中英对照磁粉检测通用工艺作业指导书

第第1012页〔〕KNMSPECIALPROCESSEQUIPMENT(CHANGSHU)CO.,LTD.TechnicsRegulationforMagneticparticleExamination作业指导书OperationGuidebookBy：磁粉检测通用工艺规程TechnicsRegulationforMagneticparticleTest1主要内容和适用范围Scope本规程规定了磁粉检测人员资格、所用设备、器材、检测技术和质量分级等。ThisregulationdefinethequalificationofMagneticparticletestperson,facility,equipment,examiningmethodandqualitygrade.本规程按JB/T4730.4-2023的要求编写。适用于铁磁性材料的机加工件、焊缝、板材坡口面等外表和近外表缺陷的检测，不适用于非磁性材料及磁性材料与非磁性材料结合部位的检测。满足GB150容器安全技术监察规程》和相关标准的要求。ThisregulationiscompilebasedonJB/T4730.4-2023.Itissuitableforferro-magneticmaterial,suchasmachiningworkpiece,weldseam,groovefaceofplateandnearsurfaceflaw.Theregulationisnotsuitablefornon-magneticsubstanceandbondedblockmadewithferro-magneticmaterialandnon-magneticsubstance.TheregulationsatisfiedwithGB-150,《Supervision,RegulationonSafetyTechnologyforPressurevessel》andcorrelativestandard.本规程适用于非荧光湿磁粉的连续磁化技术。ThisregulationissuitableforcontinuousMagnetizingtechniqueofnon-fluorescentwetmagneticparticle.检测工艺卡是本规程的补充。由Ⅱ级或以上人员按合同及本规程和JB/T4730.4-2023编制，其参数规定得更具体。1.4Examineprocesschartisasupplementofthisregulation.ThechartispreparedbegradeIIpersonormorethangradeIIperson,andthechartispreparedfollowingcontract,thisregulationandJB/T4730.4-2023.Theparameterinprocesschartismoredetailed.检测人员Testers的资格证书，并负相应的技术责任。AllpersonnelengagedinMagneticParticleexaminationmustbetrainedtechnicallyandexaminedandappraisedinaccordancewith《SpecialEquipmentNondestructiveTestingandSupervisingStandard》.Thesepersonshouldhavecorrespondingtechnicalresponsibility.Andtakecorrespondingtechnicalresponsibilities.〔距视力和远〔距〕视力应不低于5.0〔小数记录值为1.0，不得有色盲。2.2 Thepersonnelengagedinnondestructivetestingmusthaveexcellentphysicalconditionsanddophysicalcheck-uponceayear,correctedeyesightmustnotbelowerthan1.0.Thepersonnelengagedinmagneticpowdertestingandpenetrationtestingmustnotbecolorblindandweak.设备、工具和材料Facility,EquipmentandMaterialⅠ、Ⅱ级人员按以下条件和工艺卡要求选用设备、工具和材料。PersonwithgradeIandIIshouldchoosefacility,equipmentandmaterialasfollowingconditionandchart.磁化设备及校验MagnetizingEquipmentandCalibration1。MagnetizingEquipmentisshownasTable1.表1 磁粉检测设备〔按公司现有设备修改下表〕Table1MagneticParticleTestingEquipment制造厂/Manufactory

型号/Model 构造形式/Type 提升力/Liftingpower

备注/Note江苏射阳探伤机厂/JiangsuSheyangdetectiveequipmentcompany江苏射阳探伤机厂/JiangsuSheyangdetectiveequipmentcompany

DCE-E2 /portabletypeDCE-C /portabletype

AC提升力≥118NACLiftingpower≥118NAC提升力≥118NACLiftingpower≥118N

穿插磁轭/crossyoke穿插磁轭/crossyoke45N177N的提升力，118N的提升力〔0.5m。Note:Liftingforceistestedbyshim.Whenusethemaximumyokedistance,theliftingpowerofalternatingcurrentyokesshouldatleast45Nand177NforDCyoke.Theliftingpowerofcrossyokesatleast118N.(thedistancebetweenmagneticpoleandshim≤0.5mm)磁化设备的校验3.12 CalibrationofMagnetizingEquipment电流表精度校验Calibrationofamperemeterprecision磁粉检测设备的电流表，至少半年校验一次。当设备进展重要电气修理或大修后，应进展校验。