CN111380955A - Method for detecting defects of additive manufacturing part based on ultrasonic phased array - Google Patents

Method for detecting defects of additive manufacturing part based on ultrasonic phased array Download PDF

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CN111380955A
CN111380955A CN201811650007.2A CN201811650007A CN111380955A CN 111380955 A CN111380955 A CN 111380955A CN 201811650007 A CN201811650007 A CN 201811650007A CN 111380955 A CN111380955 A CN 111380955A
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phased array
detection
probe
ultrasonic phased
additive manufacturing
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何振丰
赵宇辉
赵吉宾
孙长进
王志国
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Shenyang Institute of Automation of CAS
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Shenyang Institute of Automation of CAS
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    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating 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
    • G01N29/04Analysing solids
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating 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
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/26Arrangements for orientation or scanning by relative movement of the head and the sensor
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01NINVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N29/00Investigating 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
    • G01N29/22Details, e.g. general constructional or apparatus details
    • G01N29/28Details, e.g. general constructional or apparatus details providing acoustic coupling, e.g. water

Abstract

The invention discloses a method for detecting defects of an additive manufacturing part based on an ultrasonic phased array, and belongs to the technical field of ultrasonic nondestructive testing. The method is carried out by adopting an ultrasonic phased array detection system, and proper ultrasonic phased array detection instruments, probes, wedges, reference blocks and coupling agents are selected; establishing a detection group, setting a focusing rule, calibrating sound velocity delay, calibrating sensitivity and establishing a TCG curve on data acquisition and analysis software; a manual scanning mode is adopted to carry out 100% detection on the parts; and finally, collecting, storing and analyzing the detection information. The ultrasonic phased array detection of the invention can greatly improve the detection efficiency and carry out intuitive data imaging by integrating a plurality of detection wafers into one probe.

