球墨铸铁MT1.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 铁磁 粉 检 测 规 程Magnetic Particle Examination Procedurefor ductile 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 SCOPE OF APPLICATION1.1、本规程规定大连东北核设备无损检测有限公司用磁轭对球墨铸铁的磁粉检测方法； This procedure include examination method that Magnetic Partile Examination of ductile iron castings with yoke performed by Dalian Northeast Nuclear Industrial NDT Co.,Ltd1.2、本规程适用于球墨铸铁铸件表面、近表面的缺陷检验； This procedure will be suitable for surface、Near surface flaw examination of ductile iron castings 1.3、本规程包括干磁粉、湿磁粉、萤光磁粉检验方法。 Dry 、wet、flsorescence Partile test methods will be specified in this procedure二、参考标准 REFERENCE STANDAR大连核设备无损检测有限公司参考欧洲EN1369（1996）球墨铸铁磁粉检验的需要编制此规程。The procedure is issued according to Europe (1996) Magnetic Partile Examination for ductile iron castings by Dalian Northeast Nuclear Industrial NDT Co.,Ltd 三、人员要求 PERSONAL REQUIRMENT3.1、从事磁粉检验人员需要持有美国无损检测学会颁发的资格证书； Magnetic Partile Examination personal should hold certification by ANMT3.2、磁粉检测工艺规程和工艺卡由级人员编制； Magnetic Partile Examination card and procedure qualificated by Level II personnel.3.3、MT的检测报告先由级以上人员签发。 MT 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 Qualification4.3、供应商误差要求：SDR- Supplier Deviation Request4.4、非线性指示：SM-Non-linear indication 当长度L小于三倍宽度的时候，认为是非线性指示。非线性指示的标志是SM。The indications are considered to be non-linear when the length L is smaller than three times the width W. The symbol for non-linear indications is S (surface) M (magnetic particle).4.5、线性指示：LM-Linear indication 当L大于或等于3W时，指示被认为是线性的。线性指示的标志是LM。The indications are considered to be linear when L is greater than or equal to 3 W. The symbol for linear indications is L (linear) M (magnetic particle).4.6、对齐指示：AM-Aligned Indication： 在以下情况下，考虑对齐指示：Indications are considered to be aligned in the following cases 非线性：指示之间的距离小于2mm和至少标注三个指示。- nonlinear: the distances between indications is less than 2 mm and at least three indications are noted.线性：两个指示之间的距离小于同一直线上的最长不连续之间的长度L。 - linear: the distance between two indications is smaller than the length L of the longest discontinuity in the alignment. 对齐指示被认为是唯一指示。它的长度被评价为指示长度加上距离。 - An alignment of indications is considered to be a unique indication. Its length is evaluated as the lengths of the indications plus the spaces. 4.7、截面厚度类型：Section thickness type 三种截面厚度类型被指定：Three section thickness types are specified. a: t = 16 mm b: 16mm t 50 mm where t is the section thickness.4.8、严格级别：Severity level 对于非线性指示：严格级别被以下所定义：For the non-linear indications, the severity levels are defined by最小指示的长度（最大尺寸）L1被列入考虑。the length (largest dimension) L1 of the smallest indication to be taken into account如果合适，在给定的表面，指示的区域的最大面积和。（框架105 mm * 148 mm相当于ISO版式A6）if applicable, the maximum total surface area of the indications in a given surface (the frame 105 mm * 148 mm corresponds to the ISO format A6)指示的最大长度L2the maximum length L2 of the indications对于线性和对齐指示，严格级别被以下所定义：For the linear and aligned indications, the severity levels are defined by最小指示长度（最大尺寸）L1被列入考虑。the length (largest dimension) L1 of the smallest indication to be taken into account线性和对齐指示的最大长度L2the maximum length L2 of the linear and aligned indications线性和对齐指示的长度和在框架105 mm * 148 mm中超过长度L1。the sum of the length of the linear and aligned indications exceeding the length L1 in the frame measuring 105 mm * 148 mm.