A Novel On-Site-Real-Time Method for Identifying Characteristic Parameters Using Ultrasonic Echo Groups and Neural Network

On-site and real-time non-destructive measurement of elastic constants for materials of a component in a in-service structure is a challenge due to structural complexities,such as ambiguous boundary,variable thickness,nonuniform material properties.This work develops for the first time a method that uses ultrasound echo groups and artificial neural network(ANN)for reliable on-site real-time identification of material parameters.The use of echo groups allows the use of lower frequencies,and hence more accommodative to structural complexity.To train the ANNs,a numerical model is established that is capable of computing the waveform of ultrasonic echo groups for any given set of material properties of a given structure.The waveform of an ultrasonic echo groups at an interest location on the surface the structure with material parameters varying in a predefined range are then computed using the numerical model.This results in a set of dataset for training the ANN model.Once the ANN is trained,the material parameters can be identified simultaneously using the actual measured echo waveform as input to the ANN.Intensive tests have been conducted both numerically and experimentally to evaluate the effectiveness and accuracy of the currently proposed method.The results show that the maximum identification error of numerical example is less than 2%,and the maximum identification error of experimental test is less than 7%.Compared with currently prevailing methods and equipment,the proposefy the density and thickness,in addition to the elastic constants.Moreover,the reliability and accuracy of inverse prediction is significantly improved.Thus,it has broad applications and enables real-time field measurements,which has not been fulfilled by any other available methods or equipment.

Linear and Nonlinear Ultrasonic Detections of Impact Damage in Composite Laminate

The appearance and accumulation of internal impact damage seriously influence overall performance of carbon fiber reinforced plastic(CFRP).Thus,this study evaluates the change in impact damage number by using linear and nonlinear ultrasonic Lamb wave detection methods,and compares these two detection results.An ultrasonic wave simulation model for composite structure with impact damage is established using the finite element method,and the interaction between impact damage and the ultrasonic wave is simulated.Simulation results demonstrate that the ultrasonic amplitude linearly decreases,and the relative nonlinear parameter linearly increases in proportion to the impact number,respectively.The linear-fitting slope of nonlinear parameter is 0.38 per impact number at an input frequency of 1.0 MHz.It is far higher than that of the linear ultrasonic amplitude,which is only-0.12.However,with the increase of impact damage,the linear growth of nonlinear parameters mainly depends on the decrease in ultrasonic amplitude rather than the accumulation of second harmonic amplitude.In the linear ultrasonic amplitude detection,the linear fitting slope at 1.1 MHz is-0.14,which is lower than those at 0.9 MHz and 1.0 MHz.Meanwhile,in the nonlinear ultrasonic parameter detection,the linear fitting slope at 1.1 MHz is 0.92,which is higher than those at 0.9 MHz and 1.0 MHz.The results show that higher frequencies lead to greater attenuation of ultrasonic amplitude and a larger increase in nonlinear parameters,which can enhance the sensitivity of both linear and nonlinear ultrasonic detections.The accuracy of simulation results is demonstrated through the low-velocity impact and ultrasonic experiments.The results show that compared with nonlinear ultrasonic technology,the linear ultrasonic technology is more suitable for impact damage assessment of carbon fiber reinforced plastic because of its simpler detection process and higher sensitivity.

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.

Simplified Matrix Focusing Imaging Algorithm for Ultrasonic Nondestructive Testing

Full matrix focusing method of ultrasonic phased array has been proved with advantages of good signal-to-noise ratio and imaging resolution in the field of Ultrasonic NDT.However,it is still suffering from the time-consuming data acquisition and processing.In order to solve the problem,two simplified matrix focusing methods are provided in the paper.One provided method is a triangular matrix focusing algorithm based on the principle of reciprocity for the multi-channel ultrasonic system.The other provided method is a trapezoidal matrix focusing algorithm based on the energy weight of the different channel to the focusing area.Time of data acquisition and computational is decreased with the provided simplified matrix focusing methods.In order to prove the validity of two provided algorithms,both side-drilled holes and oblique cracks are used for imaging experiments.The experimental results show that the imaging quality of the triangular matrix focusing algorithm is basically consistent to that of the full matrix focusing method.And imaging quality of the trapezoidal matrix focusing algorithm is slightly reduced with the amount of multi-channel data decreasing.Both data acquisition and computational efficiency using the triangular matrix focusing algorithm and the trapezoidal matrix focusing algorithm have been improved significantly compared with original full matrix focusing method.

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.

