無損檢測工藝規(guī)程(液體滲透)

1、NJBST Co.,Ltd.QCD-015Rev.:0Page:1 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONPROCEDURE FOR LIQUID PENETRANT EXAMINATION液 體 滲 透 檢 驗 工 藝 規(guī) 程CONTROLLED 在控本 UNCONTROLLED 非在控本 COPY NO 副本編號：PREPARED BY DATE 日期： REVIEWED BY DATE 日期： APPROVED BY DATE 日期： NJBST Co.,Ltd.QCD-015Rev.:0Page:2 of 8Title

2、: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONDEMONSTRATION CERTIFICATION This is to certify that this procedure has been demonstrated on a test specimen with known defects to the satisfaction of the Authorized Inspector according to ASME Code Section V, T-150 as required by the Section Div.1, Appendi

3、x 8. Test Specimen No.: Demo. Report No.: NDE Level : AI: NJBST Co.,Ltd.QCD-015Rev.:0Page:3 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION制造廠 材料 牌號上海滬 滲透劑 HD-RS船助劑 顯像劑 HD-XS 廠 清洗劑 HD-BX 1. General 1.1 This procedure is applied to dye liquid penetrant examination of metal material and weldment

4、 for ASME Code items. 1.2 This procedure is only suitable for detecting the defects that are open to the surface of material or weldment. 1.3 This procedure shall be demonstrated to the satisfaction of the AI prior to implementation.2. Personnel 2.1 The personnel engaged in the penetrant examination

5、 shall be qualified and certified in accordance with the requirement of NJBST Co., Ltd.s“Written Practice for NDE Personnel Training Examination, Qualification and Certification”(No.:QCD-011). 3. Penetrant Materials 3.1 The penetrant materials is intended to include all penetrants, solvents or clean

6、ing agents, developers, etc, used in the examination process. 3.2 The liquid penetrant examination materials shall be designated and recommended, as shown in Table 3.2. The materials used for examination shall be the same type. Intermixing of penetrant materials from different families or different

7、manufacturers is not permitted. Table 3.2 Manufacturer Material Model Shanghai Penetrant HD-RS (Ship Brand) Developer HD-XS Cleaning Agent HD-BX 3.3 When examining austenitic stainless steel or titanium, all materials shall be analyzed individually for chlorine and fluorine content in accordance wit

8、h the procedure shown in T-641(b) of ASME Code Section V. The total chlorine plus fluorine content shall not exceed 1%of the residue by weight. The certificate of compliance from manufacturer shall be obtained. 3.4 When examining nickel base alloys, all materials shall be analyzed individually for s

9、ulphur content in accordance with the procedure shown in T-641(a) of Section V.The sulphur content shall not exceed 1%of the residue by weight. The certificate of compliance from manufacturer shall be obtained. 1 概述 11 本規(guī)程適用于ASME規(guī)范產(chǎn)品金屬材料和焊件著色液體滲透檢驗。 12 本規(guī)程僅適用于探測材料或焊件表面開口類缺陷。 13 本規(guī)程在執(zhí)行之前，須演示至AI滿意。 2

10、人員 2.1 從事液體滲透檢驗的人員必須是根據(jù)南京定色鈦業(yè)<<NDE人員培訓、考試、資格認證實施細則>>(資料號：QCD-011)進行考試和資格任命的合格人員。 3. 滲透材料 3.1 滲透材料包括檢驗過程中使用的所有滲透劑、溶劑或清洗劑、顯像劑等。 3.2 液體滲透探傷材料，必須是指定的和推薦的，見表3.2。檢驗使用的材料必須是同一類型的。不允許用不同類型的或不同制造廠的滲透材料混合使用表3.2 3.3 當檢驗奧氏體不銹鋼或鈦材時，必須根據(jù)ASME規(guī)范第卷T-641(b)中的程序，對所有材料分別分析氯和氟的含量。殘留氯和氟總含量不得超過殘留物重量的1%，必須有制造廠相

11、應(yīng)的合格證。 3.4 當檢查鎳基合金時，必須按照ASME規(guī)范第卷T-641(a)中的程序，對所有材料分別分析硫含量。硫含量不得超過殘留物重量的1%。必須有制造廠相應(yīng)的合格證。NJBST Co.,Ltd.QCD-015Rev.:0Page:4 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION后清洗評定、記錄顯像、檢驗干燥清潔施加滲透劑預清洗，干燥表面制備Post CleaningEvaluation and RecordDevelopment and InspectionDryingCleaningPenetrant Applicatio

12、nPrecleaning and DryingSurface Preparation 4. Examination Procedure 4.1 Examination Flow Chart as shown in Fig.4.1. Fig. 4.1 4.2 Surface Preparation Prior to all penetrant examination, the surface to be examined and all adjacent areas within at least 1in. (25.4mm) shall be dry and free of dirt, grea

