Ultrasonic detection test block and detection method
By designing ultrasonic detection test blocks and phased array detection methods, the detection blind spot problem of austenitic material welded joints is solved, and the coverage of full wall thickness detection and the reliability of detection results are improved.
Patent Information
- Application Number
- CN202510504113.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-04-22
- Publication Date
- 2025-08-29
AI Technical Summary
In the prior art, the ultrasonic detection of austenite material welded joints has a poor echo signal-to-noise ratio, the transverse wave is not applicable, and the longitudinal wave detection has a surface blind spot, so it is impossible to achieve double-sided detection, and traditional ultrasonic test blocks cannot meet the detection needs.
An ultrasonic detection test block is designed, including the first parent material sub-test block and the second parent material sub-test block prepared by austenite material, and welded to form a welded joint, and multiple blind holes and groove defects are provided on different sides for longitudinal and transverse defect reference sensitivity calibration and surface wave and crawling reference sensitivity calibration. Combined with phased array ultrasonic detection equipment and different wedges, the calibration and coverage of multiple detection methods is achieved.
The full wall thickness detection of austenite material welds is achieved, the detection coverage is increased, the reliability of the detection results is improved, the blind spot problem of traditional methods is overcome, and the detection efficiency is improved.
Smart Images
Figure CN120559098A_ABST
Abstract
Description
Technical Field
[0001] The embodiments of the present disclosure belong to the technical field of material detection, and particularly relate to an ultrasonic detection test block and a detection method. Background Art
[0002] Among the relevant detection technologies, the pulse reflection method is often used for ultrasonic detection of welded joints. However, for materials with austenitic structure, shear waves are generally not suitable for the detection of austenitic materials due to their large grains, large material attenuation, and poor echo signal-to-noise ratio. In the detection of austenitic materials, longitudinal waves are often used as the main detection waveform, but a single longitudinal wave is used to detect welds, so there will be certain blind spots on the weld surface. For high-temperature and high-pressure pipelines or other sealed structures, double-sided detection is not possible, and the surface blind spots pose a hidden danger to the safe operation of components.
[0003] In conventional ultrasonic testing, for full-wall thickness testing, it is necessary to produce ultrasonic test blocks corresponding to the testing method. However, the acoustic properties of austenitic material weld joints and the base material are quite different, and traditional ultrasonic test blocks cannot meet the testing needs. Summary of the Invention
[0004] The embodiments of the present disclosure aim to solve at least one of the technical problems existing in the prior art and provide an ultrasonic detection test block and a detection method.
[0005] In one aspect, an embodiment of the present disclosure provides an ultrasonic testing block, comprising a first parent material sub-block and a second parent material sub-block made of austenitic material, the two being welded and fixed to form a weld joint, wherein the weld joint is a weld region between the two; and
[0006] A plurality of first blind holes for longitudinal defect reference sensitivity calibration are respectively provided on the first side and the second side of the ultrasonic testing block;
[0007] The third side of the ultrasonic testing block is provided with a plurality of second blind holes for calibration of transverse defect reference sensitivity;
[0008] The fourth side of the ultrasonic testing block is provided with a groove defect for calibration of surface wave reference sensitivity, creeping wave reference sensitivity and wedge delay; wherein,
[0009] The groove defect used for wedge delay calibration is located in the first parent material sub-test block.
[0010] Optionally, the plurality of first blind holes on the first side are located at a weld fusion line where the weld area connects with the second parent material sub-test block, and are arranged at intervals along a height direction of the ultrasonic testing test block;
[0011] The plurality of first blind holes on the second side are located at the center of the weld in the weld area and are arranged at intervals along the height direction of the ultrasonic testing block.
[0012] Optionally, the ultrasonic testing block is a rectangular parallelepiped structure, and its length, width and height are 350 mm, 400 mm and 120 mm respectively; the first blind hole is a φ2 mm blind hole and has a length of 50 mm.
[0013] Optionally, the number of the first blind holes on the first side is seven, and vertical distances between the centers of the seven first blind holes and the fourth side surface of the ultrasonic testing block are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively;
[0014] There are seven first blind holes on the second side, and vertical distances between the centers of the seven first blind holes and the fourth side surface of the ultrasonic testing block are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively.
[0015] Optionally, the second blind hole on the third side is opened in the second parent material sub-test block, and the second blind hole passes through the weld fusion line where the weld area connects with the second parent material sub-test block, and ends at a first distance from the weld fusion line where the weld area connects with the first parent material sub-test block;
[0016] The plurality of second blind holes on the third side are arranged at intervals along a height direction of the ultrasonic testing block.
[0017] Optionally, the number of the second blind holes on the third side is six, and the vertical distances between the centers of the six second blind holes and the fourth side surface of the ultrasonic detection test block are 10 mm, 30 mm, 50 mm, 70 mm, 90 mm, and 115 mm, respectively. The first distance is 1 mm-2 mm, and the second blind holes are φ2 mm blind holes.
