CN115060804A - Ultrasonic evaluation method for stud welding quality - Google Patents

Ultrasonic evaluation method for stud welding quality Download PDF

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Publication number
CN115060804A
CN115060804A CN202210750852.7A CN202210750852A CN115060804A CN 115060804 A CN115060804 A CN 115060804A CN 202210750852 A CN202210750852 A CN 202210750852A CN 115060804 A CN115060804 A CN 115060804A
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stud
detection probe
detection
ultrasonic
welding
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Inventor
张浩喆
何喜
王婵
董瑞琴
周文博
荆砚
赵娜
冯萍
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AECC Aviation Power Co Ltd
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AECC Aviation Power Co Ltd
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Priority to CN202210750852.7A priority Critical patent/CN115060804A/en
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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
    • G01N29/06Visualisation of the interior, e.g. acoustic microscopy
    • G01N29/0654Imaging
    • G01N29/069Defect imaging, localisation and sizing using, e.g. time of flight diffraction [TOFD], synthetic aperture focusing technique [SAFT], Amplituden-Laufzeit-Ortskurven [ALOK] technique
    • 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
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E30/00Energy generation of nuclear origin
    • Y02E30/30Nuclear fission reactors

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  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Acoustics & Sound (AREA)
  • Investigating Or Analyzing Materials By The Use Of Ultrasonic Waves (AREA)

Abstract

The invention discloses an ultrasonic evaluation method for stud welding quality, which comprises the following steps: step 1, manufacturing a reference block; step 2, selecting the frequency of the detection probe; step 3, adjusting the water distance; step 4, adjusting the detection sensitivity; step 5, scanning and setting scanning intervals; and 6, evaluating the stud welding quality. The invention adopts high-frequency narrow-sound-beam ultrasonic water immersion detection, can effectively evaluate the quality of the stud welded on the plate with the thickness of more than 0.5mm, and adopts a nondestructive mode to visually evaluate the welding rate and whether the welding area has internal defects or not through an imaging mode.

