CN115389623A - Continuous casting billet ultrasonic flaw detection process - Google Patents
Continuous casting billet ultrasonic flaw detection process Download PDFInfo
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- CN115389623A CN115389623A CN202211158893.3A CN202211158893A CN115389623A CN 115389623 A CN115389623 A CN 115389623A CN 202211158893 A CN202211158893 A CN 202211158893A CN 115389623 A CN115389623 A CN 115389623A
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- 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
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- G—PHYSICS
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Abstract
The invention relates to a continuous casting billet ultrasonic flaw detection process for carrying out ultrasonic detection on the internal quality conditions of continuous casting billets with the diameter phi of less than 800mm, such as carbon steel, low alloy steel, martensitic stainless steel and the like, wherein a reference test block and an ultrasonic detection series longitudinal wave straight probe are utilized, a main sound beam of the probe is aligned to the transverse hole defects of the reference test block at different depths, and a DAC curve is manufactured to determine the ultrasonic detection sensitivity of the continuous casting billets; firstly, checking the ultrasonic detectability of the continuous casting billet, detecting under the calibration sensitivity, and if the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability; the continuous casting billet ultrasonic detection scanning surface is an outer circumferential surface, ultrasonic detection is carried out on the outer circumferential surface of the continuous casting billet in two mutually perpendicular directions, and the ultrasonic detection result of the continuous casting billet is divided into four quality levels of 1, 2, 3 and 4 according to the detection result, so that the accuracy of ultrasonic flaw detection is ensured.
Description
Technical Field
The invention belongs to the technical field of ultrasonic detection of metal materials, and particularly relates to a continuous casting billet ultrasonic flaw detection process for performing ultrasonic detection on internal quality conditions of continuous casting billets with diameters less than phi 800mm, such as carbon steel, low alloy steel, martensitic stainless steel and the like.
Background
In the production process of the vertical continuous casting billet, factors influencing the smelting quality are more, such as: smelting in an electric furnace, refining, vacuum degassing, continuous casting and the like. If the process is not performed tightly in the process, core defects such as looseness, segregation, shrinkage cavity, central cracks and the like often occur. The method for detecting the central defect of the continuous casting slab mainly comprises acid leaching low-power detection and ultrasonic detection. Acid leaching low-power inspection is a destructive sampling inspection method, sample cutting and sample preparation inspection are required, only one section of an incoming sample can be inspected, the quality condition of a whole continuous casting blank cannot be comprehensively reflected, and hydrochloric acid etching is required in the inspection process to cause harm to the health of inspection personnel and the environment. The ultrasonic detection is a non-destructive detection, and can realize the detection of the whole continuous casting blank, so that the internal quality condition of the whole continuous casting blank can be comprehensively known, the continuous casting blank can be guided to be used according to the flaw detection result, and the detection process has no influence on personnel and environment.
Compared with the continuous casting billets and austenite steel continuous casting billets with larger specifications, the continuous casting billets of carbon steel, low alloy steel, martensite stainless steel and the like with the diameter of less than 800mm have the advantages of relatively compact and uniform structure, stronger ultrasonic sound permeability, controllable scattering attenuation and absorption attenuation influence, easily identified and evaluated defects and basic conditions of ultrasonic detection.
Disclosure of Invention
The invention aims to overcome the defects in the prior art and provide an ultrasonic flaw detection process for a continuous casting billet, which can effectively identify the central defects of the continuous casting billet of carbon steel, low alloy steel and martensitic stainless steel with the diameter less than phi 800mm, and ensure the effectiveness and accuracy of ultrasonic detection.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
an ultrasonic detection process for a continuous casting billet utilizes a reference test block and an ultrasonic detection series longitudinal straight probe, so that a main sound beam of the probe is aligned to the transverse hole defects of the reference test block at different depths, and a DAC curve is made to determine the ultrasonic detection sensitivity of the continuous casting billet; firstly, checking the ultrasonic detectability of the continuous casting billet, detecting under the calibration sensitivity, and if the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability; the continuous casting billet ultrasonic detection scanning surface is an outer circumferential surface, ultrasonic detection is carried out on the outer circumferential surface of the continuous casting billet in two mutually perpendicular directions, and the continuous casting billet ultrasonic detection result is divided into four quality levels of 1, 2, 3 and 4 according to the detection result.
