1、第 頁共12頁第 頁共12頁科恩馬特殊過程裝備(常熟)有限公司KNMSPECIALPROCESSEQUIPMENT(CHANGSHU)CO.,LTD.TechnicsRegulationforMagneticparticleExamination作業(yè)指導(dǎo)書OperationGuidebook編制PreparedBy：審核CheckedBy：批準(zhǔn)ApprovedBy磁粉檢測通用工藝規(guī)程TechnicsRegulationforMagneticparticleTest1主要內(nèi)容和適用范圍本規(guī)程規(guī)定了磁粉檢測人員資格、所用設(shè)備、器材、檢測技術(shù)和質(zhì)量分級等。Thisregulationdefineth

2、equalificationofMagneticparticletestperson,facility,equipment,examiningmethodandqualitygrade.本規(guī)程按JB/T4730.4-2005的要求編寫。適用于鐵磁性材料的機(jī)加工件、焊縫、板材坡口面等表面和近表面缺陷的檢測，不適用于非磁性材料及磁性材料與非磁性材料結(jié)合部位的檢測。滿足GB150、壓力容器安全技術(shù)監(jiān)察規(guī)程和相關(guān)標(biāo)準(zhǔn)的要求。ThisregulationiscompilebasedonJB/T4730.4-2005.Itissuitableforferro-magneticmaterial,suchas

3、machiningworkpiece,weldseam,groovefaceofplateandnearsurfaceflaw.Theregulationisnotsuitablefornon-magneticsubstanceandbondedblockmadewithferro-magneticmaterialandnon-magneticsubstance.TheregulationsatisfiedwithGB-150,Supervision,RegulationonSafetyTechnologyforPressurevesselandcorrelativestandard.本規(guī)程適

4、用于非熒光濕磁粉的連續(xù)磁化技術(shù)。ThisregulationissuitableforcontinuousMagnetizingtechniqueofnon-fluorescentwetmagneticparticle.1.4檢測工藝卡是本規(guī)程的補充。由II級或以上人員按合同及本規(guī)程和JB/T4730.4-2005編制，其參數(shù)規(guī)定得更具體。Examineprocesschartisasupplementofthisregulation.ThechartispreparedbegradeIIpersonormorethangradeIIperson,andthechartispreparedfo

5、llowingcontract,thisregulationandJB/T4730.4-2005.Theparameterinprocesschartismoredetailed.2檢測人員2Testers檢測人員必須經(jīng)過培訓(xùn)，按特種設(shè)備無損檢測人員資格考核與監(jiān)督管理規(guī)則取得與其工作相適應(yīng)的資格證書，并負(fù)相應(yīng)的技術(shù)責(zé)任。AllpersonnelengagedinMagneticParticleexaminationmustbetrainedtechnicallyandexaminedandappraisedinaccordancewithSpecialEquipmentNondestructi

6、veTestingandSupervisingStandard.Thesepersonshouldhavecorrespondingtechnicalresponsibility.Andtakecorrespondingtechnicalresponsibilities.檢測人員每年應(yīng)檢查一次身體，其未經(jīng)矯正或經(jīng)矯正的近（距）視力和遠(yuǎn)（距）視力應(yīng)不低于5.0（小數(shù)記錄值為1.0），不得有色盲。Thepersonnelengagedinnondestructivetestingmusthaveexcellentphysicalconditionsanddophysicalcheck-uponce

7、ayear,correctedeyesightmustnotbelowerthan1.0.Thepersonnelengagedinmagneticpowdertestingandpenetrationtestingmustnotbecolorblindandweak.3設(shè)備、工具和材料I、II級人員按下列條件和工藝卡要求選用設(shè)備、工具和材料。PersonwithgradeIandIIshouldchoosefacility,equipmentandmaterialasfollowingconditionandchart.磁化設(shè)備及校驗MagnetizingEquipmentandCalibr

8、ation磁化設(shè)備見表1。MagnetizingEquipmentisshownasTable1.表1磁粉檢測設(shè)備（按公司現(xiàn)有設(shè)備修改下表）制造廠/Manufactory型號/Model結(jié)構(gòu)形式/Type提升力/Liftingpower備注/Note江蘇射陽探傷機(jī)廠/JiangsuSheyangdetectiveequipmentcompanyDCE-E2便攜式/portabletypeAC提升力三118NACLiftingpower三118N交叉磁軛/crossyoke江蘇射陽探傷機(jī)廠/JiangsuSheyangdetectiveequipmentcompanyDCE-C便攜式/porta

