A multi-path acoustic wave attenuation phased array ultrasonic testing probe wedge and design method

Abstract

This disclosure provides a wedge and design method for a multipath acoustic attenuation phased array ultrasonic testing probe. The wedge includes a wedge body, multiple silencing grooves, and a damping block. The extension direction, spacing, and depth of each silencing groove are configured such that at least a portion of the reflected transverse wave generated at the detection surface can be guided to an attenuation interface formed by the groove wall of the silencing groove and the damping block. Furthermore, the reflected longitudinal wave generated at the detection surface undergoes at least six interface reflections within the wedge body before returning to the probe direction. The acoustic characteristics of the damping block are configured to absorb the reflected transverse wave. The reflected transverse wave is attenuated at the attenuation interface through a combination of scattering by the silencing groove and absorption by the damping block. After at least six interface reflections, the acoustic component of the reflected longitudinal wave returning to the probe direction forms a 180° phase difference with the incident longitudinal wave emitted by the probe, thus being attenuated through phase interference.

Description

Technical Field

[0001] The embodiments disclosed herein belong to the field of engineering testing technology, specifically relating to a wedge and design method for a multipath acoustic attenuation phased array ultrasonic testing probe. Background Technology

[0002] During the operation of large-diameter high-temperature pipelines in thermal power plants, irregular components such as tees, reducers, elbows, and weld seams are subjected to harsh conditions of high temperature and high pressure for a long time, which can easily lead to hidden defects such as cracks and lack of fusion. If these defects are not detected in a timely and accurate manner, they may cause serious safety accidents such as pipeline leakage and rupture, directly threatening the stable operation of the unit and the safety of personnel.

[0003] Currently, phased array ultrasonic testing technology has become a core technology for non-destructive testing of irregularly shaped components in large-diameter high-temperature pipelines due to its advantages such as strong focusing, wide detection range, and intuitive imaging. However, in practical applications, existing phased array ultrasonic testing probes with wedges suffer from significant signal-to-noise ratio reduction due to noise signals generated by internally reflected longitudinal and transverse waves, making it easy for minute defects to be masked. Furthermore, the traditional wedge's anechoic groove layout and damping material configuration lack specific consideration for the differences in the propagation characteristics of the two types of sound waves, making it difficult to achieve differentiated and efficient attenuation. In addition, insufficient compatibility with the probe's acoustic parameters easily leads to beam distortion, failing to meet the sensitivity and stability requirements of high-precision testing scenarios.

[0004] Therefore, there is an urgent need for a wedge design method that can effectively attenuate the difference in characteristics between reflected longitudinal and transverse waves in order to improve detection accuracy and reliability. Summary of the Invention

[0005] The embodiments disclosed herein aim to at least solve one of the technical problems existing in the prior art, and provide a wedge and design method for a multipath acoustic attenuation phased array ultrasonic testing probe.

[0006] A first aspect of the embodiments of this disclosure provides a wedge-shaped multipath acoustic attenuation phased array ultrasonic testing probe, comprising: The wedge body has a detection surface for contacting the workpiece being inspected; Multiple sound-absorbing grooves are formed inside the wedge body; And a damping block, configured at a preset interface of the sound-absorbing groove; The extension direction, spacing, and depth of each of the sound-absorbing grooves are configured as follows: This allows at least a portion of the reflected transverse wave generated at the detection surface to be guided to the attenuation interface formed by the wall of the silencing groove and the damping block; and, This ensures that the reflected longitudinal wave generated on the detection surface undergoes at least six interface reflections within the wedge body before returning to the probe direction; The acoustic characteristics of the damping block are configured to absorb the reflected transverse wave. The reflected transverse wave is attenuated at the attenuation interface by a combination of scattering by the silencing groove and absorption by the damping block. After the reflected longitudinal wave completes the at least six interface reflections, the acoustic component returning to the probe direction forms a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to be attenuated by phase interference.

[0007] Optionally, the silencing groove has a groove width of 2mm, a groove depth of 5mm, a spacing of 8mm between adjacent grooves, and the angle between the length direction of each groove and the bottom surface of the wedge is 16.96°. The dimensions of the damping block are 15mm × 10mm × 5mm; The main body of the wedge has external dimensions of 80mm×40mm×20mm, is made of aviation aluminum, and has a surface roughness Ra≤3.2μm for the wall of the silencing groove.

[0008] Optionally, the material of the wedge body has a longitudinal wave velocity of 2347 m / s and is configured to be used in conjunction with a test piece having a transverse wave velocity of 3240 m / s. The detection surface of the wedge body is configured to allow the longitudinal wave generated by the phased array probe to be incident at an angle of 36.4°.

[0009] Optionally, the wedge is configured such that, when used in conjunction with a phased array probe, it generates a transverse wave refraction angle of 55° in the test piece.

[0010] Optionally, the structure of the wedge body satisfies the following acoustic energy attenuation relationship: For the reflected transverse wave, the remaining energy after passing through the attenuation interface satisfy: , in, The initial energy of the reflected shear wave incident on the attenuation interface. The scattering attenuation coefficient of the silencing groove for the reflected transverse wave is given by [the value of the silencing groove]. The absorption attenuation coefficient of the damping block for the reflected transverse wave is given. The reflection coefficient of the remaining energy; For reflected longitudinal waves, the remaining energy received by the probe after at least six interface reflections and phase interferences. satisfy: , in, The initial reflected longitudinal wave energy, Let be the energy attenuation coefficient for a single interface reflection, and n be the number of interface reflections, where n ≥ 6. Let Δ be the energy attenuation coefficient of the longitudinal wave interface reflection. This is the phase difference with the incident longitudinal wave.