Description

Method for detecting defects of additive manufacturing part based on ultrasonic phased array
Technical Field
The invention relates to the technical field of ultrasonic nondestructive testing, in particular to a method for detecting defects of an additive manufacturing part based on an ultrasonic phased array.
Background
The metal additive manufacturing technology utilizes a high-energy laser beam to melt metal powder and directly deposit the metal powder on a substrate to form a cladding point, relative movement of the substrate and the laser beam forms a cladding line, the lines are overlapped and fused to form a cladding surface, and finally, the surfaces are fused and stacked to form a three-dimensional part. The additive manufacturing technology can directly form any complex three-dimensional geometric entity without special fixtures or tools, completely breaks away from the limitation of cutting processing, has short forming process time, is widely applied to the fields of aerospace and the like, and plays an increasingly important role in the manufacturing field. Due to the point-by-point manufacturing mode of the metal additive manufacturing technology, the metal parts manufactured by the additive are easy to generate defects such as air holes, poor fusion, cracks and the like in the manufacturing process, and the service performance of the parts is seriously damaged.
At present, nondestructive testing technologies for metal additive manufacturing products mainly focus on detecting defects and stress of the metal additive manufacturing products. The mechanical properties of the material are mainly obtained by the traditional mechanical test method, and the mechanical properties of the material of the metal additive manufactured product are evaluated and researched less by a nondestructive testing method. At present, nondestructive testing application research on metal additive metal products at home and abroad mainly focuses on electromagnetic and ray detection, and other detection methods are relatively few. The ray detection has great harm to human bodies, is not sensitive to area defects such as cracks, incomplete fusion and the like, and is easy to miss detection. The electromagnetic detection can detect the near-surface defects and stress states of the surface of the component, but the anisotropy of the structure of the metal component manufactured by the metal additive can influence the detection result, the detection range is small, and only the ferromagnetic material can be detected.
Disclosure of Invention
Aiming at the defects of poor detection effect, missed detection and the like of some parts in the conventional ultrasonic detection technology, the invention aims to provide the method for detecting the defects of the material increase manufacturing part based on the ultrasonic phased array.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
a method for detecting defects of an additive manufacturing part based on an ultrasonic phased array is used for detecting the defects of a metal part prepared by an additive manufacturing technology, and comprises the following steps:
(1) machining the surface to be detected of the part to remove impurities and ensure that the surface to be detected is smooth, wherein the surface roughness Ra is less than or equal to 6.3 mu m;
(2) selecting a proper ultrasonic phased array detection instrument, a probe, a wedge block, a reference block and a coupling agent;
(3) establishing a detection group, setting a focusing rule, calibrating sound velocity delay, calibrating sensitivity and establishing a TCG curve on data acquisition and analysis software;
(4) a manual scanning mode is adopted to carry out 100% detection on the parts;
(5) calibrating the encoder;
(6) and collecting, storing and analyzing the detection information.
The detection method is carried out by utilizing an ultrasonic phased array detection system, wherein the ultrasonic phased array detection system comprises an ultrasonic phased array detection instrument, a probe, a wedge block and a reference block; wherein: the probe is a phased array probe with the frequency of 5MHz and 16 wafers, and the wedge block is made of organic glass; the reference block is a titanium alloy test block prepared by adopting a laser additive manufacturing technology, and a plurality of different depths are arranged on the reference block
Figure BDA0001932777160000021
The material and the preparation process of the reference block and the part to be detected are the same; the surface to be detected of the part or the reference block uses engine oil as a coupling agent, and butter is used between the probe and the wedge block as the coupling agent.
In the ultrasonic phased array detection system, an ultrasonic phased array detection instrument is connected with a phased array probe through a cable, and information received by the ultrasonic phased array detection instrument is analyzed and processed by data acquisition and analysis software; and a coupling agent is arranged between the wedge block and the probe, and the probe is arranged on the surface to be detected of the part to be detected or the reference block.
The specific process of the step (3) is as follows:
and (3) establishing a detection group in data acquisition and analysis software, selecting parameters such as scanning type, sound velocity angle, wafer activation mode, focusing type, probe, wedge block, workpiece thickness, workpiece material, ultrasonic type and the like for the established group, and calibrating sound velocity delay, calibration sensitivity and establishing a TCG curve by using a reference block.
In the step (4), in order to ensure that the ultrasonic beam can scan the whole detected area of the workpiece during detection, the scanning coverage of the probe is more than 15% of the diameter or width of the probe each time, and the scanning speed of the probe is not more than 150 mm/s.
In the step (4), in the scanning process, if the deviation of any point on the scanning line exceeds 10% of the reading of the point of the scanning line or 5% of the full scanning range, the scanning range should be readjusted, and all detection parts from the last rechecking are rechecked.
In the step (5), in order to acquire the position information, the encoder needs to be calibrated, and the encoder used is a pull rope encoder.
The invention has the advantages and beneficial effects that:
1. the detection method can obviously improve the detection efficiency and the defect detection rate.
2. According to the invention, the 3D printing of the reference block is adopted, so that the positioning accuracy of the defects can be improved.
3. The invention adopts an ultrasonic phased array detection method, can produce C-scan, B-scan and S-scan images besides the A-scan image, and is beneficial to the quantification of defects.
Drawings
FIG. 1 is a schematic view of detection.
FIG. 2 is a schematic diagram of a speed of sound delay calibration.
FIG. 3 is a schematic of sensitivity calibration.
