工(gong)業無(wu)損(sun)探(tan)(tan)傷(shang)的方(fang)(fang)(fang)法(fa)很多,目前國內外最常用的探(tan)(tan)傷(shang)方(fang)(fang)(fang)法(fa)有五種,即人們常稱的五大常規(gui)探(tan)(tan)傷(shang)方(fang)(fang)(fang)法(fa)。本(ben)文將(jiang)首先(xian)介紹五大常規(gui)探(tan)(tan)傷(shang)方(fang)(fang)(fang)法(fa)及其特點,并結合汽車(che)(che)維(wei)修(xiu)(xiu)中(zhong)的特定條(tiao)件和需求,選出更適合于汽車(che)(che)維(wei)修(xiu)(xiu)的探(tan)(tan)傷(shang)方(fang)(fang)(fang)法(fa)。
五大常規方法(fa)是指(zhi)射線(xian)探傷法(fa)RT、超聲(sheng)波探傷法(fa)UT、磁(ci)粉探傷法(fa)MT、渦流探傷法(fa)ET和滲(shen)透探傷法(fa)PT。
1. 射線探(tan)傷方法
射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)是利用(yong)(yong)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)的(de)(de)(de)(de)(de)穿透(tou)性(xing)和(he)(he)直(zhi)(zhi)線(xian)(xian)(xian)(xian)(xian)(xian)性(xing)來(lai)探(tan)(tan)(tan)傷(shang)(shang)(shang)的(de)(de)(de)(de)(de)方(fang)法。這些(xie)(xie)(xie)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)雖然不(bu)會像可(ke)見光(guang)(guang)那樣憑肉眼就(jiu)(jiu)能直(zhi)(zhi)接(jie)(jie)察知,但它可(ke)使(shi)照相底(di)片感(gan)光(guang)(guang),也可(ke)用(yong)(yong)特殊的(de)(de)(de)(de)(de)接(jie)(jie)收(shou)器來(lai)接(jie)(jie)收(shou)。常用(yong)(yong)于(yu)探(tan)(tan)(tan)傷(shang)(shang)(shang)的(de)(de)(de)(de)(de)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)有(you)x光(guang)(guang)和(he)(he)同位素發(fa)出(chu)的(de)(de)(de)(de)(de)γ射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian),分(fen)別(bie)稱(cheng)為(wei)x光(guang)(guang)探(tan)(tan)(tan)傷(shang)(shang)(shang)和(he)(he)γ射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)。當這些(xie)(xie)(xie)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)穿過(照射(she)(she)(she)(she))物質(zhi)時,該物質(zhi)的(de)(de)(de)(de)(de)密度(du)越大,射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)強度(du)減(jian)弱(ruo)得(de)(de)越多,即(ji)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)能穿透(tou)過該物質(zhi)的(de)(de)(de)(de)(de)強度(du)就(jiu)(jiu)越小(xiao)。此(ci)時,若用(yong)(yong)照相底(di)片接(jie)(jie)收(shou),則(ze)底(di)片的(de)(de)(de)(de)(de)感(gan)光(guang)(guang)量(liang)就(jiu)(jiu)小(xiao);若用(yong)(yong)儀器來(lai)接(jie)(jie)收(shou),獲(huo)得(de)(de)的(de)(de)(de)(de)(de)信(xin)號就(jiu)(jiu)弱(ruo)。因此(ci),用(yong)(yong)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)來(lai)照射(she)(she)(she)(she)待探(tan)(tan)(tan)傷(shang)(shang)(shang)的(de)(de)(de)(de)(de)零部件時,若其(qi)(qi)內部有(you)氣(qi)孔、夾渣等缺陷(xian),射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)穿過有(you)缺陷(xian)的(de)(de)(de)(de)(de)路徑(jing)比(bi)沒有(you)缺陷(xian)的(de)(de)(de)(de)(de)路徑(jing)所透(tou)過的(de)(de)(de)(de)(