金属焊接残余应力的激光超声无损检测研究
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摘要
本文利用精确测量多种模态的超声波波速来测定金属材料的二阶和三阶弹性常数,并从数值模拟和实验两方面研究了金属焊接的残余应力分布。
首先,采用有限元方法模拟金属融化焊接和焊接接头冷却成型的过程。建立移动高斯热源对金属板进行焊接的三维模型,在计算焊接和冷却过程中温度场的基础上,采用生死单元法模拟了熔池单元从融化到冷却的相变过程,重点分析了焊接之后母材各位置的残余应力分布。
针对金属焊接结构,建立了激光声表面波波速的测试系统。该系统利用短脉冲激光器在被测样品表面激发出高频超声表面波,利用自行研制的点接触式PZT传感器接收超声表面波。系统采用激发源和被测样品二维平移方式,实现样品焊缝区的二维扫描,通过波形相关算法精确计算各位置的波速值,并得到焊缝附近区域内的声表面波速度分布。
设计了适用于金属材料二阶弹性常数的激光超声测量系统。该系统能探测激光线源在铝合金样品上激发的表面波、横波和纵波信号。利用扫描激光源法和波形相关技术精确计算声表面波的传播速度,并用时间飞行法计算了经样品底面反射的横波和纵波的传播速度。进而根据波速与二阶弹性常数的关系计算金属材料的二阶弹性常数。
针对各向同性的金属材料,采用线性热膨胀引起材料等效微应变的静水压力法测定其三阶弹性常数。通过水浴加热法使金属样品处于静水压力下,采用上述实验系统精确测量了激光在金属上激发的纵波、横波和表面波波速；并对材料进行应力-应变测试,得到其线性热膨胀系数。进而根据声表面波方程和等效弹性常数与各波速的关系计算金属材料的三阶弹性常数。
在测得的金属焊接区域的声表面波波速分布、二阶弹性常数、三阶弹性常数的基础上,结合单轴应力条件下的声弹性方程,计算金属焊接残余应力的分布,并验证数值模拟结果。
本文的研究结果将对金属焊接残余应力的激光超声检测提供理论和实验依据,也有助于激光超声无损检测技术进一步发展和应用。
This paper present a new method based on the measurement of velocity of laser-generated ultrasound to determinate the SOEC and TOEC, after that, both the numerical simulation and experiments are carried out to obtain the residual stresses distribution on the welded plates.
The process form melting to forming after cooling of weld area is been simulated by finite element method (FEM). A very detailed and localized three-dimensional transient thermal model is initially established, which simulates the mechanisms of melting formation, calculates the temperature distribution in the local weld area from the beginning of welding to the final cooling. Subsequently, using the preceding welding model, thermo-mechanical analysis of the welding process is performed, from which residual stresses distribution around the joint are calculated.
Experiments based on laser-generated surface acoustic wave (SAW) method were carried out to determine the velocity distribution of surface acoustic wave (SAW) around the joint. The waves are detected by self-made PZT transducer and the generated laser and sample is moved on the2D directions, which realize the2D scanning on the welding line area.
According to the Christoffel theory of elasticity, a measurement system based on laser-generated ultrasound is set up to calculate the elastic constants of metal sample. A serial of ultrasonic pulses is detected by self-made PZT transducer fixed in the detection point when scanning the line source focused from Nd:YAG laser with electronic control translation stage. Then the velocity of Rayleigh waves, longitudinal and shear wave are obtained by different traveling time with their propagation distance. At the end, the SOEC and density of the metal are determinate.
A new method of measurement of TOEC is proposed through equivalent micro strain which caused by linear thermal expansion. The isotropous sample is placed in steady stress field, then the experiment system is built up to measure the velocity of Rayleigh wave, longitudinal and shear wave accurately. At the same time, the thermal machine analysis (TMA) test between stress and strain is carried out on the sample in order to get the linear thermal expansion coefficient (LTEC). Finally, according the Rayleigh Equation as well as the relation between equivalent elastic coefficients and the velocity of ultrasound, the value of TOEC are calculated.
The velocity of SAW on different position near welding line then can be calculated by waveform related algorithm, from which the residual stresses distribution are calculated due to acoustic-elastic theory. By comparing the thermal-structure model answers with the measurement results, it is found that the numerical simulation results are in good agreement with the experimental data.
The results in this paper will provide the theoretical and experimental evidence for the determination of elastic constants and residual stresses on metal by laser-generated ultrasound; it's also helpful for the further development and application of nondestructive testing and evaluation (NDT&E) using laser ultrasonic technology.
