Crack prediction method and apparatus, electronic device, and computer-readable storage medium

Abstract

A crack prediction method and apparatus, an electronic device, and a computer-readable storage medium. The prediction method comprises: determining a leakage magnetic field at a welded joint to be detected; and predicting, on the basis of the leakage magnetic field at said welded joint, the tendency of cracking at said welded joint. Cracking at joints can be prevented, or positions where cracking may occur can be repaired or avoided in time, thereby improving the safety of device operating.

Description

Crack prediction methods, apparatus, electronic devices and computer-readable storage media

[0001] This application claims priority to Chinese Patent Application No. 2024115282413, filed on October 30, 2024, entitled "Crack Prediction Method, Apparatus, Electronic Device and Computer-Readable Storage Medium", the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to the field of thermal power generation technology, and more specifically, to a crack prediction method, apparatus, electronic device, and computer-readable storage medium. Background Technology

[0003] The development of coal-fired power units towards supercritical high-parameter designs places higher demands on the thermal strength and high-temperature oxidation resistance of boiler materials. 9Cr steels such as P91 and P92, with a Cr content of 9%–12%, which possess high thermal strength, good weldability, and low cost, are widely used in 9Cr steel pipes for high-parameter power units.

[0004] As the operating time of the unit increases, the pipes gradually age, and the metallographic structure and mechanical properties gradually decline. However, for 9Cr steels such as P91 and P92, the more serious problem is the generation of Type IV cracks in the fine grain region of the welded joint. Once formed, these cracks expand rapidly and can even cause the entire welded joint to crack, posing a serious safety hazard to the unit.

[0005] Application content

[0006] In view of the above, embodiments of this application provide a crack prediction method, apparatus, electronic device, and computer-readable storage medium, which aim to solve the above problems or at least partially solve the above problems.

[0007] In a first aspect, embodiments of this application provide a crack prediction method, the method comprising: determining a leakage magnetic field at a weld joint to be tested; and predicting the tendency for the weld joint to be tested to develop cracks based on the leakage magnetic field at the weld joint to be tested.

[0008] Secondly, embodiments of this application also provide a crack prediction device, the device comprising: a detection module for determining the leakage magnetic field at the weld joint to be detected; and a processing module for predicting the trend of crack formation in the weld joint to be detected based on the leakage magnetic field at the weld joint to be detected.

[0009] Thirdly, embodiments of this application also provide an electronic device, including: a processor; and a memory arranged to store computer-executable instructions, which, when executed, cause the processor to perform the steps described in the first aspect.

[0010] Fourthly, embodiments of this application also provide a computer-readable storage medium that stores one or more programs, which, when executed by an electronic device including multiple applications, cause the electronic device to perform the steps described in the first aspect.

[0011] The above-mentioned at least one technical solution adopted in the embodiments of this application can achieve the following beneficial effects: by detecting the leakage magnetic field at the welded joint to predict whether cracks will occur at the joint, thereby preventing cracks from occurring at the joint or timely repairing or preventing cracks in the possible locations, thus improving the safety of equipment operation. Attached Figure Description

[0012] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0013] Figure 1 shows a schematic flowchart of the crack prediction method provided in an embodiment of this application;

[0014] Figure 2 shows a structural diagram of the crack prediction device provided in an embodiment of this application;

[0015] Figure 3 shows a schematic diagram of the structure of an electronic device provided in an embodiment of this application. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0017] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such use can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the term "comprising" and its variations should be interpreted as open-ended terms meaning "including but not limited to."

[0018] As described in the background section, coal-fired power units are moving towards supercritical high-parameter development, which places higher demands on the thermal strength and high-temperature oxidation resistance of boiler materials. 9Cr steels such as P91 and P92, with a Cr content of 9%–12%, which possess high thermal strength, good weldability, and low cost, are widely used in 9Cr steel pipes for high-parameter power units.

[0019] As the operating time of the unit increases, the pipes gradually age, and the metallographic structure and mechanical properties gradually decline. However, for 9Cr steels such as P91 and P92, the more serious problem is the generation of Type IV cracks in the fine grain region of the welded joint. Once formed, these cracks expand rapidly and can even cause the entire welded joint to crack, posing a serious safety hazard to the unit.

