CN117490895A - High-temperature alloy residual stress gradient detection method and system - Google Patents
High-temperature alloy residual stress gradient detection method and system Download PDFInfo
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- CN117490895A CN117490895A CN202210878846.XA CN202210878846A CN117490895A CN 117490895 A CN117490895 A CN 117490895A CN 202210878846 A CN202210878846 A CN 202210878846A CN 117490895 A CN117490895 A CN 117490895A
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- 238000001514 detection method Methods 0.000 title claims abstract description 36
- 239000000956 alloy Substances 0.000 title claims abstract description 23
- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 22
- 239000000523 sample Substances 0.000 claims abstract description 27
- 238000012360 testing method Methods 0.000 claims abstract description 26
- 238000000034 method Methods 0.000 claims abstract description 25
- 238000009826 distribution Methods 0.000 claims abstract description 24
- 238000005259 measurement Methods 0.000 claims abstract description 16
- 239000013598 vector Substances 0.000 claims abstract description 12
- 229910000601 superalloy Inorganic materials 0.000 claims description 33
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 16
- 229910052759 nickel Inorganic materials 0.000 claims description 8
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 230000004888 barrier function Effects 0.000 claims description 3
- 238000004088 simulation Methods 0.000 claims description 3
- 238000009864 tensile test Methods 0.000 claims description 3
- 238000004364 calculation method Methods 0.000 abstract description 9
- 238000010586 diagram Methods 0.000 description 3
- 238000009659 non-destructive testing Methods 0.000 description 3
- 239000002344 surface layer Substances 0.000 description 3
- 230000001066 destructive effect Effects 0.000 description 2
- 230000005307 ferromagnetism Effects 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 238000005094 computer simulation Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000005288 electromagnetic effect Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000005457 optimization Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
Classifications
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L5/00—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes
- G01L5/0047—Apparatus for, or methods of, measuring force, work, mechanical power, or torque, specially adapted for specific purposes measuring forces due to residual stresses
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L1/00—Measuring force or stress, in general
- G01L1/12—Measuring force or stress, in general by measuring variations in the magnetic properties of materials resulting from the application of stress
Abstract
The method comprises the steps of detecting by using a high-frequency eddy current probe, firstly, calibrating and measuring by using two standard test blocks with different conductivities, and establishing a calibration vector in an impedance plane according to a calibration measurement result; and then measuring the high-temperature alloy workpiece, representing the measurement result by using a calibration vector, thereby obtaining the volume average conductivity of the vortex distribution corresponding to the measurement result, carrying out inversion calculation to obtain the conductivity value at the maximum depth of the vortex, and calculating the residual stress of the corresponding depth by using the relation between the conductivity and the elastic strain of the high-temperature alloy material. The invention also provides a high-temperature alloy residual stress gradient detection system.
Description
Technical Field
The invention belongs to the field of nondestructive testing, and particularly relates to a method and a system for detecting residual stress gradient of a superalloy.
Background
Critical hot-end components of an aeroengine generally have strict requirements on fatigue life, residual stress is usually introduced into the critical components through surface strengthening to improve the fatigue life of the part, and the value and distribution of the residual stress have great influence on the fatigue life of the part, so that obtaining the information of the residual stress on the surface of the part is of great significance for predicting the life of the engine part.
Currently, the common residual stress detection methods are divided into destructive detection and non-destructive detection, the former requiring drilling holes in the part to be detected, which is unacceptable for expensive engine parts; the latter method is commonly used as an X-ray diffraction method, but the penetration capability of X-rays on nickel-based alloys is limited, and only the depth of about 5 mu m can be measured, so that the residual stress distribution of the surface layer of the part cannot be completely estimated. And partial nondestructive testing scheme can only measure the average value of residual stress in a certain depth range, and cannot measure the gradient distribution of the residual stress. Therefore, the method for detecting the gradient distribution of the residual stress of the high-temperature alloy is beneficial to improving the accuracy of predicting the fatigue life of the engine part.
Disclosure of Invention
The invention aims to provide a high-temperature alloy residual stress gradient detection method which can be used for measuring the residual stress distribution of the surface of a high-temperature alloy workpiece along the depth direction through a nondestructive detection means. The invention also provides a high-temperature alloy residual stress gradient detection system.
