压电阻抗技术及其在铝合金疲劳损伤监测中的应用研究
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摘要
在航空、船舶、海上平台、桥梁和石化管道等重要工程领域中,材料疲劳损伤是导致结构(部件)服役性能退化的主要原因之一。由于疲劳破坏具有突发性,采用无损方法对在役构件疲劳损伤累积状况进行检测或监测,能够大幅度提高结构的安全可靠性,减小灾害发生几率,避免重大人员伤亡和财产损失。
基于压电阻抗(electro-mechanical impedance, EMI)法的结构健康监测技术具有对微小损伤检测灵敏度高、适用范围广(金属、复合材料、混凝土等结构)、抗干扰能力强、信号采集和处理方便快捷等优点,在疲劳损伤监测研究中具有广阔的应用前景。目前,EMI技术在疲劳损伤监测中的应用研究尚处于起步阶段。研究工作中存在的难点主要集中于以下几个方面：(1)理论模型发展还不完善,所建立的压电阻抗模型大多针对结构无损伤状态；(2)现有装置所提供的压电传感器驱动电压过低,振动能量对被测结构激励不充分,限制了疲劳损伤监测灵敏度的提高；(3)仅仅从压电传感器所测得的电阻抗信号中很难提取出反映损伤位置的信息,难以实现疲劳损伤精确定位；(4)对于研究工作中大多采用的压电陶瓷类传感器而言,由于它们的脆性较大,在实际应用时尚需研究出合适的封装和防护技术；(5)在材料疲劳损伤多维监测研究中,传感器网络架构、分布式信号传输及处理等关键技术,从理论模型建立到监测系统开发都需要开展大量的研究工作。
铝合金材料由于密度小、比强度高、耐蚀性好以及优良的焊接性和成型工艺性,在航空航天、船舶、高速列车等结构上获得了广泛应用。其中作为飞机机体结构用材是铝合金的一项重要应用。在飞行过程中由于外界气压变化引起机身所受应力状态交替变化,铝合金机体的疲劳破坏将导致灾难性的空中解体事故。对铝合金疲劳断裂过程的微观观察、疲劳损伤发展状况检测和剩余寿命预测,一直是工程结构和材料科学领域的研究热点。同时,铝合金具有选材和加工方便,疲劳极限小,疲劳过程便于实验室控制等优点,在基于EMI技术的疲劳损伤监测研究中获得了普遍应用。作为一种基础性疲劳损伤监测规律探索,同时为了增强同其他学者研究结果的对比性,本研究也选用了铝合金作为监测对象。
本文将EMI技术应用到铝合金试样低周疲劳循环过程的在线监测研究中。采用理论分析、数值模拟和实验测试等多种方式,围绕疲劳裂纹萌生和扩展过程的定量监测、高激励电压电阻抗测试系统(high excitation voltage electrical impedance measurement system, HEVEIMS)构建及损伤位置精确测定三个方面进行了系统研究。主要研究结果如下：
(1)压电陶瓷(piezoelectric ceramic, PZT)传感器粘结强度是影响其电阻抗信号的重要因素。理论模拟和实验验证结果均表明,随着粘结强度降低,在低频范围内谐振峰逐渐向高频方向偏移,而在高频范围内谐振峰逐渐向低频方向偏移,存在一个偏移方向发生转变的临界点。
(2)在疲劳裂纹萌生阶段,随着循环加载次数增加,损伤识别指数Δf和均方差(root mean square deviation, RMSD)的数值整体上均呈现出单调增大的变化趋势。在出现亚毫米级疲劳裂纹前,Δf和RMSD数值的变化量分别达到0.6kHz和11.68%,利用这两个指数可以对裂纹萌生阶段疲劳损伤的累积过程进行实时监测。
(3)在疲劳裂纹扩展阶段,随着循环加载次数增加,裂纹长度逐渐增大,△f和RMSD均呈现单调增大的趋势。Δf的变化规律与裂纹扩展长度之间具有很好的相似性,而RMSD对前5,000次循环时裂纹的初期扩展更为敏感。当疲劳裂纹长度扩展到2.90mm时,Af和RMSD的变化量分别达到1.1kHz和7.61%。借助这两个指数可以对疲劳裂纹的连续扩展过程进行实时监测。
(4)基准信号选取、环境噪声、结构应力状态和检测频段均会影响疲劳损伤监测效果,当环境噪声信号频率在所选取检测频段内时,会对所测得电阻抗信号产生严重干扰。结构所受拉应力逐渐增大时,PZT传感器电阻抗信号中各谐振峰逐渐向低频方向偏移,RMSD指数呈现单调增大的变化趋势。在千赫级频带内,随着检测频段提高,灵敏度呈现出先增大后减小的变化趋势,在130-210kHz频段具有最高的检测灵敏度。
(5)采用ARB-1410波形发射卡、阻抗测量电路及DPO-4032型数字示波器等设备,自行搭建了一套HEVEIMS。该系统将PZT传感器的激励电压由商用阻抗分析仪的2V提高到本装置的35V,在10-300kHz频段内对电阻抗模值、实部和虚部信号具有很高的测量精度。
(6)激励电压是影响EMI技术检测灵敏度的重要因素。随着激励电压增加,PZT传感器所提供驱动能量逐渐增大。与1V激励电压相比,当激励电压达到20V和25V时,EMI技术对亚毫米级微小疲劳裂纹的检测灵敏度提高了145%。
(7)采用表面粘贴PZT传感器的主动Lamb波技术对铝合金材料疲劳损伤进行定位检测。提取小波系数极大值对应时刻作为相应Lamb波信号出现时间,求出两者的时间延迟,进而确定出疲劳裂纹出现位置。对距离PZT传感器25mm和60mm位置处尺寸为2.44mm和1.54mm的疲劳裂纹,测量值与真实值之间的误差分别为3.2%和-1%,满足工程需要。
Fatigue damage is the main reason for the degradation of structures (components) in the fields of aerospace, ship engineering, offshore platform, bridge and petrochemical pipeline. A suitable nondestructive technique with capability to provide reliable and reproducible quantitative information for the accumulation of fatigue damage, can significantly improve the safety and reliability of the structures, reduce the risk of disasters, and avoid heavy casualties and property losses.
Electro-mechanical impedance (EMI) based structural health monitoring technology has many obvious advantages, such as high sensitivity to minor damages, wide range of adaptability (metals, composites, concrete and other structures), anti-interference ability, convenient signal acquisition and processing. This technique has good prospects in the monitoring of fatigue damages. At present, the application of EMI technique in the monitoring of fatigue damages is still in the infancy. The problems mainly focus on the