As a key equipment component, petrochemical forgings play an important role in petrochemical production. However, there may be some potential quality problems in the forging process, such as cracks, pores, uneven organization and so on. In order to ensure the quality and performance of forging parts meet the requirements, we must adopt effective detection technology and quality control means. This paper will focus on the importance of testing technology and quality control of petrochemical forgings and its implementation methods.
Detection technology of petrochemical forgings
Ultrasonic testing: Ultrasonic testing is a common non-destructive testing method, suitable for detecting cracks, pores and other defects inside the forging. By transmitting ultrasonic waves and receiving echo signals, it is possible to determine whether there is a defect inside the forging, and to position and quantitatively evaluate it. This method has the advantages of fast detection speed and high sensitivity, and is widely used in the detection of petrochemical forgings.
Magnetic particle inspection: Magnetic particle inspection is a surface and near-surface defect detection method suitable for ferromagnetic materials. By applying magnetic field to the forging surface and scattering magnetic powder, the accumulation of magnetic powder at the defect can be observed, so as to judge the location and size of the defect. This method has high sensitivity for detecting surface defects such as cracks and folds.
Liquid penetration testing: Liquid penetration testing is a method of surface opening defect detection suitable for non-ferromagnetic materials. The location of the opening defect can be found by applying an penetrant containing fluorescence or stain to the surface of the forging, washing off the excess liquid after a period of time and observing it in a dark environment. This method is effective for detecting defects such as small cracks and surface irregularity.
Metallographic testing: Metallographic testing is a method of assessing the quality of forgings by preparing metallographic samples and observing their microstructure. The metallurgical quality and heat treatment effect of forgings can be judged by checking the grain size, microstructure uniformity and inclusions of forgings. This method is of great significance for evaluating the mechanical properties and service life of forgings.
Quality control of petrochemical forgings
Raw material control: strictly control the quality of raw materials used in forging manufacturing, including chemical composition, mechanical properties and other indicators. Ensure that raw materials comply with relevant standards and requirements, and fundamentally ensure the quality of forgings.
Forging process control: formulate reasonable forging process parameters and operating specifications to ensure that the heating temperature, forging speed, cooling speed and other parameters are within the appropriate range. Strengthen the forging process monitoring and recording, timely find and deal with potential quality problems.
Heat treatment process control: according to the material and use requirements of the forging, formulate reasonable heat treatment process parameters and operating specifications. Ensure that the temperature, time and other parameters in the heat treatment process are precisely controlled to achieve the purpose of improving the structure and performance.
Detection and evaluation: The above detection technology is used to conduct a comprehensive inspection of the forgings to ensure that the quality of the forgings meets the requirements. For the detected quality problems, the cause analysis and improvement measures are carried out to prevent similar problems from happening again. At the same time, establish a quality assessment system, regularly evaluate and summarize the quality of forgings, and constantly improve the quality control level.
Personnel training and equipment maintenance: strengthen the quality awareness and skill training of employees, improve the sensitivity and handling ability of employees to quality problems. Calibrate and maintain the testing equipment regularly to ensure its accuracy and reliability.
The detection technology and quality control of petrochemical forgings are the key links to ensure the quality and performance of the forgings. Through the use of ultrasonic, magnetic powder, liquid penetration and metallographic detection technology, it is possible to carry out comprehensive and effective quality inspection of forgings. At the same time, strengthening the quality control measures of raw material control, forging process control, heat treatment process control and detection and evaluation can further improve the quality and performance stability of forging parts. In the future, with the continuous emergence of new materials and new technologies, the manufacturing of petrochemical forgings will face more challenges and opportunities. Relevant enterprises should continue to learn and master new technologies and new methods to improve production efficiency and product quality to contribute to the sustainable development of the petrochemical industry.
