JB/T 5439-1991 Ultrasonic flaw detection of ductile iron parts for compressors
Some standard content:
Mechanical Industry Standard of the People's Republic of China
JB/T 5439-1991
Ultrasonic flaw detection of ductile iron parts of compressors
Published on July 22, 1991
Implementation by the Ministry of Machinery and Electronics Industry of the People's Republic of China on July 1, 1992
Mechanical Industry Standard of the People's Republic of China
Ultrasonic flaw detection of ductile iron parts of compressors
Subject content and scope of application
JB/T 5439-1991
This standard specifies the flaw detection method and defect grade classification using A-type pulse reflection ultrasonic flaw detector. This standard applies to ultrasonic flaw detection of ductile iron parts of compressors (hereinafter referred to as "workpieces") and other similar parts. 2 Reference standards
ZBY230
ZBJ04 001
JB3111
3 Terms
3.1 Sound transmission
General technical conditions for type A pulse reflection ultrasonic flaw detectors Working performance test methods for type A pulse reflection ultrasonic flaw detection systems Nondestructive testing terms
When ultrasonic longitudinal waves are incident vertically on a defect-free workpiece with the test surface and the bottom surface parallel, the sound pressure drop caused by the sound wave going back and forth once is measured in decibels (dB).
3.2 Other terms in this standard shall be in accordance with the provisions of JB3111. 4 Flaw detectors
Flaw detection of ductile iron parts of compressors shall be performed by those who have certain basic knowledge and experience in flaw detection of ductile iron parts and have obtained a qualification certificate recognized by the relevant departments after assessment.
5 Flaw detection equipment
5.1 Flaw detector
5.1.1 A type pulse reflection ultrasonic flaw detector shall be used, and its frequency range shall be between 1~5MHz. 5.1.2
2 The instrument shall display linearly within at least 75% of the full scale, and the vertical linear error shall not be greater than 5%. 5.1.3
The instrument's horizontal linearity, resolution and attenuator accuracy shall all comply with the relevant provisions of ZBY230. 5.2 Probe
5.2.1 The chip diameter of the longitudinal wave straight probe shall be between 10~30mm, the operating frequency shall be 1~5MHz, and the frequency error shall be ±10%. The chip area of the transverse wave oblique probe shall be between 100~400mm2, and the K value shall generally be 1~3. 5.2.2
5.2.3 The acoustic insulation between the chips of the longitudinal wave dual crystal straight probe must be good. 5.3 Performance of the instrument system
The sensitivity margin and resolution of the instrument system shall be tested in accordance with the relevant provisions of ZBJ04001. 5.3.1 At the working frequency, the sensitivity margin of the longitudinal wave straight probe shall not be less than 30dB, and the sensitivity margin of the shear wave oblique probe shall be in accordance with the provisions of Appendix A (Supplement) A1.2.
Approved by the Ministry of Machinery and Electronics Industry on July 22, 1991 and implemented on July 1, 1992
JB/T5439-1991
5.3.2 At the working frequency, the resolution of the longitudinal wave straight probe shall not be less than 20dB, and the resolution of the shear wave oblique probe shall not be less than 15dB. 5.4 Test block
The standard test block is made of carbon steel or low alloy steel forging materials, and defects greater than or equal to the equivalent of Φ2mm flat bottom hole are not allowed. 5.4.1 Standard test block for longitudinal wave straight probe 5.4.1.1 When the detection distance of the workpiece is greater than or equal to 1.6 times the near field area, a longitudinal wave straight probe shall be used. 5.4.1.2 The shape and size of the standard test block for longitudinal wave straight probe flaw detection shall be in accordance with Figure 1 and Table 1. D
Height H
Diameter D
Standard test block for longitudinal wave twin crystal straight probe 5.4.2.1
When the detection distance of the workpiece is less than 1.6 times the near field area, a longitudinal wave twin crystal straight probe shall be used 145
The shape and size of the standard test block for longitudinal wave twin crystal straight probe flaw detection shall be in accordance with Figure 2 and Table 28×25
Detection distance L
JB/T5439-1991
