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1、超声波探伤通用规程 检验规程内容: Content 1.0 适用范围 / scope 2.0 参考规范 / reference 3.0 检验人员 / NDT-Personnel 4.0 超声波检测 / Ultrasonic testing 5.0 检验报告 / Examination report 1.0 适用范围 / scope 本规范是铸件的检验规程和验收标准。本规范覆盖检验区域。 This specification is the inspection procedures and acceptance criteria of casting. Inspection areas are
2、covered by this specification. 2.0 参考规范/ reference GB9445-99:中国机械工程无损检测学会无损检测人员资格及鉴定/non-destructive testing institution of the Chinese mechanical engineering society qualification and certification of NDT personnel EN473 :NDT 无损探伤试验人员的资格和资格证-总则/ qualification and certification of NDT personnelgener
3、al principles. SNT-TC-1A:无损探伤人员资质 / qualification and certification of NDT personnel EN12680-3:铸造 - 超声探伤 - 第 3 部分 : 球墨铸铁 /Founding-Ultrasonic examination -part 3: Spherical graphite cast iron castings. ISO 8501-1:表面粗糙度 /visual assessment of surface cleanliness 993062:超声波设备的校准 / Ultrasonic equipment
4、calibration and verification EN126681:无损检测超声设备的特点和验证第1部分:仪表。 EN 12668-1 :Non-destructive testing - Characterization and verification of ultrasonic examination equipment - Part 1: instruments. EN126683:无损检测超声设备的特点和验证第3部分:设备组合。 EN 12668-3 :Non-destructive testing - Characterization and verification of
5、 ultrasonic examination equipment - Part 3: Combined equipment. EN12223:无损检测超声检测校准试块No.1的规范。 EN 12223 :None destructive testing Ultrasonic examination - Specification of calibration block no.1. 3.0 检验人员 / NDT-Personnel NDT 人员至少应获得一个下述标准证书的认证: NDT-Personnel must be qualified to one of the following c
6、ertification standards: GB9445-99:中国机械工程无损检测学会无损检测人员资格及鉴定/nondestructive testing institution of the Chinese mechanical engineering society qualification and certification of NDT personnel EN473 :NDT 无损探伤试验人员的资格和资格证-总则/ qualification and certification of NDT personnelgeneral principles. SNT-TC-1A:无损探
7、伤人员资质 / qualification and certification of NDT personnel 根据 EN 473 或 ASNT SNT-TC-1A的规定,所有无损试验的检验员,都要经过培训达到2 级的资质水 平。他们若不够2 级水平,则应在2 级甚至 3 级资质水平的人员指导下工作。供货方的3 级人员,应 定期培训自己的NDT 工作人员。 All NDT inspectors must be trained and certified lever 2 inspectors according to EN 473 or ASNT SNT-TC -1A or they shou
8、ld perform the test under direct supervision of a lever 2 or lever 3(according to one of the earlier mentioned standards)inspector. The lever 3 inspector of supplier should do periodic training for their inspectors. 4 超声波检测 / Ultrasonic testing 4.1 表面条件 / surface conditioning 在零件作超声波检查以前,表面要达到ISO 85
9、01-1 规定的表面质量 Sa2.5级。 Prior to UT the surface quality of the component must reach Sa 2 1 /2 in accordance with ISO 8501-1. 未经机加工的粗糙表面应根据所需的检查要求进行打磨。 Rough surfaces on un-machined items shall be ground to the extent necessary for performing the examination. 所有的待检表面应无溶渣、剥落、灰尘和其它可能妨碍检查的杂质。 All surfaces
10、to be inspected shall be free of dross, scale, dirt and other foreign matter that may interfere with the inspection. 4.2 检查范围 / Extent of examination 应根据所述的零部件适用质量规范进行超声波探测评估。 Ultrasonic testing shall be evaluated in the zones as stated in applicable quality specification for the specific component.