Magnetizingequipmentwithanammetershallbecalibratedatleastoncehalfayear,orwhen-evertheequipmenthasbeensubjectedtomajorelectricrepair,periodicoverhaul,ordamage.电磁轭提升力校验LiftingpowerofYokes电磁轭的提升力至少半年校验一次。在磁轭损伤修复后应重校验。Themagnetizingpowerofelectromagneticyokesshallbecheckedtwiceayear.Themagnetizingpowerofallyokesshallbecheckedwhenevertheyokehasbeendamagedorrepaired.3.2灵敏度试件Shimofsensitivity标准试片主要用于检验磁粉检测设备、磁粉和磁悬液的综合性能，了解被检工件外表有效磁场强度和方向、有效检测区以及磁化方法是否正确。标准试片有A1型、C型、DM1型。其规格、尺寸和2。Thenormalshimmainlyusedforcheckingmagneticparticletestingmachine,magneticparticleandmagneticsuspension.Tocheckwhethertheeffectivemagneticdensity,effectivecheckoutzoneandMagnetizingmethodarecorrectornot.ThetypeofnormalshimareA1,C,DandM1.ThesizeandgraphareshownasTable2.表2 标准试片的类型、规格和图形类型/type规格：缺陷槽深/试片厚度，μmsize:depthofdefect/thicknessofshim,μm类型/type规格：缺陷槽深/试片厚度，μmsize:depthofdefect/thicknessofshim,μmA1-7/50图形和尺寸，mmgraphandsize,mm6A1-15/50φA1A1A1-30/50206型A1-15/1007/50A1-30/10020A1-60/100CC-8/50C10分割线8/50型人工缺陷C-15/50 5 5×5335D-7/50φD103型D-15/5010φ12mm7/50M1M1φ9mm2015/50型φ6mm30/5020Note:NormalshimoftypeCcanbeuseddivided5pieces.磁粉检测时一般应选用A1-30/100A1型标准试片使用不便时，一般可选用C-15/50型标准试片。为了更准确地推断出被检工件外表的磁化状态，当用户需要或技术文件有规定时，可选用DM1型标准试片。Asarule,modeltestpiececanbechoseA1-30/100.IfitisnotconvenienttouseA1modeltestpieceforsensitivitytotestthenarrowparts,suchasweldgroove,becauseofsmallsize,C-15/50modeltestpieceforsensitivitycanbeemployed. Forcheckingthemagnetizingsituationofthesurfacewellandtruly,andthereismentionintechniquedocument,canchoosetypeDortypeM1.磁场指示器MagneticParticleFieldIndicator磁场指示器的作用与标准试片一样，但它仅是一种粗略的校验。Thefunctionofmagneticparticlefieldindicatorissameasnormalshim,buttheindicatorisacursorycalibration.灵敏度试件的使用Modeltestpieceforsensitivity标准试片：将试片无人工缺陷的外表朝上，使试片与被检面接触良好，必要时可用透亮胶带将其整体保护在被检面上，但人工缺陷处不得贴覆。试验时边磁化边浇洒磁悬液，以人工缺陷清楚显示来确定磁化标准、磁化方向和有效磁化范围。Modeltestpiece:Theshimshallbeattachedtothesurfacetobeexamined,suchthattheartificialflawsideoftheshimistowardtheinspectedsurface.Makesuretheshimandsurfacemeetwell,ifneed,usecellulosetapefixontheinspectedsurface.Buttheartificialflawshouldnotbecover.磁场指示器：将其平放于被检面上，边磁化施加磁悬液，使缺陷清楚显示来估判。MagneticParticleFieldIndicator:Puttheindicatorontheinspectedsurface,whenthemagneticsuspensionareappliedsimultaneouslywiththemagnetizingforce,lettheflawappearonit.磁粉及磁悬液MagneticParticleandMagneticSuspension磁粉：承受BW-1型磁膏或喷灌。MagneticParticle:usetypeBW-1magneticcreamorirrigation.10～25g磁悬液浓度应按受检部位外表粗糙及使用方式确定1.2～2.4Ml/100mL的范围内或按制造厂的推举配比。3.3.2MagneticSuspension:Take10-25gmagneticparticleperlitrewater.Theconcentrationofmagneticsuspensionismeasuredbyconcentrationcentrifugetube.Theconcentrationofmagneticsuspensionsolutionusedcircularlymustbedeterminedregularly.Asarule,in100MLofmagneticsuspensionsolution,precipitationvolumeofmagneticpowderis1.2～2.4ML.被检测外表的制备Surfacepreparations假设被检外表凹凸不平，以致可能遮盖缺陷显示时，应通过磨削工机加工来制备。