磁粉检测工艺规程magnetic

磁粉检测工艺程序编号ReportNo.Q/OH(Q)03・005-2009浙江欧华造船有限公司ZhejiangOuHuaShipbuildingCo.,LtdMagneticInspectProcedure页数Pages13编写： 审核： 确认：Wrttenby Checkedby Approvedby123456磁粉、789101112131415目录Content章节题目Subject章节题目Subject页码PageTOC\o"1-5"\h\z目的Purpose 2适用范围Scope 3职责Responsibility 3检测人员Inspector 3设备器材EquipmentandApparatus 4磁悬液及反差剂Magneticparticles、Suspensionandcontrastpaint4灵敏度试片Sensitivitytestblock 5提升力试块Liftingpowertestblock 6检测时机Timefortesting 6检测方法Testmethod 7磁粉检测操作Magnetictestoperation 7显示结果的评定和记录evaluationofindicationandrecording 10复验Re-inspection 10验收标准Acceptaneestandard 11检测报告格式Testreportformat 121.目的Purpose本工艺是根据LR规范及IACS焊接质量和无损探伤检测指南要求制定的焊缝磁粉检测质量控制程序。TheworkmanshipisbasedonthequalitycontrolprocedureofseammagnetictestingoftheruleofLRandIACSguidelineofweldingqualityandNDTofshipsteelwelds.2-适用范围Scope2.1本工艺适用于检测铁磁性材料的焊接接头表面或近表面的裂纹及其它缺陷。Thisworkmanshipapplytodetectingcracksandotherflawsonthesurroundingsurfaceofweldingjointofferromagneticmaterial.2.2焊缝磁粉检测除执行本工艺外，尚应符合现行有关标准规范的规定与设计部门提出的有关要求。Withtheexceptionofthisrule,weldseammagnetictestshouldbeinaccordancewithcurrentrelatedcriterionaswellasrelatedrequestbydesigndepartment.3.职责Responsibility3.职责Responsibility3・1参照程序ReferenceprocedureLR钢质海船入级及建造规范LRsteelvesselclassificationandconstructionruleENISO5817(2003)船舶钢焊缝磁粉检测工艺和质量分级CB/T3958-2004ShippingsteelweldseammagnetictesttechnologyandqualitygradingCB/T3958-2004IACSGuidelineNon-destructivetestingofshiphullsteelwelds3・2合格标准acceptancestandard(a)LR船舶入级规范和规则LRsteelseagoingshipclassificationandbuildingruleIACS焊接质量和无损探伤检测指南(b)IACSGuidelineNon-destructivetestingofshiphullsteelwelds4.检测人员inspectora）从事磁粉检测人员应具有必要的专业知识，并具有一定的磁粉检测经验及须掌握一定的金属材料及焊接基础知识。Inspectorengagedinmagnetictesthavenecessaryprofessionalknowledgeandrelatedmagnetic

testexperience,aswellasthebasicknowledgeofmetalmaterialandwelding.b）磁粉检测人员必须持有国家有关部门（CCS等）颁发的，并与其工作相适应等级的资格证书。进行检测的人员应当根据国家公认的认证计划或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP进行二级资格鉴定和认证。一级资质的操作人员可以二级或三级资质人员的管理下进行测试。获得国家公认的认证计划或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP认证的三级资质人员有责任准备和认可无损探伤操作程序。b)Magneticinspectormusthavequalificationcertificateofcertainclassrelatedtoone'sjobissuedbynationaldepartment(CCS,etc)OperatorsshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).OperatorsqualifiedtolevelImaybeengagedinthetestsunderthesupervisionofpersonnelqualifiedtolevelIIorIII.PersonnelresponsibleforthepreparationandapprovalofNDTproceduresshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).5.设备器材5.设备器材EquipmentandApparatus5.1磁粉检测设备必须符合JB/T8290的规定。MagnetictestapparatusmustapplytotheruleforJB/T8290.5.2用以指示磁化电流的电流表应至少每年校准一次。经过重大修理的设备以及放置半年以上没有使用的设备，在修理后和重新使用前，都应当对电流表进行校准。