9、bletypeAC提升力三118NACLiftingpower三118N交叉磁軛/crossyoke注：提升力用試塊測定，當(dāng)使用磁軛最大間距時，交流電磁軛至少應(yīng)有45N的提升力，直流電磁軛至少應(yīng)有177N的提升力，交叉磁軛至少應(yīng)有118N的提升力（磁極與試件表面間隙W0.5mm）。Note:Liftingforceistestedbyshim.Whenusethemaximumyokedistance,theliftingpowerofalternatingcurrentyokesshouldatleast45Nand177NforDCyoke.Theliftingpowerofcrossyo

10、kesatleast118N.（thedistancebetweenmagneticpoleandshimW0.5mm）3.1.2磁化設(shè)備的校驗3.12CalibrationofMagnetizingEquipment（1）電流表精度校驗（1）Calibrationofamperemeterprecision第 頁共12頁第 頁共l2頁磁粉檢測設(shè)備的電流表，至少半年校驗一次。當(dāng)設(shè)備進(jìn)行重要電氣修理或大修后，應(yīng)進(jìn)行校驗。Magnetizingequipmentwithanammetershallbecalibratedatleastoncehalfayear,orwhen-evertheequi

11、pmenthasbeensubjectedtomajorelectricrepair,periodicoverhaul,ordamage.電磁軛提升力校驗LiftingpowerofYokes電磁軛的提升力至少半年校驗一次。在磁軛損傷修復(fù)后應(yīng)重新校驗。Themagnetizingpowerofelectromagneticyokesshallbecheckedtwiceayear.Themagnetizingpowerofallyokesshallbecheckedwhenevertheyokehasbeendamagedorrepaired.3.2靈敏度試件Shimofsensitivity

12、標(biāo)準(zhǔn)試片主要用于檢驗磁粉檢測設(shè)備、磁粉和磁懸液的綜合性能，了解被檢工件表面有效磁場強(qiáng)度和方向、有效檢測區(qū)以及磁化方法是否正確。標(biāo)準(zhǔn)試片有A1型、C型、D型和Ml型。其規(guī)格、尺寸和圖形見表2。Thenormalshimmainlyusedforcheckingmagneticparticletestingmachine,magneticparticleandmagneticsuspension.Tocheckwhethertheeffectivemagneticdensity,effectivecheckoutzoneandMagnetizingmethodarecorrectornot.The

13、typeofnormalshimareAl,C,DandMl.ThesizeandgraphareshownasTable2.圖形和尺寸，mmgraphandsize,mm表2標(biāo)準(zhǔn)試片的類型、規(guī)格和圖形類型規(guī)格：缺陷槽深試片厚度，msize:depthofdefect/thicknessofshim,m5Fiiiiiii5.5X5.分割線人工缺陷型型Qmm傘mmQmm注：型標(biāo)準(zhǔn)試片可剪成個小試片分別使用。Note:NormalshimoftypeCcanbeuseddivided5pieces.磁粉檢測時一般應(yīng)選用A1-30/100型標(biāo)準(zhǔn)試片。當(dāng)檢測焊縫坡口等狹小部位，由于尺寸關(guān)系，A1型標(biāo)準(zhǔn)

14、試片使用不便時，一般可選用C-15/50型標(biāo)準(zhǔn)試片。為了更準(zhǔn)確地推斷出被檢工件表面的磁化狀態(tài)，當(dāng)用戶需要或技術(shù)文件有規(guī)定時，可選用D型或M1型標(biāo)準(zhǔn)試片。Asarule,modeltestpiececanbechoseA1-30/100.IfitisnotconvenienttouseA1modeltestpieceforsensitivitytotestthenarrowparts,suchasweldgroove,becauseofsmallsize,C-15/50modeltestpieceforsensitivitycanbeemployed.Forcheckingthemagnetiz

15、ingsituationofthesurfacewellandtruly,andthereismentionintechniquedocument,canchoosetypeDortypeM1.磁場指示器MagneticParticleFieldIndicator磁場指示器的作用與標(biāo)準(zhǔn)試片相同，但它僅是一種粗略的校驗。Thefunctionofmagneticparticlefieldindicatorissameasnormalshim,buttheindicatorisacursorycalibration.靈敏度試件的使用Modeltestpieceforsensitivity標(biāo)準(zhǔn)試片：

