常用金属材料拉伸及疲劳裂纹声信号传播特性
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摘要
随着声发射检测设备性能的不断提高和分析技术的不断完善,声发射检测技术已应用到石油、石化、电力、航空、航天、冶金、铁路、交通、煤炭、建筑、机械制造与加工等领域,实现了对设备的定期检测或在线监测。通过对检测或监测中发现的声发射源进行评价,完成对设备完整性的评价,确保设备的安全运行。
在载荷作用下,材料发生损伤时便会有声发射信号产生,分析获取声发射源的声信号特性及其变化规律一直是声发射检测发展过程中关注和研究的问题。国内外开展了许多试验研究工作,取得一些研究成果,解决了声发射检测中的许多技术难题,促进了声发射检测技术的推广和应用。在诸多研究中,存在着对波导杆传播声信号特性、高温及低温下材料声信号分布特征、焊接缺陷声信号参数特性、疲劳裂纹声信号识别及提取等问题的研究不足,需要进一步开展研究工作,以解决声发射技术应用中的难题。目前我国80%以上的特种设备用材为16MnR、Q345的中厚钢板。为此,选用16MnR、Q345材料进行声发射信号研究工作,以解决声发射检测中的技术难题。本文的主要研究内容和结论概括如下：
1.波导杆声发射信号的传播特性
选用材料为20号钢,直径分别为4、6、8、10、12、14、16mm,长度为3.2m的圆钢在不同长度下的模拟断铅声信号试验研究,系统地研究了在波导杆的圆心断面、圆周表面进行模拟断铅信号,获得了波导杆尺寸对声信号的特征参数、时域波形、频谱特性的影响及变化规律,提出了声发射检测中波导杆结构尺寸的选用方法；通过焊接构件的波导杆对比试验,提出的声信号在波导杆的传播方式以信号在波导杆表面传播为主、端面传播为辅的观点,并在研究16MnR钢材料低温、高温环境下声信号分布规律的试验中,依据波导杆的选用方法采用了直径为6.4mm、长度在1.5m以内的圆钢作为低温、高温试验中的波导杆,接收到的声信号纵波分离清晰、幅值衰减较小,顺利完成了材料的试验工作。
2.16MnR钢材在低温、高温环境下的声信号变化特征
研究了16MnR钢材在-70-670。C温度范围内的不同温度下的拉伸试验,全面分析了试样拉伸过程中声信号参数随温度的变化规律,揭示了16MnR材料在一定的高温环境下呈现多次的屈服变化行为,提出了通过声发射信号变化趋势的研究,可以判断出材料的变形行为、受载荷状况及温度状况,弥补了声发射检测技术在材料低温、高温性能试验中的应用；在对声信号不同参数相关性的研究中,首次把试样拉伸过程的弹性阶段、屈服阶段、强化阶段的相关性参数分开研究,得到了三个阶段的K值虽随温度呈现不同的变化趋势,但整体表现为屈服阶段相关性高,弹性阶段相关性次之,强化阶段相关性低的变化趋势；声信号的累积计数、累积能量在表征材料不同温度下的损伤情况时表现出了很好的一致性,可以很好地表征材料在温度下的损伤。
3.16MnR钢材焊接缺陷的声信号特征
分析研究了不同焊接缺陷在拉伸过程中的声信号分布特点,荻得了不同焊接缺陷的声信号分布规律：采用幅值、计数及能量持续时间关联分析,可以判断出试样内部缺陷屈服及开裂扩展的信号特点；通过分析试验中声信号分布特征,可以判断出材料所受的载荷状态,指导声发射实际检测中的加载工作，避免盲目加载造成的突发事故,确保声发射检测构件处于安全状态。
采用断裂力学知识计算了拉伸试样中未焊透缺陷断裂时的应力值,对比验证了未焊透缺陷试样拉伸过程中开裂时产生丰富的声信号时的应力值高于应用断裂力学计算应力值,二者存在着误差,实现了声发射检测技术与断裂力学的有机结合,为声发射检测中声信号的评定提供断裂力学支持,对含缺陷构件的声发射检测有一定的指导意义。
4.Q345全尺寸大桥索塔锚固结构模型疲劳裂纹声信号特征研究
采用全尺寸大桥索塔锚固结构模型进行疲劳试验,对锚固结构左侧的疲劳裂纹进行声发射检测,研究了疲劳裂纹声发射检测时传感器的布置方法、疲劳裂纹声信号的识别和提取方法、特征参量值及裂纹信号随载荷周期性变化规律,并成功地从试验中,获取了疲劳裂纹的声信号。通过对疲劳裂纹声信号的定位,确定了疲劳裂纹产生的时间和位置,根据裂纹声信号的活性变化特征,完成了对索塔锚固结构的损伤程度评定,预测了索塔锚固结构裂纹的失效行为,为实现锚固结构的声发射在线实时检测或监测奠定了理论基础。
With the improving capability of acoustic emission equipment and perfecting analysis technology, AE technology had been used in oil, petrochemical, power, aerospace, aerospace, railway, transportation, coal, building, mechanical manufacturing and processing field, periodic measuring and on-line monitoring is realized. Complete evaluation of equipment integrity by means of AE source found in testing or monitoring, and ensure safe operation for equipment.
