CN111610257B - Array ultrasonic focusing imaging correction method for metal additive manufacturing heterogeneous tissue - Google Patents

Array ultrasonic focusing imaging correction method for metal additive manufacturing heterogeneous tissue Download PDF

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CN111610257B
CN111610257B CN202010417698.2A CN202010417698A CN111610257B CN 111610257 B CN111610257 B CN 111610257B CN 202010417698 A CN202010417698 A CN 202010417698A CN 111610257 B CN111610257 B CN 111610257B
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张俊
李晓红
杨兵
丁辉
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Wuhan University WHU
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    • G01MEASURING; TESTING
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    • G01N29/00Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
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Abstract

The invention discloses an array ultrasonic focusing imaging correction method for a metal additive manufacturing heterogeneous tissue, which comprises the following steps: constructing a spatial structure model of the heterogeneous medium; the elastic constant of the transverse isotropic structure was measured: measuring 5 elastic constants of transverse isotropy of the sample by using an X-ray diffraction calibration method to form an elastic matrix C; setting an initial angle of ultrasonic incidence of the array ultrasonic first array element position; calculating the sound ray termination point F' of the focal plane in a forward direction; reversely calculating the sound ray termination point P' of the excitation position plane; circularly calculating to obtain the sound propagation time between the excitation point and the focus point; calculating an array ultrasonic time delay matrix; and superposing the ultrasonic signals according to the delay matrix to obtain corrected focusing imaging. The method can solve the problem of failure of the traditional array ultrasonic focusing method caused by signal phase distortion generated by the additive heterogeneous tissue, and realizes high-resolution imaging detection of internal defects of the additive parts.