五、质量要求QUALITY REQUIREMENTS 5.1、设备EQUIPMENT 5.1.1湿粉Wet Particles 应该使用以下表格或等同的喷雾剂类型磁粉喷雾。磁粉颗粒应该在一种适当的液体媒介中悬浮，以SE-709磁粉检测的标准操作规程建议中推荐的浓度。这个规程还包含对其他的湿粉检测的明确要求。磁粉浓度由制造商的认证并决定。磁浮液和工件表面的温度不应超过135。The aerosol type magnetic particle sprays of following table or equivalent shall be used. recommended in SE-709, standard Recommended Practice for Magnetic Particle Examination, which contains additional specific requirements on the use of wet particles. The concentration of magnetic particle will be determined by the manufacturers certificate. Temperature of the wet particle suspension and the surface of the part shall not exceed 135. Manufacturer厂家Brand商标Model模型KangSungMicroMagnaMPS-BNawooPico Mag7C BLACKKyund-DoMagnaflux7C BLACK5.1.2 磁粉设备（磁轭）Magnetizing Equipment (Yoke) -交流电磁轭应该用于表面检测。- Alternating Current electromagnetic yoke shall be used by surface inspection.-设备调校设备应具有至少10 lb(4.5k)的提升力在使用最大杆档时。磁轭的磁化力应该每六个月检查一次或每当磁轭损坏的时候检查。如果磁轭还没有使用到一年以上，第一次使用前应进行检查。- Calibration of Equipment - The equipment shall have a lifting power of at least 10 lb(4.5k) at the maximum pole spacing that will be used. The magnetizing force of yokes shall be checked in every 6 months or whenever a yoke has been damaged. If a yoke has not been in use for a year of more, a check shall be done prior to first use.5.1.3磁场指示器Magnetic Field Indicator 当必须证明磁场的方向性和充分性时，应该使用一种场指示器放置在被检测面上。When it is necessary to verify the adequacy or direction of the magnetizing field, a field indicator shall be used by positioning the indicator on the surface to be examined. 当使用指示器时，同时对磁粉施加磁力，可指示出合适的磁通量或磁场强度，一条清楚的界定线或磁粉交叉线出现在指示器的铜币表面。When using this indicator, a suitable flux or field strength is indicated when a clearly defined line of magnetic particles from across the copper face of the indicator when the magnetic particles are applied simultaneously with the magnetizing force. 当一条清楚的磁粉定义线未形成或未在期望方向形成时，应改变或调整磁化方法。When a clearly defined line of particles is not formed or is not formed in the desired direction, the magnetizing technique shall be changed or adjusted.5.2、质量检查Quality Checks (1) 检验之前，质量和灵敏度应该被核实如下：Prior to examination, quality and sensitivity shall be verified as follows. (2) 磁轭的提升力被核实在大于4.5 kg。Lifting power of yoke shall be verified as over 4.5 kg.(3) 检验区域的照明被核实为大于1000 lux.Illumination of examination area shall be verified as above 1000 lux.(4) 磁场指示器应该用于充分性和部分磁化方向的灵敏度检查。在审查中，这部分在检测时必须产生充足的磁场以在指示器中清楚的显示测试图形。A magnetic field indicator shall be used for sensitivity check of the adequacy and direction of part magnetization. A sufficient magnetic field must be generated in the part under examination to clearly develop the test pattern in the indicator.六、检测程序EXAMINATION PROCEDURE 6.1、Surface Preparation 表面准备6.1.1 要检测的表面应该干燥且无尘，无油脂、皮棉、水锈和喷溅，油或其他可干扰检测的外来杂质。The surface to be examined shall be dry and free of all dirt, grease, lint, scale and spatter, oil or other extraneous matter that could interfere with the examination.6.1.2 表面应该或使用喷丸处理或喷砂处理，或打磨或机械加工以便最小的指示能被列入考虑。The surface may be either shot blasted with round or angular shot, or sand blasted, or ground or machined so that the smallest indication can be taken into account. 6.1.3干粉检测在材料表面温度大于135时，不能执行。Wet Particles examination shall not be performed at the material surface temperature above 135.6.2、照明Lighting 检测区域应该有足够的照明为了对检测表面的指示作出合适的评估。检测时候，工件表面的可见光强度应该最小为1000 lux。