[0018] Optionally, a fourth side of the ultrasonic testing block is provided with a plurality of first notch defects located at a weld fusion line where the weld region connects with the first parent material sub-test block and spaced apart along the width direction of the ultrasonic testing block, wherein the length direction of the first notch defects is parallel to the length direction of the weld fusion line, and is used to calibrate the surface wave reference sensitivity;
[0019] The fourth side of the ultrasonic testing block is further provided with a second notch defect and a third notch defect located at the center of the weld in the weld area, and a fourth notch defect located at the weld fusion line where the weld area connects with the first parent material sub-test block. The length direction of the second notch defect is perpendicular to the length direction of the weld fusion line, and the length directions of the third notch defect and the fourth notch defect are parallel to the length direction of the weld fusion line, for calibrating the creeping wave reference sensitivity.
[0020] The fourth side of the ultrasonic inspection test block is also provided with a fifth notch defect located in the first parent material sub-test block. The length direction of the fifth notch defect is perpendicular to the length direction of the weld fusion line and is used to calibrate the wedge delay.
[0021] Optionally, there are four first groove defects, the depths of the four first groove defects are 0.2 mm, 0.4 mm, 0.8 mm, and 1.2 mm, respectively, the widths are 0.2 mm-1 mm, the lengths are 10 mm, and the center distance between two adjacent first groove defects is 25 mm;
[0022] The second groove defect, the third groove defect, the fourth groove defect and the fifth groove defect are all 4mm-6mm in depth, 0.2mm-1mm in width and 15mm-25mm in length.
[0023] Optionally, the fifth side of the ultrasonic testing block is provided with a sixth notch defect located at the weld fusion line where the weld region connects with the first parent material sub-test block, a seventh notch defect and an eighth notch defect located at the center of the weld in the weld region, and a ninth notch defect located in the first parent material sub-test block;
[0024] The length directions of the sixth and seventh notch defects are parallel to the length direction of the weld fusion line, and the length directions of the eighth and ninth notch defects are perpendicular to the length direction of the weld fusion line, so as to verify the feasibility of the detection process and settings when the focus is deep; wherein,
[0025] The depths of the sixth, seventh and ninth groove defects are all 4mm-6mm, the widths are all 0.2mm-1mm and the lengths are all 15mm-25mm; the depth of the eighth groove defect is 4mm-6mm, the width is 0.2mm-1mm and the length is the weld root length or slightly less than the weld root length.
[0026] On the other hand, an embodiment of the present disclosure provides a detection method using an ultrasonic detection test block, using the ultrasonic detection test block described above, the detection method includes:
[0027] Provide phased array ultrasonic testing equipment, phased array probes, creeping wave and surface wave wedges;
[0028] Determine the detection frequency and calculate the phased array fan scan coverage area, creeping wave and surface wave coverage area;
[0029] Different focusing laws are set for different depths inside the ultrasonic inspection test block, the sound velocity and wedge delay are calibrated, and TCG curves are generated. The longitudinal primary wave is used to detect transverse and longitudinal defects in the middle and lower parts outside the weld blind zone and the weld root area;
[0030] Replace the creeping wave wedge, use the ultrasonic detection test block to calibrate the sensitivity and creeping wave wedge delay respectively, and use creeping wave to realize the detection of the near-surface area of the weld; and replace the surface wave wedge, use the ultrasonic detection test block to produce the distance-amplitude curve, and use surface wave to realize the detection of the upper surface area of the weld.
[0031] The ultrasonic inspection test block and inspection method of the embodiments of the present disclosure, through the improvement of the test block and the setting of focusing laws for different depths and surfaces of the weld, can meet the calibration of various inspection methods, cover the interior of the weld and the blind area of the primary longitudinal wave inspection surface, increase the inspection coverage, and improve the reliability of the inspection results. BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Figure 1 This is a schematic structural diagram of an ultrasonic testing block according to an embodiment of the present disclosure;
[0033] Figure 2 for Figure 1 A front view of an ultrasonic test block;
[0034] Figure 3 for Figure 1 Rear view of the ultrasonic test block;
[0035] Figure 4 for Figure 1 Right side view of the ultrasonic test block;
[0036] Figure 5 for Figure 1 A cross-sectional view of the second blind hole in the right view of the ultrasonic testing block in the front view;
[0037] Figure 6 for Figure 1 A top view of an ultrasonic testing block;
[0038] Figure 7 for Figure 1 Bottom view of the ultrasonic test block. DETAILED DESCRIPTION
[0039] In order to enable those skilled in the art to better understand the technical solutions of the present disclosure, the present disclosure is further described in detail below with reference to the accompanying drawings and specific implementation methods.
[0040] like Figures 1 to 7 As shown, an ultrasonic testing block 100 includes a first parent material sub-test block 110 and a second parent material sub-test block 120 made of austenitic material, which are welded to form a weld joint. The weld joint is the weld region 200 between the two. A plurality of first blind holes 130 for longitudinal defect reference sensitivity calibration are provided on the first and second sides of the ultrasonic testing block 100.