de)物質(zhi)密度(du)要小(xiao)得(de)(de)多,其(qi)(qi)強度(du)就(jiu)(jiu)減(jian)弱(ruo)得(de)(de)少些(xie)(xie)(xie),即(ji)透(tou)過的(de)(de)(de)(de)(de)強度(du)就(jiu)(jiu)大些(xie)(xie)(xie),若用(yong)(yong)底(di)片接(jie)(jie)收(shou),則(ze)感(gan)光(guang)(guang)量(liang)就(jiu)(jiu)大些(xie)(xie)(xie),就(jiu)(jiu)可(ke)以(yi)(yi)從底(di)片上反(fan)(fan)映出(chu)缺陷(xian)垂直(zhi)(zhi)于(yu)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)方(fang)向(xiang)的(de)(de)(de)(de)(de)平面(mian)投(tou)影;若用(yong)(yong)其(qi)(qi)它接(jie)(jie)收(shou)器也同樣可(ke)以(yi)(yi)用(yong)(yong)儀表來(lai)反(fan)(fan)映缺陷(xian)垂直(zhi)(zhi)于(yu)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)方(fang)向(xiang)的(de)(de)(de)(de)(de)平面(mian)投(tou)影和(he)(he)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)的(de)(de)(de)(de)(de)透(tou)過量(liang)。由(you)此(ci)可(ke)見,一般情況下(xia),射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)是不(bu)易發(fa)現裂(lie)紋(wen)的(de)(de)(de)(de)(de),或者說,射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)對裂(lie)紋(wen)是不(bu)敏感(gan)的(de)(de)(de)(de)(de)。因此(ci),射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)對氣(qi)孔、夾渣、未焊透(tou)等體積型(xing)缺陷(xian)最敏感(gan)。即(ji)射(she)(she)(she)(she)線(xian)(xian)(xian)(xian)(xian)(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)適宜用(yong)(yong)于(yu)體積型(xing)缺陷(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang),而不(bu)適宜面(mian)積型(xing)缺陷(xian)探(tan)(tan)(tan)傷(shang)(shang)(shang)。
2. 超聲(sheng)波探傷方法
人們的(de)(de)(de)(de)耳(er)朵能(neng)(neng)直接接收(shou)到的(de)(de)(de)(de)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)的(de)(de)(de)(de)頻率范圍通常(chang)(chang)(chang)是20Hz到20kHz,即音(聲(sheng)(sheng)(sheng))頻。頻率低于20 Hz的(de)(de)(de)(de)稱為次聲(sheng)(sheng)(sheng)波(bo)(bo)(bo),高(gao)于20 kHz的(de)(de)(de)(de)稱為超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)。工業上常(chang)(chang)(chang)用(yong)數兆赫茲超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)來(lai)探(tan)(tan)傷。超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)頻率高(gao),則傳播的(de)(de)(de)(de)直線(xian)性(xing)強,又(you)易于在固體中傳播,并且遇到兩種不同介質(zhi)形成的(de)(de)(de)(de)界(jie)(jie)面(mian)時(shi)易于反射,這樣就(jiu)可以用(yong)它(ta)來(lai)探(tan)(tan)傷。通常(chang)(chang)(chang)用(yong)超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)探(tan)(tan)頭(tou)(tou)與待探(tan)(tan)工件(jian)(jian)表(biao)面(mian)良好的(de)(de)(de)(de)接觸,探(tan)(tan)頭(tou)(tou)則可有效地向(xiang)工件(jian)(jian)發(fa)射超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo),并能(neng)(neng)接收(shou)(缺(que)陷)界(jie)(jie)面(mian)反射來(lai)的(de)(de)(de)(de)超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo),同時(shi)轉換成電信(xin)號(hao),再傳輸給儀器進行(xing)處理。