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2022 Vol. 40 No. 2
Published: 2022-04-15
1
LAN Jianglin,ZHONG Zhenqian,XIE Jinpeng
Optimization study of electromagnetic measurement of residual stress in structural steel
The relationship between the sensitivity coefficient of residual stress and the layer depth in electromagnetic method was studied using universal testing machine, metallographic microscope, X-ray diffractometer and electromagnetic stress meter. The corresponding residual stress in different layer depth in workpiece was measured. A more appropriate sensitivity coefficient was obtained by using the linear fitting method. Finally, the X-ray diffractometer was used for verification. The results showed that the sensitivity coefficient first increased and then decreased with the increase of layer depth. The distribution of residual stress in the near surface layer was significantly different from that in the deep layer. The sensitivity coefficient obtained by the linear fitting method was more suitable for the actual sensitivity coefficient, which could reduce the measurement error to a certain extent in the electromagnetic method.
2022 Vol. 40 (2): 1-7 [
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8
CHEN Changhua,CHEN Xinhua,ZHANG Wencheng,ZHOU Yue,WU Lian,LI Zhumao
Numerical simulation and ultrasonic testing analysis of solidification field of 42CrMo ingot
The commercial software ProCAST was used to establish the numerical simulation of heat transfer in ingot solidification. The temperature field of ingot mold in solidification was the variable of space and time, which belonged to three-dimensional unsteady heat transfer. In order to verify the influence of temperature field change on the metallurgical defects of ingot in solidification process, the 24-inch ingot mold made of 42CrMo steel was selected for numerical simulation. The temperature field, solidification fraction, shrinkage porosity and Niyama distribution in ingot solidification were simulated by analyzing the superheat degree of ingot pouring, temperature gradient in cross section, liquidus and solidus. Through the combination of simulation and actual operation process, as well as the ultrasonic testing and macroscopic inspection of anatomical verification of ingot, it was proved that the simulation technology and ultrasonic testing could improve the metallurgical quality of ingot.
2022 Vol. 40 (2): 8-12 [
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13
WU Jianpeng,LI Yao,XU Hailong,CAO Feng,ZHOU Peirong
Influence of simulated marine atmospheric environment on corrosion behaviors of XCS-lode steel and 30CrNi3Mo steel
The corrosion properties of XCS-lode steel and 30CrNi3Mo steel was studied in simulated marine atmospheric environment by the experimental method of salt-spray corrosion. The difference in corrosion behaviors of two steels was investigated by polarization curve test and electrochemical impedance spectroscopy (EIS) test. The results showed that the XCS-lode steel had higher self-corrosion potential compared to the 30CrNi3Mo steel. The impedance of corrosion product film of XCS-lode steel was significantly higher than that of 30CrNi3Mo steel. In the marine atmospheric environment, XCS-lode steel exhibited better corrosion resistance than 30CrNi3Mo steel.
2022 Vol. 40 (2): 13-17 [
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18
ZHONG Shoujun，WU Xuexing，ZHANG Zhiming
Strip structure control of 22CrMoH hot rolled round steel for automobile rear axle teeth
Orthogonal experiments of continuous casting were conducted using 22CrMoH steel for rear axle teeth of automobiles to optimize the electromagnetic stirring process in continuous casting and to improve the composition segregation in cross section of casting bloom. The large reduction rolling in uncrystallized region of austenite was adopted in cogging rolling process to promote the dynamic recrystallization of the center structure of the round steel, thus improving the primary banded structure of the hot-rolled round steel as well as the heat treatment deformation of rear axle gear. After using these measures, the banded structure of 22CrMoH hot rolled round steel for automobile rear axle teeth had reduced from Grade 2.5-3.0 to Grade 1.5-2.0 under equilibrium structure conditions, and the qualified rate of heat treatment deformation increased from 73% to 94%, which could meet the technical requirements of customers.
