CN114019024A - Method and system for measuring penetration depth of lower layer of weld joint in lap welding - Google Patents
Method and system for measuring penetration depth of lower layer of weld joint in lap welding Download PDFInfo
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Abstract
The invention relates to a method and a system for measuring the penetration depth of a lower layer of a welding seam in lap welding, wherein the method comprises the following steps: pretreating the surface of a test piece to be detected to obtain a pretreated test piece; establishing a simulation model according to the parameters of the preprocessed test piece; simulating the simulation model, and determining parameters and a focusing rule of the ultrasonic phased array detection equipment; calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain calibrated ultrasonic phased array detection equipment; detecting the weld penetration of the lap joint interface of the preprocessed test piece by using calibrated ultrasonic phased array detection equipment; and calculating the weld penetration depth of the lower layer of the weld according to the weld penetration width of the lap joint interface. By setting the focusing depth and the focusing rule, the phased array ultrasonic beam is focused at the welding seam of the dissimilar metal faying surface, the sound energy at the welding seam of the dissimilar metal faying surface is improved, the influence of factors such as sound energy attenuation and sound scattering on the signal to noise ratio is reduced, and the detection effect of the weld fusion width of the dissimilar metal faying surface is improved.
Description
Technical Field
The invention relates to the technical field of material detection, in particular to a method and a system for measuring the penetration depth of a lower welding seam layer in lap welding.
Background
The mastering of the technology of the oxyhydrogen rocket engine is one of the marks of the nation which becomes the strong aerospace, and a large amount of dissimilar metal welding seams can be formed due to the welding of a large amount of dissimilar metal materials in the manufacturing process of the oxyhydrogen rocket engine. Compared with the welding of the same material, the welding of the dissimilar materials has the characteristics of large difference of melting points of dissimilar metal materials, large difference of linear expansion coefficients, large difference of heat conductivity and specific heat capacity, complex microstructure and the like, the welding difficulty is far higher than that of the welding of the same material, and the problem that the lower layer enters the fusion depth to be insufficient or the fusion depth to be excessive is easily caused.
The direct and effective detection of the internal quality of the welding seam is the best proof of the reliability of the welding seam quality. At present, the quality reliability of the welding seam is improved through automatic welding, electronic welding and other processes at home and abroad, but the internal quality of the welding seam cannot be detected, and the quality reliability of the welding seam is still ensured according to the control of the whole welding process. Therefore, it is necessary to conduct a non-destructive testing technical study on the internal quality of the weld. However, in the current weld nondestructive testing technical research, the testing experiment for verifying and testing the technical effectiveness and reliability mainly uses single-layer flat plate welding, and the report of the nondestructive testing technical research result aiming at the dissimilar metal welding structure of the electroformed nickel superalloy multilayer and small-thickness weld is few.
Generally, the quality detection is usually carried out by adopting a ray detection technology, but the structure of the thrust chamber of the aircraft engine is complex, and a plurality of welding seams cannot be detected by the conventional X-ray. Meanwhile, for the welding of nickel and high-temperature alloy which are frequently used at present, the detection thickness is increased due to the large radiation absorption coefficient of the high-temperature alloy, the sensitivity is reduced, and the detection capability is greatly reduced; during ultrasonic detection, the influence of product sound beams is large, and for the detection of dissimilar metal welding seams, due to the fact that the two sides of the welding seams are made of different materials, the sound beams are different, the detection difficulty is large, and the existing ultrasonic detection method for the welding seams is not mastered.
Disclosure of Invention
The invention aims to provide a method and a system for measuring the penetration of a lower layer of a welding seam in lap welding. The weld joint is detected by array ultrasonic, and the penetration of the lower layer of the weld joint in the lap welding is accurately measured.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides a method for measuring the penetration depth of a lower layer of a welding seam in lap welding, which comprises the following steps:
pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
establishing a simulation model according to the parameters of the preprocessed test piece;
simulating the simulation model, and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain calibrated ultrasonic phased array detection equipment;
detecting an ultrasonic measured value of weld fusion width at a lap joint interface of the preprocessed test piece by using calibrated ultrasonic phased array detection equipment;
and calculating to obtain the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam fusion width at the lap joint interface.