5.4.3 The shape and size of the standard test block for transverse wave oblique probe flaw detection shall be in accordance with the provisions of A1.3 in Appendix A and Figure A1. 5.4.4 When the inspection surface is a curved surface, a comparison test block with the same or close radius of curvature as the workpiece (0.7~1.1 times) should be used to determine the sound energy loss caused by the different curvatures. Its shape and size are as shown in Figure 3 and Table 1. For work typical car
5.5 Coupling agent
Coupling agent with good sound permeability and no damage to the workpiece, such as engine oil, glycerin, grease, etc., can be used. 6 Timing and preparation of flaw detection
6.1 In principle, the flaw detection should be arranged after the final heat treatment. If the shape of the workpiece after heat treatment is not suitable for ultrasonic flaw detection, the flaw detection can also be arranged before heat treatment, but after heat treatment, it should still be inspected as completely as possible. 6.2 The workpiece should be inspected ultrasonically only after the appearance inspection is qualified, and all substances that affect ultrasonic detection should be removed. 6.3 The surface roughness value of the inspection surface should be R.3.2um. 7 Flaw Detection Methods
Ultrasonic flaw detection of workpieces mainly uses longitudinal wave straight probe and longitudinal wave dual crystal straight probe. If it is impossible to effectively detect with longitudinal wave flaw detection alone due to the limitation of workpiece shape and defect direction, the transverse wave inspection method specified in Appendix A may be adopted after consultation and agreement between the supplier and the buyer. 7.1 Detection Direction
7.1.1 In principle, it should be carried out from two mutually perpendicular directions on the detection surface, and the entire volume of the workpiece should be scanned as much as possible. 7.1.2 The detection direction of the main workpiece is shown in Figure 4. Connecting rod
JB/T5439-1991
High-pressure cylinder block and high-pressure cylinder head
d Crosshead
7.2 Scanning
JB/T5439—1991
The entire detection surface of the workpiece should be scanned comprehensively and continuously. The overlapping part of two adjacent scans is about 15% of the diameter of the probe crystal.
7.2.2 During scanning, the moving speed of the probe shall not exceed 150mm/s. 7.2.3 Areas that cannot be scanned due to the geometric shape of the workpiece should be noted in the flaw detection report. 7.3 Determination of the acoustic transparency of the workpiece
Couple the longitudinal wave straight probe with the defect-free part of the workpiece where the detection surface and the bottom surface are parallel, adjust the instrument so that the amplitude of the first bottom surface echo reaches 50% of the full scale, and record the attenuator reading at this time. Then adjust the attenuator so that the amplitude of the second bottom surface echo reaches 50% of the full scale. The difference between the two attenuator readings is the acoustic transparency of the measurement point. The measurement points shall not be less than three points, and the average value is used to represent the acoustic transparency of the area.
7.4 Determination of flaw detection sensitivity
7.4.1 Adjustment of the flaw detection sensitivity of the longitudinal wave straight probe First, compare the workpiece with a standard test block whose detection distance is equal to or closest to the thickness of the workpiece, and calculate the acoustic transparency compensation value and surface roughness compensation value. Then test on the test block, so that the echo amplitude of the 3mm flat bottom hole reaches 10%~20% of the full scale. Without changing the instrument parameters, test a series of test blocks with smaller detection distances one by one, measure the highest point of the echo of the 3mm flat bottom hole, draw it on the fluorescent screen, and connect these points to establish the distance-amplitude curve. The distance-amplitude curve can also be determined by the A, V, G calculation method or the A, V, G curve plate.
7.4.2 Adjustment of the flaw detection sensitivity of the longitudinal wave twin crystal probe Test a group of Φ3mm flat bottom holes with different detection distances, adjust the attenuator, so that the highest echo amplitude reaches 80% of the full scale, without changing the instrument parameters, measure the highest point of the echo of other flat bottom holes, draw it on the fluorescent screen, and connect these points to establish the distance-amplitude curve of the longitudinal wave twin crystal probe.