Under loading effect, AE signal would generate when damage produced, analyzing characteristic of AE source and its law are a problem continuously interested to developing and studying. Lots of work had been developed home and abroad, and some results are obtained, solving some technical problems, promoting the spread and application of AE technology. In some research, existing weakness in research such as propagation characteristic of signal in waveguide, characteristic distributing of AE signal, parameter characteristic of weld defect, signal recognition and extraction of fatigue crack, need further work to solve the problem. At Present,16MnR and Q345are special equipment material proportion up to80%,so,in research, we chose16MnR and Q345to study AE signal studying work, to solve problems in testing. The main research contents and conclusion are as follows:
1. Propagation characteristics of AE signal transmitting in waveguide rod
Select20steel, diameter respectively4,6,8,10,12,14,16mm,and length3.2m,break lead in different length, study system the case of breaking lead on section and circumference, conclude the characteristic parameters, wave and spectrum characteristics effect by the change of length of waveguide rod, put forward the choice of waveguide rod in AE testing; The comparison study in weld samples shows that signal propagating in waveguide rod mainly is surface propagation, and chose diameter6,4mm,length in1.5m, realized longitudinal wave separating clearly, amplitude attenuation decreased, complete the experiment successfully.
2.Characteristic of AE signal of16MnR in high, low temperature
Studying tensile experiment of16MnR in-70～670℃,analyzed the rule of AE parameter changing by temperature, show that sometime yield appeared in high temperature in 16MnR,Put forward that deformation, loading and temperature can be judged by AE signal changing, enriches AE technique applying in low and high temperature performance test. In correlation study, first put correlation parameters study respectively in elastic step, yield step and strengthening step, obtained correlation in elastic step is the highest; Accumulation counts is the same with accumulation energy in characterizing damage of material in different temperature.
3.AE signal characteristic of weld defect of16MnR
Studying signal distributing characteristic of weld defect in tensile, obtained signal distributing rule; Using amplitude count and energy duration correlation analysis, can judge yield and crack extended signal characteristic; By analyzing distributing of AE signal, can judge the loading of material, ensure safety.
Using fracture mechanical knowledge compute stress value as incomplete penetration defect fractures, comparing and verifying that the stress value in fracturing with plenty of AE signals higher than computing stress value, trying out the combination of above, provide mechanical support for AE signal evaluation, and have certain guiding significance for equipment with defect testing.
4. Characteristic studying of fatigue crack signal in Q235cable tower anchorage structures of cable-stayed bridge
A large-sized model fatigue test on the anchor structure of a cable-stayed bridge tower was conducted in the laboratory, An acoustic emission instrument was used to monitor the fatigue cracks continuously in the left anchorage, studying the sensors layout, identification and extraction of fatigue signal, characteristics parameter value,and signal changing with periodic loading, and obtained successful signal of fatigue crack. By location of fatigue crack acoustie signal, ensure the time and the position of fatigue crack generating, according activity characteristics of acoustic signal, complete the evaluation, predict the failure behavior of cable tower anchorage struetures, lay a theoretical foundation for AE testing online in cable tower anchorage structures.
