CN114184676B - Phased array ultrasonic detection evaluation method for welding seam of aluminum alloy special-shaped structure - Google Patents
Phased array ultrasonic detection evaluation method for welding seam of aluminum alloy special-shaped structure Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 107
- 238000001514 detection method Methods 0.000 title claims abstract description 60
- 238000011156 evaluation Methods 0.000 title claims abstract description 18
- 229910000838 Al alloy Inorganic materials 0.000 title claims abstract description 17
- 230000007547 defect Effects 0.000 claims abstract description 151
- 230000002159 abnormal effect Effects 0.000 claims abstract description 24
- 230000035515 penetration Effects 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims abstract description 11
- 238000005516 engineering process Methods 0.000 claims abstract description 6
- 239000011324 bead Substances 0.000 claims description 51
- 239000000523 sample Substances 0.000 claims description 33
- 230000035945 sensitivity Effects 0.000 claims description 21
- 239000002893 slag Substances 0.000 claims description 21
- 235000012431 wafers Nutrition 0.000 claims description 14
- 238000012360 testing method Methods 0.000 claims description 12
- 230000005856 abnormality Effects 0.000 claims description 3
- 230000004927 fusion Effects 0.000 claims 3
- 238000003908 quality control method Methods 0.000 abstract description 6
- 238000012512 characterization method Methods 0.000 description 10
- 238000009826 distribution Methods 0.000 description 8
- 230000008859 change Effects 0.000 description 3
- 230000001788 irregular Effects 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000002592 echocardiography Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005284 excitation Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004513 sizing Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/30—Arrangements for calibrating or comparing, e.g. with standard objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/267—Welds
- G01N2291/2675—Seam, butt welding
Abstract
The invention discloses an aluminum alloy abnormal structure weld phased array ultrasonic detection evaluation method, which comprises the following steps: detecting welding seams of the special-shaped structure by using an ultrasonic phased array full-focusing detection technology; after the defect is detected, evaluating the defect property according to the qualitative criterion and the comparison map and the comparison of the detected defect; performing position and size assessment on the defects according to a position and size assessment method; and carrying out quality grading evaluation on the defects according to a quality grading evaluation method. The invention can realize comprehensive and effective detection and quality grading evaluation of the welding seam with the non-full penetration special-shaped structure, solves the technical problem of ultrasonic detection of the welding seam with the complex non-full penetration special-shaped structure, and meets the requirements of field detection and quality control of products.
Description
Technical Field
The invention belongs to the technical field of ultrasonic detection, and particularly relates to a phased array ultrasonic detection evaluation method for an aluminum alloy special-shaped structure welding seam.
Background
TCG definition: the TCG curve is a depth compensation curve, the decreasing trend of the DAC curve along the depth direction is used to compensate the reflected echo amplitudes of different depths, and all the depth compensation values are connected into a curve, which is the TCG curve. TCG action: the TCG function makes the same size reflector echo amplitude independent of its depth in the material under test by depth compensating the a-scan echo amplitude. Thus in TCG mode it is more advantageous to find defects deeper inside the material when the flaw detector gain conditions are unchanged.
The frame structure of the aluminum alloy plate assembly welding with different thickness is designed as a non-full-melting welding seam with a dislocation abnormal structure, the detection sensitivity is determined by adopting a mode of determining an evaluation line and a waste line by TCG (phi 2+/-delta dB) in a phased array detection standard, and defects are evaluated. For weld detection, fan scanning primary wave and secondary wave detection are generally adopted, and the secondary wave is responsible for the upper surface of the weld, so that the whole weld area is covered by sound beams. In addition to the near field, the signal amplitude decreases as the sound path increases. However, the special-shaped weld joint is provided with a self-designed non-penetration structure, so that fan scanning is difficult to be adopted, and firstly, a defect signal, a structure reflection signal and a plurality of modified wave signals are difficult to distinguish; secondly, the welding bead in various joint forms can only be detected by primary waves, and the secondary waves can not reach the upper surface of the V1 welding bead; and thirdly, even if the secondary wave can detect the upper surface of the V1 welding bead, the energy is weaker due to scattering attenuation caused by the structure, and the diffusion attenuation law influenced by the pure sound path is not met.
