CN101806778B - Method for non-linear ultrasonic online detection of early fatigue damage of metal material - Google Patents
Method for non-linear ultrasonic online detection of early fatigue damage of metal material Download PDFInfo
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Abstract
A method for the non-linear ultrasonic online detection of early fatigue damage to a metal material belongs to the field of nondestructive detection. The method comprises the following steps: determining an excitation signal parameter according to the thickness of a tested piece and inputting the parameter to an arbitrary function generator to generate a sound signal; determining a threshold value of an acoustic emission instrument according to the amplitude of a no-load noise signal; performing fatigue loading on the tested piece, continuously detecting an acoustic emission signal in real time with an acoustic emission sensor, amplifying the acoustic emission signal, inputting the acoustic emission signal into the acoustic emission instrument, and judging ring with the acoustic emission instrument when the amplitude of the acoustic emission signal exceeds the preset the threshold value of the acoustic emission instrument; detecting a non-linear ultrasonic signal at equal time interval if the acoustic emission instrument does not display the ring or the times of the continuous ring is not more than an empirical value; and stopping detection if the displayed ring times is more than the empirical value, because fatigue cracks are generated and develop. On the basis of non-linear ultrasonic nondestructive detection, the method of the invention introduces acoustic emission technique, so the method does not make incorrect judgment when detecting the early fatigue damage to the metal material and realizes continuous online detection.
Description
Technical field
The present invention relates to a kind of method of utilizing non-linear ultrasonic and acoustic emission Non-Destructive Testing early fatigue damage to metal material, belong to the Non-Destructive Testing field.
Background technology
Component of machine is because fatigue and fracture failure is a kind of very general phenomenon, and according to estimates, about component of machine inefficacy 70% or more is caused by fatigue damage.Under the effect of external applied load, generally can be divided into three phases the fatigue lifetime of metallic element: the initial and accumulation (nucleation of micro-crack is grown up and the generation of macroscopic cracking) and the last fracture failure of early stage mechanical property degradation (a large amount of generations of dislocation group and the formation of resident slip band and micro-crack), damage.For the good structural detail of design, the phase one generally accounts for 60%～80% of metallic element whole fatigue lifetime.What therefore, effective detection of the early stage mechanical property degradation of development metal material and evaluation means just showed is very important.Existing ultrasonic non-destructive inspection techniques utilizes the linear physical parameters such as time-histories, the velocity of sound and decay of ripple can effectively detect and assess second and phase III of component's life.But above-mentioned linear physical parameter is very insensitive to material and the early stage mechanical property degradation of structure.
Nonlinear effect when the non-linear ultrasonic lossless detection method utilizes sound wave to propagate in metal material (wave form distortion, harmonic wave generation etc.) can detect the incipient fatigue damage of material.Early stage in fatigue, nonlinear factor β increases with the increase of all numbers of fatigue.But a large amount of appearance in the tired later stage owing to fatigue crack, β reduces on the contrary, and dispersed the increase, if utilize the non-linear ultrasonic method that tired earlier damage is detected separately, occurs easily judging by accident.Acoustic emission can carry out continuous monitoring to fatigue crack by tired Analysis of Acoustic Emission Signal is handled, but acoustic emission can not detect the metal material incipient fatigue damage situation before fatigue crack occurs as a kind of " passive " inspection technique.For addressing this problem, adopt non-linear ultrasonic and acoustic emission to detect the incipient fatigue damage of metal material parts jointly.
Summary of the invention
The objective of the invention is to propose a kind of reliable metal material fatigue damage detection method, particularly at the lossless detection method of tired earlier damage.This method can be under the situation of not destroying tested parts, utilizes the cooperation of non-linear ultrasonic and acoustic emission effectively to detect the fatigue damage of metallic element.
The method that the present invention proposes based on non-linear ultrasonic and acoustic emission Non-Destructive Testing metal material incipient fatigue damage, its ultimate principle is:
Because solid dielectric non-linear, the sinusoidal ultrasound wave of single-frequency will and solid dielectric between produce nonlinear interaction, thereby produce higher hamonic wave, the nonlinear effect that nonlinear factor β can exosyndrome material is defined as:
Wherein k=ω/c is a wave number, and ω is an angular frequency, and c is a velocity of wave, A
1And A
2Be respectively first-harmonic and secondary harmonic amplitude, be the distance of ripple propagation.For given frequency and sample length,, just can determine the ultrasound non-linear coefficient of material by measurement to first-harmonic and secondary harmonic amplitude.The non-linear microdefects such as dislocation, crystal zone slippage that mainly come from of metal material.The different fatigue degree of injury has different microdefect configurations, and the size of nonlinear factor is also different, thereby understands the incipient fatigue damage situation of material by nonlinear factor.
