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UT Solutions to Inspection on ICG (Inner Cooling Gallery) of Piston

Solution 1: CT-003/CT-004 Piston Inspecting Equipment

CT-003 ultrasonic Piston inspecting equipmentis specialized for measurement of the axial and radial offset of the ICG, as well as detection of flaws born during forging such as pores, bubbles are for quality inspection. CTS-004 ultrasonic Piston inspecting equipment is specialized for evaluation on the upper and lower sides of RCI (ringed carrier inserts) as well as Al body-bondings of the piston. Inspection on inner cooling gallery is attempted by means of PE for radial and axial thickness as to where the pulse is made. Inspection on the bondings between ringed carrier inserts and the work-blank matrix (WBM) is based on the amplitude of echoes caused by A.I. (acoustic impedance) difference between these two kinds of materials: Al Alloy (workblank of upper ring) and austenic cast iron. The upper side of ICG and the bondings between the RCI & the WBM are all PE-opted.

PIC 1 CTS-003/OO4 Piston Inspecting Equipment

Solution 2:CTS-2108PA Phased Array Detector (Supplied with Specialized Probes)

a. S-scan Mode for the ICG

FIG 1 Formulation of S-scan over the ICG

1---ICG 2---RCI (i) 3---RCI (ii) 4---Flaw 5---PA Probe 6---PA Wedge 7---Piston

When no flaw appears, 1 (ICG), 2 (RCI-i) and 3 (RCI-ii) can be located by their consistent echoes. When there’s a flaw between 1 and 2 or one between 1 and 3, for example, at 4, it will be catched also by the show-up echo in the image. While A-scan for this case is incapable of distinguishing the echo of the flaw from those of the ICG and the RCI, which leads to skips of flaws easily. The advantage of Phased Array S-scan is that it can display the spots 1, 2, and 3 at the same time and when a flaw is existent between it can be easily detected by contrast.

b. Images

i) Image 1: No flaw between 1 (ICG), 2(RCI-i) and 3 (RCI-ii). There’s clear display of corresponding echoes but none between.

PIC 2 Without Flaws Between

ii) Image 2: There’s a small dent between 1(ICG) and 3 (RCI-ii) and is displayed in the interface just as shown as bellow. But the echo at Spot 3 is seen clearly, which means that just part of the beam is blocked by the dent and the rest still reaches Spot 3 where the RCI-ii stays.

PIC 3 Display of Small Dent

iii) Image 3: There’s a bigger dent between 1(ICG) and 3 (RCI-ii) and is displayed in the interface just as shown as below. The echo of Spot 3 is almost covered up by the dent which is left there in sight.

PIC 4 Display of Bigger Dent

iv) Image 4: Flaw caused by forging between the ICG and Spot 2 (RCI-i). There’s a flaw echo evidently shown between those two.

FIG 5 FIG 6Flaw between the ICG and RCI-i

v) Image 5: bulges on the ICG: When some bead-like objects attached on the ICG, the corresponding echo of the ICG is dented in.

FIG 6 Bulges on the ICG