UT探伤通用规程.doc

超声波探伤通用规程UT General Specification14/14 Material: EN-GJS-400-18U-LT REFERRENCE: EN 12680-3 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-Personnel4.0超声波检测/ Ultrasonic testing5.0检验报告/Examination report1.0 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 covered by this specification.2.0参考规范/referenceGB9445-99：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 personnelEN473 ： 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：无损探伤人员资质/ qualification and certification of NDT personnelEN12680-3：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 cleanliness993062：超声波设备的校准/Ultrasonic equipment calibration and verificationEN126681：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 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-PersonnelNDT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 certification 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 personnelEN473 ： 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 should 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 testing4.1表面条件/surface conditioning在零件作超声波检查以前，表面要达到ISO 8501-1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 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.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 have the following character:-量程设定，设定范围需至少为10mm2m，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 with 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 for nominal frequencies 2 MHZ in pulse-echo technique with single-crystal and twin-crystal probes.-以下探头至少要有一个被使用: SEB2-00(MSEB2)和B2S(MB2S)或者有一个相同特性的探头。探头SEB2-00 (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SEB2-00 和B2S探头检测, 当需要精确测量缺陷的边界时使用MSEB2-00 和MB2S探头。-Following probe head must have at least one to be used: SEB2-00 ( MSEB2) and B2S ( MB2S) or have a same characteristic probe head. The probes of SEB2-00 (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 SEB2-00 and B2S for inspection. If needs to identify the actual borderline of the defects, use the probes of MSEB2-00 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 the 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 values for standard probes mentioned in Table 1 may be used.声程（mm）Sound pathSEB2声束直径（mm）Diameter of sound beam for SEB2MSEB2声束直径（mm）Diameter of sound beam for MSEB2B2S声束直径Diameter of sound beam for B2S20155-20-601515-60-120202512表 1.标准探头的校正值/table 1 Correction values for standard probes4.3.3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 REFERENCESEN126683 无损检测超声设备的特点和验证第三部分：设备组合。EN 12668-3 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 Reference 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. 0613164.4.3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。Initially 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 the 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 since 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 in 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 duration4.4.4.1物理状态和外形/Determination of physical state and external 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 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 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 ratio1用TIF试块上（从端部）深度35mm处的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- value2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 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 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 instrument 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 BEB102.4100.4=2.0mm4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% find 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 amplifier 4.4.5.1时基水平线性的测量/Determination of linearity of the time base1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 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 the 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 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Limits2101不小于95/Not less than 95%0806403743122017231810812245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 has to be filed at the quality responsible for the department. The requirements of filing follow the existing rules 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 setting4.5.1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 checked 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 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% 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 echo to 80% of the full screen height with the casting max wall thicknessas the FBH. And then use the DGS software of KSR3mm for 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 specified 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% 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 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 Standard4.8.1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 level123受检区域中的壁厚/wall thickness in the examined areamm-5050 to 2002005050 to 200200壁厚百分比/percentage of wall thickness-2025表层的最大缺陷面积/the largest allowed individual indication in the rim zonea,mm2b6001 0001 0001 0002 0002 000心部的最大缺陷面积/ the largest allowed individual indication in the core zonemm2b10 00015 00015 00015 00020 00030 000缺陷总面积占被检表面积的百分比Total area of discontinuities as percentage of examined surfaceb101515152020夹渣/Dross夹渣必须被清除/Dross must be removed a. 边缘区见图 1 Rim zone, see figure 1.b. 任何缺陷均不得超过表3中给出的极限值，否则要记录。No indications exceeding the limits given in table 3，otherwise needs to be recorded.图 1/ figure 1.图例索引/index1 表示表层区/Rim zone 2 表示中心区/Core zonet 表示总壁厚Wall thickness a 表示1/3的壁厚（最大不超过30mm）t/3(max.30mm)表 3 / table 3受检区域的壁厚(mm)Wall thickness of the casting in the examined area(mm)评估的极限/Evaluation limits底波衰减最小（dB）reduction of back wall echo (min dB)能够检出的最小缺陷当量(mm)/Smallest flat-bottom hole diameter detectable 回波高度高于噪声最小（dB）a Echo height above noise level min(dB) a10 to 20123620 to 100205100 to 250812250 to 50010a仅适用于由于铸件几何形状的原因而无法接受一次回波的区域。Only for areas where no back wall echo is obtained to the casting geometry.4.8.2铸件需按采购规范规定的范围内进行实验，并要满足以下要求: （不连续性）机加工表面缺陷，例如收缩、砂子和夹渣、气孔等均不允许在机加工表面上出现。因此，铸件内部的不均匀性（缺陷），如估计在机加工以后会变为表面的不均匀性（缺陷），应向采购商提出，并有采购商做出决定。The casting must be tested in the scope according to the purchase standard, and must satisfy requests below: (Discontinuity) machining surface defect, for example shrinkages, sand and slag inclusions, blowhole etc. will not be permitted in machining surface. Therefore internal discontinuities in the casting which is estimated to be change to a surface discontinuities after machining shall be brought to the attention of purchasing agent and decide upon.4.8.3各种迹象的考虑:/ Consideration of various types of indications:4.8.3.1以下的指示类型,如果不是因为由于铸件的形状或耦合问题导致的,则必须加以评价.The following types of indication, which are proven not to be due to the casting shape or the coupling, shall be taken into consideration and evaluated in the examination of castings:-一次回波的降低/reduction of the back wall echo;-中间的回波/intermediate echoes 注释 所有类型的指示有可能单独发生也可能同时发生。NOTE all types of indications can occur alone or together.4.8.3.2缺陷的评定和记录:/ Evaluation and recording of severities:应对底波损失达到或超过表3中的回波高度进行记录与评定, 对于缺陷显示超过表2里给定范围的75%时,应将其位置利用草图描述并记录在检验报告中。The damnify of the bottom echogetting to or above the height of e