The specific detection process comprises the following steps:
step 1), determining that an instrument used in the process is an A-type pulse reflection ultrasonic detector, wherein the frequency range of the A-type pulse reflection ultrasonic detector is at least 0.4 MHz-5.0 MHz, the horizontal linear error of the ultrasonic detector is not more than 1% and the vertical linear error is not more than 5% in a full scale range, and the far-field resolution of a straight probe is not less than 20dB; when the combined sensitivity of the ultrasonic detector and the probe reaches the detection sensitivity of the maximum sound path of the detected continuous casting billet, at least 10dB effective sensitivity allowance is reserved;
step 2), designing and manufacturing a reference test block, wherein the reference test block is obtained from a detected continuous casting billet, and the material, curvature, surface roughness and heat treatment conditions of the reference test block are the same as those of the detected continuous casting billet; the reference test block is a cylinder, the height of the cylinder is 60mm, three transverse hole defects are uniformly distributed on the end face of the cylinder of the reference test block at 120 degrees along the circumferential direction by taking the axis of the cylinder as the center, the central lines of the three transverse holes are parallel to the axis of the cylinder, the corresponding positions are 5%, 25% and 40% of the diameter D of the cylinder under the outer circular surface of the cylinder, the length of the transverse hole is 40mm, and the diameter phi f of the transverse hole is 1% of the diameter D of the cylinder;
step 3), determining a coupling agent used for detection: the adopted coupling agent has good sound transmission and wettability, and does not damage the surface of a workpiece;
step 4), calibrating the ultrasonic probe and determining the ultrasonic detection sensitivity: circumferential detection is carried out by using a series of longitudinal wave straight probes, so that main sound beams of the probes are aligned to the transverse hole defects at 5%, 25% and 40% of the diameter D of the cylinder below the cylindrical outer circular surface of the reference test block for calibration;
step 5), carrying out an ultrasonic detection process:
step 5.1), carrying out continuous casting blank ultrasonic detection in a continuous casting blank state, cleaning the detected surface of the continuous casting blank before detection, wherein the detected surface of the continuous casting blank has no loose oxide skin, paint and dirt and foreign matters influencing probe movement or evaluation, and if the surface of the continuous casting blank has corrugated convex-concave parts, two detection belts with the width of 100mm are ground at intervals of 90 degrees at the corrugated convex-concave parts;
step 5.2), firstly, checking the ultrasonic detectability of the continuous casting billet, and under the sensitivity determined after calibration, when the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability, wherein the ultrasonic detection scanning surface of the continuous casting billet is an outer circular surface, and performing ultrasonic detection on the outer surface of the continuous casting billet in two mutually perpendicular directions; the scanning speed of the probe is not more than 150mm/s, the adjacent two scanning processes are overlapped, the overlapping width is not less than 15% of the scanning width, and the front edge position of the first bottom wave of the ultrasonic detection is adjusted within 80% of the full scale of the horizontal scanning line; the length measurement of the continuous casting slab defects is carried out by adopting a disappearance method: after the probe is moved to find out the maximum reflection wave height of the defect, the attenuator is adjusted, the probe is moved along the defect direction when the defect wave height is reduced to the reference wave height, and when the defect wave height disappears, the distance between the central lines of the probe is the indication length of the defect;
step 5.3), determining that the ultrasonic flaw detection results of the continuous casting billets are divided into four quality grades of 1, 2, 3 and 4, wherein the quality grade is 1: the amplitude of the defect is more than or equal to DAC-3dB, and F/B is not more than-6 dB; quality grade 2: the amplitude of the defect is more than or equal to DAC, F/B is more than-6 dB and less than +6dB, and the central range of the defect is less than 100mm; quality grade 3: the amplitude of the defect wave is more than or equal to DAC +3dB, F/B is more than-6 dB, the central range of the defect is more than 100mm, or only disordered defect waves exist without bottom echo; quality grade 4: those exceeding grade 3.
In the step 1), a longitudinal wave straight probe with nominal frequency of 0.4 MHz-2 MHz is adopted as a probe of the ultrasonic detector, and the frequency error is +/-10%; selecting the size of the probe wafer within the range of phi 20-phi 30 mm; the main sound beam of the probe has no obvious double peaks and no deflection, and the probe can be used under the rated frequency and has stable and reliable performance;
in the step 2), the center of the transverse hole is parallel to the axis of the cylinder, the parallelism does not exceed +/-0.03 mm, the limit deviation of the diameter and the depth of the hole is +/-0.05 mm, and the surface roughness Ra of the hole is less than or equal to 3.2 mu m;
in step 4), the calibration is performed by adopting a test block adjustment method: the longitudinal straight wave probe collects transverse hole defect echoes from the reference test block from shallow to deep one by one, and a DAC curve is made to serve as the sensitivity of the ultrasonic detection standard, and the amplitude of the transverse hole defect at 40 percent is not lower than 20 percent of the screen height.
