CN114487102B - Ultrasonic detection method for weld joint phased array with residual height - Google Patents
Ultrasonic detection method for weld joint phased array with residual height Download PDFInfo
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- 238000001514 detection method Methods 0.000 title claims abstract description 132
- 238000003466 welding Methods 0.000 claims abstract description 99
- 238000000034 method Methods 0.000 claims abstract description 46
- 229910000963 austenitic stainless steel Inorganic materials 0.000 claims abstract description 33
- 238000012360 testing method Methods 0.000 claims description 36
- 239000000523 sample Substances 0.000 claims description 19
- 239000002184 metal Substances 0.000 claims description 12
- 230000005540 biological transmission Effects 0.000 claims 1
- 238000003384 imaging method Methods 0.000 description 72
- 238000005192 partition Methods 0.000 description 17
- 239000000463 material Substances 0.000 description 14
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- 238000007689 inspection Methods 0.000 description 7
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- 238000010586 diagram Methods 0.000 description 4
- 230000035945 sensitivity Effects 0.000 description 4
- 210000001503 joint Anatomy 0.000 description 3
- 238000002604 ultrasonography Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 2
- 238000009792 diffusion process Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000010953 base metal Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000001808 coupling effect Effects 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 230000002269 spontaneous effect Effects 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 238000005493 welding type Methods 0.000 description 1
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Abstract
The disclosure relates to the technical field of weld detection, in particular to a phased array ultrasonic detection method for a weld of medium-thick austenitic stainless steel with residual height, which comprises the following steps: detecting the middle lower part of the welding seam in the thickness direction by adopting a direct wave method on the upper surfaces of the first side and the second side of the welding seam through phased array ultrasonic detection equipment respectively, and acquiring first detection data; and detecting the middle upper part of the welding seam in the thickness direction by adopting a secondary wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring second detection data. According to the welding seam phased array ultrasonic detection method with the surplus height, based on the method, when welding seam detection is carried out, the surplus height of the welding seam is not required to be polished, detection data can be accurately and rapidly obtained under the conditions that the structural form of the welding seam is not changed and the original structural strength is not influenced, detection efficiency can be improved, and detection cost is saved.
Description
Technical Field
The disclosure relates to the technical field of weld detection, in particular to a phased array ultrasonic detection method for a weld of medium-thick austenitic stainless steel with residual height.
Background
Ultrasonic detection of austenitic stainless steel weld joints is in principle required to carry out direct wave (primary wave) detection on both sides of the welded joint according to the requirements of relevant detection standards. If limited by the conditions, there may be no detection space, and thus, the detection personnel cannot detect at the inner wall of the welded joint. For example, when the pipe diameter is small, or when there is a structural obstruction inside the container, the inspection personnel cannot perform the inspection inside, but only on one side or on one side of the welded joint. As shown in fig. 1, when the inspection is performed on one side or the other side of the welded joint, the welded joint should be ground to be flush with the adjacent base material, and then the direct wave (primary wave) inspection should be performed.
However, the austenitic stainless steel weld has larger wall thickness, wider residual height and larger number of weld seams, and if the weld seams are polished, the required labor cost and time cost are higher, and the workload is extremely large; in addition, even if the ground weld seam is remained high, the ground flatness and roughness cannot meet the standard requirements; moreover, because the austenitic stainless steel at the weld line is large in deformation and shrinkage, the weld joint after polishing the residual height is difficult to be leveled with the adjacent base metal. The above-mentioned circumstances all can lead to the ultrasonic coupling effect poor, and the ultrasonic direct wave can only detect the welding seam lower part, and can't detect the upper and middle portion of welding seam to and the welding seam surplus height is polished after or influence structural strength to a certain extent.
As shown in fig. 2, if ultrasonic detection is performed considering the residual height of the welded seam, the detection of the whole detection area of the whole volume of the welded seam can be completed only by covering the middle and upper parts of the welded seam with ultrasonic secondary waves (primary reflected waves). However, the austenitic stainless steel weld joint has columnar crystal structure, coarse grains and heterogeneous elastic anisotropy, and when ultrasonic waves propagate in the weld joint, problems such as sound velocity change, scattering attenuation, wave beam deflection, wave mode conversion and the like can be caused; and because the ultrasonic secondary wave needs to be reflected on the bottom surface of the inner wall of the welding seam, the reflection loss of the bottom surface of the acoustic energy is caused, and the absorption attenuation of an interface is caused; meanwhile, the propagation path is increased, the sound wave diffusion is increased, and the sound beam diffusion attenuation is increased; the ultrasonic reflected wave propagates in the coarse-grain anisotropic weld, which in turn causes material scattering attenuation. The above problems increase the difficulty of secondary wave detection of the weld seam of the medium-thick austenitic stainless steel.
