CN118883719B - Nondestructive inspection method and system for metal castings - Google Patents
Nondestructive inspection method and system for metal castings Download PDFInfo
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- G01N29/04—Analysing solids
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- G—PHYSICS
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- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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- G01N29/44—Processing the detected response signal, e.g. electronic circuits specially adapted therefor
- G01N29/4409—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison
- G01N29/4436—Processing the detected response signal, e.g. electronic circuits specially adapted therefor by comparison with a reference signal
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- G—PHYSICS
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Abstract
The invention relates to the field of metal ultrasonic detection, in particular to a nondestructive inspection method and system for metal castings, which comprise the steps of comparing ultrasonic detection time with variation differences of ultrasonic signals inside and outside an ultrasonic inspection time interval to obtain ultrasonic signal sensitivity, analyzing direction distribution conditions of positions among different metal surface detection areas based on the ultrasonic signal sensitivity to obtain reference metal defect detection areas, comparing stable variation differences of ultrasonic signal distribution among different reference metal defect detection areas in the ultrasonic inspection time interval, combining distance distribution between the metal surface detection areas and the different reference metal defect detection areas to obtain defect signal association, and adaptively adjusting noise threshold values according to the defect signal association and the ultrasonic signal sensitivity to perform nondestructive inspection. The invention reduces the loss of the real damage information of the metal castings and improves the accuracy of the flaw detection result of the metal castings.
Description
Technical Field
The invention relates to the field of metal ultrasonic detection, in particular to a nondestructive inspection method and system for metal castings.
Background
Among existing metal casting detection techniques, a nondestructive inspection technique is an important quality control means. The technology can detect defects such as air holes, inclusions, cracks and the like in the metal casting without damaging the metal casting, thereby ensuring the safety of the metal casting. In order to ensure the detection efficiency of the metal casting under the conventional condition, a certain area is sampled and screened on the surface of the metal casting for ultrasonic flaw detection. When the ultrasonic flaw detector is used for detecting the metal surface area, a certain amount of random noise is generated due to electromagnetic interference of electronic elements in the ultrasonic flaw detector, and the random noise can interfere accurate expression of ultrasonic signal data on the ultrasonic flaw detector, so that accuracy of flaw detection results of metal castings is reduced.
The existing data denoising algorithm is usually manually preset with a denoising threshold value of the denoising algorithm according to experience conditions, so that ultrasonic signal data representing damage of a metal casting can be excessively denoised when an ultrasonic flaw detector detects a part of metal surface areas, partial metal casting damage information is lost, and the precision of a metal casting flaw detection result is reduced.
Disclosure of Invention
The invention provides a nondestructive inspection method and a nondestructive inspection system for a metal casting, which aim to solve the existing problem that the existing data denoising algorithm is usually manually preset with a denoising threshold value of the denoising algorithm according to experience conditions and cannot be adjusted according to actual conditions of surface areas of the metal casting, so that effective information of part of the metal casting is lost.
The invention relates to a nondestructive inspection method and a nondestructive inspection system for metal castings, which adopt the following technical scheme:
The invention provides a nondestructive inspection method for metal castings, which comprises the following steps:
acquiring ultrasonic signal data of each metal surface detection area under different ultrasonic detection time;
Dividing other ultrasonic detection moments at two sides of the ultrasonic detection moment to obtain an ultrasonic flaw detection time interval of the ultrasonic detection moment, and comparing the variation difference of ultrasonic signals between the ultrasonic detection moment and other ultrasonic detection moments inside and outside the ultrasonic flaw detection time interval on the same metal surface detection region to obtain ultrasonic signal sensitivity of the metal surface detection region;
Based on the comprehensive analysis of the stable change condition of ultrasonic signal data and ultrasonic signal sensitivity in an ultrasonic flaw detection time interval at the ultrasonic detection time, screening a plurality of reference metal defect detection areas under each ultrasonic detection time from all metal surface detection areas according to the direction distribution condition of the positions among different metal surface detection areas;
Comparing the stable variation difference of the ultrasonic signal distribution in the ultrasonic flaw detection time interval between different reference metal flaw detection areas, and combining the distance distribution between the metal surface detection areas and the different reference metal flaw detection areas to obtain the correlation degree of the flaw signals at each ultrasonic detection time;
combining the defect signal association degree with the ultrasonic signal sensitivity to obtain a noise adjustment factor at each ultrasonic detection time, adaptively adjusting a noise threshold according to the noise adjustment factors, and performing nondestructive inspection.
