Ultrasonic Testing of Large Cast and Forged Components

Release Date:

2021/10/16

Ultrasonic testing (UT) is an inspection method used for quality control in the metallurgical industry and the equipment manufacturing sector. A major advantage of UT is its strong capability to detect planar defects such as cracks. The strength of the material The higher the material’s strength, the more sensitive it is to crack-related damage, and the more pronounced the reduction in strength caused by cracks—for example, in high-strength steels. Therefore, ultrasonic testing methods that aim to orient the ultrasonic beam perpendicular to the crack surface are widely used in nondestructive testing. The primary choice of members. During production, porosity and cracking defects are frequently detected in large forgings, typically manifesting as ultrasonic testing results exceeding acceptance limits—either due to dense clusters of defects or individual defects that exceed the threshold.

Exceedance of defect limits in ultrasonic testing has become the primary criterion for scrapping large forgings. Therefore, research into the prevention of internal defects in large forgings and the underlying principles governing their repair not only holds theoretical significance but also It has broader practical significance.

Nondestructive testing can replace destructive testing, but this does not mean that destructive testing is entirely unnecessary. Nondestructive testing relies on the physical properties of test specimens to assess the severity of defects and the strength of raw materials or welds. However, this method cannot yield results that are exactly the same as those obtained from destructive testing; it can only provide surrogate characteristics. The acceptance criteria for defects detected by ultrasonic testing may be based on the following two aspects:

(1) Quality management standards allow for a certain margin of tolerance in the assessment of defects in materials and welds. Such assessments generally prioritize safety to a sufficient degree.

(2) The skill adaptability criterion must take into account the service conditions of both the base material and the weld. Although its assessment is more complex than that of the quality management criterion, it can help minimize quality over-specification.

Generally speaking, defects that exceed the quality management benchmark level are not necessarily absolutely unacceptable, nor are they always required to be repaired; the final determination is made based on a more detailed assessment of the relevant conditions. A detailed evaluation is required to make the determination. The results of fracture mechanics tests on the material can serve as critical data for this assessment. Large castings, forgings, and structural components are subjected to ultrasonic testing, After defects are detected within a workpiece, accurate analysis of these defects plays a crucial role in improving subsequent smelting and ingot casting as well as forging processes. Large castings, forgings, and their structures These components are typically located in the most critical parts of the machine, where they experience high and complex loading conditions and must be free of porosity defects. However, due to the unique and intricate nature of large casting and forging manufacturing technologies, such defects are frequently encountered during production. Large forgings are prone to porosity and cracking defects; when ultrasonic flaw detection reveals defects exceeding allowable limits, this becomes the primary reason for repair welding of large castings and for scrapping forgings. During the manufacturing process, the metallurgical quality of steel and The solidification characteristics inevitably give steel ingots numerous inherent defects, such as inclusions, porosity, and cracks. Taking forgings as an example, although advances in smelting and casting technologies have reduced the number and size of these defects, , the shape, distribution, and composition will all be significantly improved; however, defects will still remain. If the forging undergoes plastic deformation under unfavorable stress conditions, with uneven strain distribution and temperature distribution, All of these factors provide the conditions for the formation and propagation of porosity defects and crack defects.

In recent years, new standards and technologies in ultrasonic testing have been continuously refined, thereby increasing the urgent need for skilled professionals with expertise in these cutting-edge technologies. There is an immediate demand for a cohort of high-caliber, highly qualified personnel. Professional ultrasonic testing personnel for large castings, forgings, and structural components must not only be thoroughly familiar with domestic industry standards but also have a solid understanding of relevant international standards (such as ASTM, ASME, DIN, JIS, EN). etc.). Currently, there are few books and academic papers dedicated to the nondestructive testing of large castings and forgings. This paper provides a relatively comprehensive overview of ultrasonic testing for such components, with particular emphasis on various types of large forgings, such as steam turbine rotors and cylindrical parts. Ultrasonic testing of forged components, vacuum-treated forgings, steel plates, clad plates, pressure vessel forgings made of carbon and alloy steels subjected to vacuum treatment and quenching-and-tempering, as well as austenitic steel forgings. A distinctive feature of this paper is that it not only This paper introduces the process characteristics of large castings and forgings, and discusses their physical properties as well as the causes of metallurgical defects and the ultrasonic signatures associated with these defects. The methods presented in this paper are all current national… A generally applicable method with practical operational significance.

In which industrial sectors are nondestructive testing devices used?

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In which industrial sectors are nondestructive testing devices used?

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To further carry forward the spirit of Lei Feng and promote the volunteer ethos of “dedication, friendship, mutual assistance, and progress,” in accordance with the spirit of the Henan Provincial Association for Science and Technology’s “Notice on Launching a Centralized ‘i-Science Popularization’ Science and Technology Volunteer Service Campaign in the Spirit of Lei Feng,” Luoyang Weicheng Engineering Testing Co., Ltd. responded enthusiastically to the call and organized a science popularization event on the safe operation of forklifts. On March 4, our company meticulously planned and conducted an emergency response drill for special equipment—forklift accidents—and invited several nearby companies that use forklifts to observe the exercise. The purpose of this drill was to simulate real-world working conditions, specifically the sudden occurrence of an accident during the process of using a forklift to handle goods.

2024-03-05

The 10th Anniversary Gratitude Celebration of Luoyang Weicheng Engineering Testing Co., Ltd. Concludes Successfully

On the afternoon of December 29, 2023, Weicheng Testing Co., Ltd. held a grand gratitude celebration—“Our Ten Years”—inviting distinguished guests, including Mr. Jia Hong, Director and Vice Chairman of the Titanium-Zirconium Industry Development and Application Center of the China Equipment Management Association, as well as Mr. Lu Fusheng, Executive Deputy Director, Vice Chairman, and Secretary-General, along with clients and partners, to jointly witness this milestone occasion. The first segment of the event: A Decade of Development The event officially commenced at 2:00 p.m., with the company welcoming all attendees

2024-01-11

In 2023, Luoyang Weicheng Engineering Testing Co., Ltd. Successfully Held the “Intensive Training and Competition” — Gamma-Ray Radiographic Inspection Emergency Drill

On October 11, Luoyang Weicheng Engineering Testing Co., Ltd. held a large-scale training and competition—specifically, a γ-ray radiographic inspection radiation emergency response drill—under the theme “Everyone Talks About Safety, Everyone Knows How to Respond to Emergencies.” The event invited leaders from the provincial, municipal, and district levels to attend and observe. Prior to the start of the emergency response drill, Cui Songbiao, General Manager of Luoyang Weicheng Engineering Testing Co., Ltd., and Gong Aifeng, Deputy General Manager, extended a warm welcome to the visiting provincial, municipal, and district leaders and pledged that Weicheng Testing would consistently focus on enhancing its professional technical expertise and emergency response capabilities as key drivers for corporate safety management.

2023-10-19

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