Standard block for defect detection of aero-engine wheel disc and preparation method of standard block

Abstract

The invention relates to the technical field of high-temperature alloy nondestructive testing, in particular to a standard block for defect detection of an aero-engine wheel disc and a preparation method of the standard block. A standard block for defect detection of an aero-engine wheel disc comprises an annular base body and a defect simulation unit located in the annular base body, the defect simulation unit and the annular base body are in metallurgical bonding, and the defect simulation unit comprises a plurality of white spot simulation units, a plurality of dirty white spot simulation units and a plurality of black spot simulation units; the white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit are independently distributed on three concentric circumferences of the annular base body. The standard block disclosed by the invention can accurately reproduce components, crystal grains and structural characteristics of white spots, dirty white spots and black spots, and the defect simulation similarity is high; metallurgical bonding is achieved, interface defects are avoided, and bonding strength is high; the size specifications are various, and the size coverage range is widened; the calibration precision is improved; the repeated use frequency is high, and the service life is prolonged.

Description

Technical Field

[0001] This invention relates to the field of nondestructive testing technology for high-temperature alloys, and more specifically, to a standard block for detecting defects in aero-engine wheel disks and its preparation method. Background Technology

[0002] As a core load-bearing component, the GH4169 alloy wheel disc of an aero-engine is susceptible to metallurgical defects such as white spots, dirty white spots, and black spots, which directly affect flight safety. Non-destructive testing (NDT) technology is a key means of defect screening, and standard blocks, as the core carrier for calibrating testing methods, verifying testing accuracy, and constructing POD models, directly determine the reliability of the test results based on the realism of their defect simulation.

[0003] The existing technology has the following core problems: 1) Defect simulation distortion: Traditional standard blocks use a single material or simple mechanical processing defects (such as drilling and grooving), which cannot reproduce the elemental segregation characteristics of white spots (low Nb content) and black spots (high Nb content), as well as the structural characteristics of nitrided inclusions attached to the surface of dirty white spots.

[0004] 2) Mismatch in grain state: The existing standard block does not take into account the difference in grain size between the defect area and the substrate. The actual defect grains are either coarse or fine, which leads to the ultrasonic propagation characteristics being inconsistent with the real wheel, resulting in a large calibration error.

[0005] 3) Insufficient size coverage: The defect size specifications are limited and cannot meet the requirements for building POD models under different detection sensitivities.

[0006] 4) Poor stability: Some standard blocks are fixed with adhesives, inlays or other methods to fix the defect simulation parts, which can easily lead to problems such as interface separation and cracks, affecting the repeatability of the test.

[0007] The aforementioned problems prevent existing standard blocks from providing accurate calibration benchmarks for non-destructive testing. The evaluation results of the POD model deviate from actual engineering applications, making it difficult to guarantee the accuracy and reliability of wheel defect detection.

[0008] In view of this, the present invention is hereby proposed. Summary of the Invention

[0009] One objective of this invention is to provide a standard block for detecting defects in aero-engine wheel disks, which can accurately reproduce the composition, grain size, and structural characteristics of white spots, dirty white spots, and black spots, with high defect simulation similarity; it features metallurgical bonding and high bonding strength; it offers a variety of sizes and specifications, covering a wide range of dimensions; it improves calibration accuracy; and it has a long service life.

[0010] Another object of the present invention is to provide a method for preparing a standard block for detecting defects in aero-engine wheel disks.

[0011] In order to achieve the above-mentioned objectives of the present invention, the following technical solution is adopted: A target block for detecting defects in aero-engine rotor discs includes an annular substrate and defect simulation units located within the annular substrate. The defect simulation units are metallurgically bonded to the annular substrate. Each defect simulation unit includes several white spot simulation units, several dirty white spot simulation units, and several black spot simulation units. The white spot simulation units, the dirty white spot simulation units, and the black spot simulation units are each independently distributed on three concentric circles of the annular substrate.

[0012] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are distributed sequentially at intervals on their respective concentric circumferences in descending order of defect size; the defect simulation units on different concentric circumferences are staggered.

[0013] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit each independently include a rod shape, each with a cross-sectional diameter of 1~5.2mm and a diameter interval of 0.1~0.2mm. In some embodiments, the number of each of the vitiligo simulation unit, the dirty vitiligo simulation unit, and the black spot simulation unit is ≥8, preferably 10 to 13.

[0014] In some implementations, the difference in radius between any two adjacent concentric circles is 45 to 60 mm.

[0015] In some embodiments, the annular matrix comprises a GH4169 alloy with a surface roughness Ra ≤ 3.2 μm.

[0016] In some embodiments, a positioning groove is provided at the 0° circumferential position of the annular base for orientation calibration during testing. The depth of the positioning groove is 1.5~2.5mm and the width is 2.5~3.5mm.

[0017] In some embodiments, the white spot simulation unit comprises, by mass percentage: Nb 4.4%~4.8%, Mo 2.8%~3.1%, Al 0.4%~0.6%, Ti 0.65%~0.9%, Ni 53.5%~55.5%, Cr 18%~21%, with the balance being Fe.

[0018] In some embodiments, the internal particle size of the white spot simulation unit is 5 to 6 levels.

[0019] In some embodiments, the dirty white spot simulation unit includes a substrate layer and a coating layer located on the surface of the substrate layer. The substrate layer comprises, by mass percentage: Nb 4.4%~4.8%, Mo 2.8%~3.1%, Al 0.4%~0.6%, Ti 0.65%~0.9%, Ni 53.5%~55.5%, Cr 18%~21%, with the balance being Fe. The coating layer includes a TiN particle layer. Preferably, the thickness of the TiN particle layer is 1~5 μm, and the adhesion amount is 5~10 mg / cm.

[0020] In some embodiments, the internal particle size of the dirty white spot simulation unit is 5 to 6 levels.