[0011] Optionally, the wedge is configured to inspect the welds of large-diameter high-temperature pipe components made of low-alloy steel, including tees, reducers, and elbows.

[0012] A second aspect of the embodiments of this disclosure provides a method for designing a wedge for a phased array ultrasonic testing probe with multipath acoustic attenuation. The method is applied to the wedge of the phased array ultrasonic testing probe described above, and includes: Parameter determination: Based on the material of the workpiece under inspection and the inspection requirements, determine the basic acoustic parameters of the wedge. The basic acoustic parameters include at least the longitudinal wave velocity of the wedge, the transverse wave velocity of the workpiece under inspection, and the longitudinal wave incident angle of the phased array probe. Model construction: Based on the basic acoustic parameters and the difference in propagation characteristics between reflected longitudinal waves and reflected transverse waves, a three-dimensional model of the wedge is constructed. The number, angle and spacing of the silencing grooves are optimized in the model so that the layout of the silencing grooves can simultaneously satisfy: guiding the reflected transverse waves to the preset damping interface, and constructing a sound path of six interface reflections for the reflected longitudinal waves. Material configuration: Damping material parameters are configured at the damping interface of the model. The damping material parameters are selected to adapt to the absorption and attenuation requirements of the reflected transverse wave and to ensure that the propagation of the main ultrasonic beam is not disturbed. Performance simulation and verification: Perform acoustic simulations on the constructed model to verify and ensure that: a) The reflected transverse wave at the damping interface can achieve combined attenuation through the scattering effect of the silencing groove and the absorption effect of the damping material; b) After the reflected longitudinal wave propagates through the acoustic path of the six interface reflections, it can form a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to achieve attenuation through phase interference.

[0013] Optionally, in the parameter determination step, the matching of acoustic parameters is determined using the sound wave refraction angle formula: sin θ L / c L = sin θ S / c S , in, θ L The angle of incidence of the longitudinal wave. c L For the longitudinal wave velocity of the wedge, θ S The angle of refraction of the transverse wave on the inspected part. c SThe sound velocity of the transverse wave in the inspected part.

[0014] Optionally, in the performance simulation and verification step, the design performance is evaluated by calculating the signal-to-noise ratio, and the design objective satisfies: In the detection of a transverse through-hole with a depth of 30mm and a diameter of Φ2×40mm, the maximum amplitude of the reflected echo is not less than 80% of the reference height, and the amplitude of the noise signal inside the gate is not higher than 8%. Among them, signal-to-noise ratio SNR = A Sig / A Noise , A Sig The amplitude of the reflected echo from the reference reflector. A Noise The amplitude of the noise signal.

[0015] Optionally, in the performance simulation and verification step, the compatibility between the wedge and the probe is also verified using the beamwidth formula: W Beam = ( λ × F ) / d , in, W Beam To focus the beam width of the sound beam, λ Because of the length of the ultrasound wave, F To focus on depth, d The aperture of the probe spindle is the excitation aperture.

[0016] The beneficial effects of the embodiments of this disclosure include: This invention optimizes the layout of the silencing groove and the configuration of the damping material. It designs a method of "composite attenuation of silencing groove + damping block" (for transverse waves) and "six reflections + phase interference attenuation" (for longitudinal waves) to address the differences in the propagation characteristics of reflected longitudinal waves and transverse waves. This solves the problem of traditional single noise reduction, keeps the amplitude of the noise signal and the amplitude of the reflected echo within a preset range, and significantly improves the detection signal-to-noise ratio.

[0017] Based on the acoustic refraction angle formula, the acoustic parameters of the wedge and the inspected part are precisely matched. Combined with the targeted design of the silencing groove and damping material, the stable propagation of the main ultrasonic beam is ensured while minimizing noise interference. Paired with a phased array probe, the focused acoustic beam width meets the standard requirements, enabling precise detection of defects such as cracks and lack of fusion in welds and heat-affected zones of irregularly shaped pipe components, significantly improving detection sensitivity and the accuracy of defect identification. Attached Figure Description

[0018] Figure 1This is a schematic diagram of the phased array spectrum of a wedge-shaped phased array ultrasonic testing probe for multipath acoustic attenuation according to an embodiment of this disclosure. Figure 2 This is a schematic diagram of a sound wave reflection structure according to an embodiment of the present disclosure; Figure 3 This is a schematic diagram of a transverse wave reflection structure according to an embodiment of the present disclosure; Figure 4 This is a schematic diagram of a longitudinal wave reflection structure according to an embodiment of the present disclosure; Figure 5 This is a signal-to-noise ratio test diagram of a wedge block according to an embodiment of this disclosure; Figure 6 This is a flowchart illustrating a multipath acoustic attenuation phased array ultrasonic testing probe wedge design method according to an embodiment of this disclosure.

[0019] In the figure, 1 is the wedge; 11 is the wedge body; 12 is the silencing groove; 13 is the damping block; and 14 is the phased array probe. Detailed Implementation

[0020] To enable those skilled in the art to better understand the technical solutions of this disclosure, the disclosure will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0021] The embodiments of this application will be further described in detail below with reference to the accompanying drawings and examples. The detailed descriptions and accompanying drawings of the following embodiments are used to exemplarily illustrate the principles of this application, but should not be used to limit the scope of this application; that is, this application is not limited to the described embodiments. In the description of this application, it should be noted that, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," etc., indicating orientation or positional relationships are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance. "Vertical" is not strictly vertical, but within the allowable error range. "Parallel" is not strictly parallel, but within the allowable error range.

[0022] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application depending on the specific circumstances.

[0023] like Figure 1-6As shown, a wedge-shaped phased array ultrasonic testing probe with multipath acoustic attenuation is provided. The wedge 1 includes a wedge body 11, a sound-absorbing groove 12, and a damping block 13.

