UT procedure超声波探伤工艺.doc

The criterion of Taizhou CATIC ShipbuildingHeavy Industry CO.,LTD泰州中航船舶重工有限公司企业标准 CO.,LTD船舶钢焊缝超声波探伤工艺Ship steel weld ultrasonic Testing Procedure编 制：COMPLILED:审 核：CONFIRMED批 准：APPROVEDUltrasonic testing procedure 超声波检测工艺1. general总则 1.1This procedure is applicable to ferrite steel welds with full-penetration welded joints and parent metal thickness is 1450mm，to check the defect .1.1 本探伤工艺适用于母材厚度为1450mm的铁素体，全焊透钢焊缝超声波探伤检查，以检测焊缝内部的危害性缺陷。1.2 This procedure prescribes ultrasonic testing method and quality classification for welded joint .本工艺对焊接两侧的母材进行超声波探伤进行了规定事项及验收等级。1.3 The personnel engaged in Ultrasonic testing shall hold UT technology qualification certificate which issued by national qualification organization (such as CCS)，UT Class II or UT Class III could operate探伤操作人员需持有如中国船级社颁发的超声波检测资格证书，II级及以上资格证者，方可上岗操作。2. normative standard and file 规范性引用文件 CB/T3559-94 Ship steel weld hand welding ultrasonic testing technical and quality classification 船舶钢焊缝手工焊超声波探伤工艺和质量分级CCS，Non-destructive testing qualification and certification of personnel,2008 中国船级社无损检测人员资格鉴定与认证规范2008A-pulse echo testing instrument A型脉冲反射式超声探伤系统性能测试方法IACS Non-destructive testing of ship hull steel welds 国际船级社 船舶钢结构焊缝无损检测LR rules for the manufacture, testing and certification of material July2009-chapter 12 劳氏材料制造、测试和认证规范2009版，第13章2. The flaw detector 探伤仪2.1 Apply digital ultrasonic detector, assigned frequency is 2.5-5MHZ, and provided with multicenter detect function.使用数字式超声波探伤，其工作频率应具有2.5-5MHZ，具有多通道探伤功能。（Masters can-340、PXUT-211B）2.2 The systematic performance of the detector and probe shall be tested according to the regulation in JB/T9214.探伤仪和探头的组合性能应满足JB/T9214的标准要求。2.3 Normally the horizontal linear error of detector shall not be more than 1% and the vertical linear error shall not be more than 5%.水平线性误差小于1%，垂直线性误差小于5%。3. probe探头 3.1 The frequency of probe is 2.55MHZ,and sound axial line angle of alternation shall not be more than 2 degree.采用探头，频率2.55MHZ，探头声轴线水平偏离角不大于2度。 3.2 The refracting angle(the value of K) is 1.0-3.0, the leading edge is less than 15mm.探头折射角（K值）取1.03.0，探头前沿距离尺寸不大于15.0mm。3.3The probe could be used after being tested.探头购置回厂应进行检测后方可使用。3.4 Double crystal probes and straight probe shall be assisted for testing of butt welds and T-type joint welds.考虑到一些焊缝的结构特点，对角焊缝及T型接头焊缝应采用双晶直探头或直探头，辅助进行扫查、探伤。1) Frequency Selection 频率的选取： Table UT-1Base metal thickness母材厚度T（mm） Frequency of probe(MHZ)探测频率（MHZ）202520252）Butt weld angle beam prove K value or reflection degree 对接焊缝按下表选择 Table UT-2Base metal thickness T母材厚度T（mm）Testing surface 探测面折射角（或K值）refracting degree (or K value)20One surface and both sides 单面双侧70；60（K2.5；K2.0）2050One surface and both sides 单面双侧70；60；45（K2.5；K2.0；K1）3)Fillet weld angle beam probe K value or reflection degree 角焊缝按下表选择： Table UT-3Web plate thickness 腹板厚度TTesting surface 探测面Scanning Span使用跨距K value or reflection degree折射角（或K值）20Web plate single surface and single side 腹板单面单侧1/2 skip distance and 1/1 skip distance1/2跨距1跨距1跨距70；60（K2.5；K2.0）2050Web plate single surface and single side腹板单面单侧face plate single surface and double side面板单面双侧1/2 skip distance and 1/1 skip distance1/2跨距1跨距1/2跨距70；60（K2.5；K2.0；）60；45（K2.0；K1.0）4. systematic performance系统性能 4.1The probes far field resolving ability :a)x30db b)z6db 探头远场分辨力a.）x30db b.）z6db 4.2. defect detector shall be checked every three months and with record.探伤仪、探头及系统功能应每三个月进行检查。5. Calibration block试块5.1. Standard calibration block CSK-IA 标准试块采用CSK-IA。5.2 Contrast calibration block RB-1 对比试块采用RB-15.3Double crystal probe shall be calibrated by standard calibration block(step bar)，双晶探头用阶梯试块。6. Ultrasonic testing process and main operation 检测流程及操作要领 6.1 All personal engaged in NDT testing should understand WPS of testing area and be familiar with the welding type details.无损检测人员要了解所要检测部位的焊接工艺，熟悉焊接节点。6.2 The spatters, iron dust, oily dirt and other foreign matters shall be free from probe unit moving area. The test surface shall be even and smooth so the probe unit shall be able to move freely on it. 