[0041] The third side of the ultrasonic testing block 100 is provided with a plurality of second blind holes 140 for calibrating transverse defect benchmark sensitivity. A fourth side of the ultrasonic testing block 100 is provided with a notched defect 150 for calibrating surface wave benchmark sensitivity, creeping wave benchmark sensitivity, and wedge delay. The notched defect for wedge delay calibration is located in the first parent material sub-block 110.
[0042] Specifically, if Figures 1 to 7 As shown, the front of the ultrasonic test block 100 is provided with multiple first blind holes 130 of varying heights for longitudinal defect benchmark sensitivity calibration. The back of the ultrasonic test block 100 is also provided with multiple first blind holes 130 of varying heights for longitudinal defect benchmark sensitivity calibration. The right side of the ultrasonic test block 100 is provided with multiple second blind holes 140 of varying heights for transverse defect benchmark sensitivity calibration. The weld area 200 on the top surface of the ultrasonic test block 100 is provided with notch defects 150 at different locations for detecting surface blind areas and for calibrating surface wave benchmark sensitivity and creeping wave benchmark sensitivity. Furthermore, the top surface of the first parent material sub-test block 110 is provided with a notch defect 150 for wedge delay calibration.
[0043] As a specific example, the first parent material sub-test block 110 and the second parent material sub-test block 120 are both austenitic high-temperature alloys, and a number of defect features are provided inside the weld joint and the parent material sub-test blocks. The surface roughness of the ultrasonic inspection test block 100 is less than or equal to 12.5, and the surface roughness can be further set to be less than or equal to 3.2.
[0044] It is easy to understand that the aforementioned defect features include a first blind hole for calibrating the baseline sensitivity of longitudinal defects at the weld fusion line and the center of the weld, a second blind hole for calibrating the baseline sensitivity of transverse defects at the weld, and a notch defect for calibrating the surface wave baseline sensitivity, creeping wave baseline sensitivity, and wedge delay.
[0045] For example, Figures 1 to 7As shown, the plurality of first blind holes 130 on the first side are located at the weld fusion line where the weld region 200 and the second parent material sub-test block 120 meet, and are spaced apart along the height direction of the ultrasonic testing block 100. The plurality of first blind holes 130 on the second side are located at the center of the weld in the weld region 200, and are spaced apart along the height direction of the ultrasonic testing block 100.
[0046] Furthermore, the ultrasonic testing block 100 is a rectangular parallelepiped structure, and its length, width, and height are 350 mm, 400 mm, and 120 mm respectively. The first blind hole 130 is a φ2 mm blind hole and has a length of 50 mm.
[0047] As a specific example, there are seven first blind holes 130 on the first side, and the vertical distances between the centers of the seven first blind holes 130 and the fourth side surface of the ultrasonic testing block 100 are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively. There are seven first blind holes 130 on the second side, and the vertical distances between the centers of the seven first blind holes 130 and the fourth side surface of the ultrasonic testing block 100 are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively.
[0048] Specifically, the first blind holes 130 on the first side of the ultrasonic inspection test block 100 are defects located at the weld fusion line. They are all φ2mm blind holes with a length of 50mm. They are arranged in sequence from top to bottom along the weld fusion line. The distances between the centers of the seven circular holes 130 and the upper surface of the test block 100 are 5mm, 15mm, 35mm, 55mm, 75mm, 95mm, and 115mm, respectively.
[0049] The first blind holes 130 on the second side of the ultrasonic inspection test block 100 are defects located at the center of the weld. They are all φ2 mm blind holes with a length of 50 mm. They are arranged in sequence from top to bottom along the center of the weld. The distances between the centers of the seven circular holes 130 and the upper surface of the test block 100 are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively.
[0050] For example, Figures 1 to 7 As shown, the second blind holes 140 on the third side are opened in the second parent material sub-test block 120. The second blind holes 140 penetrate the weld fusion line between the weld region 200 and the second parent material sub-test block 120 and terminate at a first distance from the weld fusion line between the weld region 200 and the first parent material sub-test block 110. The plurality of second blind holes 140 on the third side are spaced apart along the height direction of the ultrasonic testing test block 110.
[0051] Furthermore, the number of the second blind holes 140 on the third side is set to six, and the vertical distances between the centers of the six second blind holes 140 and the fourth side surface of the ultrasonic testing block 100 are 10 mm, 30 mm, 50 mm, 70 mm, 90 mm, and 115 mm, respectively. The first distance is 1 mm-2 mm, and the second blind holes 140 are φ2 mm blind holes.
[0052] Specifically, if Figures 1 to 7 As shown, the second blind holes 140 are defects that pass through the fusion line on one side of the weld and end 1mm-2mm away from the fusion line on the other side. They are all φ2mm blind holes. The distances between the centers of the six circular holes 140 and the upper surface of the test block 100 are 10mm, 30mm, 50mm, 70mm, 90mm, and 115mm, respectively.