[0021] In some embodiments, the black spot simulation unit comprises, by mass percentage: Nb 6.5%~10.0%, Mo 1.5%~3.6%, Al 0.5%~0.65%, Ti 1.2%~1.45%, Ni 50%~53%, Cr 17.5%~18.5%, with the balance being Fe.

[0022] In some implementations, the internal particles of the black spot simulation unit are graded as 8 to 9.

[0023] The method for preparing the standard block for detecting defects in aero-engine wheel disks, as described above, includes the following steps: Obtain several vitiligo simulation units, several dirty vitiligo simulation units, and several black spot simulation units.

[0024] Obtain an annular sleeve, on which positioning grooves are respectively provided on the three concentric circumferences at the bottom of the annular sleeve; fix the white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit independently in the positioning grooves of the three concentric circumferences to obtain the sleeve assembly.

[0025] The precursor powder of the annular matrix is ​​filled into the encapsulation assembly, and then subjected to hot isostatic pressing and processing after vacuuming.

[0026] In some embodiments, the method for obtaining the white spot simulation unit specifically includes: mixing the components of the white spot simulation unit according to stoichiometry and then performing a first vacuum induction melting, casting to obtain a first ingot, performing a first solution treatment on the first ingot, water quenching and then processing to obtain a white spot simulation unit of the target size.

[0027] In some embodiments, the melting temperature of the first vacuum induction melting is 1450~1700℃ and the power is 700~1000KW.

[0028] In some embodiments, the temperature of the first solution treatment is 1150~1200℃ and the time is 3~5h.

[0029] In some embodiments, the surface roughness Ra of the white spot simulation unit is ≤1.6μm.

[0030] In some embodiments, the method for obtaining the dirty white spot simulation unit specifically includes: mixing the components of the dirty white spot simulation unit according to stoichiometry and then performing a second vacuum induction melting, casting to obtain a second ingot, performing a second solution treatment on the second ingot, water quenching and then processing to obtain a matrix structure of the target size; performing plasma spraying on the surface of the matrix structure, then attaching TiN particles by electrostatic adsorption, and then performing a curing treatment.

[0031] In some embodiments, the melting temperature of the second vacuum induction melting is 1450~1700℃ and the power is 700~1000KW.

[0032] In some embodiments, the temperature of the second solution treatment is 1150~1200°C and the time is 3~5 hours.

[0033] In some embodiments, the surface roughness Ra of the substrate structure is ≤1.6 μm.

[0034] In some embodiments, the surface roughness Ra after plasma spraying is 3.2~6.3 μm.

[0035] In some embodiments, the curing process is carried out at a temperature of 180-220°C for 1-3 hours.

[0036] In some embodiments, the method for obtaining the black spot simulation unit specifically includes: mixing the components of the black spot simulation unit according to stoichiometry and then performing a third vacuum induction melting, casting to obtain a third ingot, performing a hot deformation treatment on the third ingot, performing a third solution treatment, air cooling, and then processing to obtain a black spot simulation unit of the target size.

[0037] In some embodiments, the melting temperature of the third vacuum induction melting is 1450~1700℃, and the power is 700~1000KW.

[0038] In some embodiments, the temperature of the heat deformation treatment is 750~850°C, and the deformation amount is 35%~45%.

[0039] In some embodiments, the temperature of the third solution treatment is 1030~1070°C and the time is 1~3h.

[0040] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are each independently fixed in the positioning grooves of the three concentric circles, and the fixing method is spot welding.

[0041] In some embodiments, the precursor powder of the annular matrix has a particle size of 0.01~20μm and a bulk density of 2.5~3g / cm³. 3 .

[0042] In some embodiments, the vacuum level is ≤1×10⁻⁶. -3 Pa.

[0043] In some embodiments, the conditions for the hot isostatic pressing treatment are: temperature of 1160~1200℃, pressure of 150~170MPa, holding time of heat and pressure of 3~5h, and furnace cooling.

[0044] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The standard block for defect detection of aero-engine wheel disk of the present invention can accurately reproduce the composition, grain and structural characteristics of white spots, dirty white spots and black spots, with high defect simulation similarity; metallurgical bonding, no interface defects, and high bonding strength; multiple size specifications, improving size coverage; improved calibration accuracy; high number of reuses, improving service life.

[0045] (2) The method for preparing the standard block for detecting defects in aero-engine wheel disks of the present invention achieves simultaneous simulation of three typical metallurgical defects through precise control of composition and matching of grain state; through metallurgical bonding and forming, there are no interface gaps, which solves the interface bonding problem between defect units and the matrix; the preparation process takes into account both structural compactness and dimensional accuracy, which solves the technical bottleneck of poor stability and short service life of existing standard blocks; it breaks through the limitations of geometric simulation of traditional standard blocks, establishes an integrated simulation system of composition, structure and performance, and significantly improves the authenticity of detection and calibration. Detailed Implementation

[0046] The embodiments of the present invention will be described in detail below with reference to examples. However, those skilled in the art will understand that the following examples are for illustrative purposes only and should not be considered as limiting the scope of the invention. Unless otherwise specified in the examples, conventional conditions or conditions recommended by the manufacturer are followed. Reagents or instruments whose manufacturers are not specified are all commercially available conventional products.

[0047] According to one aspect of the present invention, the present invention relates to a target block for defect detection of aero-engine wheel disks, comprising an annular substrate and a defect simulation unit located in the annular substrate, the defect simulation unit being metallurgically bonded to the annular substrate; the defect simulation unit comprising a plurality of white spot simulation units, a plurality of dirty white spot simulation units, and a plurality of black spot simulation units; the white spot simulation units, the dirty white spot simulation units, and the black spot simulation units are each independently distributed on three concentric circles on the cross-sectional end face of the annular substrate.

[0048] The standard block of the present invention for defect detection of aero-engine wheel disks can accurately reproduce the composition, grain and structural characteristics of white spots, dirty white spots and black spots, with high defect simulation similarity; it is metallurgically bonded, with no interface defects and high bonding strength; it has multiple size specifications, improving the size coverage range; it improves calibration accuracy; it has a high number of reuses, improving service life.

