CN114019024B - Method and system for measuring penetration of lower layer of welding seam in lap welding - Google Patents
Method and system for measuring penetration of lower layer of welding seam in lap welding Download PDFInfo
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Abstract
The invention relates to a method and a system for measuring penetration 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 parameters of the pretreatment test piece; simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection equipment; calibrating the ultrasonic phased array detection equipment with the equipment parameters and the focusing rule, so as to obtain calibrated ultrasonic phased array detection equipment; detecting the welding line width of the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment; and calculating according to the welding seam melting width of the lap joint interface to obtain the penetration of the lower layer of the welding seam. By setting the focusing depth and the focusing rule, phased array ultrasonic beams are focused at the welding seam of the dissimilar metal faying surface, so that the acoustic energy of the welding seam of the dissimilar metal faying surface is improved, the influence of factors such as acoustic energy attenuation and acoustic scattering on the signal to noise ratio is reduced, and the detection effect of the welding seam 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 penetration of a lower layer of a welding line in lap welding.
Background
The technology of mastering the oxyhydrogen rocket engine is one of the national marks of the aerospace state, and the manufacturing process of the oxyhydrogen engine involves welding of a large number of dissimilar metal materials and can form a large number of dissimilar metal welding seams. Compared with the welding of the same material, the welding of the different material has the characteristics of large difference of the melting points of the different metal materials, large difference of linear expansion coefficients, large difference of heat conductivity and specific heat capacity, complex microstructure and the like, and the welding difficulty is far greater than that of the welding of the same material, so that the problems of insufficient penetration or excessive penetration of the lower layer are 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 improvement of the quality reliability of the welding seam is realized through automatic welding, electronic welding and other processes at home and abroad, but the internal quality of the welding seam can not 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 develop nondestructive inspection technology research on the internal quality of the weld. However, in the research of the nondestructive testing technology of the welding seam at present, the testing experiments for verifying and testing the effectiveness and reliability of the technology mainly adopt single-layer flat plate welding, and few research results of the nondestructive testing technology are reported for the dissimilar metal welding structure of the multi-layer and small-thickness welding seam of the electroformed nickel superalloy.
Generally, a radiation detection technology is generally adopted for quality detection, but the thrust chamber of the aeroengine has a complex structure, and many welding seams cannot be detected by conventional X rays. Meanwhile, for the welding of the nickel and the superalloy which are more used at present, the radiation absorption coefficient of the superalloy is larger, so that the detection thickness is increased, the sensitivity is reduced, and the detection capability is greatly reduced; in ultrasonic detection, the influence of the sound beam of the product is relatively large, and for the detection of the welding seam of dissimilar metals, as the two sides of the welding seam are made of different materials, the sound beam is different, the detection difficulty is high, and the current ultrasonic detection method for the welding seam is not known.
Disclosure of Invention
The invention aims to provide a method and a system for measuring penetration of a lower layer of a welding seam in lap welding. And detecting the welding seam by array ultrasonic, so as to realize accurate measurement of penetration of the lower layer of the welding seam in lap welding.
In order to achieve the above object, the present invention provides the following solutions:
in one aspect, the invention provides a method for measuring penetration of a lower layer of a weld joint in lap welding, 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 pretreatment test piece;
simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection equipment;
calibrating the ultrasonic phased array detection equipment with the equipment parameters and the focusing rule, so as to obtain calibrated ultrasonic phased array detection equipment;
detecting ultrasonic measurement values of weld widths at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and calculating to obtain penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface.
Optionally, the preprocessing the surface of the test piece to be detected to obtain a preprocessed test piece includes:
polishing the weld seam surplus height of the surface of the test piece to be detected to enable the weld seam to be flush with the adjacent parent metal, and ensuring that the surface roughness of the weld seam is not greater than a threshold value a;
and setting a couplant on the surface of the polished test piece to obtain a pretreatment test piece.
Optionally, the parameters of the pretreatment test piece comprise materials, thicknesses and upper surface widths of welding seams of the upper welding plate and the lower welding plate.
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 rotation method; and determining equipment parameters and a focusing rule according to the optimal focusing depth and the aperture size.
