CN111060602A - Qualitative and quantitative analysis method for SiC/Al composite material ultrasonic detection defects - Google Patents
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Abstract
The invention relates to the field of nondestructive detection of defects of SiC/Al composite materials, and discloses a special test block for ultrasonic detection and a method for identifying the special defect property, which can truly reflect the special defect property in an aluminum-based composite material. It is characterized in that: (1) a special detection test block is prepared by a twice sintering method. Different from a flat-bottom hole test block for general detection, the test block can correctly present properties and equivalent of two types of defects, namely SiC agglomeration, Al segregation and/or Al line, in the SiC/Al composite material. (2) An ultrasonic phase analysis method is designed, and the ultrasonic qualitative identification of the two types of defects is proved and realized through special test blocks and actual defect test verification. The invention provides a test block and a test method basis for the ultrasonic qualitative and quantitative detection of the aluminum matrix composite material and the establishment of the ultrasonic detection standard of the aluminum matrix composite material.
Description
Technical Field
The invention relates to the technical field of preparation of an aluminum matrix composite simulation test block and ultrasonic image processing and analysis, and particularly provides an ultrasonic detection method of a SiC reinforced aluminum matrix composite.
Background
The SiC/Al composite material has excellent comprehensive properties of high specific strength, high specific stiffness, high heat conductivity and the like, is widely applied to key parts in the field of aerospace, and is an important material which is important in national requirements and concerned with national transportation and civilian life. The SiC/Al composite material is generally prepared into a compact billet by powder metallurgy, casting and other methods, and then is subjected to deformation processing such as extrusion, forging, rolling and the like in the later stage. However, due to reasons such as a preparation process, defects may be generated in the preparation process of the aluminum-based composite material, and different types of defects will affect mechanical performance indexes such as strength and toughness of the material to different degrees. The ultrasonic detection has the advantages of simple operation, high detection efficiency, low cost and the like, and is widely applied. In actual detection, since the nature of the defect is difficult to distinguish, some products containing non-dangerous defects are often repaired or scrapped, thereby causing waste. Moreover, if the nature of the defect and the spatial arrangement of the defect in the workpiece cannot be defined, the preparation process cannot be optimized, and the defect cannot be eradicated from the source, so that the qualitative analysis of the defect by ultrasonic detection is very important. The defect property, the equivalent weight and the spatial arrangement of the defects are determined, so that a large amount of financial resources and time can be saved for actual production, and a wider space is provided for the application of ultrasonic detection in practice.
There are 4 common defects in SiC reinforced aluminum matrix composites: the holes, cracks, inclusions and SiC particles are not uniformly distributed (SiC agglomeration, Al segregation and Al lines), wherein the defects of the holes, the cracks and the inclusions can obviously reduce the performance of the material, but can reduce or even eliminate the defects by optimizing the preparation process. Occasional defects of the SiC uneven distribution type caused by stirring, mixing dead zones or other factors are difficult to avoid, and the qualitative analysis of the defects is less researched. Therefore, the invention aims at carrying out ultrasonic nondestructive testing on the SiC/Al composite material, and tries to disclose the defect type caused by uneven particle distribution, the relation between the equivalent size of the defect and the actual defect and the spatial arrangement of the defect in a workpiece by utilizing the waveform phase relation in the ultrasonic testing. From the scientific research perspective, the method solves the problems of effective qualitative detection and quantification of specific defects such as SiC agglomeration, Al segregation and Al line defects in the SiC/Al composite material, and assists scientific research personnel to solve the defects existing in the material from the source by optimizing the preparation process; from the perspective of engineering application, an ultrasonic detection standard is established first, and the engineering application of the SiC/Al composite material part is assisted.
