JB/T 5440-1991 Ultrasonic flaw detection of compressor forged steel parts
Some standard content:
Mechanical Industry Standard of the People's Republic of China
JB/T 5440-1991
Ultrasonic flaw detection of compressor forged steel parts
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 compressor forged steel parts
1 Subject content and scope of application
JB/T5440-1991
This standard specifies the flaw detection method and defect grade classification using a type A pulse reflection ultrasonic flaw detector. This standard applies to ultrasonic flaw detection of compressor forged steel parts (hereinafter referred to as "workpieces") and other similar forgings. This standard does not apply to ultrasonic flaw detection of coarse-grained steel forgings such as austenite. 2 Reference standards
ZBJ04001 Test method for working performance of type A pulse reflection ultrasonic flaw detection system ZBY230
JB3111
3 Terms
3.1 Defects in dense areas
General technical conditions for type A pulse reflection ultrasonic flaw detectors Nondestructive testing terms
That is, there are 3 or more defect reflection signals at the same time within the range of 30mm sound path on the scanning line of the fluorescent screen; or 3 or more defect reflection signals are found in the same depth range on the detection surface of 30mm×30mm. 3.2 The bottom wave reduction caused by the defect BG/BF (dB) is the ratio of the first bottom wave height (BG) in the defect-free intact area to the first bottom wave height (BF) in the defective area, expressed in dB.
3.3 Other terms in this standard comply with the provisions of JB3111. 4 Flaw Detection Personnel
Flaw detection of compressor forged steel parts shall be performed by persons who have certain basic knowledge and experience in forging flaw detection and have obtained a qualification certificate recognized by the relevant departments after examination.
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 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 and other indicators shall comply with the relevant provisions of ZBY230. 5.2 Probe
The diameter of the chip of the longitudinal wave straight probe should be between 10 and 30 mm, the working frequency should be 1 to 5 MHz, and the error should be ±10%. 5.2.1
5.2.2 The chip area of the shear wave oblique probe should be between 100 and 400 mm2, and the K value should generally be 1 to 3. 5.2.3 The acoustic insulation between the chips of the longitudinal wave double crystal straight probe must be good. 5.3 Performance of the instrument system
The sensitivity margin and resolution of the instrument system should be tested in accordance with the relevant provisions of ZBJ04001. Approved by the Ministry of Machinery and Electronics Industry on July 22, 1991 and implemented on July 1, 1992
JB/T54401991
5.3.1 At the working frequency, the sensitivity margin of the longitudinal wave straight probe shall not be less than 30 dB, and the sensitivity margin of the shear wave oblique probe shall be in accordance with the provisions of Appendix A (Supplement) A1.2.
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 transverse 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 forgings. Its attenuation coefficient shall be the same or similar to that of the workpiece to be inspected, and there shall be no defects greater than or equal to the flat bottom hole equivalent of 2mm.
5.4.1 Standard test block used by longitudinal wave straight probe5.4.1.1 When the workpiece detection distance 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 used for longitudinal wave straight probe flaw detection shall be in accordance with Figure 1 and Table 1. D
Height H
Diameter D
5.4.2 Standard test block used by longitudinal wave dual crystal straight probe120
5.4.2.1 When the workpiece detection distance is less than 1.6 times the near field area, a longitudinal wave dual crystal straight probe shall be used. 170
5.4.2.2 The shape and size of the standard test block used for longitudinal wave dual crystal straight probe flaw detection shall be in accordance with Figure 2 and Table 2. 8 ×25
JB/T5440—1991
The shape and size of the standard test block used for transverse wave oblique probe flaw detection shall be in accordance with the provisions of A1.3 in Appendix A and Figure A1. @6
When the flaw detection 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) shall be used to determine the sound energy loss caused by different curvatures. Its shape and size shall be in accordance with Figure 3. R is 0.7~1.1 times the lightest half of the curvature of the workpiece. 5.5 Coupling agent. Coupling agents with good sound transmission performance and no damage to the workpiece, such as engine oil, glycerin, grease, etc., can be used. 6. Timing and preparation of flaw detection. In principle, 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 the heat treatment, but after heat treatment, it should still be inspected as completely as possible. The workpiece should be ultrasonically inspected only after the appearance inspection is qualified, and all oil stains and other attachments that affect the ultrasonic detection should be removed. 6.2. The surface roughness value of the flaw detection surface should be R.3.2um. 6.3. Detection method. The main flaw detection methods for ultrasonic flaw detection of workpieces are longitudinal wave straight probe and longitudinal wave dual crystal straight probe. If the longitudinal wave flaw detection cannot be used alone for effective detection due to the limitation of the workpiece shape and defect direction, the transverse wave flaw detection specified in Appendix A may be used after consultation and agreement between the supply and demand parties. 7.1 Detection direction
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. The detection direction of the main parts of the compressor is shown in Figure 4. 3
JB/T5440-1991
Piston rod
High-pressure cylinder block and high-pressure cylinder head
d Connecting rod
7.2 Scanning
JB/T5440-1991
The entire detection surface of the workpiece should be scanned comprehensively and continuously. The overlapping part of two adjacent scans is approximately 15% of the diameter of the probe wafer.