Optionally, calibrating the ultrasonic phased array detection device with the set device parameters and the focusing rule includes respectively performing sound velocity calibration, delay calibration and sensitivity calibration on the ultrasonic phased array detection device;
the sound velocity calibration comprises the steps of selecting thickness in echo type of equipment, wherein the first thickness is set to be the thickness of a pretreatment test piece, and the second thickness is set to be twice the thickness of the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of the pretreatment test piece, framing the primary echo and the secondary echo by using a gate of the equipment, and determining the sound path and the propagation time between the primary echo and the secondary echo; determining a calibrated sound velocity according to the sound path and the propagation time; and carrying out sound velocity calibration on the ultrasonic phased array detection equipment by using the calibrated sound velocity.
Optionally, the delay calibration includes selecting a thickness in an echo type of the device, wherein the thickness is set to a 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 equipment to preprocess the bottom echo of the test piece, and moving the probe position of the equipment back and forth to determine the sound path of the test piece; determining a wedge delay according to the sound path of the pretreatment test piece and the known wedge sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge delay.
Optionally, the sensitivity calibration includes selecting sensitivity calibration in PA calibration, selecting Kong Bo from echo types, smoothing an envelope curve by the position of the front and back mobile device probe on the standard test block, obtaining the echo peak value height difference of each angle of the probe on the standard test block, compensating different gain values for the acoustic beam lines of each angle, so that the echo peak values are the same in height, and completing the sensitivity calibration.
Optionally, the detecting, by using the calibrated ultrasonic phased array detecting device, a metallographic measurement value of a weld bead width at the overlap interface of the pretreatment test piece includes:
detecting an ultrasonic detection value of the weld bead width at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
obtaining a metallographic measurement value of the weld bead width at the lap joint interface of the pretreatment test piece according to the linear relation between the ultrasonic detection value of the weld bead width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld bead width at the lap joint interface of the pretreatment test piece;
the linear relation between the ultrasonic detection value of the weld bead fusion width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld bead 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 the weld bead width at the lap joint interface, and L represents an ultrasonic detection value of the weld bead width at the lap joint interface.
Optionally, calculating to obtain penetration depth of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface, including:
calculating to obtain the penetration of the lower layer of the welding seam by using the linear relation between the metallographic measurement value of the welding seam penetration at the lap joint interface and the penetration of the lower layer of the welding seam, wherein the linear relation between the metallographic measurement value of the welding seam penetration at the lap joint interface and the penetration of the lower layer of the welding seam is as follows:
s＝2.927l+0.867
wherein s represents penetration of the lower layer of the welding seam, and l represents metallographic measurement of welding seam width at the lap joint interface.
In another aspect, the present invention provides a system for measuring penetration of a lower layer of a weld in lap welding, comprising:
the pretreatment module is used for carrying out pretreatment on the surface of the test piece to be detected to obtain a pretreated test piece;
the model building module is used for building a simulation model according to the parameters of the pretreatment 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 device calibration module is used for calibrating the ultrasonic phased array detection device with the set device parameters and the focusing rule to obtain the calibrated ultrasonic phased array detection device;
the fusion width determining module is used for detecting ultrasonic measurement values of the fusion width of the welding line at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and the penetration determining module is used for calculating and obtaining penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam 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 penetration 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 pretreatment test piece; simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection equipment; calibrating the ultrasonic phased array detection equipment with the equipment parameters and the focusing rule, so as to obtain calibrated ultrasonic phased array detection equipment; detecting ultrasonic measurement values of weld widths at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment; and calculating to obtain penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface. The invention firstly focuses sound beams at the welding seam of the dissimilar metal faying surface to measure the welding seam width of the faying surface, and then analyzes the relation between the welding seam width 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, propagation of acoustic beams of different materials during ultrasonic detection and the like are effectively avoided, the direct and effective detection of the dissimilar metal lap joint weld joint connection quality is realized, and the reliability of the weld joint quality is improved. In addition, the invention adopts full-coverage simulation software to simulate and simulate the construction of a model for the detected dissimilar metal lap welding seam, simulates the sound beam path of ultrasonic waves in the welding seam, determines the focusing depth, ensures that the sound beam is focused on the welding seam of the dissimilar metal lap welding seam, and ensures that the detection of the fusion width of the welding seam lap is more accurate, thereby improving the accuracy of the detection of the penetration length of the lower layer.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are 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 other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a process flow of the present invention;
FIG. 2 is a schematic diagram of a detection position according to the present invention;
FIG. 3 is a schematic diagram of a test piece simulation model according to the present invention;
FIG. 4 is a schematic diagram of the detection interface width of the present invention;
FIG. 5 is a schematic diagram of the principle of the invention for measuring penetration of a lower layer of a weld seam in lap welding;
FIG. 6 is a schematic diagram for explaining the principle of penetration of the lower layer of the weld;
FIG. 7 is a schematic diagram for explaining the principle of ultrasonic detection value of weld fusion width according to the invention.
