Shandong seamless steel tube factory shares a comprehensive inspection method for seamless steel pipes, focusing on quality control. The process includes several key stages to ensure the material meets high standards. 1. **Chemical Composition Analysis**: This involves both traditional and modern techniques. Instruments like infrared C-S analyzers are used to detect carbon and sulfur in ferroalloys and raw materials. Direct reading spectrometers analyze elements such as carbon, silicon, manganese, phosphorus, sulfur, chromium, molybdenum, nickel, and more. The N-O analyzer is used for gas content analysis of nitrogen and oxygen. 2. **Geometry and Shape Inspection**: Wall thickness is measured using micrometers or ultrasonic gauges, with at least 8 points checked at both ends. Outer diameter and ellipticity are assessed using snap gauges, vernier calipers, and ring gauges. Length is verified using tape measures or automated systems. Bending is evaluated with rulers, feeler gauges, and strings. End face angles and burrs are checked with squares and cardboard. 3. **Surface Quality Inspection (100%):** Visual inspection is performed under proper lighting, following specific standards. Non-destructive testing methods include: - **Ultrasonic Testing (UT)**: Detects surface and internal cracks, following GB/T 5777-1996, Level C5. - **Eddy Current Testing (ET)**: Ideal for detecting small defects, per GB/T 7735-2004, Class B. - **Magnetic Particle Testing (MT) and Magnetic Flux Leakage Detection**: Suitable for ferromagnetic materials, standard GB/T, Level C4. - **Electromagnetic Ultrasonic Testing**: No coupling medium required, suitable for high-temperature and rough surfaces. - **Penetrant Testing**: Uses fluorescent or colored dyes to detect surface flaws. 4. **Mechanical Performance Testing**: - **Tensile Test**: Measures yield strength, tensile strength, and elongation. Specimens vary in size depending on the pipe’s dimensions. - **Impact Test**: Evaluates toughness using CVN tests, with standard and non-standard samples. - **Hardness Test**: Includes Brinell, Rockwell, and Vickers hardness measurements. - **Hydraulic Test**: Involves applying pressure and maintaining it for a set time, calculated by p=2Sδ/D. 5. **Process Performance Testing**: - **Flattening Test**: Assesses ductility using round or C-shaped samples. - **Ring Pull Test**: Checks for cracks after pulling a section. - **Flaring and Curling Test**: Conducted with specific taper angles. - **Bending Test**: Used as an alternative to flattening for large-diameter tubes. 6. **Metallographic Analysis**: - **High Magnification Test**: Examines microstructure, including non-metallic inclusions, grain size, and phases. - **Low Magnification Test**: Performed visually or with magnifying glasses up to 10x, including acid etching and sulfur tests to identify structural issues like segregation or inclusions. This detailed inspection process ensures that every seamless steel pipe produced meets the highest quality and safety standards.
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