In the invention patent of "a nondestructive measurement method for the content of an reinforcement in a particle-reinforced metal matrix composite" (publication number is CN 109212039A), Yangthenhua et al invented a method for identifying the content of the reinforcement in the composite material by means of sound velocity imaging. In the invention patent "a method for rapidly detecting the quality consistency of a particle-reinforced aluminum-based composite material with ultrasonic waves" (publication number CN101435798A), dawn et al invented an evaluation means for determining the uniformity of a tissue and the quality consistency by the change of the ultrasonic speed. In the invention patent "method for detecting uniformity and process stability of aluminum-based composite material by using ultrasonic wave" (publication number is CN 105806950a), the invention of ma he et al evaluates the uniformity of material structure and process stability by the variation of parameters such as sound velocity value, primary bottom wave gain, and grassy echo of aluminum-based composite material. However, the method does not mention a qualitative method for detecting defects of SiC/Al composite materials by ultrasonic.
Disclosure of Invention
The invention aims to provide an accurate and efficient qualitative analysis method for detecting defects of a SiC/Al composite material by ultrasonic waves, and solves the problems of effective qualitative and quantitative detection of SiC agglomeration, Al segregation and Al line defects caused by uneven SiC distribution in the existing aluminum-based composite material.
The technical scheme of the invention is as follows:
a SiC/Al composite material simulation test block with integrated structure and function is used for qualitative and quantitative analysis, and is characterized in that the preparation method of the test block is as follows:
1. fully mixing SiC powder with aluminum alloy powder according to a certain proportion (5-70 vol.% SiC), and then filling the powder into a die for cold press molding;
2. carrying out vacuum hot-pressing sintering on the SiC/Al composite material powder subjected to cold press molding to obtain a SiC/Al material billet; the preferable sintering temperature is 520-650 ℃, the sintering time is 1-4h, and the sintering pressure is 10-50 MPa;
3. 2 flat-bottom holes with the diameter of 2mm and the depth of 10mm are manufactured on one end face of the blank;
4. respectively placing aluminum alloy columns and high-content (30-70 vol.%) SiC/Al columns into the flat-bottom holes, so that the aluminum alloy columns and the high-content SiC/Al columns are in clearance fit;
5. and repeating the process 2, carrying out hot-pressing sintering again, taking out the hot-pressed ingot, and machining into a simulation test block.
The invention also provides a qualitative analysis and quantitative analysis method for detecting the defects of the aluminum matrix composite material by using the simulation test block through ultrasonic waves, which is characterized by comprising the following steps of:
(1) selecting an ultrasonic detector and a straight probe with a certain frequency, and preparing a simulation test block;
(2) adjusting the ultrasonic detection sensitivity through the simulation test block;
(3) detecting the workpiece, finding out a defect wave, and adjusting a waveform display mode of the ultrasonic detector;
(4) acquiring a bottom wave waveform;
(5) observing the phase relation between the defect and the bottom wave;
(6) and evaluating the equivalent of the found defects, carrying out anatomical metallographic observation on the defects, and observing the relation between the equivalent size and the actual size of the defects.
The qualitative and quantitative analysis method is characterized in that: the aluminum matrix composite is 5 vol.% to 70 vol.% SiC/Al.
As a preferred technical scheme:
in the step (1), an ultrasonic flaw detector with an RF mode is used, and a straight probe of 2MHz-15MHz is selected as the probe.
In the step (2), the defect wave height of the aluminum wire reaches 80% of the full screen as the reference sensitivity.
And (3) adjusting the waveform display mode of the ultrasonic detector to enable the display of the ultrasonic detector to be in an RF mode, and carrying out waveform acquisition on the Al segregation defect and the SiC agglomeration defect.
In the step (4), a bottom wave waveform is acquired in the RF mode.
In the step (5), observing the relation between the phase of the Al segregation defect and the phase of the high-content SiC/Al defect and the bottom wave phase: when Z is2<Z1Time (defect acoustic impedance)Smaller than the acoustic impedance of the material to be detected), the phases of the reflected wave and the bottom wave are the same, that is, the material to be detected has Al segregation and Al lines; when Z is2>Z1When the defect acoustic impedance is larger than the material to be tested, the phases of the reflected wave and the bottom wave are opposite, that is, SiC agglomeration exists in the material to be tested.
In the step (6), TCG defects are manufactured through a traditional non-filling type phi 2mm flat-bottom hole test block (a comparison test block), the simulation test block is combined, the echo of the Al interface flat-bottom hole of the simulation test block reaches 80% of the full screen and serves as the standard detection sensitivity, equivalent evaluation is carried out on the found defects, metallographic observation is carried out on the defects, and the relation between the equivalent size and the actual size is observed.
