焊缝横向裂纹TOFD检测研究
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摘要
林业机械大多承担繁重的任务,且涉及到人身安全。对这些机械中的损伤与缺陷进行检测,及时监测其运行状况,能降低维修成本,提高林业机械的使用效率和使用安全性,提高林业经济效益。焊接作为制造业的基础工艺和技术,在林业机械产业中也应用广泛,而焊缝的质量直接关系到设备整体结构的强度和使用寿命。超声TOFD检测技术的显著优点是缺陷检出率高,定量精度高,操作方便快捷,检测成本低,但易出现横向裂纹漏检。针对焊缝中横向裂纹D扫描图像的显示特征与点状缺陷相似,难以准确判断和识别,容易漏检的问题,通过研究TOFD检测时横向裂纹漏检的的原因,改进传统的TOFD检测方法,提出一种对边斜向非平行扫查方法。为检验该方法的实用性,提高检测效率,设计了专用的多通道斜向扫查架。采用设计的多通道斜向扫查架对横向裂纹缺陷模拟试块进行试验。试验结果表明:多通道斜向扫查架的偏斜角设置在30°~60°时,可以有效识别横向裂纹缺陷。该方法原理简单,设计的多通道斜向扫查架实用性强,对减少焊缝中横向裂纹的漏检,确保林业设备安全运行具有重大意义。
Most of the forestry machinery undertake heavy tasks and involves personal safety. Detecting the damage and defect of these machines and monitoring the condition in time could reduce the maintenance cost,improve the efficiency and safety,and improve the economic benefit of the forest. As the basic process and technology of the manufacturing industry,welding is also widely used in the forestry machinery industry. The quality of the welding is directly related to the strength and service life of the overall structure of the equipment. Ultrasonic TOFD detection technology has some remarkable advantages of high detection rate,high precision,convenient operation and low detection cost,but it is easy to miss transverse crack. In view of the transverse crack in the weld,the display characteristics of the D-scan image are similar to the point defects,and it is difficult to accurately judge and identify the problem,and it is easy to miss the problem. Through the research of the cause of transverse crack's miss in TOFD detection,the paper improved the traditional TOFD detection method,and proposed an oblique non-parallel scanning method. In order to test the practicability of the method,improve the detection efficiency,the paper designed a special multi channel oblique scanning frame. The experiment verification was made by using the designed multi-channel oblique scanning frame to the simulated test block of transverse crack defect. The test shows that the transverse crack defects can be effectively identified when the multi channel oblique scanning frame is set in the range of 30 degrees to 60 degrees. The method is simple and the designed multi channel oblique scanning frame is practical. It is of great significance to reduce the detection of transverse crack in bult weld and ensure the safe operation of the forestry machinery.
Most of the forestry machinery undertake heavy tasks and involves personal safety. Detecting the damage and defect of these machines and monitoring the condition in time could reduce the maintenance cost,improve the efficiency and safety,and improve the economic benefit of the forest. As the basic process and technology of the manufacturing industry,welding is also widely used in the forestry machinery industry. The quality of the welding is directly related to the strength and service life of the overall structure of the equipment. Ultrasonic TOFD detection technology has some remarkable advantages of high detection rate,high precision,convenient operation and low detection cost,but it is easy to miss transverse crack. In view of the transverse crack in the weld,the display characteristics of the D-scan image are similar to the point defects,and it is difficult to accurately judge and identify the problem,and it is easy to miss the problem. Through the research of the cause of transverse crack's miss in TOFD detection,the paper improved the traditional TOFD detection method,and proposed an oblique non-parallel scanning method. In order to test the practicability of the method,improve the detection efficiency,the paper designed a special multi channel oblique scanning frame. The experiment verification was made by using the designed multi-channel oblique scanning frame to the simulated test block of transverse crack defect. The test shows that the transverse crack defects can be effectively identified when the multi channel oblique scanning frame is set in the range of 30 degrees to 60 degrees. The method is simple and the designed multi channel oblique scanning frame is practical. It is of great significance to reduce the detection of transverse crack in bult weld and ensure the safe operation of the forestry machinery.
引文
[1]江广波,周新民,李加强.故障诊断技术在林业机械中应用的意义探讨[J].民营科技,2007,13(1):22-22.
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[3]王立柱,张远生,张涵.直缝埋弧焊钢管焊缝横向裂纹产生原因分析[J].焊管,2008,31(4):67-68.
[4]刘贵吉,李鹏频,甘志云,等.钢结构焊缝内部横向裂纹的超声波检验方法[J].科技视界,2013,3(36):337-338.
[5]解德海,王彬.林业机械超声检测新技术的探讨[J].林业科技情报,2004,36(3):87-87.
[6]Solov'ev A N,Sobol'B V,Krasnoshchekov A A.The Identification and Study of the Critical State of a Transverse Crack in a Zone with a Lap Based on Artificial Neural Networks[J].Russian Journal of Nondestructive Testing,2014,50(8):452-463.
[7]Pasadas D J L,Ribeiro A L,Ramos H G,et al.Defect Detection in Stainless Steel Tubes with AMR and GMR Sensors using Remote Field Eddy Current Inspection[J].Chinese Medical Sciences Journal,2015,14(3):174-179.
[8]Xiao H,Zheng J,Song G.Severity Evaluation of the Transverse Crack in a Cylindrical Part Using a PZT Wafer Based on an Interval Energy Approach[J].Smart Materials&Structures,2016,25(3):035021.
[9]孙继华,赵扬,宋江峰,等.采用激光声磁技术检测钢轨踏面缺陷[J].光电子·激光,2014,25(1):141-146.
