CN117470846A - Evaluation method of micro-porosity in aluminum alloy cast ingot - Google Patents
Evaluation method of micro-porosity in aluminum alloy cast ingot Download PDFInfo
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- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/30—Staining; Impregnating ; Fixation; Dehydration; Multistep processes for preparing samples of tissue, cell or nucleic acid material and the like for analysis
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Abstract
The invention provides an evaluation method of micro-porosity in an aluminum alloy cast ingot. The evaluation method comprises the following steps: step S1, cutting, surface machining and corrosion treatment are sequentially carried out on an aluminum alloy ingot to obtain an aluminum alloy ingot test piece; step S2, coloring the detection surface of the aluminum alloy ingot test piece by using a coloring agent, and then sequentially cleaning and drying the detection surface after the coloring treatment to obtain the treated test piece; step S3, developing the treated test piece by adopting a developing agent to obtain a developed test piece; and S4, placing a scale on the developed test piece, photographing the detection surface of the developed test piece, inputting the photograph into image processing software, distinguishing microscopic loose marks from surrounding matrixes by setting a color threshold value, counting the number density of the microscopic loose marks, and evaluating the microscopic loose marks in the aluminum alloy ingot test piece. The method has the advantages of large analysis area, strong result representativeness, high detection precision and capability of feeding back the result in real time.
Description
Technical Field
The invention relates to the technical field of metallurgical detection, in particular to an evaluation method of microporosity in an aluminum alloy cast ingot.
Background
In aluminum processing production, ingot quality affects the quality of the final product. Defects inherited from ingots are often difficult to completely repair through subsequent processing and heat treatment, so that improving the quality of aluminum alloy ingots is the basis for obtaining high-quality aluminum alloy products, and detection and evaluation of the quality of the ingots are particularly important. At present, the method for evaluating the quality of the aluminum alloy ingot is mainly focused on the aspects of chemical components, hydrogen content, slag content, grain size and the like, and the research on the method for evaluating the microporosity in the ingot is less. With the increasing application of aluminum alloy products, particularly in high-end products such as aviation, aerospace, rail transit and the like, the requirements on the mechanical properties of alloy components are very strict. However, the existence of microscopic porosity breaks the continuity of the matrix, and loose defects are likely to be the origins of fatigue cracks in the service process, so that the components are cracked and fail, and even serious accidents are caused. Therefore, the method has important significance for detecting and controlling the microscopic looseness of the aluminum alloy cast ingot.
At present, a common detection method for microscopic porosity of an aluminum alloy cast ingot comprises a low-power tissue detection method in GB/T3246.2, wherein the method comprises the steps of firstly carrying out alkali etching on the surface of the cast ingot, and then observing low-power tissues and defects on the surface of a test piece by naked eyes or a magnifying glass. The macroscopic detection method is only used for detecting large-size defects in the cast ingot, but with the continuous improvement of the quality requirements of aluminum alloy products, the detection precision of the macroscopic detection method cannot meet the requirements of high-end cast ingots on microscopic looseness. Another common method is metallography, which is to take a metallographic specimen of 10mm×10mm at a specified position of an ingot, polish and polish one of the faces, and observe the microscopic porosity therein under an optical microscope. However, the observation area of metallography is small, and the representativeness of the observation area is not strong; in addition, metallographic method is from sampling, sample preparation, and the cycle that sends again to laboratory analysis is longer, and the result feedback is slow, keeps up with the rhythm of on-the-spot adjustment casting technology.
Disclosure of Invention
The invention mainly aims to provide an evaluation method of microscopic porosity in an aluminum alloy cast ingot, which aims to solve the problems of small analysis area, poor representativeness, low detection precision, long analysis period and the like of the detection and evaluation method of microscopic porosity of the cast ingot in the prior art.
In order to achieve the above object, according to one aspect of the present invention, there is provided a method for evaluating microporosity in an aluminum alloy ingot, the method comprising: step S1, cutting, surface machining and corrosion treatment are sequentially carried out on an aluminum alloy ingot to obtain an aluminum alloy ingot test piece; step S2, coloring the detection surface of the aluminum alloy ingot test piece by using a coloring agent, and then sequentially cleaning and drying the detection surface after the coloring treatment to obtain the treated test piece; step S3, developing the treated test piece by adopting a developing agent to obtain a developed test piece; and S4, placing a scale on the developed test piece, photographing the detection surface of the developed test piece, inputting the photograph into image processing software, distinguishing microscopic loose marks from surrounding matrixes by setting a color threshold value, counting the number density of the microscopic loose marks, and evaluating the microscopic loose marks in the aluminum alloy ingot test piece.
Further, in the step S4, the color threshold r=0 to 255.