Description

Ultrasonic evaluation method for stud welding quality
Technical Field
The invention belongs to the technical field of detection, and particularly relates to an ultrasonic evaluation method for stud welding quality.
Background
The aviation stud welding part comprises a plate and a plurality of studs welded on the plate, and due to the characteristics of small stud size, thin welded plate and the like, welding quality can not be detected by adopting other modes such as ray and the like. However, both the water immersion method and the contact method have surface blind areas during ultrasonic detection, and due to the structure of parts, the thickness of the plate used for stud welding is 0.5mm at least, and the size of the plate is far larger than the blind area of conventional detection ultrasonic evaluation. And the diameter of a single screw is 4mm, the size of the stud is small, the diameter of the sound beam of the low-frequency ultrasonic focusing probe is large, and the risk of missing detection exists in the edge area when the stud with the diameter faces the stud with the diameter.
Disclosure of Invention
The invention provides an ultrasonic evaluation method for stud welding quality, which avoids missing detection and evaluates the stud welding quality.
In order to achieve the purpose, the ultrasonic evaluation method for stud welding quality comprises the following steps:
step 1, selecting a part which is made of the same material as a part to be tested and has the same size and thickness as a stud as a comparison sample material, and manufacturing a flat bottom hole in the center of the stud along the axial direction of the stud, wherein the axial depth of the flat bottom hole is positioned on a joint surface of the stud and a plate;
step 2, selecting the detection frequency of the detection probe according to the plate thickness of the welded plate;
step 3, placing the focus of the detection probe on a weld joint of the stud welding, detecting by using a narrow focal column of a focusing area, and determining a detection water distance according to the nominal focal length of the probe and the thickness of a welding plate;
step 4, adjusting detection sensitivity, namely enabling one side of the plate of the test block to face upwards and fixing the plate in a water tank, enabling water to submerge the test block and the detection probe, adjusting the position of the detection probe to enable the water distance to be larger than the detection water distance determined in the step 3, adjusting the angle of the detection probe, finding the maximum primary reflection echo, enabling the incident surface of the plate of the detection probe to be vertical, and then adjusting the evaluation sensitivity of internal defects and the evaluation sensitivity of welding rate;
step 5, setting a scanning interval, enabling one side of a plate of the part to be detected to face upwards and fixing the plate in a water tank, enabling water to submerge the part to be detected and a detection probe, scanning the part to be detected by the detection probe, and if the welding sum rate is evaluated, scanning according to the evaluation sensitivity of the internal defect set in the step 4 to obtain a C scanning image A; if the internal defects are evaluated, scanning is carried out according to the evaluation sensitivity of the welding sum rate set in the step 4 to obtain a C scanning image B; when both need to be evaluated, scanning for two times is carried out;
step 6, evaluating the stud welding quality
Evaluating the C scanning image A, and determining that the C scanning image A is unqualified if the number of signals exceeding the threshold value A exists in the stud welding area;
and evaluating the C scanning image B, respectively measuring and counting the area of each stud with the wave amplitude exceeding a set threshold value B, and respectively evaluating the integral welding rate of the single stud and the part to be tested.
Further, in the step 1, the diameter of the flat-bottom hole is 0.4mm-0.8 mm.
Further, in the step 1, when the thickness of the part to be measured is less than 2mm, a probe of 25MHz-50MHz is adopted, and when the thickness of the part to be measured is more than or equal to 2mm, a probe of 10MHz-25MHz is adopted.
Further, in step 3, the calculation formula of the detection water distance H adopted in the detection and the sensitivity adjustment is as follows: and H is F-4 multiplied by D, wherein F is the nominal focal length of the detection probe, and D is the thickness of the stud welding plate to be detected.
Further, in step 4, the procedure of adjusting the evaluation sensitivity of the internal defect is: moving the detection probe along the Z-axis direction until the water distance is H; moving the detection probe along the X-axis direction and the Y-axis direction to find the flat-bottom hole of the test block, repeatedly moving the detection probe to find the maximum reflection echo of the defect echo of the flat-bottom hole, adjusting the amplitude to 80% of the full screen height, adjusting the width of the gate to be less than or equal to 0.2mm from the gate frame to the position of the defect maximum reflection echo, and not framing the bottom wave or other echoes, namely the sensitivity during internal defect evaluation.
