Welding seam defect detecting and repairing method

Abstract

The invention discloses a welding seam defect detecting and repairing method which comprises the following steps: performing defect detection on a welding seam structure based on a plurality of defect detection modes to obtain a defect detection result; performing classification identification processing on the defect detection result to obtain corresponding defect information; and generating a corresponding repair strategy according to the defect information, and performing defect repair treatment on the weld joint structure based on the repair strategy. In the aspect of detection, detection and classification identification are carried out through multiple defect detection modes, so that weld defects are captured more comprehensively and accurately, omission and misjudgment are reduced, and the detection accuracy of a complex weld structure is improved; in the aspect of repairing, a targeted repairing strategy is generated based on accurate defect information, the quality problem caused by blind operation in traditional repairing can be effectively solved, the repairing failure risk is reduced, it is ensured that the quality of a repaired welding seam is more reliable, and the requirements of nuclear power equipment for the safety and reliability of the welding seam are met; therefore, the welding seam detection precision and the repair quality are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of nuclear energy technology, and in particular to a method for detecting and repairing weld defects. Background Technology

[0002] With the rapid development of nuclear power technology, the reliability and safety requirements of nuclear power plant equipment are becoming increasingly stringent. Non-destructive testing (NDT) and welding repair technologies play a crucial role in the manufacturing, operation, and maintenance of nuclear power equipment. However, existing NDT and welding repair technologies have several shortcomings in practical applications. Specifically, in the field of NDT, firstly, there are deficiencies in the comprehensive coverage and detection sensitivity of complex weld structures. Weld structures are complex and diverse, encompassing lap welds, butt welds, and three-plate lap welds, with a wide range of plate thicknesses (6mm~20mm). Traditional testing methods are prone to blind spots or insufficient sensitivity when dealing with such complex structures. Secondly, the testing efficiency is low. Traditional testing methods rely heavily on manual operation, and the scanning path planning lacks scientific rigor, directly resulting in low testing efficiency and failing to meet the needs of rapid testing of nuclear power equipment. Furthermore, the unreasonable design of standard test blocks is also a major weakness. The design of standard test blocks in existing technologies is not perfect enough to accurately simulate defects in actual welds, leading to inaccurate sensitivity calibration and affecting the reliability of test results. In addition, quality issues and risks also exist in welding repair. Impurities on the back of the base plate may cause defects such as porosity and slag inclusions during welding, which will adversely affect the quality of the weld. Traditional welding repair methods are often ineffective in dealing with these problems, which can easily lead to repair failure or poor repair quality.

[0003] Therefore, improving the accuracy of weld inspection and the quality of repair is a problem that needs to be solved by those skilled in the art. Summary of the Invention

[0004] This invention provides a method for detecting and repairing weld defects, aiming to improve the accuracy of weld detection and the quality of repair.

[0005] This invention provides a method for detecting and repairing weld defects, including: Defect detection results are obtained by performing defect detection on weld structures based on multiple defect detection methods. The defect detection results are classified and identified to obtain the corresponding defect information; A corresponding repair strategy is generated based on the defect information, and the weld structure is repaired based on the repair strategy.

[0006] Furthermore, the defect detection method includes ultrasonic testing. The defect detection of the weld structure based on multiple defect detection methods to obtain defect detection results includes: The weld structure is subjected to linear or area-based defect detection using a single-line array ultrasonic phased array probe.

[0007] Furthermore, the linear or area-based defect detection of the weld structure using a single-line array ultrasonic phased array probe includes: Obtain the structural parameters of the weld structure; The frequency and number of wafer probes of the single-line array ultrasonic phased array probe are set according to the structural parameters.

[0008] Furthermore, the method of detecting linear or area defects in the weld structure using a single-line array ultrasonic phased array probe further includes: Based on CIVA simulation technology, the scanning path of the single-line ultrasonic phased array probe is optimized, and the probe is controlled to perform defect detection according to the optimized scanning path.

