钢轨焊缝的相控阵超声定点扫查工艺研究
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摘要
利用相控阵超声扇形扫描对钢轨焊缝进行快速扫查,通过计算超声波在楔块-工件界面的透射率,确定扇形扫描角度范围,进而研究钢轨焊缝的定点扫查工艺,设计专用位置标示尺。使用钢轨标准试块进行试验验证发现,相控阵扫描角度设置在30°~70°之间,位置标示尺标定10个位置即可实现试块的全面检测。本方法可以有效提高钢轨焊缝的检测效率,降低检测缺陷识别难度,同时可以将检测图像进行对比分析,具有可追溯性。
In order to test rail welds rapidly, phased array ultrasonic S-scan testing technology was used. The theoretical calculation of ultrasonic energy transmission coefficient through the plexiglass wedge-steel interface was carried out, then sector scan beam deflection angle range was calculated. Finally, the fixed-point scanning process was studied, and the special location ruler was designed. In the work, the rail weld standard blocks were employed. It is found that setting sector scan beam deflection angle range from 30° to 70° and ten fixed-points in the location ruler are feasible. The phased array ultrasonic S-scan testing technology with fixed-point scanning process in rail welds can effectively improve the testing efficiency, reduce the defects recognition, and compare the testing images with traceability.
In order to test rail welds rapidly, phased array ultrasonic S-scan testing technology was used. The theoretical calculation of ultrasonic energy transmission coefficient through the plexiglass wedge-steel interface was carried out, then sector scan beam deflection angle range was calculated. Finally, the fixed-point scanning process was studied, and the special location ruler was designed. In the work, the rail weld standard blocks were employed. It is found that setting sector scan beam deflection angle range from 30° to 70° and ten fixed-points in the location ruler are feasible. The phased array ultrasonic S-scan testing technology with fixed-point scanning process in rail welds can effectively improve the testing efficiency, reduce the defects recognition, and compare the testing images with traceability.
引文
[1]邢丽贤.提速条件下钢轨伤损特点及钢轨伤损分类的研究[D].北京:中国铁道科学研究院,2008.XING Lixian.Research on defect characteristics and classification of higher speed rails[D].Beijing:China Academy of Railway Sciences,2008.
[2]Komura I,Nagai S,Kashiwaya H,et al.Improved ultrasonic testing by phased array technique and its application[J].Nuclear Engineering and Design,1985(87):185-191.
[3]Poguet J,Marguet J,Pichonnat F,et al.Phased array technology:concepts,probes and applications[J].Journal of Nondestructive Testing&Ultrasonics,2002,7(5):1-6.
[4]Garcia G,Zhang J.Application of ultrasonic phased arrays for rail flaw inspection[J].Nondestructive Tests,2006,110(43):97-104.
[5]卢超,邓丹,陈文生,等.钢轨气压焊接头的超声相控阵检测技术研究[J].失效分析与预防,2011,6(3):139-143.LU Chao,DENG Dan,CHEN Wensheng,et al.Research on ultrasonic phased array detecting technique for gas pressure welding joint of rail[J].Failure Analysis and Prevention,2011,6(3):139-143.
[6]梁佳佳,李雄兵,倪培君,等.镁合金壳体的超声相控阵检测方法[J].兵器材料科学与工程,2014,37(4):108-111.LIANG Jiajia,LI Xiongbing,NI Peijun,et al.Ultrasonic phased array testing method for magnesium alloy shell[J].Ordnance Material Science and Engineering,2014,37(4):108-111.
[7]姜学平,王鹏,郑晖,等.相控阵超声检测扇形扫描角度范围[J].无损检测,2015,37(11):10.JIANG Xueping,WANG Peng,ZHENG Hui,et al.Sectorial scan angle range for phased array ultrasonic testing[J].Nondestructive Testing,2015,37(11):10.
[8]张碧星,王文龙.凹面相控阵聚焦声场在液固界面上的反射和折射[J].物理学报,2008,57(6):3613-3619.ZHANG Bixing,WANG Wenlong.Reflection and refraction on the fluid-solid interface of acoustic field excited by a concave phased array[J].Acta Physica Sinica,2008,57(6):3613-3619.
[9]刘希玲,张荣繁,胡宏伟,等机车车轮超声自动检测系统设计[J].铁道科学与工程学报,2014,11(6):122-126.LIU Xiling,ZHANG Rongfan,HU Hongwei,et al.Design of ultrasonic automatic testing system for locomotive wheels[J].Journal of Railway Science and Engineering,2014,11(6):122-126.
[2]Komura I,Nagai S,Kashiwaya H,et al.Improved ultrasonic testing by phased array technique and its application[J].Nuclear Engineering and Design,1985(87):185-191.
[3]Poguet J,Marguet J,Pichonnat F,et al.Phased array technology:concepts,probes and applications[J].Journal of Nondestructive Testing&Ultrasonics,2002,7(5):1-6.
[4]Garcia G,Zhang J.Application of ultrasonic phased arrays for rail flaw inspection[J].Nondestructive Tests,2006,110(43):97-104.
[5]卢超,邓丹,陈文生,等.钢轨气压焊接头的超声相控阵检测技术研究[J].失效分析与预防,2011,6(3):139-143.LU Chao,DENG Dan,CHEN Wensheng,et al.Research on ultrasonic phased array detecting technique for gas pressure welding joint of rail[J].Failure Analysis and Prevention,2011,6(3):139-143.
[6]梁佳佳,李雄兵,倪培君,等.镁合金壳体的超声相控阵检测方法[J].兵器材料科学与工程,2014,37(4):108-111.LIANG Jiajia,LI Xiongbing,NI Peijun,et al.Ultrasonic phased array testing method for magnesium alloy shell[J].Ordnance Material Science and Engineering,2014,37(4):108-111.
[7]姜学平,王鹏,郑晖,等.相控阵超声检测扇形扫描角度范围[J].无损检测,2015,37(11):10.JIANG Xueping,WANG Peng,ZHENG Hui,et al.Sectorial scan angle range for phased array ultrasonic testing[J].Nondestructive Testing,2015,37(11):10.
[8]张碧星,王文龙.凹面相控阵聚焦声场在液固界面上的反射和折射[J].物理学报,2008,57(6):3613-3619.ZHANG Bixing,WANG Wenlong.Reflection and refraction on the fluid-solid interface of acoustic field excited by a concave phased array[J].Acta Physica Sinica,2008,57(6):3613-3619.
[9]刘希玲,张荣繁,胡宏伟,等机车车轮超声自动检测系统设计[J].铁道科学与工程学报,2014,11(6):122-126.LIU Xiling,ZHANG Rongfan,HU Hongwei,et al.Design of ultrasonic automatic testing system for locomotive wheels[J].Journal of Railway Science and Engineering,2014,11(6):122-126.