無損檢測技術(shù)

1、1無損檢測技術(shù)緒論無損檢測技術(shù)緒論 不改變被檢對象的原有形狀與使用性能對其不改變被檢對象的原有形狀與使用性能對其實(shí)施檢測的技術(shù)稱為無損檢測技術(shù)實(shí)施檢測的技術(shù)稱為無損檢測技術(shù) 1. 1. 無損檢測的目的無損檢測的目的 2. 2. 無損檢測技術(shù)的發(fā)展無損檢測技術(shù)的發(fā)展 3. 3. 無損檢測方法分類無損檢測方法分類 4. 4. 無損檢測的依據(jù)無損檢測的依據(jù) 5. 5. 不合格品的處理不合格品的處理 6. 6. 檢測檔案檢測檔案21. 1. 無損檢測的目的無損檢測的目的 確定被檢確定被檢 對象對象 是否具有是否具有“符合性符合性”質(zhì)量質(zhì)量質(zhì)量特性的指標(biāo)是否滿足相應(yīng)質(zhì)量特性的指標(biāo)是否滿足相應(yīng)標(biāo)準(zhǔn)、規(guī)范、

2、合同或第三方的有關(guān)規(guī)定標(biāo)準(zhǔn)、規(guī)范、合同或第三方的有關(guān)規(guī)定 3階階 段段 名名 稱稱 內(nèi)內(nèi) 容容1 1NDINDI 產(chǎn)品最終檢驗(yàn)，以檢測產(chǎn)品產(chǎn)品最終檢驗(yàn)，以檢測產(chǎn)品缺陷為目的缺陷為目的 2 2NDTNDT 產(chǎn)品生產(chǎn)過程的檢驗(yàn)與控制產(chǎn)品生產(chǎn)過程的檢驗(yàn)與控制 3 3NDENDE 對決定產(chǎn)品質(zhì)量特性指標(biāo)的對決定產(chǎn)品質(zhì)量特性指標(biāo)的因素進(jìn)行分析和評(píng)價(jià)因素進(jìn)行分析和評(píng)價(jià) 2. 2. 無損檢測技術(shù)的發(fā)展無損檢測技術(shù)的發(fā)展Inspection Testing Evaluation43.3. 無損檢測方法分類無損檢測方法分類 射射 線線 方方 法法聲聲 學(xué)學(xué) 方方 法法電電 學(xué)學(xué) 方方 法法磁磁 學(xué)學(xué) 方方 法法

3、微 波 與 介 電 方 法光 學(xué) 方 法滲滲 透透 方方 法法 滲 漏 方 法X 射射 線線 與與 射射 線線中中 子子 射射 線線 射射 線線 計(jì)計(jì) 算算 機(jī)機(jī) 層層 析析 ( ( C C T T ) )射 線 與 射 線 測 厚超超 聲聲 檢檢 測測聲聲 發(fā)發(fā) 射射 檢檢 測測聲 振 檢 測聲聲 成成 像像 與與 聲聲 全全 息息聲聲 顯顯 微微 鏡鏡渦渦 流流 檢檢 測測電 位 差 和 交 流 場 檢 測電 流 微 擾 檢 測 磁磁 粉粉 檢檢 測測漏漏 磁磁 場場 檢檢 測測B a r k h a u s e n 噪 聲 檢 測磁 聲 發(fā) 射 檢 測微 波 檢 測介 電 測 量 檢 測

4、目 視 檢 驗(yàn)光 全 息 術(shù) 檢 測錯(cuò) 位 散 斑 干 涉無損檢測方法54.4. 無損檢測的依據(jù)無損檢測的依據(jù) 施工圖樣和定貨合同施工圖樣和定貨合同 相關(guān)的技術(shù)標(biāo)準(zhǔn)和規(guī)范相關(guān)的技術(shù)標(biāo)準(zhǔn)和規(guī)范 檢測的工藝性文件檢測的工藝性文件 65.5. 不合格品的處理不合格品的處理 報(bào)廢報(bào)廢 返修返修 回用回用 降低使用條件降低使用條件 76.6. 檢測檔案檢測檔案 檢測記錄檢測記錄 檢驗(yàn)證書檢驗(yàn)證書 檢測檔案檢測檔案 （包括施工圖樣、檢測記錄、檢驗(yàn)（包括施工圖樣、檢測記錄、檢驗(yàn) 單據(jù)、檢測報(bào)告和檢驗(yàn)證書等）單據(jù)、檢測報(bào)告和檢驗(yàn)證書等） 8一、（熔）焊接缺陷及其危害一、（熔）焊接缺陷及其危害1. 1. 缺陷的

