基于纵向超声导波管道非通透缺陷检测研究

管道经过长期服役后,由于磨损、腐蚀和意外损伤等原因,对管道正常运行产生危害。在实际工况中,小的腐蚀缺陷容易发展成腐蚀穿孔,浅层的小裂纹容易发展成穿透型裂纹,因此探究如何有效检测管道小宽度非通透缺陷是很有必要的。利用ANSYS有限元仿真软件模拟纵向模态导波对管道的周向和斜向非通透缺陷的检测,得到了周向非通透缺陷的反射系数曲线,并证实时间反转法可以显著提高导波对非通透斜裂纹的检测能力。还针对空管和充水管非通透斜裂纹的定位问题进行了研究,结果表明利用时间反转法可以得到缺陷较为精确的周向与轴向位置及大致形状。     

Location and Sizing of Defects in Coated Metallic Pipes Using Limited View Scattered Data in Frequency Domain

The inverse problem of reconstructing the location and size of defects in a coated metallic pipe from single frequency limited view electromagnetic scattered field is considered. Specifically, the paper addresses the problem of assessing shape changes in the shadow region entailed by limited view data in 2D by operating in an intermediate size parameter (ka) range. The inverse scattering problem is formulated as a non-linear optimization problem solved through genetic algorithm that seeks to minimize in the least-squared sense the difference between measured data and simulated data through iterations of the solution to a forward problem. The hybrid finite element boundary integral formulations were used to solve the forward problem of coated metallic pipe with defects. The proposed inversion methodology was applied for shadow region shape change assessment to determine whether a metal pipe is coated or not, and to reconstruct the location and size of corrosion-like defect, over a range of size parameters. The study is carried out using transverse electric and transverse magnetic polarized fields. To understand the effect of coating on backscattered fields, parametric studies are conducted using numerical data. A range for size parameter \(2.0\le ka\le 4\) was found to produce the highest contrast between defect free pipe and coated metallic pipes with defects in the deep shadow region. The experiments are carried out using vector network analyzer in an anechoic chamber. The inversion results obtained using measured data were found be in good agreement with inversion results obtained using synthetic data. Estimated extent of corrosion in deep shadow region of a coated metallic pipe was found to be within 9 % of actual extent of corrosion.     

Determination of the resource abilities of oil and gas pipelines working for a long time

We have proposed a method for numerical assessment of the operating capacities of pipelines with regard for the factor of potential growth of the existing corrosion defects. We predict the lifetime of gas-main and oil-trunk pipelines with defects of different shapes and sizes.     

Failure mechanism of sucker rod coupling

Failure of sucker rod coupling or tubing is a major problem in sucker rod pumping systems, which occurs constantly in oil fields around the world. Such failures can lead to heavy maintenance work and higher expenses in oil production. To date, no economical method has yet been proposed to address the problem. In this paper, three samples with different service times are selected from California oil fields and are analyzed in details. A comparison of the dimensions and macro-morphologies of the samples with different service times is used to reveal the failure process. Failure mechanism is discussed based on the analysis of the micro-morphologies, microhardness, microstructures, and chemical composition of the samples. The analytical results indicate that the damage is initially caused by abrasion between the coupling and the tubing; the contact load decreases as the coupling diameter decreases, and the synergistic action between wear and corrosion becomes the main damage cause. Large numbers of defects (pores) in the material can accelerate both corrosion and wear aspects of the damage. Alternating stress may affect the mechanical properties of the coupling, but it is not the main factor of failure.     

ESPI and Digital Speckle Correlation Applied to Inspection of Crevice Corrosion on Aging Aircraft

A recent advance in the nondestructive inspection of crevice corrosion is reported. Crevice corrosion is one of the most hazardous defects that threaten the integrity of aging aircraft. Two optical techniques, electronic speckle pattern interferometry (ESPI) and digital speckle correlation (DSC), are employed to reveal the existence of crevice corrosion, which is usually undetectable from outside by visual inspection. The ESPI is configured to measure out-of-plane displacement. Both thermal loading and vacuum loading are used. The anomaly of fringe patterns reveals the existence of crevice corrosion hidden between two metallic plates. Not only the location of defects, but also the approximate size can be estimated. The digital speckle correlation technique takes advantage of laser speckle properties. The speckle decorrelation due to out-of-plane displacement in the region with crevice corrosion is larger than the region without defects. This difference is calculated by a digital correlation algorithm, which reveals the crevice corrosion. These two techniques can be used alternatively for field inspection of aircraft. While digital speckle correlation offers a simple, rapid approach to qualitatively detect defects, ESPI can be used as a supplementary tool if a more sensitive and quantitative evaluation is required.     