[0020] The Type IV creep cracking process in 9Cr steel welded joints is a creep loss process in the fine-grained region of the welded joint. During welding, carbides on the coarse austenite grain boundaries in the wood do not completely dissolve but precipitate on the grain boundaries of the fine-grained region formed after welding. During high-temperature creep, the strengthening carbides in the fine-grained region decrease, while the carbides on the grain boundaries grow larger and form new coarse carbides, which are called nucleation sources of creep cavities, leading to a decrease in the creep performance of the fine-grained region. When the creep cavities on the grain boundaries increase, aggregate, and connect, grain boundary separation occurs. As the separated grain boundaries continue to increase, microcracks form on the original austenite grain boundaries until macroscopic cracking occurs. Type IV cracks are essentially the aggregation and growth of creep cavities under stress, and Type IV cracks first initiate in the stress concentration area. When the stress in the welded joint changes, its magnetic properties will change.

[0021] Therefore, by detecting the stress condition of welded joints, the development trend of type IV cracks can be predicted, providing technical support for the safe and stable operation of pipelines.

[0022] The present application will now be described in detail through specific embodiments.

[0023] Figure 1 shows a flowchart of the crack prediction method provided in the embodiments of this application. As can be seen from Figure 1, this application includes at least steps S101-S102:

[0024] Step S101: Determine the leakage magnetic field at the weld joint to be tested.

[0025] The welded joint to be tested is a 9Cr steel welded joint. Of course, other welded joints applicable to the embodiments of this application are also included within the scope of protection of this application.

[0026] In some embodiments, a leakage magnetic field sensor is used to detect the leakage magnetic field at the weld joint to be tested. The leakage magnetic field sensor may be a Hall element, a giant magnetoresistive sensor, a coil sensor, a magnetoelectric sensor, etc.

[0027] The leakage magnetic field includes tangential and normal leakage magnetic fields. The tangential leakage magnetic field is the component of the leakage magnetic field parallel to the surface of the weld joint. When the joint is magnetized, if defects (such as cracks or holes) exist, these defects will disrupt the continuity of the magnetic field lines, causing magnetic flux to leak along both sides of the defect, forming a tangential leakage magnetic field. The intensity and distribution of the tangential leakage magnetic field can reflect the size and shape of the defect and the degree of its influence on the magnetic flux lines. The normal leakage magnetic field is the component of the leakage magnetic field perpendicular to the surface of the weld joint. In the presence of defects, magnetic flux will leak perpendicularly to the joint surface, forming a normal leakage magnetic field. The presence and changes of the normal leakage magnetic field can be used to identify open defects on the material surface, such as cracks.

[0028] Step S102: Based on the leakage magnetic field at the weld joint to be tested, predict the trend of crack formation in the weld joint to be tested.

[0029] Among them, the crack is a type IV crack. The trend of cracking in the welded joint indicates that the welded joint has not yet developed cracks, but based on the current leakage magnetic field prediction, cracks may appear at some point in the future, as well as the probability of cracking.

[0030] As can be seen from the method shown in Figure 1, this application predicts whether cracks will occur at the joint by detecting the leakage magnetic field at the pipe weld joint, thereby preventing cracks from occurring at the joint or timely repairing or preventing cracks at the location, thus improving the safety of joint operation.

[0031] In some embodiments of this application, in step S102, the stress and stress change trend at the weld joint to be tested can be determined by detecting the leakage magnetic field at the weld joint to be tested, and then the tendency of the joint to crack can be predicted by the stress and stress change trend.

[0032] Specifically, a first correlation between the leakage magnetic field and stress is pre-determined. Based on the leakage magnetic field at the weld joint to be inspected, this first correlation is used to determine the stress at the weld joint. Furthermore, by comparing the stress at the weld joint to be inspected with historically determined stress data for the same weld joint, the stress variation trend at the weld joint to be inspected is determined. For example, if the historical stress data for the weld joint to be inspected is 10 Pa at point 7, 11 Pa at point 10, and 12 Pa at point 1, and the current stress at point 4 is 13 Pa, the stress variation trend shows an increase of 1 Pa every 3 hours.

