磁粉檢測工藝規(guī)程magnetic

磁粉檢測工藝程序編號ReportNo.Q/OH(Q)03?005-2009浙江歐華造船有限公司ZhejiangOuHuaShipbuildingCo.,LtdMagneticInspectProcedure頁數(shù)Pages13編寫： 審核： 確認：Wrttenby Checkedby Approvedby123456磁粉、789101112131415目錄Content章節(jié)題目Subject章節(jié)題目Subject頁碼PageTOC\o"1-5"\h\z目的Purpose 2適用范圍Scope 3職責Responsibility 3檢測人員Inspector 3設備器材EquipmentandApparatus 4磁懸液及反差劑Magneticparticles、Suspensionandcontrastpaint4靈敏度試片Sensitivitytestblock 5提升力試塊Liftingpowertestblock 6檢測時機Timefortesting 6檢測方法Testmethod 7磁粉檢測操作Magnetictestoperation 7顯示結果的評定和記錄evaluationofindicationandrecording 10復驗Re-inspection 10驗收標準Acceptaneestandard 11檢測報告格式Testreportformat 121.目的Purpose本工藝是根據(jù)LR規(guī)范及IACS焊接質量和無損探傷檢測指南要求制定的焊縫磁粉檢測質量控制程序。TheworkmanshipisbasedonthequalitycontrolprocedureofseammagnetictestingoftheruleofLRandIACSguidelineofweldingqualityandNDTofshipsteelwelds.2-適用范圍Scope2.1本工藝適用于檢測鐵磁性材料的焊接接頭表面或近表面的裂紋及其它缺陷。Thisworkmanshipapplytodetectingcracksandotherflawsonthesurroundingsurfaceofweldingjointofferromagneticmaterial.2.2焊縫磁粉檢測除執(zhí)行本工藝外，尚應符合現(xiàn)行有關標準規(guī)范的規(guī)定與設計部門提出的有關要求。Withtheexceptionofthisrule,weldseammagnetictestshouldbeinaccordancewithcurrentrelatedcriterionaswellasrelatedrequestbydesigndepartment.3.職責Responsibility3.職責Responsibility3?1參照程序ReferenceprocedureLR鋼質海船入級及建造規(guī)范LRsteelvesselclassificationandconstructionruleENISO5817(2003)船舶鋼焊縫磁粉檢測工藝和質量分級CB/T3958-2004ShippingsteelweldseammagnetictesttechnologyandqualitygradingCB/T3958-2004IACSGuidelineNon-destructivetestingofshiphullsteelwelds3?2合格標準acceptancestandard(a)LR船舶入級規(guī)范和規(guī)則LRsteelseagoingshipclassificationandbuildingruleIACS焊接質量和無損探傷檢測指南(b)IACSGuidelineNon-destructivetestingofshiphullsteelwelds4.檢測人員inspectora）從事磁粉檢測人員應具有必要的專業(yè)知識，并具有一定的磁粉檢測經驗及須掌握一定的金屬材料及焊接基礎知識。Inspectorengagedinmagnetictesthavenecessaryprofessionalknowledgeandrelatedmagnetic

testexperience,aswellasthebasicknowledgeofmetalmaterialandwelding.b）磁粉檢測人員必須持有國家有關部門（CCS等）頒發(fā)的，并與其工作相適應等級的資格證書。進行檢測的人員應當根據(jù)國家公認的認證計劃或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP進行二級資格鑒定和認證。一級資質的操作人員可以二級或三級資質人員的管理下進行測試。獲得國家公認的認證計劃或按照等同于ISO9712,SNT-TC-1A,EN473或ASNTACCP認證的三級資質人員有責任準備和認可無損探傷操作程序。b)Magneticinspectormusthavequalificationcertificateofcertainclassrelatedtoone'sjobissuedbynationaldepartment(CCS,etc)OperatorsshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).OperatorsqualifiedtolevelImaybeengagedinthetestsunderthesupervisionofpersonnelqualifiedtolevelIIorIII.PersonnelresponsibleforthepreparationandapprovalofNDTproceduresshouldbequalifiedaccordingtoanationallyrecognisedschemewithagradeequivalenttolevelIIIqualificationofISO9712,SNT-TC-1A,EN473orASNTCentralCertificationProgram(ACCP).5.設備器材5.設備器材EquipmentandApparatus5.1磁粉檢測設備必須符合JB/T8290的規(guī)定。MagnetictestapparatusmustapplytotheruleforJB/T8290.5.2用以指示磁化電流的電流表應至少每年校準一次。經過重大修理的設備以及放置半年以上沒有使用的設備，在修理后和重新使用前，都應當對電流表進行校準。