As a core component of critical equipment, the quality and integrity of petrochemical forgings are critical to the safety and efficiency of the entire petrochemical production. However, various defects may occur during the manufacturing and use of forgings, such as cracks, pores, inclusions, etc., which may lead to serious consequences. Therefore, quality inspection and evaluation of petrochemical forgings is an indispensable link. As an important non-destructive testing method, ultrasonic detection technology has the advantages of large detection depth and high resolution, and is widely used in the defect detection and evaluation of petrochemical forgings.
Ultrasonic detection technology is the use of ultrasonic propagation and reflection in the material to detect the defects inside and on the surface of the material. The basic principle is: the ultrasonic wave is emitted on one side of the material to be detected, and the ultrasonic wave propagates in the material and interacts with the defects in the material, producing phenomena such as reflection, scattering and transmission. By receiving and analyzing these ultrasonic signals on the other side of the material, the location, size and type of defect can be determined.
Application of ultrasonic detection technology for petrochemical forgings
Preparation before testing: Clean the petrochemical forgings to remove impurities such as oil and rust on the surface. At the same time, the appropriate ultrasonic probe and coupling agent are selected to ensure that the ultrasonic wave can effectively propagate to the inside of the forging.
Ultrasonic scanning: The ultrasonic probe is placed on the surface of the forging and scanned along the predetermined path. By adjusting the position and Angle of the probe, ultrasonic waves are ensured to cover the entire forging.
Signal acquisition and processing: During the scanning process, the ultrasonic probe will receive the reflected signal from the forging. These signals are collected and converted into electrical signals, which are then amplified, filtered and analyzed by signal processors.
Defect identification and evaluation: According to the received ultrasonic signal, it is possible to determine whether there is a defect inside the forging and the type and severity of the defect. The commonly used evaluation methods include amplitude analysis, time domain analysis and frequency domain analysis. By comparing the difference between normal and abnormal signals, the location and size of the defect can be determined.
Result recording and reporting: Record and archive the test results to form a test report. The report shall include the basic information of forgings, testing process, defect identification and evaluation results. At the same time, the forgings need to be classified and treated according to the test results, such as repair, scrap or continue to use.
Considerations in evaluation
Probe selection: The appropriate probe needs to be selected according to the material, thickness and expected defect type of the forging. Parameters such as probe frequency, chip size and focal length will affect the detection results.
Development of scanning strategy: It is necessary to develop a reasonable scanning strategy according to the shape and size of the forging to ensure that the ultrasonic wave can cover the entire forging and detect potential defects.
Signal processing and analysis: Appropriate signal processing methods are needed to extract useful information and improve the accuracy of detection. At the same time, it is necessary to make a comprehensive judgment based on factors such as manufacturing process and use environment of forgings.
Compliance with testing standards: Relevant testing standards and specifications need to be followed to ensure the accuracy and comparability of testing. For different types of forgings and defects, different inspection standards and evaluation methods may be required.
Personnel training and qualification: It is necessary to ensure that the testing personnel have the relevant professional knowledge and skills, and obtain the corresponding qualification certification. Regular training and skill upgrading are important ways to maintain inspection quality.
Ultrasonic inspection and evaluation of petrochemical forgings is a key quality assurance measure, which is of great significance to ensure the safety and efficiency of petrochemical production. Through the application of reasonable detection strategy and signal processing method, the defects in forgings can be effectively detected and accurately evaluated. In the future, with the continuous development and progress of non-destructive testing technology, ultrasonic testing and evaluation of petrochemical forgings will face more challenges and opportunities. Relevant enterprises and researchers need to constantly explore and innovate to adapt to changes in market demand and contribute to the sustainable development of the petrochemical industry.
