球墨铸铁PT.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 铁渗 透 检 测 规 程Liquid Penetrant Examination Procedurefor Ductile Iron Castings范业军2009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、APPLICABLE SCOPE适用范围This procedure include examination method that Liquid penetrant Examination of ductile iron castings with yoke performed by Dalian Northeast Nuclear Industrial NDT Co.,Ltd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渗透检测方法及评定标准；二、REFERENCES STANDARD参考标准The following documents shall form a part of this procedure to the extent specified herein. Unless otherwise indicated, the latest issue shall apply. 用以扩展此规格下列文件应作为次程序的一部分，除非有特殊说明，否则应以此为准2.1 、General Electric Wind Energy通用电气风能GEWE.all._spc_castings_supplement (Rev. 00)通用电气风能：全部-规格-铸件-补充General Requirements Ductile Iron Castings 对球墨铸铁的一般要求2.2 American Society for Non-Destructive Testing(ASNT)美国无损检测协会SNT-TC-1A (2001)Personnel Qualification and Certification in Nondestructive Testing无损检测人员资质及证明2.3、European Standard EN1371-1 (1997) 欧洲标准Founding Liquid penetrant inspection铸件-液体渗透检测Part 1: Sand, gravity die and low pressure die castings 第一部分：沙石，硬金属及低压金属铸铁2.4、ASTM Standards 美国材料协会标准 ASTM E-165 (2002)Standard test method for liquid penetrant examination 液体渗透标准检测方法三、PERSONNEL QUALIFICATION人员要求3.1、Liquid penetrant examination shall be performed and evaluated by personnel certified to PT Level II in accordance with the “SY/P-TP-001”(Personnel Qualification and Certification) which is based upon ASNT documents SNT-TC-1A. 液体渗透检测应根据SY/P-TP-100(人员资质及证明)在ASNT文件SNT-TC-1A的基础上Y由PT二级人员操作机评定。3.2、Results of the examinations shall be evaluated by the certified Level II or Level III personnel.I 检测结果应由二级或三级资质的人员审定。四、TERMS&DEFINITIONS术语和定义4.1、FPQ- First Piece Qualification样品认证4.2、PLQ-Pilot Lot Qualification批量认证4.3、SDR- Supplier Deviation Request供应商偏差要求4.4、SP and CP, Non-linear indication单独及集合渗透，非线性标识 An indication with a largest dimension less than three times its smallest dimension. (i.e. L = 3W)最大尺寸的标识是最小尺寸的三倍或更多4.6、AP, Aligned Indication直线标识 Indications are considered to be aligned in the following cases在下列案例时标识被认为是独立的nonlinear: the distances between indications is less than 2 mm and at least three indications are noted非线性：小于2mm和至少三个标识之间的距离应被标注linear: the distance between two indications is smaller than the length L of the longest discontinuity in the alignment. 直线型：两个标识之间的距离小于直线标识中最长不连续的长度An alignment of indications is considered to be a unique indication. Its length is evaluated as the lengths of the indications plus the spaces. 直线表示被认为是独立的标识，它的长度作为标识加上区域的长度而进行评定4.7、Section thickness type切面厚度类型 Three section thickness types are specified.三个规定的切面厚度类型 a: t = 16 mm b: 16mm t 50 mm where t is the section thickness.T是切面厚度。五、QUALITY REQUIREMENTS质量要求 5.1、EQUIPMENTS设备5.1.1 Penetrant Materials渗透材料 Materials shall be demonstrated by certificate which meets the requirements of ASTM D129, D808. Following materials shall be used 渗透材料有符合ASTM D129 , D808标准的证明文件所加以说明，下类为常用材料：Material材料Type型号Manufacturer制造商Remark标注Penetrant渗透MICOR CHECKPAKangsung Industrial Co., Ltd.Remover清洗剂MICOR CHECKRAKangsung Industrial Co., Ltd.Developer显色剂MICOR CHECKDAKangsung Industrial Co., Ltd.5.12、Lighting光照The test are shall be adequately illuminated for proper evaluation of the indications revealed on the test surfaces. The intensity of the visible light at the surface of the part/work piece undergoing examination should be a minimum of 100 foot candles (1000 lux). 测试应该有足够的光照以对检测面上显示的缺陷作出正确的评估。被检工件表面的可见光强度应该至少为1000lux。5.13、Liquid Penetrant Comparator液体渗透对比仪The liquid penetrant comparator blocks described in ASME Sec. , Art. 6 shall be used.使用在ASME第五章第六节中所描述的液体渗透对比仪试片5.2 QUALITY CHECKS质量核对(1) Prior to examination, quality and sensitivity shall be verified as follows. 在检验前，质量及敏感度应按下列加以检查(2) Illumination of examination area shall be verified as above 1000 lux.