[0053] For example, Figures 1 to 7 As shown, the fourth side of the ultrasonic inspection test block 100 is provided with a plurality of first groove defects 151 located at the weld fusion line where the weld area 200 connects with the first parent material sub-test block 110 and arranged at intervals along the width direction of the ultrasonic inspection test block 100. The length direction of the first groove defects 151 is parallel to the length direction of the weld fusion line and is used to calibrate the surface wave reference sensitivity.
[0054] The fourth side of the ultrasonic inspection test block 100 is also provided with a second notch defect 152 and a third notch defect 153 located at the center of the weld in the weld area 200, and a fourth notch defect 154 located at the weld fusion line where the weld area 200 connects with the first parent material sub-test block 110. The length direction of the second notch defect 152 is perpendicular to the length direction of the weld fusion line, and the length directions of the third notch defect 153 and the fourth notch defect 154 are parallel to the length direction of the weld fusion line, which are used to calibrate the creeping wave reference sensitivity.
[0055] The fourth side of the ultrasonic testing block 100 is further provided with a fifth notch defect 155 located on the first parent material sub-test block 110. The length direction of the fifth notch defect 155 is perpendicular to the length direction of the weld fusion line and is used to calibrate the wedge delay.
[0056] Furthermore, there are four first groove defects 151, with depths of 0.2 mm, 0.4 mm, 0.8 mm, and 1.2 mm, widths of 0.2 mm to 1 mm, and lengths of 10 mm, respectively. Furthermore, the center-to-center distance between two adjacent first groove defects 151 is 25 mm. The second groove defect 152, third groove defect 153, fourth groove defect 154, and fifth groove defect 155 are all 4 mm to 6 mm deep, 0.2 mm to 1 mm wide, and 15 mm to 25 mm long.
[0057] Specifically, if Figures 1 to 7 As shown, the first groove defect 151 is a defect located at the fusion line on the weld surface. The length direction of the defect is parallel to the weld direction, and the length is 10 mm. The center spacing between adjacent first groove defects 151 is 25 mm. The width of the first groove defect 151 can be 0.2 mm-1.0 mm. The depths of the four first groove defects 151 are 0.2 mm, 0.4 mm, 0.8 mm, and 1.2 mm, respectively.
[0058] Second notch defect 152 is located at the center of the weld surface and perpendicular to the weld length. Third notch defect 153 is located at the center of the weld surface and parallel to the weld length. Fourth notch defect 154 is located at the weld fusion line and parallel to the weld length. Fifth notch defect 155 is located in first parent metal sub-test block 110 and perpendicular to the weld length. Second notch defect 152, third notch defect 153, fourth notch defect 154, and fifth notch defect 155 all have a depth of 4 mm to 6 mm, a width of 0.2 mm to 1 mm, and a length of 15 mm to 25 mm.
[0059] For example, Figures 1 to 7 As shown, the fifth side of the ultrasonic inspection test block 100 is provided with a sixth notch defect 156 located at the weld fusion line where the weld area 200 connects with the first parent material sub-test block 110, a seventh notch defect 157 and an eighth notch defect 158 located at the center of the weld in the weld area 200, and a ninth notch defect 159 located in the first parent material sub-test block 110.
[0060] The lengths of the sixth and seventh notch defects 156 and 157 are parallel to the length of the weld fusion line, while the lengths of the eighth and ninth notch defects 158 and 159 are perpendicular to the length of the weld fusion line, to verify the feasibility of the inspection process and configuration when focusing deeply. The sixth, seventh, and ninth notch defects 156, 157, and 158 are all 4mm-6mm deep, 0.2mm-1mm wide, and 15mm-25mm long. The eighth notch defect 159 is 4mm-6mm deep, 0.2mm-1mm wide, and equals or slightly less than the weld root length.
[0061] Specifically, if Figures 1 to 7 As shown, the sixth notch defect 156 is located at the fusion line on the bottom surface of the weld and is parallel to the length of the weld. The seventh notch defect 157 is located at the center of the bottom surface of the weld and is parallel to the length of the weld. The eighth notch defect 158 is located at the center of the weld on the bottom surface of the weld and is perpendicular to the length of the weld. The ninth notch defect 159 is located in the first parent material sub-test block 110 and is perpendicular to the length of the weld. The sixth notch defect 156, the seventh notch defect 157, and the ninth notch defect 158 are all 4mm-6mm deep, 0.2mm-1mm wide, and 15mm-25mm long. The eighth notch defect 159 is 4mm-6mm deep, 0.2mm-1mm wide, and is the length of the weld root or slightly less.
