SG187394A1 - Ultrasonic flaw detection method for cast stick and ultrasonic flaw detection device - Google Patents
Ultrasonic flaw detection method for cast stick and ultrasonic flaw detection device Download PDFInfo
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- 238000001514 detection method Methods 0.000 title abstract description 6
- 239000000523 sample Substances 0.000 claims abstract description 155
- 238000007689 inspection Methods 0.000 claims abstract description 137
- 238000000034 method Methods 0.000 claims abstract description 50
- 238000005266 casting Methods 0.000 claims description 39
- 238000009749 continuous casting Methods 0.000 claims description 18
- 239000000498 cooling water Substances 0.000 claims description 16
- 238000004519 manufacturing process Methods 0.000 claims description 15
- 238000005242 forging Methods 0.000 claims description 11
- 238000005520 cutting process Methods 0.000 claims description 8
- 238000010438 heat treatment Methods 0.000 claims description 4
- 230000007547 defect Effects 0.000 description 17
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
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- 238000001816 cooling Methods 0.000 description 1
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- 239000007924 injection Substances 0.000 description 1
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- 239000000463 material Substances 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- 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
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/26—Arrangements for orientation or scanning by relative movement of the head and the sensor
- G01N29/262—Arrangements for orientation or scanning by relative movement of the head and the sensor by electronic orientation or focusing, e.g. with phased arrays
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/04—Continuous casting of metals, i.e. casting in indefinite lengths into open-ended moulds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
- B22D11/16—Controlling or regulating processes or operations
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/04—Wave modes and trajectories
- G01N2291/042—Wave modes
- G01N2291/0421—Longitudinal waves
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/04—Wave modes and trajectories
- G01N2291/056—Angular incidence, angular propagation
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/106—Number of transducers one or more transducer arrays
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/26—Scanned objects
- G01N2291/262—Linear objects
- G01N2291/2626—Wires, bars, rods
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Abstract
ULTRASONIC FLAW DETECTION METHOD FOR CAST STICK AND ULTRASONIC FLAW DETECTION DEVICEAn ultrasonic flaw inspection method for a cast bar that uses a longitudinal wave as an incident wave for the inspection of the entire region of the cast-bar circular in cross-section is provided. Inperformingultrasonic flaw inspectionbyarranging a plurality of phased array type probes 1 and 2 in a circumferential direction of the cast bar S circular in cross-section at a predetermined angle a, one of the phased array type probes 1 and the other phased array type probe 2 are arranged such that an uninspected region 1A and 1B by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes 1 is complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe 2.Figure 2
Description
ULTRASONIC FLAW DETECTION METHOD FOR CAST STICK AND ULTRASONIC
FLAW DETECTION DEVICE
[0001] The present invention relates to an ultrasonic flaw inspection method for a cast bar with a circular cross-section and an ultrasonic flaw inspection device for performing the inspection method.
[0002] Generally, a continuous cast bar is manufactured by casting molten metal into a columnar, rectangular columnar, ox hollow columnar long ingot. Such casting methods include a float casting method, a direct chill casting (DC casting) method, a gas-pressure-applied Hot-top continuous casting method. For a continuous cast bar, elimination of the surface uneven layer which may cause breaking during plastic working is performed, and inspection is conducted for surface defects and internal defects after elimination of the outer peripheral portion (See Patent
Document 1). foo03] In the manufacturing process for the continuous cast bar as disclosed in Patent Document 1, a non-disruptive inspection process for internal defects by ultrasonic flaw inspection is performed between the continuous casting process and the outer periphery elimination process. The ultrasonic flaw inspection is characterizedin that the inspectionishighindetectioncapability for interiordefects suchasbreakage and that the inspectionenables easy automatic judgment of defects by processing detected electric signals as compared to an X-ray inspection that requires image processing, which in turn enables stable inspection with a high degree of accuracy. foo04] When inspecting fordefectsof acastbarinthevicinity of the surface thereof using a longitudinal wave as an incident wave, abottomreflectionechoegaredetectedas falsedefect echoes.
Therefore, an inclined angle wave is conventionally used as the incident wave. [Patent Document 1]
Japanese Unexamined Laid-open Patent Application Publication No. 2004-209516
[0005] However, when obtaining an inclined angle wave using a conventional ultrasonic £law inspection probe, the obtained wave becomes a trangverse wave. In the case of performing inspection of a surface or the vicinity thereof using a transverse wave slower in sound speed than a longitudinal wave, there was a drawback that falsedefect echoesweremore likely detecteddue tothe long temporal axes.
[0006] Furthermore, in the case of inspectinganentire region of a cast bar circular in cross-section using a conventional probe, it was required to move the probe in the circumferential direction of the continuous cast bar, or arrange a number of ultrasonic flaw inspection probes in the circumferential direction. Furthermore, it was difficult to arrange a number of probes with a high degree of precision, and the low-precision arrangement of the probes caused a deterioration of the inspection accuracy.
MEANS FOR SOLVING THE PROBLEMS
[0007] In view of the aforementioned technical background, the present invention aims to provide anultrasonic flaw inspection method foracast bar circular incross-sectioncapableof inspecting an entire region of the cast bar using a longitudinal wave as an incident wave, and also to provide an ultrasonic flaw inspection device for performing the inspection method.
[0008] That is, the present invention has a structure as recited in the following items [1] to [9].