Disclosure of Invention
In order to solve at least the above technical problems in the prior art, an embodiment of the present disclosure provides a phased array ultrasonic detection method for a weld with residual height.
In one aspect, an embodiment of the present disclosure provides a phased array ultrasonic detection method for a welding seam with a residual height, wherein edges of two metal structures are welded to form a welding seam with a residual height, a side where one metal structure is located is a first side of the welding seam, and a side where the other metal structure is located is a second side of the welding seam, and the method includes: detecting the middle lower part of the welding seam in the thickness direction by adopting a direct wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring first detection data; and detecting the middle upper part of the welding seam in the thickness direction by adopting a secondary wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring second detection data.
In some embodiments, the method further comprises: detecting the first surface of the welding seam by adopting a direct wave method through the phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring third detection data; the first surface of the weld is the same side as the upper surfaces of the first and second sides of the weld.
In some embodiments, the method further comprises: detecting the second surface of the welding seam by a secondary wave method through the phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring fourth detection data; the second surface of the weld is the side opposite the upper surfaces of the first and second sides of the weld.
In some embodiments, the number of channels of a single simultaneous excitation of the phased array ultrasonic detection device is not less than a first set point, and the number of array elements of a single phased array ultrasonic array probe is not less than a second set point.
In some embodiments, the number of channels of a single simultaneous excitation of the phased array ultrasonic detection device is not less than 32, and the number of array elements of a single phased array ultrasonic array probe is not less than 32.
In some embodiments, when the upper surfaces of the first side and the second side of the welding seam are detected by the phased array ultrasonic detection device, the first end of the welding seam along the length direction of the welding seam is a detection starting point of the phased array ultrasonic detection device, and the second end is a detection end point of the phased array ultrasonic detection device.
In some embodiments, detecting, by the phased array ultrasonic detection apparatus, a middle-lower portion of the weld in a thickness direction of the weld on upper surfaces of the first side and the second side, respectively, using a direct wave method includes: the step bias of the phased array ultrasonic detection device is one half of the width of the first surface of the welding seam, the minimum sector scanning angle and the maximum sector scanning angle at least cover the middle lower part of the welding seam in the thickness direction of the welding seam, and the focusing depth is larger than or equal to the thickness of the welding seam.
In some embodiments, detecting the middle-upper portion of the weld in the thickness direction of the weld by the phased array ultrasonic detection apparatus on the upper surfaces of the first side and the second side of the weld, respectively, using a secondary method comprises: the stepping offset, the minimum sector scanning angle and the maximum sector scanning angle of the phased array ultrasonic detection equipment at least cover the middle upper part of the welding seam in the thickness direction, and the focusing depth is more than or equal to 2 times the thickness of the welding seam.
In some embodiments, the upper surfaces of the first and second sides of the weld are detected by a phased array ultrasonic detection device using a direct wave method or a secondary wave method, respectively: the encoders of the phased array ultrasonic testing apparatus are of opposite polarity on the first and second sides of the weld.
In some embodiments, the acoustic wave transmitting and receiving mode of the phased array ultrasonic detection device is spontaneous self-receiving, and the waveform of the acoustic wave is longitudinal wave.
According to the welding seam phased array ultrasonic detection method with the surplus height, based on the method, when welding seam detection is carried out, the surplus height of the welding seam is not required to be polished, detection data can be accurately and rapidly obtained under the conditions that the structural form of the welding seam is not changed and the original structural strength is not influenced, detection efficiency can be improved, and detection cost is saved.
Drawings
The above, as well as additional purposes, features, and advantages of exemplary embodiments of the present disclosure will become readily apparent from the following detailed description when read in conjunction with the accompanying drawings. Several embodiments of the present disclosure are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings, in which:
in the drawings, the same or corresponding reference numerals indicate the same or corresponding parts.
