CN111473898B - Method for correcting influence of thickness of cladding layer on ultrasonic evaluation of stress of cladding layer - Google Patents
Method for correcting influence of thickness of cladding layer on ultrasonic evaluation of stress of cladding layer Download PDFInfo
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- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/25—Measuring force or stress, in general using wave or particle radiation, e.g. X-rays, microwaves, neutrons
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Abstract
The invention discloses a method for correcting influence of cladding layer thickness on ultrasonic evaluation of cladding layer stress, and belongs to the technical field of ultrasonic nondestructive evaluation technology and stress evaluation technology. The method establishes the corresponding correlation between the ultrasonic acoustic-elastic coefficient and the thickness of the cladding layer by means of an ultrasonic probe group in a one-transmitting and two-receiving mode and an ultrasonic acoustic-elastic coefficient calibration experiment. Based on ultrasonic signal amplitude analysis, ultrasonic nondestructive evaluation of the thickness of the cladding layer is realized, further nondestructive evaluation of the ultrasonic coefficient of the cladding layer with any thickness is realized, and finally correction of the influence of the thickness of the cladding layer on the stress of the cladding layer for ultrasonic evaluation is realized. The invention provides technical support for correcting the influence of the thickness of the cladding layer on the stress of the cladding layer for ultrasonic evaluation, and has the advantages of no damage, convenience, safety, realization of online application and the like.
Description
Technical Field
The invention belongs to the technical field of ultrasonic nondestructive evaluation, and particularly relates to a method for correcting influence of cladding layer thickness on ultrasonic evaluation of cladding layer stress.
Background
The remanufacturing industry is an effective measure for developing circular economy and promoting the realization of energy conservation and emission reduction in China, so the vigorous development of the remanufacturing industry is very important for the economic development and the technical transformation in China. Cladding technology is one of common remanufacturing technologies, so how to ensure the quality of a cladding layer is very important for ensuring the quality of remanufactured products. Relevant researches show that the stress is one of key factors influencing the quality of a cladding layer, so that scholars at home and abroad carry out a great deal of theoretical and experimental researches on the stress of the cladding layer, and the stress mainly comprises the following three aspects: optimizing a cladding process; new cladding equipment and new method research and development; and research and development of new cladding materials. Although the quality of the cladding layer is improved to a certain extent, the method focuses on controlling the stress of the cladding layer, and does not really realize the evaluation of the stress of the cladding layer, so that the method inevitably causes potential safety hazards to the service of the cladding layer and even remanufactured products thereof.
Generally, stress evaluation methods are classified into two types, namely, destructive evaluation and nondestructive evaluation. Destructive evaluation methods are a class of methods that enable their stress evaluation on the basis of (partial or complete) destruction of the integrity of the cladding layer. However, the method belongs to the field of small sample sampling detection, and the stress of the cladding layer cannot be evaluated on line; the nondestructive evaluation method is a method for realizing the nondestructive evaluation of the stress of the cladding layer by analyzing detection signals (such as electricity, magnetism, sound, light and the like) on the premise of not damaging the integrity of the cladding layer. In view of the advantages of safety, convenience, low equipment price, rapidness, realization of on-line detection and the like, the ultrasonic method draws wide attention of numerous scholars in the field of stress evaluation.
According to the ultrasonic acoustic elasticity theory, the stress can be evaluated nondestructively by measuring the propagation speed of ultrasonic waves. However, related researches show that the tissue structure, the thickness and the like of the cladding layer are important factors influencing the propagation speed of the ultrasonic wave in the cladding layer, so that a correction method for discussing the factors influencing the stress evaluation of the cladding layer is important for popularization and application of the ultrasonic technology in stress evaluation. In view of this, based on the ultrasonic acoustic elasticity theory, a set of effective correction system for evaluating the stress of the cladding layer by the ultrasonic waves and influencing the thickness of the cladding layer is discussed and established, which not only can provide technical support for evaluating the service safety and the reliability of the cladding layer, but also is important for reducing and even avoiding the service safety hidden trouble of the remanufactured product.
Disclosure of Invention
The invention aims to provide a method for correcting the influence of the thickness of a cladding layer on the stress of an ultrasonic evaluation cladding layer, aiming at the problems and the defects existing in the nondestructive evaluation of the stress of the cladding layer and the influence of the thickness of the cladding layer on the stress of the ultrasonic evaluation cladding layer.
