The UMD-104M device for testing reusable oil-well tubing

The optimal structural scheme and special features of a new automated device for the magnetic flaw detection of seamless pipes and electric-welded oil-well tubing in the process of their production and recovery of used pipes are considered. It is shown that the application of state-of-the-art technologies for manufacturing single-chip thin-filmed high-resolution matrix transducers substantially increases the functional capabilities of a flaw detector and not only ensures the reliable detection of all inadmissible flaws, such as discontinuities in metal, the wear of pipe walls, and displacement of the edges of a welded seam, but also provides higher reliability indices of sensors (breakdowns are minimal).     

Shape reconstruction of mixed type void flaws using Born inversion method

We study an approximate technique for determining the shapes of mixed type void flaws in elastic media from knowledge of the ultrasonic scattering amplitudes. It is well known that the technique is highly effective under weak scattering conditions. In the paper, two cement paste cylindrical specimens with mixed type void flaws are prepared and ultrasonic measurements are carried out by experimental means. The measurement area is restricted in the plane perpendicular to the axis of cylindrical specimen. The measured wave data are fed into the approximate technique formula—the Born inversion method and cross-sectional image is obtained. We find that good results have been obtained for strong scattering void flaws such as mixed type void flaws in cement paste cylindrical specimens.     

Terahertz spectroscopy approach of the fiber orientation influence on CFRP composite solid laminates

Terahertz ray (T-ray) imaging applications have provided one of the most promising new powerful nondestructive evaluation techniques, and new application systems are under process development for area applications. Detecting flaws and defects in fiber reinforced plastic (FRP) composite laminates due to flaws in FRP composite laminate that affect laminate properties, including stiffness, strength, and thermal behavior, is very important. In this study, a new time-domain spectroscopy system was utilized for detecting and evaluating the flaws in FRP solid composite laminates. Extensive experimental measurements in reflection mode were made to map out T-ray images. In particular, electromagnetic properties, such as refractive index, were estimated in this characterization procedure. The estimates of properties were in good agreement with known data. Using these characteristic material properties, we successfully demonstrated the characteristics of the T-ray behavior propagating through FRP composites. Furthermore, layup effect and flaws of FRP composite laminates were observed in reflection mode, and limitations were discussed in the T-ray processing.     

Non-destructive testing of plates based on the visualisation of Lamb waves by double-pulsed TV holography

We describe a new technique, currently under development, intended to detect the presence of flaws such as cracks and holes in thin-walled mechanical components. This technique combines ultrasonics with optics, both at a low power density, that allows to perform the tests in the non-destructive range. Lamb waves, a kind of surface acoustic waves that propagate in thin plates, are generated to explore metallic samples while double-pulsed TV holography, a whole-field interferometric technique, is used to detect them. This scheme provides maps of the instantaneous surface displacements produced by the waves, where the effects of the flaws can be visualised by contrast against the smooth propagation of the wavefront in defect free plates. Images with reasonable resolution can be achieved almost in real-time. Several examples of detection of typical flaws in plates using the proposed method complete this work.     

Temperature effects of imperfectly formed metal-ingots in high temperature fixed point crucibles

This paper investigates, through thermal modeling the effect on the radiance temperature of imperfectly filled thermometric fixed points. A two dimensional axisymmetric thermal model was established and the effect on the radiance temperature of various ingot imperfections such as voids and cracks in different places and of different dimensions in the ingot structure was calculated. It was found that the radiance temperature of the fixed point is quite tolerant to even relatively large flaws in the ingot structure. Only when flaws of significant dimensions near the radiating back wall were introduced was the overall radiance temperature significantly affected.     

基于低频电磁技术的管道缺陷检测方法研究

为了系统地研究基于低频电磁技术的管道缺陷检测方法,建立了其二维有限元模型。借助ANSYS参数化设计语言(APDL),进行了循环仿真计算,研究了不同尺寸缺陷的漏磁场分布;对漏磁场的信号进行微分处理,得到了所隐含的缺陷信息,并进行了实验验证。研究结果表明,该方法在锅炉水冷壁等管道缺陷的无损检测中有较强的实用性。     

Attempt Towards the Replacement of Radiography with Phased Array Ultrasonic Testing of Steel Plate Welded Joints Performed on Bridges and Other Applications

This study was carried out to demonstrate if the phased array ultrasonic testing (PAUT) can be adopted as a suitable substitute of the radiography testing (RT) of steel plate’s welded joints required by codes and standards related to some projects such as bridges construction and inspection according to AWS D1.5 Bridge welding code. Such adoption, if approved, can realize considerable cost saving without taking any additional risk. The two cited inspection techniques had been applied to test four butt welded joints performed on steel plates having thicknesses up to 35 mm. These welded joints had been performed by shielded metal arc welding (SMAW) and containing selected artificial flaws. The comparison between the detection capabilities and characterization of flaws in the welded joints by the two inspection techniques reveals that; PAUT improves the detection capability and sizing of flaws in the welded joints and it can replace RT reliably in case of applying a suitable PAUT procedure that includes simultaneous application of sectorial scan from both sides of the welded joints axes by using encoder with wide active aperture phased array probes and applying supplemental manual scanning for edge testing.     