Ammeterusedforindicationofmagneticcurrenthastobecalibratedonceperyearatleast.Apparatusaftermajorrepairorlayasideoverhalfyear,ammeterofwhichneedtobecalibratedafterrepairorbeforere-use.5.3用于磁軛法檢測的交流電磁鐵，在其最大磁極間距上的提升力應大于4.5kg，直流電磁鐵在其最大磁極間距上的提升力應大于18.1kg。ACferromagnetformagnetizingmethod,liftingpowerofwhosemax.magneticpolespanshouldbemorethan4.5kg.While,liftingpowerofDCferromagnet'smax.magneticpolespanshouldbemorethan18.1kg.Suspensionandcontrastpaint磁粉、磁懸液及反差劑SuspensionandcontrastpaintMagneticparticles、6.1磁粉應具有高導磁率和低剩磁性質，磁粉之間不應相互吸引。Magneticparticleshavenatureofhighpermeabilityandlowremanence.Magneticparticlescan'tbeinterattracted.6.2根據(jù)試件的材質、表面狀態(tài)的不同，磁粉應具有適當?shù)拇判?、粒度、分散性及色彩。磁懸液還要

有懸浮性。Correspondingtothequalityofmaterialandsurfacecondition,magneticparticlesshouldhavesuitablemagnetism,particlesize,dispersibility.Suspensionhassuspensibilityaswell.6.3磁粉檢測時應使用白色反差劑，以增加檢測對比度。Whitecontrastagentisusedduringmagnetictesttoincreasecontrast.靈敏度試片Sensitivitytestblock7?1A型靈敏度試片TypeAstandardtestblockA型靈敏度試片僅適用于連續(xù)法，用于被檢工件表面有效磁場強度和方向、有效檢測區(qū)以及磁化方法是否正確的測定。磁化電流應能使試片上顯示清晰的磁痕。TypeAstandardtestblockisonlyusedincontinuousmethod,insuchmethodtomensurateeffectivefieldstrengthanddirection>effectivetestareasaswellasmagnetizationmethodonthetestedbodysurface.Magnetizingcurrentshouldmakeclearmagneticparticleindicationonthetestblock.A型靈敏度試片的靈敏度分高、中、低三檔，其幾何尺寸見圖1型號及槽深見表1TypeAstandardtestblockisdividedinthreegrade:HighMedium、Low.Itsgeometricfigureandtypeandslotdepth,pleaseseedrawing1andtable1型號Type相對槽深relativeslotdepth靈敏度型號Type相對槽深relativeslotdepth靈敏度Sensitivity材質MaterialA-15/10015/100高High超高純低碳純鐵Super-highpurityLowCarbonSteel，CV0.03%,H0V80A/m,經退火處理annealingtreatmentoA-30/10030/100中MediumA-60/10060/100低Low注：試片相對槽深表達式中，分子為人工槽深度，分母為試片厚度Remark:expressionofrelativeslotthatnumeratorisartificialslotdepthanddenominatoristhethicknessoftestblock.um7.2磁場指示器(八角試塊)Magneticfieldindicator(aniseedtestblock)表1A型靈敏度試片TypeAstandardtestblockmeans磁場指示器是一種用于表示被檢工件表面磁場方向、有效檢測區(qū)以及磁化方法是否正確的一種粗略的校驗工具，但不能作為磁場強度及其分布的定量指示。它有著使用方便、易于保養(yǎng)的優(yōu)點。其幾何尺寸見圖1OMagneticfieldindicatorisoneroughchecksumutilitiestomensuratefielddirection^effectivetestareasaswellasmagnetizationmethodonthetestedbodysurface.However,thisindicatorcan'betherationindicationoffieldstrengthanditsdistribution.Easyuseandmaintenanceisitsadvantage.Itsgeometric

figure,pleaseseedrawing1.靈敏度試片使用方法Useofsensitivitytestblock7.3.1使用A型靈敏度試片時，應將試片無人工缺陷的面朝外。為使試片與被檢面接觸良好，可用透明膠帶將其平整粘貼在被檢面上，并注意膠帶不能覆蓋試片上的人工缺陷。測試時，應使用連續(xù)磁化法。ThetypeAstandardtestblockisattachedonthetestsurfaceinsuchamannerthatthefaceofblockhavingtheartificialflawcontactcloselywiththetestsurface.Inordertocontactcloselywithtestblock,scotchtapecanbestickonthetestsurfaceflatly,inthiscase,nopartofthetapemustcoverthepartofartificialflawofstandardtestblock.Continuousmagnetizationmethodshouldbeused.7?3?2使用磁場指示器時，應在用連續(xù)法對工件磁化的同時，將其平放在被檢面上，并對其表面施加磁懸液，以是否出現(xiàn)“*”磁痕來判定工件是否磁化適當與否。