5、分類缺陷的分類 2. 2. 機(jī)械加工中的常見缺陷機(jī)械加工中的常見缺陷 3. 3. （熔）焊接缺陷（熔）焊接缺陷4. 4. 缺陷的危害缺陷的危害 91. 缺陷的分類 按形態(tài)按形態(tài) 面積型缺陷面積型缺陷 體積型缺陷體積型缺陷 按位置按位置 表面缺陷表面缺陷 內(nèi)部缺陷內(nèi)部缺陷 按尺寸按尺寸 宏觀缺陷宏觀缺陷 微觀缺陷微觀缺陷 按性質(zhì)按性質(zhì) 形狀與尺寸缺陷形狀與尺寸缺陷 工藝性缺陷工藝性缺陷 性能缺陷（力學(xué)、性能缺陷（力學(xué)、物理或化學(xué)性能）物理或化學(xué)性能）102. 機(jī)械加工中的常見缺陷常見的機(jī)械加工缺陷 材料與加工工藝 常見的缺陷 復(fù) 合 材 料 未熔合、脫粘、粘合不良、水溶脹、柔化等 非金屬材料 塑

6、 料 氣孔、夾雜、分層等 陶 瓷 氣孔、夾雜、裂紋等 混凝土 空洞、裂紋等 金 屬 型 材 板 材 夾層、夾灰、裂紋等 管 材 裂紋、夾雜、翹皮、折疊等 棒 材 夾雜、縮孔、裂紋等 金屬加工工藝 焊 接 氣孔、夾雜、裂紋、未熔合、未焊透 鑄 造 氣孔、縮孔、裂紋、冷隔、疏松 鍛 造 縮孔、偏析、疏松、夾雜、裂紋、白點(diǎn) 熱處理裂紋、變形、脫碳、過燒、過熱 11 Casting Defects12 Defects in Forged PartsFigure 14.20 Examples of defects in forged parts. (a) Labs formed by web buckl

7、ing during forging; web thickness should be increased to avoid this problem. (b) Internal defects caused by oversized billet; die cavities are filled prematurely, and the material at the center flows past the filled regions as the dies close.133. （熔）焊接缺陷GB 6417GB 6417金屬熔化焊焊縫缺陷分類及說明金屬熔化焊焊縫缺陷分類及說明 100

8、100 裂紋 (ISO6520編號(hào)) 微觀裂紋 縱向裂紋 橫向裂紋 放射狀裂紋 弧坑裂紋 間斷裂紋群 枝狀裂紋 14Schematic illustration of various Discontinuities in Fusion Welds Source: American Welding Society.Overlap15PinholePorosityConcavityLack of PenetrationLack of FusionMismatchWormhole Porosity16Various types of cracks in butt and T joints.17183

9、.（熔）焊接缺陷 200 200 孔穴 (ISO6520編號(hào)) 氣孔(球形、均布、局部密集、鏈狀、條形、蟲形、表面氣孔) 縮孔(結(jié)晶縮孔、微縮孔、枝晶間微縮孔、弧坑縮孔) 19203.（熔）焊接缺陷 300 300 固體夾雜固體夾雜 (ISO6520(ISO6520編號(hào)編號(hào)) ) 夾渣夾渣 焊劑或熔劑夾渣焊劑或熔劑夾渣 氧化物夾雜氧化物夾雜 皺摺皺摺 金屬夾雜金屬夾雜 21Slag inclusion223.（熔）焊接缺陷 400 400 未熔合與未焊透（未熔合與未焊透（ISO6520ISO6520編號(hào)）編號(hào)） 未熔合（側(cè)壁、層間、焊根）未熔合（側(cè)壁、層間、焊根） Incompletefusi