According to an aspect of an embodiment of the present invention, there is provided a superalloy residual stress gradient detection method including the steps of:
the method comprises the following steps:
a) Providing a conductivity of sigma 1 First standard block and conductivity sigma 2 Second standard test block of (c) for sigma 1 ≤σ≤σ 2 Wherein σ is the deep electrical conductivity of the superalloy;
b) Providing an eddy current detection system, wherein the eddy current detection system comprises a high-frequency eddy current probe, the high-frequency eddy current probe is used for measuring and calibrating the first standard test block and the second standard test block, and calibration vectors alpha and beta in an impedance plane are established according to a measurement result;
c) The high-temperature alloy part is subjected to sweep frequency detection at the frequency of 0.1-100MHz to obtain the frequency f n Measured coordinate point (x) in lower impedance plane n ,y n ) Based on the calibration vectors alpha and beta (x n ,y n ) Converted into (alpha) n ,β n ) Coordinates, and hence sigma 1 、σ 2 Frequency determination by relation to alpha, betaRate f n Conductivity sigma (f) corresponding to the detection value of the high-frequency eddy current probe n )；
d) Let sigma (f) n ) Conversion to conductivity and d n Relation Γ (d) n ) Wherein d is n At a frequency f n The maximum depth d that the lower vortex can reach n Conductivity Γ of depth position dn ＝(Γ(d n )v n -Γ(d n-1 )v n-1 )/(v n -v n-1 ) Wherein v is n Is f n The distribution volume of the lower vortex, i.e. vortex arrival d n Volume of distribution at depth, d n ＝d n-1 +Δd, Δd is the thickness of the superalloy material layer, v, which can be considered as uniform in residual stress n-1 For vortex arrival d n-1 Distribution volume at depth;
e) Providing the corresponding relation tau (Γ) between the conductivity and the elastic stress of the superalloy, and obtaining each depth value d n Residual stress value τ (Γ) dn ) Thereby obtaining the gradient distribution of residual stress.
By the method, the eddy current generated in the high-temperature alloy workpiece by utilizing the electromagnetic effect can be used for accurately obtaining the residual stress values at different detection depths through inversion calculation, so that the gradient distribution of the residual stress is obtained, and the measurement accuracy is improved.
Further, sigma-0.2 is less than or equal to sigma in the step a) 1 ≤σ-0.1，σ+0.1≤σ 2 And sigma+0.2, wherein the conductivity is calculated by IACS percent.
Further, σ in the a) step is obtained by measuring a 0 stress standard test block made of the superalloy at 480kHz frequency using a conductivity probe. And measuring the 0-stress standard test block by using a common standard conductivity probe to obtain deep conductivity data of the alloy workpiece to be measured.
Further, in the step b), a step of setting non-conductive calibration gaskets on the surfaces of the first standard test block and the second standard test block is further included, and the calibration vectors alpha and beta are established according to four measurement points obtained by respectively measuring the first standard test block and the second standard test block by directly contacting the high-frequency eddy current probe and taking the non-conductive calibration gaskets as barriers. The non-conductive calibration gasket is introduced to compensate and correct the condition that the high-frequency eddy current probe cannot be tightly attached to the surface of the workpiece to be detected in the measuring process.
Further, the thickness of the non-conductive calibration pad is 20 μm to 100 μm.
Further, in the step d), simulation is performed on the eddy current distribution generated in the high-temperature alloy part by the high-frequency eddy current probe, v n Obtained by integrating the simulated isocurrent density curve. The distribution state of the vortex in the alloy under different frequencies can be calculated through software simulation, and the distribution volume of the vortex can be calculated according to the distribution simulation.
Further, in the step d), Δd is in the range of 5 μm to 200 μm. The value of Δd also represents the resolution in the depth direction of the residual stress detection.
Further, in the step e), the corresponding relation between the conductivity and the elastic stress of the superalloy is calibrated by carrying out a tensile test on the same superalloy.
Further, the superalloy is a nickel-based superalloy. The nickel-based superalloy is a common material of an aeroengine, and the nickel-based superalloy for the aeroengine has no ferromagnetism and cannot interfere vortex.
According to another aspect of the embodiment of the invention, a high-temperature alloy residual stress gradient detection system is provided, and comprises a computing device, a GPIB controller, an impedance analyzer and an eddy current probe, wherein the high-temperature alloy residual stress gradient detection method is adopted to detect residual stress of a part to be detected. By writing special software, the gradient distribution of residual stress can be directly measured and output by means of the system, the calculation process is simplified, and the measurement efficiency and accuracy are improved.