Effect of demagnetizing action of an interface on the field of surface flaws upon magnetization with an attached electromagnet

Dependences of the magnetic-field strength of flaws on a electromagnet’s current and the magnetic induction in a magnetic-circuit gap are obtained. The magnetic-field strength of flaws in magnetically hard steels is found to be higher than that of flaws in magnetically soft steels. The results obtained are explained in terms of the demagnetizing action of a surface magnetic dipole as well as the dependence of the magnetic-flux distribution over specimens on the magnetic permeability of a material and on the induction under the electromagnet’s poles.     

The role of a stressed state in the formation of stress-corrosion flaws in pipelines

In recent years, as a result of performance of intensive in-tube flaw detection, the integrity and reliable operation of trunk pipelines have been achieved. However, because of an unpredictable development of such tube flaws as stress corrosion, the probability of occurrence of emergencies in pipelines substantially increases. An analysis of the stressed state in pipelines exposed to their main load—the operating pressure—and various types of additional forces is presented. As a result, it is shown that the obtained direction, value, and location of the effective maximum stresses in the tube wall fully correspond to the pattern of statistical formation of stress-corrosion flaws in pipelines. It can be concluded from the data of this study that the standardized tube-strength margin is insufficient; during tube operation, this circumstance may lead to the formation of stresses at the level of the metal yield stress and initiation and growth of stress-corrosion cracks.     

Estimating dimensions of flaws with narrow openings along the beam direction

The problem of flaw dimension measurement along the beam direction is discussed from the viewpoint of the measurement accuracy. Practical recommendation are put forth for estimating dimensions of flaws with small openings, such as incomplete fusions in welded joints, along the beam direction using X-ray photographs.     

Instantaneous frequency estimation used for the classification of echo signals from different reflectors

A comparative analysis of the frequency parameters of echo signals from artificial reflectors of different shapes and from a natural spill-type flaw has been performed. The use of the instantaneous frequencies of ultrasonic signals that correspond to certain instants inside a pulse was suggested as an informative parameter for determining the flaw type. Instantaneous frequency is estimated based on the algorithm of the continuous wavelet transform, which increases the noise immunity of the method. It is shown that for the algorithm to be practically implemented it is appropriate to present the results in the form of dimensionless parameters, namely, normalized frequency deviations determined between the pulse center, edge, and tail. Their joint application makes it possible, in particular, to reliably distinguish echo signals that are reflected at junction flaws that rise to the surface of a test object (notches, dihedral angles, and spills of the weld joints), flat specimen surfaces, and local flaws, such as cylindrical side through holes and flat bottom drills.     

超硬微结构表面模具的精密磨削加工技术

针对超硬模具材料,研究磨削方式(顺磨和逆磨)、进给率和主轴转速等磨削参数对磨削后微结构表面的表面粗糙度和尖锐部分完整性的影响规律.基于磨削结果,对微结构表面质量不均一现象以及微结构表面磨削过程中的砂轮磨损分布进行研究.试验结果表明磨削后的微结构侧表面粗糙度小于底面粗糙度.采用逆磨可以获得更低的粗糙度和更加完整、锋利的尖锐部分.磨削后的表面粗糙度随着进给率的降低而减小,当进给率为0.2 mm·min-1时,微结构底面平均表面粗糙度Ra89 nm,侧面为Ra 60nm.磨削后,尖锐部分圆弧半径随进给率的降低呈现减小趋势,当进给率为0.5 mm·min-1时,其平均圆弧半径最小,为0.67 μm.主轴转速对表面粗糙度和尖锐部分圆弧半径的影响不大.由阶梯光栅表面结构性引起的,相对于其各个表面的磨削轨迹不相同,是导致磨削后阶梯光栅表面质量不均一现象主要原因.在微结构表面的磨削加工过程中,相对于砂轮的径向和轴向磨损,砂轮的形貌磨损更为严重.     

Testing of discs of turbine rotors of gas compressors with the dye penetrant nondestructive testing technique

The special features of diagnostics of turbine discs of ΓTK-10-4 gas compressor units tested by the dye penetrant flaw detection method are considered. It is shown that disc blades must be dismantled and carefully mechanically cleaned, the spots in discs where such flaws as cracks are generated most often being analyzed, thereby reducing the searching and detection time.     

