JB/T 8543.2-1997 Nondestructive testing of pump parts Penetrant testing
Some standard content:
JB/T8543.2--1997
Appendix A of this standard is the appendix of the standard.
Appendix B of this standard is the appendix of the suggestion.
This standard is proposed and managed by the Volumetric Pump Sub-Technical Committee of the National Pump Standardization Technical Committee. The drafting unit of this standard: Hefei General Machinery Research Institute of the Ministry of Machinery Industry. The main drafters of this standard: Liu Qing, Yuan Rong, Zhang Mingsheng. 481
1 Scope
Machinery Industry Standards of the People's Republic of China
Non-destructive Testing of Pump Product Parts
Penetrating Testing
JB/T8543.2--1997
This standard specifies the penetration testing method (including fluorescence method and coloring method) and defect grade classification for surface opening defects of workpieces. This standard applies to the detection of surface opening defects of pump product parts (hereinafter referred to as workpieces) made of metal materials. 2 Referenced standards
The clauses contained in the following standards constitute the clauses of this standard through reference in this standard. When this standard is published, the versions shown are valid. All standards will be revised, and the parties using this standard should explore the possibility of using the latest versions of the following standards. GB/T12604--90 Nondestructive Testing Terminology
3 Definitions
The definitions of terms in this standard are in accordance with the provisions of GB/T12604. 4 Inspection personnel
4.1 Inspection personnel shall be qualified by the relevant departments before they can take up their posts. The person who issues the inspection report shall hold a penetration level 1 or above qualification certificate.
4.2 Those with color blindness, color weakness and close-range corrected vision below 1.0 shall not participate in the penetration test assessment. 4.3 Inspection personnel shall be equipped with protective equipment and use them correctly in accordance with relevant regulations. 5 Penetrant testing device and penetrant flaw detection agent
5.1 Penetrant testing device
5.1.1 The penetrant testing device is mainly composed of a penetrant device, an emulsifying device, a cleaning device, a developing device, a drying device and an observation device. 5.1.2 When the fluorescence method is used for detection, the ultraviolet wavelength of the black light lamp used should be within the range of 0.32~0.40m. The black light lamp should ensure that the ultraviolet intensity at a distance of 400mm from the black light filter plate is not less than 1000μW/cm. The visible light illumination in the dark room should not be greater than 20lx.
5.1.3 When the coloring method is used for detection, it should be ensured that the illumination of the visible light of the inspected surface during observation is not less than 5001x. 5.2 Penetrant flaw detection agent
5.2.1 Penetrant flaw detection agents generally include penetrants, emulsifiers, cleaning agents and developers. 5.2.2 The penetrant flaw detector must have good detection performance, be non-corrosive to the workpiece, and have basically no toxic effect on the human body. 5.2.3 For high-nickel alloy materials, the weight ratio of the S element in the residue after the quantitative flaw detector evaporates shall not exceed 1%. 5.2.4 For austenitic stainless steel and titanium and titanium alloy materials, the weight ratio of the CI and F elements in the residue after the quantitative flaw detector evaporates shall not exceed 1%.
5.2.5 For aluminum and aluminum alloy materials, the weight ratio of the CI element content in the residue after a certain amount of flaw detection agent evaporates shall not exceed 1%. Approved by the Ministry of Machinery Industry of the People's Republic of China on April 15, 1997 482
Implementation on January 1, 1998
JB/T8543.2-1997
5.2.6 The determination of the C1 and SF element content of the flaw detection agent can be carried out according to the following method. Take 100g of the flaw detection agent sample and place it in a boiling water bath in a surface evaporation III with a diameter of 150mm for 60 minutes for evaporation. If the residue left after evaporation exceeds 0.005g, its CI and SF content should be analyzed. 5.2.7 The flaw detection agent should be selected according to the specific conditions of the workpiece. Different types of flaw detection agents cannot be mixed for the same workpiece. 5.3-General precautions
The penetrant flaw detection agent must be placed in a sealed container and stored in a low temperature and dark place. The developer must be stored in a sealed container. For penetrant flaw detection agents that have not been used for a long time, a performance comparison test should be performed before use. 6 Comparison test blocks
Comparison test blocks are mainly used to test the performance and operation process of flaw detection agents. The types are as follows: 6.1 Aluminum-gold comparison test blocks
Heat the LY12 hard aluminum alloy test block shown in Figure 1 to 510~530C in the center with a blowtorch, and then quickly put it into cold water. Through quenching treatment, strip and network cracks are generated on the surface of the test block, and then a straight groove is machined in the middle of the test block. The test block is divided into two parts and marked with A and B respectively, so as to conduct comparison tests of different flaw detection agents and different processes. The size of the comparison test block is shown in Figure 1. B
6.2 Chrome-plated comparison test block
A test block of 130mm×40mm×4mm rectangular oCr18Ni9Ti or other appropriate stainless steel material is plated with nickel of 30um±0.15mm on one side, and 0.5um chromium is plated on the nickel-plated layer, and then annealed. On the unplated surface, a steel ball with a diameter of 10mm is used to hit the hardness at three points according to the Brinell hardness method at 500N, 10000N and 12500N, so that three radial cracks are formed on the coating, so as to conduct flaw detection and operation process performance tests.
