Angle gain compensation test block and debugging method for phased array detection of curved longitudinal welds

Abstract

The present invention discloses a phased array detection angle gain compensation test block for curved longitudinal welds, belonging to the technical field of phased array ultrasonic detection. The test block comprises a body and a boss, arc surface two and arc surface three are arranged on both sides of the body, and plane one is arranged between arc surface two and arc surface three. Arc surface one is arranged on the top of the body, plane two and plane three are arranged on both sides of arc surface one, and plane one, plane two and plane three are parallel to each other. The radius of arc surface two and arc surface three are equal, and arc surface two, arc surface three and arc surface four on the boss are coaxially arranged. The axes of arc surface two, arc surface three and arc surface four are located on the median perpendicular plane of plane one, and the central axis of arc surface one is located on the median perpendicular plane. The plane passing through the axis of arc surface four and parallel to plane one is tangent to arc surface one. The present invention adopts the phased array ultrasonic detection angle gain compensation test block of the above structure, which can solve the problem that the existing ultrasonic test block cannot be used for making angle gain compensation curves when phased array fan-shaped scanning is used to detect curved longitudinal welds.

Description

Technical Field

[0001] The invention belongs to the technical field of phased array ultrasonic testing, and in particular relates to an angle gain compensation test block for curved surface longitudinal weld phased array ultrasonic testing and a debugging method thereof. Background Art

[0002] Phased array ultrasonic testing technology is a new direction and new driving force for the development of non-destructive testing technology at home and abroad, and is one of the most advanced testing technologies. Phased array ultrasonic technology is a method of using electronic means to control the sound beam of a phased array ultrasonic probe to achieve ultrasonic emission and reception. The phased array ultrasonic probe has multiple small chips, namely array elements. Each array element is independently excited and has different time delays. The ultrasonic waves emitted by all array elements form an overall wavefront, which can achieve dynamic focusing and effectively control the shape and direction of the transmitted ultrasonic beam. It provides greater capabilities than single or multiple conventional ultrasonic probe systems to determine the shape, size and direction of defects. Phased array ultrasonic testing technology has an imaging function, and the test results are displayed in the form of images, which are divided into A scan, B scan, S scan, E scan and P scan, etc., which are intuitive and easy to understand. The stored data has a dynamic playback function and can also record the scanning position. These functions are difficult to achieve with conventional ultrasonic testing technology.

[0003] Phased array ultrasonic testing technology has begun to be applied in my country. For example, it is used to detect pipeline girth welds in the West-East Gas Pipeline Project, and thin-walled pipe girth welds in Lu'an, Anqing Thermal Power Plant and Tongling Power Plant in Anhui Province. It is also used to detect the roots of steam turbine blades and turbine discs, train axles, insulation panels of nuclear power plant main pumps, and longitudinal and girth seams of special equipment containers. It has a huge application space, reflecting the superiority of phased array ultrasonic testing.

[0004] There are a lot of curved longitudinal welds to be inspected during the installation and maintenance of special equipment pressure vessels, power plant boilers, oil and gas pipelines, ships and other industries. Conventional ultrasonic testing of curved longitudinal welds must meet two conditions before they can be inspected, namely: one is that the radius of curvature is 50mm to 250mm, and the other is that the ratio of the inner and outer diameters is greater than or equal to 70%. In other words, conventional ultrasonic testing has limitations, while phased array ultrasonic testing has no limitations, showing the advantages of phased array technology. The advantages of phased array ultrasonic testing technology are mainly reflected in the use of multiple angles for detection, namely, sector scanning detection and dynamic focusing. However, the most effective method for phased array ultrasonic testing is to use sector scanning technology. The most common and efficient way of phased array sector scanning detection is to use non-parallel scanning (that is, the phased array probe keeps a certain distance from the center line of the weld and moves parallel to the weld direction, and an encoder is used to record the walking position). There are two problems with phased array sector scanning detection: one is that the angle changes within a certain range during the sector scanning process, which not only changes the incident point, but also changes the effective active aperture of the wafer. The other is that the phased array ultrasonic sector scanning moves back and forth on the test block when making the distance-amplitude curve, while the actual detection uses non-parallel scanning. These two problems determine that the phased array ultrasonic sector scanning detection must produce an angle gain compensation curve. The angle gain compensation curve must be produced using a test block. At present, the domestic and international standards for phased array ultrasonic testing have the following deficiencies in the test block for making angle gain compensation:

