wave detection method of wind tunnel body structure butt-jointed seam |
| CN108241023A (en) * | 2018-01-22 | 2018-07-03 | 北京北方车辆集团有限公司 | Armored vehicle car body weld seam multi-beam ultrasound examination technique and its determining method |
| CN111458406A (en) * | 2019-12-31 | 2020-07-28 | 南京晨光集团有限责任公司 | Ultrasonic detection method for austenitic stainless steel fillet weld |
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| 张鸿博;: "电阻焊钢管焊缝手动超声波检测工艺及方法", 石油机械, no. 11, pages 44 - 57 * |
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