10、on 未焊透未焊透23Incomplete FusionSource: American Welding Society.24Incomplete Fusion253.（熔）焊接缺陷 500500 形狀缺陷形狀缺陷 (ISO6520(ISO6520編號(hào)編號(hào)) ) 263.（熔）焊接缺陷 600600 其他缺陷 (ISO6520編號(hào)) 電弧擦傷 飛濺 鎢飛濺 表面撕裂 磨痕 鑿痕 打磨過量 定位焊缺陷 層間錯(cuò)位 27The low temperatures of the North Atlantic caused the steel to be brittle.These are the fir

11、st ships mass produced with welds.Fractures occurred mainly in the vicinity of stress raisers.The problem may be prevented by employing higher quality steels and improvement of the design of the ship.Liberty Ships-World War II4. 缺陷的危害 28 29焊接檢驗(yàn)標(biāo)準(zhǔn)焊接檢驗(yàn)標(biāo)準(zhǔn) GB J 94 球形儲(chǔ)罐施工及驗(yàn)收規(guī)范 GB J 236 現(xiàn)場設(shè)備、工業(yè)管道焊接工程施工及驗(yàn)收

12、規(guī)范 GB/T 12467-90 焊接質(zhì)量保證 一般原則 GB/T 12468-90 焊接質(zhì)量保證 對企業(yè)的要求 GB/T 12469-90 焊接質(zhì)量保證 鋼熔化焊接頭的要求和缺 陷分級(jí) ISO 5817-1992 Arc-welded joints in steel Guidance on quality levels for imperfections GB11345-89 鋼焊縫手工超聲波探傷方法和探傷結(jié)果的分級(jí) GB/T 3323-2005 鋼熔化焊對接接頭射線照相和質(zhì)量分級(jí) 30參考書目參考書目天津大學(xué)，中石化第四建設(shè)公司。焊接質(zhì)量管理與檢驗(yàn)。北京：機(jī)械工業(yè)出版社，1993 鄭中興。

13、 材料無損檢測與安全評(píng)估。北京：中國標(biāo)準(zhǔn)出版社，2004李喜孟。無損檢測。北京：機(jī)械工業(yè)出版社，2001Liquid Penetrant TestingTracy, Noel and Patrick, Moore O., Nondestructive Testing Handbook - Third Edition: Vol. 2, Liquid Penetrant Testing, American Society of Nondestructive Testing, Columbus, OH. (1999).Magnetic Particle TestingBetz, C.E., Prin

14、ciples of Magnetic Particle Testing, Magnaflux, Hardwood Heights, Illinois, (1997).Ultrasonic TestingBuirks, Albert S. (tech. ed.), Green Jr., Robert E. (tech. ed.), and McIntire, Paul (ed.), Nondestructive Testing Handbook, Volume 7, Ultrasonic Testing, American Society of Nondestructive Testing. C

15、olumbus, OH. (1999).Electromagnetic TestingDan, Harvey E., Eddy Current Testing Theory and Practice, (1995).Radiographic TestingRadiography in Modern Industry 4th edition. (2001). Rochester, New York: Eastman Kodak Company.Bryant, Lawrence E. (tech. ed.) and McIntire, Paul (ed.), Nondestructive Test

16、ing Handbook, Volume 3, Radiography and Radiation Testing, American Society of Nondestructive Testing, Columbus, OH. (1999)31二、二、 焊接檢驗(yàn)的內(nèi)容焊接檢驗(yàn)的內(nèi)容 32The ENDIntroduction to Nondestructive TestingOutline Introduction to NDT Overview of Six Most Common NDT Methods Selected ApplicationsThe use of noninvas

17、ive techniques to determine the integrity of a material, component or structure or quantitatively measuresome characteristic ofan object. i.e. Inspect or measure without doing harm.Definition of NDTMethods of NDTVisualLiquid PenetrantMagnetic ParticleEddy CurrentUltrasonicX-ray MicrowaveAcoustic Emi

18、ssionThermographyLaser InterferometryReplicationFlux LeakageAcoustic MicroscopyMagnetic MeasurementsTap TestingWhat are Some Uses of NDE Methods? Flaw Detection and Evaluation Leak Detection Location Determination Dimensional Measurements Structure and Microstructure Characterization Estimation of M