Ifusemagneticfieldindicator,thetestbodyshouldbemagnetizedincontinuousmethod.Meanwhile,theindicatorhastobelayonthetestsurfaceandaddedwithsuspension.Themagneticparticleindication“*”appearsornotdetermineswhetherthetestbodyisalreadyproperlymagnetizedornot.提升力試塊Liftingpowertestblock提升力試塊Liftingpowertestblock8.1提升力試塊應用與復核和確定電磁軛系統(tǒng)是否達到標準的規(guī)范要求。Liftingpowertestblockapplytorecheckandensureifthethemagnetizingsystemmeetsthestandardornot.8.2試塊應經鑒定并作重量標定。Thetestblockhavetobeidentifiedandweightcalibration.檢測時機Timefortesting通常，焊縫的磁粉檢測應安排在焊接工序完成之后進行，對于有延遲裂紋傾向的材料磁粉檢測應安排在焊后48小時進行Generally,themagnetictestforseamistestedintheconditionwhenalltheworkingandtreatingprocesseshavebeencompleted.However,incasewherethesurfacetreatmentcaninterferewiththedetectionofflaws,themagnetictestshouldbearranged48hafterwelding.

10.檢測方法Testmethod焊縫的磁粉檢測以磁軛法為主，選用類型見表211.磁粉檢測操作11.磁粉檢測操作分類條件Classificationcondition分類名稱Classification施加磁粉的磁化時間Timeforapplicationofmagneticparticles連續(xù)法Continuousmethod磁粉種類Classesofmagneticparticles非熒光磁粉Nonfluorescentmagneticparticles磁粉的分散劑Carrierfluidofmagneticparticles干法或濕法Dryandwetmethod磁化電流的種類Typesofmagnetizingcurrents父流或直流DC/AC表2 磁軛檢測方法選用類型Table2ClassificationofthemethodsMagnetictestoperation檢測操作包括前處理、磁化、磁痕觀察、記錄等多項操作。背景不好需加反差劑。Testingoperationshallincludesuchoperationasthepretreatment、magnetization>observationofmagneticparticleindication、recordingandsoon.ThecontrastPaintshouldbeaddedifthebackgroundcolorisnotwell.11.1前處理Pretreatment11?1?1試件處理的范圍必須大于探傷范圍。焊縫處原則上應由探傷范圍向母材方向擴大50mm。Taketherangeofpretreatmentbroaderthanthetestrangewithoutfail.Inthecaseofaweldingseam,basicallyanareabroaderbyapproximately50mmthantherangeonthebasemetalside.11.1.2被檢試件的表面粗糙度Ra不大于12.5口m。Theroughnessofthetestbodysurfaceisnotmorethan12.5um.11?1?3如試件上的油脂或其他附著物、涂料、鍍層等影響探傷靈敏度或是磁懸液受到污染時，必須把它們清除掉，并清洗干凈。Incaseswherethefatsandoilsadheredonthetestbody,stainsandotheradheredmatters,coatedfilmssuchaspaint、plating,etc.affecttheinfluenceonthetestaccuracy,orwherethereisafeartostainthesuspension,removetheseandmakethetestbodycleanwithoutfail.11.1.4每次檢測前必須對電磁軛系統(tǒng)作提升力試驗。Beforetest,themagnetizingsystemmustbedonewithliftingpowertest.磁化Magnetization11?2?1通電方式工件磁化通電方式選用連續(xù)法。采用連續(xù)法時，磁粉或磁懸液必須在通電時間內施加完畢，通電時間為1~3s。為保證磁化效果應至少反復磁化二次，停施磁懸液至少1s后才可停止磁化。Themagnetizationenergizedmethodofthetestbodyadoptscontinuousmethod.Duringcontinuousmethod,themagneticparticlesorsuspensionmustbefinishedaddingontime.Nearlyl-3s.Inordertoensuregoodeffectmagnetizationeffect,magnetizationtwiceatleastisnecessary.Stoppingmgnetizationatleast1safterstoppingaddingthesuspension.11?2?2磁化方向Magnetizationdirection被檢工件的每一被檢區(qū)至少應進行兩次獨立的檢測，兩次檢測的磁力線方向應大致相互垂直。條件允許時，可使用旋轉磁場以及交直流復合磁化方法。Thetestareaoftestbodyhastobecheckedtwiceatleast,andthemagneticlineofforcedirectionsofthistwicetestshouldberoughlyperpendicular.Iftheconditionispermitted,rotatingmagneticfieldandAC/DCcompositemagnetizationmethod.11?2?3磁化規(guī)范Magnetizationcriterion采用磁軛磁化工件時，其磁化電流應根據(jù)靈敏度試片或提升力校驗來確定。