航空铝合金缺陷及应力脉冲涡流无损检测研究
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摘要
脉冲涡流检测技术是近几十年来迅速发展起来的一种无损检测新技术,其宽频谱的激励方式可以在航空铝合金复杂结构件检测中获得较多的材料状态信息,包括航空铝合金结构件缺陷及应力信息,因而成为目前航空无损检测领域的一个研究热点。本文在分析了国内外脉冲涡流无损检测技术研究现状的基础上,开展了脉冲涡流检测技术对航空铝合金缺陷及应力的检测研究,主要研究内容及创新点如下:
1.圆柱型脉冲涡流探头的优化设计
根据脉冲涡流探头的几何特征和边界条件,结合数值建模理论,建立了脉冲涡流圆柱型探头的2D数值计算模型。通过提取在不同电导率条件下的脉冲涡流差值信号峰值特征,得出了脉冲涡流差值信号的峰值与电导率的变化成线性关系的结论,首次提出脉冲涡流差值信号的峰值可用于评估航空铝合金电导率的分布;论文深入研究了脉冲涡流探头在不同几何尺寸参数对航空铝合金的灵敏度,即:(1)线圈内径、(2)线圈宽度、(3)线圈高度,提出了脉冲涡流探头的优化设计方法;此外,论文也研究了其他参数(如激励脉冲频率、提离距离、有无铁氧体磁芯等)对航空铝合金灵敏度的影响,为脉冲涡流探头的优化设计提供理论指导。
2.航空铝合金缺陷脉冲涡流无损检测技术的研究
论文对航空铝合金表面、亚表面以及由于腐蚀造成的金属厚度减薄缺陷进行了脉冲涡流检测研究。根据实验数据与脉冲涡流检测原理,得出了脉冲涡流检测系统对航空铝合金缺陷深度检测的灵敏度高于缺陷宽度的灵敏度;建立了脉冲涡流检测三种缺陷的深度定量检测模型;在脉冲涡流检测技术对航空铝合金不同类型缺陷定量检测的基础上,重点探讨了脉冲涡流瞬时信号的特征提取技术,频谱幅值为论文在频域里提取的新特征值;并对提取的各种特征进行了最优组合,提出了脉冲涡流检测技术对航空铝合金不同缺陷的最优分类识别算法。
3.航空铝合金应力脉冲涡流无损检测技术的研究
为了达到对航空铝合金残余应力的无损评估,论文首先推导了脉冲涡流应力检测原理,基于应力与材料电导率的相关性,提出了脉冲涡流检测技术对航空铝合金应力检测的新型无损检测方法,为脉冲涡流检测技术对航空铝合金残余应力的评估提供帮助。论文在如下几个方面展开了深入研究:
(1)采用实验的方法,对铝合金AL5083进行了弹性应力拉伸实验,实验结果表明脉冲涡流差值信号的峰值与加载应力的大小成线性关系,结合COMSOL有限元电导率仿真结果,得出了脉冲涡流差值信号的峰值可以用来评估应力的大小以及被测材料电导率的分布的结论。
(2)为了进一步检测残余应力,对不同塑性变形标准的铝合金材料进行了弹性拉伸实验,脉冲涡流差值信号的峰值与拉伸应力成非线性关系。通过提取“等效弹性系数”,实现了对航空铝合金样本的塑性变形的检测,即脉冲涡流圆型探头与矩形探头横向测量AL2024的“等效弹性系数”随着塑性变形的增加呈单调递减趋势。所有实验均证实脉冲涡流响应对拉伸应力与塑性变形非常敏感。
(3)为了达到对航空铝合金不同深度应力检测的目的,采用可变的脉冲宽度进行了实验。通过标准的电导率脉冲涡流信号创造性地建立了参考电导率平面,并采用此平面对不同厚度、不同电导率的多层金属进行检测,证实了所建电导率平面的有效性。另外,论文也通过弯曲应力的实验进行了验证,证明了所提出参考电导率平面测量不同深度应力分布的有效性,可以采用参考电导率平面测量导电材料的电导率不均匀分布而逆推出导电材料弯曲应力不同深度的分布。因此,由实验证明这种检测方法可以对航空铝合金不同深度应力分布进行检测。
Pulsed eddy current (PEC) is a new nondestructive testing (NDT) technique developed in recent years. More conductive material information including defects and the stress can be gotten from detection of complex aluminum-alloy structure of aerospace by using wideband exciting, PEC technique has become a hot research area in aviation NDT. On the basis of analyzing the state of the art of the research on PEC technique both inland and overseas, the defects and the stress of aerospace aluminum-alloy are studied in this paper. The brief structure of the research and novel approaches are as follows:
1. Optimization design of PEC circular probe
Based on the geometric characteristics and boundary conditions of PEC probe, a 2D finite element model of PEC probe is built. The peak value of the difference signals of PEC is adopted to evaluate electricity conductivity by Finite Element Method. The results show that the peak value of the difference signal is a linear relation with the change of the electrical conductivity, and can be adopted to estimate on the electrical conductivity distribution of the conductivity material. This paper reports an investigation into the sensitivity for a pancake PEC probe to variations in the material conductivity of specimens. Three experimental coil parameters are modeled: (a) coil inner radius; (b) coil width; (c) coil height. The optimization design of PEC circular probe is proposed. This paper also investigates relationship between other parameters including excited frequency, lift-off, the ferrite cores and aerospace aluminum-alloy. It will provide the theory guide of PEC sensor design.
2. Estimation on defect of the aerospace aluminum-alloy using PEC technique