Further, the number density of the above-mentioned microporosity is noted as n when 0 pieces/cm 2 N is less than or equal to 10/cm 2 When the grade of the microporosity is evaluated as grade I; when 10 pieces/cm 2 N is less than or equal to 50/cm 2 When the grade of the microporosity is evaluated as grade II; when 50 pieces/cm 2 N is less than or equal to 100/cm 2 When the grade of the microporosity is rated as grade III; when 100 pieces/cm 2 When < n, the grade of microporosity is evaluated as grade IV, and the grade of microporosity from grade I to grade IV indicates that the degree of microporosity in the aluminum alloy ingot test piece is gradually increased.
Further, the coloring process includes: spraying a coloring agent on the detection surface of the aluminum alloy ingot test piece for standing treatment to obtain a detection surface after the coloring treatment; the time range of the standing treatment is 10-30 min, and the ratio of the mass of the coloring agent to the area of the detection surface of the aluminum alloy ingot test piece is 200-300: 1g/m 2 。
Further, the developing process includes: spraying an imaging agent on the detection surface of the processed test piece for imaging treatment to obtain an imaged test piece; horizontally standing the developed test piece for 10-30 min, and then observing; the distance between the nozzle for spraying the developer and the detection surface of the treated test piece is 100 mm-300 mm, and the spraying is repeated for 2-3 times.
Further, the mass ratio of the developer to the colorant is 0.7-1.5: 1.
further, the etching process includes: performing infiltration treatment on the detection surface of the test piece obtained after the light is emitted by the light source by adopting alkaline solution to obtain an infiltrated test piece; washing, wiping and drying the infiltrated test piece in sequence to obtain an aluminum alloy ingot test piece; wherein the concentration of the alkaline solution is 60 g/L-120 g/L, and the alkaline solution is sodium hydroxide solution and/or potassium hydroxide solution; the temperature of the corrosion treatment is 20-40 ℃, and the time of the corrosion treatment is 3-15 min.
Further, the test piece obtained by washing is subjected to the wiping by dipping absorbent cotton in an acidic solution, the volume fraction of the acidic solution is 20% -30%, and the acidic solution is selected from any one of nitric acid and sulfuric acid.
Further, the drying process includes: and drying the detection surface of the aluminum alloy ingot test piece by using an air gun or a blower, wherein the air outlet of the air gun or the blower and the detection surface are 30-60 degrees.
Further, the water temperature range of the cleaning treatment is 10-40 ℃, and/or the shape of a water column contacted with the detection surface is fan-shaped, and/or the distance between the water outlet nozzle and the detection surface is 100-300 mm.
By applying the technical scheme of the invention, the invention provides a method for detecting and evaluating the microscopic porosity of the cast ingot, which can be used rapidly and comprehensively and is convenient to use on site. In particular, the coloration and visualization of the present invention is based primarily on the capillary principle. When a microscopic loose opening exists on the detection surface of the ingot test piece, a tiny and tortuous channel below the opening is equivalent to a capillary tube, and capillary action is generated on the colorant at the opening. The colorant has a low surface tension and is sucked into the holes when attached to the openings of the holes; in the cleaning process, the surface tension of water is large, so that the colorant in the hole cannot be cleaned. After spraying the developer, the developer is like a piece of 'Xuan paper' attached above the loose holes, and the colorant in the holes is sucked out; subsequently, the dye of the colorant will bloom and magnify in the developer, thereby magnifying the microporosity, and visually observing the microporosity in the ingot at a macroscopic scale. Thus, after imaging, a magnified trace of the porosity holes can be seen, which is also the main reason that microporosity can be observed at low magnification. Furthermore, the above evaluation method of the present application can not only count the number and distribution of the micro-porosity in a larger area of the test piece, but also preliminarily predict the size of the micro-porosity volume according to the size of the imaging trace. Compared with the prior art, the method has the advantages that the cost of the raw materials and the auxiliary materials is low, special equipment is not needed, the process operation is simple, the analysis area is large, the result is convenient to count, the result representativeness is high, the detection precision is high, and the result can be fed back in real time; the method is suitable for microscopic porosity measurement of various aluminum alloy ingots such as primary/regeneration, deformation/casting and the like; the method is particularly suitable for detecting, counting and evaluating the quantity and distribution of the micro-looseness in the large-size aluminum alloy cast ingot.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the invention. In the drawings:
fig. 1 shows a graph of the detection result of microscopic porosity in an aluminum alloy ingot test piece provided in embodiment 1 of the present application, wherein (a) represents a full view of the detection surface, and (b) represents an enlarged view of a local porosity region in the full view of the detection surface shown in (a);
FIG. 2 is a graph showing the comparative results of microscopic porosity measurements of three different gauges of aluminum alloy ingot test pieces provided in example 2 of the present application;
FIG. 3 is a graph showing the result of microscopic porosity detection in an aluminum alloy ingot test piece according to comparative example 1 of the present application, wherein (a) represents a full view of the detection surface and (b) represents an enlarged view of a partial porosity region in the full view of the detection surface shown in (a);
FIG. 4 is an enlarged view of a partially loosened area in a full view of the detection surface in an aluminum alloy ingot test piece rated as grade I for a grade of microporosity provided in example 3 of the present application;
FIG. 5 is an enlarged view of a partially loosened area in a full view of the detection surface in an aluminum alloy ingot test piece rated grade II for microporosity provided in example 6 of the present application;
FIG. 6 shows an enlarged view of a partially loosened area in a full view of the detection surface in an aluminum alloy ingot test piece rated III for microporosity provided in example 4 of the present application; and
fig. 7 shows an enlarged view of a partially loosened area in a full view of the detection surface in an aluminum alloy ingot test piece rated IV for microporosity provided in example 5 of the present application.