Whentheinspectedsurfaceisrugged,andcaneffecttheindicationofdefects,mustmachinetheinspectsurface.假设被检面为焊接接头，其两侧各100mm范围内不得有松散的锈蚀、氧化皮、飞溅、油污或其他粘附磁粉、阻碍检测的污物。 Nogrease,rust,oxideskin,spatterorothermagneticpowderadherencemattersonbothside(100mm)ofweldingseam.Ra25μm。Surfaceroughness(Ra)oftestedworkpiecesmustnotbemorethan12.5m.假设被检工件外表残留有涂层，当涂层厚度均匀且不超过0.05mm，不影响检测结果时，经合同各方同意，可以带涂层进展磁粉检测。4.4 Ifmagneticpowderisdifficulttoremovefrominspectedsurface,andthethicknessofcoatislessthan0.05mm,whichcannoteffecttheexamineresult,candomagneticparticleexaminationwiththecoat.检测时机TestingTime筒体焊接接头校圆且内部缺陷返修合格后进展。5.1. Forweldjointonshell,testingmustbecarriedoutafterre-rollingandrepairing.封头在成型且内部缺陷返修合格后进展。Fortheheadwithrepairing,testingmustbecarryoutaftermoldingandrepairing.机加工件加工成成品，以最终热处理后检测的结果为准。 Magneticpowdertestingforfastnersandforgedpiecesmustbeconductedafterthefinalheat-treatmentunlessadditionallyrequested.有延迟裂纹倾向的材料，应在焊后24小时之后进展。5.4 Formaterialsofdelayedcracking,testingmustbecompletedwithin24hafterwelded.磁化操作MagnetizationProcedure承受沟通电磁轭和穿插磁轭湿法连续磁化技术。Ⅰ、Ⅱ级人员每天检测前，应对系统综合性能、磁悬液浓度和磁悬液润湿性能等进展检验，合格前方可进展操作。Forthistechnique,alternatingcurrentelectromagneticyokesandcrossmagneticyokescanbeused.Beforetesting,thetestermustcheckcombinationpropertyofsystem,concentrationofmagneticsuspensionandwettingabilityofmagneticsuspension.磁轭磁化标准确实定1注的规定。TheliftingpowerofyokesmustfollowTable1.75mm～200mm50mm的范围内，其磁化范围应依据标准试片实测结果来选择。有效磁化区域每次应有不少于15mm的重叠。Spacebetweenmagneticpolesofmagneticyokemustbewithintherangeof75～200mm.Theeffectiveareatestedreaches50mmoutsideonbothsidesonthelineofbothpolesofmagneticyoke,andtheremustbe15mmoverlappedmagnetizedareaeachtime.使用穿插磁轭装置时，四个磁极端面与检测面之间应尽量贴合，最大间隙不应大于1.5mm。应4m/min明显显示，否则不得使用，以防漏检。Whenmagnetismyokesareused,theyokessurfaceshouldabutinspectedsurfacemaximum.Themaximumdistancecannotmorethan1.5mm.Thetestingspeedshouldbeequality,andnomorethan4m/min.Whenusemodeltestpiece,thecircleandreticleshouldindicateclearly,otherwise,cannotuse.承受连续磁化方法，在通电磁化的同时，施加水磁悬液，持续磁化时间为1～3s，为保证磁化效果应21s后才可停顿磁化。Forthecontinuousmethod,applicationofmagneticpowderandmagneticsuspensionsolutionmustbecompletedduringthecourseofmagnetization.Magnetizationtimeis1-3s.Itisveryimportantmagnetization2timestoensuremagneticeffect,and1smustbetakenaftermagnetization.被检工件的每一被检区除穿插磁轭磁化外，至少进展2次独立的检测，2次检测的的磁力线方向应大致相互垂直。 Atleasttwoseparateexaminationsshallbeperformedoneacharea.Thelinesofmagneticfluxshallbeapproximatelyperpendicularofthoseusedduringthefirstexamination.被检件修复后的检测Retestafterrepairing6.16.3条的程序重检测。Retestingmustbeperformedaccordingtorelatedregulationsof6.1～6.3afterrepairing.退磁及后处理6.5 Demagnetization磁粉材料或剩磁干扰后序加工或使用时，检测后可承受适当的方法清理或退磁。Workpiecesmustbedemagnetizedaftertesting,ifitisrequired.磁痕显示的分类和记录AppraisalAndRecordsofMagneticTrace磁痕的分类和处理AppraisalofMagneticTrace磁痕显示分为相关显示、非相关显示和伪显示。Therearethreeindications:correlativeindication,non-correlativeindicationandpseudo-indication.3的缺陷磁痕，按条状磁痕处理；长度与宽度之比不大于3的磁痕，按圆形磁痕处理。