[0009] [1] An ultrasonic flaw inspection method for a cast bar, wherein, in performing ultrasonic flaw inspection by arranging a plurality of phased array type probes in a circumferential directionof the cast bar circular incrosg-section at a predetermined angle, one of the phased array type probes and the other phased array type probe are arranged such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes is complemented with an inspected . region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
[0010] [2] The ultrasonic flaw inspection method as recited in the aforementioned item 1, wherein the two phased array type probes are arranged at an arrangement angle o which satisfies following two formulas: 2 Xx {180°-20,+8;) = a = 20,-03-6, 180° [30,+3(180° -208,)] = 9, where 9,: effective inclined angle of a phased array type probe 85: central angle of OP 0;: 1/2 of a central angle of a dead zone of avertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe
P: incident point of an inclined angle incident wave at the maximum scanning angle of the phased array type probe.
[0011] f3] The ultrasonic flaw ingpection method for a cast bar as recited in the aforementioned item 2, wherein the two phased array type probes are arranged so that the incident waves travel downward. [oox21 [4] The ultrasonic flaw inspection method for a cast bar as recited in any one of the aforementioned items 1 to 3, wherein a plurality of phased array type probes are arranged at a vicinity of a casting mold cutlet of a horizontal continuous casting mold : and ultrasonic flaw inspection is continuously performed for a continuous cast bar which is being continuously cast.
[0013] [5] The ultrasonic flaw inspection method ag recited in the aforementioned item 4, wherein the continuous cast bar is loosely inserted into a through-hole of a dam-1like member arranged apart fromthe casting mold outlet at a downstream side to interrupt flow of the cecoling water, and wherein the phased array type probes are arranged in a state in which the probes are in contact with the cooling water that the flow is interrupted.
[0014] [6] An ultrasonic flaw inspection device for a cast bar, compriging a plurality of phased array type probes arranged in a circumferential direction of the cast bar circular in cross-gection, and one of the phased array type probes and the other phased array type probe are arranged such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes is complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
[0015] [7] The ultrasonic flaw inspection device for a cast bar as recited in the aforementioned item 6, wherein the two phased array type probes are arranged at an arrangement angle o which satisfies following two formulas: 2 x (180°~20,403) 5 oo S 29,-93-84
180°- [363+3(180° -28,)] = 0, where €,: effective inclined angle of a phased array type probe
B83: central angle of CP 04: 1/2 of a central angle of a dead zone of a vertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe
P: incident point of an inclined angle incident wave at the maximum gcanning angle of the phased array type probe.
[0016] {8] A consistent manufacturingmethod for a forged product, wherein, in a consistent production method of a cast product in which a continuous cast bar circular in cross-section which is being continuously cast froma castingmoldoutlet of ahorizontal continuous casting device is subjected to short-length cutting, peeling, and heat-treatment inanarbitrary order, and subsequently subjected to forging, ultrasonic flaw inspection is performed immediately after casting or between arbitrary processes, and wherein the ultrasonic flaw inspection is performed by arranging a plurality of phased array ULype probes in a circumferential divection of the cast bar circular incross-gection at a predetermined angle, and arranging one of the phased array type probes and the other phased array type probe such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes ig complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
[6017] {9] Theconsistentmanufacturingmethod fora forged product as recited in the aforementioned item 8, wherein the ultrasonic flaw inspection is performed by arranging two phased array type probes at an arrangement angle « which satisfies following two formulas: 2 x (180°-20,+03) = oo = 20,-93-6, 180°- [30;+3(180° -28,)]1 Z &, where 8,: effective inclined angle of a phased array type probe 65: central angle of OP 84: 1/2 0f acentral angle of a dead zone of a vertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe
P: incident point of an inclined angle incident wave at the maximum scanning angle of the phased array type probe.
[oo1g] According to the ultrasonic flaw inspection method as recited in the aforementioned Item {1], a refracted longitudinal wave and a longitudinal wave are injected to the cast bar circular in cross-section using phased array type probes to perform ultrasonic flaw inspection of the entire region of the cast bar including the vicinity of the surface. Also, with a longitudinal
I)
wave high in sound velocity, false defect echoes are not likely : to appear on a flaw inspection display and flaw inspection of a wide region can be performed with a single probe, which enables to attain high inspection accuracy. foc1l9] According to the ultrasonic flaw inspection method as recited in the aforementioned Item [2], an arrangement angle o of probes which can complement uninspected regions of each of the two phased array type probes can be derived.
[0020] According to the ultrasonic flaw inspection method as recited in the aforementioned Item [3], the ultrasonic wave which propagated throughwaterissufficientlyattenuatedbeforereaching the surface of the water, and therefore occurrence of false defect signals can be reduced, enabling highly accurate flaw inspection.
[0021] According to the ultrasonic flaw inspection method as recited in the aforementioned Item [4], the inspection efficient ig excellent since horizontal continuous casting and ultrasonic flaw inspection can be continuously performed, and the inspection result can be reflected in the following processes, or can be fed back for casting conditions. In addition, since there are no end surfaces in the inspection target regions, there are no dead zones in end surfaces. Therefore, cut pieces cut after the inspection can be treated ag pieces inspected up to the end surfaces.
[0022] According to the ultrasonic flaw inspection as recited in the aforementioned Item [5], continuous ultrasonic flaw inspection can be performed with a simple device subsequent to horizontal continucus casting.
[0023] According to the ultrasonic flaw inspection device as recited in the aforementioned Items [6] and [7], the aforementioned ultrasonic flaw inspection can be performed.