Description

Array ultrasonic focusing imaging correction method for metal additive manufacturing heterogeneous tissue
Technical Field
The invention belongs to the field of printing detection, relates to an ultrasonic array focusing imaging technology, and particularly relates to an array ultrasonic focusing imaging correction method for manufacturing a heterogeneous tissue by using a metal additive.
Background
Metal additive manufacturing is a revolutionary, core technology for advanced and smart manufacturing. The reciprocating cyclic characteristic of metal additive manufacturing, namely 'point-by-point scanning/layer-by-layer accumulation', inevitably generates various special process defects different from those of the traditional manufacturing. The lack of quality detection means in the additive manufacturing process has become a significant bottleneck restricting the technical development and popularization and application thereof.
The array ultrasonic detection technology comprises laser phased array ultrasonic, piezoelectric phased array ultrasonic, full-focus ultrasonic and the like. For homogeneous isotropic materials, these detection techniques perform phase adjustment by time delay superposition, enabling focused imaging of internal defects. However, the point-to-point stacking characteristic of metal additive manufacturing causes the generation of a layered columnar crystal structure along the growth direction, and the layered columnar crystal structure is characterized by acoustic anisotropy. And each printed layer is different according to the scanning direction, and the periodic grain inclination is continuously accumulated by a molten pool and a heat affected zone thereof, so that the characteristic acoustic heterogeneous characteristic is generated. If the heterogeneous additive structure is similar to a spatial structure formed by a series of micro areas with similar crystal grain orientation and heterogeneous interfaces thereof, when ultrasound passes through each homogeneous micro area, the propagation direction and speed can generate time delay and phase distortion different from those of an anisotropic medium due to the disturbance of the heterogeneous interfaces. The traditional focusing method fails due to abnormal time delay and phase aberration accumulation caused by metal additive heterogeneous tissues. Therefore, in order to realize high-resolution detection of the internal defect of the additive tissue, it is necessary to provide a method capable of correcting the time delay of the array ultrasound and realizing focusing imaging.
Disclosure of Invention
The invention aims to provide an array ultrasonic focusing imaging correction method for a metal additive manufacturing heterogeneous tissue, which aims to solve the problem that a traditional array ultrasonic focusing method fails due to abnormal time delay and phase distortion of ultrasonic signals generated by the additive heterogeneous tissue, and finally realizes high-resolution imaging detection of internal defects of an additive product.
In order to solve the technical problems, the technical scheme adopted by the invention is as follows:
an array ultrasonic focusing imaging correction method for a metal additive manufacturing heterogeneous tissue is characterized by comprising the following steps:
s1, constructing a spatial structure model of the heterogeneous medium, which specifically comprises the following steps: intercepting a sample with a certain length along the printing growth direction of the additive product sample, obtaining a grain orientation distribution diagram by utilizing an electron back scattering diffraction technology, setting a region with similar grain orientation as a homogeneous region to be used as a homogeneous layer, and measuring the layer thickness d and the grain inclination angle alpha of each layeri,i=1,2…N, N is the total number of layers, and a spatial structure model formed by the layer thickness and the inclination angle of each layer of crystal grains is constructed;
s2, measuring an elastic constant of the transverse isotropic structure: measuring 5 elastic constants C of transverse isotropy of additive product sample by using X-ray diffraction calibration method11、C12、C13、C33And C44Forming an elastic matrix C;
s3, drawing slowness curve graphs of different sound beam propagation angles, which specifically comprises the following steps: constructing a quantitative relation v ═ f (theta, alpha) between the sound beam propagation angle theta and the propagation velocity v of the transverse isotropic material based on the Criserstoff equationiAnd C), drawing a slowness curve graph of the adjacent homogeneous layers;
s4, setting an initial angle of ultrasonic incidence of a first array element position of the array ultrasonic, specifically: taking the included angle between the connecting line of the first array element excitation point P and the focusing point F and the normal of the excitation point as an initial incident angle;
s5, calculating the sound ray termination point F' of the focal plane in a forward direction, specifically: setting an initial angle of ultrasonic incidence at an excitation position, and sequentially determining the sound velocity c passing through each homogeneous layer in the spatial structure model according to the initial incidence angle, the grain inclination angle and the slowness curve diagramsiAnd a propagation path L of refracted sound rayssiUntil reaching the depth of the focus point F, and calculating the coordinates F' of the sound ray end point, and the ultrasonic propagation time ts=∑Lsi/csi
S6, reversely calculating the sound ray termination point P' of the excitation position plane, specifically: according to a reciprocity principle, taking the F' point and the middle point of the F point as emission points, and sequentially calculating the sound velocity c in the backward propagation process according to the method of S5RiAnd a propagation path L of refracted sound raysRiAnd the sound ray end point P' on the excitation plane, the inverse ultrasound propagation time tR=∑LRi/cRiObtaining the total time t' of ultrasonic propagation as t ═ tR+ts
S7, circularly calculating to obtain the total sound propagation time t between the excitation point and the focus pointj'=tR+tsJ represents the number of calculations, j is large2 or lower, in particular: and (5) taking the middle point of the excitation points P and P 'as a transmitting point, and circulating the step (S5) and the step (S6) until the total time change delta t't of the ultrasonic propagation of two adjacent cyclesj′-tj-1' less than threshold t0At this point, time tj' Total propagation time t as first array position with respect to the focal point F1
S8, calculating an array ultrasonic time delay matrix, which specifically comprises the following steps: repeating the steps S4-S7, calculating the total propagation time of all M excitation array elements of the array ultrasound relative to the focus point F in sequence, and subtracting the total propagation time t of the first array element1To obtain the time delay matrix Δ t ═ 0, t2-t1,t3-t1,…,tM-t1];
S9, superposing the ultrasonic signals according to the time delay matrix to obtain corrected focusing imaging, which specifically comprises the following steps: sequentially translating and superposing signals S (M, t) of all the excitation array elements, wherein M is 1 and 2 … M according to a delay matrix to obtain signals for correcting a focus point
Figure GDA0003096037830000021
m represents the excitation array element number.
Preferably, in step S4, the specific excitation and reception form of the array ultrasound is a laser ultrasound array or a piezoelectric ultrasound array, and the array arrangement form is a one-dimensional array or a two-dimensional array.
Preferably, in step S1, the thickness d of the homogeneous layer is specifically defined as a weld pool fusion line.
Preferably, in step S1, the thickness d of the homogeneous layer is smaller than or equal to the print layer thickness of the additive sample.
Preferably, in step S1, the number of homogeneous layers is determined according to the actual target detection depth and layer thickness.