In view of the above, conventional methods for detecting and evaluating welds cannot be used to detect and evaluate profiled welds. At present, a method for effectively detecting and evaluating quality of a complex special-shaped welding line with an incomplete melting structure is not available, and the requirements of field detection and quality control of products are difficult to meet.
Disclosure of Invention
The invention aims to provide an aluminum alloy abnormal structure welding seam phased array ultrasonic detection evaluation method, which can realize comprehensive and effective detection and quality grading evaluation of non-full penetration abnormal structure welding seams, solves the technical problem of complex non-full penetration abnormal structure welding seam ultrasonic detection, and meets the requirements of product field detection and quality control.
In order to achieve the above purpose, the technical solution adopted by the invention is as follows:
the phased array ultrasonic detection and assessment method for the welding seam of the aluminum alloy special-shaped structure comprises the following steps:
detecting welding seams of the special-shaped structure by using an ultrasonic phased array full-focusing detection technology;
after the defect is detected, evaluating the defect property according to the qualitative criterion and the comparison map and the comparison of the detected defect;
after the defect property evaluation is completed, evaluating the position and the size of the defect by utilizing a special-shaped welding seam reference block;
and after the defect position and size are evaluated, performing quality grading evaluation on the defects.
Further, phased array linear array probes and wedges matched with the phased array linear array probes are used for phased array ultrasonic detection of the special-shaped weld joints.
Further, two adjacent aluminum alloy plates of the abnormal structure are marked as a t1 plate and a t2 plate, the joint of the t1 plate and the t2 plate belongs to a dislocation abnormal weld, the weld bead at the outer side of the abnormal structure is a V1 weld bead, and the weld bead at the inner side of the abnormal structure is a V2 weld bead; leading the CAD graph of the special-shaped weld joint into a phased array ultrasonic flaw detector before detection; when an abnormality or a defect is found by using the t1 plate side of the outer side surface of the V1 weld bead as a detection surface, detection is increased on the t2 plate side to assist in judging the defect.
Further, the V1 welding bead and the V2 welding bead of the special-shaped welding seam are detected by adopting longitudinal vertical scanning and longitudinal inclined scanning, and after the defect display is found, the scanning is assisted by adopting transverse scanning and sawtooth, rotation and surrounding modes.
Furthermore, the special-shaped structure is a staggered special-shaped structure, the welding seam belongs to a special-shaped welding seam which is not fully melted, and the unfused position is positioned at the unfused part of the t1 plate and the t2 plate.
Further, ultrasonic phased array probes with transverse wave refraction angle 55 DEG wedge blocks are used for the V1 welding bead and the V2 welding bead, and the parameters of the probes are as follows: the center frequency was 5MHz, the number of wafers 64, the wafer pitch was 0.30mm, the wafer gap was 0.1mm, and the deflection direction aperture size was 8mm.
Further, the welding seam of the special-shaped welding seam reference block is identical to the welding seam structure form of the detected special-shaped structure.
And further, detecting sensitivity adjustment is carried out by utilizing a special-shaped welding seam reference block.
Further, the detected image display mode adopts a full focus display mode and an auxiliary A type display mode.
Further, the defect properties include: air holes, slag inclusions, cracks, unfused and not welded through, wherein the air holes and the slag inclusions belong to non-planar defects, and the cracks, the unfused and the not welded through belong to planar defects; the assessment content includes: defect properties, defect location and size, quality classification of defects.
The technical effects of the invention include:
the invention detects the non-full-melted welding seam with a dislocation abnormal structure by utilizing the full-focusing detection technology of an ultrasonic phased array detection method, and takes the gain value when the echo amplitude of the transverse hole with the highest phi 2mm is 80% of that of the fluorescent screen as the scanning sensitivity of the abnormal welding seam in a set of special reference blocks with the same structure as the detected abnormal welding seam. After the internal defects of the special-shaped structure welding line are found, the defects are positioned, the gain value when the echo amplitude of a transverse hole with phi 2mm, which is similar to the positions of the defects, is 80% of that of the fluorescent screen is used as the reference sensitivity in a set of special-purpose reference test blocks which are the same as the special-shaped welding line structure, and the defect size is assessed by using the gain value, so that the comprehensive effective detection and quality grading assessment of the welding line of the non-full-penetration special-shaped structure welding line are realized, the technical problem of ultrasonic detection of the welding line of the complex non-full-penetration special-shaped structure welding line is solved, and the requirements of product field detection and quality control are met.