Integrity assessment of a corroded API X70 pipe with a single defect by burst pressure analysis

Gas pipes invariably develop defects. Assessment and repairing methods vary depending on the defect type. When evaluating corrosion in the base metal of a pipe, the burst pressure is usually calculated using conventional evaluation equations, and the possibility of operating the pipe is determined. These equations are applied differently depending on the pipe's physical properties and environment. Therefore, in this study, the failure behavior and burst pressure of a pipe are determined through a full scale hydrostatic burst test; the results are used to simulate the lengths and depths of defects through the finite element method for the shapes and physical properties identical to those of a full-scale pipe. Thus, the corrosion in the base metal of an API X70 pipe was assessed by a stress-based method, and an evaluation equation suitable for use was proposed.     

含缺陷涂层X80钢热影响区的电化学阻抗分析

为了进一步探讨X80钢涂层缺陷对耐土壤腐蚀性能及使用寿命的影响,将有无涂层缺陷的X80钢浸泡在玉门土壤模拟溶液中,采用电化学方法分析了其电化学阻抗谱。结果表明:无缺陷涂层的X80钢具有良好的防腐蚀效果;线缺陷涂层在不同测试期内的阻抗谱曲线都呈现为具有2个时间常数的双容抗弧特征;存在涂层缺陷时,外界腐蚀性介质会到达基体,使之腐蚀,随着腐蚀时间的延长,腐蚀产物会在缺陷处堆积;阴极反应形成的OH-增加会促使局部碱性环境的形成,进而导致X80钢涂层与基体界面剥离,发生缝隙腐蚀。     

扫描电化学显微镜原位观察碳钢涂层缺陷处的交流腐蚀行为

将原位微区电化学与传统宏观电化学技术相结合,应用电化学扫描显微镜(SECM)技术和电化学阻抗谱技术并结合微观形貌分析,研究了碳钢涂层缺陷处在不同交流电流强度下的腐蚀行为。结果表明：SECM拓扑形貌直观反映了碳钢涂层缺陷处局部腐蚀过程中电化学活性点的变化。交流电流使涂层缺陷处腐蚀活性点的数量明显增多,且使表面腐蚀产物积累对腐蚀产生的抑制作用明显减弱;浸泡初期涂层缺陷处的腐蚀为电子转移控制过程,浸泡10 h后转为扩散控制过程;随着交流电流强度的增大和浸泡时间的延长涂层的剥离程度提高,点蚀坑的深度和宽度随之增大。     

Evaluation of corrosion defects in oil pipelines based on the approaches of fracture mechanics

We study the development of corrosion defects in an industrial oil pipeline. Defects appearing in the pipeline after 5 and 10 yr of operation are measured by the ultrasonic method. It is shown that, after 10 yr of operation, the pipe wall becomes thinner by 22% (as compared with its initial thickness). To evaluate the defectiveness of state of the pipeline, we use the concepts of J -integral and crack-opening displacement δ. The experimental data on corrosion defects are used to find the values of J-integral.     

Corrosive degradation of a dense Si3N4 in a burner rig

The demands for greater efficiency and reduced environmental pollution are two of the main factors behind the intense research and development for new and improved materials for propulsion and power generation systems. On the grounds of density and retention of properties at high temperatures, ceramics are attractive alternatives to metallic materials. While much attention is focused on the problem of mechanical reliability, the question of corrosion resistance, and more importantly the synergism between corrosion and strength, are critical factors affecting the life of components. This investigation addresses the corrosion of a Si3N4, hot-pressed with 3% Al2O3 and 8% Y2O3, in a combustion atmosphere paying particular attention to corrosion. The results show that the dominant surface reaction in an atmosphere containing SO2 and compounds of sodium was oxidation, giving a surface product of silica, but the kinetics were in some cases not parabolic as often reported. It was also shown that strength progressively decreased with increasing corrosion test temperature, probably due to the formation of subsurface defects. This revised version was published online in November 2006 with corrections to the Cover Date.     