2022 Vol. 40 (2): 18-21 [
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22
QI Yinghao，ZHANG Ke，WANG Yongfeng，ZHAO Jiulai
Analysis on test methods of linear errors for ultrasonic flaw detectors
The working principle of ultrasonic flaw detector was introduced, and the influence of horizontal linearity and vertical linearity on defect location and quantification was obtained. Two measuring appliances, i.e., ultrasonic verification device (including pulse signal generator and standard attenuator) and reference block, were discussed. Meanwhile, two testing methods were adopted. The advantages and disadvantages of two results were obtained. The influencing factors were analyzed and the corresponding suggestions for use were proposed.
2022 Vol. 40 (2): 22-25 [
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26
LIU Jianping,FENG Jianguo,LIU Yuan
TOFD process for welded joints of port crane
There are a large number of welded joints in port hoisting machinery structure,and the inspection requirements are high. The diffraction time difference ultrasonic inspection (TOFD) is an effective means to improve the inspection quality. According to NB/T 47013.10 standard，the paper introduces the main technical steps and process methods of testing butt welds of port crane by TOFD method. At the same time, it can provide reference for TOFD testing of other types of products or equipment.
2022 Vol. 40 (2): 26-30 [
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31
LI Yahong,SHENG Chunxiang,ZHOU Xuxu,ZHANG Pei
Cause analysis of unqualified tensile properties for 20CrMnTi steel forgings
The causes of unqualified tensile properties of 20CrMnTi steel were analyzed based on the chemical composition, hardness, microstructure, forging flow line and nonmetallic inclusions as well as appearance and fracture morphology of tensile samples. Moreover, some suggestions and measures were proposed. The results showed that the forging flow line of tensile samples was changed due to the quenching deformation. A part of the deformed forging flow line was cut off during grinding, which was the main reason to cause the unqualified tensile properties. In addition, the knife edge, the outoftolerance dimension as well as unqualified shape and position tolerance in the machining process further reduced the tensile properties.
2022 Vol. 40 (2): 31-36 [
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37
WU Xiaolin,GE Longgui,LIU Wen,CHEN Zelei,WANG Xinshe
Failure analysis of drill rod in short term fracture
The fracture was observed for a drill rod after service for a short time. The fracture morphology and metallurgical structure of the failed drill rod were analyzed. According to the analysis results, it was thought that the reason for shortterm fracture on its head was the heavier surface decarburization on the drill rod head. Moreover, the surface decarburization was mainly formed in the heating process before forging. During the service of the drill rod, cracks were formed easily in a short time on the heavier decarburized surface of the drill rod head under the forced condition, then the fracture was caused due to the gradual extension of cracks.
2022 Vol. 40 (2): 37-41 [
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42
LI Lushui,LIU Kexiu,LIU Zhaojie,MA Kuo,WANG Lian,FENG Xiaoliang
Fracture cause analysis of wire rope for automobile crane
When a automobile crane at a construction site was used for lifting the steel reinforcements, the fracture of wire rope connected to the auxiliary hook occurred. Through macro analysis, dimensional measurement, breaking force tensile test, metallographic analysis, scanning electron microscope morphology observation and energy spectrum analysis, the technical reasons for wire rope fracture were analyzed. The results showed that the outer wire of the automobile crane wire rope had severe wear with local broken wires and cracking. The number of local broken wires had exceeded the scrapping standard in GB/T 5972—2016, resulting in the fracture of wire rope due to insufficient local bearing capacity.
2022 Vol. 40 (2): 42-47 [
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48
SU Chongtao，GUO Xiaojing
Analysis on microstructure and cracking of low-carbon steel plate in resistance spot welding
In the peeling process of resistance spot welding samples using cross tensile equipment, it was found that the cracking position and fracture morphology of the solder joints were different. In order to study the factors that affect the cracking of the spotwelding joints during cross tensile test, the microstructure, hardness distribution and fracture condition after cross tension were observed and detected using the low carbon steel cold-rolled plates (H260LA, H340LA and DP780) as the samples. The factors affecting the cracking of welded joints were analyzed by comparing the microstructure and hardness distribution of different samples. The results showed that the content of martensite increased gradually in the nugget and the heat affected zone with increasing the contents of carbon and alloying elements in the base metal, which led to the increase of inter-structural stress and influenced the crack propagation. In addition, the local softening phenomenon of hardness was observed in each area of the welded joint, which had an important effect on the cracking of the solder joint in cross tensile tests.