Symbol description: 1 probe, 2 focusing rule, 3 detection interface melting width, 4 piezoelectric wafer, 5 wedge, 6 sound beam, 7 welding seam edge and 8 test piece.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Dissimilar metal lap welding is more difficult than lap welding of the same metal material. The reason is that the dissimilar metal materials have large differences in melting points, large differences in linear expansion coefficients, large differences in thermal conductivity and specific heat capacity, and complex microstructures. Due to the above-mentioned difficulties of dissimilar metal lap welding, the lower layer of the weld seam of the dissimilar metal lap welding has a problem of insufficient penetration or excessive penetration. The measurement of the weld seam of dissimilar metal lap welding includes X-ray detection and ultrasonic detection. The problem with X-ray detection is that dissimilar metals include superalloys, which have a large absorption coefficient for X-rays, which results in a detection thickness that is greater than the true thickness. The detection is not accurate enough. The ultrasonic detection has the problems that when the thickness of the dissimilar metals of the upper layer and the lower layer is smaller than 5mm, sound beams 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 is difficult to detect. In this regard, the invention provides a method and a system for measuring penetration of a lower layer of a welding seam in lap welding. And detecting the welding seam by array ultrasonic, so as to realize accurate measurement of penetration of the lower layer of the welding seam in lap welding.
The weld joint lower layer enters penetration depth, which means the reaching depth of the weld joint in the lower layer metal when the dissimilar metals of the upper layer and the lower layer are overlapped and subjected to electron beam welding, and is the distance between the interface between the dissimilar metals of the two layers and the tip of the weld joint. As shown in fig. 6, where s represents the penetration of the lower layer of the weld.
The metallographic measurement of the weld bead fusion width is that the metallographic method is adopted to observe the section of the weld bead under a microscope, and the width of the weld bead on the interface between dissimilar metals is measured to obtain a width value.
The ultrasonic detection value of the weld bead fusion width refers to the gap width L between different kinds of intermetallic interface echoes obtained by measuring the phased array linear array scanning detection on an obtained line scanning image by adopting the detection method provided by the invention. As shown in fig. 7, L is an ultrasonic detection value of the weld bead fusion width.
In order that the above-recited objects, features and advantages of the present invention will become more readily apparent, a more particular description of the invention will be rendered by reference to the appended drawings and appended detailed description.
Example 1
As shown in fig. 1, the embodiment provides a method for measuring penetration of a lower layer of a welding seam 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 surplus height of the weld seam on the surface of the test piece to be detected, enabling the weld seam to be flush with the adjacent parent metal, and ensuring that the surface roughness of the weld seam is not greater than a threshold value a; and setting a couplant on the surface of the polished test piece to obtain a pretreatment test piece. Wherein the value of 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 thresholds with other values according to actual needs. The couplant is used for ensuring the close contact between the probe 1 and the test piece and ensuring that the probe 1 can slide smoothly on the test piece.
S2: establishing a simulation model according to the parameters of the pretreatment test piece;
the parameters of the pretreatment test piece comprise the material and thickness of the upper and lower welding plates and the width of the upper surface of the welding line. The simulation module establishes a simulation model according to the groove shape and the detection thickness of the welding line. Taking an electron beam welding seam as an example, the shape of the welding seam is selected to be V-shaped according to the characteristics of the vacuum electron beam welding seam.