Monitoring of polymeric membrane fouling in hollow fiber module using ultrasonic nondestructive testing

This study describes the development of novel protocols extending the real-time ultrasonic reflectometry(UTDR) for the detection of membrane fouling in hollow fiber module during ultrafiltration(UF) of oily water treatment. A specially designed acoustic sensor with a frequency of 2.5 MHz was used. The hollow fiber membranes used were polysulphone(PSf) UF membranes with MWCO 40 kDa. The wastewaters with three different oily concentrations of 100, 500 and 1 000 mg/L were investigated. Diesel oil was utilized as the primary foulant. The results show that the permeate flux declines with operation time and its value becomes lower with the increase of the oily concentration in wastewater. It is found that ultrasonic measurement can detect the fouling and cleaning processes. A new signal analysis protocol-ultrasonic reflected energy was developed. Ultrasonic reflected energy obtained indicates the deposition of oily layer as a function of operation time and its removal after cleaning. The overall flux decline is reasonably correlated with the changes in ultrasonic reflected energy. This research provides the evidence that the ultrasonic reflectometry technique is capable of monitoring membrane fouling and cleaning in hollow fiber modules.

Determination of discontinuities in marble blocks via a nondestructive ultrasonic technique

Miners working in the marble industry have always been interested in identifying structural weaknesses in marble blocks before they are transported to marble processing plants. To achieve this difficult task, several simple methods have been developed among miners but observation-based methods do not consistently provide satisfactory results. A nondestructive method developed for testing concrete could be used for this purpose. In this study, this simple method based on differences in ultrasonic wave propagation in different materials was presented, and the test results performed both in the laboratory and a marble quarry were discussed.

Application of ultrasonic CT method in nondestructive detection of interior defects in large scale concrete structural member of bridge

The ultrasonic computed tomography （USCT） method is derived from the basic principles of X-ray section scanning. This method records the arriving times of ultrasonic wave between the probes and the sources to ealculate the elastic wave velocity values in the section using the arrival times. Through analyzed the distribution Of elastic wave velocity in aim area, the information of the strength and the homogeneity of the investigated zone could be got indirectly. The authors introduced the operational principle of USCT and a practical case of using this method to detect the interior defects in large scale concrete structural member. Compared with other exploration methods, this method is more efficient and accurate.

GFRP损伤X射线和超声无损检测的融合方法

针对玻璃纤维复合材料(glass fiber reinforced plastic,GFRP)无损检测中X射线和超声技术检测效果不佳的问题,利用X射线图像的高分辨率和超声图像的高对比度特点进行互补成像融合,通过整合X射线图像的缺陷边缘细节信息和超声图像的高对比度大致轮廓信息,形成新图像以提高缺陷显示效果。将基于十字扇形滤波器的频域算法用于去除X射线图像中的横、竖条纹噪声,采用形态学滤波算法去除超声图像中的椒盐噪声,并提出了基于区域分割和静态小波变换的图像融合算法,用以融合X射线和超声图像特征。测试结果表明,相较于处理前的X射线和超声图像,融合后的图像标准差SD值平均提高154.1%,熵H值平均降低92.2%,缺陷检测图像对比度有所提高且边缘细节清晰。算法有效除去了两种图像中的条纹噪声和椒盐噪声,能改善X射线图像对比度低、超声图像分辨率差的不足,为复合材料缺陷检测提供了新思路。

钦州地区超声回弹综合法测强曲线研究

采用了钦州地区广泛使用的砂石材料、水泥和水胶比等,预制了4种不同强度等级(C25、C30、C35、C40)的混凝土试块,标准养护28 d后,对试块开展回弹、超声和抗压试验,并对试验结果进行分析。由分析结果可知,全国统一测区超声回弹综合法碎石骨料曲线式在钦州地区使用时误差较大。根据《超声回弹综合法检测混凝土强度技术规程》,采用计算模型——多项式函数f_(cu)^(n)=aV+bR+c与幂函数f_(cu)^(n)=aV^(b)R^(c),对综合法测强回归曲线进行拟合,初步建立钦州地区混凝土抗压强度的测强回归曲线,对实际工程有一定的参考意义。