13、se,lint, scale, welding flux, weld spatter， paint， oil and other extraneous matter. If necessary, surface shall be prepared by grinding or machining. 4.3 Precleaning 4.3.1 The areas to be examined and adjacent areas within at least 1in. (25.4mm) shall be cleaned using cleaning agent before the penet

14、rant is applied. 4.3.2 After cleaning, drying of the surface to be examined shall be accomplished by normal evaporation or with forced air, as appropriate. The minimum drying time shall ensure that the cleaning solution has evaporated prior to application of the penetrant. 4.4 Penetrant Application

15、4.4.1 The penetrant may be applied on the surface 4. 檢驗程序 4.1 檢驗程序流程圖見圖4.1 圖4.1 4.2 表面制備 所有滲透檢驗前，被檢工件表面及其附近至少為1英寸(25.4mm)的區(qū)域內(nèi)都應(yīng)干燥清洗干凈，不得有任何臟物、纖維屑、氧化皮、焊劑、油和其它外來物。必要時，應(yīng)對表面進行打磨或機加工。 4.3 預清洗 4.3.1 在施加滲透劑之前，被檢區(qū)域及其附近至少為1英寸(25.4mm)的區(qū)域內(nèi)均需用清潔劑進行清洗。 4.3.2 清洗后，通過適當?shù)姆椒?自然揮發(fā)或人工通風)，對被檢表面進行干燥；最少干燥的時間以保證在施加滲透劑之前清潔劑

16、已完全揮發(fā)為界。 4.4 施加滲透劑 4.4.1 可以用浸漬、涂刷或噴涂等任一合適的方法，在被檢工件NJBST Co.,Ltd.QCD-015Rev.:0Page:5 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION 滯留時間材料 型式 (min) 滲透劑 顯象劑鋁、鎂、 鑄件和焊縫 5 7鋼、黃銅、青銅、鈦 軋材-擠壓件 10 7高溫合金 鍛件，板材 Material Form Dwell Times (min) Penetrant DeveloperAluminum, magn- Castings & welds 5 7es

17、ium. steel, brass or bronze, titanium Wrought material- and high temperature extrusions, forgings, 10 7alloys plate of workpieces to be examined by any suitable means such as dipping, brushing or spraying. 4.4.2 The temperature of the penetrant and the surface to be examined shall not be below 500F(

18、100C) nor above 1250F(520C) throughout the examination period. When it is not practical to conduct a liquid penetrant examination within above temperature range, the examination procedure at the proposed lower or higher temperature range shall be qualified using a quench cracked aluminum block accor

19、ding to ASME Code Section V, T-653. 4.4.3 Penetration time is critical. The minimum dwell time is shown in Table 4.4.3. For suitable temperature, the area being examined shall remain wetted by the penetrant for the dwell time.Table 4.4.3 Recommended minimum dwell times 4.5 Excess Penetrant Removal E

20、xcess solvent removable penetrant shall be removed by wiping with a cloth or absorbent paper. The remaining traces shall be removed by lightly wiping the surface with a cloth or absorbent paper moistened with solvent. To avoid over removing, flushing the surface with solvent shall be prohibited. 4.6

21、 Developer Application 4.6.1 The developer shall be applied as soon as possible after excess penetrant removal and drying surface. The surface may be dried by normal evaporation before the developer is applied. The drying time shall be within 5 to 20 min. 4.6.2 The developer shall be applied by spra

22、ying. A uniform thin coating shall be provided and the coating thickness shall be suitable. 4.6.3 Prior to applying wet developer to the surface, the developer must be thoroughly agitated. 4.6.4 Dipping or flooding the part with non-aqueous developer is prohibited, since it will dissolve the penetra

23、nt in the discontinuities through its solvent action. 4.7 Interpretation 4.7.1 Developing time for final interpretation begins表面施加滲透劑。 4.4.2 在整個檢驗期間，滲透劑和被檢表面的溫度不得低于500F(100C)，不得高于1250F(520C)。當在上述溫度范圍內(nèi)不能滿足時，則按照ASME規(guī)范第V卷T-653，對提議采用的溫度范圍，使用有淬火裂紋的鋁試塊進行驗證。 4.4.3 嚴格控制滲透時間，最小滯留時間見表4.4.3。適當?shù)臏囟葪l件下，在滯留時間內(nèi)，被檢區(qū)

24、域必須用滲透劑保持潮濕。表4.4.3 推薦的最少滯留時間 4.5 多余滲透劑的清除 多余滲透劑必須用布或吸紙擦去，剩下的痕跡必須用蘸有溶劑的布或紙在表面輕輕地擦去。為了防止清洗過分，禁止用溶劑清洗表面。 4.6 施加顯像劑 4.6.1 多余的滲透劑被清除且工件干燥后，必須盡快地施加顯像劑。顯像劑施加之前，工件表面可以自然揮發(fā)干燥，干燥時間必須在5-20分鐘以內(nèi)。 4.6.2 施加顯像劑必須采用噴涂法，薄且均勻，涂層厚度適中。 4.6.3 在施加濕型顯像劑至工件表面之前，顯像劑必須充分攪拌。 4.6.4 禁用非水濕顯像劑浸漬或灌洗工件，因非水濕顯像劑會通過溶解作用將缺陷中的滲透劑溶解掉。 4.7