following aspects:(1) The development of theoretical models are not perfect, the existed piezoelectric impedance models are only applicable for the structures without damage;(2) The driving voltage of currently available device is quite low, the vibration energy is not sufficient for monitored structures, and the improvement of sensitivity to fatigue damages is obviously limited;(3) It is difficult to extract damage location information from the measured electrical impedance signals, and the location of fatigue damage can't be measured precisely;(4) The piezoelectric sensors used in most of the EMI studies is brittle, proper packaging and protective teclinology should be developed before the application of this method to a real structure;(5) In the multi-dimensional monitoring of fatigue damages, many researches should be performed on the key technology such as the establishment of sensor network, the transmission and processing of distributed signals, from the development of theoretical models and monitoring systems.
Aluminum alloy has been widely applied in the structures of aerospace, ship engineering, high-speed trains, due to the low density, high specific strength, good corrosion resistance, excellent weldability and molding manufacturability. The airframe structure material is one of the most important applications of aluminum alloy. During the flight process, the stress state of the body changes alternatively with the outside air pressure. The fatigue failure of the aluminum alloy body will lead to disastrous air disintegration accident. The microscopic observation of fatigue fracture process, the fatigue damage state detection, and the remaining life prediction of aluminum alloy have always been paid attention in the engineering and material science field. On the other hand, aluminum alloy has many advantages such as the convenient material selection and forming, the small fatigue limit, and the easily controlled fatigue process. This material has been widely used in the monitoring of fatigue damage with the EMI technique. As a basic exploration of fatigue damage monitoring principle, the aluminum alloy was also selected in this study to enhance the comparability with other researchers.
In this paper, EMI technique was used for online monitoring of the entire process of fatigue failure in aluminum alloy specimens. With the manners of theoretical model, numerical simulation, and experimental testing, systematical studies were performed from three aspects, which were quantitative monitoring of the initiation and propagation process of fatigue crack, the establishment of high excitation voltage electrical impedance measurement system (HEVEIMS), and the accurate location method of fatigue crack. The major conclusions are as follows:
(1) The bonding condition of piezoelectric ceramic (PZT) sensor is an important factor which affects the electrical impedance signal obviously. Theoretical simulation and experimental investigation results show that, with decrease in bonding quality, the resonant impedance peaks shifted to higher and lower frequency, respectively, in the low and high frequency ranges. There exists a critical frequency, and the shifted direction of impedance peaks changes at this point.
