CN108387639B - Nondestructive testing method for multilayer bonding component - Google Patents
Nondestructive testing method for multilayer bonding component Download PDFInfo
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- CN108387639B CN108387639B CN201810011200.5A CN201810011200A CN108387639B CN 108387639 B CN108387639 B CN 108387639B CN 201810011200 A CN201810011200 A CN 201810011200A CN 108387639 B CN108387639 B CN 108387639B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating 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
- G01N29/04—Analysing solids
- G01N29/048—Marking the faulty objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating 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
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating 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
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/28—Details, e.g. general constructional or apparatus details providing acoustic coupling, e.g. water
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
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Abstract
The invention relates to a nondestructive testing method of a multilayer bonding member, which is used for testing a tested piece consisting of a metal shell, an attenuation material layer and a composite material layer and comprises the following steps: detecting the detected piece from one side of the composite material layer by a high-energy ultrasonic penetration method, determining the defect, and marking the defect on the outer side of the position judged as the defect; detecting the detected piece from one side of the metal shell by a multi-pulse reflection method, determining the bonding quality of the interface of the metal shell and the attenuation material layer, and marking the debonding defect on the inner side of the debonding defect; and determining the position of the defect by combining the marks on the inner side and the outer side of the detected piece and a knocking method. The invention adopts the high-energy excitation technology, and solves the problem that the common ultrasonic detection method cannot detect the high-sound attenuation layer and the composite material prepared by the winding process; the multi-pulse reflection method and the knocking method are combined, so that the problem that defects at different depths cannot be distinguished by an ultrasonic penetration method is solved; can provide an accurate position for the repair of the detected piece and reduce the production cost.
Description
Technical Field
The invention relates to the technical field of ultrasonic nondestructive testing, in particular to a nondestructive testing method for a multilayer bonding member.
Background
The cabin of the supersonic aircraft has begun to adopt a novel structure of multilayer bonding members of winding phenolic resin matrix composite material/rubber buffer layer/inner metal shell, which can reduce the weight of the cabin, and in addition, the outer layer winding composite material of the cabin can play a heat-proof role to protect the inner side parts from being damaged by high temperature. However, the structure is impacted by high-temperature and high-speed airflow load in the using process, the mechanical property of the composite material heat-proof layer is greatly reduced when the bonding quality of the composite material is poor or the inner side of the composite material is layered, and even serious consequences such as falling off of the composite material heat-proof layer in the flying process and the like can be caused to cause serious accidents, so that the quality of the composite material heat-proof layer needs to be detected by adopting an effective nondestructive detection technology.
The thickness of the winding composite material in the component is more than or equal to 5mm, the thickness of the rubber buffer layer is less than or equal to 2mm, and the thickness of the metal shell is more than or equal to 4 mm. The preparation process of the component comprises the following steps: firstly, adhering a rubber buffer layer on the outer surface of a metal shell; secondly, winding a composite material prepreg on the rubber buffer layer; finally, the composite material of the member is heated and pressurized for curing. The inner surface of the metal shell of the component is provided with a plurality of bosses and chaste trees, the formed shape is irregular cylinder shape, and the component is provided with two bonding interfaces of the metal shell, an attenuation material layer and an attenuation material layer, a composite material layer, and the nondestructive testing case with the structure is fresh at home and abroad.
At present, the winding structure of domestic pure composite materials is common, and the defects in the winding structure are usually detected by a nondestructive detection method of ultrasonic detection. However, when the conventional ultrasonic detection method is adopted for the multilayer bonding irregular component consisting of the metal shell, the attenuation material layer and the composite material layer, the problems that the appearance is complex and difficult to couple, the material acoustic signal attenuation is large and difficult to penetrate, the multilayer bonding is difficult to distinguish, the difference between the acoustic impedance of the metal inner shell and the acoustic impedance of the rubber layer is large and difficult to detect and the like occur.
Disclosure of Invention
Technical problem to be solved
The invention aims to solve the technical problems that when the existing ultrasonic nondestructive testing method is used for testing a multilayer bonding irregular component consisting of a metal shell, an attenuation material layer and a composite material layer, due to the fact that the shape is complex and difficult to couple, the material sound signal attenuation is large and difficult to penetrate, multilayer bonding is difficult to distinguish, the difference between the acoustic impedance of a metal inner shell and the acoustic impedance of the attenuation material layer is large and difficult to detect, and the like.
(II) technical scheme
In order to solve the above technical problem, the present invention provides a nondestructive testing method for a multilayer bonded member, which is used for testing a tested piece composed of a metal shell, an attenuation material layer and a composite material layer, and comprises the following steps:
s1, detecting the detected piece from one side of the composite material layer by a high-energy ultrasonic penetration method, judging the area with the penetrating wave amplitude lower than the defect threshold value as a defect, and marking the outer side of the judged defect;
s2, detecting the detected piece from one side of the metal shell by a multi-pulse reflection method, determining the bonding quality at the interface of the metal shell and the attenuation material layer, judging the debonding defect at the debonding position, and marking the debonding defect at the inner side of the debonding defect;
s3, judging that the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered in the area with the defect mark on the outer side and the debonding defect mark-free inner side, and the interface of the metal shell and the attenuation material layer is well bonded;
and for the area with the outer side with the defect mark and the inner side with the debonding defect mark, the interface of the metal shell and the attenuation material layer is determined to be debonding.