[0005] ① In the current non-destructive testing standards at home and abroad, the test blocks for angle gain compensation curves produced by phased array sector scanning are suitable for curved circumferential welds and flat welds, and there are no test blocks suitable for curved longitudinal welds. For example, ASTM E2491 in ASME of the United States, ISO13588 of the European Union, and DL / T1718 and GB / T32563 in China do not stipulate the use of phased array sector scanning to detect longitudinal welds with a curvature radius of 50mm to 250mm to produce angle gain compensation test blocks.

[0006] ② Since the curvature radius of the curved longitudinal weld is 50mm to 250mm, it is unrealistic and impossible to operate if too many test blocks are used to make angle gain compensation in a one-to-one ratio.

[0007] This seriously hinders the application of phased array ultrasonic testing technology in curved longitudinal weld detection. Summary of the invention

[0008] The purpose of the present invention is to provide a phased array detection angle gain compensation test block for curved longitudinal welds, so as to solve the problem that the existing ultrasonic test block cannot be used to produce an angle gain compensation curve when phased array sector scanning is used to detect curved longitudinal welds; the present invention also provides a debugging method for the phased array detection angle gain compensation test block for curved longitudinal welds.

[0009] To achieve the above-mentioned object, the present invention provides a curved longitudinal weld phased array detection angle gain compensation test block, comprising a body and a boss, wherein the boss is arranged on one side of the body;

[0010] Arc surface 2 and arc surface 3 are arranged on both sides of the body, and plane 1 is arranged between arc surface 2 and arc surface 3, and plane 1 is connected with arc surface 2 and arc surface 3 to form the bottom surface of the body;

[0011] The top of the body is provided with an arc surface 1, and two planes 2 and 3 are respectively provided on both sides of the arc surface 1. The arc surface 1 is connected with the two planes 2 and 3 to form the top surface of the body; the top surface of the boss is flush with the top surface of the body; the plane 1, the two planes and the three planes are parallel to each other;

[0012] The radii of the second arc surface and the third arc surface are equal, and the side surface of the boss is provided with a fourth arc surface, and the second arc surface, the third arc surface and the fourth arc surface are coaxially arranged;

[0013] The axes of the arc surface 2, the arc surface 3 and the arc surface 4 are located on the median perpendicular plane of the plane 1, and the axes are located at fixed positions in the arc surface 1; the central axis of the arc surface 1 is located on the median perpendicular plane, and the position of the central axis on the median perpendicular plane is variable;

[0014] A plane passing through the axis of arc surface 4 and parallel to plane 1 is tangent to arc surface 1.

[0015] Preferably, the radii of the arc surface 2 and the arc surface 3 are 100 mm, the radius of the arc surface 4 is 50 mm; and the length of the plane 1 is 70 mm.

[0016] Preferably, the radius of the arc surface one is 50-250 mm, the arc length of the cross section of the arc surface one is 61-88 mm, the length of the plane two is 62-83 mm, and the length of the plane three is 50-61 mm.

[0017] Preferably, the radius of the arc surface 1 is 50 mm, 60 mm, 72 mm, 88 mm, 107.5 mm, 131 mm, 160 mm, 195 mm, or 230 mm.

[0018] Preferably, the length L of the test block is less than 200 mm, the height H is less than 95 mm, the width W is not greater than 60 mm, and the height h of the boss is not greater than 25 mm.

