UT探伤通用规程的知识

1、超声波探伤通用规程检验规程内容：Content 1.0 适用范围 / scope2.0 参考规范 / reference3.0 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 acceptancecriteria of casting. Inspection areas are covered by

2、 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 testinginstitution 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 principl

3、es.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 cleanliness 993062：超声波设备的校准 / Ultrasonic equipment calibration and ver

4、ificationEN12668- 1 :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.EN12668 3: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 exami

5、nation 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 testi ng -Ultras onic exam in atio n - Specificatio n 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

6、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 testinginstitution 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 / qualif

7、ication 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

8、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

9、.5级。1Prior to UT the surface quality of the component must reach Sa 2/2 in accordancewith 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

10、 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 a

11、nd coupling medium4.3.1 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( Theinstrument EPOCH 4 and EPOCH LsThall be used in my factory)and shall have the following character:-量程设定，设定

12、范围需至少为10m叶2m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 10mmto 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 maximumsteps 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

13、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 MH Z in pulse-echo techniqu

14、e with single-crystal and twin-crystal probes.-以下探头至少要有一个被使用：SEB2-0(MSEB2)和B2S(MB2S)或者有一个相同特性的探 头。探头SEB2-O0 (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-O0和B2S探头检测,当需要精确测量缺陷的边界时使用 MSEB2-O0 和 MB2S 探头。-Followi ng probe head must have at least o ne to be used: SEB2-0 ( MSEB2) and B2S ( MB2

15、S) 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 borderli ne of the

16、 defects, use the probes of MSEB2-0a nd 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

17、 sound beam may be compe nsated for. This may be done based on calculati ons (for sin gle crystal probes in the far field) or base on measurementsof flat bottom holes (for dual twin crystal).在表1中提到的标准值可供用。The values for sta ndard probes men ti oned in Table 1 may be used.声程(mm)Sound pathSEB2声束直径 (mm

18、) 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 B2Sv 20155-20-601515-60-120202512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。Ultras onic jelly shall be used.4.4 校准 /Calibration按照现行标准993062对超声

19、波设备进行校准。Ultras onic equipme nt calibrati on and verificati on must be carried out accord ing to prese nt 993062 sta ndards.4.4.1 标准参考/NORMATIVE REFERENCESEN12668 3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 test ing - Characterizati on and verificati on of ultras onic exam in atio n equipme n

20、t - Part 3: Comb ined equipme nt.EN12223无损检测超声检测校准试块 No.1的规范。EN 12223 None destructive test ing-Ultras onic exam in ati on - Specificati on ofcalibrati on block no .1.442设备/EQUIPMENT参考试块K1 DS/EN 12223Refere nee 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 ）Refere nee block V2

21、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Referenee block TIF no. 061316443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。In itially whe n a new comb in ati on of ultras onic in strume nt and probe is take n in to use, it is n ecessary t

22、o make a base measureme nt, which is registered in the registeri ng scheme for base measureme nts.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 poin ts, sig n for perform ing 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

23、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 establish ing a sig nal to no ise ratio and pulse duratio n a weekly test is sufficie nt 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 u

24、ser has a suspici on 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物理状态和外形Determ ination of physical state and externalaspects每日Daily（如果使用if in use）根据标准反射体的灵敏度Determ in ati on of sen sit

25、ivity from sta ndardreflector信噪比Determ in atio n of signal to no ise ratio每周Weekly（如果使用if in use）脉冲持续时间Determ in ati on pulse durati on4.4.4.1 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

26、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

27、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 th

28、e 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

29、standard reflector. Gain is set to lowest value. Note the dB- value 2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 refer

30、ence 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

31、. 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 h

32、eight. 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：EB

33、= 102.4 100.4=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 measureme nt. With deviati ons 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

34、Period测试内容Test时基水平线性Determ in ati on of lin earity of the time base每周Weekly （如果使用if inuse）幅度垂直线性Determ in ati on for lin earity of the amplifier4.4.5.1 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 ti

35、me 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 positi ons of the in terve ning 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,

36、up to 80 % screen height. Check if the flank, for everyecho, still coin cides with the scale marks. The deviati on may not exceed2 % of the whole scree n 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孔的最咼反射波，调至80 %屏咼。Use the same time ba

37、se and probe as used for determ in ati on of lin earity of the time base. The echo from a 3mm hole in 35mm dept in the TIF-block is used as sta ndard 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 tabl