(2) At the fatigue crack initiation stage, the trends of damage identification indicators Δ f and root mean square deviation (RMSD) increased monotonically with fatigue cycles. Before the formation of macroscopic submillimeter fatigue crack, the changing values of Δf and RMSD were0.6kHz and11.68%. The initial pre-crack damages can be real-time monitored with these two indicators.
(3) At the fatigue crack propagation stage, the crack length increased gradually, and the trends of Δf and RMSD increased monotonically with fatigue cycles. The increment trend of Δf was evidently similar to that of crack length, and the RMSD values were more sensitive to the initial expansion of crack length in the first5,000cycles. When the crack length expanded to2.90mm, the changing values of Δf and RMSD were1.1kHz and7.61%, respectively. The process of crack propagation can be real-time monitored with these two indicators.
(4) The selection of baseline, environmental noise, the state of structural stress, and the testing frequency band can affect the fatigue monitoring results of EMI technique obviously. The measured electrical impedance signals are seriously influenced when the frequency of environmental noise is in the selected monitoring band. The resonant peaks in the electrical impedance signals shift to lower frequency and the values of RMSD increase monotonically, when the tensile stress in the monitored specimens increases gradually. In the kHz frequency range, the sensitivity first increases and then decreases with the increase of testing frequency band, and the frequency band of130-210kHz has the highest testing sensitivity.
(5) A HEVEIMS was established with ARB-1410wave generation card, impedance measurement circuit and DPO-4032digital oscilloscope. The excitation voltage of PZT sensor was extended from2V to35V, and the measurement accuracy of electrical impedance modulus, real and imaginary parts is quite high in the frequency band of10-300kHz.
(6) The excitation voltage of PZT sensor is an important factor of EMI sensitivity. The driving energy of PZT sensor increases with excitation voltage. Compared with1V excitation voltage, the sensitivity to submillimeter small fatigue cracks increased145%, when the excitation voltage increased to20and25V.
(7) The location of fatigue damage in aluminum alloy was measured with active Lamb wave technique, which was excited by PZT sensor bonded on the surface of the specimen. The time delay between the excitation and reflection signals was calculated according to the extracted maximum values of wavelet coefficients, and then the location of fatigue crack was determined. For the2.44mm and1.54mm fatigue cracks generated at25mm and60mm from the PZT sensor, the relative error between the measured and the real values were3.2%and-1%, respectively, and the location accuracy satisfies the engineering requirement.
基于压电阻抗(electro-mechanical impedance, EMI)法的结构健康监测技术具有对微小损伤检测灵敏度高、适用范围广(金属、复合材料、混凝土等结构)、抗干扰能力强、信号采集和处理方便快捷等优点,在疲劳损伤监测研究中具有广阔的应用前景。目前,EMI技术在疲劳损伤监测中的应用研究尚处于起步阶段。研究工作中存在的难点主要集中于以下几个方面：(1)理论模型发展还不完善,所建立的压电阻抗模型大多针对结构无损伤状态；(2)现有装置所提供的压电传感器驱动电压过低,振动能量对被测结构激励不充分,限制了疲劳损伤监测灵敏度的提高；(3)仅仅从压电传感器所测得的电阻抗信号中很难提取出反映损伤位置的信息,难以实现疲劳损伤精确定位；(4)对于研究工作中大多采用的压电陶瓷类传感器而言,由于它们的脆性较大,在实际应用时尚需研究出合适的封装和防护技术；(5)在材料疲劳损伤多维监测研究中,传感器网络架构、分布式信号传输及处理等关键技术,从理论模型建立到监测系统开发都需要开展大量的研究工作。