Preferably, in step S5, the slowness map specifically includes quasi-longitudinal waves and two polarization types of transverse waves.
Preferably, in step S7, the threshold t is set0' the range is 1.5-2.5 ns.
The invention has the beneficial effects that:
according to the method, firstly, a heterogeneous medium is divided into a series of continuous homogeneous areas, and time delay change of array ultrasound after the array ultrasound passes through the continuous areas is calculated, so that array ultrasound focusing imaging is corrected, and high-resolution detection of internal defects in metal additive manufacturing is realized; secondly, the invention constructs a space structure model based on the self organization characteristics of the printing material, and the construction method can be suitable for two mainstream metal additive manufacturing technologies of direct energy deposition and selective powder bed cladding; finally, the time delay method is suitable for various array forms such as laser array ultrasound, piezoelectric array ultrasound and the like, so that various detection forms such as non-contact type and contact type of industrial components can be realized based on the array ultrasound, and the time delay method can be applied to online and offline detection.
Drawings
FIG. 1 is a schematic spatial structure of a heterogeneous tissue according to an embodiment of the present invention;
FIG. 2 is a schematic illustration of an ultrasound propagation slowness curve and propagation direction in an embodiment of the present invention;
fig. 3 is a schematic diagram of a path of ultrasound traversing a continuous region in an embodiment of the present invention.
Fig. 4 is a schematic diagram of delayed superposition of ultrasonic signals according to an embodiment of the present invention.
Detailed Description
The embodiments of the present invention will be described in further detail with reference to the drawings and examples. The following examples are intended to illustrate the invention but are not intended to limit the scope of the invention.
The invention is described in detail below with reference to the following drawings and specific embodiments.
Example 1:
an array ultrasonic focusing imaging correction method for metal additive manufacturing heterogeneous tissues comprises the following steps:
s1, constructing a spatial structure model of a heterogeneous medium:
additive printing of stainless steel of certain thickness by using laser direct energy deposition additive manufacturing methodCutting a sample with a certain length along the printing growth direction of the additive manufactured sample, obtaining a grain orientation distribution diagram by using an Electron Back Scattering Diffraction (EBSD) technology, setting areas with similar grain orientations as homogeneous areas to be used as a homogeneous layer, and measuring the layer thickness d and the grain inclination angle alpha of each homogeneous layeri(i ═ 1,2 … N, N is the total number of layers), a spatial structure model was constructed consisting of the layer thickness of the homogeneous layer and the grain tilt angle, as shown in fig. 1;
s2, measuring the elastic constant of the transverse isotropic structure:
measurement of 5 elastic constants C of transverse isotropy of sample by X-ray diffraction calibration11、C12、C13、C33And C44Forming an elastic matrix C;
s3, drawing slowness curve graphs of different sound beam propagation angles:
constructing a quantitative relation v ═ f (theta, alpha) between the sound beam propagation angle theta and the propagation velocity v of the transverse isotropic material based on the Criserstoff equationiC), and plotting slowness curves of adjacent printed layers, as shown in fig. 2;
s4, setting an initial angle of ultrasonic incidence of a first array element position of the array ultrasonic:
taking the included angle between the connecting line of the first array element excitation point P and the focusing point F and the normal of the excitation point as an initial incident angle;
s5, calculating the sound ray termination point F' of the focal plane in a forward direction:
setting an initial angle of ultrasonic incidence at an excitation position: sequentially determining the sound velocity c passing through each homogeneous layer in the space structure model according to the initial incident angle, the grain inclination angle and the slowness curve chartsiAnd a propagation path L of refracted sound rayssiUntil reaching the depth of the focus point F, and calculating the coordinates F' of the sound ray end point, and the ultrasonic propagation time ts=∑Lsi/csiAs shown in fig. 3;
s6, reversely calculating the sound ray termination point P' of the excitation position plane:
according to the reciprocity principle, taking the F' point and the middle point of the F point as the emission points, and sequentially adopting the method S5Calculating the speed of sound c in the process of back propagationRiAnd a propagation path L of refracted sound raysRiAnd the sound ray end point P' on the excitation plane, the inverse ultrasound propagation time tR=∑Lsi/csiAs shown in fig. 3, the total ultrasound propagation time t' is obtained as t ═ tR+ts
S7, circularly calculating to obtain the total sound propagation time t between the excitation point and the focus pointj'=tR+tsThe subscript j represents the number of calculations:
taking the middle point of the excitation points P and P 'as a transmitting point, and circulating the steps S5 and S6 until the total time change Delta t' of the ultrasonic propagation of two adjacent cycles is tj′-tj-1' less than threshold t0At this point, time tj' Total propagation time t as first array position with respect to the focal point F1Threshold value t0' the range is 1.5-2.5ns, preferably 2ns in this example;
s8, calculating an array ultrasonic time delay matrix:
repeating the steps S4-S7, calculating the propagation time of all M excitation array elements of the array ultrasound relative to the focusing point F in sequence, and subtracting the first array element propagation time t1To obtain the time delay matrix Δ t ═ 0, t2-t1,t3-t1,…,tM-t1];
S9, superposing the ultrasonic signals according to the time delay matrix to obtain corrected focusing imaging:
sequentially translating and superposing signals S (M, t) of all the excitation array elements, wherein M is 1 and 2 … M according to a delay matrix to obtain signals for correcting a focus point
Figure GDA0003096037830000051
m denotes the excitation array element number as shown in fig. 4.
According to the method, the heterogeneous medium is divided into a series of continuous homogeneous areas, and the time delay change of the array ultrasound after passing through the continuous areas is calculated, so that the array ultrasound focusing imaging signal is corrected, and the method can be applied to high-resolution detection of internal defects in metal additive manufacturing; the method constructs a space structure model based on the grain orientation distribution characteristics and the mechanical property parameters of the self-organization of the printing material, and the construction method can be suitable for two mainstream metal additive manufacturing technologies of direct energy deposition and selective powder bed cladding; the array ultrasonic time delay method is suitable for various array forms such as laser array ultrasonic and piezoelectric array ultrasonic, and therefore non-contact and contact of industrial parts can be achieved based on array ultrasonic.
It should be noted that, in general, the thickness of the homogeneous layer is equal to the thickness of the printing layer, that is, each printing layer is a homogeneous layer, and this is relevant to the printing process, and of course, some of the printing layers include multiple homogeneous layers, specifically based on the grain orientation distribution map obtained by the electron back scattering diffraction technique.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes or modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.