Further, in step 4, the process of adjusting the evaluation sensitivity of the welding sum ratio is as follows: and moving the Z axis to ensure that the water distance is H unchanged, moving the detection probe to a plate without a stud, adjusting the amplitude to 80% of the full-screen height, adjusting the width of the gate to be less than or equal to 0.2mm from the monitoring gate frame to the maximum echo position, and not framing other echoes, wherein the gain value of the ultrasonic equipment is the sensitivity of the welding sum rate evaluation.
Further, in step 5, when the frequency of the detection probe is 10MHz-25MHz, the scanning distance is less than or equal to 0.2mm, and when the frequency of the detection probe is 25MHz-50MHz, the scanning distance is less than or equal to 0.1 mm.
Further, in step 6, if the ultrasonic echo signal in the stud welding area exceeds 80%, the stud welding area is determined to be defective.
Further, in step 6, if the area of the region of the scanned image B of a single stud C, where the amplitude exceeds 20%, is greater than 20% of the size area of the whole stud, the stud is not qualified.
Further, in step 6, if the sum of the area sizes of the areas where the amplitudes of the C-scan images of all the studs exceed 20% is greater than 5% of the sum of the areas of all the studs, the part to be measured is unqualified.
Compared with the prior art, the invention has at least the following beneficial technical effects:
the invention adopts ultrasonic water immersion detection, the ultrasonic water immersion detection has higher working frequency and narrower sound beam, and the quality of the stud welded on the plate with the thickness of more than 0.5mm can be effectively evaluated; and the nondestructive mode of ultrasonic imaging is adopted, so that the parts to be detected are visually evaluated from two aspects of welding sum rate and whether the welding area has internal defects, and the detection is more comprehensive.
Furthermore, the working frequency adopted by the method is high, the diameter of a probe acoustic beam used for detection is small, the adopted scanning interval is small, so that the scanning process has higher resolution, and meanwhile, the surface dead zone of the high-frequency ultrasonic technology is small, so that the thickness of the detected plate is smaller.
Further, the calculation formula of the detected water distance H is as follows: and H-F-4 XD, a narrow sound beam region with the most concentrated probe energy can be placed at the weld joint, so that the detection capability of defects in the weld joint region is improved.
Furthermore, the method adopts automatic scanning after the parameters are adjusted, can evaluate indexes such as defects, welding rate and the like through images, and is simple to operate. Therefore, the method has the advantages of high resolution, simplicity in operation and the like.
Furthermore, according to different evaluation requirements, different sensitivities are adjusted, different C scanning images are evaluated, and the welding quality of the stud with the small plate thickness and the small diameter is comprehensively evaluated.
Drawings
FIG. 1 is a flow chart of an ultrasonic evaluation method for stud welding quality according to the present invention;
fig. 2 is a schematic diagram of a reference block.
In the drawings: 1. stud, 2, welding seam, 3, flat bottom hole, 4 and welding plate.
Detailed Description
In order to make the objects and technical solutions of the present invention clearer and easier to understand. The present invention will be described in further detail with reference to the following drawings and examples, wherein the specific examples are provided for illustrative purposes only and are not intended to limit the present invention.
In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, indicate orientations or positional relationships based on those shown in the drawings, and are used only for convenience in describing the present invention and for simplicity in description, and do not indicate or imply that the referenced devices or elements must have a particular orientation, be constructed and operated in a particular orientation, and thus, are not to be construed as limiting the present invention. Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present invention, "a plurality" means two or more unless otherwise specified. In the description of the present invention, it should be noted that, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meanings of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Referring to fig. 1, an ultrasonic evaluation method of stud welding quality includes the steps of:
step 1, manufacturing a reference block:
in order to determine the sensitivity used in ultrasonic evaluation, it is necessary to fabricate a flat-bottom hole defect test block simulating the internal defects of stud welding.
And selecting the part with the same material as the part to be measured and the same bolt size and plate thickness as the comparison sample material. The part comprises a welding plate 4 and a stud 1 welded on the welding plate, a welding seam 2 is arranged at the welding position of the stud 1 and the welding plate, a flat bottom hole 2 with phi 0.4 mm-phi 0.8mm is manufactured in the center of the stud 1 along the axial direction of the stud 1, and the axial depth of the flat bottom hole 2 is positioned on the joint surface of the stud and the plate, namely the position of the welding seam of the marked stud in figure 2.