[0062] As an example, when the ultrasonic testing block 100 according to the embodiment of the present disclosure is used for testing, the specific testing steps are as follows:
[0063] S01. Pre-treat the surface of the ultrasonic inspection test block 100 to remove surface oil and other factors that may affect detection. S02. Prepare phased array ultrasonic testing equipment, phased array probes, and specialized wedges for creeping waves and surface waves. S03. Determine the frequency for testing and calculate the coverage area of the phased array sector scan, creeping waves, and surface waves. S04. Using the ultrasonic inspection test block 100, set different focal laws for defects of different depths within the ultrasonic inspection test block 100, calibrate the sound velocity and wedge delay, and generate TCG curves. Use the primary longitudinal wave to detect transverse and longitudinal defects in the lower middle portion and weld root area outside the weld blind zone, and record the test data. S05. Replace the creeping wave wedge. Using the ultrasonic inspection test block 100, calibrate the sensitivity and creeping wave wedge delay. Use creeping waves to detect near-surface areas of the weld, and record the test data. S06. Replace the surface wave wedge. Use the ultrasonic inspection test block 100 to generate a distance-amplitude curve. Use surface waves to detect the upper surface area of the weld, and record the test data.
[0064] In step S03, the coverage of a longitudinal wave scan can be simulated by the phased array equipment software. The creeping wave scan depth can be calculated using the following formula: In this formula, d is the creeping wave detection depth, and λ is the wavelength in the ultrasonic detection test block 100.
[0065] In step S04, for weld inspection of the thick-walled austenitic ultrasonic testing block 100, the focal laws for different depths in Setting 3 of Appendix I of NB / T47013.15 can be used as a reference. The refracted wave is a longitudinal wave, and the angle range meets the Hanneng coverage requirements, with a maximum of 75°. A TCG curve can be produced using the second blind hole 140 in the second parent material sub-test block 120. The first blind hole 130 on the first side is used to calibrate the sensitivity for detecting defects at the fusion line and longitudinal defects at the opposite fusion line. The first blind hole 130 on the second side is used to calibrate the sensitivity for detecting longitudinal defects at the center of the weld. The second blind hole 140 in the weld area 200 is used to calibrate the sensitivity for detecting transverse defects in the weld. When focusing deeper, the sixth, seventh, and eighth notches can be used to verify the feasibility of the inspection process and settings.
[0066] In step S05, a creeping wave focusing rule is set for the surface blind area, the phased array probe is aligned with the groove depth required by the process sensitivity, the phased array probe is moved back and forth, the creeping wave signal is confirmed according to the creeping wave characteristics, the probe is moved back and forth so that the distance between the probe front and the groove remains at the process set distance, the gain is adjusted so that the signal reaches 80% of the wave height under the full screen scale, and the sensitivity setting is completed. The ultrasonic inspection test block 100 can complete the creeping wave sensitivity setting through the second groove defect 152, the third groove defect 153, the fourth groove defect 154 and the fifth groove defect 155. The fifth groove defect 155 can be used to set the detection sensitivity of the first parent material sub-test block 110, the second groove defect 152 can be used to set the detection sensitivity of the weld transverse defect, the third groove defect 153 can be used to set the detection sensitivity of the longitudinal defect in the center of the weld, and the fourth groove defect 154 can be used to set the detection sensitivity of the longitudinal defect at the fusion line of the weld.
[0067] In step S06, based on the agreed groove depth, one of the four first groove defects 151 is selected, and the probe is placed at a certain position away from the defect so that the main acoustic beam of the surface wave is perpendicular to the groove defect. The probe is rotated to maximize the amplitude of the reflected echo, and then the echo is adjusted to 80% of the wave height of the full screen. The probe is then placed at at least three different distances, and the maximum wave height at each distance is measured. The maximum wave heights at different distances are connected into a smooth curve, which is the surface wave horizontal distance-amplitude curve. At this sensitivity, the corresponding coupling compensation is then added as the scanning sensitivity for detection and recording. The surface wave sensitivity of the ultrasonic inspection test block 100 of the embodiment of the present disclosure is set to the first groove defect 151. The probe can be placed on the opposite side of the groove defect to set the sensitivity to detect the weld surface, or the probe can be placed on the same side of the groove defect to set the sensitivity to detect the surface defects of the first parent material sub-test block 110.
[0068] The ultrasonic testing block of the embodiment of the present disclosure has the following beneficial effects:
[0069] 1. The sensitivity setting of full-wall-thickness weld inspection of thick austenitic forgings can be completed with a single test block, and the inspection process can be verified.
[0070] 2. Creeping wave detection and surface wave detection can be used to cover the blind area of the surface of the primary longitudinal wave detection, which can better play the advantages of each detection method, make the sound beam better focused at the required distance on the test block, increase the sound energy in the focused area, reduce the influence of the material on the signal-to-noise ratio, and improve the defect detection effect on the surface and near-surface of the workpiece.
[0071] 3. Phased array primary longitudinal wave detection can be used to improve the detection rate of adjacent defects by setting focusing laws at different depths, and can also effectively solve the problems of single incident angle and low detection efficiency of traditional ultrasonic detection.
[0072] 4. The utilization rate of the test blocks is high, which can avoid the conventional single method of making corresponding test blocks, reduce the test block production cycle, and improve the detection efficiency. The present disclosure can also be used for the production of curved test blocks.