Claims (7)

1. An array ultrasonic focusing imaging correction method for a metal additive manufacturing heterogeneous tissue is characterized by comprising the following steps:
s1, constructing a spatial structure model of the heterogeneous medium, which specifically comprises the following steps: intercepting a sample with a certain length along the printing growth direction of the additive product sample, obtaining a grain orientation distribution diagram by utilizing an electron back scattering diffraction technology, setting a region with similar grain orientation as a homogeneous region to be used as a homogeneous layer, and measuring the layer thickness d and the grain inclination angle alpha of each layeriI is 1,2 … N, N is the total layer number, and a spatial structure model formed by the layer thickness and the inclination angle of each layer of crystal grains is constructed;
s2, measuring an elastic constant of the transverse isotropic structure: measuring 5 elastic constants C of transverse isotropy of additive product sample by using X-ray diffraction calibration method11、C12、C13、C33And C44Form a bulletA sexual matrix C;
s3, drawing slowness curve graphs of different sound beam propagation angles, which specifically comprises the following steps: constructing a quantitative relation v ═ f (theta, alpha) between the sound beam propagation angle theta and the propagation velocity v of the transverse isotropic material based on the Criserstoff equationiAnd C), drawing a slowness curve graph of the adjacent homogeneous layers;
s4, setting an initial angle of ultrasonic incidence of a first array element position of the array ultrasonic, specifically: taking the included angle between the connecting line of the first array element excitation point P and the focusing point F and the normal of the excitation point as an initial incident angle;
s5, calculating the sound ray termination point F' of the focal plane in a forward direction, specifically: setting an initial angle of ultrasonic incidence at an excitation position, and sequentially determining the sound velocity c passing through each homogeneous layer in the spatial structure model according to the initial incidence angle, the grain inclination angle and the slowness curve diagramsiAnd a propagation path L of refracted sound rayssiUntil reaching the depth of the focus point F, and calculating the coordinates F' of the sound ray end point, and the ultrasonic propagation time ts=∑Lsi/csi
S6, reversely calculating the sound ray termination point P' of the excitation position plane, specifically: according to a reciprocity principle, taking the F' point and the middle point of the F point as emission points, and sequentially calculating the sound velocity c in the backward propagation process according to the method of S5RiAnd a propagation path L of refracted sound raysRiAnd the sound ray end point P' on the excitation plane, the inverse ultrasound propagation time tR=∑LRi/cRiObtaining the total time t' of ultrasonic propagation as t ═ tR+ts
S7, circularly calculating to obtain the total sound propagation time t between the excitation point and the focus pointj'=tR+tsJ represents the number of times of calculation, j is greater than or equal to 2, specifically: and (5) taking the middle point of the excitation points P and P 'as a transmitting point, and circulating the step (S5) and the step (S6) until the total time change delta t't of the ultrasonic propagation of two adjacent cyclesj′-tj-1' less than threshold t0At this point, time tj' Total propagation time t as first array position with respect to the focal point F1
Step (ii) ofS8, calculating an array ultrasonic time delay matrix, which specifically comprises the following steps: repeating the steps S4-S7, calculating the total propagation time of all M excitation array elements of the array ultrasound relative to the focus point F in sequence, and subtracting the total propagation time t of the first array element1To obtain the time delay matrix Δ t ═ 0, t2-t1,t3-t1,…,tM-t1];
S9, superposing the ultrasonic signals according to the time delay matrix to obtain corrected focusing imaging, which specifically comprises the following steps: sequentially translating and superposing signals S (M, t) of all the excitation array elements, wherein M is 1 and 2 … M according to a delay matrix to obtain signals for correcting a focus point
Figure FDA0003096037820000021
m represents the excitation array element number.
2. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in step S4, the specific excitation and reception form of the array ultrasound is a laser ultrasound array or a piezoelectric ultrasound array, and the array arrangement form is a one-dimensional array or a two-dimensional array.
3. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in step S1, the thickness d of the homogeneous layer is specifically defined as a weld line of the molten pool.
4. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in step S1, the thickness d of the homogenous layer is less than or equal to the print layer thickness of the additive sample.
5. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in step S1, the number of homogeneous layers is determined according to the actual target detection depth and layer thickness.
6. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in step S5, the slowness graph specifically includes quasi-longitudinal waves and two polarization types of transverse waves.
7. The array ultrasonic focused imaging correction method for the metal additive manufacturing heterogeneous tissue according to claim 1, characterized in that: in the step S7, the threshold t0' the range is 1.5-2.5 ns.
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