CN104181207A - Sensing element for monitoring fatigue damage of metal structure based on PVD and application thereof - Google Patents
Sensing element for monitoring fatigue damage of metal structure based on PVD and application thereof Download PDFInfo
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- CN104181207A CN104181207A CN201410413313.XA CN201410413313A CN104181207A CN 104181207 A CN104181207 A CN 104181207A CN 201410413313 A CN201410413313 A CN 201410413313A CN 104181207 A CN104181207 A CN 104181207A
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Abstract
The invention relates to a sensing element for monitoring fatigue damage of a metal structure based on PVD and application of the sensing element. The sensing element comprises a conductive sensing layer and an isolated insulating layer, wherein the isolated insulating layer is arranged on the upper surface of a metal substrate, and the conductive sensing layer is arranged on the upper surface of the isolated insulating layer. The application of the sensing element comprises the following steps: (1) distributing the sensing element at a dangerous fatigue part of the metal structure by virtue of a PVD method; (2) connecting the sensing element into a monitoring system through a lead; and (3) reversely calculating a crack propagation condition of the metal structure according to the change of resistance signals which are output by the sensing element and are received by the monitoring system. The sensing element and the application thereof have the beneficial effects that the sensing element is integrated with the metal structure by virtue of PVD, so that the bonding strength is high, and the durability is good; as the sensing element is thin, the original size and assembling size of the metal structure are not influenced.
Description
Technical field
The invention belongs to monitoring sensory field, relate to a kind of sensing element, be specifically related to a kind of Structural Metallic Fatigue damage monitoring sensing element and application thereof based on PVD (physical vapour deposition (PVD)).
Background technology
Structural Metallic Fatigue damage monitoring is emphasis and the difficult point of modern structure health monitoring always.On the one hand, metal is the most common main load-bearing part, and the catastrophic failure (particularly aircraft accident) of damaging initiation because of Structural Metallic Fatigue is too numerous to enumerate; On the other hand, the manufacturing environment (high temperature) of metal construction, working environment (high-mechanic, heavily stressed, vibration, wearing and tearing, burn into electromagnetic environment, temperature difference etc.) are all harsher, the integrated degree of existing damage sensor and metal construction is lower, and environmental suitability is in urgent need to be improved.
Structure fatigue damage monitoring sensor is the Core Feature device of implementation structure fatigue damage monitoring, mainly contains at present following a few class:
(1) foil gauge
Strain-ga(u)ge technique is with a long history, and its ultimate principle is to utilize foil gauge to carry out monitor strain because of the small resistance variations that distortion produces, and is still at present the main flow of external aircraft structural damage monitoring.At F-18, F-22, on the aircaft configuration key positions such as F-35, all arrange foil gauge, wherein on F-22 use aircraft, have 1400 positions and arranged foil gauge, its fundamental purpose is the local stress-strain spectrum obtaining on tired key position, and then calculate the damage accumulative total situation that provides aircraft monitoring site by fatigue, reach the object to damage monitoring with this.
Strain monitoring problem is that the impression in the corresponding field of force of foil gauge has stronger directivity, under the stressed complex situations of structural member, paste in advance foil gauge and be difficult to accurately location, the simultaneously life-span of foil gauge self short (domestic be generally 2 years), be difficult to and the overhauling the same longevity of interval of aircaft configuration, but also easily damage, be difficult for repairing.
(2) sonac
Sonac is to utilize sound wave to penetrate inside configuration from object structures outside, does not destroy the Dynamic Non-Destruction Measurement of ground detection architecture internal state.It is by analyzing through the sound wave of object of receiving, and has not damaged or defect thereby detect in object structures.The security that current the method is applied to static structures member in large quantities detects, as the fatigue crack of plate-girder, tank, bucket etc. detects.
Sonac is difficult to rotating machinery structure to carry out damage check conventionally, is also difficult for implementing online auto monitoring.
