Ultrasonic probe, ultrasonic testing equipment, ultrasonic testing method, and manufacturing method of seamless pipe or tube

• US 20090217763A1
• Filed: 08/28/2006
• Published: 09/03/2009
• Est. Priority Date: 08/26/2005
• Status: Active Grant

• Current Assignee: Nippon Steel Corporation
• Original Assignee: Nippon Steel & Sumitomo Metal Corporation (Nippon Steel Corporation)
• Inventors: Yamano, Masaki
• Granted Patent: US 8,490,490 B2
• Time in Patent Office: Days
• US Class Current: 73/622
• CPC Class Codes: G01N 2291/0289 Internal structure, e.g. defects, grain size, texture
• CPC Class Codes: G01N 2291/0421 Longitudinal waves
• CPC Class Codes: G01N 2291/0422 Shear waves, transverse waves, horizontally polarised waves
• CPC Class Codes: G01N 2291/056 Angular incidence, angular propagation
• CPC Class Codes: G01N 2291/106 one or more transducer arrays
• CPC Class Codes: G01N 2291/2634 cylindrical from outside
• CPC Class Codes: G01N 29/043 in the interior, e.g. by shear waves
• CPC Class Codes: G01N 29/2487 Directing probes, e.g. angle probes directing arrangements G01N29/221
• CPC Class Codes: G01N 29/262 by electronic orientation or focusing, e.g. with phased arrays phased arrays per se G10K11/34
• CPC Class Codes: G01N 29/265 by moving the sensor relative to a stationary material

Abstract

The ultrasonic testing method according to the invention includes the steps of arranging an ultrasonic probe 1 having a plurality of transducers 11 so as to face a tubular test object P, and causing the transducers appropriately selected from the plurality of transducers to transmit and receive ultrasonic waves so that the ultrasonic waves are propagated in the tubular test object in a plurality of different propagation directions, wherein a ultrasonic testing condition by the ultrasonic probe is set so that respective external refraction angles θr of the ultrasonic waves in the plurality of propagation directions are approximately equivalent and/or respective internal refraction angles θk of the ultrasonic waves in the plurality of propagation directions are approximately equivalent.

Claims

1. An ultrasonic testing method comprising the steps of:

arranging an ultrasonic probe having a plurality of transducers so as to face a tubular test object, and

causing transducers appropriately selected from said plurality of transducers to transmit and receive ultrasonic waves so that the ultrasonic waves are propagated in said tubular test object in a plurality of different propagation directions, wherein

an ultrasonic testing condition by said ultrasonic probe is set so that respective external refraction angles θ

r of the ultrasonic wave in said plurality of propagation directions are approximately equivalent and/or respective internal refraction angles θ

k of the ultrasonic wave in said plurality of propagation directions are approximately equivalent.

2. The ultrasonic testing method according to claim 1, wherein

said ultrasonic probe has the plurality of transducers arranged in a matrix state on a plane or curved surface, and

said transducers are selected so that the respective external refraction angles θ

r of the ultrasonic wave in said plurality of propagation directions are approximately equivalent and/or the respective internal refraction angles θ

k of the ultrasonic wave in said plurality of propagation directions are approximately equivalent.

3. The ultrasonic testing method according to claim 2, wherein

a circumferential angle of incidence α

i and an axial angle of incidence β

i of the ultrasonic wave into said tubular test object in said plurality of propagation directions are respectively determined based on the following equation (1) so that the respective external refraction angles θ

r of the ultrasonic wave represented by the following equation (1) in said plurality of propagation directions are approximately equivalent, and

said transducers are selected so that said determined circumferential angle of incidence α

i and axial angle of incidence β

i are obtained;

θ

r=sin<sup>−

1</sup>({(Vs/Vi)²·

(sin² β

i+cos² β

i·

sin² α

i)}^1/2) 

 

(1)

where, in the above equation (1), Vs means a propagation velocity of the ultrasonic wave propagated in the tubular test object, and Vi means the propagation velocity of the ultrasonic wave in a coupling medium filled between the ultrasonic probe and the tubular test object.

