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基于磁记忆参数的焊缝可靠性评价
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摘要
由于钢材焊接成设备后,焊缝内部总是或多或少的存在着各种缺陷和应力集中等,这会严重降低设备的强度和使用寿命,导致设备失效、断裂、爆炸等严重后果。所以对焊接设备进行安全可靠的评价,具有重大的经济效益和社会效益。
     金属磁记忆检测技术作为一门新兴的无损检测方法,不仅能够检测出材料的塑性变形及宏观裂纹,还能有效地评价焊缝的应力集中及微观缺陷,因而在焊缝的质量评定方面有广阔的应用前景。但是各种因素使得磁记忆检测的信号具有一定的分散性和不确定性,客观现象和主观描述或预测之间存在着某些偏差,而这些偏差又表现出某种统计规律性,因此引入近似概率可靠性的统计理论及方法,是解决磁记忆定量评价中参数分散性与不确定性问题的一种较好的途径。
     本文通过将金属磁记忆技术和可靠性理论相结合,利用磁记忆技术在早期损伤检测上的优势,全方位地进行基于磁记忆参数的焊缝可靠性评价研究。首先在焊缝静载和疲劳实验数据的基础上,对多种载荷条件下焊缝累积损伤部位的磁记忆信号进行特征提取,分析焊缝临界断裂时的磁记忆信号特征,获得静载和疲劳载荷实验条件下的磁记忆参数变化规律。为验证焊缝磁记忆特征信号对应力分布的表征规律,进一步应用ANSYS有限元软件进行静载和疲劳载荷下焊缝应力分布的仿真计算,对比研究焊缝磁记忆漏磁场平面分布图与应力分布云图的相关性。最后,对疲劳载荷条件下的焊缝可靠性进行分析,在可靠性干涉模型的基础上进行算法优化,建立基于磁记忆参数的焊缝可靠性模型,并对焊缝的可靠度进行计算,为焊缝可靠性研究的实际工程评估提供理论性基础和方法研究。由此可见,本文的研究不仅具有重要的理论价值,而且具有广阔应用前景。
The Steel equipment with welded joint, where more or less exist different variety ofdefects and stress concentration,which will reduce the strength and service life of equipment,lead to serious consequences of equipment failure, rupture, explosion.So it is prone towelding failure.
     Magnetic memory testing technology, a new nondestructive testing method, can not onlydiscover the plastic deformation and the macroscopic of material, but also can assess thestress concentration districts and the microcosmic defects of metal endangered state beforethe injury to early diagnosis. However, due to some randomness, there is some dispersion anduncertainty of magnetic memory signals and deviation of the objective phenomena andsubjective description or prediction of phenomena, while these deviations show a statisticalregularity, therefore, introducing statistical theory and methods of the approximateprobability reliability,which is a better way to solve the dispersion and uncertainty of themagnetic memory parameters in the quantitative evaluation.
     Combining the magnetic memory testing technology and the theory of reliability, andusing the advantages of the magnetic memory technology in the early damage detection.Thepaper carrys out the weld reliability evaluation based on the magnetic memory parameters.Firstly, extracting the magnetic memory feature signals of welded joint cumulative damageparts on the basis of weld static and fatigue experimental data, and analysing feature ofmagnetic memory parameter in the welded joint critical fracture characteristics, achieving thevariation of the magnetic memory under the static and fatigue loading experiment.In order toverify characterization of the welded joint magnetic memory signal to the stress distribution,applying ANSYS software to simulate the weld stress distribution of the static and fatigueloads, comparing and researching correlation of the welded joint magnetic memory leakageplane distribution fig and the stress distributioncloud image. Lastly, analysing the weldedjoint reliability under fatigue load, making optimization algorithm on the basis of theinterference reliability model, founding the welded joint reliability model based on magneticmemory parameters, computing the welded joint reliability, and providing the theoreticalbasis and methods for the actual welded joint reliability projects of assessment. Thus, thisstudy not only has important theoretical value, but also has broad application prospects.
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