Experimental Investigation into Internal Stress Detection of Aluminum Alloy by Phased Array Longitudinal-Wave Ultrasonic Testing

doi:10.12141/j.issn.1000-565X.220322

Abstract

Abstract:

Aluminum alloy materials are widely used in the fields such as aerospace, automotive manufacturing and shipbuilding. However, the load stress and residual stress during the manufacturing and equipment process directly affect the mechanical properties and fatigue life of aluminum alloy components. In this paper, for the purpose of evaluating the internal stress of aluminum alloy and on the basis of acoustic elasticity principle, the phased array longitudinal-wave detection technology was studied, and an internal stress detection method of aluminum alloy was set up based on the time difference during longitudinal wave propagation. Then, an experimental system for phased array longitudinal-wave ultrasonic stress detection was set up, and calibration experiments were carried out to reveal the linear relationship between the internal stress of aluminum alloy and the time difference during longitudinal wave propagation, with the correlation equations being also formulated. The results show that, within the tensile stress range of 0~286 MPa, the absolute calibration errors of 5 mm and 3 mm aluminum alloy plates are respectively less than 2.85 MPa and 10.82 MPa, the corresponding relative errors are respectively not more than 2.36% and 13.93%, and the maximum relative errors of both specifications occur within the stress range of less than 28.58 MPa, meaning that it is necessary to improve the resolution and accuracy of ultrasonic measurement in small stress detection. The phased array longitudinal-wave system was then used to detect the stress 5 mm aluminum alloy plate specimens, and an average stress error of (1.174±4.567) MPa, an absolute error of less than 9.42 MPa as well as an estimated initial residual stress of 3.329 MPa was obtained. The experimental results show that the proposed phased array longitudinal-wave ultrasonic method is effective in detecting the average stress of 5 mm aluminum alloy plate; that the method based on the time difference during longitudinal wave propagation can be used to detect the stress type, stress size and residual stress; and that the proposed method is effective in improving the detection accuracy and efficiency of the internal stress detection of aluminum alloy.

Key words: aluminum alloy, phased array longitudinal-wave detection, internal stress, acoustic time difference

CLC Number:

TB559

ZOU Dapeng, ZENG Xinfa, REN Bin, et al.. Experimental Investigation into Internal Stress Detection of Aluminum Alloy by Phased Array Longitudinal-Wave Ultrasonic Testing[J]. Journal of South China University of Technology(Natural Science Edition), 2023, 51(7): 34-41.