(3) Fibre Optical Sensor
The ultimate principle of Fibre Optical Sensor is by the light input optical fibre of light source, and through Optical Fiber Transmission to modulator zone, in modulator zone, extraneous measured parameter interacts with the light that enters modulator zone, the optical property that makes light changes and forms modulated flashlight as light intensity, wavelength, frequency, phase place etc., then sends into photo-detector, detuner and obtain measured parameter through optical fiber.
Fibre Optical Sensor is applied to actual metal monitoring structural health conditions, also has many problems to need further to be studied, for example: Fibre Optical Sensor is with the integration problem of monitored structure; The preferred arrangement problem of Fibre Optical Sensor; For the life-span compared with for long metal construction, the integrity problem of Fibre Optical Sensor.
(4) piezoelectric sensor
Piezoelectric intelligent interlayer (PZT SMART Layer) utilizes improved flexible print circuit technology, a distributed piezoelectric sensor/drive networks is compound in advance on a slice insulating carrier film and forms thin layer, smart layer is embedded into inside configuration, can be to arrangement works time, carries out real-time, online monitoring.Piezoelectricity self-diagnosable system has become an important directions of smart material and structure research for the health monitoring of structure at present.
The problem that piezoelectric sensor exists is fragility compared with large and ultimate strain is little, and unsuitable large area is used.
(5) calibrate AE sensor
Acoustic emission is a kind of common physical phenomenon, and the processes such as most metals and nonmetallic materials deformation and fracture have acoustic emission to occur, and therefore, acoustic emission diagnosis almost can not be subject to the restriction of material, and dynamic monitoring is carried out in the germinating to crackle and expansion.
Calibrate AE sensor can only detect under structure stand under load and current intelligence, and needs special acoustic emission detector.In addition, the signal of calibrate AE sensor output is very faint, the reflection at environment, tie point place, the character of emissive source, elastic wave all can exert an influence to testing result in propagation, physical dimension, the characteristic of transmitter (sensor) and the performance of detecting instrument on material internal and border, and how to make acoustic emission monitoring system sensor used work reliably, enduringly under bad working environments to be equally one have a difficult problem to be solved.
(6) eddy current sensor
The ultimate principle of eddy current sensor is the mutual relationship of eddy current and detected pieces.Have detection speed fast, can directly not contact with test specimen, without advantages such as couplants.EDDY CURRENT can be divided into single-frequency eddy current, multifrequency Eddy, impulse eddy current, far-field eddy etc. by the difference of energisation mode and detection principle.
The problem that eddy current sensor exists is: due to factors such as Lift-off effects, monitoring information is easily interfered, thereby produces false alarm information.
(7) other emerging monitoring sensor
In recent years, people, by by multiple damage monitoring technological incorporation or the correlation technique (particularly surface engineering technology) of introducing other subject, have been developed again some new fatigue damage monitoring sensors.
Structure monitoring system (SMS) company of Australia has developed relative vacuum sensor (CVM-Comparative Vacuum Monitoring sensor), be used on FT-5 schoolaeroplane, phantom III fighter plane and the C-130 transport of Air Passenger A380 and Pakistan Air Force, the subject matter of this sensor is to carry.
Aero-Space institute of Xi'an Communications University has researched and developed " information smart coat sensor ", has obtained good result in laboratory, but has in actual applications the problem that false alarm rate is high, and permanance is still to be tested.
Summary of the invention
Goal of the invention: the problem that the present invention is directed to above-mentioned prior art existence is made improvement, and first object of the present invention is to provide a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD.Second object of the present invention is to provide a kind of application of the sensing element based on PVD Structural Metallic Fatigue damage monitoring.
Technical scheme: a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD, comprises
Conduction sensing layer, and;
Dielectric isolation layer, for stoping conducting between metallic matrix and described conduction sensing layer, and conducts to described conduction sensing layer by the fatigue damage of described metallic substrates;
Described dielectric isolation layer is located at the upper surface of described metallic substrates, and described conductive layer is located at the upper surface of described dielectric isolation layer.