Drawings
FIG. 1 is a schematic diagram of a system for detecting residual stress gradients in a superalloy in an embodiment;
FIG. 2 is a schematic diagram of a standard test block in one embodiment;
FIG. 3 is a schematic diagram of a position of a detection result in an impedance plane according to an embodiment.
The above drawings are provided for the purpose of explaining the present invention in detail so that those skilled in the art can understand the technical concept of the present invention, and are not intended to limit the present invention. For simplicity of illustration, the above figures show only schematically the structures related to the technical features of the present invention, and do not show the complete apparatus and all the details strictly to the actual scale.
Detailed Description
The invention will now be described in further detail with reference to the accompanying drawings by means of specific embodiments.
Reference herein to "an embodiment" means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment herein. The appearances of such phrases in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments limited to the same embodiment. Those skilled in the art will appreciate that embodiments herein may be combined with other embodiments without structural conflict.
In the description herein, terms such as "upper," "lower," "left," "right," "transverse," "longitudinal," "height," "length," "width," and the like that indicate an azimuth or positional relationship are intended to accurately describe the embodiments and simplify the description, and do not limit the details or structures involved to having to have a particular azimuth, mount or operate in a particular azimuth, and are not to be construed as limiting embodiments herein.
In the description herein, the terms "first," "second," and the like are used merely to distinguish between different objects and should not be construed as indicating relative importance or defining the number, particular order, or primary and secondary relationships of the technical features described. In the description herein, the meaning of "plurality" is at least two.
In order to accurately measure the residual stress gradient of the surface layer of the superalloy workpiece in a nondestructive testing manner, an embodiment of the present invention provides a residual stress gradient detection device as shown in fig. 1, which includes a computing device 1, a GPIB controller 2, an impedance analyzer 3 and a high-frequency eddy current probe 4, and in various embodiments, the computing device 1 may be configured as a general-purpose computer or a special-purpose computing device with corresponding processing software, such as a customized singlechip or other devices with corresponding computing and processing functions. The high-frequency eddy current probe 4 is used for carrying out sweep frequency detection on a sample, the impedance analyzer 3 is used for analyzing and processing sweep frequency detection data, and the GPIB controller 2 is used for carrying out data, instruction conversion and transmission between the computing device 1 and the impedance analyzer 3.
The device is used for measuring the residual stress of the high-temperature alloy part, and comprises the following steps:
setting the deep conductivity of the alloy to be tested, namely the conductivity in a natural stress-free state as sigma, and providing the conductivity as sigma before detection 1 First standard block 5 and conductivity sigma 2 Second standard test block 6 of (c) for sigma 1 ≤σ≤σ 2 . In a preferred embodiment, σ 1 、σ 2 The method meets the following conditions: sigma-0.2 is less than or equal to sigma 1 ≤σ-0.1，σ+0.1≤σ 2 And less than or equal to sigma+0.2, wherein the values of the electric conductivity are all calculated by IACS percent. In various embodiments, the value of σ may be measured from a 0-stress standard test block specially manufactured from the superalloy at 480kHz using a commercial conductivity probe, depending on the alloy composition to be measured.
Next, measurement calibration is performed by abutting the high-frequency eddy current probe 4 against the surfaces of the first standard test block 5 and the second standard test block 6, respectively, as shown in fig. 2, and measuring is performed by combining fig. 3, whereby a measurement point a (x 1 ,y 1 )、b(x 2 ,y 2 ). In some preferred embodiments, in addition to performing direct measurement, nonconductive calibration pads 7 with a thickness s are placed on the surfaces of the first standard test block 5 and the second standard test block 6, and measurement is performed again with the nonconductive calibration pads 7 as barriers to obtain a measurement point c (x 3 ,y 3 )、d(x 4 ,y 4 ). The non-conductive calibration pad 7 is arranged to calibrate the situation that the high-frequency eddy current probe 4 cannot be tightly attached to the surface of the part to be measured, and the non-conductive calibration pad 7 simulates the situation that air blocking exists between the eddy current probe 4 and the part to be measured. In some embodiments, other thanThe thickness s of the conductive calibration pad 7 is set to 20 μm to 100 μm, typically 30 μm. The four a, b, c, d points are utilized to construct calibration vectors alpha and beta under the impedance plane, for example, alpha and beta can be the connecting line direction of any two groups of points which do not form parallel relation in a, b, c, d, and the included angle of alpha and beta is preferably close to 90 degrees for calculating and measuring accuracy. In some embodiments, the non-conductive calibration pad 7 is not provided, and the c, d coordinates are all noted as (0, 0).