Step 2, selecting detection probe frequency in ultrasonic detection equipment: the detection probe is a water immersion focusing ultrasonic probe, and the detection frequency of the detection probe needs to be selected according to the plate thickness of the welded plate. When the thickness of the plate is less than 2mm, a probe of 25MHz-50MHz is adopted, and when the thickness of the plate is more than or equal to 2mm, a probe of 10MHz-25MHz is adopted. The surface detection dead zone of the probe with the frequency of 10MHz-25MHz is more than 2mm, and the surface detection dead zone with the frequency of 25MHz-50MHz is less than 2 mm. The width of the probe sound beam of 25MHz-50MHz is 0.3-0.5mm, and the width of the probe sound beam of 10MHz-25MHz is 0.5-0.8 mm.
Step 3, adjusting water distance
In order to realize high-sensitivity and high-resolution detection, it is necessary to adjust a suitable water distance, that is, a distance between the detection probe and the part, place the focus of the detection probe on the weld of the stud welding, and perform detection using a narrow acoustic beam region of the focal region.
If the nominal focal length of the detection probe is F and the thickness of the stud welding plate to be detected is D, the calculation formula of the detection water distance H adopted in the detection and the sensitivity adjustment is as follows: H-F-4 XD.
Step 4, adjusting the detection sensitivity
And (3) placing one side of the plate of the test block upwards, fixing the test block in a water tank of ultrasonic detection equipment to enable water to submerge the test block and the detection probe, and adjusting the Z axis of the detection probe to enable the water distance to be larger than the detection water distance H in the step 3. And adjusting the A axis and the B axis of the detection probe to adjust the angle of the detection probe, finding out the maximum echo of primary reflection, and ensuring that the incident surface of the detection probe plate is vertical.
4.1 adjustment of evaluation sensitivity for internal Defect
The Z axis of the ultrasonic detection device is moved to ensure that the water distance is H at the moment, and the Z axis can not be moved any more after the Z axis is moved. Through mobile device X, Y axle, find the defect echo of flat bottom hole 3 on the test block (if defect echo and probe interface wave can't distinguish, change the probe that is higher than current frequency, repeat step 3), and remove the detection probe repeatedly and find the biggest reflection echo of flat bottom hole defect echo, transfer the wave amplitude to ultrasonic detection equipment signal display screen 80% of full scale again, and with the gate frame of C scanning formation of image collection data to defect biggest reflection echo department, the gate width is transferred to 0.2mm or less, and ensure that C scanning formation of image gate does not frame to bottom wave or other echoes. At this time, the gain value of the ultrasonic detection device is the sensitivity of the internal defect evaluation.
4.2 adjustment of evaluation sensitivity of the weld sum ratio
Ensure that the water distance is still H, after which the Z axis cannot be moved any more. Moving the detection probe to a plate without a stud, adjusting the amplitude to 80% of the full screen height, adjusting the width of the gate to 0.2mm or less from the monitoring gate frame to the maximum echo position, and ensuring that other echoes are not framed. At the moment, the gain value of the ultrasonic equipment is the sensitivity for evaluating the welding rate.
Step 5, scanning and setting of scanning interval
And (3) placing the plate with one side of the part to be detected upwards, fixing the part to be detected in a water tank of ultrasonic detection equipment, enabling water to submerge the part to be detected and a detection probe, and compiling a C scanning program to ensure that the scanning range of the scanning program can cover all studs. The setting of the scanning interval of the probe of 10MHz to 25MHz is not more than 0.2mm, and the setting of the scanning interval of the probe of 25MHz to 50MHz is not more than 0.1 mm. If the welding sum rate is evaluated, scanning is carried out after the sensitivity is set according to the 4.2 steps to obtain a C scanning image A; if internal defects are evaluated, scanning is carried out after the sensitivity is set according to the step 4.1 to obtain a C scanning image B; when both need to be evaluated, two scanning operations are required.
Step 6, evaluating stud welding quality
6.1 evaluation of internal defects
And evaluating the C scanning image A obtained by adjusting the sensitivity by the 4.1 method, and determining that the ultrasonic echo signal is unqualified if the ultrasonic echo signal exceeds 80% in the stud welding area.
6.2 evaluation of the weld-addition ratio
And evaluating the C scanning image B obtained by adjusting the sensitivity by a 4.2 method, and respectively measuring and counting the area of each stud with the wave amplitude exceeding 20%. For a single stud, if the area of the region on the scanned image B of the single stud C with the amplitude exceeding 20% is more than 20% of the area of the whole stud size, the stud is unqualified. And for the whole part to be measured, if the sum of the area sizes of the areas of the C scanning images on all the studs, which exceed 20%, is more than 5% of the sum of the areas of all the studs, the part is unqualified.
The above-mentioned contents are only for illustrating the technical idea of the present invention, and the protection scope of the present invention is not limited thereby, and any modification made on the basis of the technical idea of the present invention falls within the protection scope of the claims of the present invention.