[0009] Furthermore, the optimization of the scanning path of the single-line ultrasonic phased array probe based on CIVA simulation technology, and the control of the single-line ultrasonic phased array probe to perform defect detection according to the optimized scanning path, includes: When the weld structure is a lap weld, the single-line array ultrasonic phased array probe is controlled to scan the upper plate side and the lower plate side corresponding to the lap weld, and the single-line array ultrasonic phased array probe is controlled to move along the length direction of the lap weld, and the lap weld is longitudinally tilted to be scanned using a slanted parallel scanning method. When the weld structure is a butt weld, the single-line array ultrasonic phased array probe is controlled to move along the length of the butt weld, and the butt weld is longitudinally tilted and scanned using a slanted parallel scanning method.

[0010] Furthermore, the classification and identification processing of the defect detection results to obtain corresponding defect information includes: The defect detection results are compared with a preset defect feature database; Based on the comparison results, the defect category and defect parameters corresponding to the defect detection results are determined, and the defect category and defect parameters are set as the defect information.

[0011] Furthermore, the defect feature database is pre-constructed by collecting defect data from different simulated test blocks; wherein each simulated test block contains artificial reflectors of different locations, sizes, and orientations, including cracks, grooves, and holes.

[0012] Furthermore, the defect detection methods include penetrant testing and visual inspection. The step of performing defect detection on the weld structure based on multiple defect detection methods to obtain defect detection results also includes: Based on the aforementioned penetrant testing and / or visual inspection, circular and linear defects are detected in the weld structure.

[0013] Furthermore, the step of generating a corresponding repair strategy based on the defect information and performing defect repair processing on the weld structure based on the repair strategy includes: When the defect information is a surface defect, a surface defect patching and repair strategy is generated; When the defect information is an internal defect, an internal defect handling strategy is generated; When the defect information is other defects, a board repair strategy is generated; wherein, the other defects include defects that cannot be repaired by reflow soldering and impurities in the weld structure that are higher than a preset threshold.

[0014] Furthermore, the step of generating a corresponding repair strategy based on the defect information and performing defect repair processing on the weld structure based on the repair strategy further includes: When the defect information is an unremovable defect, a crack arrestor hole repair strategy is generated, and the corresponding defect is controlled to continue to expand according to the crack arrestor hole repair strategy.

[0015] The weld defect detection and repair method provided in this invention first performs defect detection on the weld structure to obtain results, then classifies and identifies the results to obtain defect information, and finally generates a repair strategy based on the defect information and implements the repair. In terms of detection, this allows for systematic and standardized detection and classification using multiple defect detection methods, thereby capturing weld defects more comprehensively and accurately. This reduces omissions and misjudgments caused by manual operation and methodological limitations in traditional detection, improving the accuracy of detection for complex weld structures. Simultaneously, in terms of repair, the targeted repair strategy generated based on accurate defect information effectively solves quality problems caused by blind operation in traditional repair, reduces the risk of repair failure, and ensures more reliable weld quality after repair, meeting the high requirements of nuclear power equipment for weld safety and reliability. This significantly improves weld detection accuracy and repair quality. Attached Figure Description

[0016] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the following description of the embodiments will be briefly introduced. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1This is a flowchart illustrating a weld defect detection and repair method provided in an embodiment of the present invention. Figure 2 This is a schematic diagram of a lap weld in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of a butt weld in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 4 This is a schematic diagram showing the location of the lap weld in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 5 This is a schematic diagram showing the location of the butt weld in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 6 This is a schematic diagram of another location of the lap weld in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of a simulated test block in a weld defect detection and repair method provided in an embodiment of the present invention; Figure 8 This is another schematic diagram of a simulated test block in a weld defect detection and repair method provided in an embodiment of the present invention. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0020] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0021] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0022] Please see below. Figure 1 The present invention provides a method for detecting and repairing weld defects, specifically including steps S101 to S103.

[0023] Step S101: Perform defect detection on the weld structure based on multiple defect detection methods to obtain defect detection results; Step S102: Classify and identify the defect detection results to obtain the corresponding defect information; Step S103: Generate a corresponding repair strategy based on the defect information, and perform defect repair processing on the weld structure based on the repair strategy.