[0024] The wedge body 11 has a detection surface for contacting the workpiece being inspected, a plurality of noise-reducing grooves 12 are formed inside the wedge body 11, and a damping block 13 is disposed at a preset interface of the noise-reducing grooves 12.

[0025] The extension direction, spacing, and depth of each of the sound-absorbing grooves 12 are configured as follows: This allows at least a portion of the reflected transverse wave generated at the detection surface to be guided to the attenuation interface formed by the wall of the silencing groove 12 and the damping block 13, and This ensures that the reflected longitudinal wave generated on the detection surface undergoes at least six interface reflections within the wedge body 11 before returning to the probe direction.

[0026] The acoustic characteristics of the damping block 13 are configured to absorb the reflected transverse wave; wherein the reflected transverse wave is attenuated at the attenuation interface by a combination of scattering by the silencing groove 12 and absorption by the damping block 13.

[0027] After the reflected longitudinal wave completes the at least six interface reflections, the acoustic component returning to the probe direction forms a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to be attenuated by phase interference.

[0028] In some embodiments, the silencing groove 12 has a groove width of 2mm, a groove depth of 5mm, an adjacent groove spacing of 8mm, and the angle between the length direction of each groove and the bottom surface of the wedge is 16.96°. The damping block 13 has dimensions of 15mm × 10mm × 5mm, the wedge body 11 has external dimensions of 80mm × 40mm × 20mm, is made of aviation aluminum, and the surface roughness Ra of the groove wall of the silencing groove 12 is ≤ 3.2μm.

[0029] In some embodiments, the material of the wedge body 11 has a longitudinal wave velocity of 2347 m / s and is configured to be used in conjunction with a test piece having a transverse wave velocity of 3240 m / s. The detection surface of the wedge body 11 is configured to allow the longitudinal wave generated by the phased array probe 14 to be incident at an angle of 36.4°.

[0030] In some embodiments, the wedge is configured such that, when used in conjunction with the phased array probe 14, it generates a transverse wave refraction angle of 55° in the test piece.

[0031] In some embodiments, the structure of the wedge body 11 satisfies the following acoustic energy attenuation relationship: For the reflected transverse wave, the remaining energy after passing through the attenuation interface satisfy: , in, The initial energy of the reflected shear wave incident on the attenuation interface. The scattering attenuation coefficient of the silencing groove 12 for the reflected transverse wave is given by the silencing groove 12. The absorption attenuation coefficient of the damping block 13 for the reflected transverse wave is given. The reflection coefficient is the residual energy.

[0032] For reflected longitudinal waves, the remaining energy received by the probe after at least six interface reflections and phase interferences. satisfy: , in, The initial reflected longitudinal wave energy, Let be the energy attenuation coefficient for a single interface reflection, and n be the number of interface reflections, where n ≥ 6. Let Δ be the energy attenuation coefficient of the longitudinal wave interface reflection. This is the phase difference with the incident longitudinal wave.

[0033] In some embodiments, the wedge is configured to inspect welds on large-diameter, high-temperature pipe components made of low-alloy steel, including tees, reducers, and elbows.

[0034] A second aspect of the embodiments of this disclosure provides a method for designing a wedge for a phased array ultrasonic testing probe with multipath acoustic attenuation. The method is applied to the wedge of the phased array ultrasonic testing probe described above, and includes: Parameter determination: Based on the material of the workpiece under inspection and the inspection requirements, the basic acoustic parameters of the wedge are determined. The basic acoustic parameters include at least the longitudinal wave velocity of the wedge, the transverse wave velocity of the workpiece under inspection, and the longitudinal wave incident angle of the phased array probe 14.

[0035] Model construction: Based on the basic acoustic parameters and the difference in propagation characteristics between reflected longitudinal waves and reflected transverse waves, a three-dimensional model of the wedge is constructed. In the model, the number, angle and spacing of the silencing grooves 12 are optimized so that the layout of the silencing grooves 12 can simultaneously satisfy: guiding the reflected transverse waves to the preset damping interface, and constructing a sound path of six interface reflections for the reflected longitudinal waves.

[0036] Material configuration: Damping material parameters are configured at the damping interface of the model. The damping material parameters are selected to adapt to the absorption and attenuation requirements of the reflected transverse wave and to ensure that the propagation of the main ultrasonic beam is not disturbed.

[0037] Performance simulation and verification: Perform acoustic simulations on the constructed model to verify and ensure that: a) The reflected transverse wave at the damping interface can achieve combined attenuation through the scattering effect of the silencing groove 12 and the absorption effect of the damping material.

[0038] b) After the reflected longitudinal wave propagates through the acoustic path of the six interface reflections, it can form a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to achieve attenuation through phase interference.

[0039] In some embodiments, the matching of acoustic parameters is determined in the parameter determination step using the formula for the sound wave refraction angle: sin θ L / c L = sin θ S / c S , in, θ L The angle of incidence of the longitudinal wave. c L For the longitudinal wave velocity of the wedge, θ S The angle of refraction of the transverse wave on the inspected part. c S The sound velocity of the transverse wave in the inspected part.

[0040] In some embodiments, during the performance simulation and verification step, the design performance is evaluated by calculating the signal-to-noise ratio, and the design objective satisfies: In the detection of a transverse through-hole with a depth of 30mm and a diameter of Φ2×40mm, the highest amplitude of the reflected echo is not less than 80% of the reference height, and the amplitude of the noise signal inside the gate is not higher than 8%. The signal-to-noise ratio is [not specified]. SNR = A Sig / A Noise , A Sig The amplitude of the reflected echo from the reference reflector. A Noise The amplitude of the noise signal.