[0024] According to the consistent manufacturing method of a forged product as recited in the aforementioned Items [8] and
[9], since the aforementioned ultrasonic flaw inspection is conducted between processes, high quality forged products can be manufactured with high efficiency.
[0025] [Fig. 1] Fig. 1 is a explanatory view showing uninspected regions of phased array type probes inanultrasonic £law inspection of a cast article with a circular cross-section. [Fig. 2} Fig. 2 1s a view showing propagation of an ultrasonic wave in ultrasonic flaw inspection of a cast article according to the present invention and an arrangement angle of two phased array type probes. [Fig. 3] Fig. 3 is anenlargedviewof anessential portion shown in Fig. 2. [Big. 4A] Fig. 4A ig a schematic front view showing an embodiment of an ultrasonic flaw inspection device according to the present invention. [Fig. 4B] Fig. 4B is a side view of the ultrasonic flaw inspection device shown in Fig. 4A. (Fig. 5] Fig. 5 is a perspective view including a partial crosg-section schematically showing another embodiment of the ultrasonic flaw inspection device according to the present : invention. [Fig. 6A] Fig. 6A is a process flowchart of a consistent manufacturing method of a forged product from casting to forging, wherein an inspection process using an ultrasonic flaw inspection device according to the present invention is employed. [Fig. 6B] Fig. 6B is a process flowchart of a consistent manufacturing method of a forged product from casting to forging, wherein an inspection process using an ultrasonic flaw inspection device according to the present invention is employed. (Fig. 6C] Fig. 6C is a process flowchart of a consistent manufacturing method of a forged product from casting to forging, wherein an inspection process using an ultrasonic flaw inspection device according to the present invention is employed.
[0026] 1: phased array type probe 1A, 2A: out-of-scanning region {(uninspected region) 18, 2B: dead zone {uningpected region) 10, 40: ultrasonic flaw inspection device 33: casting mold 35: cooling water 41: through-hole 42: dam-like member
S: cast bar (continuous cast bar)
[0027] A phased array type probe used in the present invention has a plurality of probes arranged in parallel with each other (probe block), and ig electrically controllable in focal point, which enables multi-focusging (combination of vertical flaw inspection and inclined angle flaw inspection) during the inspection and wide region inspection. In the case of a longitudinal wave having a faster sound speed than a transverse wave, false defect echoes are lesg likely to appear on a flaw inspection display, and therefore the inspection accuracy is high.
A single probe block can conduct a wide range flaw inspection and thereforedeteriorationof ingpectionaccuracydue todeterioration of positional accuracy cased by arranging a number of probes in a circumferential direction in a conventional inspection method will not occur, resulting in high inspection accuracy.
[6028] The aforementioned phased array type probe can perform a wide range of inspection for flaws with a longitudinal inclined angle (including vertical} wave, but uninspected regions still remain inevitably. Inthe present invention, aplurality of phased array type probes are arranged around a cast bar circular in cross-section in a clrcumferential direction thereof at predetermined angles so as to complement each other’ s uninspected region, which enables inspection covering an entire region of the cast bar including the vicinity of the surface.
[0029] Fig. 1 shows an example in which two phased array type probes 1 and 2 are arranged with respect to a cast bar 8 circular in cross-section. : : : fco3o] With respect to the first phased array type probe 1, “1A” and “1A” denote out-of-scanning regions deviated froma maximum scanning range, and “1B” denotes a dead zone which occurs since the bottom echo that appears when an incident light is injected in a vertical direction cannot be distinguished from a defect echo.
These regions 1A, 1A and 1B are uninspected regions that the first phased array type probe 1 cannot inspect for flaws. The out-of-gscanning regions 1A and 1A can be reduced by enlarging the scanning region, but such regions cannot be completely eliminated because the scanning target is circular in cross-section. Also, the aforementioned dead zone 1B is a region which is inevitably created. Similarly, with respect to the second phased array type probe 2, “2A” and “2A” denote out-of-scanning regions deviated from a maximum gcanning range, and “2B” is a dead zone due to a false defect echo, or anuninspected region that cannot be ingpected for flaws by the second phased array type probe 2.
[0031] Agunderstood from Fig. 1, by arranging the £irgst phased array type probe 1 and the second phased array type probe 2 zo as to avoid overlapping of their uninsgpected regions, an entire region can be inspected. Specifically, if the margin C between the out~of-gcanning region 1A of the first phased array type probe 1 and the out-of-scanning region 2A of the second phased array type probe 2, and a margin D between the out-of-scanning region 2A of the second phased array type probe 2 and the dead zone 1B of the first phased array type probe 1 are secured, the entire region can be inspected. : :
[0032] Hereinafter, inaccordance with the aforementioned way of thinking, a method of obtaining conditions that, when the margin
C is equal to 0 (margin C=0), the margin D becomes equal to 0 or more (margin D 20), or uninspected regions of the two phased array type probes 1 and 2 do not overlap, will be explained with reference to the ultrasonic wave propagation path diagram shown in Fig. 2.
[0033] Fig. 2 shows a state in which the margin C is equal to 0 {margin C=0}, and the ocut-of-scanning region 1A of the first phased array type probe 1 and the out-of-scanning region 2A of the second phased array type probe 2 are in contact with each other in an non-overlapped state. The two phased array type probes 1 and 2 have the same functions, and will be explained using the game reference symbol.