[0049] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are distributed sequentially at intervals on their respective concentric circumferences in descending order of defect size; the defect simulation units on different circumferences are staggered to avoid detection interference. In some embodiments, on the same concentric circumference, the defect sizes of the white spot simulation unit, the dirty white spot simulation unit, or the black spot simulation unit are arranged from largest to smallest in a clockwise direction.

[0050] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are each independently rod-shaped, with a cross-sectional diameter of 1~5.2mm, such as 1mm, 1.5mm, 2mm, 3mm, 4mm, 5mm, or 5.2mm, to meet different sensitivity detection requirements and provide comprehensive data support for POD model construction; the diameter intervals are each independently 0.1~0.2mm, such as 0.1mm, 0.12mm, 0.15mm, 0.18mm, or 0.2mm. The height is 3~5mm. In some embodiments, the number of each of the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit is ≥8, such as 8, 9, 10, 11, 12, 13, 15, etc., preferably 10 to 13. The defect simulation units of this invention have multiple size specifications, thus improving the size coverage.

[0051] In some implementations, the difference in radius between any two adjacent concentric circles is 45-60 mm, for example, 45 mm, 50 mm, 55 mm, 60 mm, etc.

[0052] In some embodiments, the annular substrate comprises a GH4169 alloy with a surface roughness Ra ≤ 3.2 μm, such as 1 μm, 1.5 μm, 2 μm, 3 μm, 3.2 μm, etc. The substrate uses the same GH4169 alloy as the actual wheel to ensure matching of mechanical properties and acoustic characteristics.

[0053] In some embodiments, the mass fraction of the constituent elements of the cyclic matrix GH4169 alloy is as follows: C 0.02%~0.06%, Cr 17.00%~21.00%, Ni 50.00%~55.00%, Co≤1.00%, Mo 2.80%~3.30%, Al 0.20%~0.80%, Ti 0.65%~1.15%, Nb 5.00%~5.50%, B≤0.006%, Mg≤0.005%, Mn≤0.35%, Si≤0.35%, P≤0.015%, S≤0.015%, Cu≤0.005%, with the balance being Fe. In some embodiments, the mass fraction of the constituent elements of the annular matrix GH4169 alloy in various embodiments of the present invention is as follows: C 0.05%, Cr 20%, Ni 52%, Co 0.8%, Mo 3%, Al 0.5%, Ti 0.8%, Nb 5.2%, B 0.002%, Mg 0.002%, Mn 0.2%, Si 0.25%, P 0.01%, S 0.01%, Cu 0.002%, with the balance being Fe.

[0054] In some embodiments, a positioning groove is provided at the 0° circumferential position of the annular base for orientation calibration during testing. The depth of the positioning groove is 1.5~2.5mm, for example, 1.5mm, 2mm, 2.5mm, etc., and the width is 2.5~3.5mm, for example, 2.5mm, 3mm, or 3.5mm, etc.

[0055] In some embodiments, the white spot simulation unit comprises, by mass percentage: Nb 4.4%~4.8% (e.g., 4.4%, 4.5%, 4.6%, 4.7%, 4.8%), Mo 2.8%~3.1% (e.g., 2.8%, 2.85%, 2.9%, 3%, 3.1%, etc.), Al 0.4%~0.6% (e.g., 0.4%, 0.45%, 0.5%, 0.55%, 0.6%, etc.), Ti 0.65%~0.9% (e.g., 0.65%, 0.7%, 0.75%, 0.8%, 0.9%, etc.), Ni 53.5%~55.5% (e.g., 53.5%, 54%, 55%, 55.5%, etc.), Cr 18%~21% (e.g., 18%, 18.5%, 19%, 20%, 21%, etc.), with the balance being Fe. In some embodiments, the internal particle size of the white spot simulation unit is 5-6 levels (coarse grains).

[0056] In some embodiments, the dirty white spot simulation unit includes a substrate layer and a coating layer located on the surface of the substrate layer. The substrate layer, by mass percentage, comprises: Nb 4.4%~4.8% (e.g., 4.4%, 4.5%, 4.6%, 4.8%, etc.), Mo 2.8%~3.1% (e.g., 2.8%, 2.9%, 3%, 3.1%, etc.), Al 0.4%~0.6% (e.g., 0.4%, 0.5%, 0.7%, etc.), Ti 0.65%~0.9% (e.g., 0.65%, 0.7%, 0.8%, 0.9%, etc.), Ni The coating consists of 53.5%~55.5% (e.g., 53.5%, 54%, 55%, 55.5%, etc.), Cr 18%~21% (e.g., 18%, 19%, 20%, 21%, etc.), with the balance being Fe; the coating layer includes a TiN particle layer; preferably, the thickness of the TiN particle layer is 1~5μm, e.g., 1μm, 2μm, 3μm, 5μm, etc. Simulated oxide inclusions are deposited at a concentration of 5~10mg / cm, e.g., 5mg / cm, 6mg / cm, 7mg / cm, 10mg / cm, etc. In some embodiments, the internal particle size of the dirty white spot simulation unit is grade 5~6 (coarse grains). The TiN particle attachment structure of the dirty white spot defect replicates the inclusion characteristics of the actual defect.

[0057] In some embodiments, the black spot simulation unit comprises, by mass percentage: Nb 6.5%~10.0% (e.g., 6.5%, 7%, 8%, 9%, 10%, etc.), Mo 1.5%~3.6% (e.g., 1.5%, 2%, 3%, 33%, 3.6%, etc.), Al 0.5%~0.65% (e.g., 0.5%, 0.55%, 0.6%, 0.65%, etc.), Ti 1.2%~1.45% (e.g., 1.2%, 1.3%, 1.4%, 1.45%, etc.), Ni 50%~53% (50%, 51%, 52%, 53%, etc.), Cr 17.5%~18.5% (e.g., 17.5%, 17.8%, 18%, 18.5%, etc.), with the balance being Fe. In some embodiments, the internal grain size of the black spot simulation unit is grade 8~9 (refined grain size).