7.4.3 Compensation
7.4.3.1 Surface roughness compensation: When detecting and quantifying defects, compensation should be made for the energy consumption caused by surface roughness. 7.4.3.2 Acoustic permeability compensation: During detection and defect quantification, acoustic permeability compensation shall be performed for the errors in the detection sensitivity and defect quantification caused by the acoustic permeability of the test block.
7.4.3.3 Curved surface compensation: For workpieces with curved detection surfaces, a comparison test block with the same or similar curvature radius (0.7~1.1 times) as the workpiece shall be used for calibration, otherwise appropriate curved surface compensation shall be performed. 7.4.4 The detection sensitivity shall not be lower than the Φ3mm flat-bottom hole equivalent of the maximum detection distance. 7.5 Recheck of flaw detection sensitivity
During flaw detection, the flaw detection sensitivity shall be checked, and if it is found that the flaw detection sensitivity has changed, it shall be readjusted. When the gain level decreases by more than 2B, the workpieces inspected since the last calibration shall be re-detected; when the gain level increases by more than 2dB, all recorded defects shall be re-quantified.
8 Defect Detection
8.1 Defect Record
8.1.1 Defects where the amplitude of the reflected echo is equal to or higher than the distance-amplitude curve. 8.1.2 Defects where the amplitude of the reflected echo does not reach the distance-amplitude curve but causes the disappearance of the first bottom echo. 8.1.3 The area where there are no bottom waves and defect echoes. 8.1.4 Although it does not belong to the above three situations, the flaw detector can determine that it is a crack or shrinkage defect. 8.2 Determination of defect size
8.2.1 When the defect echo amplitude is equal to or higher than the distance-amplitude curve, its boundary can be determined by the 6dB method. The size of the workpiece thickness direction is determined by the upper and lower boundaries of the defect determined by detection in different directions. 5
JB/T5439-1991
When the defect wave does not reach the distance-amplitude curve, but the first bottom echo disappears, the scope of the defect should be calculated from the center position of the probe when the bottom reflection wave just disappears to the center position of the probe when the bottom reflection wave appears. The depth of the defect is determined by the peak position on the far left of a group of continuous defect echoes.
When the distance between two defects is less than the diameter of the larger defect, the two defects can be converted into one defect, and the defect area is measured according to the actual measurement. The area of a single defect is calculated as the product of the maximum size of the defect and its maximum size in the vertical direction. For defects in question, other effective methods can also be used for verification. Defect grade classification
Hazardous defects such as cracks and shrinkage holes are not allowed in the workpiece. The defect grade classification of the workpiece is specified in Table 3, but the defect grade classification of cylindrical solid shaft workpieces is specified in Table 4. The cross-sectional area where the defect is located is the minimum cross-sectional area of the defect detected. The cross-sectional area of both hollow shafts and solid shafts is calculated as solid shafts. Table 3
Non-defect report
Non-defect report should include the following contents:
Defects beyond the distance-amplitude curve
Defect area is less than or equal to 5% of the cross-sectional area of the defect
Defect area is less than or equal to 10% of the cross-sectional area of the defect
Defect area is less than or equal to 20% of the cross-sectional area of the defect
Defect area is greater than 20% of the cross-sectional area of the defect
Defects of bottom wave disappearance
Defect area is less than or equal to 10% of the cross-sectional area of the defect
Defect area is less than or equal to 20% of the cross-sectional area of the defect
Defect area is less than or equal to 3% of the cross-sectional area of the defect 0%
The defect area is greater than 30% of the cross-sectional area where the defect is located
The axial length of the defect is less than or equal to the positive square root of 5% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 10% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 20% of the cross-sectional areaThe axial length of the defect is greater than or equal to the positive square root of 20% of the cross-sectional areaNon-defect report number, date of issue:
Unit entrusted with the non-defect detection,
Name, number, material grade, heat treatment status, surface roughness of the non-defect detection surface, sound permeability, sketch of the workpiece; model of the ultra-detector, probe model, non-defect detection frequency, coupling agent, non-defect detection sensitivity: On the sketch, mark the detection area. If there are parts that cannot be detected due to geometric shape restrictions, they must also be marked on the sketch; Type, size and location of defects:
Defect level and non-defect detection conclusion:
Signed by the non-defect detector and the auditor. The qualification certificate number, level, name and non-defect detection date of the non-defect detector. A1
Testing equipment
JB/T5439-1991
Appendix A
Shear wave test
(Supplement)
A1.1 The instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. A1.2 The combined sensitivity margin of the instrument and probe shall not be less than 10dB at the maximum test sound range. A1.3 The shape and size of the calibration test block shall be in accordance with Figure A1 and Table A1. 2
Nominal thickness of material
>50-100
>100~150
>150~200
Preparation of distance-amplitude curve
Thickness of calibration test block T
Using the basic calibration test block shown in Figure A1, an oblique probe is used to detect the transverse holes of the test block with depth positions of T/4, T/2, and 3T/4, and each amplitude point is marked on the fluorescent screen. Connecting these points will obtain the distance-amplitude curve. 7
JB/T 5439-1991
Shear wave oblique probe flaw detection should be scanned at least in two directions perpendicular to each other on the flaw detection surface. While scanning, the probe should be deflected continuously, and the deflection angle should not be less than 15°.