S3: simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection equipment;
the simulation of the simulation model is performed to determine parameters and a focusing rule of the ultrasonic phased array detection equipment, and the method comprises the following steps: determining the optimal focusing depth and aperture size of the simulated sound field by adopting a single factor rotation method; and determining equipment parameters and a focusing rule according to the optimal focusing depth and the aperture size. For example, after a sample model is drawn in three-dimensional drawing software, simulation software is introduced to determine parameters of the probe 1 and a focusing mode, a single factor rotation method is adopted, sound fields at the welding seam of the lap joint are simulated by respectively changing focusing depth and aperture size, and optimal parameters of focusing depth and aperture size are determined by observing main lobe width and field intensity of the simulated sound fields, so that the transverse resolution of sound beams at the welding seam of the lap joint is highest, and the focusing effect is best. The ultrasonic phased array detection equipment uses an ultrasonic phased array detector, an instrument channel is 32 channels, the size of array elements of the probe 1 is 0.4mm, the spacing of the array elements is 0.5mm, the center frequency of the probe 1 is 5MHz, a wedge block is 0 DEG, and the wedge block material is organic glass. And inputting parameters of a probe 1 and a wedge block into phased array detection equipment, entering a focusing rule, setting a scanning mode selection line, scanning and determining the sound beam coverage of a detected area, selecting a plane by a focusing surface, setting the focusing depth to be the thickness of an upper metal plate, and focusing the sound beam at a welding seam of a lap joint surface. The full excitation of 32 array elements is selected, the aperture size is 4, and the stepping bias is 0.
S4: calibrating the ultrasonic phased array detection equipment with the equipment parameters and the focusing rule, so as to obtain calibrated ultrasonic phased array detection equipment;
calibrating ultrasonic phased array detection equipment with set equipment parameters and focusing rules, wherein the calibration comprises sound velocity calibration, delay calibration and sensitivity calibration of the ultrasonic phased array detection equipment respectively; the sound velocity calibration comprises the steps of selecting thickness in echo type of the equipment, wherein the thickness I is set to be the thickness of the pretreatment test piece, and the thickness II is set to be twice the thickness of the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of the pretreatment test piece, framing the primary echo and the secondary echo by using a gate of the equipment, and determining the sound path and the propagation time between the primary echo and the secondary echo; determining a calibrated sound velocity according to the sound path and the propagation time; and carrying out sound velocity calibration on the ultrasonic phased array detection equipment by using the calibrated sound velocity. Delay calibration includes selecting a thickness in an echo type of the device, wherein the thickness is set to a 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 equipment to preprocess the bottom echo of the test piece, and moving the probe 1 of the equipment back and forth to determine the sound path of the test piece; determining a wedge delay according to the sound path of the pretreatment test piece and the known wedge sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge delay. The sensitivity calibration comprises the steps of selecting sensitivity calibration in PA calibration, selecting Kong Bo in echo types, moving the position of the probe 1 of the equipment back and forth on a standard test block, smoothing an envelope line to obtain the height difference of echo peak values of the probe 1 at each angle on the standard test block, and compensating different gain values for the acoustic beam lines at each angle to ensure that the heights of the echo peak values are the same, thereby completing the sensitivity calibration. In the sensitivity calibration, a phi 2 transverse through hole with the depth of 25mm of a CSK-IA standard test block can be adopted for calibration, and in the specific implementation, the width of the upper part of a welding line is consistent with the actual width, the depth is the detection thickness, namely 4mm, and the echo height of the test block reaches 80% wave height on the premise that the echo peak heights are the same.
S5: detecting ultrasonic measurement values of weld widths at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
specifically, detecting an ultrasonic measurement value of the welding seam melting 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 welding seam melting 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 measurement value of the weld bead width at the lap joint interface of the pretreatment test piece according to the linear relation between the ultrasonic detection value of the weld bead width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld bead width at the lap joint interface of the pretreatment test piece; the linear relation between the ultrasonic detection value of the weld bead fusion width at the lap joint interface of the pretreatment test piece and the metallographic measurement value of the weld bead 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 the weld bead width at the lap joint interface, and L represents an ultrasonic detection value of the weld bead width at the lap joint interface.
S6: and calculating to obtain penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface.
