CN115166045A - Electromagnetic ultrasonic phased array sensor with array elements of runway coils - Google Patents
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- 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
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Abstract
The invention discloses an electromagnetic ultrasonic phased array sensor for detecting defects of an aluminum alloy material. The parameters involved in design mainly comprise the form of the single-array element coil, the spacing D of the single-array element coil conductors, the width W of the single-array element, the lift-off distance H, the number N of the array elements in the array, the spacing D of the array elements, the width W and the height H of the permanent magnet. Compared with the traditional sensor, the sensor designed by the invention has the advantages of enhancing the strength of the excitation signal and the received signal, reducing the side lobe of a focused sound field, improving the defect identification capability, having excellent imaging effect and the like. Through experiments, the sensor is used for successfully detecting the groove type defect with the size of 200mm multiplied by 2mm on the bottom surface of the 6061 aluminum alloy piece with the size of 200mm multiplied by 20mm, the imaging result clearly reflects the position and the shape of the defect, and the excellent performance of the designed sensor is verified.
Description
Technical Field
The invention relates to an electromagnetic ultrasonic phased array sensor for detecting defects of an aluminum alloy material, and belongs to the technical field of electromagnetic ultrasonic nondestructive testing. Compared with a conventional electromagnetic ultrasonic sensor, the sensor improves the signal-to-noise ratio of a received signal, reduces side lobes of a focused sound field and improves the defect identification capability.
Background
The aluminum alloy material is widely applied to the fields of aerospace, automobile manufacturing, ship processing and the like due to the characteristics of light weight, high strength, good corrosion resistance and the like. However, some defects often occur in the production, transportation and service processes of materials, so that the properties of the materials are changed, and finally serious safety liability accidents are caused. Therefore, the method has important value and significance in actual production and life when being used for accurately and efficiently carrying out nondestructive testing on the strain.
The conventional industrial nondestructive detection modes comprise five types, namely ray detection, magnetic particle detection, penetration detection, eddy current detection and ultrasonic detection. The ray detection method has high cost and is harmful to human body. Meanwhile, when the photographing angle is not appropriate, the radiographic method is prone to miss-detection. The magnetic particle testing can be used for detecting forgings, castings and the like, and has the advantage that the magnetic particle testing can be used for detecting test pieces with complex structures, such as pump parts, compressor parts and other equipment. But it is limited to test pieces for magnetic materials and can only detect defects close to the near surface, and is not suitable for the detection of non-magnetic materials and deep defects. Compared with magnetic particle detection, penetration detection makes up the defect that non-magnetic materials cannot be detected. The penetration detection can detect the test piece of nonmagnetic materials, such as plastics, ceramics and other materials, and can comprehensively detect the defects with complex shapes at one time. The main limitations are that the detection procedure is too complicated, the efficiency is low, the detection sensitivity is low, and the requirement on detection personnel is high. Eddy current testing is a non-destructive testing method based on the principle of electromagnetic induction. In the eddy current detection, a coil serves as a transducer, the coil transmits energy to a tested piece, an alternating magnetic field generated by eddy current acts on the coil, and related information is obtained through the change of an electric signal in the coil. Therefore, the eddy current detection has the advantages of no coupling and high detection sensitivity. However, this method is shallow in detection depth and can only detect surface defects. Ultrasonic testing is a nondestructive testing method using mechanical waves with frequency higher than 20kHz, namely ultrasonic waves. The ultrasonic detection has the characteristics of strong penetrating power and high sensitivity for detecting plane defects such as cracks, inclusions and the like. But it is not possible to inspect complex shaped workpieces and requires a couplant to fill the gap between the probe and the test piece.
Because the piezoelectric ultrasonic detection technology needs a coupling agent during detection, the electromagnetic ultrasonic technology capable of non-contact measurement is concerned by people. The electromagnetic ultrasonic detection technology utilizes an electromagnetic coupling mode to excite and receive ultrasonic waves, and mainly comprises a coil, an external magnetic field and a test piece. When alternating current is introduced into a coil on the surface of the test piece, eddy current is generated on the surface of the test piece, and the eddy current generates vibration under the action of mechanical force under the action of an external magnetic field to form an ultrasonic wave source. When the sensor receives ultrasonic waves, the movement of particles in a test piece generates induced electromotive force in the coil under the action of an external magnetic field, and the voltage of an output end is changed.