11、 4.3 设备和耦合介质灵敏度 / Equipment and coupling medium 4.3.1 超声波探伤仪 Ultrasonic instrument 超声波探伤仪须符合EN 12668-1 中规定的要求 (本厂使用 EPOCH 4 和 EPOCH LT) ,须具有以 下特点 : The uultrasonic instrument shall meet the requirements given in EN12668-1(The instrument EPOCH 4 and EPOCH LT shall be used in my factory )and shall hav
12、e the following character: - 量程设定,设定范围需至少为10mm 2m ,需能够连续选择,需适合于钢中传播的纵波和 横波; -range setting, from at least 10mm to 2m continuously selectable, for longitudinal and transverse; - 增益,须能够在一个至少为80dB 的范围内进行调节,调节的最大差级为2dB,测量精度 为 1 dB; -gain, adjustable in 2dB maximum steps over a range of at least 80dB wit
13、h measuring accuracy of 1dB; - 时基和垂直线性度须小于显示屏幕调节范围的5%,水平线性小于 1%; -time-base and vertical linearities less than 5% of the adjustment range of the screen, the horizontal linearity shall be better than 1%; 4.3.2 探头和传感器的频率 /Probes and transducer frequencies -采用单晶探头和双晶探头的脉冲回波技术中,其适用的频率为2MHZ, -suitability
14、 for nominal frequencies 2 MHZin pulse-echo technique with single-crystal and twin-crystal probes. -以下探头至少要有一个被使用: SEB2-0 0(MSEB2)和 B2S(MB2S)或者有一个相同特性的探 头。探头 SEB2-0 0 (MSEB2)用于铸件壁厚0200mm 处,探头 B2S(MB2S)用于铸件壁厚 200500mm处。首先使用 SEB2-0 0 和 B2S 探头检测 , 当需要精确测量缺陷的边界时使用 MSEB2-0 0 和 MB2S 探头。 -Following probe h
15、ead must have at least one to be used: SEB2-0 0 ( MSEB2) and B2S ( MB2S) or have a same characteristic probe head. The probes of SEB2-0 0 (MSEB2) are used for the casting thickness of 0200mm. The probes of B2S ( MB2S) are used for the casting thickness of 200500mm. First use the probe of SEB2-0 0 an
16、d B2S for inspection. If needs to identify the actual borderline of the defects, use the probes of MSEB2-0 0 and MB2S. -声束直径的补偿 / the compensation of diameter of sound beam 为了判定一个缺陷的大小是“可测量”还是“不可测量”,声束的直径可以进行补偿。补 偿可以通过计算(对在远场中的单晶探头),或根据平底孔的测量值(双晶探头)进行。 声束直径的补偿只能被用在不可测量缺陷的部分。 -In order to determine t
17、he size of an indication is “ measurable ” or “ not measurable ” , the diameter of the sound beam may be compensated for. This may be done based on calculations (for single crystal probes in the far field) or base on measurements of flat bottom holes (for dual twin crystal). 在表 1 中提到的标准值可供用。 The val
18、ues for standard probes mentioned in Table 1 may be used. 声程( mm) Sound path SEB2 声束直径 (mm) Diameter of sound beam for SEB2 MSEB2 声束直径 (mm) Diameter of sound beam for MSEB2 B2S 声束直径 Diameter of sound beam for B2S 20 15 5 - 20-60 15 15 - 60-120 20 25 12 表 1.标准探头的校正值 /table 1 Correction values for sta
19、ndard probes 4.3.3 耦合剂 / couplant 使用超声波浆糊。 Ultrasonic jelly shall be used. 4.4 校准 /Calibration 按照现行标准 993062对超声波设备进行校准。 Ultrasonic equipment calibration and verification must be carried out according to present 993062 standards. 4.4.1标准参考 /NORMATIVE REFERENCES EN126683 无损检测超声设备的特点和验证第三部分:设备组合。 EN 12
20、668-3 Non-destructive testing - Characterization and verification of ultrasonic examination equipment - Part 3: Combined equipment. EN12223 无损检测超声检测校准试块No.1的规范。 EN 12223 None destructive testing Ultrasonic examination - Specification of calibration block no.1. 4.4.2设备/EQUIPMENT 参考试块 K1 DS/EN 12223 R