Then the high-frequency eddy current probe 4 is utilized to carry out sweep frequency detection on the part to be detected, and the frequency f is set n The lower measured result is a coordinate point (x n ,y n ) This point falls within the area enclosed by the four a, b, c, d points. By basic linear algebraic computation, the (x n ,y n ) Is converted into coordinates (alpha) based on calibration vectors alpha and beta n ,β n ). In the process of constructing calibration vectors alpha and beta, sigma is also established 1 、σ 2 The relation between α and β, that is, the electrical conductivity corresponding to each coordinate point in the impedance plane can be determined by multiplying (x n ,y n ) Conversion to (alpha) n ,β n ) Back frequency f n Conductivity sigma (f) corresponding to data measured by the lower high frequency eddy current probe n )＝K 1 α n +K 2 β n +K 3 Can also be solved, wherein K 1 、K 2 、K 3 Is constant.
For example, in an embodiment where the non-conductive calibration pad 7 is not provided, let α= (x) 1 ,y 1 ),β＝(x 2 ,y 2 ) Measuring point x (x n ,y n ) Converted coordinates are (alpha) n ,β n ) I.e. origin to x (x n ,y n ) Vector x=of (2)
α n α+β n Beta, where alpha corresponds to sigma 1 Beta corresponds to sigma 2 Thus σ (f n )＝α n σ 1 +β n σ 2 。
Carrying out sweep frequency detection in the frequency range of 0.1MHz-100MHz to obtain a series of frequency-conductivity data sets { f } n ,σ(f n )}。
The conductivity at a particular depth is then found by inversion calculations. Due to frequency f n The lower vortex has a certain distribution volume v inside the part n Corresponding conductivity sigma (f n ) Is v n Average value of conductivity in the range. Setting frequency f n The lower vortex can reach a depth d n Then the relation of frequency to conductivity sigma (f n ) Can be further converted into a depth-to-conductivity relationship Γ (d n ) Frequency-conductivity data set { f n ,σ(f n ) The data set d can be converted into a depth-conductivity data set d n ,Γ(d n ) }. The residual stress values set within the Δd thickness range can be regarded as approximately the same, then d n Conductivity Γ at dn Can be composed of
Γ dn ＝(Γ(d n )v n -Γ(d n-1 )v n-1 )/(v n -v n-1 ) Calculated, where d n ＝d n-1 +Δd due to d n And f n One-to-one correspondence, thus d n And v n And also in one-to-one correspondence with d n-1 There is also a corresponding distribution volume v n-1 This process is equivalent to that of d n Differential calculation is performed thereby to collect depth-conductivity data { d } n ,Γ(d n ) Conversion to conductivity gradient set { d } n ,Γ dn }. In some embodiments, Δd ranges from 5 μm to 200 μm, and Δd is smaller near the surface region, e.g., 10 μm, and Δd is larger in the deep region, e.g., 200 μm. The value of Δd actually determines the measurement resolution, and the surface layer residual stress gradient of the workpiece subjected to surface strengthening processing is larger, and the deep layer residual stress gradient is relatively smaller. In some embodiments, different frequencies f n Distribution volume v of lower vortex n The method can be used for inquiring and fetching from a database which is established in advance, and can also be used for establishing an eddy current model to integrate an eddy current isopycnic curve through computer simulation calculation.
Finally, according to the corresponding relation tau (Γ) between the measured material conductivity and the elastic stress, each depth d is calculated n The corresponding elastic stress value is used for obtaining the elastic stressForce gradient set { d } n ,τ(Γ dn ) From this data set, elastic stress values at arbitrary depths within the measurement range can be obtained. Wherein τ (Γ) can be obtained by consulting a manual for material properties, or by calibrating the relationship between conductivity and elastic stress by specifically performed tensile tests, which are linear with each other, τ (Γ) dn )＝K(Γ dn -Γ 0 ) Wherein K is a calibration constant, Γ 0 To the conductivity at zero stress obtained by measuring the zero stress test block.
The calculation and storage processes are automatically completed by a built-in program through a calculation device 1 of the residual stress gradient detection device. In some embodiments, the residual stress gradient detection device is not adopted, and the analysis and calculation can also be implemented by manually using general data processing software to analyze and calculate the data acquired by the high-frequency eddy current probe 4 in the same way.