The method is used for solving the technical problems of ultrasonic detection and evaluation of the special-shaped structure welding seam phased array, meets the field detection requirement, realizes the quality control of the internal defects of the special-shaped welding seam, can replace the field ray detection of the welding seam, and has higher economic benefit and social benefit.
Drawings
FIG. 1 is a schematic view of a weld of a profiled structure in accordance with the invention
FIG. 2 is a schematic structural diagram of a special-shaped weld joint reference block in the invention;
FIG. 3a is an A-scan display image of an air vent in the present invention;
FIG. 3b is a full focus display image of a vent in the present invention;
FIG. 3c is an A-scan display image of a groove sprocket vent in accordance with the present invention;
FIG. 3d is a fully focused display image of a groove sprocket vent in accordance with the present invention;
FIG. 4a is an A-scan display image of slag inclusion in the present invention;
FIG. 4b is a fully focused display image of slag inclusion in the present invention;
FIG. 5a is an A-scan display image of an internal small crack in the present invention;
FIG. 5b is a full focus display image of an internal small crack in the present invention;
FIG. 5c is an A-scan display image of a large crack extending to a surface opening in the present invention;
FIG. 5d is a full focus display image of a large crack extending to a surface opening in the present invention;
FIG. 6a is an example of an A-scan display image of an unfused groove in the present invention;
FIG. 6b is an illustration of a second scan display image of an unfused groove of the present invention;
FIG. 6c is a full focus display image of groove unfused in the present invention;
FIG. 7a is an A-scan display image of root unfused in the present invention;
FIG. 7b is a full focus display image of root unfused in the present invention;
FIG. 8a is an illustration of an A-scan display image of an incomplete penetration in accordance with the present invention;
FIG. 8b is an illustration of an unbent, fully focused display image of the present invention;
FIG. 8c is an illustration of an A-scan display image of an incomplete penetration in accordance with the present invention;
fig. 8d is an illustration of a full focus display image of an incomplete penetration in accordance with the present invention.
Detailed Description
The following description fully illustrates the specific embodiments of the invention to enable those skilled in the art to practice and reproduce it.
The phased array ultrasonic detection evaluation method for the welding seam of the aluminum alloy special-shaped structure comprises the following specific steps:
step 1: detecting welding seams of the special-shaped structure by using an ultrasonic phased array full-focusing detection technology;
as shown in fig. 1, a schematic view of a weld of a profiled structure in accordance with the invention is shown.
In the special-shaped structure, the joint of two adjacent aluminum alloy plates (t 1 plate 1 and t2 plate 7) belongs to a dislocation special-shaped weld, wherein a V1 weld 2 is a weld on the outer side (A surface) of the special-shaped structure, a V2 weld 4 is a weld on the inner side (A surface) of the special-shaped structure, and a V3 weld 5 is a weld on a connecting rib plate 6 of the special-shaped structure; the unfused location 3 belongs to the unfused portion of the t1 and t2 panels 1 and 7.
And before detection, the CAD image of the detected special-shaped weld joint is led into a phased array ultrasonic flaw detector.
The welding lines of the special-shaped structures in various joint forms are required to be welded in a combined mode, ultrasonic detection is carried out after the special-shaped structures form a frame, and detection is carried out on the outer side of the frame, so that the A surface of the special-shaped welding line (V1 welding bead) on one side of the t1 plate 1 is taken as a detection surface, and the detection on one side of the t1 plate 1 is taken as a main detection surface; full coverage of the weld zone can be achieved by adopting a full focus detection technology, and detection on one side of the t2 plate 7 can be increased when an abnormality or defect is found to assist in judging the defect.