[0019] The debugging method of the above-mentioned curved surface longitudinal weld phased array detection angle gain compensation test block comprises the following steps:

[0020] S1. Set the fan angle range of the theoretical detection process according to the weld of the workpiece to be inspected;

[0021] S2. Use the sound beam angle for making the distance-amplitude curve, place the phased array probe on the first arc surface of the test block, make the incident point of the sound beam angle for making the distance-amplitude curve coincide with the axis position, find the maximum echo of the sound beam at this angle on the fourth arc surface or the second arc surface or the third arc surface, and adjust it to 80% of the full screen height. This wave height is the reference wave height, and the gain value at this time is the reference value 0dB;

[0022] S3. On arc surface 1 of the test block, adjust the maximum echo of the sound beam at other angles within the fan-shaped angle range on arc surface 4 or arc surface 2 or arc surface 3 in turn, and adjust it to 80% of the full screen height. The curve formed by connecting the gain values ​​corresponding to different angles is the angle gain compensation curve.

[0023] The test block of the patent of the present invention is a bowl-shaped boss-shaped test block formed by four arcs of different radii and three planes of different lengths, which solves the shortcomings of using phased array ultrasonic testing of curved longitudinal welds to make a large number of angle gain compensation test blocks, and the lack of angle gain compensation test blocks made of curved longitudinal welds in the current domestic and foreign phased array ultrasonic standards. The test block of the patent of the present invention has the following advantages:

[0024] ① When using phased array ultrasonic sector scanning to detect curved longitudinal welds, a large number of one-to-one test blocks are required. The patent of the present invention only needs nine test blocks with different radii of arc surface to solve the angle gain compensation of all longitudinal welds with a radius between 50mm and 250mm.

[0025] ② The arc surface 2 and arc surface 3 with a radius of 100mm on the test block are used to adjust the angle gain compensation of the low-frequency phased array probe. The arc surface 4 with a radius of 50mm is used to adjust the angle gain compensation of the high-frequency phased array probe.

[0026] ③ The patent of this invention fills the blank of the current domestic and international phased array ultrasonic testing standards that do not have a test block for angle gain compensation for longitudinal welds with a detection radius of 50mm to 250mm.

[0027] ④ The patented test block of the present invention has a novel and unique shape, a simple structure and is easy to process.

[0028] ⑤ The patented test block of the present invention is small in size, light in weight, and easy to carry, which is convenient for practical application on site.

[0029] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 It is a schematic diagram of the three-dimensional structure of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 50 mm;

[0031] Figure 2 It is a front view structural schematic diagram of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 50 mm;

[0032] Figure 3 It is a schematic diagram of a top view structure of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method embodiment of the present invention when the radius of the arc surface is 50 mm;

[0033] Figure 4 It is a right-side structural schematic diagram of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 50 mm;

[0034] Figure 5 It is a schematic diagram of the three-dimensional structure of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 230mm;

[0035] Figure 6 It is a front view structural schematic diagram of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 230mm;

[0036] Figure 7 It is a schematic diagram of a top view structure of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method embodiment of the present invention when the radius of the arc surface is 230mm;

[0037] Figure 8 It is a right view structural schematic diagram of an embodiment of a curved longitudinal weld phased array detection angle gain compensation test block and debugging method of the present invention when the radius of the arc surface is 230mm.

[0038] Reference numerals

[0039] 1. Main body; 2. Boss; 3. Arc surface 1; 4. Arc surface 2; 5. Arc surface 3; 6. Plane 1; 7. Arc surface 4; 8. Plane 2; 9. Plane 3; 10. Vertical midplane; 11. Axis. DETAILED DESCRIPTION

[0040] The present invention will be further described below in conjunction with the accompanying drawings and examples. It should be noted that the following examples are based on the technical solution and provide detailed implementation methods and specific operating processes, but the protection scope of the present invention is not limited to the following examples.

