Vacuum electron beam narrow gap butt weld phased array inspection test block and use method

Abstract

The invention relates to a vacuum electron beam narrow gap butt weld phased array inspection test block and a use method thereof. A test block is obtained by cutting a circular weld portion on a welded hollow cylindrical workpiece with the same material, size, structure and heat treatment. The diameter and wall thickness of the test block are the same as those of the welded hollow cylindrical workpiece. The surface roughness Ra of the test block is less than or equal to 6.3 μm. Three longitudinal grooves are processed along both sides of the fan-shaped surface at a distance from the outer circle of the test block on the weld fan-shaped surface. Three transverse holes are processed at a distance from the outer circle of the test block on the center line of another weld fan-shaped surface of the test block. An array probe of a phased array flaw detector is placed on the outer surface of the test block. A coupling agent is applied between the array probe and the test block. The phased array flaw detector is adjusted to realize fan-shaped scanning. A reference sensitivity is determined to ensure that artificial defects of longitudinal grooves and transverse holes in the test block are clearly displayed. Measurement is performed based on clear images of different transverse holes and longitudinal grooves. Compared with the design nominal values ​​of the transverse holes and longitudinal grooves of the test block, an imaging geometric dimension measurement error of less than or equal to ±5% is obtained.

Description

Technical Field

[0001] The invention belongs to the technical field of nondestructive testing, and in particular relates to a vacuum electron beam narrow gap butt weld phased array testing block and a use method thereof. Background Art

[0002] Vacuum electron beam welding uses a directional high-speed electron beam to impact the workpiece to convert kinetic energy into heat energy and melt the workpiece to form a weld. Vacuum electron beam welding has the following characteristics: the electron beam can accurately determine the position of the weld, and the accuracy and repeatability errors are 0; thick workpieces do not need to be grooved or filled with metal, the weld chemical composition is pure, the weld joint is strong and of good quality; the thermal energy density is large, the penetration is large, the speed is fast, and the weld is deep and narrow. Vacuum electron beam welding has the characteristics of large penetration, fast speed, and deep and narrow welds. It is easy to produce defects such as lack of fusion and lack of penetration in the weld, especially the lack of fusion defects are almost parallel to the weld. When using ultrasonic phased array to detect welds on site, it is impossible to determine the reliability and accuracy of the flaw detection process. Therefore, it is urgent to provide a vacuum electron beam narrow gap weld phased array detection test block and a method of use to solve the above problems. Summary of the invention

[0003] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a vacuum electron beam narrow gap butt weld phased array inspection test block and a method of use, thereby solving the reliability and accuracy problems of the phased array inspection process during on-site inspection of vacuum electron beam narrow gap butt welds.

[0004] To achieve this object, the present invention adopts the following technical solutions: A vacuum electron beam narrow gap butt weld phased array inspection test block is selected. A welded hollow cylindrical workpiece with the same material, size, structure and heat treatment process is selected. The welded hollow cylindrical workpiece is tested for defects by flaw detection. A test block is obtained by cutting and processing the annular weld portion on the workpiece. The test block is a sector body, and its diameter and wall thickness T are consistent with those of the welded hollow cylindrical workpiece. The surface roughness of this test block is Ra≤6.3μm. There is a weld zone in the middle of the test block. The weld zone forms two weld sectors on the surface of the sector body. In one weld Three longitudinal grooves are machined on both sides of the upper weld fan surface, and three Φ2mm×40mm transverse holes are machined on the center line of the other weld fan surface; the array probe of the phased array flaw detector is placed on the outer surface of the test block, the phased array flaw detector and the array probe are adjusted to perform a sector-shaped scan, and a time gain correction curve TCG is made. This is used as the benchmark sensitivity, and measurements are performed based on clear images of different transverse holes and longitudinal grooves. Compared with the design nominal values ​​of the transverse holes and longitudinal grooves, the imaging geometric dimension measurement error is obtained to be ≤±5%.

[0005] Furthermore, three longitudinal grooves are machined along both sides of the weld sector at 2.5mm, 1 / 2T, and T-2.5mm from the surface of the outer circle of the test block, and the dimensions of the longitudinal grooves are 5mm long × 0.15mm wide × 2mm deep, with a dimensional tolerance of ±0.01mm. On the center line of another weld sector of this test block, three Φ2mm×40mm transverse holes are machined at 2mm, 1 / 2T, and T-2mm from the surface of the outer circle of the test block; the transverse hole diameter tolerance is ±0.01mm; the hole bottom flatness error should not exceed ±0.03mm, and the surface roughness Ra of all holes should not be greater than 3.2μm.