FIG. 1 is a schematic diagram of ultrasonic detection after grinding the weld seam residual height in the prior art;
FIG. 2 is a schematic view of ultrasonic testing without grinding the weld seam residual height in the prior art;
FIG. 3 is a block diagram of a method for ultrasonic inspection of a phased array of welds with residual height in accordance with an embodiment of the present disclosure;
FIG. 4 is a second flow chart diagram of a method for ultrasonic detection of a phased array of welds with residual height in an embodiment of the disclosure;
FIG. 5 is a schematic view of the dimensions, semi-through hole locations and dimensions of a V-groove of a weld butt joint test piece in an embodiment of the present disclosure;
FIG. 6 is a schematic view of a first side and a second side of a weld butt joint test piece according to an embodiment of the present disclosure, with the position and dimensions of the open slot in the bottom surface and the open slot in the surface, and with the initial position and orientation detected;
FIG. 7 is a secondary wave image of 32 probe array elements or 32 channels excited simultaneously by a single phased array ultrasonic detector in an embodiment of the disclosure;
FIG. 8 is a secondary wave image of a probe array element number of 16 or a phased array ultrasonic detector with a single simultaneous excitation channel number of 16 in an embodiment of the disclosure;
FIG. 9 is a sector scan imaging of the first side of the test piece half-vias 502, 503, 504 in an embodiment of the present disclosure;
FIG. 10 is a sector scan imaging of the second side of the test piece half-vias 502, 503, 504 in an embodiment of the present disclosure;
FIG. 11 is a B-scan imaging of a first side of a test piece to a bottom open slot 601, 602 in an embodiment of the present disclosure;
FIG. 12 is a B-scan imaging of a bottom surface open slot 601, 602 by a second side of a test piece in an embodiment of the present disclosure;
FIG. 13 is a sector scan imaging of the first side of the test piece half-vias 501, 502 in an embodiment of the present disclosure;
FIG. 14 is a sector scan imaging of the second side of the test piece half-vias 501, 502 in an embodiment of the present disclosure;
FIG. 15 is a B-scan imaging of a second side of a test piece to a surface open slot 603 in an embodiment of the present disclosure;
FIG. 16 is a B-scan imaging of a first side of a test piece to a surface open slot 603 in an embodiment of the present disclosure;
Fig. 17 is a schematic diagram of a relative positional relationship between a fan-scan imaging of an open slot 603 on a first side surface of a test piece and a weld model in an embodiment of the disclosure.
Detailed Description
In order to make the objects, features and advantages of the present disclosure more comprehensible, the technical solutions in the embodiments of the present disclosure will be clearly described in conjunction with the accompanying drawings in the embodiments of the present disclosure, and it is apparent that the described embodiments are only some embodiments of the present disclosure, but not all embodiments. Based on the embodiments in this disclosure, all other embodiments that a person skilled in the art would obtain without making any inventive effort are within the scope of protection of this disclosure.
The present disclosure provides a phased array ultrasonic detection method for a welding seam with residual height, wherein edges of two metal structures are welded to form a welding seam with residual height, one side where the metal structure is located is a first side of the welding seam, and the other side where the metal structure is located is a second side of the welding seam, as shown in fig. 3, and the method includes:
Step S102: detecting the middle lower part of the welding seam in the thickness direction by adopting a direct wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring first detection data;
Step S104: and detecting the middle upper part of the welding seam in the thickness direction by adopting a secondary wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring second detection data.
In some embodiments, as shown in fig. 4, the method further comprises:
Step S102-1: detecting the first surface of the welding seam by adopting a direct wave method through the phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring third detection data; the first surface of the weld is the same side as the upper surfaces of the first and second sides of the weld.
Step S104-1: detecting the second surface of the welding seam by a secondary wave method through the phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the welding seam respectively, and acquiring fourth detection data; the second surface of the weld is the side opposite the upper surfaces of the first and second sides of the weld.
In the embodiment of the disclosure, when detecting the welding seam, the residual height of the welding seam is not required to be polished, namely, phased array ultrasonic detection is performed on the welding seam with the residual height. Specifically, a phased array ultrasonic detector is used for single-sided double-sided detection of the welding line with the residual height, and an image display interface of the phased array ultrasonic detector presents a welding line form to assist interpretation defects.
For example, the number of channels of the phased array ultrasonic detection device for single simultaneous excitation is not less than a first set value, and the number of array elements of a single phased array ultrasonic array probe is not less than a second set value. For example, a phased array ultrasonic detector with at least 32 channels of array elements excited at the same time by a phased array ultrasonic detection device has a center frequency of no more than 5MHz, at least 32 array elements, at least 1mm array element width and at least 20mm aperture of a driven shaft, and corresponding inclined wedges with longitudinal waves as emergent waves, 16.5 DEG wedge angles and 45 DEG emergent angles, and the probe is connected to the detector by installing the wedge on the probe.
