CN113533518B - Large-angle longitudinal wave probe and preparation method thereof - Google Patents
Large-angle longitudinal wave probe and preparation method thereof Download PDFInfo
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- CN113533518B CN113533518B CN202110795108.4A CN202110795108A CN113533518B CN 113533518 B CN113533518 B CN 113533518B CN 202110795108 A CN202110795108 A CN 202110795108A CN 113533518 B CN113533518 B CN 113533518B
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- 239000002131 composite material Substances 0.000 claims abstract description 36
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 20
- 239000010959 steel Substances 0.000 claims abstract description 20
- 238000005520 cutting process Methods 0.000 claims abstract description 14
- 239000000945 filler Substances 0.000 claims abstract description 9
- 238000000151 deposition Methods 0.000 claims abstract description 6
- 238000000227 grinding Methods 0.000 claims abstract description 6
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- 239000004642 Polyimide Substances 0.000 claims description 9
- 229920001721 polyimide Polymers 0.000 claims description 9
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 8
- 229910052804 chromium Inorganic materials 0.000 claims description 8
- 239000011651 chromium Substances 0.000 claims description 8
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 claims description 8
- 229910052737 gold Inorganic materials 0.000 claims description 8
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- 239000003822 epoxy resin Substances 0.000 claims description 7
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- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 6
- 229910052721 tungsten Inorganic materials 0.000 claims description 6
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B61—RAILWAYS
- B61K—AUXILIARY EQUIPMENT SPECIALLY ADAPTED FOR RAILWAYS, NOT OTHERWISE PROVIDED FOR
- B61K9/00—Railway vehicle profile gauges; Detecting or indicating overheating of components; Apparatus on locomotives or cars to indicate bad track sections; General design of track recording vehicles
- B61K9/08—Measuring installations for surveying permanent way
- B61K9/10—Measuring installations for surveying permanent way for detecting cracks in rails or welds thereof
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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
- G01N29/24—Probes
- G01N29/2437—Piezoelectric probes
- G01N29/245—Ceramic probes, e.g. lead zirconate titanate [PZT] probes
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0234—Metals, e.g. steel
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Abstract
The invention relates to a large-angle longitudinal wave probe and a preparation method thereof, wherein the piezoelectric material is firstly partially cut; secondly, filling filler in the gaps formed by cutting to form a composite piezoelectric material; then, grinding the composite piezoelectric material to obtain a composite piezoelectric material wafer; then, depositing electrode layers at the top and the bottom of the composite piezoelectric material wafer; furthermore, the deposited composite piezoelectric material wafer is sliced and ground to form a piezoelectric element; and finally, bonding a backing layer and wedge blocks on two sides of the piezoelectric element, thereby obtaining the large-angle longitudinal wave probe. The large-angle longitudinal wave probe can detect nuclear damage defects and stress values within a certain depth range below the surface of the rail bottom angle of the steel rail, can be mounted to the rail bottom of the steel rail in a static state on the premise of ensuring the running safety performance, can automatically and effectively detect the harmful nuclear damage defects of the outer side surface of the rail bottom in real time on line, and has high use value.
Description
Technical Field
The invention relates to the field of in-service damage and stress concentration monitoring of railway steel rails, in particular to a large-angle longitudinal wave probe and a preparation method thereof.
Background
The rail bottom corner edge nuclear damage defect is easy to develop and expand due to the fact that the rail bottom corner edge nuclear damage defect is subjected to continuous impact of a vehicle and internal stress is concentrated, and rail breakage is caused. The edge of the rail bottom corner is the position with the largest stress of the rail, and the edge is the thinnest, so that the damage defect of the hazard nucleus is easily caused by stress concentration. The conventional ultrasonic probe flaw detection method for the rail bottom angle edge nuclear flaw is to manually detect the flaw by incidence of sound waves from the rail bottom surface of the steel rail, utilize the reflection of the flaw on the ultrasonic waves, determine the size of the flaw by measuring the amplitude of the reflected sound waves, and manually move the probe to obtain the flaw profile. However, when the ultrasonic probe is applied to an on-line monitoring condition, the conventional ultrasonic probe cannot be flexibly arranged, the thickness of the outer side surface of the rail bottom is small, and a defect echo is also easily influenced by the surface state of the rail bottom and an outer edge interface, so that a nuclear damage defect is not easily identified.
Disclosure of Invention
The invention aims to provide a large-angle longitudinal wave probe and a preparation method thereof, which can effectively monitor the nuclear damage defects and stress concentration at the outer edges of two sides of the rail bottom angle of a steel rail.