Preferably, the step S3 further includes, for the area with the defect mark on the outer side and the debonding defect mark on the inner side, detecting the object by tapping from one side of the composite material layer, and determining whether the debonding of the attenuating material layer-composite material layer interface or the delamination of the composite material layer exists.
Preferably, in step S1, the high-energy ultrasound penetration method includes exciting an ultrasound transmitting probe by using a high-energy excitation technique, wherein a first ultrasound instrument transmitting terminal used in the high-energy ultrasound penetration method is connected to a signal input terminal of a pulse train transmitter, a signal output terminal of the pulse train transmitter is connected to the ultrasound transmitting probe, and a period of an excitation pulse transmitted is consistent with a frequency of the ultrasound transmitting probe; and detecting the region which can be reached by a tool on the detected piece by adopting a manual water spraying ultrasonic penetration method, and detecting the residual region on the detected piece by adopting a manual contact coupling ultrasonic penetration method.
Preferably, the step S1 includes:
s1-1, determining basic detection parameters: determining basic detection parameters of a first ultrasonic instrument used in the high-energy ultrasonic penetration method;
s1-2, determining detection sensitivity: adjusting the dB value of the first ultrasonic instrument through a first comparison block, so that when the first ultrasonic instrument detects a defect-free area on the first comparison block, the height of a through wave is 80%, and the dB value +3dB of the first ultrasonic instrument is the detection sensitivity of the detected piece at the thickness; adjusting an electronic gate of the first ultrasonic instrument to enable a defect threshold value to be 20%;
s1-3, scanning and judging defects: scanning the detected piece according to the determined basic detection parameters and detection sensitivity, judging the area of which the percentage of the penetrating wave amplitude in the full-screen height of the first ultrasonic instrument is lower than the defect threshold value as a defect, and marking the outer side of the detected piece with the defect.
Preferably, the step S2 includes:
s2-1, determining basic detection parameters: determining basic detection parameters of a second ultrasonic instrument used in the multi-pulse reflection method;
s2-2, determining detection sensitivity: adjusting the dB value and the time base range of the second ultrasonic instrument through the first comparison test block, so that the 50% wave height corresponding to multiple echoes of the interface is not less than 80% when the second ultrasonic instrument detects the debonding area on the first comparison test block; when detecting the bonding area on the first comparison test block, the 50% wave height of the interface multiple echoes is not more than 20%; the 50% wave height refers to the percentage of the wave height at the horizontal five-grid position of the display screen of the second ultrasonic instrument in the full screen height of the display screen;
s2-3, determining a threshold: determining an injury threshold value and a boundary threshold value, wherein the injury threshold value ranges from 70% to 90%, and the boundary threshold value ranges from 30% to 50%;
s2-4, scanning and judging debonding defects: scanning the detected piece according to the determined basic detection parameters and detection sensitivity, and judging as a debonding defect when 50% of wave height of multiple echoes of the interface is greater than or equal to the damage judging threshold;
when a debonding defect is found, moving a probe of the second ultrasonic instrument to the debonding defect from at least four directions to determine the boundary of the debonding defect, when the wave height of 50% of multiple echoes of an interface reaches the boundary threshold value, determining the center position of a sound beam of the probe at the moment as the boundary of the debonding defect, marking the debonding defect on the inner side of the detected piece, and sequentially connecting the debonding defect marks to obtain the profile of the debonding defect.
Preferably, in the steps S1 and S2, a first comparison block is used to determine the detection sensitivity;
the first comparison test block comprises a first metal layer, a first attenuation material layer and a first composite material layer, the first metal layer, the first attenuation material layer and the first composite material layer are respectively made of metal, attenuation material and composite material which are the same as the material of the detected piece, and the bonding process is the same as that of the detected piece;
the bottom surface of the first metal layer is a plane and is provided with a bonding area and a debonding area; in the bonding area, the bottom surface of the first metal layer is sequentially bonded with the first attenuation material layer and the first composite material layer; the debonding region is not bonded and is used for simulating debonding defects between the metal shell and the attenuation material.
Preferably, in the first comparison test block, the first metal layer is in a step shape, the height difference between two adjacent steps is not more than 3mm, the highest step height is greater than the thickest part of the metal shell in the detected piece, and the lowest step height is less than the thinnest part of the metal shell in the detected piece;
and when the detection sensitivity is determined, detecting the position where the thickness of the first metal layer is the same as the thickness of the metal shell at the detection point of the detected piece or the thickness difference is minimum.