1. Instrument probe requirements
The instrument vertical linear deviation is not more than 5%, the instrument vertical linear deviation is not more than 1%, and the rest performances meet the calibration standards JJF 1338-2012 of the phased array ultrasonic flaw detector.
And phased array ultrasonic detection is carried out on the special-shaped welding seam by adopting a phased array linear array probe and a wedge block matched with the phased array linear array probe. Wherein, the V1 welding bead 2 and the V2 welding bead 4 use an ultrasonic phased array probe with a transverse wave refraction angle 55 DEG wedge block, and specific parameters of the probe are a center frequency of 5MHz, the number of wafers of 64, a wafer spacing of 0.30mm, a wafer gap of 0.1mm and a deflection direction aperture size of 8mm. V3 weld bead 5 uses the ultrasonic phased array probe with 0 degree wedge block, the specific parameter of the probe is: the center frequency is 5MHz, the number of wafers is 32, the wafer spacing is 0.30mm-0.60mm, and the deflection direction aperture size is 8mm-10mm.
2. Test block
The test block adopts a complete set of special-shaped weld special-purpose reference test blocks with the same structure as the detected special-shaped weld, and is used for adjusting the detection sensitivity and evaluating the defect position and size.
FIG. 2 is a schematic structural diagram of a special-shaped weld joint reference block according to the invention.
The special-shaped welding seam reference block is provided with transverse holes (each block is provided with 1 transverse hole, the transverse holes are respectively positioned at 9 positions in the table 1, 9 blocks of each special-shaped structure welding seam are one set), and the transverse holes penetrate through the end face and the back face of the block body 1 (namely, two openings are respectively positioned on the end face and the back face).
TABLE 1 Cross hole machining position requirement of phi 2mm by 40mm
| Position number | The center position of the transverse hole |
| 1 | V1 bead 2 is 2mm from the surface |
| 2 | V1 bead 2mm from surface and groove 2mm |
| 3 | V1 bead 2mm from surface and groove 2mm |
| 4 | V1 bead 2 1/2 height |
| 5 | V1 bead 2 1/2 height 2mm from groove |
| 6 | V1 bead 2 1/2 height 2mm from groove |
| 7 | V1 bead 2mm from root |
| 8 | V2 bead 4 is 2mm from root |
| 9 | V2 bead 4 is 2mm from surface |
3. Scanning mode
The probe adopts vertical scanning and vertical oblique scanning to detect the V1 welding bead 2 and the V2 welding bead 4 of the special-shaped welding seam, and the vertical oblique scanning needs to scan from two directions along the detected welding bead in order to detect defects with different orientations. After the defect display is found, the scanning is assisted by adopting the modes of transverse scanning, sawtooth, rotation, surrounding and the like. Since the V3 bead 5 is a bead connecting the rib plates 6, quality control is not important, and only the V1 bead 2 and the V2 bead 4 are detected.
4. Detecting parameter settings
According to the actual condition of the detected abnormal-shaped welding seam, a CAD image of the detected abnormal-shaped welding seam which is put into the instrument in advance is called out in a phased array detection instrument, when one side of a t1 plate 1 is detected, the display image structure is coincident with the CAD image structure in the instrument, the detection surface is A surface, the center frequency of a probe is 5MHz, the number of wafers is 64, the wafer spacing is 0.30mm, the wafer spacing is 0.1mm, the aperture size in the deflection direction is 8mm, the excitation aperture is 19.1mm, the 55-degree transverse wave wedge is arranged, and the focusing area is a welding seam area.
5. Scanning mode
The special-shaped weld joint is detected by adopting a full-focusing scanning mode.
6. Adjustment of sensitivity
The detection sensitivity of the special-shaped weld joint needs to be adjusted by using a special-shaped weld joint reference block with the same structural form as the detected weld joint.
After the instrument probes are arranged according to specific specified parameters, the probes are used for respectively detecting a set of special-shaped weld special-purpose reference blocks of which the special-shaped structural weld meets the table 1, gain values when echo amplitudes of phi 2mm transverse holes distributed on different welding passes and positions on the special-shaped weld special-purpose reference blocks are 80% of fluorescent screens are respectively recorded, and the highest gain value in the special-shaped weld special-purpose reference blocks is used as the scanning sensitivity of the special-shaped weld.
