CN103185747B - Ultrasonic detection probe and manufacturing method and tooling mechanical device thereof - Google Patents
Ultrasonic detection probe and manufacturing method and tooling mechanical device thereof Download PDFInfo
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- CN103185747B CN103185747B CN201310097677.7A CN201310097677A CN103185747B CN 103185747 B CN103185747 B CN 103185747B CN 201310097677 A CN201310097677 A CN 201310097677A CN 103185747 B CN103185747 B CN 103185747B
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Abstract
The invention discloses an ultrasonic detection probe and a manufacturing method and a tooling mechanical device thereof. The probe comprises a piezoelectric compound wafer, an acoustic matching layer, a wedge block and a sound absorption part. According to the ultrasonic detection probe, noise sent out by the back of the compound wafer and the periphery of the wedge block can be absorbed by the sound absorption part; the sound absorption part is made of a compound sound absorption material mixing an epoxy resin and inorganic powder; and the acoustic impedance with a solid character is close to the wedge block, so that external reflective waves can be adsorbed better, and on-service and on-line detection of roots of blades with high resolution of a small dead zone on a special occasion can be achieved. Besides, multiple sections of sleeves of the tooling mechanical device have three-dimensional included angle surfaces or cambered surface sections, and certain angles can be formed when adjacent sleeves are coupled, so that under the condition that rotating blades are not detached from the device, the ultrasonic detection probe penetrates through a tiny air inlet of an engine of a plane, bypasses other parts and accurately reaches a detection position at a root of a blade, and accordingly the small dead zone detection can be achieved.
Description
Technical Field
The invention relates to the technical field of ultrasonic nondestructive testing, in particular to an ultrasonic testing probe, a manufacturing method thereof and a tooling mechanical device.
Background
After the airplane flies for a period of time, the problems of aging, fatigue wear, cracks and the like of some key parts can occur, and the service life and the safety of the airplane are seriously influenced. In particular, the surface of the root of the engine blade is easy to crack, so that the flying accident of machine damage and human death is easy to occur. Therefore, after the airplane flies for a certain time, relevant key components must be detected so as to be replaced or repaired in time, and the driving safety of the airplane is guaranteed.
At present, the conventional standard ultrasonic detection probe widely applied to medicine, military, industry and agriculture can solve the basic detection problem under most detection environments, but because the particularity of an aircraft engine, particularly a fighter plane used for national defense, is basically infeasible in detaching detection, in some special detection occasions in the aviation and nuclear power industries, a specially customized probe is needed to realize in-service and in-place detection in the special detection occasions so as to solve the detection problem caused by the environment or the particularity of a detected workpiece.
Disclosure of Invention
In order to solve the technical problems, the invention aims to provide an ultrasonic detection probe, a manufacturing method thereof and a tooling mechanical device.
The purpose of the invention is realized by the following technical scheme:
the invention provides an ultrasonic detection probe, which comprises a piezoelectric composite wafer, an acoustic matching layer and a wedge, wherein the piezoelectric composite wafer is used for generating ultrasonic waves; the wedge block is used for enabling the sound waves to generate transverse wave angles in the detected workpiece; the acoustic matching layer is arranged between the piezoelectric composite wafer and the wedge block and used for improving the sensitivity of the probe; the ultrasonic detection probe further includes:
and the sound absorption component is used for being poured on the back of the piezoelectric composite wafer and the periphery of the wedge block.
Still further, wherein the sound absorbing member comprises epoxy resin and metallic inorganic sound absorbing material powder.
Still further, wherein the ultrasonic detection probe further comprises:
and the shell is used for accommodating the piezoelectric wafer, the acoustic matching layer, the wedge block and the shell of the sound absorption component.
Still further, wherein the ultrasonic detection probe further comprises: the coupling liquid transmission pipe is used for transmitting the coupling liquid to the surface of the detected workpiece;
or,
the ultrasonic detection probe further includes: the coupling liquid transmission pipe is used for transmitting the coupling liquid to the surface of the detected workpiece; the coupling liquid transmission pipe is arranged in the shell.
Still further, wherein the piezoelectric wafer comprises:
a piezoelectric ceramic substrate;
a polymer for filling around the piezoelectric ceramic substrate.