Preferably, the tapping method in step S3 includes:
s3-1, determining a hole threshold: aligning a knocking detector to the defect of the attenuation material layer in the second reference block, detecting from one side of the composite material, reading the stress duration time displayed by the knocking detector, and recording as a cavity threshold value;
s3-2, detecting and judging the delamination or debonding defects of the composite material: dividing the area to be detected on the detected piece into squares with the same size, respectively detecting each square one by one through the knocking detector, judging that the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered when the stress duration displayed by the knocking detector is greater than or equal to the cavity threshold value, and marking defects.
Preferably, in the step S3-1, a second comparison block is used to determine a hole threshold;
the second comparison test block comprises a second composite material layer and a second attenuation material layer, the second composite material layer and the second attenuation material layer are made of composite materials and attenuation materials which are the same as the detected piece in material and thickness, and the bonding process is the same as that of the detected piece; and the second attenuation material layer is provided with a hole which is dug through.
Preferably, the cavity is circular, and the diameter range is 10-15 mm.
(III) advantageous effects
The technical scheme of the invention has the following advantages: when the ultrasonic penetration method is adopted to determine the area of the detected piece which possibly has defects, the ultrasonic transmitting probe is excited by adopting the high-energy excitation technology, the optimal transmitting energy is obtained by exciting the ultrasonic transmitting probe through the adjustable pulse series, and the generated ultrasonic signal can sufficiently penetrate through the attenuation material layer with high acoustic attenuation in the detected piece and the composite material layer prepared by the winding process, so that the problem that the common ultrasonic detection method cannot detect the high attenuation material is solved; after the position of a detected part with a defect is determined by adopting an ultrasonic penetration method, the interface debonding of a metal shell-attenuation material layer and the interface debonding of the attenuation material layer-composite material layer (or the delamination in the composite material) in a defect area are distinguished by combining a multi-pulse reflection method for detecting from the inner side and a tapping method for detecting from the outer side, so that the problem that the defects with different depths cannot be distinguished by adopting the ultrasonic penetration method is solved; the nondestructive testing method provided by the invention can provide an accurate position for the repair of the tested piece, and the production cost is greatly reduced.
Drawings
FIG. 1 is a schematic view showing steps of a nondestructive inspection method of a multilayer bonded member in an embodiment of the invention;
FIG. 2 is a schematic illustration of a first ultrasonic meter excited by a high energy excitation technique in an embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating the steps of a multiple pulse echo method according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of the steps of a tapping method in an embodiment of the present invention;
FIG. 5 is a side view of a first reference block in an embodiment of the present invention;
FIG. 6 is a bottom view of a first reference block in an embodiment of the present invention;
FIG. 7 is a schematic longitudinal sectional view of a test object to be tested by a water jet method according to an embodiment of the present invention;
FIG. 8 is a schematic cross-sectional view of a test object inspected by a contact coupling method according to an embodiment of the present invention;
FIG. 9 is a schematic illustration of another excitation signal for exciting the first ultrasonic meter in an embodiment of the present invention;
FIG. 10 is a schematic diagram showing the structure of a second reference block in the embodiment of the present invention;
in the figure: 1: a detected piece; 2: a water-spraying probe; 3: a water spraying sleeve; 4: a probe arm; 5: a contact coupling method probe;
6: a first ultrasonic instrument; 7: a burst transmitter; 8: an ultrasonic emission probe;
11: first metal layer, 12: first attenuating material layer, 13: a first composite material layer; 14: a bonding area; 15: a debonding region;
16: a second composite material layer; 17: a second attenuating material layer; 18: a void.
Detailed Description
In order to make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are some, but not all, embodiments of the present invention. All other embodiments, which can be obtained by a person skilled in the art without any inventive step based on the embodiments of the present invention, are within the scope of the present invention.
As shown in fig. 1, a nondestructive testing method for a multilayer bonding member according to an embodiment of the present invention is used for testing a tested object composed of a metal shell, an attenuation material layer and a composite material layer, and includes the following steps:
in step S1, the test piece 1 is inspected from the composite material layer side by the high-energy ultrasonic penetration method, and a region where the amplitude of the penetrating wave is lower than the defect threshold is determined as a defect, and a defect mark is made on the outer side of the determined defect. The outer side here refers to the side on which the composite layer is located.
As shown in fig. 2, the high-energy ultrasonic penetration method includes exciting an ultrasonic transmission probe 8 by a high-energy excitation technique, wherein a transmission terminal of a first ultrasonic instrument 6 used for the high-energy ultrasonic penetration method is connected to a signal input terminal of a burst transmitter 7, and a signal output terminal of the burst transmitter 7 is connected to the ultrasonic transmission probe 8. And the period of the transmitted excitation pulse coincides with the frequency of the ultrasonic transmission probe 8. The high-energy excitation technology excites the ultrasonic emission probe 8 through adjustable pulse series to obtain the optimal emission energy, and the generated ultrasonic waves can sufficiently penetrate through the attenuation material layer with high sound attenuation in the detected piece 1 and the composite material layer prepared by the winding process.
