Phased array ultrasonic detection method for anisotropic metal plate welding seam

Abstract

The invention discloses a phased array ultrasonic detection method for anisotropic metal plate weld joints. The phased array ultrasonic detection method comprises the following steps: S1, preparation work before detection; s2, selecting instruments and detection parameters; s3, adjusting the detection system; s4, detection is carried out, wherein base metal detection is carried out on the peripheral area of the metal plate weld joint, and it is ensured that no defect affecting acoustic beam propagation exists in the base metal of the metal plate; s2, according to the instruments and the detection parameters selected in the step S2, scanning all the areas of the weld joint in sequence, and storing scanning detection data; and S5, detection result analysis: analyzing the stored scanning detection data, finding out defect signals, recording corresponding defect information, and correcting the defect information to obtain final accurate information corresponding to the defect signals. According to the method, a large number of calibration test blocks do not need to be manufactured, and the final accurate information corresponding to the defect signal can be obtained only by correcting the found defect information, so that the workload is reduced, and the detection efficiency is improved.

Description

Technical Field

[0001] The invention relates to the technical field of ultrasonic nondestructive testing, and in particular to a phased array ultrasonic testing method for anisotropic metal plate welds. Background Art

[0002] At present, welding is widely used to connect components in bridge steel structures. Ultrasonic testing or radiographic testing is usually used to control the internal quality of welded joints. Radiographic testing cannot be carried out on a large scale due to long testing cycles and environmental pollution, and the image quality and defect detection rate of radiographic testing of corner joints are poor.

[0003] Phased array ultrasonic testing methods usually use linear motion parallel to the extension direction of the weld to perform sector scanning detection, and use an encoder to record the scanning position. Phased array ultrasonic testing methods specifically include direct method and single reflection method. Due to the anisotropy of TMCP steel, it has a significant impact on the propagation direction and echo height of ultrasonic shear waves. When using traditional phased array ultrasonic testing methods, it is easy to have inaccurate positioning of weld defects. It may also be impossible to fully scan the entire weld area due to unreasonable detection parameter settings, resulting in missed weld defects.

[0004] For example, the invention patent application with application publication number CN110006995A discloses a phased array ultrasonic detection method for metal thick plate welds with gradually varying sound velocity and non-uniformity. When this technical solution is actually used for the detection of metal thick plate welds with gradually varying sound velocity and non-uniformity, it can reversely check the corresponding physical depth through the mapping relationship function, thereby reducing the depth error of detecting non-uniform material defects using phased array ultrasonic detection technology.

[0005] For example, the invention patent application with authorization announcement number CN110007003B discloses a zoning method for phased array ultrasonic detection of thick metal plate welds with non-uniform sound velocity. It utilizes the laws and characteristics of ultrasonic emission and reflection, combines phased array ultrasonic technology with sector scanning, and measures sound velocity zoning on metal materials with non-uniform sound velocity. A reasonable average sound velocity is fitted by reverse deduction for each zoning, so that the depth error of artificial defects of different depths is less than or equal to 10% of the actual depth or 2 mm.

[0006] When using the above two schemes to detect thick metal plate welds, it is often necessary to produce a large number of calibration test blocks and conduct a large number of calibration test tests to obtain relatively accurate mapping relationship functions and sound velocity partitions; if only one set of calibration test blocks is produced, the positioning and quantification of defects in thick metal plate welds will often be inaccurate due to factors such as the calibration test blocks and the workpiece being inspected are not from the same batch of base materials, and there are differences in the thickness of the calibration test blocks and the workpiece being inspected. Summary of the invention

[0007] The object of the present invention is to provide a phased array ultrasonic detection method for anisotropic metal plate welds to solve the problems raised in the above background technology.