The above technical object of the present invention is achieved by the following technical means.
A method of making a large angle longitudinal wave probe, comprising the steps of:
S1, performing partial cutting on a piezoelectric material;
S2, filling a filler into a gap formed by partially cutting the piezoelectric material to form a composite piezoelectric material;
S3, grinding the composite piezoelectric material to obtain a composite piezoelectric material wafer;
s4, depositing the composite piezoelectric material wafer;
s5, processing the deposited composite piezoelectric material wafer to form a piezoelectric element;
S6, respectively bonding a backing layer and a wedge block on the top and the bottom of the piezoelectric element, thereby obtaining the large-angle longitudinal wave probe.
In aspects and any one of the possible implementations described above, there is further provided an implementation, the piezoelectric material is PZT-5H ceramic.
In the aspect and any possible implementation manner as described above, there is further provided an implementation manner, in which in step S3, the thickness of the composite piezoelectric material is specifically ground so that the resonant frequency thereof reaches 3-10MHz.
In the aspect and any possible implementation manner described above, there is further provided an implementation manner, where the step S4 is specifically to deposit metal on the electrode layers on the top and bottom of the composite piezoelectric material wafer by adopting an electronic vapor deposition manner.
In aspects and any one of the possible implementations described above, there is further provided an implementation in which the metal is gold and chromium, and each has a thickness of 5-15nm and 50-150nm, respectively.
In the aspect and any possible implementation manner as described above, there is further provided an implementation manner, where the backing layer in the step S6 is tungsten/epoxy resin.
In the aspect and any possible implementation manner as described above, there is further provided an implementation manner, where a material of the wedge in the step S6 is polyimide.
The invention also provides a large-angle longitudinal wave probe which is manufactured according to the manufacturing method provided by the invention.
In aspects and any one of the possible implementations described above, there is further provided an implementation, the high-angle longitudinal wave probe includes a piezoelectric element, a positive electrode, a negative electrode, a backing layer, and a wedge, wherein the positive electrode and the negative electrode are disposed on a top and a bottom of the piezoelectric element, respectively; the positive electrode is adhered to the backing layer; the negative electrode is adhered to the wedge block.
In aspects and any one of the possible implementations described above, there is further provided an implementation in which the angle of refraction of the high angle probe is 77 ° to 80 °.
In aspects and any one of the possible implementations described above, there is further provided an implementation in which the acoustic impedance of the wedge is about 10-15MRayl.
The beneficial technical effects of the invention
The embodiment provided by the invention has the following beneficial effects:
According to the large-angle longitudinal wave probe and the preparation method, the piezoelectric material is firstly partially cut; secondly, filling filler in the gaps formed by cutting to form a composite piezoelectric material; then, grinding the composite piezoelectric material to obtain a composite piezoelectric material wafer; then, depositing electrode layers at the top and the bottom of the composite piezoelectric material wafer; furthermore, the deposited composite piezoelectric material wafer is sliced and ground to form a piezoelectric element; and finally, bonding a backing layer and wedge blocks on two sides of the piezoelectric element, thereby obtaining the large-angle longitudinal wave probe. The large-angle longitudinal wave probe can detect nuclear damage defects and stress values within a certain depth range below the surface of the rail bottom angle of the steel rail, can be mounted to the rail bottom of the steel rail in a static state on the premise of ensuring the running safety performance, can automatically and effectively detect the harmful nuclear damage defects of the outer side surface of the rail bottom in real time on line, and has high use value.
Drawings
Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a schematic diagram of a preparation flow of a large-angle longitudinal wave probe in an embodiment of the invention;
FIG. 2 is a schematic diagram of a large angle longitudinal wave probe in an embodiment of the invention;
FIG. 3 is a schematic view showing the layout of a large-angle longitudinal wave probe on a steel rail in an embodiment of the invention;
FIG. 4 is a schematic view of the installation and connection of a large angle longitudinal wave probe on the rail bottom of a steel rail in an embodiment of the invention.
Wherein reference numerals are as follows: 1a piezoelectric element; 2, a negative electrode; 3, an anode; 4a backing layer; 5 wedge blocks; 6, a large-angle longitudinal wave probe; 7, a temperature sensor; 8, rail bottoms of the steel rails; 9 rail welding seams; 10, emitting a large-angle longitudinal wave probe shielding wire; 11, emitting a large-angle longitudinal wave probe; 12 receiving a large-angle longitudinal wave probe; 13 receive the high angle longitudinal wave probe shield wire.