The ultrasonic acoustic-elastic theory shows that the propagation speed of ultrasonic waves in a medium and stress are in a linear relation, namely the propagation speed of the ultrasonic waves is gradually reduced along with the increase of tensile stress, so that the nondestructive evaluation of the stress can be realized through the measurement of the propagation speed of the ultrasonic waves. However, the ultrasonic propagation speed is not sensitive to stress variations. It is generally considered that the change in the propagation velocity of ultrasonic waves in steel is about 0.01% when the stress changes by 100 MPa. Therefore, on the basis of conventional instruments and equipment, how to realize stress evaluation by using ultrasonic waves and ensure the precision of stress evaluation results needs to be solved. Aiming at the problem, the invention uses the linear elastic ultrasonic wave acoustoelastic theory as a basis, adopts an ultrasonic probe group with a one-transmitting and two-receiving mode, uses ultrasonic signal time delay to replace the ultrasonic propagation speed as a characteristic parameter for evaluating stress, further establishes the corresponding relation between the ultrasonic acoustoelastic coefficient of the cladding layer and the thickness of the cladding layer, realizes the nondestructive evaluation of the thickness of the cladding layer through an ultrasonic technology, and finally realizes the correction of the influence of the thickness of the cladding layer on the ultrasonic evaluation of the cladding layer stress.
In order to achieve the purpose, the invention adopts the technical scheme that:
a method for correcting influence of cladding layer thickness on ultrasonic evaluation of cladding layer stress comprises the following specific steps:
selecting a substrate to be clad, determining a process method for preparing cladding layers, optimizing process parameters of the process method, preparing a plurality of groups of cladding layers with different thicknesses on the surface of the substrate, and ensuring that the surface roughness Ra of the cladding layers meets the requirements of ultrasonic detection by adopting a machining method;
preparing a reference sample and a plurality of cladding layer samples for static load tension according to a metal material room temperature tension test method, measuring the mechanical properties of the reference sample and the cladding layer samples with different thicknesses, fixing ultrasonic parameters to be constant in an elastic deformation state of the samples, collecting ultrasonic signals of the cladding layer under a preset load, and calculating the time delay of the ultrasonic signals caused by stress;
performing linear fitting on the time delay and the stress of the ultrasonic signal by adopting a linear function based on an ultrasonic acoustic elasticity theory to obtain ultrasonic acoustic elasticity coefficients of cladding layer samples with different thicknesses, and fitting the ultrasonic acoustic elasticity coefficients and the thickness of the cladding layer by adopting a power function to obtain the following relation (1) of the ultrasonic acoustic elasticity coefficients and the thickness of the cladding layer;
k＝a·hb (1)
in the formula, a and b are coefficients, k is an ultrasonic acoustic elastic coefficient, and h is the thickness of a cladding layer;
respectively carrying out stress relief treatment on the cladding layer sample and the reference sample, selecting optimal detection parameters according to the attenuation degree of ultrasonic energy (the attenuation of the ultrasonic energy caused by the thickness change of the cladding layer is not more than 50%), fixing the constant ultrasonic propagation direction, collecting and extracting the ultrasonic signal amplitudes of the reference sample and the cladding layer sample in a stress-free state, and fitting the ultrasonic signal amplitudes and the thickness of the cladding layer by adopting a power function to obtain a following relation functional formula (2) of the ultrasonic signal amplitudes and the cladding layer thickness;
A＝m·hn (2)
in the formula, m and n are coefficients, A is the amplitude of the ultrasonic signal, and h is the thickness of the cladding layer;
step five, selecting ultrasonic detection parameters and ultrasonic propagation directions in the step four, collecting ultrasonic signals of the cladding layer sample to be evaluated, extracting the amplitude of the ultrasonic signals, substituting the amplitude into the formula (2), and obtaining the thickness of the cladding layer sample to be evaluated;
substituting the thickness of the cladding layer sample to be evaluated into a formula (1) to obtain the ultrasonic acoustic elastic coefficient of the cladding layer sample with the thickness, wherein the ultrasonic acoustic elastic formula is shown in a formula (3);
Δt＝k·σ (3)
in the formula, Δ t is ultrasonic signal time delay, k is an ultrasonic acoustic elastic coefficient, and σ is stress;
step seven, calculating the time delay of the ultrasonic signals of the cladding layer samples with different thicknesses and the reference sample in the stress-free state, and fitting the result by adopting a power function to obtain a relation (4) between the time delay of the ultrasonic signals and the thickness of the cladding layer;
ΔT＝x·hy (4)
in the formula, x and y are coefficients, delta T is ultrasonic signal time delay, and h is the thickness of a cladding layer;
step eight, substituting the thickness of the cladding layer to be evaluated into the formula (4) to obtain the ultrasonic signal time delay;
and step nine, acquiring the ultrasonic signal of the cladding layer sample to be evaluated by adopting the ultrasonic detection parameters in the step two, calculating the time delay between the ultrasonic signal and the ultrasonic signal of the reference sample, and superposing the linear function and the ultrasonic time delay in the step eight to obtain the time delay of the ultrasonic signal, so as to correct the influence of the thickness of the cladding layer on the stress of the cladding layer to be evaluated, substituting the linear function and the ultrasonic time delay into the formula (3), and finally obtaining the stress of the cladding layer to be evaluated.