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 attenuation coefficient of the workpiece material
7.3.1 In the defect-free and intact area of the workpiece, select three representative locations where the detection surface is parallel to the bottom surface, adjust the instrument so that the amplitude of the first bottom echo (B,) is 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 echo (B2) is 50% of the full scale. The difference between the two attenuator readings is the dB difference (BB). 7.3.2 The calculation formula for the attenuation coefficient is:
Where: α——attenuation coefficient, dB/m;
α= (B -B,)-6dB
（B,-B,）——the difference between the two attenuator readings, dB: S——the detection sound path of the workpiece, m.
7.3.3 The average value of the attenuation coefficients of three locations on the workpiece is taken as the attenuation coefficient of the workpiece. 7.4 Determination of flaw detection sensitivity
7.4.1 Determination of flaw detection sensitivity of longitudinal wave straight probe When the thickness of the detected part is greater than 1.6 times the near field area of the probe, in principle, the bottom wave (using A, V, G calculation method) can be used to determine the flaw detection sensitivity. For those who cannot obtain the bottom wave due to geometric limitations, the test block method can be used directly to determine the flaw detection sensitivity. 7.4.2 Determination of flaw detection sensitivity of longitudinal wave twin crystal straight probe Select test blocks with flat bottom holes of different diameters as needed, and test a group of flat bottom holes with different detection distances (at least 6). Adjust the attenuator so that the highest echo amplitude reaches 80% of the full scale. Without changing the parameters of the instrument, measure the highest point of the echo of other flat bottom holes, draw it on the fluorescent screen, and connect these points, which is the distance-amplitude curve of the longitudinal wave twin crystal straight probe corresponding to flat bottom holes of different diameters. 7.4.3 Compensation
7.4.3.1 Surface roughness compensation: During flaw detection and defect quantification, compensation shall be made for energy consumption caused by surface roughness. 7.4.3.2 Material attenuation compensation: During flaw detection and defect quantification, attenuation compensation shall be made for changes in flaw detection sensitivity and defect equivalent caused by material attenuation.
7.4.3.3 Curved surface compensation: For workpieces with curved detection surfaces, a comparison test block with the same or close radius of curvature as the workpiece (0.7~1.1 times) may be used. Otherwise, compensation shall be made for the loss of acoustic energy caused by different curvatures. 7.4.4 The flaw detection sensitivity shall generally not be lower than the equivalent of a Φ2mm flat-bottom hole at the maximum detection distance of the workpiece. 7.5 Review of flaw detection sensitivity
During flaw detection, the flaw detection sensitivity should be checked. If the flaw detection sensitivity changes, it should be readjusted. When the gain level decreases by more than 2dB, the workpieces inspected since the last calibration should be re-detected: when the gain level increases by more than 2B, all recorded defects should be re-quantified.
8 Defect detection
8.1 Determination of defect equivalent
8.1.1 The defect equivalent is determined by the A, V, and G calculation method. For those located in the near field area where the defect equivalent cannot be determined by the above method, a dual crystal straight probe can be used, and test blocks with flat-bottom holes of different diameters can be used to determine the defect equivalent by comparison. 8.1.2 The boundaries of dense area defects and single large defects can be determined by the half-wave height method. 8.1.3 When calculating the defect equivalent, if the material attenuation coefficient exceeds 4dB/m, it should be corrected. 5
Defect record
JB/T5440-1991
Record the position and amplitude of a single defect with an equivalent flat bottom hole diameter exceeding Φ2mm. 8.2.1
Record the dense area defects with an equivalent flat bottom hole diameter exceeding Φ2mm, and the position and distribution of the largest defect. The area of the dense area defects is measured in a 30mm×30mm square. 8.2.3
Record the amount of bottom echo reduction caused by the defect and its distribution range. Although it does not belong to the above situation, defects that the flaw detector can determine to be harmful should also be recorded. The material attenuation coefficient should be recorded.
