A method and auxiliary tool for detecting a fillet weld

Abstract

This application relates to the field of weld inspection, and in particular to a phased array inspection method and auxiliary tool for fillet welds. The method includes the following steps: selecting the inspection instrument and probe, selecting the coupling agent, setting the focusing rule, preparing a comparison test block, scanning the comparison test block, selecting the scanning method and scanning the workpiece to be inspected, measuring defect size parameters, evaluating the defect, and locating the defect. This application uses a phased array detector to determine and evaluate defect parameters and locate the defect in water-cooled wall fillet welds, thereby enabling the detection of defect conditions in spiral water-cooled wall fillet welds during use and providing a basis for maintenance. An auxiliary tool for phased array inspection of fillet welds is also disclosed, providing assistance for inspection scanning and facilitating the inspection of fillet welds in different locations, thus promoting monitoring work.

Description

Technical Field

[0001] This application relates to the field of weld inspection, and in particular to a phased array inspection method and auxiliary tool for fillet welds. Background Technology

[0002] The water-cooled wall is the main heat-receiving part of the boiler. It consists of several rows of steel tubes spirally distributed around the boiler furnace. Its interior contains flowing water or steam, while it receives heat from the flames in the furnace. The heated tube walls are evaporative heating surfaces formed by many parallel tubes and are laid on the inner wall of the boiler furnace. The function of the water-cooled wall is to absorb the radiant heat from the high-temperature flames or flue gas in the furnace, generating steam or hot water inside the tubes, and reducing the furnace wall temperature to protect the furnace wall.

[0003] During the installation of spiral water-cooled walls, external welding straps are typically used for connection. To ensure a stronger weld between the water-cooled wall tube bank and the straps, a filler plate is placed between adjacent tubes of the water-cooled wall tube bank and welded. During the welding process between the straps and the water-cooled wall tube bank and filler plate, due to structural stress and excessively rapid cooling, cracks perpendicular to the straps may appear in the fillet welds. This is a critical area of ​​concern for potential damage to the cooling wall and requires close monitoring and inspection during use.

[0004] In response to the aforementioned related technologies, the inventors propose a phased array detection method for fillet welds to effectively detect the condition of fillet welds, and propose an auxiliary tool used in the phased array detection process of fillet welds. Summary of the Invention

[0005] To detect defects in the fillet welds of spiral water-cooled walls during use, this application provides a phased array detection method and auxiliary tool for fillet welds.

[0006] The phased array detection method and auxiliary tool for fillet welds provided in this application adopt the following technical solution:

[0007] Firstly, a phased array detection method for fillet welds is disclosed, including the following steps:

[0008] Select the testing instrument and probe; select a phased array detector and match the probe;

[0009] Select a coupling agent; the coupling agent used should be the same as the one used during the setup and calibration of the detection system;

[0010] Set focus rules; set focus depth and focus angle;

[0011] Scan the workpiece to be inspected; place the probe on the surface of the workpiece and perform a parallel oblique scan along the direction to be inspected. During the scan, the probe rotates within the set angle range between the main sound beam and the workpiece.

[0012] Determine the defect size parameters; establish the defect measurement benchmark; and determine the defect location, height, and length using the signals obtained from the scanning.

[0013] Defects are assessed; if the echo amplitude of a defect exceeds the judgment range, it is deemed unqualified; otherwise, the defect is deemed qualified.

[0014] Defect location; when a defect is found, locate and calibrate the defect according to the distance displayed by the instrument.

[0015] By adopting the above technical solution, a phased array detector is used to determine and evaluate the defect parameters of the water-cooled wall tie fillet weld, and locate the defect position. This enables the detection of the defect status of the spiral water-cooled wall tie fillet weld during use, and also provides a basis for maintenance.

[0016] Optionally, prepare a comparative test block; prepare a comparative test block according to the size, material, fillet weld angle, fillet weld seam, and welding process of the spiral water-cooled wall and strap, and arrange transverse holes on the weld of the comparative test block;

[0017] By scanning the comparison test block and repeatedly testing the artificial reflector on the comparison test block, the angle range between the main sound beam of the probe and the fillet weld, and the vertical distance of the probe leading edge, which are effective for detecting the artificial reflector inside the fillet weld, are analyzed. The parameters of the angle range between the main sound beam of the probe and the fillet weld, and the vertical distance of the probe leading edge, determined in the scanning of the comparison test block, are used as the parameters for scanning and testing the actual workpiece to be tested.

[0018] By adopting the above technical solution, a comparative test block is used to simulate the condition of the actual water-cooled wall tie fillet weld. The optimal test parameters are determined through testing the comparative test block and used as control parameters for actual on-site testing. Due to the complexity of the location and environment of the actual water-cooled wall tie fillet weld, there are many inconveniences in inspection and maintenance. Using a comparative test block to simulate and determine the test parameters can effectively reduce trial and error time during the testing process and facilitate ensuring that the test parameters closely match the actual condition.

[0019] Optionally, when identifying a defect, the amplitude of the defect and the height of the defect itself can be measured at the location of the defect's maximum reflected wave amplitude.

[0020] The height of a defect is determined as follows: if two defects do not overlap in their X-axis projections, the greater defect height is used as the height of a single defect; if two defects overlap in their X-axis projections, the sum of their heights is used as the height of a single defect.

[0021] By adopting the above technical solution, a defect determination method is disclosed.