Optionally, the pretreatment of the surface of the test piece to be detected to obtain a pretreated test piece includes:
polishing the weld reinforcement on the surface of the test piece to be detected to enable the weld to be flush with the adjacent base metal and ensure that the roughness of the surface of the weld is not greater than a threshold a;
and (4) setting a coupling agent on the surface of the polished test piece to obtain a pretreated test piece.
Optionally, the parameters of the preprocessed test piece include the material and thickness of the upper and lower welding plates and the width of the upper surface of the welding seam.
Optionally, the simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection device includes: determining the optimal focusing depth and aperture size of the simulated sound field by adopting a single-factor alternation method; and determining the device parameters and the focusing rule according to the optimal focusing depth and the optimal aperture size.
Optionally, the calibrating of the ultrasonic phased array detection device with the set device parameters and the set focusing rule includes performing sound velocity calibration, delay calibration and sensitivity calibration on the ultrasonic phased array detection device respectively;
the sound velocity calibration comprises selecting a thickness in the echo type of the equipment, wherein the first thickness is set as the thickness of the pretreatment test piece, and the second thickness is set as the thickness of twice the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of a preprocessed test piece, framing the primary echo and the secondary echo by using a gate of equipment, and determining a sound path and propagation time between the primary echo and the secondary echo; determining the calibrated sound velocity according to the sound path and the propagation time; and calibrating the sound velocity of the ultrasonic phased array detection equipment by using the calibrated sound velocity.
Optionally, the delay calibration includes selecting a thickness in the echo type of the device, where the thickness is set as the thickness of the pretreatment test piece, and the tolerance is set as one tenth of the thickness of the pretreatment test piece; utilizing a gate frame of the device to frame the bottom echo of the pretreatment test piece, and moving the probe position of the device back and forth to determine the sound path of the pretreatment test piece; determining wedge block delay according to the sound path of the preprocessed test piece and the known wedge block sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge block delay.
Optionally, the sensitivity calibration includes selecting sensitivity calibration in PA calibration, selecting aperture waves in echo types, moving the position of the device probe on the standard test block back and forth to smooth the envelope, obtaining the echo peak height difference of the probe at each angle on the standard test block, compensating different gain values for the sound beam line at each angle, making the echo peak heights the same, and completing the sensitivity calibration.
Optionally, the method for detecting the metallographic measurement value of the weld fusion width at the joint interface of the pretreatment test piece by using the calibrated ultrasonic phased array detection device includes:
detecting an ultrasonic detection value of weld fusion width at a lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
obtaining a metallographic measured value of the weld fusion width at the lap interface of the pretreatment test piece according to a linear relation between an ultrasonic detection value of the weld fusion width at the lap interface of the pretreatment test piece and the metallographic measured value of the weld fusion width at the lap interface of the pretreatment test piece;
the linear relation between the ultrasonic detection value of the weld fusion width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld fusion width at the lap joint interface of the pretreatment test piece is as follows:
l＝0.316L+0.122
wherein L represents a metallographic measurement value of weld fusion width at the lap interface, and L represents an ultrasonic detection value of weld fusion width at the lap interface.
Optionally, calculating the weld penetration depth of the lower layer of the weld according to the ultrasonic measurement value of the weld penetration width at the lap joint interface includes:
calculating by utilizing a linear relation between a metallographic measured value of weld penetration width at the lap joint interface and the weld penetration depth of the lower layer of the weld, wherein the linear relation between the metallographic measured value of the weld penetration width at the lap joint interface and the weld penetration depth of the lower layer of the weld is as follows:
s＝2.927l+0.867
wherein s represents the penetration of the lower layer of the weld joint, and l represents the metallographic measurement value of the weld joint weld width at the lap joint interface.