In some embodiments, it may be desirable to pre-obtain parameters related to the metal structure and weld prior to weld inspection using phased array ultrasonic inspection equipment. For example, the relevant parameters include shape, size, material, weld type, etc. of the metal structure. For example, the relevant parameters include that the metal structure is a flat plate or an arc plate, the dimension comprises length, width and thickness, the material is austenitic stainless steel, and the type of welding seam is V-shaped.
In some embodiments, when the welding seam phased array ultrasonic detection is performed, a first group of partition detection parameters are set, and a direct wave method is adopted for detecting the welding seam of the middle and lower parts in the thickness direction; and setting a second group of partition detection parameters, and detecting the welding seam at the upper part in the thickness direction by adopting a secondary wave method. The lower middle of the weld is explained as: an intermediate position or a portion between the intermediate position and the bottom of the weld in the thickness direction; the upper middle part of the weld is explained as: the middle position of the weld joint in the thickness direction or the part between the middle position and the top of the weld joint tends to be.
For example, the two sets of partition detection parameters include focus rule parameters, calibration, ultrasound parameters, scanning, and the like, respectively.
For example, a first set of zone focus parameters: the method comprises the steps of setting a minimum sector scanning angle and a maximum sector scanning angle to at least cover the middle and lower half parts of the welding seam in the thickness direction of the welding seam, setting an angle step not more than 1 degree, focusing in a real depth focusing mode, and generating a focusing rule, wherein the number of the array elements which can be excited is at least 32, the serial number of the first array element which is excited is 1, the stepping offset (the distance between the front edge of the wedge and the central line of the welding seam) is set to be half of the width of the welding seam on the upper surface, and the minimum sector scanning angle and the maximum sector scanning angle can at least cover the middle and lower half parts of the welding seam in the thickness direction of the welding seam.
For example, calibration: the sound velocity calibration is performed, the sound velocity calibration may not be performed if the workpiece material is a known material sound velocity, the wedge delay calibration is performed, and then the sensitivity calibration (ACG) and the time gain correction (TCG) are performed for the first group of partitions.
For example, setting an ultrasound parameter; the starting depth and depth range of the display are mainly set so that the thickness direction range of the first group of detection zones can be covered, and the gain is displayed.
For example, a scan parameter is set: the position of the scanning initial point 0 is one end of the length direction of the welding seam, the polarities of encoders at the scanning of the two sides of the welding seam are opposite, the scanning area at least comprises the length range of defects to be detected, the pulse repetition frequency is at least 50Hz and not more than 500Hz, the scanning step is not more than 1mm, and the maximum scanning speed and the comprehensive setting of the resolution of the encoders do not cause interruption of scanned images.
For example, the second component zone focus parameters: the method comprises the steps of setting a step offset, a minimum sector scanning angle and a maximum sector scanning angle to at least cover the middle half part of the welding seam in the thickness direction, wherein the angle step is not more than 1 degree, the focusing mode is true depth focusing, and the focusing depth is more than or equal to 2 times of the welding seam thickness, so that a focusing rule is generated.
For example, calibration: and (3) performing sound velocity calibration, if the workpiece material is a known material sound velocity, performing wedge delay calibration, and performing sensitivity calibration (ACG) and time gain correction (TCG) on the second group of the partitions.
For example, ultrasound parameters are set: the starting depth and depth range of the display are mainly set so that the thickness direction range of the second group detection section can be covered, and the gain is displayed.
For example, a scan parameter is set: the position of the scanning initial point 0 is one end of the welding seam in the length direction (the end is the same as the position of the scanning initial point 0 in the first group of partition detection parameters), the polarities of encoders in scanning on two sides of the welding seam are opposite, the scanning area at least comprises the length range of defects to be detected, the pulse repetition frequency is at least 50Hz and not more than 500Hz, the scanning step is not more than 1mm, and the maximum scanning speed and the comprehensive setting of the encoder resolution are not to enable the scanned images to be discontinuous.
In some embodiments, during phased array ultrasonic detection operation, after a couplant is coated on a weld joint, two groups of partitioned single-sided double-sided scanning is performed on the outer surface of the weld joint, detection data (including first detection data, second detection data, third detection data and fourth detection data) are collected, and the detection data are stored for analysis.