在其最大磁極間距上，交流電磁鐵的提升力應大于4.5kg，直流電磁鐵的提升力應大于18.1kg。Ifthetestbodyisyokemagnetized,itsmagneticcurrentshouldbeaccordingtosensitivitytestblockandlftingpowertestblock.liftingpowerofwhoseBetweenitsmax.magneticpolespan,theliftingpowerofACelectromagnetshouldbemorethan4.5kg,whileliftingpowerofDCferromagnetshouldbemorethan18.1kg.磁軛的磁極間距應控制在50~200mm之間，檢測的有效區(qū)域為兩極連接兩側各50mm的范圍內，磁化區(qū)域每次應有15mm的重疊。Mgneticpolespanofmagnetyokeshouldbebetween50?200mm,andthetestareaisformedtherangeofthetwopolesconnectionwith50mmbothside.Magnetizationareashouldbe15mmoverlappingeachtime.磁粉的施加Applicationofmagneticparticles11.3.1施加磁粉時，應將適量的、分布均勻的磁粉施加在有效探傷范圍的檢測面上，使之吸附在缺陷部位，此時必須使檢測面不再被磁粉沾污，以形成對比良好的缺陷磁痕。為此，應根據(jù)試件的磁特性、形狀、尺寸、表面狀態(tài)、磁化方法及檢測環(huán)境，選擇合適的磁粉和分散劑種類、磁懸液濃度以及磁粉施加方法。Applythesufficientquantityofmagneticparticlesundertheuniformcondition,gentlytothetestsurfaceintheeffectiveareaforflawdetectionandletthemadsorbtotheflawedpart.Atthistime,avoidmakingthetestsurfacedirtywithmagneticparticlesforensuringtheformationofmagneticparticleindicationofgoodcontrast.Forthispurpose,suitabletypesofmagneticparticlesandcarrierfluid,dispersingconcentrationofmagneticparticlesinthesuspensionandmagneticparticleapplicationmethodmustbeselectedaccordingtothemagneticcharacteristics,shape,dimensions,surfaceconditionoftestbody,suspectedcharacteristicsofflaws,magnetizingmethodandtestingenvironment.11.3.2在連續(xù)法檢測時，應在磁化過程中完成施加磁粉。此時必須注意磁化結束后形成的磁痕不要被流動著的磁懸液所破壞。Inthecontinuousmethod,completetheapplicationofmagneticparticleduringthemagnetizingoperation.Inthiscase,caremustbetakensoasthemagneticparticleindicationformedbythesuspensioncarrierfluidaftercompletionofmagnetizingoperationnottobeerased.11?3?3采用干法時，必須確認磁粉和檢測面已完全干燥后，再把適量的磁粉輕輕地噴灑到試件上。為了便于形成缺陷磁痕，可以輕微地振動檢測面或利用柔和的氣流去除多余的磁粉，但必須注意不得破壞已形成的缺陷磁痕。Inthedrymethod,gentlyblastorscatterasuitablequantityofmagneticparticlesafterconfirmingthesufficientdrynessofmagneticpariclesandthetestsurface.Inthiscase,theexcessmagneticparticlesmayberemovedwithagentleairstreamorthelikeaftergivinglightvibrationtothetestsurfaceorapplyingasufficientquantityofmagneticparticlesfortheeasyformationofmagneticparticleindication,butcaremustbetakensoasnottoerasetheformedmagneticparticleindication.11?3?4采用濕法時，應確認整個檢測面能被磁懸液良好地濕潤后再把磁懸液澆在檢測面上，或將試件浸漬在磁懸液中，磁化后輕輕取出。無論哪一種方法，都要注意不使檢測面上磁懸液流速過快。Inthewetmethod,applythemagneticparticlesbypouringthesuspensiononthetestbody,afterconfirmationthatthewholetestsurfaceisingoodwetconditionorbyimmersingthetestbodyintothesuspensioninwhichmagneticparticlesarewelldispersedandgentlytakingitout.Ineithercase,caremustbetakentoavoidtheexcessivespeedofsuspensionflowonthetestsurface.11.3.5采用交叉磁軛檢測時，在磁化的同時噴灑磁懸液，磁懸液一般均勻地噴灑在交叉磁軛行進方向的前方。Whencrossmagnetictestisadopted,suspensionshouldbesprayedsteadilyinfrontofcrossmagnetictestareaduringmagnetization.

