复合缺陷电磁-声一体化检测方法的可靠性评估  

Reliability Evaluation of Electromagnetic-Acoustic Integrated Testing Method for Composite Defects

作　　者：段志荣 张晓明 井德强 杨淑言 黄磊 张鸿博 李亮 解社娟 陈振茂[2] Zhirong Duan;Xiaoming Zhang;Deqiang Jing;Shuyan Yang;Lei Huang;Hongbo Zhang;Liang Li;Shejuan Xie;Zhenmao Chen(Shaanri Special Equipment Inspection and Testing Institute,Xi'an,710048;State Key Laboratory for Strength and Vibration of Mechanical Structures,Shaanri Engineering Research Center of Nondestructive Testing and Structural Integrity Evaluation,School of Aerospace Engineering,Xi'an Jiaotong University,Xi'an,710049;CNPC Tubular Goods Research Institute,Xi'an,710077)

机构地区：[1]陕西省特种设备检验检测研究院,西安710048 [2]复杂服役环境重大装备结构强度与寿命全国重点实验室,陕西省无损检测与结构完整性评价工程技术中心,西安交通大学航天航空学院,西安710049 [3]中国石油集团工程材料研究院有限公司,西安710077

出　　处：《固体力学学报》2025年第1期27-38,共12页Chinese Journal of Solid Mechanics

基　　金：国家重点研发计划项目(2022YFC3005001,2023YFF0615200);国家自然科学基金项目NSAF(No.U2130206);国家自然科学基金项目NSFC(No.12222207)资助.

摘　　要：金属结构广泛应用于现代工业的各个领域,在其制造和服役过程中会产生各种复杂缺陷,例如金属结构的表面和底部都出现缺陷的复合缺陷情况,这严重影响到金属结构的力学性能和使用寿命.使用单一的检测方法难以满足实际检测需求,而两种或多种检无损测方法实施检测工作存在检测效率低、成本高等问题.为解决这一难题,本文开发了一种新型电磁-声一体化检测方法(脉冲涡流-电磁超声复合检测方法),并基于检出概率理论重点对所提方法的检测能力进行深入评估.首先针对铝合金试件同时存在表面裂纹和底部减薄缺陷的复合缺陷情况开发了脉冲涡流-电磁超声一体化检测方法的数值计算方法和实验系统,并基于频谱分析理论研究复合信号的分离方法.其次根据概率与统计学基本原理建立了检出概率的数学模型,并通过数值模拟结果和实验结果建立了复合缺陷尺寸的信号特征量数据库.最后对信号特征量数据库进行信号统计分析,并根据建立的检出概率模型对表面裂纹和底部减薄缺陷的尺寸参数进行检出概率分析,确定脉冲涡流-电磁超声复合检测方法的最小可检尺寸.Metal structures are widely used in modern industrial fields,but their manufacturing and service processes often produce composite defects that affect the mechanical properties and service life.Defects can appear both on the surface and beneath the structure,making it challenging for a single nondestructive testing(NDT)method to address all issues.Furthermore,using multiple NDT methods can result in low efficiency and high costs.To address this,a novel electromagnetic-acoustic integrated testing method,called PECT-EMAT,has been developed in this study,with its detection capability evaluated based on the theory of probability of detection(POD).Firstly,we established a simulation method and experimental system for PECT-EMAT to test aluminum alloy specimens with both surface cracks and bottom thinning defects,and explored a signal separation method using spectrum analysis.Next,we built a POD model based on statistical methods and created a signal database for composite defects.Finally,we conducted a statistical analysis of this database to determine the minimum detectable size of the PECT-EMAT hybrid testing method.The research findings indicate that:(1)For metal structures with both surface cracks and bottom thinning defects,the proposed PECT-EMAT method can effectively identify composite defects through signal separation.(2)The PECT signals and EMAT signals separated from the original detection signals exhibit distinct characteristics for detecting surface cracks and bottom thinning defects,respectively,leading to the establishment of a signal features'database for composite defects.(3)POD analysis reveals that the minimum detectable lengths for surface cracks are 2.72 mm in simulation and 2.12 mm in experiments,while for bottom thinning defects,they are 4.13 mm and 1.92 mm,respectively.This study provides a theoretical foundation for the adoption of the PECT-EMAT hybrid testing method and offers a reliable technical means for detecting complex defects in engineering structures.

关 键 词：复合缺陷 电磁-声一体化检测 检出概率 

分 类 号：TG115.28[金属学及工艺—物理冶金]