[0034] The symbols in Fig. 2 denote as follows. In Fig. 2, only the left half propagation path in the cast bar S$ is shown, and the right half propagation path is not illustrated.
[0035] ax: arrangement angle of the two phased array type probes
Bq: maximum scanning angle of the phased array type probe
Bn: effective inclined angle of the phased array type probe
Oy: central angle of the OF
By: 1/2 of the central angle of the dead zone by a vertical incident wave of the phased array type probe
Og: central angle of the margin D
O: incident point of the vertical incident wave of phased array type probe
P: incident point of the inclined angle incident wave of phased array type probe at the time of the maximum scanning angle
Q: vertical line re: radius of the cast bax
From Fig. 2, when the margin C is equal to 0 (margin C=0), the arrangement angle o of the two phased array type probes 1 and 2 is expressed by the following formula (i), and the central angle 9s of the dead zone 1B in which the dead zone iB of the first phased array type probe 1 and the out-of-scanning region 2A of the second phased array type probe 2 do not overlap must satisfy the following formula (ii).
[0036] c= 2 x (180° - 20,+ 63} ..(1) 180°- [383 + 3 (180° - 202)] 2 Bs (ii)
The aforementioned formula (i) expresses the minimum value (qin) of the arrangement angle o of the two phased array type probes 1 and 2, and therefore,
Olin = 2 X (180° ~ 28, + 03) Li1dd)
From the formula (ii), the central angle 8; of the margin
D is expressed by the following formula (iv). {0037] Os= 180°- [303 + 3 (180° - 2683)1 - 84 we (iv)
The aforementioned arrangement angle a can be enlarged until the margin D becomes 0 (margin D= 0}, and therefore the maximum value ony of the arrangement angle a is expressed by the following formula (v).
[0038] Olmax = Omin + Os = 20; = 03 = 04 wv) : :
Consequently, the range of the arrangement angle o for inspecting the entire region of the cast bar S can be defined by a range that satisfies the aforementioned formula (ii) and falls within the range covering from the minimum value oy, expressed by the formula (iii) to the maximum value ogax expressed by the formula (v}). That is, by arranging the two phased array type probes lL and 2 so as to satisfy the following two formulas, the entire region of the cast bar S circular in cross-section canbe inspected.
[0039] 180°- [363 + 3 {180° - 20,)] 2 8, 2 x (180°-20,+83) = oS 20,-05-0,
Next, the numerical values to be substituted into each of the aforementioned formulas will be explained.
[0040] The maximum scanning angle 6. is an angle to be determined according to the specifications of the phased array type probe.
[0041] The effective inclined angle 6, is an angle that is determined by the angle of refractionand the aforementioned maximum scanning angle 0,, preferably considering the degree of attenuation of the ultrasonic wave and the defect size to be detected.
[0042] The central angle 6; of OP, as shown in Fig. 3, can be expressed by the following formula (vi) with the distance x; between the OP and the radius r of the cast bar S.
[0043] 03= Sint (x,/r)} avi)
However, if a measurement of the distance x; between OP is difficult, then because the relationship of x; and the size x, of the phased array type probe can be expressed by x;,~x,, the central angle @; can be derived from the following formula (vi’) using the measured x,.
[0044] 8:= Sint (x,/r) (vit)
The 1/2 of the central angle of the OP (i.e., 0,) expresses the size of the aforementioned dead zone 1B, and can be derived by the actual measurement.
[0045] Therefore, from the actually measured value, formula (iii), formula (iv), and formula (vi’), the arrangement angle « of the two phased array type probes 1 and 2 that can inspect the entire region can be determined.
[0046] The aforementioned formula for calculating the arrangement angle o is based on two phased array type probes having the same specifications. However, when using phased array type probes different in specification, the arrangement angle can be derived based on the injection position of each probe and/or various angles. Furthermore, when using three or more phased array type probes, they shouldbe arranged ina way such that the out-of ~gcanning regions of the adjacent probes do not overlap and the dead zone of one probe do not overlap with the ocut-of-scanning regions of other probes. [Example of the arrangement angle of two phased array type probes]
For ultrasonic flaw inspection for a cast bar S$ having a radius r of 215 mm, when the effective inclined angle 6; of the phased array type probes 1 and 2 was 70° (0;=40°}, the size x, of the phased array type probes 1 and 2 was 28.7 mm (x;=28.7 mm}, and the gize 8, 0f the dead zonewas 17.52 (04=17.5°), 8;=7.6° was derived from the formula (vi').
[0047] Therefore, fromthe formulas (iii) and (v), opyin= 95.29, and ogax = 114.9° was derived. Consequently, by arranging the two phased array type probes 1 and 2 within a range of the arrangement angles a: 95.2 to 114.9°, the entire region can be inspected.
However, considering wobbles caused by the traveling of the cast bar S during the inspection, it is preferable to arrange the probes at the intermediate point of the aforementioned range or thevicinity thereof by avoiding the arrangement at Onin and ogax- {o048] Algo, the plurality of phased array type probes can be arranged at angles that complement the uninspected regions with eachother, and therefore the phased array type probes canbe arranged anywhere inthe circumferential directionof thecastbar. However, as shown in the ultrasonic flaw inspection device 10 and 40, it is preferable that the phased array type probes 1 and 2 are arranged obliquely upward of the cast bar 8 to inject ultrasonic waves from upward to downward. If ultrasonic waves are irradiated from downward to upward, the ultrasonic wave that did not enter the cast bar 8 will be reflected by the surface of the water and its echo canbe detectedas a falsedefect signal. However, by injecting ultrasonic waves from upward to downward, the ultrasonic waves that propagate the surface of the water sufficiently attenuate before reaching the surface of the water, and therefore its echo i7 will not be detected as a false defect signal, enabling highly accurate flaw inspection. Also, whenemployinga copying mechanism for retaining the positional relationship of the phased array type probes 1 and 2 even if the cast bar S is displaced, there are less arrangement limitations when the probes are arranged above the cast bar 8. For this reason, it is preferable to arrange them above the cast bar S.