Preferably, the method for acquiring the ultrasonic signal sensitivity comprises the following steps:
Comparing the difference of ultrasonic signal data between the ultrasonic detection time of the target and the whole ultrasonic detection time under the same metal surface detection area to obtain the significance of the process trace of the metal surface detection area at different ultrasonic detection times;
in an ultrasonic flaw detection time interval of the target ultrasonic detection time, analyzing the difference of ultrasonic signal data between the target ultrasonic detection time and other ultrasonic detection time to obtain flaw detection ultrasonic information deviation degrees of the metal surface detection area at different ultrasonic detection times;
and obtaining the ultrasonic signal sensitivity of the metal surface detection area according to the process trace significance and the flaw detection ultrasonic information deviation.
Preferably, the method for obtaining the significance of the process trace comprises the following steps:
acquiring the data average value of ultrasonic signals at all ultrasonic detection moments;
And comparing the difference between the ultrasonic signal data and the ultrasonic signal data mean value at the target ultrasonic detection time to obtain the process trace significance of the metal surface detection area at the target ultrasonic detection time.
Preferably, the method for acquiring the deviation degree of the flaw detection ultrasonic information comprises the following steps:
In an ultrasonic flaw detection time interval of the target ultrasonic detection time, taking other ultrasonic detection times except the target ultrasonic detection time as flaw detection ultrasonic times;
obtaining a local flaw detection signal change value of a target ultrasonic detection time and each flaw detection ultrasonic detection time;
and synthesizing the local flaw detection signal variation values to obtain flaw detection ultrasonic information deviation degree of each metal surface detection area at different ultrasonic detection moments.
Preferably, the method for acquiring the reference metal defect detection area comprises the following steps:
For any ultrasonic detection time, acquiring a defect reference detection area under the ultrasonic detection time according to the stable change condition of ultrasonic signal data and the sensitivity of ultrasonic signals in the ultrasonic flaw detection time interval at the ultrasonic detection time;
and taking any metal surface detection area except the defect reference detection area as a comparison surface area, and screening out a plurality of reference metal defect detection areas under each ultrasonic detection moment in the direction range from the defect reference detection area to the comparison surface area.
Preferably, the method for acquiring the defect reference detection area comprises the following steps:
For any ultrasonic detection time, acquiring an ultrasonic signal standard deviation of each metal surface detection area in an ultrasonic flaw detection time interval of the ultrasonic detection time;
and screening out a defect reference detection area under each ultrasonic detection time from all the metal surface detection areas according to the metal damage reference degree.
Preferably, the method for obtaining the correlation degree of the defect signal comprises the following steps:
Comparing the variation difference of the ultrasonic signal distribution stability condition in the ultrasonic flaw detection time interval between different reference metal flaw detection areas at any ultrasonic detection time under the ultrasonic detection time to obtain the consistency of the flaw signals at the ultrasonic detection time;
acquiring detection area distances among different reference metal defect detection areas;
and obtaining the defect signal correlation degree under the ultrasonic detection time according to the defect signal correlation degree and the detection area distance.
Preferably, the method for obtaining the defect signal consistency comprises the following steps:
acquiring the stability of ultrasonic signals of each reference metal defect detection area in an ultrasonic flaw detection time interval;
And obtaining the defect signal consistency under the ultrasonic detection time according to the difference of the ultrasonic signal stability of different reference metal defect detection areas between the ultrasonic detection time intervals.
Preferably, the method for obtaining the noise adjustment factor is as follows:
And for any ultrasonic detection time, obtaining a noise adjustment factor of each metal surface detection area at the ultrasonic detection time according to the product of the ultrasonic signal sensitivity of each metal surface detection area and the defect signal correlation degree at the ultrasonic detection time.
The invention also provides a nondestructive inspection system for the metal castings, which comprises a memory and a processor, wherein the processor executes a computer program stored in the memory so as to realize the steps of the nondestructive inspection method for the metal castings.
The technical scheme of the invention has the advantages that the ultrasonic detection time is divided into an ultrasonic flaw detection time interval, and the ultrasonic signal sensitivity of a metal surface detection area is obtained by comparing the ultrasonic detection time with the change difference of ultrasonic signals inside and outside the ultrasonic flaw detection time interval, wherein the ultrasonic signal sensitivity better reflects the complex condition of the internal material space of a casting of the metal surface detection area;
The method comprises the steps of obtaining a plurality of reference metal defect detection areas according to the directional distribution condition of positions among different metal surface detection areas, comparing the stable variation difference of ultrasonic signal distribution in ultrasonic flaw detection time intervals among different reference metal defect detection areas, combining the distance distribution among the metal surface detection areas and different reference metal defect detection areas to obtain the defect signal correlation degree under each ultrasonic detection moment, wherein the defect signal correlation degree better reflects the similarity condition of the structure characteristics of the internal material structure of the reference metal surface detection areas and the surrounding space at the ultrasonic detection moment, then adaptively adjusting a noise threshold according to the defect signal correlation degree and the sensitivity of the ultrasonic signal, and carrying out nondestructive flaw detection.