FIG. 4 is a schematic diagram of creating a TCG curve.
FIG. 5 is a size chart of a comparative titanium alloy test block prepared by 3D printing.
Fig. 6 is a schematic view of a test sample.
FIG. 7 shows the results of the detection.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be described in detail with reference to the accompanying drawings and examples.
The invention relates to a method for detecting defects of an additive manufacturing part based on an ultrasonic phased array, which is carried out by using an ultrasonic phased array detection system. As shown in fig. 1, the ultrasonic phased array inspection system includes an ultrasonic phased array inspection instrument, a probe, a wedge block and a reference block; the ultrasonic phased array detection instrument is connected with the phased array probe through a cable, and information received by the ultrasonic phased array detection instrument is analyzed and processed by data acquisition and analysis software; a coupling agent is placed between the wedge block and the probe, and the probe is placed on the surface to be detected of the part to be detected or the reference block, wherein: the probe is a phased array probe with the frequency of 5MHz and 16 wafers, and the wedge block is made of organic glass; the reference block is a titanium alloy test block prepared by adopting a laser additive manufacturing technology, and a plurality of different depths are arranged on the reference block
Figure BDA0001932777160000031
The material and the preparation process of the reference block and the part to be detected are the same; the surface to be detected of the part or the reference block uses engine oil as a coupling agent, and butter is used between the probe and the wedge block as the coupling agent.
The method for detecting the defects of the ultrasonic phased array comprises the following steps:
(1) machining the surface to be detected of the part to remove impurities and ensure that the surface to be detected is smooth, wherein the surface roughness Ra is less than or equal to 6.3 mu m;
(2) selecting a proper ultrasonic phased array detection instrument, a probe, a wedge block, a reference block and a coupling agent;
(3) establishing a detection group, setting a focusing rule, calibrating sound velocity delay, calibrating sensitivity and establishing a TCG curve on data acquisition and analysis software;
(4) a manual scanning mode is adopted to carry out 100% detection on the parts;
(5) calibrating the encoder;
(6) and collecting, storing and analyzing the detection information.
In the step (4), in order to ensure that the ultrasonic sound beam can scan the whole detected area of the workpiece during detection, the scanning coverage of the probe is more than 15% of the diameter or width of the probe each time, and the scanning speed of the probe is not more than 150 mm/s.
Example 1:
in this embodiment, the reference test block is a titanium alloy test block prepared by the same material and process for detecting the defects of the titanium alloy part prepared by the laser additive manufacturing technology.
Description of the terms:
group (2):
in data acquisition analysis software, a group is a well-defined configuration of all the parameters needed to generate one or more ultrasound speeds using a conventional probe or phased array probe. One group may use the same probe for pulse transmission and signal reception, or two different probes for pulse transmission and signal reception, respectively, and one probe may be used for multiple groups.
Calibrating the sound speed delay:
the purpose of calibrating the phased array sound speed delays is to adjust the delay of each sound speed so that all sound speeds obtain an indication of the presence of a defect in a known reflector at the correct depth. Each group must perform such a calibration procedure, see fig. 2.
Calibrating the sensitivity:
the purpose of calibrating the sensitivity of the phased array is to adjust the gain of each sound velocity so that the amplitude of the known reflectors for all sound velocities appears at the same level, see fig. 3.
Creating a TCG curve:
the Time Correction Gain (TCG) functions by: during data acquisition, the receiver gain is modified to compensate for attenuation of the ultrasound waves in the material, see FIG. 4. The TCG curve may define gain values that are added to the group gain, and to create a TCG curve, a calibration block is required with reflectors at different depths but of the same size.
Setting a focusing rule:
parameters such as scanning type, sound velocity angle, wafer activation mode, focusing type, probe, wedge, workpiece thickness, workpiece material, ultrasonic type, etc. are set for the created group.
The specific detection process of this embodiment is as follows:
(1) the surface to be detected needs to be machined, impurities are removed, and the surface is smooth (the surface roughness Ra is less than or equal to 6.3 mu m).
(2) The detecting instrument is an ultrasonic phased array detecting device, the probe is a 5MHz and 16 wafer phased array probe, the wedge block material is organic glass, and the wedge block material is prepared
Figure BDA0001932777160000051
The laser material increase of cross bore makes the titanium alloy test block, see figure 5, detects the surface and uses machine oil to make the couplant, uses butter to make the couplant between probe and the voussoir.
(3) Establishing a phased array detection group, setting a focusing rule, calibrating sound velocity delay, calibrating sensitivity and establishing a TCG curve on data acquisition and analysis software.
(4) And (3) detecting the beam sample piece by 100% in a manual scanning mode, and scanning the part with the thickness of more than 30mm in a double-sided scanning mode. In order to ensure that the ultrasonic sound beam can scan the whole detected area of the workpiece during detection, the coverage of each scanning of the probe is more than 15% of the diameter or width of the probe, and the scanning speed of the probe is generally not more than 150 mm/s. During scanning, if the deviation of any point on the scanning line exceeds 10% of the reading of the point of the scanning line or 5% of the full scanning range, the scanning range should be readjusted, and all detection parts from the last rechecking are rechecked.
(5) The encoder is calibrated. In order to collect the position information, the encoder needs to be calibrated, and the used encoder is a pull rope encoder.
(6) And collecting, storing and analyzing data. Data acquisition software is used to acquire and store data, and the stored data is then analyzed.
The detection results of this example are as follows:
and (3) carrying out 100% ultrasonic flaw detection on the titanium alloy beam sample, and finding out that 0 part exceeds the standard, wherein the detection sample is shown in figure 6, and the detection result is shown in figure 7. All inspection areas meet the requirements of industrial application.