[0024] This embodiment first performs defect detection on the weld structure to obtain results, then classifies and identifies the results to obtain defect information, and finally generates a repair strategy based on the defect information and implements the repair. In terms of detection, this allows for systematic and standardized detection and classification using multiple defect detection methods, thereby more comprehensively and accurately capturing weld defects. This reduces omissions and misjudgments caused by manual operation and methodological limitations in traditional detection, improving the accuracy of detection for complex weld structures. Simultaneously, in terms of repair, the targeted repair strategy generated based on accurate defect information effectively solves quality problems caused by blind operation in traditional repair, reduces the risk of repair failure, and ensures more reliable weld quality after repair, meeting the high requirements of nuclear power equipment for weld safety and reliability. This significantly improves weld detection accuracy and repair quality.

[0025] In practical applications, this embodiment can be used to inspect and repair the welds on the bottom plate of the PTR refueling tank in nuclear power plants, ensuring the quality and safety of these welds. Furthermore, this embodiment can also effectively inspect and repair complex weld structures in nuclear power equipment, such as the welds of critical components like reactor pressure vessels and steam generators. These components have complex weld structures and extremely high safety and reliability requirements, making traditional inspection and repair methods often inadequate. However, the weld defect inspection and repair method provided in this embodiment can achieve comprehensive coverage and accurate inspection of these complex weld structures. Simultaneously, based on the inspection results, targeted repair strategies can be generated to ensure that the repaired weld quality meets the high standards required for nuclear power equipment.

[0026] In some optional embodiments, image processing and artificial intelligence technologies can be combined to perform more refined classification and identification of weld defects, thereby further improving the accuracy and efficiency of detection. Simultaneously, automated welding technologies and intelligent monitoring systems can be introduced during the repair process to achieve precise control and real-time monitoring, ensuring repair quality and safety.

[0027] In one embodiment, the defect detection method includes ultrasonic detection, and step S101 includes: The weld structure is subjected to linear or area-based defect detection using a single-line array ultrasonic phased array probe.

[0028] This embodiment utilizes the high-precision detection capabilities of a single-line array ultrasonic phased array probe to achieve detailed scanning of the weld structure. This probe can not only linearly scan the weld and capture defects along its length, but also perform area scanning, comprehensively covering the weld area to ensure that all potential defects are detected without omission.

[0029] In a specific embodiment, the step of detecting linear or area defects in the weld structure using a single-line array ultrasonic phased array probe includes: Obtain the structural parameters of the weld structure; The frequency and number of wafer probes of the single-line array ultrasonic phased array probe are set according to the structural parameters.

[0030] To improve defect detection, this embodiment employs single-line array ultrasonic phased array probes with different frequencies and crystal counts, depending on the weld structure and plate thickness. Specifically, the single-line array ultrasonic phased array probe has a frequency range of 2MHz to 5MHz and a crystal count of 16 or 32. This configuration allows for flexible adjustment of sensitivity and resolution according to different detection needs, ensuring comprehensive coverage of welds of varying thicknesses. For example, for a 6mm thick lap weld between a base plate and a skirt plate, a 16-crystal probe with a frequency set to 2MHz to 3MHz can be used to improve detection sensitivity and resolution; while for a 20mm thick butt weld, a 32-crystal probe with a frequency set to 4MHz to 5MHz can be used to enhance the detection capability for deep defects. In practical applications, the configuration and application of the single-line array ultrasonic phased array probe in this embodiment are shown in Table 1 below. Table 1 In one embodiment, the step of detecting linear or area defects in the weld structure using a single-line array ultrasonic phased array probe further includes: Based on CIVA simulation technology, the scanning path of the single-line ultrasonic phased array probe is optimized, and the probe is controlled to perform defect detection according to the optimized scanning path.

[0031] This embodiment achieves efficient inspection of weld structures by utilizing CIVA simulation technology and the acoustic beam coverage of a single-line array ultrasonic phased array probe. Specifically, CIVA simulation technology can simulate the propagation process of ultrasonic waves in the weld, thereby predicting the inspection effect under different scanning paths. Based on the simulation results, the scanning path of the single-line array ultrasonic phased array probe can be optimized to ensure that the acoustic beam can fully cover the weld area, while reducing unnecessary repeated scanning and improving inspection efficiency. In practical applications, corresponding parameters and conditions can be set in the CIVA simulation software according to the structural characteristics of the weld and inspection requirements, simulation calculations can be performed, and the scanning path can be adjusted and optimized based on the simulation results. Subsequently, the optimized scanning path is input into the corresponding inspection system, and the single-line array ultrasonic phased array probe is controlled to perform defect inspection according to this path. In this way, efficient and accurate inspection of weld structures can be achieved, while reducing inspection costs and time.