Ammeterusedforindicationofmagneticcurrenthastobecalibratedonceperyearatleast.Apparatusaftermajorrepairorlayasideoverhalfyear,ammeterofwhichneedtobecalibratedafterrepairorbeforere-use.5.3用于磁轭法检测的交流电磁铁，在其最大磁极间距上的提升力应大于4.5kg，直流电磁铁在其最大磁极间距上的提升力应大于18.1kg。ACferromagnetformagnetizingmethod,liftingpowerofwhosemax.magneticpolespanshouldbemorethan4.5kg.While,liftingpowerofDCferromagnet'smax.magneticpolespanshouldbemorethan18.1kg.Suspensionandcontrastpaint磁粉、磁悬液及反差剂SuspensionandcontrastpaintMagneticparticles、6.1磁粉应具有高导磁率和低剩磁性质，磁粉之间不应相互吸引。Magneticparticleshavenatureofhighpermeabilityandlowremanence.Magneticparticlescan'tbeinterattracted.6.2根据试件的材质、表面状态的不同，磁粉应具有适当的磁性、粒度、分散性及色彩。磁悬液还要

有悬浮性。Correspondingtothequalityofmaterialandsurfacecondition,magneticparticlesshouldhavesuitablemagnetism,particlesize,dispersibility.Suspensionhassuspensibilityaswell.6.3磁粉检测时应使用白色反差剂，以增加检测对比度。Whitecontrastagentisusedduringmagnetictesttoincreasecontrast.灵敏度试片Sensitivitytestblock7・1A型灵敏度试片TypeAstandardtestblockA型灵敏度试片仅适用于连续法，用于被检工件表面有效磁场强度和方向、有效检测区以及磁化方法是否正确的测定。磁化电流应能使试片上显示清晰的磁痕。TypeAstandardtestblockisonlyusedincontinuousmethod,insuchmethodtomensurateeffectivefieldstrengthanddirection>effectivetestareasaswellasmagnetizationmethodonthetestedbodysurface.Magnetizingcurrentshouldmakeclearmagneticparticleindicationonthetestblock.A型灵敏度试片的灵敏度分高、中、低三档，其几何尺寸见图1型号及槽深见表1TypeAstandardtestblockisdividedinthreegrade:HighMedium、Low.Itsgeometricfigureandtypeandslotdepth,pleaseseedrawing1andtable1型号Type相对槽深relativeslotdepth灵敏度型号Type相对槽深relativeslotdepth灵敏度Sensitivity材质MaterialA-15/10015/100高High超高纯低碳纯铁Super-highpurityLowCarbonSteel，CV0.03%,H0V80A/m,经退火处理annealingtreatmentoA-30/10030/100中MediumA-60/10060/100低Low注：试片相对槽深表达式中，分子为人工槽深度，分母为试片厚度Remark:expressionofrelativeslotthatnumeratorisartificialslotdepthanddenominatoristhethicknessoftestblock.um7.2磁场指示器(八角试块)Magneticfieldindicator(aniseedtestblock)表1A型灵敏度试片TypeAstandardtestblockmeans磁场指示器是一种用于表示被检工件表面磁场方向、有效检测区以及磁化方法是否正确的一种粗略的校验工具，但不能作为磁场强度及其分布的定量指示。它有着使用方便、易于保养的优点。其几何尺寸见图1OMagneticfieldindicatorisoneroughchecksumutilitiestomensuratefielddirection^effectivetestareasaswellasmagnetizationmethodonthetestedbodysurface.However,thisindicatorcan'betherationindicationoffieldstrengthanditsdistribution.Easyuseandmaintenanceisitsadvantage.Itsgeometric

figure,pleaseseedrawing1.灵敏度试片使用方法Useofsensitivitytestblock7.3.1使用A型灵敏度试片时，应将试片无人工缺陷的面朝外。为使试片与被检面接触良好，可用透明胶带将其平整粘贴在被检面上，并注意胶带不能覆盖试片上的人工缺陷。测试时，应使用连续磁化法。ThetypeAstandardtestblockisattachedonthetestsurfaceinsuchamannerthatthefaceofblockhavingtheartificialflawcontactcloselywiththetestsurface.Inordertocontactcloselywithtestblock,scotchtapecanbestickonthetestsurfaceflatly,inthiscase,nopartofthetapemustcoverthepartofartificialflawofstandardtestblock.Continuousmagnetizationmethodshouldbeused.7・3・2使用磁场指示器时，应在用连续法对工件磁化的同时，将其平放在被检面上，并对其表面施加磁悬液，以是否出现“*”磁痕来判定工件是否磁化适当与否。