A4 Defect record
1Record defects where the echo amplitude exceeds the distance-amplitude curve. A4.1
A4.2Hazardous defects that the flaw detector considers necessary to record. A5
Acceptance criteria
Acceptance criteria shall be agreed upon by both the supplier and the buyer.
Flaw detection report
Flaw detection reports shall comply with the provisions of Chapter 10 of this standard. Additional notes:
This standard was proposed by the National Technical Committee for Compressor Standardization. This standard was drafted by the Hefei General Machinery Research Institute of the Ministry of Machinery and Electronics Industry. The main drafter of this standard was Yuan Rong.
People's Republic of China
Mechanical Industry Standard
Ultrasonic Flaw Detection of Ductile Iron Parts of Compressors
JB/T 54391991
Published and issued by the China Academy of Mechanical Science
Printed by the China Academy of Mechanical Science
(No. 2 Shouti South Road, Beijing
Postal Code 100044)
Format 880×1230
Sheet 3/4
Word Count 16.000
First Printing in October 1991
Printing Number 1-500 in October 1991
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://www.JB.ac.cn1661When the defect echo amplitude is equal to or higher than the distance-amplitude curve, its boundary can be determined by the 6dB method. The size of the workpiece in the thickness direction is determined by the upper and lower boundaries of the defect determined by the detection in different directions. 5
JB/T5439-1991
When the defect wave does not reach the distance-amplitude curve, but the first bottom echo disappears, the range of the defect should be calculated from the center position of the probe when the bottom reflection wave just disappears to the center position of the probe when the bottom reflection wave appears. The depth of the defect is determined by the peak position on the left of a group of continuous defect echoes.