[0022] Optionally, when locating defects, the length is measured using a measuring ruler from the leading edge of the probe along the direction of the main sound beam of the probe, according to the horizontal distance displayed by the instrument, and then calibrated.

[0023] By adopting the above technical solution, a specific method for defect location and calibration is disclosed.

[0024] Secondly, an auxiliary tool is disclosed for clamping the probe during scanning of the workpiece to be inspected;

[0025] The auxiliary tool includes: a clamp assembly capable of holding the probe, and a support rod assembly connected to the clamp assembly;

[0026] The support rod assembly includes an outer support body and an inner support body;

[0027] The outer support is configured as a cylindrical body, and the inner support is fitted into the interior of the outer support from one end of the cylindrical body; the clamp assembly is disposed at the other end of the cylindrical body; the inner support has a first state that can drive the outer support to rotate, and a second state that can drive the clamp assembly to rotate.

[0028] By adopting the above technical solution, an auxiliary tool for phased array inspection of fillet welds is disclosed. This auxiliary tool can assist in inspection scanning even when the actual spiral water-cooled wall has a wide distribution range, varying distances from the plane, and diverse surrounding environments. It allows inspectors to easily inspect fillet welds at different locations by controlling the auxiliary tool. This reduces the requirements for the operating platform and environment for inspectors, and facilitates the monitoring work. Furthermore, the auxiliary tool is disclosed to be able to rotate the probe in both planar and vertical planes, thereby accurately controlling the inspection angle.

[0029] Optionally, the chuck assembly has a chuck seat body;

[0030] The end of the chuck seat away from the outer support body is provided with a clamping groove;

[0031] The end of the chuck seat near the outer support body is provided with an arc-shaped protrusion with teeth;

[0032] The protrusion has a through shaft hole, and the rotating shaft is movably mounted on the outer support body through the shaft hole.

[0033] The above technical solution discloses the structure of the chuck assembly, which uses a clamping groove to hold the probe for detection and controls the convex body to drive the probe to rotate.

[0034] Optionally, an outer ring gear is fixedly sleeved on the outer side wall of the inner support body, and an inner ring gear is fixedly installed on the inner side wall of the outer support body. The outer ring gear can mesh with the inner ring gear, so that the inner support body has a first state that can drive the outer support body to rotate.

[0035] The inner support body is provided with teeth near the chuck assembly that can directly or indirectly drive the protrusion to rotate, so that the inner support body has a second state that can drive the chuck assembly to rotate.

[0036] By adopting the above technical solution, it is disclosed that by controlling the inner support body, the rotation of the outer support body can be controlled, thereby driving the overall rotation of the clamp assembly mounted on the outer support body, and thus driving the probe to rotate. This rotation is a rotation within a single plane. Furthermore, by controlling the inner support body, the convex body can also be driven to rotate, thereby driving the probe to rotate. This rotation is a rotation within a single vertical plane. In other words, by controlling the inner support body, the probe can be rotated in two mutually perpendicular planes, thereby adjusting the probe to the required detection direction angle range.

[0037] Optionally, the outer support body is provided with a rotating gear that meshes with the teeth of the protrusion near the chuck assembly, and the rotating gear is fixed to the outer support body via a rotating shaft;

[0038] The inner support body has a recessed space at one end near the chuck assembly. An inner drive tooth is provided in the recessed space, which can mesh with the rotating gear to drive the rotating gear to rotate.

[0039] By adopting the above technical solution, a structural method for indirectly controlling and driving the convex body through the internal support body is disclosed.

[0040] Optionally, the inner support has a stepped shoulder; the stepped shoulder is fitted into the outer support and is movable along the central axis.

[0041] A stop is provided at the shoulder of the step in the inner support body. The stop is fixed at the shoulder of the step by a torsion spring, and the stop has a force to rotate away from the central axis under the action of the torsion spring.

[0042] A slotted notch is provided inside the outer support body. The notch is constricted on the side closer to the chuck assembly along the central axis and flared on the side farther from the chuck assembly.

[0043] The notch is provided in two layers, and the two layers of notches are arranged in a staggered manner;

[0044] The stop block can slide into or out of the notch.

[0045] By adopting the above technical solution, a structure for limiting the inner and outer supports is disclosed.

[0046] Optionally, a control gear is provided at the end of the inner support body away from the clamp assembly. The control gear meshes with the transmission gear driven by the control motor, and the rotation direction and rotation angle of the inner support body can be controlled by controlling the transmission motor.

[0047] By adopting the above technical solution, a structure for controlling the movement of the internal support body is disclosed.

[0048] This application includes at least one of the following beneficial technical effects:

[0049] 1. The phased array detector of this application determines and evaluates the defect parameters of the water-cooled wall tie fillet weld, locates the defect position, and thus effectively detects the defect status of the spiral water-cooled wall tie fillet weld in use, and also provides a basis for maintenance.

[0050] 2. This application effectively addresses the environmental challenges of actual spiral water-cooled wall inspection by using auxiliary tools, providing assistance for inspection and scanning. This allows inspectors to more easily control the auxiliary tools to inspect fillet welds at different locations. It helps reduce the requirements of the operating platform and environment for inspectors, and facilitates the monitoring work. Attached Figure Description

[0051] Figure 1 This is a flowchart of the phased array detection method for fillet welds in this application.

[0052] Figure 2 This is a diagram showing the state of the water-cooled wall straps.

