Tandem Ultrasonic Array Probe for Welded Steel Pipe Flaw Detection
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Solution Overview
Problem
Current ultrasonic flaw detection techniques struggle to accurately detect minute flaws in welded steel pipes, particularly those with micro-diameter penetrators dispersed in wide regions, due to narrow beam widths and difficulties in detecting plane-shaped flaws and flaws near the surface, leading to incomplete detection and reduced mechanical characteristics.
Innovation Solution
The use of a tandem ultrasonic flaw detection method with an array probe, where the beam width is optimized to detect scattered-type penetrators by varying the beam focus and incident angles, allowing for improved sensitivity and detection of flaws without creating dead zones, enabling the detection of micro-diameter penetrators dispersed in wide regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a point focus type probe with high frequency is used to detect minute flaws, then detection precision is improved, but device complexity and cost increase due to requiring many channels
Solution Approach 1:
The patent combines wave transmission and wave reception functions into a single array probe, eliminating the need for separate probes and multiple channels. This merging approach maintains high detection precision while significantly reducing equipment complexity and cost.
Solution Approach 2:
The array probe serves multiple functions: it acts as both a wave transmission probe and a wave reception probe. This multi-functionality allows the system to detect flaws throughout the entire wall thickness without requiring separate probes for different functions, thereby reducing device complexity.
2Measurement precision
If angle beam testing is used to detect flaws in welded portions, then detection capability is improved, but detection completeness deteriorates due to dead zones near the surface and inability to detect plane-shaped flaws
Solution Approach 1:
The patent uses dynamic focusing capability of the array probe to adjust the focal point position along the wall thickness direction. This allows the detection beam to be dynamically positioned at different depths, eliminating dead zones and enabling detection of flaws at various locations including those near the surface and plane-shaped flaws that static angle beam testing cannot detect.
3Measurement precision
If the ultrasonic beam is focused to a narrow width to detect minute flaws, then measurement precision is improved, but detection coverage deteriorates due to narrow beam width
Solution Approach 1:
The array probe enables dynamic adjustment of the focal point position along the wall thickness direction while maintaining a narrow beam width. This allows the system to scan through the entire wall thickness with high precision, achieving both narrow beam width for minute flaw detection and comprehensive coverage by moving the focal point dynamically.
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 enhances the detection of minute flaws within the welded steel pipe, improving mechanical characteristics and ensuring accurate evaluation of the welded portion's quality, enabling the use of welded steel pipes under more severe service conditions.
Implementation Method 1
an ultrasonic wave is obliquely incident on an inspection surface of the sample to detect the flaw
Implementation Method 2
detect the flaw inside the sample based on the reflected wave from the flaw
Implementation Method 3
forming a focus beam by an array probe so that blow holes can be detected
Data Source
Figure 1
Figure 2A~2D
Figure 3
AI summary
The present invention has a structure capable of detecting the scattered-type penetrator having oxides each with the size of several µm sparsely and widely dispersed. Specifically, the structure includes a wave transmission unit 6 for transmitting an ultrasonic wave to the welded surface of the welded portion 2 in a pipe axial direction of the pipe 1 such that the beam width of a transmission beam 8 is brought into a range from 0.5 mm to 2.5 mm, and a wave reception unit 7 for receiving at least a portion of the reflection wave (reception beam 9) at the welded surface. The wave transmission unit 6 and the wave reception unit 7 include transmission/reception units formed of different groups of transducer elements on at least one or more array probes 5 arranged in the circumferential direction of the pipe.