As shown in Figure 5, early stage in fatigue, nonlinear factor β increases with the increase of all numbers of fatigue.But a large amount of appearance in the tired later stage owing to fatigue crack, β reduces on the contrary, and dispersed the increase, if utilize the non-linear ultrasonic method that the incipient fatigue damage of metal material is detected separately, occurs easily judging by accident.For example, the ultrasound non-linear coefficient approximately equal when tired all numbers shown in Fig. 5 are 12000 weeks and 29000 weeks so only can't be judged the residing fatigue stage of metal material according to the value of β.
Acoustic emission (Acoustic Emission, be called for short AE) claim the stress wave emission again, be meant material or interior of articles because of internal stress surpass yield limit enter the irreversible plastic yield stage or have crackle to form and when expansion, fracture snap-out release go out the phenomenon that strain energy produces the transient state stress wave.Acoustic emission is with instrument detecting, record, analysis acoustic emission signal and utilizes acoustic emission signal to infer the technology of acoustic emission source that it is the very sensitive technology of microprocess (being crack initiation, expansion) in the test material.Because acoustic emission signal from the defective of material itself, is a kind of " passive " inspection technique, can cause what influence and obstruction hardly to the engineering structure of being on active service for a long time continuously in the development and change of the main position of labour monitoring works structure defective.But acoustic emission can't detect the commitment before the generation fatigue crack.
Therefore can utilize the germinating and the development of acoustic emission monitoring fatigue crack, the commitment of non-linear ultrasonic technology for detection fatigue, can solve the erroneous judgement problem that non-linear ultrasonic detects fatigue damage, can realize again the tired overall process of metal material parts is detected.
The present invention adopts following technical scheme.This device mainly comprises non-linear ultrasonic detection module and acoustic emission monitor(ing) module.As shown in Figure 1, the non-linear ultrasonic detection module mainly contains arbitrary-function generator 1, power amplifier 2, high energy low-pass filter 3, stimulus sensor 4, receiving sensor 5, oscillograph 6 and computing machine 10; The acoustic emission monitor(ing) module mainly contains calibrate AE sensor 7, acoustic emission preamplifier is AE prime amplifier 8, Acoustic radiating instrument 9 and computing machine 10.
The function of each module is as follows:
Arbitrary-function generator 1 can generate Tone burst pumping signal automatically according to the test specimen parameter of input and excitation frequency, periodicity and the amplitude of selection in the non-linear ultrasonic detection module.The waveform that power amplifier 2 is produced arbitrary-function generator 1 carries out signal and amplifies.The function of high energy low-pass filter 3 then is the high-frequency harmonic signal that filtering is produced by power amplifier 2 radio frequency doors in testing process.High voltage pumping signal about the 300V that is exaggerated reaches compressional wave stimulus sensor 4 by concentric cable.Be coupled into test specimen by stimulus sensor 4 pumping signals.The receiving sensor 5 that is installed in opposite side detects the light current of coming by the test specimen transmission and presses ultrasonic signal, and gives oscillograph 6 and show and preserve.
Calibrate AE sensor 7 can be gathered the acoustic emission signal that is produced by test specimen in the acoustic emission monitor(ing) module.Send into Acoustic radiating instrument 9 after acoustic emission signal is amplified through AE prime amplifier 8 and carry out signal Processing, when the acoustic emission signal amplitude threshold value default above Acoustic radiating instrument, Acoustic radiating instrument is judged ring.
In order to encourage the strongest signal, the centre frequency of stimulus sensor 4 is consistent with exciting signal frequency.In order to receive the strongest second harmonic signal, the centre frequency of receiving sensor 5 is 2 times of stimulus sensor 4 centre frequencies.Stimulus sensor 4, receiving sensor 5 and calibrate AE sensor 7 contact with test specimen by couplant such as vaseline etc.
Oscillograph 6 is reception, demonstration and processing of being responsible for signal with computing machine 10.By the processing and the analysis of 10 pairs of acoustic emission signals of computing machine, can judge whether fatigue crack occurs.Handle by 10 pairs of non-linear ultrasonic signal of computing machine, calculate the ultrasound non-linear factor beta, and understand the incipient fatigue damage situation of test specimen according to β.
