1、精品醫(yī)學(xué)文檔 精品醫(yī)學(xué)文檔 PAGE 14/14 14/14精品醫(yī)學(xué)文檔 超聲波探傷通用規(guī)程UT General Specification Material: EN-GJS-400-18U-LT REFERRENCE: EN 12680-3 檢驗規(guī)程內(nèi)容： Content 1.0適用范圍/scope 2.0參考規(guī)范/reference 3.0檢驗人員/ NDT-Personnel4.0超聲波檢測/ Ultrasonic testing5.0檢驗報告/Examination report1.0 適用范圍 / scope本規(guī)范是鑄件的檢驗規(guī)程和驗收標(biāo)準(zhǔn)。本規(guī)范覆蓋檢驗區(qū)域。This specif

2、ication is the inspection procedures and acceptance criteria of casting. Inspection areas are covered by this specification.2.0參考規(guī)范/referenceGB9445-99：中國機械工程無損檢測學(xué)會無損檢測人員資格及鑒定/non-destructive testing institution of the Chinese mechanical engineering society qualification and certification of NDT pers

3、onnelEN473 ： NDT 無損探傷試驗人員的資格和資格證-總則/ qualification and certification of NDT personnelgeneral principles.SNT-TC-1A：無損探傷人員資質(zhì)/ qualification and certification of NDT personnelEN12680-3：鑄造-超聲探傷-第3部分:球墨鑄鐵/Founding-Ultrasonic examination -part 3: Spherical graphite cast iron castings.ISO 8501-1：表面粗糙度/visu

4、al assessment of surface cleanliness993062：超聲波設(shè)備的校準(zhǔn)/Ultrasonic equipment calibration and verificationEN126681：無損檢測超聲設(shè)備的特點和驗證第1部分：儀表。EN 12668-1：Non-destructive testing - Characterization and verification of ultrasonic examination equipment - Part 1: instruments.EN126683：無損檢測超聲設(shè)備的特點和驗證第3部分：設(shè)備組合。EN 126

5、68-3：Non-destructive testing - Characterization and verification of ultrasonic examination equipment - Part 3: Combined equipment.EN12223：無損檢測超聲檢測校準(zhǔn)試塊No.1的規(guī)范。EN 12223：None destructive testing Ultrasonic examination - Specification of calibration block no.1.3.0檢驗人員/ NDT-PersonnelNDT人員至少應(yīng)獲得一個下述標(biāo)準(zhǔn)證書的認(rèn)證

6、：NDT-Personnel must be qualified to one of the following certification standards: GB9445-99：中國機械工程無損檢測學(xué)會無損檢測人員資格及鑒定/nondestructive testing institution of the Chinese mechanical engineering society qualification and certification of NDT personnelEN473 ： NDT 無損探傷試驗人員的資格和資格證-總則/ qualification and certi

7、fication of NDT personnelgeneral principles.SNT-TC-1A：無損探傷人員資質(zhì)/ qualification and certification of NDT personnel根據(jù)EN 473 或ASNT SNT-TC-1A的規(guī)定，所有無損試驗的檢驗員，都要經(jīng)過培訓(xùn)達(dá)到2級的資質(zhì)水平。他們?nèi)舨粔?級水平，則應(yīng)在2級甚至3級資質(zhì)水平的人員指導(dǎo)下工作。供貨方的3級人員，應(yīng)定期培訓(xùn)自己的NDT工作人員。All NDT inspectors must be trained and certified lever 2 inspectors accordin

8、g to EN 473 or ASNT SNT-TC -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 超聲波檢測/Ultrasonic testing4.1表面條件/surface

9、 conditioning在零件作超聲波檢查以前，表面要達(dá)到ISO 8501-1規(guī)定的表面質(zhì)量Sa2.5級。Prior to UT the surface quality of the component must reach Sa 2 1/2 in accordance with ISO 8501-1.未經(jīng)機加工的粗糙表面應(yīng)根據(jù)所需的檢查要求進(jìn)行打磨。Rough surfaces on un-machined items shall be ground to the extent necessary for performing the examination.所有的待檢表面應(yīng)無溶渣、剝落、

10、灰塵和其它可能妨礙檢查的雜質(zhì)。All surfaces to be inspected shall be free of dross, scale, dirt and other foreign matter that may interfere with the inspection.4.2檢查范圍/Extent of examination應(yīng)根據(jù)所述的零部件適用質(zhì)量規(guī)范進(jìn)行超聲波探測評估。Ultrasonic testing shall be evaluated in the zones as stated in applicable quality specification for t