When defects are found in the scanning process, the defects are positioned, and a gain value when the echo amplitude of the phi 2mm transverse hole, which is close to the positions of the defects, of the welding line is 80% of that of the fluorescent screen is used as reference sensitivity.
7. Image display mode
The full focus display mode and the auxiliary A type display mode are adopted.
Step 2: when a defect is detected, the nature of the defect is assessed according to qualitative criteria and a comparison map compared with the detected defect.
1. Defect Property assessment
After the defects are detected, the defects are detected in different directions, and the defects are detected by combining various scanning modes such as saw teeth, longitudinal direction, transverse direction, rotation, surrounding and the like, the shape and amplitude of the echo of the defects are changed, the position distribution condition of the defects is determined, and the welding process is used for preliminarily judging the defects to be circular defects (the defects with the ratio of the length to the self height not more than 3) and strip-shaped defects (the defects with the ratio of the length to the self height more than 3).
The defect properties mainly include: air holes, slag inclusions, cracks, unfused and unwelded, wherein the air holes and slag inclusions belong to non-planar defects and the cracks, unfused and unwelded belong to planar defects.
2. Qualitative criterion
2.1. Air holes
Morphology distribution characteristics: the outline is smooth, round or oval, and has no length.
As shown in fig. 3a, an a-scan display image of the air vent in the present invention; as shown in fig. 3b, a full focus display image of the air holes in the present invention; FIG. 3c is a view showing the A-scan of the bevel-chain air hole of the present invention; as shown in fig. 3d, the full focus display image of the groove chain vent in the present invention is shown.
A scan display characterization: the reflected echo amplitude is low; the reflected echo occupies a smaller width, the front and rear edges are smoother, and no saw tooth shape exists; the probe is rotated, the echo amplitude is reduced from 80% to 10% at about 12 degrees, and the amplitude change is relatively uniform without abrupt change.
Full focus display characterization: the amplitude is very low; the outline is smooth and round or oval; most often in a dense state or chain.
2.2. Slag inclusion
Morphology distribution characteristics: the shape is irregular, the outline is not smooth, the strip-shaped or block-shaped slag inclusion is usually arranged in the extending direction of the strip-shaped slag inclusion and is generally parallel to the welding line, the slag inclusion is generally randomly arranged at each part of the welding line, and the slag inclusion is irregular.
As shown in fig. 4a, an a-scan display image of slag inclusion in the present invention; as shown in fig. 4b, is a fully focused display image of slag inclusion in the present invention.
A scan display characterization: the wave bottom of the reflected echo has larger occupied width, uneven front and back edges, saw-tooth shape, thick bottom and thin top. The reflected echo amplitude is not high, the waveform is in a dendritic shape, and small peaks are arranged on the main peak edge; rotating the probe, generally about 8 degrees, and reducing the echo amplitude from 80% to 10%; for strip slag inclusion, the probe is moved along the length direction, the wave crest is fluctuated and is not stable; the large irregular slag inclusion has high reflected echo amplitude, large pulse width, beam shape and small branches at the wave crest.
Full focus display characterization: the amplitude of the reflected echo is higher than that of the air hole; the outline is not smooth, and the outline is mostly in a strip shape or a block shape; in a single or dense state.
2.3. Cracking of
Morphology distribution characteristics: the longitudinal cracks are mostly long, thin-line-shaped along the longitudinal direction of the welding seam, the tail part is mostly arc-shaped and bent, and some parts have tiny branches; the longitudinal cracks are generally communicated from the surface of the welding seam to the inside of the welding seam; some internal un-opened cracks may extend from the middle of the weld to the root of the weld. The transverse cracks are generally short, fine and arc-shaped and are almost distributed perpendicularly to the central line of the welding seam; most of which occur at the weld surface.
As shown in fig. 5a, an a-scan display image of an internal small crack in the present invention; as shown in fig. 5b, a full focus display image of an internal small crack in the present invention; as shown in fig. 5c, an a-scan display image of a large crack extending to the surface opening in the present invention; as shown in fig. 5d, is a full focus display image of a large crack extending to the surface opening in the present invention.