Defect grade classification
The grade classification of a single defect shall be as specified in Table 3. Table 3
Defect equivalent diameter
The grade classification of the bottom echo reduction caused by the defect shall be as specified in Table 4. Table 4
Bottom wave reduction (BG/BF)
The classification of dense area defect levels shall be in accordance with the provisions of Table 5. Equal
Percentage of dense area defect area to total inspection area2
>14~20
>20~26
9.4 The levels in Tables 3, 4 and 5 shall be used as independent levels when evaluating the quality of workpieces. For defects determined to be dangerous by the inspection personnel, their classification is not subject to the restrictions of the above provisions. 9.5
Non-destructive testing report
Non-destructive testing report shall include the following contents:
Unit entrusted with NDT, NDT report number, and issue date:7
>10~20
Name, number, material grade, heat treatment status, surface roughness of the inspection surface, and workpiece size of forged steel parts Sketch: Model of NDT instrument, probe model, inspection frequency, coupling agent, inspection sensitivity, and scanning method: In the sketch, indicate the inspection area. If there are parts that cannot be inspected due to geometric shape restrictions, they must also be indicated on the sketch: defect type, size, and location;
Defect grade and NDT conclusion:
Signatures of NDT personnel and auditors. Qualification number, grade, and inspection date of NDT personnel. A1
Testing equipment
JB/T5440-1991
Appendix A
Shear wave test
(Supplement)
The performance of the instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. The combined sensitivity margin of the instrument and probe shall not be less than 10dB when the maximum detection sound range of the workpiece is reached. The shape and size of the calibration test block are in accordance with Figure A1 and Table A1. 40
Nominal thickness of material
>25~50
>50-100
>100150
>150~200
Preparation of distance-amplitude curve
Test block thickness T
Using the basic calibration test block shown in Figure A1, using an oblique probe, the horizontal holes of the test block with depth positions of T/4, T/2, and 3T/4 are respectively found to find the positions of each maximum reflection amplitude point, and mark them on the fluorescent screen. Connecting these points will obtain its distance-amplitude curve, 7
JB/T5440-1991
The oblique probe should be scanned at least in two directions perpendicular to each other on the flaw detection surface. During the scanning, the probe should be continuously deflected, and the deflection angle should not be less than 15°.
Defect record
A4.1Record defects whose echo amplitude exceeds the distance-amplitude curve, and determine their geometric size and position. Hazardous defects that the flaw detector considers necessary to record. A4.2
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 Compressor Forged Steel Parts
JB/T54401991
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)
Word Count 16.000
Format 880×1230
1/16 Sheet 3/4
First Edition in October 1991 First Printing in October 1991 Printing Quantity 1-500
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://wwwJB.ac.cn1661_0 /
*Caolu Yiwei* provides high-quality documents. If the documents you downloaded are missing, blurred, or you encounter rare files that cannot be found, please send a message to me! I will definitely help you solve it! I have more than 200,000 domestic and international standards, including a full range of GB national standards and domestic industry and department standards, a full range of BSIEN
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and many other international standards. Docin download website:5
Non-destructive testing report
Non-destructive testing report should include the following contents:
Unit that commissioned the non-destructive testing, non-destructive testing report number, and date of issuance:7
>10~20
Name, number, material grade, heat treatment status, surface roughness of the non-destructive testing surface, and workpiece size of the forged steel part Sketch: Model of non-destructive testing instrument, model of probe, non-destructive testing frequency, coupling agent, non-destructive testing sensitivity, and scanning method: On the sketch, indicate the inspection area. If there are parts that cannot be detected due to geometric shape restrictions, they must also be indicated on the sketch: defect type, size, and location;
Defect grade and non-destructive testing conclusion:
Signatures of non-destructive testing personnel and reviewers. Qualification number, grade, and non-destructive testing date of non-destructive testing personnel. A1
Testing equipment
JB/T5440-1991
Appendix A
Shear wave test
(Supplement)
The performance of the instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. The combined sensitivity margin of the instrument and probe shall not be less than 10dB when the maximum detection sound range of the workpiece is reached. The shape and size of the calibration test block are in accordance with Figure A1 and Table A1. 40
Nominal thickness of material
>25~50
>50-100
>100150
>150~200
Preparation of distance-amplitude curve
Test block thickness T
Using the basic calibration test block shown in Figure A1, using an oblique probe, the horizontal holes of the test block with depth positions of T/4, T/2, and 3T/4 are respectively found to find the positions of each maximum reflection amplitude point, and mark them on the fluorescent screen. Connecting these points will obtain its distance-amplitude curve, 7wwW.bzxz.Net
JB/T5440-1991
The oblique probe should be scanned at least in two directions perpendicular to each other on the flaw detection surface. During the scanning, the probe should be continuously deflected, and the deflection angle shall not be less than 15°.