11、he specific component.4.3設(shè)備和耦合介質(zhì)靈敏度/Equipment and coupling medium 4.3.1超聲波探傷儀 Ultrasonic instrument 超聲波探傷儀須符合EN 12668-1中規(guī)定的要求(本廠使用EPOCH 4和EPOCH LT)，須具有以下特點: 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 s

12、hall have the following character:量程設(shè)定，設(shè)定范圍需至少為10mm2m，需能夠連續(xù)選擇，需適合于鋼中傳播的縱波和橫波；range setting, from at least 10mm to 2m continuously selectable, for longitudinal and transverse;增益，須能夠在一個至少為80dB的范圍內(nèi)進(jìn)行調(diào)節(jié)，調(diào)節(jié)的最大差級為2dB，測量精度為1 dB；gain, adjustable in 2dB maximum steps over a range of at least 80dB with measur

13、ing accuracy of 1dB;時基和垂直線性度須小于顯示屏幕調(diào)節(jié)范圍的5%,水平線性小于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探頭和傳感器的頻率/Probes and transducer frequencies采用單晶探頭和雙晶探頭的脈沖回波技術(shù)中，其適用的頻率為2MHZ，suitability for nominal frequenc

14、ies 2 MHZ in pulse-echo technique with single-crystal and twin-crystal probes.以下探頭至少要有一個被使用: SEB2-00(MSEB2)和B2S(MB2S)或者有一個相同特性的探頭。探頭SEB2-00 (MSEB2)用于鑄件壁厚0200mm處，探頭B2S(MB2S)用于鑄件壁厚200500mm處。 首先使用SEB2-00 和B2S探頭檢測, 當(dāng)需要精確測量缺陷的邊界時使用MSEB2-00 和MB2S探頭。Following probe head must have at least one to be used: S

15、EB2-00 ( MSEB2) and 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

16、the actual borderline of the defects, use the probes of MSEB2-00 and MB2S. 聲束直徑的補償/ the compensation of diameter of sound beam為了判定一個缺陷的大小是“可測量”還是“不可測量”，聲束的直徑可以進(jìn)行補償。補償可以通過計算（對在遠(yuǎn)場中的單晶探頭），或根據(jù)平底孔的測量值（雙晶探頭）進(jìn)行。聲束直徑的補償只能被用在不可測量缺陷的部分。In order to determine the size of an indication is “measurable” or “not me

17、asurable”, the diameter 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中提到的標(biāo)準(zhǔn)值可供用。The values for standard probes mentioned in Table 1 may be used.聲程

18、（mm）Sound pathSEB2聲束直徑（mm）Diameter of sound beam for SEB2MSEB2聲束直徑（mm）Diameter of sound beam for MSEB2B2S聲束直徑Diameter of sound beam for B2S20155-20-601515-60-120202512表 1.標(biāo)準(zhǔn)探頭的校正值/table 1 Correction values for standard probes4.3.3耦合劑/ couplant使用超聲波漿糊。Ultrasonic jelly shall be used.4.4校準(zhǔn) /Calibration

19、按照現(xiàn)行標(biāo)準(zhǔn)993062對超聲波設(shè)備進(jìn)行校準(zhǔn)。Ultrasonic equipment calibration and verification must be carried out according to present 993062 standards.4.4.1標(biāo)準(zhǔn)參考/NORMATIVE REFERENCESEN126683 無損檢測超聲設(shè)備的特點和驗證第三部分：設(shè)備組合。EN 12668-3 Non-destructive testing - Characterization and verification of ultrasonic examination equipment

20、 - Part 3: Combined equipment.EN12223 無損檢測超聲檢測校準(zhǔn)試塊No.1的規(guī)范。EN 12223 None destructive testing Ultrasonic examination - Specification of calibration block no.1.4.4.2設(shè)備/EQUIPMENT參考試塊K1 DS/EN 12223 Reference block V1 DS/EN 12223 no. 2572參考試塊K2 DS/EN 27963（可利用兩個寬度12.5mm和20mm）Reference block V2 DS/EN 27963

21、 no. 50434-22274 (it is available in two widths 12,5mm and 20mm)參考試塊TIF（長橫孔試塊）Reference block TIF no. 0613164.4.3測試范圍/ SCOPE OF THE TEST新的設(shè)備和探頭組合最初使用時，必須對它作一個基本的測量，并且記錄在登記簿上。Initially when a new combination of ultrasonic instrument and probe is taken into use, it is necessary to make a base measurem