Detailed Description
In order to make the technical problems, technical solutions and advantages to be solved by the present invention more apparent, the following detailed description will be given with reference to the accompanying drawings and specific examples, but the embodiments of the present invention are not limited thereto.
As shown in fig. 1, the present embodiment provides a method for preparing a large-angle longitudinal wave probe, which includes the following steps:
step 1, partially cutting a piezoelectric material;
The piezoelectric material can generate voltage between two end surfaces when being subjected to pressure, namely, the two end surfaces can generate different charges when the piezoelectric material is deformed under the pressure, and the mutual conversion of vibration and electricity can be realized, so that the piezoelectric material is selected as a raw material to manufacture a large-angle longitudinal wave probe, particularly preferably, the piezoelectric material is realized by using PZT-5H ceramics, and the PZT-5H ceramics have stronger defect finding capability due to the characteristics of good resolution and signal to noise ratio, and therefore, the piezoelectric material is used for partial cutting by using the PZT-5H ceramics.
Step 2, filling filler into the gap formed by the partial cutting of the piezoelectric material to form a composite piezoelectric material, and filling the gap formed by the partial cutting of the PZT-5H ceramic by using the filler in order to connect the cut PZT-5H ceramic together to form a whole;
step 3, grinding the composite piezoelectric material to obtain a composite piezoelectric material wafer;
Step 4, depositing electrode layers at the top and the bottom of the composite piezoelectric material wafer;
Step 5, slicing and grinding the deposited composite piezoelectric material wafer to form a piezoelectric element;
and 6, respectively bonding a backing layer and a wedge block on the top and the bottom of the piezoelectric element, thereby obtaining the large-angle longitudinal wave probe.
Preferably, in said step 1, the PZT-5H ceramic is partially diced using a25 μm dicing machine, wherein the PZT-5H ceramic pillars are 65 μm long and wide in size, the dicing machine dicing voids are 25 μm, and the spacing between the PZT-5H ceramic pillars and dicing voids is 90 μm, and it is expected that the piezoelectric ceramic volume fraction is 60%, so that the effective electromechanical coupling, density and piezoelectric coefficient of the large angle longitudinal wave probe can be adjusted.
Preferably, in the step 3, the thickness of the composite piezoelectric material is specifically ground to make the resonant frequency reach 3-10MHz, specifically, in the invention, the resonant frequency of 5MHz is selected to make the ultrasonic wave length of the manufactured large-angle longitudinal wave probe short, and the resonant frequency can be used to monitor the micro cracks which initiate the rail break.
Preferably, in step 4, a metal is deposited on the electrode layers on the top and bottom surfaces of the composite piezoelectric material wafer by adopting an electronic vapor deposition method, and gold and chromium are selected from the metal so that the gold and chromium attached to the composite piezoelectric material wafer are uniform and should not fall off. The chromium is used for better bonding gold and PZT-5H ceramic, the hardware has good conductivity and stable chemical property, the surface of the composite piezoelectric material wafer is not easy to oxidize for a long time, and a good conductive electrode layer can be formed. The upper and lower electrode layers are the negative electrode 2 and the positive electrode 3 in fig. 1, and the thicknesses of gold and chromium are 5-15nm and 50-150nm respectively.
The thicknesses of gold and chromium in the present invention were selected to be 10nm and 100nm, respectively. Preferably, the composite wafer is diced into 8 x 8mm pieces and then ground to a thickness of about 320 μm to yield the piezoelectric element. 8mm is the length and width dimension of the piezoelectric composite wafer equivalent to the integral vibration source, so that the sound pressure distribution of the manufactured probe in the circumferential direction and the axial direction, namely the sound energy distribution shape of the radiation sound beam in space, is determined, and the equivalent vibration source dimension ensures the energy concentration of the radiation sound beam of the probe, so that the target crack can be effectively detected; 320 μm is the thickness of the piezoelectric composite wafer, and determines the center frequency of the vibration of the manufactured probe, so that the vibration frequency excited by the probe is in an optimal resonance state around 5 MHz.