The invention also provides a system for measuring the penetration of the lower layer of the welding seam in lap welding, which comprises the following components:
the pretreatment module is used for pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
the model establishing module is used for establishing a simulation model according to the parameters of the preprocessed test piece;
the simulation module is used for simulating the simulation model and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
the equipment calibration module is used for calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain the calibrated ultrasonic phased array detection equipment;
the fusion width determining module is used for detecting an ultrasonic measured value of the weld fusion width at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and the fusion depth determining module is used for calculating the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the weld fusion width at the lap joint interface.
According to the specific embodiment provided by the invention, the invention discloses the following technical effects:
the invention provides a method and a system for measuring the penetration depth of a lower layer of a welding seam in lap welding, wherein the method comprises the following steps: pretreating the surface of a test piece to be detected to obtain a pretreated test piece; establishing a simulation model according to the parameters of the preprocessed test piece; simulating the simulation model, and determining parameters and a focusing rule of the ultrasonic phased array detection equipment; calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain calibrated ultrasonic phased array detection equipment; detecting an ultrasonic measured value of weld fusion width at a lap joint interface of the preprocessed test piece by using calibrated ultrasonic phased array detection equipment; and calculating to obtain the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam fusion width at the lap joint interface. The method comprises the steps of firstly focusing an acoustic beam at a weld joint of the dissimilar metal faying surface, measuring the weld penetration of the faying surface, and analyzing the relation between the weld penetration of the faying surface and the penetration of the lower layer to obtain the final penetration length of the lower layer. The problems of insufficient sensitivity during ray detection, sound beam propagation of different materials during ultrasonic detection and the like are effectively solved, the direct and effective detection of the connection quality of the lap joint weld of the dissimilar metals is realized, and the reliability of the weld quality is improved. In addition, the invention adopts full-coverage simulation software to simulate and construct a model of the detected dissimilar metal lap weld, simulate the sound beam path of ultrasonic waves in the weld, determine the focusing depth, ensure that the sound beam is focused on the weld of the dissimilar metal lap surface, and enable the detection of the weld lap surface weld width to be more accurate, thereby improving the accuracy of the detection of the lower layer weld penetration length.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed 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 invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic process flow diagram of the present invention;
FIG. 2 is a schematic view of the detection position of the present invention;
FIG. 3 is a schematic diagram of a specimen simulation model according to the present invention;
FIG. 4 is a schematic view of detecting interfacial melt width according to the present invention;
FIG. 5 is a schematic view illustrating the principle of measuring the penetration of the lower layer of the weld in lap welding according to the present invention;
FIG. 6 is a schematic view illustrating the principle of the present invention for the penetration of the lower layer of the weld;
FIG. 7 is a schematic diagram illustrating the principle of ultrasonic detection of weld bead fusion width according to the present invention.
Description of the symbols: 1 probe, 2 focusing rules, 3 detection of interface fusion width, 4 piezoelectric wafers, 5 wedges, 6 sound beams, 7 weld edges and 8 test pieces.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the 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, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
The lap welding of dissimilar metals is more difficult than the lap welding of the same metal material. The reasons are that the difference in melting point of dissimilar metal materials is large, the difference in linear expansion coefficient is large, the difference in thermal conductivity and specific heat capacity is large, and the microstructure is complicated. Due to the above-mentioned difficulty of the dissimilar metal lap welding, there is caused a problem that the lower layer of the weld of the dissimilar metal lap welding enters insufficient penetration or excessive penetration. The measurement of the welding seam of the dissimilar metal lap welding comprises X-ray detection and ultrasonic detection. Among them, the X-ray detection has a problem that the dissimilar metal includes a superalloy, and the absorption coefficient of the superalloy for X-rays is large, which results in a detection thickness larger than a true thickness. The detection is not accurate enough. The ultrasonic detection has the problems that when the thickness of the upper and lower layers of dissimilar metals is less than 5mm, the sound beam cannot penetrate through a non-welding seam area between the two layers, the sound beam attenuation is large, the accessibility is poor, and the penetration of the lower layer of the welding seam into the weld penetration is difficult to detect. Therefore, the invention provides a method and a system for measuring the penetration of the lower layer of a welding seam in lap welding. The weld joint is detected by array ultrasonic, and the penetration of the lower layer of the weld joint in the lap welding is accurately measured.