Ifusemagneticfieldindicator,thetestbodyshouldbemagnetizedincontinuousmethod.Meanwhile,theindicatorhastobelayonthetestsurfaceandaddedwithsuspension.Themagneticparticleindication“*”appearsornotdetermineswhetherthetestbodyisalreadyproperlymagnetizedornot.提升力试块Liftingpowertestblock提升力试块Liftingpowertestblock8.1提升力试块应用与复核和确定电磁轭系统是否达到标准的规范要求。Liftingpowertestblockapplytorecheckandensureifthethemagnetizingsystemmeetsthestandardornot.8.2试块应经鉴定并作重量标定。Thetestblockhavetobeidentifiedandweightcalibration.检测时机Timefortesting通常，焊缝的磁粉检测应安排在焊接工序完成之后进行，对于有延迟裂纹倾向的材料磁粉检测应安排在焊后48小时进行Generally,themagnetictestforseamistestedintheconditionwhenalltheworkingandtreatingprocesseshavebeencompleted.However,incasewherethesurfacetreatmentcaninterferewiththedetectionofflaws,themagnetictestshouldbearranged48hafterwelding.

10.检测方法Testmethod焊缝的磁粉检测以磁轭法为主，选用类型见表211.磁粉检测操作11.磁粉检测操作分类条件Classificationcondition分类名称Classification施加磁粉的磁化时间Timeforapplicationofmagneticparticles连续法Continuousmethod磁粉种类Classesofmagneticparticles非荧光磁粉Nonfluorescentmagneticparticles磁粉的分散剂Carrierfluidofmagneticparticles干法或湿法Dryandwetmethod磁化电流的种类Typesofmagnetizingcurrents父流或直流DC/AC表2 磁轭检测方法选用类型Table2ClassificationofthemethodsMagnetictestoperation检测操作包括前处理、磁化、磁痕观察、记录等多项操作。背景不好需加反差剂。Testingoperationshallincludesuchoperationasthepretreatment、magnetization>observationofmagneticparticleindication、recordingandsoon.ThecontrastPaintshouldbeaddedifthebackgroundcolorisnotwell.11.1前处理Pretreatment11・1・1试件处理的范围必须大于探伤范围。焊缝处原则上应由探伤范围向母材方向扩大50mm。Taketherangeofpretreatmentbroaderthanthetestrangewithoutfail.Inthecaseofaweldingseam,basicallyanareabroaderbyapproximately50mmthantherangeonthebasemetalside.11.1.2被检试件的表面粗糙度Ra不大于12.5口m。Theroughnessofthetestbodysurfaceisnotmorethan12.5um.11・1・3如试件上的油脂或其他附着物、涂料、镀层等影响探伤灵敏度或是磁悬液受到污染时，必须把它们清除掉，并清洗干净。Incaseswherethefatsandoilsadheredonthetestbody,stainsandotheradheredmatters,coatedfilmssuchaspaint、plating,etc.affecttheinfluenceonthetestaccuracy,orwherethereisafeartostainthesuspension,removetheseandmakethetestbodycleanwithoutfail.11.1.4每次检测前必须对电磁轭系统作提升力试验。Beforetest,themagnetizingsystemmustbedonewithliftingpowertest.磁化Magnetization11・2・1通电方式工件磁化通电方式选用连续法。采用连续法时，磁粉或磁悬液必须在通电时间内施加完毕，通电时间为1~3s。为保证磁化效果应至少反复磁化二次，停施磁悬液至少1s后才可停止磁化。Themagnetizationenergizedmethodofthetestbodyadoptscontinuousmethod.Duringcontinuousmethod,themagneticparticlesorsuspensionmustbefinishedaddingontime.Nearlyl-3s.Inordertoensuregoodeffectmagnetizationeffect,magnetizationtwiceatleastisnecessary.Stoppingmgnetizationatleast1safterstoppingaddingthesuspension.11・2・2磁化方向Magnetizationdirection被检工件的每一被检区至少应进行两次独立的检测，两次检测的磁力线方向应大致相互垂直。条件允许时，可使用旋转磁场以及交直流复合磁化方法。Thetestareaoftestbodyhastobecheckedtwiceatleast,andthemagneticlineofforcedirectionsofthistwicetestshouldberoughlyperpendicular.Iftheconditionispermitted,rotatingmagneticfieldandAC/DCcompositemagnetizationmethod.11・2・3磁化规范Magnetizationcriterion采用磁轭磁化工件时，其磁化电流应根据灵敏度试片或提升力校验来确定。