探测区焊缝两侧母材表面上的油垢、飞溅、氧化皮等必须清除。探测面应光滑平整，便于探头的扫查。6.3The probe unit moving area shall following the different span below: 探头的移动扫查范围应满足下述内容：Full distance testing(1/1skip distance): width formula of testing surface全声程探测，探测面宽度公式： W2Ttg+Half distance testing(1/2skip distance): width formula of testing surface半声程探测，探测面宽度公式： WTtg+Remark: W-width of testing surface(mm),T-parent metal thickness(mm),-Angle of reflection（）, -probe back distance式中W探测面宽度mm; T母材厚度mm;探头折射角（）;探头后沿长度7. adjustment of time base line时基线的调整 Time base line shall be adjusted using calibration block CSK-IA and making sure the maximum inspected sound path shall be above 3/4 of full time base line. 用CSK-IA标准试块对仪器的时基线按比例调整。最大探测距离深度至少调整到示波屏基线满刻度3/4以上。8. Distance-amplitude curve 距离波幅曲线 8.1 The distance-amplitude curve shall be prepared according to the figures actually measured on calibration block RB-2 with applied probe and instrument. According to the different thickness of parent mental, sensitivity of distance-amplitude curve please see the below table: 距离波幅曲线应以实际探测用的仪器、探头经时基线调整后，根据探测距离范围在CTRB-1或CTRB-2、CTRB-3标准试块上实测制作。根据被检焊缝母材厚度不同，距离波幅曲线簇的灵敏度见下表。Parent metal thickness T母材厚度T（mm）ARL线（判废线）DRL线（测长区分线）MRL线（测长线）50 33-10db3-16db50 3+2 pensation补偿Sensitivity compensation includes couplant compensation, material attenuation compensation and curved surface compensation; As to the inspected locations there is a contrast test shall be done for inspected location with standard calibrated block to make sure the compensations and improve the sensitivity during onsite Ultrasonic testing.补偿：包括耦合补偿，衰减曲面，对于待检测的位置应与标准试块做对比试验，确认补偿值，并在实际检测中提高相应得灵明度。10. Scanning method 探头扫查方式In order to determine location, direction and shape of defects to observe dynamic wave pattern of defects and distinguish between defect signal and false defect signal ,four basic scanning-to-test methods with probes, including back and forth ,left and right ,turning and surrounding ,can be employed. See Fig.UT-6确定缺陷位置、方向、形状以及判别缺陷信号和假信号，采用前后、左右、摆动（转角）、环绕四种基本扫查方式（如下图）Back and forth left and right turning surrounding 前后扫查 左右扫查 摆动扫查 环绕扫查 Fig.UT-6 Scanning methods 四种基本扫查方式 In order to test longitudinal defects, Angle probes must be placed on the tested surface vertical to center centre line of weld for saw tooth pattern scanning-to-test, see Fig.UT-7.And the fore-and-aft movement range of probes must guarantee testing of whole section of weld. Besides, while moving the probe backward and forward vertical to weld ,turn it left and right with the degree of 1015.Moving range in perpendicular direction shall be a little larger than 1 span or it can be divided into 1/2 span and 112 span .探测纵向缺陷，以前后和左右扫查组合成锯齿形扫查方式（如下图）。探头沿焊缝方向每次移动间距应不大于晶片直径或宽度，在移动过程中作1015 摆动。垂直焊缝方向移动范围应稍大于一 跨距，也可将移动范围分为半跨距和一跨距两个区域（如下图） 1P Turn（10-15） 1PFig.UT-7 Longitudinal defect scanning method in weld beam 纵向缺陷扫查方式 A parallel and declined parallel scan shall be applied to test the transverse defect in weld seam and heat-affected zone. During test ,a declined parallel scan shall be carried out on the edge of both sides of the weld seam and the angle between probe unit and weld center line shall be 1020,see Fig UT-8.探测横向缺陷应采用斜探头平行扫查如下图所示。探头在焊缝两侧边缘并与焊缝中心线成1020交角，从四个方向进行扫查。 10-20 Weld center UT-8 Transverse defect scanning method in weld beam 焊缝中横向焊缝扫查方式 Test transverse defects in T fillet weld by methods of parallel scanning as below UT-9; and straight beam probe can be used as assistant scanning at tank top plate ,selection of straight pr 探测T型角焊缝的横向缺陷，可采用平行扫查方式，如下图所示。并可使用直探头在内底板上辅助检查。 Inner bottom Inner bottom Defects Location 1 Location1Location 2 Bulkhead Location 2 Bulkhead Ut-9 T fillet weld Ultrasonic testing T型角焊缝检测 11. The scan speed of probe 探头扫查速度11.1 The scan speed of probe shall not exceed 100mm/s so that the echo of defects can be taken over by probe enough and it can be displayed and recorded definitely.为使缺陷回波充分地被探头接收，并在示波屏上有明显的显示或在记录装置上能得到明确的记录，扫查速度应当适当，通常100mm/S。