Claims (7)

1. A method for detecting defects of an additive manufacturing part based on an ultrasonic phased array is characterized by comprising the following steps: the method is used for detecting defects of metal parts prepared by an additive manufacturing technology, and comprises the following steps:
(1) machining the surface to be detected of the part to remove impurities and ensure that the surface to be detected is smooth, wherein the surface roughness Ra is less than or equal to 6.3 mu m;
(2) selecting a proper ultrasonic phased array detection instrument, a probe, a wedge block, a reference block and a coupling agent;
(3) establishing a detection group, setting a focusing rule, calibrating sound velocity delay, calibrating sensitivity and establishing a TCG curve on data acquisition and analysis software;
(4) a manual scanning mode is adopted to carry out 100% detection on the parts;
(5) calibrating the encoder;
(6) and collecting, storing and analyzing the detection information.
2. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1, wherein the method comprises the following steps: the detection method is carried out by utilizing an ultrasonic phased array detection system, wherein the ultrasonic phased array detection system comprises an ultrasonic phased array detection instrument, a probe, a wedge block and a reference block; wherein: the probe is a phased array probe with the frequency of 5MHz and 16 wafers, and the wedge block is made of organic glass; the reference block is a titanium alloy test block prepared by adopting a laser additive manufacturing technology, and a plurality of different depths are arranged on the reference block
Figure FDA0001932777150000011
The material and the preparation process of the reference block and the part to be detected are the same; the surface to be detected of the part or the reference block uses engine oil as a coupling agent, and a probeButter is used as coupling agent between the wedge block and the base.
3. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1 or 2, wherein: in the ultrasonic phased array detection system, an ultrasonic phased array detection instrument is connected with a phased array probe through a cable, and information received by the ultrasonic phased array detection instrument is analyzed and processed by data acquisition and analysis software; and a coupling agent is arranged between the wedge block and the probe, and the probe is arranged on the surface to be detected of the part to be detected or the reference block.
4. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1, wherein the method comprises the following steps: the specific process of the step (3) is as follows:
and (3) establishing a detection group in data acquisition and analysis software, selecting parameters such as scanning type, sound velocity angle, wafer activation mode, focusing type, probe, wedge block, workpiece thickness, workpiece material, ultrasonic type and the like for the established group, and calibrating sound velocity delay, calibration sensitivity and establishing a TCG curve by using a reference block.
5. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1, wherein the method comprises the following steps: in the step (4), in order to ensure that the ultrasonic sound beam can scan the whole detected area of the workpiece during detection, the scanning coverage of the probe is more than 15% of the diameter or width of the probe each time, and the scanning speed of the probe is not more than 150 mm/s.
6. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1, wherein the method comprises the following steps: in the step (4), in the scanning process, if the deviation of any point on the scanning line exceeds 10% of the reading of the point of the scanning line or 5% of the full scanning range, the scanning range should be readjusted, and all detection parts from the last rechecking are rechecked.
7. The method for detecting the defects of the ultrasonic phased array based additive manufacturing part according to claim 1, wherein the method comprises the following steps: in the step (5), in order to acquire the position information, the encoder needs to be calibrated, and the used encoder is a pull rope encoder.
CN201811650007.2A 2018-12-31 2018-12-31 Method for detecting defects of additive manufacturing part based on ultrasonic phased array Pending CN111380955A (en)

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