Based on the method provided by the embodiment of the disclosure, when the welding seam is detected, the welding seam surplus height is not required to be polished, the detection data can be accurately and rapidly obtained under the condition that the structural form of the welding seam is not changed and the original structural strength is not influenced, the detection efficiency can be improved, and the detection cost is saved.
The following is a description of the feasibility of the phased array ultrasonic detection method with residual height for a weld seam provided by the embodiments of the present disclosure, in conjunction with specific embodiments.
Firstly, manufacturing a welding joint test piece, simulating a real welding seam structure with residual height, and detecting the welding joint test piece by using a phased array ultrasonic detection method.
And manufacturing a flat butt welding joint test piece with a medium-thick wall austenitic stainless steel groove type and a welding line type of V type. As shown in fig. 5 and 6, specific parameters of the welded joint test piece are: the height of the truncated edge of the V-shaped groove is 2mm, the offset of the truncated edge is 2mm, the groove depth is 43, the groove angle is 64 degrees, and the weld joint width is 59.57mm. The test piece had a thickness of 45mm, a width of 300mm in the vertical weld direction, a length of 300mm in the parallel weld direction, and an artificial defect of a circular half through hole having a diameter of 2mm, a length of 50mm, and depths of 5mm, 15mm, 25mm, and 35mm, respectively, was processed in one end in the length direction of the welded joint, as shown in fig. 5 as half through hole 501, half through hole 502, half through hole 503, and half through hole 504.
As shown in fig. 6, a bottom surface open groove with the length of 10mm, the self height of 2mm and the width of 1mm is processed on a welding line with the length of 105mm from the same end of the half through hole artificial defect; processing a bottom open groove with the length of 15mm, the self height of 4mm and the width of 1mm at the position 205mm away from the same end of the half through hole artificial defect, such as an open groove 601 and an open groove 602 in fig. 6; an external surface open groove with a length of 25mm, a self height of 2mm and a width of 1mm is machined at 240mm from the same end of the half-through hole artificial defect, such as open groove 603 in fig. 6.
A phased array ultrasonic detector with 32 channels at maximum number of array elements excited at the same time at a single time is selected, wherein the central frequency is 2.25MHz, the number of array elements is 32, the array element width is 1mm, the array element gap is 0.2mm, the aperture of a driven shaft is 20mm, a phased array ultrasonic linear array probe and a corresponding inclined wedge are adopted, the emergent wave mode of the inclined wedge is longitudinal wave, the wedge angle is 16.5 degrees, the emergent angle is 45 degrees, the height of a first wafer is 46.5mm, the main shaft offset is 52.6mm, the width of the driven shaft of the wedge is 20mm, the minor shaft offset is 20mm, the probe is arranged on the probe, and the probe is connected to the phased array ultrasonic detector.
Aiming at a medium-thickness austenitic stainless steel welding seam with a certain thickness, the number of channels excited by a phased array ultrasonic detector at a single time and the number of array elements of a single phased array ultrasonic array probe have great influence on a secondary wave detection method. For example, when other conditions are the same and all probe array elements are excited respectively, the contrast probe array element numbers are respectively 32 and 16 (or the channel numbers of single simultaneous excitation of the phased array ultrasonic detector are respectively 32 and 16), and the secondary wave imaging detection difference of the half through hole 501 and the half through hole 502 in fig. 5 is detected. As in fig. 7, the dashed box of image 701 is the image of the half through hole 501 in fig. 5, the image 702 is the image of the half through hole 502 in fig. 5, the dashed box of image 801 is the image of the half through hole 501 in fig. 5, and the image 802 is the image of the half through hole 502 in fig. 5. As can be seen from a comparison of fig. 7 and 8, the imaging resolution and signal-to-noise ratio of fig. 7 are significantly better than those of fig. 8, and the imaging of the half-via of fig. 8 is distorted, and the uncorrelated display imaging is more and significantly stronger than, or even stronger than, the imaging of the half-via. Therefore, a 16 phased array ultrasonic detector with a 16 array element number probe or channel number is not suitable for secondary detection.
Setting the thickness of a workpiece in an operation interface of the phased array ultrasonic detector to be 45mm, selecting austenitic stainless steel as a material, enabling the sound velocity to be 5800m/s, enabling the workpiece type to be a flat butt welding seam, enabling a welding seam groove type to be V-shaped, enabling the blunt edge height of the groove to be 2mm, enabling the blunt edge offset to be 2mm, enabling the groove depth to be 43, enabling the groove angle to be 64 degrees, enabling the welding seam width to be 59.57mm, and enabling the image display interface of the phased array ultrasonic detector to display the welding seam type to assist in judging defects.