[0041] In some embodiments, the compatibility between the wedge and the probe is also verified using the beamwidth formula during the performance simulation and verification step. W Beam = ( λ × F ) / d , in, W Beam To focus the beam width of the sound beam, λ Because of the length of the ultrasound wave, F To focus on depth,d The aperture of the probe spindle is the excitation aperture.

[0042] Specifically, such as Figure 5 As shown, based on the shortcomings of the aforementioned background technology, this invention provides a wedge design method for a phased array ultrasonic testing probe with multipath acoustic wave attenuation, comprising the following steps: S1. Determine the wedge parameters according to the workpiece material and testing requirements. Specifically, based on the workpiece material and testing requirements, determine the basic parameters of the wedge body. The basic parameters include at least the longitudinal wave velocity of the wedge, the transverse wave velocity of the workpiece, and the longitudinal wave incident angle of the phased array probe.

[0043] S2. Optimize the acoustic slot parameters according to the characteristics of longitudinal and transverse waves. Specifically, based on the differences in the propagation characteristics of reflected longitudinal and transverse waves, optimize the number, angle, and spacing of the acoustic slots so that the acoustic slots can both allow the reflected transverse waves to be accurately incident on the preset interface and provide a dedicated channel for the reflected longitudinal waves to undergo six interface reflections.

[0044] S3. The anechoic groove is equipped with damping material at its preset interface to accommodate transverse waves. Specifically, a damping block is configured at the preset interface of the anechoic groove. The damping block is adapted to the absorption and attenuation requirements of reflected transverse waves and does not interfere with the propagation of the main ultrasonic beam.

[0045] S4. The scattering of the anechoic groove and the absorption of the damping block achieve combined attenuation of the reflected shear wave. Specifically, the scattering effect of the anechoic groove and the absorption effect of the damping block achieve multi-path combined attenuation of the reflected shear wave.

[0046] S5. Six-stage reflection and phase interference attenuate the reflected longitudinal wave with a 180° phase difference. Specifically, through the design of a six-stage interface reflection channel and phase interference, a 180° phase difference is formed between the reflected longitudinal wave and the incident longitudinal wave emitted by the probe, achieving multi-path attenuation of the reflected longitudinal wave.

[0047] In some embodiments, the damping block has a size of 15mm×10mm×5mm, the wedge has an overall size of 80mm×40mm×20mm, the wedge body is made of aviation aluminum, the machining accuracy is controlled within ±0.05mm, and the groove wall roughness Ra≤3.2μm.

[0048] In some embodiments, in step S1, based on the material of the workpiece under inspection and the inspection requirements, the longitudinal wave velocity of the wedge material is set to 2347 m / s, matching the transverse wave velocity of the workpiece material to 3240 m / s, and the longitudinal wave incident angle of the phased array probe 14 is set to 36.4°. This setting ensures that a 16.96° reflected transverse wave and a 36.4° reflected longitudinal wave are generated at the incident point.

[0049] Formula for calculating the angle of refraction of sound waves: , In the formula: The longitudinal wave incident angle for the phased array probe is 14. For the longitudinal wave velocity of the wedge material, The angle of refraction of transverse waves in the inspected part. The transverse wave velocity of the material under test is determined. By precisely setting the acoustic parameters of the wedge and the test piece, such as the longitudinal wave velocity, transverse wave velocity, and incident angle, and verifying the parameter matching based on Snell's law, it is ensured that the propagation paths of the incident and reflected waves meet the design expectations. This provides a precise angle and acoustic reference for subsequent anechoic groove layout and multi-path attenuation, avoiding noise suppression failure or sound beam distortion caused by parameter mismatch.

[0050] In some embodiments, in step S2, the number, angle, and spacing of the silencing grooves are designed based on the propagation path characteristics of the reflected transverse and longitudinal waves. This ensures that the reflected transverse wave can accurately strike the interface formed by the silencing groove and the damping block, while providing a propagation path for the reflected longitudinal wave through six interface reflections. By customizing the number, angle, and spacing of the silencing grooves to address the differences in propagation characteristics between the reflected transverse and longitudinal waves, the design guarantees that the reflected transverse wave accurately strikes the noise reduction interface while providing a dedicated path for the reflected longitudinal wave through six interface reflections. This achieves non-interference between the two sound wave attenuation paths, improving the targeting and efficiency of noise reduction.

[0051] In some embodiments, in step S3, a damping block is configured at the corresponding position of the anechoic groove. The damping material must meet the requirement of efficient absorption of reflected transverse waves without affecting the normal propagation of the main ultrasonic beam. Configuring a suitable damping material at the corresponding position of the anechoic groove satisfies the requirement of efficient absorption of reflected transverse waves while avoiding interference with the propagation of the main ultrasonic beam, achieving the dual goals of noise reduction and beam stability. This resolves the contradiction that traditional damping material configurations easily lead to beam attenuation or insufficient noise absorption.

[0052] In some embodiments, in step S4, the reflected shear wave energy is decomposed into three parts at the interface between the anechoic groove and the damping block. Part of the energy is attenuated by scattering through the anechoic groove, part of the energy is absorbed and attenuated by the damping block, and the remaining energy returns or is reflected back to the probe interface along the original path. This significantly reduces the energy of the reflected shear wave received by the probe.