Further, the communication mode of the piezoelectric ceramic substrate in the piezoelectric wafer is 1, and the communication mode of the polymer is 3.
Still further, wherein the wedge comprises:
processing a surface mount with an angle of 25-40 degrees;
a sound absorbing trap with an angle of 9-21 degrees;
end faces with included angles of 90-170 degrees.
The invention also provides a manufacturing method of the ultrasonic detection probe, which comprises the following steps:
preparing a piezoelectric composite wafer;
testing the acoustic impedance of the piezoelectric composite wafer and the acoustic impedance of the wedge, and calculating the acoustic impedance of the acoustic matching layer according to the acoustic impedance; determining the thickness of the acoustic matching layer according to the longitudinal wave wavelength of the main frequency signal of the transducer in the acoustic matching layer; preparing an acoustic matching layer according to the acoustic impedance and the thickness of the acoustic matching layer;
the piezoelectric composite wafer, the acoustic matching layer and the wedge block are pasted and cured to form a probe core part;
and (3) pouring sound absorption materials on the back of the piezoelectric composite wafer and around the wedge block, and curing to form the probe.
Still further, the method for manufacturing the ultrasonic detection probe further comprises:
and (4) filling the solidified probe and the coupling liquid transmission pipe into a shell.
The invention also provides a tooling mechanical device, wherein the tooling mechanical device comprises:
the section of two ends of the multi-section sleeve is provided with a three-dimensional included angle surface or an arc surface;
a steel wire connecting the sleeves;
an electrical cable and a conduit housed within the sleeve.
One or more embodiments of the present invention may have the following advantages over the prior art:
the ultrasonic detection probe provided by the invention can absorb the noise emitted from the back of the piezoelectric composite wafer and the periphery of the wedge through the sound absorption part, the sound absorption part is made of the composite sound absorption material of epoxy resin mixed with inorganic powder, the solid characteristic acoustic impedance is close to the wedge, and the interface reflected wave can be better absorbed, so that the aim of realizing in-service and in-situ detection of the root part of the small-blind-area high-resolution blade in a special occasion is fulfilled.
According to the tool mechanical device provided by the invention, as the multiple sections of the sleeves have the three-dimensional included angle surfaces or cambered surface sections, a certain angle can be generated by coupling between the adjacent sleeves, so that the ultrasonic detection probe can pass through a tiny air inlet of an aircraft engine and pass through other parts and then accurately reach a blade root detection position under the condition that a rotary blade is not dismounted, and the in-service and in-situ detection of the root part of a high-resolution blade in a small blind area in a special occasion can be realized.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic diagram of the structure of an ultrasonic testing probe of the present invention;
FIG. 2 is a schematic structural diagram of a piezoelectric composite wafer of an ultrasonic inspection probe;
FIG. 3 is a schematic structural diagram of a wedge of the ultrasonic inspection probe;
FIG. 4 is a schematic structural diagram of a stainless steel pipe sleeve of a tooling machine;
FIG. 5 is a schematic view of an ultrasonic inspection probe formed in cooperation with a tooling mechanism;
FIG. 6 is a schematic structural view of the ultrasonic inspection probe connected to a tooling mechanism;
FIG. 7 is a schematic diagram of a simulation of an ultrasonic inspection probe made in accordance with the present invention for inspecting a blade;
FIG. 8 is a schematic view of the structure inside the pipe sleeve after the ultrasonic inspection probe is connected to the tooling mechanism;
FIG. 9 is a schematic diagram of the test system connections of the ultrasonic inspection probe.
Wherein 1 is a piezoelectric composite wafer, 2 is an acoustic matching layer, 3 is a wedge, 4 is a sound absorption part, 5 is a coupling liquid transmission pipe, 6 is a shell, and 7 is a tool mechanical device.
Detailed Description
It is easily understood that, according to the technical solution of the present invention, a plurality of structural modes and manufacturing methods of the present invention can be proposed by those skilled in the art without changing the spirit of the present invention. Therefore, the following detailed description and the accompanying drawings are merely specific illustrations of the technical solutions of the present invention, and should not be construed as all of the present invention or as limitations or limitations of the technical solutions of the present invention.