Figures/Tables 10

Fig.1

Fig.2

Fig.3

Fig.4

Table 1

Fig.5

Fig.6

Fig.7

Table 2

Table 3

References 17

1	靳聪，史亦韦，卢超，等．铝合金预拉伸板残余应力的超声测量［J］．无损检测，2015，37（11）：68-72．
	JIN Cong， SHI Yi-wei， LU Chao，et al ．Ultrasonic measurement of residual stress in aluminum alloy pre-stretched aluminum alloy plate by using ultrasonic and its verification［J］．Nondestructive Testing，2015，37（11）：68-72．
2	路浩，邢立伟，邢敬伟．超声波法焊接残余应力测量技术［J］．焊管，2019，42（8）：50-55．
	LU Hao， XING Li-wei， XING Jing-wei ．Ultrasonic method measurement of welding residual stress［J］．Welded Pipe and Tube，2019，42（8）：50-55．
3	郑雪鹏，吴伟．GH4169合金环锻件残余应力超声检测［J］．科学技术与工程，2020，20（4）：1349-1354．
	ZHENG Xue-peng， WU Wei ．Ultrasonic testing of residual stress in GH4169 alloy ring forgings［J］．Science Technology and Engineering，2020，20（4）：1349-1354．
4	徐浪，潘勤学，宿亮，等．焊接残余应力超声无损检测技术［J］．计测技术，2012，32（6）：29-32，53．
	XU Lang， PAN Qinxue， SU Liang，et al ．Compensation technology for nondestructive testing of welded residual stress by ultrasonic［J］．Metrology & Measurement Technology，2012，32（6）：29-32，53．
5	刘海波，张祥，刘彦坤，等．电磁超声单向应力横纵波联合测量方法研究［J］．机械设计与制造，2021（9）：241-246．
	LIU Hai-bo， ZHANG Xiang， LIU Yan-kun，et al ．Study on combined measurement method of electromagnetic ultrasonic unidirectional stress transverse and longitudinal waves［J］．Mechanical Design and Manufacturing，2021（9）：241-246．
6	郑凯，武兴，李俊燕，等．高温下金属材料厚度的激光超声检测研究［J］．机械工程学报，2021，57（10）：21-27．
	ZHENG Kai， WU Xing， LI Junyan，et al ．Laser ultrasonic evaluation of metallic material thickness at high temperature［J］．Journal of Mechanical Engineering，2021，57（10）：21-27．
7	刘永强，杨世锡，甘春标．一种基于激光超声的薄层金属材料厚度检测方法研究［J］．振动与冲击，2018，37（12）：147-152．
	LIU Yongqiang， YANG Shixi， GAN Chunbiao ．Thickness measurement for thin metal material with the use of laser generated ultrasound［J］．Journal of Vibration and Shock，2018，37（12）：147-152．
8	REINA G， FOGLIA M ．On the mobility of all-terrain rovers［J］．Industrial Robot：An International Journal，2013，40（2）：123-131．
9	郑康琳，张劲泉，王陶，等．双横波声速法检测单向受压混凝土构件永存应力［J］．应用声学，2021，40（3）：367-375．
	ZHENG Kanglin， ZHANG Jinquan， WANG Tao，et al ．Study on the method of double shear wave velocity to detect the permanent stress of concrete members under uniaxial compression［J］．Journal of Applied Acoustics，2021，40（3）：367-375．
10	宋文涛，徐春广．超声法的残余应力场无损检测与表征［J］．机械设计与制造，2015（10）：9-12，17．
	SONG Wen-tao， XU Chun-guang ．Residual stress field nondestructive testing and characterization using method of ultrasonic［J］．Mechanical Design and Manufacturing，2015（10）：9-12，17．
11	XU Y， YANG Z， ZHOU H，et al ．Application of acoustoelasticity in studying compressive stress state in Polymer bonded explosive［C］∥ Proceedings of 2015 IEEE Far East NDT New Technology ＆ Application Forum （FENDT）．Zhuhai：IEEE，2015：109-113．
12	何伟明，郝艳捧，邹舟诣奥，等．GIS盆式绝缘子应力超声检测技术应用与展望［J］．广东电力，2021，34（1）：13-20．
	HE Weiming， HAO Yanpeng， ZOU Zhouyi’ao，et al ．Application and prospect of ultrasonic testing technology for stress in GIS basin insulators［J］ Guangdong Electric Power，2021，34（1）：13-20．
13	刘彦坤，刘海波，李亚鹏，等．基于电磁超声瑞利波的平面应力测量方法［J］．无损检测，2020，42（9）：33-38．
	LIU Yankun， LIU Haibo， LI Yapeng，et al ．Plane stress measurement method based on the electromagnetic ultrasonic Rayleigh wave［J］．Nondestructive Testing，2020，42（9）：33-38．
14	胡恒山．拉梅常数的力学意义与剪切模量出现于纵波速度公式的原因［J］．地球物理学进展，2018，33（1）：219-222．
	HU Heng-shan ．Note on the Lamé constant and the reason for the presence of the shear modulus in the compressional wave speed formula［J］．Progress in Geophysics，2018，33（1）：219-222．
15	徐春广，李焕新，王俊峰，等．残余应力的超声横纵波检测方法［J］．声学学报，2017，42（2）：195-204．
	XU Chunguang， LI Huanxin， WANG Junfeng，et al ．Ultrasonic shear and longitudinal wave testing method for residual stress［J］．Acta Acustica，2017，42（2）：195-204．
16	杨兴，冯强，孙赞朋，等．6061铝合金在多向锻造过程中显微组织与拉伸性能的演变［J］．机械工程材料，2018，42（7）：73-77．
	YANG Xing， FENG Qiang， SUN Zanpeng，et al ．Evolution of microstructure and tensile properties of 6061 aluminum alloy during multi-directional forging［J］．Materials for Mechanical Engineering，2018，42（7）：73-77．
17	靳世久，杨晓霞，陈世利，等．超声相控阵检测技术的发展及应用［J］．电子测量与仪器学报，2014，28（9）：925-934．
	JIN Shijiu， YANG Xiaoxia， CHEN Shili，et al ．Development and application of ultrasonic phased array testing technology［J］．Journal of Electronic Measurement and Instrumentation，2014，28（9）：925-934．

