铝合金搅拌摩擦焊超声检测研究进展

doi:10.11868/j.issn.1001-4381.2021.000633

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摘要

铝合金搅拌摩擦焊(friction stir welding, FSW)焊接参数选择不当将会产生隧道孔、未焊透(lack of penetration, LOP)和吻接等取向复杂、细微紧贴的缺陷。首先, 本文简述了FSW焊缝与典型缺陷特征, 总结了超声检测时面临纵向分辨力低、缺陷表征不完整、材料与缺陷声阻抗接近和灵敏度不足等难点。随后, 从常规超声、超声衍射时差法(time-of-flight diffraction, TOFD)、相控阵超声检测技术和其他超声检测技术等方面综述了现有的铝合金FSW超声检测研究工作。最后, 结合超声信号处理方法和机器学习方法对研究前景进行展望: 可以通过分析和提取信号特征, 进一步提升超声检测分辨力和信噪比, 并实现取向复杂缺陷和细微紧贴缺陷的精准辨识与定量。

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	金士杰
	田鑫
	林莉

关键词 ：搅拌摩擦焊, 铝合金, 超声检测, 缺陷

Abstract：

The defects in friction stir welding (FSW) of aluminum alloy, e.g., tunnel defect, lack of penetration (LOP) and kissing bond, are with complex shape and narrow gap by inappropriate welding parameters. Firstly, the characteristics of FSW welding and typical defects were briefly described, and the difficult points in ultrasonic testing were summarized from the low time resolution, incomplete characterization of irregular defects, close acoustic impedance between kissing bond and Al alloy and the reduction of detection sensitivity. Subsequently, the research work on the ultrasonic testing for FSW of aluminum alloy were reviewed from the following four aspects, including conventional ultrasonic testing, time-of-flight diffraction (TOFD), phased array ultrasonic testing and other ultrasonic testing techniques. Finally, the research on the ultrasonic signal processing methods and machine learning methods was prospected. The signal characteristics were analyzed and extracted to further improve the resolution and signal-to-noise ratio of ultrasonic testing and realize the accurate identification and quantification for complex shape defects and subtle defects.

Key words： friction stir welding aluminum alloy ultrasonic testing defect

收稿日期: 2021-07-09 出版日期: 2022-08-16

中图分类号:	TG146.21
	TB553

基金资助:国家重点研发项目(2019YFA0709003);大连市科技创新基金项目(2020JJ26GX041);中央高校基本科研业务费(DUT20ZD204)

通讯作者: 金士杰,林莉 E-mail: jinshijie@dlut.edu.cn;linli@dlut.edu.cn

作者简介: 林莉(1970—)，女，教授，博士，研究方向：材料无损检测与评价，联系地址：辽宁省大连市高新园区凌工路2号大连理工大学无损检测研究所(116024)，E-mail：linli@dlut.edu.cn
金士杰(1984—)，男，副教授，博士，研究方向：材料无损检测与评价，联系地址：辽宁省大连市高新园区凌工路2号大连理工大学无损检测研究所(116024)，E-mail：jinshijie@dlut.edu.cn

引用本文:

金士杰, 田鑫, 林莉. 铝合金搅拌摩擦焊超声检测研究进展[J]. 材料工程, 2022, 50(8): 45-59.
Shijie JIN, Xin TIAN, Li LIN. Research progress in ultrasonic testing for friction stir welding of aluminum alloy. Journal of Materials Engineering, 2022, 50(8): 45-59.

链接本文:

http://jme.biam.ac.cn/CN/10.11868/j.issn.1001-4381.2021.000633 或 http://jme.biam.ac.cn/CN/Y2022/V50/I8/45

Fig.1 铝合金FSW焊接示意图

Fig.2 铝合金FSW焊接接头分区示意图

Fig.3 FSW接头横截面超声衰减系数变化趋势^[31]

Fig.4 不同深度底面开口槽TOFD仿真检测信号
(a)d=1 mm；(b)d=7 mm

Fig.5 不同类型缺陷的金相照片^[56]
(a)LOP；(b)隧道孔

Fig.6 铝合金FSW焊缝根部缺陷金相照片^[32]
(a)OM图；(b)SEM图；(c)区域A放大；(d)区域B放大；(e)区域C放大

Fig.7 去噪前后的FSW焊缝TOFD检测图像^[58]
(a)去噪前；(b)去噪后

Fig.8 不同检测频率f时的C扫查图像^[31]
(a)f=10 MHz；(b)f=20 MHz

Fig.9 FSW焊缝中不同缺陷的C扫查图像(1)及平均信号功率3D显示(2)^[73]
(a)LOP；(b)吻接

Fig.10 不同形态根部LOP的金相照片(1)及相控阵超声检测结果(2)^[88]
(a)垂直LOP；(b)弯曲LOP

Fig.11 不同铝合金FSW试件激光超声检测结果^[94]
(a)完好试样；(b)LOP缺陷试样

Fig.12 现有铝合金FSW超声检测难点及方法实施效果

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