[0058] In some embodiments, the substrate of the present invention is an annular body with an outer diameter of 200 mm, a height of 30 mm, and an inner diameter of 80 mm. Three sets of concentric circles are 50 mm, 100 mm, and 150 mm away from the center, respectively, and 11 defect units are evenly distributed on each set of circles.

[0059] According to another aspect of the present invention, the present invention also relates to a method for preparing the aforementioned standard block for detecting defects in aero-engine wheel disks, comprising the following steps: Obtain several vitiligo simulation units, several dirty vitiligo simulation units, and several black spot simulation units.

[0060] Obtain an annular sleeve, on which positioning grooves are respectively provided on the three concentric circumferences at the bottom of the annular sleeve; fix the white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit independently in the positioning grooves of the three concentric circumferences to obtain the sleeve assembly.

[0061] The precursor powder of the annular matrix is ​​filled into the encapsulation assembly, and then subjected to hot isostatic pressing and processing after vacuuming.

[0062] The present invention provides a method for preparing a standard block for detecting defects in aero-engine rotor disks. This method achieves simultaneous simulation of three typical metallurgical defects through precise composition control (Nb content gradient design) and grain state matching (coarse / refined grains). By using metallurgical bonding molding, there are no interface gaps, solving the interface bonding problem between defect units and the matrix. The preparation process balances structural density and dimensional accuracy, overcoming the technical bottlenecks of poor stability and short service life of existing standard blocks. It breaks through the limitations of traditional geometric simulation of standard blocks, establishing an integrated simulation system of composition, structure, and performance, significantly improving the realism of detection and calibration.

[0063] In some embodiments, the method for obtaining the white spot simulation unit specifically includes: mixing the components of the white spot simulation unit according to stoichiometry and then performing a first vacuum induction melting, casting to obtain a first ingot, performing a first solution treatment on the first ingot, water quenching, and then processing (e.g., wire electrical discharge machining) to obtain a white spot simulation unit of the target size; preferably, the melting temperature of the first vacuum induction melting is 1450~1700℃ (e.g., 1450℃, 1550℃, 1560℃, 1570℃, 1580℃, 1590℃, or 1600℃, etc.) to ensure compositional uniformity (compositional deviation ≤ ±0.05wt%), and the power is 700~1000KW; the temperature of the first solution treatment is 1150~1200℃ (e.g., 1150℃, 1160℃, 1170℃, 1190℃, or 1200℃, etc.), and the time is 3~5h (e.g., 3h, 3.5h, 4h, or 5h, etc.). The surface roughness Ra of the white spot simulation unit is ≤1.6μm (e.g., 0.5μm, 1μm, 1.2μm, 1.6μm, etc.). The combination of these conditions in this invention enables the accurate reproduction of the composition, grain size, and structural features of the white spot simulation unit, improving the similarity of defect simulation.

[0064] In some embodiments, the method for obtaining the dirty white spot simulation unit specifically includes: mixing the components of the dirty white spot simulation unit according to stoichiometry and then performing a second vacuum induction melting; casting to obtain a second ingot; subjecting the second ingot to a second solution treatment; water quenching and processing to obtain a matrix structure of the target size; performing plasma spraying on the surface of the matrix structure; then attaching TiN particles using electrostatic adsorption; and finally performing a curing treatment. In some embodiments, the melting temperature of the second vacuum induction melting is 1450~1700℃ (e.g., 1550℃, 1560℃, 1580℃, 1600℃, etc.), and the power is 700~1000KW. Ensure compositional uniformity (compositional deviation ≤ ±0.05wt%); in some embodiments, the temperature of the second solution treatment is 1150~1200℃ (e.g., 1150℃, 1160℃, 1180℃, 1200℃) and the time is 3~5h (e.g., 3h, 3.5h, 4h or 5h, etc.); in some embodiments, the surface roughness Ra of the matrix structure is ≤1.6μm (e.g., 0.5μm, 1μm, 1.6μm, etc.); some In some embodiments, the surface roughness Ra after plasma spraying is 3.2~6.3μm (e.g., 3.2μm, 3.5μm, 4μm, 5μm, 6μm, 6.3μm, etc.); in some embodiments, the curing temperature is 180~220℃ (e.g., 180℃, 190℃, 200℃, 210℃, 220℃, etc.) and the time is 1~3h (e.g., 1h, 1.5h, 2h or 3h, etc.) to ensure firm particle adhesion. The combination of these conditions in this invention enables accurate reproduction of the composition, grain size, and structural features of the dirty white spot simulation unit, improving the similarity of defect simulation.

[0065] In some embodiments, the method for obtaining the black spot simulation unit specifically includes: mixing the components of the black spot simulation unit according to stoichiometry and then performing a third vacuum induction melting process; casting the mixture to obtain a third ingot; subjecting the third ingot to heat deformation treatment; performing a third solution treatment; air cooling; and then processing the ingot (e.g., wire electrical discharge machining) to obtain a black spot simulation unit of the target size; the melting temperature of the third vacuum induction melting process is 1450~1700℃ (e.g., 1550℃, 1570℃, 1580℃, 1600℃), and the power is 700~1 The heat treatment temperature is 750~850℃ (e.g., 750℃, 780℃, 800℃, 820℃, 840℃, 850℃, etc.), and the deformation amount is 35%~45% (e.g., 35%, 40%, 45%, 45%, etc.). The third solution treatment temperature is 1030~1070℃ (e.g., 1030℃, 1040℃, 1050℃, 1070℃, etc.), and the time is 1~3h (e.g., 1h, 1.5h, 2h, 3h, etc.). The combination of these conditions in this invention enables the accurate reproduction of the composition, grain size, and structural characteristics of the black spot simulation unit, improving the similarity of defect simulation.

[0066] In some implementations, the diameters of the first ingot, the second ingot, and the third ingot are each 70-85 mm.