During detection, a manual water spraying ultrasonic penetration method (a water spraying method for short) is adopted to detect the areas which can be reached by the tool on the detected piece 1, and a manual contact coupling ultrasonic penetration method (a contact coupling method for short) is adopted to detect the residual areas on the detected piece 1. The ultrasonic transmission probe 8 can adopt different types of probes according to specific use cases.
Preferably, step S1 includes:
s1-1, determining basic detection parameters: basic detection parameters of the first ultrasonic instrument 6 used in the high-energy ultrasonic penetration method are determined. Preferably, there is a certain time interval between the bursts, e.g. 10-4～10-2s, when the number of cycles included in each pulse train is 5-15 and the number of cycles is less than 5, exciting ultrasonic energy is low; when the number of cycles is more than 15, the excited ultrasonic signal is unstable and cannot be used for detection, and the voltage of the excitation pulse is 200-500V.
S1-2, determining detection sensitivity: and adjusting the dB value of the first ultrasonic instrument 6 through the first comparison test block, so that when the first ultrasonic instrument 6 detects a defect-free area on the first comparison test block, the height of the through wave is 80%, and the dB value +3dB of the first ultrasonic instrument 6 is the detection sensitivity of the detected piece 1 at the thickness. The first comparison test block is a multi-layer bonding piece composed of metal-attenuation material-composite material, each layer of material is the same as the tested piece 1, and preferably, the bonding process between the layers is also the same as the tested piece 1. When determining the detection sensitivity of a certain detection point on the detected piece 1, a first comparison test block with the same thickness or the smallest thickness difference with the three layers of materials, namely the metal shell, the attenuation material layer and the composite material layer, at the detection point is adopted.
And adjusting an electronic gate of the first ultrasonic instrument 6 to enable the defect threshold value to be 20% so as to ensure accurate defect judgment.
S1-3, scanning and judging defects: scanning according to the determined basic detection parameters and detection sensitivity, wherein the scanning range is all areas of the detected piece 1, judging the area with the penetrating wave amplitude accounting for the percentage of the full-screen height of the first ultrasonic instrument 6 and being lower than the defect threshold value as a defect, and marking the outer side of the detected piece 1 with the defect.
In step S2, the inspected article 1 is inspected from one side of the metal case by a multiple pulse reflection method, the quality of the adhesion at the interface of the metal case and the attenuation material layer is determined, the debonding defect is determined for the debonding position, and a debonding defect mark is made on the inner side of the debonding defect determined. The inner side here refers to the side on which the metal housing is located.
Preferably, as shown in fig. 3, step S2 includes:
s2-1, determining basic detection parameters: and determining basic detection parameters of a second ultrasonic instrument used in the multi-pulse reflection method. Preferably, the frequency of the probe is 2.25-5 MHz, the diameter of the wafer is less than or equal to 10mm, and the scanning step is less than or equal to 5 mm.
S2-2, determining detection sensitivity: adjusting the dB value and the time base range of the second ultrasonic instrument through the first comparison test block, so that the 50% wave height corresponding to multiple echoes of the interface is not less than 80% when the second ultrasonic instrument detects the debonding area 15 on the first comparison test block; when the bonding area 14 on the first comparison test block is detected, the 50% wave height of multiple echoes of the interface is not more than 20%; the 50% wave height refers to the percentage of the wave height at five horizontal grid positions of the display screen of the second ultrasonic instrument to the full screen height of the display screen.
The first comparison test block is a multi-layer bonding piece composed of metal-attenuation material-composite material, each layer of material is the same as the tested piece 1, and preferably, the bonding process between the layers is also the same as the tested piece 1. When the detection sensitivity of a certain detection point on the detected piece 1 is determined, the detection bonding area 14 should adopt a first comparison test block with the same thickness or the smallest thickness difference with the three layers of materials, namely the metal shell, the attenuation material layer and the composite material layer, corresponding to the detection point, and the detection debonding area 15 should adopt a first comparison test block with the same thickness or the smallest thickness difference of the metal layer and the metal shell at the detection point.
S2-3, determining a threshold: and determining an appraisal threshold and a boundary threshold, wherein the range of the appraisal threshold is 70-90%, and the range of the boundary threshold is 30-50%.
S2-4, scanning and judging debonding defects: scanning the detected piece 1 according to the determined basic detection parameters and detection sensitivity, and judging as a debonding defect when 50% of wave height of multiple echoes of the interface is greater than or equal to an injury judgment threshold;
when the debonding defect is found, the probe of the second ultrasonic instrument is moved to the debonding defect from at least four directions to determine the boundary of the debonding defect, when the wave height of 50% of the multiple echoes of the interface reaches the boundary threshold value, the center position of the sound beam of the probe at the moment is determined as the boundary of the debonding defect, debonding defect marks are made on the inner side of the detected piece 1, and the debonding defect marks are sequentially connected to obtain the outline of the debonding defect.