The electromagnetic ultrasonic detection technology solves the problem that a coupling agent is required to be used in the piezoelectric ultrasonic detection technology, and non-contact measurement is realized. The non-contact measurement mode can be widely applied to extreme temperature conditions, and meanwhile, the requirements on parameters such as surface roughness of a test piece and the like are not high. In addition to this, non-contact measurement provides the basis for high-speed online measurement. Compared with the piezoelectric ultrasonic detection technology, the transverse wave can be excited only by the wedge block, and the electromagnetic ultrasonic sensor can generate ultrasonic waves in various forms such as transverse waves, surface waves and the like under a certain excitation condition by changing the form of the coil.
For electromagnetic ultrasonic detection technology, a major disadvantage is the low transduction efficiency. In order to overcome the defect of low energy conversion efficiency by utilizing the advantages of an electromagnetic ultrasonic detection technology, the electromagnetic ultrasonic phased array technology becomes the key for solving the problems. The electromagnetic ultrasonic phased array technology enables the sound beam to be focused on a certain point inside the test piece by setting the delay time of the excitation signal of each channel. The focusing of the acoustic beam effectively enhances the signal intensity at the focusing point, and overcomes the defect of low transducer efficiency of the sensor through the superposition effect. Meanwhile, the deflection of the sound beam enables the electromagnetic ultrasonic phased array to have wider application.
The invention designs the electromagnetic ultrasonic phased array sensor with the array element being the runway coil, thereby greatly enhancing the signal-to-noise ratio of the received signal and increasing the defect detection efficiency. Meanwhile, the phased array technology is utilized to realize sector scanning imaging of the defect.
Disclosure of Invention
Aiming at the problems of small coil signal intensity, low detection sensitivity and incapability of imaging defects of a single electromagnetic ultrasonic sensor, the invention designs a sensor which has higher signal-to-noise ratio of a received signal, smaller defects capable of being resolved and better defect imaging quality, namely an electromagnetic ultrasonic phased array sensor with an array element of a runway coil. The parameters involved in design mainly comprise the form of the single-array element coil, the spacing D of the single-array element coil conductors, the width w of the single-array element, the lift-off distance h, the number N of the array elements and the distance D between the array elements. And the width W and height H of the permanent magnet.
In order to achieve the purpose, the invention adopts the following design scheme:
an electromagnetic ultrasonic phased array sensor with an array element being a runway coil mainly comprises a permanent magnet 1, an exciting coil 2 and a test piece 3. According to the transduction principle of the electromagnetic ultrasonic sensor, the test piece belongs to one part of the sensor, but in actual detection, the material of the test piece to be tested is not fixed, so that the part of the test piece to be tested is in the range of the design, and the design only aims at the permanent magnet and the coil part. The method is characterized in that: the permanent magnet 1 is made of neodymium iron boron materials to generate a strong bias magnetic field. The coil 2 part is composed of a plurality of array elements, and the coil form of each array element is a runway coil. The permanent magnet 1 is positioned on the symmetry axis of the coil 2 and is tightly attached to the surface of the coil 2.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coils is characterized in that: compared with the traditional single array element which is a linear lead and a single-turn annular lead, the single-array element has the advantages that the coil form is changed, the number of leads is increased, and the signal-to-noise ratio of received signals is improved.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coils is characterized in that: the runway coil wire spacing d of the single array element avoids the generation of artifacts during defect imaging caused by splitting of ultrasonic wavelets. At the same time, the size of the sensor is reduced.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coil is characterized in that: the lifting distance h of the sensor ensures the non-contact property of the sensor. Meanwhile, the intensity of the generated ultrasonic signal is ensured to the maximum extent.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coil is characterized in that: the number N of the array elements of the sensor ensures that the sensor realizes the functions of focusing and deflecting the acoustic beam. At the same time, the requirements on the hardware system of the excitation and acquisition sensor are reduced.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coils is characterized in that: the array element width w of the sensor enables the signal-to-noise ratio of signals received by the sensor to be high, meanwhile, the side lobe of a sound field is small relative to the strength of a main lobe, and the influence of the side lobe of the sound field on imaging is reduced. In addition, under the designed array element width, the transverse resolution of the sensor is large, and smaller defects can be resolved by the sensor.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coils is characterized in that: the array element interval D of the sensor is designed, so that the signal-to-noise ratio of signals received by the sensor is improved, the influence of sound field side lobes on imaging is reduced, and the transverse resolution of the sensor is improved.
