球墨铸铁UT.doc

大连东北核工业设备无损检测有限公司 DALIAN NORTHEAST NUCLEAR INDUSTRY EQUIPMENT NON-DESTRUCTIVE TEST CO.,LTD 球 墨 铸 铁超 声 检 测 规 程Ultrasonic Examination Procedure forductile iron castings范业军2009年11月15日 内 容- CONTENT 一、适用范围APPLICABLE SCOPE 二、参考标准 REFERENCES STANDARD三、人员要求PERSONNEL QUALIFICATION四、术语和定义TERMS & DEFINITIONS 五、质量要求QUALITY REQUIREMENTS六、检测程序EXAMINATION PROCEDURE七、结论与报告EVALUATION AND REPORTING 一、适用范围APPLICABLE SCOPE本规程规定了大连东北核设备无损检测有限公司对球墨铸铁的超声波检测方法及评定标准；This procedure include examination method that Ultrasonic Examination of ductile iron castings with yoke performed by Dalian Northeast Nuclear Industrial NDT Co.,Ltd二、参考标准REFERENCES STANDARD2.1、美国无损检测协会American Society for Non-Destructive Testing(ASNT)SNT-TC-1A (2001)无损检测的资格和证书 Personnel Qualification and Certification in Nondestructive Testing2.2、欧洲标准European StandardEN 12680-3 (2003)铸造第三部分球墨铸铁超声检测Founding- Ultrasonic examination, Part3. Spheroidal graphite cast iron castings三、人员要求PERSONNEL QUALIFICATION3.1、从事超声检测人员需要持有美国无损检测学会颁发的资格证书； Ultrasonic Examination personal should hold certification by ANMT3.2、超声检测工艺规程和工艺卡由级人员编制； Ultrasonic Examination card and procedure qualificated by Level II personnel.3.3、UT的检测报告先由级以上人员签发。 UT examination report issued by Level II personnel.四、术语和定义TERMS AND DEFINITIONS4.1、样品认证：FPQ- First Piece Qualification4.2、批量认证：PLQ-Pilot Lot Qualification 4.3、供货商误差要求：SDR- Supplier Deviation Request五、质量要求QUALITY REQUIREMENTS 5.1、设备EQUIPMENT5.1.1超声波设备Ultrasonic Equipment 将使用脉冲反射式超声波仪表 Pulse-echo type ultrasonic instruments shall be used. 设备的最后检测日期和下次要求检测将在测试设备上表明。此期限不超过2个月。- The date of the last calibration and the date of the next required calibration shall be displayed on the test equipment. This time period shall not exceed 2 months.对于在钢中所传播的纵向和横向波段所设定范围从10毫米到2米将被连续检验，Range setting, from at least 10mm to 2m, shall be continuously selectable, for longitudinal and transverse waves transmitted in steel.测量结果以至少80dB内精度为1dB的区间进行调整，最大幅度为2dB. Gain shall be adjustable in 2 dB maximum steps over a range of al least 80dB with a measuring accuracy of 1 dB. 时基坐标和垂直曲线不得少于屏幕调整范围的5%。- Time-base and vertical linearities shall be less than 5% of the adjustment range of screen.设备将适合频率从0.5Mhz到5Mhz的单晶和双晶式探头。-Equipment shall be suitable for single or twin crystal probes which have frequencies from 0.5 Mhz up to and 5 Mhz. 5.1.2 探头 /换能器Probes/Transducers 测试时应使用24mm，2.0MHZ的单晶探头。为了使换能器与铸件表面在测量时准确，通常在换能器的接触面上加以软薄片。- Single Element Longitudinal Wave Probes - Tests shall be performed using a single element, 24 mm diameter, 2.0 MHz transducer. A soft membrane over the transducer contact surface shall be used to provide adequate coupling between the transducer and casting surface. Lower frequencies may be used if approved by GE Wind Energy.对于距探测面较近的检测区域将使用双晶探头。- Dual Element Longitudinal Wave Probes Twin crystal probes should be used for the examination of areas close to the test surface.单晶斜探头-对于特殊的表面条件，斜探头能够测量大约100mm的声程，对于在45至70度角也同样有效，频率值将选择有利于检测的0.5 Mhz 到 5 Mhz之间。- Single Element Angle Beam Probes For special geometrical conditions, angle probes can be used up to a sound beam path length of about 100mm, preferably with nominal angles between 45 and 70 degree. The frequency value shall be selected to suit the examination and shall be within the range of 0.5 Mhz and 5 Mhz.Higher frequencies can be used for examination wall thicknesses of less than 20mm or areas close to the surface.双晶斜探头-对于不连续性的近表面检测，建议使用双晶体或斜探头。- Dual Element Angle Beam Probes For the detection of near-surface discontinuities, the use of twin crystal and/or angle probes is recommended.5.1.3 耦合剂-液体耦合剂的粘性应在探头与铸件表面充分提供，使其良好耦合。在校准以及之后的检测操作中应使用相同的耦合剂。 Couplant - The viscosity of the liquid couplant used shall be adequate to provide good coupling between the transducer and surface of the casting. The same coupling medium shall be used for calibration and all subsequent examination operations.5.2质量检查QUALITY CHECKS5.2.1证明的有效期-除特别说明外，仪器质量检查每周都应进行，如果在任何检查期间证明检测设备的功能性不足时，自最后有效的设备测量日起，每次都应该重复检测。