Specifically, the weld lower layer entering penetration is obtained according to the calculation of the weld width of the lap joint interface, the linear relation between the metallographic measurement value of the weld width at the lap joint interface and the weld lower layer entering penetration is calculated to obtain the weld lower layer entering penetration, and the linear relation between the metallographic measurement value of the weld width at the lap joint interface and the weld lower layer entering penetration is as follows:
s＝2.927l+0.867
wherein s represents penetration of the lower layer of the welding seam, and l represents metallographic measurement of welding seam width at the lap joint interface.
According to the specific embodiment, as shown in fig. 2, GH4169 with the size of 100x100mm and an electroformed nickel test plate with the thickness of 4mm and 5mm are selected, the two welding surfaces are polished to be smooth, and the welding plate is cleaned by absolute ethyl alcohol, so that the surfaces to be welded are clean and free of greasy dirt. The upper layer GH4169 and the lower layer are lapped by adopting a mode of electroforming nickel, and the edges of the center of the plate are welded by adopting a vacuum electron beam welding method. Wherein, the welding voltage is fixed at 60kV, the welding speed is 1600mm/min, the focusing mode selects upper surface focusing, and the welding current selects 55mA. The irregular weld seam excess height on the surface of the weld seam is polished to be flush with the adjacent base metal, coarse matters influencing the movement of the probe 1 are removed, the surface roughness is less than or equal to 6.3 mu m, and the probe 1 is completely coupled and can move freely. And marking the welding line and the placement position of the probe 1 and selecting a proper coupling agent.
As shown in fig. 3, the workpiece model is imported into simulation software. The parameters and focusing modes of the probe 1 are determined, the aperture size is fixed through a single factor rotation method, the focusing depth is set to be 1-9 mm (the step is 1 mm) respectively, the width and the field length of a main lobe of a sound field at a welding seam of a lap joint face are observed, the optimal focusing depth is determined to be 4mm, the focusing depth is fixed again, the aperture sizes are set to be 4,8 and 16 array element widths respectively, the width and the field intensity of the main lobe of the sound field at the welding seam of the lap joint face are observed, and the optimal aperture size is determined to be 16. The depth of focus is then chosen to be 4mm and the aperture size 16 array elements wide. Connecting phased array detection equipment with a computer, and opening a phased array software connecting plate card; the phased array probe 1 with 32 array elements is adopted, the size of the array elements is 0.4mm, the spacing of the array elements is 0.5mm, the center frequency of the probe 1 is 5MHz, a wedge block with 0 degree is selected, and the wedge block material is organic glass. The probe 1 and wedge parameters are 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 consistent with the actual width, and the depth is the detection thickness, namely 4mm. The entering focus rule calculator sets a focus rule. Selecting a linear array mode, detecting by using an echo method, selecting a plane on a focusing surface, selecting 32 array elements for excitation, wherein the aperture size is 16, the focusing depth is 4mm, and the stepping bias is 0. When calibrating, placing the probe 1 on a workpiece, selecting the thickness of the echo type in sound velocity calibration, setting the thickness 1 as the thickness of the workpiece and setting the thickness 2 as twice the thickness of the workpiece, finding out a primary echo and a secondary echo on the bottom surface of the workpiece, respectively framing the two waves by a gate, and clicking for calibration; the probe 1 is placed on a workpiece, the thickness is selected in the echo type in the delay calibration, the thickness is set to be the thickness of the workpiece, the tolerance is set to be one tenth of the thickness, the echo of the bottom surface of the workpiece is framed by a gate, the probe 1 is pushed and pulled back and forth, the envelope is smoothed and placed in a red wire frame, and the calibration is clicked. The probe 1 is placed above a phi 2 transverse through hole with the depth of 25mm of a CSK-IA standard test block, sensitivity calibration in PA calibration is selected, echo type selection Kong Bo is performed, a gate frames the transverse hole to back, the probe 1 is pushed and pulled back and forth, an envelope line is smoothed, and calibration is clicked. After calibration is completed, a couplant is applied to a position to be detected, the probe 1 spans the welding line, the gain is adjusted, a line scanning image corresponding to the welding line width of the dissimilar metal faying surface appears on the detection interface, the acquired detection data file is stored, and the penetration is calculated according to the detection data file. In addition, the lap joint interface melting width can be analyzed and measured through phased array ultrasonic analysis software, and then the lower layer entering penetration length is obtained according to the relation between the lap joint interface melting width and the lower layer entering penetration. And transversely performing linear cutting on the detection workpiece from the detection position to obtain a welding seam cross section, performing metallographic processing on the cross section to obtain a welding seam clear image, measuring the fusion width of the lap joint surface and the penetration depth of the lower layer, and comparing with the ultrasonic detection lap joint interface fusion width detection length. The detection results are shown in fig. 4 and 5, the melting width of the detection interface is 1.79mm after measurement, and the actual penetration of the lower layer of the welded seam after metallographic treatment is 2.89mm. And the predicted penetration depth of the lower layer is 2.88mm and the error is 0.35% according to the linear relation. The conclusion above 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 penetration of a lower layer of a welding seam in lap welding by applying the method of the embodiment, which comprises the following steps:
the pretreatment module is used for carrying out pretreatment on the surface of the test piece to be detected to obtain a pretreated test piece;
the model building module is used for building a simulation model according to the parameters of the pretreatment 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 device calibration module is used for calibrating the ultrasonic phased array detection device with the set device parameters and the focusing rule to obtain the calibrated ultrasonic phased array detection device;
the fusion width determining module is used for detecting ultrasonic measurement values of the fusion width of the welding line at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment;
and the penetration determining module is used for calculating and obtaining penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface.