4. The ultrasonic testing method according to claim 2, wherein

the circumferential angle of incidence α

i and the axial angle of incidence β

i of the ultrasonic wave into said tubular test object in said plurality of propagation directions are respectively determined based on the following equations (1) to (6) so that the respective internal refraction angles θ

k of the ultrasonic wave represented by the following equation (2) in said plurality of propagation directions are approximately equivalent, and

said transducers are selected so that said determined circumferential angle of incidence α

i and axial angle of incidence β

i are obtained;

θ

k=cos<sup>−

1</sup>(cos θ

r·

cos φ

−

sin θ

r·

cos γ

·

sin φ

) 

 

(2)

where the external refraction angle θ

r, a propagation angle γ

, and an angle φ

in the above equation (2) are represented respectively by the following equations (1), (3), and (4);

$\begin{array}{cc}\mathrm{\theta <br><br>}<br><br><br><br>r={\sin }^{-1}<br><br>\left({\left\{{\left(\mathrm{Vs}/\mathrm{Vi}\right)}^2·<br><br>\left({\sin }^2<br><br>\mathrm{\beta <br><br>}<br><br><br><br>i+{\cos }^2<br><br>\mathrm{\beta <br><br>}<br><br><br><br>i·<br><br>{\sin }^2<br><br>\mathrm{\alpha <br><br>}<br><br><br><br>i\right)\right\}}^{1/2}\right)& \left(1\right)\\ \mathrm{\gamma <br><br>}={\tan }^{-1}<br><br>\left(\frac{\sin <br><br><br><br>\mathrm{\beta <br><br>}<br><br><br><br>i}{\cos <br><br><br><br>\mathrm{\beta <br><br>}<br><br><br><br>i·<br><br>\sin <br><br><br><br>\mathrm{\alpha <br><br>}<br><br><br><br>i}\right)& \left(3\right)\\ \mathrm{\phi <br><br>}={\sin }^{-1}<br><br>\left(k·<br><br>\sin <br><br><br><br>{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}\right)-{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}& \left(4\right)\end{array}$

where, in the above equation (1), Vs means the propagation velocity of the ultrasonic wave propagated in the tubular test object, and Vi means the propagation velocity of the ultrasonic wave in the coupling medium filled between the ultrasonic probe and the tubular test object; and

k and θ

′

in the above equation (4) are represented respectively by the following equations (5) and (6);

$\begin{array}{cc}k=\frac{1}{1-2<br><br>\left(t/D\right)}& \left(5\right)\\ \underset{\_}{\tan }<br><br><br><br>{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}=\cos <br><br><br><br>\mathrm{\gamma <br><br>}·<br><br>\tan <br><br><br><br>\mathrm{\theta <br><br>}<br><br><br><br>r& \left(6\right)\end{array}$

where t/D in the above equation (5) means a ratio of thickness to outer diameter of the tubular test object.

5. The ultrasonic testing method according to claim 1, wherein

said ultrasonic probe has the plurality of transducers arranged along an annular curved surface obtained by cutting a predetermined spheroid with two parallel planes facing to each other that do not pass through a center of the spheroid and do not sandwich the center of the spheroid, said two parallel planes being orthogonal to the rotational axis of the spheroid,

in the step of arranging said ultrasonic probe so as to face said tubular test object, said ultrasonic probe is arranged so that a longer axis direction of said ultrasonic probe is along an axial direction of said tubular test object, a shorter axis direction of said ultrasonic probe is along a circumferential direction of said tubular test object, and the center of said spheroid correctly faces an axial center of said tubular test object, and

a shape of said annular curved surface is determined so that the respective external refraction angles θ

r of the ultrasonic wave in said plurality of propagation directions are approximately equivalent, and/or the respective internal refraction angles Ok of the ultrasonic wave in said plurality of propagation directions are approximately equivalent.

6. The ultrasonic testing method according to claim 5, wherein

respective angles of incidence θ

w of the ultrasonic wave into said tubular test object in said plurality of propagation directions are calculated based on the following equation (7) so that the respective external refraction angles θ

r of the ultrasonic wave represented by the following equation (7) in said plurality of propagation directions are approximately equivalent, and

the shape of said annular curved surface is determined so that said calculated angle of incidence θ

w is obtained;

sin θ

r=Vs/Vi·

sin θ

w 

 

(7)

where, in the above equation (7), Vs means the propagation velocity of the ultrasonic wave propagated in the tubular test object, and Vi means the propagation velocity of the ultrasonic wave in the coupling medium filled between the ultrasonic probe and the tubular test object.