在其最大磁极间距上，交流电磁铁的提升力应大于4.5kg，直流电磁铁的提升力应大于18.1kg。Ifthetestbodyisyokemagnetized,itsmagneticcurrentshouldbeaccordingtosensitivitytestblockandlftingpowertestblock.liftingpowerofwhoseBetweenitsmax.magneticpolespan,theliftingpowerofACelectromagnetshouldbemorethan4.5kg,whileliftingpowerofDCferromagnetshouldbemorethan18.1kg.磁轭的磁极间距应控制在50~200mm之间，检测的有效区域为两极连接两侧各50mm的范围内，磁化区域每次应有15mm的重叠。Mgneticpolespanofmagnetyokeshouldbebetween50〜200mm,andthetestareaisformedtherangeofthetwopolesconnectionwith50mmbothside.Magnetizationareashouldbe15mmoverlappingeachtime.磁粉的施加Applicationofmagneticparticles11.3.1施加磁粉时，应将适量的、分布均匀的磁粉施加在有效探伤范围的检测面上，使之吸附在缺陷部位，此时必须使检测面不再被磁粉沾污，以形成对比良好的缺陷磁痕。为此，应根据试件的磁特性、形状、尺寸、表面状态、磁化方法及检测环境，选择合适的磁粉和分散剂种类、磁悬液浓度以及磁粉施加方法。Applythesufficientquantityofmagneticparticlesundertheuniformcondition,gentlytothetestsurfaceintheeffectiveareaforflawdetectionandletthemadsorbtotheflawedpart.Atthistime,avoidmakingthetestsurfacedirtywithmagneticparticlesforensuringtheformationofmagneticparticleindicationofgoodcontrast.Forthispurpose,suitabletypesofmagneticparticlesandcarrierfluid,dispersingconcentrationofmagneticparticlesinthesuspensionandmagneticparticleapplicationmethodmustbeselectedaccordingtothemagneticcharacteristics,shape,dimensions,surfaceconditionoftestbody,suspectedcharacteristicsofflaws,magnetizingmethodandtestingenvironment.11.3.2在连续法检测时，应在磁化过程中完成施加磁粉。此时必须注意磁化结束后形成的磁痕不要被流动着的磁悬液所破坏。Inthecontinuousmethod,completetheapplicationofmagneticparticleduringthemagnetizingoperation.Inthiscase,caremustbetakensoasthemagneticparticleindicationformedbythesuspensioncarrierfluidaftercompletionofmagnetizingoperationnottobeerased.11・3・3采用干法时，必须确认磁粉和检测面已完全干燥后，再把适量的磁粉轻轻地喷洒到试件上。为了便于形成缺陷磁痕，可以轻微地振动检测面或利用柔和的气流去除多余的磁粉，但必须注意不得破坏已形成的缺陷磁痕。Inthedrymethod,gentlyblastorscatterasuitablequantityofmagneticparticlesafterconfirmingthesufficientdrynessofmagneticpariclesandthetestsurface.Inthiscase,theexcessmagneticparticlesmayberemovedwithagentleairstreamorthelikeaftergivinglightvibrationtothetestsurfaceorapplyingasufficientquantityofmagneticparticlesfortheeasyformationofmagneticparticleindication,butcaremustbetakensoasnottoerasetheformedmagneticparticleindication.11・3・4采用湿法时，应确认整个检测面能被磁悬液良好地湿润后再把磁悬液浇在检测面上，或将试件浸渍在磁悬液中，磁化后轻轻取出。无论哪一种方法，都要注意不使检测面上磁悬液流速过快。Inthewetmethod,applythemagneticparticlesbypouringthesuspensiononthetestbody,afterconfirmationthatthewholetestsurfaceisingoodwetconditionorbyimmersingthetestbodyintothesuspensioninwhichmagneticparticlesarewelldispersedandgentlytakingitout.Ineithercase,caremustbetakentoavoidtheexcessivespeedofsuspensionflowonthetestsurface.11.3.5采用交叉磁轭检测时，在磁化的同时喷洒磁悬液，磁悬液一般均匀地喷洒在交叉磁轭行进方向的前方。Whencrossmagnetictestisadopted,suspensionshouldbesprayedsteadilyinfrontofcrossmagnetictestareaduringmagnetization.