[0033] The first correlation was determined by: using a leakage magnetic field sensor to detect the leakage magnetic field at a defect-free location after normal heat treatment of a welded joint; using a leakage magnetic field sensor to detect the leakage magnetic field of an in-service welded joint under different known stresses; and obtaining multiple sets of stress and leakage magnetic field data to calibrate the first correlation between leakage magnetic field and stress.

[0034] In some embodiments of this application, the trend of joint formation predicted by stress and stress variation trends is specifically determined based on a second correlation. This second correlation is a pre-determined correspondence between different stresses and crack formation. Specifically, the crack formation of welded joints under different stresses is detected, and the second correlation between different stresses and cracks is determined by acquiring multiple sets of stress and crack data.

[0035] Specifically, based on the stress of the weld joint under test, a second correlation is used to determine whether cracking will occur at this stress level. If no cracking occurs at this time, the future cracking trend of the weld joint is determined based on the stress change trend and the second correlation. For example, if the stress change trend is an increase of 1 Pa every 3 hours, and the current stress is 20 Pa, the second correlation indicates that cracking will occur at the weld joint when the stress reaches 22 Pa. Therefore, the cracking trend of the weld joint under test is that cracking may occur in 6 hours. Furthermore, the crack size (such as length and width) of the weld joint under test can be determined based on the second correlation.

[0036] In the embodiments of this application, by predicting the trend of crack formation in the welded joint, it is possible to determine whether the welded joint will develop cracks in the future, as well as the time and size of future crack formation, so that technicians can prevent cracks from forming in the joint in advance and protect the safe operation of the equipment.

[0037] In some embodiments of this application, when predicting the trend of crack formation in the welded joint, the welded joint with the crack formation trend is monitored in real time. The real-time leakage magnetic field is compared with the historical leakage magnetic field data of the welded joint, and / or the real-time leakage magnetic field of the welded joint is compared with the leakage magnetic field data of the surrounding area to determine whether the welded joint has already formed cracks.

[0038] Among them, an array of magnetic flux leakage sensors is used to monitor the welded joint in real time.

[0039] Specifically, when the real-time leakage magnetic field data differs significantly from the historical leakage magnetic field data (e.g., the difference is greater than a preset error value), it can be confirmed that a crack has occurred in the welded joint, causing a change in the leakage magnetic field. And / or, when the real-time leakage magnetic field data differs significantly from the leakage magnetic field of the surrounding area (e.g., the difference is greater than a preset error value), it can be confirmed that a crack has occurred in the welded joint.

[0040] In other embodiments, the presence of cracks in the welded joint is determined by the real-time leakage magnetic field, a first correlation, and a second correlation. Specifically, the stress corresponding to the real-time leakage magnetic field is determined by the real-time leakage magnetic field and the first correlation, and the stress is used to determine whether the stress has caused cracks.

[0041] In this embodiment of the application, the presence or absence of cracks in the welded joint can be confirmed by detecting the leakage magnetic field of the welded joint, thus enabling technicians to repair the welded joint in a timely manner.

[0042] In some embodiments of this application, a crack prediction device is provided, which corresponds one-to-one with the crack prediction methods described in the above embodiments. As shown in Figure 2, the crack prediction device includes a detection module 201 and a processing module 202. Detailed descriptions of each functional module are as follows:

[0043] Detection module 201 is used to determine the leakage magnetic field at the weld joint to be tested;

[0044] The processing module 202 is used to predict the tendency of the weld joint to be tested to develop cracks based on the leakage magnetic field at the weld joint to be tested.

[0045] In some embodiments of this application, in the above-described apparatus, the processing module 202 is specifically used to determine the stress and stress change trend at the weld joint to be tested based on the leakage magnetic field at the weld joint to be tested; and to predict the trend of crack formation in the weld joint to be tested based on the stress and stress change trend at the weld joint to be tested.

[0046] In some embodiments of this application, in the above-described apparatus, the processing module 202 is specifically used to determine a first correlation between the leakage magnetic field and the stress; based on the leakage magnetic field at the weld joint to be tested, determine the stress at the weld joint to be tested based on the first correlation; and determine the stress change trend at the weld joint to be tested based on the stress at the weld joint to be tested and the historical stress data at the weld joint to be tested.