The test areas shall be adequately illuminated for proper evaluation of the indications revealed on the test surface. The intensity of the visible light at the surface of the part/work piece undergoing examination should be a minimum of 1000 lux. 6.3、预检Preliminary Examination 在磁粉检测进行前，应先进行目视检测以指定任何不连续的表面缺口，这些缺口会由于他们的宽度会吸引和聚集磁粉。要检测的工件表面的可见光强度应该至少是1000 lux。Before the magnetic particle examination is conducted, visual examination shall be conducted to locate any discontinuity surface openings which may not attract and hold magnetic particles because of their width. The intensity of the visible light at the surface of the part/work piece undergoing examination should be a minimum of 1000 lux. 6.4、磁化方向Direction of Magnetization 在各个区域至少两个单独的检测应该被执行，以这种方式，第二磁通量的磁力线近似垂直于第一磁通量的磁力线。At least two separate examinations shall be performed on each area in the manner that the line of second magnetic flux is approximately perpendicular to that of first.6.5、磁粉施加Application of Particles 6.5.1在检测前，被检测表面可以喷反差剂以便检查。The surface to be inspected may be white painted to provide a contrast before inspection.6.5.2检测应使用连续法。Examination shall be carried by the continuous method. 6.5.3当磁场穿过这部分时，喷雾罐里的磁粉应该喷洒在被检测区域上。Magnetic particles which contained in aerosol cans shall be sprayed over the area being examined, while the magnetic field is passed through the parts. 6.6、检测Examination 6.6.1检测应该在足够的照明下执行。检测时，光在工件表面的强度应该至少为1000 lux。The examination is performed under adequate illuminations. The intensity of the light at the surface of the part/piece undergoing examination should be a minimum of 1000 lux. 6.6.2扫描格式类似于直线网格的方法应该被建立和用来显示已经被检测过的区域。Scanning Grid A method such as a rectilinear grid pattern shall be established and used to show areas that have been inspected. 6.6.3检测重叠Examination Overlapping 所有检测应该以足够的重叠实施，以保证在要求的灵敏度下覆盖百分之百的范围。All examinations shall be conducted with sufficient overlap to assure 100% coverage at the required sensitivity.6.6.4检测区域Examination Area 1) 在EPQ和PLQ中要求执行百分之百的表面裂纹检测。During FPQ and PLQ it is required to perform 100% surface crack inspection.2) 在成批生产中，表面裂纹检测必须在部件说明书或图纸的检测区域执行，或在FPQ和PLQ的问题区域。During series production surface crack inspection must be performed in the test areas in the component specification or drawings and in the trouble areas that were found during FPQ and PLQ. 6.7、退磁和后清理Demagnetization and post cleaning 当剩余的磁性残留在工件上会干扰后加工或使用时，检测完成后，工件应该消磁和随时检查。When residual magnetism in the part could interfere with subsequent processing or usage, the part shall be demagnetized and checked any time after completion of the examination.1) 需要进行退磁来减少剩余的磁性。对于直流电，重复反向和逐渐减少电流。Demagnetization is required to reduce residual magnetism. For direct current, repeatedly reverse direction and progressively decrease current. 2) 就像用于检测一样，在同一位置放置磁轭来完成退磁，运用电流和从表面两英尺位置提升磁轭。Demagnetization shall be accomplished by placing the yoke in the same position as used for examinations, applying current and lifting the yoke from the surface for a distance of two feet .3) 用磁通量剂来检查退磁。剩余的磁性应该少于3高斯。Check the degree of demagnetization with magnetic flux meter on the surface. Residual magnetism shall be less than 3 gauss.4) 整个表面应该用干净的干布擦拭，所有临时的塞子都应该从孔和洞移走。The complete surface shall be then wiped by using clean dry cloths. All temporary plugs shall be removed from holes and cavities. 