Detailed Description
It should be noted that, in the case of no conflict, the embodiments and features in the embodiments may be combined with each other. The invention will be described in detail below with reference to the drawings in connection with embodiments.
As analyzed in the background of the application, the existence of micro-porosity damages the continuity of the matrix, and the porosity defect is likely to be the origin of fatigue cracking in the service process, so that the cracking failure of the component is caused, and even serious accidents are caused. The method for detecting and evaluating the microscopic porosity of the cast ingot in the prior art has the problems of small analysis area, poor representativeness, low detection precision, long analysis period and the like, and in order to solve the problems, the application provides a method for evaluating the microscopic porosity in the aluminum alloy cast ingot.
The micro-porosity in the aluminum alloy ingot is caused by the combined action of various factors such as volume shrinkage, dissolved gas precipitation, inter-dendrite feeding inhibition and the like in the solidification process. Because of the density difference of the liquid phase and the solid phase of the aluminum alloy, volume shrinkage is generated when the liquid phase changes from the solid phase, and if the volume shrinkage of the liquid phase to the solid phase cannot be completely supplemented by the external liquid phase, loose holes are formed in the solidified tissue; in addition, a certain amount of gas (generally hydrogen) is usually dissolved in the aluminum alloy melt, and because the solubility difference of the gas in the liquid phase and the solid phase is large, the gas is continuously enriched into the liquid phase in the solidification process, and when the concentration of the gas in the liquid phase exceeds the dissolving capacity of the gas, the gas is separated out to form gas holes; two types of voids are commonly associated with aluminum alloy ingots. In addition, the cooling speed of each part of the ingot is greatly different, so that the sizes and the distribution of the loose holes in each part of the ingot are also different. Therefore, the invention provides a method for detecting the microporosity of an aluminum alloy cast ingot in a larger area; the microscopic loose morphology in the aluminum alloy cast ingot is irregular, is generally in a three-dimensional dendritic shape, and has a certain volume space below the surface of the cast ingot.
In an exemplary embodiment of the present application, there is provided a method for evaluating microporosity in an aluminum alloy ingot, the method comprising: step S1, cutting, surface machining and corrosion treatment are sequentially carried out on an aluminum alloy ingot to obtain an aluminum alloy ingot test piece; step S2, coloring the detection surface of the aluminum alloy ingot test piece by using a coloring agent, and then sequentially cleaning and drying the detection surface after the coloring treatment to obtain the treated test piece; step S3, developing the treated test piece by adopting a developing agent to obtain a developed test piece; and S4, placing a scale on the developed test piece, photographing the detection surface of the developed test piece, inputting the photograph into image processing software, distinguishing microscopic loose marks from surrounding matrixes by setting a color threshold value, counting the number density of the microscopic loose marks, and evaluating the microscopic loose marks in the aluminum alloy ingot test piece.
The invention provides a method for detecting and evaluating the microscopic porosity of an ingot, which can be used rapidly and comprehensively and is convenient to use on site. In particular, the coloration and visualization of the present invention is based primarily on the capillary principle. When a microscopic loose opening exists on the detection surface of the ingot test piece, a tiny and tortuous channel below the opening is equivalent to a capillary tube, and capillary action is generated on the colorant at the opening. The colorant has a low surface tension and is sucked into the holes when attached to the openings of the holes; in the cleaning process, the surface tension of water is large, so that the colorant in the hole cannot be cleaned. After spraying the developer, the developer is like a piece of 'Xuan paper' attached above the loose holes, and the colorant in the holes is sucked out; subsequently, the dye of the colorant will bloom and magnify in the developer, thereby magnifying the microporosity, and visually observing the microporosity in the ingot at a macroscopic scale. Thus, after imaging, a magnified trace of the porosity holes can be seen, which is also the main reason that microporosity can be observed at low magnification. Furthermore, the above evaluation method of the present application can not only count the number and distribution of the micro-porosity in a larger area of the test piece, but also preliminarily predict the size of the micro-porosity volume according to the size of the imaging trace. Compared with the prior art, the method has the advantages that the cost of the raw materials and the auxiliary materials is low, special equipment is not needed, the process operation is simple, the analysis area is large, the result is convenient to count, the result representativeness is high, the detection precision is high, and the result can be fed back in real time; the method is suitable for microscopic porosity measurement of various aluminum alloy ingots such as primary/regeneration, deformation/casting and the like; the method is particularly suitable for detecting, counting and evaluating the quantity and distribution of the micro-looseness in the large-size aluminum alloy cast ingot.