Non-linear ultrasonic and acoustic emission detection method that the present invention proposes are carried out according to the following steps:
1) determines excitation signal cycle number, frequency and amplitude according to the thickness of test specimen, in order to reduce the harmonic interference that instrument and enchancement factor produce, get test specimen thickness direction can hold not with the overlapping maximum cycle number of received signal as sine pulse string signal periodicity.Selected pumping signal parameter input arbitrary-function generator 1 is generated required single audio frequency signal.Noise signal amplitude during according to zero load is determined the Acoustic radiating instrument threshold value.
2) according to the detection system of building shown in Figure 1.
3) carrying out fatigue to test specimen loads, in the test specimen fatigue process, detect acoustic emission signal continuously in real time by calibrate AE sensor 7, and acoustic emission signal is amplified back input Acoustic radiating instrument 9 via AE prime amplifier 8 carry out Treatment Analysis, when the threshold value that the acoustic emission signal amplitude is preset above Acoustic radiating instrument 9, Acoustic radiating instrument is judged ring.Data deposit computing machine in the most at last.
4) do not surpass the empirical value that experiment is determined if Acoustic radiating instrument 9 shows ring or continuous ringing number of times, then constant duration detects non-linear ultrasonic signal.
Concrete steps are as follows:
The single audio frequency ultrasonic signal that is produced by function generator 1 is sent to after power amplifier 2 amplifies, by the high-frequency harmonic signal of high energy low-pass filter 3 filterings by the power amplifier generation, this signal is transferred to stimulus sensor 4 then, excitation longitudinal ultrasonic ripple in test specimen.The receiving sensor 5 that is installed in opposite side detects the light current of coming by the test specimen transmission and presses ultrasonic signal, and gives oscillograph 6 and show and preserve.The signal that utilizes 10 pairs of oscillographs of computing machine 6 to preserve carries out Fourier transform, obtains fundamental voltage amplitude A
1With secondary harmonic amplitude A
2, and through type (1) calculates the ultrasound non-linear factor beta, understands the incipient fatigue damage situation of test specimen according to β.
Repeat above-mentioned steps at regular intervals and detect non-linear ultrasonic signal.
5) surpassed the empirical value that experiment is determined if Acoustic radiating instrument 9 shows the continuous ringing number of times, showing has fatigue crack initiation and development, detection of end.
The present invention mainly has the following advantages: (1) makes non-linear ultrasonic erroneous judgement can not occur when detecting the incipient fatigue damage of metal material in introducing acoustic emission on the basis of non-linear ultrasonic Non-Destructive Testing; (2) adopt non-linear ultrasonic and acoustic emission can realize the tired overall process of metal material parts is detected; (3) realized continuous on-line detection to test specimen.
Description of drawings
Fig. 1 pick-up unit schematic diagram;
Among the figure: 1, function generator, 2, power amplifier, 3, the high energy low-pass filter, 4, stimulus sensor, 5, receiving sensor, 6, oscillograph, 7, calibrate AE sensor, 8, the AE prime amplifier, 9, Acoustic radiating instrument, 10, computing machine.
Fig. 2 detection method process flow diagram;
Fig. 3 test specimen size synoptic diagram;
Fig. 4 non-linear ultrasonic detection signal figure;
(a) pumping signal, (b) received signal, (c) fundamental voltage amplitude, (d) secondary harmonic amplitude
Fig. 5 nonlinear factor and tired all number relation curves;
Embodiment
Describe present embodiment in detail below in conjunction with Fig. 1～Fig. 5.
As shown in Figure 3, test specimen is thick 7.5mm in this experimental example, the AZ31 magnesium alloy dog hone lamella spare of long 150mm.Density is 1770kg/m
3, longitudinal wave velocity is 5763m/s.Yield limit 199MPa, strength degree 259MPa.
1) determines that according to the stimulus sensor centre frequency exciting signal frequency is 5MHz, in order to reduce the harmonic interference that instrument and enchancement factor produce, get test specimen thickness direction can hold not with the overlapping maximum cycle number of received signal as sine pulse string signal periodicity, shown in Fig. 4 (a).A pair of centre frequency is respectively the Panametrics arrowband PZT ultrasonic probe of 5MHz and 10MHz as excitation and receiving sensor.
2) select R15 calibrate AE sensor and LOCAN320 Acoustic radiating instrument for use.Noise signal amplitude during according to zero load determines that the Acoustic radiating instrument threshold value is 40dB.The acoustic emission signal amplitude surpasses 40dB, and Acoustic radiating instrument is just judged ring, if according to experiment experience 5 continuous ringing takes place then think that test specimen has germinated fatigue crack.
3) build detection system according to Fig. 1 pick-up unit schematic diagram.Utilize MTS810 fatigue of materials experimental machine that test specimen is carried out fatigue and load, loading stress get yield limit ± 65% (± 129MPa), tired frequency 10Hz.