首先,采用有限元方法模拟金属融化焊接和焊接接头冷却成型的过程。建立移动高斯热源对金属板进行焊接的三维模型,在计算焊接和冷却过程中温度场的基础上,采用生死单元法模拟了熔池单元从融化到冷却的相变过程,重点分析了焊接之后母材各位置的残余应力分布。
针对金属焊接结构,建立了激光声表面波波速的测试系统。该系统利用短脉冲激光器在被测样品表面激发出高频超声表面波,利用自行研制的点接触式PZT传感器接收超声表面波。系统采用激发源和被测样品二维平移方式,实现样品焊缝区的二维扫描,通过波形相关算法精确计算各位置的波速值,并得到焊缝附近区域内的声表面波速度分布。
设计了适用于金属材料二阶弹性常数的激光超声测量系统。该系统能探测激光线源在铝合金样品上激发的表面波、横波和纵波信号。利用扫描激光源法和波形相关技术精确计算声表面波的传播速度,并用时间飞行法计算了经样品底面反射的横波和纵波的传播速度。进而根据波速与二阶弹性常数的关系计算金属材料的二阶弹性常数。
针对各向同性的金属材料,采用线性热膨胀引起材料等效微应变的静水压力法测定其三阶弹性常数。通过水浴加热法使金属样品处于静水压力下,采用上述实验系统精确测量了激光在金属上激发的纵波、横波和表面波波速；并对材料进行应力-应变测试,得到其线性热膨胀系数。进而根据声表面波方程和等效弹性常数与各波速的关系计算金属材料的三阶弹性常数。
在测得的金属焊接区域的声表面波波速分布、二阶弹性常数、三阶弹性常数的基础上,结合单轴应力条件下的声弹性方程,计算金属焊接残余应力的分布,并验证数值模拟结果。
本文的研究结果将对金属焊接残余应力的激光超声检测提供理论和实验依据,也有助于激光超声无损检测技术进一步发展和应用。
This paper present a new method based on the measurement of velocity of laser-generated ultrasound to determinate the SOEC and TOEC, after that, both the numerical simulation and experiments are carried out to obtain the residual stresses distribution on the welded plates.
The process form melting to forming after cooling of weld area is been simulated by finite element method (FEM). A very detailed and localized three-dimensional transient thermal model is initially established, which simulates the mechanisms of melting formation, calculates the temperature distribution in the local weld area from the beginning of welding to the final cooling. Subsequently, using the preceding welding model, thermo-mechanical analysis of the welding process is performed, from which residual stresses distribution around the joint are calculated.
Experiments based on laser-generated surface acoustic wave (SAW) method were carried out to determine the velocity distribution of surface acoustic wave (SAW) around the joint. The waves are detected by self-made PZT transducer and the generated laser and sample is moved on the2D directions, which realize the2D scanning on the welding line area.
According to the Christoffel theory of elasticity, a measurement system based on laser-generated ultrasound is set up to calculate the elastic constants of metal sample. A serial of ultrasonic pulses is detected by self-made PZT transducer fixed in the detection point when scanning the line source focused from Nd:YAG laser with electronic control translation stage. Then the velocity of Rayleigh waves, longitudinal and shear wave are obtained by different traveling time with their propagation distance. At the end, the SOEC and density of the metal are determinate.
A new method of measurement of TOEC is proposed through equivalent micro strain which caused by linear thermal expansion. The isotropous sample is placed in steady stress field, then the experiment system is built up to measure the velocity of Rayleigh wave, longitudinal and shear wave accurately. At the same time, the thermal machine analysis (TMA) test between stress and strain is carried out on the sample in order to get the linear thermal expansion coefficient (LTEC). Finally, according the Rayleigh Equation as well as the relation between equivalent elastic coefficients and the velocity of ultrasound, the value of TOEC are calculated.
The velocity of SAW on different position near welding line then can be calculated by waveform related algorithm, from which the residual stresses distribution are calculated due to acoustic-elastic theory. By comparing the thermal-structure model answers with the measurement results, it is found that the numerical simulation results are in good agreement with the experimental data.
The results in this paper will provide the theoretical and experimental evidence for the determination of elastic constants and residual stresses on metal by laser-generated ultrasound; it's also helpful for the further development and application of nondestructive testing and evaluation (NDT&E) using laser ultrasonic technology.
引文
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