In addition, the purpose of the surface treatment of the cutting, machining and corrosion treatments sequentially performed on the aluminum alloy ingot is to obtain a qualified test surface. Specifically, the detection surface of the aluminum alloy cast ingot is processed to be smooth and visible light by cutting and processing, and the effect of chemical corrosion is to expose the opening of the hole on the detection surface of the aluminum alloy cast ingot, so that the phenomenon that the colorant cannot enter the hole due to the blocking of the hole opening by fine aluminum scraps/aluminum skin during turning/milling processing is avoided.
In an embodiment of the present application, in the step S4, the color threshold r=0 to 255.
The color threshold value can make microscopic looseness on a detection surface in an aluminum alloy ingot test piece visible to naked eyes and clearly imaged after coloring and imaging, so that the detection precision of the evaluation method on microscopic looseness is improved.
In one embodiment of the present application, the microporosity is noted as n when 0/cm 2 N is less than or equal to 10/cm 2 When the grade of the micro-porosity is evaluated as grade I, the micro-porosity degree in the aluminum alloy ingot test piece is lower; when 10 pieces/cm 2 N is less than or equal to 50/cm 2 When the grade of the microporosity is evaluated as grade II, the grade represents that the microporosity degree in the aluminum alloy ingot test piece is general; when 50 pieces/cm 2 N is less than or equal to 100/cm 2 When the microporosity rating was rated IIIThe grade represents that the degree of micro-porosity in the aluminum alloy ingot test piece is serious; when 100 pieces/cm 2 When < n, the microporosity grade is evaluated as grade IV, which represents that the microporosity degree in the aluminum alloy ingot test piece is serious.
The micro-porosity in the aluminum alloy ingot test piece is counted by using the number density, so that the volume ratio of the micro-porosity in the aluminum alloy ingot test piece is obtained, and the micro-porosity in the aluminum alloy ingot test piece is qualitatively and quantitatively evaluated.
In one embodiment of the present application, the coloring process includes: spraying a coloring agent on the detection surface of the aluminum alloy ingot test piece for standing treatment to obtain a detection surface after the coloring treatment; the time range of the standing treatment is 10-30 min, and the ratio of the mass of the coloring agent to the area of the detection surface of the aluminum alloy ingot test piece is 200-300: 1g/m 2 。
The above-mentioned standing treatment and the time are preferable to help the colorant to be sufficiently sucked into the microscopically porous holes, the mass of the colorant is too small to be useful for displaying the amount of the microscopically porous holes, too much mass of the colorant causes waste, and the ratio of the mass of the colorant to the area of the detection surface of the aluminum alloy ingot test piece is preferable to be within the above range to help to fill the microscopically porous holes in the aluminum alloy ingot test piece with the colorant as much as possible without causing waste.
In addition, the colored coloring agent is sprayed on the detection surface of the test piece by using the pressure container, so that the coloring agent can be uniformly covered on the detection surface as much as possible; if the time exceeds 2 hours, the coloring treatment is required to be carried out again, wherein the coloring agent is preferably a DPT-5 type coloring agent.
In one embodiment of the present application, the developing process includes: spraying an imaging agent on the detection surface of the processed test piece for imaging treatment to obtain an imaged test piece; horizontally standing the developed test piece for 10-30 min, and then observing; the distance between the nozzle for spraying the developer and the detection surface of the treated test piece is 100 mm-300 mm, and the spraying is repeated for 2-3 times.
The above horizontal rest and its time are preferred to help promote the imaging agent to sufficiently aspirate out the colorant in the micro-porous pores, thereby magnifying the micro-porous image. The developer is preferably sprayed on the detection surface of the test piece by using a pressure container, and the distance between the nozzle for spraying the developer and the detection surface of the test piece after treatment is preferable, so that the impact force of the developer on the detection surface of the test piece after treatment can be buffered, and the developer can be uniformly covered on the detection surface as much as possible. Specifically, spraying the imaging agent from one end of the treated test piece to the other end of the treated test piece for 2-3 times, and then standing for 10-30 min to inspect the imaging trace of the loose holes on the surface of the test piece.
In one embodiment of the present application, the mass ratio of the developer to the colorant is 0.7-1.5: 1.
the mass ratio of the developer to the colorant is favorable for improving the synergistic effect of the developer and the colorant, so that the colorant in the micro-porosity holes is more fully developed, and the detection precision of the micro-porosity is further improved.