[0053] Figure 3 This is a partial view of the fillet weld joint of the water-cooled wall.

[0054] Figure 4 This is a partial view of the fillet weld of the water-cooled wall tie (after the tie is removed).

[0055] Figure 5 This is a schematic diagram of phased array testing of fillet weld seams on water-cooled walls.

[0056] Figure 6 This is a front view structure diagram of an example of an auxiliary tool.

[0057] Figure 7 yes Figure 6 CC cross-sectional view of the auxiliary tool embodiment.

[0058] Figure 8 This is a left-side structural diagram of an example of an auxiliary tool.

[0059] Figure 9 yes Figure 8 A cross-sectional view of the DD structure in an example of an auxiliary tool.

[0060] Figure 10 This is a front view structure diagram of an example of an auxiliary tool.

[0061] Figure 11 yes Figure 10 A cross-sectional view of the auxiliary tool embodiment.

[0062] Figure 12 This is a left-side structural diagram of an example of an auxiliary tool.

[0063] Figure 13 yes Figure 12 A cross-sectional view of the BB structure in an embodiment of the auxiliary tool.

[0064] Figure 14 This is a structural diagram of the comparative test block.

[0065] Figure 15 This is a sector scan image of a phased array instrument on a short transverse hole on a fillet weld of a comparison test block.

[0066] Figure 16 The image shows the short transverse hole on the fillet weld of the comparison test block scanned by a phased array instrument (A-scan).

[0067] Figure 17.1a , 17.2a Images 17.3a and 17.4a are defect maps detected by phased array. Figure 17.1b , 17.2b Figures 17.3b and 17.4b are the corresponding diagrams of the fillet welds of the spiral water-cooled wall straps.

[0068] Figure 18 This is a diagram showing the defect location markings on different fillet welds.

[0069] Explanation of reference numerals in the attached figures:

[0070] 11. Water-cooled wall tube; 12. Binding strap; 13. Fillet weld; 14. Filler plate; 15. Probe; 16. Short transverse hole; 2. Chuck assembly; 21. Chuck seat; 22. Chuck groove; 23. Protrusion; 24. Shaft hole; 25. Protruding rotating shaft; 3. Support rod assembly; 4. Outer support body; 41. Inner ring gear; 42. Connecting gear; 43. Connecting shaft; 44. Notch; 45. Protruding shaft collar; 46. Bearing; 5. Inner support body; 51. First cylinder; 52. Second cylinder; 53. Step shoulder; 54. Outer ring gear; 55. Inner drive gear; 551. Ring gear; 552. Rack; 56. Third support body; 57. Insertion hole; 58. Insertion shaft; 59. Stop block. Detailed Implementation

[0071] The present application will be further described in detail below with reference to the accompanying drawings.

[0072] This application discloses a phased array detection method for fillet welds.

[0073] In response to the problem of multiple leaks in water-cooled wall tubes 11 during a water pressure test at a power plant, it was found after the water pressure test that the leaks were all at the fillet welds 13 where the water-cooled wall tubes 11 and the binding straps 12 were connected. After removing several sections of the binding straps 12 and conducting a penetration test on the fillet welds 13 at that location, multiple cracks were found.

[0074] Preliminary conclusions were drawn from the analysis of its causes:

[0075] The leakage of water-cooled wall tube 11 was caused by the crack that originated from the fusion line of the fillet weld 13 of the binding strap 12, which extended to the water-cooled wall tube 11 and eventually penetrated the tube wall.

[0076] The fillet weld 13 has a local hardened martensite morphology, which is prone to cracking and cracks will initiate at this location.

[0077] The fillet weld 13 of the water-cooled wall tube 11 and the weld of the flat steel-water-cooled wall are approximately cross-shaped, which easily causes stress concentration; the fillet weld 13 is too long, and the stress is difficult to release during continuous welding; the presence of martensite and other undesirable structures in the microstructure weakens the ability to resist cracks; and the superposition of load-bearing stresses, etc., all contribute to the complex stress state at the fillet weld 13, leading to stress concentration and promoting crack development.

[0078] Introduction to the basic information of the workpiece being inspected.

[0079] Each binding strap 12 is 26mm thick and 130mm wide. Binding strap 12 is made of SA387-11CL2 material, equivalent to 15CrMo material. The pipe bank material is 12Cr1MoVG. The filler plate 14 has a specification of 6*23mm and is made of 12Cr1MoV material. The welding material for binding strap 12 is E5515-B2, and the weld height is 8mm. (The last sentence appears to be a separate, unrelated statement.) Figure 2-4 This is a diagram showing the state of the water-cooled wall strapping.

[0080] In this process, phased array testing is performed on the workpiece under inspection. The preparation work for phased array testing mainly includes the following:

[0081] Select the testing instrument and probe 15. A Phascan (32 / 128 configuration) phased array detector is used, with probe 15 matched to a Doppler probe 5L32-0.5-10-D2 (5MHz, 32 crystals, 0.5mm crystal spacing, 10mm individual crystal length), and fitted with a wedge block SD2-N55S with a 55° natural refraction angle for transverse waves. Alternatively, an integrated wedge probe 15 can be used. Each piezoelectric crystal of probe 15 can be independently controlled by a signal, and when connected to the phased array detector, it can generate ultrasonic beams at different angles, enabling dynamic focusing and real-time scanning.

