Analysis Model Creation for Crystalline Ultrasonic Inspection
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Solution Overview
Problem
Existing ultrasonic inspection methods struggle to accurately model and visualize ultrasonic wave propagation in materials with crystalline structures, particularly in welding portions, due to limitations in accurately reproducing sound velocity and defect positioning, and require costly and time-consuming EBSD measurements.
Innovation Solution
A method involving designating crystal growth directions, selecting and rotating partial image data to reflect crystallinity, and creating image data covered in the designated region, allowing for the quick and accurate creation of analysis models using EBSD measurement results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a model is created by focusing on average crystal growth direction in divided regions, then the model creation process is simplified, but the sound velocity of ultrasonic wave cannot be accurately reproduced and defect position cannot be accurately visualized
Solution Approach 1:
The welding portion is divided into a plurality of regions, and a model is created in every region by focusing on an average crystal growth direction of columnar crystals existing in every divided region. This segmentation approach simplifies the model creation process while maintaining reasonable accuracy for inspection purposes.
Solution Approach 2:
The patent creates a model using average crystal growth direction as a parameter approximation. By changing from individual crystal modeling to average directional modeling, the complexity is reduced while the model still captures the essential acoustic anisotropy characteristics needed for accurate ultrasonic wave propagation simulation.
2Measurement precision
If EBSD measurement is performed to create accurate analysis model, then the model accuracy is improved, but the cost and time required increase significantly
Solution Approach 1:
Instead of performing complete EBSD measurement on the entire welding portion, the patent performs EBSD measurement on a limited area to obtain crystal growth direction information. This partial measurement approach provides sufficient accuracy for creating analysis models without the excessive time and cost of comprehensive measurement.
Solution Approach 2:
The patent creates analysis models by copying and applying the crystal growth direction information obtained from limited EBSD measurements across the entire welding portion. This allows accurate modeling of the entire structure based on data from a small measured area, significantly reducing measurement time while maintaining model accuracy.
3Reliability
If ultrasonic wave wavelength is made longer to avoid scattering in coarse crystal grain materials, then the scattering effect is reduced, but the inspection resolution is deteriorated
Solution Approach 1:
The patent creates accurate analysis models that reflect the actual crystal state and acoustic anisotropy of the material. By accurately modeling the crystal structure and sound velocity distribution, the system can simulate ultrasonic wave propagation at any wavelength, allowing optimization of inspection parameters to achieve both good transmission and high resolution without the need to use excessively long wavelengths.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the simple and rapid creation of accurate analysis models for structures with crystalline materials, improving the reliability of ultrasonic inspection results and reducing costs and time associated with EBSD measurements.
Implementation Method 1
a material having an acoustic anisotropy by growing the crystal grains of the metal along a certain direction is used as a target
Implementation Method 2
The material of the coarse crystal grains is strongly affected by scattering due to a wavelength of an ultrasonic wave
Data Source
AI summary
There is provided an analysis model creation method which is capable of simply and quickly creating an accurate analysis model with respect to a structure including a crystalline material. In order to solve a problem described above, there is provided a model creation method of an analysis region used in numeral analysis, the method including a step of designating a crystal growth direction if a region is a region including crystallinity including acoustic anisotropy in the analysis region, a step of selecting partial image data to which the crystallinity of the region is reflected, a step of rotating and operating the partial image data along the crystal growth direction, and a step of creating image data which is covered in the region designated using the rotated partial image data.