In one embodiment of the present application, the etching process includes: performing infiltration treatment on the detection surface of the test piece obtained after the light is emitted by the light source by adopting alkaline solution to obtain an infiltrated test piece; washing, wiping and drying the infiltrated test piece in sequence to obtain an aluminum alloy ingot test piece; wherein the concentration of the alkaline solution is 60 g/L-120 g/L, and/or the alkaline solution is sodium hydroxide solution and/or potassium hydroxide solution; and/or the temperature of the corrosion treatment is 20-40 ℃, and/or the time of the corrosion treatment is 3-15 min.
The type and concentration of the above alkaline solution, and the temperature and time of the etching treatment are preferably determined after extensive experimentation. The preferred above specific etching process helps to promote adequate exposure of the openings of the holes on the sensing face of the aluminum alloy ingot.
In some preferred embodiments of the present application, the test piece obtained by washing is wiped by dipping absorbent cotton in an acidic solution, the volume fraction of the acidic solution is 20% -30%, and/or the acidic solution is selected from any one of nitric acid or sulfuric acid, so that the neutralization effect of the acidic solution in absorbent cotton on the alkaline solution on the surface of the test piece is improved.
The drying treatment aims to dry and remove water remained on the detection surface of the aluminum alloy ingot test piece, and preferably the drying treatment comprises the following steps: and drying the detection surface of the aluminum alloy ingot test piece by using an air gun or a blower, wherein an air outlet of the air gun or the blower forms 30-60 degrees with the detection surface, so that water on the detection surface flows away from one side of the test piece to the other side, and the efficiency and the effect of the drying treatment are improved.
In an embodiment of the present application, the water temperature range of the cleaning process is 10 ℃ to 40 ℃, and/or the water column contacting with the detection surface is fan-shaped, and/or the distance between the water outlet nozzle and the detection surface is 100mm to 300mm.
The colorant on the detection surface is washed by flowing water, and the detection surface can be gently wiped by the palm wearing the rubber glove while washing until the color of the colorant is not observed on the detection surface. The preferred conditions of the above washing treatment help to buffer the impact of the water on the detection surface, thereby reducing the interference of the washing treatment with the colorant in the microscopic loose holes.
The advantageous effects of the present application will be further described below with reference to examples.
Example 1
The cast ingot selected in the embodiment is 7A65 alloy, the specification is phi 520mm multiplied by 1620mm, and the state is a soaking state. The method of the invention is used for detecting the microscopic porosity of the selected cast ingot, and comprises the following specific steps:
(1) Sampling: a test piece of an ingot having a length of 260 mm. Times.40 mm. Times.20 mm in thickness was cut out from the ingot by a sawing machine, and a region having a length of 260 mm. Times.40 mm in width was selected as a detection surface.
(2) Surface pretreatment: the detection surface of the test piece is processed to be flat and visible light by a lathe, and then the detection surface is corroded, and the specific steps comprise:
a. placing the ingot with the detection surface facing upwards in sodium hydroxide solution horizontally to perform surface corrosion, wherein the concentration of corrosive liquid is 80g/L, the temperature is 30 ℃, and the corrosion time is 5min;
b. rapidly transferring the corroded ingot test piece into flowing clean water, and flushing a detection surface;
c. wiping the detection surface of the test piece by dipping absorbent cotton in 25% sulfuric acid solution, and neutralizing the alkaline solution remained on the detection surface;
d. and (3) washing the detection surface of the ingot test piece with clear water, and blow-drying the detection surface by using an air gun.
(3) Coloring: the test piece detection surface was subjected to a coloring treatment using 2.5g of DTP-5 type coloring agent, and the specific steps of the coloring treatment include: firstly, the colored colorant is sprayed on the detection surface of the test piece by using a pressure container, so that the colorant is uniformly covered on the detection surface as much as possible, and then the test piece is kept stand for 15min.
(4) Cleaning: cleaning the colorant on the detection surface of the ingot test piece by using flowing clear water, wherein the water temperature is about 20 ℃, the distance between the spray head and the detection surface is 200mm, and cleaning the detection surface by using the palm wearing the rubber glove while washing until the color of the colorant cannot be observed on the detection surface;
(5) And (3) drying: and drying the detection surface of the test piece by adopting an air gun, wherein an air outlet of the air gun is 45 degrees with the detection surface, so that water on the detection surface flows away from one side of the test piece to the other side of the test piece.
(6) Developing: the detection surface of the ingot test piece is subjected to imaging treatment by using 2.5g of DTP-5 type imaging agent, and the specific steps comprise: firstly, spraying an imaging agent on a detection surface of a test piece by using a pressure container, and ensuring that the imaging agent is uniformly covered on the detection surface as much as possible; the distance between the nozzle and the detection surface is about 200mm, spraying is carried out for 2 times from one end of the test piece to the other end of the test piece, then standing is carried out for 15min, and the imaging trace on the detection surface of the test piece is observed.