Prediction of the corrosion cracking of structures under the conditions of high-temperature creep

On the basis of the continual model of corrosion crack growth proposed earlier and the well-known incremental-type creep theory, we make an attempt to predict the corrosion cracking of structures under the conditions of high-temperature creep. We propose the mathematical statement of the problem taking into account the influence on corrosion cracking of the properties of corrosive media and the redistribution of stresses in time caused by creep. The Bubnov–Galerkin method is applied for the solution of this problem. An example of prediction of the phenomenon of corrosion cracking in the case of creep of a pipe under the action of internal pressure is analyzed.     

利用WBE及EIS测试技术对管道缺陷区动态冲刷腐蚀行为的研究

油气管道内缺陷的存在会使油气输运过程中出现局部区域流体急剧变化,导致管道腐蚀失效。本文通过微电极阵列测试技术(WBE)以及宏观电化学测试技术(EIS)研究管道缺陷处的冲刷腐蚀行为,以COMSOL Multiphysics中的流体力学模块辅助分析缺陷不同区域在流动状态下的腐蚀机制。结果表明,缺陷不同区域之间的流场变化导致腐蚀差异性,紧邻缺陷的上缘与下缘区域承受较大的湍流动能及壁面剪切力表现为阳极,腐蚀较为严重;缺陷底层区域以及远离缺陷两侧的区域由于湍流动能较小而边界层厚度大,离子传质作用较弱,表现为阴极,缺陷底层区域相比于缺陷上下缘区腐蚀进行缓慢。随着流动腐蚀时间的延长,缺陷上下缘区域腐蚀更为严重,缺陷整体有沿深度方向扩展加深的趋势。     

基于超声导波检测的角钢型材缺陷特性分析

输电线路铁塔长期暴露在大气环境之中受到腐蚀,会造成角钢型材不同位置出现壁厚减小的情况,严重时可能导致铁塔断裂倒塌.为此,对角钢型材内壁锈蚀情况的检测技术进行探究.首先,对超声兰姆波的传播机理进行分析,确定角钢型材超声兰姆波的检测模态;然后,基于有限元理论对角钢型材进行三维数值建模,通过数值模拟探究了导波在钢材中的传播特...     

CF8611/AC531复合材料性能及与7B04铝合金电偶腐蚀的电化学研究

借助电化学工作站、扫描电镜和能谱仪等设备,测量了CF8611/AC531复合材料的正面(FS)试件和侧面(SS)试件及7B04-T74铝合金在3.5%(质量分数,下同)NaCl或3.5%NaCl+12.5%Cu_2SO_4电解液中的极化曲线及电偶腐蚀参量,并观测了微观形貌;基于电化学理论、稳态腐蚀场和参数化扫描,建立了复合材料磨损状态下二者的电偶腐蚀动态模型。结果表明:该型复合材料性能稳定,但原始表面存在碳纤维裸露缺陷,缺陷位置常在碳纤维束重叠区,密度均值4.3个/mm^2,面积均值0.0184mm^2/个;阴极反应速率与缺陷面积密切相关,据此划分了活性阴极区和惰性阴极区;电偶腐蚀中,铝合金的主要腐蚀形式为点蚀,未见复合材料失效;电偶腐蚀有限元模型有效、可用,总电偶电流I_g与缺陷面积S正线性相关;当S_FS∶S_SS约为5.53∶1时,二者对7B04-T74铝合金的电偶效应相同。     

A study on fitness-for-service assessment for crack-like defects and corrosion in nuclear reactor pressure tubes

This paper looks forward to thoroughly assess zirconium alloy (Zr-2) pressure tubes used in nuclear power reactors for crack like and corrosion type defects. It emphasizes on the use of reliability concept for determining the probability of failure of zirconium alloy pressure tubes based on deuterium ingress. The in depth analysis carried out to calculate the reliability index for the above two problems is based on FORM approach. A steady state corrosion rate is assumed to estimate the growth in the dimensions of corrosion defects. The methodology suggested in this paper is useful for designers and plant engineers in timely detection of the cracks and leaks in the pressure tubes used in nuclear reactors and initiate suitable corrective actions based on their criticality.     

