Inconel 783螺栓超声相控阵导波检测技术研究
Research on phased array guided waves testing technology on Inconel 783 bolts
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摘要: 螺栓是工业领域重要的连接件,在电力行业,螺栓在高温高压、振动等各种恶劣工况下服役,受到拉应力的作用,容易发生断裂,导致严重的生产事故。因此,必须探索一种有效可行的检测方案,实现在役螺栓的检测。目前对螺栓裂纹检测较为常见的方法是常规超声检测,其缺点主要有检测效率低、声波传播受侧壁反射干扰、缺陷不易识别等;相控阵技术相对于常规超声,具有电子控制聚焦和扫查、检测效率高、缺陷显示直观等优点。导波是一种适于杆状工件传播的弹性波,传播距离远,衰减相对更小,在螺栓的裂纹检测中具有独特的优势。结合相控阵技术和导波技术开展研究,计算了在Inconel 783螺栓中传播的导波的频散曲线,分析了适用于Inconel 783螺栓检测的导波参数,发现L(0,1)模态具有更高的速度,适于表征缺陷;以5MHz的频率激发导波,在传播过程中衰减较小,可用于螺栓检测。针对Inconel 783螺栓,研究了检测方法和工艺,研制了一套适于Inconel 783螺栓的超声柱面导波相控阵检测主机和64阵元环型一维线阵相控阵探头,并设计制作了两种不同尺寸的Inconel 783螺栓试块,用于实施对比检测试验。在试块上进行的实际检测结果表明,该超声相控阵导波检测系统能够成功检出螺栓内部的裂纹缺陷,并且达到了较高的定位准确度和分辨力。Abstract: Bolts are important connection components in industry. In power plants, bolts serve under rough condition such as high temperature, high pressure, and severe vibration. Besides, they suffer from tensile stress, leading to the high possibility of crack failure and consequent serious accident. Thus, it’s necessary to find out a testing method to realize the precaution of bolts’ crack failure. So far, the most common testing method of bolts cracks is traditional Ultrasonic Testing. Compared to Phased Array Ultrasonic Testing, the former one shows disadvantages such as low inspecting efficiency, vulnerability of disturb of surface reflections, and difficulty in cracks’ recognition, while the later one has merits like electronically controlled focus and scan, high efficiency, and convenience for flaws recognition. Guided Waves transfer well in bar-shaped components, with small attenuation, to a long distance. Thus, they are suitable for bolt cracks inspection. This article talks about the research on technology combining Phased Array Ultrasonic Testing and Guided Waves. The research team made the calculation of Frequency Dispersion Curve of Guided Waves transferring in Inconel 783 bolts, and analyzed the Guided Waves’ parameters suitable for Inconel 783 bolts inspection. The results showed that modal L(0, 1) possessed the highest velocity, which was ideal to represent the flaw’s reflection. And Guided Waves transmitted at the frequency of 5MHz could be used in bolts inspection due to their small attenuation. The research team focused on the Inconel 783 bolts to design inspection procedure and parameters. A system suitable for Inconel 783 bolts inspection was developed consisting of a Phased Array Guided Waves host computer and a cylindrical linear probe with 64 elements. Related simulating testing blocks were also fabricated in two different sizes for comparative test. The results from the comparative test showed that the inspection system was capable of discovery of finding out the cracks inside the bolts, with high positioning accuracy and resolving ability.