Drawings
In order to more clearly illustrate the embodiments of the invention or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, it being obvious that the drawings in the following description are only some embodiments of the invention, and that other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a flow chart of the steps of a method for non-destructive inspection of metal castings according to the present invention;
FIG. 2 is a schematic view of an ultrasonic flaw detector of the present invention;
FIG. 3 is a schematic diagram of the flaw detection process of the metal flaw detector of the present invention;
FIG. 4 is a schematic view of internal defects of a metal surface detection zone according to the present invention;
FIG. 5 is a schematic diagram of a conventional process trace of the present invention versus a true defect of a metal casting;
FIG. 6 is a schematic view of the internal defect peripheral cracks of the metal casting of the present invention.
Detailed Description
In order to further describe the technical means and effects adopted by the invention to achieve the preset aim, the following description refers to the specific implementation, structure, characteristics and effects of a nondestructive inspection method and system for metal castings according to the invention in detail by combining the accompanying drawings and preferred embodiments. In the following description, different "one embodiment" or "another embodiment" means that the embodiments are not necessarily the same. Furthermore, the particular features, structures, or characteristics of one or more embodiments may be combined in any suitable manner.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.
The invention provides a nondestructive inspection method and a nondestructive inspection system for metal castings.
Referring to fig. 1, a flowchart of steps of a nondestructive inspection method for metal castings according to an embodiment of the present invention is shown, the method includes the steps of:
And S001, acquiring ultrasonic signal data of each metal surface detection area under different ultrasonic detection time.
It should be noted that, the existing data denoising algorithm generally presets the denoising threshold value of the denoising algorithm manually according to experience conditions, so that the ultrasonic flaw detector may excessively denoise ultrasonic signal data representing damage of the metal casting when detecting part of metal surface areas, and part of damage information of the metal casting is lost, thereby reducing the precision of flaw detection results of the metal casting. Referring to fig. 2, a schematic diagram of an ultrasonic flaw detector is shown. Referring to fig. 3, a schematic diagram of a flaw detection process of a metal flaw detector is shown, wherein a gray rectangle represents an ultrasonic flaw detector, a broken line arrow represents ultrasonic waves emitted by the ultrasonic flaw detector, and a rectangular side indicated by an arrow of a metal casting surface represents the metal casting surface.
In a specific implementation manner of the embodiment of the invention, the method for acquiring the ultrasonic signal data comprises the steps of presetting the number of areasEqually dividing the surface of a metal casting intoA metal surface detection area, in which any one of the metal surface detection areas is used as an example, an ultrasonic flaw detector is usedThe ultrasonic detection method comprises the steps of (1) detecting the flaw at a constant speed, recording ultrasonic signal data displayed on an ultrasonic flaw detector once every 1 second, obtaining ultrasonic signal data of a metal surface detection area under all ultrasonic detection moments until the ultrasonic flaw detector detects all areas of the metal surface detection area, and obtaining the ultrasonic signal data of each metal surface detection area under all ultrasonic detection moments.
It should be noted that, before the ultrasonic flaw detector detects a flaw on the next new metal surface detection area, the embodiment re-records the sequence of ultrasonic detection time so that the number of ultrasonic detection time in each metal surface detection area is consistent, and when the embodiment subsequently analyzes any one ultrasonic detection time, there is an ultrasonic detection time corresponding to each metal surface detection area.
In particular, the present embodiment usesThe present embodiment is not specifically limited, and will be described by way of exampleThe speed of movement of the ultrasonic flaw detector, the time interval for recording data can be determined according to the specific implementation.
So far, the ultrasonic signal data of each metal surface detection area under different ultrasonic detection time points are obtained through the method.
And step S002, dividing other ultrasonic detection time points at two sides of the ultrasonic detection time point to obtain an ultrasonic flaw detection time interval of the ultrasonic detection time point, and comparing the variation difference of ultrasonic signals between the ultrasonic detection time point and other ultrasonic detection time points inside and outside the ultrasonic flaw detection time interval on the same metal surface detection area to obtain the ultrasonic signal sensitivity of the metal surface detection area.
It should be noted that, when the ultrasonic flaw detector is used to detect the flaw of the metal casting, the ultrasonic flaw detector moves to different metal surface positions along with the advancement of the ultrasonic detection time, in normal cases, if a defect exists in the metal casting, the defect part sometimes covers the metal surface positions adjacent to a plurality of ultrasonic detection times, please refer to fig. 4, which shows a schematic diagram of the internal defect of the metal surface detection area, wherein t1, t2 and t3 respectively represent the metal casting surface positions at the t1 st ultrasonic detection time, the t2 nd ultrasonic detection time and the t3 rd ultrasonic detection time when the ultrasonic flaw detector detects the same metal surface detection area, and the rectangular edge indicated by the arrow on the metal casting surface represents the metal casting surface. Therefore, other ultrasonic detection moments at two sides of the ultrasonic detection moment can be divided, an ultrasonic flaw detection time interval of the ultrasonic detection moment is obtained, and the subsequent distinction of the metal surface area with the defects is facilitated.
