CN112213387A - Ultrasonic flaw detection method - Google Patents
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Abstract
The invention discloses an ultrasonic flaw detection method, which comprises the following steps: step 1, ultrasonic flaw detection positioning: finding out the specific position of the defect by ultrasonic flaw detection positioning; step 2, sampling and sample preparation: taking the surface with the maximum equivalent of flaw detection defect as a reference surface, taking the corresponding position of the center of the probe as the circle center, respectively extending the rated length up and down, taking a tensile sample blank sample with the rated diameter, and processing the blank sample into a round bar or a square bar; step 3, sample heat treatment: carrying out softening annealing treatment; step 4, tensile test; step 5, fracture observation and analysis: and observing the tensile fracture to find the defect, and comparing the change of the tensile property, thereby obtaining the property of determining the defect. Compared with the conventional method which only depends on ultrasonic positioning sampling, the method can quickly and effectively find out the flaw detection defects, can visually observe the appearance, size and distribution of the defects and the influence on the mechanical property of the material, can quickly evaluate the harmfulness of the flaw detection defects to the material, and provides a direction for timely improving the process and stabilizing the product quality.
Description
Technical Field
The invention belongs to the field of steel quality detection.
Background
At present, most of steel materials for rail transit, energy, high-end manufacturing and the like have ultrasonic flaw detection requirements, and according to statistics, about 50% of quality objections are not related to ultrasonic flaw detection, but the ultrasonic flaw detection can only be judged as suspected defects, and the defects are difficult to find and determine accurately, so that how to react quickly for steel manufacturers is achieved, the root of the problem is found, the process is effectively improved, and the difficulty is brought to the quality stabilization.
The existing technology is to find out the existing positions of the defects through ultrasonic flaw detection, and then to analyze the defects, and the specific steps are as follows:
1. flaw detection and positioning: (1) finding out suspected defects (shown in figure 1) except 3N (3 times static field area) by using a straight probe; (2) finding out near-table suspected defects by using a tilt probe (as shown in figure 2);
2. sampling: sampling is carried out on the flaw detection positioning position (depth, the range covered by the probe-the length and the width of the flaw detection surface of the workpiece), sampling is carried out on the sampling position within 10mm (generally 1-2mm) from the flaw position, the detection surface is in the direction parallel to the probe or in the direction vertical to the probe (shown by a dotted line in figures 1-2), and the direction vertical to the probe is generally selected. To obtain the defect position more accurately, two methods are commonly used: (1) grinding and magnetic powder inspection for many times at a distance of about 3-5mm (parallel to the probe surface) above the defect position, and sawing the surface as a detection surface when obvious magnetic marks appear; (2) wire-cut or saw-cut sampling at about 1mm (parallel or perpendicular to the probe face, typically vertical) from the defect site;
3. and (3) analysis: and (4) analyzing the sample by macroscopic analysis, metallographic analysis, EDS (electronic Desorption system) and the like.
There are problems:
1) the sampling process is complicated, time and labor are consumed, the sampling period is long, and the sampling time is generally 12-24 h/block by adopting linear cutting;
2) the suspected defects of ultrasonic flaw detection cannot be efficiently and accurately analyzed. Because the real flaw detection defect position is not easy to obtain, the targeted analysis cannot be carried out to judge the real flaw detection suspected defect. According to the difference of the precision of flaw detection equipment and the sound velocity of ultrasonic waves in steel, the flaw detection positioning error reaches about +/-2.3% of the sound path (height), and meanwhile, in consideration of the measurement error, the positioning error is about +/-2.5%, for example, for steel with the height of 500mm, the positioning error is +/-12.5 mm. However, the defect proportion in steel is generally very small, and the distribution of larger defects is generally only 3-5mm along the depth direction, the length direction and the width direction. Therefore, no matter linear cutting or sawing sampling is adopted, flaw detection defect positions are likely to be missed, and the probability of success of flaw detection sampling analysis is less than 50% according to statistics.
3) The analysis difficulty after sampling is large. The size, characteristics, distribution and influence on material characteristics of the defects cannot be observed visually, the distribution of the defects is dispersed and three-dimensional only by one detection surface after sampling, the characteristics of the whole flaw detection defect are not visual and the efficiency is low by analyzing the head leakage defect on one surface, and the probability of missing the flaw detection defect is high.