12.显示结果的评定和记录evaluationofindicationandrecording12.Allindicationsshallbeevaluatedintermsoftheacceptancestandardsofpart14.所有显示结果都需根据14章的验收标准来评定。Discontinuitiesonornearthesurfaceareindicatedbytheretentionofexaminationmedium.However,localizedsurfaceirregularitiesduetomachiningmarksorothersurfaceconditionsmayproducefalseindications.检测媒介会显示表面或者靠近表面的不连续性。不过，由于匹配的标记或其他的表面状况而导致的检测表面不规则会产生错误的现实结果。Broadareasofparticleaccumulationwhichcouldmaskindicationsfromdiscontinuitiesareprohibited,andsuchareasshallbecleanedandreexamined.Anyotherfalseindicationsshallberemovedandtheareareexamined.磁粉聚集的区域可以把不连续性屏蔽了，这些区域需做清洁并复检。任何其他的错误显示都需处理并且该区域需做复检。Anyindicationwhichisbelievedtobenonrelevantshallbereexaminedtoverifywhetherornotrelevantindicationsarepresent.那些被认为不相关的显示结果就应该重新检测以确认是否存在相关的显示结果。Techniquessuchasgrinding,crossmagnetization,andtheuseoftheresidualmethodshallbeusedinthereexaminationofsuspectednonrelevantindication.在怀疑为不相关显示结果的复检时，应采取例如打磨，交叉磁化和剩磁法之类的方法。Allexaminationconditionsandresultsshallberecordedonthereports.所有检测状况和结果都需记录在报告上13.复验Re-inspectionMagneticparticleexaminationreportsshallbemaintainedasadigitalfileinaLDMofERPsystemfortwo(2)years,exceptspecifiedbythecontractspecifications&rulesoftheClassificationSociety磁粉检测报告需用EPR系统的LDM电子版本保持两年，除非合同规格书和船级社的规范没有标明。13.复验Re-inspection13.1当出现下列情况之一时，应进行复验:Re-inspectionisexecutedwhenoneoffollowingsituationhappens:检测结束时，用灵敏度试片验证检测灵敏度不符合要求；Aftertest,sensitivitytestblockisusedbuttheresultcan'meetthestandard发现检测过程中操作方法有误； Wrongoperationisfoundduringtest.供需双方有争议或认为有其他需要时;Disputebetweenbuyerandsellerorotherrequestisneeded

经返修后的部位。Theflawedplacewherehasbeenrepaired.13.2复验应按11.1.4~1135中有关条文进行。Reinspectionshouldaccordtorelatedarticlesinll.l.仁11.3.5.14.验收标准14.验收标准Acceptancestandard(1)ViewingConditions图像状况Non-Fluorescent非荧光Daylightviewingisadequate.Artificiallightmayalsobeused,buttheminimumintensityoflightatthesurfacetobeinspectedis500lux.日照应充足。同时也需要人工照明，表面检测时光度最少需要500lux。Fluorescent荧光Blocklightintensityshallnotbelessthan800W/cmA2withabackgroundlightingof10lux.黑光灯强度不应低于800W/CMA2,亮度为10lux。(2)AcceptanceStandard验收标准AcceptanceStandardforweldsareshowninTable3焊接的验收标准见图表3.Table2Welddefectacceptancelevelsforfabrication表3生产焊接缺陷验收标准Surfacediscontinuity表面不连续性ClassificationaccordingtoISO6520-1根据ISO6520-1分级Acceptan