[0032] In a specific embodiment, the optimization of the scanning path of the single-line ultrasonic phased array probe based on CIVA simulation technology, and the control of the single-line ultrasonic phased array probe to perform defect detection according to the optimized scanning path, includes: When the weld structure is a lap weld, the single-line array ultrasonic phased array probe is controlled to scan the upper plate side and the lower plate side corresponding to the lap weld, and the single-line array ultrasonic phased array probe is controlled to move along the length direction of the lap weld, and the lap weld is longitudinally tilted to be scanned using a slanted parallel scanning method. When the weld structure is a butt weld, the single-line array ultrasonic phased array probe is controlled to move along the length of the butt weld, and the butt weld is longitudinally tilted and scanned using a slanted parallel scanning method.

[0033] This embodiment employs different scanning strategies based on different weld structures. Here, lap welds refer to upper and lower plates overlapping, while butt welds refer to left and right plates joining together. It's understood that in actual lap structures, there can be multiple layers (more than two), such as a three-layer lap weld with upper, middle, and lower plates. For lap welds, due to the gap between the upper and lower plates, ultrasonic waves may refract and reflect during propagation, increasing the difficulty of detection. Therefore, this embodiment controls a single-line array ultrasonic phased array probe to scan the upper and lower plate sides corresponding to the lap weld to obtain more comprehensive defect information. Simultaneously, the probe is moved along the length of the lap weld, and a longitudinally inclined scanning method is used to further increase the beam coverage and improve the accuracy and reliability of the detection. For butt welds, due to their relatively simple structure, ultrasonic waves experience less interference during propagation. Therefore, this embodiment can directly control the single-line array ultrasonic phased array probe to move along the length of the butt weld and use a slanted parallel scanning method for longitudinal tilting scanning, thus achieving effective detection of the butt weld. This approach ensures targeted detection of different types of weld structures, improving detection efficiency and accuracy.

[0034] In practical application scenarios, combined with Figure 2 For lap welds, a single-line array ultrasonic phased array probe can be manually scanned from the upper and lower plate sides, with the probe moving along the weld length. The specific probe scanning direction is as follows: Figure 2 The directions are shown as 1, 2, 3, 4, 5, and 6.

[0035] Combination Figure 3 For butt welds, a single-line array ultrasonic phased array probe can be used for manual scanning on both sides of the weld. The probe moves along the length of the weld. The specific scanning direction is as follows: Figure 3 The directions are shown as 1, 2, 3, 4, 5, and 6.

[0036] Here, due to the special structure of the lap weld and the excess height of the butt weld, an oblique parallel scan was added. During the oblique parallel scan, the probe should be positioned at an angle of no more than 20° to the weld centerline on both sides of the weld, performing longitudinal oblique scans in two directions. Figure 2 and Figure 3 Directions 2, 3, 4, and 6.

[0037] In one embodiment, step S102 includes: The defect detection results are compared with a preset defect feature database; Based on the comparison results, the defect category and defect parameters corresponding to the defect detection results are determined, and the defect category and defect parameters are set as the defect information.

[0038] In this embodiment, after obtaining the defect detection results, they are compared with a preset defect feature database to determine the defect category and defect parameters corresponding to the defect detection results. For example, the preset defect feature database may contain feature information of various weld defects, such as the shape, size, and location of the defects. By comparing the actual defect results obtained from the detection with these data, the category of the defect, such as cracks, porosity, and slag inclusions, can be quickly and accurately identified, and the specific parameters of the defect, such as the length, width, and depth of the defect, can be obtained.