A kind of preferred version as a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: described dielectric isolation layer is Al
2o
3layer, AlN layer, Si
3n
4one in layer or BN layer.
A kind of preferred version as a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: the thickness of described dielectric isolation layer is 2～10 μ m.
A kind of preferred version as a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: described conduction sensing layer is the one in H62 layer of brass, pure copper layer, pure titanium layer, LY12 aluminium alloy layer, 316 stainless steel layers.
A kind of preferred version as a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: the thickness of described conduction sensing layer is 2～10 μ m.
An application for the sensing element of the above-mentioned Structural Metallic Fatigue damage monitoring based on PVD, comprises the steps:
(1), utilize PVD method to lay sensing element at the tired dangerous position of metal construction, described sensing element comprises conduction sensing layer and dielectric isolation layer;
(2), described sensing element is accessed to monitoring system by wire;
(3) the anti-Crack Extension situation that pushes away metal construction of variation of the resistance signal of the described sensing element output of, receiving according to described monitoring system, when sample frequency is 0.4Hz, if described sensing element resistance signal phase step type rises 5%～10%, described metal construction is plastic yield; Exceed 15% when described sensing element resistance signal phase step type rises, described metal construction is fatigue crack initiation; When described sensing element resistance signal phase step type declines 10%～20%, described metal construction is fracture fast.
A kind of preferred version as the application of a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: the definite of tired dangerous position of the described metal construction of step (1) comprises the following steps:
(1) set up structural finite element model;
(2) definition material properties;
(3) grid division;
(4) set up contact model;
(5) boundary condition is set;
(6) loading environment is set;
(7) finite element model calculates and analyzes, and determines dangerous position.
A kind of preferred version as the application of a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: the described monitoring system of step (2) comprises the sensing element, DC constant flowing power, data collecting card, the terminal that are laid on workpiece, described DC constant flowing power with described in be located at sensing element on workpiece and form loop, described data collecting card respectively with described terminal, described in the sensing element that is laid on workpiece be connected.Described terminal is provided with signal processing and analysis software.
Beneficial effect: the present invention discloses a kind of Structural Metallic Fatigue damage monitoring sensing element and application thereof based on PVD and has following beneficial effect:
(1) the integrated of sensing element and metal construction realized by PVD technology, do not need cementing agent and clamping device, and bond strength is high, good endurance;
(2) sensing element is very thin, only has several microns, does not affect original size and the fitted position of metal construction;
(3) sensing element is metal material, can bearing load, wear-resistant, corrosion-resistant, the life-span is long, can adapt to the working environment of metal construction, with the same longevity of metal construction itself;
(4) sensing element monitor signal can reflect each stage of Structural Metallic Fatigue damage, applied widely.
Brief description of the drawings
Fig. 1 is the structural representation of the Structural Metallic Fatigue damage monitoring sensing element based on PVD of the present invention;
Fig. 2 is the structural representation of 2A12-T4 aluminium alloy center orifice plate;
Fig. 3 is the structural representation with the aluminium alloy center orifice plate of center hole shape conduction sensing layer;
Fig. 4 is the structural representation of covering plate;
Fig. 5 is fatigue damage monitoring system schematic diagram;
Fig. 6 is 2A12-T4 aluminium alloy center orifice plate stress cloud atlas;
Fig. 7 is the output signal of sensing element and the graph of a relation of time in 2A12-T4 sample fatigue damage monitoring test;
Wherein:
1-metallic matrix 2-dielectric isolation layer
3-conduction sensing layer 4-aluminium alloy center orifice plate
5-center hole shape conduction sensing layer 6-covers plate
Embodiment:
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described in detail.
Specific embodiment 1
As shown in Figure 1, a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD, comprises
Conduction sensing layer, and;
Dielectric isolation layer, stops conducting between metallic matrix and conduction sensing layer, and the fatigue damage of metallic substrates is conducted to conduction sensing layer;
Dielectric isolation layer is located at the upper surface of metallic substrates, and conductive layer is located at the upper surface of dielectric isolation layer.