The term "penetration" used herein refers to the depth of the weld in the lower layer of metal, which is the distance between the interface between two layers of dissimilar metals and the tip of the weld, when the dissimilar metals on the upper and lower layers are lapped and welded by electron beams. As shown in fig. 6, where s represents the weld seam lower layer penetration.
The metallographic measurement value of the weld joint fusion width refers to a width value obtained by observing the cross section of a weld joint under a microscope by adopting a metallographic method and measuring the width of the weld joint on a dissimilar metal interface.
The ultrasonic detection value of the weld joint weld width refers to that the detection method provided by the invention is adopted to carry out phased array linear scanning detection, and the gap width L between the dissimilar metal interface echoes is measured on the obtained linear scanning image. As shown in fig. 7, where L is the ultrasonic detection value of the weld bead weld width.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example 1
As shown in fig. 1, the present embodiment provides a method for measuring penetration depth of a lower layer of a weld joint in lap welding, which specifically includes the following steps:
s1: pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
the specific processing method comprises the steps of polishing the weld reinforcement on the surface of the test piece to be detected to enable the weld to be flush with the adjacent base metal and ensure that the roughness of the surface of the weld is not greater than a threshold value a; and (4) setting a coupling agent on the surface of the polished test piece to obtain a pretreated test piece. The value a is preferably 6.3 μm, and it should be noted that 6.3 μm is only a preferred embodiment provided by the present invention, and those skilled in the art can select other threshold values according to actual needs. The coupling agent is used for ensuring the close contact between the probe 1 and the test piece and ensuring the smooth sliding of the probe 1 on the test piece.
S2: establishing a simulation model according to the parameters of the preprocessed test piece;
the parameters of the pretreated test piece comprise the material and the thickness of the upper and lower welding plates and the width of the upper surface of the welding line. And the simulation module establishes a simulation model according to the groove shape and the detection thickness of the welding seam. Taking the electron beam weld as an example, the shape of the weld is selected to be V-shaped according to the characteristics of the vacuum electron beam weld.
S3: simulating the simulation model, and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
wherein the simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection device comprises: determining the optimal focusing depth and aperture size of the simulated sound field by adopting a single-factor alternation method; and determining the device parameters and the focusing rule according to the optimal focusing depth and the optimal aperture size. For example, after a sample model is drawn in three-dimensional drawing software, simulation software is introduced, parameters and a focusing mode of the probe 1 are determined, a single-factor alternation method is adopted, a sound field at the welding seam of the faying surface is simulated by respectively changing the focusing depth and the aperture size, and the optimal focusing depth and aperture size parameters are determined by observing the main lobe width and the field strength of the simulated sound field, so that the transverse resolution of a sound beam at the welding seam of the faying surface is the highest, and the focusing effect is the best. The ultrasonic phased array detection equipment uses an ultrasonic phased array detector, an instrument channel is a 32-channel single-line array/double-line array probe 1 with matching frequency of 2-10MHz and 16-32 wafers, the size of an array element of the probe 1 is 0.4mm, the distance between the array elements is 0.5mm, the central frequency of the probe 1 is 5MHz, a wedge block of 0 degree is selected as the wedge block, and the wedge block is made of organic glass. Inputting parameters of a probe 1 and a wedge block in phased array detection equipment, entering a focusing rule setting, selecting a line scanning mode and determining the coverage range of an acoustic beam in a detected area, selecting a plane on a focusing surface, and setting the focusing depth as the thickness of an upper layer metal plate so that the acoustic beam is focused on a welding seam of a lap joint surface. And selecting 32 array elements for full excitation, wherein the aperture size is 4, and the stepping bias is 0.