铝合金材料由于密度小、比强度高、耐蚀性好以及优良的焊接性和成型工艺性,在航空航天、船舶、高速列车等结构上获得了广泛应用。其中作为飞机机体结构用材是铝合金的一项重要应用。在飞行过程中由于外界气压变化引起机身所受应力状态交替变化,铝合金机体的疲劳破坏将导致灾难性的空中解体事故。对铝合金疲劳断裂过程的微观观察、疲劳损伤发展状况检测和剩余寿命预测,一直是工程结构和材料科学领域的研究热点。同时,铝合金具有选材和加工方便,疲劳极限小,疲劳过程便于实验室控制等优点,在基于EMI技术的疲劳损伤监测研究中获得了普遍应用。作为一种基础性疲劳损伤监测规律探索,同时为了增强同其他学者研究结果的对比性,本研究也选用了铝合金作为监测对象。
本文将EMI技术应用到铝合金试样低周疲劳循环过程的在线监测研究中。采用理论分析、数值模拟和实验测试等多种方式,围绕疲劳裂纹萌生和扩展过程的定量监测、高激励电压电阻抗测试系统(high excitation voltage electrical impedance measurement system, HEVEIMS)构建及损伤位置精确测定三个方面进行了系统研究。主要研究结果如下：
(1)压电陶瓷(piezoelectric ceramic, PZT)传感器粘结强度是影响其电阻抗信号的重要因素。理论模拟和实验验证结果均表明,随着粘结强度降低,在低频范围内谐振峰逐渐向高频方向偏移,而在高频范围内谐振峰逐渐向低频方向偏移,存在一个偏移方向发生转变的临界点。
(2)在疲劳裂纹萌生阶段,随着循环加载次数增加,损伤识别指数Δf和均方差(root mean square deviation, RMSD)的数值整体上均呈现出单调增大的变化趋势。在出现亚毫米级疲劳裂纹前,Δf和RMSD数值的变化量分别达到0.6kHz和11.68%,利用这两个指数可以对裂纹萌生阶段疲劳损伤的累积过程进行实时监测。
(3)在疲劳裂纹扩展阶段,随着循环加载次数增加,裂纹长度逐渐增大,△f和RMSD均呈现单调增大的趋势。Δf的变化规律与裂纹扩展长度之间具有很好的相似性,而RMSD对前5,000次循环时裂纹的初期扩展更为敏感。当疲劳裂纹长度扩展到2.90mm时,Af和RMSD的变化量分别达到1.1kHz和7.61%。借助这两个指数可以对疲劳裂纹的连续扩展过程进行实时监测。
(4)基准信号选取、环境噪声、结构应力状态和检测频段均会影响疲劳损伤监测效果,当环境噪声信号频率在所选取检测频段内时,会对所测得电阻抗信号产生严重干扰。结构所受拉应力逐渐增大时,PZT传感器电阻抗信号中各谐振峰逐渐向低频方向偏移,RMSD指数呈现单调增大的变化趋势。在千赫级频带内,随着检测频段提高,灵敏度呈现出先增大后减小的变化趋势,在130-210kHz频段具有最高的检测灵敏度。
(5)采用ARB-1410波形发射卡、阻抗测量电路及DPO-4032型数字示波器等设备,自行搭建了一套HEVEIMS。该系统将PZT传感器的激励电压由商用阻抗分析仪的2V提高到本装置的35V,在10-300kHz频段内对电阻抗模值、实部和虚部信号具有很高的测量精度。
(6)激励电压是影响EMI技术检测灵敏度的重要因素。随着激励电压增加,PZT传感器所提供驱动能量逐渐增大。与1V激励电压相比,当激励电压达到20V和25V时,EMI技术对亚毫米级微小疲劳裂纹的检测灵敏度提高了145%。
(7)采用表面粘贴PZT传感器的主动Lamb波技术对铝合金材料疲劳损伤进行定位检测。提取小波系数极大值对应时刻作为相应Lamb波信号出现时间,求出两者的时间延迟,进而确定出疲劳裂纹出现位置。对距离PZT传感器25mm和60mm位置处尺寸为2.44mm和1.54mm的疲劳裂纹,测量值与真实值之间的误差分别为3.2%和-1%,满足工程需要。
Fatigue damage is the main reason for the degradation of structures (components) in the fields of aerospace, ship engineering, offshore platform, bridge and petrochemical pipeline. A suitable nondestructive technique with capability to provide reliable and reproducible quantitative information for the accumulation of fatigue damage, can significantly improve the safety and reliability of the structures, reduce the risk of disasters, and avoid heavy casualties and property losses.
Electro-mechanical impedance (EMI) based structural health monitoring technology has many obvious advantages, such as high sensitivity to minor damages, wide range of adaptability (metals, composites, concrete and other structures), anti-interference ability, convenient signal acquisition and processing. This technique has good prospects in the monitoring of fatigue damages. At present, the application of EMI technique in the monitoring of fatigue damages is still in the infancy. The problems mainly focus on the following aspects:(1) The development of theoretical models are not perfect, the existed piezoelectric impedance models are only applicable for the structures without damage;(2) The driving voltage of currently available device is quite low, the vibration energy is not sufficient for monitored structures, and the improvement of sensitivity to fatigue damages is obviously limited;(3) It is difficult to extract damage location information from the measured electrical impedance signals, and the location of fatigue damage can't be measured precisely;(4) The piezoelectric sensors used in most of the EMI studies is brittle, proper packaging and protective teclinology should be developed before the application of this method to a real structure;(5) In the multi-dimensional monitoring of fatigue damages, many researches should be performed on the key technology such as the establishment of sensor network, the transmission and processing of distributed signals, from the development of theoretical models and monitoring systems.