(7) And (3) statistics: placing the scale on an ingot test piece, and photographing the whole and partial areas of the detection surface; inputting the photos into image processing software, and counting loose quantity distribution in unit area.
Example 1 test pieces of ingot were subjected to microporosity as shown in FIG. 1, and the number density of microporosity in the test pieces was 17 pieces/cm 2 Grade ii of microporosity.
Example 2
In this embodiment, three ingots with different specifications are selected, and are named as 1#, 2# and 3#, the three ingots are 7050 alloy, and the specifications of 1#, 2# and 3# are as follows: phi 450mm multiplied by 1480mm, phi 450mm multiplied by 1480mm and phi 400mm multiplied by 2000mm, and the state is a soaking state. The method of the invention is used for carrying out microscopic loose comparative detection analysis on three cast ingots, and comprises the following specific steps:
(1) Sampling: test pieces 260mm long by 40mm wide by 20mm thick were cut out of the three ingots by a sawing machine, respectively, and a region 260mm×40mm was selected as a detection surface.
(2) Surface pretreatment: the detection surfaces of the three test pieces are processed to be smooth and visible light by utilizing a lathe, and then the detection surfaces of the three cast ingots are subjected to corrosion treatment, and the specific steps comprise:
a. placing three ingot test pieces in sodium hydroxide solution with the detection surface facing upwards for surface corrosion, wherein the concentration of corrosive liquid is 75g/L, the temperature is 32 ℃, and the corrosion time is 4min;
b. rapidly transferring the corroded ingot test piece into flowing clean water, and flushing the detection surfaces of the three test pieces simultaneously;
c. wiping detection surfaces of the three test pieces respectively by dipping absorbent cotton in 28% sulfuric acid solution;
d. and cleaning the detection surface of the test piece with clear water, and blow-drying the detection surface with an air gun.
(3) Coloring: the detection surface of the three ingot casting test pieces is colored by 3g of DTP-5 coloring agent, and the specific steps are as follows: the colorant was sprayed onto the test surface of the test piece using a pressure vessel to ensure as much as possible even coverage of the colorant on the test surface, followed by 13 minutes of standing.
(4) Cleaning: the detection surface of the three test pieces is washed by flowing clean water, the water temperature is about 15 ℃, the water pipe outlet is blocked by fingers, so that water flow forms a fan-shaped water column, the distance between the spray head and the test pieces is about 200mm, and the color of the colorant cannot be observed on the detection surface.
(5) And (3) drying: the detection surfaces of the three test pieces are dried by using an air gun, and the air outlet of the air gun forms an angle of about 45 degrees with the surfaces of the test pieces, so that water on the detection surfaces flows away from one side to the other side.
(6) Developing: three test pieces were placed horizontally, 3g of DTP-5 type developer was sprayed on the detection surface of the test piece, the distance between the nozzle and the surface of the test piece was kept at about 250mm, the spray was reciprocally applied 2 times from one end to the other end of the surface of the test piece, and then left standing for 10 minutes, and microscopic loose marks on the detection surface of the test piece were observed.
(7) And (3) statistics: the photos of the three test pieces are input into image processing software, and loose quantity distribution in unit area is counted.
The test results of the three ingot casting test pieces in the embodiment 2 are shown in fig. 2, and it can be seen that the loose test results in the three ingot casting test pieces have certain difference, the loose band width in the test piece # 1 is about 30mm, loose development traces are distributed in a dispersed manner, and the size of a single development trace is larger; the number of looseness in the No. 2 test piece is large, the looseness band is wide, the distribution of the imaging traces is dense, and the size of a single imaging trace is slightly smaller than that of the No. 1 test piece; while little apparent evidence of porosity was observed in the 3# test piece. The number density of the microporosity in the test piece of the No. 1 cast ingot is 11 pieces/cm 2 Grade II of micro-loosening grade; the number density of the microporosity in the test piece of the No. 2 ingot casting is 33 pieces/cm 2 The micro-loosening grade is grade II.
Example 3
The difference from example 1 is that the ingot was 7075 alloy, the specification was Φ400mm×1630mm, and the number density of microporosity in the test piece was 5 pieces/cm 2 An enlarged view of the local porosity area in the overall view of the test surface in the test piece of the aluminum alloy ingot is shown in fig. 4.
Example 4
The difference from example 1 is that the ingot was 7085 alloy, the specification was Φ400mm×1620mm, and the number density of microporosity in the test piece was 63 pieces/cm 2 An enlarged view of the partial porosity area in the overall view of the test surface in the test piece of the aluminum alloy ingot is shown in fig. 6.