[0053] Formula for energy attenuation of reflected transverse waves: , In the formula: The initial energy of the reflected transverse wave incident on the interface between the silencing groove and the damping block. This refers to the residual energy of the reflected shear wave received by the probe after attenuation. The scattering attenuation coefficient of the anechoic groove for reflected transverse waves is given by [the value of the anechoic groove]. Let be the absorption attenuation coefficient of the damping material for the reflected transverse wave. The residual energy reflection coefficient is used. Through the dual effects of scattering by the anechoic groove and absorption by the damping block, the reflected shear wave energy is decomposed and attenuated, significantly reducing the shear wave noise energy received by the probe. Combined with the energy attenuation formula, the attenuation effect can be quantitatively controlled, effectively reducing the interference of shear wave noise on the detection signal and clearing obstacles for the identification of minute defects.

[0054] Optionally, in step S5, after six interface reflections, the reflected longitudinal wave undergoes two energy decompositions at the interface between the anechoic groove and the damping block. Its long reflection path allows for natural energy attenuation, while simultaneously creating a phase difference of approximately 180° between the sixth reflected longitudinal wave and the incident longitudinal wave emitted by the probe. The remaining energy of the reflected longitudinal wave is then canceled out through phase interference. Formulas for energy attenuation and phase interference of reflected longitudinal waves: , In the formula: The initial energy of the reflected longitudinal wave incident on the interface. This refers to the remaining energy of the reflected longitudinal wave received by the probe after six reflections and phase interference. This represents the energy attenuation coefficient of longitudinal wave interface reflection. A composite mechanism of natural attenuation through six interface reflections and phase interference cancellation is employed to process reflected longitudinal waves. This mechanism utilizes the long sound path to achieve natural energy loss and maximizes the cancellation of remaining energy through phase interference. This solution addresses the characteristics of high energy and difficult attenuation of longitudinal waves, further reducing the overall noise level.

[0055] In some embodiments, the inspected workpiece is a large-diameter, high-temperature pipeline component of a thermal power plant made of low-alloy steel, including the weld seams of tees, reducers, and elbows. By clearly defining the inspected workpiece as a large-diameter, high-temperature pipeline component of a thermal power plant made of low-alloy steel, including weld seams of tees, reducers, and elbows, the inspection requirements of specific application scenarios are precisely matched, solving the problem of defect detection for such components under high-temperature and high-pressure conditions, and improving the pertinence and practicality of the design method.

[0056] In some embodiments, when the wedge designed using this method is applied to phased array ultrasonic testing, in the testing of a horizontal through-hole with a depth of 30 mm and a diameter of Φ2×40 mm, the maximum amplitude of the reflected echo is not less than 80% of the reference height, and the amplitude of the noise signal inside the gate is not higher than 8%.

[0057] Signal-to-noise ratio calculation and target formula: , Among them, noise signal amplitude It is mainly determined by the energy of the unattenuated reflected P-waves and S-waves: , In the formula: The amplitude of the reflected echo from the reference reflector. This refers to the energy and amplitude conversion coefficient. The signal-to-noise ratio formula is used to quantify the detection performance indicators, clarifying the quantitative standards for the amplitude of the reflected echo and the amplitude of the noise signal. This ensures that the designed wedge has a stable and reliable noise reduction effect and detection accuracy, directly meeting the stringent requirements for defect identification in engineering inspections and avoiding missed defects due to substandard performance.

[0058] In some embodiments, the transverse wave refraction angle of the wedge is 55°, which is compatible with a 5L320.6×10 phased array probe 14. This meets the requirements of NB / T47013.15-2023 "Non-destructive testing of pressure equipment - Part 15: Phased array ultrasonic testing" standard. Formula for verifying the compatibility between the wedge and the probe: , In the formula: To focus the beam width of the sound beam, Because of the length of the ultrasound wave, To focus on depth, The excitation aperture of the probe spindle is determined. The refraction angle of the wedge transverse wave and the compatible probe model are defined, and the compatibility is verified by the beamwidth formula to ensure the compatibility between the wedge and the phased array detection system. At the same time, it meets industry standard requirements, improves the compliance and versatility of the design method, and can be directly integrated into the existing detection process.

[0059] The present invention has the following beneficial effects: This invention optimizes the layout of the silencing groove and the configuration of the damping material. It designs a method of "composite attenuation of silencing groove + damping block" (for transverse waves) and "six reflections + phase interference attenuation" (for longitudinal waves) to address the differences in the propagation characteristics of reflected longitudinal waves and transverse waves. This solves the problem of traditional single noise reduction, keeps the noise signal amplitude within 8%, and maintains the reflected echo amplitude at more than 80% of the reference height, significantly improving the detection signal-to-noise ratio.

[0060] Based on the acoustic refraction angle formula, the acoustic parameters of the wedge and the inspected part are precisely matched. Combined with the targeted design of the silencing groove and damping material, the stable propagation of the main ultrasonic beam is ensured while minimizing noise interference. Paired with the 5L320.6×10 phased array probe 14, the focused acoustic beam width meets the standard requirements, enabling precise detection of defects such as cracks and lack of fusion in welds and heat-affected zones of irregularly shaped pipe components, significantly improving detection sensitivity and the accuracy of defect identification.

[0061] Furthermore, as described in the background section, there are issues with insufficient accuracy and reliability in the inspection of irregularly shaped components such as tees, reducers, and elbows in large-diameter high-temperature pipelines of thermal power plants.

[0062] The main reason for the above problems is: (1) Reflected longitudinal waves and reflected transverse waves will be generated simultaneously inside the wedge. The noise signals formed by the two types of sound waves will significantly reduce the detection signal-to-noise ratio, causing the echo signals of small defects (such as Φ2mm level cracks) to be masked by noise, which can easily lead to missed detection.

[0063] (2) Traditional wedges adopt a single noise reduction approach. The sound-absorbing grooves are mostly parallel with equal spacing. The selection of damping materials lacks specificity and does not fully consider the essential differences between reflected longitudinal waves and transverse waves in terms of propagation speed, reflection angle, and energy attenuation law. Therefore, it is impossible to achieve differentiated and efficient attenuation, and the detection sensitivity is difficult to meet the requirements of high-precision detection.