[0073] It is not difficult to understand that the ultrasonic inspection test block of the embodiment of the present disclosure is respectively provided with longitudinal blind hole defects, transverse blind hole defects, surface wave notch defects, and creeping wave notch defects of the weld. The parent material section of the transverse blind hole defect can be used to draw the TCG curve. During the inspection process, the blind holes at the weld fusion line and the weld center of the ultrasonic inspection test block can be used to calibrate the detection sensitivity of the weld fusion line and the weld center, respectively. Notch defects of different depths at different locations on the surface of the ultrasonic inspection test block are used to calibrate the creeping wave sensitivity of the weld fusion line and the weld center. In addition, notch defects of different depths on the surface of the ultrasonic inspection test block are also used to calibrate the surface wave sensitivity.
[0074] On the other hand, an embodiment of the present disclosure provides a detection method using an ultrasonic detection test block, using the ultrasonic detection test block described above. The specific structure of the ultrasonic detection test block can be referred to the relevant description above and will not be described in detail here. The detection method includes: providing a phased array ultrasonic detection device, a phased array probe, and creeping wave and surface wave wedges. Determining the detection frequency and calculating the phased array fan scan coverage area, creeping wave and surface wave coverage area. Setting different focusing laws for different depths inside the ultrasonic detection test block, calibrating the sound velocity and wedge delay, and producing a TCG curve. Using the longitudinal wave primary wave, transverse and longitudinal defects in the lower middle part and the root area outside the weld blind area are detected. Replacing the creeping wave wedge, using the ultrasonic detection test block to calibrate the sensitivity and creeping wave wedge delay, respectively, using the creeping wave to detect the near-surface area of the weld. And, replacing the surface wave wedge, using the ultrasonic detection test block to produce a distance-amplitude curve, and using the surface wave to detect the upper surface area of the weld.
[0075] As a specific embodiment, the detection process is as follows:
[0076] S01. Pre-treat the surface of the ultrasonic inspection test block 100 to remove surface oil and other factors that may affect detection. S02. Prepare phased array ultrasonic testing equipment, phased array probes, and specialized wedges for creeping waves and surface waves. S03. Determine the frequency for testing and calculate the coverage area of the phased array sector scan, creeping waves, and surface waves. S04. Using the ultrasonic inspection test block 100, set different focal laws for defects of different depths within the ultrasonic inspection test block 100, calibrate the sound velocity and wedge delay, and generate TCG curves. Use the primary longitudinal wave to detect transverse and longitudinal defects in the lower middle portion and weld root area outside the weld blind zone, and record the test data. S05. Replace the creeping wave wedge. Using the ultrasonic inspection test block 100, calibrate the sensitivity and creeping wave wedge delay. Use creeping waves to detect near-surface areas of the weld, and record the test data. S06. Replace the surface wave wedge. Use the ultrasonic inspection test block 100 to generate a distance-amplitude curve. Use surface waves to detect the upper surface area of the weld, and record the test data.
[0077] In step S03, the coverage of a longitudinal wave scan can be simulated by the phased array equipment software. The creeping wave scan depth can be calculated using the following formula: In this formula, d is the creeping wave detection depth, and λ is the wavelength in the ultrasonic detection test block 100.
[0078] In step S04, for weld inspection of the thick-walled austenitic ultrasonic testing block 100, the focal laws for different depths in Setting 3 of Appendix I of NB / T47013.15 can be used as a reference. The refracted wave is a longitudinal wave, and the angle range meets the Hanneng coverage requirements, with a maximum of 75°. A TCG curve can be produced using the second blind hole 140 in the second parent material sub-test block 120. The first blind hole 130 on the first side is used to calibrate the sensitivity for detecting defects at the fusion line and longitudinal defects at the opposite fusion line. The first blind hole 130 on the second side is used to calibrate the sensitivity for detecting longitudinal defects at the center of the weld. The second blind hole 140 in the weld area 200 is used to calibrate the sensitivity for detecting transverse defects in the weld. When focusing deeper, the sixth, seventh, and eighth notches can be used to verify the feasibility of the inspection process and settings.
[0079] In step S05, a creeping wave focusing rule is set for the surface blind area, the phased array probe is aligned with the groove depth required by the process sensitivity, the phased array probe is moved back and forth, the creeping wave signal is confirmed according to the creeping wave characteristics, the probe is moved back and forth so that the distance between the probe front and the groove remains at the process set distance, the gain is adjusted so that the signal reaches 80% of the wave height under the full screen scale, and the sensitivity setting is completed. The ultrasonic inspection test block 100 can complete the creeping wave sensitivity setting through the second groove defect 152, the third groove defect 153, the fourth groove defect 154 and the fifth groove defect 155. The fifth groove defect 155 can be used to set the detection sensitivity of the first parent material sub-test block 110, the second groove defect 152 can be used to set the detection sensitivity of the weld transverse defect, the third groove defect 153 can be used to set the detection sensitivity of the longitudinal defect in the center of the weld, and the fourth groove defect 154 can be used to set the detection sensitivity of the longitudinal defect at the fusion line of the weld.