16、將試片無人工缺陷的表面朝上，使試片與被檢面接觸良好，必要時可用透明膠帶將其整體體貼在被檢面上，但人工缺陷處不得貼覆。試驗時邊磁化邊澆灑磁懸液，以人工缺陷清晰顯示來確定磁化規(guī)范、磁化方向和有效磁化范圍。(1)Modeltestpiece:Theshimshallbeattachedtothesurfacetobeexamined,suchthattheartificialflawsideoftheshimistowardtheinspectedsurface.Makesuretheshimandsurfacemeetwell,ifneed,usecellulosetapefixontheinsp

17、ectedsurface.Buttheartificialflawshouldnotbecover.磁場指示器：將其平放于被檢面上，邊磁化施加磁懸液，使缺陷清晰顯示來估判。(2)MagneticParticleFieldIndicator:Puttheindicatorontheinspectedsurface,whenthemagneticsuspensionareappliedsimultaneouslywiththemagnetizingforce,lettheflawappearonit.3.3磁粉及磁懸液MagneticParticleandMagneticSuspension3.3

18、.1磁粉：采用BW-1型磁膏或噴灌。MagneticParticle:usetypeBW-1magneticcreamorirrigation.3.3.2磁懸液：一般載體媒介為水，每升加1025g磁粉。磁懸液濃度的測定采用磁懸液濃度測定管進(jìn)行。磁懸液濃度應(yīng)按受檢部位表面粗糙及使用方式確定，一般其沉淀濃度應(yīng)控制在1.22.4Ml/100mL的范圍內(nèi)或按制造廠的推薦配比。MagneticSuspension:Take10-25gmagneticparticleperlitrewater.Theconcentrationofmagneticsuspensionismeasuredbyconcentr

19、ationcentrifugetube.Theconcentrationofmagneticsuspensionsolutionusedcircularlymustbedeterminedregularly.Asarule,in100MLofmagneticsuspensionsolution,precipitationvolumeofmagneticpowderis1.22.4ML.Surfacepreparations若被檢表面凹凸不平，以致可能遮蓋缺陷顯示時，應(yīng)通過磨削工機(jī)加工來制備。Whentheinspectedsurfaceisrugged,andcaneffecttheindic

20、ationofdefects,mustmachinetheinspectsurface.4.2若被檢面為焊接接頭，其兩側(cè)各100mm范圍內(nèi)不得有松散的銹蝕、氧化皮、飛濺、油污或其他粘附磁粉、妨礙檢測的污物。Nogrease,rust,oxideskin,spatterorothermagneticpowderadherencemattersonbothside(100mm)ofweldingseam.4.3被檢工件的表面粗糙度不大于mmSurfaceroughness(R/oftestedworkpiecesmustnotbemorethan12.5m.4.4如果被檢工件表面殘留有涂層，當(dāng)涂層

21、厚度均勻且不超過0.05mm,不影響檢測結(jié)果時，經(jīng)合同各方同意，可以帶涂層進(jìn)行磁粉檢測。Ifmagneticpowderisdifficulttoremovefrominspectedsurface,andthethicknessofcoatislessthan0.05mm,whichcannoteffecttheexamineresult,candomagneticparticleexaminationwiththecoat.檢測時機(jī)TestingTime筒體焊接接頭校圓且內(nèi)部缺陷返修合格后進(jìn)行。5.1.Forweldjointonshell,testingmustbecarriedouta

22、fterre-rollingandrepairing.封頭在成型且內(nèi)部缺陷返修合格后進(jìn)行。Fortheheadwithrepairing,testingmustbecarryoutaftermoldingandrepairing.機(jī)加工件加工成成品，以最終熱處理后檢測的結(jié)果為準(zhǔn)。Magneticpowdertestingforfastnersandforgedpiecesmustbeconductedafterthefinalheat-treatmentunlessadditionallyrequested.有延遲裂紋傾向的材料，應(yīng)在焊后24小時之后進(jìn)行。Formaterialsofdelay

23、edcracking,testingmustbecompletedwithin24hafterwelded.6磁化操作MagnetizationProcedure采用交流電磁軛和交叉磁軛濕法連續(xù)磁化技術(shù)。I、II級人員每天檢測前，應(yīng)對系統(tǒng)綜合性能、磁懸液濃度和磁懸液潤濕性能等進(jìn)行檢驗，合格后方可進(jìn)行操作。Forthistechnique,alternatingcurrentelectromagneticyokesandcrossmagneticyokescanbeused.Beforetesting,thetestermustcheckcombinationpropertyofsystem,c

