Method for adjusting dynamic sensitivity of ultrasonic phased array flaw detector

Abstract

The invention discloses a method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector, and relates to the technical field of phased array ultrasonic nondestructive testing. The objective of the invention is to solve the problem that the dynamic sensitivity is poor when the conventional GE UTXX type water immersion phased array detection equipment is used for nondestructive detection. According to the scheme, the dynamic sensitivity can be improved by about 20% under the condition that the detection accuracy is not influenced. And meanwhile, other operators can operate independently through simple training, so that the working efficiency is greatly improved, the operation difficulty and errors are reduced, and high use value and economic benefits are achieved. The method for adjusting the dynamic sensitivity of the ultrasonic phased array flaw detector can be obtained.

Description

Technical Field

[0001] The invention relates to the technical field of phased array ultrasonic nondestructive testing, and in particular to a method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector. Background Art

[0002] Phased Array Ultrasonic Testing (PAUT) is an efficient and accurate nondestructive testing technology that can be widely used in aviation, automotive, energy, construction and other fields. Compared with traditional single crystal and dual crystal probes, PAUT uses an array of multiple transmitters and receivers to send and receive ultrasonic signals in the material to detect defects and anomalies in the material. When using phased array technology for testing, how to adjust the dynamic sensitivity becomes a major problem. Dynamic sensitivity is one of the important indicators for evaluating the performance of nondestructive testing technology. The higher the dynamic sensitivity, the smaller, deeper and more subtle defects the detection system can detect.

[0003] Therefore, how to adjust the dynamic sensitivity of the phased array to achieve the optimal state has become a technical problem that troubles every inspector and needs to be solved urgently in the industry. Summary of the invention

[0004] The purpose of the present invention is to solve the problem of poor dynamic sensitivity of the current GE UTXX type water immersion phased array detection equipment when performing non-destructive testing, and to provide a method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector.

[0005] A method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector is performed according to the following steps:

[0006] Step S1: Select a probe;

[0007] Select two phased array probes with 128-element wafers, named PA1 and PA2;

[0008] Step S2: adjusting the probe angle;

[0009] Adjust the angles of the two phased array probes PA1 and PA2 in step S1;

[0010] Step S3: adjusting the probe distance;

[0011] Adjust the distance between the phased array probes PA1 and PA2 and the aluminum alloy plate to be tested;

[0012] Step S4: setting detection parameters;

[0013] Set the probe parameters of the phased array ultrasonic testing equipment according to the depth range, geometry, and type and size of the defects of the aluminum alloy plate to be tested;

[0014] Step S5: calibrating the device;

[0015] Before testing, the phased array ultrasonic equipment is calibrated;

[0016] Step S6: On-site environment preparation;

[0017] Before using phased array ultrasonic equipment for testing, confirm the on-site environment of the test;

[0018] Step S7: ultrasonic phased array flaw detection;

[0019] ①Use phased array ultrasonic equipment to perform flaw detection on the aluminum alloy plate to obtain the test data;

[0020] ② Process the test data obtained in step ① to obtain the test results;

[0021] ③ According to the test results obtained in step ②, determine whether the aluminum alloy plate to be tested has defects.

[0022] Beneficial effects of the present invention:

[0023] (1) In order to achieve the goal of adjusting the dynamic sensitivity to the best, the present invention is based on phased array ultrasonic nondestructive testing technology. By selecting a suitable phased array probe, adjusting the probe angle, determining the water layer parameters corresponding to the focal law, setting the repetition frequency, gain, suppression and other scanning parameters, the various components of the equipment are calibrated and measured in a standardized manner to ensure that the detection environment meets the corresponding standards. The scheme of the present invention can increase the dynamic sensitivity by about 20% without affecting the detection accuracy. At the same time, since the scheme can enable other operators to operate independently through simple training, it greatly improves work efficiency, reduces operational difficulty and errors, and has high use value and economic benefits.