[0049] Furthermore, it is preferable to set a sufficient distance (WD) between the cast bar S and the phased array type probes 1 and 2 so that repetitive echoes of the surface wave do not become false defect echoes.
[0050] Furthermore, a reflection echo from a wall surface of the inspection tank can become a false defect signal, and therefore it is preferable that the tank is large enough to prevent a false defect signal. It is preferable that the distance from the peripheral surface of the cast bar S to the wall surface of the tank is gufficiently enough to attenuate the ultrasonic wave that propagates through the water. Also, sound absorbent material can be arranged on the wall surface of the tank to eliminate the sound waves that become the cause of false defect echoes. [0051.1 It should be understood that Figg. I to 3 show, for the convenience of explaining, that the first phased array type probe 1 is arranged directly above, but do not show the most suitable positions of the phased array type probes 1 and 2 for the cast bar §. In the ultrasonic flaw inspection device 10 and 40, the phased array type probes 1 and 2 are arranged in such a way that the vertical line Q shown in Figs. 2 and 3 is arranged vertically. [ULTRASONIC FLAW INSPECTION DEVICE] (FIRST EMBODIMENT)
The ultrasonic flaw inspection device 10 shown in Figs. 4A and 4B is equipped with a water tank 11 and two phased array type probes 1 and 2, and configured to perform inspection of a cast bar S while moving the cast bar S.
[0052] The water tank 11 hag walls arranged orthogonal to the travelling direction of the cast bar S, and the walls are provided with through-holes 12 and 13 to allow passage of the cast bar 8.
Water which is a contact medium is stored in the water tank 11 at a water level gufficiently higher than the through-holes 12 and 13. The two phased array type probes 1 and 2 are attached to both ends of a horizontal arm 16 provided at a tip end of a vertical arm 15 of a suspension system via brackets 17 in an angle adjustable manner so that ultrasonic waves are irradiated against the cast bar 8 travelling below the probes from diagonally upward portions of the probes. Acopyingroller 18 configured to come into contact with the cast bar 8 is attached to themiddle portionof the horizontal arm 16 in the right-and-left direction to control movements of the arms 15 and 16 corresponding to positional displacements of the cast bar 8 to always keep a certain positional relationship of the cast bar 8 and the phased array type probes 1 and 2.
[0053] The ultrasonic flaw inspection device 10 can inspect the travelling cast bar S$ regardless of the length of the cast bar 8S. For example, continuous inspection can be performed for a continuous cast bar S which is being continuously cast from the casting mold of a horizontal continuous casting device at a casting speed. Also, a cut cast bar can be ingpected by moving the cast bar S at a predetermined speed using a moving device. In this way, by moving the cast bar S inside the tank 11, an inspection target can be subjected to inspection regardless of the length. Needless to say, in cases where an inspection target is smaller than the tank, the phaged array type probes can be moved with the inspection target fixed.
[0054] The phased array type probes 1 and 2 are controlled by a control device (not shown) to detects flaws of the cast bar
S. The signal emitted from the phased array type probes 1 and 2 are outputted to a signal processor 20, and then outputted to an ultrasonic flawinspectiondevice2l afterpredeterminedprocessing.
The ultrasonic inspection judgment device 21 determines whether or not defects or flaws are present based on the inputted signals, and decides whether or not the cast bar S is anon-defective product.
Further, in the case of continucus inspection of a continuous cast bar 8 continuously cast from a casting mold of a horizontal casting device, efficient inspection can be performed. In addition, a judgment result can be fed back to the casting conditions, or defective portions can be marked with spray or the like and removed after cutting the cast bar into predetermined lengths witha cutting device (not illustrated) arranged at a downstream side.
Alternatively, it can be configured such that detected defective positions are stored and the cast bar is cut into a predetermined length while removing only the defective portions by a cutting device.
[0055] Furthermore, in the ultrasonic flaw inspection device 10, the continuous cast bar S can be subjected to ultrasonic flaw inspection while being moved. Therefore, inspection target portions include no end surface, which in turn means that there is no dead zone on end surfaces since there is no end surface in the inspection target portion. As a result, short pieces obtained by cutting after the inspection can be treated as pieces inspected up to the end surfaces. (SECOND EMBODIMENT)
[0056] The ultrasonic flaw inspection device 10 of the first embodiment uses a water tank and is advantageous in that it is easy to submerge the cast bar and a sufficient amount of contact medium can be secured.
[0057] However, the ultrasonic flaw inspection method of the present invention canallow inspection using cooling water supplied to a cast bar froma casting mold of a horizontal continuous casting device, without using a water tank. Using cooling water simplifies the structure of the inspection device.
[0058] Fig. 5 shows a horizontal continuous casting device 30andanultrasonic flawinspectiondevice40 installed immediately at the downstream side of the casting mold.