4) detect acoustic emission signal continuously in real time by calibrate AE sensor 7, and acoustic emission signal is amplified back input Acoustic radiating instrument 9 via AE prime amplifier 8 carry out Treatment Analysis, Acoustic radiating instrument 9 is judged ring when the acoustic emission signal amplitude surpasses 40dB.Data deposit computing machine in the most at last.
5) if Acoustic radiating instrument 9 does not show ring or continuous ringing number of times not to be surpassed 5 times, then every tired 300 weeks of test specimen are detected a non-linear ultrasonic signal.
Concrete steps are as follows:
The single audio frequency ultrasonic signal that is produced by function generator 1 is shown in Fig. 4 (a), be sent to after power amplifier 2 amplifies, by the high-frequency harmonic signal of high energy low-pass filter 3 filterings by the power amplifier generation, this signal is transferred to stimulus sensor 4 then, excitation longitudinal ultrasonic ripple in test specimen.The receiving sensor 5 that is installed in opposite side detects the light current of coming by the test specimen transmission and presses ultrasonic signal shown in Fig. 4 (b), and gives oscillograph 6 and show and preserve.The signal that utilizes 10 pairs of oscillographs of computing machine 6 to preserve carries out Fourier transform, obtains the fundamental voltage amplitude A of frequency in the 5MHz position
1Shown in Fig. 4 (c) and frequency at the secondary harmonic amplitude A of 10MHz position
2Shown in Fig. 4 (d), and through type (1) calculating ultrasound non-linear factor beta, draw as shown in Figure 5 nonlinear factor and tired all number relation curves.Understand the incipient fatigue damage situation of test specimen according to this curve.
6) if Acoustic radiating instrument 9 continuous ringing number of times surpass detection of end 5 times.
Claims (1)
1. method for non-linear ultrasonic online detection of early fatigue damage to metal material is characterized in that, adopts as lower device, and this device comprises non-linear ultrasonic detection module and acoustic emission monitor(ing) module; The non-linear ultrasonic detection module includes arbitrary-function generator, power amplifier, high energy low-pass filter, test specimen successively, is installed in stimulus sensor and receiving sensor, oscillograph and the computing machine of test specimen both sides respectively; The acoustic emission monitor(ing) module includes calibrate AE sensor, acoustic emission preamplifier, the Acoustic radiating instrument that is installed in test specimen one side; Acoustic radiating instrument also connects the aforementioned calculation machine;
Carry out according to the following steps:
1) determines excitation signal cycle number, frequency and amplitude according to the thickness of test specimen; Selected pumping signal parameter input arbitrary-function generator is generated the single audio frequency signal; Noise signal amplitude during according to zero load is determined the Acoustic radiating instrument threshold value;
2) build the above-mentioned device that comprises non-linear ultrasonic detection module and acoustic emission monitor(ing) module;
3) carrying out fatigue to test specimen loads, in the test specimen fatigue process, detect acoustic emission signal continuously in real time by calibrate AE sensor, and acoustic emission signal is amplified back input Acoustic radiating instrument via acoustic emission preamplifier carry out Treatment Analysis, when the acoustic emission signal amplitude threshold value default above Acoustic radiating instrument, Acoustic radiating instrument is judged to be ring; Deposit data in computing machine;
4) do not surpass the empirical value that experiment is determined if Acoustic radiating instrument shows ring or continuous ringing number of times, then constant duration detects non-linear ultrasonic signal; Concrete detection non-linear ultrasonic signal step is as follows:
The single audio frequency ultrasonic signal that is produced by arbitrary-function generator is sent to after power amplifier amplifies, by the high-frequency harmonic signal of high energy low pass filter filters out by the power amplifier generation, this signal is transferred to stimulus sensor then, excitation longitudinal ultrasonic ripple in test specimen; The receiving sensor that is installed in opposite side detects the light current of coming by the test specimen transmission and presses ultrasonic signal, and gives oscillograph and show and preserve; The signal that utilizes computing machine that oscillograph is preserved carries out Fourier transform, obtains fundamental voltage amplitude A
1With secondary harmonic amplitude A
2, and through type (1) calculates the ultrasound non-linear factor beta, understands the incipient fatigue damage situation of test specimen according to β;
Wherein k=ω/c is a wave number, and ω is an angular frequency, and c is a velocity of wave, A
1And A
2Be respectively first-harmonic and secondary harmonic amplitude, x is the distance that ripple is propagated;
5) surpassed the empirical value that experiment is determined if Acoustic radiating instrument shows the continuous ringing number of times, showing has fatigue crack initiation and development, detection of end.
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