The invention has the following beneficial effects:
the invention relates to an ultrasonic flaw detection process for effectively identifying the central defects of continuous casting billets of carbon steel, low alloy steel and martensitic stainless steel with the diameter of less than phi 800mm, and ensures accurate ultrasonic flaw detection. In the detection process: and three transverse hole defects 2 are uniformly distributed on the cylindrical end surface of the reference test block at an angle of 120 degrees in the circumferential direction by taking the axis of the cylinder as the center, and the reference test block is used for determining the ultrasonic detection sensitivity. The outer surface of the continuous casting billet is subjected to ultrasonic detection in two mutually perpendicular directions by the sensitivity, and the quality grades of the continuous casting billet are divided into 1, 2, 3 and 4 according to the ultrasonic detection result, so that the effectiveness and the accuracy of the ultrasonic detection result are ensured. In the ultrasonic flaw detection of the continuous casting billet, the process is adopted to quickly judge the defect echo, so that the detection efficiency and the accuracy of the detection result are improved.
Drawings
FIG. 1 is a schematic diagram of the position of a transverse hole on the end face of a reference block in the detection process of the present invention.
FIG. 2 is a schematic cross-sectional view of a cross-section of a reference block end face 1 of the detection process of the present invention.
Detailed Description
Example 1: as shown in fig. 1 and 2, in the continuous casting billet ultrasonic detection process, a reference test block and an ultrasonic detection series longitudinal straight probe are utilized, so that a main sound beam of the probe is aligned to transverse hole defects of different depths of the reference test block, and a DAC curve is manufactured to determine the ultrasonic detection sensitivity of the continuous casting billet; firstly, checking the ultrasonic detectability of the continuous casting billet, detecting under the calibration sensitivity, and if the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability; the ultrasonic detection scanning surface of the continuous casting billet is an outer circumferential surface, the outer circumferential surface of the continuous casting billet is subjected to ultrasonic detection in two mutually perpendicular directions, and the ultrasonic detection result of the continuous casting billet is divided into four quality levels of 1, 2, 3 and 4 according to the detection result.
The specific detection process comprises the following steps:
step 1), determining that the instrument used in the process is an A-type pulse reflection ultrasonic flaw detector model: EPOCH 1000, which uses a series of longitudinal wave straight probes with nominal frequency of 0.4 MHz-2 MHz. In the full scale range, the horizontal linearity error of the ultrasonic detector is not more than 1%, the vertical linearity error is not more than 5%, and the far field resolution of the straight probe is not less than 20dB; when the combined sensitivity of the ultrasonic detector and the probe reaches the detection sensitivity of the maximum sound path of the detected continuous casting billet, at least 10dB effective sensitivity allowance is reserved;
step 2), designing and manufacturing a reference test block: the thickness of the obtained cylindrical blank with the diameter of 400mm is 60mm, as shown in figure 2. On the cylindrical end face of the reference block, three transverse hole defects 2 were uniformly distributed at 120 ° in the circumferential direction around the cylindrical axis, the three hole center lines were all parallel to the cylindrical axis, and the corresponding positions were 40% D (160 mm), 25% D (100 mm), 5%D (20 mm) (D is the diameter of the cylinder) from the cylindrical surface. The defect length of the transverse holes is 40mm, and the diameter of the transverse holes is phi 4mm.
The center of the transverse hole is parallel to the axis of the cylinder, the parallelism is not more than +/-0.03 mm, the limit deviation of the diameter and the depth of the hole is +/-0.05 mm, and the surface roughness Ra of the hole is less than or equal to 3.2 mu m.
And 3) adopting chemical paste as a coupling agent for detection. The adopted coupling agent has good sound permeability and wettability, and does not damage the surface of a workpiece; such as a chemical paste or water, etc.
Step 4), calibrating the ultrasonic probe, and determining the ultrasonic detection sensitivity: using a series of longitudinal straight probes to circumferentially probe, the main beam of the probe is aligned to the cylindrical surface of the reference block subcutaneously 5%D, 25% D, 40% of the cross-hole defect calibration at D (D is the diameter of the cylinder). The calibration adopts a test block adjusting method: the longitudinal wave straight probe collects transverse hole defect echoes from shallow to deep from a reference test block one by one, a DAC curve is manufactured to be used as the sensitivity of an ultrasonic detection reference, and the wave amplitude at the position of 160 mm/phi 4mm is not lower than 20% of the screen height.