According to a further preferred technical scheme, the base body in the first step is made of a low-carbon steel plate.
Further preferably, in the first step, the roughness Ra is 1.0.
According to a further preferable technical scheme, the multiple groups of cladding layers in the step one have different thicknesses and are not less than 5 groups.
According to a further preferable technical scheme, the reference sample in the second step is a base material without a cladding layer.
According to a further preferable technical scheme, the cladding layer sample in the second step is a composite sample of 'matrix + cladding layer'.
According to a further preferable technical scheme, the superposition of the time delay in the step nine is linear superposition, and the sign of the time delay depends on the influence rule of the thickness of the cladding layer and the stress on the propagation speed of the ultrasonic wave.
The method realizes the nondestructive evaluation of the thickness of the cladding layer by means of an ultrasonic technology, and further realizes the ultrasonic nondestructive evaluation of the stress of the cladding layer based on an ultrasonic acoustic-elastic theory. In order to realize the correction of the influence of the thickness of the cladding layer on the stress of the cladding layer for ultrasonic evaluation, the method obtains the functional relation between the ultrasonic acoustic elastic coefficient and the thickness of the cladding layer by preparing cladding layer samples with different thicknesses and by means of an ultrasonic acoustic elastic coefficient calibration experiment, realizes the nondestructive evaluation of the thickness of the cladding layer by an ultrasonic technology, further obtains the ultrasonic acoustic elastic coefficient of the cladding layer sample with any thickness, finally realizes the correction of the influence of the thickness of the cladding layer on the stress of the ultrasonic evaluation cladding layer, and improves the precision of a stress evaluation result.
The invention not only provides a nondestructive method for evaluating the stress of the cladding layer, but also provides a convenient and effective method for realizing the nondestructive evaluation of the stress of the cladding layer with any thickness, and has the advantages of rapidness, convenience, safety, realization of on-line evaluation and the like.
Drawings
FIG. 1 is a graph showing the relationship between the sono-elastic coefficient of ultrasonic waves and the thickness of a plasma cladding layer in the present invention;
FIG. 2 is a graph showing the relationship between the amplitude of the ultrasonic signal of the plasma cladding layer and the thickness of the plasma cladding layer in the present invention.
Detailed Description
The embodiments of the present invention will be described in detail below with reference to the accompanying drawings: the present embodiment is implemented on the premise of the technical solution of the present invention, and a detailed implementation manner and a specific operation process are given, but the protection scope of the present invention is not limited to the following embodiments.