[0024] (2) The present invention proposes how to select a suitable probe model and frequency, how to adjust the probe angle, how to adjust the probe water layer distance, how to set the detection parameters, which standards should be applied, how to calibrate the various indicators of the equipment, and how to control the detection environment, thereby achieving the best match of dynamic sensitivity in the detection process of defects at different depths. Through experimental verification, the present invention can significantly improve sensitivity and accuracy, and is suitable for detection tasks of various materials and structures. The present invention can be used to train any qualified ultrasonic operator, and there is no need to add or modify additional software and hardware to the equipment, and it is easy to operate and implement.

[0025] The invention can obtain a method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1A diagram showing a method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to the present invention. DETAILED DESCRIPTION

[0027] Specific implementation method 1: This implementation method provides a method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector, which is performed according to the following steps:

[0028] Step S1: Select a probe;

[0029] Select two phased array probes with 128-element wafers, named PA1 and PA2;

[0030] Step S2: adjusting the probe angle;

[0031] Adjust the angles of the two phased array probes PA1 and PA2 in step S1;

[0032] Step S3: adjusting the probe distance;

[0033] Adjust the distance between the phased array probes PA1 and PA2 and the aluminum alloy plate to be tested;

[0034] Step S4: setting detection parameters;

[0035] Set the probe parameters of the phased array ultrasonic testing equipment according to the depth range, geometry, and type and size of the defects of the aluminum alloy plate to be tested;

[0036] Step S5: calibrating the device;

[0037] Before testing, the phased array ultrasonic equipment is calibrated;

[0038] Step S6: On-site environment preparation;

[0039] Before using phased array ultrasonic equipment for testing, confirm the on-site environment of the test;

[0040] Step S7: ultrasonic phased array flaw detection;

[0041] ①Use phased array ultrasonic equipment to perform flaw detection on the aluminum alloy plate to obtain the test data;

[0042] ② Process the test data obtained in step ① to obtain the test results;

[0043] ③ According to the test results obtained in step ②, determine whether the aluminum alloy plate to be tested has defects.

[0044] Specific implementation method 2: The difference between this implementation method and specific implementation method 1 is that the specific steps of adjusting the probe angle in step S2 are as follows:

[0045] (1) Use one side of the phased array probe PA1 as the reference point, adjust the angles of other parts, and make the sound wave perpendicular to the aluminum alloy plate to be tested through B-scan observation. Similarly, make the sound wave of the phased array probe perpendicular to the aluminum alloy plate to be tested;

[0046] (2) Adjust the phased array probe PA1 to ensure that the distance between the phased array probe PA1 and the water layer is less than or equal to ±0.1 mm.

[0047] The other steps are the same as those in the first specific implementation.

[0048] Specific implementation method 3: This implementation method is different from specific implementation methods 1 or 2 in that the specific steps of adjusting the probe distance in step S3 are as follows:

[0049] Test the standard test block under different water layers to find a set of data that meets the focal law, determine the appropriate water layer, and use the preset focal law to take 75mm as the basic water layer.

[0050] The other steps are the same as those in the first or second embodiment.

[0051] Specific implementation method 4: The difference between this implementation method and specific implementation methods 1 to 3 is that the probe parameters of the phased array ultrasonic detection equipment described in step S4 include but are not limited to transmission voltage, transmission pulse width, transmission pulse repetition frequency and receiving gain.

[0052] The other steps are the same as those in Specific Embodiments 1 to 3.

[0053] Specific implementation method five: The difference between this implementation method and specific implementation methods one to four is that the size of the aluminum alloy plate to be tested in step S4 is 210mm*1000mm*2000mm, and 33 artificial defects with different buried depths are made on the aluminum alloy plate to be tested.

[0054] The other steps are the same as those in Specific Embodiments 1 to 4.

[0055] Specific implementation method 6: The difference between this implementation method and specific implementation methods 1 to 5 is that the parameters of the calibration equipment in step S5 include but are not limited to the probe, reference test block and mechanical accuracy.

[0056] The other steps are the same as those in Specific Embodiments 1 to 5.

[0057] Specific implementation method 7: The difference between this implementation method and specific implementation methods 1 to 6 is that the confirmation parameters of the on-site environment in step S6 include temperature and humidity.

