Ultrasonic Material Quality Testing Model for Forged Components
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Solution Overview
Problem
Conventional ultrasonic testing for material quality in forged components is operator-dependent and lacks accuracy, particularly for materials like large grain size austenitic steels, leading to inconsistent inspection results and a need for a more reliable evaluation system that can continuously monitor and classify material quality.
Innovation Solution
A computer-implemented method using ultrasonic scan data, historical data analysis, and a neural network-based testing model to determine material quality by defining quality ranges for parameters such as ultrasonic wave attenuation, surface quality, and cleanliness, enabling automatic classification and anomaly detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional ultrasonic testing with manual inspection is used, then the inspection can be performed on various metal pieces, but the inspection results are influenced by operator skills and experience leading to inconsistency
Solution Approach 1:
The system performs automatic evaluation of ultrasonic scan data through computer-implemented methods, where the inspection system evaluates its own results without human intervention. The automated evaluation algorithm processes scan data, generates reports, and determines material quality independently, eliminating dependence on operator skills and experience while maintaining consistent inspection results across different operators and time periods.
2Productivity
If automated ultrasonic scanning is implemented, then productivity increases, but the system lacks the ability to continuously monitor and evaluate material quality fluctuations
Solution Approach 1:
The system continuously monitors material quality by processing ultrasonic scan data through automated evaluation algorithms that provide real-time feedback on material properties. The system generates quality metrics and comparisons that enable continuous monitoring of material quality fluctuations, allowing for immediate detection of changes in material characteristics while maintaining high inspection throughput through automation.
3Ease of operation
If manual inspection classification is used, then the system is simple to operate, but it requires great professional skills and experience to make proper analysis
Solution Approach 1:
The system replaces manual inspection and classification processes with computer-implemented automated evaluation methods. The automated algorithm processes ultrasonic scan data, applies evaluation criteria, and generates quality assessments without human intervention. This substitution eliminates the need for operators to possess extensive professional skills and experience while maintaining or improving evaluation accuracy through consistent application of predefined criteria.
4Adaptability or versatility
If ultrasonic scanning is used for all metal pieces, then the inspection method is universally applicable, but it fails for materials with large grain size like austenitic steels
Solution Approach 1:
The system adapts to different material types by changing inspection parameters such as ultrasonic frequency, wave mode, and evaluation criteria based on the specific material being inspected. For materials with large grain size like austenitic steels, the system modifies parameters to optimize penetration and reduce noise from grain structure, thereby maintaining detection capability across diverse material types while preserving universal applicability.
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
The solution provides a reliable, accurate, and automated system for evaluating material quality, reducing operator influence and improving the consistency of inspection results, enabling objective grading and real-time monitoring of material quality fluctuations.
Implementation Method 1
utilize high frequency sound waves penetrating through the piece. The sound waves propagate in the piece
Implementation Method 2
part of the waves reflects from the surfaces of the piece and from the faults of the piece. The reflected waves can be detected
Implementation Method 3
multiple parameters comprise at least two of following: ultrasonic wave attenuation and transparency
Data Source
Figure 1
Figure 2a~2b
Figure 3~9
AI summary
An apparatus and a computer implemented method for determining material quality of a component, the method comprising: receiving ultrasonic scan data for a plurality of scanned components; maintaining the scan data within a data storage system; determining historical data associated with multiple parameters based on the scan data of the data storage system; generating a testing model using the historical data, wherein the testing model is configured to define multiple quality ranges for each parameter; scanning a component using at least one ultrasonic probe to provide component data; and determining quality information of the component using the testing model and the component data.