Examples
Taking the example of preparing a plasma cladding layer on the surface of low-carbon steel as an example, the step of correcting the influence of the thickness of the cladding layer on ultrasonic evaluation of the stress of the cladding layer is described, and the specific process is as follows:
step one, selecting a Q235 steel plate with the thickness of 30mm as a matrix, preparing a matrix sample, and determining main process parameters of plasma cladding as follows: peak current 220A, base current 140A, frequency 60Hz, duty ratio 50%, cladding speed 0.2m/min, wire feeding speed 3.0m/min, preparing five groups of cladding layers with different thicknesses on the surface of the substrate, after machining, the thicknesses of the plasma cladding layers are 0.20 mm, 0.25 mm, 0.30 mm, 0.45 mm and 0.55mm respectively, and the surface roughness Ra is 1.0;
and step two, preparing a cladding layer sample of plasma 'matrix + cladding layer' with the whole thickness of 3.0mm for static load stretching according to a GB/T2002-228 metal material room temperature tensile test method, and measuring the yield strength of the cladding layer sample. Combining an ultrasonic acoustic-elastic coefficient calibration experiment, wherein the maximum loading stress is yield strength, the stress interval is 50MPa, and the stress holding time is 30s, acquiring ultrasonic signals of a plasma cladding layer at different stresses after the amplitude of the ultrasonic signals is stable, and calculating the time delay of the ultrasonic signals caused by the stress by adopting a cepstrum analysis method;
fitting the time delay and the stress of the ultrasonic signal by adopting a linear function based on an ultrasonic acoustic elasticity theory to obtain ultrasonic acoustic elasticity coefficients of 0.178, 0.160, 0.135, 0.118 and 0.10ns/MPa when the thicknesses of the cladding layers are respectively 0.20, 0.25, 0.30, 0.45 and 0.55mm, and fitting the result by adopting a power function to obtain a relation between the ultrasonic acoustic elasticity coefficients and the thicknesses of the cladding layers, see formula (5) and figure 1;
k＝0.0732·h-0.5487 (5)
step four, carrying out vacuum heat treatment on the substrate sample and the plasma cladding layer sample, wherein the technological parameters are as follows: the highest heating temperature is 600 ℃, the heat preservation time is 1h, and the sample is taken out after the temperature is cooled to 100 ℃ along with the furnace. Selecting parameters of which the amplitude difference of ultrasonic signals is 30% when the thickness of the plasma cladding layer is 0.55 and 0.20, fixing the propagation direction of ultrasonic waves to be parallel to the plasma cladding direction, collecting the ultrasonic signals of the plasma cladding layer, extracting the highest amplitude value of the ultrasonic signals, and fitting the result by adopting a formula (2) to obtain a relation function of the amplitude value of the ultrasonic signals and the thickness of the cladding layer, which is shown in a formula (6) and an attached figure 2.
A＝1.6183·h-0.3044 (6)
And step five, collecting the ultrasonic signal of the plasma cladding layer to be evaluated, extracting the amplitude of the ultrasonic signal of the plasma cladding layer to be evaluated to be 0.885, and substituting the amplitude of the ultrasonic signal of the plasma cladding layer into the formula (6) to obtain the thickness of the plasma cladding layer of 0.62 mm.
And step six, substituting the plasma cladding layer to be evaluated with the thickness of 0.62mm into the formula (5) to obtain the ultrasonic wave acoustic elastic coefficient of the plasma cladding layer sample, substituting the formula (3), wherein the ultrasonic wave acoustic elastic formula is shown in the formula (7).
Δt＝0.0952·σ (7)
And step seven, taking the ultrasonic signal of the substrate in the vacuum stress relief annealing state as a reference signal, calculating the ultrasonic signal of the plasma cladding layer with different thicknesses and the time delay of the signal, and obtaining a relational expression between the time delay of the ultrasonic signal and the thickness of the cladding layer by adopting an expression (4), which is shown in an expression (8).
ΔT＝47.5176·h0.8574 (8)
And step eight, substituting the plasma cladding layer to be evaluated with the thickness of 0.62mm into the formula (8) to obtain the ultrasonic signal time delay of 31.5 ns.
And step nine, collecting the ultrasonic signal of the plasma cladding layer to be evaluated, calculating the time delay between the ultrasonic signal and the ultrasonic signal of the base material in the stress-free state, wherein the time delay is 50.8ns, linearly overlapping the time delay with the ultrasonic signal time delay in the step eight, wherein the time delay is 19.3ns, substituting the formula (7), obtaining the stress of the plasma cladding layer to be evaluated, wherein the stress of the plasma cladding layer to be evaluated is about 203MPa, and finally realizing the correction of the influence of the thickness of the cladding layer on the stress of the ultrasonic.