It should be further noted that, under conventional circumstances, the defect portion inside the metal casting may destroy the uniform distribution of the substances inside the normal metal casting, so that the defect portion itself has a certain irregular area surface, and when the metal flaw detector passes over the surface of the metal casting corresponding to the defect portion, the ultrasonic information received by the metal flaw detector has a larger fluctuation, so that the corresponding detected ultrasonic signal data has a larger change. The ultrasonic signal sensitivity of the metal surface detection area can be obtained by comparing the variation difference of ultrasonic signals between the ultrasonic detection time and other ultrasonic detection time within and outside the ultrasonic flaw detection time interval, wherein if the ultrasonic signal sensitivity is larger, the more complex the condition of the internal substance space of the casting of the metal surface detection area is indicated, and the more likely the internal damage of the metal surface detection area is reflected.
The process of obtaining the ultrasonic flaw detection time interval is as follows:
Presetting an ultrasonic detection time quantity Taking any ultrasonic detection time as an example, the ultrasonic detection time is precededUltrasonic detection time and after the ultrasonic detection timeAnd the time period formed by the ultrasonic detection time is taken as an ultrasonic flaw detection time interval of the ultrasonic detection time. And acquiring an ultrasonic flaw detection time interval of each ultrasonic detection time. Wherein the present embodiment usesThe present embodiment is not specifically limited, and will be described by way of exampleDepending on the particular implementation.
In particular, if the number of actual ultrasonic detection times before and after the ultrasonic detection time does not satisfy the preset valueAnd acquiring an ultrasonic flaw detection time interval of the ultrasonic detection time according to the number of the ultrasonic detection times actually existing before and after the ultrasonic detection time.
Preferably, in some implementation modes of the embodiment of the invention, the ultrasonic signal sensitivity acquisition method comprises the steps of taking any ultrasonic detection time as a target ultrasonic detection time, comparing ultrasonic signal data differences between the target ultrasonic detection time and the whole ultrasonic detection time under the same metal surface detection area to obtain the process trace significance of the metal surface detection area at different ultrasonic detection times, analyzing the ultrasonic signal data differences between the target ultrasonic detection time and other ultrasonic detection times in an ultrasonic flaw detection time interval of the target ultrasonic detection time to obtain flaw detection ultrasonic information deviation of the metal surface detection area at different ultrasonic detection times, and obtaining the ultrasonic signal sensitivity of the metal surface detection area according to the process trace significance and the flaw detection ultrasonic information deviation. The specific process is as follows:
1. and obtaining the significance of the process trace.
It should be noted that, in the same metal surface detection area, besides the internal defects of the metal casting, conventional process traces generated in the casting process of the metal may be remained, for example, the fusible crystal in the metal casting may not be completely melted to remain a certain amount of crystalline particles, and the conventional process traces do not affect the conventional use of the metal casting and are generally divided into allowable defect ranges, and the conventional process traces also cause corresponding ultrasonic signal data to generate a certain range fluctuation, and the number of corresponding ultrasonic detection moments is smaller because the crystalline particles are smaller. Referring to FIG. 5, a schematic diagram of a conventional process trace in comparison to a real defect of a metal casting is shown, wherein the rectangle indicated by the arrow on the surface of the metal casting represents the surface of the metal casting. Therefore, the difference of ultrasonic signal data between the ultrasonic detection time and the whole ultrasonic detection time of the target can be compared under the same metal surface detection area, and the process trace significance of the metal surface detection area at different ultrasonic detection times can be obtained. Wherein the greater the degree of process trace significance, the more obvious the trace containing conventional processes in the metal surface detection area, the more likely the internal damage that reflects the metal surface detection area is erroneously identified.
Preferably, in some implementation manners of the embodiment of the invention, the method for acquiring the process trace saliency comprises the steps of acquiring an ultrasonic signal data average value under all ultrasonic detection time, and comparing the difference between the ultrasonic signal data under the target ultrasonic detection time and the ultrasonic signal data average value to obtain the process trace saliency of the metal surface detection area on the target ultrasonic detection time. The specific process is as follows:
Taking any metal surface detection area as an example, taking the average value of ultrasonic signal data at all ultrasonic detection moments as the average value of the ultrasonic signal data in the metal surface detection area, and taking the absolute value of the difference value between the ultrasonic signal data at the target ultrasonic detection moment and the average value of the ultrasonic signal data as the process trace significance of the metal surface detection area at the target ultrasonic detection moment. And acquiring the significance of the process trace of each metal surface detection area at different ultrasonic detection time.