[0082] Select a coupling agent. Use an effective and suitable medium for the workpiece being inspected as the ultrasonic coupling agent. The coupling agent material should have good sound transmission and suitable flowability, be non-damaging to the workpiece being inspected, the human body, and the environment, and be easy to clean after inspection. The coupling agent used in the actual inspection should be the same as the coupling agent used during the setup and calibration of the inspection system.

[0083] Set the focusing rule. Set the angle parameter to 40°~70° and use focused sound beam detection. The focusing depth should be set reasonably (based on the basic conditions of this workpiece, the strap is 12mm thick and 26mm, so the focusing depth is set to 26mm).

[0084] In this embodiment, the wide distribution and varying heights of the spiral water-cooled walls from the plane, along with the diverse surrounding environments, present certain challenges for the scanning process. However, the uniformity and standardization of the weld direction and height of the straps 12 and the spiral water-cooled wall tubes 11 rows on the workpiece under test allow for the fabrication of comparative test blocks to simulate real-world conditions. This enables testing in a plane or laboratory setting, thus aiding in determining the appropriate scanning parameters.

[0085] Prepare a comparison test block. Prepare a comparison test block according to the dimensions of the workpiece. The material of the comparison test block is the same as the material being tested. The fracture type of the welded joint of the comparison test block is the same as the welded joint being tested, and it is made using the same welding process. When adding the wedge block to probe 15, the angle of probe 15 also needs to be considered. Analysis shows that the direct cause of the water-cooled wall leakage is the crack initiation at the fusion line of the fillet weld 13 of the binding strap 12, which extends to the water-cooled wall tube 11 and penetrates the tube wall. The direction of the crack is perpendicular to the fillet weld 13. Therefore, short transverse holes 16 of Φ1×5mm and Φ1×10mm are respectively arranged on the weld of the comparison test block, with a distance of 50mm between the two transverse holes.

[0086] A comparative test block was scanned to simulate the inspection of the fillet weld 13 of the spiral water-cooled wall of an actual workpiece. Probe 15 was used to scan the comparative test block. Through multiple inspections of the artificial reflector on the comparative test block, parameters such as the angle range between the main acoustic beam of probe 15 and the fillet weld 13, and the vertical distance of the leading edge of probe 15 were analyzed to effectively detect the artificial reflector inside the fillet weld 13. Multiple inspections of the artificial reflector on the comparative test block revealed that when the angle between the main acoustic beam of probe 15 and the fillet weld 13 is between 25° and 35°, and the vertical distance of the leading edge of probe 15 is approximately 25mm, effective detection of the artificial reflector inside the fillet weld 13 is possible.

[0087] Select the scanning method and perform the scan. The parameters determined during the scanning of the control block, such as the angle range between the main acoustic beam of probe 15 and the fillet weld 13 of strap 12, and the vertical distance of the leading edge of probe 15, will be used as parameters for inspecting the fillet weld 13 of the spiral water-cooled wall of the actual workpiece. During the actual inspection scan, place probe 15 on the upper surface of strap 12 and perform a parallel oblique scan along the weld direction. During the scan, probe 15 must continuously rotate within the set angle range (e.g., 25°~35°) between the main acoustic beam and the fillet weld 13 of strap 12, and scan in both the up and down directions. This prevents missed detections due to the directional nature of defects. Figure 5 The diagram shown is a phased array test diagram of the fillet weld seam of the water-cooled wall.

[0088] Determine defect size parameters. Defect quantification is based on Φ1×5-12dB. For defects whose echo amplitude reaches or exceeds Φ1×5-12dB, determine their location, amplitude, or defect height and indication length. Measure the defect amplitude and defect height at the location of maximum reflected amplitude. Determination of defect height: If two defects do not overlap in their X-axis projections, the larger defect height is taken as the individual defect height; if two defects overlap in their X-axis projections, the sum of their heights is taken as the individual defect height (including spacing).

[0089] Defect assessment. A defect with an echo amplitude greater than or equal to Φ1×5-12dB and an indication height greater than or equal to 5mm shall be deemed unqualified; a defect with an echo amplitude greater than or equal to Φ1×5-6dB shall be deemed unqualified.

[0090] Defect location. When a defect is found, use a steel ruler to measure the horizontal distance from the leading edge of probe 15 along the main sound beam direction of probe 15, according to the horizontal distance displayed by the instrument, to locate the defect.

[0091] When scanning and inspecting the actual workpiece, the distribution range and location of the spiral water-cooled wall may not be convenient for the inspectors to carry out their work. Therefore, it is necessary to use auxiliary tools to hold the probe 15 in order to facilitate the inspection of different locations.

[0092] In this embodiment, when scanning the workpiece to be inspected, for positions where it is inconvenient for direct manual operation, an auxiliary tool is used to clamp the probe 15 for operation. After a defect is detected, a work platform for manual operation is set up. If no defect is detected, there is no need to set up a work platform. Since the proportion of defects on the entire workpiece in the inspection area is always relatively small, setting up a full work platform for inspection work would waste a lot of manpower, material resources and time.

[0093] The embodiments of this application disclose auxiliary tools for detection.

[0094] The auxiliary tool includes a clamp assembly 2 capable of holding the probe 15 and a support rod assembly 3 connected to the clamp assembly 2. The support rod assembly 3 includes an outer support body 4 and an inner support body 5; the outer support body 4 is configured as a cylindrical body, and the inner support body 5 is fitted into the interior of the outer support body 4 from one end of the cylindrical body; the clamp assembly 2 is located at the other end of the cylindrical body; the inner support body 5 has a first state capable of driving the outer support body 4 to rotate and a second state capable of driving the clamp assembly 2 to rotate.

