CN114113321B - Phased array ultrasonic detection system and method for blade root groove of gas turbine compressor impeller - Google Patents

Phased array ultrasonic detection system and method for blade root groove of gas turbine compressor impeller Download PDF

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Publication number
CN114113321B
CN114113321B CN202111343029.6A CN202111343029A CN114113321B CN 114113321 B CN114113321 B CN 114113321B CN 202111343029 A CN202111343029 A CN 202111343029A CN 114113321 B CN114113321 B CN 114113321B
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phased array
blade root
array ultrasonic
defect
root groove
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CN114113321A (en
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张炯
肖俊峰
南晴
高斯峰
唐文书
李永君
高松
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Xian Thermal Power Research Institute Co Ltd
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Xian Thermal Power Research Institute Co Ltd
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/04Analysing solids
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/26Arrangements for orientation or scanning by relative movement of the head and the sensor
    • G01N29/262Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/28Details, e.g. general constructional or apparatus details providing acoustic coupling, e.g. water
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/30Arrangements for calibrating or comparing, e.g. with standard objects
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00Indexing codes associated with group G01N29/00
    • G01N2291/02Indexing codes associated with the analysed material
    • G01N2291/028Material parameters
    • G01N2291/0289Internal structure, e.g. defects, grain size, texture
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N2291/00Indexing codes associated with group G01N29/00
    • G01N2291/04Wave modes and trajectories
    • G01N2291/044Internal reflections (echoes), e.g. on walls or defects

Abstract

The invention discloses a phased array ultrasonic detection system and method for a blade root groove of a gas turbine compressor impeller, wherein the system comprises a phased array ultrasonic probe, a detection tool, a reference block and a phased array ultrasonic detector, and the method comprises the following steps: s1: processing a comparison test block with equal proportion, same material or similar material; s2: performing TCG calibration; s3: finding the highest reflection echo of the defect of the reference block; s4: determining a defect judgment reference; s5: and carrying out actual detection on the blade root groove to be detected. According to the invention, by designing the special phased array ultrasonic probe, the detection tool and the comparison test block, effective simulation of cracks of the blade root groove of the impeller of the air compressor and accurate positioning of the phased array ultrasonic probe and the defect position in defect detection are realized; the acute angle of the blade root groove of the impeller of the air compressor is scanned by utilizing ultrasonic primary wave and secondary wave technology, so that the defects of different positions and trend are comprehensively detected.

Description

Phased array ultrasonic detection system and method for blade root groove of gas turbine compressor impeller
Technical Field
The invention belongs to the field of ultrasonic detection, and particularly relates to a phased array ultrasonic detection system and method for a blade root groove of a gas turbine compressor impeller.
Background
The compressor movable blade of the gas turbine is a main component of the compressor for doing work on gas at the inlet of the gas turbine, and is used as a comprehensive function of the rotary machinery which needs to bear loads such as centrifugal stress, airflow impact force, vibration stress and the like in the operation process. The compressor movable blade and the compressor rotor are matched through the compressor impeller blade root groove, so that the key of transmitting the moment of the compressor rotor to the compressor movable blade is that the compressor impeller blade root groove not only bears the load effect which is equal or larger, but also has more severe working environment due to corrosion, fretting wear and the like, and the detection of the health state of the compressor impeller blade root groove is particularly important for ensuring the safe and stable operation of the gas turbine.
In the start-stop process of the gas turbine, the stress is maximum at the acute angle of the front end (upstream side) and the rear end (downstream side) of the blade root groove of the compressor impeller, and after a certain number of start-stop cycles, cracks can occur at the acute angle of the bottom of the blade root groove of the compressor impeller.
As the crack propagates, the stiffness of the wheel rim between the root slots may decrease, resulting in loosening of the compressor blades. In addition, the variation in blade root holding stiffness may affect the frequency response of the compressor blades, ultimately causing high cycle fatigue damage such as wear of the impeller blade root slots, blade cracking, etc. The radial expansion of the crack along the front and rear surfaces of the rim may further cause the compressor wheel to fracture, thereby causing major accidents of the unit.
Disclosure of Invention
The invention aims to solve the technical problem of providing a phased array ultrasonic detection system and method for a blade root groove of a gas turbine compressor impeller, which are used for realizing in-situ phased array ultrasonic detection on a weak area of the blade root groove of the gas turbine impeller, discovering possible defects such as cracks in advance and ensuring the operation safety of a gas turbine unit.