[0039] In a specific embodiment, the defect parameters may include the specific location coordinates of the defect and information such as the defect length. The defect display location of the weld can be determined by a specified reference coordinate system, for example... Figures 4-6 As shown, for lap welds, the upper plate is designated A, and the lower plate B; for three-plate lap welds, the upper plate is designated A, the middle plate B, and the lower plate B'. For butt welds, the coordinate system is based on a top-down view of the PTR tank (used in nuclear power plants for reactor refueling pools and spent fuel pool cooling and treatment systems), viewed clockwise, and then the counter-clockwise side is designated A. The coordinate system is set as follows: The X direction can be set based on actual needs; The Y direction represents the distance from the defect to the weld centerline, and its specific direction is as follows: Figure 4 and Figure 5 As shown in Y- and Y+; The Z-direction represents the depth of the defect relative to the scanning surface. The scanning surface is the zero point of the depth, and the downward direction is positive. This is because when scanning the lower plate, if a defect is found in the weld, the depth may be negative.

[0040] Therefore, when recording the defect length, such as Figure 4 and Figure 5 As shown, L1 is the left end point of the defect, and L2 is the right end point of the defect. When the defect is longitudinal, the position of X is recorded; when the defect is transverse, the position of Y is recorded (the 0 point of Y is the weld centerline); when the defect is inclined, the X or Y direction is determined according to the inclination direction. For example, based on whether the included angle is greater than 45 degrees, the direction (X / Y) the crack approaches determines the inclination direction.

[0041] In a specific embodiment, the defect feature database is pre-constructed by collecting defect data from different simulated test blocks; wherein each simulated test block contains artificial reflectors of different locations, sizes, and orientations, including cracks, grooves, and holes.

[0042] This embodiment uses simulated test blocks of different specifications to simulate various defects that may occur in actual welds, such as the types and sizes of defects in actual welds, to ensure that the test blocks are consistent with actual working conditions and improve the accuracy of sensitivity verification. These simulated test blocks can include cracks, grooves, and artificial reflectors such as holes in different locations, sizes, and directions, thus comprehensively covering the types of defects that may occur in welds. By performing defect detection on these simulated test blocks and recording the characteristic information of various defects, such as the shape, size, and location of defects, the aforementioned defect feature database can be constructed. In addition, the detection sensitivity and accuracy can be verified through simulated test blocks, thereby ensuring the reliability and consistency of the detection results.

[0043] In practical application scenarios, combined with Figure 7 and Figure 8 In this embodiment, a batch of simulated test blocks were fabricated, which included artificial reflectors of different locations, sizes, and orientations, including crack-type, groove-type, and hole-type artificial reflectors. The main size ranges of the artificial reflectors were: 5×2 crack type, 5×4 crack type, 10×4 crack type, 10×2 crack type, 5×1 groove type, and Ø1 deep 2 flat-bottomed hole. The main locations of the artificial reflectors were: upper and lower surfaces of the heat-affected zone, fusion zone, weld embedment, and weld surface (scanning surface). The main orientations of the artificial reflectors were: transverse, longitudinal, and inclined.

[0044] In one embodiment, the defect detection method includes penetration testing and visual inspection, and step S101 further includes: Based on the aforementioned penetrant testing and / or visual inspection, circular and linear defects are detected in the weld structure.

[0045] In addition to using ultrasonic testing to detect linear or area-specific defects in weld structures, this embodiment can also detect circular and linear defects through penetrant testing and / or visual inspection. For example, a penetrant can be used to treat the weld surface, allowing the agent to penetrate into tiny defects. Excess agent is then removed by cleaning, and a developer is used to extract the penetrating agent from the defects, creating a clearly visible defect image, thus enabling the detection of circular and linear defects in the weld structure. Alternatively, the weld appearance can be directly observed visually or with a magnifying glass to check for obvious cracks, porosity, slag inclusions, and other defects. This method, combining multiple detection methods, can more comprehensively detect various potential defects in the weld structure, improving the accuracy and reliability of the detection. Furthermore, detection parameters and strategies can be flexibly adjusted for different types and sizes of defects to ensure optimal detection results.