Setting a first group of partition detection parameters, and adopting a direct wave method for detecting defects of a welded joint of a middle lower part in the thickness direction:
(1) First set of zone focusing parameters: the method comprises the steps of inputting the basic parameters of the array probe and the basic parameters of a longitudinal wave wedge block in a self-receiving mode, selecting a sector scanning mode, setting the number of excitable array elements as 32, setting the number of excited first array elements as 1, setting stepping offset as 30mm, setting the minimum sector scanning angle as 40 degrees and the maximum sector scanning angle as 85 degrees, wherein the parameters at least can cover the depth range from 15mm to 45mm in the thickness direction of the welding joint, the angle step distance is 1 degree, the focusing mode is true depth focusing, and the focusing depth is 45mm, so that a focusing rule is generated.
(2) And (3) calibrating: the material sound speed is 5800m/s, the sound speed calibration is not needed, then the wedge delay calibration is performed, and then the sensitivity calibration (ACG) and the time gain correction (TCG) are performed.
(3) Setting ultrasonic parameters; the initial depth of display was set to 0mm and the depth range was 60.6mm, the depth range in the thickness direction that could cover the first group of detection zones was set to 15mm to 45mm, and the display gain was set to 35dB.
(4) Setting scanning parameters: the position of the scanning initial point 0 is one end of the side of the artificial defect of the circular half through hole in the length direction of the welding line, and the distance between the scanning initial point 0 and one end of the test piece is half of the width of the wedge driven shaft, namely 20mm. The polarity of the encoder is positive when the test piece A side (namely the first side, hereinafter referred to as the A side) is scanned, the polarity of the encoder is negative when the test piece B side (namely the second side, hereinafter referred to as the B side) is scanned, the scanning area range is 220mm, the pulse repetition frequency is 70Hz, the scanning step is 1mm, the maximum scanning speed is 120mm/s, and the encoder resolution is 48Steps/mm.
(5) After the couplant is coated on the test piece, single-sided double-sided scanning of a first group of partitions is performed on the outer surface of the welding seam, fan-shaped scanning imaging of the half through holes 502, 503 and 504 and B scanning imaging of the opening grooves 601 and 602 on the bottom surface are acquired, and detection data are acquired.
The fan-shaped scanning imaging acquired by the half through hole 502, the half through hole 503 and the half through hole 504 on the side of the test piece A is shown as imaging 901, imaging 902 and imaging 903 in fig. 9 by adopting the first group of partition detection parameters, the imaging of the half through hole 502, the half through hole 503 and the half through hole 504 is clear, the imaging 901 of the half through hole 502 with the weakest imaging has the echo height of 44%, the signal to noise ratio reaches 20.83dB, and the detection requirement is met.
The fan-shaped scanning imaging acquired by the first group of partition detection parameters on the side of the test piece B is shown as imaging 1001, imaging 1002 and imaging 1003 in fig. 10, the imaging of the half through hole 502, the imaging of the through hole 503 and the imaging of the through hole 504 are clear, the imaging 1001 of the half through hole 502 with the weakest imaging is 45% in echo height, the signal to noise ratio reaches 19.08dB, and the detection requirement is met.
By adopting the first group of partition detection parameters, B scanning imaging (imaging sound beam angle 51 DEG) is carried out on the opening groove 601 and the opening groove 602 on the bottom surface on the side A of the test piece, as shown by imaging 1101 and imaging 1102 in FIG. 11, the imaging 1101 is 11.6mm in length and 1.6mm in length error, the signal-to-noise ratio reaches 28.30, the imaging 1102 is 15.5 in measured length and 0.5mm in error, and the signal-to-noise ratio reaches 28.30, so that the detection requirement is met.
By adopting the first group of partition detection parameters, B scanning imaging (imaging sound beam angle 51 DEG) is acquired by the opening groove 601 and the opening groove 602 on the bottom surface on the side B of the test piece, as shown by imaging 1201 and imaging 1202 in FIG. 12, the imaging 1201 has a measured length of 11.7mm, an error of 1.7mm, a signal-to-noise ratio of 26.02dB, the imaging 1202 has a measured length of 15.9mm, an error of 0.9mm, and a signal-to-noise ratio of 27.04dB, and the detection requirement is met.