检验区域的照明应1000LUX之上时加以核准(3) A Liquid penetrant comparator shall be used for sensitivity check of the adequacy of penetrant examination.液体渗透对比仪用在渗透检验敏感度核对上.六、EXAMINATION PROCEDURE检测程序6.1、Surface Preparation表面处理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. 检验表面应干燥并且无油，污染物，保护网。水垢，飞溅物或其他影响检测的因素6.2、Lighting照明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. 检测区域应进行 适当的照明以保证检测面所标注的标识能准确评定，检测工件表面可见光强度最少为1000LUX6.3、Preliminary Examination初步检测Before the penetrant examination is conducted, visual examination shall be conducted to locate any discontinuity surface openings which may not attract and hold penetrant 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. 在渗透检测进行之前，应进行目测以定位任何不连续性表面开口，这些开口可能因为宽度导致不吸附和进行渗透。被检工件表面的可见光照度应该至少为1000lux。6.4、Temperature温度The temperature of the penetrant and the surface of the part to be processed shall not below 50(10) nor above 125(52) throughout the examination permitted provided the part temperature remains in the range of 50(10) to 125(52) during examination. When it is not practical to conduct a examination within the above temperature range, the examination procedure at the proposed lower or higher temperature range require qualification in accordance with ASME Sec. , Art 6, T-653 and another written procedure shall be developed for use.渗透和工件表面加工温度不应低于10，不能高于52，在检测期间所符合检测的工件的温度应保持在10至52之间，当在以上温度范围内不能进行检测时，ASME第五部分第六节T-653和其他书面程序中所给出的最高和最低温度应根据使用加以更改。6.5、Removal of Excess Penetrant抽样和附加渗透Excess solvent removable penetrants shall be removed from all surfaces as follows :按下列要求附加溶剂抽样渗透从表面除去1) The surfaces shall be thoroughly wiped with a cloth or absorbent paper, repeating the operation until most traces of the penetrant have been removed. 表面应彻底用用麻布或吸纸擦抹， 知道渗透痕迹全部除去。2) All remaining excess penetrants shall be removed by lightly wiping the surfaces with a cloth or absorbent paper moistened with a solvent.所有附加渗透应用麻布或带有吸附剂的吸纸轻轻擦去。3) To minimize the removal of the penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. 为了缩小不连续性的抽样渗透，应小心清理以防止过量使用溶剂6.6、Surface Drying表面干燥Surfaces shall be dried by normal evaporation, blotting, wiping or forced air表面应通过正常的蒸发，吸释，擦拭或气扫加以干燥。6.7、Application of Developer显色剂的使用The developer shall be applied as soon as possible after the penetrant removal and the part has been dried, until the surface is completely covered. It is suggested that the aerosol can be held about 10 inches from the work surface and the developer be applied in short dusting strokes. The application of excessive developer shall be avoided, since it is possible for a thick coating of developer to mask indications. Conversely, a developer coating too thin in application prevents adequate background contrast from being achieved. Prior to applying the liquid developer, the suspension must be thoroughly agitated to ensure uniform dispersion of the particles. Final interpretation of indications shall be made within 7 to 60min after the minimum developing time of Is satisfied.在抽样渗透和工件干燥之后当可能时使用显色剂，知道表面完全覆盖，建议当工件表面10英寸时使用喷雾器，显色剂只能用在短距离除尘，这样可以避免过量使用显色剂。因为显色剂的涂层厚可以起到掩盖表示的作用，相反，显色剂的涂层太薄会妨碍正确背景的对比，在使用液体显色剂之前，应先摇晃以确保磁粉能均匀分布，最后的判定应在最有利驻留时间表中所述的最小显色时间之后的6至7秒中内决定。6.8、Post-cleaning-后继清理Remove all penetrant testing materials from the surfaces examined using solvent cleaners and clean upon completion of this examination.使用清洗溶剂从表面除去渗透材料并对整个实验进行清洗最短驻留时间表Material材料Form操作Type of Discontinuity不连续样式Dwell Times驻留时间 (1)Penetrant渗透Developer显色剂Aluminum, Magnesium, Steel, Brass and bronze, Titanium and high temperature alloys铝，镁，钢，黄铜及青铜，钛和高温合金Casting and Welds铸铁机焊缝Wrought materials- extrusion,forging, plat制造材料，锻压，铸造，板材Cold shuts, porosity, lack of fusion, cracks(all from)Laps, cracks (all form)冷隔，空隙，裂缝。