[0095] refer to Figure 6-7 The chuck assembly 2 has a chuck seat 21, one end of which is provided with a chuck groove 22; the other end is provided with an arc-shaped protrusion 23 with teeth; the protrusion 23 is provided with a through shaft hole 24, and the convex rotating shaft 25 of the protrusion 23 is movably mounted on the outer support body 4 through the shaft hole 24.

[0096] refer to Figure 6-9 The support rod assembly 3 includes an outer support body 4 and an inner support body 5.

[0097] The inner support 5 includes a first cylinder 51 and a second cylinder 52. The outer diameter of the first cylinder 51 is smaller than the outer diameter of the second cylinder 52, and the outer diameter of the second cylinder 52 is smaller than the inner diameter of the cylindrical outer support 4. The first cylinder 51 and the second cylinder 52 are connected, and a stepped shoulder 53 is formed at the connection between the first cylinder 51 and the second cylinder 52. The first cylinder 51 and the stepped shoulder 53 are fitted into the outer support 4 and can move along the central axis.

[0098] The outer wall of the first cylinder 51 has an outer ring gear 54, and the inner wall of the outer support 4 has an inner ring gear 41 fixedly installed. The outer ring gear 54 can mesh with the inner ring gear 41, so that the inner support 5 has a first state in which it can drive the outer support 4 to rotate. The inner support 5 is provided with teeth near the chuck assembly 2 that can directly or indirectly drive the teeth of the protrusion 23 to rotate, so that the inner support 5 has a second state in which it can drive the chuck assembly 2 to rotate.

[0099] As an example A, refer to Figure 6-9 The teeth of both the outer ring gear 54 and the inner ring gear 41 are parallel to the central axis. After meshing, rotating the inner support body 5 can drive the outer support body 4 to rotate. Furthermore, the teeth of the outer ring gear 54 and the inner ring gear 41 can separate after movement. After pushing the inner support body 5 upward along the central axis, the teeth of the outer ring gear 54 and the inner ring gear 41 separate. At this time, rotating the inner support body 5 cannot drive the outer support body 4 to rotate.

[0100] A rotating gear 42 is provided on the outer support body 4 near the chuck assembly 2, engaging with the teeth of the protrusion 23. The rotating gear 42 is fixed to the outer support body 4 via a rotating shaft 43. The rotating shaft 43 is fixedly mounted on the inner wall of the outer support body 4, and the rotating gear 42 is sleeved on the rotating shaft 43, allowing it to rotate around the rotating shaft 43. Furthermore, the rotating gear 42 engages with the teeth of the protrusion 23 of the chuck assembly 2. When the rotating gear 42 rotates, it drives the protrusion 23 to rotate, thereby causing the chuck assembly 2 to rotate.

[0101] An inner space is provided at one end of the inner support body 5 near the chuck assembly 2. An inner drive tooth 55 is provided in the inner space. The inner drive tooth 55 is an annular tooth 551 provided on the inner wall of the first cylinder 51 in the inner space.

[0102] In use, when the outer ring gear 54 and the inner ring gear 41 mesh, rotating the inner support body 5 causes the outer ring gear 54 on the first cylinder 51 to rotate, which in turn causes the outer support body 4 to rotate. This rotates the chuck assembly 2 connected to the outer support body 4 to a suitable circumferential position, meaning the probe 15 clamped on the chuck assembly 2 is in a suitable circumferential position. Then, by pushing the inner support body 5 to move along the central axis towards the chuck assembly 2, the outer ring gear 54 separates from the inner ring gear 41. At this time, by pushing, the inner drive teeth 55 can mesh with the connecting gear 42. Rotating the inner support body 5 causes the inner drive teeth 55 on the inner wall of the recessed space of the first cylinder 51 to drive the connecting gear 42 to rotate. The connecting gear 42 drives the protrusion 23 of the chuck assembly 2 to rotate, thereby causing the chuck assembly 2 to rotate and the angle of the probe 15 to rotate. That is, indirectly through the rotation of the teeth of the inner support body 5 and the protrusion 23. In this embodiment, the first state in which the inner support 5 drives the outer support 4 to rotate and the second state in which the clamp assembly 2 rotates cannot be performed simultaneously.

[0103] By meshing the outer ring gear 54 and the inner ring gear 41, the inner support body 5 is rotated to adjust the probe 15's rotation within the circumferential plane. Separating the outer ring gear 54 and the inner ring gear 41, and meshing the inner drive gear 55 with the connecting gear 42, the inner support body 5 is rotated to adjust the probe 15's rotation within a plane perpendicular to the circumferential plane. This allows for adjustment of the probe 15's position, ensuring that the probe 15's angle meets the requirements for angle control when scanning the workpiece.

[0104] As an embodiment B, the main difference from embodiment A is that an inner space is constructed at one end of the inner support body 5 near the chuck assembly 2. An inner drive tooth 55 is provided in the inner space. The inner drive tooth 55 is a rack 552 arranged along the central axis direction in the inner space of the first cylinder 51. The rack 552 is fixedly arranged on the inner side wall of the inner space of the first cylinder 51.