[0064] (3) The acoustic parameters (such as transverse wave refraction angle and sound velocity) of some wedges and phased array probe 14 are not well matched, which can easily lead to distortion of the focused sound beam. Furthermore, it is difficult to meet the explicit requirements of NB / T47013.15-2023 "Non-destructive testing of pressure equipment - Part 15: Phased array ultrasonic testing" for the signal-to-noise ratio, defect detection rate and system stability of weld seam testing of high-temperature pressure equipment, which limits its application effect in special scenarios of thermal power plants.

[0065] like Figure 1-6 This invention provides a wedge design method for a phased array ultrasonic testing probe with multipath acoustic attenuation. This embodiment is designed for the inspection requirements of weld joints in the reheat hot section of a thermal power plant. The weld joint has a specification of Ф540×18mm and is made of SA335P91 low alloy steel. It belongs to the weld joint of a large-diameter high-temperature pipeline component in a thermal power plant. It is subjected to high temperature (540℃) and high pressure (17MPa) conditions for a long time. It is necessary to accurately identify micro-defects such as cracks and lack of fusion in the weld and heat-affected zone (minimum detectable defect size ≥ Φ2mm).

[0066] Technical parameters collected: Workpiece parameters: Material SA335P91 (low alloy steel), transverse wave velocity. The weld width is 25mm, the inspection area is 35mm, and the measured wall thickness is 16.34mm. The inspection instrument and probe are: PHASCANⅡ (ED0064LAA123) phased array instrument, adapted with 5L320.6×10 linear probe, probe frequency 5.00MHz, main axis array element number 32, array element spacing 0.60mm. The standard requirements are: inspection level B, qualified level I, calibration test block PRB-Ⅰ, and coupling agent chemical paste.

[0067] Design Basis: Based on Snell's Law, the parameters of the wedge foundation are determined to ensure the transverse wave refraction angle. θ S =55°; Performance targets: reflected echo amplitude ≥ 80% of reference height, noise signal amplitude ≤ 8%, signal-to-noise ratio SNR Meets defect identification requirements. Adaptability requirements: The focused acoustic beamwidth of the wedge and the 5L320.6×10 probe...W Beam ≤1.0mm.

[0068] Wedge Design Implementation Steps S1: Determine the wedge foundation parameters. Based on the material of the inspected part and the testing requirements, set the longitudinal wave velocity of the wedge material. Based on the probe characteristics and refraction angle requirements, the 14-wave incident angle of the phased array probe was calculated and set. This ensures that a 16.96° reflected transverse wave and a 36.4° reflected longitudinal wave are generated at the incident point. The matching of parameters is verified by the formula for the sound wave refraction angle to avoid distortion of the sound beam propagation.

[0069] Step S2: Optimize the design of the anechoic groove layout. Using ultrasonic sound field simulation software, simulate the propagation paths of the reflected transverse wave (16.96°) and the reflected longitudinal wave (36.4°). Design anechoic groove parameters: 3 grooves, 2mm width, 5mm depth, 8mm spacing between adjacent grooves, and an angle of 16.96° between the groove and the bottom surface of the wedge to ensure that the reflected transverse wave is accurately incident on the interface between the anechoic groove and the damping block. Reserve a longitudinal wave reflection channel: The groove layout avoids the six reflection paths of the longitudinal wave, ensuring that the reflected longitudinal wave can be reflected sequentially through the six interfaces inside the wedge, finally reaching the interface between the anechoic groove and the damping block. The damping block size is 15mm×10mm×5mm, and the overall size of the wedge is 80mm×40mm×20mm. The main body material of the wedge is aviation aluminum, with a machining accuracy controlled within ±0.05mm, and the groove wall roughness Ra≤3.2μm.

[0070] Step S3: Configure suitable damping material. Damping material selection: Select butyl rubber damping blocks that are compatible with the acoustic impedance and wedge material to ensure the absorption attenuation coefficient of the reflected transverse wave. Installation position: Fix the damping block to the end of the silencing groove to form a tight fit with the groove body. The size of the damping block is 15mm×10mm×5mm. Do not change the overall structural size of the wedge and the sound beam exit angle to avoid interfering with the propagation of the main ultrasonic beam. Step S4: Achieving multi-path attenuation of reflected shear waves. After the reflected shear wave propagates to the interface between the anechoic groove and the damping block, the energy is decomposed into three parts: 30% of the energy is attenuated by scattering through the anechoic groove (scattering attenuation coefficient). 45% of the energy is absorbed and attenuated by the damping block (absorption attenuation coefficient). The remaining 25% of the energy returns or is reflected back to the probe interface along the original path (remaining energy reflection coefficient). The formula for energy attenuation of reflected transverse waves. The residual energy of the reflected shear wave received by the probe was calculated. The energy attenuation reached 93.75%.

[0071] Step S5: Achieve multipath attenuation and phase interference of reflected P-waves. The reflected P-wave completes six interface reflections along the designed path. The energy attenuation coefficient of a single interface reflection is calculated. After six reflections, the energy decays to 1 / 3 of the initial energy. The longitudinal wave undergoes two energy decompositions at the interface between the anechoic groove and the damping block. After further attenuation, the sixth reflected longitudinal wave merges with the incident longitudinal wave emitted by the probe. The phase difference (in radians); through the formula of energy attenuation of reflected longitudinal waves and phase interference. Calculation, because The formula simplifies to: , Combined with long path loss, the final remaining energy is ≤5% of the initial energy, achieving effective cancellation.

