CN115479962A - Method for rapidly and accurately calculating residual stress inside and on inner surface of welding joint - Google Patents
Method for rapidly and accurately calculating residual stress inside and on inner surface of welding joint Download PDFInfo
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Abstract
The invention discloses a method for rapidly and accurately calculating residual stress inside and on an inner surface of a welded joint, which is characterized by using a residual stress joint test method to finish the test of the whole residual stress of the welded joint, establishing an actual distribution model of the residual stress of the welded joint along the thickness direction, and determining the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface. During field test, according to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress of the outer surface of the welding joint of the in-service equipment is quantitatively tested by an X-ray diffraction method, and the residual stress of the inner part and the inner surface of the welding joint is rapidly and accurately calculated.
Description
Technical Field
The invention relates to the technical field of residual stress measurement, in particular to a method for rapidly and accurately calculating residual stress inside and on the inner surface of a welding joint.
Background
In the development process of modern industry, welding process has become an indispensable part of the development process, and many important industrial equipment devices adopt welding structures, such as in-service pipelines connected by welding, large storage tanks and pressure vessels, and the like. It is worth noting that the welded joint is the weakest link of the device in use because the welded joint is easy to have defects of cracks, inclusions, holes and the like due to uneven structure and composition and has larger welding residual stress. Ensuring safe use of the weld joint becomes an urgent problem to be solved.
Disclosure of Invention
Aiming at the defects and shortcomings in the prior art, the test and research on the residual stress of the welding joint discover that: the residual stress of the outer surface of the welding joint has a quantitative relation with the residual stress of the inner surface and the inner surface, but the specific proportional relation is related to factors such as welding process, thickness, groove form and the like. And for the field test of the residual stress of the welding joint of the in-service equipment, the residual stress inside and inside the welding joint can be quickly and accurately calculated by establishing an actual distribution model of the residual stress of the welding joint along the thickness direction under the condition of not influencing the normal use of the equipment according to the external surface residual stress tested by a nondestructive testing method, so that the quantification of the whole residual stress of the welding joint is realized, the safe use of the equipment is favorably ensured, and the technical support is provided for more accurate safety evaluation of the equipment.
The invention provides a method for rapidly and accurately calculating residual stress inside and on the inner surface of a welding joint. The testing process specifically comprises the steps of firstly testing the residual stress of the inner surface and the outer surface of the welding joint by adopting an X-ray diffraction method, then testing the residual stress of the inner part of the welding joint along the thickness direction by adopting a contour method, completing the testing calculation of the whole residual stress of the welding joint, establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and determining the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner part and the residual stress of the outer surface.
During field test, the residual stress of the outer surface of the welding joint of the in-service equipment can be quantitatively tested by an X-ray diffraction method according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition of not influencing the normal use of the in-service equipment, so that the residual stress of the inner part and the inner surface of the welding joint can be rapidly and accurately calculated.
According to the invention, the safety evaluation work of the welding joint of the in-service equipment can be conveniently, efficiently and quickly carried out by quickly and accurately calculating the residual stress inside and on the inner surface of the welding joint.
The invention completes the test of the whole residual stress of the welding joint, establishes an actual distribution model of the residual stress of the welding joint along the thickness direction, and determines the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface. During field test, according to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress of the outer surface of the welding joint of the in-service equipment is quantitatively tested by an X-ray diffraction method, and the residual stress of the inner part and the inner surface of the welding joint is rapidly and accurately calculated.
The method for rapidly and accurately calculating the residual stress inside and on the inner surface of the welding joint, which is established by the invention, can rapidly and accurately calculate the whole residual stress of the welding joint of the in-service equipment by a nondestructive testing method under the condition of not influencing the normal use of the in-service equipment in the field testing process. The method can achieve accurate distribution results of the integral residual stress of the welding joint under the conditions of no damage, convenience and less equipment investment, and has important significance for accurately evaluating the performance of the welding joint.
In order to achieve the purpose, the invention adopts the following technical scheme:
a method for rapidly and accurately calculating residual stress inside and on the inner surface of a welding joint is characterized by comprising the following steps: firstly, testing residual stress of the inner surface and the outer surface of a welding joint by adopting an X-ray diffraction method, then testing residual stress inside the welding joint along the thickness direction by adopting a contour method, completing test calculation of the whole residual stress of the welding joint, and establishing an actual distribution model of the residual stress of the welding joint along the thickness direction so as to determine the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface;
during field test, according to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress of the outer surface of the welding joint of the in-service equipment is quantitatively tested by an X-ray diffraction method, and the residual stress of the inner part and the inner surface of the welding joint is calculated.