[0105] In use, when the outer ring gear 54 and the inner ring gear 41 are meshed, rotating the inner support body 5 causes the outer ring gear 54 to drive the inner ring gear 41 to rotate, which in turn drives the outer support body 4 to rotate. By pushing the inner support body 5 to move along the central axis towards the chuck assembly 2, the outer ring gear 54 is separated from the inner ring gear 41. At this time, by pushing, the rack 552 can be meshed with the rotating gear 42. Rotating the inner support body 5 causes the rack 552 to drive the rotating gear 42 to rotate, which in turn drives the convex body 23 to rotate, thereby causing the chuck assembly 2 to rotate and the angle of the probe 15 to rotate. That is, indirectly through the rotation of the teeth of the inner support body 5 and the convex body 23. In this embodiment, the first state in which the inner support body 5 drives the outer support body 4 to rotate and the second state in which it drives the chuck assembly 2 to rotate cannot occur simultaneously.

[0106] As an example of embodiment C, refer to Figure 10-13 The main difference from Embodiment B is that the first cylinder 51 and the second cylinder 52 are provided with a through hole along the central axis, and a third support 56 is provided in the through hole. The rack 552 is fixedly provided at one end of the third support 56 near the chuck assembly 2.

[0107] In use, the outer ring gear 54 and the inner ring gear 41 mesh. Rotating the inner support body 5 causes the outer ring gear 54 to drive the inner ring gear 41 to rotate, which in turn drives the outer support body 4 to rotate. By moving the third support body 56, the rack 552 fixed on the third support body 56 meshes with the rotating gear 42. Moving the third support body 56 causes the rack 552 to drive the rotating gear 42 to rotate, which in turn drives the convex body 23 to rotate, thereby causing the chuck assembly 2 to rotate and the angle of the probe 15 to rotate. That is, indirectly through the rotation of the teeth of the inner support body 5 and the convex body 23. In this embodiment, the first state in which the inner support body 5 drives the outer support body 4 to rotate and the second state in which the chuck assembly 2 to rotate can be performed simultaneously.

[0108] As an example D, refer to Figure 10-13 The main difference from embodiment C is that in this embodiment, the connecting gear 42 is not provided, and the rack 552 fixed on the third support 56 can directly mesh with the teeth of the protrusion 23 of the chuck assembly 2.

[0109] In use, the outer ring gear 54 and the inner ring gear 41 mesh. Rotating the inner support body 5 causes the outer ring gear 54 to drive the inner ring gear 41 to rotate, which in turn drives the outer support body 4 to rotate. By moving the third support body 56, the rack 552 fixed on the third support body 56 meshes with the teeth of the protrusion 23. Moving the third support body 56 causes the rack 552 to drive the protrusion 23 to rotate, which in turn causes the chuck assembly 2 to rotate, thus rotating the angle of the probe 15. That is, the rotation is directly achieved through the teeth of the inner support body 5 and the protrusion 23. In this embodiment, the first state of the inner support body 5 driving the outer support body 4 to rotate and the second state of driving the chuck assembly 2 to rotate can be performed simultaneously.

[0110] In embodiment D, reference Figure 12 , 13 A through-hole 57 is provided on the second cylinder 52, and a matching through-hole 57 is provided on the third support 56. The insertion shaft 58 can pass through the through-hole 57 on the second cylinder 52 and the third support 56 to limit its movement.

[0111] In embodiments A and B, a stop 59 can also be provided on the step shoulder 53 of the inner support body 5. The stop 59 is fixed to the step shoulder 53 by a torsion spring, and the stop 59 has a force to rotate away from the central axis under the action of the torsion spring. A slotted notch 44 is provided inside the outer support body 4. The notch 44 is constricted on the side near the chuck assembly 2 along the central axis direction and flared on the side away from the chuck assembly 2. The constricted shape is a plane perpendicular to the central axis direction, and the flared shape is a downwardly extending flared opening. The opening of the notch 44 on the inner wall of the outer support body 4 is larger than the size of the wall extending into the outer support body 4. When the inner support body 5 moves along the central axis direction, the stop 59 on the step shoulder 53 can be pushed into the notch 44 by the force of the torsion spring when passing through the notch 44, so that the stop 59 can slide into the notch 44. At this point, when the inner support 5 is pushed upward, the side wall of the stop 59 abuts against the constricted side of the notch 44, preventing further upward movement and maintaining the stability of the inner support 5 within the outer support 4, thus preventing excessive movement. When the inner support 5 is pulled downward, the side wall of the stop 59 slides out from the flared side of the notch 44, thereby enabling the inner support 5 to move within the outer support 4.

[0112] In Examples A and B, reference is made to... Figure 7 , 9The notch 44 has two layers, upper and lower, with different heights and staggered arrangement at an angle difference of 90 degrees. When the stop block 59 enters the lower notch 44, the outer ring gear 54 on the first cylinder 51 of the inner support body 5 meshes with the inner ring gear 41 provided in the outer support body 4. Rotating the second cylinder 52 causes the outer ring gear 54 on the first cylinder 51 to drive the inner ring gear 41 to rotate, which in turn drives the outer support body 4 to rotate. Once the required rotation angle is reached, pull the inner support body 5 downwards. At this time, the stop block 59 exits from the lower notch 44, rotates 90 degrees, and pushes the inner support body 5 upwards. The stop block 59 enters the upper notch 44. At this time, the inner drive tooth 55 (ring tooth 551 or rack 552) set in the recessed space of the first cylinder 51 meshes with the rotating gear 42. Rotate the inner support body 5, and the rack 552 drives the rotating gear 42 to rotate. The rotating gear 42 drives the protrusion 23 to rotate, thereby causing the chuck assembly 2 to rotate and the angle of the probe 15 to rotate.

