基于TDC的L_(CR)波切向应力检测方法的研究

基于固体中声速与应力的关系以及临界折射纵波(critically refracted longitudinal wave,LCR)的产生机理,提出一种利用LCR波从表面检测物体内部切向应力的实施方法,并对测量系统的硬件结构和工作原理进行详细阐述。针对应力改变导致的LCR波传播时间的微量变化,系统采用基于逻辑门绝对传输时间原理工作的"时间—数字转换器"(time to digi-tal converter,TDC)来满足高精度的时间间隔测量要求。在测量过程中采用"单端发射—双端接收"的布局模式进一步降低测量误差,以提高应力检测的精度。     

用临界折射纵波测量切向应力时的影响因素研究

研究了基于声弹性理论,利用临界折射纵波(critically refracted longitudinal wave,LCR波)从构件表面测量内部切向应力时的几个关键问题。应力测量接收到的波形非常复杂,其他的波形影响了对LCR波的识别,相关的影响因素也很多,包括楔块角和试块厚度的影响,进行了这两影响因素在LCR波传播中的对比实验,以构建适合测量切向应力的模型系统,达到对各影响因素优化组合的目的。     

临界折射纵波探头声束特性的边界元分析与测量

与其他超声应力测量方法相比,临界折射纵波(LCR波)方法对应力场敏感,受材料组织结构效应影响小,在材料表面或近表面残余应力无损测量中具有突出的优势.本文应用边界元方法对LCR波探头发射的临界折射纵波的传播特性和声束特性进行分析并进行了实验测量.建立了IIW试块圆弧反射部分的三维边界元模型.通过数值分析,清楚显示了LCR波在IIW试块中的传播过程,给出了LCR波探头的主声束指向特性.计算结果为有关LCR波应力测量中声波能量有效渗透深度和能量层厚度的确定提供了理论依据.利用IIW试块实验测量了LCR波探头的声束特性,实验测量与数值分析结果符合得很好.本文的研究结果对研究厚板材料内部切向残余应力的LCR波测量方法具有指导意义.     

管道焊缝残余应力超声环形组合测量方法

重点阐述基于临界折射纵波(LCR波)的超声环形组合探头管道焊缝残余应力的测量方法,该方法用于实际测量,可提高管道焊缝残余应力检测的效率。详细介绍了检测系统硬件和软件,并对残余应力与纵波声速的线性关系进行实验分析,通过切块分离法验证了该方法测量输送管道焊缝残余应力的可行性。     

超声法的残余应力场无损检测与表征

残余应力对机械构件的服役性能具有重大影响,尤其是对其强度、疲劳寿命和尺寸稳定性。如何快速、无损和准确的评估出构件表面或一定深度内的残余应力状态一直是研究难点和热点问题。为了解决这一问题,基于声弹性理论,采用超声波无损检测技术,研究超声波传播速度和方向与应力的关系,对比不同类型超声波对应力的敏感程度,发现沿应力方向传播的纵波波速受应力的影响最大。设计了一发一收斜入射探头,通过激发出的临界折射纵波(LCR波)来检测被测件的残余应力。针对深度梯度残余应力的检测,建立了超声梯度检测模型,利用超声频率与渗透深度的关系推导了应力梯度计算公式。设计C形应力试样,通过该试样产生的应力梯度来验证残余应力场的超声表征。     

用LCR波检测零件内部切向应力的实验研究

本文介绍了一种基于声弹性理论,利用临界折射纵波（Critically Refracted Longitudinal．LCR）从表面测量零件内部切向应力的方法．依据固体中超声波传播特性与应力状态的关系,搭建了基于传播声时的实验测量系统．在传播声时的测量中采用“过零检测”方式减小由超声波信号幅度变化造成的误差,利用时间-数字芯片实现高精度的时间间隔测量。     