In step S3, the position of the defect is determined by combining the marks on both sides of the test object 1. For the area with the defect mark on the outer side and without the debonding defect mark on the inner side, the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered, and the interface of the metal shell and the attenuation material layer is well bonded;
and for the area with the outer side with the defect mark and the inner side with the debonding defect mark, the interface of the metal shell and the attenuation material layer is determined to be debonding.
Preferably, step S3 further includes, for the area with the outer defective mark and the inner debonding defective mark, detecting the test piece 1 from the composite material layer side by the tapping method, and determining whether or not there is the debonding of the damping material layer-composite material layer interface or the delamination of the composite material layer.
As shown in fig. 4, the tapping method in step S3 includes:
s3-1, determining a hole threshold: and aligning the knocking detector to the position of the second reference block where the attenuation material layer has the layering defect of the cavity, detecting from one side of the composite material, reading the stress duration displayed by the knocking detector, and recording as a cavity threshold.
The second reference block is a multi-layer adhesive member made of an attenuation material-composite material, the material and thickness of each layer of material are the same as those of the object 1, and preferably, the interlayer adhesion process is also the same as that of the object 1. The attenuation material layer of the second reference block has a cavity 18 for simulating the interfacial debonding of the attenuation material layer-composite material layer or the delamination of the composite material layer in the tested piece 1. More preferably, the hollow 18 is circular and has a diameter in the range of 10 to 15 mm.
S3-2, detecting and judging the delamination or debonding defects of the composite material: the region to be detected on the detected piece 1 is divided into squares with equal size, and preferably, the size of the squares divided by the region to be detected is not more than 20 × 20 mm. Detecting each square one by one through knocking a detector, and ensuring that all areas to be detected on the detected piece 1 are detected; and when the stress duration displayed by the knocking detector is greater than or equal to the cavity threshold, judging that the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered, and marking the defects.
As shown in fig. 5 and 6, in the present embodiment, the first comparison block includes the first metal layer 11, the first attenuation material layer 12, and the first composite material layer 13, and is made of a metal, an attenuation material, and a composite material, which are the same as the material of the test piece 1, respectively, and the bonding process is the same as that of the test piece 1.
The bottom surface of the first metal layer 11 is a plane and is provided with a bonding area 14 and a debonding area 15; in the bonding area 14, the first attenuation material layer 12 and the first composite material layer 13 are sequentially bonded on the bottom surface of the first metal layer 11; the debonding region 15 is not bonded for simulating debonding between metal and attenuating material. When determining the detection sensitivity, the position where the thickness of the first metal layer 11 is the same as the thickness of the metal shell or the thickness difference is the smallest at the detection point of the object 1 is detected.
Preferably, as shown in fig. 5, in the first reference block, the first metal layer 11 is in a step shape, the height difference between two adjacent steps is not more than 3mm, and further preferably, the height difference is 1 to 3mm, the highest step height is greater than the thickest part of the metal shell in the test piece 1, and the lowest step height is less than the thinnest part of the metal shell in the test piece 1, that is, the height range of the step includes the thickness range of the metal shell of the test piece 1.
In another embodiment, a first reference block with a slope-shaped first metal layer 11 may be adopted, the thickness of the first metal layer 11 is uniformly changed, and the height range includes the thickness range of the metal shell of the object 1. Obviously, a local standard having the same shape and structure as those of the part of the test object 1 may be used as the first reference block, and the first reference block may be secured to simulate the good adhesion region and the debonded region of the metal case at different thicknesses.
Specifically, in the embodiment, the acoustic detection of the irregular cylindrical wound composite material multilayer bonding member with the minimum circumscribed circle diameter of 1.1m is taken as an example for detection, and the multilayer bonding member is composed of a metal shell, an attenuation material layer and a composite material layer from inside to outside, wherein the thickness range of the metal shell is 4-10 mm, the thickness of a nitrile rubber buffer layer (attenuation material) is 1.5mm, and the thickness of a glass fiber phenolic resin matrix composite material (composite material) is 10 mm.
As shown in fig. 7 and 8, the entire region on the test object 1 is inspected by the manual water jet ultrasonic penetration method and the manual contact-coupled ultrasonic penetration method. Fig. 7 is a schematic diagram of a test object 1 detected by a water-spraying method, wherein the test object 1 is in a longitudinal section, a water-spraying probe 2 is arranged on a probe arm 4, a water-spraying sleeve 3 is sleeved on the water-spraying probe 2, the water-spraying sleeves 3 are arranged on two sides of the test object 1, and during detection, the water-spraying probe 2 is connected with a pulse train emitter 7 to emit a high-energy ultrasonic signal. Fig. 8 is a schematic diagram of detecting the detected object 1 by the contact coupling method, wherein the detected object 1 is in a cross section, the probes 5 by the contact coupling method are arranged on two sides of the detected object 1, and during detection, the probes 5 by the contact coupling method are connected with the pulse train transmitter 7 to transmit high-energy ultrasonic signals.