Preferably, in the step 6, the backing layer 4 and the wedge 5 are adhered to two sides of the piezoelectric element, wherein the backing layer is made of tungsten/epoxy resin, the acoustic impedance of the tungsten/epoxy resin is 10-20MRayl, the MRayl is MRayl, the acoustic impedance of the tungsten/epoxy resin is about 16.0MRayl, the acoustic impedance of the wedge is 10-15MRayl, and the acoustic impedance of the wedge is about 13.0MRayl. The wedge 5 is made of polyimide, and the polyimide has small thermal expansion coefficient and cold contraction coefficient, is high and low temperature resistant, is small in deformation, is favorable for long-term maintenance of an adhesive interface with the piezoelectric element, and cannot influence radiation and reception of acoustic signals due to structural debonding caused by long-time external environment change. The angle of the polyimide wedge block is strictly calculated according to the Snell's law by taking the actually measured sound velocity of the polyimide wedge block material and the designed refraction angle of the sound wave into the Snell's formula, so as to obtain the incident angle of the sound wave, wherein the angle is the angle of the polyimide wedge block. In the application of the invention, the refraction angle of the large-angle longitudinal wave probe is 77-80 degrees, and the angle of the polyimide wedge block, namely the inclination angle between the wedge block inclined plane and the horizontal plane, can be calculated by designing the determined longitudinal wave refraction angle according to the method for determining the angle of the polyimide wedge block, so that the error range of the wedge block angle is ensured to be less than 1 minute during processing. By controlling the machining precision error of the wedge inclination angle, the large-angle longitudinal wave probe with the refraction angle of 77-80 degrees can be manufactured well. In order to make the sound wave enter the rail bottom angle better when the wedge block contacts with the rail, the wedge block coupling surface is precisely grinded and processed to be consistent with the bending angle of the rail surface, thus avoiding the scattering of sound energy and making the energy enter a certain depth below the workpiece surface rather than on the surface better.
Preferably, the filling agent is filled after the piezoelectric material is cut, the filling agent is epoxy resin, the filled epoxy resin is used as a non-piezoelectric material layer, the piezoelectric material is used as a piezoelectric material layer, and a piezoelectric communication structure is formed by the filling agent and the non-piezoelectric material layer, and the piezoelectric material layer form a piezoelectric communication structure.
Preferably, as shown in fig. 2, the large-angle longitudinal wave probe comprises a piezoelectric element 1, a negative electrode 2, a positive electrode 3, a backing layer 4 and a wedge 5, wherein the positive electrode 3 and the negative electrode 2 are respectively arranged at the top and the bottom of the piezoelectric element 1; the positive electrode 3 is adhered to the backing layer 4; the negative electrode 2 is adhered to the wedge 5.
Preferably, as shown in fig. 3, a pair of large-angle longitudinal wave probes are arranged on a steel rail, wherein two large-angle longitudinal wave probes 6 span two sides of a welding seam 9 of a steel rail bottom 8, the front edge distance between the two large-angle longitudinal wave probes is set to be 70mm, temperature sensors 7 are respectively arranged at the two probes, the temperature change condition of the two large-angle longitudinal wave probes is monitored by the temperature sensors 7, the temperature sensors 7 are arranged near the two large-angle longitudinal wave probes 6, the real temperature of a measured workpiece is measured, the change of the amplitude caused by the temperature change is checked, and the temperature of the environment temperature when the stress workpiece test block is detected is accurately detected, so that the accuracy of measured data can be ensured.
Preferably, as shown in fig. 4, the structural schematic diagram of the installation and connection of the probe of the invention is that a large-angle longitudinal wave transmitting probe 11 and a large-angle longitudinal wave receiving probe 12 are installed at the upper part of the outer side surface of the rail bottom 8 of the steel rail, and straddling the two sides of the rail bottom welding seam 9, and the outer surfaces of the large-angle longitudinal wave transmitting probe 11 and the large-angle longitudinal wave receiving probe 12 are respectively provided with a stainless steel protective shell for protecting the probes 11 and 12 in contact with the surface of the rail bottom 8 of the steel rail. In order to ensure that fixed-point bonding is more reliable, the magnet is arranged in the stainless steel shell, the weight borne by coupling glue is reduced, the steel rail bottom 8 and the probes 11 and 12 are better attached, sound wave incidence is facilitated, the temperature sensors 7 are arranged on the outer shell surfaces of the large-angle longitudinal wave transmitting probe 11 and the large-angle longitudinal wave receiving probe 12, and therefore the change condition of the influence of the temperature change condition on the amplitude of reflected waves of defects in the monitored steel rail and the sound time can be seen. The transmitting probe shielding wire 10 and the transmitting probe shielding wire 13 are coaxial cables, wherein one ends of the transmitting probe shielding wire 10 and the receiving probe shielding wire 13 are respectively connected to positive and negative electrodes of the transmitting large-angle longitudinal wave probe 11 and the receiving large-angle longitudinal wave probe 12, the other ends are respectively connected to an ultrasonic transmitting and receiving instrument with a transmitting-receiving channel, and an excitation signal adopted by the ultrasonic transmitting and receiving instrument is a pulse signal with a center frequency of 5 MHz. The wave measurement value is obtained by exciting the large-angle longitudinal wave transmitting probe 11 and the large-angle longitudinal wave receiving probe 12 opposite to the steel rail welding seam 9, the acoustic wave responses of the large-angle longitudinal wave transmitting probe 11 and the large-angle longitudinal wave receiving probe 12 are obtained, the ultrasonic instrument records and processes the measured acoustic wave data and temperature data, the error caused by temperature on stress measurement is eliminated, and the judgment result of defects and stress is given. In order to ensure that the accuracy of the stress detection value is always maintained within the error range, the stress parameter needs to be calibrated by using a stress standard sample test block at regular intervals and using the stress standard sample test block with standard load stress inside. The large-angle longitudinal wave response of the nuclear injury in the monitoring area is given through the signal processing of the large-angle longitudinal wave waveform, and a feasible technical method is provided for monitoring the expansion and stress concentration of the nuclear injury defect at the rail bottom.