[0067] In some embodiments, the first vacuum induction melting, the second vacuum melting, and the third vacuum melting each independently include: melting, pouring, cooling, void breaking, slow cooling with mold, and demolding in sequence.

[0068] In some embodiments, the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are each independently fixed in the positioning grooves of the three concentric circles, and the fixing method is spot welding.

[0069] In some embodiments, the precursor powder of the annular matrix (e.g., GH4169 ultrafine powder) has a particle size of 0.01~20μm (e.g., 0.01μm, 1μm, 2μm, 10μm, 15μm, 20μm, etc.) and a bulk density of 2.5~3g / cm³. 3 (e.g., 2.5g / cm) 3 2.6g / cm 3 2.8g / cm 3 3g / cm 3 wait).

[0070] In some embodiments, a circular sleeve with a diameter of Φ (e.g., 200~500) mm × (25~35) mm is welded from GH4169 alloy sheet, with a defect unit positioning groove reserved at the bottom; the top of the sleeve is welded and sealed, with a vacuum interface reserved; GH4169 ultrafine powder is filled into the sleeve through the vacuum interface, while vacuuming is performed until the vacuum level meets the appropriate requirements.

[0071] The vacuum level is ≤1×10⁻⁶. -3 Pa, for example 0.5 × 10 -3 Pa, 0.6×10 -3 Pa, 0.8×10 -3 Pa, 1×10 -3 Pa, etc.

[0072] In some embodiments, the conditions for the hot isostatic pressing treatment are: temperature of 1160~1200℃ (e.g., 1160℃, 1170℃, 1180℃, 1200℃, etc.), pressure of 150~170MPa (e.g., 150MPa, 155MPa, 160MPa, 170MPa, etc.), heat and pressure holding time of 3~5h (e.g., 3h, 4h, 5h, etc.), and furnace cooling.

[0073] In some embodiments, the processing after hot isostatic pressing includes: removing excess material from the sheath, machining to the target size, and surface finishing to Ra≤3.2μm.

[0074] The present invention further inspects a standard block used for defect detection of aero-engine wheel disks, including: Non-destructive testing: Ultrasonic testing (frequency 5MHz) is used to inspect the internal bonding state of the test block to ensure that there are no defects such as cracks or holes (detection sensitivity ≥ Φ0.8mm flat bottom hole).

[0075] Physicochemical testing: Cut standard sample blocks and test the matrix grain size (7~8 grade), defect unit composition and grain state (meeting design requirements).

[0076] The standard block of this invention can be widely used for calibration of non-destructive testing technologies such as ultrasonic testing and eddy current testing of GH4169 alloy wheel disks of aero engines. Specifically, it includes: (1) sensitivity calibration of testing equipment; (2) validity verification of testing methods; (3) construction of probability of defect detection (POD) model; (4) skill assessment of testing personnel; and (5) comparative evaluation of different testing technologies.

[0077] The following explanation, in conjunction with specific embodiments, further clarifies the situation.

[0078] Example 1 A standard block for detecting defects in aero-engine rotor discs includes an annular substrate and defect simulation units located within the annular substrate. The defect simulation units are metallurgically bonded to the annular substrate. The defect simulation units include 11 white spot simulation units, 11 dirty white spot simulation units, and 11 black spot simulation units. The white spot, dirty white spot, and black spot simulation units are each independently distributed on three concentric circles of the annular substrate. The white spot simulation units are distributed on the first circle, the dirty white spot simulation units on the second circle, and the black spot simulation units on the third circle. The radius of the first circle is 50 mm, the radius of the second circle is 100 mm, and the radius of the third circle is 150 mm. On the same circle, the defect size decreases clockwise, and the defect units on different circles are staggered.

[0079] The annular substrate is made of GH4169 alloy, with a height of 30 mm, an inner diameter of 80 mm, an outer radius of 200 mm, and a surface roughness Ra of 2.5 μm. A positioning groove is provided at the 0° circumferential position of the annular substrate for orientation calibration during testing. The positioning groove has a depth of 2 mm and a width of 3 mm.

[0080] The white spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 1.5 mm, and the diameter difference between any two adjacent white spot simulation units is 0.2 mm. The white spot simulation unit comprises, by mass percentage: Nb 4.5%, Mo 3%, Al 0.5%, Ti 0.7%, Ni 54%, Cr 20%, with the balance being Fe. The internal particle size of the white spot simulation unit is 5-6 grades.

[0081] The dirty white spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 1.5 mm and a diameter difference of 0.2 mm between any two adjacent dirty white spot simulation units. The dirty white spot simulation unit comprises a matrix layer and a coating layer on the surface of the matrix layer. The matrix layer, by mass percentage, comprises: Nb 4.5%, Mo 3%, Al 0.5%, Ti 0.7%, Ni 54%, Cr 20%, with the balance being Fe. The coating layer comprises a TiN particle layer with a thickness of 3.5 μm and an adhesion amount of 7 mg / cm.

[0082] The black spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 1.5 mm and a diameter difference of 0.2 mm between any two adjacent black spot simulation units. The black spot simulation unit comprises, by mass percentage: Nb 8%, Mo 3%, Al 0.6%, Ti 1.3%, Ni 52%, Cr 18%, with the balance being Fe. The internal particle size of the black spot simulation unit is 8-9 grade.

[0083] The method for preparing the above-mentioned standard block in this embodiment includes the following steps: (a) Obtain several vitiligo simulation units, several dirty vitiligo simulation units and several black spot simulation units.

[0084] The method for obtaining the white spot simulation unit specifically includes: mixing the components of the white spot simulation unit according to stoichiometry and then performing a first vacuum induction melting process; casting the mixture to obtain a first ingot; subjecting the first ingot to a first solution treatment; water quenching; and then machining to obtain a white spot simulation unit of the target size. The melting temperature of the first vacuum induction melting process is 1580℃, and the power is 800KW. The temperature of the first solution treatment is 1180℃, and the time is 4h. The surface roughness Ra of the white spot simulation unit is 0.8μm.