Disclosure of Invention
The invention aims to solve the technical problem of finding out the suspected ultrasonic defects in the steel material quickly and accurately, judging the three-dimensional characteristics of the defects accurately and providing a direction for defect hazard assessment and process quick improvement.
In order to achieve the purpose, the invention adopts the technical scheme that: an ultrasonic flaw detection method, comprising the steps of:
The step 1 comprises the positioning of defects during flaw detection by a straight probe and the positioning of defects during flaw detection by an inclined probe;
the defect positioning method during flaw detection of the straight probe comprises the following steps of:
1) setting initial parameters of an ultrasonic instrument;
2) calibrating the ultrasonic instrument;
3) determining the bottom wave or reference sensitivity of detection, and increasing the sensitivity of compensation or making an AVG curve on the basis of the sensitivity;
4) testing the deviation of the sound beam axis of the probe, adjusting the probe to ensure that the defect is positioned on the central axis of the probe, wherein the depth of the defect is the reading displayed at the highest wave position of the current instrument;
5) marking a defect position on the workpiece;
the positioning of the oblique probe during flaw detection comprises the following steps:
1) setting initial parameters of an instrument;
2) inputting a nominal angle or a K value of the probe;
3) measuring the length of the front edge of the probe and inputting the length into an instrument;
4) inputting a nominal angle or a K value of the probe;
5) adjusting the instrument ratio by using a standard test block or a reference test block;
6) and marking a defect position on the workpiece.
The step 2 comprises the following steps:
1) taking the defect position on the workpiece obtained in the step 1 as a reference surface, extending by 55mm up and down or left and right, and taking a phi 25 or phi 30 tensile sample blank sample;
2) processing the tensile sample blank sample into a round bar, a square bar or other shapes required by tensile test, wherein the diameter of the round bar is 10mm or 15 mm;
3) the processed size, precision and roughness meet the standard of a sample, and the phenomena of surface hardening, bending, deformation, sprain and scratch of the processed surface are prevented in the processing process.
In the step 3, aiming at the material hardness of the workpiece, if the hardness is more than or equal to 300HB, softening and annealing treatment is carried out, the annealing temperature is AC 1-20-30 ℃, and the hardness after annealing is less than or equal to 280 HB; if the hardness is < 300HB, no heat treatment is required.
The step 4 comprises the following steps:
1) selecting a ZWICK model Z600E tensile testing machine;
2) the check sample corresponds to the serial number;
3) measuring the average value according to the standard, calculating the area of the cross section, and marking a slight gauge length on the sample by using a gauge length dotting machine;
4) the stretching rate was set to be uniform, the elastic segment was set to 10MPa/S, the yield stage was set to 0.0008/S, and after yielding was set to 0.005/S.
In step 5, the fracture is observed: if visible holes appear, the defects of looseness, pores and shrinkage cavities exist;
and (3) fracture analysis: if the tensile fracture is observed, defects of inclusion, shrinkage cavity, white point, air hole, crack and component segregation are found, and the size, distribution and influence on mechanical performance of the defects are visually observed.
In the step 5:
if the content of large-size inclusions in the sample is high, large cracks can be formed, and the sample is broken at the highest inclusion content;
if white spots, bubbles, shrinkage cavities and crack defects exist in the sample, the plasticity and the surface shrinkage of the material are reduced;
if the sample has an abnormal structure defect at the position of component segregation, no or little plastic deformation occurs at the fracture position, and a quasi-cleavage streak is generated.
In the step 5, the defect characteristics are further analyzed, EDS analysis is combined, the appearance, characteristics and components of the defect are analyzed in detail, the defect is accurately determined, and a direction is provided for defect hazard assessment and process improvement.
Compared with the conventional method which only depends on ultrasonic positioning sampling, the method can quickly and effectively find out the flaw detection defects (the sampling workload is reduced by 70-90% compared with the conventional method, the probability of finding the defects is improved by more than 30%), can visually observe the appearance, size and distribution of the defects and the influence on the mechanical property of the material, can quickly evaluate the harmfulness of the flaw detection defects on the material, and provides a direction for timely improving the process and stabilizing the product quality.