21、eference block V1 DS/EN 12223 no. 2572 参考试块 K2 DS/EN 27963(可利用两个宽度 12.5mm和20mm) Reference block V2 DS/EN 27963 no. 50434-22274 (it is available in two widths 12,5mm and 20mm) 参考试块 TIF(长横孔试块 ) Reference block TIF no. 061316 4.4.3测试范围 / SCOPE OF THE TEST 新的设备和探头组合最初使用时,必须对它作一个基本的测量,并且记录在登记簿上。 Initiall
22、y when a new combination of ultrasonic instrument and probe is taken into use, it is necessary to make a base measurement, which is registered in the registering scheme for base measurements. 每一个测量点完成,记录好数值,对于剩余的测量点,做好任务标记。 For test points where a value is achieved, note the value. For the rest of t
23、he points, sign for performing the task. 探头必须每工作日校验 , 对于测定信噪比和脉冲持续时间距离上一次使用每周一次已是 足够的。 仪器常规每周校验一次,但是如果使用中对仪器有怀疑,必须立即校验。 The user test of probes must be performed daily. For establishing a signal to noise ratio and pulse duration a weekly test is sufficient and only for probes, which have been used s
24、ince the last test. The test of the ultrasonic instrument is performed once a week. If the user has a suspicion that an error has occurred, the test must be performed immediately. 4.4.4 直探头 /NORMAL PROBES 测试包括下面的 4点: The test includes the following 4 points: 测试周期 Period 测试内容 Test 每日 Daily (如果使用 if i
25、n use ) 物理状态和外形 Determination of physical state and external aspects 根据标准反射体的灵敏度 Determination of sensitivity from standard reflector 每周 Weekly (如果使用 if in use ) 信噪比 Determination of signal to noise ratio 脉冲持续时间 Determination pulse duration 4.4.4.1 物理状态和外形 /Determination of physical state and extern
26、al aspects 目视检查探头和连接线是否有损坏或磨损;检查电路连接的稳定性;如果保护膜有损伤 则要更换,晶片和保护膜间的油中不能有气隙,更换其中的油通常是必须的。 Visually inspect probe and cable for damage and wear. Check for instability of electrical contact. Replace protection membrane if defect. The oil between crystal and membrane must be without air bobbles. It might be
27、 necessary to change the oil. 4.4.4.2 用标准反射体测量灵敏度 /Determination of sensitivity from standard reflector 用TIF 试块 上深度35mm处的3mm孔作为标准反射体 ,找出最大回波并调至 80屏高,增 益设置为最低,记录此时的 dB值并且对照初始记录值,如果偏差超过 6dB,则要寻找纠正 原因或者 更换 探头。 Use the echo from the 3mm hole in 35mm dept in the TIF-block as standard reflector. Maximize
28、the echo and set it to 80% of the screen height. Gain is set to lowest value. Note the dB- value and compare it to the base measurement. With deviations more than 6 dB find the reason and correct it or replace the probe. 4.4.4.3 信噪比测量 /Determination of signal to noise ratio 1用 TIF 试块上(从端部)深度35mm 处的
29、3mm 孔作为标准反射体, 增益设置最低 , 记录此时 dB 数值。 1. The echo from the 3mm hole in 35mm dept in the TIF-block (from the end) is to be used as standard reflector. Gain is set to lowest value. Note the dB- value 2从试块上拿下探头并擦干净耦合剂。 2. Remove the probe from the block and clean it for couplant. 3提高增益直至噪声信号达到与35mm 反射体同样的
30、高度,记录提高的数值,称为信 噪比。记录 dB 值并且对照初始测量值, 如果偏差超过 6dB, 寻找纠正原因或者更换探头。 3. Increase the gain until the noise reaches the same level as the reference echo in 35mm distance. Note the increase, which is called signal to noise ratio. Note the dB- value and compare it to the base measurement. With deviations more