It should be noted that, if the process trace is more significant, it is indicated that the trace containing the conventional process in the metal surface detection area is more obvious, and it is reflected that the metal surface detection area is more likely to have an internal damage which is erroneously identified.
2. And obtaining the deviation degree of flaw detection ultrasonic information.
It should be noted that if a defect area exists in the metal casting, a certain trace of cracks may exist around the defect area, the fluctuation of the crack on the corresponding ultrasonic signal data is small, if random noise is distributed on the ultrasonic signal data, the defect information represented by the crack is lost in the denoising process, and the cracks are distributed around the defect area, so that the cracks are generally contained in the metal surface corresponding to the ultrasonic flaw detection time interval. Referring to FIG. 6, a schematic view of a peripheral crack of an internal defect of a metal casting is shown. Therefore, the difference of ultrasonic signal data between the target ultrasonic detection time and other ultrasonic detection time can be analyzed in the ultrasonic flaw detection time interval of the target ultrasonic detection time, and flaw detection ultrasonic information deviation degree of the metal surface detection area at different ultrasonic detection times can be obtained. The larger the deviation of the flaw detection ultrasonic information is, the more likely to have fine internal cracks in the detection area of the metal surface is.
Preferably, in some implementation modes of the embodiment of the invention, the method for acquiring the deviation degree of the flaw detection ultrasonic information comprises the steps of taking other ultrasonic detection moments except the target ultrasonic detection moment as the flaw detection ultrasonic moment in an ultrasonic flaw detection time interval of the target ultrasonic detection moment, acquiring local flaw detection signal variation values of the target ultrasonic detection moment and each flaw detection ultrasonic detection moment, and synthesizing the local flaw detection signal variation values to acquire the deviation degree of the flaw detection ultrasonic information of each metal surface detection region at different ultrasonic detection moments. The specific process is as follows:
In the metal surface detection area, the absolute value of the difference value of ultrasonic signal data between the target ultrasonic detection time and each flaw detection ultrasonic detection time is used as the local flaw detection signal change value of the target ultrasonic detection time and each flaw detection ultrasonic detection time, and the average value of the local flaw detection signal change values of the target ultrasonic detection time and all flaw detection ultrasonic detection times is used as the flaw detection ultrasonic information deviation degree of the metal surface detection area at the target ultrasonic detection time. And acquiring flaw detection ultrasonic information deviation degree of each metal surface detection area in different ultrasonic detection time.
The larger the deviation of the flaw detection ultrasonic information is, the more likely the fine internal cracks exist in the detection area of the metal surface.
3. Ultrasound signal sensitivity is acquired.
As one example, the ultrasound signal sensitivity may be calculated by the following formula:
In the formula, Represent the firstUltrasonic signal sensitivity of the individual metal surface detection zones; Is shown in the first The number of all ultrasonic detection moments in the individual metal surface detection areas; Represent the first The metal surface detection area is at the firstProcess trace saliency at each ultrasonic detection time; Represent the first The metal surface detection area is at the firstDeviation degree of flaw detection ultrasonic information at each ultrasonic detection time.
It should be noted that, if the sensitivity of the ultrasonic signal is larger, the more complex the space formation condition of the internal substance of the casting of the metal surface detection region is, the more likely the internal damage of the metal surface detection region is reflected.
So far, the ultrasonic signal sensitivity of each metal surface detection area is obtained through the method.
Step S003, based on the comprehensive analysis of the stable change condition of ultrasonic signal data and ultrasonic signal sensitivity in the ultrasonic flaw detection time interval at the ultrasonic detection time, a plurality of reference metal defect detection areas under each ultrasonic detection time are screened out from all metal surface detection areas according to the directional distribution condition of the positions among different metal surface detection areas.
It should be noted that, the defects existing in the metal casting generally extend along a certain direction, so that the ultrasonic signal data on the corresponding area of the surface of the metal casting is relatively easier to generate larger fluctuation, and the data is more unstable. Based on the stable change condition of ultrasonic signal data and the comprehensive analysis of ultrasonic signal sensitivity in the ultrasonic flaw detection time interval at the ultrasonic detection time, a plurality of reference metal defect detection areas under each ultrasonic detection time are screened out from all metal surface detection areas according to the directional distribution condition of the positions among different metal surface detection areas.
Preferably, in some implementation manners of the embodiment of the invention, the method for acquiring the reference metal defect detection area comprises the steps of acquiring a defect reference detection area under ultrasonic detection according to stable change condition of ultrasonic signal data and ultrasonic signal sensitivity of the ultrasonic detection time in an ultrasonic flaw detection time interval for any ultrasonic detection time, taking any metal surface detection area except the defect reference detection area as a comparison surface area, and screening out a plurality of reference metal defect detection areas under each ultrasonic detection time in a direction range from the defect reference detection area to the comparison surface area. The specific process is as follows:
1. and acquiring a defect reference detection area.