The present invention will be described in further detail with reference to the following examples and accompanying drawings.
Fig. 1 is a schematic structural view of an ultrasonic detection probe according to an embodiment of the present invention, and each part and the function of each part of the embodiment of the present invention will be described in detail with reference to fig. 1.
As shown in fig. 1, the ultrasonic detection probe of the present invention includes: the device comprises a piezoelectric composite wafer 1, an acoustic matching layer 2, a wedge 3, a sound absorption part 4, a coupling liquid transmission pipe 5 and a shell 6.
The piezoelectric composite wafer 1 has a plurality of piezoelectric conversion elements for generating ultrasonic waves. The structure of the piezoelectric composite wafer is schematically shown in fig. 2, and the piezoelectric composite wafer is composed of a piezoelectric ceramic substrate and a polymer filled around the piezoelectric ceramic substrate. The base material of the piezoelectric composite wafer is high-quality PZT-5 piezoelectric ceramics, the base material is composed of a plurality of piezoelectric crystal fibers, and polymer materials are filled around the piezoelectric crystal fibers to form a plurality of piezoelectric conversion elements. The communication mode of the piezoelectric composite wafer is 1-3 type, wherein a plurality of piezoelectric crystal fibers are communicated in one dimension, and the polymer materials are communicated in three dimensions. The thickness of the piezo-electric composite wafer is preferably in the range of 300 microns to 400 microns depending on the frequency required for the wafer.
The wedge 3 is used for generating a transverse wave angle in the workpiece by sound waves, and the material of the wedge can be engineering plastics. The wedge has a structure as shown in FIG. 3, the processing angle of the surface mounting is 32.5 degrees, and the processing angle of the surface mounting can generate transverse waves of 48-50 degrees in a detected workpiece; the angle of the sound absorbing trap is 13 degrees, and the end face is processed to form an included angle of 154 degrees so as to better absorb the reflected wave from the wedge reflecting surface. The length and width of the wedge block are smaller than those of an air inlet hole of the engine, so that the probe can penetrate through a tiny air inlet hole (7 mm) of the aircraft engine to reach the surface of a detected workpiece.
And the acoustic matching layer 2 is arranged between the piezoelectric composite wafer and the wedge block, and can improve the sensitivity and bandwidth of the probe. It is usually made in flakes, made by mixing epoxy resin with inorganic powder. The thickness of the acoustic matching layer isAnd thirdly, the longitudinal wave wavelength of a main frequency signal of a transducer (equipment for converting high-frequency electric energy into mechanical vibration) in the acoustic matching layer.
And the sound absorption part 4 is used for absorbing noise diffused by the back of the piezoelectric composite wafer and the periphery of the wedge, and is formed by pouring a mixture comprising glue and inorganic sound absorption material powder on the back of the piezoelectric composite wafer and the periphery of the wedge. The sound absorption component is preferably made of composite sound absorption material of epoxy resin mixed with inorganic powder, and the acoustic impedance of solid characteristics is close to that of a wedge, so that interface reflection waves can be better absorbed, and the purpose of small blind areas is achieved.
The coupling liquid delivery pipe 5 is a pipe for delivering the coupling liquid, and is used for delivering the coupling liquid to the surface of the detected workpiece. The surface of the probe and the surface of the blade of the workpiece to be detected can be detected only by a certain coupling medium, and the surface of the blade of the workpiece to be detected cannot be contacted by human hands, so the coupling liquid transmission pipe can externally transmit the coupling liquid to the surface of the blade of the workpiece to be detected. The coupling liquid transmission pipe is made of high-quality PVC, is corrosion-resistant and is quite soft.
And the shell 6 is used for isolating external high temperature from entering the probe and is made of special engineering plastic resistant to the environment high temperature of 250 ℃. Because the temperature in the detection environment is high, generally between 60 ℃ and 90 ℃, the shell must be made of high-temperature resistant materials, and the high temperature has great influence on the performance and the service life of the interior of the probe.
A specific method for manufacturing the ultrasonic testing probe is given below.