In the present specification, each embodiment is described in a progressive manner, and each embodiment is mainly described in a different point from other embodiments, and identical and similar parts between the embodiments are all enough to refer to each other. For the system disclosed in the embodiment, since it corresponds to the method disclosed in the embodiment, the description is relatively simple, and the relevant points refer to the description of the method section.
The principles and embodiments of the present invention have been described herein with reference to specific examples, the description of which is intended only to assist in understanding the methods of the present invention and the core ideas thereof; also, it is within the scope of the present invention to be modified by those of ordinary skill in the art in light of the present teachings. In view of the foregoing, this description should not be construed as limiting the invention.
Claims (8)
1. A method of measuring penetration of a lower layer of a weld in lap welding, comprising:
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 pretreatment test piece;
simulating the simulation model to determine parameters and a focusing rule of the ultrasonic phased array detection equipment;
calibrating the ultrasonic phased array detection equipment with the equipment parameters and the focusing rule, so as to obtain calibrated ultrasonic phased array detection equipment;
detecting ultrasonic measurement values of weld widths at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment; focusing the sound beam on the welding seam of the dissimilar metal faying surface, and measuring the welding seam width of the faying surface;
calculating to obtain penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface;
the method comprises the steps of detecting the welding line width of the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment, wherein the method comprises the steps of detecting the welding line width of the detection interface of the pretreatment test piece by using the calibrated ultrasonic phased array detection equipment; calculating the weld bead fusion width of the pretreatment test piece by using the linear relation between the fusion width at the detection interface and the weld bead fusion width of the actual pretreatment test piece; the linear relation between the melting width at the detection interface and the welding seam melting width of the actual pretreatment test piece is as follows:
l＝0.316L+0.122
wherein L represents a welding line width metallographic measurement value of the lap joint interface, and L represents an ultrasonic welding line width measurement value of the lap joint interface;
the step of calculating the weld seam lower layer entering penetration according to the lap joint interface weld seam width comprises the step of calculating the weld seam lower layer entering penetration by utilizing a linear relation between the lap joint interface weld seam width and the weld seam lower layer entering penetration, wherein the linear relation between the lap joint interface weld seam width and the weld seam lower layer entering penetration is as follows:
s＝2.927l+0.867
s represents a welding seam lower layer entering penetration metallographic measurement value, and l represents a lap joint interface welding seam width metallographic measurement value.
2. The method for measuring penetration of a lower layer of a weld seam in lap welding according to claim 1, wherein the preprocessing of the surface of the test piece to be detected to obtain a preprocessed test piece comprises the following steps:
polishing the weld seam surplus height of the surface of the test piece to be detected to enable the weld seam to be flush with the adjacent parent metal, and ensuring that the surface roughness of the weld seam is not greater than a threshold value a;
and setting a couplant on the surface of the polished test piece to obtain a pretreatment test piece.
3. The method of claim 1, wherein the parameters of the pre-treated test piece include the material, thickness, and upper surface width of the weld.