Drawings
The following is a brief description of the contents of each figure and the symbols in the figures in the description of the invention:
FIG. 1 is a schematic view of a straight probe inspection;
FIG. 2 is a schematic diagram of a tilted probe inspection;
FIG. 3 is a schematic diagram of a phi 25 tensile specimen blank;
FIG. 4 is a schematic diagram of a phi 30 tensile specimen blank;
FIG. 5 is a schematic view of a No. 1 tensile specimen;
FIG. 6 is a schematic view of a No. 2 tensile specimen;
FIG. 7 is a drawing graph of No. 1-4
The dotted line in fig. 1 and 2 is the detection surface
Detailed Description
The following description of the embodiments with reference to the drawings is provided to describe the embodiments of the present invention, and the embodiments of the present invention, such as the shapes, configurations, mutual positions and connection relationships of the components, the functions and working principles of the components, the manufacturing processes and operation methods, etc., will be further described in detail to help those skilled in the art to more fully, accurately and deeply understand the inventive concept and technical solutions of the present invention.
The invention relates to a sampling and analyzing method for specifically finding suspected defects of ultrasonic flaw detection, which can quickly and effectively find the defects, can macroscopically observe the size, distribution and type of the defects and the influence on the mechanical property of a material, and is suitable for analyzing the suspected defects of ultrasonic flaw detection of axles, ring members, wheels, round steel, square steel and the like.
The method provides a direction for rapidly and accurately finding out the ultrasonic defects in the steel material, accurately judging the three-dimensional characteristics of the defects and rapidly improving the defect hazard assessment and process. The method takes the specific position of the flaw (the coverage area of the flaw plane corresponding to the maximum flaw equivalent and the flaw depth) as the middle part (non-clamping part) of the tensile blank sample, and the tensile fracture is observed and analyzed by breaking on a testing machine (under the test conditions of normal temperature, low temperature and high temperature and by stretching).
The ultrasonic flaw detection method comprises the following steps:
1) positioning of defects during flaw detection by straight probe
1.1) setting initial parameters (detection range, sound velocity, delay, repetition frequency, frequency band, emission mode and the like) of an ultrasonic instrument;
1.2) calibrating the sound velocity in the material detected by the ultrasonic instrument and the probe zero point (sound time from the probe wafer to the incident point). Eliminating the influence of sound velocity and zero point on the calculation parameters of instrument sound path, horizontal distance, vertical distance and the like;
1.3) determining the detected bottom wave or reference sensitivity, and increasing the compensated sensitivity or making an AVG curve on the basis of the sensitivity;
1.4) testing the deviation of the sound beam axis of the probe, wherein the defect is positioned on the central axis of the probe, and the defect depth is the reading displayed at the highest wave position of the current instrument;
1.5) finding the defect distance corresponding to the highest echo of the defect during scanning, and marking the defect position on the workpiece.
2) Positioning of oblique probe during flaw detection
2.1) setting initial parameters (detection range, sound velocity, delay, repetition frequency, frequency band, emission mode and the like) of the instrument;
the calibration instrument measures the speed of sound in the material and the probe zero point (the acoustic time from the probe wafer to the point of incidence). Eliminating the influence of sound velocity and zero point on the calculation parameters of instrument sound path, horizontal distance, vertical distance and the like;
2.2) inputting a nominal angle or a K value of the probe;
2.3) measuring the length of the front edge of the probe and inputting the length into an instrument;
2.4) inputting a nominal angle or a K value of the probe;
2.5) adjusting the instrument proportion by using a standard test block or a reference test block (CSK IIIA and the like);
and 2.6) finding the defect distance corresponding to the highest echo of the defect during scanning, and marking the position of the defect on the workpiece.
taking the specific position of the defect equivalent maximum surface for flaw detection positioning as a reference surface (central surface), extending by 55mm up and down or left and right, taking a tensile sample blank sample, wherein the size of the tensile sample is according to the position of the defect, as shown in figures 3 and 4;
processing a stretched blank sample:
grinding the gauge length until the size requirement is met, wherein the precision and the roughness meet the standard of a sample; the sample should be protected from work surface hardening, bending, deformation, strain, scratches, etc. during the machining process. The processing sample size is 1# and 2# tensile sample, and the 2# tensile sample processing step (R4) can also be directly used for tensile test by using a tensile sample blank sample, as shown in FIGS. 5 and 6.
