超声红外锁相热像无损检测技术的研究
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摘要
构件表面或内部的微裂纹、分层等界面类缺陷是导致构件破损、失效的主要原因之一。对构件上的缺陷进行高效、准确地检测与评估是监视构件质量、保证设备安全运行的有效手段。超声红外锁相热像检测法是一种以调幅超声波做激励源、采用锁相技术的红外无损检测方法。它能够快速、可靠地检测金属、复合材料等构件的表面及内部接触界面类缺陷,如裂纹等,具有检测效率高、探测深度深等优点。因此,超声红外锁相热像检测法在航空航天、汽车制造、铁路安全等领域具有广阔的应用前景。为发挥超声红外锁相热像检测法的技术优势,本文从检测原理的理论分析、检测参数的选择、红外图像序列的锁相处理、缺陷的定量化评估等方面进行系统地研究。
运用波动理论、接触动力学和传热学等理论对超声红外锁相热像法的缺陷检测过程进行了理论分析;采用有限元法对调幅超声波激励构件于缺陷处衰减生热、在构件表面形成温度场的机-热耦合过程进行了仿真计算,并在频域内对计算得出的温度场进行分析,研究了红外图像序列分析参数与缺陷检测参数对检测结果的影响规律。
研制激励头部件及超声驱动电源,根据检测要求设计激励头部件的气动加载装置和五自由度的运动工作台,实现了对构件任意位置进行调幅超声波激励,完成了超声红外锁相热像检测法激励系统的研制与搭建,给出此系统的性能与技术指标。
为开发该检测法的红外成像软件系统,对热像仪输出数据进行分析与读取,得到红外图像序列;研究红外图像序列锁相处理的算法,提出了基于短时傅立叶变换幅值-相位极值法和基于小波变换增强法,通过所提算法与常用的相关算法、傅立叶变换法的对比性试验研究,指出了其优越性。
采用所研制的检测系统对预制表面微裂纹和内部模拟界面缺陷进行检测试验,校验该检测系统的实用性;通过对Q235材料试件表面微裂纹和内部模拟界面缺陷的系统检测试验,研究了检测参数对检测结果的影响规律,分析了检测构件上存在多个生热点时,热波间的干扰对缺陷检测的影响;通过对不同深度缺陷的检测试验,分析了检测参数对超声红外锁相热像法可探测深度的影响规律。
为了实现对缺陷的定量化检测,将先进的图像处理技术与模糊逻辑理论应用到超声红外锁相热像法的缺陷定量化检测中。根据幅值图与相位图上幅值与相位的分布特点,提出了基于Canny边缘算子的阈值优化法,用以对缺陷几何特征进行识别,进而计算出缺陷尺寸,实现了对缺陷形状的判断与尺寸的计算;采用自适应模糊神经网络,通过试验参数与试验数据建立起模糊推理系统,该系统能够对缺陷深度进行准确判定。从而实现了超声红外锁相热像法对缺陷的准确探测及定量检测。
Cracks and delaminations at surface or interior can induce material and component failure. So this is important especially to monitor quality of structure and performance of equipment, that nondestructive testing and evaluating defects. Ultrasound infrared lock-in thermography (ULT), which uses modulated ultrasonic wave to excite surface of a sample and lock-in method to process thermal image sequence, is active infrared non-destructive testing. It can be used to detect surface’s and interior contacting interface-type defects in metal and composite, as such cracks.It has advantages in detection efficiency and detection depth. So ultrasound infrared lock-in thermography has broad application prospects in aerospace, automotive industry, railroad transportation. In order to develop the detectability, theoretically analyzing detection’s principle, selecting inspection’s parameters, processing infrared image sequence and quantitatively evaluating defects are investigated.
Firstly, detecting defect by Ultrasound infrared lock-in thermography is analyzed theoretically using wave theory, contact dynamics and heat transfer theory. Mechanical-heat coupling, that amplitude modulated ultrasound is injected into the sample to be converted into heat mainly in defects, and the heat travels to the surface by conduction and induces surface’s temperature change, is calculated and simulated. Calculated surface’s temperature is analyzed on frequency domain. Effects of parameters of processing infrared image sequence and detecting defect on detection are researched.
Secondly, ultrasonic horn, included transducer and amplitude transformer, ultrasonic power amplifier are designed and developed. According to requirement of detection simple pneumatic control system and worktable with 5-D are designed and manufactured. Ultrasonic horn can reached the excited position at sample and excite sample effectively using developed ultrasonic exciting system.
Thirdly, collected data by a camera with higher performance is analyzed and read to obtain infrared image sequence. Lock-in algorithms for processing infrared image sequence are investigated, algorithms included amplitude and phase extremum method based on short time Fourier transform with box window and enhancement method based on Wavelet transform are proposed. By compare proposed algorithms with conventional algorithms included correlation algorithm and fast Fourier transform, advantages of proposed algorithms is validated.
Fourthly,some experiments are carried out in a natural ambient environment to detect prefabricated surface’s cracks of metal plats and interior simulated defects using developed inspecting system of ULT. Performance of the inspecting system and detectability of ULT is verified. Effects of inspection’s parameters and interfere between thermal waves produced by some defects or heat sources on detecting defects are researched. Detections defects at different depth are completed to analyze effect of inspection’s parameter on detectable depth of ULT.