The invention has the beneficial effects that:
the simulation test block fully simulates the defects of Al segregation, Al lines and SiC agglomeration generated in the actual production process of a workpiece, and qualitatively and quantitatively analyzes the specific defects in the aluminum-based composite material by an ultrasonic phase analysis method.
Drawings
FIG. 1 is a phase relationship between a notch and a bottom wave; (a) when Z is2<Z1When the wave is in the same phase as the bottom wave; (b) when Z is2>Z1The reflected wave and the bottom wave are in opposite phases.
FIG. 2 is a plan view of a 17 vol.% SiC/Al block.
FIG. 3 is a diagram of a 17 vol.% SiC/Al block.
FIG. 4 is an artificial defect waveform; (a) an Al defect wave shape; (b) a bottom wave waveform; (c) SiC agglomeration defect waveforms; (d) bottom wave waveform.
FIG. 5 is an artificial defect waveform; (a) an Al segregation defect waveform; (b) SiC agglomeration defect waveform.
FIG. 6 shows the defect types observed by phase analysis and metallographic methods; (a) and (b) the defect phase is opposite to the bottom wave phase; (c) and (d) the phase of the defect is the same as that of the bottom wave; (e) SiC agglomeration microstructure; (f) al segregation microstructure.
FIG. 7 is a graph of the equivalent weight determined for the reference block and the simulated block; (a) detecting defect equivalent of the reference block to phi 2mm-18 dB; (b) the equivalent weight of the defect detected by the simulation test block is phi 2 mm.
Fig. 8 is a metallographic picture of a defect.
Detailed Description
First, phase analysis
The ultrasonic detection technology is that when ultrasonic wave is transmitted in the material, the acoustic impedance of the defective area tissue is different from that of the normal area tissue, the ultrasonic wave generates a reflection echo at the interface, the position and the equivalent size of the defect are determined according to the size and the position of the echo, and the sound pressure echo reflectivity formula is RP＝(Z2cosα-Z1cosβ)/(Z2cosα+Z1cos β) where Z1Is acoustic impedance of a first medium, Z2When a single crystal straight probe is used for detection, the incident angle and the reflection angle are both 90 degrees, so that cos α is cos β is 1, the sound pressure echo reflectivity is only related to the acoustic impedance of the substance, and the physical parameters of 17 vol.% SiC/Al and 40 vol.% SiC/Al composite material are shown in Table 1.
TABLE 1 physical parameters of materials of different compositions
According to the above formula, when the ultrasonic wave is projected onto the grain unevenness defect in the material to be inspected (17 vol.% SiC/Al), the magnitude of the ultrasonic reflection at the interface depends on the difference in acoustic impedance between the two, when Z is2<Z1When the phase of the reflected wave is the same as that of the bottom wave, that is, when Al segregation and Al lines exist in the material; when Z is2>Z1In this case, since the reflected wave and the bottom wave have opposite phases, that is, SiC agglomeration is present in the test material, the defect type can be identified by using the phase relationship between the defect echo and the bottom wave, as shown in fig. 1.
In order to verify the feasibility of the method, 17 vol.% of SiC/Al composite material is prepared by the same preparation method, and two flat-bottomed cylinders with Al and 40 vol.% of SiC/Al are respectively prepared on the end surfaces of the material to respectively simulate Al segregation and SiC agglomeration. The structure of the device is schematically shown in figure 2.
Second, defect quantification
Respectively manufacturing a TCG curve by using phi 2mm flat-bottom holes with different depths of a reference block as reference sensitivity; and by the simulation test block, the echo height of the aluminum wire interface reaches 80% of the full screen as the reference sensitivity. And scanning the workpiece through TCG curves made by the two test blocks, qualitatively analyzing the found defects, then quantitatively analyzing the defects, and comparing the equivalent sizes of the simulation test block and the comparison test block with the metallographic analysis to obtain the relation of the actual sizes of the defects.