Verification validity Instrument quality checks shall be performed at least weekly unless otherwise stated. If during any check it is determined that the testing equipment is notfunctioning properly, each inspection performed since the last valid equipment calibration shall be repeated. 5.2.2检测试块-根据下列检测仪器的执行选择测量试块，试块在扩检区域和重点检测状态将给出几种互不干扰的多次底面反射，任何试块都应有良好的声波转换性，表面平行光滑及所要求检测范围的十分之一厚最为合适。 Calibration Block - A calibration or test block is needed to perform the following checks of the test instrument. This block shall give several non-interfering multiple back reflections for the sweep range and other test conditions of interest. Any block having good ultrasonic transmittance, flat parallel faces, and a thickness of about one tenth of the required sweep range is adequate.5.2.3垂直线性-将用观察线性检测来使用相同换能器测量试块的检测中多种次序样式。第一个底面反射将被设定为100%全屏高度，二次底面反射的10%和多次反射将被减少全屏高度的50%及25%。每次后面的底面反射的幅度都应被记录。如果较后面反射的单个高度按比例依次减少到第一个底面反射的设定标准，垂直线性将被认为是合格的，对于较高次序反射的削减的最大合理误差为预期底面反射高度的正负5%以上。Vertical Linearity - linearity check shall be made by observing a multiple order pattern from a calibration block using the same transducer to be used in examination. The first back reflection shall be set at 100 percent full screen height (FSH). The higher order backreflections 10 percent and higher in amplitude shall also be positioned on the screen and theiramplitudes noted. The first back reflection shall be reduced to 50 percent and then 25 percent of FSH. The amplitudes of the higher order back reflections shall be noted at each step. The vertical linearity will be considered acceptable if the signal heights of the higher order reflections decrease in proportion to the decrease set for the first back reflection. The maximum acceptable error for the decrease of the higher order reflections is the greater of plus or minus 5 percent of the expected back reflection height.5.2.4水平直线-测量试块用在多次反射技术上时应检查直线，直线可能出现的涉及测量铸件距离的错误应不超过全屏宽度的正负5%。Horizontal Linearity The linearity shall be checked on a calibration block using themultiple order technique. The linearity shall be such that the possible error involved in measuring over a distance equal to the maximum metal travel distance encountered in the casting shall not exceed plus or minus 5 percent of the full screen width.六、检测程序EXAMINATION PROCEDURE 6.1检测表面-铸件表面不应有任何影响检测的物体，例如氧化、污垢、油脂或其他外部因素，表面可带最大为500 minches的粗加工例如：浇铸，喷砂，气扫，打磨或加工，所有表面条件必须确保符合所要求的灵敏度。Test Surface The surface of the casting shall be free from any substance that might interfere with the examination, such as oxidation, dirt, grease, or other foreign matter. Surfaces may be as-cast, sandblasted, shot blasted, ground or machined with a maximum roughness of 500 minches (12.5 mm). All surface conditions must be adequate to ensure sufficient acoustic coupling for attainment of the required inspection sensitivity.6.2扫描速度- 对于单元件纵波和角梁测试每秒将不超过150mm。Scan Speed - The scanning speed for single element longitudinal wave and angle beam tests shall not exceed 150 mm per second. 6.3扫描格式-如直线格式方法应被建立以及显示区域应被检测。Scanning Grid A method such as a rectilinear grid pattern shall be established and used to show areas that have been inspected. 6.4重叠扫描-对于扫描所要求的全部覆盖区域应通过系统交叉扫描而建立。Overlapping Scan Complete coverage of all areas specified for scanning shall be conducted by carrying out systematically over-lapping scans.6.5检测区域Examination Area -在样品和批量认证期间需100%超声波，在系列产品超声测试必须在检测区域执行期间，应该在工件规格或图纸以及在样品和批量认证期间所发现的缺陷区域中明确。100% ultrasonic testing is required during FPQ and PLQ. During series production ultrasonic testing must be performed in the test area, which are defined in the component specification or drawings, and in trouble areas that were found during FPQ and PLQ.6.6测量时间-铸件超声检测应在所有进行热处理之后执行。 