Setting a second group of partition detection parameters, and adopting a secondary wave method for detecting defects of the welding joint at the upper part in the thickness direction:
(1) Second set of zone focusing parameters: the method comprises the steps of inputting the basic parameters of the array probe and the basic parameters of a longitudinal wave wedge block in a self-receiving mode, selecting a sector scanning mode, setting the number of excitable array elements as 32, setting the number of excited first array elements as 1, setting the stepping offset as 45mm, setting the minimum sector scanning angle as 23 degrees and the maximum sector scanning angle as 56 degrees, wherein the parameters at least can cover the depth range from the surface to 15mm in the thickness direction of the welding joint, the angle step distance is 1 degree, the focusing mode is true depth focusing, and the focusing depth is 90mm, so that a focusing rule is generated.
(2) And (3) calibrating: the material sound speed is 5800m/s, sound speed calibration is not needed, then wedge delay calibration is performed, and then sensitivity calibration (ACG) and time gain correction (TCG) are performed.
(3) Setting ultrasonic parameters; the initial depth of display was set to 56.4mm and the depth range was 60.9mm, and the thickness direction surface of the second group of detection zones was covered to the depth range of 15mm, and the display gain was set to 42dB.
(4) Setting scanning parameters: the position of the scanning initial point 0 is one end of the weld joint length direction round semi-through hole artificial defect side, the polarity of the encoder is positive when the test piece A side is scanned, the polarity of the encoder is negative when the test piece B side is scanned, the scanning area range is 250mm, the pulse repetition frequency is 70Hz, the scanning step is 1mm, the maximum scanning speed is 120mm/s, and the encoder resolution is 48Steps/mm.
(5) And (3) after the couplant is coated on the test piece, performing single-sided double-sided scanning of a second group of areas on the outer surface of the welding seam, and acquiring sector scanning imaging of the half through holes 501 and 502 and B scanning imaging of the surface open grooves 603 to obtain detection data.
The second group of partition detection parameters are adopted, fan-shaped scanning imaging acquired by the half through holes 501 and 502 on the side of the test piece A is shown as an imaging 1301 and an imaging 1302 in FIG. 13, the half through holes 501 and 502 are imaged clearly, the imaging 1301 of the half through hole 501 with the weakest imaging is 72% in echo height, the signal to noise ratio reaches 21.58dB, and the detection requirement is met.
The fan-shaped scanning imaging acquired by the half through holes 501 and 502 at the side of the test piece B by adopting the second group of partition detection parameters is shown as an imaging 1401 and an imaging 1402 in fig. 14, the half through holes 501 and 502 are imaged clearly, the imaging 1302 of the half through hole 502 with the weakest imaging has an echo height of 66%, the signal to noise ratio reaches 16.39dB, and the detection requirement is met.
B scanning imaging (imaging sound beam angle 25 degrees) acquired on the surface open groove 603 at the side of the test piece B by adopting a second group of partition detection parameters, as shown in imaging 1501 in FIG. 15, the length of the imaging 1501 is 20.8mm, the error is 0.8mm, and the imaging 1501 is higher in imaging signal-to-noise ratio as the secondary sound beam passes through the surface open groove 603 at the side of the base material, thereby reaching 23.90dB and meeting the detection requirement.
With the second set of partition detection parameters, B-scan imaging (imaging beam angle 47 °) of the surface open groove 603 collected on the test piece a side, as shown in imaging 1601 in fig. 16, the imaging 1601 has a length of 26.8mm and an error of 6.8mm, since the secondary beam is imaged on the surface open groove 603 through the weld side, the weld is a coarse grain structure, the crystal grains are larger, and the grain noise is more imaged, but the imaging on the B-side slope surface can be easily distinguished as the imaging of the surface open groove 603 according to the relative positional relationship between the secondary imaging range and the weld model, and the uncorrelated display outside the weld model and outside the secondary imaging range can be easily distinguished, as shown in imaging 1701 in fig. 17. Although the imaging signal-to-noise ratio of the surface open groove 603 is low, the signal-to-noise ratio reaches 13.20dB, and the detection requirement is still met.
Through the test of the welded joint test piece, the feasibility of the welding seam phased array ultrasonic detection method can be determined.