[0046] Therefore, this embodiment provides three weld defect detection methods: penetrant testing, visual inspection, and single-line array ultrasonic phased array probe testing. Penetrant testing and visual inspection are mainly used to screen for circular and linear defects on the weld surface, while single-line array ultrasonic phased array probe testing can penetrate deep into the weld to perform high-precision detection of linear or area-specific defects. These three weld defect detection methods enable comprehensive, multi-angle inspection of the weld structure from the surface to the interior, ensuring that all potential defects are captured without omission.

[0047] In one embodiment, step S103 includes: When the defect information is a surface defect, a surface defect patching and repair strategy is generated; When the defect information is an internal defect, an internal defect handling strategy is generated; When the defect information is other defects, a board repair strategy is generated; wherein, the other defects include defects that cannot be repaired by reflow soldering and impurities in the weld structure that are higher than a preset threshold.

[0048] In this embodiment, targeted repair strategies are adopted based on different defect information to ensure the integrity and safety of the weld structure. Specifically: When the defect information is a surface defect, i.e., a weld (circular or linear) is detected on the surface of the weld structure through penetrant testing or visual inspection, a corresponding surface defect repair strategy is generated. Specifically, the surface defect repair strategy includes: Use a grinding wheel to grind and remove defects, with a grinding depth ≤0.5mm; Use PT (penetration testing) to confirm the effectiveness of defect elimination; Argon arc welding machine was used for re-welding repair to ensure that the weld quality met the standards; After welding is completed, PT testing, UT testing (ultrasonic testing), and VT testing (visual inspection) are performed to ensure that the repair quality meets the standards.

[0049] When the defect information is an internal defect, meaning that a weld (linear or area-based defect) is detected on the surface of the weld structure via ultrasonic testing, a corresponding internal defect repair strategy is generated. Specifically, the internal defect repair strategy includes: Use a grinding wheel to grind the defective area to completely remove the defect; PT testing was used to confirm that the defect had been eliminated; Clean impurities from the back of the base plate to ensure the welding area is clean and free of contamination; If there are too many impurities on the back of the base plate, making reflow repair infeasible, the plate-laying repair solution (i.e., the subsequent plate-laying repair strategy) should be adopted directly.

[0050] When the defect information indicates a defect that cannot be repaired by reflow soldering or a situation with numerous impurities on the back of the base plate, a corresponding board-layout repair strategy is generated. Specifically, the board-layout repair strategy includes: (1) Design of spare parts for the mounting plate: Determine the dimensions and specifications of the substrate based on the EOMM file, and draw the machining drawings; Ensure the thickness of the lining plate is ≥6mm and that the folded edges are smoothly rounded. The lining material is the same as the original base plate material (e.g., SA516-70) and has the same thickness.

[0051] (2) Plate processing and inspection: The lining plate is processed using a CNC cutting machine and the surface is polished to reduce processing stress. Perform PT testing on the surface of the substrate to ensure it is free of defects; The substrate is pickled and passivated to improve its corrosion resistance.

[0052] (3) Plate installation: Ensure the area where the board is applied is flat and free of foreign matter; Place the defective part at the center of the lining plate; The first layer was welded using an argon arc welding machine, and PT testing was performed immediately after the welding was completed. After passing the inspection, the filling and cover welding are carried out to ensure the quality of the weld.

[0053] (4) Quality inspection: After welding is completed, visual inspection (VT), penetrant testing (PT), ultrasonic testing (UT), and magnetic particle testing (MT) are performed. Ensure that the weld quality meets the first-class standard and the defect level is ≤ I.

[0054] (5) Surface treatment and acceptance: The welded plate is then subjected to pickling and passivation treatment. Inspect the surface treatment quality to ensure there are no obvious defects; Create a complete restoration record and conduct regular follow-up checks.

[0055] Furthermore, in one embodiment, step S103 further includes: When the defect information is an unremovable defect, a crack arrestor hole repair strategy is generated, and the corresponding defect is controlled to continue to expand according to the crack arrestor hole repair strategy.

[0056] For defects that cannot be completely eliminated, a crack arrestor hole solution can be used to prevent defect propagation. This solution specifically includes: Machine crack-stopping holes at the defect locations, with a hole diameter ≥ 2mm; PT testing was used to confirm that there were no residual defects at the location of the crack arrest hole; Grind the area around the crack arrestor hole to ensure a smooth surface; Welding repairs were performed on the area of ​​the crack arrestor hole to ensure that the weld quality met the standards.

