Ultrasonic defect testing method and apparatus

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36455101, 36441325, 36447424, 36441322, 36447437, 36447405, 73626, 73611, 73625, 73624, 12866101, 12866007, 12866009, 348135, E21B 4900

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054756138

DESCRIPTION:

BRIEF SUMMARY
TECHNICAL FIELD

The present invention relates to defect testing method and apparatus using ultrasonic wave, and more particularly to ultrasonic defect testing method and apparatus for a part having a complex three-dimensional free curved shape.


BACKGROUND ART

As is well known, as civilian society has been developed, industries have highly developed and the trend is even rising.
For various equipments which support civilian society and industrial economy, it is required to maintain the inherent functions thereof not only at installation thereof but also over a sufficiently long period.
As chemical technology advances, most of those equipments comprise a plurality of parts to perform complex functions. Accordingly, the assembling and engagement structures are three-dimensional and complex. In order to sufficiently maintain the functions, periodic and non-periodic tests of the functions are essential in addition to the tests at new installation. Depending on actual status of use, a periodic test is legally obliged.
It is desirable to check those equipments at new installation as well as at the periodic or non-periodic function tests during use for the maintenance purpose, by disassembling them into individual parts or part units (hereinafter collectively referred to as parts). However, where the equipment has a complex assembling and engagement structure, the test by disassembling is very troublesome, and does not meet economical requirement, and lowers run efficiency. Under certain circumstances, the test by disassembling may impair the functions of the parts and hence nondestructive testing has been widely used.
Recently, because of the fact that many equipments are made of metals, the nondestructive testing by ultrasonic wave disclosed in JP-A-53-143293, JP-A-577691 and JP-A-62-21014 have been used widely.
Where a part of an equipment is a plane or of simple curved shape such as a pipe, an ultrasonic defect testing system is simple and little skill is required for the test. However, in the recent mechanical equipments for automobiles, ships, aeroplanes and generators, parts are widely used having a complex three-dimensional free curved surface such as a turbine blade, a pump casing, a main steam tube joint, a large size valve or a tube table. Among others, in nuclear facilities, medical facilities and laboratories, it is strongly demanded that those parts of the complex shapes maintain their functions almost perfectly for years. Because of the difficulty of the test by the disassembling, the ultrasonic defect testing of the parts having the complex three-dimensional free curved surfaces is demanded. It is also demanded to record and keep the defect data for subsequent use or for the study of elongation of the lifetime of the same or a similar type of equipment.
However, the ultrasonic defect testing for the part having such a complex three-dimensional free curved surface has an essential shortcoming which cannot be solved by the existing and practiced ultrasonic defect testing system for the part having a simple plane or curved surface.
Since a defect image cannot be superimposed on an image of a part, that is, an image representing a contour of an object under test, it is not possible to discriminate an echo reflected from the contour of the object to be tested from one reflected from the defect. Namely, where there is no image of the object under test, or where there is an image of the object but it includes outer surface corrosion, or where the object under test was not made as the same image as displayed, an optimum defect testing condition cannot be determined unless shapes of inner and outer surfaces are grasped, or it is not possible to decide whether an echo derived by the ultrasonic defect test is one reflected from the inner surface of the object under test or from the defect.
Specifically, the defect testing conditions include a defect testing approach position, a scanning direction, a refraction angle of a probe, an operating frequency of the probe, a dimension of a resonator of the probe,

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