Ultrasonic Nondestructive Testing of Superplastic Solid-State Welding Joint for Different Steels

Based on quantitative microscopic examinations of welds and welding rate for different steels(40Cr and T10A) joint,which possess the ultra-fine microstructure after high frequency hardening(HFH) and salt-bath cyclic quenching(SCQ),the suitable defect grey scale threshold value was determined,and the welding rate of superplastic solid-state welding of different steels(40Cr and T10 A steel) was systematically inspected and analyzed by means of self-made ultrasonic imaging inspection system.The experimental results showed that the superplastic solid-state weld of different steels can be inspected more accurately,reliably and quickly by this system,and the results were in good accordance with that of metallographic observation.The welding rate of superplastic welding is in linear relation with tensile strength of joint.

Nondestructive Testing and Characterization of Residual Stress Field Using an Ultrasonic Method

To address the difficulty in testing and calibrating the stress gradient in the depth direction of mechanical components, a new technology of nondestructive testing and characterization of the residual stress gradient field by ultrasonic method is proposed based on acoustoelasticity theory. By carrying out theoretical analysis, the sensitivity coefficients of different types of ultrasonic are obtained by taking the low carbon steel（12%C） as a research object. By fixing the interval distance between sending and receiving transducers, the mathematical expressions of the change of stress and the variation of time are established. To design one sending-one receiving and oblique incidence ultrasonic detection probes, according to Snell law, the critically refracted longitudinal wave（LCR wave） is excited at a certain depth of the fixed distance of the tested components. Then, the relationship between the depth of LCR wave detection and the center frequency of the probe in Q235 steel is obtained through experimental study. To detect the stress gradient in the depth direction, a stress gradient LCR wave detection model is established, through which the stress gradient formula is derived by the relationship between center frequency and detecting depth. A C-shaped stress specimen of Q235 steel is designed to conduct stress loading tests, and the stress is measured with the five group probes at different center frequencies. The accuracy of ultrasonic testing is verified by X-ray stress analyzer. The stress value of each specific depth is calculated using the stress gradient formula. Accordingly, the ultrasonic characterization of residual stress field is realized. Characterization results show that the stress gradient distribution is consistent with the simulation in ANSYS. The new technology can be widely applied in the detection of the residual stress gradient field caused by mechanical processing, such as welding and shot peening.

Surface wave transducer for ultrasonic nondestructive testing of polymer components

In the point of application to ultrasonic nondestructive testing of surface stress and defect in polymer component, the oblique suxface wave transducer is investigated on its acoustic property and especially the mechanism of acoustic attenuation of acoustic entrant material inside the transducer. A new kind of room temperature vulcanized silicone elastomer as wedge material, in which ultrasound can propagate in very low speed with weak attenuation, is developed through a great deal of trials. The corresponding ultrasonic transducer is also designed for further researches and application to detect surface stress and surface crack in aerospace transparent component.

Simulation and experiments of ultrasonic propagation in nickel-based alloy weldments

In order to obtain good understanding of complicated beam propagation behaviors in nickel-based alloy weldments , ray tracing simulation is established to predict the ultrasonic beam path in a special welded structure of dissimilar steels. Also experimental examinations are carried out to measure the ultrasonic beam paths in the weldment. Then comparisons of the modeling predictions with experimental results are presented to reveal the complicated beam propagation behaviors.

Focusing behaviors of ultrasonic phased arrays in anisotropic and inhomogeneous weldments

It meets some difficulties in the case of ultrasonic phased arrays testing for the nickel-based alloy welded joint, since the ultrasound will propagate with curvilinear paths in this kind anisotropic joint. Thus, it is hard to calculate the phased array time delays properly according to the traditional focusing approach, which is based on the assumption that the sound beam will propagate in straight lines. In order to focus the phased arrays beam in this kind anisotropic joint, we provide a modified focusing approach by combining the ray tracing method and the bisectional searching optimization. With the help of this focusing approach, the curved ray path connecting each element position in phased arrays to the expected focus point in weldments can be determined, so that it can be used to calculate the proper time delay and control the beam focusing in the anisotropic weldment. Furthermore, some experimental examinations are carried out to compare the focusing behaviors between the traditional and the modified focusing approach. It shows that the provided focusing approach is more accurate than the traditional method in the case of inspection on the nickel-based alloy weldments.

Locating flaws in anisotropic and inhomogeneous weldments using ray tracing method

Ultrasonic inspections on nickel-based alloy weldments meets some difficulties due to the curvilinear propagating paths will appear in both anisotropic and inhomogeneons welded joints. Thus, it is difficult to determine the exact location of flaws using the traditional ultrasonic testing method which is based on the assumption that the sound beam will propagate in straight lines. In order to overcome this problem, we provide a new model-based inspection approach to locate the flaws in the nickel-based alloy weldments. Furthermore, some experimental examinations are carried out to compare the locating accuracy between the traditional and the modeled-based approach. It shows that the provided model-based inspection method is more accurate than the traditional method in inspection of the nickel-based alloy weldments.

Definition and Verification of Shape Meter Method

Based on quantitative microscopic examinations of welds and welding rate for different steels (40Cr and T10A) joint, which possess the ultra fine microstructure after high frequency hardening (HFH) and salt bath cyclic quenching (SCQ), the suitable defect grey scale threshold value was determined, and the welding rate of superplastic solid state welding of different steels (40Cr and T10A steel) was systematically inspected and analyzed by means of self made ultrasonic imaging inspection system. The experimental results showed that the superplastic solid state weld of different steels can be inspected more accurately, reliably and quickly by this system, and the results were in good accordance with that of metallographic observation. The welding rate of superplastic welding is in linear relation with tensile strength of joint.