[0006] A method for using a vacuum electron beam narrow gap butt weld phased array inspection test block comprises the following steps: Step 1), select a welded hollow cylindrical workpiece of the same material, size, structure and heat treatment process. The welded hollow cylindrical workpiece has no defects after flaw detection. A test block is obtained by cutting and processing according to the annular weld position on it. The test block is a sector body, and its diameter and wall thickness T are consistent with those of the welded hollow cylindrical workpiece. There is a weld area in the middle of the cut and processed test block, and this weld area is a part of the annular weld. The surface roughness of this test block Ra≤6.3μm, and in this test block, the weld area has two weld sectors on the surface of the sector body; Step 2), determining the defect position and defect direction on the weld fan surface, and setting artificial defects, namely longitudinal grooves and transverse holes, on the weld fan surface of the test block according to the defect position and defect direction; Step 3), on one weld sector, at 2.5mm, 1 / 2T, T-2.5mm from the outer circle of the test block, three longitudinal grooves are machined along both sides of the weld sector, the size of the longitudinal groove is 5mm long × 0.15mm wide × 2mm deep, and the size tolerance is ±0.01mm; on the center line of another weld sector, 3 Φ2mm×40mm transverse holes are machined at 2mm, 1 / 2T, T-)mm from the outer circle of the test block; the transverse hole diameter tolerance is ±0.01mm; the hole bottom flatness error should not exceed ±0.03mm, and the surface roughness Ra of all holes should not be greater than 3.2μm; Step 4) Place the array probe of the phased array flaw detector on the outer surface of the test block, apply coupling agent between the probe and the test block, apply pressure to ensure good coupling, and adjust the phased array flaw detector and the array probe to perform a sector scan; the details are as follows: Step 4.1) Adjust the echoes of Φ2mm×40mm horizontal holes of three different depths to 80% screen height in turn, and make a time gain correction curve TCG, which is used as the reference sensitivity; secondly, adjust the phased array flaw detector and array probe to perform sector scanning; Step 4.2), adjust the longitudinal groove echoes of three different depths to 80% screen height in turn, and make a time gain correction curve TCG, which is used as the benchmark sensitivity; repeat step 4.2), make a time gain correction curve TCG, and use it as the benchmark sensitivity, measure according to the clear images of different transverse holes and longitudinal grooves, and compare with the design nominal values ​​of transverse holes and longitudinal grooves to obtain the imaging geometric dimension measurement error ≤±5%; through this calibration, the phased array flaw detector can carry out vacuum electron beam narrow gap weld phased array detection.

[0007] The beneficial effects of the present invention are as follows: The present invention provides a vacuum electron beam narrow gap weld phased array inspection test block and a use method thereof. The test block is obtained by cutting and processing an annular weld portion on a welding workpiece with the same material, size, structure and heat treatment process, and artificial defects are processed on the test block to simulate the defects caused by actual welding. An ultrasonic phased array is used to perform simulated inspection and calibration on the flaw detection test block, thereby improving the reliability and accuracy of on-site inspection. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 It is a schematic diagram of a weld of a workpiece in a specific implementation manner of the present invention.

[0009] Figure 2 It is a schematic diagram of the weld area of ​​the flaw detection test block in a specific implementation manner of the present invention.

[0010] Figure 3 It is a schematic diagram of a flaw detection test block in a specific implementation manner of the present invention.

[0011] Figure 4 It is a schematic diagram of a weld sector of a flaw detection test block in a specific implementation manner of the present invention.

[0012] Figure 5 It is another weld sector schematic diagram of the flaw detection test block in a specific implementation manner of the present invention.

[0013] Figure 6 It is a schematic diagram of a time gain correction curve TCG in a specific implementation manner of the present invention.

[0014] In the figure, 1 is a welded hollow cylindrical workpiece; 2 is an annular weld; 3 is a test block; 4 is a weld area; 5 is a weld fan; 6 is a longitudinal groove on the weld fan; and 7 is a transverse hole 7 on another weld fan. DETAILED DESCRIPTION

[0015] The present invention is further described in detail below in conjunction with the accompanying drawings and embodiments.

[0016] Embodiment 1: A vacuum electron beam narrow gap butt weld phased array inspection test block, a welded hollow cylindrical workpiece 1 of the same material, size, structure and heat treatment process is selected, the welded hollow cylindrical workpiece 1 is detected to have no defects by flaw detection, and a test block 3 is obtained by cutting and processing the annular weld 2 thereon. The test block 3 is a sector body, and its diameter and wall thickness T are consistent with those of the welded hollow cylindrical workpiece. There is a weld area 4 in the middle of the cut and processed test block 3, and the weld area 4 is a part of the annular weld 2. The surface roughness of the test block 3 is Ra≤6.3μm, and the weld area 4 is formed on the surface of the sector body. There are two weld sectors 5, three longitudinal grooves 6 are processed along both sides of one weld sector 5, and three Φ2mm×40mm transverse holes 7 are processed on the center line of the other weld sector 5; the array probe of the phased array flaw detector is placed on the outer surface of the test block 3, the phased array flaw detector and the array probe are adjusted to perform sector scanning, and a time gain correction curve TCG is made. This is used as a reference sensitivity, and measurements are performed based on clear images of different transverse holes 7 and longitudinal grooves 6. Compared with the design nominal values ​​of the transverse holes 7 and the longitudinal grooves 6, it is obtained that the imaging geometric dimension measurement error is ≤±5%.