Defect record
A4.1Record defects whose echo amplitude exceeds the distance-amplitude curve, and determine their geometric size and position. Hazardous defects that the flaw detector considers necessary to record. A4.2
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 Forged Steel Parts of Compressor
JB/T54401991
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)
Word Count 16.000
Format 880×1230
1/16 Sheet 3/4
First Edition in October 1991 First Printing in October 1991 Printing Quantity 1-500
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://wwwJB.ac.cn1661_0 /
*Caolu Yiwei* provides high-quality documents. If the documents you downloaded are missing, blurred, or you encounter rare files that cannot be found, please send a message to me! I will definitely help you solve it! I have more than 200,000 domestic and international standards, including a full range of GB national standards and domestic industry and department standards, a full range of BSIEN
NFASNZS
SSPC ANSIIEC
AASHTO
TBRRCC
National ship classification
and many other international standards. Docin download website:5
Non-destructive testing report
Non-destructive testing report should include the following contents:
Unit that commissioned the non-destructive testing, non-destructive testing report number, and date of issuance:7
>10~20
Name, number, material grade, heat treatment status, surface roughness of the non-destructive testing surface, and workpiece size of the forged steel part Sketch: Model of non-destructive testing instrument, model of probe, non-destructive testing frequency, coupling agent, non-destructive testing sensitivity, and scanning method: On the sketch, indicate the inspection area. If there are parts that cannot be detected due to geometric shape restrictions, they must also be indicated on the sketch: defect type, size, and location;
Defect grade and non-destructive testing conclusion:
Signatures of non-destructive testing personnel and reviewers. Qualification number, grade, and non-destructive testing date of non-destructive testing personnel. A1
Testing equipment
JB/T5440-1991
Appendix A
Shear wave test
(Supplement)
The performance of the instrument and probe shall meet the requirements of 5.1, 5.2 and 5.3. The combined sensitivity margin of the instrument and probe shall not be less than 10dB when the maximum detection sound range of the workpiece is reached. The shape and size of the calibration test block are in accordance with Figure A1 and Table A1. 40
Nominal thickness of material
>25~50
>50-100
>100150
>150~200
Preparation of distance-amplitude curve
Test block thickness T
Using the basic calibration test block shown in Figure A1, using an oblique probe, the horizontal holes of the test block with depth positions of T/4, T/2, and 3T/4 are respectively found to find the positions of each maximum reflection amplitude point, and mark them on the fluorescent screen. Connecting these points will obtain its distance-amplitude curve, 7
JB/T5440-1991
The oblique probe should be scanned at least in two directions perpendicular to each other on the flaw detection surface. During the scanning, the probe should be continuously deflected, and the deflection angle shall not be less than 15°.
Defect record
A4.1Record defects whose echo amplitude exceeds the distance-amplitude curve, and determine their geometric size and position. Hazardous defects that the flaw detector considers necessary to record. A4.2
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 Forged Steel Parts of Compressor
JB/T54401991
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)
Word Count 16.000
Format 880×1230
1/16 Sheet 3/4
First Edition in October 1991 First Printing in October 1991 Printing Quantity 1-500
Price 1.20 Yuan
Mechanical Industry Standard Service Network: http://wwwJB.ac.cn1661_0 /
*Caolu Yiwei* provides high-quality documents. If the documents you downloaded are missing, blurred, or you encounter rare files that cannot be found, please send a message to me! I will definitely help you solve it! I have more than 200,000 domestic and international standards, including a full range of GB national standards and domestic industry and department standards, a full range of BSIEN
NFASNZS
SSPC ANSIIEC
AASHTO
TBRRCC
National ship classification
and many other international standards. Docin download website:
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