It should be noted that in the process of extending the defect existing in the metal casting, the defect generally extends in a fluctuation manner from a certain area within a certain direction range, and the damage condition of the defect to the material space in the metal casting is gradually reduced, so that the defect reference detection area under each ultrasonic detection time can be obtained according to the stable change condition of ultrasonic signal data and the sensitivity of the ultrasonic signal in the ultrasonic detection time interval, and the initial metal surface area where the defect begins to extend is represented.
Preferably, in some implementation manners of the embodiment of the invention, the defect reference detection area acquisition method comprises the steps of acquiring an ultrasonic signal standard deviation of each metal surface detection area in an ultrasonic flaw detection time interval of ultrasonic detection time for any ultrasonic detection time, acquiring metal damage reference degree of each metal surface detection area according to the ultrasonic signal standard deviation and ultrasonic signal sensitivity, and screening out the defect reference detection area under each ultrasonic detection time from all the metal surface detection areas according to the metal damage reference degree. The specific process is as follows:
Taking any metal surface detection area as an example, taking the standard deviation of all ultrasonic signal data in the metal surface detection area in an ultrasonic flaw detection time interval at the ultrasonic detection time as the standard deviation of the ultrasonic signal in the metal surface detection area at the ultrasonic detection time, and taking the product of the standard deviation of the ultrasonic signal and the sensitivity of the ultrasonic signal in the metal surface detection area as the metal damage reference degree of the ultrasonic detection time in the metal surface detection area.
Further, acquiring metal damage reference degrees in all metal surface detection areas at the ultrasonic detection moment, and taking the metal surface detection area with the maximum metal damage reference degree as a defect reference detection area under the ultrasonic detection moment.
2. And acquiring a reference metal defect detection area.
Taking any one comparison surface area as an example, taking the point of the ultrasonic detection moment on the defect reference detection area as a defect starting point, taking the point of the ultrasonic detection moment on the comparison surface area as a defect ending point, and taking a line segment between the defect starting point and the defect ending point as a defect direction datum line.
Further, a degree is presetClockwise rotating the defect direction reference line by taking the defect starting point as a starting pointThe back ray is taken as a clockwise boundary line, and the defect direction datum line is rotated anticlockwiseThe back ray is taken as a anticlockwise boundary, an included angle area formed by the clockwise boundary and the anticlockwise boundary is taken as a defect reference extension area, and each metal surface detection area through which the defect reference extension area passes is taken as a reference metal defect detection area under the ultrasonic detection time. And acquiring a plurality of reference metal defect detection areas under each ultrasonic detection time. Wherein the present embodiment usesThe present embodiment is not specifically limited, and will be described by way of exampleDepending on the particular implementation.
So far, a plurality of reference metal defect detection areas under each ultrasonic detection time are obtained through the method.
Step S004, comparing the stable variation difference of the ultrasonic signal distribution in the ultrasonic flaw detection time interval between different reference metal flaw detection areas, and combining the distance distribution between the metal surface detection areas and different reference metal flaw detection areas to obtain the correlation degree of the flaw signals at each ultrasonic flaw detection time.
It should be noted that, for any defect damage existing in the metal casting, the defect damage damages the structural distribution of the material space in the metal casting, and changes the stress condition of the material space in the metal casting where the defect damage is located, so that the material space around the defect damage is more easily damaged. Therefore, the stable variation difference of the distribution of ultrasonic signals in the ultrasonic flaw detection time interval between different reference metal flaw detection areas can be compared, and the correlation degree of the flaw signals at each ultrasonic flaw detection time can be obtained by combining the distance distribution between the metal surface detection areas and the different reference metal flaw detection areas. The higher the correlation of the defect signals, the more similar the internal substance structure under the surface position in the reference metal surface detection area at the corresponding ultrasonic detection moment is to the structure characteristics in the surrounding space, and the more likely the internal defects are reflected under the surface position in the reference metal surface detection area at the corresponding ultrasonic detection moment.
Preferably, in some implementation manners of the embodiment of the invention, the defect signal correlation obtaining method includes comparing variation differences of ultrasonic signal distribution stability conditions in ultrasonic flaw detection time intervals between different reference metal defect detection areas at any ultrasonic detection time to obtain defect signal continuity at the ultrasonic detection time, obtaining detection area distances between different reference metal defect detection areas, and obtaining the defect signal correlation at the ultrasonic detection time according to the defect signal continuity and the detection area distances. The specific process is as follows:
1. And obtaining the defect signal consistency.
It should be noted that the defect existing in the metal casting is usually a closed coherent region, so that the defect signal coherence under the ultrasonic detection time can be obtained by comparing the variation difference of the stable ultrasonic signal distribution condition in the ultrasonic flaw detection time interval between different reference metal defect detection regions under the metal surface detection region. And if the defect signal continuity is larger, the defect area under the corresponding ultrasonic detection time is more consistent.