[0058] The other steps are the same as those in Specific Embodiments 1 to 6.

[0059] Specific implementation eight: The difference between this implementation and specific implementations one to seven is that the flaw detection method in step S7 includes but is not limited to the water immersion vertical incidence method.

[0060] The other steps are the same as those in Specific Embodiments 1 to 7.

[0061] Specific implementation method nine: The difference between this implementation method and specific implementation methods one to eight is that the detection data processing method in step S7 includes three types of display methods: A, B and C. C scan is used for observation, A scan is used for positioning, and B scan is used for dynamic confirmation.

[0062] The other steps are the same as those in Specific Embodiments 1 to 8.

[0063] Specific implementation method ten: The difference between this implementation method and specific implementation methods one to nine is that the method for judging whether the aluminum alloy plate to be inspected has defects in step S7 includes but is not limited to C-scan high contrast color display.

[0064] The other steps are the same as those in Specific Embodiments 1 to 9.

[0065] The following examples are used to verify the beneficial effects of the present invention:

[0066] Embodiment 1: A method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector is performed according to the following steps:

[0067] This embodiment uses a size of 210mm*1000mm*2000mm, and refers to ASTM E127-2020 to make the aluminum alloy plate to be tested. 33 artificial defects with different burial depths are made on this aluminum alloy plate (see the attached figure for specific burial depths and positions). This aluminum alloy plate is used as a sample for collecting experimental data and verifying the dynamic sensitivity effect. The equipment components select 2 IMASONIC model probes as probe holders with adjustable mechanical angles for placing probes (the mechanical angle needs to be accurate to 0.001 degrees), a moving shaft that can be lifted and moved, and software for receiving and processing ultrasonic signals (three types of displays, A, B, and C, can be generated, and dynamic C scans can be observed). All of the above requirements must pass the audit requirements.

[0068] Step 1: Select the probe;

[0069] The probe includes a plurality of transmitting elements and receiving elements for transmitting and receiving ultrasonic signals, and the detection device is used to process and analyze the received signals;

[0070] Phased array probes of different models and frequencies are suitable for different detection tasks and depth ranges. Therefore, two IMASONIC phased array probes with 128-element chips were selected, named PA1 and PA2 respectively; the 128-element chip phased array probe has great advantages over other 8-element and 16-element phased array probes:

[0071] 1.1 Higher spatial resolution: The more elements a probe has, the higher the spatial resolution of the scene it detects, and the more accurately the position and shape of the target can be detected;

[0072] 1.2 Wider detection range: The 128-element chip phased array probe has a larger detection range than the 8-element or 16-element chip phased array probe. This means that the 128-element chip phased array probe can detect the target in a wider area, thereby obtaining more comprehensive information about the target;

[0073] 1.3 Higher signal-to-noise ratio: The 128-element chip phased array probe has a higher signal-to-noise ratio than the 8-element or 16-element chip phased array probe. This means that the 128-element chip phased array probe can detect targets more accurately while reducing the impact of noise, thereby improving the detection efficiency and accuracy of the probe;

[0074] 1.4 More sophisticated signal processing: The 128-element phased array probe can perform more sophisticated signal processing than the 8-element or 16-element phased array probe. In phased array imaging, more complex beam imaging and other processing can be performed, thereby improving the imaging effect and quality of the probe.

[0075] Step 2: Adjust the probe angle;

[0076] The angle of the phased array probe also affects dynamic sensitivity. Generally speaking, the best sensitivity is achieved when the probe is perpendicular to the surface of the object being inspected.