铝合金FSW接头未焊透及弱结合缺陷的检测分析

针对运载火箭贮箱某型号铝合金产品搅拌摩擦焊焊缝开展检测工艺研究,采用着色渗透检测、相控阵超声检测、射线检测等方法进行对比检测试验,对发现存在超标缺陷的部位通过切割取样进行显微组织分析,最后对缺陷类型及成因进行了分析。试验结果表明,相控阵超声检测技术能够有效发现铝合金搅拌摩擦焊焊缝根部未焊透和弱结合缺陷,可以准确定位缺陷并测量出缺陷的深度和长度。该方法弥补了其他无损检测方法的不足,可作为类似结构产品检测的可靠手段。

基于SoS核函数调制的超声图像伪影剔除方法

针对超声图像伪影严重的问题,提出了一种基于SoS核函数调制的超声图像伪影剔除方法,该方法能同时剔除由等声程线扩散、传感器拖尾现象和检测噪声产生的伪影.该方法利用SoS核函数对测得的超声回波信号进行调制,对调制后的信号等间隔低速率采样来获取离散序列值,再对离散序列进行离散傅里叶变换得到傅里叶系数序列,利用谱估计算法对回波信号参数进行估计,获取检测信号的特征参数,最后对回波信号进行自适应重构,计算声场得到超声图像.试验结果表明,聚焦和直探头对槽和通孔类缺陷的去伪影效果明显,与传统B扫图像相比,峰值信噪比分别达到了24.306、23.213、15.074和16.444 dB,结构相似度分别为0.931、0.932、0.746和0.773,表明该算法有效提高了缺陷图像的质量.

改进FFT算法在频域全聚焦超声成像中研究

针对钢块中孔洞缺陷的超声成像检测,目前普遍采用时域超声成像算法。该方法中的延时叠加过程需要进行重复、繁琐的迭代运算,无法满足高质量实时成像的需求,频域超声成像算法具有更高的成像分辨率和更快的成像速度。提出了一种针对任意非0值输入的基2-FFT输入分级截断算法,将该算法应用在频域FMC-PSM算法成像中,得到改进的FMC-PSM算法,用于钢块中孔洞缺陷检测超声成像。实验结果证明,相较于标准FMC-PSM算法,改进的频域FMC-PSM算法能够在呈现更高质量图像的同时将成像速度提高了15%,有望解决超声成像中成像质量和成像效率难以兼顾的问题。

双探头梯形矩阵聚焦成像方法

R角是曲面变壁厚结构,传统超声检测方法难以对其轮廓和缺陷进行完整成像显示。针对此问题,首先,提出双探头全聚焦成像方法,实现R角区域的完整成像显示;其次,为了改善双探头全聚焦成像效率较低的问题,采用梯形矩阵聚焦成像算法,实现高效实时成像;最后,对典型变壁厚R角试件开展聚焦成像实验,验证了双探头梯形矩阵聚焦成像方法的有效性。结果表明,与传统单探头全聚焦成像方法相比,双探头梯形矩阵聚焦成像方法能够显示R角结构的完整内轮廓,并清楚显示和定位内部缺陷。

基于“教学做一体化”模式的高职超声波检测课程教学改革

以长沙航空职业技术学院理化测试与质检技术专业《超声波检测》课程教学改革为例,详细介绍课程改革的背景、具体措施及改革成效。立足于现代职业教育对“岗、课、赛、证”的新要求,从职业院校学生特点、课程教学内容重构、教学策略(过程)设计、教学条件建设、提升课堂教学质量的具体手段、日常管理及校企合作等方面入手,深入分析了超声检测课程教学做一体化实施的全过程。

固井水泥环内部缺陷超声波检测仿真研究

固井水泥环内部的各种缺陷会导致层间窜流、井口带压等事故。无损检测技术作为一种非破坏性的检测方法,可以对固井水泥环内部的缺陷进行检测。基于超声波在连续介质中的传播规律,采用COMSOL仿真软件模拟压电效应以及超声波在水泥环中的传播状态和反射规律,研究水泥环缺陷反射信号的相关特性。研究结果表明:选择1.0 MHz 5周期Hanning窗调制的超声正弦波作为激励信号,超声探头可以在50μs内接收到水泥环缺陷的反射信号;不同类型的缺陷中,矩形缺陷的检测效果最佳;当缺陷主方向与超声波入射方向垂直时,检测效果最佳。研究结果验证了超声波无损检测技术可以快速准确地确定固井水泥环内部缺陷的类型和位置,同时调整超声波入射角度有助于提升检测效果,可为超声波在水泥环内部缺陷检测中的应用提供一定的指导意义。