[0047] In some embodiments of this application, in the above-described apparatus, the processing module 202 is specifically used to determine the leakage magnetic field at the defect-free location of a normal pipe welded joint after heat treatment; detect the leakage magnetic field at different stress locations of the in-service pipe welded joint; and determine a first correlation between the leakage magnetic field and stress based on the leakage magnetic field at the defect-free location and the leakage magnetic field at different stress locations.

[0048] In some embodiments of this application, in the above-described apparatus, the processing module 202 is specifically used to determine a second correlation between different stresses and crack generation; based on the stress and stress change trend at the weld joint to be tested, the trend of crack generation in the weld joint to be tested is predicted through the second correlation.

[0049] In some embodiments of this application, in the above-described apparatus, the processing module 202 is specifically used to monitor the real-time leakage magnetic field at the weld joint with a tendency to develop cracks; compare the real-time leakage magnetic field of the weld joint with the historical leakage magnetic field data of the weld joint, and / or compare the real-time leakage magnetic field of the weld joint with the leakage magnetic field data of the surrounding area to determine whether the weld joint has developed cracks.

[0050] In some embodiments of this application, in the above-described apparatus, the crack is a type IV crack, and the weld joint to be tested is a 9Cr steel weld joint.

[0051] It should be noted that any of the above crack prediction devices can implement the aforementioned crack prediction method one by one, which will not be elaborated here.

[0052] Figure 3 shows a schematic diagram of the structure of an electronic device provided in an embodiment of this application. As shown in Figure 3, at the hardware level, the electronic device includes a processor, and optionally also includes an internal bus, a network interface, and a memory. The memory may include RAM, such as high-speed random-access memory (RAM), or non-volatile memory, such as at least one disk storage device. Of course, the electronic device may also include other hardware required for other services.

[0053] The processor, network interface, and memory can be interconnected via an internal bus, which can be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, or an EISA (Extended Industry Standard Architecture) bus, etc. Buses can be categorized as address buses, data buses, control buses, etc. For ease of illustration, Figure 3 uses only a single bidirectional arrow, but this does not imply that there is only one bus or one type of bus.

[0054] Memory is used to store programs. Specifically, programs may include program code, which includes computer operation instructions. Memory may include main memory and non-volatile memory, and provides instructions and data to the processor.

[0055] The processor reads the corresponding computer program from non-volatile memory into main memory and then runs it, forming a crack prediction device at the logical level. The processor executes the program stored in memory and specifically performs the aforementioned method.

[0056] The processor may be an integrated circuit chip with signal processing capabilities. In implementation, each step of the above method can be completed by integrated logic circuits in the processor's hardware or by instructions in software form. The processor can be a general-purpose processor, including a Central Processing Unit (CPU), a Network Processor (NP), etc.; it can also be a Digital Signal Processor (DSP), an Application Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), or other programmable logic devices, discrete gate or transistor logic devices, or discrete hardware components. It can implement or execute the methods, steps, and logic block diagrams disclosed in the embodiments of this application. The general-purpose processor can be a microprocessor or any conventional processor. The steps of the methods disclosed in the embodiments of this application can be directly embodied in the execution of a hardware decoding processor, or executed by a combination of hardware and software modules in the decoding processor. The software modules can reside in random access memory, flash memory, read-only memory, programmable read-only memory, electrically erasable programmable memory, registers, or other mature storage media in the art. The storage medium is located in the memory, and the processor reads the information in the memory and, in conjunction with its hardware, completes the steps of the above method.

[0057] The electronic device can execute the crack prediction method provided in several embodiments of this application and realize the function of the crack prediction device in the embodiment shown in FIG2. The embodiments of this application will not be described again here.

[0058] This application also proposes a computer-readable storage medium that stores one or more programs, the programs including instructions that, when executed by an electronic device including multiple applications, enable the electronic device to perform the crack prediction methods provided in various embodiments of this application.

[0059] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including but not limited to disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0060] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions specified in one or more flowchart illustrations and / or one or more block diagrams.

[0061] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means that implement the functions specified in one or more flowcharts and / or one or more block diagrams.

[0062] These computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process, such that the instructions, which execute on the computer or other programmable apparatus, provide steps for implementing the functions specified in one or more flowcharts and / or one or more block diagrams.