A scan display characterization: the echo amplitude of the surface open through crack is very high, the echo amplitude of the crack without the opening inside is not high, and the greater the self height of the crack is, the higher the echo amplitude is; the longitudinal crack extension length is generally larger, and the amplitude rise and fall are slower; the probe is rotated in situ, the longitudinal surface opening through crack can find defect echo in the range of 40-65 degrees, and the amplitude change is slow; the internal unopened crack typically only finds a defect echo in the range of about 8 °.
Full focus display characterization: the internal unopened crack has lower amplitude, is not strong in display, and can see diffraction signals of upper and lower endpoints; the probe is moved, the two diffraction signals appear and disappear simultaneously, when the gain value is improved, the two points are connected in a hidden way, and the two diffraction signals can be distinguished from air holes or slag inclusion according to the two diffraction signals; the surface opening through crack has high amplitude and strong display, and the far end of the crack can overflow the surface of the welding seam in a full-focus image, so that the far end diffraction signal is difficult to judge.
2.4. Unfused
Morphology distribution characteristics: has a length and extends longitudinally along the weld, and is often accompanied by air holes and slag inclusions due to root unfused and groove unfused.
As shown in fig. 6a, an example of a scan display image of an unfused groove in the present invention is shown; as shown in fig. 6b, an example two of a scan display image of the groove unfused in the present invention is shown; as shown in fig. 6c, the full focus display image of the groove unfused in the present invention is shown.
As shown in fig. 7a, an a-scan display image showing the root unfused in the present invention; as shown in fig. 7b, is a full focus display image of the root unfused in the present invention.
A scan display characterization: the echo amplitude is generally lower than the surface opening through crack and higher than slag inclusion. The amplitude of the unfused echo of the groove is generally higher than that of the unfused echo of the root; the probe is rotated in situ, and defect echoes can be generally found within the range of 7-15 degrees.
Full focus display characterization: the image shape is regular; the position is fixed and is positioned at the groove or root of the welding line.
2.5. Lack of penetration of weld
Morphology distribution characteristics: has a certain length and extends longitudinally along the weld, resembles a crack, but has no tail tip, is positioned at the root of the weld, and is sometimes associated with air holes and slag inclusions.
FIG. 8a shows an example of an A-scan display image without penetration in the present invention; FIG. 8b shows an exemplary first full focus display image without penetration in the present invention; FIG. 8c shows an example two of an A-scan display image that is not completely welded according to the present invention; as shown in fig. 8d, an example two of a full focus display image is shown without penetration in the present invention.
A scan display characterization: the echo amplitude is higher and is generally similar to that of unfused; the waveform is similar to the crack; for special-shaped welding seams, due to the limitation of an instrument display mode, special-shaped welding seam structural waves and incomplete welding defect waves cannot be obtained in a fluorescent screen at the same time.
Full focus display characterization: the image is regular in shape, fixed in position and positioned at the root of the welding seam; the special-shaped weld joint is difficult to distinguish from a non-penetration structure of the special-shaped weld joint, and when the height of the special-shaped weld joint is not less than 3mm, upper and lower end point diffraction signals are visible.
Step 3: after the defect property evaluation is completed, evaluating the position and the size of the defect by utilizing a special-shaped welding seam reference block;
1. defect location and sizing
1.1. Non-planar circular defect
When the ratio of the defect length to the height of the defect is not more than 3 and the defect is a non-planar defect, the position of the defect is the highest position of the echo amplitude of the defect, and the defect size is evaluated by the reference sensitivity and recorded as phi 2 multiplied by 40 plus or minus delta dB.
1.2. Non-planar bar defects
When the ratio of the defect length to the height of the defect is more than 3 and the defect is a non-planar defect, the probe is moved back and forth and left and right, the positions of the starting point and the end point of the defect echo, which are on the welding line and have the amplitude not lower than the reference sensitivity, are recorded, and the distance between the two points is the defect length;
finding the highest echo amplitude of the defect, recording the position of the defect as the highest amplitude position, evaluating the position by using reference sensitivity, and recording the position as phi 2 x 40+/-delta dB; and the depth of the defect displayed by the instrument at this time is recorded as the depth of the non-planar strip defect.