Influence of topographical features on the fluoride corrosion of Ni-Ti orthodontic archwires

Different manufacturing processes of Ni–Ti archwires respond differently to corrosion due to the surface conditions involved. In this study, several topographical features and their influence upon fluoride corrosion were studied. Four topographies (smooth, dimple, scratch, and crack) according to the main surface defect were characterized (n = 40). Static corrosion tests were performed in artificial saliva with fluorated prophylactic gel (12500 ppm) for 28 days. The surface was characterized by SEM and laser confocal microscopy. Standard electrochemical corrosion (open circuit potential, corrosion potential and corrosion current density) was performed. Statistical analysis was carried out using the ANOVA test (α ≤ 0.05). An increase was observed in the surface defects and/or roughness of the cracked and scratched surfaces. These defects produced an important increase in corrosion behavior. The best surfaces for the orthodontic archwires were the smooth and dimpled surfaces, respectively. The increase in defects was independent of roughness. Manufacturing processes that produce surface cracks should be avoided in orthodontic applications.     

Corrosion resistance of biomimetic calcium phosphate coatings on magnesium due to varying pretreatment time

Calcium phosphate coatings were prepared on magnesium substrates via a biomimetic coating process. The effects of a magnesium hydroxide pretreatment on the formation and the ultimate corrosion protection of the coatings were studied. The pretreatment layer was found to affect the amount of defects present in the coatings. Corrosion resistance of the coatings was studied in vitro using two simulated body fluids, 0.8% NaCl and Hanks solution. In NaCl, the resistance to corrosion of all samples decreases with time as corrosion proceeded through cracks and other defects in the coatings. Samples with no pretreatment displayed the highest corrosion resistance as these samples had the fewest defects in the coating. However, in Hanks solution, corrosion resistance increased with time due to additional nucleation of calcium phosphate from the fluid on to the substrate. In this solution, additional pretreatment time was beneficial to the overall corrosion resistance.     

Reliability analysis of pipelines carrying H2S for risk based inspection of heavy water plants

Reliability analysis of pipelines containing corrosion defects due to H₂S is presented. The pipeline carrying H₂S is more susceptible to the internal corrosion thereby reducing the pipeline's load carrying capacity. The objective of this study is to obtain the pipelines' failure probabilities that are required in establishing a Risk Based Inspection (RBI) programme for heavy water plants. The reliability assessment of pipelines involves the estimation of failure pressure and evaluating the limit state function. Several failure pressure models were studied for this purpose and it was found that the modified B31G failure pressure model is most suitable for the pipeline failure pressure modeling. Due to the presence of non-linearity in the limit state function and non-normal variables, the first order reliability method has been employed for carrying out the reliability analysis. The uncertainty of the random variables on which the limit state function depends is modeled using normal and non-normal probabilistic distributions. The failure probabilities and the categories of the pipelines connected to the first pair of first stage of exchange towers are presented. In addition, a sensitivity analysis was carried out on random variables involved in the problem. The results of sensitivity analysis are also presented.     

耐热不锈钢管锈蚀原因分析

采用扫描电镜和X射线能谱分析等方法,对一批进口的耐热不锈钢管表面锈蚀原因进行了分析.结果表明,管子表面锈蚀是由海水浸入所致,同时该批管子部分焊缝区存在缩孔和裂纹等焊接缺陷,这些焊接缺陷降低了其耐腐蚀性能,从而加速了腐蚀过程的发生.     

High corrosion resistance film on rebar by cerium modification

A cerium film was prepared on the surface of rebar by chemical conversion method to enhance its corrosion resistance.The film in the simulated concrete pore solution was measured by electrochemical method,transmission electron microscope(TEM)and X-ray photoelectron spectroscopy(XPS).The effect of temperature on film formation was studied,and the optimum temperature was determined at 35℃.The film produced by too high formation temperature has more defects,resulting in the lower corrosion resistance.The Ce film resistance increased with time evolution until 800 h,then decreased and stabilized.The Ce film layer has a double-layer film structure,the upper layer is an oxide of cerium,and the underlayer is an oxide of iron.Results revealed that after being immersed in the simulated concrete pore solution,the corrosion resistance of the Ce film was enhanced by self-densification.