[0113] In Examples A and B, reference is made to... Figure 7 , 9 Furthermore, a convex ring 45 can be provided inside the outer support body 4, positioned above the notch 44 and below the inner ring gear 41. This serves to define the position between the inner support body 5 and the outer support body 4. Additionally, a bearing 46 is provided below the convex ring 45.

[0114] In embodiment AD, a control gear (not shown in the figure) connected to a drive motor can also be provided on the outside of the inner support body 5. Specifically, it is located at the lower part of the second cylinder 52. The control gear meshes with the drive gear connected to the motor, and the rotation direction and rotation angle of the inner support body 5 are controlled by controlling the drive motor. Furthermore, a control device, such as a microcontroller or embedded control device, can be provided to control the rotation of the drive motor and control the rotation of the inner support body 5 according to the detected control parameters.

[0115] By using auxiliary tools during testing, it is possible to easily detect locations that are inconvenient to operate manually, and the operation is convenient and simple.

[0116] In the embodiments of this application, process verification was conducted to further verify the feasibility, rationality, and reliability of the adopted scheme. The verification included laboratory verification and field verification.

[0117] 1. Laboratory validation

[0118] Instrument and probe 15 selection: Phascan (32 / 128 configuration) phased array detector is used, probe 15 is matched with Doppler probe 5L32-0.5-10-D2 (5MHz, 32 crystals, crystal spacing 0.5mm, single crystal length 10mm), and a wedge block SD2-N55S with a transverse wave natural refraction angle of 55° is added.

[0119] Setting the focusing rule: The fan-shaped scanning angle parameter is set to 40°~70°, focusing sound beam detection is used, and the focusing depth is set to 26mm.

[0120] Comparison Specimen Shape: The material of the comparison specimen is the same as that of the tested material. The fracture type of the welded joint of the specimen is the same as that of the tested welded joint, and it is manufactured using the same welding process. Since the direct cause of the water-cooled wall leakage is the crack initiating at the fusion line of the fillet weld 13 of the binding strap 12, which propagates to the water-cooled wall tube 11 and penetrates the tube wall, and the direction of the crack is perpendicular to the fillet weld 13, short transverse holes 16 of Φ1×5mm and Φ1×10mm are respectively arranged on the weld of the comparison specimen, with a distance of 50mm between the two transverse holes. The structure of the comparison specimen is as follows: Figure 11 The location of the short horizontal hole 16 (artificial reflector) is marked in the figure.

[0121] Scanning method: When the phased array test comparison block is inspected, the probe 15 scans along the binding strap 12. The angle between the main sound beam of the probe 15 and the fillet weld 13 of the binding strap 12 is 30°, and the vertical distance of the leading edge of the probe 15 is 25mm.

[0122] The short transverse hole 16 on the fillet weld 13 of the comparison test block is shown in the phased array instrument sector scan image. Figure 12 The short transverse hole 16 on the fillet weld 13 of the comparison test block is shown in the A-scan image of the phased array instrument. Figure 13 As can be seen from the figure, the comparison test block can accurately and reliably scan the position of the short transverse hole 16.

[0123] 2. On-site verification

[0124] Instrument and probe 15 selection: Phascan (32 / 128 configuration) phased array detector is used, probe 15 is matched with Doppler probe 5L32-0.5-10-D2 (5MHz, 32 crystals, crystal spacing 0.5mm, single crystal length 10mm), and a wedge block SD2-N55S with a transverse wave natural refraction angle of 55° is added.

[0125] Setting the focusing rule: The fan-shaped scanning angle parameter is set to 40°~70°, focusing sound beam detection is used, and the focusing depth is set to 26mm.

[0126] Scanning method: The probe 15 is placed on the upper surface of the strap 12 and scanned obliquely parallel to the weld direction. During the scanning process, the probe 15 should rotate continuously between 25° and 35° between the main beam and the fillet weld 13 of the strap 12, and should scan in both the up and down directions. This is to prevent missed detections due to the directional nature of the defects.

[0127] Figure 14 The image displays multiple sets of phased array defect detection maps and corresponding images of the fillet weld 13 of the spiral water-cooled wall tie band 12. Specifically, images 14.1a and 14.1b show the map and weld at the first tie band 12 at 25 meters along the right wall of furnace #1; images 14.2a and 14.2b show the map and weld at the third tie band 12 at 25 meters along the right wall of furnace #1; images 14.3a and 14.3b show the map and weld at the fourth tie band 12 at 25 meters along the right wall of furnace #1; and images 14.4a and 14.4b show the map and weld at the second tie band 12 at 36 meters along the right wall of furnace #2. By comparing the maps and welds, the location of the defects can be accurately and reliably identified.

[0128] By analyzing and evaluating the detection spectrum, defects deemed unqualified are located and calibrated. When a defect is found to be unqualified, the defect is located by measuring the horizontal distance displayed on the instrument using a steel ruler, starting from the leading edge of probe 15 and moving along the main sound beam direction of probe 15. For example... Figure 15 A diagram showing the location markings for defects on fillet weld 13.

