玄文博,姚欢,江小斌,等. 利用S1曲线预测B型套筒角焊缝条状缺陷的准确率[J]. 油气储运,2025,44(4):1−10.
引用本文: 玄文博,姚欢,江小斌,等. 利用S1曲线预测B型套筒角焊缝条状缺陷的准确率[J]. 油气储运,2025,44(4):1−10.
XUAN Wenbo, YAO Huan, JIANG Xiaobin, et al. Accuracy of predicting strip defects in fillet welds on type-B sleeves using S1 curve[J]. Oil & Gas Storage and Transportation, 2025, 44(4): 1−10.
Citation: XUAN Wenbo, YAO Huan, JIANG Xiaobin, et al. Accuracy of predicting strip defects in fillet welds on type-B sleeves using S1 curve[J]. Oil & Gas Storage and Transportation, 2025, 44(4): 1−10.

利用S1曲线预测B型套筒角焊缝条状缺陷的准确率

Accuracy of predicting strip defects in fillet welds on type-B sleeves using S1 curve

  • 摘要:
    目的 B型套筒角焊缝缺陷尤其是水平熔合线区内(如未焊透、裂纹等)条状缺陷的检测,是相控阵超声检测中的工程难题,优化检测工艺、提高缺陷的检出率及长度测量准确率显得尤为迫切。
    方法 以人工刻槽代替角焊缝内的条状缺陷,建立B型套筒角焊缝的有限元模型,获取不同走向刻槽的声散射信号并计算散射系数矩阵,进一步得到反映散射能量与刻槽走向之间关系的S1曲线,并利用S1曲线分析楔块角度、母管厚度对刻槽长度测量准确率的影响;通过全聚焦仿真成像及实验,分别对S1曲线预测的准确率进行验证。
    结果 全聚焦方法对水平熔合线区所有走向刻槽的检出率为100%;从刻槽长度测量结果看,将线阵探头与35°楔块配合应用,对120°~150° 刻槽的测量效果最好,准确率均高于70%且全聚焦图像与刻槽实际形貌相近,但对其他角度范围内的刻槽仅能检测出1个或2个端角;同时,使用30°、35° 及40° 不同角度的楔块组合进行角焊缝检测,可使适宜于检测的刻槽角度增加约20°。与全聚焦图像测量结果相比,S1曲线对刻槽长度测量准确率预测结果误差不超过14%。
    结论 在实际工程应用中,可用S1曲线对B型套筒角焊缝缺陷检测工艺参数进行优化,还可根据缺陷大致走向选择适宜的楔块角度,有效提高缺陷检测的准确率。

     

    Abstract:
    Objective Defects in fillet welds connecting type-B sleeves, particularly strip defects such as incomplete penetration and cracks within horizontal weld junction zones, present significant engineering challenges in phased array ultrasonic testing (PAUT). To effectively detect these defects, it is crucial to address practical issues in fillet weld testing, including the optimization of testing techniques and the improvement of both defect detection probabilities and accuracy in length measurements.
    Methods A finite element model for fillet welds on B-type sleeves was developed, incorporating artificial notches to simulate strip defects in the welds. This model was used to acquire acoustic scattering signals from notches at various orientations and to compute scattering coefficient matrices. The results enabled the derivation of an S1 curve, which reflects the relationship between scattered energy and notch orientations. Additionally, the influence of wedge angles and pipeline thickness on accuracy in notch length measurements was analyzed using the S1 curve. Total focus simulation imaging and experiments were conducted to validate the accuracy prediction based on the S1 curve.
    Results The total focus method exhibited a 100% detection probability of notches at all orientations within the horizontal weld junction zone. The combined application of a linear array probe and a 35° wedge yielded the optimal length measurements for notches ranging from 120° to 150°, achieving accuracy greater than 70%, with total focus images closely resembling the actual notch morphology. Conversely, for notches beyond this angle range, only 1 or 2 end corners were detected. The combined use of 30°, 35°, and 40° wedges in fillet weld testing expanded the range of notch angles suitable for testing by about 20°. Compared with the measurement results obtained via total focus imaging, the prediction results for accuracy in notch length measurements based on the S1 curve showed errors not exceeding 14%.
    Conclusion The S1 curve approach provides a means to optimize defect detection parameters for fillet welds connecting B-type sleeves in practical engineering applications. Suitable wedge angles can be selected based on the rough orientations of defects, effectively improving detection accuracy.

     

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