[0085] The method for obtaining the dirty white spot simulation unit specifically includes: mixing the components of the dirty white spot simulation unit according to stoichiometry and then performing a second vacuum induction melting, casting to obtain a second ingot, performing a second solution treatment on the second ingot, water quenching and processing to obtain a matrix structure of the target size; performing plasma spraying on the surface of the matrix structure, then attaching TiN particles by electrostatic adsorption, and then performing a curing treatment; the melting temperature of the second vacuum induction melting is 1580℃ and the power is 800KW; the temperature of the second solution treatment is 1180℃ and the time is 4h; the surface roughness Ra of the matrix structure is 0.8μm; the surface roughness Ra after plasma spraying is 4μm; the temperature of the curing treatment is 200℃ and the time is 2h.

[0086] The method for obtaining the black spot simulation unit specifically includes: mixing the components of the black spot simulation unit according to stoichiometry and then performing a third vacuum induction melting process; casting to obtain a third ingot; subjecting the third ingot to heat deformation treatment; performing a third solution treatment; air cooling; and then processing to obtain the black spot simulation unit of the target size. The melting temperature of the third vacuum induction melting process is 1580℃, and the power is 800KW. The temperature of the heat deformation treatment is 800℃, and the deformation amount is 40%. The temperature of the third solution treatment is 1050℃, and the time is 2 hours.

[0087] (b) Obtain an annular sleeve, weld a seal at the top of the sleeve, and reserve a vacuum port; positioning grooves are respectively set on the three concentric circumferences at the bottom of the annular sleeve; fix (spot weld) the white spot simulation unit, dirty white spot simulation unit, and black spot simulation unit independently in the positioning grooves of the three concentric circumferences to obtain the sleeve assembly. Fill the sleeve assembly with precursor powder of the annular matrix through the vacuum port. The precursor powder has an average particle size of 7.6 μm and a loose packing density of 2.8 g / cm³. 3 Vacuumed to 0.8×10 -3After Pa, hot isostatic pressing is performed: the temperature is 1180℃, the pressure is 160MPa, the holding time is 4h, and furnace cooling is used; then processing is performed to remove the excess part of the cladding, process to the target size, and finish the surface.

[0088] Example 2 A standard block for detecting defects in aircraft engine rotor discs differs from Example 1 in that: The white spot simulation unit comprises, by mass percentage: Nb 4.8%, Mo 2.8%, Al 0.6%, Ti 0.65%, Ni 55.5%, Cr 18%, with the balance being Fe.

[0089] The matrix layer of the dirty white spot simulation unit comprises, by mass percentage: Nb 4.8%, Mo 2.8%, Al 0.6%, Ti 0.65%, Ni 55.5%, Cr 18%, with the balance being Fe. The thickness of the TiN particle layer is 5 μm, and the adhesion amount is 10 mg / cm.

[0090] The black spot simulation unit comprises, by mass percentage: Nb 10.0%, Mo 1.5%, Al 0.65%, Ti 1.2%, Ni 53%, Cr 17.5%, with the balance being Fe.

[0091] The preparation method of the standard block in this embodiment is the same as that in Example 1, except that the above-mentioned component measurement ratio is used.

[0092] Example 3 A standard block for detecting defects in aircraft engine rotor discs differs from Example 1 in that: The white spot simulation unit comprises, by mass percentage: Nb 4.4%, Mo 3.1%, Al 0.4%, Ti 0.9%, Ni 53.5%, Cr 21%, with the balance being Fe.

[0093] The matrix layer of the dirty white spot simulation unit comprises, by mass percentage: Nb 4.4%, Mo 3.1%, Al 0.4%, Ti 0.9%, Ni 53.5%, Cr 21%, with the balance being Fe.

[0094] The black spot simulation unit comprises, by mass percentage: Nb 6.5%, Mo 3.6%, Al 0.5%, Ti 1.45%, Ni 50%, Cr 18.5%, with the balance being Fe.

[0095] The preparation method of the standard block in this embodiment is the same as that in Example 1, except that the above-mentioned component measurement ratio is used.

[0096] Example 4 A standard block for detecting defects in aircraft engine rotor discs differs from Example 1 in that: The defect simulation unit includes 13 white spot simulation units, 13 dirty white spot simulation units, and 13 black spot simulation units.

[0097] The minimum diameter of the cross-section of the vitiligo simulation unit is 1 mm, and the diameter difference between any two adjacent vitiligo simulation units is 0.1 mm.

[0098] The minimum diameter of the cross-section of the dirty white spot simulation unit is 1 mm, and the diameter difference between any two adjacent dirty white spot simulation units is 0.1 mm.

[0099] The minimum diameter of the cross-section of the black spot simulation unit is 1 mm, and the diameter difference between any two adjacent black spot simulation units is 0.1 mm.

[0100] Example 5 A standard block for detecting defects in aero-engine rotor discs includes an annular substrate and defect simulation units located within the annular substrate. The defect simulation units are metallurgically bonded to the annular substrate. The defect simulation units include 11 white spot simulation units, 11 dirty white spot simulation units, and 11 black spot simulation units. The white spot, dirty white spot, and black spot simulation units are each independently distributed on three concentric circles of the annular substrate. The white spot simulation units are distributed on the first circle, the dirty white spot simulation units on the second circle, and the black spot simulation units on the third circle. The radius of the first circle is 50 mm, the radius of the second circle is 100 mm, and the radius of the third circle is 150 mm. On the same circle, the defect size decreases clockwise, and the defect units on different circles are staggered.

[0101] The annular substrate is made of GH4169 alloy, with a height of 30 mm, an inner diameter of 80 mm, an outer radius of 200 mm, and a surface roughness Ra of 3.2 μm. A positioning groove is provided at the 0° circumferential position of the annular substrate for orientation calibration during testing. The positioning groove has a depth of 2.5 mm and a width of 3.5 mm.