Example 5
The difference from example 1 is that the ingot was 7050 alloy, the specification was Φ520mm×1320mm, and the final test piece showedThe number density of the micro-porosity is 117 pieces/cm 2 An enlarged view of the partial porosity area in the overall view of the test surface in the test piece of the aluminum alloy ingot is shown in fig. 7.
Example 6
The difference from example 1 is that the mass of the colorant is 3.12g and the number density of microporosity in the final test piece is 17 pieces/cm 2 An enlarged view of the local porosity area in the overall view of the test surface in the test piece of the aluminum alloy ingot is shown in fig. 5.
Example 7
The difference from example 1 is that the mass of the colorant is 1.98g and the number density of microporosity in the final test piece is 16 pieces/cm 2 Grade ii of microporosity.
Example 8
The difference from example 1 is that the mass ratio of imaging agent to the colorant is 1.5:1, the number density of microporosity in the final test piece is 17 pieces/cm 2 Grade ii of microporosity.
Example 9
The difference from example 1 is that the mass ratio of imaging agent to the colorant is 0.6:1, the number density of microporosity in the final test piece is 15 pieces/cm 2 Grade i of microporosity.
Example 10
The difference from example 1 is that the concentration of the sodium hydroxide solution is 120g/L and the number density of microporosity in the final test piece is 17 pieces/cm 2 Grade ii of microporosity.
Example 11
The difference from example 1 is that the concentration of the sodium hydroxide solution is 50g/L and the number density of microporosity in the final test piece is 14 pieces/cm 2 Grade ii of microporosity.
Comparative example 1
Comparative example 1 the same ingot test piece as in example 1 was used, and the surface corrosion treatment was not performed on the test surface in step 2 in comparative example 1.
The specific steps of comparative example 1 include the following:
(1) Sampling: consistent with example 1.
(2) Surface pretreatment: and (3) processing the test piece detection surface into a flat surface and a visible light surface by using a lathe.
(3) Coloring: the test piece detection surface is subjected to coloring treatment by using 2.5g of DTP-5 type coloring agent, and the specific steps comprise: firstly, spraying a colored colorant on a detection surface of a test piece by using a pressure container, and ensuring that the colorant is uniformly covered on the detection surface as much as possible; and then allowed to stand for 15min.
(4) Cleaning: cleaning the colorant on the detection surface of the ingot test piece by using flowing clear water, wherein the water temperature is about 20 ℃, the distance between the spray head and the detection surface is 200mm, and cleaning the detection surface by using the palm wearing the rubber glove while washing until the color of the colorant cannot be observed on the detection surface;
(5) And (3) drying: and drying the detection surface of the test piece by adopting an air gun, wherein an air outlet of the air gun is 45 degrees with the detection surface, so that water on the detection surface flows away from one side of the test piece to the other side of the test piece.
(6) Developing: the detection surface of the ingot test piece is subjected to imaging treatment by using 2.5g of DTP-5 type imaging agent, and the specific steps comprise: firstly, spraying an imaging agent on a detection surface of a test piece by using a pressure container, and ensuring that the imaging agent is uniformly covered on the detection surface as much as possible; the distance between the nozzle and the detection surface is about 200mm, spraying is carried out for 2 times from one end of the test piece to the other end of the test piece, then standing is carried out for 15min, and the imaging trace on the detection surface of the test piece is observed.
(7) And (3) statistics: and placing the scale on the ingot test piece, and photographing the whole and partial areas of the detection surface.
As shown in FIG. 3, the test results of the microporosity of the test piece of the ingot in comparative example 1 revealed that no significant microporosity trace was observed in the test piece of the ingot which had not been subjected to the surface corrosion treatment, indicating that the surface corrosion in the second step of the present invention was an indispensable step.
From the above description, it can be seen that the above embodiments of the present invention achieve the following technical effects:
the invention provides a method for detecting and evaluating the microscopic porosity of an ingot, which can be used rapidly and comprehensively and is convenient to use on site. In particular, the coloration and visualization of the present invention is based primarily on the capillary principle. When a microscopic loose opening exists on the detection surface of the ingot test piece, a tiny and tortuous channel below the opening is equivalent to a capillary tube, and capillary action is generated on the colorant at the opening. The colorant has a low surface tension and is sucked into the holes when attached to the openings of the holes; in the cleaning process, the surface tension of water is large, so that the colorant in the hole cannot be cleaned. After spraying the developer, the developer is like a piece of 'Xuan paper' attached above the loose holes, and the colorant in the holes is sucked out; subsequently, the dye of the colorant will bloom and magnify in the developer, thereby magnifying the microporosity, and visually observing the microporosity in the ingot at a macroscopic scale. Thus, after imaging, a magnified trace of the porosity holes can be seen, which is also the main reason that microporosity can be observed at low magnification. Furthermore, the above evaluation method of the present application can not only count the number and distribution of the micro-porosity in a larger area of the test piece, but also preliminarily predict the size of the micro-porosity volume according to the size of the imaging trace. Compared with the prior art, the method has the advantages that the cost of the raw materials and the auxiliary materials is low, special equipment is not needed, the process operation is simple, the analysis area is large, the result is convenient to count, the result representativeness is high, the detection precision is high, and the result can be fed back in real time; the method is suitable for microscopic porosity measurement of various aluminum alloy ingots such as primary/regeneration, deformation/casting and the like; the method is particularly suitable for detecting, counting and evaluating the quantity and distribution of the micro-looseness in the large-size aluminum alloy cast ingot.