Preferably, in some implementations of the embodiments of the present invention, the method for obtaining the defect signal consistency includes obtaining an ultrasonic signal stability of each reference metal defect detection area in an ultrasonic flaw detection time interval, and obtaining the defect signal consistency at the ultrasonic flaw detection time according to a difference of ultrasonic signal stabilities of different reference metal defect detection areas between the ultrasonic flaw detection time intervals. The specific process is as follows:
Taking any one reference metal defect detection area as an example, in the reference metal defect detection area, taking an inverse proportion normalization value of all ultrasonic signal data variances in an ultrasonic flaw detection time interval at the ultrasonic detection time as ultrasonic signal stability in the reference metal defect detection area at the ultrasonic detection time.
In particular, the embodiment adoptsThe model presents the inverse proportional relationship and the normalization process,For model input, the implementer may choose the inverse proportion function and the normalization function according to the actual situation.
Further, as an example, defect signal continuity may be calculated by the following formula:
In the formula, Represent the firstDefect signal consistency under ultrasonic detection time; Represent the first The number of all reference metal defect detection areas at each ultrasonic detection time; Represent the first At the first ultrasonic detection timeUltrasonic signal stability in the individual reference metal defect detection areas; Represent the first At the first ultrasonic detection timeUltrasonic signal stability in the individual reference metal defect detection areas; Representing preset super parameters, preset in this example For preventing denominator from being 0; The representation takes absolute value.
It should be noted that, if the defect signal consistency is larger, the description is thatThe more coherent the defect area under each ultrasonic detection time.
2. And obtaining the association degree of the defect signals.
Under the ultrasonic detection time, taking the distance between the centers of any two reference metal defect detection areas as the detection area distance, taking the average value of the distances of all detection areas as the defect distance average value under the ultrasonic detection time, and taking the product of the defect distance average value and the defect signal consistency under the ultrasonic detection time as the defect signal relevance under the ultrasonic detection time.
It should be noted that, if the correlation of the defect signal is larger, it is described that the structure of the internal substance at the surface position in the reference metal surface detection area at the corresponding ultrasonic detection time is more similar to the structure characteristics in the surrounding space, reflecting that the internal defect is more likely to exist at the surface position in the reference metal surface detection area at the corresponding ultrasonic detection time.
So far, the defect signal association degree under each ultrasonic detection time is obtained through the method.
And step S005, combining the defect signal association degree with the ultrasonic signal sensitivity to obtain a noise adjustment factor at each ultrasonic detection time, adaptively adjusting a noise threshold according to the noise adjustment factors, and performing nondestructive inspection.
Preferably, in some implementation manners of the embodiment of the invention, the method for acquiring the noise adjustment factor is that, for any one ultrasonic detection time, the noise adjustment factor of each metal surface detection area under the ultrasonic detection time is obtained according to the product of the ultrasonic signal sensitivity of each metal surface detection area and the correlation degree of the defect signal under the ultrasonic detection time. The specific process is as follows:
Taking any metal surface detection area as an example, taking a normalized value of a product between ultrasonic signal sensitivity of the metal surface detection area and defect signal association degree under the ultrasonic detection time as a noise adjustment factor of the metal surface detection area under the ultrasonic detection time.
In particular, the present embodiment usesThe linear normalization function performs normalization processing, wherein the normalization function can be determined according to specific implementation cases.
Further, taking a noise adjustment factor of the metal surface detection area under the ultrasonic detection time as a weight to be compared with a preset denoising threshold valueAnd denoising the ultrasonic signal data of the metal surface detection region at the ultrasonic detection time by using the self-adaptive denoising threshold value to acquire the denoising ultrasonic signal data of the metal surface detection region at the ultrasonic detection time. And acquiring denoising ultrasonic signal data of each metal surface detection region under each ultrasonic detection time.
In particular, the process of denoising data according to the denoising threshold is a well-known content of denoising algorithm, and this embodiment is described by taking a wavelet denoising algorithm as an example, where the denoising algorithm may be determined according to specific implementation cases.
Further, an ultrasonic signal data amplitude threshold value is obtained from a metal casting damage detection platformWill have a value greater thanAnd marking the damage of each real damage ultrasonic signal data at the position of the metal casting at the ultrasonic detection time to finish damage detection.
Through the steps, the nondestructive inspection method of the metal castings is completed.
Another embodiment of the present invention provides a nondestructive inspection system for metal castings, the system including a memory and a processor that, when executing a computer program stored in the memory, performs the above-described method steps S001 to S005.
