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WO2025027359A1 - Inspection de soudure en cours de traitement - Google Patents

Inspection de soudure en cours de traitement Download PDF

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Publication number
WO2025027359A1
WO2025027359A1 PCT/IB2023/000478 IB2023000478W WO2025027359A1 WO 2025027359 A1 WO2025027359 A1 WO 2025027359A1 IB 2023000478 W IB2023000478 W IB 2023000478W WO 2025027359 A1 WO2025027359 A1 WO 2025027359A1
Authority
WO
WIPO (PCT)
Prior art keywords
weld
probe
layer
cooling
nondestructive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IB2023/000478
Other languages
English (en)
Inventor
Michael Edwin WRIGHT
Janusz Bialach
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Liburdi Engineering Ltd
Original Assignee
Liburdi Engineering Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Liburdi Engineering Ltd filed Critical Liburdi Engineering Ltd
Priority to PCT/IB2023/000478 priority Critical patent/WO2025027359A1/fr
Publication of WO2025027359A1 publication Critical patent/WO2025027359A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
    • G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
    • G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
    • G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
    • G01N27/9013—Arrangements for scanning
    • G01N27/902—Arrangements for scanning by moving the sensors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K31/00—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups
    • B23K31/12—Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by only one of the preceding main groups relating to investigating the properties, e.g. the weldability, of materials
    • B23K31/125—Weld quality monitoring