Preparation method of simulation test block
(1) Fully mixing SiC powder and aluminum alloy powder according to a certain proportion, and then filling the powder into a die for cold press molding;
(2) carrying out vacuum hot-pressing sintering on the SiC/Al composite material powder subjected to cold press molding to obtain a SiC/Al material billet (the sintering temperature is 520-650 ℃, the sintering time is 1-4h, and the sintering pressure is 10-50 MPa);
(3) 2 flat-bottom holes with the diameter of 2mm and the depth of 10mm are manufactured on one end face of the blank;
(4) respectively placing the Al or aluminum alloy column and the high-content SiC/Al column into the flat-bottom hole to enable the Al or aluminum alloy column and the high-content SiC/Al column to be in clearance fit;
(5) and (5) repeating the process (2), carrying out hot-pressing sintering again, taking out the hot-pressed ingot, and machining into a simulation test block.
Example 1
A Masterscan 340 ultrasonic flaw detector is selected, the probe is a 5MHz single crystal straight probe, when the sensitivity is that the bottom wave height is 80% of the full screen, the sensitivity is improved by 30dB, the display of the instrument is in an RF mode, waveforms are adopted for two artificial defects in the figure 2, and the result is shown in the figure 4. Experimental results show that the Al segregation phase waveform is downward, and the bottom wave phase waveform is also downward, which indicates that the ultrasonic waves are transmitted from high impedance to low impedance, i.e. the ultrasonic waves are transmitted from 17 vol.% of SiC/Al with high impedance to Al segregation with low impedance and from 17 vol.% of SiC/Al with high impedance to air with low impedance, so that the phases of the two are the same; the phase waveform of 40 vol.% SiC/Al agglomeration is upward, and the phase waveform of the bottom wave is opposite to the phase waveform, which indicates that the sound waves are from 17 vol.% SiC/Al with low impedance to 40 vol.% SiC/Al agglomeration with high impedance and from 17 vol.% SiC/Al with high impedance to air with low impedance, so that the phase waveforms of the two are opposite, which is in accordance with the theory of the phase analysis method, and therefore SiC agglomeration, Al segregation and Al line defects caused by uneven SiC distribution can be accurately and efficiently distinguished by the method.
Comparative example 1
A Masterscan 340 ultrasonic flaw detector is selected, a 5MHz single crystal straight probe is adopted as the probe, when the sensitivity is that the bottom wave height is 80% of the full screen, the sensitivity is improved by 30dB, the detection is carried out in a full wave mode, waveforms are adopted for two artificial defects in the figure 2, and the result is shown in figure 5.
Research results show that the defect type cannot be effectively distinguished from the waveform characteristics of the defect by the method.
Example 2
A Masterscan 340 ultrasonic flaw detector is selected, the probe is a 5MHz single crystal straight probe, the sensitivity is that the echo height of an aluminum wire defect interface is 80% of full screen, the workpiece is detected under the condition that the display of the detector is in an RF mode, and a defect waveform is adopted. The phase analysis method is used for determining the nature of the defects, and the metallographic method is used for verifying the nature of the defects, so that the results show that the defect nature distinguished by the phase analysis method is the same as the defect type observed by the metallographic method.
Example 3
Respectively making a TCG curve by using the echo height of phi 2mm flat-bottom holes with different depths of a reference block as 80 percent to serve as reference sensitivity; and then, using the simulation test block to enable the echo height of the aluminum wire to reach 80% of the full screen as the reference sensitivity. And scanning the workpiece through TCG curves made by the two test blocks respectively, and carrying out quantitative analysis on the found defects. The equivalent size determined by the reference block and the simulation block is compared with the metallographic analysis to obtain the relation of the actual size of the defect (fig. 7 and 8). And carrying out comparative analysis on the equivalent size of the defect and the actual size of the defect by a metallographic method. The result shows that the equivalent size of the defect determined by the simulation test block is very close to the actual size of the defect, and the equivalent size of the defect and the actual size of the defect are greatly different by the traditional test block.
The invention is not the best known technology.
The above embodiments are merely illustrative of the technical ideas and features of the present invention, and the purpose thereof is to enable those skilled in the art to understand the contents of the present invention and implement the present invention, and not to limit the protection scope of the present invention. All equivalent changes and modifications made according to the spirit of the present invention should be covered within the protection scope of the present invention.