12.顯示結果的評定和記錄evaluationofindicationandrecording12.Allindicationsshallbeevaluatedintermsoftheacceptancestandardsofpart14.所有顯示結果都需根據(jù)14章的驗收標準來評定。Discontinuitiesonornearthesurfaceareindicatedbytheretentionofexaminationmedium.However,localizedsurfaceirregularitiesduetomachiningmarksorothersurfaceconditionsmayproducefalseindications.檢測媒介會顯示表面或者靠近表面的不連續(xù)性。不過，由于匹配的標記或其他的表面狀況而導致的檢測表面不規(guī)則會產生錯誤的現(xiàn)實結果。Broadareasofparticleaccumulationwhichcouldmaskindicationsfromdiscontinuitiesareprohibited,andsuchareasshallbecleanedandreexamined.Anyotherfalseindicationsshallberemovedandtheareareexamined.磁粉聚集的區(qū)域可以把不連續(xù)性屏蔽了，這些區(qū)域需做清潔并復檢。任何其他的錯誤顯示都需處理并且該區(qū)域需做復檢。Anyindicationwhichisbelievedtobenonrelevantshallbereexaminedtoverifywhetherornotrelevantindicationsarepresent.那些被認為不相關的顯示結果就應該重新檢測以確認是否存在相關的顯示結果。Techniquessuchasgrinding,crossmagnetization,andtheuseoftheresidualmethodshallbeusedinthereexaminationofsuspectednonrelevantindication.在懷疑為不相關顯示結果的復檢時，應采取例如打磨，交叉磁化和剩磁法之類的方法。Allexaminationconditionsandresultsshallberecordedonthereports.所有檢測狀況和結果都需記錄在報告上13.復驗Re-inspectionMagneticparticleexaminationreportsshallbemaintainedasadigitalfileinaLDMofERPsystemfortwo(2)years,exceptspecifiedbythecontractspecifications&rulesoftheClassificationSociety磁粉檢測報告需用EPR系統(tǒng)的LDM電子版本保持兩年，除非合同規(guī)格書和船級社的規(guī)范沒有標明。13.復驗Re-inspection13.1當出現(xiàn)下列情況之一時，應進行復驗:Re-inspectionisexecutedwhenoneoffollowingsituationhappens:檢測結束時，用靈敏度試片驗證檢測靈敏度不符合要求；Aftertest,sensitivitytestblockisusedbuttheresultcan'meetthestandard發(fā)現(xiàn)檢測過程中操作方法有誤； Wrongoperationisfoundduringtest.供需雙方有爭議或認為有其他需要時;Disputebetweenbuyerandsellerorotherrequestisneeded

經返修后的部位。Theflawedplacewherehasbeenrepaired.13.2復驗應按11.1.4~1135中有關條文進行。Reinspectionshouldaccordtorelatedarticlesinll.l.仁11.3.5.14.驗收標準14.驗收標準Acceptancestandard(1)ViewingConditions圖像狀況Non-Fluorescent非熒光Daylightviewingisadequate.Artificiallightmayalsobeused,buttheminimumintensityoflightatthesurfacetobeinspectedis500lux.日照應充足。同時也需要人工照明，表面檢測時光度最少需要500lux。Fluorescent熒光Blocklightintensityshallnotbelessthan800W/cmA2withabackgroundlightingof10lux.黑光燈強度不應低于800W/CMA2,亮度為10lux。(2)AcceptanceStandard驗收標準AcceptanceStandardforweldsareshowninTable3焊接的驗收標準見圖表3.Table2Welddefectacceptancelevelsforfabrication表3生產焊接缺陷驗收標準Surfacediscontinuity表面不連續(xù)性ClassificationaccordingtoISO6520-1根據(jù)ISO6520-1分級Acceptan