Definitions

  • One or more aspects of embodiments according to the present disclosure relate to welding systems, and more particularly to a system and method for in-process weld inspection.
  • welding is used in numerous applications, for joining pieces of metal. Under certain conditions, some welding processes may form welds that include defects.
  • a system including: a weld head; and a nondestructive weld defect sensing probe, the weld head being configured to move relative to a substrate and to form a weld layer on the substrate, and the nondestructive weld defect sensing probe being configured to move relative to the substrate, at a distance of less than 50 centimeters from the weld head, and to sense defects in the formed weld layer.
  • the substrate includes two pieces and the forming of the weld layer includes forming the weld layer on a line of contact between the pieces.
  • the pieces form a channel along the line of contact.
  • the weld layer is a layer of a plurality of layers formed, or to be formed, to join the two pieces.
  • each of the two pieces is a plate.
  • each of the two pieces is a pipe.
  • the nondestructive weld defect sensing probe includes an eddy current probe.
  • the eddy current probe includes two outer coils and a plurality of inner coils, an inner coil of the plurality of inner coils having a smaller diameter than an outer coil of the outer coils.
  • the system further includes a defect sensing circuit connected to the outer coils, the defect sensing circuit being configured to drive a first coil of the outer coils with a drive signal suitable for the detection of subsurface defects.
  • the nondestructive weld defect sensing probe is separated from the weld layer by a gap.
  • the gap has a height of between 0.05 millimeters and 0.5 millimeters.
  • the system further includes a cooling system for cooling the nondestructive weld defect sensing probe.
  • the cooling system includes a cooling fluid passage in the nondestructive weld defect sensing probe.
  • the nondestructive weld defect sensing probe is separated from the weld layer by a gap; and the cooling system includes a gas passage for causing cooling gas to flow through the gap.
  • the cooling system is configured to cause welding shield gas to flow through the gap.
  • a probe tip of the nondestructive weld defect sensing probe is capable of withstanding a temperature of 200 degrees Celsius.
  • a method including: forming a portion of a weld layer, and testing the portion of the weld layer for defects, the testing occurring within 20 seconds of the forming.
  • the testing includes testing the portion of the weld layer with an eddy current probe.
  • the method further includes cooling the eddy current probe.
  • the cooling of the eddy current probe includes cooling the eddy current probe with welding shield gas.
  • FIG. 1 is a schematic cross-sectional view of two pieces being joined by a weld, and a first weld layer of the weld, according to an embodiment of the present disclosure
  • FIG. 2 is a perspective view of an orbital welding system joining two pipes with a weld, according to an embodiment of the present disclosure
  • FIG. 3A is a drawing of coils of an eddy current probe, according to an embodiment of the present disclosure
  • FIG. 3B is a photograph of an eddy current probe, according to an embodiment of the present disclosure.
  • FIG. 4 is a schematic cross-sectional view of two pieces being joined by a weld, with the probe tip of an eddy current probe in a channel at the line of contact between the pieces, according to an embodiment of the present disclosure.
  • two pieces of metal (e.g., metal plates or pipes) 105 may be joined by filling a groove 115 (which may have a triangular or trapezoidal (e.g., rectangular (as illustrated in FIG. 1 ) or square) cross section), at the line of contact 117 between the pieces of metal, with molten metal, in one or more passes, each pass resulting in the forming of a weld layer 120.
  • the pieces of metal 105 (together with any partially completed weld) may together be referred to as the substrate.
  • the filler metal may be supplied by a filler wire, and heat may be supplied by an arc.
  • the arc In a gas tungsten arc welding (GTAW) (or tungsten inert gas (TIG)) process, the arc may be formed between a tungsten electrode and the weld pool; in a gas metal arc welding (GMAW) (or metal inert gas (MIG)) process, the arc may be formed between the filler wire and the weld pool.
  • GTAW gas tungsten arc welding
  • TOG tungsten inert gas
  • MIG metal inert gas
  • the heat may be supplied by another heat source, e.g., a laser.
  • two pipes 105 when performing machine (i.e., automated) pipe welding (which may also be referred to as orbital welding), two pipes 105 may be positioned end to end.
  • the ends of the two pipes may be shaped such that a channel, or “groove” 115 is formed around the outer circumferences of the ends of the pipes.
  • a weld head including the heat source and a filler wire feed system may be caused, by a suitable motorized drive system, to move relative to the substrate (e.g., the weld head may move (e.g., rotate about the joint), while the pieces being joined (e.g., the pipes) are held fixed, or the pieces being joined may move (e.g., rotate) while the weld head is held fixed), while the weld head deposits metal into the channel to form the weld.
  • the channel 115 may be partially or entirely filled, using one or more weld passes, each pass forming an additional weld layer 120 in the channel.
  • various welding parameters may be selected to produce desirable weld pool characteristics
  • the weave may be selected so that the weld has the same width as a channel in the substrate, and the layer height (i.e., the thickness of the weld layer 120 deposited in the channel 115) may be selected so that the final weld will meet certain requirements (e.g., strength).
  • a nondestructive weld defect sensing probe 220 is secured to the weld head so that it moves with the weld head relative to the substrate, e.g., relative to the two pipes 105.
  • the defect sensing probe 220 may follow the weld head, and it may be employed to sense defects in the weld shortly after the weld layer 120 is formed.
  • the distance between the defect sensing probe 220 and the weld head is selected to be as small as possible while being sufficiently large to allow the weld to cool sufficiently, by the time it reaches the defect sensing probe 220, to avoid damaging (by excessive heating) the defect sensing probe 220.
  • the delay between the forming of a portion of the weld layer 120 and the time the portion reaches the defect sensing probe 220 may be less than 10 minutes, e.g., it may be between 1 second and 100 seconds.
  • the distance, along the weld layer 120, between the weld pool and the defect sensing probe 220 may be less than 50 centimeters (cm), e.g., it may be between 1 .0 cm and 50.0 cm.
  • the defect sensing probe 220 may include one or more eddy current defect sensors.
  • Each eddy current defect sensor may include one or more drive coils and one or more sensing coils, connected to one or more defect detection circuits.
  • a defect detection circuit may drive a drive coil of an eddy current defect sensor with a time-varying current so that it produces a time-varying magnetic field. This time-varying magnetic field may cause time-varying eddy currents to flow in the weld layer 120 being inspected, and a sensing coil may be employed to detect the time-varying eddy currents.
