航空发动机整体叶环中纤维断丝超声检测方法

doi:10.11900/0412.1961.2019.00441

金属学报

2020, Vol. 56

Issue (8): 1175-1184 DOI: 10.11900/0412.1961.2019.00441

本期目录 | 过刊浏览

航空发动机整体叶环中纤维断丝超声检测方法

武玉鹏¹^,², 张博¹(

), 李经明¹, 张双楠¹, 吴颖¹, 王玉敏¹, 蔡桂喜¹

1 中国科学院金属研究所沈阳 110016
2 中国科学技术大学材料科学与工程学院沈阳 110016

Ultrasonic Detection for Fiber Broken in Aero-Engine Integral Bladed Ring

WU Yupeng¹^,², ZHANG Bo¹(

), LI Jingming¹, ZHANG Shuangnan¹, WU Ying¹, WANG Yumin¹, CAI Guixi¹

1 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
2 School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China

引用本文:

武玉鹏, 张博, 李经明, 张双楠, 吴颖, 王玉敏, 蔡桂喜. 航空发动机整体叶环中纤维断丝超声检测方法[J]. 金属学报, 2020, 56(8): 1175-1184.
Yupeng WU, Bo ZHANG, Jingming LI, Shuangnan ZHANG, Ying WU, Yumin WANG, Guixi CAI. Ultrasonic Detection for Fiber Broken in Aero-Engine Integral Bladed Ring[J]. Acta Metall Sin, 2020, 56(8): 1175-1184.

全文: PDF(2938 KB) HTML

摘要:

基于超声头波(head-waves)理论，当探头以一定角度激励出的折射纵波传播到界面时产生能量较高的爬波，据此建立了连续SiC纤维增强钛合金基复合材料(Ti-MMC)整体叶环中SiC纤维环断丝缺陷超声爬波检测的有限元仿真模型，分析了多层介质界面超声波传播特性及爬波遇到断丝缺陷时的衍射现象。仿真结果表明，在缺陷上方的水层中会产生明显的缺陷信号波。根据仿真结果，设计制作了超声爬波(5 MHz，20°)-水浸聚焦(5 MHz，直径6 mm)组合探头和带有纤维断丝的人工缺陷试样，采用超声C扫描设备进行了检测实验。结果表明，超声爬波法能够成功地检测纤维环试样中不同深层的3层断丝缺陷(裂纹自身高度约0.42 mm)。该方法简单、经济、快速，有望解决Ti-MMC整体叶环中深埋型纤维环断丝缺陷的无损检测难题。

关键词 ：整体叶环, 连续SiC纤维, 复合材料, 超声检测, 爬波

Abstract：

The fiber fracture is a very dangerous defect in the aeroengine integral bladed rings which is manufactured by continuous SiC fibers-reinforced titanium alloy matrix composite (Ti-MMC). Currently the lack of an effective method for inspecting the fiber fracture seriously influences the quality control of the aeroengine integral bladed rings, therefore solving the problem of non-destructive testing for deep buried radial micro-cracks is an insurmountable barrier for the application of Ti-MMC integral bladed rings in aviation. In this work, based on the theory of ultrasonic head-waves, the refraction longitudinal waves with the proper angle generated by the creeping wave probe are propagated on the interface, which means the creeping wave with high energy is generated. The finite element simulation model of the creeping wave is established for inspecting the defect of SiC fibers breakage in Ti-MMC aero-engine bling structure. Based on the results of the finite element simulation, significant defect signal waves are generated in the water layer above the defect. After that, not only the ultrasonic propagation characteristics at the interface of multilayer media but also the diffraction phenomenon of the creeping wave when they encounter the broken wire defect are analyzed. And the detection signal amplitude is not only affected by the incident angle of the creeping probe but also is related to the thickness of titanium alloy. In order to receive the diffracted waves with high sensitivity, the assembled probe, which is composed by a creeping wave exciter (5 MHz, 20°) and an immersion focusing sensor (5 MHz, diameter 6 mm), is specially designed and manufactured according to the results of the finite element simulation. In addition, the artificial sample with the broken fiber is prepared and then tested by the ultrasonic C-scan testing system with the assembled probe. The results show that the three-layer broken wire defects (the crack height is about 0.42 mm) with different depths in the artificial sample can be detected successfully. The C-scan results can match the defect positions of the artificial sample which means this detection method is valid. This method is simple, economical and fast, and is expected to solve the problem of nondestructive testing for broken wire in the deep embedded fiber ring in the Ti-MMC aero-engine bling structure.

Key words： integral bladed ring continuous SiC fiber composite ultrasonic testing creeping wave

收稿日期: 2019-12-23

ZTFLH:

O426.9

基金资助:国家自然科学基金项目(51605468);中国科学院仪器设备功能开发技术创新项目(Y8M1734171);辽宁省自然科学基金项目(2019-MS-334)

作者简介: 武玉鹏，男，1994年生，硕士生

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https://www.ams.org.cn/CN/10.11900/0412.1961.2019.00441 或 https://www.ams.org.cn/CN/Y2020/V56/I8/1175

图1 整体叶环制造工艺示意图

图2 SiC纤维增强钛合金基复合材料(Ti-MMC)整体叶环坯中缺陷形态示意图

图3 一种特殊纵波P1入射形成的头波系统[23]

图4 TOFD检测原理示意图

图5 整体叶环坯纤维断丝超声爬波与水浸聚焦组合检测法示意图

图6 简单结构头波系统组成仿真模型

图7 超声激励信号

图8 不同时刻(t)的声场分布

图9 整体叶环坯纤维断丝超声检测仿真模型

图10 不同时刻的声场分布

图11 缺陷衍射波进入水中时的声场

图12 有无缺陷时的信号对比

图13 探头角度对检测信号幅度的影响

图14 钛合金层厚度对检测信号幅度的影响

图15 带预制纤维断丝缺陷的Ti-MMC试样

图16 探头组件示意图

图17 人工试样C扫描检测结果

图18 人工试样中典型位置的A扫信号

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