[0008] To achieve the above object, the present invention provides the following technical solutions:

[0009] A phased array ultrasonic detection method for anisotropic metal plate welds comprises the following steps:

[0010] S1. Preparation work before testing: clean the surface of the metal plate weld and the surrounding area of ​​the weld; obtain the specific specification information of the metal plate; mark the weld information and the rolling direction of the metal plate base material on the metal plate;

[0011] S2. Selection of instruments and testing parameters: Select the type of phased array ultrasonic testing instrument, encoder, linear array shear wave sensor and wedge, and determine the focus depth, refraction angle, number of scans, offset, sector scan mode and sector scan range;

[0012] S3. Calibration of the detection system: Calibrate the detection system according to the operating instructions and detection standards of the selected instrument, including: wedge delay calibration, sound velocity calibration, sensitivity calibration, encoder calibration and TCG curve production;

[0013] S4. Implement inspection: Conduct parent material inspection on the surrounding area of ​​the metal plate weld to ensure that there are no defects in the parent material of the metal plate that affect the propagation of the sound beam;

[0014] Scan each area of ​​the weld in turn according to the instrument and detection parameters selected in step S2, and save the scanning detection data;

[0015] S5. Detection result analysis: Analyze the saved scanning detection data, find out the defect signal, record the corresponding defect information, correct the defect information, and obtain the final accurate information corresponding to the defect signal.

[0016] As a further solution of the present invention, the pre-test preparation work of step S1 further includes: performing appearance inspection on the surface of the metal plate weld to ensure that the appearance of the metal plate weld meets the qualified acceptance requirements;

[0017] Determine the relationship between the sound beam propagation direction during detection and the rolling direction of the metal plate base material.

[0018] As a further solution of the present invention, the specific specification information of the metal plate in step S1 includes the base material thickness, weld length, weld width, joint form, groove setting and welding process; the marked weld-related information includes the weld starting point and the weld center line.

[0019] As a further solution of the present invention, the method for selecting the linear array shear wave sensor in step S2 is: when the thickness of the metal plate is less than or equal to 25 mm, the linear array shear wave sensor adopts a 5L16-A10 phased array probe; when the thickness of the metal plate is 25-64 mm, the linear array shear wave sensor adopts a 5L32-A32 phased array probe.

[0020] As a further solution of the present invention, in step S2: when detecting the lower part of the metal plate weld, the focusing depth of the linear array shear wave sensor is set to 1 times the thickness of the metal plate; when detecting the upper part of the metal plate weld, the focusing depth of the linear array shear wave sensor is set to 1.75 times the thickness of the metal plate.

[0021] As a further solution of the present invention, in step S2: the acoustic beam path in the metal plate is simulated by BEAMTOOL software to determine the simulated refraction angle range A 小 ~A 大 , the offset between the moving trajectory of the phased array probe and the center line of the weld and the minimum number of scans to ensure that the entire inspection area is scanned, A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline is located. 大 It is the maximum angle between the propagation direction of the sound beam and the vertical plane where the center line of the weld is located; at the same time, ensure that the angle between the propagation direction of the sound beam and the groove surface is less than or equal to 6°.

[0022] As a further solution of the present invention, the method for determining the refraction angle range in step S2 is:

[0023] S21, according to the formula L 小 =2T tanA 小 , find the minimum distance L between the two probe incident points 小 According to the formula L 大 =2T tanA 大 , find the maximum distance L between the two probe incident points 大 ; In the above formula, T is the thickness of the metal plate, A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline is located. 大 It is the maximum angle between the propagation direction of the sound beam and the vertical plane where the center line of the weld is located;

[0024] S22. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 小 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 小 ;

[0025] S23. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 大 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 大 ;

[0026] S24, set the refraction angle range to A1 小 ~A1 大 ; The angle step value during the incident angle adjustment process is 0.5°.

[0027] As a further solution of the present invention, the analysis and correction method of the defect information in step S5 is:

[0028] S51, reading the incident angle A1 of the defect and the depth H1 of the defect from the scanning surface in the defect information;

[0029] S52, selecting the propagation direction of the sound beam during the detection as the forward and backward movement direction of the phased array probe, using two phased array probes with incident angles A1 to move forward and backward on the metal plate, finding the maximum reflected echo, recording the distance L between the incident points of the two phased array probes, and using the formula A=arctan(L / 2T) to calculate the actual angle A, where T is the thickness of the metal plate, and A is the actual refraction angle of the sound beam that finds the defect in the metal plate;

[0030] S53. Calculate the actual sound velocity C in the metal plate using the formula sinA1 / sinA=C1 / C, where C1 is the sound velocity in the test block when the detection system is adjusted;

[0031] S54, the actual position information of the defect is: the actual depth of the defect from the scanning surface H = (C / C1)(cosA / cosA1)H1, the horizontal distance of the defect from the incident point of the sound beam Y = (C / C1)(sinA / cosA1)H1;

[0032] S55. Use the V-path method to determine the specific equivalent value of the defect, judge the defect according to the detection standard, and obtain the final accurate information corresponding to the defect signal.