  • the eddy currents produced in a weld that has a defect may differ from the eddy currents produced in a perfect weld; as such, the sensed eddy currents may be used (by the defect detection circuit) to determine whether defects are present.
  • the frequency content of the time-varying current driven through the drive coil may affect the depth at which eddy currents flow in the weld layer 120.
  • most of the current in the weld layer 120 may flow within one skin depth of the surface of the weld layer 120, and the current may be increasing weak at greater depths within the weld layer 120.
  • the skin depth may be inversely proportional to the square root of the frequency of the drive current; as such, lower frequency drive currents may be suitable for detecting defects within the bulk of the weld layer 120 (sensing in this mode may be referred to as volumetric sensing), and higher frequency drive currents may be suitable for detecting surface defects.
  • FIG. 3A shows a coil configuration, in some embodiments.
  • Two large coils 305 may be used for relatively low frequency (volumetric) measurements (which may use one or more frequencies in the range from 500 Hz to 500 kHz) which may be used to detect subsurface defects, with one of the two large coils 305 being operated as the drive coil and the other of the two large coils 305 being operated as the sensing coil.
  • a plurality of additional coils e.g., smaller coils
  • 310a, 310b may be operated in a G4 (Axial) mode or in a G3 (Transverse) mode to detect defects in or near the surface of the weld layer 120.
  • a first pair of smaller coils 310a may be operated as the drive coil and the other three smaller coils 310b may be operated as sensing coils.
  • other coil driving and sensing arrangements are employed, e.g., one coil of the first pair of smaller coils 310a may be may be operated as a drive coil and the other one of the first pair of smaller coils calls 310a may be operated as a sensing coil.
  • FIG. 3B is a photograph of an eddy current probe, in some embodiments.
  • the eddy current probe includes a probe tip 325 and a probe body 330.
  • the probe tip 325 includes the coils 305, 310 and may be sufficiently narrow to fit in the channel 115.
  • the probe body may include provisions for cooling the probe (as discussed in further detail below).
  • FIG. 4 is a cross-sectional view of a weld in progress, in which one weld layer 120 has been formed.
  • the tip 325 of the eddy current probe extends into the channel 115, and is employed to test the weld layer 120 for defects.
  • This mode of operation may be superior to alternate approaches in which the entire weld (which may include a plurality of weld layers 120) is tested, after it is completed, using eddy current inspection, in that (i) the present method may make it possible to detect defects in lower weld layers 120, which may be too far below the surface of the completed weld to be detected using eddy current inspection and (ii) welding conditions resulting in a low-quality weld layer (e.g., incorrect arc parameters, incorrect filler wire feed rate, or insufficient shield gas) may be detected quickly (e.g., within less than 20 seconds, e.g., within a time interval between 0.1 seconds and 30.0 seconds) of the occurrence of such conditions.
  • welding conditions resulting in a low-quality weld layer e.g., incorrect arc parameters, incorrect filler wire feed rate, or insufficient shield gas
  • the probe tip 325 may be supported in a metal (e.g., stainless steel) holder.
  • a metal e.g., stainless steel
  • Such a holder may have an opening between the lower surface of the probe tip 325 and the weld, so as to avoid shielding the weld from the magnetic field produced by the drive coils and so as to avoid shielding the sensing coils from the magnetic fields produced by eddy currents in the weld layer 120.
  • This holder may be pressed (e.g., by a spring) against the top surface of the weld layer 120 and it may support the probe tip 325 so that a small gap 410 exists between lower surface of the probe tip 325 and the upper surface of the weld layer 120.
  • the gap 410 may prevent any roughness of the upper surface of the weld layer 120 from abrading or otherwise damaging the lower surface of the probe tip 325, and it may act as an insulating layer reducing the rate of conductive heat transfer from the weld layer 120 to the probe tip 325.
  • air, or another gas may be caused to flow through the gap 410 to further reduce the rate of conductive heat transfer and to cool the probe tip 325.
  • the height of the gap 410 i.e. , the separation between the lower surface of the probe tip 325 and the upper surface of the weld layer 120
  • Liquid cooling of the eddy current probe may also be employed; cooling passages may be present for this purpose in the probe body 330 or in the probe tip 325 (or in both) to remove heat from the probe tip and from the probe body 330.
  • heat-resistant materials may be used to construct the probe tip 325 or the entire eddy current probe, to further improve its ability to be operated near a recently- formed weld layer 120.
  • the probe tip 325, or the entire eddy current probe is capable of withstanding a temperature of 200 Celsius.
  • a portion of something means “at least some of” the thing, and as such may mean less than all of, or all of, the thing.
  • “a portion of” a thing includes the entire thing as a special case, i.e., the entire thing is an example of a portion of the thing.
  • the word “or” is inclusive, so that, for example, “A or B” means any one of (i) A, (ii) B, and (iii) A and B.
  • a method e.g., an adjustment
  • a first quantity e.g., a first variable
  • a second quantity e.g., a second variable
  • the second quantity is an input to the method or influences the first quantity
  • the second quantity may be an input (e.g., the only input, or one of several inputs) to a function that calculates the first quantity, or the first quantity may be equal to the second quantity, or the first quantity may be the same as (e.g., stored at the same location or locations in memory as) the second quantity.
  • a rectangle is a special case of a trapezoid (e.g., a rectangle is an example of a trapezoid) and a square is a special case of a rectangle (e.g., a square is an example of a rectangle).
  • the device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein should be interpreted accordingly.
  • a layer is referred to as being “between” two layers, it can be the only layer between the two layers, or one or more intervening layers may also be present.
  • any numerical range recited herein is intended to include all sub-ranges of the same numerical precision subsumed within the recited range.
  • a range of "1.0 to 10.0" or “between 1.0 and 10.0” is intended to include all subranges between (and including) the recited minimum value of 1 .0 and the recited maximum value of 10.0, that is, having a minimum value equal to or greater than 1 .0 and a maximum value equal to or less than 10.0, such as, for example, 2.4 to 7.6.
  • a range described as “within 35% of 10” is intended to include all subranges between (and including) the recited minimum value of 6.5 (i.e.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Quality & Reliability (AREA)
  • Mechanical Engineering (AREA)
  • Biochemistry (AREA)
  • General Health & Medical Sciences (AREA)
  • General Physics & Mathematics (AREA)
  • Immunology (AREA)
  • Pathology (AREA)
  • Investigating Or Analyzing Materials By The Use Of Magnetic Means (AREA)