在载荷作用下,材料发生损伤时便会有声发射信号产生,分析获取声发射源的声信号特性及其变化规律一直是声发射检测发展过程中关注和研究的问题。国内外开展了许多试验研究工作,取得一些研究成果,解决了声发射检测中的许多技术难题,促进了声发射检测技术的推广和应用。在诸多研究中,存在着对波导杆传播声信号特性、高温及低温下材料声信号分布特征、焊接缺陷声信号参数特性、疲劳裂纹声信号识别及提取等问题的研究不足,需要进一步开展研究工作,以解决声发射技术应用中的难题。目前我国80%以上的特种设备用材为16MnR、Q345的中厚钢板。为此,选用16MnR、Q345材料进行声发射信号研究工作,以解决声发射检测中的技术难题。本文的主要研究内容和结论概括如下：
1.波导杆声发射信号的传播特性
选用材料为20号钢,直径分别为4、6、8、10、12、14、16mm,长度为3.2m的圆钢在不同长度下的模拟断铅声信号试验研究,系统地研究了在波导杆的圆心断面、圆周表面进行模拟断铅信号,获得了波导杆尺寸对声信号的特征参数、时域波形、频谱特性的影响及变化规律,提出了声发射检测中波导杆结构尺寸的选用方法；通过焊接构件的波导杆对比试验,提出的声信号在波导杆的传播方式以信号在波导杆表面传播为主、端面传播为辅的观点,并在研究16MnR钢材料低温、高温环境下声信号分布规律的试验中,依据波导杆的选用方法采用了直径为6.4mm、长度在1.5m以内的圆钢作为低温、高温试验中的波导杆,接收到的声信号纵波分离清晰、幅值衰减较小,顺利完成了材料的试验工作。
2.16MnR钢材在低温、高温环境下的声信号变化特征
研究了16MnR钢材在-70-670。C温度范围内的不同温度下的拉伸试验,全面分析了试样拉伸过程中声信号参数随温度的变化规律,揭示了16MnR材料在一定的高温环境下呈现多次的屈服变化行为,提出了通过声发射信号变化趋势的研究,可以判断出材料的变形行为、受载荷状况及温度状况,弥补了声发射检测技术在材料低温、高温性能试验中的应用；在对声信号不同参数相关性的研究中,首次把试样拉伸过程的弹性阶段、屈服阶段、强化阶段的相关性参数分开研究,得到了三个阶段的K值虽随温度呈现不同的变化趋势,但整体表现为屈服阶段相关性高,弹性阶段相关性次之,强化阶段相关性低的变化趋势；声信号的累积计数、累积能量在表征材料不同温度下的损伤情况时表现出了很好的一致性,可以很好地表征材料在温度下的损伤。
3.16MnR钢材焊接缺陷的声信号特征
分析研究了不同焊接缺陷在拉伸过程中的声信号分布特点,荻得了不同焊接缺陷的声信号分布规律：采用幅值、计数及能量持续时间关联分析,可以判断出试样内部缺陷屈服及开裂扩展的信号特点；通过分析试验中声信号分布特征,可以判断出材料所受的载荷状态,指导声发射实际检测中的加载工作，避免盲目加载造成的突发事故,确保声发射检测构件处于安全状态。
采用断裂力学知识计算了拉伸试样中未焊透缺陷断裂时的应力值,对比验证了未焊透缺陷试样拉伸过程中开裂时产生丰富的声信号时的应力值高于应用断裂力学计算应力值,二者存在着误差,实现了声发射检测技术与断裂力学的有机结合,为声发射检测中声信号的评定提供断裂力学支持,对含缺陷构件的声发射检测有一定的指导意义。
4.Q345全尺寸大桥索塔锚固结构模型疲劳裂纹声信号特征研究
采用全尺寸大桥索塔锚固结构模型进行疲劳试验,对锚固结构左侧的疲劳裂纹进行声发射检测,研究了疲劳裂纹声发射检测时传感器的布置方法、疲劳裂纹声信号的识别和提取方法、特征参量值及裂纹信号随载荷周期性变化规律,并成功地从试验中,获取了疲劳裂纹的声信号。通过对疲劳裂纹声信号的定位,确定了疲劳裂纹产生的时间和位置,根据裂纹声信号的活性变化特征,完成了对索塔锚固结构的损伤程度评定,预测了索塔锚固结构裂纹的失效行为,为实现锚固结构的声发射在线实时检测或监测奠定了理论基础。
With the improving capability of acoustic emission equipment and perfecting analysis technology, AE technology had been used in oil, petrochemical, power, aerospace, aerospace, railway, transportation, coal, building, mechanical manufacturing and processing field, periodic measuring and on-line monitoring is realized. Complete evaluation of equipment integrity by means of AE source found in testing or monitoring, and ensure safe operation for equipment.