[0041] like Figure 1-8As shown, a curved longitudinal weld phased array detection angle gain compensation test block includes a body 1 and a boss 2, the boss 2 is arranged on one side of the body 1, and the boss 2 and the body 1 are an integral structure. The shape of the body 1 is similar to a bowl. Arc surface 2 4 and arc surface 3 5 are arranged on both sides of the body 1, and plane 1 6 is arranged between arc surface 2 4 and arc surface 3 5, and plane 1 6 is connected with arc surface 2 4 and arc surface 3 5 to form the bottom surface of the body 1. Arc surface 1 3 is arranged in the middle of the top of the body 1, and plane 2 8 and plane 3 9 are arranged on both sides of arc surface 1 3, respectively, and arc surface 1 3 is connected with plane 2 8 and plane 3 9 to form the top surface of the body 1. The top surface of the boss 2 is flush with the top surface of the body 1, that is, the boss 2 and the body 1 share a top surface. Plane 1 6, plane 2 8 and plane 3 9 are three parallel planes.

[0042] The radius of arc surface 2 4 and arc surface 3 5 are equal, and the radius is 100mm. The length of plane 1 6 between arc surface 2 4 and arc surface 3 5 is 70mm. Arc surface 4 7 is arranged on the side of boss 2, and the radius of arc surface 4 7 is 50mm. Arc surface 2 4, arc surface 3 5 and arc surface 4 7 are arranged coaxially, that is, arc surface 2 4 and arc surface 3 5 are located on the same cylindrical surface, and the cylindrical surface where arc surface 4 7 is located coincides with the axis 11 of the cylindrical surface where arc surface 2 4 and arc surface 4 7 are located. Arc surface 2 4 and arc surface 3 5 with a radius of 100mm are used to debug the angle gain compensation of low-frequency phased array probes below 7.5MHz. Arc surface 4 7 with a radius of 50mm is used to debug the angle gain compensation of high-frequency phased array probes of 7.5MHZ and above.

[0043] The axis 11 of the arc surface 24, the arc surface 35 and the arc surface 47 is located on the median perpendicular plane 10 of the plane 16, and the position of the axis 11 in the arc surface 3 is fixed. The central axis of the arc surface 3 (the axis of the cylindrical surface where the arc surface 3 is located) is also located on the median perpendicular plane 10 of the plane 16, and the position of the central axis on the median perpendicular plane 10 is variable. The plane passing through the axis 11 of the arc surface 47 and parallel to the plane 16 is tangent to the arc surface 3.

[0044] The radius of the arc surface 3 varies in the range of 50-250mm, the arc length of the cross section of the arc surface 3 is 61-88mm, the length of the plane 2 8 is 62-83mm, and the length of the plane 3 9 is 50-61mm. The radius of the arc surface 3 is 50mm, 60mm, 72mm, 88mm, 107.5mm, 131mm, 160mm, 195mm, and 230mm. The arc surface 3 with different radii corresponds to a different test block. Through these nine test blocks with arc surface 3 with different radii, the angle gain compensation of all longitudinal welds with a radius between 50mm and 250mm can be solved.

[0045] The length L of the test block is less than 200 mm, the height H is less than 95 mm, the width W is not greater than 60 mm, and the height h of the boss 2 is not greater than 25 mm.

[0046] Embodiment 1

[0047] The longitudinal weld of the pipe with the inspection specification of Φ100mm×12mm, the weld groove form is V-shaped, the groove angle is 30°, and the blunt edge height is 1.5mm. A test block with a radius of 50mm and a curved surface of 3 is used to debug the angle gain compensation curve.

[0048] The testing instrument is ISONIC2009 phased array ultrasonic testing instrument. The parameters of the phased array probe are: a one-dimensional 16-chip special probe for small-diameter tubes, a frequency of 7.5MHz or 10MHz, a centerline spacing of 0.5mm between two adjacent chips, a chip width or array element width of 0.4mm, a gap between two adjacent chips of 0.1mm, a chip curvature radius of 35mm, a wedge angle of 39°, a wedge sound velocity of 2337m / s, a wedge longitudinal curvature radius of 50mm, and 16 chips are excited at one time.

[0049] Angle gain compensation test block for phased array ultrasonic testing of curved longitudinal welds: a test block with a radius of 50mm for the arc surface 3 is used, the length of the test block is 198.35mm, the width is 60mm, the height is 93.7mm, the length of plane 2 8 is 82.85mm, the length of plane 3 9 is 60.1mm, and the arc length of arc surface 3 is 61.09mm.