Aluminum alloy has been widely applied in the structures of aerospace, ship engineering, high-speed trains, due to the low density, high specific strength, good corrosion resistance, excellent weldability and molding manufacturability. The airframe structure material is one of the most important applications of aluminum alloy. During the flight process, the stress state of the body changes alternatively with the outside air pressure. The fatigue failure of the aluminum alloy body will lead to disastrous air disintegration accident. The microscopic observation of fatigue fracture process, the fatigue damage state detection, and the remaining life prediction of aluminum alloy have always been paid attention in the engineering and material science field. On the other hand, aluminum alloy has many advantages such as the convenient material selection and forming, the small fatigue limit, and the easily controlled fatigue process. This material has been widely used in the monitoring of fatigue damage with the EMI technique. As a basic exploration of fatigue damage monitoring principle, the aluminum alloy was also selected in this study to enhance the comparability with other researchers.
In this paper, EMI technique was used for online monitoring of the entire process of fatigue failure in aluminum alloy specimens. With the manners of theoretical model, numerical simulation, and experimental testing, systematical studies were performed from three aspects, which were quantitative monitoring of the initiation and propagation process of fatigue crack, the establishment of high excitation voltage electrical impedance measurement system (HEVEIMS), and the accurate location method of fatigue crack. The major conclusions are as follows:
(1) The bonding condition of piezoelectric ceramic (PZT) sensor is an important factor which affects the electrical impedance signal obviously. Theoretical simulation and experimental investigation results show that, with decrease in bonding quality, the resonant impedance peaks shifted to higher and lower frequency, respectively, in the low and high frequency ranges. There exists a critical frequency, and the shifted direction of impedance peaks changes at this point.
(2) At the fatigue crack initiation stage, the trends of damage identification indicators Δ f and root mean square deviation (RMSD) increased monotonically with fatigue cycles. Before the formation of macroscopic submillimeter fatigue crack, the changing values of Δf and RMSD were0.6kHz and11.68%. The initial pre-crack damages can be real-time monitored with these two indicators.
(3) At the fatigue crack propagation stage, the crack length increased gradually, and the trends of Δf and RMSD increased monotonically with fatigue cycles. The increment trend of Δf was evidently similar to that of crack length, and the RMSD values were more sensitive to the initial expansion of crack length in the first5,000cycles. When the crack length expanded to2.90mm, the changing values of Δf and RMSD were1.1kHz and7.61%, respectively. The process of crack propagation can be real-time monitored with these two indicators.
(4) The selection of baseline, environmental noise, the state of structural stress, and the testing frequency band can affect the fatigue monitoring results of EMI technique obviously. The measured electrical impedance signals are seriously influenced when the frequency of environmental noise is in the selected monitoring band. The resonant peaks in the electrical impedance signals shift to lower frequency and the values of RMSD increase monotonically, when the tensile stress in the monitored specimens increases gradually. In the kHz frequency range, the sensitivity first increases and then decreases with the increase of testing frequency band, and the frequency band of130-210kHz has the highest testing sensitivity.
(5) A HEVEIMS was established with ARB-1410wave generation card, impedance measurement circuit and DPO-4032digital oscilloscope. The excitation voltage of PZT sensor was extended from2V to35V, and the measurement accuracy of electrical impedance modulus, real and imaginary parts is quite high in the frequency band of10-300kHz.
(6) The excitation voltage of PZT sensor is an important factor of EMI sensitivity. The driving energy of PZT sensor increases with excitation voltage. Compared with1V excitation voltage, the sensitivity to submillimeter small fatigue cracks increased145%, when the excitation voltage increased to20and25V.
(7) The location of fatigue damage in aluminum alloy was measured with active Lamb wave technique, which was excited by PZT sensor bonded on the surface of the specimen. The time delay between the excitation and reflection signals was calculated according to the extracted maximum values of wavelet coefficients, and then the location of fatigue crack was determined. For the2.44mm and1.54mm fatigue cracks generated at25mm and60mm from the PZT sensor, the relative error between the measured and the real values were3.2%and-1%, respectively, and the location accuracy satisfies the engineering requirement.
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