S4: calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain calibrated ultrasonic phased array detection equipment;
calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule, wherein the calibration comprises sound velocity calibration, delay calibration and sensitivity calibration of the ultrasonic phased array detection equipment; the sound velocity calibration comprises selecting a thickness in the echo type of the equipment, wherein the first thickness is set as the thickness of the pretreatment test piece, and the second thickness is set as the thickness of twice the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of a preprocessed test piece, framing the primary echo and the secondary echo by using a gate of equipment, and determining a sound path and propagation time between the primary echo and the secondary echo; determining the calibrated sound velocity according to the sound path and the propagation time; and calibrating the sound velocity of the ultrasonic phased array detection equipment by using the calibrated sound velocity. The delay calibration includes selecting a thickness among echo types of the device, wherein the thickness is set as a thickness of the pre-processed test piece, and the tolerance is set as one tenth of the thickness of the pre-processed test piece; utilizing a gate frame of the device to frame the bottom echo of the pretreatment test piece, and moving the position of a probe 1 of the device back and forth to determine the sound path of the pretreatment test piece; determining wedge block delay according to the sound path of the preprocessed test piece and the known wedge block sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge block delay. The sensitivity calibration comprises selecting sensitivity calibration in PA calibration, selecting hole waves in echo types, moving the position of the equipment probe 1 on a standard test block back and forth to smooth an envelope curve, obtaining the height difference of echo peak values of the probe 1 at all angles on the standard test block, compensating different gain values for sound beam lines at all angles to ensure that the heights of the echo peak values are the same, and finishing the sensitivity calibration. In the sensitivity calibration, a phi 2 transverse through hole with the depth of 25mm of a CSK-IA type standard test block can be adopted for calibration, during specific implementation, the width of the upper part of a welding line is set to be consistent with the actual width, the depth is the detection thickness, namely 4mm, and the echo height of the standard test block reaches 80% of the wave height on the premise that the echo peak values are the same in height.
S5: detecting an ultrasonic measured value of weld fusion width at a lap joint interface of the preprocessed test piece by using calibrated ultrasonic phased array detection equipment;
specifically, detecting the ultrasonic measurement value of the weld fusion width at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment, wherein the ultrasonic measurement value of the weld fusion width at the lap joint interface of the pretreatment test piece is detected by using the calibrated ultrasonic phased array detection equipment; obtaining a metallographic measured value of the weld fusion width at the lap interface of the pretreatment test piece according to a linear relation between an ultrasonic detection value of the weld fusion width at the lap interface of the pretreatment test piece and the metallographic measured value of the weld fusion width at the lap interface of the pretreatment test piece; the linear relation between the ultrasonic detection value of the weld fusion width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld fusion width at the lap joint interface of the pretreatment test piece is as follows:
l＝0.316L+0.122
wherein L represents a metallographic measurement value of weld fusion width at the lap interface, and L represents an ultrasonic detection value of weld fusion width at the lap interface.
S6: and calculating to obtain the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam fusion width at the lap joint interface.
Specifically, the weld lower layer entering penetration is obtained through calculation according to the lap joint interface weld penetration, the weld lower layer entering penetration is obtained through calculation according to a linear relation between a metallographic measured value of the weld penetration at the lap joint interface and the weld lower layer entering penetration, and the linear relation between the metallographic measured value of the weld penetration at the lap joint interface and the weld lower layer entering penetration is as follows:
s＝2.927l+0.867
wherein s represents the penetration of the lower layer of the weld joint, and l represents the metallographic measurement value of the weld joint weld width at the lap joint interface.