金属材料表面残余应力超声测量方法

针对金属材料零件制造中的表面残余应力无损检测难题,提出一种平面应力状态超声测量方法.基于线弹性理论,引入晶粒取向表征因子,揭示晶粒取向对超声传播的影响机制.虑及材料力学性质(弹性常数、晶粒取向等)和应力状态对声速的共同影响,建立平面应力分量-声速解耦模型.基于临界折射纵波(LCR波)表面应力测量原理,分析温度与耦合状态对超声信号衰减、畸变以及声时的影响规律,并设计出一种一发双收直接耦合造波探头.以单向拉伸的变截面铝合金板和搅拌摩擦焊后的轧制铝合金板为典型对象,利用自主开发的超声应力测量系统进行表面应力测量试验,分别与有限元法和小孔法进行对比,应力测量结果具有良好的一致性,可为金属材料表面残余应力测量提供可行方案.     

基于相位-频率测量的材料残余应力超声表征方法*

针对材料中残余应力无损检测的问题,提出一种基于相位-频率关系测量超声信号传播时间的方法,并以声弹性理论为基础,采用纵波和横波相结合的测量模式,建立残余应力的超声测量方法。该超声测量方法应用于焊接接头的残余应力测量,不仅能够表征两轴方向上的残余应力,而且还适用于短距离声时的精确测量,测量精度达到9 mm试样距离上0.3 ns的分辨率(加载应力为20 MPa)。制作16Mn钢材料的焊接接头,并采用所提出的超声测量方法对焊接接头的残余应力分布进行测量。同时,采用理论计算、X射线衍射技术等分别对16Mn钢材料的声弹性参数及焊接接头残余应力分布进行验证测量。研究结果表明基于相位-频率精确测量声时的残余应力超声测量方法具有较高的应力分辨率和较好的测量稳定性,可适用于焊接接头两轴方向上的残余应力表征。     

智能豪克能应力消除及检测系统

针对机械构件存在的残余应力,研究开发了智能豪克能应力消除及检测系统。该系统将智能机器人与豪克能应力消除设备及磁测应力测量系统三者集成,模拟豪克能执行器消除残余应力的最佳运动轨迹及方式,通过豪克能方式来改变构件原有的应力场,消除残余拉应力,并产生一定数值的压应力。磁测应力测量系统自动测量构件焊缝残余应力并具备应力梯度测量、应力云图测量功能,其中加工参数、工作参数、动态变化曲线和应力测量结果可以统计、查询、打印、汇总,同时具备保存和无线传输功能。     

用磁法检测不锈钢残余应力的探讨

残余应力的存在,将影响构件的静载强度、疲劳强度、抗应力腐蚀等性能及尺寸的稳定性,严重时将直接引发裂纹缺陷。以地磁场为磁源,根据残余应力使材料磁导率改变的特性,通过微磁检测技术检测304不锈钢表面的磁场强度变化,为其内部残余应力进行了定位和初步定量。通过测量退火前后304不锈钢内部磁场强度的变化来确定残余应力的变化。通过检测数据发现残余应力大小与磁场强度之间有密切关系,在退火前后其残余应力改变的幅值一定,而磁场强度所改变的幅值也相对稳定。用磁法检测304不锈钢的残余应力是可行的。     

Nondestructive testing and characterization of residual stress field using an ultrasonic method

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel(12%C) as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave (LCR wave) is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designedto conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.     

RAPID AND NONDESTRUCTIVE MEASUREMENT SYSTEM FOR WELDING RESDlUAL STRESS BY ULTRASONIC METHOD

Traditional methods of residual stress measurement are generally destructive or semi-destructive, as well as expensive, time-consuming and complex to implement. With the new development of welded structure, traditional methods can not satisfy the need of full life task management. So the acoustical theory is introduced, since the ultrasonic technique provides a useful nondestructive tool in the evaluation of stresses. In this study an ultrasonic stress measurement experimental installation is established, which consists of a special transducer, a signal emission unit and a signal recipient processing unit. Longitudinal critically refracted wave is selected as the measurement wave mode. The supporting software is programmed by Labview software. The longitudinal residual stress and transverse residual stress of twin wire welded plate are measured by this installment, in which the measuring process is real-time, quick and nondestructive. The experiment results indicate that the system can satisfy the need of life evaluation for welded structure. The system is light and portable.     