While the foregoing description illustrates and describes the preferred embodiments of the present invention, it is to be understood that the invention is not limited to the forms disclosed herein, but is not to be construed as limited to other embodiments, and is capable of numerous other combinations, modifications and environments and is capable of changes or modifications within the scope of the claimed invention, either as a result of the foregoing teachings or as a result of knowledge in the relevant art. And that modifications and variations which do not depart from the spirit and scope of the invention are intended to be within the scope of the appended claims.
Claims (5)
1. The preparation method of the large-angle longitudinal wave probe is characterized by comprising the following steps of:
S1, partially cutting a piezoelectric material, wherein the piezoelectric material is PZT-5H ceramic, and the PZT-5H ceramic is partially cut by a 25 μm cutting machine, wherein the length and width dimensions of PZT-5H ceramic columns are 65 μm, the cutting gap of the cutting machine is 25 μm, the interval between the PZT-5H ceramic columns and the cutting gap is 90 μm, and the volume fraction of the piezoelectric ceramic is expected to be 60%;
S2, filling a filler into a gap formed by partially cutting the piezoelectric material to form a composite piezoelectric material;
s3, grinding the composite piezoelectric material to enable the resonance frequency to reach 3-10MHz, and obtaining a composite piezoelectric material wafer;
S4, depositing the composite piezoelectric material wafer, namely depositing gold and chromium on electrode layers at the top and the bottom of the composite piezoelectric material wafer in an electronic evaporation mode, wherein the respective thicknesses are 5-15nm and 50-150nm;
s5, processing the deposited composite piezoelectric material wafer to form a piezoelectric element;
s6, respectively bonding a backing layer and a wedge block at the top and the bottom of the piezoelectric element, wherein the backing layer is made of tungsten/epoxy resin, the acoustic impedance of the backing layer is 10-20MRayl, the MRayl is megarayleigh,
The acoustic impedance of the wedge is 10-15MRayl, thereby obtaining a large-angle longitudinal wave probe with the refraction angle of 77-80 degrees,
The large-angle longitudinal wave probe comprises a piezoelectric element, an anode, a cathode, a backing layer and a wedge block, wherein the anode and the cathode are respectively arranged at the top and the bottom of the piezoelectric element; the positive electrode is adhered to the backing layer; the negative electrode is adhered to the wedge block; when a pair of large-angle longitudinal wave probes are arranged on a steel rail, the two large-angle longitudinal wave probes span the two sides of a welding line at the bottom of the steel rail, temperature sensors are respectively arranged at the two large-angle longitudinal wave probes, and the temperature change conditions of the two large-angle longitudinal wave probes are monitored by the temperature sensors; the stainless steel protective shell is arranged outside the two large-angle longitudinal wave probes and used for protecting the two large-angle longitudinal wave probes when contacting the bottom surface of the steel rail.
2. The high angle longitudinal wave probe of claim 1, wherein the resonant frequency of the composite piezoelectric material is 5MHz.
3. The high angle longitudinal wave probe of claim 1, wherein the gold and chromium have thicknesses of 10nm and 100nm, respectively.
4. The large angle longitudinal wave probe according to claim 1, wherein the acoustic impedance of the tungsten/epoxy in step S6 is 16MRayl.
5. The large angle longitudinal wave probe according to claim 1, wherein the wedge in step S6 is made of polyimide.
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| CN202110795108.4A CN113533518B (en) | 2021-07-14 | 2021-07-14 | Large-angle longitudinal wave probe and preparation method thereof |
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