The invention is realized by adopting the following technical scheme:
the phased array ultrasonic detection system comprises a phased array ultrasonic probe, a detection tool, a reference block and a phased array ultrasonic detector;
the phased array ultrasonic probe comprises a shell, a back lining, electrode leads, a wafer, a matching layer and a wedge block; the shell is provided with a corresponding signal transmission interface, and an electric signal generated by the phased array ultrasonic probe is transmitted to the phased array ultrasonic detector through a cable; the backing is in direct contact with the back of the wafer, so that high-amplitude ultrasonic waves emitted by the wafer to the back and reflected back by the workpiece can be absorbed, meanwhile, the wafer is subjected to vibration stopping effect, the width of ultrasonic pulse signals is reduced, and the axial resolution is improved; electrode leads are led out from the back of each array element of the wafer and are gathered to a signal transmission interface on the shell; the wafer consists of a plurality of array elements, and each array element can independently excite and receive ultrasonic waves; the matching layer is in direct contact with the wafer and serves as a medium to transmit ultrasonic waves emitted by the wafer into the wedge; the wedge block is connected with the probe shell, a couplant is filled between the upper surface of the wedge block and the matching layer and is in direct contact with the upper surface of the wedge block, and the lower surface of the wedge block is in direct contact with a blade root groove to be detected through the couplant;
the detection tool is used for stably fixing the phased array ultrasonic probe on the upper surface of the blade root groove comparison test block to be detected, stably coupling and continuously scanning the phased array ultrasonic probe on the surface of the blade root groove to be detected, and accurately measuring and recording the position and the swing angle of the phased array ultrasonic probe;
the external dimension of the reference block is identical with that of the blade root groove to be detected, and the artificial defects with different lengths, depths, shapes and trend are processed at the position where the defect is easy to occur, so that various defect forms easy to occur in the blade root groove are simulated.
The invention is further improved in that the detection tool is fixed on the upper surface of the comparison test block of the blade root groove of the compressor impeller in a magnet or mechanical fixing mode, and no obvious relative displacement occurs between the detection tool and the upper surface of the comparison test block in the detection process.
The invention is further improved in that the defect-prone parts of the reference block are sharp angles at the front end and the rear end.
The invention is further improved in that the phased array ultrasonic detector is connected with the phased array ultrasonic probe through a cable, and the phased array ultrasonic detector is at least 64 channels and can adjust pulse voltage and pulse width.
The phased array ultrasonic detection method for the blade root groove of the gas turbine compressor impeller is based on the phased array ultrasonic detection system for the blade root groove of the gas turbine compressor impeller, and comprises the following steps:
s1: according to the size, shape and material processing proportion of the blade root groove to be detected, and the comparison test block of the same material or similar material, processing defects with different sizes, shapes and trend at the acute angle of the blade root groove comparison test block;
s2: connecting a phased array ultrasonic probe with a phased array ultrasonic detector, setting pulse voltage, pulse width and focusing rule, and performing TCG calibration on a standard test block;
s3: fixing a phased array ultrasonic probe on the upper surface of a reference block through a detection tool, transmitting ultrasonic waves to conduct fan-shaped scanning on the acute angle of the root slot reference block, finding the highest reflection echo through moving the phased array ultrasonic probe, and if the set defect reflection echo cannot be clearly resolved, adjusting pulse voltage, pulse width and focusing rule until the defect reflection echo is clearly resolved;
s4: after finding out the reflected echo of the defect on the reference block, synthesizing the image and waveform display of the S scanning and the A scanning, and adjusting the gain and scanning range of the phased array ultrasonic detector to make the reflected echo display clearer, wherein the image and waveform of the S scanning and the A scanning at the moment are used as the reference for judging the defect;
s5: fixing the phased array ultrasonic probe on the upper surface of a blade root groove to be detected through a detection tool, scanning through the detection tool, and judging that the detection part has no crack if the reflected echo at the acute angle of the blade root groove does not exceed a reference; and if the reflected echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
The invention is further improved in that the defect size at the acute angle of the reference block is set according to the minimum size defect allowed, and the shape and trend of the defect are set by counting the found defect and analyzing the structure and stress condition of the blade root groove.
The invention is further improved in that the acute angle of the blade root groove is detected by adopting the primary wave and the secondary wave.
The invention further improves that the focusing mode of the ultrasonic wave adopts depth focusing, and the focusing position is near the depth position at the acute angle of the blade root groove.