The electromagnetic ultrasonic phased array sensor with the array elements being the runway coils is characterized in that: the width W and the height H of the permanent magnet, the width W and the height H of the permanent magnet provide a stronger uniform bias magnetic field, and the coil designed in a matching way reduces the whole occupied volume of the sensor to the maximum extent and controls the size of the sensor as much as possible.
The invention can obtain the following beneficial effects:
1. compared with a single wire or a single inflection coil adopted in a conventional sensor, the signal-to-noise ratio of a received signal is greatly improved by adopting the runway coil as a single array element; the design of the wire spacing d between the coils avoids the generation of ultrasonic wave, and improves the imaging quality of the electromagnetic ultrasonic phased array sensor.
2. The strength of the excitation signal is improved by the design of the lift-off distance h;
3. due to the design of the width w and the distance D of the array elements, the excitation signal intensity is enhanced, the sidelobe amplitude of a sound field is reduced, the transverse resolution of the sensor is improved, the defect that the sensor can distinguish a smaller size is overcome, and the imaging performance of the sensor is improved.
4. The design of the width W and height H of the permanent magnet provides a stronger bias magnetic field and places the coil in a uniform magnetic field vertically downward. Meanwhile, the permanent magnet design matched with the coil reduces the size of the sensor.
Drawings
FIG. 1: a schematic diagram of sensor design parameters;
FIG. 2: detecting by a sensor and a coil real object image;
FIG. 3: a groove defect imaging result graph;
in the figure, 1, a permanent magnet, 2, a coil, 3 and a test piece.
Detailed Description
The present invention is further illustrated by the following examples in conjunction with the accompanying drawings and examples, and the following examples are illustrative only and not intended to limit the scope of the present invention.
The schematic diagram of the magnetic ultrasonic detection principle is shown in fig. 1. As can be seen from the figure, the three parts which form the electromagnetic ultrasonic sensor are a 1-permanent magnet, a 2-coil and a 3-test piece respectively. Among them, the test piece is a 6061 aluminum alloy which is excellent in workability, has excellent weldability, and is widely used in the industrial field, and has a specification of 200X 20 (unit: mm). The main parts of the design are the design of a 1-permanent magnet and the design of a 2-coil, the related parameters are shown in figure 2, and the specific dimensions are determined according to simulation results. And finally, verifying the performance of the sensor through experiments.
And (4) establishing a two-dimensional model in COMSOL finite element simulation, and determining the final sensor size according to the simulation result. For the formal determination of the sensor coils, a geometric model of the single array element as shown in fig. 3 is established. The sine wave signal modulated by a five-period Hanning window with the current amplitude of 1A and the center frequency of 1MHz is introduced into the coil. And extracting the displacement amplitude which forms an included angle of theta =30 degrees with the central line of the sensor and has the depth of R =10 mm. It can be observed that the displacement amplitude of the four-runway coil form is about four times of that of the observation point of the single-runway coil and 9.5 times of that of a single straight wire, which shows that the runway coil improves the amplitude of the excitation signal and enhances the signal-to-noise ratio of the received signal. Thus, the coil form of the sensor is finally determined as a racetrack coil. As the lift-off distance h of the electromagnetic ultrasonic sensor increases, the amplitude of the received signal exponentially decays, thereby determining the lift-off distance h of the sensor as the minimum thickness of the FPC board of the coil, i.e., 0.1mm.
And for the wire spacing of the runway coil of the single array element, a sine wave signal modulated by a five-period Hanning window with the current amplitude of 1A and the center frequency of 1MHz is also introduced into the coil. According to the material property of the aluminum material, the transverse wave sound velocity of the ultrasonic wave is 3130m/s, so that the ultrasonic wave propagation cloud chart can be obtained according to the relation among frequency, sound velocity and wavelength, the transverse wave wavelength lambda of the acoustic wave is 3.13mm, and the pitches of the coil wires are respectively set to be 1/8 lambda and lambda. For a racetrack coil, the ultrasound splits into multiple wavelets when the wire spacing is λ, and does not split when the wire spacing is 1/8 λ. Thus, to avoid artifacts from phase-controlled scanning imaging and to better create a defective image, the pitch of the wires is set to 1/8 λ, i.e., 0.39mm.