1.3. Planar strip-shaped defect
When the ratio of the defect length to the self height is more than 3 and the defect is a planar defect, the probe is moved back and forth and left and right, the starting point and the end point position of which the defect echo amplitude is not lower than the reference sensitivity are recorded, and the distance between the two points is the defect length; finding the highest echo amplitude of the defect, recording the position of the defect as the highest amplitude position, evaluating the position by using reference sensitivity, and recording the position as phi 2 multiplied by 40 plus or minus delta dB; recording the depth of the defect displayed by the instrument at the moment as the depth of the planar strip-shaped defect;
when the defect is a non-open defect, respectively finding out strongest diffraction signals of an upper end point and a lower end point of the defect, respectively recording horizontal and depth display data of the two points, and measuring actual positions of the two points on a welding line cross section by combining probe positions on a special-shaped welding line special-purpose reference block corresponding to the detected welding line, wherein the two-point connecting line is the approximate position distribution of the planar strip-shaped defect and the self height of the defect;
when the defect is an opening defect, firstly finding the strongest diffraction signal of a defect lower end point (a point inside a welding line), and recording the level and depth display data of the point; moving a probe to find the highest position of the defect echo, taking a gain value when the highest amplitude of the defect is 80% as a reference, fixing the probe, finding a point when the amplitude of the A scanning display is reduced to 10%, and recording the level and depth display data of the point; the actual positions of the two points on the cross section of the welding line can be measured by combining the positions of the probes on the special-shaped welding line reference block corresponding to the detected welding line, and the connecting line of the two points is the approximate position distribution of the planar strip-shaped defect and the self height of the defect.
1.4. Assessment of multiple defects
Two or more adjacent defects (non-circular) are displayed with a spacing in the X-axis direction of less than the length of the smaller defect, a spacing in the Y-axis direction of less than 5mm, and a spacing in the Z-axis direction of less than the height of the smaller defect itself, which are to be treated as one defect, the depth of the defect, the length of the defect, and the height of the defect itself are determined as follows:
defect depth: taking two smaller defect depth values as single defect depth; defect amplitude: taking the larger amplitude of the two defects as a single defect amplitude; defect indication length: the distance between the front end point and the rear end point of the two defects on the X-axis projection; defect itself height: if the projections of the two defects on the X axis are not overlapped, taking the self-height of the larger defect as the self-height of the single defect; if two defects overlap in the X-axis projection, the sum of the two defect self-heights is taken as the single defect self-height (pitch count).
Step 4: after evaluating the nature, location and size of the detected defects, the defects are rated in quality.
The display of planar defects such as cracks, unfused and incomplete penetration was rated as class III.
The quality classification of the circular defects was carried out as specified in table 2; the quality classification of the non-planar strip defects was evaluated as specified in table 3.
TABLE 2 quality grading of circular defects
TABLE 3 quality grading of non-planar strip defects
The terminology used herein is for the purpose of description and illustration only and is not intended to be limiting. As the present invention may be embodied in several forms without departing from the spirit or essential attributes thereof, it should be understood that the above-described embodiments are not limited by any of the details of the foregoing description, but rather should be construed broadly within its spirit and scope as defined in the appended claims, and therefore all changes and modifications that fall within the metes and bounds of the claims, or equivalences of such metes and bounds are therefore intended to be embraced by the appended claims.