Step 5), ultrasonic flaw detection:
and 5.1) carrying out continuous casting blank ultrasonic detection in a continuous casting blank state, cleaning the detected surface of the continuous casting blank before detection, wherein the detected surface of the continuous casting blank has no loose oxide skin, paint or dirt and foreign matters influencing probe movement or evaluation. If the surfaces of the continuous casting billets have corrugated convex-concave parts, two detection belts with the width of 100mm are ground at the positions of the corrugated convex-concave parts at 90 degrees.
And 5.2) firstly, checking the ultrasonic detectability of the continuous casting billet, and under the sensitivity determined after calibration, when the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, determining that the continuous casting billet has sufficient ultrasonic detectability. The ultrasonic detection scanning surface of the continuous casting slab is an outer circular surface, and the ultrasonic detection is carried out on the outer surface of the continuous casting slab in two mutually perpendicular directions as far as possible; the scanning speed of the probe is not more than 150mm/s, certain overlap is required between two adjacent scans, and the overlap width is not less than 15% of the scanning width. And adjusting the front edge position of the first bottom wave of the ultrasonic detection within 80% of the full scale of the scanning line.
The length measurement of the defects of the continuous casting billet is carried out by adopting an absolute sensitivity length measurement method: after the probe is moved to find out the maximum reflection wave height of the defect, the attenuator is adjusted, the probe is moved along the defect direction when the defect wave height is reduced to the reference wave height, and when the defect wave height disappears, the distance between the central lines of the probe is the indication length of the defect.
And 5.3) determining that the ultrasonic flaw detection results of the continuous casting billets are divided into four quality grades of 1, 2, 3 and 4.
Quality grade 1: the amplitude of the defect is more than or equal to DAC-3dB, and F/B is not more than-6 dB;
quality grade 2: the amplitude of the defect is more than or equal to DAC, F/B is more than-6 dB and less than +6dB, and the range of the defect center is less than 100mm;
quality grade 3: the amplitude of the defect wave is more than or equal to DAC +3dB, the F/B is more than-6 dB, the range of the center of the defect is more than 100mm, or only the disordered defect wave is generated without bottom echo;
quality grade 4: those exceeding grade 3.
Claims (5)
1. An ultrasonic detection process for a continuous casting billet is characterized in that: making a DAC curve to determine the ultrasonic detection sensitivity of the continuous casting billet by using a reference test block, an ultrasonic detector and a series of longitudinal straight probes, and aligning a main sound beam of the probes with the defects of transverse holes with different depths of the reference test block; firstly, checking the ultrasonic detectability of the continuous casting billet, detecting under the calibration sensitivity, and if the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability; the continuous casting billet ultrasonic detection scanning surface is an outer circumferential surface, ultrasonic detection is carried out on the outer circumferential surface of the continuous casting billet in two mutually perpendicular directions, and the continuous casting billet ultrasonic detection result is divided into four quality levels of 1, 2, 3 and 4 according to the detection result.
2. The ultrasonic testing process for the continuous casting billet as claimed in claim 1, wherein the ultrasonic testing process comprises the following steps: the specific detection process comprises the following steps:
step 1), determining that an instrument used in the process is an A-type pulse reflection ultrasonic detector, wherein the frequency range of the A-type pulse reflection ultrasonic detector is at least 0.4 MHz-5.0 MHz, the horizontal linear error of the ultrasonic detector is not more than 1% and the vertical linear error is not more than 5% in a full scale range, and the far-field resolution of a straight probe is not less than 20dB; when the combined sensitivity of the ultrasonic detector and the probe reaches the detection sensitivity of the maximum sound path of the detected continuous casting billet, at least 10dB effective sensitivity allowance is reserved;
step 2), designing and manufacturing a reference test block, wherein the reference test block is obtained from a detected continuous casting billet, and the material, curvature, surface roughness and heat treatment conditions of the reference test block are the same as those of the detected continuous casting billet; the reference test block is a cylinder, the height of the cylinder is 60mm, three transverse hole defects are uniformly distributed on the end face of the cylinder of the reference test block at 120 degrees along the circumferential direction by taking the axis of the cylinder as the center, the central lines of the three transverse holes are parallel to the axis of the cylinder, the corresponding positions are 5%, 25% and 40% of the diameter D of the cylinder under the outer circular surface of the cylinder, the length of the transverse hole is 40mm, and the diameter phi f of the transverse hole is 1% of the diameter D of the cylinder;