For the design of the array element width w of the sensor, an 8-array-element runway coil model is established, and the spacing between the leads is 0.39mm. Considering that the width of the single array element is increased by 0.78mm every time a runway is added, the minimum width of 0.39mm is taken as the width of the array element, the width of the single array element is increased by 0.78mm, the maximum width is set to be 3.51mm, and the single array element with the width corresponds to the coils of five runways. When the width of the array element is larger, the side lobe of the sound field is larger, and when the width of the array element is smaller, the side lobe of the sound field is smaller. The transverse resolution of the sensor generally shows a trend of increasing with the increase of the width of the array element, but the width of the array element has less influence on the transverse resolution of the sensor, and the transverse resolution of the sensor with the width of the array element of 0.39mm is only 0.4mm higher than that of the sensor with the width of the array element of 3.51 mm. Under the condition that the lateral resolution is influenced by the width to a small extent, the array element width is large, so that the displacement value at the focus can be improved, the width of the array element is too large, the side lobe of a sound field is increased, the imaging effect is influenced, and finally the width of the array element is determined to be 2.73mm, namely, four runway coils are used as a single array element.
For the design of the sensor array element distance D, 8 array element runway coil models are established, the distance between the wires is 0.39mm, the lift-off distance is 0.1mm, and the array element width is 2.73mm. The excitation signal is a sine wave signal modulated by a five-period Hanning window with the center frequency of 1MHz, and the transverse wave wavelength of ultrasonic waves at the frequency is 3.13mm. Considering that the width of the array element is 2.73mm, the minimum value of the array element spacing is determined to be 3.13mm, the maximum value of the array element spacing is set to be 6.26mm, and the performance of the sensors under five groups of different array element spacings is studied by taking one quarter of the wavelength, namely 0.7825mm as a step. When the array element interval is larger, the main lobe width is smaller, the side lobe is larger, and the displacement value at the focus shows a descending trend. The higher the lateral resolution of the sensor, the higher the lateral resolution of the sensor with an array element spacing of 6.26mm is by 1.5mm compared to the lateral resolution of the sensor with an array element spacing of 3.13mm. In conjunction with the above conclusions, the array element pitch of the sensor is set to be 4.69mm. Under the interval, the stress value of a sound field generated by the excitation signal of the sensor at a focus is larger, the transverse resolution ratio is higher, and the side lobe of the sound field is smaller.
For the design of the width W and the height H of the permanent magnet of the sensor, in order to ensure that all coils are in a uniform magnetic field, the width W of the permanent magnet is determined to be 36mm by combining the number of array elements of the sensor, the width of a single array element is 2.73mm, the interval between the array elements is 4.69mm, and the height H of the permanent magnet is set to be 25mm for controlling the overall size of the sensor.
The defect detection is carried out on 6061 aluminum alloy by combining with the designed sensor, and the size of a tested piece is 200 multiplied by 20 (unit: mm). A groove defect with the size of 200 multiplied by 2 (unit: mm) exists on the bottom surface of the test piece and is far from the symmetry axis of the test piece. The defect was imaged using a sector scan, and the results are shown. As can be seen from the figure, the designed sensor is used for accurately and clearly imaging the defects, and the excellent performance of the designed sensor is reflected.
In summary, the invention designs an electromagnetic ultrasonic phased array sensor with an array element being a runway coil for detecting the defects of aluminum alloy materials, sensor parameters including the form of the coil, the spacing D of wires, the lifting distance L, the number N of the array elements, the width W of a single array element, the spacing D of the array elements, the width W of a permanent magnet, the height H of the permanent magnet and the like are designed through finite element simulation, and finally the excellent performance of the sensor is verified through an experimental mode. Compared with the traditional sensor, the sensor designed by the invention has the advantages of enhancing the signal intensity of the excitation signal and the received signal, reducing the side lobe of a focusing sound field, improving the defect identification capability, having good imaging effect and the like.