22、ent, which is registered in the registering scheme for base measurements.每一個測量點完成，記錄好數(shù)值，對于剩余的測量點，做好任務(wù)標(biāo)記。For test points where a value is achieved, note the value. For the rest of the points, sign for performing the task.探頭必須每工作日校驗，對于測定信噪比和脈沖持續(xù)時間距離上一次使用每周一次已是足夠的。儀器常規(guī)每周校驗一次，但是如果使用中對儀器有懷疑，必須立即校驗。The us

23、er test of probes 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

24、has occurred, the test must be performed immediately.4.4.4直探頭/NORMAL PROBES測試包括下面的4點：The test includes the following 4 points:測試周期Period 測試內(nèi)容Test每日Daily（如果使用if in use）物理狀態(tài)和外形Determination of physical state and external aspects根據(jù)標(biāo)準(zhǔn)反射體的靈敏度Determination of sensitivity from standard reflector每周Weekly（如果

25、使用if in use）信噪比Determination of signal to noise ratio脈沖持續(xù)時間Determination pulse duration4.4.4.1物理狀態(tài)和外形/Determination of physical state and external aspects目視檢查探頭和連接線是否有損壞或磨損；檢查電路連接的穩(wěn)定性；如果保護(hù)膜有損傷則要更換，晶片和保護(hù)膜間的油中不能有氣隙，更換其中的油通常是必須的。Visually inspect probe and cable for damage and wear. Check for instabilit

26、y 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用標(biāo)準(zhǔn)反射體測量靈敏度/Determination of sensitivity from standard reflector用TIF試塊上深度35mm處的3mm孔作為標(biāo)準(zhǔn)反射體，找出最大回波并調(diào)至80屏高，增益設(shè)置為最低，記錄此時的dB值并且

27、對照初始記錄值，如果偏差超過6dB，則要尋找糾正原因或者更換探頭。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 t

28、he reason and correct it or replace the probe.4.4.4.3信噪比測量/Determination of signal to noise ratio1用TIF試塊上（從端部）深度35mm處的3mm孔作為標(biāo)準(zhǔn)反射體，增益設(shè)置最低，記錄此時dB數(shù)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-

29、value2從試塊上拿下探頭并擦干凈耦合劑。2. Remove the probe from the block and clean it for couplant.3提高增益直至噪聲信號達(dá)到與35mm反射體同樣的高度，記錄提高的數(shù)值，稱為信噪比。記錄dB值并且對照初始測量值，如果偏差超過6dB，尋找糾正原因或者更換探頭。3. Increase the gain until the noise reaches the same level as the reference echo in 35mm distance. Note the increase, which is called sig

30、nal 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脈沖持續(xù)時間的測量/Determination of pulse duration.1設(shè)置時基范圍為50mm，增益調(diào)至最低。1. Set the time base to 50 mm. Set Gain to lowest value.2找出V1試塊上25mm厚

31、處的第一次底波的最高反射，并調(diào)至80屏高。2. Set first bottom echo from the thickness 25 mm at the V1-block to 80% screen height.3讀出10水平線處回波的寬度，按照鋼中的聲程讀數(shù)（見圖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：測量回波寬度（EB）/Example:

32、 Measuring echo breadth (EB)使用數(shù)字超聲儀器，波寬可以用圖A、圖B所示的閘門來測量: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:圖Figure A圖Figure BEB102.4100.4=2.0mm4對照初始測量值，如果偏差超過50，尋找糾正原因或者更換探頭。4. Compare the

33、 measured value with the base measurement. With deviations more than 50% find and correct the reason to the deviation or replace the probe.4.4.5超聲波儀器/ULTRASONIC INSTRUMENT測試包括下面的2點：/The test includes the following 2 points:測試周期Period 測試內(nèi)容Test每周Weekly（如果使用if in use）時基水平線性Determination of linearity of

34、 the time base幅度垂直線性Determination for linearity of the amplifier 4.4.5.1時基水平線性的測量/Determination of linearity of the time base1直探頭放置在V1試塊上一側(cè)，時基范圍調(diào)至125mm。1. Place the normal probe on the side of the V1 block. Set the time base to 125mm.2檢查第一次和最后的回波是否與時基線相一致，并檢查中間其他回波的位置。2. Check if the first and last

35、echo coincides with the first and last scale marks respectively. Check also the positions of the intervening echo.3依次調(diào)節(jié)這些回波到80屏高，注意TOF要設(shè)置為flank模式，對每一個回波，要與比例線一致，偏差不能超過水平整個屏幕寬度的2。3. Bring the echoes, in turn, up to 80 % screen height. Check if the flank, for every echo, still coincides with the scale