analysis from a hardness perspective: and (3) softening and annealing the material with the hardness of more than or equal to 300HB at the annealing temperature of AC 1-20-30 ℃, wherein the annealed sample can be a flaw detection defect large sample or a tensile sample blank sample shown in the first drawing and the second drawing. The hardness after annealing is less than or equal to 280 HB;
the hardness of the material is less than or equal to 280HB, and heat treatment is not required.
And 4, performing a tensile test, comprising the following steps:
1. selecting a ZWICK model Z600E tensile testing machine;
2. the check sample corresponds to the serial number;
3. measuring the average value according to the standard, calculating the cross section area, and marking a slight gauge length on the sample by using a gauge length dotting machine (the fracture performance of the sample is not influenced by gauge length points);
4. the stretching speed is set uniformly, and a relatively slow speed is selected to prevent the stretching speed from being too fast and not breaking at the flaw detection position. The elastic segment was set at 10MPa/S, the yield stage was set at 0.0008/S and after yielding was set at 0.005/S.
And 5, observing the tensile fracture, directly observing the fracture morphology, finding the defects, comparing the change of tensile property, carrying out targeted analysis, and determining the properties of the defects, thereby specifically evaluating the damage of the defects, improving the process in time and stabilizing the product quality.
And (4) fracture observation: in general, defects such as porosity, and shrinkage can be seen in stretch breaks. Large inclusion particles and their distribution are observed directly on tensile fractures.
Fracture analysis: the extension direction of the crack in the stretching process is carried out along the area with the minimum energy consumption (namely the weakest atomic bonding force) and is related to the direction of the maximum stress, the flaw detection defects in the steel destroy the continuity of a matrix, the fracture is the part with the weakest material performance or the strongest stress, the defects of inclusion, shrinkage cavity, white spot, air hole, crack, component segregation and the like can be found by observing the stretching fracture, and the size, distribution and influence of the defects on the mechanical performance are intuitively observed
The tensile fracture surface can be roughly divided into three regions: a fibrous zone, an irradiation zone, and a shear lip zone. If the content of large-size inclusions in a sample is high, the continuity of a matrix is obviously influenced, the inclusions and the matrix drop off at the stage of forming a large number of microcrack shrinkage cavities along with the action of external load, the size of formed cracks is large, microcracks are quickly linked to grow, and finally, the cracks occur at the position with large size of the inclusions.
The tensile sample has the defects of white spots, bubbles, shrinkage cavities, cracks and the like, and can directly influence the initiation and expansion modes of the cracks, so that the fracture characteristics of the sample are influenced, and meanwhile, the existence of a large amount of nonmetallic inclusions, cracks and holes is also the main reason for reducing the plasticity and the surface shrinkage of the material.
In the stretching process, due to the fact that abnormal structures such as M, MA at the composition segregation positions are large in number and dense, the local elastic limit is increased, plastic deformation is limited, the surrounding non-segregation areas yield and release stress increased externally through plastic deformation, fracture occurs when the stress of local fracture is achieved as the stress of the segregation areas is increased continuously, plastic deformation does not occur or rarely occurs before the segregation positions fracture, and quasi-cleavage stripes are generated.
In order to further analyze the defect characteristics, the EDS analysis is combined, the defect appearance, characteristics and components are analyzed in detail, the defects are accurately determined, and a direction is provided for defect hazard assessment and process improvement.
The following is a description of a specific primary flaw detection test:
workpiece: 42CrMo4 ring member: Φ 3000mm 300mm 200mm, hardness: 260-275 HB, locally discovering intensive defects by flaw detection, and detecting the maximum flat bottom hole equivalent phi of 1.3 mm.
1) Preparation for flaw detection
Flaw detection equipment: CTS-9009
A probe: 2.5P20
Coupling agent: engine oil
The flaw detection method comprises the following steps: flaw detection by a straight probe contact method; and phi 2-6dB flat bottom hole equivalent is taken as flaw detection sensitivity.