[0050] Debugging process:

[0051] The longitudinal weld of a pipe with a specification of Φ100mm×12mm is tested by using a phased array detection process with the primary wave sector scanning and the secondary wave sector scanning set up simultaneously to produce a distance-amplitude curve (i.e., DAC curve) and a corresponding angle gain compensation curve. The steps for producing the angle gain compensation curve for phased array ultrasonic testing of curved longitudinal welds are as follows:

[0052] S1. Set the fan angle range of the theoretical detection process to 38°~72°;

[0053] S2. Use the sound beam angle for making the distance-amplitude curve, that is, a 60° sound beam, place the phased array probe on the arc surface 3, make the incident point of the 60° sound beam coincide with the position of the axis 11, find the maximum echo of the angle sound beam on the arc surface 297 of the boss 2, and adjust it to 80% of the full screen height. This wave height is the reference wave height, and the gain value at this time is the reference value 0dB;

[0054] S3. On the arc surface 3, the maximum echo of the sound beam at other angles within the fan-shaped angle range (i.e., 38° to 72°) on the arc surface 7 of the boss 2 is adjusted in turn, and it is adjusted to 80% of the full screen height. The curve formed by connecting the gain values ​​corresponding to different angles is the angle gain compensation curve.

[0055] Embodiment 2:

[0056] The longitudinal weld of the pipe with the inspection specification of Φ500mm×30mm, the weld groove form is V-shaped, the groove angle is 23°, and the blunt edge height is 2mm. A test block with a radius of 230mm and a curved surface of 3 is used to debug the angle gain compensation curve.

[0057] The detection instrument is an ISONIC2009 phased array ultrasonic detection instrument, and the phased array probe parameters are: one-dimensional 32 chips, frequency is 5MHz, the center line spacing between two adjacent chips is 0.5mm, the chip width or array element width is 0.4mm, the gap between two adjacent chips is 0.1mm, the wedge angle is 36°, the wedge sound velocity is 2337m / s, the longitudinal curvature radius of the wedge is 230mm, and 16 chips (i.e. 9-24) are excited at one time.

[0058] Angle gain compensation test block for phased array ultrasonic testing of curved longitudinal welds: a test block with a radius of 230mm for the arc surface 3 is used, the length of the test block is 199.8mm, the width is 60mm, the height is 93.7mm, the length of plane 2 8 is 62.8mm, the length of plane 3 9 is 50mm, and the arc length of arc surface 3 is 87.45mm.

[0059] Debugging process:

[0060] The longitudinal weld of a pipe with a specification of Φ500mm×30mm is tested by using a phased array detection process with the primary wave sector scanning and the secondary wave sector scanning set up simultaneously to produce a distance-amplitude curve (i.e., DAC curve) and a corresponding angle gain compensation curve. The steps for producing the angle gain compensation curve for phased array ultrasonic testing of curved longitudinal welds are as follows:

[0061] S1. Set the fan angle range of the theoretical detection process to 38°~75°;

[0062] S2. Use the sound beam angle for making the distance-amplitude curve, that is, a 50° sound beam, place the phased array probe on the arc surface 1 3, make the incident point of the 50° sound beam coincide with the position of the axis 11, find the maximum echo of the angle sound beam on the arc surface 2 4 and the arc surface 3 5 of R100, and adjust it to 80% of the full screen height. This wave height is the reference wave height, and the gain value at this time is the reference value 0dB;

[0063] S3. On arc surface 1 3, adjust the maximum echo of the sound beams at other angles within the fan-shaped angle range (i.e. 38° to 75°) on arc surface 2 4 and arc surface 3 5 of R100 in turn, and adjust them to 80% of the full screen height. The curve formed by connecting the gain values ​​corresponding to different angles is the angle gain compensation curve.

[0064] The present invention adopts the curved surface longitudinal weld phased array detection angle gain compensation test block of the above structure, which can solve the problem that the existing ultrasonic test block cannot be used to produce an angle gain compensation curve when the phased array sector scanning is used to detect the curved surface longitudinal weld.