[0033] Compared with the prior art, the beneficial effects of the present invention are: the present invention can accurately detect the internal defects of the weld of anisotropic metal plates (such as TMCP steel plates), thereby playing a role in controlling the quality of the weld;

[0034] During the inspection process, the sector scanning range is set to 1 to 1.2 times the acoustic beam path value used to ensure that the entire area to be inspected can be fully covered; by setting the angle between the acoustic beam propagation direction and the groove surface to be less than or equal to 6°, the propagation direction of the detection acoustic beam is basically perpendicular to the hazardous defects, thereby achieving accurate positioning and quantification of hazardous defects. The inspection process does not require the production of a large number of calibration test blocks, which is conducive to improving inspection efficiency;

[0035] The method of the present invention can also eliminate the problem of too many false signals in the detection data due to unclean surface; it can reduce the detection data analysis work, and can also replace X-ray detection to eliminate the radiation risk caused by X-ray detection; there is no need to correct all the detection parameters, only the information of the defects found needs to be corrected, which reduces the workload and improves the detection efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 It is a schematic diagram of a process of a phased array ultrasonic detection method for anisotropic metal plate welds;

[0037] Figure 2 It is a schematic diagram of detection of the detection system on a metal plate in the present invention;

[0038] Figure 3 It is a schematic diagram of the incident angle A1 and the depth H1 of the defect from the scanning surface in the defect information;

[0039] Figure 4 Schematic diagram of the distance L between the incident points of two phased array probes at the maximum reflection echo on the metal plate;

[0040] Figure 5 A schematic diagram of the actual defect location information.

[0041] In the figure: 100, metal plate weld; 101, weld center line; 102, moving trajectory; 1, detection scanning device; 11, phased array probe; 12, encoder. DETAILED DESCRIPTION

[0042] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0043] See also Figures 1-2 The present invention provides a technical solution: a phased array ultrasonic detection method for anisotropic metal plate welds, wherein the anisotropic metal plate is specifically a TMCP steel plate, comprising the following steps:

[0044] S1. Preparation work before detection: perform appearance inspection on the surface of the metal plate weld 100 to ensure that the appearance of the metal plate weld 100 meets the qualified acceptance requirements; clean the surface of the metal plate weld 100 and the surrounding area of ​​the weld, the surrounding area of ​​the weld specifically includes: the moving area of ​​the phased array probe 11 and the encoder 12, and the position area that may cause the sound beam reflection. The phased array probe 11 and the encoder 12 constitute the detection scanning device 1; obtain the specific specification information of the metal plate, specifically, the specific specification information includes the base material thickness, weld length, weld width, joint form, groove setting and welding process; mark the weld starting point, weld center line 101 and the rolling direction of the metal plate base material on the metal plate; determine the relationship between the sound beam propagation direction during detection and the rolling direction of the metal plate base material.

[0045] S2. Selection of instruments and detection parameters: The instruments used include: 32-bit phased array ultrasonic detection instrument, encoder, linear array shear wave sensor and wedge block. Specifically, when the thickness of the metal plate is less than or equal to 25 mm, the linear array shear wave sensor adopts 5L16-A10 phased array probe 11; when the thickness of the metal plate is 25-64 mm, the linear array shear wave sensor adopts 5L32-A32 phased array probe 11. The type of wedge block matches the model of the linear array shear wave sensor.

[0046] Focusing depth: when detecting the lower part of the metal plate weld 100, the focusing depth of the linear array shear wave sensor is set to 1 times the thickness of the metal plate; when detecting the upper part of the metal plate weld 100, the focusing depth of the linear array shear wave sensor is set to 1.75 times the thickness of the metal plate;

[0047] Refraction angle: Simulate the path of the sound beam in the metal plate on the BEAMTOOL software and determine the simulated refraction angle range A 小 ~A 大 , the offset between the moving trajectory 102 of the phased array probe 11 and the weld centerline 101 and the minimum number of scans to ensure that the entire inspection area is scanned, wherein A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline 101 is located. 大 is the maximum angle between the propagation direction of the acoustic beam and the vertical plane where the weld centerline 101 is located;

[0048] At the same time, ensure that the angle between the sound beam propagation direction and the groove surface is less than or equal to 6°;