Claims (7)
1. An electromagnetic ultrasonic phased array sensor for detecting defects of an aluminum alloy material comprises a coil and a permanent magnet; the electromagnetic ultrasonic phased array sensor is characterized by comprising the following structural characteristics: the form of the single-array element coil, the spacing D of the single-array element coil leads, the width W of the single-array element, the lift-off distance H, the number N of the array elements, the distance D between the array elements, the width W and the height H of the permanent magnet;
the single-array element coil is in a runway coil form, so that the signal-to-noise ratio of excitation and receiving signals is improved;
the distance d between the single-array element coil wires avoids the generation of artifacts caused by the split of ultrasonic wavelets when defect imaging is carried out and reduces the size of the electromagnetic ultrasonic phased array sensor;
the lifting distance h ensures the intensity of the generated ultrasonic signal;
the number N of the array elements of the electromagnetic ultrasonic phased array sensor ensures that the sensor realizes the functions of focusing and deflecting the sound beam, and reduces the requirements on a hardware system of an excitation and acquisition sensor;
the array element width w of the electromagnetic ultrasonic phased array sensor and the array element distance D of the sensor enable the signal-to-noise ratio of signals received by the sensor to be high, meanwhile, the side lobes of a sound field are small relative to the strength of a main lobe, and the influence of the side lobes of the sound field on imaging is reduced;
the width W and the height H of the permanent magnet provide a strong uniform bias magnetic field for the coil, and the coil designed in a matched mode reduces the whole occupied volume of the electromagnetic ultrasonic phased array sensor to the maximum extent and controls the size of the electromagnetic ultrasonic phased array sensor.
2. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, is characterized in that: a sine wave signal modulated by a five-period Hanning window with the current amplitude of 1A and the center frequency of 1MHz is introduced into the coil; and extracting the displacement amplitude which forms an included angle of theta =30 degrees with the central line of the sensor and has the depth of R =10 mm.
3. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, wherein: said h is determined as the minimum thickness of the FPC board of the coil, i.e. 0.1mm.
4. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, is characterized in that: for the racetrack coil, when the distance between the leads is lambda, the ultrasonic wave is split into a plurality of wavelets, and when the distance between the leads is 1/8 lambda, the ultrasonic wave is not split; thus, to avoid artifacts from phase-controlled scanning imaging and to better create a defective image, the pitch of the wires is set to 1/8 λ, i.e., 0.39mm.
5. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, wherein: for the design of the array element width w of the sensor, an 8-array-element runway coil model is established, and the distance between the wires is 0.39mm; the width of the array element is determined to be 2.73mm.
6. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, wherein: for the sensor array element distance D, establishing 8 array element runway coil models, and establishing 8 array element runway coil models, wherein the wire distance is 0.39mm, the lift-off distance is 0.1mm, and the array element width is 2.73mm; the array element interval is set to be 4.69mm; the stress value of a sound field generated by the excitation signal of the sensor at a focus is large, the transverse resolution is high, and the side lobe of the sound field is small.
7. The electromagnetic ultrasonic phased array sensor for the defect detection of the aluminum alloy material as claimed in claim 1, is characterized in that: for the design of the width W and the height H of the permanent magnet of the sensor, in order to ensure that all coils are in a uniform magnetic field, the width W of the permanent magnet is determined to be 36mm by combining the number of array elements of 8, the width of a single array element is 2.73mm, the interval between the array elements is 4.69mm, and the height H of the permanent magnet is set to be 25mm for controlling the overall size of the sensor.
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117233263A (en) * | 2023-11-15 | 2023-12-15 | 中北大学 | Narrow-sound-beam electromagnetic ultrasonic sensor and device for detecting defects in axial direction of pipeline |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN117233263A (en) * | 2023-11-15 | 2023-12-15 | 中北大学 | Narrow-sound-beam electromagnetic ultrasonic sensor and device for detecting defects in axial direction of pipeline |
| CN117233263B (en) * | 2023-11-15 | 2024-02-06 | 中北大学 | Narrow-sound-beam electromagnetic ultrasonic sensor and device for detecting defects in axial direction of pipeline |
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Application publication date: 20221011 |