Specifically, the water spraying probe 2 and the contact coupling probe 5 are both low-damping probes, and the frequency is 1MHz, so that not only can sufficient ultrasonic energy penetrate through the detected element 1, but also higher detection sensitivity can be ensured.
The basic detection parameters are determined in step S1-1. The diameter of a water column used by a water spraying method is 10mm, the diameter of a probe wafer used by a contact coupling method is 10mm, the scanning steps of the water column and the probe wafer are both 5mm, the scanning direction is parallel to the axial direction of the detected piece 1, the stepping direction is parallel to the circumferential direction of the detected piece 1, and high transverse resolution is guaranteed.
As shown in fig. 2, in step S1, a Toneburst sine pulse train transmitter 7 is used in the present embodiment, the period of the excitation pulse is consistent with the probe frequency, the number of the single pulse train including the period is set to 10, and the voltage amplitude of the excitation pulse train is 400V.
In another embodiment, a bipolar square wave pulse train may also be used to excite the ultrasonic emission probe 8, where the bipolar square wave pulse train is shown in fig. 9, where the emission voltage amplitude V of the square wave train does not exceed half of the breakdown voltage of the ultrasonic transducer wafer, the period T of the square wave train is 1/f, and f is the resonant frequency of the ultrasonic transducer; the single square wave pulse train comprises 10-20 cycles of the bipolar square wave.
As shown in fig. 5 and 6, in the present embodiment, the first metal layer 11 of the first reference block is stepped, and the height difference between two adjacent steps is 2 mm. The height of the ladder is 4mm, 6mm, 8mm, 10mm, guarantee the height of test block covers the thickness scope of examining piece 1. A first attenuation material layer 12 with the thickness of 1.5mm is bonded on the area of one half of the plane of a first metal layer 11, a first composite material layer 13 with the thickness of 10mm is bonded on the first attenuation material layer 12, the bonding process is the same as that of an actual product, the other half of the first metal layer 11 is not bonded, and debonding between metal and rubber is simulated.
In step S1-2, the detection sensitivity of the first ultrasonic meter 6 is determined by the first contrast block. If the metal thickness of a detection point in the detected piece 1 is equal to 4mm, 6mm, 8mm or 10mm, determining the detection sensitivity by using a first comparison block with the thickness of the first metal layer 11 equal to the metal thickness of the detection point, and if the metal thickness of the detection point in the detected piece 1 is not equal to 4mm, 6mm, 8mm or 10mm, determining the detection sensitivity by using the first comparison block with the thickness of the first metal layer 11 closest to the metal thickness of the detection point, namely the first comparison block with the smallest thickness difference, so as to ensure the accuracy of the detection sensitivity.
In step S1-3, a scan is performed according to the determined basic detection parameters and detection sensitivity, and for the portion determined as a defect, a defect mark is made on the outside of the object 1, that is, the outer surface of the irregular cylindrical wound composite multilayer adhesive member.
Step S2 includes determining basic detection parameters of the second ultrasonic apparatus used in the multiple pulse echo method in step S2-1, specifically, the probe frequency used by the second ultrasonic apparatus is 5MHz, ensuring high detection sensitivity; the diameter of the wafer is 10mm, the scanning step is 5mm, and good transverse resolution is guaranteed.
In step S2-2, the detection sensitivity is determined by the first reference block, the first reference block with the thickness of the first metal layer 11 being the same as the thickness of the metal shell in the object 1 is selected, the debonding area 15 and the bonding area 14 are detected from the metal side of the first reference block, and if the metal thickness at the detection point of the object 1 is not equal to 4mm, 6mm, 8mm or 10mm, the first reference block with the smallest difference between the thickness of the first metal layer 11 and the metal thickness at the detection point on the object 1 is used to determine the detection sensitivity, thereby ensuring the accuracy of the detection sensitivity.
The specific steps for adjusting the detection sensitivity of the second ultrasonic instrument are as follows:
a) initially adjusting the dB value and the time base range of a second ultrasonic instrument in a debonding area 15 on a first comparison test block, so that 50% of wave height corresponding to multiple echoes of an interface of the debonding area 15 is equal to 80%;
b) on the premise of meeting the requirements of a), finely adjusting the dB value and the time base range of the second ultrasonic instrument in the bonding area 14 on the first comparison test block to ensure that 50% of wave height corresponding to multiple echoes of the interface is equal to 10%;
c) the parameters of the dB values and the time base range are adjusted repeatedly until the requirements of a) and b) are met.
In step S2-3, a threshold is determined, in this embodiment, the selected critique threshold is 80%; the boundary threshold value is 40%, and the accuracy of the detection result is ensured.