Step 1: manufacture of piezoelectric composite wafer
The piezoelectric composite wafer is composed of a piezoelectric ceramic substrate and a polymer filled around the piezoelectric ceramic substrate, and is mainly manufactured by a cutting and filling method. The method comprises the following specific steps:
(11) lead zirconate-lead titanate, whose properties are listed in table 1 below, was selected or fabricated as the piezoelectric substrate.
TABLE 1
(12) Selecting a filling polymer material: the filling polymer is epoxy resin mixed with inorganic powder.
(13) And preparing the 1-3 type PZT piezoelectric composite wafer by adopting a cutting and filling method.
And determining the thickness of the piezoelectric composite wafer to be 0.1-0.8 mm according to the required frequency). Under the condition of ensuring that the electrical impedance of the piezoelectric composite material is close to the emission electrical impedance of the instrument, the dielectric constant is selected to be 1000, and then the scheme for manufacturing the piezoelectric wafer is as follows: in order to ensure the longitudinal resolution of the piezoelectric composite wafer, the wafer needs to be cut, the width of a cutting knife is 40 micrometers, and the cutting distance is 0.1mm, because the dielectric constant of the epoxy resin is very small (only 4.7) and can not be considered. The piezoelectric composite wafer as shown in FIG. 2 was formed, with an aspect ratio of 3:1 and a dielectric constant of 1000.
Step 2, processing of wedge block
Still as shown in fig. 3, the machining angle of the patch surface of the wedge is 32.5 degrees, and transverse waves of 48-50 degrees can be generated in the workpiece; the angle of the sound absorption trap is 13 degrees, and the end face is processed into an included angle of 154 degrees so as to better absorb the reflected wave from the wedge reflection surface. The length and width of the wedge block are smaller than the tiny air inlet of the engine, so that the probe can penetrate through the tiny air inlet (7 mm) of the aircraft engine and reach the surface of the detected workpiece.
And 3, calculating the acoustic impedance of the piezoelectric composite wafer and the acoustic impedance of the wedge, calculating the acoustic impedance of the acoustic matching layer according to the acoustic impedance, selecting a material according to the acoustic impedance of the acoustic matching layer, and calculating the thickness of the acoustic matching layer according to the longitudinal wave wavelength of the main frequency signal of the transducer in the acoustic matching layer. The method comprises the following specific steps:
(21) and testing the acoustic impedance of the piezoelectric composite wafer.
(22) And testing the acoustic impedance of the wedge.
(23) According to the MASON model, the acoustic impedance of the acoustic matching layer is calculated, a material with proper sound velocity density is selected according to the acoustic impedance, and a PVC material with proper sound velocity density is selected in the embodiment.
(24) The thickness of the acoustic matching portion is calculated according to the following formula:
and the third is the longitudinal wave wavelength of the main frequency signal of the transducer (converting high-frequency electric energy into mechanical vibration) in the acoustic matching part. And determining the acoustic stack design of the transducer according to the KLM electromechanical coupling equivalent circuit model, wherein the acoustic impedance of the acoustic matching layer conforms to the parameters obtained by MASON mode calculation, and the attenuation coefficient of the sound absorption material can reach 40 dB/MHz/cm.
And 3, bonding the piezoelectric wafer, the acoustic matching layer and the wedge block to form the probe core part. And (4) putting the solidified core into a shell, and fixing the coupling liquid transmission pipe on the side surface of the core.
Step 4, manufacturing the sound absorption part
The key technology for manufacturing the sound absorption part is the configuration of the sound absorption material, the sound absorption part is formed by mixing epoxy resin mixed with metal inorganic powder according to a certain proportion, the characteristic acoustic impedance of the cured material is close to that of the wedge, the impedance of the wedge can reach within +/-10%, and the reflected wave energy of the interface inside the wedge is absorbed by the sound absorption material more, so that the width of the initial wave is better inhibited.
And (3) pouring the sound absorption material, namely pouring the prepared sound absorption glue into the shell of the probe, so that the core part of the probe, the transmission pipe and the shell are solidified, and vacuumizing and exhausting are performed.
The invention also provides a tooling mechanical device which is used for replacing human hands to deliver the probe to the surface of the detected workpiece. The said mechanical device is a metal device, and the whole device has several casing pipes and steel wires connecting the casing pipes.