In the present embodiment: dielectric isolation layer is AlN layer.
Dielectric isolation layer has following requirement: (1) is isolating metal matrix and the conducting between sensing layer of conducting electricity effectively; (2) damage of metallic matrix is conducted to PVD sensing element conduction sensing layer, stop to occur that damage does not occur metallic matrix and the false-alarm situation that damage causes occurs dielectric isolation layer; (3) good endurance, can long-term work.
In this specific embodiment, the thickness of dielectric isolation layer is 2 μ m.
In this specific embodiment, conduction sensing layer is H62 layer of brass.
In the present embodiment, the thickness of conduction sensing layer is 6 μ m.
An application for the sensing element of the above-mentioned Structural Metallic Fatigue damage monitoring based on PVD, comprises the steps:
(1), utilize PVD method to lay sensing element at the tired dangerous position of metal construction, sensing element comprises conduction sensing layer and dielectric isolation layer;
(2), sensing element is accessed to monitoring system by wire;
(3), the anti-Crack Extension situation that pushes away metal construction of variation of the resistance signal of the sensing element received according to monitoring system output, when sample frequency is 0.4Hz, if sensing element resistance signal phase step type rises 5%～10%, metal construction is plastic yield; Exceed 15% when sensing element resistance signal phase step type rises, metal construction is fatigue crack initiation; When sensing element resistance signal phase step type declines 10%～20%, metal construction is fracture fast.
A kind of preferred version as the application of a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: step (2) monitoring system comprises the sensing element, DC constant flowing power, data collecting card, connection wire, terminal and the signal processing and analysis software that are laid on workpiece, the annexation of each several part as shown in Figure 5, DC constant flowing power forms loop with being located at sensing element on workpiece, and data collecting card is connected with terminal, the sensing element that is laid on workpiece respectively.Terminal is provided with signal processing and analysis software.
A kind of preferred version as the application of a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD in the present invention: the definite of tired dangerous position of step (1) metal construction comprises the following steps:
(1) set up structural finite element model;
(2) definition material properties;
(3) grid division;
(4) set up contact model;
(5) boundary condition is set;
(6) loading environment is set;
(7) finite element model calculates and analyzes, and determines dangerous position.
Taking 2A12-T4 aluminium alloy center orifice plate (its structure is shown in that figure is as shown in Figure 2) typical structure as example,
(1) set up structural finite element model, select Shell63 unit, input entity constant is also the thickness 2 of 2A12-T4 aluminium alloy center orifice plate, and draws the geometric figure of center orifice plate, forms solid model;
(2) definition material properties, selects Isotropic (isotropic material), input Young modulus 7.2e10, Poisson ratio 0.3;
(3) grid division, selects the free lattice order in region Mesh|Free to carry out grid division to the finite element model of setting up;
(4) set up contact model, in this example, do not have contact problems, therefore skip;
(5) boundary condition is set, by the ordinate variable quantity of the horizontal symmetry axis of 2A12-T4 aluminium alloy center orifice plate be decided to be 0, the horizontal ordinate variable quantity of vertical axis of symmetry is decided to be 0;
(6) loading environment is set, applies the uniformly distributed load of 100N at finite element model two ends;
(7) finite element model calculates and analyzes, obtain 2A12-T4 aluminium alloy center orifice plate stress cloud atlas, (structure has symmetry as shown in Figure 6, only show half herein), visible circular hole periphery 5mm regional stress is concentrated the most obvious, therefore determines that circular hole periphery 5mm region is dangerous position.
Determine after the tired dangerous position of metal construction, the region that does not need plating has been hidden with covering plate, only exposed the metallic matrix part of the integrated sensing element of needs; Prepare successively one deck dielectric isolation layer and conduction sensing layer by vacuum vapor plating or sputter coating or ion film plating in metallic matrix part again.