奥氏体不锈钢涡流阵列C扫成像检测技术的仿真研究与应用

为了解探头设计参数对涡流阵列C扫成像效果的影响和涡流阵列C扫成像检测技术对奥氏体不锈钢材料典型缺陷定性能力,采用CIVA软件仿真方法建立奥氏体不锈钢试样上平底孔、刻槽试样的涡流阵列C扫模型,研究涡流阵列探头的设计参数如探头工作模式、线圈外径和阵列排数对涡流阵列C扫成像的影响,并通过试验分析了裂纹、圆形缺陷等典型表面开口缺陷的涡流阵列C扫成像特征。结果表明,对于涡流阵列探头,绝对发射-接收式工作模式对缺陷方向敏感,不利于涡流阵列C扫成像,而绝对桥式工作模式对缺陷不敏感,有利于涡流阵列C扫成像;涡流阵列探头的线圈外径越小,阵列排数越多,涡流阵列C扫成像的纵向分辨力越小,更有利于涡流阵列C扫成像;奥氏体不锈钢均匀表面对涡流阵列C扫成像技术干扰少,涡流阵列C扫成像技术能够反映表面开口缺陷形状特征,可在一定程度上对表面开口缺陷进行定性。     

A statistical model of elasto-plastic asperity contact between rough surfaces

This work models statistically elasto-plastic contact between two rough surfaces using the results of a previous finite element analysis of an elasto-plastic sphere in contact with a rigid flat. The individual asperity contact model used accounts for a varying geometrical hardness effect that has recently been documented in previous works (where geometrical hardness is defined as the uniform pressure found during fully plastic contact). The contact between real surfaces with known material and surface properties, such as the elastic modulus, yield strength, and roughness are modeled. The asperity is modeled as an elastic-perfectly plastic material. The model produces predictions for contact area, contact force, and surface separation. The results of this model are compared to other existing models of asperity contact. Agreement exists in some cases and in other cases it corrects flaws, especially at large deformations. The model developed by Chang, Etsion and Bogy is also shown to have serious flaws when compared to the others. This work also identifies significant limitations of the statistical models (including that of Greenwood and Williamson).     

New examples for near-edge fine structures in electron energy loss spectroscopy

The electron energy loss near-edge structures of the K and L edges of elements occurring in sulfides and oxides of copper and zinc have been investigated. Furthermore, the K edge of carbon in some carbonates and the L edges of sulfur and phosphorus in sulfates and phosphates have been measured and the near-edge fine structures of these edges have been found to be characteristic for the complex ions CO^2-₃, SO^2-₄. Thus, near-edge fine structures of EELS edges can be very useful as a fingerprint for rapid identification of chemical compounds such as carbonates, sulfates, phosphates and some oxides in the TEM.     

Reliability of the spark inspection of cable product insulation

The types of manufacturing flaws in cable products and the causes of their occurrence were studied. Methods for improving the reliability of the detection of flaws and the classification of flaws that are detectable by high-voltage tests directly in a production line were proposed.     

A method for improving the accuracy of evaluating the dimensions of flaws in walls of tubular elements of structures

An algorithm for evaluating the real accuracy of the basic measuring instrument (exterior or in-tube flaw detector) in measuring parameters of flaws of a particular inspected tube was proposed on condition that the basic measuring equipment has no systematic error, while a verification instrument is considered as “absolutely” precise or “reference.” A statistical method of increasing the accuracy of evaluating the dimensions of flaws in thin-walled tube elements was developed on the basis of a correlation between the dimensions of flaw parameters. It can be taken as a basis for finding real values of parameters of flaws and for performing reliable calculations of the residual strength and residual life, for scheduling optimal periods for the next inspection of pipelines, and for ranging segments of a pipeline by a risk criterion, thus providing optimal scheduling of repairs.     

基于"生死单元"技术的焊缝缺陷模拟

应用有限元方法，计算分析带几何缺陷焊接接头力学性能。通过杀死焊接接头有限元模型中相应位置的单元，模拟存在的几何缺陷。计算分析带有气孔或咬边缺陷的焊接接头应力分布特性和应力集中程度，验证了应用生死单元模拟几何缺陷的有效性。通过对建模方法的比较，表明生死单元技术能够灵活模拟缺陷。     

An Intelligent System for Vibrodiagnostics of Oil and Gas Equipment

An intelligent system for the diagnostics and monitoring of oil and gas equipment with a computerized device for identification measurements of vibration signals is described. The system operates based on the expert knowledgebases of the FRASH- and S-methods and the databases of tabulated quantitative and qualitative properties of objects. It has been shown that the temporal properties of the condition of objects and their autocorrelation functions are clearly described by identification parameters. The example of applying the intelligent technology of identification measurements to the vibration-based diagnostics of an HM 12500-210 no. 12 pump unit has shown that such diagnostics and monitoring is more efficient as it recognizes not only states that include groups of flaws with similar characteristics but also the flaws themselves. An instance of the intelligent computer-aided system for the diagnostics and monitoring of oil and gas equipment using modern information–communication technologies is presented.