7. The ultrasonic testing method according to claim 5, wherein

the respective angles of incidence θ

w of the ultrasonic wave into said tubular test object in said plurality of propagation directions are calculated based on the following equation (7) so that the respective internal refraction angles θ

k of the ultrasonic wave represented by the following equation (2) in said plurality of propagation directions are approximately equivalent, and

the shape of said annular curved surface is determined so that said calculated angle of incidence θ

w is obtained;

θ

k=cos<sup>−

1</sup>(cos θ

r·

cos φ

−

sin θ

r·

cos γ

·

sin φ

) 

 

(2)

where the external refraction angle θ

r, the propagation angle γ

, and the angle φ

in the above equation (2) are represented respectively by equations (7), (3), and (4);

$\begin{array}{cc}\sin <br><br><br><br>\mathrm{\theta <br><br>}<br><br><br><br>r=\mathrm{Vs}/\mathrm{Vi}·<br><br>\sin <br><br><br><br>\mathrm{\theta <br><br>}<br><br><br><br>w& \left(7\right)\\ \mathrm{\gamma <br><br>}={\tan }^{-1}<br><br>\left(\frac{\sin <br><br><br><br>\mathrm{\beta <br><br>}<br><br><br><br>i}{\cos <br><br><br><br>\mathrm{\beta <br><br>}<br><br><br><br>i·<br><br>\sin <br><br><br><br>\mathrm{\alpha <br><br>}<br><br><br><br>i}\right)& \left(3\right)\\ \mathrm{\phi <br><br>}={\sin }^{-1}<br><br>\left(k·<br><br>\sin <br><br><br><br>{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}\right)-{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}& \left(4\right)\end{array}$

where, in the above equation (7), Vs means the propagation velocity of the ultrasonic wave propagated in the tubular test object, and Vi means the propagation velocity of the ultrasonic wave in the coupling medium filled between the ultrasonic probe and the tubular test object; and

k and θ

′

in the above equation (4) are represented respectively by the following equations (5) and (6);

$\begin{array}{cc}k=\frac{1}{1-2<br><br>\left(t/D\right)}& \left(5\right)\\ \underset{\_}{\tan }<br><br><br><br>{\mathrm{\theta <br><br>}}^{\mathrm{\prime <br><br>}}=\cos <br><br><br><br>\mathrm{\gamma <br><br>}·<br><br>\tan <br><br><br><br>\mathrm{\theta <br><br>}<br><br><br><br>r& \left(6\right)\end{array}$

where t/D in the above equation (5) means the ratio of thickness to outer diameter of the tubular test object.

8. The ultrasonic testing method according to claim 5, wherein

in the step of arranging said ultrasonic probe so as to face said tubular test object, the ultrasonic probe is arranged so that the center of said spheroid correctly faces the axial center of said tubular test object and is located in a vicinity of an external surface of said tubular test object, and

the shape of said annular curved surface is determined so that the ultrasonic wave transmitted from at least the transducer arranged on the longer axis of said ultrasonic probe among said plurality of transducers is propagated into said tubular test object at an angle of refraction of shear wave of 35°

or more.

21. A manufacturing method of a seamless pipe or tube including:

a first process of manufacturing a seamless pipe or tube by piercing a billet; and

a second process of detecting a flaw in the seamless pipe or tube manufactured in said first process by using the ultrasonic testing method according to claim 1.

9. An ultrasonic testing equipment for detecting a flaw by ultrasonic waves in a tubular test object, comprising:

an ultrasonic probe arranged so as to face said tubular test object in which a plurality of transducers are arranged respectively in a row direction and a column direction in a matrix state on a plane or curved surface, and a transmission/reception control means for controlling transmission/reception of ultrasonic waves by said ultrasonic probe, wherein

said transmission/reception control means

selects a group of transducers including at least one transducer from said plurality of transducers and causes the selected one group of transducers to transmit and receive the ultrasonic wave in one propagation direction in said tubular test object, and

selects another group of transducers including at least one transducer at a position different both in the row direction and column direction from that of any transducer constituting said one group of transducers and causes the another selected group of transducers to transmit and receive the ultrasonic wave in another propagation direction from said one propagation direction.