2022 Vol. 40 (2): 48-52 [
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53
CHANG Guodong,WU Min
Failure analysis of tube bundle of coal moisture control steam rotary dryer in a coking plant
The tube bundle of one rotary dryer with moisture regulating steam in a coking plant was cracked in the process of operation. The failed steel pipe was analyzed by the means of chemical composition, metallographic microscope, scanning electron microscope and energy dispersive spectrum. According to the test results of macro and micro fracture morphology, microstructure, corrosion pit and mechanical property, it was found that the failure reason of steel pipe was stress corrosion cracking. The crack was originated from the pitting corrosion on the surface of steel pipe, and the stress was from the thermal stress generated when the steel pipe was subjected to alternating low and high temperature.
2022 Vol. 40 (2): 53-56 [
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57
ZHU Jiao,ZHONG Zhenqian,YU Xueliang,LI Jie
Cause analysis of bolt fracture
The material trademark of one bolt was 0Cr17Ni4Cu4Nb (17-4PH). The surface of bolt was coated with zinc after quenching and tempering heat treatment. Then it was installed on the equipment and the fastening stress was applied. In the next year, the equipment was shipped and put into marine environment. The fracture of bolt was observed after service for two and half years. The mechanical properties, microstructure, hardness, fracture morphology and chemical composition of the bolt materials were analyzed and tested. The results showed that the hydrogen content in surface coating was high. The high material strength and sensitivity to hydrogen embrittlement were the main reason to cause hydrogen embrittlement fracture of the bolt. In the process of service, the fastening force was applied onto the surface of the thread segment, which resulted in the diffusion and enrichment of hydrogen in the bolt surface coating to the nearby root of the thread. When the local hydrogen content reached the critical concentration of hydrogeninduced cracking, the hydrogen embrittlement fracture occurred in the bolt.
2022 Vol. 40 (2): 57-63 [
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64
WANG Yan，KUANG Jun
Discussion on extension and application of inspection and testing system design in management system certification
The design idea of inspection and testing system, which is mainly based on management mode, automatic intellectualization and informationization of the instrument was introduced. The importance of inspection and testing design in system certification is expounded, including quality management, environment management, occupational health and safety management. The principles of process design as well as the interface relationships with architecture, structure, ventilation, water supply and drainage, and electrical are proposed, which essentially improve the design quality and reduce the risk in design and later use. We should keep up with the pace of industry development and constantly optimize the design concept, communicate the management system certification audit and related needs, and extend the influence of design services.
2022 Vol. 40 (2): 64-68 [
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69
ZHANG Yishuai，WANG Liangjun，SONG Xiaoyong，WANG Qingwen
Analysis of measurement uncertainty of processing dimension of wheel tensile sample
The sources of measurement uncertainty of processing dimension in the wheel tensile test were analyzed. The measurement uncertainty of the metal materials in tensile test at room temperature was evaluated by establishing mathematical model and repeatability tests. The results showed that, as a standardized testing laboratory, the proposed method could be used to evaluate the measurement uncertainty of metal materials at room temperature tensile test under the conditions of controlled personnel, machines, raw materials, methods, environment and management, and the inclusion factor
k
= 2. The evaluation results showed that the maximum allowable error was less than ±0.04 mm within the measurement range of 150 mm, and the expanded uncertainty of indication error measurement result was μ= 0.04 mm,
k
= 2.
2022 Vol. 40 (2): 69-71 [
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