Scanning and judging the debonding defect in the step S2-4, scanning according to the determined basic detection parameters and detection sensitivity, and judging the debonding defect when the 50% wave height of the multiple echoes of the interface is greater than or equal to the damage judging threshold, namely the 50% wave height is greater than or equal to 80%; and when the 50% wave height of the interface multiple echo is a boundary threshold value, namely the 50% wave height is equal to 40%, determining the boundary of the debonding defect, marking the inner side of the detected piece 1, namely the inner surface of the irregular cylindrical winding composite material multilayer bonding member, and sequentially connecting the marks to obtain the profile of the debonding defect.
In the embodiment, the height of multiple ultrasonic reflection pulses of the interface of the metal shell and the attenuation material layer is used for judging the interface bonding condition of the metal shell and the attenuation material layer, and the height difference of the multiple ultrasonic reflection pulses of the well-bonded area and the debonding area 15 is amplified, so that the well-bonded area and the debonding area 15 are easily distinguished, and the detection result has high reliability.
As shown in fig. 10, in this example, the second composite material layer 16 of the second comparative block had a thickness of 10mm, and the second attenuation material layer 17 had a thickness of 1.5 mm. When the second reference block is manufactured, after 1 hole with phi of 15mm is dug in the second attenuation material layer 17, the second composite material layer 16 is bonded with the second attenuation material layer 17, and the bonding process is the same as that of an actual product.
In step S3-1, a cavity threshold is determined, the tap detector is aligned with the cavity 18 dug out of the second reference block, detection is performed from the composite material side, and the stress duration time displayed by the tap detector is read and recorded as the cavity threshold.
And (3) detecting and judging the delamination or debonding defect of the composite material in step (S3-2), dividing the region to be detected on the detected piece 1 into 15mm by 15mm squares with the same size, respectively detecting each square one by using a knocking detector, judging the delamination or the delamination of the composite material layer on the interface of the attenuation material layer and the composite material layer when the stress duration displayed by the knocking detector is greater than or equal to a cavity threshold value, and marking the defect.
The method is used for actually detecting the large irregular winding composite material multilayer bonding members in multiple batches, and the result shows that the method can quickly detect the debonding defect or the layering defect of phi 15mm or less in the multilayer bonding members, can accurately determine the position of the defect, and meets the requirements of product design and repair.
The invention adopts the high-energy excitation technology to excite the ultrasonic emission probe 8 when the ultrasonic penetration method is used for detection, thus solving the problem that the common ultrasonic detection method can not detect the attenuation material layer with high sound attenuation and the composite material prepared by the winding process; the problem that the defects at different depths cannot be distinguished by an ultrasonic penetration method is solved by combining a multi-pulse reflection method for detecting from the inner side and a tapping method for detecting from the outer side; in addition, an accurate position can be provided for the repair of the detected piece 1, and the production cost is greatly reduced.
Finally, it should be noted that: the above examples are only intended to illustrate the technical solution of the present invention, but not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; and such modifications or substitutions do not depart from the spirit and scope of the corresponding technical solutions of the embodiments of the present invention.
Claims (6)
1. A nondestructive testing method of a multilayer bonding member is used for testing a tested piece consisting of a metal shell, an attenuation material layer and a composite material layer, and is characterized by comprising the following steps:
s1, detecting the detected piece from one side of the composite material layer by a high-energy ultrasonic penetration method, judging the area with the penetrating wave amplitude lower than the defect threshold value as a defect, and marking the outer side of the judged defect;
s2, detecting the detected piece from one side of the metal shell by a multi-pulse reflection method, determining the bonding quality at the interface of the metal shell and the attenuation material layer, judging the debonding defect at the debonding position, and marking the debonding defect at the inner side of the debonding defect;
s3, judging that the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered in the area with the defect mark on the outer side and the debonding defect mark-free inner side, and the interface of the metal shell and the attenuation material layer is well bonded;
for the region with the defect mark on the outer side and the debonding defect mark on the inner side, the interface of the metal shell and the attenuation material layer is determined to be debonding;
in step S1, the high-energy ultrasonic penetration method includes exciting an ultrasonic transmitting probe by a high-energy excitation technique, wherein a transmitting end of a first ultrasonic instrument used in the high-energy ultrasonic penetration method is connected to a signal input end of a pulse train transmitter, a signal output end of the pulse train transmitter is connected to the ultrasonic transmitting probe, and a period of an excitation pulse transmitted is consistent with a frequency of the ultrasonic transmitting probe; detecting the areas which can be reached by a tool on the detected piece by adopting a manual water spraying ultrasonic penetration method, and detecting the residual areas on the detected piece by adopting a manual contact coupling ultrasonic penetration method;
the step S2 includes:
s2-1, determining basic detection parameters: determining basic detection parameters of a second ultrasonic instrument used in the multi-pulse reflection method;