The steel wire can adopt two steel wires with the outer diameter of 0.8 mm.
The sleeve can be made of stainless steel, the number of the sections of the sleeve is determined according to the telescopic path and the telescopic angle, for example, 30 sections of sleeves can be selected for the blades of an airplane engine. The structure of the pipe sleeve is shown in fig. 4, the section of two ends of each section of the pipe sleeve is arranged into a special three-dimensional included angle surface or cambered surface, and a telescopic tensioning mode is adopted to form the required direction and angle. When the two sections of stainless steel sleeves are relaxed, a gap of 0.1-0.5 mm is reserved between corresponding connecting surfaces of the two sections of stainless steel sleeves; when the device is used, the steel wire is pulled, the corresponding connecting surfaces of the two sections of stainless steel sleeves are tightly coupled together, and a specific direction and an angle can be formed between the two sections of stainless steel sleeves. For example, two sections of stainless steel tubing, one with a radius of R35, R13 and the other with a radius of R34, R11, are drawn taut to form a slight upward angle 178, 176.
The probe is installed in a tooling mechanical device, the schematic diagram of the ultrasonic detection probe after being matched and formed with the tooling mechanical device is shown in fig. 5, the structural diagram is shown in fig. 6, and the simulation diagram is shown in fig. 7, the ultrasonic detection probe can be delivered to the surface of a workpiece to be detected through the tooling mechanical device, and the use method of the tooling mechanical device is described as follows:
the ultrasonic detection probe is connected with the tail end of a tool mechanical device, the incident direction of a sound beam is adjusted, the ultrasonic detection probe is firmly bonded by glue, a cable wire and a coupling liquid transmission pipe of the ultrasonic detection probe penetrate through a sleeve in the tool mechanical device together to form a schematic diagram shown in figure 8, when the ultrasonic detection probe is used, a steel wire is continuously pulled, corresponding connecting surfaces of two adjacent sections of stainless steel sleeves are tightly coupled together to form a certain angle and direction, and therefore the ultrasonic detection probe is sent to the surface of a detected workpiece.
When the ultrasonic detection probe is used for detecting a detected workpiece, an echo performance test is performed on the detected workpiece, and the connection mode of a test system is as shown in fig. 9: the 5800PR ultrasonic pulse-receiving instrument of OLYMPUS and the TEK-2012B digital oscilloscope are used for testing, and the tested echo signals are collected into a computer for fast Fourier transform to obtain a spectrogram.
The time domain and frequency domain technical parameters of the ultrasonic detection probe, the test report and the echo which are actually measured and manufactured by the invention are shown in the table 2:
TABLE 2
Through echo performance test, the performance of the ultrasonic detection probe is obtained as follows:
relative sensitivity-50.62 dB;
the center frequency is 5.02 MHz;
a pulse width 890ns of 20 dB;
-6dB relative bandwidth 47.22%;
the initial wave width after +50dB is not more than 10 mm.
Therefore, the expansion of the initial wave blind area can be well inhibited under the condition of increasing the sensitivity. Therefore, the invention is suitable for the in-service and in-situ detection of the small blind area high-resolution blade root in special occasions.
The ultrasonic detection probe provided by the invention can absorb the noise emitted from the back of the piezoelectric composite wafer and the periphery of the wedge through the sound absorption part, the sound absorption part is made of the composite sound absorption material of epoxy resin mixed with inorganic powder, the solid characteristic acoustic impedance is close to the wedge, and the interface reflected wave can be better absorbed, so that the aim of realizing in-service and in-situ detection of the root part of the small-blind-area high-resolution blade in a special occasion is fulfilled.
According to the tool mechanical device provided by the invention, as the plurality of sections of the sleeves have three-dimensional included angle surfaces or cambered surface sections, a certain angle can be generated by coupling between adjacent sleeves, so that an ultrasonic detection probe can pass through a tiny air inlet of an aircraft engine and pass through other parts and then accurately reach the surface of the root part of the blade of a workpiece to be detected under the condition that a rotary blade is not dismounted, and the in-service and in-situ detection of the root part of the blade with small blind area and high resolution in special occasions can be realized.