6.3 Cleaning and storage of comparison test block
The comparison test block should be cleaned after use to avoid affecting the effect of future use. When cleaning, it is usually carefully scrubbed with acetone and then placed in a sealed container filled with a mixture of acetone and anhydrous alcohol (mixing ratio is 1:1) for storage, or stored by other equivalent methods. 7 General requirements
7.1 Timing of inspection
In principle, the inspection should be carried out after the final processing and heat treatment. However, the inspection between the intermediate processes determined by the supply and demand parties is not subject to this restriction.
7.2 Inspection temperature
The ambient temperature of the penetration test should be within the range of 15~50C. If the temperature conditions cannot be met due to the restrictions of the site conditions, the operation method should be modified according to Appendix A (Appendix to the standard). 483
JB/T8543.2--.1997
7.3 Preparation of the inspected surface
7.3.1 There should be no rust, scale, splash, iron filings, burrs, oil stains and various protective layers on the surface of the workpiece. 7.3.2 The roughness R of the machined surface of the inspected workpiece is 6.3um, and the roughness R of the non-machined surface of the inspected workpiece is 25um. 7.3.3 When testing the part, the preparation work range should extend at least 25mm outward from the periphery of the testing part. 7.4 Classification and selection of testing methods
7.4.1 Classification of testing methods
7.4.1.1 According to the different types of penetrants and developers, the testing methods can be classified according to Table 1 and Table 2. 7.4.1.2 The testing steps for the combination of various methods in Table 1 and Table 2 are shown in Table 3. 7.4.2 Selection of testing methods
7.4.2.1 The testing method can be determined based on the surface roughness of the tested workpiece, the testing sensitivity, the testing batch, and the water source and power supply at the testing site.
For workpieces with smooth surfaces and high testing sensitivity requirements, the post-emulsification type staining method or the post-emulsification type fluorescence method should be used, or the solvent removal type fluorescence method can be used.
For workpieces with rough surfaces and low testing sensitivity requirements, the water washing type staining method or the water washing type fluorescence method should be used. 7.4.2.3
7.4.2.4 For on-site inspections without water or power supply, the solvent removal staining method should be used. 7.4.2.5 For large batches of workpiece inspections, the water wash staining method or water wash fluorescence method should be used. 7.4.2.6 For local inspections of large workpieces, the solvent removal staining method or solvent removal fluorescence method should be used. The fluorescence method has a higher detection sensitivity than the staining method. 7.4.2.7
Method name
Fluorescent penetrant testing
Dye penetrant testing
Method name
Dry development method
Wet development method
Developer-free development method
Penetrant used
And developer type
Detection method
Water-washable fluorescent penetrant—developer type Water-washable fluorescent penetrant or water-washable dye penetrant—developer type
Type of penetrant
Water-washable fluorescent penetrant
Post-emulsifier fluorescent penetrant
Solvent-removable fluorescent penetrant
Water-washable dye penetrant
Post-emulsifier dye penetrant
Solvent-removable colored penetrant
Type of developer
Dry developer
Developing developer
Quick-drying developer
No developer required
Pretreatment Penetration Emulsification Cleaning
Method generation
Method generation
Drying development
Drying observation Post-treatment
Used penetrant and
Type of developer
Water-washable fluorescent penetrant or water-washable
Colored penetrant·Quick-drying developer
Water-washable fluorescent penetrant·No developer required
Post-emulsified fluorescent penetrant--noon type
Developer
Post-emulsified fluorescent penetrant-wet type!