36、 marks. The deviation may not exceed 2 % of the whole screen width.4.4.5.2幅度垂直線性的測量/Determination of linearity of the amplifier使用和測量水平線性時相同的時基范圍和探頭，找到TIF試塊上深度為35mm處的3mm孔的最高反射波，調(diào)至80屏高。Use the same time base and probe as used for determination of linearity of the time base. The echo from a 3mm hole in

37、 35mm dept in the TIF-block is used as standard reflector. Maximize the echo from the hole and set it to 80 % screen height.根據(jù)下表數(shù)值調(diào)節(jié)靈敏度，檢查回波高度是否在規(guī)定的范圍內(nèi)。The amplification is set as stated in the table below. Check if the echo is within the specified limits.增益幅Amplification Expected期望屏高screen height (

38、%)范圍Limits2101不小于95/Not less than 95%0806403743122017231810812245可見的低于8/Visible beneath 8%4.4.6整理結(jié)果并歸檔/HANDLING THE RESULTS AND FILING初始測量數(shù)值記錄表應(yīng)該與超聲儀器一起保存。The registration scheme for base measurements is always to be kept together with the ultrasonic instrument.定期校驗的數(shù)字記錄也應(yīng)該與超聲儀器一起保存。當(dāng)記錄表填滿后，新的記錄表應(yīng)該與

39、初始記錄值的復(fù)印件放在一起，并且歸檔在質(zhì)量部門可靠地方。The registration scheme for frequent tests has to be kept together with the ultrasonic instrument. When the scheme is filled in, it must be filed together with a copy of the base measurements. It has to be filed at the quality responsible for the department. The requireme

40、nts of filing follow the existing rules for quality documentation. 4.4.7如果校驗不符合要求，則要根據(jù)填寫“失敗的校驗信息”。If the requirements are not met fill a “Failed calibration message” accordingly.4.5量程的設(shè)定/Range setting4.5.1須進(jìn)行量程的設(shè)定,量程的設(shè)定直接在鑄件上進(jìn)行,條件是鑄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 di

41、rectly on the casting if its thickness is known and if it has parallel surfaces. 4.5.2使用單晶探頭時，儀器中至少應(yīng)顯示出兩次的回波，使用雙晶探頭時，儀器中至少應(yīng)顯示出一次的回波。Field shall have a minimum dimension of two back wall echoes for mono-crystal probes. Field shall have a minimum dimension of one back wall echo for bi-crystal probes.4

42、.5.3如果一個特殊的零件需要使用特殊的刻度量程校正程序,必須符合特種質(zhì)量規(guī)范.In case that a specific components needs for a special scale range adjustment procedure, it shall be covered by the Specific Quality Specification.4.6靈敏度的設(shè)定/Sensitivity setting根據(jù)DGS圖 來完成.Shall be carried out by means of a DGS diagram.對于檢測靈敏度的設(shè)定，KSR3的平底孔的回波高度須至

43、少占到待檢驗的厚度范圍端部的顯示屏高度的40%。（儀器EPOCH 4和EPOCH LT具備DGS軟件，探傷時，在鑄件上把最厚處當(dāng)作大平底，一次回波調(diào)至滿屏的80%，然后使用KSR3mm的DGS曲線即可）。 The initialization of the testing sensitivity shall be set in such a way that the echo heights of the flat-bottomed holes of KSR3mm shall be at least 40% of the screen height at the end the thickne

44、ss range to be examined. (The ultrasonic instrument EPOCH 4 and EPOCH LT have software of DGS. When detecting, adjust the back wall echo to 80% of the full screen height with the casting max wall thicknessas the FBH. And then use the DGS software of KSR3mm for inspection.)例如：/illustrating:4.7檢驗/ Ins

45、pection 4.7.1打300mmx300mm的格子進(jìn)行掃查。Scanning shall be carried out by 300mmx300mm grid conditions.4.7.2掃查速度/Scanning rate 掃查速度不要超過150mm/s,指定掃查的區(qū)域應(yīng)完全的被掃查到，并有系統(tǒng)性的覆蓋(15%)掃查。 The scanning speed shall not exceed 150mm/s. A complete coverage of the specified scanning area shall be conducted by carrying out sy

46、stematically overlapping（15%）scans.4.7.3掃查區(qū)域/UT scanning area在進(jìn)行首件資格認(rèn)證（FPQ）和試驗批量資格認(rèn)證（PLQ）生產(chǎn)時，要對零件進(jìn)行100%的超聲檢查。在批量生產(chǎn)時，只要對規(guī)范中或零件圖紙上標(biāo)明的試驗區(qū)域進(jìn)行檢查，以及在FPO和PLO檢查中發(fā)現(xiàn)有問題的區(qū)域進(jìn)行檢查。另外，在目測檢查中（VT），對某個區(qū)域如覺得有問題，也應(yīng)進(jìn)行超聲檢查。為保證產(chǎn)品的安全，在其它區(qū)域應(yīng)進(jìn)行抽樣檢查。100% ultrasonic testing in accordance is required during FPQ and PLQ. During