When the distance between two defects is less than the diameter of the larger defect, the two defects can be converted into one defect, and the defect area is calculated according to the actual measurement. The area of a single defect is calculated by the product of the maximum size of the defect and its maximum size in the vertical direction. For defects in question, other effective methods can also be used for verification. Defect grade classification
Hazardous defects such as cracks and shrinkage cavities are not allowed in the workpiece. The defect grade classification of the workpiece is as specified in Table 3, but the defect grade classification of cylindrical solid shaft workpieces is as specified in Table 4. The cross-sectional area where the defect is located is the minimum cross-sectional area of the detected defect. The cross-sectional areas of hollow shafts and solid shafts are calculated as solid shafts. Table 3
Flaw detection report
The flaw detection report should include the following:
Defects exceeding the distance-amplitude curve
The defect area is less than or equal to 5% of the cross-sectional area where the defect is located
The defect area is less than or equal to 10% of the cross-sectional area where the defect is located
The defect area is less than or equal to 20% of the cross-sectional area where the defect is located
The defect area is greater than 20% of the cross-sectional area where the defect is located
Bottom wave disappearance defects
The defect area is less than or equal to 10% of the cross-sectional area where the defect is located
The defect area is less than or equal to 20% of the cross-sectional area where the defect is located
The defect area is less than or equal to 3% of the cross-sectional area where the defect is located 0%
The defect area is greater than 30% of the cross-sectional area where the defect is located
The axial length of the defect is less than or equal to the positive square root of 5% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 10% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 20% of the cross-sectional areaThe axial length of the defect is greater than or equal to the positive square root of 20% of the cross-sectional areaNon-defect report number, date of issue:
Unit entrusted with the non-defect detection,
Name, number, material grade, heat treatment status, surface roughness of the non-defect detection surface, sound permeability, workpiece size sketch; Ultrasonic detector model, probe model, non-defect detection frequency, coupling agent, non-defect detection sensitivity: On the sketch, mark the detection area. If there are parts that cannot be detected due to geometric shape restrictions, they must also be marked on the sketch; Type, size and location of defects:
Defect level and non-defect detection conclusion:
Signed by the non-defect detection personnel and the reviewer. The qualification certificate number, level, name and non-defect detection date of the non-defect detection personnel. A1
Testing equipment
JB/T5439-1991
Appendix A
Shear wave test
(Supplement)
A1.1 The instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. A1.2 The combined sensitivity margin of the instrument and probe shall not be less than 10dB at the maximum test sound range. A1.3 The shape and size of the calibration test block shall be in accordance with Figure A1 and Table A1. 2
Nominal thickness of material
>50-100
>100~150
>150~200
Preparation of distance-amplitude curve
Thickness of calibration test block T
Using the basic calibration test block shown in Figure A1, an oblique probe is used to detect the transverse holes of the test block with depth positions of T/4, T/2, and 3T/4, and each amplitude point is marked on the fluorescent screen. Connecting these points will obtain the distance-amplitude curve. 7
JB/T 5439-1991bzxZ.net
Shear wave oblique probe flaw detection should be scanned at least in two directions perpendicular to each other on the flaw detection surface. While scanning, the probe should be deflected continuously, and the deflection angle should not be less than 15°.
A4 Defect record
1Record defects where the echo amplitude exceeds the distance-amplitude curve. A4.1
A4.2Hazardous defects that the flaw detector considers necessary to record. A5
Acceptance criteria
Acceptance criteria shall be agreed upon by both the supplier and the buyer.
Flaw detection report
Flaw detection reports shall comply with the provisions of Chapter 10 of this standard. Additional notes:
This standard was proposed by the National Technical Committee for Compressor Standardization. This standard was drafted by the Hefei General Machinery Research Institute of the Ministry of Machinery and Electronics Industry. The main drafter of this standard was Yuan Rong.
People's Republic of China
Mechanical Industry Standard
Ultrasonic Flaw Detection of Ductile Iron Parts of Compressors
JB/T 54391991
Published and issued by the China Academy of Mechanical Science
Printed by the China Academy of Mechanical Science
(No. 2 Shouti South Road, Beijing
Postal Code 100044)
Format 880×1230
Sheet 3/4
Word Count 16.000
First Printing in October 1991
Printing Number 1-500 in October 1991
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://www.JB.ac.cn1661When the defect echo amplitude is equal to or higher than the distance-amplitude curve, its boundary can be determined by the 6dB method. The size of the workpiece in the thickness direction is determined by the upper and lower boundaries of the defect determined by the detection in different directions. 5
JB/T5439-1991
When the defect wave does not reach the distance-amplitude curve, but the first bottom echo disappears, the range of the defect should be calculated from the center position of the probe when the bottom reflection wave just disappears to the center position of the probe when the bottom reflection wave appears. The depth of the defect is determined by the peak position on the left of a group of continuous defect echoes.