In the description of the present specification, a description referring to terms "one embodiment," "some embodiments," "examples," "specific examples," or "some examples," etc., means that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the present disclosure. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, the different embodiments or examples described in this specification and the features of the different embodiments or examples may be combined and combined by those skilled in the art without contradiction.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include at least one such feature. In the description of the present disclosure, the meaning of "a plurality" is two or more, unless explicitly defined otherwise.
The foregoing is merely a specific embodiment of the disclosure, but the protection scope of the disclosure is not limited thereto, and any person skilled in the art can easily think about changes or substitutions within the technical scope of the disclosure, and it should be covered in the protection scope of the disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
Claims (6)
1. An ultrasonic detection method of a welding seam phased array with residual height, wherein edges of two metal structures are welded to form a middle-thick-wall austenitic stainless steel welding seam with residual height, one side of the metal structure is a first side of the middle-thick-wall austenitic stainless steel welding seam, and the other side of the metal structure is a second side of the middle-thick-wall austenitic stainless steel welding seam, and the method comprises the following steps:
Detecting middle lower parts of the middle-thick austenitic stainless steel weld joint in the thickness direction by adopting a direct wave method through phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the middle-thick austenitic stainless steel weld joint, and acquiring first detection data, wherein the stepping bias of the phased array ultrasonic detection equipment is one half of the width of the first surface of the middle-thick austenitic stainless steel weld joint, and at least the middle lower parts of the middle-thick austenitic stainless steel weld joint in the thickness direction are covered by a minimum sector scanning angle and a maximum sector scanning angle, and the focusing depth is more than or equal to the thickness of the weld joint;
The upper surfaces of the first side and the second side of the medium-thickness austenitic stainless steel welding seam are respectively detected by phased array ultrasonic detection equipment by adopting a secondary wave method, second detection data are obtained, the stepping bias, the minimum sector scanning angle and the maximum sector scanning angle of the phased array ultrasonic detection equipment at least cover the upper part of the medium-thickness austenitic stainless steel welding seam in the thickness direction, and the focusing depth is more than or equal to 2 times the thickness of the medium-thickness austenitic stainless steel welding seam;
The number of channels excited at the same time at a time is not less than 32 when the phased array ultrasonic detection equipment detects, the number of array elements of a single phased array ultrasonic array probe is not less than 32, the center frequency of the phased array ultrasonic array probe is not more than 5MHz, the array element width is at least 1mm, the aperture of a driven shaft is at least 20mm, and corresponding inclined wedges, the emergent wave mode of each inclined wedge is longitudinal wave, the wedge angle is 16.5 degrees, and the emergent angle is 45 degrees.
2. The method of claim 1, wherein the method further comprises: detecting the first surface of the medium-wall austenitic stainless steel welding seam by adopting a direct wave method through the phased array ultrasonic detection equipment on the upper surfaces of the first side and the second side of the medium-wall austenitic stainless steel welding seam, and acquiring third detection data;
the first surface of the medium-wall austenitic stainless steel weld is opposite to the upper surfaces of the first side and the second side of the medium-wall austenitic stainless steel weld.
3. The method of claim 2, wherein the method further comprises: the phased array ultrasonic detection equipment is used for detecting the second surface of the medium-wall austenitic stainless steel weld joint by adopting a secondary wave method on the upper surfaces of the first side and the second side of the medium-wall austenitic stainless steel weld joint, and fourth detection data are obtained;
The second surface of the medium-wall austenitic stainless steel weld is a surface on the same side as the upper surfaces of the first side and the second side of the medium-wall austenitic stainless steel weld.
4. A method according to any one of claims 1 to 3, wherein, upon detection of the upper surfaces of the first and second sides of the medium-wall austenitic stainless steel weld by the phased array ultrasonic detection apparatus, the first end of the medium-wall austenitic stainless steel weld in its length direction is a detection start point of the phased array ultrasonic detection apparatus, and the second end is a detection end point of the phased array ultrasonic detection apparatus.
5. A method according to any one of claims 1 to 3, wherein the upper surfaces of the first and second sides of the medium wall austenitic stainless steel weld seam, respectively, are detected by a phased array ultrasonic detection apparatus using a direct wave method or a secondary wave method:
the encoders of the phased array ultrasonic testing apparatus are of opposite polarity on the first and second sides of the medium wall austenitic stainless steel weld.
6. A method according to any one of claims 1 to 3, wherein the acoustic wave transmission and reception means of the phased array ultrasonic detection apparatus is self-emission and self-reception, and the waveform of the acoustic wave is longitudinal wave.
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