11.2 Orientation and coverage rate: During testing, direction of probe (especially angel probe)shall strictly follow the instruction of scanning method. Because of the change of incidence angle can have a great influence on testing sensitivity. Theoretically ,reflected wave of defects was found maximum when the incidence wave was perpendicularity to the defects surface; and the coverage rate of each scan of the probe shall have a certain proportion to avoid leakage. 方向性和覆盖率：扫查过程中，探头的方向（斜探头尤甚）应严格按照扫查方式的规定。因为探头放置方向的改变在单探头探伤时将因入射波的方向改变而使缺陷检出灵敏度变化；在双探头法探伤时，则可使反射或透射波不能为另一探头接收，故保持一定的方向更为重要。为免漏检，每次扫查应有一定比例的声束覆盖率。12.Defects Quantitative method 缺陷定量方法In the actual ultrasonic testing, it is difficult to determine the real size of defects, because of many kinds of shape and properties of nature defects. To A-pulse echo testing ,there is some information for evaluating defects: 6dB method is applied to measure indication length, amplitude of reflected wave ,back wall loss, extending scope along surface. 在实际超声波检测中，由于自然缺陷的形状是各种各样的，缺陷性质又不尽相同，所以目前还很难确定缺陷的真实尺寸。对于A型显示方式来说，为平定缺陷尺寸，可以利用的信息有：来自缺陷的波高、背反射的损失、沿件表面测量出的缺陷延伸范围。13. Quality classification 焊缝质量评级13.1The weld quality is divided into class according to the amplitude ,length of defect and place 根据缺陷的波高和指示长度及分布状态，把焊缝质量分为级。13.2 The amplitude of defect which is higher than ARL line(in IV zone) is evaluated as class V. 高于ARL线（位于区）的缺陷回波均评为级。13.3 When defects assess as dangerous defects (dangerous defects including crack ,lack of fusion and lack of penetration),it will be evaluated as class V.当缺陷判定为危害性缺陷时（危害性缺陷包括：裂纹，未焊透和未融合等），评为V级。13.4 The amplitude of un-dangerous defect lower than and equal MRL line (in I zone) is evaluated as class I. 低于或等于MRL（位于区）的缺陷回波可评为级。13.5 The amplitude of defect which is from MRL line to ARL line shall be evaluated by the UT-6 indication length evaluation of single defect. 超过MRL线到ARL线之间的缺陷回波根据所测定的单个缺陷指示长度按表UT-6评级。 Table UT-6Class 分级Indication length of single defect:单个缺陷指示长度mm1/3T1）；min2）8；max3）241/2T，min 12；max 363/4T；min 16；max 48T；min 20；max 60 over IV class 超过级Notes:1)T- Parent metal thickness, when thickness of plates, on both sides of butt-jointed seam, is different, the thinner should prevail.2) min- the allowable value of length when T is lower than a certain thickness. For example I class, when T24mm, the allowable length of single indication is 8 mm.3) max-the allowable values of length when T is larger than a certain thickness. For example I class, when T72mm, the allowable length of single indication is 24mm. 注：1）T被检焊缝厚度，若焊缝两侧母材厚度不同，以较薄侧厚度为准。2）最小指母材T小于某一厚度时的允许值；例如级焊缝，当母材T在等于小于24mm时，可允许单个缺陷指示长度为8mm。3）最大指母材T大于某一厚度时的上限值；例如级焊缝，当母材T大于72mm时，其单个缺陷指示长度不允许大于24mm。13.6.When the amplitude of defect which is higher than MRL line and less than ARL line ,the超过MRL线到ARL线之间的缺陷回波，其指示长度小于8mm均按4mm计长。13.7.If the distance among different direction indications is less than the lesser one length, the indication length will be evaluated by sum of various single indications except for distance between indications.若各方向相邻缺陷的间距小于其中较小的缺陷长度时，应作为一条缺陷处理，以缺陷相加之和作为指示长度。13.8 When the length of single indication is not excess to the values of table UT-6,total length of all indication in the random length of weld beam 6T or 150mm(selection the lesser one )shall not exceed to the limit in table UT-7. 当单个缺陷指示长度未超过表UT-6限值时，则在任意6T或150 mm（二者取小）焊缝长度内的相加总长，不允许超过Table UT-7限值. Table UT-7ClassTotal length Mm 总长度2T2.5T3T4TOver IV class13.9 If there are two indications in random length of weld beam 6T or 150 mm(selection the less one),the length of them shall be summed to evaluate.若两个缺陷在任意6T或150mm（二者取小者）焊缝长度内都能取到其一部分，则应将这两缺陷的指示长度计入总长评级。13.10 If the testing length of weld beam is less 6T or 150 mm(selection the less one),the limits of tableUT-7 can be descending in proportion. The minimum total length can be evaluated by single indication in table UT-6.若被检焊缝长度小于6T或150mm（二者取小者）时，则表2中的限值按比例递减。但最小总长可按表1的单个缺陷指示长度限值评级。13.11. When crack ,lack of fusion, lack of penetration etc. dangerous defects found on inspected