[0072] The wedge is machined and assembled according to design parameters: the wedge body is made of aviation aluminum, the wedge angle is 36°, the front end distance is 23mm, and the machining accuracy is controlled within ±0.05mm. The sound-absorbing groove is machined using laser cutting technology to ensure that the number, angle, and spacing of the grooves meet design requirements, and the groove wall roughness Ra≤3.2μm. The damping block is assembled using epoxy resin adhesive to fix the damping blocks to the corresponding positions in the sound-absorbing groove. After curing, the interface fit is checked to ensure no gaps.

[0073] Detection system calibration and debugging: Instrument and probe calibration, encoder calibration, testing within a 500mm range to ensure movement error ≤1mm, encoder resolution 26.8mm / s; Sound velocity calibration: using PRB-Ⅰ test block, the sound velocity of the wedge and the inspected workpiece is calibrated by primary and secondary bottom wave calibration. The calibration result shows a refraction angle of 55.0°, and the sound velocity measurement error ≤0.5%. TCG calibration: calibration points are set within the target detection area, and gain compensation is performed on artificial reflectors of different depths and angles to ensure consistent echo amplitude of artificial reflectors of different depths in the same group. The calibration curve covers an angle range of 40°-70°.

[0074] Detection parameter settings: Focusing parameters: Select depth focusing, focusing depth 30mm, sound path range 65mm, thickness range 0-36mm. Scanning parameters: Angle range 40°-70°, angle step 1°, scanning step 1mm, scanning speed 150mm / s (using formula). Verification and adjustments based on actual working conditions: Coupling compensation: Set +4dB coupling compensation, and adjust the detection sensitivity to Ф2-18dB.

[0075] On-site inspection was conducted, including pre-treatment of the pipeline inspection surface by grinding to ensure a surface roughness Ra≤12.5μm, free of oil, rust, and scale. The inspection surface was arranged on a single side. The scanning operation employed a longitudinal vertical scanning method, with the probe moving along the weld length and the incident sound beam perpendicular to the direction of movement, focusing on detecting longitudinal defects. During the scanning process, the sector scan image was observed in real-time using the instrument's built-in sound beam display software to ensure complete coverage of the inspection area (weld and heat-affected zone) without any missed areas. Signal acquisition and analysis involved collecting reflected echo signals and analyzing them using the signal-to-noise ratio formula. Calculation, where The amplitude of the echo from the reference reflector. ( (Energy and amplitude conversion coefficient, value 0.8). Analysis of the detection spectrum: In the S-scan and B-scan images, the amplitude of the blue noise signal is ≤8%, and the echo amplitude of the reference reflector is ≥80% of the reference height, meeting the performance target requirements. Defect identification: Suspected defect signals are located and quantitatively analyzed, combined with the focused acoustic beamwidth formula: ,in:

[0076] , To ensure the accuracy of defect identification.

[0077] Verification of Test Results and Process Validation: Verification was performed on the PRB-Ⅰ test block. All reference reflectors in the test block were clearly displayed, and the dimensional measurement deviation was ≤±0.1mm, meeting the standard requirements. On-site Test Results: No defects exceeding the Class I qualification standard were found within the RH63 weld joint inspection area. The reflected echo amplitude met the standard, and the noise signal was controlled within the allowable range. The test results were qualified. Report Compilation: The wedge design parameters, calibration data, test parameters, signal spectrum, and analysis results were recorded to form a complete test report, which was then archived.

[0078] refer to Figure 1 , Figure 1 The varying depths of the image within the square frame represent noise signal waves generated inside the phased array wedge. This noise reduces the signal-to-noise ratio (with a maximum amplitude of 41%), making it easy to miss detections of surfaces and minute defects. Therefore, it is necessary to perform noise reduction processing to ensure that the noise signal does not exceed 10% of the amplitude, thereby improving detection sensitivity.

[0079] refer to Figure 5 The maximum amplitude of the reflected echo from the 30mm deep, Φ2×20mm diameter horizontal through-hole reached 80% of the reference height, while the noise signal amplitude (signal inside the gate) was 8%. According to... Figure 1 Noise signal (maximum 41% of signal amplitude) and Figure 5Noise signal comparison: Based on the sound pressure relationship calculation formula, the dB difference between the two noise signals with different amplitudes is Δ = 20lgH2 / H1 = 20lg41 / 8 = 14.2dB. The calculation results show that the improved wedge signal-to-noise ratio is increased by 14.2dB.

[0080] It is understood that the above embodiments are merely exemplary embodiments used to illustrate the principles of this disclosure, and this disclosure is not limited thereto. For those skilled in the art, various modifications and improvements can be made without departing from the spirit and substance of this disclosure, and these modifications and improvements are also considered to be within the scope of protection of this disclosure.

Claims

1. A wedge-shaped multipath acoustic wave attenuation phased array ultrasonic testing probe, characterized in that, include: The wedge body has a detection surface for contacting the workpiece being inspected; Multiple sound-absorbing grooves are formed inside the wedge body; And a damping block, configured at a preset interface of the sound-absorbing groove; The extension direction, spacing, and depth of each of the sound-absorbing grooves are configured as follows: This allows at least a portion of the reflected transverse wave generated at the detection surface to be guided to the attenuation interface formed by the wall of the silencing groove and the damping block; and, This ensures that the reflected longitudinal wave generated on the detection surface undergoes at least six interface reflections within the wedge body before returning to the probe direction; The acoustic characteristics of the damping block are configured to absorb the reflected transverse wave. The reflected transverse wave is attenuated at the attenuation interface by a combination of scattering by the silencing groove and absorption by the damping block. After the reflected longitudinal wave completes the at least six interface reflections, the acoustic component returning to the probe direction forms a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to be attenuated by phase interference.