Abstract

L'invention concerne un système et un procédé d'inspection de soudure en cours de traitement. Dans certains modes de réalisation, le système comprend : une tête de soudage ; et une sonde de détection non destructive de défaut de soudure, la tête de soudage étant configurée pour se déplacer par rapport à un substrat et pour former une couche de soudure sur le substrat, et la sonde de détection non destructive de défaut de soudure étant configurée pour se déplacer par rapport au substrat, à une distance de moins de 50 centimètres par rapport à la tête de soudage, et pour détecter des défauts dans la couche de soudure formée.
PCT/IB2023/000478 2023-08-03 2023-08-03 Inspection de soudure en cours de traitement Pending WO2025027359A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/IB2023/000478 WO2025027359A1 (fr) 2023-08-03 2023-08-03 Inspection de soudure en cours de traitement

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/IB2023/000478 WO2025027359A1 (fr) 2023-08-03 2023-08-03 Inspection de soudure en cours de traitement

Publications (1)

Publication Number Publication Date
WO2025027359A1 true WO2025027359A1 (fr) 2025-02-06

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Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19980070749A (ko) * 1997-01-23 1998-10-26 기무라다츠야 2전극편면가스쉴드 아크용접방법 및 장치
CA2566933A1 (fr) * 2006-10-17 2008-04-17 Athena Industrial Technologies Inc. Appareil et methode d'inspection
US20090167298A1 (en) * 2006-03-10 2009-07-02 European Advanced Superconductors Gmbh & Co., Kg System and method for the nondestructive testing of elongate bodies and their weldbond joints
JP2010054352A (ja) * 2008-08-28 2010-03-11 Hitachi Ltd 渦電流探傷方法、渦電流探傷プローブ、及び渦電流探傷装置
CA2945425A1 (fr) * 2014-04-14 2015-10-22 Eddyfi Ndt Inc. Sonde a reseau de courant de foucault avec emetteurs independants
US20160178581A1 (en) * 2014-12-22 2016-06-23 Edison Welding Institute, Inc. System for evaluating weld quality using eddy currents
CA3065011A1 (fr) * 2018-12-12 2020-06-12 Zetec, Inc. Sonde de courant de foucault
US20200278321A1 (en) * 2017-09-27 2020-09-03 Hitachi Zosen Corporation Eddy current flaw detection device

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR19980070749A (ko) * 1997-01-23 1998-10-26 기무라다츠야 2전극편면가스쉴드 아크용접방법 및 장치
US20090167298A1 (en) * 2006-03-10 2009-07-02 European Advanced Superconductors Gmbh & Co., Kg System and method for the nondestructive testing of elongate bodies and their weldbond joints
CA2566933A1 (fr) * 2006-10-17 2008-04-17 Athena Industrial Technologies Inc. Appareil et methode d'inspection
JP2010054352A (ja) * 2008-08-28 2010-03-11 Hitachi Ltd 渦電流探傷方法、渦電流探傷プローブ、及び渦電流探傷装置
CA2945425A1 (fr) * 2014-04-14 2015-10-22 Eddyfi Ndt Inc. Sonde a reseau de courant de foucault avec emetteurs independants
US20160178581A1 (en) * 2014-12-22 2016-06-23 Edison Welding Institute, Inc. System for evaluating weld quality using eddy currents
US20200278321A1 (en) * 2017-09-27 2020-09-03 Hitachi Zosen Corporation Eddy current flaw detection device
CA3065011A1 (fr) * 2018-12-12 2020-06-12 Zetec, Inc. Sonde de courant de foucault

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