19、echanical and Physical Properties Stress (Strain) and Dynamic Response Measurements Material Sorting and Chemical Composition Determination Fluorescent penetrant indicationWhen are NDE Methods Used?To assist in product development To screen or sort incoming materialsTo monitor, improve or control ma

20、nufacturing processesTo verify proper processing such as heat treatingTo verify proper assemblyTo inspect for in-service damageThere are NDE application at almost any stage in the production or life cycle of a component.Six Most Common NDT Methods Visual Liquid Penetrant Magnetic Ultrasonic Eddy Cur

21、rent X-rayMost basic and common inspection method.Tools include fiberscopes, borescopes, magnifying glasses and mirrors.Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.Portable video inspection unit with zoom allows inspection of large tanks an

22、d vessels, railroad tank cars, sewer lines.Visual Inspection A liquid with high surface wetting characteristics is applied to the surface of the part and allowed time to seep into surface breaking defects. The excess liquid is removed from the surface of the part. A developer (powder) is applied to

23、pull the trapped penetrant out the defect and spread it on the surface where it can be seen. Visual inspection is the final step in the process. The penetrant used is often loaded with a fluorescent dye and the inspection is done under UV light to increase test sensitivity.Liquid Penetrant Inspectio

24、nMagnetic Particle InspectionThe part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. This indication can be v

25、isually detected under proper lighting conditions. Magnetic Particle Crack Indications RadiographyThe radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a r

26、adioactive source. High Electrical PotentialElectrons-+X-ray Generator or Radioactive Source Creates RadiationExposure Recording DeviceRadiation Penetrate the SampleFilm RadiographyTop view of developed film X-ray filmThe part is placed between the radiation source and a piece of film. The part will

27、 stop some of the radiation. Thicker and more dense area will stop more of the radiation. = more exposure= less exposureThe film darkness (density) will vary with the amount of radiation reaching the film through the test object.Radiographic ImagesConductive materialCoilCoils magnetic fieldEddy curr

28、entsEddy currents magnetic fieldEddy Current TestingEddy Current TestingEddy current testing is particularly well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements. Here a small surface probe is scanned over the part surface i

29、n an attempt to detect a crack.High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws.Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound. f

30、platecrack0246810initial pulsecrack echoback surface echoOscilloscope, or flaw detector screenUltrasonic Inspection (Pulse-Echo) Ultrasonic ImagingHigh resolution images can be produced by plotting signal strength or time-of-flight using a computer-controlled scanning system.Gray scale image produce

31、d using the sound reflected from the front surface of the coinGray scale image produced using the sound reflected from the back surface of the coin (inspected from “heads” side)Ultrasonic ImagingHigh resolution images can be produced by plotting signal strength or time-of-flight using a computer-con

32、trolled scanning system.Common Application of NDT Inspection of Raw Products Inspection Following Secondary Processing In-Services Damage InspectionInspection of Raw Products Forgings, Castings, Extrusions, etc. Machining Welding Grinding Heat treating Plating etc.Inspection Following Secondary Proc

33、essing Cracking Corrosion Erosion/Wear Heat Damage etc.Inspection For In-Service DamagePower Plant InspectionProbeSignals produced by various amounts of corrosion thinning.Periodically, power plants are shutdown for inspection. Inspectors feed eddy current probes into heat exchanger tubes to check f

34、or corrosion damage.Pipe with damageWire Rope InspectionElectromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices. Storage Tank InspectionRobotic crawlers use ultrasound to inspect the w

35、alls of large above ground tanks for signs of thinning due to corrosion.Cameras on long articulating arms are used to inspect underground storage tanks for damage. Aircraft Inspection Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and

36、 corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below. Jet Engine Inspection Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassemb

37、led. Fluorescent penetrant inspection is used to check many of the parts for cracking. Sioux City, Iowa, July 19, 1989A defect that went undetected in an engine disk was responsible for the crash of United Flight 232. Crash of United Flight 232Pressure Vessel InspectionThe failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, the tanks are inspected using radiography and ultrasonic testing.Rail InspectionSpecial cars are used to inspect thousands of miles of rail to find cracks that could l