[0102] The white spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 2 mm, and the diameter difference between any two adjacent white spot simulation units is 0.15 mm. The white spot simulation unit comprises, by mass percentage: Nb 4.4%, Mo 3.1%, Al 0.4%, Ti 0.9%, Ni 53.5%, Cr 20%, with the balance being Fe. The internal particle size of the white spot simulation unit is 5-6 grades.

[0103] The dirty white spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 2 mm and a diameter difference of 0.15 mm between any two adjacent dirty white spot simulation units. The dirty white spot simulation unit comprises a matrix layer and a coating layer on the surface of the matrix layer. The matrix layer, by mass percentage, comprises: Nb 4.4%, Mo 3.1%, Al 0.4%, Ti 0.9%, Ni 53.5%, Cr 20%, with the balance being Fe. The coating layer comprises a TiN particle layer with a thickness of 1–5 μm and an adhesion amount of 7 mg / cm.

[0104] The black spot simulation unit is rod-shaped with a minimum cross-sectional diameter of 2 mm, and the diameter difference between any two adjacent black spot simulation units is 0.15 mm. The black spot simulation unit comprises, by mass percentage: Nb 6.5%, Mo 3.6%, Al 0.5%, Ti 1.45%, Ni 50%, Cr 18.5%, with the balance being Fe. The internal particle size of the black spot simulation unit is 8-9 levels.

[0105] The method for preparing the above-mentioned standard block in this embodiment includes the following steps: (a) Obtain several vitiligo simulation units, several dirty vitiligo simulation units and several black spot simulation units.

[0106] The method for obtaining the white spot simulation unit specifically includes: mixing the components of the white spot simulation unit according to stoichiometry and then performing a first vacuum induction melting process; casting the mixture to obtain a first ingot; subjecting the first ingot to a first solution treatment; water quenching; and then machining to obtain a white spot simulation unit of the target size. The melting temperature of the first vacuum induction melting process is 1600℃, and the power is 850KW. The temperature of the first solution treatment is 1120℃, and the time is 3h. The surface roughness Ra of the white spot simulation unit is 1.5μm.

[0107] The method for obtaining the dirty white spot simulation unit specifically includes: mixing the components of the dirty white spot simulation unit according to stoichiometry and then performing a second vacuum induction melting, casting to obtain a second ingot, performing a second solution treatment on the second ingot, water quenching and processing to obtain a matrix structure of the target size; performing plasma spraying on the surface of the matrix structure, then attaching TiN particles by electrostatic adsorption, and then performing a curing treatment; the melting temperature of the second vacuum induction melting is 1600℃ and the power is 850KW; the temperature of the second solution treatment is 1200℃ and the time is 3h; the surface roughness Ra of the matrix structure is 1.5μm; the surface roughness Ra after plasma spraying is 5μm; the temperature of the curing treatment is 220℃ and the time is 1h.

[0108] The method for obtaining the black spot simulation unit specifically includes: mixing the components of the black spot simulation unit according to stoichiometry and then performing a third vacuum induction melting process; casting to obtain a third ingot; subjecting the third ingot to hot deformation treatment, followed by a third solution treatment; air cooling and then processing to obtain the black spot simulation unit of the target size; the melting temperature of the third vacuum induction melting process is 1600℃, and the power is 850KW; the temperature of the hot deformation treatment is 850℃, and the deformation amount is 45%; the temperature of the third solution treatment is 1070℃, and the time is 1h.

[0109] (b) Obtain an annular sleeve, weld a seal at the top of the sleeve, and reserve a vacuum port; positioning grooves are respectively set on the three concentric circumferences at the bottom of the annular sleeve; fix (spot weld) the white spot simulation unit, dirty white spot simulation unit, and black spot simulation unit independently in the positioning grooves of the three concentric circumferences to obtain the sleeve assembly. Fill the sleeve assembly with precursor powder of the annular matrix through the vacuum port. The precursor powder has an average particle size of 7.6 μm and a loose packing density of 2.8 g / cm³. 3 Vacuum up to 1×10 -3 After Pa, hot isostatic pressing is performed: the temperature is 1200℃, the pressure is 170MPa, the holding time is 3h, and furnace cooling is used; then processing is performed to remove the excess part of the cladding, process to the target size, and finish the surface.

[0110] As can be seen from the above, the preparation method of the standard block for defect detection of aero-engine wheel disks in various embodiments of the present invention achieves simultaneous simulation of three typical metallurgical defects through precise control of composition and matching of grain state; solves the interface bonding problem between defect units and the matrix through metallurgical bonding molding; the preparation process takes into account both structural compactness and dimensional accuracy, solving the technical bottlenecks of poor stability and short service life of existing standard blocks; breaks through the limitations of geometric simulation of traditional standard blocks, establishes an integrated simulation system of composition, structure and performance, and significantly improves the authenticity of detection and calibration. POD model error ≤5%, reusable ≥200 times.

[0111] Existing methods can only simulate geometric defects and cannot reproduce elemental segregation and grain differences; bonding / embedding fixation is prone to interface separation; there are ≤5 types of defects, resulting in low size coverage. POD model error is ≥15%, and it can be reused ≤50 times.

[0112] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A standard block for detecting defects in aircraft engine rotor discs, characterized in that, It includes a ring-shaped matrix and a defect simulation unit located in the ring-shaped matrix. The defect simulation unit is metallurgically bonded to the ring-shaped matrix. The defect simulation unit includes a number of white spot simulation units, a number of dirty white spot simulation units, and a number of black spot simulation units. The white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit are each independently distributed on three concentric circles of the annular substrate.