The above is only an embodiment of the present invention and is not intended to limit the present invention, and various modifications and variations of the present invention will be apparent to those skilled in the art. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. An evaluation method of microporosity in an aluminum alloy ingot, which is characterized by comprising the following steps:
step S1, cutting, surface machining and corrosion treatment are sequentially carried out on an aluminum alloy ingot to obtain an aluminum alloy ingot test piece;
step S2, coloring the detection surface of the aluminum alloy ingot test piece by using a coloring agent, and then sequentially cleaning and drying the detection surface after the coloring treatment to obtain a treated test piece;
step S3, developing the treated test piece by adopting a developing agent to obtain a developed test piece;
and S4, placing a scale on the developed test piece, photographing the detection surface of the developed test piece, inputting the photograph into image processing software, distinguishing microscopic loose marks from surrounding matrixes by setting a color threshold, counting the number density of the microscopic loose marks, and evaluating the microscopic loose marks in the aluminum alloy ingot test piece.
2. The evaluation method according to claim 1, wherein in the step S4, the color threshold r=0 to 255.
3. The method of evaluation according to claim 1 or 2, wherein the microporosity is recorded as n when 0 pieces/cm 2 N is less than or equal to 10/cm 2 When the grade of the microporosity is evaluated as grade I; when 10 pieces/cm 2 N is less than or equal to 50/cm 2 When the grade of the microporosity is evaluated as grade II; when 50 pieces/cm 2 N is less than or equal to 100/cm 2 When the grade of the microporosity is rated as grade III; when 100 pieces/cm 2 When < n, the grade of microporosity is evaluated as grade IV, and the grade of microporosity from grade I to grade IV indicates that the degree of microporosity in the aluminum alloy ingot test piece is gradually increased.
4. The evaluation method according to claim 1 or 2, wherein the coloring process comprises:
spraying the coloring agent on the detection surface of the aluminum alloy ingot test piece for standing treatment to obtain the coloring agentDetecting the surface after treatment; the time range of the standing treatment is 10-30 min, and the ratio of the mass of the coloring agent to the area of the detection surface of the aluminum alloy ingot test piece is 200-300: 1g/m 2 。
5. The evaluation method according to claim 1 or 2, wherein the process of the development processing includes:
spraying an imaging agent on the detection surface of the processed test piece to perform the imaging treatment to obtain the developed test piece;
horizontally standing the developed test piece for 10-30 min, and then observing;
and (3) repeatedly spraying the imaging agent for 2-3 times, wherein the distance between the nozzle for spraying the imaging agent and the detection surface of the treated test piece is 100-300 mm.
6. The evaluation method according to claim 1 or 2, wherein a mass ratio of the developer to the colorant is 0.7 to 1.5:1.
7. the evaluation method according to claim 1 or 2, wherein the etching treatment process comprises:
performing infiltration treatment on the detection surface of the test piece obtained after the light is emitted by the light source by adopting alkaline solution to obtain an infiltrated test piece;
washing, wiping and drying the infiltrated test piece in sequence to obtain the aluminum alloy ingot test piece;
the concentration of the alkaline solution is 60 g/L-120 g/L, and the alkaline solution is sodium hydroxide solution and/or potassium hydroxide solution; the temperature of the corrosion treatment is 20-40 ℃, and the time of the corrosion treatment is 3-15 min.
8. The method according to claim 7, wherein the wiping is performed on the test piece obtained by washing with absorbent cotton dipped in an acidic solution, the acidic solution having a volume fraction of 20% to 30%, the acidic solution being selected from any one of nitric acid and sulfuric acid.
9. The evaluation method according to claim 1 or 2, wherein the drying process includes:
and drying the detection surface of the aluminum alloy ingot test piece by using an air gun or a blower, wherein the air outlet of the air gun or the blower and the detection surface are 30-60 degrees.
10. The evaluation method according to claim 1 or 2, wherein the water temperature of the cleaning treatment is in a range of 10 ℃ to 40 ℃, and/or the water column in contact with the detection surface is in a fan shape, and/or the distance between the water outlet nozzle and the detection surface is 100mm to 300mm.
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