Time of Test - Ultrasonic inspection of castings shall be performed after all quality heattreatment.6.7检测测量Calibration for examination6.7.1 Reference block The reference block shall have the same ultrasonic properties as the casting to be examined and shall have the same surface finish. The reference block shall contain flat-bottomed holes according to .参考试块-参考试块应使用相同的超声工具如铸件的检测以及相同的表面处理。参考试块将根据表3 含有平底孔。6.7.2范围集合-范围集合将被实施。它要么在参考试块中进行要么在测量试件中进行，如果它的厚度是可知的，如果它的表面是平行的。铸铁可自身检测或直接在铸铁上进行。Range setting Range setting shall be carried out. It can be done either on the reference block or calibration block and checked on the casting itself or carried out directly on the casting, if its thickness is known and if it has parallel surfaces.6.7.3 DGS或DAC方法将被使用建立适当的检测灵敏度。The DGS or DAC method shall be used to establish the proper test sensitivity. 6.7.4观察灵敏度（最小性）-系统的敏感性将被建立根据表3所述全屏高度的回声高度至少要是屏幕高度的40%在被检测厚度的范围内。Detection (Minimum) Sensitivity The sensitivity of the system shall be set in such a way that the echo heights of the FBH given in the shall be at least 40% of the screen height at the end of the thickness range to be examined.6.7.5测试灵敏度-当对缺陷的探测，扩散应以屏幕可见噪音标准的方法设定。Search sensitivity When searching for discontinuities, the amplification shall be set in such a way that the noise level is visible on the screen. 6.7.6对声音动态，表面质量和声波通过铸件的速度应加以描述记录，应确定转换错误，当确定转换错误时，不仅连接区域而且向对面质量也应纳入考虑。Account shall be taken of the sound attenuation, surface quality and velocity of sound through the casting. The transfer correction shall be determined. When determining the transfer correction, not only the quality of the coupling areas but also the surface quality of the opposite surface shall be taken into consideration.6.8扫描技术Scanning technique根据下列技术或技术组合的具体部分图应被使用According to specific part drawing following technique or combination of techniques shall be applied.-单直探头Single Straight beam technique-双直探头Double Straight beam technique-单晶探头Single Angle beam technique-双晶探头Double Angle beam technique6.9 DGS方法 如果DGS方法用来测量应按下列方法进行DGS Method If DGS method is to be used calibration shall be as follows. 6.9.1测试灵敏性必须在铸件上建立，铸件表面必须平坦以及和对立平面平行，参考底面反射将在参考面上的指定位置确定，从而得出最弱的底面反射不归因于几何的干扰。Test sensitivity must be established on the casting where the surface is essentially flat and parallel to an opposing flat surface. The reference back reflection shall be obtained at theposition on the reference surface that produces the weakest back reflection not attributed togeometric interference. 6.9.2使用测量试块作检测灵敏度时，如果铸件对于确定参考底面反射没有合适的表面。测量试块的表面条件和底面的反射和声音动态必须等于或低于铸件检测的。A calibration block may be used to establish the test sensitivity if the casting has nosuitable surface for establishing the reference back reflection. The surface condition and sound attenuation of the calibration block must be similar or worse than the casting being inspected.6.9.3如果用在确定DGS底板参考的切面或试块厚度小于最大铸件测试厚度，那么仪器结果将被以超过测量厚度的铁板每25mm5dB幅度增加。If the section or block thickness (T) used to establish the DGS backwall references isless than the maximum test thickness of the casting(t), then the instrument gain shall be increased by 0.5 dB per inch (25 mm) of metal path beyond the calibration thickness: DGain = (t-T)inches X 0.5 dB / inch 6.10 DAC方法-如果DAC方法用来测量应按下列进行DAC Method If DAC method is to be used calibration shall be as follows. 6.10.1测量试块用来确定DAC时必须由一个与铸铁检测相似的铸件试块作比较，否则仪器的结果必须被曾加以对测量试块和铸件之间不同的解释。 The calibration block used to establish the DAC must have a surface condition and sound attenuation similar or worse than the casting being inspected. Otherwise the instrument gain must be increased (transfer) to account for differences between the calibration block and the casting. 6.10.2如果在铸件的某一位置所需转换，这个铸件表面应是平整并平行与向对面，参考底面反射将在参考面上的指定位置确定，从而得出最弱的底面反射不归因于几何的干扰。 