[0059] In the continuous casting device 30, the molten metal
M flows into a cylindrical casting meld 33 from a tundish 31 via a molten metal nozzle 32. At the outlet side of the casting mold 33, a cooling water supplying passage 34 for supplying cooling water 35 to the periphery of the continuous cast bar 8 is provided.
The discharge opening 34a of the cooling water supplying passage 34 is formed into an annular shape surrounding the continuous cast bar S, and directed in the casting direction of the continuous cast bar S$. The cooling water 35 ejected from the discharge opening 34a is supplied to the entire periphery of the continuous cast bar S, and flows in the casting direction on the surface of the continuous cast bar 8 which is being continuously cast to cool the continuous cast bar 8S.
[0060] The ultrasonic flaw inspection device 40 is equipped with an annular dam-1like member 42 having a through-hole 41 through which the continuous cast bar S is loosely inserted and two phased array type probes 1 and 2. The dam-like member 42 is fixed to a platform via a supporting leg 43 at a height level of the continuous cast bar S, and the inner diameter of the through-hole 41 is formed to be larger than the outer diameter of the continuous cast bar
S. Consequently, the continuous cast bar 8 which is being continuously cast travels through the through-hole 41 without contacting the periphery of the through-hole 41, and the cooling water 35 flows through the gap between the outer peripheral surface of the continuous cast bar S and the inner peripheral surface of the through-hole 41.
[0061] In the inspection device 40, the cooling water 35 discharged from the discharge opening 34a and flowed in the casting direction on the surface of the continuous cast bar 8 hits against the dam-like member 40, anda part of the coolingwater is accumulated at the upstream side of the dam-1like member 42, and the rest thereof flows through the through-hole 41.
[0062] The two phased array type probes 1 and 2 are supported by supporting members (not illustrated) with the tip end portions arranged in the deep cooling water accumulated at the upstream side of the dam-like member 42 at a predetermined arrangement angle o. The inspection result is outputted to the signal processor 20 and then to the ultrasonic inspection judgment device 21. The ultrasonic inspection judgment device 21 determines presence or absence of defects and/or flaws based on the inputted signal to decide the quality of the continuous cast bar S, and the judgment result will be fed back to the casting conditions.
[0063] The ultrasonic flaw inspection device 40 uses the cooling water for cooling the casting mold 33 ag contact medium, and therefore no transferring equipment for transferring the cast bar 8S to the inspection device is required. This simplifies the peripheral devices for inspection. [o064] Furthermore, the ultrasonic flaw inspection can be performed by arranging the phased array type probes 1 and 2 on the peripheral surface of the through-hole 41 of the dam- like member 40. [ULTRASONIC FLAW INSPECTION IN CONSISTENT CONTINUOUS OPERATION]
The ultrasonic flaw inspection method of the present invention can be applied not only to inspection of a continuous cast bar immediately after the casting, but alse can be applied : to inspection of a continuous cast bar at any step between consistent continuous operation steps until the cast bar is shipped after various processing steps including cutting, heat treatment, and peeling of the cast bar. Furthermore, in the case of manufacturing a forged product by consistently performing from the continuous casting to production of a forged product after the casting, the ultrasonic flaw inspection can be performed immediately after casting or between arbitrary steps.
[0065] Figs. 6A to 6C show a process flow of a consistent production from casting to forging. (FIG. 6A)
A long continuous cast bar obtained by horizontal continuous casting is cut into a plurality of short pieces, and the short piece is heat treated for homogenization, and then peeling is performed to eliminate the black skin, or hard casting skin, of the surface layer portion. The short piece from which the black skin was eliminated is shipped after the appearance inspection.
Alternately, the short piece after the appearance inspection is subjected to forging. The forging step includes cutting (production of a preliminary product), preliminary heating, and forge forming.
[0066] In the consistent continuous operation, the ultrasonic flaw inspection can be performed between any steps, and the inspection can be performed at a single or plural portions. The reference symbol “K” denotes a process for inspecting a travelling continuous cast bar which is being cast from the casting mold of : the horizontal continuous casting device, and the inspection can be performed by either the ultrasonic flaw inspection device 10 equipped with a water tank or the ultrasonic flaw inspection device 40 using cooling water of the casting mold. The reference symbol “L” denotes a process for inspecting a long continuous cast bar cut intoshortpiecesinastateinwhichablackskinisnoteliminated.
The reference symbol “M” denotes a process for inspecting a short piece after peeling from which the black skin was eliminated. In the processes “LI” and “M,” an ultrasonic flaw inspection device equipped with a water tank can be used. (FIG. 6B)
A long continuous cast bar obtained by horizontal continuous casting is cut into a plurality of short pieces, and subjected to peeling to eliminate the black skin of the surface layer. The short piece from which the black skinwas eliminated is heat treated for homogenization, and further preheated to perform a forging process. [C067] In the congistent continuous operation, the ultrasonic flaw inspection can be performed at a single or plural portions between arbitral processes. The reference symbols “K,” “.,” and “M” shown in Fig. 6B are the same as the inspection processes “K,” “L,” and “MM” shown in Fig. 6A. (FIG. 6C)
A long continuous cast bar produced by horizontal continuous casting is cut into a plurality of short pieces, heat treated for homogenization, and then subjected to peeling to eliminate the black skin of the surface layer. The short piece from which the black skin was eliminated is subjected to forging.