[0063] In a typical configuration, a computing device includes one or more processors (CPU), input / output interfaces, network interfaces, and memory.

[0064] Memory may include non-persistent storage in computer-readable media, such as random access memory (RAM) and / or non-volatile memory, such as read-only memory (ROM) or flash RAM. Memory is an example of computer-readable media.

[0065] Computer-readable media includes both permanent and non-permanent, removable and non-removable media that can store information using any method or technology. Information can be computer-readable instructions, data structures, modules of programs, or other data. Examples of computer storage media include, but are not limited to, phase-change memory (PRAM), static random access memory (SRAM), dynamic random access memory (DRAM), other types of random access memory (RAM), read-only memory (ROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage, magnetic tape, magnetic magnetic disk storage or other magnetic storage devices, or any other non-transferable medium that can be used to store information accessible by a computing device. As defined herein, computer-readable media does not include transient computer-readable media, such as modulated data signals and carrier waves.

[0066] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0067] Those skilled in the art will understand that embodiments of this application can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0068] The above are merely embodiments of this application and are not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.

Claims

1. A crack prediction method, wherein, The method includes: Determine the leakage magnetic field at the weld joint to be tested; Based on the leakage magnetic field at the weld joint to be tested, the tendency for the weld joint to develop cracks is predicted.

2. The method according to claim 1, wherein, The method of predicting the tendency of the weld joint to develop cracks based on the leakage magnetic field at the weld joint to be tested includes: Based on the leakage magnetic field at the weld joint to be tested, the stress and stress change trend at the weld joint to be tested are determined. Based on the stress and stress variation trend at the weld joint to be tested, the trend of crack formation in the weld joint to be tested is predicted.

3. The method according to claim 2, wherein, The determination of the stress and stress variation trend at the weld joint under test based on the leakage magnetic field at the weld joint under test includes: Determine the primary correlation between leakage magnetic field and stress; Based on the leakage magnetic field at the weld joint to be tested, the stress at the weld joint to be tested is determined using the first correlation relationship. Based on the stress at the weld joint to be tested and the historical stress data at the weld joint to be tested, the stress change trend at the weld joint to be tested is determined.

4. The method according to claim 3, wherein, The determination of the first correlation between the leakage magnetic field and stress includes: Determine the leakage magnetic field at defect-free locations where normal pipe welded joints have undergone heat treatment; Detecting the leakage magnetic field at welded joints of in-service pipelines under different stresses; Based on the leakage magnetic field at defect-free locations and the leakage magnetic field at different stress locations, the first correlation between the leakage magnetic field and stress is determined.

5. The method according to claim 2, wherein, The method of predicting the tendency for crack formation in the weld joint under test based on the stress and stress variation trend at the weld joint under test includes: Determine the second correlation between different stresses and crack initiation; Based on the second correlation, and the stress at the weld joint to be detected, The trend of change is used to predict the tendency of the welded joint to be tested to develop cracks.

6. The method according to claim 1, wherein, The method further includes: Monitor the real-time leakage magnetic field at welded joints that have a tendency to develop cracks; The real-time leakage magnetic field of the welded joint is compared with the historical leakage magnetic field data of the welded joint, and / or the real-time leakage magnetic field of the welded joint is compared with the leakage magnetic field data of the surrounding area to determine whether the welded joint has developed cracks.

7. The method according to any one of claims 1 to 6, wherein, The crack is a type IV crack, and the welded joint to be tested is a 9Cr steel welded joint.

8. A crack prediction device, wherein, The device includes: The detection module is used to determine the leakage magnetic field at the weld joint to be tested; The processing module is used to predict the tendency of the weld joint to develop cracks based on the leakage magnetic field at the weld joint to be tested.

9. An electronic device, comprising: processor; And a memory arranged to store computer-executable instructions, wherein, when executed, the executable instructions cause the processor to perform the steps of the crack prediction method as described in any one of claims 1-7.

10. A computer-readable storage medium storing one or more programs, wherein, When the one or more programs are executed by an electronic device comprising multiple applications, the electronic device performs the steps of the crack prediction method as described in any one of claims 1-7.

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