Claims (7)
1. A method for correcting the influence of the thickness of a cladding layer on the stress of an ultrasonic evaluation cladding layer is characterized by comprising the following specific steps of:
selecting a substrate to be clad, determining a process method for preparing cladding layers, optimizing process parameters of the process method, preparing a plurality of groups of cladding layers with different thicknesses on the surface of the substrate, and ensuring that the surface roughness Ra of the cladding layers meets the requirements of ultrasonic detection by adopting a machining method;
preparing a reference sample and a plurality of cladding layer samples for static load tension according to a metal material room temperature tension test method, measuring the mechanical properties of the reference sample and the cladding layer samples with different thicknesses, fixing ultrasonic parameters to be constant in an elastic deformation state of the samples, collecting ultrasonic signals of the cladding layer under a preset load, and calculating the time delay of the ultrasonic signals caused by stress;
performing linear fitting on the time delay and the stress of the ultrasonic signal by adopting a linear function based on an ultrasonic acoustic elasticity theory to obtain ultrasonic acoustic elasticity coefficients of cladding layer samples with different thicknesses, and fitting the ultrasonic acoustic elasticity coefficients and the thickness of the cladding layer by adopting a power function to obtain the following relation (1) of the ultrasonic acoustic elasticity coefficients and the thickness of the cladding layer;
k＝a·hb (1)
in the formula, a and b are coefficients, k is an ultrasonic acoustic elastic coefficient, and h is the thickness of a cladding layer;
respectively carrying out stress relief treatment on the cladding layer sample and the reference sample, selecting optimal detection parameters according to the attenuation degree of ultrasonic energy (the attenuation of the ultrasonic energy caused by the thickness change of the cladding layer is not more than 50%), fixing the constant ultrasonic propagation direction, collecting and extracting the ultrasonic signal amplitudes of the reference sample and the cladding layer sample in a stress-free state, and fitting the ultrasonic signal amplitudes and the thickness of the cladding layer by adopting a power function to obtain a following relation functional formula (2) of the ultrasonic signal amplitudes and the cladding layer thickness;
A＝m·hn (2)
in the formula, m and n are coefficients, A is the amplitude of the ultrasonic signal, and h is the thickness of the cladding layer;
step five, selecting ultrasonic detection parameters and ultrasonic propagation directions in the step four, collecting ultrasonic signals of the cladding layer sample to be evaluated, extracting the amplitude of the ultrasonic signals, substituting the amplitude into the formula (2), and obtaining the thickness of the cladding layer sample to be evaluated;
substituting the thickness of the cladding layer sample to be evaluated into a formula (1) to obtain the ultrasonic acoustic elastic coefficient of the cladding layer sample with the thickness, wherein the ultrasonic acoustic elastic formula is shown in a formula (3);
Δt＝k·σ (3)
in the formula, Δ t is ultrasonic signal time delay, k is an ultrasonic acoustic elastic coefficient, and σ is stress;
step seven, calculating the time delay of the ultrasonic signals of the cladding layer samples with different thicknesses and the reference sample in the stress-free state, and fitting the result by adopting a power function to obtain a relation (4) between the time delay of the ultrasonic signals and the thickness of the cladding layer;
ΔT＝x·hy (4)
in the formula, x and y are coefficients, delta T is ultrasonic signal time delay, and h is the thickness of a cladding layer;
step eight, substituting the thickness of the cladding layer to be evaluated into the formula (4) to obtain the ultrasonic signal time delay;
and step nine, acquiring the ultrasonic signal of the cladding layer sample to be evaluated by adopting the ultrasonic detection parameters in the step two, calculating the time delay between the ultrasonic signal and the ultrasonic signal of the reference sample, and superposing the linear function and the ultrasonic time delay in the step eight to obtain the time delay of the ultrasonic signal, so as to correct the influence of the thickness of the cladding layer on the stress of the cladding layer to be evaluated, substituting the linear function and the ultrasonic time delay into the formula (3), and finally obtaining the stress of the cladding layer to be evaluated.
2. The method for correcting the influence of the thickness of the cladding layer on the stress of the ultrasonically evaluated cladding layer according to claim 1, wherein the material of the substrate in the step one is a low carbon steel plate.
3. The method of claim 1, wherein the roughness Ra is 1.0.
4. The method of claim 1, wherein the step one of the sets of cladding layers is not less than 5 sets.
5. The method for correcting the influence of the thickness of the cladding layer on the stress of the cladding layer through ultrasonic evaluation according to claim 1, wherein the reference sample in the second step is a base material without the cladding layer.
6. The method for correcting the influence of the thickness of the cladding layer on the stress of the cladding layer through ultrasonic evaluation according to claim 1, wherein the cladding layer samples in the step two are composite samples of 'base material + cladding layer'.
7. The method for correcting the influence of the thickness of the cladding layer on the stress of the cladding layer through ultrasonic evaluation according to claim 1, wherein the superposition of the time delays in the step nine is linear superposition, and the signs of the time delays depend on the influence rule of the thickness of the cladding layer and the stress on the propagation speed of the ultrasonic wave.
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