If a transfer is required it must be established at a position on the casting where thesurface is essentially flat and parallel to an opposing flat surface. The reference back reflection shall be obtained at the position on the reference surface that produces the weakest back reflection not attributed to geometric interference. 6.10.3下列方程式应被用来转换，ACal等于从测量试块，铸件的底板反射波的振幅处（%FSH），Acasting=从铸件底板反射波振幅（%FSH）Tca=测试块的厚度，Tcasting=底板反射波获得处铸件的厚度。The following equation shall be used for the transfer, where Acal = amplitude(% FSH) of backwall echo from the calibration block, casting, Acasting = amplitude(% FSH) of backwall echo from the casting, Tcal = thickness of the calibration block, and Tcasting = thickness of the casting where the backwall echo is obtained: DGain = 20 log Acal / Acasting X Tcal / Tcasting Note : if DGain is 0 dB, then no adjustment in gain shall be made.6.10.4校准试块必须包含铸件上最大检测距离深度的反射物体。The calibration block must contain reflectors to the depth of the maximum test distance in the casting.6.11如果应用对偶直射波技术校正，应该以DAC方法为基础实施。If Dual Element Straight Beam Technique is to be used calibration shall be conducted based upon DAC method. 6.12如果使用斜射波技术，灵敏度应该被校正如6.7.5.斜射波技术应该只被使用于探测不连续性，而不是用于评估。但是如果裂纹缺陷类指示被发现，结果应该被记录和否定。If Angle beam technique is to be used, sensitivity shall be adjusted as 6.7.5. Angle beamtechnique can be used only to detect discontinuities not for evaluation. But crack-likeindications are found, results shall be reported and rejected.七、EVALUATION AND REPORTING 评估与报告7.1墙截面区域墙的截面应该被如图所示划分为以后区域。Wall section zones the wall section shall be divided into zones as shown.7.2尺寸Sizing7.2.1不连续的尺寸测定主要平行于检测表面Determination of the dimensions of discontinuities mainly parallel to the examination surface.为了测定缺陷的尺寸主要平行于检测表面，建议在缺陷区域使用最小声束直径的探头。In order to determine the dimensions of discontinuities mainly parallel to the examination surface, it is recommended that probes with the smallest possible sound-beam diameter at the discontinuity location are used. 对于尺寸的测定，应该按照（表1）根据他们的回波高度（表四）来记录。探头应该在检测区域移动来辨别这点，在那里信号的振幅在最后一个最高点后降低6dB。For the determination of the dimensions which shall be recorded according to on account of their echo height (table4), the probe shall be moved over the examination area to identify those points where the signal amplitude falls 6 dB below the last maximum.对于回波降低量，探头应该在检测区域移动来辨别这些点，在那里后壁回波根据表格4降低12dB或者20dB。在这两种情况下，这些点应该被尽可能准确的标记。- For backwall echo reduction, the probe shall be moved over the examination area to identify those points where the backwall echo is reduced by 12 dB or 20 dB acocording to .- In both case, the points shall be marked as accurately as possible.不连续可测量的尺寸由两个标记点之间的连线给出。使用斜探头，不连续的边缘点应该投影于检测表面，只要铸件几何形状允许。The measurable dimensions of the discontinuity are given by a connecting line between the marked points. With angle probes, the edge points of the discontinuities shall be projected onto the examination surface so far as the casting geometry allows.7.2.2. 穿壁方向的规格和不连续性的测定Determination of the dimensions of discontinuities in through-wall direction 尽可能的，检测区域在穿壁方向上的不连续的规格使用普通探头在对边测量。As far as possible, dimensions of discontinuities in through-wall direction to the examination area are measured using normal probes from opposite sides.7.3考虑指示的各种类型Consideration of various types of indications以下各种类型的指示，已证明为不是由于铸件形状或者耦合引起，应该在铸件检测中列入考虑和评估。The following types of indications, 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.-后壁回波降低量Reduction of the backwall echo-中间波Intermediate echoes7.4评价和记录指示：Evaluation and recording of indications7.4.1如果他们的值超过表1和2给出的限定的75%，所有后壁回波降低量或回波高度达到或超过如表四给出的限定，应该被评价和记录。All backwall echo reductions or echo heights reaching or exceeding the limits given in shall be evaluated and shall be recorder if their values exceeds 75% of the limits given in 7.4.2只要这样的指示被发现，他们的位置应该被指出和包括在检测报告中。Whenever such indications are found, their location shall be indicated and included in the examination report.7.4.3应该使用表格、草图和曲线图描述记录的指示位置。The location of the indications to be