To estimate on the defects of aerospace aluminum-alloy, experiments including the surface defects, the subsurface defects and the thickness changes are carried out using PEC technology. Based on the extraction features in time domain and frequency domain, the research results show that the defect depth sensitivity of aerospace aluminum-alloy is higher than the aluminum-alloy defect width. The quantitative model of defect depth is established for the different defects. The peak value of the spectrum is a new feature in frequency domain. All features extracted are selected and combined to identify the three kinds of defects, the research results show that the combination of the peak value of the spectrum in frequency domain and the peak time in time domain can be more efficient to identify three kinds of the defects.
3. Estimation on stress of aerospace aluminum-alloy using PEC technique
In order to estimate on the residual stress of aerospace aluminum-alloy, this paper introduces the occuring theory, testing and estimation of the residual stress. Based on the correlation between applied stress and the electrical conductivity, the PEC technique is proposed to estimate on the stress. The brief structure of the research and novel approaches are as follows:
(1)In order to investigate the relationship between the peak value of the difference signal and the elastic stress, the elastic stress of AL5083 is carried out. The experimental results show that the peak value of the difference signal is a linear with the applied elastic stress. On the other hand, the peak value of the difference signal by COMSOL FEM software simulation is a linear with the electrical conductivity changes. Therefore, the peak value can be adopted to estimate the electrical conductivity distribution and the applied stress distribution.
(2)In order to estimate the residual stress, flat bar samples made of various aluminum-alloys have been tested with different PEC probes such as circular and rectangular coils. The research results show that the elastic dependencies exhibit non-linearity in many cases. These verify that there are the elastic stress and plastic deformation on aluminum-alloys. The plastic deformation sample on aluminum-alloys can be tested using PEC probe through“equivalent elastic coefficient”extracted.“Equivalent elastic coefficient”of AL2024 is decreased with the plastic deformation increased using the circular probe and rectangular transverse probe. Overall the PEC responses obtained on the tested materials have demonstrated sufficient sensitivities to tensile stress and plastic deformation.
(3)In order to estimate on the different depth stress, PEC response of variable pulse width excitation has been calibrated with respect to known values of electrical conductivity standards. The obtained calibration dependence in principle component analysis (PCA) space has been used to evaluate electrical conductivities of other test materials. The experimental results show that the electrical conductivity PCA space is very efficient to estimate on the stress of the multi-layer metal materials. To verify the validity of the calibration dependence in PCA space, the experiment of bending AL2024 is also carried out. The experimental results verify our stress profile inspection methods using PCA based PCA. The agreement between theory and experiment shows that the present method can be used to estimate on the stress profile of aerospace aluminum-alloys.