The invention has at least the following beneficial technical effects:
according to the phased array ultrasonic detection system for the blade root groove of the gas turbine compressor impeller, provided by the invention, the effective simulation of the crack of the blade root groove of the gas turbine impeller and the accurate positioning of the phased array ultrasonic probe and the defect position in the detection are realized through designing the special phased array ultrasonic probe, the detection tool and the reference block, and the reliable and complete phased array ultrasonic detection system is provided for the in-situ detection of the crack of the blade root groove of the gas turbine impeller.
According to the phased array ultrasonic detection method for the blade root groove of the gas turbine compressor impeller, provided by the invention, the acute angle of the blade root groove of the gas turbine impeller is scanned by utilizing ultrasonic primary wave and secondary wave technologies, so that the comprehensive detection of defects in different positions and trend is realized; the accurate detection of the defect position and trend is realized by utilizing a mode of combining S scanning and A scanning, adjusting pulse width, pulse voltage, focusing rule, accurately determining the position and direction of the phased array ultrasonic probe and the like.
Drawings
FIG. 1 is a schematic diagram of a phased array ultrasonic inspection system and method for a blade root slot of a gas turbine compressor impeller in accordance with the present invention.
Reference numerals illustrate:
the device comprises a 1-phased array ultrasonic probe, a 101-shell, a 102-backing, a 103-electrode lead, a 104-wafer, a 105-matching layer, a 106-wedge block, a 2-detection tool, a 3-comparison test block, a 301-comparison test block upper surface, a 302-acute angle position, a 4-phased array ultrasonic detector, 5-ultrasonic waves, 501-primary waves and 502-secondary waves.
Detailed Description
Exemplary embodiments of the present disclosure will be described in more detail below with reference to the accompanying drawings. While exemplary embodiments of the present disclosure are shown in the drawings, it should be understood that the present disclosure may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. It should be noted that, without conflict, the embodiments of the present invention and features of the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
Referring to fig. 1, the phased array ultrasonic detection system for the blade root groove of the gas turbine compressor impeller provided by the invention comprises a phased array ultrasonic probe 1, a detection tool 2, a reference block 3 and a phased array ultrasonic detector 4.
The phased array ultrasonic probe 1 comprises a shell 101, a backing 102, an electrode lead 103, a wafer 104, a matching layer 105 and a wedge 106; the shell 101 is provided with a corresponding signal transmission interface, and can transmit an electric signal generated by the phased array ultrasonic probe 1 to the phased array ultrasonic detector 4 through a cable; the backing 102 is in direct contact with the back of the wafer 104, can absorb high-amplitude ultrasonic waves emitted by the wafer 104 to the back and reflected back by the workpiece, has vibration stopping effect on the wafer, reduces the width of ultrasonic pulse signals and improves the axial resolution; electrode leads 103 are led out from the back of each array element of the wafer 104 and are gathered to a signal transmission interface on the shell 101; the wafer 104 is composed of a plurality of array elements, each array element can independently excite and receive ultrasonic waves, and is the most core part in the phased array ultrasonic probe 1; the matching layer 105 is in direct contact with the wafer 104, and transmits ultrasonic waves emitted from the wafer 104 into the wedge 106 as a medium; the wedge 106 is connected with the probe housing 101 through a screw, a couplant is filled between the upper surface and the matching layer 105 and is in direct contact with the upper surface, and the lower surface is in direct contact with a blade root groove to be detected through the couplant.
The detection tool 2 stably fixes the phased array ultrasonic probe 1 on the upper surface 301 of the blade root groove reference block to be detected, can realize stable coupling and continuous scanning of the phased array ultrasonic probe 1 on the surface of the blade root groove to be detected, and can accurately measure and record the position and the swing angle of the phased array ultrasonic probe 1.
The external dimension of the reference block 3 is identical with that of the blade root groove to be detected, artificial defects with different lengths, depths, shapes and trend are processed at the position where the defects are easy to occur, and various defect forms easy to occur of the blade root groove are simulated.
The detection tool 2 is fixed on the upper surface 301 of the reference block of the blade root groove of the compressor impeller in a magnet or mechanical fixing mode, and obvious relative displacement does not occur between the detection tool 2 and the upper surface 301 of the reference block in the detection process.
The defect-prone locations of the reference block 3 are generally sharp corners 302 at the front and rear ends.
The phased array ultrasonic detector 4 is connected with the phased array ultrasonic probe 1 through a cable, and the phased array ultrasonic detector 4 is provided with at least 64 channels, and the pulse voltage and the pulse width can be adjusted.