[0077] 2.1 Since the element wafers of the phased array probe are arranged at an inclined angle, place the phased array probe on an angle-adjustable bracket for adjustment;

[0078] 2.2 Select one side of the probe (PA2) as the reference point, and adjust the angles of other parts to make the sound wave perpendicular to the experimental board (observed by B scan);

[0079] 2.3 Continue to adjust the angles of the other probe (PA1) on both sides to make the sound wave perpendicular to the experimental board (observe through B scan);

[0080] 2.4 Observe the water layers of the two probes. If they are different, readjust the PA1 probe based on 2.2 so that the difference between the PA1 probe and the PA2 probe is no more than ±0.1mm (confirmed by the parameters on the A scan);

[0081] 2.5 During the synchronization of water layers, if the mechanical angle of PA1 probe reaches the limit and the gap with PA2 water layer is not greater than ±0.1mm, the reference point of PA2 in 2.2 should be corrected again, and steps 2.3 and 2.4 should be repeated until the gap between the water layers of the two probes meets ±0.1mm (confirmed by the parameters on the A scan);

[0082] 2.6 Save the set mechanical angle and check it every day. If there is any deviation, repeat the above steps for debugging.

[0083] Step 3: Adjust the probe distance;

[0084] The distance between the phased array probe and the object to be detected will also affect the dynamic sensitivity. Generally speaking, the closer the probe is to the surface of the object to be detected, the higher the sensitivity. However, if the distance is too close, the probe may be disturbed by the surface of the object, and the detection area will be reduced accordingly, affecting the detection effect. Therefore, it is necessary to determine the corresponding probe distance, that is, the water layer.

[0085] 3.1 Test a set of aluminum alloy test blocks (2.5-200mm) that meet ASTM E127-2020, test the standard test blocks under different water layers, find a set of data that meets the focal law, and thus determine the appropriate water layer; the standard test block is a 0-200mm American standard aluminum alloy longitudinal wave standard test block;

[0086] 3.2 Use the preset focal law to take 75mm as the base water layer.

[0087] Step 4: Set detection parameters;

[0088] 4.1 Set the transmitting and receiving parameters of the phased array probe according to the depth range, geometry, type and size of the defect of the detection target. These parameters include pulse repetition frequency, transmit pulse width, transmit voltage, etc., which also need to be adjusted according to the specific situation;

[0089] 4.2 Repetition frequency: Before testing, the appropriate repetition frequency should be adjusted to achieve the best dynamic sensitivity. The repetition frequency should not be too large to cause a phantom wave to appear between the interface wave and the bottom wave (observe the existence of a phantom wave through B-type scanning). The repetition frequency should also not be too small, which will affect the detection speed. It should be adjusted until the moment when the phantom wave just disappears, which is the optimal repetition frequency;

[0090] 4.3 The emission pulse width and emission voltage shall comply with the requirements of ISO 18563-1 2015;

[0091] 4.4 When the clutter is too high, appropriate filtering can be performed, provided that the vertical linearity of the instrument is not affected;

[0092] 4.5 Use the TCG curve prepared in advance, and appropriately gain the equivalent of each standard test block depth, obtained through experiments, and scan with a gain of 6db to find defects of all depths;

[0093] 4.6 Before scanning, the bottom wave should be compared between the standard test block and the test plate. If there is any difference, make corresponding compensation.

[0094] Step 5: Calibrate the device;

[0095] Before using phased array ultrasonic equipment for testing, the equipment needs to be calibrated. Calibration can ensure the consistency between the output signal of the equipment and the actual measurement value, thereby improving the detection accuracy and reliability. Calibration includes probes, reference test blocks, and mechanical accuracy. Probe calibration can ensure that the geometric and electrical characteristics of the probe meet the requirements, the standard reference test block can ensure that the output signal of the equipment is consistent with the actual output measurement value, and the mechanical accuracy can ensure that the probe angle of the equipment and the movement of each axis in three-dimensional space remain precise and correct.

[0096] 5.1 Mechanical accuracy should be measured every 12 months to determine the maximum travel, positioning accuracy, and repeat positioning accuracy of each axis in three-dimensional space;

[0097] 5.2 Phased array ultrasound boards should be measured every 12 months to determine the following parameters: transmit voltage, pulse rise time, recoil duration, gain variation, vertical linearity, and receive delay;

[0098] 5.3 Phased array ultrasonic probes should be measured every 12 months to determine the following parameters: relative pulse-echo sensitivity, probe sensitivity, frequency, bandwidth, pulse duration, and crosstalk between chips;

[0099] 5.4 The standard reference test block should be measured every 5 years to determine the following parameters: flat bottom hole material brand, flat bottom hole diameter, distance amplitude curve, flat bottom hole burial depth, number of flat bottom holes, and surface finish of the comparison test block.