Further, the method for nondestructively and quantitatively testing the residual stress of the inner surface and the outer surface of the welding joint by using an X-ray diffraction method specifically comprises the following steps:
when the X-ray diffraction method is adopted to test the residual stress on the surface of the test piece, the test position is pretreated firstly: firstly, polishing the surface by adopting a mechanical polishing mode, then carrying out electrolytic polishing after mechanical polishing, and using an electrolytic polishing instrument to eliminate the sample surface layer distortion tissue caused by mechanical processing;
after the pre-test treatment work and the equipment debugging work are finished, testing the residual stress to be tested in different directions of the marked test points by using an X-ray stress analyzer and quantitatively correcting the test result of the X-ray stress analyzer.
Further, the method for testing the residual stress in the welding joint by the contour method specifically comprises the following steps:
firstly, symmetrically cutting a test piece along a surface to be measured by using a slow wire cutting technology in an electric spark cutting process; then using a three-coordinate measuring instrument to collect the profile displacement data of the cutting surface; carrying out averaging processing, abnormal point screening and contour curve fitting processing on the collected data;
after the contour data are processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed contour data are set in the geometric model as a user-defined displacement boundary condition, and physical property parameters of the material, namely Poisson's ratio and elastic modulus, are determined; and (4) performing stress reconstruction calculation through finite element software to obtain the distribution of the residual stress inside the welding joint perpendicular to the cutting surface.
Further, establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, specifically comprising the following processes:
correcting the near-surface internal residual stress data tested by the profile method through the surface residual stress data tested by the X-ray diffraction method; and after the correction is finished, performing data fitting through a function curve, further establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and determining the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface.
Further, based on the established actual distribution model of the residual stress of the welding joint along the thickness direction; in the actual use process, an X-ray diffraction method is adopted to carry out quantitative test on the residual stress of the outer surface of the welding joint of the in-service equipment, the test result is quantitatively corrected, and then the residual stress of the inner part and the inner surface of the welding joint is rapidly and accurately calculated according to the established actual distribution model of the residual stress of the welding joint along the thickness direction.
Compared with the prior art, the method and the preferred scheme thereof can realize accurate and quantitative test of the integral residual stress of the welding joint by a combined test method of an X-ray diffraction method and a profile method.
According to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface can be determined. During field test, quantitative test data of the residual stress of the outer surface of the welding joint of the in-service equipment can be obtained through an X-ray diffraction method under the condition that the normal use condition of the in-service equipment is not influenced, and the residual stress of the inner part and the inner surface of the welding joint can be rapidly and accurately calculated according to the built distribution model of the residual stress of the welding joint along the thickness direction.
Drawings
FIG. 1 is a schematic flow chart illustrating a method for rapidly and accurately calculating residual stresses inside and on the inner surface of a welded joint according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of the X-ray diffraction method for testing the residual stress on the outer surface of the welded joint in the embodiment of the invention;
FIG. 3 is a schematic diagram of the contour method for testing the residual stress inside the welded joint along the thickness direction according to the embodiment of the invention;
FIG. 4 is a schematic diagram of a finite element software stress reconstruction calculation according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a model of the actual distribution of the residual stress of the welded joint along the thickness direction (the residual stress is perpendicular to the direction of the weld seam) according to the embodiment of the invention;
fig. 6 is a model diagram showing the actual distribution of the residual stress of the welded joint in the thickness direction (the residual stress in the direction parallel to the weld seam) according to the embodiment of the present invention.
Detailed Description
In order to make the features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in detail as follows:
it should be noted that the following detailed description is exemplary and is intended to provide further explanation of the disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.
It is noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of exemplary embodiments according to the present application. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, and it should be understood that when the terms "comprises" and/or "comprising" are used in this specification, they specify the presence of stated features, steps, operations, devices, components, and/or combinations thereof, unless the context clearly indicates otherwise.
The invention aims to realize the rapid and accurate calculation of the residual stress inside and on the inner surface of the welding joint of in-service equipment, complete the quantification of the whole residual stress of the welding joint and provide technical support for more accurate equipment safety evaluation. The embodiment provides a method for rapidly and accurately calculating residual stress of the inner surface and the inner surface of a welding joint, wherein an actual distribution model of the residual stress of the welding joint along the thickness direction is established, and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined. During field test, the quantitative test of the residual stress of the outer surface of the welding joint of the in-service equipment by an X-ray diffraction method can be realized according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition of not influencing the normal use of the in-service equipment, and the residual stress of the inner part and the inner surface of the welding joint can be calculated quickly and accurately.