2. The standard block for detecting defects in aero-engine wheel disks according to claim 1, characterized in that, At least one of the following conditions must be met: (1) The white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit are distributed in a descending order of defect size on their respective concentric circles; the defect simulation units on different concentric circles are staggered. (2) The shape of the white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit are each independently rod-shaped, the cross-sectional diameter is 1~5.2mm and the diameter interval is 0.1~0.2mm. (3) Each of the white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit is ≥8, preferably 10 to 13; (4) The difference in radius between any two adjacent concentric circles is 45~60mm; (5) The annular matrix comprises GH4169 alloy with a surface roughness Ra≤3.2μm; (6) A positioning groove is provided at the 0° circumferential position of the annular base for orientation calibration during testing. The depth of the positioning groove is 1.5~2.5mm and the width is 2.5~3.5mm.

3. The standard block for detecting defects in aero-engine wheel disks according to claim 1, characterized in that, At least one of the following conditions must be met: (1) The white spot simulation unit comprises, by mass percentage: Nb 4.4%~4.8%, Mo 2.8%~3.1%, Al 0.4%~0.6%, Ti 0.65%~0.9%, Ni 53.5%~55.5%, Cr 18%~21%, with the balance being Fe; (2) The internal particle size of the white spot simulation unit is 5 to 6 levels.

4. The standard block for detecting defects in aero-engine wheel disks according to claim 1, characterized in that, At least one of the following conditions must be met: (1) The dirty white spot simulation unit includes a substrate layer and a coating layer located on the surface of the substrate layer. The substrate layer, by mass percentage, includes: Nb 4.4%~4.8%, Mo 2.8%~3.1%, Al 0.4%~0.6%, Ti 0.65%~0.9%, Ni 53.5%~55.5%, Cr 18%~21%, with the balance being Fe. The coating layer includes a TiN particle layer. Preferably, the thickness of the TiN particle layer is 1~5μm, and the adhesion amount is 5~10mg / cm. (2) The internal particle size of the dirty white spot simulation unit is 5 to 6 levels.

5. The standard block for detecting defects in aero-engine wheel disks according to claim 1, characterized in that, At least one of the following conditions must be met: (1) The black spot simulation unit comprises, by mass percentage: Nb 6.5%~10.0%, Mo 1.5%~3.6%, Al 0.5%~0.65%, Ti 1.2%~1.45%, Ni 50%~53%, Cr 17.5%~18.5%, with the balance being Fe; (2) The internal particles of the black spot simulation unit are grade 8 to 9.

6. The method for preparing a standard block for detecting defects in an aero-engine wheel disk as described in any one of claims 1 to 5, characterized in that, Includes the following steps: Acquire several vitiligo simulation units, several dirty vitiligo simulation units, and several black spot simulation units; Obtain an annular sleeve, wherein positioning grooves are respectively provided on the three concentric circumferences at the bottom of the annular sleeve; fix the white spot simulation unit, the dirty white spot simulation unit, and the black spot simulation unit independently in the positioning grooves of the three concentric circumferences to obtain a sleeve assembly; The precursor powder of the annular matrix is ​​filled into the encapsulation assembly, and then subjected to hot isostatic pressing and processing after vacuuming.

7. The method for preparing a standard block for detecting defects in aero-engine wheel disks according to claim 6, characterized in that, The method for obtaining the white spot simulation unit specifically includes: mixing the components of the white spot simulation unit according to stoichiometry and then performing a first vacuum induction melting, casting to obtain a first ingot, performing a first solution treatment on the first ingot, water quenching and then processing to obtain a white spot simulation unit of the target size. Preferably, the melting temperature of the first vacuum induction melting is 1450~1700℃, and the power is 700~1000KW; Preferably, the temperature of the first solution treatment is 1150~1200℃ and the time is 3~5h; Preferably, the surface roughness Ra of the white spot simulation unit is ≤1.6μm.

8. The method for preparing a standard block for detecting defects in aero-engine wheel disks according to claim 6, characterized in that, The method for obtaining the dirty white spot simulation unit specifically includes: mixing the components of the dirty white spot simulation unit according to stoichiometry and then performing a second vacuum induction melting, casting to obtain a second ingot, performing a second solution treatment on the second ingot, water quenching and processing to obtain a matrix structure of the target size; performing plasma spraying on the surface of the matrix structure, then attaching TiN particles by electrostatic adsorption, and then performing curing treatment. Preferably, the melting temperature of the second vacuum induction melting is 1450~1700℃, and the power is 700~1000KW; Preferably, the temperature of the second solution treatment is 1150~1200℃ and the time is 3~5h; Preferably, the surface roughness Ra of the substrate structure is ≤1.6μm; Preferably, the surface roughness Ra after plasma spraying is 3.2~6.3μm; Preferably, the curing process is carried out at a temperature of 180~220℃ for 1~3 hours.

9. The method for preparing a standard block for detecting defects in aero-engine wheel disks according to claim 6, characterized in that, The method for obtaining the black spot simulation unit specifically includes: mixing the components of the black spot simulation unit according to stoichiometry and then performing a third vacuum induction melting, casting to obtain a third ingot, performing a hot deformation treatment on the third ingot, performing a third solution treatment, air cooling and then processing to obtain a black spot simulation unit of the target size. Preferably, the melting temperature of the third vacuum induction melting is 1450~1700℃, and the power is 700~1000KW; Preferably, the temperature of the heat deformation treatment is 750~850℃, and the deformation amount is 35%~45%; Preferably, the temperature of the third solution treatment is 1030~1070℃ and the time is 1~3h.

10. The method for preparing a standard block for detecting defects in aero-engine wheel disks according to claim 6, characterized in that, At least one of the following conditions must be met: (1) The white spot simulation unit, the dirty white spot simulation unit and the black spot simulation unit are respectively and independently fixed in the positioning grooves of the three concentric circles, and the fixing method is spot welding; (2) The precursor powder of the annular matrix has a particle size of 0.01~20μm and a loose packing density of 2.5~3g / cm³. 3 ; (3) The vacuum level is ≤1×10 -3 Pa; (4) The conditions for hot isostatic pressing are: temperature of 1160~1200℃, pressure of 150~170MPa, heat and pressure holding time of 3~5h, and furnace cooling.