铝板电磁超声检测技术关键问题研究
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摘要
铝合金板材具有强度高、密度低、耐腐蚀性强等特性,是制造航天设备、军工设备及高速列车的主要材料,随着航天技术、探月工程、国产飞机、航空母舰及高速铁路等项目的大力开展和日趋成熟,我国铝合金材料的需求量越来越大,材料质量决定了产品质量,铝合金检测技术的需求变得越来越重要。
电磁超声检测技术因其无需耦合剂,耐高温又易操作等优势被广泛研究。目前,电磁超声检测技术被广泛应用在钢板、铝板、钢管等缺陷检测中,已经成为国内外主流的无损检测方法之一。但其缺点为换能效率较低、信号微弱,是实际应用中需要克服的主要困难。
本文在回顾了国内外多年来电磁超声技术的发展和应用,在总结前人们研究成果的基础上,对EMAT换能机理进行了探讨,针对EMAT工作的三个过程：电磁场、电磁超声耦合以及声场传播,分析相应的换能原理,进行详细的数学描述,推导出电磁超声换能过程的完整方程和边界条件。依据产生波型的不同,分析出EMAT的各个组成部分中高频激励线圈和永磁铁的不同配置情况,及对应不同配置情况激发出波型的种类和它的声波传播形式。
本文利用ANSYS有限元仿真软件对电磁超声换能器的电磁场进行了仿真分析,得出被测铝板中涡流及洛伦兹力的分布情况。同时将电磁场得到的结果与结构场进行耦合,得出被测铝板中质点的应力、应变及位移情况,从而达到对EMAT辐射声场进行仿真分析的目的。由于EMAT换能效率低,信号微弱,为了提高其换能效率,对其模型进行优化。针对优化的主要对象：线圈与被测铝板间的提离距离、线圈及永磁铁的各个参数对换能效率的影响做了详细分析,最终确定出各参数的优化组合。通过仿真分析得出EMAT被测铝板的内部辐射声场分布及被测铝板表面的指向角,并通过实验验证了这个仿真结果的正确性。通过改变被测铝板的厚度和激励电流频率得到相应辐射声场的变化情况。然后分析了三种不同配置的换能器辐射声场分布的各自指向性特点。
表面波具有单模式、能量集中、在试样的表层传播等特点,其适用于金属板表面大范围健康状况检测,本文详细的论述了电磁超声表面波产生的原理及传播特性,在此基础上,利用ANSYS软件进行了有限元仿真。利用折线形线圈及单磁铁的组合,建立了EMAT的3-D有限元模型。为简化有限元求解过程,将其产生的电磁超声表面波分为：电磁场、涡流、洛伦兹力、波动四个部分,以铝板为对象,以有限元仿真为基础,搭建了由激励、接收和电磁超声换能器三部分组成的电磁超声表面波金属板探伤检测装置。这个检测装置利用FPGA产生正、负两路频率和周波数可调的脉冲串,并采用多级放大来解决电磁超声回波中接收信号比较微弱的问题,通过产生的表面波对金属板中的缺陷进行了检测,及进行了声场指向性试验。实际试验是在长600mm,宽300mm,厚20mm的铝板上进行的,经试验验证,电磁超声表面波探伤检测装置可以在铝板中产生表面波,并通过产生的表面波可以对板中的缺陷进行检测。通过声场指向性试验可以证明,表面波传播具有指向性,回波信号经过小波降噪处理后,能够达到预期效果,信号能够清晰展示。
Aluminum alloy plate, which has the characteristics of high strength and low density as well as strong in corrosion resistance, is widely used in manufacturing fields such as aerospace equipment, military equipment and high-speed train. With space technology, lunar exploraion project, domestic large planes, aircraft carrier and high-speed rail project developing at such a tremendous pace and becoming mature, demand of aluminum alloy material in our country is more an more big. More importantly, quality of the products largely depends on quality of the material to be used. Therefore, the need for aluminum alloy detecting technology has became increasingly significant.
Electromagnetic ultrasonic testing technology has been widely studied owning to its advantages of no coupling agent needed, high-temperature resistance and easy operation. At present, electromagnetic ultrasonic testing technology has widespreadly applicated in defects detection of steel and aluminum plate as well as steel pipe. The technology is becoming one of the mainstream nondestructive testing methods at home and abroad. Nevertheless, its lower-changing-efficiency and weak-signal features remain the major obstacle to be overcomed for its practical application.
The paper reviews the development and application of electromagnetic ultrasound technology. Based on summarizing of the previous achievements obtained by researchers, corresponding EMAT transducing mechanism is explored. Aiming at three processes of EMAT:electromagnetic field and electromagnetic ultrasound coupling as well as acoustic field propagation, the paper analyzes the corresponding transducing principle. And futher, a detailed mathematical description is presented and complete formula and boundary conditions is deduced in the process of electromagnetic ultrasound transducing. In accordance with different types of generated wave, various configuration of permnent magnet and high frequency incentive coil in every EMAT components are given and analyzed. The simulated waveform categories and its acoustic propagation form aroused by various configuration are also obtained.