By way of specific example, as shown in fig. 2, GH4169 and electroformed nickel test plates with the size of 100 × 100mm are selected, the thicknesses of the test plates are respectively 4mm and 5mm, two welding surfaces are polished to be flat, and the welding plates are cleaned by absolute ethyl alcohol, so that the surfaces to be welded are clean and free of oil stains. The upper GH4169 layer and the lower electroformed nickel layer are overlapped, and the vacuum electron beam welding method is adopted to weld the edges at the center of the plate. Wherein the welding voltage is fixed at 60kV, the welding speed is 1600mm/min, the upper surface is selected for focusing in a focusing mode, and the welding current is selected to be 55 mA. And polishing the irregular weld reinforcement on the surface of the weld to enable the weld reinforcement to be flush with the adjacent base metal and removing rough objects influencing the movement of the probe 1, so that the surface roughness of the weld reinforcement is less than or equal to 6.3 mu m, and the probe 1 is completely coupled and can move freely. And marking the positions of the welding seams and the probe 1 and selecting a proper coupling agent.
As shown in fig. 3, the workpiece model is imported into the simulation software. Determining parameters of a probe 1 and a focusing mode, fixing the aperture size through a single factor alternation method, respectively setting the focusing depth to be 1-9 mm (stepping to be 1mm), observing the width and the field length of a main lobe of a sound field at a weld joint of a faying surface, determining the optimal focusing depth to be 4mm, then fixing the focusing depth, respectively setting the aperture size to be 4, 8 and 16 array element widths, observing the width and the field intensity of the main lobe of the sound field at the weld joint of the faying surface, and determining the optimal aperture size to be 16. The depth of focus is then selected to be 4mm and the aperture size is 16 array element width. Connecting phased array detection equipment with a computer, and opening a phased array software connection board card; adopt 32 array element's phased array probe 1, array element size is 0.4mm, and array element interval is 0.5mm, and 1 central frequency of probe is 5MHz, chooses for use 0 voussoir, and the voussoir material is organic glass. The probe 1 and wedge parameters were entered in the phased array software. Setting the shape of a workpiece model as a double-layer plate, wherein the proportion of the size to the actual workpiece is 1: 1. according to the characteristics of the electron beam welding seam, the shape of the welding seam is V-shaped, the shape of the welding seam in the model is V-shaped, the width of the upper part of the welding seam is set to be consistent with the actual width, and the depth is the detection thickness, namely 4 mm. The focusing rule is set by entering a focusing rule calculator. The linear array mode is selected, the echo method is used for detection, the plane is selected for the focal plane, 32 array elements are selected for excitation, the aperture size is 16, the focal depth is 4mm, and the stepping bias is 0. During calibration, the probe 1 is placed on a workpiece, the thickness of the echo type is selected in sound velocity calibration, the thickness 1 is set to be the thickness of the workpiece, the thickness 2 is set to be twice the thickness of the workpiece, a primary echo and a secondary echo of the bottom surface of the workpiece are found, the two waves are framed by a gate respectively, and click calibration is carried out; placing the probe 1 on a workpiece, selecting the thickness of the echo type in delay calibration, setting the thickness as the thickness of the workpiece, setting the tolerance as one tenth of the thickness, framing the echo on the bottom surface of the workpiece by using a gate, pushing and pulling the probe 1 forwards and backwards to enable the envelope line to be smooth and place in a red line frame, and clicking for calibration. The probe 1 is placed above a phi 2 transverse through hole with the depth of 25mm of a CSK-IA type standard test block, sensitivity calibration in PA calibration is selected, an echo type is selected to be a hole wave, after a gate frame is used for closing a transverse hole and returning, the probe 1 is pushed and pulled back and forth, envelope lines are made to be smooth, and click calibration is conducted. And after the calibration is finished, applying a coupling agent to the position to be detected, crossing the welding line by the probe 1, adjusting the gain to enable a line scanning image corresponding to the weld line fusion width of the dissimilar metal faying surface to appear on a detection interface, storing an acquired detection data file, and calculating to obtain the fusion depth according to the detection data file. In addition, the lap joint interface fusion width can be analyzed and measured through phased array ultrasonic analysis software, and then the lower layer fusion depth entering length can be obtained according to the