[0080] In step S06, based on the agreed groove depth, one of the four first groove defects 151 is selected, and the probe is placed at a certain position away from the defect so that the main acoustic beam of the surface wave is perpendicular to the groove defect. The probe is rotated to maximize the amplitude of the reflected echo, and then the echo is adjusted to 80% of the wave height of the full screen. The probe is then placed at at least three different distances, and the maximum wave height at each distance is measured. The maximum wave heights at different distances are connected into a smooth curve, which is the surface wave horizontal distance-amplitude curve. At this sensitivity, the corresponding coupling compensation is then added as the scanning sensitivity for detection and recording. The surface wave sensitivity of the ultrasonic inspection test block 100 of the embodiment of the present disclosure is set to the first groove defect 151. The probe can be placed on the opposite side of the groove defect to set the sensitivity to detect the weld surface, or the probe can be placed on the same side of the groove defect to set the sensitivity to detect the surface defects of the first parent material sub-test block 110.
[0081] As another specific embodiment, the detection process is as follows:
[0082] N01. Pre-treat the surface of the ultrasonic test block 100. N02. Prepare portable phased array ultrasonic testing equipment, phased array probes, and specialized wedges for creeping waves and surface waves. N03. Determine the testing frequency and calculate the coverage area of the phased array sector scan, creeping waves, and surface waves. N04. Using the ultrasonic test block 100, set focal laws for internal and surface defects within the ultrasonic test block 100, respectively. N05. Calibrate the sensitivity of longitudinal waves, creeping waves, and surface waves using the ultrasonic test block 100. N06. Perform on-site testing and record the data.
[0083] In step N01, it includes polishing the scanning surface, removing foreign objects on the surface that hinder the movement of the probe, ensuring that the surface roughness of the probe scanning area is Ra≤12.5, and determining the scanning range and marking it.
[0084] In step N02, prepare the phased array probe. For austenitic material testing, select an appropriate frequency based on the material's properties, typically between 1 MHz and 5 MHz. A higher probe frequency should be selected while ensuring ultrasonic penetration. Prepare the phased array ultrasonic wedges (creeping wave or surface wave wedges). These wedges are typically made of plexiglass or polystyrene. The phased array ultrasonic testing system, consisting of the phased array probe and instrument, can simultaneously excite at least 32 elements.
[0085] In steps N03, N04, and N05, the settings for a single longitudinal wave (direct method) inspection outside the weld blind area can refer to the contents of Appendix I of NB / T47013.15. The inspection thickness is between 80mm and 120mm, and the focal depth is recommended to be set to 90-120mm. The entire wall thickness range is inspected at least three times using the focal law, and it is ensured that each section of the inspection meets the inspection standards and has a certain coverage rate. The surface of the ultrasonic inspection test block 100 is engraved with longitudinal and transverse groove defects to calibrate the creeping wave detection sensitivity of the weld and fusion line. The surface of the ultrasonic inspection test block 100 is engraved with groove defects of different depths at the weld fusion line to calibrate the surface wave detection sensitivity of the weld and fusion line.
[0086] In step N05, the creeping wave signal is confirmed by moving the phased array probe back and forth, based on the signal on the phased array device that moves with the probe. The relative position of the probe and the weld is determined based on the weld width to ensure proper coverage. The gain is adjusted to achieve 80% of the full-screen scale, completing the sensitivity setting.
[0087] In step N05, move the phased array probe back and forth to confirm the surface wave signal based on the surface wave characteristics. The surface wave signal can be confirmed by pressing with a finger between the probe and the groove defect to see if the ultrasonic signal changes.
[0088] It is understood that the above embodiments are merely exemplary embodiments for illustrating the principles of the present disclosure, and the present disclosure is not limited thereto. Those skilled in the art may make various modifications and improvements without departing from the spirit and substance of the present disclosure, and such modifications and improvements are also considered to be within the scope of protection of the present disclosure.
Claims
1. An ultrasonic testing block, characterized in that: The ultrasonic testing block includes a first parent material sub-test block and a second parent material sub-test block made of austenitic material, the two are welded and fixed to form a weld joint, and the weld joint is a weld area between the two; and A plurality of first blind holes for longitudinal defect reference sensitivity calibration are respectively provided on the first side and the second side of the ultrasonic testing block; The third side of the ultrasonic testing block is provided with a plurality of second blind holes for calibration of transverse defect reference sensitivity; The fourth side of the ultrasonic testing block is provided with a groove defect for calibration of surface wave reference sensitivity, creeping wave reference sensitivity and wedge delay; wherein, The groove defect used for wedge delay calibration is located in the first parent material sub-test block.
2. The ultrasonic testing block according to claim 1, characterized in that: The plurality of first blind holes on the first side are located at the weld fusion line where the weld area connects with the second parent material sub-test block, and are arranged at intervals along the height direction of the ultrasonic testing test block; The plurality of first blind holes on the second side are located at the center of the weld in the weld area and are arranged at intervals along the height direction of the ultrasonic testing block.