s2-2, determining detection sensitivity: adjusting the dB value and the time base range of the second ultrasonic instrument through the first comparison test block, so that the 50% wave height corresponding to multiple echoes of the interface is not less than 80% when the second ultrasonic instrument detects the debonding area on the first comparison test block; when detecting the bonding area on the first comparison test block, the 50% wave height of the interface multiple echoes is not more than 20%; the 50% wave height refers to the percentage of the wave height at the horizontal five-grid position of the display screen of the second ultrasonic instrument in the full screen height of the display screen;
s2-3, determining a threshold: determining an injury threshold value and a boundary threshold value, wherein the injury threshold value ranges from 70% to 90%, and the boundary threshold value ranges from 30% to 50%;
s2-4, scanning and judging debonding defects: scanning the detected piece according to the determined basic detection parameters and detection sensitivity, and judging as a debonding defect when 50% of wave height of multiple echoes of the interface is greater than or equal to the damage judging threshold;
when a debonding defect is found, moving a probe of the second ultrasonic instrument to the debonding defect from at least four directions to determine the boundary of the debonding defect, when the wave height of 50% of multiple echoes of an interface reaches the boundary threshold value, determining the center position of a sound beam of the probe at the moment as the boundary of the debonding defect, marking the debonding defect on the inner side of the detected piece, and sequentially connecting the debonding defect marks to obtain the profile of the debonding defect;
the step S3 further includes, for an area having a defect mark on the outer side and a debonding defect mark on the inner side, detecting the test object from one side of the composite material layer by a tapping method, and determining whether or not there is a debonding of the attenuating material layer-composite material layer interface or a delamination of the composite material layer;
the tapping method in step S3 includes:
s3-1, determining a hole threshold: aligning a knocking detector to the defect of the attenuation material layer in the second reference block, detecting from one side of the composite material, reading the stress duration time displayed by the knocking detector, and recording as a cavity threshold value;
s3-2, detecting and judging the delamination or debonding defects of the composite material: dividing the area to be detected on the detected piece into squares with the same size, respectively detecting each square one by one through the knocking detector, judging that the interface of the attenuation material layer and the composite material layer is debonded or the composite material layer is layered when the stress duration displayed by the knocking detector is greater than or equal to the cavity threshold value, and marking defects.
2. The nondestructive inspection method of the multilayer adhesive member according to claim 1, wherein said step S1 includes:
s1-1, determining basic detection parameters: determining basic detection parameters of a first ultrasonic instrument used in the high-energy ultrasonic penetration method;
s1-2, determining detection sensitivity: adjusting the dB value of the first ultrasonic instrument through a first comparison block, so that when the first ultrasonic instrument detects a defect-free area on the first comparison block, the height of a through wave is 80%, and the dB value +3dB of the first ultrasonic instrument is the detection sensitivity of the detected piece at the thickness; adjusting an electronic gate of the first ultrasonic instrument to enable a defect threshold value to be 20%;
s1-3, scanning and judging defects: scanning the detected piece according to the determined basic detection parameters and detection sensitivity, judging the area of which the percentage of the penetrating wave amplitude in the full-screen height of the first ultrasonic instrument is lower than the defect threshold value as a defect, and marking the outer side of the detected piece with the defect.
3. The nondestructive inspection method for a multilayer adhesive member according to claim 1, characterized in that: in the step S1 and the step S2, a first comparison block is adopted to determine the detection sensitivity;
the first comparison test block comprises a first metal layer, a first attenuation material layer and a first composite material layer, the first metal layer, the first attenuation material layer and the first composite material layer are respectively made of metal, attenuation material and composite material which are the same as the material of the detected piece, and the bonding process is the same as that of the detected piece;
the bottom surface of the first metal layer is a plane and is provided with a bonding area and a debonding area; in the bonding area, the bottom surface of the first metal layer is sequentially bonded with the first attenuation material layer and the first composite material layer; the debonding region is not bonded and is used for simulating debonding defects between the metal shell and the attenuation material.
4. The nondestructive inspection method for a multilayer adhesive member according to claim 3, characterized in that: in the first comparison test block, a first metal layer is in a step shape, the height difference between two adjacent steps is not more than 3mm, the highest step height is larger than the thickest part of the metal shell in the detected piece, and the lowest step height is smaller than the thinnest part of the metal shell in the detected piece;
and when the detection sensitivity is determined, detecting the position where the thickness of the first metal layer is the same as the thickness of the metal shell at the detection point of the detected piece or the thickness difference is minimum.
5. The nondestructive inspection method for a multilayer adhesive member according to claim 1, characterized in that: in the step S3-1, a second comparison block is adopted to determine a hole threshold;
the second comparison test block comprises a second composite material layer and a second attenuation material layer, the second composite material layer and the second attenuation material layer are made of composite materials and attenuation materials which are the same as the detected piece in material and thickness, and the bonding process is the same as that of the detected piece; and the second attenuation material layer is provided with a hole which is dug through.
6. The nondestructive inspection method for a multilayer adhesive member according to any one of claims 4 and 5, characterized in that: the cavity is circular, and the diameter range is 10 ~ 15 mm.
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| CN114113328A (en) * | 2021-11-03 | 2022-03-01 | 哈尔滨飞机工业集团有限责任公司 | Method for detecting debonding defect of aluminum panel and honeycomb glued joint |
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