31、than 6 dB find the reason and correct it or replace the probe. 4.4.4.4 脉冲持续时间的测量 /Determination of pulse duration. 1设置时基范围为 50mm,增益调至最低。 1. Set the time base to 50 mm. Set Gain to lowest value. 2找出 V1试块上 25mm厚处的第一次底波的最高反射,并调至80屏高。 2. Set first bottom echo from the thickness 25 mm at the V1-block to
32、80% screen height. 3读出 10水平线处回波的宽度,按照钢中的声程读数(见图A、B) 3. Read the breadth of the echo measured at the horizontal line in 10 % of the screen height. The reading is in mm steel (see figure. A、B). 例如:测量回波宽度( EB)/Example: Measuring echo breadth (EB) 使用数字超声仪器,波宽可以用图A、图B所示的闸门来测量 : A digital ultrasonic instr
33、ument is used the echo width can be measured by means of the gate as shown in figure 2 and 3. Set the instrument to measure on the flank: 图Figure A 图Figure B EB102.4100.4=2.0mm 4对照初始测量值,如果偏差超过50,寻找纠正原因或者 更换探头。 4. Compare the measured value with the base measurement. With deviations more than 50% fin
34、d and correct the reason to the deviation or replace the probe. 4.4.5 超声波仪器 /ULTRASONIC INSTRUMENT 测试包括下面的 2点:/The test includes the following 2 points: 测试周期 Period 测试内容 Test 每周 Weekly (如果使用 if in use ) 时基水平线性 Determination of linearity of the time base 幅度垂直线性 Determination for linearity of the ampl
35、ifier 4.4.5.1 时基水平线性的测量 /Determination of linearity of the time base 1直探头放置在 V1试块上一侧,时基范围调至125mm 。 1. Place the normal probe on the side of the V1 block. Set the time base to 125mm. 2检查第一次和最后的回波是否与时基线相一致,并检查中间其他回波的位置。 2. Check if the first and last echo coincides with the first and last scale marks
36、respectively. Check also the positions of the intervening echo. 3依次调节这些回波到 80屏高,注意 TOF要设置为 flank模式,对每一个回波,要与 比例线一致,偏差不能超过水平整个屏幕宽度的2。 3. Bring the echoes, in turn, up to 80 % screen height. Check if the flank, for every echo, still coincides with the scale marks. The deviation may not exceed 2 % of t
37、he whole screen width. 4.4.5.2 幅度垂直线性的测量 /Determination of linearity of the amplifier 使用和测量水平线性时相同的时基范围和探头,找到TIF试块上深度为 35mm 处的3mm孔 的最高反射波,调至 80屏高。 Use the same time base and probe as used for determination of linearity of the time base. The echo from a 3mm hole in 35mm dept in the TIF-block is used
38、as standard reflector. Maximize the echo from the hole and set it to 80 % screen height. 根据下表数值调节灵敏度,检查回波高度是否在规定的范围内。 The amplification is set as stated in the table below. Check if the echo is within the specified limits. 增益幅 Amplification Expected 期望屏高 screen height (%) 范围 Limits 2 101 不小于 95/Not
39、less than 95% 0 80 6 40 3743 12 20 1723 18 10 812 24 5 可见的低于 8/Visible beneath 8% 4.4.6 整理结果并归档 /HANDLING THE RESULTS AND FILING 初始测量数值记录表应该与超声仪器一起保存。 The registration scheme for base measurements is always to be kept together with the ultrasonic instrument. 定期校验的数字记录也应该与超声仪器一起保存。当记录表填满后,新的记录表应该与 初始
40、记录值的复印件放在一起,并且归档在质量部门可靠地方。 The registration scheme for frequent tests has to be kept together with the ultrasonic instrument. When the scheme is filled in, it must be filed together with a copy of the base measurements. It hasto be filed at the quality responsible for the department. The requirement