[0057] In addition, risk analysis and quality control can be carried out: Impact of impurities on the back of the base plate: Impurities may cause defects such as porosity and slag inclusions during welding, affecting the quality of the weld. Therefore, impurities can be cleaned by grinding or a plate application method can be used to avoid the impact of impurities on the welding quality. And to conduct welding quality control: Strictly control welding parameters to ensure interpass temperature ≤150℃; A multi-layer, multi-pass welding process is adopted to ensure good weld surface formation; After welding is completed, 100% non-destructive testing is performed to ensure the quality of the repair.

[0058] In summary, the weld defect detection and repair method provided in this embodiment can solve at least the following problems: 1. Address the issues of insufficient comprehensive coverage and detection sensitivity in complex weld structures: Weld structures are complex and diverse, including lap welds, butt welds, and three-plate lap welds, with a wide range of plate thicknesses (6mm~20mm). Traditional inspection methods are prone to blind spots or insufficient sensitivity when dealing with complex structures. This embodiment combines multiple inspection methods, including penetrant testing, visual inspection, and single-line array ultrasonic phased array probe testing, which can comprehensively cover the weld structure and reduce blind spots. Furthermore, the scanning path of the single-line array ultrasonic phased array probe is optimized using CIVA simulation technology, improving the sensitivity and accuracy of the inspection.

[0059] 2. Solve the problem of low detection efficiency: Traditional inspection methods require extensive manual operation and suffer from unscientific scanning path planning, resulting in low inspection efficiency and failing to meet the rapid inspection needs of nuclear power equipment. This embodiment, however, combines CIVA simulation technology with a single-line array ultrasonic phased array probe to automate and intelligently manage the inspection process, reducing reliance on manual operation and significantly improving efficiency. In practice, technicians simply set the relevant parameters and conditions in the CIVA simulation software, which automatically performs simulation calculations and outputs an optimized scanning path. This process not only avoids oversights and errors that may occur with manual scanning path planning but also makes the inspection process more standardized and regulated.

[0060] 3. Address the issue of unreasonable standard test block design: The design of the standard test block in the original technology was not perfect and could not accurately simulate defects in actual welds, resulting in inaccurate sensitivity calibration and affecting the reliability of the test results. This embodiment, however, fully considers the types and sizes of defects in actual welds, ensuring that the test block can truly reflect the characteristics of the weld structure and potential defects. Furthermore, rigorous sensitivity calibration of the test block verifies the accuracy and reliability of the detection method.

[0061] 4. Addressing quality issues and risks in welding repair: Impurities on the back of the base plate can cause defects such as porosity and slag inclusions during welding, affecting weld quality. Traditional welding repair methods are often ineffective in addressing these problems, leading to repair failures or poor repair quality. This embodiment, however, uses precise classification and identification to accurately determine the type and parameters of defects, providing a reliable basis for subsequent repair strategy development. In formulating the repair strategy, targeted repair measures are adopted based on different defect information, such as surface defect patching, internal defect treatment, and plate-filling repair, ensuring the effectiveness of the repair and the integrity of the weld structure. Furthermore, this embodiment pays special attention to the impact of impurities on weld quality, effectively avoiding their adverse effects by grinding to remove impurities or using plate-filling methods. Regarding welding quality control, welding parameters are strictly controlled, and a multi-layer, multi-pass welding process is employed to ensure good weld surface formation. 100% non-destructive testing further guarantees the repair quality.

[0062] In practical applications, the weld defect detection and repair method provided in this embodiment can solve the ultrasonic testing process for several weld types on the PTR001BA base plate. The method has been verified through test blocks and on-site inspection, demonstrating its reliability. Furthermore, it has been reviewed by industry experts, confirming its reliability as well. This embodiment, through a scientific welding repair scheme, ensures repair quality, extends equipment lifespan, and reduces downtime and maintenance costs caused by equipment failure. This improves the reliability and safety of nuclear power plant equipment, ensures the long-term stable operation of nuclear power plants, and provides new technical means for quality control in nuclear energy engineering and defect analysis in materials science, thereby promoting technological progress in related fields.