10. The ultrasonic testing equipment according to claim 9, wherein said transmission/reception control means controls transmission time-shift or reception time-shift of the ultrasonic waves of said one group of transducers and said another group of transducers so that a surface echo on said tubular test object of the ultrasonic wave transmitted from said one group of transducers and another surface echo on said tubular test object of the ultrasonic wave transmitted from said another group of transducers are received at approximately the same time.

11. An ultrasonic probe for detecting a flaw by ultrasonic waves in a tubular test object, comprising

a plurality of transducers arranged along an annular curved surface, wherein

said annular curved surface is obtained by cutting a predetermined spheroid with two parallel planes facing to each other that do not pass through a center of the spheroid and do not sandwich the center of the spheroid, said two parallel planes being orthogonal to the rotational axis of the spheroid.

12. The ultrasonic probe according to claim 11, further comprising at least one straight beam probe arranged along a straight line that passes through the center of said spheroid and is orthogonal to said two parallel planes.

13. An ultrasonic testing equipment comprising:

the ultrasonic probe according to claim 11 arranged so as to face said tubular test object so that a longer axis direction of the ultrasonic probe is along an axial direction of said tubular test object, a shorter axis direction of the ultrasonic probe is along a circumferential direction of said tubular test object, and the center of said spheroid correctly faces an axial center of said tubular test object; and

a transmission/reception control means for controlling transmission/reception of ultrasonic waves by said ultrasonic probe, wherein

said transmission/reception control means causes at least two transducers among said plurality of transducers to transmit the ultrasonic waves to and receive the same from said tubular test object.

14. The ultrasonic testing equipment according to claim 13, wherein said ultrasonic probe is arranged so that the center of said spheroid is located in a vicinity of an external surface of said tubular test object.

15. The ultrasonic testing equipment according to claim 13, wherein

said transmission/reception control means controls transmission time-shift or reception time-shift of the ultrasonic waves of one transducer and another transducer among at least two transducers that transmit the ultrasonic waves to and receive the same from said tubular test object, so that a surface echo on said tubular test object of the ultrasonic wave transmitted from said one transducer and another surface echo on said tubular test object of the ultrasonic wave transmitted from said another transducer are received at approximately the same time.

16. The ultrasonic testing equipment according to claim 13, wherein an adjustment means for adjusting an angle of incidence of the ultrasonic wave transmitted from each of said plurality of transducers to said tubular test object is provided.

17. The ultrasonic testing equipment according to claim 16, wherein

each of said plurality of transducers has a plurality of piezoelectric elements divided into a rectangular shape along a radial direction of each transducer, and

said adjustment means adjusts the angle of incidence of the ultrasonic wave transmitted to said tubular test object by electrically controlling transmission/reception time-shift of the ultrasonic wave by said plurality of piezoelectric elements.

18. The ultrasonic testing equipment according to claim 13, comprising a follow-up apparatus for maintaining a relative position of said ultrasonic probe with respect to said tubular test object approximately constant in a plane orthogonal to the axial direction of said tubular test object.

19. The ultrasonic testing equipment according to claim 18, wherein

said follow-up apparatus comprises one or more non-contact displacement gauges for measuring a distance up to the external surface of said tubular test object, a positioning mechanism for moving said ultrasonic probe along two directions orthogonal to the axial direction of said tubular test object and a positioning control means for controlling the positioning mechanism;

and

said positioning control means controls said positioning mechanism based on the distance measured by said non-contact displacement gauges so that the relative position of said ultrasonic probe with respect to said tubular test object is approximately constant.

20. An ultrasonic testing method wherein, using the ultrasonic testing equipment according to claim 13, a flaw in all or part of said tubular test object is detected by relatively rotating said ultrasonic probe along the circumferential direction of said tubular test object and relatively moving the same along the axial direction of said tubular test object.

22. A manufacturing method of a seamless pipe or tube including:

a first process of manufacturing a seamless pipe or tube by piercing a billet; and

a second process of detecting a flaw in the seamless pipe or tube manufactured in said first process by using the ultrasonic testing method according to claim 20.