七、EVALUATION AND REPORTING 评估与报告7.1、概要General 7.1.1表面的机械损伤会通过磁粉检测被显现出来，所有的指示不全是缺陷，然而，因为一定冶金学的不连续和磁导率变化会产生相似的指示，这种指示与不可接受的不连续的显示无关。Mechanical discontinuities at the surface will be indicated by the retention of the examination medium. All indications are not necessarily defects, however, since certain metallurgical discontinuities and magnetic permeability variations may produce similar indications which are not relevant to the detection of unacceptable discontinuities.7.1.2任何被认为非相关的指示都应该被再次检测以保证核实是否是真实的缺陷显示。表面清理应先于再次检测。能够掩盖缺陷指示的非相关指示是不可接受的。Any indication which is believed to be nonrelevant shall be reexamined to verify whether or not actual defects are present. Surface conditioning may precede the reexamination. Nonrelevant indications which would mask indications of defects are unacceptable.7.1.3相关指示是由那些不合格加工的不连续性导致的。Relevant indications are those which result from unacceptable mechanical discontinuities. 7.1.4伤痕的指示可能会大于引起缺陷磁痕不连续性，然而，伤痕的尺寸和/或缺陷的尺寸是接受或否定的基础。An indication of a discontinuity may be larger than the discontinuity that causes it ; however, the size of the indication and/or the size of the discontinuities is the basis of acceptance or rejection.7.2、使用表格2和表格3的指标分类Classification of the indications using table 2 and 3 7.2.1为了给不连续指示分类，有必要放置一个105mm * 148mm得框架在最不利的位置，也就是，对不连续使用最大的严格程度。In order to classify a discontinuity indication, it is necessary to place a 105mm * 148mm frame in the most unfavorable location, i.e. showing the greatest severity for discontinuities.7.2.2非线性指标Non linear indications 只有那些长度大于L1得指示被列入考虑（见表格2）Only those indications with a length greater than L1 shall be taken into account (see Table 2)应该计算所有表面区域指示的总和。The sum of the surface areas of these indications shall be calculated.应该测量这些指示的长度。The length of these indications shall be measured.使用表格2，应该建立SM指示的级别。The level of the SM indications shall be established using Table 2.7.2.3线性和均衡指标Linear and Aligned Indications 如果单独指示的长度L大于在要求中的严格等级中定义的最小考虑长度，则应该被测量。指示的总和包含在105 mm * 148 mm框架内的应该被计算。The length L of the isolated indication greater than the minimum length taken into account, defined by the required severity level, shall be measured. The sum of the indications included in the 105 mm * 148 mm frame shall be calculated. 检测部位的剖面厚度应该被计算。The section thickness t at the inspection location shall be measured.应该使用表3建立LM和AM的指示级别。The level of the LM and AM indications shall be established using table 3.线性和对齐指示的长度大于最小长度的应该求和，其结果应该与表三中指定的累计长度做比较。The length of the linear & aligned indications greater than the minimum length shall be summated and result shall be compared to the “cumulative” length specified in Table 3.7.3、使用相关图形的指标分类Classification of the indications using the reference figures7.3.1严格等级5相当于最大的指示。严格登记1相当于最小的指示。 The severity level 5 corresponds to the largest indications. The severity level 001 corresponds to the smallest indications.7.3.2通常，只使用1、2、3、4、5级的参考图表。Normally, only the reference figures for severity level 1,2,3,4 and 5 are used.7.3.3参考图标等同于非线性及线性和对齐指示（见列表2和列表3），在附件B和C中表明。The reference figures equating to the non-linear as well as the linear and aligned indications (see Table 2 and 3) are shown in annexes B and C.7.3.4当指示的相同总和的表面（非线性）和/或相似表面的线性或对齐指示的相同长度被发现，一个真实的图表和一个参考图表是等同的。最大允许的不连续可能同时出现在105mm * 148mm的面积内。An actual figure and a reference figure are equivalent when the same total surface of indications (non-linear) and/or the same length of linear or aligned