[0068] In the consistent continuous operation, the ultrasonic flaw inspection can be performed at a single or plural portions between arbitral processes. The reference symbols “K,” “L,” and “M” shown in Fig. CB are the same as the inspection processes “K,” “L,” and “WM” shown in Fig. 6A.
[0069] As explained above, by performing ultrasonic flaw inspection in a continual production performed from continuous casting to forging, highquality forged products canbe manufactured in an efficient manner.
[0070] The inspection method for a continuous cast bar according to the present invention can be applied to casting of all kinds of metals. For example, it can be applied to continuous casting of aluminum or aluminum alloy.
[0071] This application claims priority to Japanese Patent
Application No. 2007-336453 filed on December 27, 2007, the entire disclosure of which is incorporated herein by reference in its entirety. [ona] Tt should be understood that the terms and expressions used herein are used for explanation and have no intention to be used toconstrueinalimitedmanner, donot eliminate any equivalents cof features shown and mentioned herein, and allow various modificationg falling within the claimed scope of the present invention.
[0073] According to the ultrasonic flaw inspection method for a cast bar according to the present invention, since a refracted longitudinal wave or longitudinal wave are used as incident light, and a plurality of phased array type probes complement uninspected regions with each other, an entire region of the cast bar circular incross-sectioncanbe inspected. Byusingthis inspectionmethod, healthy cast bars can be manufactured efficiently.
Claims (9)
1. An ultrasonic flaw inspection method for a cast bar, wherein, in performing ultrasonic flaw inspection by arranging a plurality of phased array type probes in a circumferential directionof the cast bar circular incrogs-gection at a predetermined angle, one of the phased array type probes and the other phased array type probe are arranged such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes is complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
2. The ultrasonic flaw inspection method as recited in claim 1, wherein the two phased array type probes are arranged at an arrangement angle o which satisfies following two formulas: 2 x {(180°-26,48:) = a = 20,-03-0, 180°~ [303+3 (180° -28,}] = 0, where 6: effective inclined angle of a phased array type probe G3: central angle of OP B4: 1/2 of a central angle of a dead zone of a vertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe : P: incident point of an inclined angle incident wave at the : maximum scanning angle of the phased array type probe.
3. The ultrasonic flaw inspection method for a cast bar as recited in claim 2, wherein the two phased array type probes are arranged so that the incident waves travel downward.
4. The ultrasonic flaw ingpection method for a cast bar as recited in any one of claims 1 to 3, wherein a plurality of phased array type probes are arranged at a vicinity of a casting mold outlet of a horizontal continuous casting meld and ultrasonic flaw inspection is continuously performed for a continuous cast bar which ig being continuously cast.
5. Theultrasgsonic flaw inspectionmethod as recited in claim 4, wherein the continuous cast bar is loosely inserted into a through-hole of a dam-like member arranged apart from the casting mold outlet at a downstream side to interrupt flow of the cooling water, and wherein the phased array type probes are arranged in a state in which the probes are in contact with the cooling water that the flow is interrupted.
6. An ultrasonic flaw inspection device for a cast bar, comprising a plurality of phased array type probes arranged in a circumferential direction of the cast bar circular in cross-gection, and one of the phased array type probes and the other phased array type probe are arranged such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes is complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
7. The ultrasonic flaw inspection device for a cast bar as recited in claim 6, wherein the two phased array type probes are arranged at an arrangement angle a which satisfies following two formulas; 2 x (180°-20,+0;3) = o S 20,-05-8, 180°- [36,543 (180° -208,}] = 8, where B;: effective inclined angle of a phased array type probe 83: central angle of OP 84: 1/2 of a central angle of a dead zone of avertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe P: incident point of an inclined angle incident wave at the maximum scanning angle of the phased array type probe.
8. A consistent manufacturing method for a forged product, wherein, in a consistent production method of a cast product in which a continuous cast bar circular in cross-section which is being continuously cast froma castingmoldoutlet of a horizontal continuous casting device is subjected to short-length cutting, peeling, and heat-treatment inanarbitrary order, and subsequently subjected to forging, ultrasonic flaw inspection is performed immediately after casting or between arbitrary processes, and wherein the ultrasonic flaw inspection is performed by arranging a plurality of phased array type probes in a circumferential directionof the cast bar circular incross-section at a predetermined angle, and arranging one of the phased array type probes and the other phased array type probe such that an uninspected region by a refracted longitudinal wave and a longitudinal wave of the one of the phased array type probes is complemented with an inspected region by a refracted longitudinal wave and a longitudinal wave of the other phased array type probe.
9. The congistent manufacturing method for a forged product ag recited in claim 8, wherein the ultrasonic flaw inspection is performed by arranging twophasedarray type probes at an arrangement angle o which satigfies following two formulas: 2 x {(180°-20,4+8,) So = 26,-0,-04 180°- [303+3 (180° -203)] 2 6, where
0,: effective inclined angle of a phased array type probe + 03: central angle of OP : : Bs: 1/2 of a central angle of a dead zone of avertical incident wave of the phased array type probe 0: incident point of the vertical incident wave of the phased array type probe P: incident point of an inclined angle incident wave at the maximum scanning angle of the phased array type probe.