[0017] On the weld sector 5, at 2.5mm, 1 / 2T, T-2.5mm away from the outer circumference of the test block 3, three longitudinal grooves 6 are machined along both sides of the weld sector 5, the dimensions of the longitudinal grooves 6 are 5mm long × 0.15mm wide × 2mm deep, and the dimensional tolerance is ±0.01mm. On the center line of the other weld sector 5 of this test block 3, three Φ2mm×40mm transverse holes 7 are machined at 2mm, 1 / 2T, T-2mm away from the outer circumference of the test block; the diameter tolerance of the transverse holes 7 is ±0.01mm; the flatness error of the hole bottom should not exceed ±0.03mm, and the surface roughness Ra of all holes should not be greater than 3.2μm.

[0018] A method for using a vacuum electron beam narrow gap butt weld phased array inspection test block comprises the following steps: Step 1), select a welded hollow cylindrical workpiece 1 of the same material, size, structure and heat treatment process, the welded hollow cylindrical workpiece 1 is tested for defects by flaw detection, and a test block 3 is obtained by cutting and processing the annular weld 2 thereon. The test block 3 is a sector body, and its diameter and wall thickness T are consistent with those of the welded hollow cylindrical workpiece 1. The surface roughness of the test block 3 is Ra≤6.3μm, and the weld area 4 forms two weld sectors 5 on the surface of the sector body; Step 2) determining the defect position and defect direction on the weld fan surface 5, and setting artificial defects (longitudinal grooves and transverse holes) on the weld fan surface 5 of the test block according to the defect position and defect direction.

[0019] Step 3), on one weld sector 5, at 2.5mm, 1 / 2T, T-2.5mm from the outer circumference of the test block 3, three longitudinal grooves 6 are processed along both sides of the weld sector 5, the size of the longitudinal groove 6 is 5mm long × 0.15mm wide × 2mm deep, and the size tolerance is ±0.01mm; on the center line of another weld sector 5, at 2mm, 1 / 2T, T-2mm from the outer circumference of the test block, three Φ2mm×40mm transverse holes 7 are processed; the diameter tolerance of the transverse hole 7 is ±0.01mm; the flatness error of the bottom of the hole should not exceed ±0.03mm, and the surface roughness Ra of all holes should not be greater than 3.2μm; Step 4), place the array probe of the phased array flaw detector on the outer surface of the test block 3, apply coupling agent between the probe and the test block, apply pressure to ensure good coupling, adjust the phased array flaw detector and the array probe to perform sector scanning; make Figure 6 Time gain correction curve TCG, TCG curve reflects the law of change of the gain corresponding to the echo height of a regular reflector or the specified height with the distance. The horizontal axis is generally the sound path distance, and the vertical axis is generally the gain dB value corresponding to the echo height or the specified height. Each curve corresponds to the equivalent of a regular reflector. The TCG curve is a depth compensation curve, which compensates for reflectors of the same size and different depths detected by the sound beam at the same angle, so that the echo amplitudes of reflectors of the same size and different depths are quantified, and all compensation values ​​are connected into a curve, namely the benchmark TCG curve. Use this curve as a benchmark to evaluate defects. The details are as follows: Step 4.1) Adjust the echoes of Φ2mm×40mm horizontal holes of three different depths to 80% screen height in turn, and make a time gain correction curve TCG, which is used as the reference sensitivity; secondly, adjust the phased array flaw detector and array probe to perform sector scanning; Step 4.2), adjust the longitudinal groove echoes of three different depths to 80% of the screen height in turn, and make a time gain correction curve TCG, which is used as the benchmark sensitivity; repeat step 4.2), make a time gain correction curve TCG, and use it as the benchmark sensitivity, measure according to the clear images of different transverse holes 7 and longitudinal grooves 6, and compare with the design nominal values ​​of the transverse holes 7 and longitudinal grooves 6 to obtain an imaging geometric dimension measurement error of ≤±5%; through this calibration, the phased array flaw detector can carry out vacuum electron beam narrow gap weld phased array detection.