根據(ju)(ju)超(chao)聲(sheng)(sheng)(sheng)波(bo)(bo)(bo)在介質(zhi)中傳播的(de)(de)(de)(de)速(su)(su)度(常(chang)(chang)(chang)稱聲(sheng)(sheng)(sheng)速(su)(su))和傳播的(de)(de)(de)(de)時(shi)間,就(jiu)可知道缺(que)陷的(de)(de)(de)(de)位置。當缺(que)陷越大(da),反射面(mian)則越大(da),其反射的(de)(de)(de)(de)能(neng)(neng)量也就(jiu)越大(da),故可根據(ju)(ju)反射能(neng)(neng)量的(de)(de)(de)(de)大(da)小(xiao)來(lai)查知各(ge)缺(que)陷(當量)的(de)(de)(de)(de)大(da)小(xiao)。常(chang)(chang)(chang)用(yong)的(de)(de)(de)(de)探(tan)(tan)傷波(bo)(bo)(bo)形有縱波(bo)(bo)(bo)、橫波(bo)(bo)(bo)、表(biao)面(mian)波(bo)(bo)(bo)等,前二者(zhe)適用(yong)于探(tan)(tan)測(ce)內(nei)部缺(que)陷,后(hou)者(zhe)適宜于探(tan)(tan)測(ce)表(biao)面(mian)缺(que)陷,但對表(biao)面(mian)的(de)(de)(de)(de)條件(jian)(jian)要(yao)求(qiu)高(gao)。
3. 磁粉探傷方法
磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)探傷(shang)(shang)是建立在(zai)漏磁(ci)(ci)(ci)(ci)(ci)(ci)原理基礎(chu)上(shang)的(de)(de)(de)一種(zhong)(zhong)磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)探傷(shang)(shang)方(fang)(fang)(fang)法(fa)。當磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)線(xian)穿過鐵磁(ci)(ci)(ci)(ci)(ci)(ci)材料及其(qi)制(zhi)(zhi)品(pin)時(shi),在(zai)其(qi)(磁(ci)(ci)(ci)(ci)(ci)(ci)性)不(bu)(bu)連續(xu)處將產生漏磁(ci)(ci)(ci)(ci)(ci)(ci)場(chang),形(xing)成磁(ci)(ci)(ci)(ci)(ci)(ci)極。此(ci)(ci)時(shi)撒(sa)上(shang)干磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)或澆上(shang)磁(ci)(ci)(ci)(ci)(ci)(ci)懸液,磁(ci)(ci)(ci)(ci)(ci)(ci)極就會吸附磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen),產生用(yong)(yong)(yong)(yong)(yong)(yong)肉(rou)(rou)眼能直(zhi)接(jie)觀察的(de)(de)(de)明(ming)顯(xian)(xian)磁(ci)(ci)(ci)(ci)(ci)(ci)痕。因此(ci)(ci),可借助于(yu)(yu)該(gai)磁(ci)(ci)(ci)(ci)(ci)(ci)痕來顯(xian)(xian)示(shi)鐵磁(ci)(ci)(ci)(ci)(ci)(ci)材料及其(qi)制(zhi)(zhi)品(pin)的(de)(de)(de)缺(que)(que)陷(xian)(xian)(xian)情(qing)況(kuang)。磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)探傷(shang)(shang)法(fa)可探測露出(chu)表(biao)面,用(yong)(yong)(yong)(yong)(yong)(yong)肉(rou)(rou)眼或借助于(yu)(yu)放大鏡(jing)也(ye)不(bu)(bu)能直(zhi)接(jie)觀察到的(de)(de)(de)微小(xiao)缺(que)(que)陷(xian)(xian)(xian),也(ye)可探測未露出(chu)表(biao)面,而是埋藏(zang)在(zai)表(biao)面下幾毫米的(de)(de)(de)近表(biao)面缺(que)(que)陷(xian)(xian)(xian)。用(yong)(yong)(yong)(yong)(yong)(yong)這種(zhong)(zhong)方(fang)(fang)(fang)法(fa)雖(sui)然也(ye)能探查氣孔、夾雜(za)、未焊(han)透(tou)等(deng)體積型缺(que)(que)陷(xian)(xian)(xian),但(dan)對面積型缺(que)(que)陷(xian)(xian)(xian)更靈敏,更適于(yu)(yu)檢查因淬火、軋制(zhi)(zhi)、鍛造、鑄造、焊(han)接(jie)、電鍍(du)、磨削、疲勞等(deng)引起的(de)(de)(de)裂紋。 磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)探傷(shang)(shang)中(zhong)對缺(que)(que)陷(xian)(xian)(xian)的(de)(de)(de)顯(xian)(xian)示(shi)方(fang)(fang)(fang)法(fa)有多(duo)種(zhong)(zhong),有用(yong)(yong)(yong)(yong)(yong)(yong)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)顯(xian)(xian)示(shi)的(de)(de)(de),也(ye)有不(bu)(bu)用(yong)(yong)(yong)(yong)(yong)(yong)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)顯(xian)(xian)示(shi)的(de)(de)(de)。用(yong)(yong)(yong)(yong)(yong)(yong)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)顯(xian)(xian)示(shi)的(de)(de)(de)稱為(wei)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)探傷(shang)(shang),因它(ta)顯(xian)(xian)示(shi)直(zhi)觀、操作簡單(dan)、人們樂(le)于(yu)(yu)使用(yong)(yong)(yong)(yong)(yong)(yong),故它(ta)是最常用(yong)(yong)(yong)(yong)(yong)(yong)的(de)(de)(de)方(fang)(fang)(fang)法(fa)之一。不(bu)(bu)用(yong)(yong)(yong)(yong)(yong)(yong)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)顯(xian)(xian)示(shi)的(de)(de)(de),習慣上(shang)稱為(wei)漏磁(ci)(ci)(ci)(ci)(ci)(ci)探傷(shang)(shang),它(ta)常借助于(yu)(yu)感應線(xian)圈、磁(ci)(ci)(ci)(ci)(ci)(ci)敏管(guan)、霍爾元件等(deng)來反映缺(que)(que)陷(xian)(xian)(xian),它(ta)比磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)探傷(shang)(shang)更衛生,但(dan)不(bu)(bu)如前者(zhe)直(zhi)觀。由于(yu)(yu)目前磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)探傷(shang)(shang)主要用(yong)(yong)(yong)(yong)(yong)(yong)磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)來顯(xian)(xian)示(shi)缺(que)(que)陷(xian)(xian)(xian),因此(ci)(ci),人們有時(shi)把磁(ci)(ci)(ci)(ci)(ci)(ci)粉(fen)(fen)(fen)探傷(shang)(shang)直(zhi)接(jie)稱為(wei)磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)探傷(shang)(shang),其(qi)設(she)(she)備(bei)稱為(wei)磁(ci)(ci)(ci)(ci)(ci)(ci)力(li)(li)探傷(shang)(shang)設(she)(she)備(bei)。
4. 渦流探(tan)傷方(fang)法
渦(wo)(wo)(wo)(wo)流(liu)(liu)探(tan)傷(shang)是(shi)由交流(liu)(liu)電(dian)流(liu)(liu)產(chan)生的(de)(de)交變磁(ci)場(chang)作(zuo)用(yong)于(yu)待探(tan)傷(shang)的(de)(de)導電(dian)材(cai)料(liao)(liao),感應出電(dian)渦(wo)(wo)(wo)(wo)流(liu)(liu)。如果材(cai)料(liao)(liao)中有缺陷,它將(jiang)干擾(rao)(rao)所產(chan)生的(de)(de)電(dian)渦(wo)(wo)(wo)(wo)流(liu)(liu),即(ji)(ji)形成干擾(rao)(rao)信(xin)號(hao)。用(yong)渦(wo)(wo)(wo)(wo)流(liu)(liu)探(tan)傷(shang)儀檢測出其干擾(rao)(rao)信(xin)號(hao),就(jiu)可知道(dao)缺陷的(de)(de)狀(zhuang)況。影(ying)響渦(wo)(wo)(wo)(wo)流(liu)(liu)的(de)(de)因(yin)素(su)很(hen)多,即(ji)(ji)是(shi)說(shuo)渦(wo)(wo)(wo)(wo)流(liu)(liu)中載有豐(feng)富的(de)(de)信(xin)號(hao),這些信(xin)號(hao)與材(cai)料(liao)(liao)的(de)(de)很(hen)多因(yin)素(su)有關,如何將(jiang)其中有用(yong)的(de)(de)信(xin)號(hao)從諸多的(de)(de)信(xin)號(hao)中一(yi)(yi)一(yi)(yi)分離出來(lai),是(shi)目(mu)前渦(wo)(wo)(wo)(wo)流(liu)(liu)研(yan)究工作(zuo)者的(de)(de)難題,多年來(lai)已經(jing)取得了一(yi)(yi)些進展,在一(yi)(yi)定條件(jian)下可解決一(yi)(yi)些問題,但還遠不能滿足(zu)現場(chang)的(de)(de)要求(qiu),有待于(yu)大力(li)發(fa)展。