1.圆柱型脉冲涡流探头的优化设计
根据脉冲涡流探头的几何特征和边界条件,结合数值建模理论,建立了脉冲涡流圆柱型探头的2D数值计算模型。通过提取在不同电导率条件下的脉冲涡流差值信号峰值特征,得出了脉冲涡流差值信号的峰值与电导率的变化成线性关系的结论,首次提出脉冲涡流差值信号的峰值可用于评估航空铝合金电导率的分布;论文深入研究了脉冲涡流探头在不同几何尺寸参数对航空铝合金的灵敏度,即:(1)线圈内径、(2)线圈宽度、(3)线圈高度,提出了脉冲涡流探头的优化设计方法;此外,论文也研究了其他参数(如激励脉冲频率、提离距离、有无铁氧体磁芯等)对航空铝合金灵敏度的影响,为脉冲涡流探头的优化设计提供理论指导。
2.航空铝合金缺陷脉冲涡流无损检测技术的研究
论文对航空铝合金表面、亚表面以及由于腐蚀造成的金属厚度减薄缺陷进行了脉冲涡流检测研究。根据实验数据与脉冲涡流检测原理,得出了脉冲涡流检测系统对航空铝合金缺陷深度检测的灵敏度高于缺陷宽度的灵敏度;建立了脉冲涡流检测三种缺陷的深度定量检测模型;在脉冲涡流检测技术对航空铝合金不同类型缺陷定量检测的基础上,重点探讨了脉冲涡流瞬时信号的特征提取技术,频谱幅值为论文在频域里提取的新特征值;并对提取的各种特征进行了最优组合,提出了脉冲涡流检测技术对航空铝合金不同缺陷的最优分类识别算法。
3.航空铝合金应力脉冲涡流无损检测技术的研究
为了达到对航空铝合金残余应力的无损评估,论文首先推导了脉冲涡流应力检测原理,基于应力与材料电导率的相关性,提出了脉冲涡流检测技术对航空铝合金应力检测的新型无损检测方法,为脉冲涡流检测技术对航空铝合金残余应力的评估提供帮助。论文在如下几个方面展开了深入研究:
(1)采用实验的方法,对铝合金AL5083进行了弹性应力拉伸实验,实验结果表明脉冲涡流差值信号的峰值与加载应力的大小成线性关系,结合COMSOL有限元电导率仿真结果,得出了脉冲涡流差值信号的峰值可以用来评估应力的大小以及被测材料电导率的分布的结论。
(2)为了进一步检测残余应力,对不同塑性变形标准的铝合金材料进行了弹性拉伸实验,脉冲涡流差值信号的峰值与拉伸应力成非线性关系。通过提取“等效弹性系数”,实现了对航空铝合金样本的塑性变形的检测,即脉冲涡流圆型探头与矩形探头横向测量AL2024的“等效弹性系数”随着塑性变形的增加呈单调递减趋势。所有实验均证实脉冲涡流响应对拉伸应力与塑性变形非常敏感。
(3)为了达到对航空铝合金不同深度应力检测的目的,采用可变的脉冲宽度进行了实验。通过标准的电导率脉冲涡流信号创造性地建立了参考电导率平面,并采用此平面对不同厚度、不同电导率的多层金属进行检测,证实了所建电导率平面的有效性。另外,论文也通过弯曲应力的实验进行了验证,证明了所提出参考电导率平面测量不同深度应力分布的有效性,可以采用参考电导率平面测量导电材料的电导率不均匀分布而逆推出导电材料弯曲应力不同深度的分布。因此,由实验证明这种检测方法可以对航空铝合金不同深度应力分布进行检测。
Pulsed eddy current (PEC) is a new nondestructive testing (NDT) technique developed in recent years. More conductive material information including defects and the stress can be gotten from detection of complex aluminum-alloy structure of aerospace by using wideband exciting, PEC technique has become a hot research area in aviation NDT. On the basis of analyzing the state of the art of the research on PEC technique both inland and overseas, the defects and the stress of aerospace aluminum-alloy are studied in this paper. The brief structure of the research and novel approaches are as follows:
1. Optimization design of PEC circular probe
Based on the geometric characteristics and boundary conditions of PEC probe, a 2D finite element model of PEC probe is built. The peak value of the difference signals of PEC is adopted to evaluate electricity conductivity by Finite Element Method. The results show that the peak value of the difference signal is a linear relation with the change of the electrical conductivity, and can be adopted to estimate on the electrical conductivity distribution of the conductivity material. This paper reports an investigation into the sensitivity for a pancake PEC probe to variations in the material conductivity of specimens. Three experimental coil parameters are modeled: (a) coil inner radius; (b) coil width; (c) coil height. The optimization design of PEC circular probe is proposed. This paper also investigates relationship between other parameters including excited frequency, lift-off, the ferrite cores and aerospace aluminum-alloy. It will provide the theory guide of PEC sensor design.
2. Estimation on defect of the aerospace aluminum-alloy using PEC technique