Magnetictracesofdefects,withalength-widthratiolargerthan3,mustbetreatedaslineardefects,andthosewithalength-widthratiolessthanorequalto3willbetreatedasrounddefects.0.5mm的磁痕不计。Magnetictracesofdefectswiththelengthlessthan0.5mmcanbeneglected.两条或两条以上缺陷磁痕在同始终线上且间距不大于2mm时，按一条磁痕处理，其长度为两条磁痕之各加间距。Providedthattwoormoremagnetictracesofdefectsareonthesamelineandthespacebetweenthemislessthanorequalto2mm,theywillberegardedasone,andthelengthisthesumofthetwodefectsplusspace.缺陷磁痕长轴方向与工件〔轴类或管类〕轴线或母线的夹角大于或等于30°时，按横向缺陷处理，其他按纵向缺陷处理。7.1.5Whentheincludedanglebetweenthelongaxisdirectionofmagnetictraceofdefectsandtheaxisofworkpiecesorbusbarislargerthanorequalto300,theywillbedealtwithasbroadwisedefectsandtherestaslengthwiseones.缺陷磁痕的观看Observationofmagnetictracedefects缺陷磁痕的观看应在磁痕形成后马上进展。Observationmustbecarriedoutaftermagnetictraceformingassoonaspossible.非荧光磁粉检测时，缺陷磁痕的评定应在可见光下进展，通常工件被检外表可见光照度应大于或等于1000lx；当现场承受便携式设备检测，由于条件所限无法满足时，可见光照度可以适当降低，但不得低500lx。Whennon-fluorescentmagneticpowdertestingmethodisemployed,appraisalofmagnetictracesmustbeperformedundervisiblelight,andtheilluminanceofvisiblelightmustnotbehigherthan1000lxonthetestedsurfaceofworkpieces.Whenhandytestingmachineisemployed,illuminanceofvisiblelightmustnotbehigherthan500lx除能确认磁痕是由于工件材料局部磁性不均或操作不当造成的之外，其他磁痕显示均应作为缺陷处2～10倍放大镜进展观看。7.2.3 The2～10foldmagnifiercanbeusedtoobservethesmallandthinmagnetictracesofdefects.缺陷磁痕显示记录Recordofmagnetictracedefects缺陷磁痕的显示记录可承受照相、录像各可剥性塑料薄膜等方式记录，同时应用草图标示。Picture,kinescopeandanyothermethodcanbeusedtorecord,atthesametime,makedraftofthedefects.复验Retest当消灭以下状况之一时，需要复验，复验按本规程第6.1条至6.3条的程序重检测。Retestingmustbeperformedaccordingtorelatedregulationsof6.1～6.3.Retestingisnecessaryunderanyconditionasfollows:检测完毕时，用标准试片验证检测灵敏度不符合要求时；Whenthetestingisover,sensitivityistestedunacceptablewiththetestpieceforsensitivity.觉察检测过程中操作方法有误或技术条件转变时；(2) Operationmethodsarefoundinappropriateduringthecourseoftesting.合同各方有争议或认为有必要时。(2) Supplierandpurchaserareindisputewitheachother,orforotherreasons.磁粉检测质量分级Levelappraisalofdefects不允许存在的缺陷Defectsbelowarenotallowedtoexist.不允许存在任何裂纹和白点；Cracksandwhitespots;结实件和轴类零件不允许任何横向缺陷显示。(2) Transversedefectsonfastenerandshaftpart.焊接接头的磁粉检测质量分级Levelappraisalofdefectsinweldjoint焊接接头的磁粉检测质量分级见表3。LevelappraisalofdefectsinweldjointisshownasTable3.等级/level线性缺陷磁痕/lineardefectsⅠ不允许/inadmissibilityⅡ不允许/inadmissibilityⅢL≤3.0〔等级/level线性缺陷磁痕/lineardefectsⅠ不允许/inadmissibilityⅡ不允许/inadmissibilityⅢL≤3.0〔35mm×100mm〕/rounddefects(areaofevaluationis35mm×100mm)d≤1.51个/d≤1.5,andnomorethan1intheevaluatedaread≤3.02个/d≤3.0,andnomorethan2intheevaluatedaread≤4.54个/d≤4.5,andnomorethan4intheevaluatedareaⅣⅣ大于Ⅲ级/greaterthanlevelIIIL表示线性缺陷磁痕长度，mm；d表示圆形缺陷磁痕长径，mm。Note:Lshowthelengthoflineardefects,mm;dshowthediameterofrounddefects,mm.受压加工部件和材料磁粉检测质量分级Levelappraisalofdefectsforpressurepartandmaterial受