Although the embodiments of the present invention have been described above, the above descriptions are only for the convenience of understanding the present invention, and are not intended to limit the present invention. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. An ultrasonic testing probe comprising: the acoustic matching device comprises a piezoelectric composite wafer, an acoustic matching layer, a wedge block and a shell; the piezoelectric composite wafer is used for generating ultrasonic waves; the wedge block is used for enabling the sound waves to generate a transverse wave angle in the detected workpiece; the acoustic matching layer is arranged between the piezoelectric composite wafer and the wedge block and used for improving the sensitivity of the probe; characterized in that, ultrasonic detection probe still includes:
the sound absorption component is used for being poured on the back of the piezoelectric composite wafer and the periphery of the wedge block;
a housing for housing the piezoelectric wafer, acoustic matching layer, wedge, sound absorbing component, the wedge comprising:
processing a surface mount with an angle of 25-40 degrees;
the sound absorption trap is formed by making sound absorption backing materials into cuspate traps, and the angle of the sound absorption trap is 9-21 degrees;
end faces with included angles of 90-170 degrees.
2. The ultrasonic detection probe of claim 1, wherein the sound absorbing member comprises epoxy and metallic inorganic sound absorbing material powder.
3. The ultrasonic detection probe of claim 1,
the ultrasonic detection probe further includes: the coupling liquid transmission pipe is used for transmitting the coupling liquid to the surface of the detected workpiece;
or,
the ultrasonic detection probe further includes: the coupling liquid transmission pipe is used for transmitting the coupling liquid to the surface of the detected workpiece; the coupling liquid transmission pipe is arranged in the shell.
4. The ultrasonic detection probe of claim 1, wherein the piezoelectric wafer comprises:
a piezoelectric ceramic substrate;
a polymer for filling around the piezoelectric ceramic substrate.
5. The ultrasonic detection probe according to claim 4, wherein the piezoelectric ceramic substrate in the piezoelectric wafer has a communication mode of 1, and the polymer has a communication mode of 3.
6. A method for manufacturing an ultrasonic inspection probe, comprising:
preparing a piezoelectric composite wafer;
testing the acoustic impedance of the piezoelectric composite wafer and the acoustic impedance of the wedge block, and calculating the acoustic impedance of the acoustic matching layer according to the acoustic impedance; determining the thickness of the acoustic matching layer according to the longitudinal wave wavelength of the main frequency signal of the transducer in the acoustic matching layer; preparing an acoustic matching layer according to the acoustic impedance and the thickness of the acoustic matching layer;
adhering and curing the piezoelectric composite wafer, the acoustic matching layer and the wedge block to form a probe core part;
and (3) pouring sound absorption materials on the back of the piezoelectric composite wafer and the periphery of the wedge block, and curing to form the probe.
7. The method of manufacturing an ultrasonic detection probe according to claim 6, further comprising:
and (4) filling the solidified probe and the coupling liquid transmission pipe into a shell.
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| WO2017085512A1 (en) * | 2015-11-20 | 2017-05-26 | Doosan Babcock Limited | Inspection device and method |
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| CN103901114A (en) * | 2014-03-25 | 2014-07-02 | 常州市常超电子研究所有限公司 | Double-wafer longitudinal wave angle probe |
| CN104990988A (en) * | 2015-07-15 | 2015-10-21 | 常州市常超电子研究所有限公司 | Anti-interference ultrasonic probe |
| CN108852412A (en) * | 2018-07-30 | 2018-11-23 | 深圳嘉瑞电子科技有限公司 | A kind of volume probe weakening imaging interference |
| CN112903823A (en) * | 2021-01-19 | 2021-06-04 | 广州多浦乐电子科技股份有限公司 | Ultrasonic detection temperature correction method and temperature-resistant ultrasonic array probe |
| CN113624849B (en) * | 2021-08-11 | 2024-04-26 | 广州多浦乐电子科技股份有限公司 | Delay block capable of optimizing inherent wave and ultrasonic probe |
| CN114354766B (en) * | 2021-12-30 | 2024-05-03 | 中国特种设备检测研究院 | Method for manufacturing damping backing of ultrasonic probe |
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