38、e below. Check if the echo is within thespecified limits.增益幅 AmplificationExpected期望屏咼 screenheight (%)范围Limits+ 2101不小于 95% /Not less than 95%080-64037%43%122017%23%18108%12%245可见的低于 8% /Visible beneath8%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 registrati on scheme for

39、 base measureme nts is always to be kept together with the ultras onic in strume nt.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 registrati on scheme for freque nt tests has to be kept together with the ultras onicinstrument. When the scheme is filled in, it must be filed t

40、ogether with a copy of thebase measureme nts. It has to be filed at the quality resp on sible for the departme nt. The requireme nts of fili ng follow the existi ng rules for quality docume ntatio n.447如果校验不符合要求，则要根据填写“失败的校验信息”。If the requireme nts are not met fill a“ Failed calibrati on messageord

41、in gfy.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 itsthick ness 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 dime nsion

42、 of two back wall echoes for mono-crystal probes. Fieldshall have a minimum dime nsion 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 Qua

43、lity Specificati on.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 平行的表面 当作大平底，一次回波调至满屏的80%，然后使用KSR3mm的DGSdB40曲线即可）。The initializationof the testing sensitivityshall

44、be set in such a way that theecho heights of the flat-bottomed holes ofKSR3mm shall be at least 40% of thescree n height at the end the thick ness range to be exam in ed. （The ultras onicin strume nt EPOCH 4 and EPOCH LT have software of DGS. When detecti ng, adjust thback wall echo to 80% of the fu

45、ll screen height with the casting max wall thicknessvparallel surfacesas the FBH. And the n use the DGS software of KSR3mm for in specti on.） 例如：/ illustrating:Evaluation of indications by DGS graph.This is just an illustrating yraph and not attached to a specific probe.4.7 检验/ Inspection4.7.1打300mm

46、x300mm的格子进行扫查。Scanning shall be carried out by 300mmx300mm grid con diti ons.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 sca nning speed shall not exceed 150mm/s. A complete coverage of the specified sca nning area shall be con ducted by carry ing out systematically

47、 overlapp in（ 15%） sca ns.4.7.3 扫查区域 /UT sca nning 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 ser

48、ies production ultrasonic testing must be performed in the test areas, which are defined in the comp onent specificati on or on the comp onent draw in gs, and in trouble areas that were found duri ng FPQ and PLQ. In additi on UT is required in areas where defects can be presumed based on the results

49、 of for example VT. The rema ining areas should be in spected spot-check with respect to product safety.102030I-ii1-i i- nAd nitinn for尸oint of intersectio n between di a 3m m c u r/e and lOOmin sound path0102050100200mm Sound oath4.8 验收标准 /Acceptanee 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

50、评估。Whe n sin gle disc on ti nu ous bulk defect the limits in table 2 and 3, should be no ted and be evaluated表 2 / table 2质量等级 /quality level特征Feature单位Unit123受检区域中的壁厚/wallthick ness in the exam ined areamm-v 50 50 to 200 200v 5050 to 200 200壁厚百分比/percentage ofwall thick ness%-2025表层的最大缺陷面积/thelarge

51、st allowed in dividualindication in the rimazonemm2b6001 0001 0001 0002 0002 000心部的最大缺陷面积/ thelargest allowed in dividualin dicati on in the core zonemm2b10 00015 00015 000 15 00020 00030 000缺陷总面积占被检表面积的百分比Total area of disc on ti nuities as perce ntage of exam ined surface%b101515152020夹渣/Dross夹渣必须

52、被清除/Dross must be removeda. 边缘区见图1Rim 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 berecorded.图 1/ figure 1.图例索引/index1表示表层区/Rim zone2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评估的极限 /

53、Evaluation limits受检区域的壁厚(mm)Wall thickness of the casti ng in the exam ined area(mm)底波衰减最小(dB)reducti onof backwall echo (min dB)能够检出的最小缺陷当量(mm)/Smallestflat-bottomhole diameter detectablea 回波高度高于噪声最小(dB)Echo height above noise levelami n(dB) 10 to 20123 20 to 10056 100 to 2508 250 to 500201012a仅适用于

54、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，并有米购商做出决定。The cast ing must be tested in the scope accord ing to the purchase sta ndard, and must satisfy requests below: (Disc on ti nu ity) machi ning surface defect, for example shri nkages, sand and sla