25、 判斷 4.7.1 最終判斷顯像時間應(yīng)從施加NJBST Co.,Ltd.QCD-015Rev.:0Page:6 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATIONas soon as a wet developer coating is dry. The minimum developing time shall be 7min. 4.7.2 Final interpretation shall be made within 7 to 60 min after the requirements of Para. 4.7.1 are sat

26、isfied. 4.7.3 The developing trace can be examined either by natural light or artificial light. A minumum light intensity of 50 fc (500Lx) is required to ensure adequate sensitivity during the examination and evaluation of indications. 4.7.4 The surface shall be divided into several parts to be exam

27、ined if the surface is so large that the examination can not be finished within the given time. The developing condition can be observed either by eyes or by means of a magnifier. 4.8 Post-cleaning The penetrant materials shall be clearly removed away from parts after examination. The post cleaning

28、must be performed if remaining penetrant materials can result in corrosion by the combination with other materials during the operation. The suitable cleaning process shall be adopted for post cleaning such as flushing with water, mechanical cleaning, solvent soaking, etc. The developer shall be cle

29、aned as soon as possible after examination if the part requests the post cleaning so as to avoid it condensed on the part. 5. Evaluation of Indications 5.1 Broad areas of pigmentation which could mask indications of discontinuities are unacceptable and such areas shall be cleaned and reexamined. 5.2

30、 An indication is the evidence of a mechanical imperfection. Only indications with major dimensions greater than 1/16in (1.6mm) shall be considered relevant. 5.3 Linear indications are those indications in which the length is more than three times the width . Rounded indications are indications whic

31、h are circular or ellipsoidal with the length less than three times the width. 5.4 Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant. Surface conditioning may proceed before the reexamination. 5.5 The indication of a discontinuity may be large

32、r than the discontinuity that causes it; however, the size of the indication is the basis of acceptance or rejection. 6. Acceptance Standards The following relevant indications are unacceptable:a. any cracks or relevant linear indications; b. relevant rounded indications greater than 3/16in. (4.8mm)

33、; c. four or more relevant rounded indications in a line separated by 1/16 in. (1.6mm) or less (edge to edge);干顯像劑后或從濕顯像劑涂層干燥后立即起算，不得少于7分鐘。 4.7.2 在滿足4.7.1 要求后，最終判斷必須在7-60分鐘內(nèi)作出。 4.7.3 顯像痕跡可以通過自然光或人工白光進行檢驗，要求最小燈光強度為50fc(500LX)，以保證在檢驗和評價顯示過程中有充分的靈敏度。 4.7.4 如果受檢表面太大，無法在規(guī)定時間內(nèi)完成檢驗，則應(yīng)將表面分成幾個部進行檢驗。顯像情況可以用肉眼

34、或放大鏡進行觀察。 4.8 后清洗 檢驗后，必須完全清除工件上的滲透材料，如果殘余滲透材料在操作過程中與其它材料混合后會導致腐蝕，則必須進行后清洗。可以采用如用水沖洗、機械清潔、溶劑浸泡等適當?shù)那鍧嵐ぷ?，來進行后清洗。 如果需要后清洗，則檢驗后必須盡快進行，以免顯像劑凝固在工件上。 5. 顯示評價 5.1 大面積顏料沉淀會掩蓋缺陷顯示，是不合格的，這些區(qū)域應(yīng)清洗干凈并重新檢驗。 5.2 明顯的機械性不連續(xù)為其顯現(xiàn)特征，只有在顯示主要尺寸大于1/16英寸(1.6mm)時，才是缺陷顯示。 5.3 線性缺陷是指長度大于三倍寬度的缺陷。面形缺陷是指長度小于3倍寬度的圓形或橢圓形缺陷。 5.4 任何有

35、疑問或難以判斷的顯示，必須重新檢驗以確認是否是缺陷顯示，重新檢驗前可先作表面修整。 5.5 缺陷顯示可能大于缺陷本身，但是以顯示的尺寸作為合格與否的依據(jù)。 6. 合格標準 下列缺陷顯示為不合格： a.任一裂紋或相應(yīng)的線性缺陷; b.大于3/16英寸（4.8mm）的面形缺陷； c.一條直線上有4個或4個以上的面形缺陷，其邊界到邊界間距離等于或小于1/16英寸(1.6mm)NJBST Co.,Ltd.QCD-015Rev.:0Page:7 of 8Title: PROCEDURE FOR LIQUID PENETRANT EXAMINATION 7. The repaired area shall be reexamined according to the original examination procedure. 8. Report The liquid penetrant examination report shall include examination condition, used penetrant material and a sketch of parts examined and examination results. The report shall be pre