Claims (10)
1. A SiC/Al composite material simulation test block with integrated structure and function is characterized in that the preparation method of the test block comprises the following steps:
(1) fully mixing SiC powder and aluminum alloy powder according to a certain proportion, and then filling the powder into a die for cold press molding;
(2) carrying out vacuum hot-pressing sintering on the SiC/Al composite material powder subjected to cold press molding to obtain a SiC/Al material billet;
(3) 2 flat-bottom holes with the diameter of 2mm and the depth of 10mm are manufactured on one end face of the blank;
(4) placing the aluminum alloy cylinder and 30-70 vol.% SiC/Al cylinder into the flat bottom hole respectively, and enabling the aluminum alloy cylinder and the SiC/Al cylinder to be in clearance fit;
(5) and (5) repeating the process (2), carrying out hot-pressing sintering again, taking out the hot-pressed ingot, and machining into a simulation test block.
2. The structurally and functionally integrated SiC/Al composite simulation test block as set forth in claim 1, wherein: in the step (2), the adopted sintering temperature is 520-650 ℃, the sintering time is 1-4h, and the sintering pressure is 10-50 MPa.
3. A qualitative analysis and quantitative analysis method for detecting defects of an aluminum-based composite material through ultrasonic waves is characterized by comprising the following steps of:
(1) selecting an ultrasonic detector and a straight probe with a certain frequency, and preparing a simulation test block;
(2) adjusting the ultrasonic detection sensitivity through the simulation test block;
(3) detecting the workpiece, finding out a defect wave, and adjusting a waveform display mode of the ultrasonic detector;
(4) acquiring a bottom wave waveform;
(5) observing the phase relation between the defect and the bottom wave;
(6) and evaluating the equivalent of the found defects, carrying out anatomical metallographic observation on the defects, and observing the relation between the equivalent size and the actual size of the defects.
4. The qualitative and quantitative analysis method according to claim 3, wherein: the aluminum matrix composite is 5 vol.% to 70 vol.% SiC/Al.
5. The qualitative and quantitative analysis method according to claim 3, wherein: in the step (1), an ultrasonic flaw detector with an RF mode is used, and a 2MHz-15MHz straight probe is selected as a probe.
6. The qualitative and quantitative analysis method according to claim 3, wherein: in the step (2), the standard sensitivity is set to make the height of the aluminum interface wave reach 80% of the full screen.
7. The qualitative and quantitative analysis method according to claim 3, wherein: and (3) adjusting the waveform display mode of the ultrasonic detector to enable the display of the ultrasonic detector to be in an RF mode, and carrying out waveform acquisition on the Al segregation defect and the SiC agglomeration defect.
8. The qualitative and quantitative analysis method according to claim 3, wherein: in the step (4), a bottom wave waveform is acquired in the RF mode.
9. The qualitative and quantitative analysis method according to claim 3, wherein: in the step (5), observing the relation between the phase of the Al segregation defect and the phase of the high-content SiC/Al defect and the bottom wave phase: when the acoustic impedance of the defect is smaller than that of the detected material, the phases of the reflected wave and the bottom wave are the same, namely the detected material has Al segregation and Al lines; when the acoustic impedance of the defect is larger than that of the detected material, the phases of the reflected wave and the bottom wave are opposite, namely SiC agglomeration exists in the detected material.
10. The qualitative and quantitative analysis method according to claim 3, wherein: in the step (6), TCG defects are manufactured through a traditional non-filling type phi 2mm flat-bottom hole test block, a simulation test block is combined, the echo of the Al interface flat-bottom hole of the simulation test block reaches 80% of the full screen and serves as the reference detection sensitivity, equivalent evaluation is carried out on the found defects, metallographic observation is carried out on the defects, and the relation between the equivalent size and the actual size is observed.
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| CN112362757A (en) * | 2020-11-20 | 2021-02-12 | 株洲硬质合金集团有限公司 | Manufacturing method of hard alloy test block for ultrasonic detection of flat bottom hole |
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