The scheme specifically adopted comprises the following steps:
(1) Nondestructive quantitative test of residual stress of inner surface and outer surface of welded joint by X-ray diffraction method
When the X-ray diffraction method is adopted to test the residual stress on the surface of the test piece, the test position is pretreated. The surface may first be polished by mechanical grinding, but this results in a machining residual compressive stress of several hundred microns in depth at the surface. Therefore, the electropolishing is required to be performed after the mechanical polishing, and the electropolishing apparatus is used to eliminate the distorted texture of the surface layer of the sample caused by the mechanical processing so as to ensure the accuracy of the subsequent test.
And after the pre-test treatment work and the equipment debugging work are finished, testing the residual stress to be tested in different directions of the marked test points by using an X-ray stress analyzer. Due to the difference of the components and the structures of the weld metal, the heat affected zone and the base material, errors can be generated in the quantitative test result of the X-ray diffraction method. Therefore, the test result of the X-ray stress analyzer needs to be quantitatively corrected to ensure the accuracy of the test result.
(2) Contour method for testing internal residual stress of welded joint
Firstly, a test piece is symmetrically cut along a surface to be measured by using a slow-moving wire cutting technology in an electric spark cutting process. And collecting the profile displacement data of the cutting surface by using a three-coordinate measuring instrument. In order to ensure the accuracy of the profile data, a series of operations such as averaging, abnormal point screening, profile curve fitting and the like need to be performed on the data.
After the contour data are processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed contour data are set in the geometric model as a user-defined displacement boundary condition, and physical property parameters of the material, namely Poisson's ratio and elastic modulus, are determined. And performing stress reconstruction calculation through finite element software to obtain residual stress distribution inside the welding joint perpendicular to the cutting surface.
(3) Establishing an actual distribution model of the residual stress of the welding joint along the thickness direction
Because the X-ray penetration capability is limited, the X-ray diffraction method can only accurately test the residual stress on the surface of the welded joint within the thickness range of dozens of microns, so the profile method is adopted to complete the test of the residual stress inside the welded joint. However, due to the limitation of the cutting technology, the deformation generated on the near-surface area on the cutting surface is large, so that the test result of the near-surface residual stress of the profile method is not accurate. And correcting the near-surface internal residual stress data tested by the profile method through the surface residual stress data tested by the X-ray diffraction method. After the correction is finished, data fitting is carried out through a proper function curve, an actual distribution model of the residual stress of the welding joint along the thickness direction is further established, and the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface are determined.
(4) Calculating the residual stress inside and on the inner surface of the welded joint
When in field test, the X-ray diffraction method is a nondestructive testing method, and the testing equipment is convenient to carry, the testing process is convenient and fast, and the testing result is accurate. Under the condition of not influencing the normal use of in-service equipment, the X-ray diffraction method is adopted to carry out quantitative test on the residual stress of the outer surface of the welding joint of the in-service equipment, and the test result is quantitatively corrected. According to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress inside and on the inner surface of the welding joint can be calculated quickly and accurately.
Taking a V-groove welded joint as an example, the present embodiment further introduces the scheme with reference to the example:
the process flow is schematically shown in FIG. 1. And quantitatively testing the residual stress of the welded joint integrally by using the combined testing method of the X-ray diffraction method and the profile method. The method comprises the following specific steps:
(1) After the test piece surface was pretreated, the weld joint surface residual stress was tested using an X-ray stress analyzer, as shown in fig. 2. And correcting test data deviation caused by uneven structures of weld metal, a heat affected zone and a base metal area, and ensuring the accuracy of a test result.
(2) As shown in fig. 3, a profile method is used to test the residual stress in the welded joint, a slow-running wire cutting machine is used to symmetrically cut the surface to be measured, and a three-coordinate measuring instrument is used to measure the profile displacement data of the cut surface.
(3) As shown in fig. 4, the obtained profile data is subjected to a series of operations such as averaging, abnormal point screening, profile curve fitting and the like, then a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed profile data is set in the geometric model as a user-defined displacement boundary condition, physical property parameters such as poisson's ratio and elastic modulus of the material are determined, and the residual stress distribution in the welding joint perpendicular to the cutting surface is obtained through stress reconstruction calculation.
(4) As shown in fig. 5 and 6, the surface residual stress data measured by the X-ray diffraction method is used to correct the near-surface internal residual stress data measured by the profile method, an appropriate function curve is selected for data fitting, an actual distribution model of the residual stress of the welded joint along the thickness direction is established, and the quantitative relationship between the internal surface residual stress and the external surface residual stress and the quantitative relationship between the internal residual stress and the external surface residual stress are determined.