[0065] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that they can still modify or replace the technical solution of the present invention with equivalents, and these modifications or equivalent replacements cannot cause the modified technical solution to deviate from the spirit and scope of the technical solution of the present invention.

Claims

1. A curved longitudinal weld phased array detection angle gain compensation test block, characterized in that: It comprises a body (1) and a boss (2), wherein the boss (2) is arranged on one side of the body (1); Arc surface 2 (4) and arc surface 3 (5) are arranged on both sides of the body (1); plane 1 (6) is arranged between arc surface 2 (4) and arc surface 3 (5); plane 1 (6) is connected with arc surface 2 (4) and arc surface 3 (5) to form the bottom surface of the body (1); The top of the body (1) is provided with an arc surface 1 (3), and two planes 2 (8) and 3 (9) are respectively provided on both sides of the arc surface 1 (3); the arc surface 1 (3) is connected with the two planes 2 (8) and 3 (9) to form the top surface of the body (1); the top surface of the boss (2) is flush with the top surface of the body (1); the plane 1 (6), the two planes (8) and the three planes (9) are parallel to each other; The radii of the second arc surface (4) and the third arc surface (5) are equal, the side surface of the boss (2) is provided with a fourth arc surface (7), and the second arc surface (4), the third arc surface (5) and the fourth arc surface (7) are coaxially arranged; The axes (11) of the arc surface 2 (4), the arc surface 3 (5) and the arc surface 4 (7) are located on the mid-vertical plane (10) of the plane 1 (6), and the axes (11) are located at a fixed position in the arc surface 1 (3); the central axis of the arc surface 1 (3) is located on the mid-vertical plane (10), and the position of the central axis on the mid-vertical plane (10) is variable; A plane passing through the axis (11) of the arc surface four (7) and parallel to the plane one (6) is tangent to the arc surface one (3).

2. The angle gain compensation test block for phased array detection of curved longitudinal welds according to claim 1, characterized in that: The radius of the arc surface 2 (4) and the arc surface 3 (5) is 100 mm, the radius of the arc surface 4 (7) is 50 mm; the length of the plane 1 (6) is 70 mm.

3. The angle gain compensation test block for phased array detection of curved longitudinal welds according to claim 1, characterized in that: The radius of the arc surface one (3) is 50-250 mm, the arc length of the cross section of the arc surface one (3) is 61-88 mm, the length of the plane two (8) is 62-83 mm, and the length of the plane three (9) is 50-61 mm.

4. The angle gain compensation test block for phased array detection of curved longitudinal welds according to claim 3, characterized in that: The radius of the arc surface 1 (3) is 50mm, 60mm, 72mm, 88mm, 107.5mm, 131mm, 160mm, 195mm, and 230mm.

5. The angle gain compensation test block for phased array detection of curved longitudinal welds according to claim 1, characterized in that: The length L of the test block is less than 200 mm, the height H is less than 95 mm, the width W is not greater than 60 mm, and the height h of the boss (2) is not greater than 25 mm.

6. A method for debugging a curved longitudinal weld phased array detection angle gain compensation test block according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Set the fan angle range of the theoretical detection process according to the weld of the workpiece to be inspected; S2. Use the sound beam angle for making the distance-amplitude curve, place the phased array probe on the first curved surface (3) of the test block, make the incident point of the sound beam angle for making the distance-amplitude curve coincide with the position of the axis (11), find the maximum echo of the sound beam at this angle on the fourth curved surface (7) or the second curved surface (4) or the third curved surface (5), and adjust it to 80% of the full screen height. This wave height is the reference wave height, and the gain value at this time is the reference value 0dB; S3. On the test block arc surface 1 (3), adjust the maximum echo of the sound beam at other angles within the fan-shaped angle range on arc surface 4 (7) or arc surface 2 (4) and arc surface 3 (5) in turn, and adjust it to 80% of the full screen height. The curve formed by connecting the gain values ​​corresponding to different angles is the angle gain compensation curve.

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