4. The method for measuring penetration of a lower layer of a weld seam in lap welding according to claim 1, wherein said simulating the simulation model to determine ultrasonic phased array detection equipment parameters and a focusing rule comprises: determining the optimal focusing depth and aperture size of the simulated sound field by adopting a single factor rotation method; and determining equipment parameters and a focusing rule according to the optimal focusing depth and the aperture size.
5. The method for measuring penetration of a lower layer of a weld seam in lap welding according to claim 1, wherein the calibrating of the ultrasonic phased array detection device with set device parameters and focusing rules comprises respectively performing sound velocity calibration, delay calibration and sensitivity calibration on the ultrasonic phased array detection device;
the sound velocity calibration comprises the steps of selecting thickness in echo type of equipment, wherein the first thickness is set to be the thickness of a pretreatment test piece, and the second thickness is set to be twice the thickness of the pretreatment test piece; respectively determining a primary echo and a secondary echo of the bottom surface of the pretreatment test piece, framing the primary echo and the secondary echo by using a gate of the equipment, and determining the sound path and the propagation time between the primary echo and the secondary echo; determining a calibrated sound velocity according to the sound path and the propagation time; and carrying out sound velocity calibration on the ultrasonic phased array detection equipment by using the calibrated sound velocity.
6. The method of measuring penetration of a lower layer of a weld in lap welding according to claim 5, wherein said delay calibration includes selecting a thickness in an echo type of the apparatus, wherein the thickness is set to a 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 equipment to preprocess the bottom echo of the test piece, and moving the probe position of the equipment back and forth to determine the sound path of the test piece; determining a wedge delay according to the sound path of the pretreatment test piece and the known wedge sound velocity; and performing delay calibration on the ultrasonic phased array detection equipment by using the wedge delay.
7. The method for measuring penetration of a lower layer of a welding seam in lap welding according to claim 5, wherein the sensitivity calibration comprises selecting sensitivity calibration in PA calibration, selecting Kong Bo from echo types, moving a probe of a device back and forth on a standard test block, smoothing an envelope line to obtain the height difference of echo peak values of the probe on the standard test block at each angle, and compensating different gain values for acoustic beams at each angle to make the heights of echo peak values the same, thereby completing the sensitivity calibration.
8. A system for measuring penetration of a lower layer of a weld in lap welding, comprising:
the pretreatment module is used for carrying out pretreatment on the surface of the test piece to be detected to obtain a pretreated test piece;
the model building module is used for building a simulation model according to the parameters of the pretreatment 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 device calibration module is used for calibrating the ultrasonic phased array detection device with the set device parameters and the focusing rule to obtain the calibrated ultrasonic phased array detection device;
the fusion width determining module is used for detecting ultrasonic measurement values of the fusion width of the welding line at the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment; focusing the sound beam on the welding seam of the dissimilar metal faying surface, and measuring the welding seam width of the faying surface;
the method comprises the steps of detecting the welding line width of the lap joint interface of the pretreatment test piece by using calibrated ultrasonic phased array detection equipment, wherein the method comprises the steps of detecting the welding line width of the detection interface of the pretreatment test piece by using the calibrated ultrasonic phased array detection equipment; calculating the weld bead fusion width of the pretreatment test piece by using the linear relation between the fusion width at the detection interface and the weld bead fusion width of the actual pretreatment test piece; the linear relation between the melting width at the detection interface and the welding seam melting width of the actual pretreatment test piece is as follows:
l＝0.316L+0.122
wherein L represents a welding line width metallographic measurement value of the lap joint interface, and L represents an ultrasonic welding line width measurement value of the lap joint interface;
the penetration determining module is used for calculating the penetration of the lower layer of the welding seam according to the ultrasonic measurement value of the welding seam width at the lap joint interface;
the step of calculating the weld seam lower layer entering penetration according to the lap joint interface weld seam width comprises the step of calculating the weld seam lower layer entering penetration by utilizing a linear relation between the lap joint interface weld seam width and the weld seam lower layer entering penetration, wherein the linear relation between the lap joint interface weld seam width and the weld seam lower layer entering penetration is as follows:
s＝2.927l+0.867
s represents a welding seam lower layer entering penetration metallographic measurement value, and l represents a lap joint interface welding seam width metallographic measurement value.
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