Claims (6)
1. The phased array ultrasonic detection evaluation method for the welding seam of the aluminum alloy special-shaped structure is characterized by comprising the following steps of:
the CAD graph of the special-shaped weld joint to be detected is led into a phased array ultrasonic flaw detector before detection, the test block adopts a complete set of special-shaped weld joint special-purpose comparison test block which is the same as the special-shaped weld joint structure to be detected, and the special-shaped weld joint special-purpose comparison test block is used for adjusting detection sensitivity and evaluating the position and the size of the defect, and the welding joint of the special-shaped weld joint special-purpose comparison test block is the same as the welding joint structure form of the special-shaped structure to be detected; the special reference block for each special-shaped welding line is provided with 1 transverse hole, the transverse holes are respectively positioned at 9 positions in the meter, each special-shaped structure welding line corresponds to 9 test blocks, and the transverse holes penetrate through the end face and the back face of the test block body;
Carrying out phased array ultrasonic detection on the welding seam of the special-shaped structure by utilizing an ultrasonic phased array full-focusing detection technology and adopting a phased array linear array probe and a wedge matched with the phased array linear array probe; the two adjacent aluminum alloy plates of the abnormal structure are marked as a t1 plate and a t2 plate, the joint of the t1 plate and the t2 plate belongs to a dislocation abnormal weld, the weld bead at the outer side of the abnormal structure is a V1 weld bead, and the weld bead at the inner side of the abnormal structure is a V2 weld bead; taking the side of the t1 plate on the outer side surface of the V1 welding bead as a detection surface, and increasing detection on the side of the t2 plate when abnormality or defect is found so as to assist in judging the defect;
when the welding line is detected, a CAD image of the detected special-shaped welding line which is put into the instrument in advance is called out in the phased array detection instrument according to the actual condition of the detected special-shaped welding line, and the displayed image structure is coincident with the CAD image structure in the instrument;
utilize special reference block of abnormal shape welding seam to detect sensitivity adjustment, detect sensitivity includes: scanning sensitivity and reference sensitivity; after an instrument probe is set according to specific specified parameters, respectively detecting a plurality of special-shaped weld joint special-purpose reference blocks by the probe, respectively recording gain values when the echo amplitude of transverse holes distributed on different welding beads and positions on the special-shaped weld joint special-purpose reference blocks is 80% of that of a fluorescent screen, and taking the highest gain value in the special-shaped weld joint special-purpose reference blocks as the scanning sensitivity of the special-shaped structure weld joint;
when the defect is detected, firstly positioning the defect, and taking a gain value when the echo amplitude of a transverse hole closest to the defect position in the special-shaped welding seam reference test block is 80% of that of the fluorescent screen as reference sensitivity; evaluating the defect property according to the qualitative criterion and the comparison map and the comparison of the detected defect;
after the defect property evaluation is completed, evaluating the position and the size of the defect by utilizing a special-shaped welding seam reference block;
and after the defect position and size are evaluated, performing quality grading evaluation on the defects.
2. The ultrasonic detection and assessment method for the welding seam phased array of the aluminum alloy abnormal structure according to claim 1 is characterized in that the V1 welding bead and the V2 welding bead of the abnormal welding seam are detected by adopting longitudinal vertical scanning and longitudinal inclined scanning, and after defects are found, the scanning is assisted by adopting transverse scanning and sawtooth, rotation and surrounding modes.
3. The ultrasonic detection and assessment method for the welding seam phased array of the aluminum alloy abnormal structure according to claim 1, wherein the abnormal structure is a staggered abnormal structure, the welding seam belongs to an incomplete fusion abnormal welding seam, and the incomplete fusion position is positioned at the incomplete penetration and the incomplete fusion position of the t1 plate and the t2 plate.
4. The ultrasonic detection and assessment method for the welding seam phased array of the aluminum alloy abnormal structure according to claim 1, wherein an ultrasonic phased array probe with a transverse wave refraction angle 55 DEG wedge is used for a V1 welding bead and a V2 welding bead, and the parameters of the probe are as follows: the center frequency was 5MHz, the number of wafers 64, the wafer pitch was 0.30mm, the wafer gap was 0.1mm, and the deflection direction aperture size was 8mm.
5. The ultrasonic detection and assessment method for the welding seam phased array of the aluminum alloy special-shaped structure according to claim 1, wherein the detected image display mode adopts a full-focus display mode and an auxiliary A-type display mode.
6. The ultrasonic detection and assessment method for the weld phased array of the aluminum alloy special-shaped structure according to claim 1, wherein the defect property comprises: air holes, slag inclusions, cracks, unfused and not welded through, wherein the air holes and the slag inclusions belong to non-planar defects, and the cracks, the unfused and the not welded through belong to planar defects; the assessment content includes: defect properties, defect location and size, quality classification of defects.
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