Under loading effect, AE signal would generate when damage produced, analyzing characteristic of AE source and its law are a problem continuously interested to developing and studying. Lots of work had been developed home and abroad, and some results are obtained, solving some technical problems, promoting the spread and application of AE technology. In some research, existing weakness in research such as propagation characteristic of signal in waveguide, characteristic distributing of AE signal, parameter characteristic of weld defect, signal recognition and extraction of fatigue crack, need further work to solve the problem. At Present,16MnR and Q345are special equipment material proportion up to80%,so,in research, we chose16MnR and Q345to study AE signal studying work, to solve problems in testing. The main research contents and conclusion are as follows:
1. Propagation characteristics of AE signal transmitting in waveguide rod
Select20steel, diameter respectively4,6,8,10,12,14,16mm,and length3.2m,break lead in different length, study system the case of breaking lead on section and circumference, conclude the characteristic parameters, wave and spectrum characteristics effect by the change of length of waveguide rod, put forward the choice of waveguide rod in AE testing; The comparison study in weld samples shows that signal propagating in waveguide rod mainly is surface propagation, and chose diameter6,4mm,length in1.5m, realized longitudinal wave separating clearly, amplitude attenuation decreased, complete the experiment successfully.
2.Characteristic of AE signal of16MnR in high, low temperature
Studying tensile experiment of16MnR in-70～670℃,analyzed the rule of AE parameter changing by temperature, show that sometime yield appeared in high temperature in 16MnR,Put forward that deformation, loading and temperature can be judged by AE signal changing, enriches AE technique applying in low and high temperature performance test. In correlation study, first put correlation parameters study respectively in elastic step, yield step and strengthening step, obtained correlation in elastic step is the highest; Accumulation counts is the same with accumulation energy in characterizing damage of material in different temperature.
3.AE signal characteristic of weld defect of16MnR
Studying signal distributing characteristic of weld defect in tensile, obtained signal distributing rule; Using amplitude count and energy duration correlation analysis, can judge yield and crack extended signal characteristic; By analyzing distributing of AE signal, can judge the loading of material, ensure safety.
Using fracture mechanical knowledge compute stress value as incomplete penetration defect fractures, comparing and verifying that the stress value in fracturing with plenty of AE signals higher than computing stress value, trying out the combination of above, provide mechanical support for AE signal evaluation, and have certain guiding significance for equipment with defect testing.
4. Characteristic studying of fatigue crack signal in Q235cable tower anchorage structures of cable-stayed bridge
A large-sized model fatigue test on the anchor structure of a cable-stayed bridge tower was conducted in the laboratory, An acoustic emission instrument was used to monitor the fatigue cracks continuously in the left anchorage, studying the sensors layout, identification and extraction of fatigue signal, characteristics parameter value,and signal changing with periodic loading, and obtained successful signal of fatigue crack. By location of fatigue crack acoustie signal, ensure the time and the position of fatigue crack generating, according activity characteristics of acoustic signal, complete the evaluation, predict the failure behavior of cable tower anchorage struetures, lay a theoretical foundation for AE testing online in cable tower anchorage structures.
引文
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