In a preferred embodiment, the part to be inspected is made of a nickel-based superalloy, such as a nickel-based single crystal alloy or the like. The nickel-based superalloy for aviation has no ferromagnetism and can not interfere with the eddy current detection process. And in other embodiments, the method can also be used for detecting the residual stress of other high-temperature alloy parts such as titanium alloy and the like.
The above-described embodiments are intended to explain the present invention in further detail with reference to the figures so that those skilled in the art can understand the technical concept of the present invention. Optimization or equivalent replacement of the method steps or part structures involved falls within the scope of the claims of the present invention.
Claims (10)
1. The method for detecting the gradient of the residual stress of the superalloy is characterized by comprising the following steps of:
a) Providing a conductivity of sigma 1 First standard block and conductivity sigma 2 Second standard test block of (c) for sigma 1 ≤σ≤σ 2 Wherein σ is the deep electrical conductivity of the superalloy;
b) Providing an eddy current detection system, wherein the eddy current detection system comprises a high-frequency eddy current probe, the high-frequency eddy current probe is used for measuring and calibrating the first standard test block and the second standard test block, and calibration vectors alpha and beta in an impedance plane are established according to a measurement result;
c) The high-temperature alloy part is subjected to sweep frequency detection at the frequency of 0.1-100MHz to obtain the frequency f n Measured coordinate point (x) in lower impedance plane n ,y n ) Based on the calibration vectors alpha and beta (x n ,y n ) Converted into (alpha) n ,β n ) Coordinates, and hence sigma 1 、σ 2 Relation with alpha, beta to find the frequency f n Conductivity sigma (f) corresponding to the detection value of the high-frequency eddy current probe n )；
d) Let sigma (f) n ) Conversion to conductivity and d n Relation Γ (d) n ) Wherein d is n At a frequency f n Depth d to which lower vortex can reach n Conductivity Γ of depth position dn ＝(Γ(d n )v n -Γ(d n-1 )v n-1 )/(v n -v n-1 ) Wherein v is n Is f n The distribution volume of the lower vortex, i.e. vortex arrival d n Volume of distribution at depth, d n ＝d n-1 +Δd, Δd is the thickness of the superalloy material layer, v, which can be considered as uniform in residual stress n-1 For vortex arrival d n-1 Distribution volume at depth;
e) Providing the corresponding relation tau (Γ) between the conductivity and the elastic stress of the superalloy, and obtaining each depth value d n Residual stress value τ (Γ) dn ) Thereby obtaining the gradient distribution of residual stress.
2. The method for detecting residual stress gradient of superalloy according to claim 1, wherein σ -0.2 is equal to or less than σ in step a) 1 ≤σ-0.1，σ+0.1≤σ 2 And sigma+0.2, wherein the conductivity is calculated by IACS percent.
3. The method according to claim 1 or 2, characterized in that σ in the a) is obtained by measuring a 0-stress standard test block manufactured from the superalloy at a frequency of 480kHz using a conductivity probe.
4. The method according to claim 1 or 2, wherein in the step b), a non-conductive calibration pad is disposed on the surfaces of the first standard test block and the second standard test block, and the calibration vectors α and β are established according to four measurement points obtained by directly contacting and measuring the first standard test block and the second standard test block with the high-frequency eddy current probe, respectively, and using the non-conductive calibration pad as a barrier.
5. The method of claim 4, wherein the nonconductive calibration pad has a thickness of 20 μm to 100 μm.
6. The method according to claim 1 or 2, wherein in the step d), a simulation is performed on a vortex distribution generated in the superalloy component by the high-frequency vortex probe, v n Obtained by integrating the simulated isocurrent density curve.
7. The method for detecting residual stress gradient of superalloy according to claim 1 or 2, wherein Δd in step d) is in the range of 5 μm to 200 μm.
8. The method for detecting the residual stress gradient of the superalloy according to claim 1 or 2, wherein in the step e), the correspondence between the electrical conductivity and the elastic stress of the superalloy is calibrated by a tensile test of the same superalloy.
9. The superalloy residual stress gradient detection method according to claim 1 or 2, wherein the superalloy is a nickel-based superalloy.
10. A superalloy residual stress gradient detection system comprising a computing device, a GPIB controller, an impedance analyzer and a high-frequency eddy current probe, wherein the superalloy residual stress gradient detection method according to any one of claims 1 to 8 is used for residual stress detection of a part to be detected.
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