[0129] Analysis of the defects detected by the method of this application shows a very high degree of consistency and conformity with the actual crack locations found after removal by planing or cutting, thus proving the reliability and effectiveness of the method of this application. After treating the defective fillet weld 13 of the spiral water-cooled wall strap 12, a water pressure test was conducted. The weld showed no pressure drop within the specified time, demonstrating good pressure holding capacity, proving that the defective weld was effectively treated.

[0130] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A method of detecting a fillet weld using a phased array, the method comprising: The method comprises the steps of: selecting a detection instrument and a probe; selecting a phased array detection instrument and matching the probe; selecting a coupling agent; the coupling agent used should be the same as that used when the detection system is set and calibrated; setting the focusing rule; setting the focusing depth and the focusing angle; scanning the workpiece to be detected; placing the probe on the surface of the workpiece to be detected and performing oblique parallel scanning along the direction to be detected; during the scanning process, the probe rotates within the set angle range of the main sound beam and the workpiece to be detected; measuring the defect size parameters; determining the defect measurement reference, determining the defect position and height through the signals obtained by scanning; evaluating the defect; if the defect echo amplitude exceeds the judgment range, the defect is evaluated as unqualified; otherwise, the defect is evaluated as qualified; defect positioning; when a defect is found, the defect is positioned and calibrated according to the distance displayed by the instrument.

2. The weld seam phased array inspection method of claim 1, wherein, The method further comprises the steps of: manufacturing a comparison test block; manufacturing the comparison test block according to the size, material, angle of the fillet weld, the fillet weld, and the welding process, and arranging a horizontal hole on the weld of the comparison test block; scanning the comparison test block; through multiple detections of the artificial reflector on the comparison test block, analyzing the effective detection of the artificial reflector inside the fillet weld, and determining the angle range of the probe main sound beam and the fillet weld of the binding belt and the vertical distance of the probe front edge, the parameters of the angle range of the probe main sound beam and the fillet weld of the binding belt and the vertical distance of the probe front edge determined in the scanning of the comparison test block are used as the parameters for scanning and detecting the actual workpiece to be detected.

3. The fillet weld phased array detection method according to claim 1 or 2, wherein, when a defect is determined, the amplitude of the defect and the height of the defect itself are measured at the position of the maximum reflection amplitude of the defect; the determination of the height of the defect itself, if two defects do not overlap in X-axis projection, the height of the defect itself is taken as the height of a single defect; if two defects overlap in X-axis projection, the sum of the heights of the two defects is taken as the height of a single defect.

4. The fillet weld phased array detection method according to claim 1 or 2, wherein, when the defect is positioned, the length is measured along the direction of the probe main sound beam from the probe front edge with a measuring scale according to the horizontal distance displayed by the instrument, and is calibrated.

5. An auxiliary tool characterized by The auxiliary tool is used for clamping the probe during the scanning of the workpiece to be detected; The auxiliary tool is used for clamping the probe during the scanning of the workpiece to be detected; The auxiliary tool comprises a chuck assembly capable of clamping the probe and a support rod assembly connected with the chuck assembly; The support rod assembly comprises an outer support body and an inner support body; The outer support body is configured as a cylindrical body, the inner support body is sleeved into the inner part of the outer support body from one end of the cylindrical body, the chuck assembly is arranged at the other end of the cylindrical body, and the inner support body has a first state capable of driving the outer support body to rotate and a second state capable of driving the chuck assembly to rotate.

6. The auxiliary tool according to claim 5, wherein, the chuck assembly has a chuck seat body; a clamping groove is formed at the end of the chuck seat body away from the outer support body; a circular arc-shaped convex body with teeth is arranged at the end of the chuck seat body close to the outer support body. The convex body is provided with a through shaft hole, and the rotating shaft is movably arranged on the outer support body through the shaft hole.

7. The auxiliary tool according to claim 6, characterized in that, The outer side wall of the inner support body is fixedly provided with an outer ring gear, and the inner side wall of the outer support body is fixedly provided with an inner ring gear, the outer ring gear can engage with the inner ring gear, so that the inner support body has a first state capable of driving the outer support body to rotate; The inner support body is provided with teeth capable of directly or indirectly driving the convex body to rotate near the chuck assembly, so that the inner support body has a second state capable of driving the chuck assembly to rotate.

8. The auxiliary tool according to claim 7, characterized in that, The outer support body is provided with a gear near the chuck assembly, which engages with the teeth of the convex body, and the gear is fixed on the outer support body through a transmission shaft; The inner support body is provided with an inner recess space near one end of the chuck assembly, and the inner recess space is provided with an inner drive gear, which can engage with the gear to drive the gear to rotate.

9. The auxiliary tool according to claim 5, characterized in that, The inner support body has a stepped shoulder, which is sleeved into the inner part of the outer support body and can move along the central axis direction; The inner support body is provided with a stop block, which is fixed on the stepped shoulder by a torsion spring, and the stop block has a rotating force away from the central axis direction under the action of the torsion spring; The inner part of the outer support body is provided with a slot-shaped opening, which is closed on the side close to the chuck assembly and is expanded on the side away from the chuck assembly along the central axis direction; The opening is provided with two layers, and the two layers are arranged in a staggered manner; The stop block can slide into or out of the opening.

10. The auxiliary tool according to claim 5, characterized in that, The end of the inner support body away from the chuck assembly is provided with a control gear, which engages with a transmission gear driven by a control motor, and the rotating direction and angle of the inner support body can be controlled by controlling the transmission motor.

Images