In this paper, ANSYS finite element simulation software is employed for electromagnetic field simulation and analysis of electromagnetic ultrasonic transducer, distributing situation of eddy current and lorentz force in the tested aluminum plate are gained. After coupling structue field with the results obtained from the electromagnetic field, particle's stress and strain parameters as well as displacement in the tested work piece can be obtained. Thus, the purpose of simulating and analyzing of the EM AT radiation acoustic field is achieved. As for lower-changing-efficiency and weak-signal shortcomings, the EMAT model is optimized in order to enhance its transduction efficiency. Aiming at main optimization objects:lift-off distance between coils and tested work piece as well as various parameters of permanent magnet and coil effecting on transduction efficiency, detailed analysis has been done. Eventually, optimum combination of various parameters is determined. Through simulation and analysis, internal radiation acoustic field distribution and pointing angle on surface of the EMAT tested work piece can be obtained. Moreover, validation and accuracy of the results can be experimentally verified. By altering thickness and incentive electric current frequency of the tested work piece, variation of the radiating acoustic field can be obtained accordingly. Furthermore, respective directional characteristics of radiation acoustic field distribution under three configuration of the transducer are analyzed.
Surface wave, featured by single-mode and energy-concentrated, is suitable for large scale quality detecting on metal plate surface. This paper discusses producing principle and propagation feature of electromagnetic ultrasonic surface wave. Finite element simulation has be done with utilization of ANSYS software. Combining broken line type coil with single magnet, EMAT3-D finite element model is established. To simplify finite element solving, the generated electromagnetic ultrasonic surface wave are divided into four parts:electromagnetic field, eddy current, lorentz force and fluctuation. Aiming at aluminum plate testing, electromagnetic surface wave metal plate inspecting device is developed based on finite element simulation. The device is composed of three parts:incentive part, receiving part and electromagnetic ultrasonic transducer. The detection device generates positive and negative two channels pulse sequence with adjustable frequency and cycle by use of FPGA. Multi-level amplification resolves the problem of weak signal receiving in electromagnetic ultrasonic echo wave. Defects in metal plate has been tested through the generated surface waves, while at the same time, acoustic field directional experiment has been done. The actual test is conducted on a aluminum plates with600mm length,300mm width and20mm thickness. Experiment shows that electromagnetic ultrasound surface wave detection device can generate surface wave in aluminum plate, through which defects in the aluminum plate can be tested. It is proved that surface wave propagation is directional through acoustic field directional experiment. After wavelet de-noising treatment, echo signal can achieve the expecting result and can be clearly demonstrated.
电磁超声检测技术因其无需耦合剂,耐高温又易操作等优势被广泛研究。目前,电磁超声检测技术被广泛应用在钢板、铝板、钢管等缺陷检测中,已经成为国内外主流的无损检测方法之一。但其缺点为换能效率较低、信号微弱,是实际应用中需要克服的主要困难。
本文在回顾了国内外多年来电磁超声技术的发展和应用,在总结前人们研究成果的基础上,对EMAT换能机理进行了探讨,针对EMAT工作的三个过程：电磁场、电磁超声耦合以及声场传播,分析相应的换能原理,进行详细的数学描述,推导出电磁超声换能过程的完整方程和边界条件。依据产生波型的不同,分析出EMAT的各个组成部分中高频激励线圈和永磁铁的不同配置情况,及对应不同配置情况激发出波型的种类和它的声波传播形式。
本文利用ANSYS有限元仿真软件对电磁超声换能器的电磁场进行了仿真分析,得出被测铝板中涡流及洛伦兹力的分布情况。同时将电磁场得到的结果与结构场进行耦合,得出被测铝板中质点的应力、应变及位移情况,从而达到对EMAT辐射声场进行仿真分析的目的。由于EMAT换能效率低,信号微弱,为了提高其换能效率,对其模型进行优化。针对优化的主要对象：线圈与被测铝板间的提离距离、线圈及永磁铁的各个参数对换能效率的影响做了详细分析,最终确定出各参数的优化组合。通过仿真分析得出EMAT被测铝板的内部辐射声场分布及被测铝板表面的指向角,并通过实验验证了这个仿真结果的正确性。通过改变被测铝板的厚度和激励电流频率得到相应辐射声场的变化情况。然后分析了三种不同配置的换能器辐射声场分布的各自指向性特点。
表面波具有单模式、能量集中、在试样的表层传播等特点,其适用于金属板表面大范围健康状况检测,本文详细的论述了电磁超声表面波产生的原理及传播特性,在此基础上,利用ANSYS软件进行了有限元仿真。利用折线形线圈及单磁铁的组合,建立了EMAT的3-D有限元模型。为简化有限元求解过程,将其产生的电磁超声表面波分为：电磁场、涡流、洛伦兹力、波动四个部分,以铝板为对象,以有限元仿真为基础,搭建了由激励、接收和电磁超声换能器三部分组成的电磁超声表面波金属板探伤检测装置。这个检测装置利用FPGA产生正、负两路频率和周波数可调的脉冲串,并采用多级放大来解决电磁超声回波中接收信号比较微弱的问题,通过产生的表面波对金属板中的缺陷进行了检测,及进行了声场指向性试验。实际试验是在长600mm,宽300mm,厚20mm的铝板上进行的,经试验验证,电磁超声表面波探伤检测装置可以在铝板中产生表面波,并通过产生的表面波可以对板中的缺陷进行检测。通过声场指向性试验可以证明,表面波传播具有指向性,回波信号经过小波降噪处理后,能够达到预期效果,信号能够清晰展示。
Aluminum alloy plate, which has the characteristics of high strength and low density as well as strong in corrosion resistance, is widely used in manufacturing fields such as aerospace equipment, military equipment and high-speed train. With space technology, lunar exploraion project, domestic large planes, aircraft carrier and high-speed rail project developing at such a tremendous pace and becoming mature, demand of aluminum alloy material in our country is more an more big. More importantly, quality of the products largely depends on quality of the material to be used. Therefore, the need for aluminum alloy detecting technology has became increasingly significant.