The above description is only of the preferred embodiments of the present invention and is not intended to limit the invention, but any modifications, equivalent substitutions, improvements, etc. within the principles of the present invention should be included in the scope of the present invention.
Claims (3)
1. The nondestructive inspection method for the metal castings is characterized by comprising the following steps of:
acquiring ultrasonic signal data of each metal surface detection area under different ultrasonic detection time;
Dividing other ultrasonic detection moments at two sides of the ultrasonic detection moment to obtain an ultrasonic flaw detection time interval of the ultrasonic detection moment, and comparing the variation difference of ultrasonic signals between the ultrasonic detection moment and other ultrasonic detection moments inside and outside the ultrasonic flaw detection time interval on the same metal surface detection region to obtain ultrasonic signal sensitivity of the metal surface detection region;
Based on the comprehensive analysis of ultrasonic signal standard deviation and ultrasonic signal sensitivity of ultrasonic signal data in an ultrasonic flaw detection time interval at ultrasonic detection time, screening a plurality of reference metal defect detection areas under each ultrasonic detection time from all metal surface detection areas according to the directional distribution conditions of positions among different metal surface detection areas;
comparing ultrasonic signal stability of ultrasonic signals in ultrasonic flaw detection time intervals between different reference metal flaw detection areas, and combining distance distribution between the metal surface detection areas and the different reference metal flaw detection areas to obtain a flaw signal association degree at each ultrasonic detection time;
Combining the defect signal association degree with ultrasonic signal sensitivity to obtain a noise adjustment factor at each ultrasonic detection time;
the method for acquiring the ultrasonic signal sensitivity comprises the following steps:
acquiring the data average value of ultrasonic signals at all ultrasonic detection moments;
comparing the difference between the ultrasonic signal data and the ultrasonic signal data mean value at the target ultrasonic detection time to obtain the process trace significance of the metal surface detection area at the target ultrasonic detection time;
In an ultrasonic flaw detection time interval of the target ultrasonic detection time, taking other ultrasonic detection times except the target ultrasonic detection time as flaw detection ultrasonic times;
obtaining a local flaw detection signal change value of a target ultrasonic detection time and each flaw detection ultrasonic detection time;
Synthesizing the local flaw detection signal variation values to obtain flaw detection ultrasonic information deviation degrees of each metal surface detection area at different ultrasonic detection moments;
Obtaining ultrasonic signal sensitivity of a metal surface detection area according to the process trace significance and the flaw detection ultrasonic information deviation;
The method for acquiring the reference metal defect detection area comprises the following steps:
For any ultrasonic detection time, taking the standard deviation of all ultrasonic signal data in each metal surface detection area as the standard deviation of the ultrasonic signal in each metal surface detection area in an ultrasonic flaw detection time interval of the ultrasonic detection time;
screening out defect reference detection areas under each ultrasonic detection time from all metal surface detection areas according to the metal damage reference degree;
Taking any one metal surface detection area except the defect reference detection area as a comparison surface area, and screening out a plurality of reference metal defect detection areas under each ultrasonic detection moment in the direction range from the defect reference detection area to the comparison surface area;
the defect signal association degree obtaining method comprises the following steps:
taking the inverse proportion normalized value of all ultrasonic signal data variances of each reference metal defect detection area in the ultrasonic flaw detection time interval at the ultrasonic detection time as the ultrasonic signal stability of each reference metal defect detection area in the ultrasonic flaw detection time interval at the ultrasonic detection time;
Obtaining defect signal consistency under ultrasonic detection time according to the difference of ultrasonic signal stability between ultrasonic flaw detection time intervals of different reference metal defect detection areas;
taking the distance between the centers of any two reference metal defect detection areas as the detection area distance under the ultrasonic detection time;
and obtaining the defect signal correlation degree under the ultrasonic detection time according to the defect signal correlation degree and the detection area distance.
2. The nondestructive inspection method for metal castings according to claim 1, wherein the noise adjustment factor obtaining method is as follows:
And for any ultrasonic detection time, obtaining a noise adjustment factor of each metal surface detection area at the ultrasonic detection time according to the product of the ultrasonic signal sensitivity of each metal surface detection area and the defect signal correlation degree at the ultrasonic detection time.
3. A metal cast nondestructive inspection system comprising a memory, a processor, and a computer program stored on the memory and executable on the processor, wherein the computer program when executed by the processor performs the steps of a metal cast nondestructive inspection method according to any one of claims 1-2.
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| CN118010849A (en) * | 2024-04-10 | 2024-05-10 | 丰宁满族自治县启源建筑有限公司 | Expressway bridge and culvert damage detection method and system |
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| CN118010849A (en) * | 2024-04-10 | 2024-05-10 | 丰宁满族自治县启源建筑有限公司 | Expressway bridge and culvert damage detection method and system |
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