2) Flaw detection positioning
Firstly, the sound velocity in the material detected by the instrument and the probe zero point (the sound velocity between the probe wafer and the incidence point) are calibrated.
② testing the probe sound beam axis deviation
And thirdly, finding the defect distance corresponding to the highest echo of the defect during scanning, and marking the position of the defect on the workpiece.
3) Specific location of defect
And the plane corresponding to the position of the probe corresponding to the highest echo of the defect and the defect indication distance is the suspected flaw detection defect surface.
And (3) observing a tensile sample and a fracture:
taking a suspected flaw detection defect surface as a reference surface, taking a position corresponding to the center of a probe as a circle center, taking a phi 25 or phi 30 sample blank sample, processing the sample into a No. 2 tensile sample, and selecting 4 ring pieces, and taking 1 tensile sample respectively. The equivalent weight of the flat bottom hole with the largest flaw detection defect is phi 2.9.
The white substances of the fracture of the 1# to 4# samples are mainly Al2O3 non-metal inclusions through EDS (electron-dispersive spectroscopy) spectral analysis, and the inclusions are nodule substances of a tundish nozzle in continuous casting and are related to insufficient insertion depth of the tundish nozzle through production process investigation. The tensile fracture inclusion length of the sample No. 1 accounts for more than 70% of the total fracture surface length, and the tensile fracture inclusion length of the sample No. 4 is not long, but the inclusion is relatively wide, so that the strength, elongation and reduction of fracture surface of the two samples are poor. The 2# sample is mingled with the stretched edge, so the performance is not good, the cross section of the 3# sample can show that the mingling is very small, and the influence on the performance of the sample is not great on the cross section of 3 very small mingled impurities which are dispersedly distributed. The drawing curves of 1# to 4# are shown in FIG. 7, and the mechanical properties are shown in the following table.
| Sample number | RP0.2 Mpa | Rm Mpa | A50 | Z％ | |
| 1# | 617 | 828 | 14.0 | 26 | |
| 2# | 617 | 822 | 19.0 | 35 | |
| 3# | 659 | 859 | 20.5 | 48 | |
| 4# | 624 | 835 | 11.5 | 25 |
The invention has been described above with reference to the accompanying drawings, and it is obvious that the invention is not limited to the specific implementation in the above-described manner, and it is within the scope of the invention to adopt various insubstantial modifications of the inventive method concept and solution, or to apply the inventive concept and solution directly to other applications without modification.
Claims (8)
1. An ultrasonic flaw detection method is characterized in that: the method comprises the following steps:
step 1, ultrasonic flaw detection positioning: finding out the specific position of the defect by ultrasonic flaw detection positioning;
step 2, sampling and sample preparation: taking the surface with the maximum equivalent of flaw detection defect as a reference surface, taking the corresponding position of the center of the probe as the circle center, respectively extending the rated length up and down, taking a tensile sample blank sample with the rated diameter, and processing the blank sample into a round bar or a square bar;
step 3, sample heat treatment: carrying out softening annealing treatment;
step 4, tensile test;
step 5, fracture observation and analysis: and observing the tensile fracture to find the defect, and comparing the change of the tensile property, thereby obtaining the property of determining the defect.
2. The ultrasonic flaw detection method according to claim 1, characterized in that: the step 1 comprises the positioning of defects during flaw detection by a straight probe and the positioning of defects during flaw detection by an inclined probe;
the defect positioning method during flaw detection of the straight probe comprises the following steps of:
1) setting initial parameters of an ultrasonic instrument;
2) calibrating the ultrasonic instrument;
3) determining the bottom wave or reference sensitivity of detection, and increasing the sensitivity of compensation or making an AVG curve on the basis of the sensitivity;
4) testing the deviation of the sound beam axis of the probe, and adjusting the probe to ensure that the defect is positioned on the central axis of the probe, wherein the depth of the defect is the reading displayed at the highest wave position of the current instrument;
5) marking a defect position on the workpiece;
the positioning of the oblique probe during flaw detection comprises the following steps:
1) setting initial parameters of an instrument;
2) inputting a nominal angle or a K value of the probe;
3) measuring the length of the front edge of the probe and inputting the length into an instrument;
4) inputting a nominal angle or a K value of the probe;
5) adjusting the instrument ratio by using a standard test block or a reference test block;
6) and marking a defect position on the workpiece.