Developer
Detection methodwwW.bzxz.Net
Post-emulsification fluorescent penetrant Quick Ten
Developer
Solvent-removable fluorescent penetrant
Developer
Solvent-removable fluorescent penetrant or solvent-removable colored penetrant--wet
Developer
Solvent-removable fluorescent penetrant or solvent-removable colored penetrant t||Agent removal type color penetrant quick drying
Type developer
Solvent removal type fluorescent penetrant
Use developer
Post-emulsified color penetrant 1000-type
Post-emulsified color penetrant one-condensation
Developer
Post-emulsified color penetrant quick drying
Wu developer
8 Operation
JB/T 8543.2-1997
Table 3 (end)
Pretreatment
Operation procedures can be carried out according to the operation procedures of various detection methods determined in Table 3. 8.1 Pretreatment
Post-treatment
8.1.1 Pretreatment is the surface cleaning performed again after surface cleaning. Its purpose is to clean all dirt on the surface to be tested that hinders penetration detection.
-Generally, solvent cleaning, steam cleaning, alkali cleaning, acid cleaning or other effective methods can be used. 8.1.2
8.1.3 Before the workpiece is penetrated, it is not advisable to perform shot blasting, sand blasting and other treatments. If such treatments are required in the manufacturing process, a secondary acid cleaning treatment should be performed before penetration.
8.1.4 After the pre-treatment, the surface of the workpiece must be fully dried before the penetration treatment can be performed. The drying time is at least 5 minutes. 8.1.5 The surface of the workpiece after the pre-treatment should be kept clean and not contaminated. Otherwise, it should be cleaned again. 8.2 Penetration treatment
8.2.1 Method of applying penetrant
The application method should be selected according to the size, shape, quantity and inspection location of the workpiece. The selected method should ensure that the inspected area is completely covered by the penetrant 48.5
JB/T8543.2---1997
and remains wet during the entire penetration time. The specific application methods are as follows: a) Spraying: Partial or full inspection of the workpiece can be carried out with an electrostatic spraying device, a spray gun and a low-power pump. b) Brushing: Partial inspection of the workpiece can be carried out with a brush, cotton yarn, etc. c) Pouring: Partial inspection of large workpieces can be carried out by pouring the penetrant directly on the inspected surface. d) Dipping: Full inspection of small workpieces can be carried out by soaking the entire workpiece in the penetrant. 8.2.2 Penetration time
Under the temperature condition of 1550℃, the penetration time is generally not less than 10mm. When the overflow condition cannot be met, the operation method should be modified according to Appendix A.
8.3 Emulsification treatment
8.3.1 Before emulsification treatment, the residual penetrant attached to the surface of the inspected workpiece should be dripped as much as possible. When using a water-salt emulsifier, the excess penetrant should be removed by water spraying. If there is no special provision, the water pressure should generally be controlled at 0.14MPa. 8.3.2 Emulsification can be applied to the inspected surface of the workpiece by dipping, spraying, etc., and brushing is not allowed. 8.3.3 The emulsification time depends on the performance of the emulsifier and penetrant and the surface roughness of the inspected workpiece. In principle, the emulsification time for oil-based emulsifiers should be within 2 minutes, and the emulsification time for water-based emulsifiers should be within 5 minutes. Over-emulsification will make the test invalid. 8.4 Cleaning and Removal Processing
8.4.1 When cleaning and removing excess penetrants from the inspected surface, excessive cleaning should be avoided to reduce the quality of the test, and insufficient cleaning should also be avoided to make it difficult to identify the defect display. Cleaning can only be done in one direction, and it should not be done back and forth to prevent over-cleaning. When using fluorescent penetrants, it can be cleaned while observing under ultraviolet light. 8.4.2 Both water-washable and post-emulsified penetrants can be cleaned with water. When flushing, the angle between the water jet and the inspected surface should not be greater than 30°, the water pressure should not be greater than 0.34MPa, and the water temperature should be preferably 1550°C. 8.4.3 When using solvents or other cleaning agents to remove penetrants, first wipe with a clean, non-linting cloth until most of the penetrants are removed, and then wipe with a clean, non-linting cloth or paper with solvents or other cleaning agents until it is wiped clean. However, do not wipe back and forth, and do not flush the inspected surface directly with solvents or cleaning agents. 8.5 Drying treatment
8.5.1 After using a wet developer or before using a dry developer, the test must be dried. 8.5.2
Drying treatment can generally be done with hot air or natural drying. When drying, the temperature of the inspected surface shall not exceed 50°C. 8.5.3 When cleaning with solvents or cleaning agents, it shall be dried naturally and shall not be heated. 8.5.4 The drying time is 5 to 10 minutes.