3. The ultrasonic testing block according to claim 2, characterized in that: The ultrasonic testing block is a rectangular parallelepiped structure, and its length, width and height are 350 mm, 400 mm and 120 mm respectively; the first blind hole is a φ2 mm blind hole and has a length of 50 mm.
4. The ultrasonic testing block according to claim 3, characterized in that: There are seven first blind holes on the first side, and vertical distances between the centers of the seven first blind holes and the fourth side surface of the ultrasonic testing block are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively; There are seven first blind holes on the second side, and vertical distances between the centers of the seven first blind holes and the fourth side surface of the ultrasonic testing block are 5 mm, 15 mm, 35 mm, 55 mm, 75 mm, 95 mm, and 115 mm, respectively.
5. The ultrasonic testing block according to claim 3, characterized in that: The second blind hole on the third side is opened in the second parent material sub-test block, and the second blind hole passes through the weld fusion line where the weld area connects with the second parent material sub-test block, and ends at a first distance from the weld fusion line where the weld area connects with the first parent material sub-test block; The plurality of second blind holes on the third side are arranged at intervals along a height direction of the ultrasonic testing block.
6. The ultrasonic testing block according to claim 5, characterized in that: There are six second blind holes on the third side, and the vertical distances between the centers of the six second blind holes and the fourth side surface of the ultrasonic testing block are 10 mm, 30 mm, 50 mm, 70 mm, 90 mm, and 115 mm, respectively. The first distance is 1 mm-2 mm, and the second blind holes are φ2 mm blind holes.
7. The ultrasonic testing block according to claim 3, characterized in that: A plurality of first notch defects are provided on the fourth side of the ultrasonic testing block, located at the weld fusion line where the weld region connects with the first parent material sub-test block, and spaced apart along the width direction of the ultrasonic testing block. The length direction of the first notch defects is parallel to the length direction of the weld fusion line, and are used to calibrate the surface wave reference sensitivity. The fourth side of the ultrasonic testing block is further provided with a second notch defect and a third notch defect located at the center of the weld in the weld area, and a fourth notch defect located at the weld fusion line where the weld area connects with the first parent material sub-test block. The length direction of the second notch defect is perpendicular to the length direction of the weld fusion line, and the length directions of the third notch defect and the fourth notch defect are parallel to the length direction of the weld fusion line, for calibrating the creeping wave reference sensitivity. The fourth side of the ultrasonic inspection test block is also provided with a fifth notch defect located in the first parent material sub-test block. The length direction of the fifth notch defect is perpendicular to the length direction of the weld fusion line and is used to calibrate the wedge delay.
8. The ultrasonic testing block according to claim 7, characterized in that: There are four first groove defects, the depths of the four first groove defects are 0.2 mm, 0.4 mm, 0.8 mm, and 1.2 mm, respectively, the widths are 0.2 mm to 1 mm, the lengths are 10 mm, and the center distance between two adjacent first groove defects is 25 mm; The second groove defect, the third groove defect, the fourth groove defect and the fifth groove defect are all 4mm-6mm in depth, 0.2mm-1mm in width and 15mm-25mm in length.
9. The ultrasonic testing block according to any one of claims 1 to 8, characterized in that: The fifth side of the ultrasonic testing block is provided with a sixth notch defect located at the fusion line of the weld where the weld region joins the first parent material sub-test block, a seventh notch defect and an eighth notch defect located at the center of the weld in the weld region, and a ninth notch defect located in the first parent material sub-test block; The length directions of the sixth and seventh notch defects are parallel to the length direction of the weld fusion line, and the length directions of the eighth and ninth notch defects are perpendicular to the length direction of the weld fusion line, so as to verify the feasibility of the detection process and settings when the focus is deep; wherein, The depths of the sixth, seventh and ninth groove defects are all 4mm-6mm, the widths are all 0.2mm-1mm and the lengths are all 15mm-25mm; the depth of the eighth groove defect is 4mm-6mm, the width is 0.2mm-1mm and the length is the weld root length or slightly less than the weld root length.
10. A detection method using an ultrasonic detection test block, characterized in that: Using the ultrasonic testing block according to any one of claims 1 to 9, the testing method comprises: Provide phased array ultrasonic testing equipment, phased array probes, creeping wave and surface wave wedges; Determine the detection frequency and calculate the phased array fan scan coverage area, creeping wave and surface wave coverage area; Different focusing laws are set for different depths inside the ultrasonic inspection test block, the sound velocity and wedge delay are calibrated, and TCG curves are generated. The longitudinal primary wave is used to detect transverse and longitudinal defects in the middle and lower parts outside the weld blind zone and the weld root area; Replace the creeping wave wedge, use the ultrasonic detection test block to calibrate the sensitivity and creeping wave wedge delay respectively, and use creeping wave to realize the detection of the near-surface area of the weld; and replace the surface wave wedge, use the ultrasonic detection test block to produce the distance-amplitude curve, and use surface wave to realize the detection of the upper surface area of the weld.