(5) During field test, the residual stress of the outer surface of the welding joint of the in-service equipment can be quantitatively tested by an X-ray diffraction method according to the established actual distribution model of the residual stress of the welding joint along the thickness direction under the condition of not influencing the normal use of the in-service equipment, so that the residual stress of the inner surface and the inner surface of the welding joint can be rapidly and accurately calculated.
The foregoing is directed to preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. However, any simple modification, equivalent change and modification of the above embodiments according to the technical essence of the present invention will still fall within the protection scope of the technical solution of the present invention.
The present invention is not limited to the above preferred embodiments, and any other method for rapidly and accurately estimating the residual stress inside and on the inner surface of the welded joint can be obtained according to the teaching of the present invention.
Claims (5)
1. A method for rapidly and accurately calculating residual stress inside and on the inner surface of a welding joint is characterized by comprising the following steps: firstly, testing residual stress of the inner surface and the outer surface of a welding joint by adopting an X-ray diffraction method, then testing residual stress inside the welding joint along the thickness direction by adopting a contour method, completing test calculation of the whole residual stress of the welding joint, and establishing an actual distribution model of the residual stress of the welding joint along the thickness direction so as to determine the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface;
during field test, according to the established actual distribution model of the residual stress of the welding joint along the thickness direction, the residual stress of the outer surface of the welding joint of the in-service equipment is quantitatively tested by an X-ray diffraction method, and the residual stress of the inner part and the inner surface of the welding joint is calculated.
2. The method for rapidly and accurately estimating the residual stress inside and on the inner surface of the welding joint according to claim 1, wherein the method comprises the following steps: the method for nondestructively and quantitatively testing the residual stress of the inner surface and the outer surface of the welded joint by using an X-ray diffraction method specifically comprises the following steps:
when the X-ray diffraction method is adopted to test the residual stress on the surface of the test piece, the test position is pretreated firstly: firstly, polishing the surface by adopting a mechanical polishing mode, then carrying out electrolytic polishing after mechanical polishing, and using an electrolytic polishing instrument to eliminate the sample surface layer distortion tissue caused by mechanical processing;
after the pre-test treatment work and the equipment debugging work are finished, testing the residual stress to be tested in different directions of the marked test points by using an X-ray stress analyzer and quantitatively correcting the test result of the X-ray stress analyzer.
3. The method for rapidly and accurately estimating the residual stress inside and on the inner surface of the welding joint according to claim 1, wherein the method comprises the following steps: the method for testing the residual stress in the welding joint by the contour method specifically comprises the following steps:
firstly, symmetrically cutting a test piece along a surface to be measured by using a slow-moving wire cutting technology in an electric spark cutting process; then collecting the profile displacement data of the cutting surface by using a three-coordinate measuring instrument; carrying out averaging processing, abnormal point screening and contour curve fitting on the collected data;
after the contour data are processed, a corresponding geometric model is established in finite element software by using a numerical simulation method, the processed contour data are set in the geometric model as a user-defined displacement boundary condition, and physical property parameters of the material, namely Poisson's ratio and elastic modulus, are determined; and performing stress reconstruction calculation through finite element software to obtain residual stress distribution inside the welding joint perpendicular to the cutting surface.
4. The method for rapidly and accurately estimating the residual stress inside and on the inner surface of the welding joint according to claim 1, wherein the method comprises the following steps: establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and specifically comprising the following processes:
correcting the near-surface internal residual stress data tested by the profile method through the surface residual stress data tested by the X-ray diffraction method; and after the correction is finished, performing data fitting through a function curve, further establishing an actual distribution model of the residual stress of the welding joint along the thickness direction, and determining the quantitative relation between the residual stress of the inner surface and the outer surface and the quantitative relation between the residual stress of the inner surface and the residual stress of the outer surface.
5. The method for rapidly and accurately estimating the residual stress inside and on the inner surface of the welding joint according to claim 1, wherein the method comprises the following steps: based on the established actual distribution model of the residual stress of the welding joint along the thickness direction; in the actual use process, an X-ray diffraction method is adopted to carry out quantitative test on the residual stress of the outer surface of the welding joint of the in-service equipment, the test result is quantitatively corrected, and then the residual stress of the inner part and the inner surface of the welding joint is rapidly and accurately calculated according to the established actual distribution model of the residual stress of the welding joint along the thickness direction.
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