折皮 7 Min10 Min7 Min6 MinCarbide-tipped tools硬性合金工具Lack of fusion,Porosity, cracks5 Min7 MinNote (1): For temperature range from 50 to 125 (10 to 52)6.9、Procedure for Nonstandard Temperature非标准温度程序1） When it is not practical to conduct a liquid penetrant examination within the temperature range of 50 (10) to 125 (52), the examination shall be carried out according to proper process by proving the same sensitivity using the quench cracked aluminum block(liquid penetrant comparator block) prepared as specified in ASME Section V, para. T-653, as specified on the below paragraph. 当在10至52之间温度范围内不能进行检测时，检测应在具有同等敏感条件的铝块上进行，根据ASME第五章T-653所规定的标准。2） To qualify a procedure at a temperature of less than 50 (10), the proposed procedure shall be applied to block “B” after the block and all materials has been cooled and held at the proposed examination temperature . A standard procedure shall be applied to block “A” in the 50 (10) to 125 (52) temperature range. If the indications obtained under the proposed condition on block “B” are essentially the same as obtained on block “A”, the proposed procedure shall be considered qualified from purposed temperature to 16为了使工艺在10以下能达到标准，建议工艺在试块B 和所有材料冷却之后和保持建议的试验温度之后进行，标准工艺应在10至52温度范围之间进行，如果标识在试块B和试块A的理想条件大致相同时获得，那么所推荐程序在推荐温度到达16时被认为合格工艺。3） To qualify a procedure at temperature above 125(52) block “B” shall be held at proposed temperature throughout examination. The indications shall be compared as described in para. 5.10(2) while block “B” is at the proposed temperature and block “A” is at 50 (10) to 125 (52) temperature range. When proposed temperature will be the upper temperature limit and the lower temperature limit will 为了使工艺在52以上能达到标准，试块B的温度应保持在推荐温度，标识进行比对按5.10（2）段中描述当试块B在推荐温度时和试块A在10至52之间时，当推荐温度高于上限或低于52时， Be 125(52). If further examination procedure is qualified at more than the first temperature, the first proposed temperature will be the lower limit, and the upper limit will be the second proposed temperature. 如果之后检测程序温度高于第一次温度是，第一次温度将视为最低限度，最高限度将视为第二次推荐温度。4） The above qualification record shall be attached on this procedure when used.以上认证记录将附在此程序中当使用6.10检测区域。6.10、Examination Area1）During FPQ and PLQ it is required to perform 100% surface crack inspection.在FPQ和PLQ要求执行100%表面裂纹检测。2) 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. 在系列产品裂纹检验期间必须在监测区域在工件规格或图纸及在FPQ and PLQ中发现的缺陷区域执行。七、EVALUATION AND REPORTING结论与报告7.1 General概述Relevant indications are those which result from mechanical continuities 由于加工连续性所产生的相关标识1） Any questionable are doubtful indications shall be retested to verify whether or not actual defects are present任何可疑的标识都应该重新检测确定是否真事存在2） Localized surface imperfections, such as may occur from machining marks, surface conditions or an incomplete bond between the base metal and cladding, may produce similar indication which are not relevant to the detection of unacceptable discontinuities.表面固有缺陷，例如可能由由于加工标注，表面条件，或在基板和包层之间不完整连接而产生的，可能产生不影响不连续性检测的相似标识。7.2、Classification of the indication and interpretation of results标识分类及结果分析7.2.1 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. 为了区分不连续性标识，在大多数不利的位置放一个105mm*148mm框架是必要的，即对不连续性显示最为精确性。7.2.2 Indications shall be considered to be equivalent when the same number of non-linear spots and/or the same length of linear indications of similar appearance are detected. Maximum permissible discontinuities may appear simultaneously on the area of 105 * 148mm. 当非线性基点数量和或挑选相似直线的相同长度时，标识将被认为是相同的，最大的允许不连续性可能会同时出现在105mm*148mm框架中。7.2.3 The casting shall be considered as conforming with this standard when the observed severity level is equal to or better than that specified in the order. If for any indication type, the observed severity level is worse than that specified in the order, the casting shall be considered not to conform with this standard 当观察标准水平与要求中相同或优于时，铸件将被认为符合此标准，如果对于任何表示类型，当观察标准水平低于要求时，铸件将被认为不符合此标准。7.2.4 For severity levels 1,2,3,4 and