Claims (10)

1. An ultrasonic evaluation method for stud welding quality is characterized by comprising the following steps:
step 1, selecting a part which is made of the same material as a part to be tested and has the same size and thickness as a stud as a comparison sample material, and manufacturing a flat bottom hole (2) in the center of the stud (1) along the axial direction of the stud (1), wherein the axial depth of the flat bottom hole (2) is positioned on a joint surface of the stud and a plate;
step 2, selecting the detection frequency of the detection probe according to the plate thickness of the welded plate;
step 3, placing the focus of the detection probe on a weld joint of the stud welding for detection, and determining a detection water distance according to the nominal focal length of the probe and the thickness of a welding plate;
step 4, one side of the plate of the test block faces upwards and is fixed in the water tank, water is enabled to submerge the test block and the detection probe, the position of the detection probe is adjusted to enable the water distance to be larger than the detection water distance determined in the step 3, then the angle of the detection probe is adjusted to find the primary reflection maximum echo, the incident surface of the plate of the detection probe is enabled to be vertical, and then the evaluation sensitivity of the internal defect and the evaluation sensitivity of the welding rate are adjusted;
step 5, setting a scanning interval, enabling one side of a plate of the part to be detected to face upwards and fixing the plate in a water tank, enabling water to submerge the part to be detected and a detection probe, and scanning the part to be detected by the detection probe; if the welding sum rate is evaluated, scanning according to the evaluation sensitivity of the internal defects set in the step 4 to obtain a C scanning image A; if the internal defects are evaluated, scanning is carried out according to the evaluation sensitivity of the welding sum rate set in the step 4 to obtain a C scanning image B; when both need to be evaluated, scanning for two times is carried out;
and 6, evaluating the stud welding quality:
evaluating the C scanning image A, and if the number of signals exceeding the threshold value A exists in the stud welding area, determining that the part to be detected is unqualified;
and evaluating the C scanning image B, respectively measuring and counting the area of each stud with the wave amplitude exceeding a set threshold value B, and respectively evaluating the integral welding rate of a single stud and the part to be measured.
2. An ultrasonic evaluation method of stud welding quality according to claim 1, characterized in that in step 1, the diameter of the flat bottom hole (2) is 0.4mm-0.8 mm.
3. An ultrasonic method for evaluating the quality of stud welding according to claim 1, wherein in said step 1, a probe of 25MHz to 50MHz is used when the thickness of the part to be tested is less than 2mm, and a probe of 10MHz to 25MHz is used when the thickness is 2mm or more.
4. The ultrasonic evaluation method for stud welding quality according to claim 1, wherein in the step 3, the calculation formula of the detection water distance H adopted in the detection and the sensitivity adjustment is as follows: and H is F-4 multiplied by D, wherein F is the nominal focal length of the detection probe, and D is the thickness of the stud welding plate to be detected.
5. The ultrasonic evaluation method of stud welding quality according to claim 1, wherein in step 4, adjusting the evaluation sensitivity of internal defects comprises:
moving the detection probe along the Z-axis direction until the water distance is H; moving the detection probe along the X-axis direction and the Y-axis direction to find the flat-bottom hole (2) of the test block, repeatedly moving the detection probe to find the maximum reflection echo of the defect echo of the flat-bottom hole (2), adjusting the amplitude to 80% of the full screen height, adjusting the width of the gate to be less than or equal to 0.2mm from the gate frame to the position of the defect maximum reflection echo, and determining the sensitivity of the gate when evaluating the internal defect without framing the bottom wave or other echoes.
6. An ultrasonic evaluation method of stud welding quality according to claim 1, wherein in the step 4, the process of adjusting the evaluation sensitivity of the welding sum ratio is:
and moving the Z axis to ensure that the water distance is H unchanged, moving the detection probe to a plate without a stud, adjusting the wave amplitude to 80% of the full screen height, adjusting the width of the gate to be less than or equal to 0.2mm from the monitoring gate frame to the maximum echo position, and not framing other echoes, wherein the gain value of the ultrasonic equipment is the sensitivity of the welding sum rate evaluation.
7. The ultrasonic evaluation method of stud welding quality according to claim 1, wherein in step 5, when the frequency of the detection probe is 10MHz to 25MHz, the scanning interval is 0.2mm or less, and when the frequency of the detection probe is 25MHz to 50MHz, the scanning interval is 0.1mm or less.
8. An ultrasonic evaluation method of stud welding quality according to claim 1, wherein in step 6, if the ultrasonic echo signal of the stud welding area exceeds 80%, the stud welding area is rejected.
9. The ultrasonic evaluation method of stud welding quality according to claim 1, characterized in that in step 6, if the area of the region with the wave amplitude exceeding 20% on the scanning image B of a single stud C is more than 20% of the whole stud size area, the stud is unqualified.
10. The ultrasonic evaluation method for stud welding quality according to claim 1, wherein in the step 6, if the amplitude of the C-scan image of all studs exceeds 20% and the sum of the area sizes of all studs is more than 5% of the sum of the areas of all studs, the part to be tested is unqualified.
CN202210750852.7A 2022-06-29 2022-06-29 Ultrasonic evaluation method for stud welding quality Pending CN115060804A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CN202210750852.7A CN115060804A (en) 2022-06-29 2022-06-29 Ultrasonic evaluation method for stud welding quality

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CN202210750852.7A CN115060804A (en) 2022-06-29 2022-06-29 Ultrasonic evaluation method for stud welding quality

Publications (1)

Publication Number Publication Date
CN115060804A true CN115060804A (en) 2022-09-16

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CN202210750852.7A Pending CN115060804A (en) 2022-06-29 2022-06-29 Ultrasonic evaluation method for stud welding quality

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