A phased array ultrasonic detection method for a blade root groove of a gas turbine compressor impeller comprises the following steps:
s1: and processing the comparison test block 3 with the same material or similar materials according to the same proportion of the size, the shape and the material of the blade root groove to be detected, and processing defects with different sizes, shapes and trend at the acute angle 302 of the blade root groove comparison test block.
S2: the phased array ultrasonic probe 1 is connected with the phased array ultrasonic detector 4, pulse voltage, pulse width, focusing rule and the like are set, and TCG calibration is performed on a standard test block.
S3: the phased array ultrasonic probe 1 is fixed on the upper surface 301 of the reference block through the detection tool 2, the ultrasonic wave 5 is transmitted to conduct sector scanning on the acute angle 302 of the root slot reference block, and the highest reflection echo is found through moving the phased array ultrasonic probe 1. If the set defect reflection echo can not be clearly resolved, pulse voltage, pulse width, focusing rule and the like can be adjusted until the defect reflection echo is clearly resolved.
S4: after finding out the reflected echo of the defect on the reference block 3, synthesizing the image and waveform display of the S scanning and the A scanning, and adjusting the gain, the scanning range and the like of the phased array ultrasonic detector 4 to make the reflected echo display clearer, and taking the image and waveform of the S scanning and the A scanning at the moment as the reference for judging the defect.
S5: fixing the phased array ultrasonic probe 1 on the upper surface of a blade root groove to be detected through a detection tool 2, scanning through the detection tool 2, and judging that no crack exists at the detection part if the reflected echo at the acute angle of the blade root groove does not exceed a reference; and if the reflected echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
The defect size at the acute angle 302 of the reference block is set according to the minimum allowed size defect, and the shape and trend of the defect are set by counting the found defect and analyzing the structure and stress condition of the blade root groove.
The primary wave 501 and the secondary wave 502 can be used for detecting the acute angle position 302 of the blade root slot.
The focusing mode of the ultrasonic wave 5 adopts depth focusing, and the focusing position is near the depth position of the acute angle 302 of the blade root groove.
The invention is further described:
the phased array ultrasonic probe 1 is stably coupled to the upper surface 301 of the reference block through the detection tool 2 and is aligned to the acute angle 302 of the root groove of the impeller blade of the air compressor. The phased array ultrasonic detector 4 emits pulse current to excite the phased array ultrasonic probe 1 to generate ultrasonic waves 5, the excitation sequence of each array element of the phased array probe wafer 104 is controlled to control the deflection angle of the sound beam, the defect that the acute angle 302 can be scanned by both the primary wave 501 and the secondary wave 502 is ensured, and the phased array ultrasonic probe 1 is moved to find the highest echo of the defect primary wave 501 and the defect secondary wave 502, so that the highest echo is used as the phased array ultrasonic detection sensitivity.
The phased array ultrasonic probe 1 is coupled to the upper surface of the blade root groove of the gas turbine compressor impeller to be detected through the detection tool 2, the blade root groove of the gas turbine compressor impeller in service is detected according to the set sensitivity standard, if reflection echoes are found, whether the gas turbine compressor impeller is cracked or not is evaluated according to the sensitivity standard, and the position and the trend of the crack are determined through A scanning and S scanning display.
The above embodiments are only for illustrating the technical concept and features of the present invention, and are intended to enable those skilled in the art to understand the content of the present invention and implement the same according to the content of the present invention, and are not intended to limit the scope of the present invention. All equivalent changes or modifications made in accordance with the spirit of the present invention should be construed to be included in the scope of the present invention.

Claims (8)

1. The phased array ultrasonic detection system for the blade root groove of the gas turbine compressor impeller is characterized by comprising a phased array ultrasonic probe (1), a detection tool (2), a reference block (3) and a phased array ultrasonic detector (4);
the phased array ultrasonic probe (1) comprises a shell (101), a back lining (102), an electrode lead (103), a wafer (104), a matching layer (105) and a wedge block (106); the shell (101) is provided with a corresponding signal transmission interface, and an electric signal generated by the phased array ultrasonic probe (1) is transmitted to the phased array ultrasonic detector (4) through a cable; the backing (102) is in direct contact with the back of the wafer (104), can absorb high-amplitude ultrasonic waves emitted by the wafer (104) to the back and reflected back by the workpiece, and has vibration stopping effect on the wafer, so that the width of ultrasonic pulse signals is reduced, and the axial resolution is improved; the electrode leads (103) are led out from the back of each array element of the wafer (104) and are gathered to a signal transmission interface on the shell (101); the wafer (104) is composed of a plurality of array elements, and each array element can be independently excited and receive ultrasonic waves; the matching layer (105) is in direct contact with the wafer (104) and serves as a medium for transmitting ultrasonic waves emitted by the wafer (104) into the wedge block (106); the wedge block (106) is connected with the probe shell (101), a coupling agent is filled between the upper surface of the wedge block (106) and the matching layer (105) and is in direct contact with the upper surface of the wedge block (106), and the lower surface of the wedge block is in direct contact with a blade root groove to be detected through the coupling agent;
the detection tool (2) stably fixes the phased array ultrasonic probe (1) on the upper surface (301) of the blade root groove reference block to be detected, can realize stable coupling and continuous scanning of the phased array ultrasonic probe (1) on the surface of the blade root groove to be detected, and can accurately measure and record the position and the swing angle of the phased array ultrasonic probe (1);
the external dimension of the reference block (3) is identical with that of the blade root groove to be detected, and the artificial defects with different lengths, depths, shapes and trends are processed at the positions where defects are easy to occur, so that various defect forms easy to occur in the blade root groove are simulated.