Electromagnetic ultrasonic testing technology has been widely studied owning to its advantages of no coupling agent needed, high-temperature resistance and easy operation. At present, electromagnetic ultrasonic testing technology has widespreadly applicated in defects detection of steel and aluminum plate as well as steel pipe. The technology is becoming one of the mainstream nondestructive testing methods at home and abroad. Nevertheless, its lower-changing-efficiency and weak-signal features remain the major obstacle to be overcomed for its practical application.
The paper reviews the development and application of electromagnetic ultrasound technology. Based on summarizing of the previous achievements obtained by researchers, corresponding EMAT transducing mechanism is explored. Aiming at three processes of EMAT:electromagnetic field and electromagnetic ultrasound coupling as well as acoustic field propagation, the paper analyzes the corresponding transducing principle. And futher, a detailed mathematical description is presented and complete formula and boundary conditions is deduced in the process of electromagnetic ultrasound transducing. In accordance with different types of generated wave, various configuration of permnent magnet and high frequency incentive coil in every EMAT components are given and analyzed. The simulated waveform categories and its acoustic propagation form aroused by various configuration are also obtained.
In this paper, ANSYS finite element simulation software is employed for electromagnetic field simulation and analysis of electromagnetic ultrasonic transducer, distributing situation of eddy current and lorentz force in the tested aluminum plate are gained. After coupling structue field with the results obtained from the electromagnetic field, particle's stress and strain parameters as well as displacement in the tested work piece can be obtained. Thus, the purpose of simulating and analyzing of the EM AT radiation acoustic field is achieved. As for lower-changing-efficiency and weak-signal shortcomings, the EMAT model is optimized in order to enhance its transduction efficiency. Aiming at main optimization objects:lift-off distance between coils and tested work piece as well as various parameters of permanent magnet and coil effecting on transduction efficiency, detailed analysis has been done. Eventually, optimum combination of various parameters is determined. Through simulation and analysis, internal radiation acoustic field distribution and pointing angle on surface of the EMAT tested work piece can be obtained. Moreover, validation and accuracy of the results can be experimentally verified. By altering thickness and incentive electric current frequency of the tested work piece, variation of the radiating acoustic field can be obtained accordingly. Furthermore, respective directional characteristics of radiation acoustic field distribution under three configuration of the transducer are analyzed.
Surface wave, featured by single-mode and energy-concentrated, is suitable for large scale quality detecting on metal plate surface. This paper discusses producing principle and propagation feature of electromagnetic ultrasonic surface wave. Finite element simulation has be done with utilization of ANSYS software. Combining broken line type coil with single magnet, EMAT3-D finite element model is established. To simplify finite element solving, the generated electromagnetic ultrasonic surface wave are divided into four parts:electromagnetic field, eddy current, lorentz force and fluctuation. Aiming at aluminum plate testing, electromagnetic surface wave metal plate inspecting device is developed based on finite element simulation. The device is composed of three parts:incentive part, receiving part and electromagnetic ultrasonic transducer. The detection device generates positive and negative two channels pulse sequence with adjustable frequency and cycle by use of FPGA. Multi-level amplification resolves the problem of weak signal receiving in electromagnetic ultrasonic echo wave. Defects in metal plate has been tested through the generated surface waves, while at the same time, acoustic field directional experiment has been done. The actual test is conducted on a aluminum plates with600mm length,300mm width and20mm thickness. Experiment shows that electromagnetic ultrasound surface wave detection device can generate surface wave in aluminum plate, through which defects in the aluminum plate can be tested. It is proved that surface wave propagation is directional through acoustic field directional experiment. After wavelet de-noising treatment, echo signal can achieve the expecting result and can be clearly demonstrated.
引文
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