Nozzle Welding Inspection via Axial Projection
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Solution Overview
Problem
The existing automatic nozzle welding methods require large grooves for inspection, increasing the inspected area and costs, especially when multiple nozzle head portions are adjacent, leading to higher inspection and potential defect detection challenges.
Innovation Solution
A nozzle manufacturing method that involves forming a portion projecting from the parent material for initial inspection, processing it into a base, welding with a nozzle base material, and performing a second inspection on the welded portion, which is formed at a separated position, allowing for efficient inspection while minimizing the impact on the parent material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a groove with a large opening is formed to cause the welded portion of the nozzle to face the pipe body, then the welded portion can be inspected, but the area to be inspected increases and inspection cost increases
Solution Approach 1:
The nozzle structure is segmented into a head portion and a welded portion, where the welded portion is separated and extended toward the pipe body. This segmentation allows the welded portion to be inspected independently without requiring a large opening groove, thereby reducing the inspected area while maintaining inspection capability.
Solution Approach 2:
The welded portion is extended in the axial direction toward the pipe body, creating a three-dimensional configuration that allows inspection access from multiple angles. This dimensional change enables effective inspection without requiring a large radial opening, thus reducing the inspected area.
2Measurement precision
If the area to be inspected of the welded portion is increased, then inspection coverage is improved, but inspection cost increases
Solution Approach 1:
The welded portion is segmented and extended axially, allowing inspection to be focused on this specific separated region rather than a large area. This segmentation enables effective inspection coverage while minimizing the total inspected area and associated costs.
3Adaptability or versatility
If multiple head portions of the nozzle are arranged adjacent to each other, then the nozzle structure is complete, but the size of the welded portion increases and inspection cost increases
Solution Approach 1:
Each head portion is segmented with its own extended welded portion that faces the pipe body axially. This segmentation allows multiple nozzles to be arranged adjacently without requiring a large common groove, as each welded portion is independently positioned and sized, thereby reducing the total inspected area.
4Manufacturing precision
If automatic welding is performed on a groove formed between the groove of the pipe body and the groove of the welded portion, then welding quality is improved, but a large opening groove is required which increases inspection area
Solution Approach 1:
The welded portion is extended axially toward the pipe body, creating a groove configuration that allows automatic welding while requiring a smaller opening area. This axial extension provides access for welding operations while minimizing the radial opening size, thus reducing the inspected area.
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 method enables suitable inspection of both the base and the nozzle welded portion with reduced inspection costs and increased efficiency, allowing for effective detection of abnormalities without increasing the size of the inspected area.
Implementation Method 1
a forming step of forming a portion including a surface to be inspected so that the portion projects from a front surface of the parent material
Implementation Method 2
a base material welding step of welding the base and a nozzle base material to be a base material of the nozzle to form a nozzle welded portion
Data Source
Figure 1
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AI summary
A welding method for a nozzle 10 is for welding the nozzle 10 to a parent material 1 and includes a forming step of forming a portion subjected to a first inspection so that the portion projects from a surface of the parent material 1, a base processing step S4 of processing the formed portion into a base 5 of the nozzle 10, and a base material welding step S6 of welding the base 5 with a nozzle base material 22 serving as a base material of the nozzle 10 to form a nozzle welded portion 15 subjected to a second inspection. The formed portion has a surface to be inspected on which the first inspection is performed. The surface to be inspected has a flat surface in parallel with a surface orthogonal to a projection direction toward which the formed portion projects from the surface of the parent material.