8.6 Development
8.6.1 When using a dry developer, it must be dried first, and then the developer is evenly sprayed or applied to the entire inspected surface by an appropriate method and maintained for a period of time.
8.6.2 When using a quick-drying developer, it must be dried before the developer can be evenly sprayed or applied to the inspected surface, but the workpiece must not be immersed in the developer. After spraying the developer, the workpiece should be dried naturally or blown dry with low-temperature air. 8.6.3 When using a condensing developer, after the inspected surface has been cleaned, the developer can be directly sprayed or applied to the inspected surface or the workpiece can be immersed in the developer, and then Quickly remove excess developer and then dry it. 8.6.4 The developer should be stirred evenly before use. The developer should be applied thinly and evenly. It should not be applied repeatedly at the same location. 8.6.5 When applying the developer, the distance between the nozzle and the inspected surface should be 300~400mm, and the angle between the spraying direction and the inspected surface should be 30°~40%. 8.6.6 It is forbidden to pour quick-drying developer on the inspected surface to avoid washing away the penetrant in the defect. 8.6.7 The developing time depends on the type of developer, the size of the defect and the temperature of the inspected workpiece. It is generally 7~15 minutes, but it cannot be less than the developing time specified by the developer manufacturer. 8.7 Observation
8.7.1 The observation of the displayed trace should be carried out within 7~30 minutes after the developer is applied. If the size of the displayed trace can be controlled not to change, the above time can also be exceeded.
JB/T 8543.2--1997
8.7.2 When using the fluorescence method, the observer should stay in the dark room for more than 5 minutes to allow the eyes to adapt to the dark room before observation. 8.7.3 When a display mark appears, it is necessary to determine whether the mark is a defect display. If necessary, a 5~10x magnifying glass should be used for observation or re-inspection
8.8 Re-inspection
8.8.1 Re-inspection is required when any of the following situations occurs: - At the end of the test, the penetrant is found to be ineffective by using a comparison test block for verification; - It is found that the operating method is wrong during the test; The supply and demand parties have disputes or believe that there are other needs; Parts after repair.
8.8.2 When deciding to retest, the test surface must be thoroughly cleaned to remove the traces left by the last test. If necessary, soak it with organic solvent. When it is confirmed to be clean, retest according to the provisions of 8.1 to 8.7. 8.9 Post-processing
After the test, the residual developer should be removed to prevent the residual developer from corroding the surface of the workpiece or affecting its use. The removal method can be brushing, washing with water, wiping with cloth or paper, etc. 9 Classification of defect display traces and defect grade assessment 9.1 Classification of defect display traces
9.1.1 Except for those confirmed to be caused by external factors or improper operation, any other display marks greater than or equal to 0.5mm shall be treated as defect marks.
9.1.2 Defect display marks with a length-to-width ratio greater than 3 shall be treated as linear defects; defect display marks with a length-to-width ratio less than or equal to 3 shall be treated as circular defects. 9.1.3 When the angle between the major axis of the defect display mark and the axis or generatrix of the workpiece is greater than or equal to 30°, it shall be treated as a transverse defect, and the others shall be treated as longitudinal defects.
9.1.4 When the defect display marks are on the same straight line and the spacing is less than or equal to 2mm, they shall be treated as one defect, and its length shall be the sum of the defects plus the spacing.