[0100] Step 6: On-site environment preparation;

[0101] Phased array ultrasonic testing is a high-precision non-destructive testing technology. The impact of the on-site environment may also affect the test results. Therefore, before using phased array ultrasonic equipment for testing, it is necessary to prepare the on-site environment. For example, it is necessary to ensure that the temperature and humidity on site are stable, and avoid interference factors such as electromagnetic interference and sound wave reflection.

[0102] Step 7: Ultrasonic phased array flaw detection;

[0103] ①Use phased array ultrasonic equipment to perform flaw detection on the aluminum alloy plate to obtain the test data;

[0104] ② Process the test data obtained in step ① to obtain the test results;

[0105] ③ According to the test results obtained in step ②, determine whether the aluminum alloy plate to be tested has defects.

Claims

1. A method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector, characterized in that The preparation method is carried out according to the following steps: Step S1: Select a probe; Select two phased array probes with 128-element wafers, named PA1 and PA2; Step S2: adjusting the probe angle; Adjust the angles of the two phased array probes PA1 and PA2 in step S1; Step S3: adjusting the probe distance; Adjust the distance between the phased array probes PA1 and PA2 and the aluminum alloy plate to be tested; Step S4: setting detection parameters; Set the probe parameters of the phased array ultrasonic testing equipment according to the depth range, geometry, and type and size of the defects of the aluminum alloy plate to be tested; Step S5: calibrating the device; Before testing, the phased array ultrasonic equipment is calibrated; Step S6: On-site environment preparation; Before using phased array ultrasonic equipment for testing, confirm the on-site environment of the test; Step S7: ultrasonic phased array flaw detection; ①Use phased array ultrasonic equipment to perform flaw detection on the aluminum alloy plate to obtain the test data; ② Process the test data obtained in step ① to obtain the test results; ③ According to the test results obtained in step ②, determine whether the aluminum alloy plate to be tested has defects.

2. The method for adjusting the dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The specific steps for adjusting the probe angle in step S2 are as follows: (1) Use one side of the phased array probe PA1 as the reference point, adjust the angles of other parts, and make the sound wave perpendicular to the aluminum alloy plate to be tested through B-scan observation. Similarly, make the sound wave of the phased array probe perpendicular to the aluminum alloy plate to be tested; (2) Adjust the phased array probe PA1 to ensure that the distance between the phased array probe PA1 and the water layer is less than or equal to ±0.1 mm.

3. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The specific steps for adjusting the probe distance in step S3 are as follows: Test the standard test block under different water layers to find a set of data that meets the focal law, determine the appropriate water layer, and use the preset focal law to take 75mm as the basic water layer.

4. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The probe parameters of the phased array ultrasonic detection equipment described in step S4 include but are not limited to transmission voltage, transmission pulse width, transmission pulse repetition frequency and receiving gain.

5. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The size of the aluminum alloy plate to be tested in step S4 is 210 mm*1000 mm*2000 mm, and 33 artificial defects with different buried depths are made on the aluminum alloy plate to be tested.

6. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The parameters of the calibration equipment in step S5 include but are not limited to the probe, the reference test block and the mechanical accuracy.

7. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The confirmed parameters of the on-site environment in step S6 include temperature and humidity.

8. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The flaw detection method in step S7 includes but is not limited to the water immersion vertical incidence method.

9. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The detection data processing mode in step S7 includes three types of display modes: A, B and C. C scan is used for observation, A scan is used for positioning, and B scan is used for dynamic confirmation.

10. The method for adjusting dynamic sensitivity of an ultrasonic phased array flaw detector according to claim 1, characterized in that The method for judging whether the aluminum alloy plate to be inspected has defects in step S7 includes but is not limited to C-scan high-contrast color display.

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