When the distance between two defects is less than the diameter of the larger defect, the two defects can be converted into one defect, and the defect area is calculated according to the actual measurement. The area of a single defect is calculated by the product of the maximum size of the defect and its maximum size in the vertical direction. For defects in question, other effective methods can also be used for verification. Defect grade classification
Hazardous defects such as cracks and shrinkage cavities are not allowed in the workpiece. The defect grade classification of the workpiece is as specified in Table 3, but the defect grade classification of cylindrical solid shaft workpieces is as specified in Table 4. The cross-sectional area where the defect is located is the minimum cross-sectional area of the detected defect. The cross-sectional areas of hollow shafts and solid shafts are calculated as solid shafts. Table 3
Flaw detection report
The flaw detection report should include the following:
Defects exceeding the distance-amplitude curve
The defect area is less than or equal to 5% of the cross-sectional area where the defect is located
The defect area is less than or equal to 10% of the cross-sectional area where the defect is located
The defect area is less than or equal to 20% of the cross-sectional area where the defect is located
The defect area is greater than 20% of the cross-sectional area where the defect is located
Bottom wave disappearance defects
The defect area is less than or equal to 10% of the cross-sectional area where the defect is located
The defect area is less than or equal to 20% of the cross-sectional area where the defect is located
The defect area is less than or equal to 3% of the cross-sectional area where the defect is located 0%
The defect area is greater than 30% of the cross-sectional area where the defect is located
The axial length of the defect is less than or equal to the positive square root of 5% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 10% of the cross-sectional area where the defect is locatedThe axial length of the defect is less than or equal to the positive square root of 20% of the cross-sectional areaThe axial length of the defect is greater than or equal to the positive square root of 20% of the cross-sectional areaNon-defect report number, date of issue:
Unit entrusted with the non-defect detection,
Name, number, material grade, heat treatment status, surface roughness of the non-defect detection surface, sound permeability, workpiece size sketch; Ultrasonic detector model, probe model, non-defect detection frequency, coupling agent, non-defect detection sensitivity: On the sketch, mark the detection area. If there are parts that cannot be detected due to geometric shape restrictions, they must also be marked on the sketch; Type, size and location of defects:
Defect level and non-defect detection conclusion:
Signed by the non-defect detection personnel and the reviewer. The qualification certificate number, level, name and non-defect detection date of the non-defect detection personnel. A1
Testing equipment
JB/T5439-1991
Appendix A
Shear wave test
(Supplement)
A1.1 The instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. A1.2 The combined sensitivity margin of the instrument and probe shall not be less than 10dB at the maximum test sound range. A1.3 The shape and size of the calibration test block shall be in accordance with Figure A1 and Table A1. 2
Nominal thickness of material
>50-100
>100~150
>150~200
Preparation of distance-amplitude curve
Thickness of calibration test block T
Using the basic calibration test block shown in Figure A1, an oblique probe is used to detect the transverse holes of the test block with depth positions of T/4, T/2, and 3T/4, and each amplitude point is marked on the fluorescent screen. Connecting these points will obtain the distance-amplitude curve. 7
JB/T 5439-1991
Shear wave oblique probe flaw detection should be scanned at least in two directions perpendicular to each other on the flaw detection surface. While scanning, the probe should be deflected continuously, and the deflection angle should not be less than 15°.
A4 Defect record
1Record defects where the echo amplitude exceeds the distance-amplitude curve. A4.1
A4.2Hazardous defects that the flaw detector considers necessary to record. A5
Acceptance criteria
Acceptance criteria shall be agreed upon by both the supplier and the buyer.
Flaw detection report
Flaw detection report shall comply with the provisions of Chapter 10 of this standard. Additional notes:
This standard was proposed by the National Technical Committee for Compressor Standardization. This standard was drafted by the Hefei General Machinery Research Institute of the Ministry of Machinery and Electronics Industry. The main drafter of this standard was Yuan Rong.
People's Republic of China
Mechanical Industry Standard
Ultrasonic Flaw Detection of Ductile Iron Parts of Compressors
JB/T 54391991
Published and issued by the China Academy of Mechanical Science
Printed by the China Academy of Mechanical Science
(No. 2 Shouti South Road, Beijing
Postal Code 100044)
Format 880×1230
Sheet 3/4
Word Count 16.000
First Printing in October 1991
Printing Number 1-500 in October 1991
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://www.JB.ac.cn166
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