[0049] The method for determining the refraction angle range specifically includes the following steps:

[0050] S21, according to the formula L 小 =2T tanA 小, find the minimum distance L between the two probe incident points 小 According to the formula L 大 =2T tanA 大 , find the maximum distance L between the two probe incident points 大 ; In the above formula, T is the thickness of the metal plate, A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline 101 is located. 大 is the maximum angle between the propagation direction of the acoustic beam and the vertical plane where the weld centerline 101 is located;

[0051] S22. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 小 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 小 ;

[0052] S23. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 大 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 大 ;

[0053] S24, set the refraction angle range to A1 小 ~A1 大 ; The angle step value during the incident angle adjustment process is 0.5°.

[0054] The sector scanning range is set to 1 to 1.2 times the acoustic beam path value used, which is convenient for image observation and can detect the entire inspected area.

[0055] S3. Calibration of the detection system: The detection system shall be calibrated according to the operating instructions and detection standards of the selected instrument, including: wedge delay calibration, sound velocity calibration, sensitivity calibration, encoder calibration and TCG curve preparation.

[0056] S4. Implement inspection: perform parent material inspection on the surrounding area of ​​the metal plate weld 100 to ensure that there are no defects in the parent material of the metal plate that affect the propagation of the sound beam;

[0057] According to the refraction angle range, scanning times and the offset between the phased array probe 11 and the weld centerline 101 determined in step S2, lines are drawn on the metal plate in sequence to determine the moving track 102 of the phased array probe 11;

[0058] According to the moving track 102 of the phased array probe 11, each area of ​​the weld is scanned in turn, and the scanning detection data is saved.

[0059] S5. Detection result analysis: Analyze the saved scanning test data, find out the defect signal, record the corresponding defect information, correct the defect information, and obtain the final accurate information corresponding to the defect signal. The specific analysis and correction process is as follows:

[0060] S51, read the defect information to find the incident angle A1 of the defect and the depth H1 of the defect from the scanning surface, such as Figure 3 As shown;

[0061] S52, select the propagation direction of the sound beam during the detection as the forward and backward movement direction of the phased array probe 11, use two phased array probes 11 with incident angles A1 to move back and forth on the metal plate, find the maximum reflected echo, and record the distance L between the incident points of the two phased array probes 11, such as Figure 4 As shown, the actual angle A is calculated using the formula A=arctan(L / 2T), where T is the thickness of the metal plate and A is the actual refraction angle of the sound beam that finds the defect in the metal plate;

[0062] S53. Calculate the actual sound velocity C in the metal plate using the formula sinA1 / sinA=C1 / C, where C1 is the sound velocity in the test block when the detection system is adjusted;

[0063] S54, the actual position information of the defect is: the actual depth of the defect from the scanning surface H = (C / C1)(cosA / cosA1)H1, the horizontal distance of the defect from the incident point of the sound beam Y = (C / C1)(sinA / cosA1)H1, such as Figure 5 As shown;

[0064] S55. Use the V-path method to determine the specific equivalent value of the defect and judge the defect according to the detection standard.

[0065] It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above and that the invention can be implemented in other specific forms without departing from the spirit or essential features of the invention. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description, and it is intended that all variations falling within the meaning and scope of the equivalent elements of the claims be included in the invention. Any reference numeral in a claim should not be considered as limiting the claim to which it relates.

Claims

1. A phased array ultrasonic detection method for anisotropic metal plate welds, characterized in that: The steps include: S1. Preparation work before testing: clean the surface of the metal plate weld and the surrounding area of ​​the weld; obtain the specific specification information of the metal plate; mark the weld information and the rolling direction of the metal plate base material on the metal plate; S2. Selection of instruments and testing parameters: Select the type of phased array ultrasonic testing instrument, encoder, linear array shear wave sensor and wedge, and determine the focus depth, refraction angle, number of scans, offset, sector scan mode and sector scan range; S3. Calibration of the detection system: Calibrate the detection system according to the operating instructions and detection standards of the selected instrument, including: wedge delay calibration, sound velocity calibration, sensitivity calibration, encoder calibration and TCG curve production; S4. Implement inspection: Conduct parent material inspection on the surrounding area of ​​the metal plate weld to ensure that there are no defects in the parent material of the metal plate that affect the propagation of the sound beam; Scan each area of ​​the weld in turn according to the instrument and detection parameters selected in step S2, and save the scanning detection data; S5. Detection result analysis: Analyze the saved scanning detection data, find out the defect signal, record the corresponding defect information, correct the defect information, and obtain the final accurate information corresponding to the defect signal.

2. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 1, characterized in that: The preparatory work before the inspection in step S1 also includes: performing an appearance inspection on the surface of the metal plate weld to ensure that the appearance of the metal plate weld meets the qualified acceptance requirements; Determine the relationship between the sound beam propagation direction during detection and the rolling direction of the metal plate base material.

3. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 1, characterized in that: The specific specification information of the metal plate in step S1 includes the base material thickness, weld length, weld width, joint form, groove setting and welding process; The marked weld related information includes the weld start point and weld centerline.

4. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 1, characterized in that: The method for selecting the linear array shear wave sensor in step S2 is: when the thickness of the metal plate is less than or equal to 25 mm, the linear array shear wave sensor adopts a 5L16-A10 phased array probe; when the thickness of the metal plate is 25-64 mm, the linear array shear wave sensor adopts a 5L32-A32 phased array probe.

5. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 1, characterized in that: In step S2: when detecting the lower part of the metal plate weld, the focusing depth of the linear array shear wave sensor is set to 1 times the thickness of the metal plate; when detecting the upper part of the metal plate weld, the focusing depth of the linear array shear wave sensor is set to 1.75 times the thickness of the metal plate.

6. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 1, characterized in that: In step S2: the path of the acoustic beam in the metal plate is simulated by BEAMTOOL software to determine the simulated refraction angle range A 小 ~A 大 , the offset between the moving trajectory of the phased array probe and the center line of the weld and the minimum number of scans to ensure that the entire inspection area is scanned, where A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline is located. 大 It is the maximum angle between the propagation direction of the sound beam and the vertical plane where the center line of the weld is located; At the same time, ensure that the angle between the sound beam propagation direction and the groove surface is less than or equal to 6°.

7. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 6, characterized in that: The method for determining the refraction angle range in step S2 is: S21, according to the formula L 小 =2T tanA 小 , find the minimum distance L between the two probe incident points 小 According to the formula L 大 =2T tanA 大 , find the maximum distance L between the two probe incident points 大 ; In the above formula, T is the thickness of the metal plate, A 小 A is the minimum angle between the propagation direction of the sound beam and the vertical plane where the weld centerline is located. 大 It is the maximum angle between the propagation direction of the sound beam and the vertical plane where the center line of the weld is located; S22. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 小 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 小 ; S23. Place two probes according to the propagation direction of the sound beam during the test. The distance between the incident points of the two probes is L. 大 ; Fix the positions of the two probes and adjust the incident angles of the two probes at the same time. Keep the incident angles of the two probes the same during the adjustment process. Adjust and detect at the same time to find the incident angle with the maximum reflected echo and record it as A1 大 ; S24, set the refraction angle range to A1 小 ~A1 大 ; The angle step value during the incident angle adjustment process is 0.5°.

8. The phased array ultrasonic detection method for anisotropic metal plate welds according to claim 7, characterized in that: The analysis and correction method of the defect information in step S5 is: S51, reading the incident angle A1 of the defect and the depth H1 of the defect from the scanning surface in the defect information; S52, selecting the propagation direction of the sound beam during the detection as the forward and backward movement direction of the phased array probe, using two phased array probes with incident angles A1 to move forward and backward on the metal plate, finding the maximum reflected echo, recording the distance L between the incident points of the two phased array probes, and using the formula A=arctan(L / 2T) to calculate the actual angle A, where T is the thickness of the metal plate, and A is the actual refraction angle of the sound beam that finds the defect in the metal plate; S53. Calculate the actual sound velocity C in the metal plate using the formula sinA1 / sinA=C1 / C, where C1 is the sound velocity in the test block when the detection system is adjusted; S54, the actual position information of the defect is: the actual depth of the defect from the scanning surface H = (C / C1)(cosA / cosA1)H1, the horizontal distance of the defect from the incident point of the sound beam Y = (C / C1)(sinA / cosA1)H1; S55. Use the V-path method to determine the specific equivalent value of the defect, judge the defect according to the detection standard, and obtain the final accurate information corresponding to the defect signal.

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