零件表面损伤对再制造修复件承载能力影响的超声相控阵检测研究

零件使用过程中出现的表面损伤会影响其再制造修复时的界面结合质量,从而降低承载能力。为得到零件表面损伤大小对修复件承载能力的影响,对表面预制不同宽度损伤的基体材料进行等离子喷焊再制造修复,采用超声相控阵对施加三点弯曲载荷的修复件进行检测。根据检测结果,提取A扫波形图中二次底波声程,得到不同载荷下二次底波声程变化曲线,根据曲线转折点得出修复件界面裂纹萌生时的载荷F_A;通过定量化处理C扫俯视图中缺陷并计算其面积占比,得到不同载荷下缺陷面积占比的变化曲线,根据曲线转折点得出界面初始缺陷演化时的载荷F_C。结果表明,F_A和F_C都能够反映修复件承载能力与基体表面损伤的线性关系;在误差小于5%的前提下,表面损伤宽度每增加1 mm,修复件承载能力约下降0.1 kN;并且相较于F_A,F_C的大小降低了11.12%,从而能够建立表面损伤对修复件承载能力的影响规律,为评定表面损伤零件的再制造质量提供了及时有效的途径。

Influence of surface damage on load carrying capacity of remanufactured repair parts based on ultrasonic phased array

The surface damage during the use of parts will affect the interface bonding quality during remanufacturing and repair, so that reducing the bearing capacity. In order to obtain the effect of surface damage on the load carrying capacity of repaired parts, plasma arc welding was used to repair the matrix materials with different width of the surface prefabricated damage, and ultrasonic phased array was used to detect the repaired parts with three-point bending load. According to the test results, the sound path of the second bottom wave is extracted from the A-scan waveform, and the change curve of the sound path of the second bottom wave under different loads is obtained, which can get the load at the interface crack initiation of the repair part ( FA ) from the turning point of the curve. By quantifying the defects in the C-scan top view and calculating the area proportion, the change curve of the defect area proportion under different loads is obtained, which can get the load at the interface initial defect evolution of the repair part (FC ) from the turning point of the curve. The results show that both FA and FC can reflect the linear relationship between the load carrying capacity of the repaired parts and the surface damage of the matrix; on the premise of the error less than 5%, the load carrying capacity of the repaired parts decreases by 0. 1 kN for every 1 mm increase in the width of the surface damage. Moreover, compared with FA , the size of FC decreases by 11. 12%, which provides a timely and effective way to evaluate the remanufacturing quality of surface damaged parts.