step 3), determining a coupling agent used for detection: the adopted coupling agent has good sound transmission and wettability, and does not damage the surface of a workpiece;
step 4), calibrating the ultrasonic probe and determining the ultrasonic detection sensitivity: circumferential detection is carried out by using a series of longitudinal wave straight probes, so that main sound beams of the probes are aligned to the transverse hole defects at 5%, 25% and 40% of the diameter D of the cylinder below the cylindrical outer circular surface of the reference test block for calibration;
step 5), carrying out an ultrasonic detection process:
step 5.1), carrying out continuous casting blank ultrasonic detection in a continuous casting blank state, cleaning the detected surface of the continuous casting blank before detection, wherein the detected surface of the continuous casting blank has no loose oxide skin, paint and dirt and foreign matters influencing probe movement or evaluation, and if the surface of the continuous casting blank has corrugated convex-concave parts, two detection belts with the width of 100mm are ground at intervals of 90 degrees at the corrugated convex-concave parts;
step 5.2), firstly, checking the ultrasonic detectability of the continuous casting billet, and under the sensitivity determined after calibration, when the signal-to-noise ratio of the center of the continuous casting billet is greater than or equal to 8dB, considering that the continuous casting billet has sufficient ultrasonic detectability, wherein the ultrasonic detection scanning surface of the continuous casting billet is an outer circular surface, and performing ultrasonic detection on the outer surface of the continuous casting billet in two mutually perpendicular directions; the scanning speed of the probe is not more than 150mm/s, the adjacent two scanning processes are overlapped, the overlapping width is not less than 15% of the scanning width, and the front edge position of the first bottom wave of the ultrasonic detection is adjusted within 80% of the full scale of the horizontal scanning line; the length measurement of the continuous casting slab defects is carried out by adopting a disappearance method: after the probe is moved to find out the maximum reflection wave height of the defect, the attenuator is adjusted, when the defect wave height is reduced to the reference wave height, the probe is moved along the defect direction, and when the defect wave height disappears, the distance between the central lines of the probe is the indication length of the defect;
step 5.3), determining that the ultrasonic flaw detection results of the continuous casting billets are divided into four quality grades of 1, 2, 3 and 4, wherein the quality grade is 1: the amplitude of the defect is more than or equal to DAC-3dB, and F/B is not more than-6 dB; quality grade 2: the amplitude of the defect is more than or equal to DAC, F/B is more than-6 dB and less than +6dB, and the central range of the defect is less than 100mm; quality grade 3: the amplitude of the defect wave is more than or equal to DAC +3dB, F/B is more than-6 dB, the central range of the defect is more than 100mm, or only disordered defect waves exist without bottom echo; quality grade 4: those exceeding grade 3.
3. The ultrasonic detection process for the continuous casting billet according to claim 2, characterized in that: in the step 1), a longitudinal wave straight probe with nominal frequency of 0.4 MHz-2 MHz is adopted as a probe of the ultrasonic detector, and the frequency error is +/-10%; selecting the size of the probe wafer within the range of phi 20-phi 30 mm; the main sound beam of the probe has no obvious double peak and no deflection, and both the main sound beam and the deflection are used under rated frequency.
4. The ultrasonic detection process of the continuous casting billet according to claim 2, characterized in that: in the step 2), the center of the transverse hole is parallel to the axis of the cylinder, the parallelism is not more than +/-0.03 mm, the limit deviation of the diameter and the depth of the hole is +/-0.05 mm, and the surface roughness Ra of the hole is not more than 3.2 mu m.
5. The ultrasonic detection process of the continuous casting billet according to claim 2, characterized in that: in step 4), the calibration is performed by adopting a test block adjustment method: the longitudinal straight wave probe collects transverse hole defect echoes from the reference test block from shallow to deep one by one, and a DAC curve is made to serve as the sensitivity of the ultrasonic detection standard, and the amplitude of the transverse hole defect at 40 percent is not lower than 20 percent of the screen height.
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| CN117129575A (en) * | 2023-10-27 | 2023-11-28 | 汕头市超声检测科技有限公司 | Sensitivity calculation method based on serial matrix scanning |
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| CN117129575A (en) * | 2023-10-27 | 2023-11-28 | 汕头市超声检测科技有限公司 | Sensitivity calculation method based on serial matrix scanning |
| CN117129575B (en) * | 2023-10-27 | 2023-12-29 | 汕头市超声检测科技有限公司 | Sensitivity calculation method based on serial matrix scanning |
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