2. The phased array ultrasonic detection system for the blade root slot of the compressor impeller of the gas turbine according to claim 1, wherein the detection tool (2) is fixed on the upper surface (301) of the blade root slot of the compressor impeller in a magnet or mechanical fixing mode, and no obvious relative displacement occurs between the detection tool and the upper surface (301) of the reference block in the detection process.
3. The phased array ultrasonic detection system of a gas turbine compressor impeller blade root slot of claim 1, wherein the defect-prone locations of the reference block (3) are at acute angles (302) of the front and rear ends.
4. The phased array ultrasonic detection system for the blade root groove of the gas turbine compressor impeller according to claim 1, wherein the phased array ultrasonic detector (4) is connected with the phased array ultrasonic probe (1) through a cable, and the phased array ultrasonic detector (4) is provided with at least 64 channels, so that pulse voltage and pulse width can be adjusted.
5. A phased array ultrasonic detection method for a blade root slot of a gas turbine compressor impeller, which is characterized in that the method is based on the phased array ultrasonic detection system for the blade root slot of the gas turbine compressor impeller according to any one of claims 1 to 4, and comprises the following steps:
s1: according to the blade root groove size, shape and material processing proportion to be detected, and the comparison test block (3) of the same material or similar material, defects with different sizes, shapes and trend are processed at the acute angle (302) of the blade root groove comparison test block;
s2: connecting a phased array ultrasonic probe (1) with a phased array ultrasonic detector (4), setting pulse voltage, pulse width and focusing rule, and performing TCG calibration on a standard test block;
s3: fixing a phased array ultrasonic probe (1) on the upper surface (301) of a reference block through a detection tool (2), transmitting ultrasonic waves (5) to conduct sector scanning on an acute angle (302) of the reference block of a blade root groove, finding out the highest reflection echo through moving the phased array ultrasonic probe (1), and if the set defect reflection echo cannot be clearly resolved, adjusting pulse voltage, pulse width and focusing rule until clear resolution of the defect reflection echo is achieved;
s4: after finding out the reflection echo of the defect on the reference block (3), synthesizing the image and waveform display of the S scanning and the A scanning, enabling the reflection echo display to be clearer by adjusting the gain and the scanning range of the phased array ultrasonic detector (4), and taking the image and waveform of the S scanning and the A scanning at the moment as a reference for judging the defect;
s5: fixing the phased array ultrasonic probe (1) on the upper surface of a blade root groove to be detected through a detection tool (2), scanning through the detection tool (2), and judging that the detection part has no crack if the reflected echo at the acute angle of the blade root groove does not exceed a reference; and if the reflected echo at the acute angle of the blade root groove exceeds the reference, displaying and positioning the position of the defect through S scanning and A scanning, and quantifying the size of the defect.
6. The ultrasonic detection method for the phased array of the blade root grooves of the gas turbine compressor impeller according to claim 5, wherein the defect size of the acute angle (302) of the reference block is set according to the minimum allowed size defect, and the shape and the trend of the defect are set by counting the found defect and analyzing the structure and the stress condition of the blade root grooves.
7. The ultrasonic detection method for the blade root slot phased array of the gas turbine compressor impeller according to claim 5, wherein the primary wave (501) and the secondary wave (502) are adopted to detect the acute angle position (302) of the blade root slot.
8. The ultrasonic detection method for the phased array of the blade root grooves of the gas turbine compressor impeller according to claim 5, wherein the focusing mode of ultrasonic waves (5) adopts depth focusing, and the focusing position is near the depth position of the acute angle part (302) of the blade root groove.
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