In room temperature, air ambient, adopt MTS810 type hydraulic servo fatigue experimental machine to carry out fatigue loading to the testpieces of integrated sensing element, loading parameters is as follows: f=20Hz, R=0.03, σ
max=150Mpa, continues to load until sample fracture is carried out all-the-way tracking record to the resistance signal of sensing element during this time, and sample frequency is 0.4Hz.
In 2A12-T4 typical sample fatigue damage monitoring test, the output signal situation of change of sensing element as shown in Figure 7.In figure, each point represents a measurement data, and horizontal ordinate is corresponding with test period, and ordinate is corresponding with the output signal of sensing element.Fig. 7 shows, from giving 2A12-T4 typical sample imposed load until sample fracture, the sudden change of three phase step types has occurred the Monitoring Data of sensing element.
The accumulation of the counter structure of phase step type rising for the first time plastic yield, this phase step type rises and comprises altogether three measuring-signals, and the variable quantity of former and later two Monitoring Data is in 6%～7% left and right;
Phase step type rising for the second time has reflected the germinating of crackle in structure, and this phase step type rises and only comprise two measuring-signals, and the variable quantity of former and later two Monitoring Data has exceeded 20%.After crack initiation, the fluctuation ratio of Monitoring Data is larger, think that this should be because the closed effect of crackle causes, under the effect of cyclic loading, crackle is one one and closes slowly expansion forward, in the time of crack closure, the Monitoring Data of sensing element can show as and reduce, when showing as again increase after crack opening, but along with the continuous expansion of crackle, the general morphologictrend of Monitoring Data still increases.
Be phase step type decline, corresponding sample unstable fracture for the third time.Former and later two adjacent measurement data variable quantities, between 13% to 16%, then directly become again infinity.This is, while just having entered instable growth of crack because of structure, necking phenomenon to occur, and causes sensing element part and matrix conducting, causes the sharply decline of Monitoring Data, and after fracture, malformation recovers completely, and sensing element opens circuit, and output signal becomes infinity.
Test findings shows, sensing element can effectively be monitored each stage of Structural Metallic Fatigue damage, and monitoring index can be selected the amplitude of variation of sensing element resistance signal.
Specific embodiment 2
Roughly the same with specific embodiment 1, difference is:
1, in the present embodiment, dielectric isolation layer is Si3N4 layer, and its thickness is 10 μ m;
2, in the present embodiment, conduction sensing layer is pure copper layer, and its thickness is 2 μ m.
Specific embodiment 3
Roughly the same with specific embodiment 1, difference is:
1, in the present embodiment, dielectric isolation layer is BN layer, and its thickness is 5 μ m;
2, in the present embodiment, conduction sensing layer is pure titanium layer, and its thickness is 10 μ m.
Specific embodiment 4
Roughly the same with specific embodiment 1, difference is:
1,, in the present embodiment, dielectric isolation layer is Al
2o
3layer;
2,, in the present embodiment, conduction sensing layer is LY12 aluminium alloy layer.
Specific embodiment 5
Roughly the same with specific embodiment 1, difference is only:
1,, in the present embodiment, conduction sensing layer is 316 stainless steel layers.
By reference to the accompanying drawings embodiments of the present invention are described in detail above.But the present invention is not limited to above-mentioned embodiment, in the ken possessing at affiliated technical field those of ordinary skill, can also under the prerequisite that does not depart from aim of the present invention, make a variety of changes.
Claims (8)
1. the Structural Metallic Fatigue damage monitoring sensing element based on PVD, is characterized in that, comprising:
Conduction sensing layer, and;
Dielectric isolation layer, for stoping conducting between metallic matrix and described conduction sensing layer, and conducts to described conduction sensing layer by the fatigue damage of described metallic substrates;
Described dielectric isolation layer is located at the upper surface of described metallic substrates, and described conductive layer is located at the upper surface of described dielectric isolation layer.
2. a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD as claimed in claim 1, is characterized in that, described dielectric isolation layer is Al
2o
3layer, AlN layer, Si
3n
4one in layer, BN layer.
3. a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD as claimed in claim 1, is characterized in that, the thickness of described dielectric isolation layer is 2～10 μ m.