[0063] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the systems disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the descriptions are relatively simple; relevant parts can be referred to in the method section. It should be noted that those skilled in the art can make various improvements and modifications to this application without departing from the principles of this application, and these improvements and modifications also fall within the protection scope of the claims of this application.

[0064] It should also be noted that, in this specification, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A method for detecting and repairing weld defects, characterized in that, include: Defect detection results are obtained by performing defect detection on weld structures based on multiple defect detection methods. The defect detection results are classified and identified to obtain the corresponding defect information; A corresponding repair strategy is generated based on the defect information, and the weld structure is repaired based on the repair strategy.

2. The method for detecting and repairing weld defects according to claim 1, characterized in that, The defect detection method includes ultrasonic testing. The defect detection of the weld structure based on multiple defect detection methods, to obtain the defect detection results, includes: The weld structure is subjected to linear or area-based defect detection using a single-line array ultrasonic phased array probe.

3. The method for detecting and repairing weld defects according to claim 2, characterized in that, The method of detecting linear or area defects in the weld structure using a single-line array ultrasonic phased array probe includes: Obtain the structural parameters of the weld structure; The frequency and number of wafer probes of the single-line array ultrasonic phased array probe are set according to the structural parameters.

4. The method for detecting and repairing weld defects according to claim 2, characterized in that, The method of detecting linear or area defects in the weld structure using a single-line array ultrasonic phased array probe further includes: Based on CIVA simulation technology, the scanning path of the single-line ultrasonic phased array probe is optimized, and the probe is controlled to perform defect detection according to the optimized scanning path.

5. The method for detecting and repairing weld defects according to claim 4, characterized in that, The process of optimizing the scanning path of the single-line ultrasonic phased array probe based on CIVA simulation technology and controlling the probe to perform defect detection according to the optimized scanning path includes: When the weld structure is a lap weld, the single-line array ultrasonic phased array probe is controlled to scan the upper plate side and the lower plate side corresponding to the lap weld, and the single-line array ultrasonic phased array probe is controlled to move along the length direction of the lap weld, and the lap weld is longitudinally tilted to be scanned using a slanted parallel scanning method. When the weld structure is a butt weld, the single-line array ultrasonic phased array probe is controlled to move along the length of the butt weld, and the butt weld is longitudinally tilted and scanned using a slanted parallel scanning method.

6. The method for detecting and repairing weld defects according to claim 1, characterized in that, The process of classifying and identifying the defect detection results to obtain corresponding defect information includes: The defect detection results are compared with a preset defect feature database; Based on the comparison results, the defect category and defect parameters corresponding to the defect detection results are determined, and the defect category and defect parameters are set as the defect information.

7. The method for detecting and repairing weld defects according to claim 6, characterized in that, The defect feature database is pre-constructed by collecting defect data from different simulated test blocks; wherein each simulated test block contains artificial reflectors of different locations, sizes, and orientations, including cracks, grooves, and holes.

8. The method for detecting and repairing weld defects according to claim 2, characterized in that, The defect detection methods include penetrant testing and visual inspection. The method of performing defect detection on the weld structure based on multiple defect detection methods to obtain defect detection results also includes: Based on the aforementioned penetrant testing and / or visual inspection, circular and linear defects are detected in the weld structure.

9. The method for detecting and repairing weld defects according to claim 8, characterized in that, The step of generating a corresponding repair strategy based on the defect information and performing defect repair processing on the weld structure based on the repair strategy includes: When the defect information is a surface defect, a surface defect patching and repair strategy is generated; When the defect information is an internal defect, an internal defect handling strategy is generated; When the defect information is other defects, a board repair strategy is generated; wherein, the other defects include defects that cannot be repaired by reflow soldering and impurities in the weld structure that are higher than a preset threshold.

10. The method for detecting and repairing weld defects according to claim 9, characterized in that, The step of generating a corresponding repair strategy based on the defect information and performing defect repair processing on the weld structure based on the repair strategy further includes: When the defect information is an unremovable defect, a crack arrestor hole repair strategy is generated, and the corresponding defect is controlled to continue to expand according to the crack arrestor hole repair strategy.

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