41、s of filing follow the existingrules for quality documentation. 4.4.7如果校验不符合要求,则要根据填写“失败的校验信息”。 If the requirements are not met fill a “Failed calibration message” accordingly. 4.5 量程的设定 /Range setting 4.5.1须进行量程的设定 , 量程的设定直接在铸件上进行, 条件是铸件的厚度是已知的并且具 有平行的表面 . Range setting shall be carried out. It che
42、cked directly on the casting if its thickness is known and if it has parallel surfaces. 4.5.2使用单晶探头时,仪器中至少应显示出两次的回波,使用双晶探头时,仪器中至少应 显示出一次的回波。 Field shall have a minimum dimension of two back wall echoes for mono-crystal probes. Field shall have a minimum dimension of one back wall echo for bi-crystal
43、 probes. 4.5.3 如果一个特殊的零件需要使用特殊的刻度量程校正程序, 必须符合特种质量规范 . In case that a specific components needs for a special scale range adjustment procedure, it shall be covered by the Specific Quality Specification. 4.6 灵敏度的设定 / Sensitivity setting 根据 DGS 图 来完成 . Shall be carried out by means of a DGS diagram. 对于
44、检测灵敏度的设定, KSR3 的平底孔的回波高度须至少占到待检验的厚度范围端部的 显示屏高度的 40%。 (仪器 EPOCH 4 和 EPOCH LT 具备 DGS 软件,探伤时,在铸件上把 最厚处 当作大平底, 一次回波调至满屏的80%,然后使用 KSR3mm 的 DGS 曲线即可) 。 The initialization of the testing sensitivity shall be set in such a way that the echo heights of the flat-bottomed holes of KSR3mm shall be at least 40%
45、of the screen height at the end the thickness range to be examined. (The ultrasonic instrument EPOCH 4 and EPOCH LT have software of DGS. When detecting, adjust the back wall echoto 80% of the full screen height with the casting max wall thicknessas the FBH. And then use the DGS software of KSR3mm f
46、or inspection.) 例如: / illustrating: 4.7 检验/ Inspection 4.7.1 打 300mmx300mm 的格子进行扫查。 Scanning shall be carried out by 300mmx300mm grid conditions. 4.7.2 扫查速度 /Scanning rate 扫查速度不要超过150mm/s,指定扫查的区域应完全的被扫查到, 并有系统性的覆盖 (15%) 扫查。 The scanning speed shall not exceed 150mm/s. A complete coverage of the spec
47、ified scanning area shall be conducted by carrying out systematically overlapping (15%)scans. 4.7.3 扫查区域 /UT scanning area 在进行首件资格认证(FPQ)和试验批量资格认证(PLQ)生产时,要对零件进行100%的超声检查。 在批量生产时, 只要对规范中或零件图纸上标明的试验区域进行检查,以及在 FPO 和 PLO 检查中发 现有问题的区域进行检查。另外,在目测检查中(VT ) ,对某个区域如觉得有问题,也应进行超声 检查。为保证产品的安全,在其它区域应进行抽样检查。 100%
48、 ultrasonic testing in accordance is required during FPQ and PLQ. During series production ultrasonic testing must be performed in the test areas, which are defined in the component specification or on the component drawings, and in trouble areas that were found during FPQ and PLQ. In addition UT is
49、 required in areas where defects can be presumed based on the results of for example VT. The remaining areas should be inspected spot-check with respect to product safety. 4.8 验收标准 /Acceptance Standard 4.8.1 当单个不连续的体积型缺陷达到表2 和表 3中的极限值时,应该记录下来并做出评估。 When single discontinuous bulk defect the limits in table 2 and 3, should be noted and be evaluated 表 2 / table 2 特征 Feature 单位 Unit 质量等级 /quality level 123 受 检 区 域 中的 壁厚 /wall thickness in the examined area mm -5050 to 2002005050 to 200
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