设备	特性参数	取值
电子万能拉伸试验机	最大试验力/kN	100
	精度等级	0.5级
	有效测试范围	0.5% FS
超声检测板卡	采样率/MHz	100
	最大增益/dB	40
	延迟/μs	0~20
相控阵纵波换能器	中心频率/MHz	20
	阵元数	64
	阵元中心距/mm	0.6

拉伸应力/MPa	5 mm厚板标定误差		3 mm厚板标定误差
拉伸应力/MPa	绝对误差/MPa	相对误差/%	绝对误差/MPa	相对误差/%
0.000	2.036		10.817
28.571	-0.675	-2.36	-3.980	-13.93
57.143	0.492	0.86	-1.942	-3.40
85.714	-0.926	-1.08	-1.433	-1.67
114.286	-1.052	-0.92	-3.987	-3.49
142.857	0.116	0.08	-3.478	-2.43
171.428	-1.302	-0.76	3.153	1.84
200.000	1.158	0.58	-5.523	-2.76
228.571	-2.846	-1.25	4.168	1.82
257.143	2.200	0.86	-1.446	-0.56
285.714	0.782	0.27	3.654	1.28
最大值	2.200	0.86	10.817	1.84
最小值	-2.846	-2.36	-5.523	-13.93
平均值	-0.002	-0.34	0.000 4	-2.12

拉伸应力/MPa	与标准样比较的声时差/ns	基于式（13）的应力计算结果
拉伸应力/MPa	与标准样比较的声时差/ns	应力/MPa	绝对误差/MPa	相对误差/%
0.000	-0.1	3.329	3.329
28.571	-1.6	22.724	-5.847	-20.46
57.143	-4.5	60.221	3.078	5.39
85.714	-7.2	95.132	9.418	10.99
114.286	-8.8	115.820	1.534	1.34
142.857	-11.4	149.438	6.581	4.61
171.428	-13.2	172.712	1.284	0.75
200.000	-15.0	195.986	-4.014	-2.01
228.571	-17.4	227.018	-1.553	-0.68
257.143	-19.9	259.343	2.200	0.86
285.714	-21.7	282.617	-3.097	-1.08
最大值	-0.1	282.617	9.418	10.99
最小值	-21.7	3.329	-5.847	-20.46
平均值	-10.982	144.031	1.174	-0.03