relation between the lap joint interface fusion width and the lower layer fusion depth entering length. And transversely performing linear cutting on the detection workpiece from the detection position to obtain a cross section of the welding seam, performing metallographic treatment on the cross section to obtain a clear image of the welding seam, measuring the fusion width of the lap joint surface and the fusion depth of the lower layer, and comparing the fusion width with the fusion width detection length of the ultrasonic detection lap joint interface. The detection results are shown in fig. 4 and 5, the detection interface fusion width is 1.79mm through measurement, and the actual penetration depth of the lower layer of the welding seam, which is measured after metallographic treatment, is 2.89 mm. And the predicted lower layer penetration depth is calculated to be 2.88mm according to the linear relation, and the error is 0.35%. The above conclusion shows that the array ultrasonic detection method provided by the invention is feasible for detecting the penetration of the lower layer of the dissimilar metal lap weld, and the result is reliable.
Example 2
The embodiment provides a system for measuring the penetration of a lower layer of a weld joint in lap welding, which applies the method of the embodiment, and comprises the following steps:
the pretreatment module is used for pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
the model establishing module is used for establishing a simulation model according to the parameters of the preprocessed test piece;
the simulation module is used for simulating the simulation model and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
the equipment calibration module is used for calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain the calibrated ultrasonic phased array detection equipment;
the fusion width determining module is used for detecting an ultrasonic measured value of the weld fusion width at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and the fusion depth determining module is used for calculating the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the weld fusion width at the lap joint interface.
The embodiments in the present description are described in a progressive manner, each embodiment focuses on differences from other embodiments, and the same and similar parts among the embodiments are referred to each other. For the system disclosed by the embodiment, the description is relatively simple because the system corresponds to the method disclosed by the embodiment, and the relevant points can be referred to the method part for description.
The principles and embodiments of the present invention have been described herein using specific examples, which are provided only to help understand the method and the core concept of the present invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (10)
1. A method for measuring the penetration depth of a lower layer of a weld joint in lap welding is characterized by comprising the following steps:
pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
establishing a simulation model according to the parameters of the preprocessed test piece;
simulating the simulation model, and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain calibrated ultrasonic phased array detection equipment;
detecting an ultrasonic measured value of weld fusion width at a lap joint interface of the preprocessed test piece by using calibrated ultrasonic phased array detection equipment;
and calculating to obtain the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam fusion width at the lap joint interface.
2. The method for measuring the penetration depth of the lower layer of the weld joint in the lap welding according to claim 1, wherein the pretreatment is performed on the surface of the test piece to be detected to obtain a pretreated test piece, and comprises the following steps:
polishing the weld reinforcement on the surface of the test piece to be detected to enable the weld to be flush with the adjacent base metal and ensure that the roughness of the surface of the weld is not greater than a threshold a;
and (4) setting a coupling agent on the surface of the polished test piece to obtain a pretreated test piece.
3. The method for measuring the penetration of the lower layer of a weld joint in lap welding according to claim 1, wherein the parameters of the pre-processed test piece include the material and thickness of the upper and lower weld plates and the width of the upper surface of the weld joint.
4. The method for measuring the penetration depth of the lower layer of a weld joint in lap welding according to claim 1, wherein the simulating the simulation model and determining the parameters and the focusing rule of the ultrasonic phased array detection equipment comprises: determining the optimal focusing depth and aperture size of the simulated sound field by adopting a single-factor alternation method; and determining the device parameters and the focusing rule according to the optimal focusing depth and the optimal aperture size.