Claims

1. A vacuum electron beam narrow gap butt weld phased array inspection test block, characterized in that: A welded hollow cylindrical workpiece (1) of the same material, size, structure and heat treatment process is selected, and a test block (3) is obtained by cutting and processing the annular weld (2) thereon. The test block (3) is a sector body, and its diameter and wall thickness T are consistent with those of the welded hollow cylindrical workpiece (1). The surface roughness Ra of the test block (3) is ≤ 6.3 μm. A weld zone (4) is provided in the middle of the test block (3). The weld zone (4) is a part of the annular weld (2). The weld zone (4) forms two weld sectors (5) on the surface of the sector body. On one weld sector (5), a weld is formed along the weld. Three longitudinal grooves (6) are processed on both sides of the weld fan surface (5), and three Φ2mm×40mm transverse holes (7) are processed on the center line of another weld fan surface (5); an array probe of a phased array flaw detector is placed on the outer surface of the test block (3), the phased array flaw detector and the array probe are adjusted to perform a sector scan, and a time gain correction curve TCG is prepared. This is used as a reference sensitivity, and measurements are performed based on clear images of different transverse holes (7) and longitudinal grooves (6). Compared with the design nominal values ​​of the transverse holes (7) and longitudinal grooves (6), the imaging geometric dimension measurement error is obtained to be ≤±5%.

2. A vacuum electron beam narrow gap butt weld phased array inspection test block according to claim 1, characterized in that: On the weld fan surface (5), at 2.5 mm, 1 / 2T, and T-2.5 mm from the outer circumference of the test block (3), three longitudinal grooves (6) are machined along both sides of the weld fan surface (5), the dimensions of the longitudinal grooves (6) being 5 mm in length × 0.15 mm in width × 2 mm in depth, and the dimensional tolerance being ±0.01 mm. On the center line of another weld fan surface (5) of the test block (3), at 2 mm, 1 / 2T, and T-2 mm from the outer circumference of the test block, three Φ2 mm × 40 mm transverse holes (7) are machined; the diameter tolerance of the transverse holes (7) is ±0.01 mm; the flatness error of the hole bottom should not exceed ±0.03 mm, and the surface roughness Ra of all holes should not be greater than 3.2 μm.

3. A method for using a vacuum electron beam narrow gap butt weld phased array inspection test block, characterized in that: The steps include: Step 1), selecting a welded hollow cylindrical workpiece (1) of the same material, size, structure and heat treatment process, wherein the welded hollow cylindrical workpiece (1) is free of defects after flaw detection, and a test block (3) is obtained by cutting and processing the annular weld (2) thereon, wherein a weld zone (4) is provided in the middle of the cut and processed test block (3), wherein the weld zone (4) is a part of the annular weld (2), and the test block (3) is a sector body, wherein the diameter and wall thickness T are the same as those of the welded hollow cylindrical workpiece (1), and the surface roughness Ra of the test block (3) is ≤ 6.3 μm, and the weld zone (4) forms two weld sectors (5) on the surface of the sector body; Step 2), determining the defect position and defect direction on the weld fan surface (5), and setting artificial defects, namely longitudinal grooves and transverse holes, on the weld fan surface (5) of the test block according to the defect position and defect direction; Step 3), three longitudinal grooves (6) are machined along both sides of a weld sector (5) at 2.5 mm, 1 / 2T, and T-2.5 mm from the outer circumference of the test block (3), and the dimensions of the longitudinal grooves (6) are 5 mm in length × 0.15 mm in width × 2 mm in depth, and the dimensional tolerance is ±0.01 mm; three Φ2 mm × 40 mm transverse holes (7) are machined at 2 mm, 1 / 2T, and T-2 mm from the outer circumference of the test block on the center line of another weld sector (5); the diameter tolerance of the transverse holes (7) is ±0.01 mm; the flatness error of the hole bottom should not exceed ±0.03 mm, and the surface roughness Ra of all holes should not be greater than 3.2 μm; Step 4), place the array probe of the phased array flaw detector on the outer surface of the test block (3), apply coupling agent between the probe and the test block, apply pressure to ensure good coupling, and adjust the phased array flaw detector and the array probe to perform a sector scan; the details are as follows: Step 4.1) Adjust the echoes of Φ2mm×40mm horizontal holes of three different depths to 80% screen height in turn, and make a time gain correction curve TCG, which is used as the reference sensitivity; secondly, adjust the phased array flaw detector and array probe to perform sector scanning; Step 4.2), adjust the longitudinal groove echoes of three different depths to 80% of the screen height in turn, and make a time gain correction curve TCG, which is used as the reference sensitivity; repeat step 4.2), make a time gain correction curve TCG, and use it as the reference sensitivity, measure based on the clear images of different transverse holes (7) and longitudinal grooves (6), and compare with the design nominal values ​​of the transverse holes (7) and longitudinal grooves (6), and obtain an imaging geometric dimension measurement error of ≤±5%; through this calibration, the phased array flaw detector can carry out vacuum electron beam narrow gap weld phased array detection.

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