[1]	LUO Zhen, SU Jie, WANG Xiaohua, et al. Analysis of the Progress of Laser-Arc Hybrid Welding of Aluminum Alloys [J]. Journal of South China University of Technology(Natural Science Edition), 2024, 52(3): 57-74.
[2]	ZHANG Junhao, CHENG Xiuquan, XIA Qinxiang, et al. Study on Residual Stress Control of Damaged Aircraft Component Based on Non-uniform Overlap Ratio Laser Shock Peening [J]. Journal of South China University of Technology(Natural Science Edition), 2022, 50(3): 73-79.
[3]	XU Daofen, CHEN Kanghua, XING Jun, et al. Microstructure and Corrosion Behavior of 2219 Aluminum Alloy Forging's Joint by TIG Welding [J]. Journal of South China University of Technology (Natural Science Edition), 2020, 48(3): 116-125.
[4]	JIAO Huibin CHEN Kanghua YANG Zhen CHEN Songyi WANG Huiping MA Yunlong. Influence of Si and heat treatment on microstructures and corrosion behavior of Al–Zn–Mg–Cu alloys [J]. Journal of South China University of Technology (Natural Science Edition), 2018, 46(11): 68-75.
[5]	ZHOU Zhao-yao CAO Xiao-bing QIN Jie XIAO Zhi-yu. Effects of Mechanical Vibration on Microstructure and Properties of A356 Aluminum Alloy During Squeeze Casting [J]. Journal of South China University of Technology (Natural Science Edition), 2017, 45(2): 46-51.
[6]	LI Dong-feng ZHANG Xin-ming YIN Bang-wen LIU Sheng-dan LEI Yue DENG Yun-lai . Effect of Rolling Deformation on Quench Sensitivity to Exfoliation Corrosion of Thick Al-5Zn-3Mg-1Cu-0. 12Zr Alloy Plate [J]. Journal of South China University of Technology (Natural Science Edition), 2016, 44(6): 70-76.
[7]	Zhu Qiang Xue Jia-xiang Xu Min Dong Chang-wen Wang Lei-lei Heng Gong-chun. A Probe into Backward Median Current Waveform Welding of Aluminum Alloys [J]. Journal of South China University of Technology (Natural Science Edition), 2015, 43(3): 15-20,28.
[8]	Li Dong-feng Zhang Xin-ming Liu Sheng-dan Yin Bang-wen Lei Yue. Effect of Rolling Deformation on Microstructure and Mechanical of Al-5Zn-3Mg-1Cu Alloy [J]. Journal of South China University of Technology (Natural Science Edition), 2015, 43(11): 75-80.
[9]	Jiang Ri- peng Li Xiao- qian Ju Zeng- ye Zhang Min. Simulation and Experimental Investigation of Multi- Field Coupling for Semi- Continuous Casting of Aluminum Alloy with Ultrasonic Treatment [J]. Journal of South China University of Technology (Natural Science Edition), 2014, 42(4): 85-90.
[10]	Zuo Xi Li Wen-fang Mu Song-lin. Influence of Additives on Morphology and Performance of Colored Ti-Zr Conversion Coating at Room Temperature [J]. Journal of South China University of Technology (Natural Science Edition), 2014, 42(10): 7-13.
[11]	Zhan Li-hua Li Yan-guang Huang Ming-hui Zhang Meng. Constitutive Equation Describing Creep Ageing of 2124 Aluminum Alloy [J]. Journal of South China University of Technology(Natural Science Edition), 2012, 40(4): 107-111.
[12]	Yi Ai-hua Li Wen-fang Du Jun Mu Song-lin Liu Ning-hua. Formation Mechanism and Properties of Colored Ti /Zr-Based Conversion Coating on Aluminum Alloy [J]. Journal of South China University of Technology(Natural Science Edition), 2012, 40(1): 101-106,124.
[13]	Wu Yun-xin Gong Hai Liao Kai. Evaluation Model of Residual Stress Field of Pre-Stretched Aluminum Alloy Plate [J]. Journal of South China University of Technology (Natural Science Edition), 2011, 39(1): 90-94.
[14]	Chen Wei-ping He Zeng-xian Huang Dan Luo Jie. Dynamic Response of Laminated SiC/Al Composites Subjected to Ballistic Impact [J]. Journal of South China University of Technology (Natural Science Edition), 2010, 38(9): 90-95,101.
[15]	Du Jun Chen Dong-chu Li Wen-fang Zhang Yong-jun Peng Ji-hua. Microstructure and Corrosion Resistance of Ceramic Coatings Formed on Aluminum Alloy by Micro-Arc Oxidation [J]. Journal of South China University of Technology (Natural Science Edition), 2007, 35(3): 6-10.