24、oncentrationofmagneticsuspensionandwettingabilityofmagneticsuspension.磁軛磁化規(guī)范的確定(1)磁軛的提升力應(yīng)符合表1注的規(guī)定。(1)TheliftingpowerofyokesmustfollowTable1.磁軛的磁極間距應(yīng)控制在75mm200mm之間，檢測的有效區(qū)域為兩極連線兩側(cè)各50mm的范圍內(nèi)，其磁化范圍應(yīng)根據(jù)標(biāo)準(zhǔn)試片實測結(jié)果來選擇。有效磁化區(qū)域每次應(yīng)有不少于15mm的重疊。(2)Spacebetweenmagneticpolesofmagneticyokemustbewithintherangeof75200mm.

25、Theeffectiveareatestedreaches50mmoutsideonbothsidesonthelineofbothpolesofmagneticyoke,andtheremustbe15mmoverlappedmagnetizedareaeachtime.使用交叉磁軛裝置時，四個磁極端面與檢測面之間應(yīng)盡量貼合，最大間隙不應(yīng)大于1.5mm。應(yīng)連續(xù)拖動檢測，檢測速度應(yīng)均勻，一般不應(yīng)大于4m/min。用標(biāo)準(zhǔn)試片試驗時，其圓形及十字線各方向均應(yīng)明顯顯示，否則不得使用，以防漏檢。Whenmagnetismyokesareused,theyokessurfaceshouldabutins

26、pectedsurfacemaximum.Themaximumdistancecannotmorethan1.5mm.Thetestingspeedshouldbeequality,andnomorethan4m/min.Whenusemodeltestpiece,thecircleandreticleshouldindicateclearly,otherwise,cannotuse.6.2采用連續(xù)磁化方法，在通電磁化的同時，施加水磁懸液，持續(xù)磁化時間為13s，為保證磁化效果應(yīng)至少反復(fù)磁化2次，停施磁懸液至少1s后才可停止磁化。Forthecontinuousmethod,applicatio

27、nofmagneticpowderandmagneticsuspensionsolutionmustbecompletedduringthecourseofmagnetization.Magnetizationtimeis1-3s.Itisveryimportantmagnetization2timestoensuremagneticeffect,and1smustbetakenaftermagnetization.被檢工件的每一被檢區(qū)除交叉磁軛磁化外，至少進(jìn)行2次獨立的檢測，2次檢測的的磁力線方向應(yīng)大致相互垂直。Atleasttwoseparateexaminationsshallbeper

28、formedoneacharea.Thelinesofmagneticfluxshallbeapproximatelyperpendicularofthoseusedduringthefirstexamination.被檢件修復(fù)后的檢測Retestafterrepairing被檢件經(jīng)修補的區(qū)域按本規(guī)程第6.1條至第6.3條的程序重新檢測。Retestingmustbeperformedaccordingtorelatedregulationsof6.16.3afterrepairing.退磁及后處理Demagnetization磁粉材料或剩磁干擾后序加工或使用時，檢測后可采用適當(dāng)?shù)姆椒ㄇ謇砘蛲?/p>

29、磁。Workpiecesmustbedemagnetizedaftertesting,ifitisrequired.AppraisalAndRecordsofMagneticTrace磁痕的分類和處理AppraisalofMagneticTrace磁痕顯示分為相關(guān)顯示、非相關(guān)顯示和偽顯示。Therearethreeindications:correlativeindication,non-correlativeindicationandpseudo-indication.長度與寬度之比大于3的缺陷磁痕，按條狀磁痕處理；長度與寬度之比不大于3的磁痕，按圓形磁痕處理。Magnetictraceso

30、fdefects,withalength-widthratiolargerthan3,mustbetreatedaslineardefects,andthosewithalength-widthratiolessthanorequalto3willbetreatedasrounddefects.長度小于0.5mm的磁痕不計。Magnetictracesofdefectswiththelengthlessthan0.5mmcanbeneglected.兩條或兩條以上缺陷磁痕在同一直線上且間距不大于2mm時，按一條磁痕處理，其長度為兩條磁痕之各加間距。Providedthattwoormorema

31、gnetictracesofdefectsareonthesamelineandthespacebetweenthemislessthanorequalto2mm,theywillberegardedasone,andthelengthisthesumofthetwodefectsplusspace.缺陷磁痕長軸方向與工件（軸類或管類）軸線或母線的夾角大于或等于30時，按橫向缺陷處理，其他按縱向缺陷處理。Whentheincludedanglebetweenthelongaxisdirectionofmagnetictraceofdefectsandtheaxisofworkpiecesorb