渦(wo)流(liu)探(tan)傷(shang)的(de)(de)顯著特(te)點(dian)是對(dui)導電材料(liao)就能起作用,而(er)不一(yi)定(ding)是鐵磁(ci)材料(liao),但(dan)對(dui)鐵磁(ci)材料(liao)的(de)(de)效果較(jiao)差。其(qi)次(ci),待(dai)探(tan)工件(jian)表(biao)面的(de)(de)光潔度、平整度、邊介等對(dui)渦(wo)流(liu)探(tan)傷(shang)都有較(jiao)大影響(xiang),因此(ci)常將渦(wo)流(liu)探(tan)傷(shang)用于形狀(zhuang)較(jiao)規則、表(biao)面較(jiao)光潔的(de)(de)銅管等非鐵磁(ci)性(xing)工件(jian)探(tan)傷(shang)。
5. 滲透探傷方法
滲(shen)(shen)透(tou)探傷(shang)是(shi)利(li)用毛細(xi)現(xian)(xian)象來(lai)進行(xing)探傷(shang)的(de)(de)方(fang)法。對于(yu)(yu)(yu)表(biao)面(mian)光(guang)(guang)(guang)滑而(er)清潔(jie)的(de)(de)零(ling)部(bu)件,用一(yi)種帶色(se)(se)(常(chang)(chang)為紅色(se)(se))或帶有熒(ying)光(guang)(guang)(guang)的(de)(de)、滲(shen)(shen)透(tou)性很(hen)強的(de)(de)液(ye)體,涂覆(fu)于(yu)(yu)(yu)待探零(ling)部(bu)件的(de)(de)表(biao)面(mian)。若表(biao)面(mian)有肉眼不(bu)能直接察知(zhi)的(de)(de)微(wei)裂(lie)紋(wen)(wen),由(you)于(yu)(yu)(yu)該液(ye)體的(de)(de)滲(shen)(shen)透(tou)性很(hen)強,它將(jiang)沿(yan)著裂(lie)紋(wen)(wen)滲(shen)(shen)透(tou)到(dao)其(qi)根部(bu)。然后將(jiang)表(biao)面(mian)的(de)(de)滲(shen)(shen)透(tou)液(ye)洗去,再涂上對比(bi)度(du)較(jiao)大的(de)(de)顯示液(ye)(常(chang)(chang)為白色(se)(se))。放置片刻后,由(you)于(yu)(yu)(yu)裂(lie)紋(wen)(wen)很(hen)窄,毛細(xi)現(xian)(xian)象作用顯著,原滲(shen)(shen)透(tou)到(dao)裂(lie)紋(wen)(wen)內的(de)(de)滲(shen)(shen)透(tou)液(ye)將(jiang)上升到(dao)表(biao)面(mian)并擴散,在白色(se)(se)的(de)(de)襯底上顯出(chu)較(jiao)粗的(de)(de)紅線,從而(er)顯示出(chu)裂(lie)紋(wen)(wen)露于(yu)(yu)(yu)表(biao)面(mian)的(de)(de)形狀,因(yin)此,常(chang)(chang)稱為著色(se)(se)探傷(shang)。若滲(shen)(shen)透(tou)液(ye)采用的(de)(de)是(shi)帶熒(ying)光(guang)(guang)(guang)的(de)(de)液(ye)體,由(you)毛細(xi)現(xian)(xian)象上升到(dao)表(biao)面(mian)的(de)(de)液(ye)體,則會在紫外燈照射下發出(chu)熒(ying)光(guang)(guang)(guang),從而(er)更(geng)能顯示出(chu)裂(lie)紋(wen)(wen)露于(yu)(yu)(yu)表(biao)面(mian)的(de)(de)形狀,故常(chang)(chang)常(chang)(chang)又將(jiang)此時(shi)的(de)(de)滲(shen)(shen)透(tou)探傷(shang)直接稱為熒(ying)光(guang)(guang)(guang)探傷(shang)。此探傷(shang)方(fang)法也可用于(yu)(yu)(yu)金(jin)屬(shu)(shu)和(he)非(fei)金(jin)屬(shu)(shu)表(biao)面(mian)探傷(shang)。其(qi)使(shi)用的(de)(de)探傷(shang)液(ye)劑有較(jiao)大氣味,常(chang)(chang)有一(yi)定毒(du)性。
除以上五大常規方(fang)法(fa)外,近年來又有(you)了紅外、聲發射等一(yi)些新的探傷方(fang)法(fa)。
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