9.1.5 If the defect display marks are at the junction of the important area and the non-important area of the workpiece, they shall be counted as the important area. 9.1.6 According to the different stress conditions of each part of the workpiece, the surface of the workpiece can be divided into important areas (A area) and non-important areas (B area). 9.1.6.1 The division of important areas (A area) and non-important areas (B area) of pump shaft, crankshaft and connecting rod is shown in Figure 2, Figure 3 and Figure 4. 2b
,=0.1d, and a=≥25
2=0.1d and a≥25
JB/T 8543.2---1997
9.1.6.2 Among other parts, the 2a range of welds, threaded areas, mating surfaces, sealing surfaces, transition fillets and keyways (oil holes) are all important areas (A area), and the rest are non-important areas (B area). 9.2 Defect grade assessment
9.2.1 Unqualified defects
—Crack-type defect display
—Transverse defect display;
—Three or more defect displays on any straight line and the edge spacing is less than 1.0mm. 9.2.2 Evaluation of linear defect display level
Evaluation of linear defect display level shall be in accordance with the provisions of Table 4. 488
9.2.3 Evaluation of circular defect display level
JB/T 8543.2—1997
Length and quantity of linear defect traces
No defect traces
0.55. and ≤2
5L8.3
8N level
L≤1, and 2
L≤5.H≤3
5L8. and 4
8八10. and 1
The circular defect display grade is evaluated in the evaluation area, which is a square of 10mmX10mm. The evaluation area should be selected at the most serious defect 9.2.3.1
grading. The maximum long diameter of the defect display trace participating in the evaluation in the evaluation area is 5mm. If it is larger than 5mm, it is calculated according to the linear defect display trace. The classification of circular defect display is shown in Table 5.
The length and number of circular defect marks displayedB
No defect marks displayed
3 points per place, and 1 place
≤5 points per place, and ≤1 place
5 points per place, and 2 places
>N level
3 points per place, and 1 place
5 points per place, and 1 place
5 points per place, and 2 places
≤5 points per place, 3 places
9.2.4 In the circular defect assessment area, if there are linear defects at the same time, they should be rated separately and the sum of the grades minus 1 is used as the final grade.
10 Test report
The test report should include the following contents [the form of the form can be found in Appendix B (Suggested Appendix)]: 10.1 Workpiece name, number, shape and size, material, heat treatment status, surface roughness and qualified grade. 10.2 Inspection method (expressed by the symbols specified in Table 1 and Table 2), operating procedures, types and brands of flaw detection agents. 10.3 Operating conditions include:
Penetration time and penetration temperature:
Emulsification time;
Pressure and temperature of cleaning water;
Drying temperature and time;
Development time and observation time.
10.4 Inspection results include:
Schematic diagram of inspection area and defect traces;
Defect type;
Defect trace display level;
Inspection conclusion.
10.5 Inspection personnel qualifications and signatures, reviewers and signatures, and report issuance date. 489
A1 Overview
JB/T 8543.2--1997
Appendix A
(Standard Appendix)
Test methods for non-standard temperatures
When penetrant testing cannot be carried out within the temperature range of 15-50°C, it is required to identify the test methods at lower or higher temperatures. Usually, aluminum alloy comparison test blocks are used for this purpose. Identification method
A2.1 Identification of penetrant testing methods at temperatures below 15°C After the test block and all materials used have dropped to the predetermined temperature, the prepared low-temperature test method is applied to area B. Then the test block is heated to between 15 and 50°C, and the standard method is used to test area A. The crack indication marks of areas A and B are compared. If the indication marks are basically the same, the method to be adopted can be considered feasible. A2.2 Identification of the penetrant testing method under the condition of temperature higher than 50°C If the test temperature to be used is higher than 50°C, heat the test block to this temperature and test it in area B. Then heat the test block to between 15 and 50°C, test it in area A using the standard method, and compare the crack indications in areas A and B. If the indications are basically the same, the method to be used can be considered feasible. Appendix B
(Suggested Appendix)
Penetrant Test Report
Name of Workpiece
Main Material
Test Method
Ambient Temperature
Penetrant Agent Model
Implementation Standard
Tester:
(Attached Pages May Be Attached)
Defect Location
Manufacturer
Nominal Thickness
Testing Location
Comparison Test Block
Cleaning Agent Model
Defect Length
Audit:
Workpiece Number
Surface Condition
Testing Ratio
Observation Method
Developer Model
Defect Location
Report Number:
Defect Length
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