3. The ultrasonic flaw detection method according to claim 1, characterized in that: the step 2 comprises the following steps:
1) taking the defect position on the workpiece obtained in the step 1 as a reference surface, extending the defect position by 55mm up and down or left and right, and taking a phi 25 or phi 30 tensile sample blank sample;
2) processing the tensile sample blank sample into a round bar with phi 10mm and phi 15mm, a square bar or other shapes required by tensile tests;
3) the processed size, precision and roughness meet the standard of a sample, and the phenomena of surface hardening, bending, deformation, sprain and scratch of the processed surface are prevented in the processing process.
4. The ultrasonic flaw detection method according to claim 1, characterized in that: in the step 3, aiming at the material hardness of the workpiece, if the hardness is more than or equal to 300HB, softening and annealing treatment is carried out, the annealing temperature is AC 1-20-30 ℃, and the hardness after annealing is less than or equal to 280 HB; if the hardness is < 300HB, no heat treatment is required.
5. The ultrasonic flaw detection method according to claim 1, characterized in that: the step 4 comprises the following steps:
1) selecting a ZWICK model Z600E tensile testing machine;
2) the check sample corresponds to the serial number;
3) measuring the average value according to the standard, calculating the area of the cross section, and marking a slight gauge length on the sample by using a gauge length dotting machine;
4) the stretching rate was set to be uniform, the elastic segment was set to 10MPa/S, the yield stage was set to 0.0008/S, and after yielding was set to 0.005/S.
6. The ultrasonic flaw detection method according to claim 1, characterized in that: in step 5, the fracture is observed: if visible holes appear, the defects of looseness, pores and shrinkage cavities exist;
and (3) fracture analysis: if the tensile fracture is observed, defects of inclusion, shrinkage cavity, white point, air hole, crack and component segregation are found, and the size, distribution and influence on mechanical performance of the defects are visually observed.
7. The ultrasonic flaw detection method according to claim 6, characterized in that: in the step 5:
if the content of large-size inclusions in the sample is high, large cracks can be formed, and the part with the highest content of the inclusions is broken;
if white spots, bubbles, shrinkage cavities and crack defects exist in the sample, the plasticity and the surface shrinkage of the material are reduced;
if the sample has an abnormal structure defect at the position of component segregation, no or little plastic deformation occurs at the fracture position, and a quasi-cleavage streak is generated.
8. The ultrasonic flaw detection method according to claim 7, characterized in that: in the step 5, the defect characteristics are further analyzed, EDS analysis is combined, the appearance, characteristics and components of the defect are analyzed in detail, the defect is accurately determined, and a direction is provided for defect hazard assessment and process improvement.
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| Application Number | Priority Date | Filing Date | Title |
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| CN113884378A (en) * | 2021-08-19 | 2022-01-04 | 广州Jfe钢板有限公司 | A method for rapid detection of segregation in thin steel sheets after annealing with unidirectional strain |
| CN113960163A (en) * | 2021-09-26 | 2022-01-21 | 江苏裕隆锻造有限公司 | Inspection and analysis method for heat treatment cracks of 30CrMo valve body |
| CN114674922A (en) * | 2022-03-07 | 2022-06-28 | 江苏联峰能源装备有限公司 | Ultrasonic detection low-power evaluation method for large-size continuous casting round billet |
| CN115014900A (en) * | 2022-06-21 | 2022-09-06 | 湖南华菱湘潭钢铁有限公司 | A method for analyzing internal defects of iron and steel materials |
| CN116787082A (en) * | 2023-07-31 | 2023-09-22 | 中航试金石检测科技(西安)有限公司 | Processing methods for compact tensile specimens for fracture toughness |
| CN119715636A (en) * | 2025-02-26 | 2025-03-28 | 有研金属复合材料(北京)股份公司 | Analysis and detection method for defects of large-size aluminum alloy round ingot |
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