Finally, in order to detect defect quantitatively using ULT, advanced image processing technology and fuzzy control theory are introduced into the ultrasound lock-in thermography technology. Based on distribution of amplitude and phase in amplitude image and phase image for detecting defect, optimization method using threshold based on operator‘canny’is proposed to recognize geometric feature of defect and size of defect is calculated. Adaptive Neuro-Fuzzy Inference Stystem is obtained, when modulation frequency and phase as inputs and the defect depth as output are used for training fuzzy-neural network. The system can used for measuring defect depth.
运用波动理论、接触动力学和传热学等理论对超声红外锁相热像法的缺陷检测过程进行了理论分析;采用有限元法对调幅超声波激励构件于缺陷处衰减生热、在构件表面形成温度场的机-热耦合过程进行了仿真计算,并在频域内对计算得出的温度场进行分析,研究了红外图像序列分析参数与缺陷检测参数对检测结果的影响规律。
研制激励头部件及超声驱动电源,根据检测要求设计激励头部件的气动加载装置和五自由度的运动工作台,实现了对构件任意位置进行调幅超声波激励,完成了超声红外锁相热像检测法激励系统的研制与搭建,给出此系统的性能与技术指标。
为开发该检测法的红外成像软件系统,对热像仪输出数据进行分析与读取,得到红外图像序列;研究红外图像序列锁相处理的算法,提出了基于短时傅立叶变换幅值-相位极值法和基于小波变换增强法,通过所提算法与常用的相关算法、傅立叶变换法的对比性试验研究,指出了其优越性。
采用所研制的检测系统对预制表面微裂纹和内部模拟界面缺陷进行检测试验,校验该检测系统的实用性;通过对Q235材料试件表面微裂纹和内部模拟界面缺陷的系统检测试验,研究了检测参数对检测结果的影响规律,分析了检测构件上存在多个生热点时,热波间的干扰对缺陷检测的影响;通过对不同深度缺陷的检测试验,分析了检测参数对超声红外锁相热像法可探测深度的影响规律。
为了实现对缺陷的定量化检测,将先进的图像处理技术与模糊逻辑理论应用到超声红外锁相热像法的缺陷定量化检测中。根据幅值图与相位图上幅值与相位的分布特点,提出了基于Canny边缘算子的阈值优化法,用以对缺陷几何特征进行识别,进而计算出缺陷尺寸,实现了对缺陷形状的判断与尺寸的计算;采用自适应模糊神经网络,通过试验参数与试验数据建立起模糊推理系统,该系统能够对缺陷深度进行准确判定。从而实现了超声红外锁相热像法对缺陷的准确探测及定量检测。
Cracks and delaminations at surface or interior can induce material and component failure. So this is important especially to monitor quality of structure and performance of equipment, that nondestructive testing and evaluating defects. Ultrasound infrared lock-in thermography (ULT), which uses modulated ultrasonic wave to excite surface of a sample and lock-in method to process thermal image sequence, is active infrared non-destructive testing. It can be used to detect surface’s and interior contacting interface-type defects in metal and composite, as such cracks.It has advantages in detection efficiency and detection depth. So ultrasound infrared lock-in thermography has broad application prospects in aerospace, automotive industry, railroad transportation. In order to develop the detectability, theoretically analyzing detection’s principle, selecting inspection’s parameters, processing infrared image sequence and quantitatively evaluating defects are investigated.
Firstly, detecting defect by Ultrasound infrared lock-in thermography is analyzed theoretically using wave theory, contact dynamics and heat transfer theory. Mechanical-heat coupling, that amplitude modulated ultrasound is injected into the sample to be converted into heat mainly in defects, and the heat travels to the surface by conduction and induces surface’s temperature change, is calculated and simulated. Calculated surface’s temperature is analyzed on frequency domain. Effects of parameters of processing infrared image sequence and detecting defect on detection are researched.
Secondly, ultrasonic horn, included transducer and amplitude transformer, ultrasonic power amplifier are designed and developed. According to requirement of detection simple pneumatic control system and worktable with 5-D are designed and manufactured. Ultrasonic horn can reached the excited position at sample and excite sample effectively using developed ultrasonic exciting system.
Thirdly, collected data by a camera with higher performance is analyzed and read to obtain infrared image sequence. Lock-in algorithms for processing infrared image sequence are investigated, algorithms included amplitude and phase extremum method based on short time Fourier transform with box window and enhancement method based on Wavelet transform are proposed. By compare proposed algorithms with conventional algorithms included correlation algorithm and fast Fourier transform, advantages of proposed algorithms is validated.
Fourthly,some experiments are carried out in a natural ambient environment to detect prefabricated surface’s cracks of metal plats and interior simulated defects using developed inspecting system of ULT. Performance of the inspecting system and detectability of ULT is verified. Effects of inspection’s parameters and interfere between thermal waves produced by some defects or heat sources on detecting defects are researched. Detections defects at different depth are completed to analyze effect of inspection’s parameter on detectable depth of ULT.
Finally, in order to detect defect quantitatively using ULT, advanced image processing technology and fuzzy control theory are introduced into the ultrasound lock-in thermography technology. Based on distribution of amplitude and phase in amplitude image and phase image for detecting defect, optimization method using threshold based on operator‘canny’is proposed to recognize geometric feature of defect and size of defect is calculated. Adaptive Neuro-Fuzzy Inference Stystem is obtained, when modulation frequency and phase as inputs and the defect depth as output are used for training fuzzy-neural network. The system can used for measuring defect depth.
引文
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