2. The wedge-shaped multipath acoustic wave attenuation phased array ultrasonic testing probe according to claim 1, characterized in that, The silencing groove has a width of 2mm, a depth of 5mm, a spacing of 8mm between adjacent grooves, and an angle of 16.96° between the length direction of each groove and the bottom surface of the wedge. The dimensions of the damping block are 15mm × 10mm × 5mm; The main body of the wedge has external dimensions of 80mm×40mm×20mm, is made of aviation aluminum, and has a surface roughness Ra≤3.2μm for the wall of the silencing groove.

3. The wedge-shaped multipath acoustic attenuation phased array ultrasonic testing probe according to claim 1, characterized in that, The material of the wedge body has a longitudinal wave velocity of 2347 m / s and is configured to be used in conjunction with the test piece having a transverse wave velocity of 3240 m / s. The detection surface of the wedge body is configured to allow the longitudinal wave generated by the phased array probe to be incident at an angle of 36.4°.

4. The wedge-shaped multipath acoustic attenuation phased array ultrasonic testing probe according to claim 1, characterized in that, The wedge is configured such that, when used in conjunction with a phased array probe, it generates a transverse wave refraction angle of 55° in the test piece.

5. The wedge-shaped multipath acoustic attenuation phased array ultrasonic testing probe according to claim 1, characterized in that, The structure of the wedge body satisfies the following sound energy attenuation relationship: For the reflected transverse wave, the remaining energy after passing through the attenuation interface satisfy: ， in, The initial energy of the reflected shear wave incident on the attenuation interface. The scattering attenuation coefficient of the silencing groove for the reflected transverse wave is given by [the value of the silencing groove]. The absorption attenuation coefficient of the damping block for the reflected transverse wave is given. The reflection coefficient of the remaining energy; For reflected longitudinal waves, the remaining energy received by the probe after at least six interface reflections and phase interferences. satisfy: ， in, The initial reflected longitudinal wave energy, Let be the energy attenuation coefficient for a single interface reflection, and n be the number of interface reflections, where n ≥ 6. Let Δ be the energy attenuation coefficient of the longitudinal wave interface reflection. This is the phase difference with the incident longitudinal wave.

6. A wedge-shaped multipath acoustic attenuation phased array ultrasonic testing probe according to any one of claims 1-5, characterized in that, The wedge is configured to inspect the welds of large-diameter high-temperature pipe components made of low-alloy steel, including tees, reducers, and elbows.

7. A method for designing a wedge for a phased array ultrasonic testing probe with multipath acoustic wave attenuation, wherein the method is applied to the wedge of the phased array ultrasonic testing probe described in claim 1, characterized in that, include: Parameter determination: Based on the material of the workpiece under inspection and the inspection requirements, determine the basic acoustic parameters of the wedge. The basic acoustic parameters include at least the longitudinal wave velocity of the wedge, the transverse wave velocity of the workpiece under inspection, and the longitudinal wave incident angle of the phased array probe. Model construction: Based on the basic acoustic parameters and the difference in propagation characteristics between reflected longitudinal waves and reflected transverse waves, a three-dimensional model of the wedge is constructed. The number, angle and spacing of the silencing grooves are optimized in the model so that the layout of the silencing grooves can simultaneously satisfy: guiding the reflected transverse waves to the preset damping interface, and constructing a sound path of six interface reflections for the reflected longitudinal waves. Material configuration: Damping material parameters are configured at the damping interface of the model. The damping material parameters are selected to adapt to the absorption and attenuation requirements of the reflected transverse wave and to ensure that the propagation of the main ultrasonic beam is not disturbed. Performance simulation and verification: Perform acoustic simulations on the constructed model to verify and ensure that: a) The reflected transverse wave at the damping interface can achieve combined attenuation through the scattering effect of the silencing groove and the absorption effect of the damping material; b) After the reflected longitudinal wave propagates through the acoustic path of the six interface reflections, it can form a 180° phase difference with the incident longitudinal wave emitted by the probe, so as to achieve attenuation through phase interference.

8. The wedge design method for a phased array ultrasonic testing probe with multipath acoustic wave attenuation according to claim 7, characterized in that, In the parameter determination step, the matching of acoustic parameters is determined using the sound wave refraction angle formula: sin θ L / c L = sin θ S / c S , in, θ L The angle of incidence of the longitudinal wave. c L For the longitudinal wave velocity of the wedge, θ S The angle of refraction of the transverse wave on the inspected part. c S The sound velocity of the transverse wave in the inspected part.

9. The wedge design method for a phased array ultrasonic testing probe with multipath acoustic wave attenuation according to claim 7, characterized in that, In the performance simulation and verification step, the design performance is evaluated by calculating the signal-to-noise ratio, and the design objective satisfies: In the detection of a transverse through-hole with a depth of 30mm and a diameter of Φ2×40mm, the maximum amplitude of the reflected echo is not less than 80% of the reference height, and the amplitude of the noise signal inside the gate is not higher than 8%. Among them, signal-to-noise ratio SNR = A Sig / A Noise , A Sig The amplitude of the reflected echo from the reference reflector. A Noise The amplitude of the noise signal.

10. The wedge design method for a phased array ultrasonic testing probe with multipath acoustic wave attenuation according to claim 7, characterized in that, In the performance simulation and verification steps, the compatibility between the wedge and the probe is also verified using the beamwidth formula: W Beam = ( λ × F ) / d ， Among them, W Beam To focus the beam width of the sound beam, λ Because of the length of the ultrasound wave, F To focus on depth, d The aperture of the probe spindle is the excitation aperture.

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