5. The method for measuring the penetration depth of the lower layer of the weld joint in the lap welding according to claim 1, wherein the calibrating of the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule comprises the steps of respectively carrying out sound velocity calibration, delay calibration and sensitivity calibration on the ultrasonic phased array detection equipment;
the sound velocity calibration comprises selecting a thickness in the echo type of the equipment, wherein the first thickness is set as the thickness of the pretreatment test piece, and the second thickness is set as the thickness of twice the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of a preprocessed test piece, framing the primary echo and the secondary echo by using a gate of equipment, and determining a sound path and propagation time between the primary echo and the secondary echo; determining the calibrated sound velocity according to the sound path and the propagation time; and calibrating the sound velocity of the ultrasonic phased array detection equipment by using the calibrated sound velocity.
6. The method of measuring weld penetration in lap welding of claim 5, wherein the delay calibration comprises selecting a thickness among echo types of the apparatus, wherein the thickness is set to the thickness of the pre-processed test piece and the tolerance is set to one tenth of the thickness of the pre-processed test piece; utilizing a gate frame of the device to frame the bottom echo of the pretreatment test piece, and moving the probe position of the device back and forth to determine the sound path of the pretreatment test piece; determining wedge block delay according to the sound path of the preprocessed test piece and the known wedge block sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge block delay.
7. The method for measuring the penetration depth of the lower layer of the weld joint in lap welding according to claim 5, wherein the sensitivity calibration comprises selecting sensitivity calibration in PA calibration, selecting hole waves in echo types, moving the position of an equipment probe on a standard test block back and forth to smooth an envelope curve, obtaining the height difference of echo peak values of the probe at all angles on the standard test block, compensating different gain values for sound beam lines at all angles, enabling the heights of the echo peak values to be the same, and completing the sensitivity calibration.
8. The method for measuring the penetration depth of the lower layer of the weld joint in lap welding according to claim 1, wherein the detecting the weld joint width of the lap interface of the pretreatment test piece by using the calibrated ultrasonic phased array detection equipment comprises detecting the weld joint width of the detection interface of the pretreatment test piece by using the calibrated ultrasonic phased array detection equipment; calculating to obtain the weld penetration of the pretreatment test piece by utilizing the linear relation between the weld penetration at the detection interface and the actual weld penetration of the pretreatment test piece; the linear relation between the weld bead width of the actual pretreatment test piece and the weld bead width at the detection interface is as follows:
l＝0.316L+0.122
wherein L represents a metallographic measurement value of the weld width of the lap interface, and L represents an ultrasonic measurement value of the weld width of the lap interface.
9. The method for measuring the penetration depth of the lower layer of the weld seam in lap welding according to claim 1, wherein the calculating of the penetration depth of the lower layer of the weld seam according to the lap interface weld width comprises calculating the penetration depth of the lower layer of the weld seam by using the linear relation between the lap interface weld width and the penetration depth of the lower layer of the weld seam, and the linear relation between the lap interface weld width and the penetration depth of the lower layer of the weld seam is as follows:
s＝2.927l+0.867
wherein s represents that the lower layer of the weld enters a weld penetration metallographic measurement value, and l represents a weld penetration metallographic measurement value of the lap interface.
10. A system for measuring the penetration of a lower weld layer in lap welding, comprising:
the pretreatment module is used for pretreating the surface of a test piece to be detected to obtain a pretreated test piece;
the model establishing module is used for establishing a simulation model according to the parameters of the preprocessed test piece;
the simulation module is used for simulating the simulation model and determining parameters and a focusing rule of the ultrasonic phased array detection equipment;
the equipment calibration module is used for calibrating the ultrasonic phased array detection equipment with the set equipment parameters and the set focusing rule to obtain the calibrated ultrasonic phased array detection equipment;
the fusion width determining module is used for detecting an ultrasonic measured value of the weld fusion width at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and the fusion depth determining module is used for calculating the penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the weld fusion width at the lap joint interface.
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