RAPID AND NONDESTRUCTIVE MEASUREMENT SYSTEM FOR WELDING RESDIUAL STRESS BY ULTRASONIC METHOD

Traditional methods of residual stress measurement are generally destructive or semi-destructive, as well as expensive, time-consuming and complex to implement. With the new development of welded structure, traditional methods can not satisfy the need of full life task management. So the acoustical theory is introduced, since the ultrasonic technique provides a useful nondestructive tool in the evaluation of stresses. In this study an ultrasonic stress measurement experimental installation is established, which consists of a special transducer, a signal emission unit and a signal recipient processing unit. Longitudinal critically refracted wave is selected as the measurement wave mode. The supporting software is programmed by Labview software. The longitudinal residual stress and transverse residual stress of twin wire welded plate are measured by this installment, in which the measuring process is real-time, quick and nondestructive. The experiment results indicate that the system can satisfy the need of life evaluation for welded structure. The system is light and portable.     

Computer-controlled system for measuring two-dimensional acoustic velocity fields

An automatic system is described for measuring two-dimensional acoustic velocity fields in solid samples. The measurement is performed by a computer-controlled, mechanically scanned transducer in a liquid bath, and is based on measuring the phase delay of the acoustic wave by a two-pulse echo method. Applications include measuring stress fields due both to externally applied and residual stresses, and microstructure studies of solid samples.     

基于收发分体声波换能器的二维温度场重建

基于声学测温原理,运用发射端和接收端之间的声波信号飞行时间进行温度场重建,是工业应用领域中燃烧或加热处理过程温度测量的研究热点。本文采用收发分体声波换能器,确定其合理安装方式,运用Markov径向基拟合待测区域的声速分布,通过声速矩阵的奇异值分解,反演计算出温度场。仿真实验中设计了复杂程度不同的4种模型温度场,并考虑声波飞行时间在不同水平下的测量误差对重建结果的影响;实际测试中验证了本文方法在室温无加热、单峰对称、单峰偏斜的温度分布下的重建效果。实验结果表明,本文提出的收发分体声波换能器安装方式结合基于Markov径向基拟合的重建算法,在温度场重建中具有较高的精度和较强的抗干扰性。     

基于激光测振仪的兰姆波离面和面内位移检测

激励模态和频响特性是超声导波传感器性能评估的两个重要指标,而传统的传感器,如压电传感器和电磁声传感器(Electromagnetic acoustic transducer,EMAT)等,受自身带宽和模态选择性的影响,无法有效地实现这两个参数的评估。激光测振仪可以测量结构中弹性波原始的离面和面内位移,且测量不受带宽的限制,因而是进行超声导波传感器激励模态测定和频响特性测量的理想方法之一。采用此种方法对一种周向一致激励兰姆波的EMAT进行测试,结果表明,此传感器在150～210 kHz的范围内能激励产生出单一S0模态兰姆波,在50～150 kHz范围内,A0模态与S0模态共存。利用激光测振仪检测离面和面内位移的方法,是进行传感器评估和兰姆波接收的有效方法,在超声导波的非接触测量、高温波导体检测及弹性波传播3D可视化方面也有广阔的应用前景。     

基于广义互功率谱的温度检测方法

声温法是基于声波与CT技术相结合的非接触测温法,声波信号飞渡时间的精确测量是温度场检测的关键环节,在低信噪比、复杂混响的背景环境下,传统相关算法无法准确计算出声信号的时延。采用广义互功率谱相位分析算法来克服背景环境中乘积性干扰和卷积性干扰,通过对采样信号进行白化处理,并随信噪比的变化调整互功率谱的权值,来提高时延估计算法的抗噪声与抗混响能力。理论推导和实验结果分析证明,与传统相关函数分析算法和互功率谱相位时延算法进行比较,新互谱算法能有效克服噪声和混响干扰,锐化峰值,准确估计出声信号的时延。