UT探伤通用规程1.docx

1、UT探伤通用规程1超声波探伤通用规程UT General Specification Material: EN-GJS-400-18U-LT REFERRENCE: EN 12680-3 检验规程内容： Content 1.0适用范围/scope 2.0参考规范/reference 3.0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 pr

2、ocedures and acceptance criteria of casting. Inspection areas are covered by 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 testing institution of the Chinese mechanical engineering society qualification and certification of NDT personnelEN473 ： NDT 无损探伤试验人员的资格

3、和资格证-总则/ qualification and certification of NDT personnelgeneral principles.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 cle

4、anliness993062：超声波设备的校准/Ultrasonic equipment calibration and verificationEN126681：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.EN126683：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

5、 - Characterization and verification of ultrasonic examination 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 testing Ultrasonic examination - Specification 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 quali

6、fied to one of the following certification 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 testing institution 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 personnelgen

7、eral principles.SNT-TC-1A：无损探伤人员资质/ qualification 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 -

8、1A or they should perform 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

9、达到ISO 8501-1规定的表面质量Sa2.5级。Prior to UT the surface quality of the component must reach Sa 2 1/2 in accordance with 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

10、to be inspected shall be 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

11、耦合介质灵敏度/Equipment and coupling medium 4.3.1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（The instrument EPOCH 4 and EPOCH LT shall be used in my factory）and shall have the following char

12、acter:-量程设定，设定范围需至少为10mm2m，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 10mm to 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 maximum steps over a range of at least 80dB with measuring accuracy of 1dB;-时基和

13、垂直线性度须小于显示屏幕调节范围的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 MHZ in pulse-e

14、cho technique with single-crystal and twin-crystal probes.-以下探头至少要有一个被使用: SEB2-00(MSEB2)和B2S(MB2S)或者有一个相同特性的探头。探头SEB2-00 (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SEB2-00 和B2S探头检测, 当需要精确测量缺陷的边界时使用MSEB2-00 和MB2S探头。-Following probe head must have at least one to be used: SEB2-00 ( MSEB2) an

15、d B2S ( MB2S) 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 borderl

16、ine of the defects, use the probes of MSEB2-00 and 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 d

17、iameter of the sound beam may be compensated for. This may be done based on calculations (for single crystal probes in the far field) or base on measurements of flat bottom holes (for dual twin crystal). 在表1中提到的标准值可供用。The values for standard probes mentioned in Table 1 may be used.声程（mm）Sound pathSE

18、B2声束直径（mm）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 B2S20155-20-601515-60-120202512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。Ultrasonic jelly shall be used.4.4校准 /Calibration按照现行标准993062对超声波

19、设备进行校准。Ultrasonic equipment calibration and verification must be carried out according to present 993062 standards.4.4.1标准参考/NORMATIVE REFERENCESEN126683 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 testing - Characterization and verification of ultrasonic examination equipment - Part 3: Combi

20、ned equipment.EN12223 无损检测超声检测校准试块No.1的规范。EN 12223 None destructive testing Ultrasonic examination - Specification of calibration block no.1.4.4.2设备/EQUIPMENT参考试块K1 DS/EN 12223 Reference 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）Reference block V2 DS/EN 27963 no. 50434-22274

21、 (it is available in two widths 12,5mm and 20mm)参考试块TIF（长横孔试块）Reference block TIF no. 0613164.4.3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。Initially when a new combination of ultrasonic instrument and probe is taken into use, it is necessary to make a base measurement, which is re

22、gistered in the registering scheme for base measurements.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 points, sign for performing 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次，但是如果使用中对仪器有怀疑，必须立即校验。The user test of probe

23、s must be performed daily. For establishing a signal to noise ratio and pulse duration a weekly test is sufficient 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 user has a suspicion that an error has occurred, th

24、e 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每日Daily（如果使用if in use）物理状态和外形Determination of physical state and external aspects根据标准反射体的灵敏度Determination of sensitivity from standard reflector每周Weekly（如果使用if in use）信噪比D

25、etermination of signal to noise ratio脉冲持续时间Determination pulse duration4.4.4.1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 and cable for damage and wear. Check for instability of electrical

26、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6d

27、B，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 the base measurement. With deviations more than 6 dB find the reason and co

28、rrect 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 standard reflector. Gain is set to lowest value. Note the dB- value2从试块上拿下探头并擦

29、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 reference echo in 35mm distance. Note the increase, which is called signal to noise rat

30、io. 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. 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

31、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 height. 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:图Figure A图Figure BEB102.4100.4=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 measur