脉冲电磁式EMAT-涡流检测复合系统的研究

常规电磁超声换能器(EMAT)中永磁体难以应用于实际情况、产生的信号幅值较小,根据电磁超声检测和涡流检测在检测范围内的互补性,本文设计了脉冲电磁式EMAT—涡流检测复合传感器结构,采用多物理场耦合技术验证了复合检测方法的可行性,并讨论了影响传感器检测灵敏度的关键参数。结果表明:该复合传感器能够激发用于检测表面缺陷的涡流信号和检测深层缺陷的超声波信号,并且对不同宽度和深度缺陷具有良好的灵敏度;此外,对励磁线圈与涡流线圈进行参数优化设计,为电磁超声和涡流的复合检测应用提供思路。

无损检测方法在大尺寸堆石混凝土试验仓强度检测中的应用研究

【目的】混凝土常规力学性能试验方法并不适用于堆石混凝土,而缩尺试验能否应用于堆石混凝土仍有待验证。目前,无损检测方法已广泛应用于混凝土强度测定,但其在大尺寸堆石混凝土中的适用性还有待研究。【方法】为此,将大尺寸堆石混凝土试验仓作为研究对象,采用回弹法和超声回弹综合法对不同龄期、不同测距下的试验仓进行现场无损检测,并计算其抗压强度。【结果】结果显示:使用回弹法得到的强度推定值相对集中,试验仓90 d龄期的整体强度虽达到设计强度,但与其他研究的试验结果相比较小;将90 d龄期的检测结果代入全国统一测区混凝土抗压强度换算公式后,计算的强度变异系数最高达到48.22%,离散程度大;测距超过2 400 mm后,堆石混凝土C15试验仓3个龄期的波形平缓且波速分布范围较大,波速范围为994~4 391 m/s;C15试验仓在180 d时3 820 m/s以上的声速占比较大,为65.12%;使用超声回弹综合法得到的强度结果在60~180 d龄期内随龄期的增长而逐渐增大。【结论】结果表明:回弹法并不适用于堆石混凝土的强度推定;全国统一测区混凝土抗压强度换算公式并不适用于堆石混凝土,超声回弹综合法需要建立专用的堆石类堆石混凝土抗压强度换算公式,且当测距超过2 400 mm时不建议使用超声回弹综合法;可为无损检测方法在堆石混凝土中的应用提供参考,以避免不必要的检测。

在役管道应力无损检测方法试验研究

油气管道在长期运行时,会在各种地质灾害和其他异常荷载的影响下产生变形,进而引发管道安全事故。对在役管道进行定期的应力检测是一种行之有效的评估管道安全的手段。为探究更适用于在役管道的应力检测方法,选用主要材料为X70和X80钢板的在役管道进行拉伸试验,利用超声波法、磁各向异性法和矫顽力法检测不同荷载下钢板的应力,并对应力测试结果进行分析。在8组单向拉伸实验中,超声波法有5组试验数据拟合优度在0.99以上;在双向拉伸试验中,超声波法的拟合效果线性度最好,矫顽力法和磁各向异性法的数据拟合效果较为离散。随着提离值的增大,轴向矫顽力与环向矫顽力都呈下降趋势,磁各向异性法的检测信号也随着提离值的增大呈现降低趋势;超声检测的结果随着温度的升高而呈线性增加,矫顽力的测量结果随温度的升高而呈整体的下降趋势,磁各向异性技术的测量结果随温度的升高呈现先升高后降低的趋势。通过对3种方法试验结果对比分析,超声波法对在役管道应力检测精确度最高,为今后在役油气管道选择更高效的无损检测方法指明方向。

基于激光超声的铝合金组织性能无损检测研究

目前对铝合金析出相和力学性能的检测主要采用扫描电镜(SEM)、透射电镜(TEM)、万能试验机等方式,费时费力且属于破坏性检测。采用激光超声无损检测技术对Al-Cu-Mg铝合金进行检测,通过变分模态分解法(Variational Modal Decomposition,VMD)对时域下的激光超声信号进行降噪处理,得到激光超声信号的衰减系数和声速等特征值,同时采用扫描电镜、电子背散射衍射(EBSD)、静拉伸实验获得Al-Cu-Mg铝合金的析出相和力学性能,将激光超声信号特征值与Al-Cu-Mg铝合金的析出相和力学性能进行耦合。结果发现:激光超声信号特征值与Al-Cu-Mg铝合金的析出相、晶粒尺寸、屈服强度以及显微硬度有较好的相关性。这为Al-Cu-Mg铝合金的微观组织和力学性能快速无损检测提供了一种新方法。