4. a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD as claimed in claim 1, is characterized in that, described conduction sensing layer is the one in H62 layer of brass, pure copper layer, pure titanium layer, LY12 aluminium alloy layer, 316 stainless steel layers.
5. a kind of Structural Metallic Fatigue damage monitoring sensing element based on PVD as claimed in claim 1, is characterized in that, the thickness of described conduction sensing layer is 2～10 μ m.
6. an application for the sensing element of the Structural Metallic Fatigue damage monitoring based on PVD as described in claim 1～5, comprises the steps:
(1), utilize PVD method to lay sensing element at the tired dangerous position of metal construction, described sensing element comprises conduction sensing layer and dielectric isolation layer;
(2), described sensing element is accessed to monitoring system by wire;
(3) the anti-Crack Extension situation that pushes away metal construction of variation of the resistance signal of the described sensing element output of, receiving according to described monitoring system, when sample frequency is 0.4Hz, if described sensing element resistance signal phase step type rises 5%～10%, described metal construction is plastic yield; Exceed 15% when described sensing element resistance signal phase step type rises, described metal construction is fatigue crack initiation; When described sensing element resistance signal phase step type declines 10%～20%, described metal construction is fracture fast.
7. the application of the sensing element of the Structural Metallic Fatigue damage monitoring based on PVD as claimed in claim 6, is characterized in that, the definite of tired dangerous position of the described metal construction of step (1) comprises the following steps:
(1) set up structural finite element model;
(2) definition material properties;
(3) grid division;
(4) set up contact model;
(5) boundary condition is set;
(6) loading environment is set;
(7) finite element model calculates and analyzes, and determines dangerous position.
8. the application of the sensing element of the Structural Metallic Fatigue damage monitoring based on PVD as claimed in claim 6, it is characterized in that, the described monitoring system of step (2) comprise the sensing element that is laid on workpiece, DC constant flowing power, data collecting card, terminal, described DC constant flowing power with described in the sensing element that is laid on workpiece form loop, described data collecting card respectively with described terminal, described in the sensing element that is laid on workpiece be connected.
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| CN105738567A (en) * | 2014-12-10 | 2016-07-06 | 中国飞机强度研究所 | Aluminum powder coating transducer and processing technology thereof |
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| CN105523195A (en) * | 2015-10-19 | 2016-04-27 | 中国人民解放军空军工程大学 | Material selection method of aircraft structure based on series material property indexes |
| CN107655937A (en) * | 2017-08-25 | 2018-02-02 | 南京航空航天大学 | A kind of structural damage monitors in real time and localization method |
| CN108020583B (en) * | 2017-10-30 | 2021-04-13 | 江阴市恒润环锻有限公司 | Flange for crack regional monitoring by adopting finite element meshing method |
| CN108020583A (en) * | 2017-10-30 | 2018-05-11 | 江阴市恒润环锻有限公司 | A kind of flange that crackle subregion monitoring is carried out using FEA Meshing Method |
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| CN111289578A (en) * | 2020-03-27 | 2020-06-16 | 西北大学 | Method for detecting microcracks of ultrahigh-pressure container |
| CN111896589A (en) * | 2020-07-03 | 2020-11-06 | 西南交通大学 | Bridge steel structure monitoring system based on intelligent coating |
| CN112158359A (en) * | 2020-10-12 | 2021-01-01 | 中国地质大学（北京） | Method for detecting fatigue fracture of wing |
| CN112158359B (en) * | 2020-10-12 | 2022-01-04 | 中国地质大学（北京） | Method for detecting fatigue fracture of wing |
| CN115791460A (en) * | 2022-11-18 | 2023-03-14 | 中国矿业大学 | Sensor for propagation speed of blasting crack in rock material and testing method thereof |
| CN115791460B (en) * | 2022-11-18 | 2023-08-22 | 中国矿业大学 | Sensor for crack propagation speed of internal blasting of rock material and testing method thereof |
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Application publication date: 20141203 |