47、series production ultrasonic testing must be performed in the test areas, which are defined in the component specification or on the component drawings, and in trouble areas that were found during FPQ and PLQ. In addition UT is required in areas where defects can be presumed based on the results of

48、for example VT. The remaining areas should be inspected spot-check with respect to product safety. 4.8驗收標(biāo)準(zhǔn)/Acceptance Standard4.8.1當(dāng)單個不連續(xù)的體積型缺陷達(dá)到表2和表3中的極限值時，應(yīng)該記錄下來并做出評估。When single discontinuous bulk defect the limits in table 2 and 3, should be noted and be evaluated表 2 / table 2特征Feature 單位Unit質(zhì)量等

49、級/quality level123受檢區(qū)域中的壁厚/wall thickness in the examined areamm-5050 to 2002005050 to 200200壁厚百分比/percentage of wall thickness-2025表層的最大缺陷面積/the largest allowed individual indication in the rim zonea,mm2b6001 0001 0001 0002 0002 000心部的最大缺陷面積/ the largest allowed individual indication in the core zo

50、nemm2b10 00015 00015 00015 00020 00030 000缺陷總面積占被檢表面積的百分比Total area of discontinuities as percentage of examined surfaceb101515152020夾渣/Dross夾渣必須被清除/Dross must be removed 邊緣區(qū)見圖 1 Rim zone, see figure 1.任何缺陷均不得超過表3中給出的極限值，否則要記錄。No indications exceeding the limits given in table 3，otherwise needs to b

51、e recorded.圖 1/ figure 1.圖例索引/index1 表示表層區(qū)/Rim zone 2 表示中心區(qū)/Core zonet 表示總壁厚Wall thickness a 表示1/3的壁厚（最大不超過30mm）t/3(max.30mm)表 3 / table 3受檢區(qū)域的壁厚(mm)Wall thickness of the casting in the examined area(mm)評估的極限/Evaluation limits底波衰減最?。╠B）reduction of back wall echo (min dB)能夠檢出的最小缺陷當(dāng)量(mm)/Smallest fla

52、t-bottom hole diameter detectable 回波高度高于噪聲最小（dB）a Echo height above noise level min(dB) a10 to 20123620 to 100205100 to 250812250 to 50010a僅適用于由于鑄件幾何形狀的原因而無法接受一次回波的區(qū)域。Only for areas where no back wall echo is obtained to the casting geometry.4.8.2鑄件需按采購規(guī)范規(guī)定的范圍內(nèi)進(jìn)行實驗，并要滿足以下要求: （不連續(xù)性）機加工表面缺陷，例如收縮、砂子和夾渣

53、、氣孔等均不允許在機加工表面上出現(xiàn)。因此，鑄件內(nèi)部的不均勻性（缺陷），如估計在機加工以后會變?yōu)楸砻娴牟痪鶆蛐裕ㄈ毕荩瑧?yīng)向采購商提出，并有采購商做出決定。The casting must be tested in the scope according to the purchase standard, and must satisfy requests below: (Discontinuity) machining surface defect, for example shrinkages, sand and slag inclusions, blowhole etc. will not

54、 be permitted in machining surface. Therefore internal discontinuities in the casting which is estimated to be change to a surface discontinuities after machining shall be brought to the attention of purchasing agent and decide upon.4.8.3各種跡象的考慮:/ Consideration of various types of indications:4.8.3.

55、1以下的指示類型,如果不是因為由于鑄件的形狀或耦合問題導(dǎo)致的,則必須加以評價.The following types of indication, which are proven not to be due to the casting shape or the coupling, shall be taken into consideration and evaluated in the examination of castings:一次回波的降低/reduction of the back wall echo;中間的回波/intermediate echoes 注釋 所有類型的指示有可能單獨發(fā)生也可能同時發(fā)生。NOTE all types of indications can occur alone or together.4.8.3.2缺陷的評定和記錄:/ Evaluation and recording of severities:應(yīng)對底波損失達(dá)到或超過表3中的回波高度進(jìn)行記錄與評定, 對于缺陷顯示超過表2里給定范圍的75%時,應(yīng)將其位置利用草圖描述并記錄在檢驗報告中。The damnify of the bottom echogetting to or ab