To estimate on the defects of aerospace aluminum-alloy, experiments including the surface defects, the subsurface defects and the thickness changes are carried out using PEC technology. Based on the extraction features in time domain and frequency domain, the research results show that the defect depth sensitivity of aerospace aluminum-alloy is higher than the aluminum-alloy defect width. The quantitative model of defect depth is established for the different defects. The peak value of the spectrum is a new feature in frequency domain. All features extracted are selected and combined to identify the three kinds of defects, the research results show that the combination of the peak value of the spectrum in frequency domain and the peak time in time domain can be more efficient to identify three kinds of the defects.
3. Estimation on stress of aerospace aluminum-alloy using PEC technique
In order to estimate on the residual stress of aerospace aluminum-alloy, this paper introduces the occuring theory, testing and estimation of the residual stress. Based on the correlation between applied stress and the electrical conductivity, the PEC technique is proposed to estimate on the stress. The brief structure of the research and novel approaches are as follows:
(1)In order to investigate the relationship between the peak value of the difference signal and the elastic stress, the elastic stress of AL5083 is carried out. The experimental results show that the peak value of the difference signal is a linear with the applied elastic stress. On the other hand, the peak value of the difference signal by COMSOL FEM software simulation is a linear with the electrical conductivity changes. Therefore, the peak value can be adopted to estimate the electrical conductivity distribution and the applied stress distribution.
(2)In order to estimate the residual stress, flat bar samples made of various aluminum-alloys have been tested with different PEC probes such as circular and rectangular coils. The research results show that the elastic dependencies exhibit non-linearity in many cases. These verify that there are the elastic stress and plastic deformation on aluminum-alloys. The plastic deformation sample on aluminum-alloys can be tested using PEC probe through“equivalent elastic coefficient”extracted.“Equivalent elastic coefficient”of AL2024 is decreased with the plastic deformation increased using the circular probe and rectangular transverse probe. Overall the PEC responses obtained on the tested materials have demonstrated sufficient sensitivities to tensile stress and plastic deformation.
(3)In order to estimate on the different depth stress, PEC response of variable pulse width excitation has been calibrated with respect to known values of electrical conductivity standards. The obtained calibration dependence in principle component analysis (PCA) space has been used to evaluate electrical conductivities of other test materials. The experimental results show that the electrical conductivity PCA space is very efficient to estimate on the stress of the multi-layer metal materials. To verify the validity of the calibration dependence in PCA space, the experiment of bending AL2024 is also carried out. The experimental results verify our stress profile inspection methods using PCA based PCA. The agreement between theory and experiment shows that the present method can be used to estimate on the stress profile of aerospace aluminum-alloys.
引文
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