[10]赵鹏,刘毅勇,张忠政,等.厚壁焊缝横向裂纹超声与射线检测的探讨[J].机械制造,2016,54(2):60-62.
[11]罗志伟,张驰,刘斌,等.焊缝横向裂纹声波衍射信号特征与采集方法[J].焊接,2016,60(6):26-29.
[12]Lee J,Park J,Cho Y.A Novel Ultrasonic NDE for Shrink Fit Welded Structures Using Interface Waves[J].Ultrasonics,2016,68(1):1-7.
[13]孟亚惠.TOFD技术在埋地管道检测中的应用[J].管道技术与设备,2012,20(1):27-29.
[14]白艳,邢涛.TOFD技术检测盲区的研究[J].森林工程,2010,26(4):50-52.
[15]Baby S,Balasubramanian T,Pardikar R J,et al.Time-of-flight Diffraction(TOFD)Technique for Accurate Sizing of Surfacebreaking Cracks[J].Insight-Non-destructive Testing and Condition Monitoring,2003,45(6):600-604.
[16]Lu C,Wang Q,Liu F N.Ultrasonic TOFD in the Application of Thick Wall Tube Welding Seam Detection Pre-Research[J].Advanced Materials Research,2014,912(4):12-17.
[17]Zhang P L,Dong J,Cao L.Analysis the Results of TOFD Inspection in Butt Joint Welds[J].Applied Mechanics&Materials,2012,246-247(2):66-70.
[18]金南辉,成德芳,牟彦春.TOFD检测技术在压力容器定期检验中的应用前景[J].压力容器,2009,26(6):59-62.
[19]苗丕渝,张柏雄,赵小桦.对某横向缺陷的TOFD检测和分析[J].无损探伤,2012,36(6):40-42.
[20]梅华锋,林光辉,岳高峰.一种减少TOFD横向缺陷漏检的方法探讨[J].小水电,2014,31(5):17-20.
[21]宋光辉.混合气体保护焊对焊缝金属组织与性能的影响[J].林业机械与木工设备,2000,28(6):32-36.
[2]Tabatabaeipour M,Hettler J,Delrue S,et al.Non-destructive Ultrasonic Examination of Root Defects in Friction Stir Welded Buttjoints[J].Ndt&E International,2016,80(2):23-34.
[3]王立柱,张远生,张涵.直缝埋弧焊钢管焊缝横向裂纹产生原因分析[J].焊管,2008,31(4):67-68.
[4]刘贵吉,李鹏频,甘志云,等.钢结构焊缝内部横向裂纹的超声波检验方法[J].科技视界,2013,3(36):337-338.
[5]解德海,王彬.林业机械超声检测新技术的探讨[J].林业科技情报,2004,36(3):87-87.
[6]Solov'ev A N,Sobol'B V,Krasnoshchekov A A.The Identification and Study of the Critical State of a Transverse Crack in a Zone with a Lap Based on Artificial Neural Networks[J].Russian Journal of Nondestructive Testing,2014,50(8):452-463.
[7]Pasadas D J L,Ribeiro A L,Ramos H G,et al.Defect Detection in Stainless Steel Tubes with AMR and GMR Sensors using Remote Field Eddy Current Inspection[J].Chinese Medical Sciences Journal,2015,14(3):174-179.
[8]Xiao H,Zheng J,Song G.Severity Evaluation of the Transverse Crack in a Cylindrical Part Using a PZT Wafer Based on an Interval Energy Approach[J].Smart Materials&Structures,2016,25(3):035021.
[9]孙继华,赵扬,宋江峰,等.采用激光声磁技术检测钢轨踏面缺陷[J].光电子·激光,2014,25(1):141-146.
[10]赵鹏,刘毅勇,张忠政,等.厚壁焊缝横向裂纹超声与射线检测的探讨[J].机械制造,2016,54(2):60-62.
[11]罗志伟,张驰,刘斌,等.焊缝横向裂纹声波衍射信号特征与采集方法[J].焊接,2016,60(6):26-29.
[12]Lee J,Park J,Cho Y.A Novel Ultrasonic NDE for Shrink Fit Welded Structures Using Interface Waves[J].Ultrasonics,2016,68(1):1-7.
[13]孟亚惠.TOFD技术在埋地管道检测中的应用[J].管道技术与设备,2012,20(1):27-29.
[14]白艳,邢涛.TOFD技术检测盲区的研究[J].森林工程,2010,26(4):50-52.
[15]Baby S,Balasubramanian T,Pardikar R J,et al.Time-of-flight Diffraction(TOFD)Technique for Accurate Sizing of Surfacebreaking Cracks[J].Insight-Non-destructive Testing and Condition Monitoring,2003,45(6):600-604.
[16]Lu C,Wang Q,Liu F N.Ultrasonic TOFD in the Application of Thick Wall Tube Welding Seam Detection Pre-Research[J].Advanced Materials Research,2014,912(4):12-17.
[17]Zhang P L,Dong J,Cao L.Analysis the Results of TOFD Inspection in Butt Joint Welds[J].Applied Mechanics&Materials,2012,246-247(2):66-70.
[18]金南辉,成德芳,牟彦春.TOFD检测技术在压力容器定期检验中的应用前景[J].压力容器,2009,26(6):59-62.
[19]苗丕渝,张柏雄,赵小桦.对某横向缺陷的TOFD检测和分析[J].无损探伤,2012,36(6):40-42.
[20]梅华锋,林光辉,岳高峰.一种减少TOFD横向缺陷漏检的方法探讨[J].小水电,2014,31(5):17-20.
[21]宋光辉.混合气体保护焊对焊缝金属组织与性能的影响[J].林业机械与木工设备,2000,28(6):32-36.