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2007336453A JP5260045B2 (en) | 2007-12-27 | 2007-12-27 | Method and apparatus for ultrasonic inspection of cast bar |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| SG187394A1 true SG187394A1 (en) | 2013-02-28 |
Family
ID=40824222
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| SG2012095097A SG187394A1 (en) | 2007-12-27 | 2008-12-22 | Ultrasonic flaw detection method for cast stick and ultrasonic flaw detection device |
Country Status (5)
| Country | Link |
|---|---|
| JP (1) | JP5260045B2 (en) |
| KR (1) | KR20100101610A (en) |
| CN (2) | CN101960304B (en) |
| SG (1) | SG187394A1 (en) |
| WO (1) | WO2009084508A1 (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2993361B1 (en) * | 2012-07-10 | 2014-08-01 | Snecma | METHOD FOR CHARACTERIZING AN OBJECT COMPRISING AT LEAST LOCALLY A SYMMETRY PLAN |
| JP5638052B2 (en) * | 2012-10-16 | 2014-12-10 | 昭和電工株式会社 | Ultrasonic flaw detection inspection method for cast bars |
| CN103353480A (en) * | 2013-07-09 | 2013-10-16 | 中国科学院声学研究所 | Automatic ultrasonic flaw detection method and device for locomotive wheel shaft |
| CN104655734B (en) * | 2013-11-20 | 2017-10-31 | 中国科学院声学研究所 | The ultrasonic phase array probe system that a kind of horizontal triage of tubing or bar is surveyed |
| CN105522131A (en) * | 2016-02-02 | 2016-04-27 | 吉林大学 | Magnesium alloy bar power ultrasonic semi-continuous casting and flaw detection device and method |
| CN105772660A (en) * | 2016-04-06 | 2016-07-20 | 河南金阳铝业有限公司 | Aluminum ingot cooling well with flaw detection device |
| KR101936547B1 (en) * | 2018-07-18 | 2019-04-03 | 엔디티엔지니어링(주) | Non-contact Type Billet Ultrasonic Tester |
| CN112782286A (en) * | 2020-12-24 | 2021-05-11 | 中航贵州飞机有限责任公司 | Portable ultrasonic longitudinal wave water immersion probe tool and use method |
Family Cites Families (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS59116541A (en) * | 1982-12-24 | 1984-07-05 | Kobe Steel Ltd | Method for detecting flaw of square steel piece by using both electronic sector scanning and electronic linear scanning |
| JPS633254A (en) * | 1986-06-24 | 1988-01-08 | Nippon Steel Corp | Ultrasonic flaw detector for square billet |
| JPH0278949A (en) * | 1988-09-14 | 1990-03-19 | Toshiba Corp | Ultrasonic flaw detecting device |
| JP3264828B2 (en) * | 1996-05-10 | 2002-03-11 | 住友電気工業株式会社 | Defect detection method of lead sheath pipe for electric wire |
| CN2328012Y (en) * | 1998-02-24 | 1999-07-07 | 宝山钢铁(集团)公司 | Water tank for ultrasonic flow detection |
| JP2922508B1 (en) * | 1998-07-31 | 1999-07-26 | 三菱電機株式会社 | Automatic ultrasonic flaw detector |
| JP3638814B2 (en) * | 1999-03-31 | 2005-04-13 | 三菱電機株式会社 | Automatic ultrasonic flaw detector |
| CN1167950C (en) * | 2002-09-26 | 2004-09-22 | 大连理工大学 | Nondestructive inspection method for electric insulator steel foot and cast zinc ring combined face |
| JP2004209516A (en) * | 2002-12-27 | 2004-07-29 | Showa Denko Kk | Method and facility for producing aluminum alloy continuously cast rod and this continuously cast rod, and instrument and method for inspecting aluminum alloy cast rod and this cast rod |
| CN1330438C (en) * | 2003-03-26 | 2007-08-08 | 昭和电工株式会社 | Horizontally continuously cast rod of aluminum alloy and method and equipment for producing the rod |
| CN2762131Y (en) * | 2004-12-16 | 2006-03-01 | 攀钢集团攀枝花钢铁研究院 | Liquid coupling medium supply device for ultrasonic detector |
| CA2712540C (en) * | 2005-08-26 | 2015-12-08 | Masaki Yamano | Ultrasonic probe, ultrasonic testing equipment, ultrasonic testing method, and manufacturing method of seamless pipe or tube |
| JP2007139546A (en) * | 2005-11-17 | 2007-06-07 | Showa Denko Kk | Apparatus for manufacturing metal rod-shaped material, method of manufacturing aluminum alloy continuously cast rod and non-destructive inspection device |
-
2007
- 2007-12-27 JP JP2007336453A patent/JP5260045B2/en active Active
-
2008
- 2008-12-22 KR KR1020107014125A patent/KR20100101610A/en not_active Application Discontinuation
- 2008-12-22 WO PCT/JP2008/073327 patent/WO2009084508A1/en active Application Filing
- 2008-12-22 SG SG2012095097A patent/SG187394A1/en unknown
- 2008-12-22 CN CN200880127512.7A patent/CN101960304B/en not_active Expired - Fee Related
- 2008-12-22 CN CN201210554760.8A patent/CN103063747B/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP2009156755A (en) | 2009-07-16 |
| WO2009084508A1 (en) | 2009-07-09 |
| CN101960304B (en) | 2013-07-10 |
| KR20100101610A (en) | 2010-09-17 |
| CN101960304A (en) | 2011-01-26 |
| CN103063747A (en) | 2013-04-24 |
| JP5260045B2 (en) | 2013-08-14 |
| CN103063747B (en) | 2016-05-04 |
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