32、usbarislargerthanorequalto300,theywillbedealtwithasbroadwisedefectsandtherestaslengthwiseones.7.2缺陷磁痕的觀察Observationofmagnetictracedefects7.2.1缺陷磁痕的觀察應(yīng)在磁痕形成后立即進(jìn)行。Observationmustbecarriedoutaftermagnetictraceformingassoonaspossible.非熒光磁粉檢測時，缺陷磁痕的評定應(yīng)在可見光下進(jìn)行，通常工件被檢表面可見光照度應(yīng)大于或等于lOOOlx；當(dāng)現(xiàn)場采用便攜式設(shè)備檢測，由于條件所限

33、無法滿足時，可見光照度可以適當(dāng)降低，但不得低于500lx。Whennon-fluorescentmagneticpowdertestingmethodisemployed,appraisalofmagnetictracesmustbeperformedundervisiblelight,andtheilluminanceofvisiblelightmustnotbehigherthanl000lxonthetestedsurfaceofworkpieces.Whenhandytestingmachineisemployed,illuminanceofvisiblelightmustnotbeh

34、igherthan500lx除能確認(rèn)磁痕是由于工件材料局部磁性不均或操作不當(dāng)造成的之外，其他磁痕顯示均應(yīng)作為缺陷處理。當(dāng)辨認(rèn)細(xì)小磁痕時，應(yīng)采用210倍放大鏡進(jìn)行觀察。The210foldmagnifiercanbeusedtoobservethesmallandthinmagnetictracesofdefects.缺陷磁痕顯示記錄Recordofmagnetictracedefects缺陷磁痕的顯示記錄可采用照相、錄像各可剝性塑料薄膜等方式記錄，同時應(yīng)用草圖標(biāo)示。Picture,kinescopeandanyothermethodcanbeusedtorecord,atthesametime

35、,makedraftofthedefects.7.4復(fù)驗Retest當(dāng)出現(xiàn)下列情況之一時，需要復(fù)驗，復(fù)驗按本規(guī)程第6.1條至6.3條的程序重新檢測。Retestingmustbeperformedaccordingtorelatedregulationsof6.16.3.Retestingisnecessaryunderanyconditionasfollows:(1)檢測結(jié)束時，用標(biāo)準(zhǔn)試片驗證檢測靈敏度不符合要求時；Whenthetestingisover,sensitivityistestedunacceptablewiththetestpieceforsensitivity.(2)發(fā)現(xiàn)檢

36、測過程中操作方法有誤或技術(shù)條件改變時；Operationmethodsarefoundinappropriateduringthecourseoftesting.合同各方有爭議或認(rèn)為有必要時。(2)Supplierandpurchaserareindisputewitheachother,orforotherreasons.磁粉檢測質(zhì)量分級Levelappraisalofdefects7.5.1不允許存在的缺陷Defectsbelowarenotallowedtoexist.(1)不允許存在任何裂紋和白點；Cracksandwhitespots;(2)堅固件和軸類零件不允許任何橫向缺陷顯示。T

37、ransversedefectsonfastenerandshaftpart.焊接接頭的磁粉檢測質(zhì)量分級Levelappraisalofdefectsinweldjoint焊接接頭的磁粉檢測質(zhì)量分級見表3。LevelappraisalofdefectsinweldjointisshownasTable3.表3焊接接頭的磁粉檢測質(zhì)量分級bleLev3elappraisalofdefectsinweldjoint等級/level線性缺陷磁痕/lineardefects圓形缺陷磁痕(評定框尺寸為35mmxl00mm)/rounddefects(areaofevaluationis35mmxioomm

38、)I不允許/inadmissibilitydW1.5,且在評定框內(nèi)不大于1個/dW1.5,andnomorethan1intheevaluatedareaII不允許/inadmissibilitydW3.0，且在評定框內(nèi)不大于2個/dW3.0,andnomorethan2intheevaluatedareaIIILW3.0dW4.5，且在評定框內(nèi)不大于4個/dW4.5,andnomorethan4intheevaluatedareaIV大于III級/greaterthanlevelIII注：L表示線性缺陷磁痕長度，mm；d表示圓形缺陷磁痕長徑，mm。Note:Lshowthelengthoflineardefects,mm;dshowthediameterofrounddefects,mm.受壓加工部件和材料磁粉檢測質(zhì)量分級Levelappraisalofdefectsforpressurepart