Fatigue crack dynamic monitoring of weathering steel joint based on ultrasonic phased array
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摘要: 借助超声相控阵技术对耐候钢对接接头开展疲劳失效过程动态监测. 基于超声波探头的信号特征，研究其扇形扫描反射过程，建立实时扫查方案， 并对10 mm厚的耐候钢对接接头实施实时监测.结果表明，当疲劳寿命为5 × 104次时，相控阵检测到多个裂纹从对接接头焊趾部位萌生，并沿着板厚扩展，当疲劳寿命超过3.5 × 105次时，裂纹开始快速扩展. 与疲劳试验断口对比发现，基于相控阵检测得到的裂纹尺寸与试验结果基本一致，验证了相控阵裂纹动态检测的准确性. 根据裂纹深度a、裂纹长度2c与循环次数N关系，明确了裂纹动态演化行为，并获得中厚板耐候钢对接接头表面裂纹的扩展演化规律.Abstract: In this paper, ultrasonic phased array technology was used to monitor the fatigue failure process of weathering steel butt joints. Based on the signal characteristics of ultrasonic probe, the fan-shaped scanning reflection process was studied, and a real-time scanning scheme was established for real-time monitoring of 10 mm thick weather resistant steel butt joints. The results show that when the fatigue life was 5 × 104 cycles, multiple cracks initiated at the weld toe of the butt joint and propagated along the plate thickness were detected by phased array. The cracks begin to expand rapidly when the fatigue life exceeded 3.5 × 105 cycles. Compared with the fatigue test fracture surface, it was found that the crack size based on the phased array detection was basically consistent with the test results, which validated the accuracy of the phased array crack dynamic detection. According to the relationship between the crack depth a, crack length c and cycle number N, the dynamic evolution of cracks was determined, the law of surface crack growth and evolution of weathering steel butt joint of medium and thick plate was built up.
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Keywords:
- ultrasonic phased array /
- weathering steel /
- crack size /
- fatigue life
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图 3 超声相控阵设备及工作原理
Figure 3. Ultrasonic phased array equipment and working principle. (a) ultrasonic phased array hardware; (b) diagram of working mechanism
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图 4 定义被检试件焊缝形式与超声相控阵成像
Figure 4. Definition of weld form and phased array imaging of tested piece. (a) definition of weld form; (b) phased array imaging
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图 5 试件B1-2的宏观断口
Figure 5. Fracture of specimens B1-2. (a) Fracture location; (b) Fracture morphology
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图 6 初步寻找疑似疲劳源(沿着焊缝长度方向)
Figure 6. Preliminary search for suspected fatigue source (along the length of weld). (a) 5 × 104 cycles; (b) 7 × 104 cycles; (c) 1.1 × 105 cycles
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图 7 疲劳源及主裂纹形成
Figure 7. Fatigue source and main crack formation. (a) 1.5 × 105 cycles; (b) 2.1 × 105 cycles; (c) 2.4 × 105 cycles; (d) 2.5 × 105 cycles; (e) 2.9 × 105 cycles
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图 8 疲劳裂纹扩展形态演化示意图
Figure 8. Schematic diagram of crack growth morphology evolution. (a) crack propagation detected by phased array; (b) schematic diagram of crack propagation and evolution
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图 10 试件B1-2不同循环次数下的裂纹尺寸变化
Figure 10. Crack size change of specimen B1-2 under different cycles
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图 11 试件B1-2裂纹深度a与裂纹长度c的拟合曲线
Figure 11. Fitting curve of crack depth a and crack length c of specimen B1-2
表 1 SMA490BW母材与CHW-55CNH焊丝成分(质量分数, %)
Table 1 Compositions of SMA490BW base metal and CHW-55CNH wire
材料 C Mn Si P S Cr Fe SMA490BW ≤0.18 ≤1.4 0.15 ~ 0.65 ≤0.035 ≤0.035 0. 45 ~ 0.75 余量 CHW-55CNH ≤0.1 1.2 ~ 1.6 ≤0.6 ≤0.025 ≤0.02 0.3 ~ 0.9 余量 
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表 2 焊接工艺参数
Table 2 Welding process parameters
焊接电压
U/V焊接电流
I/A焊接速度
v/(mm·s−1)23 227 3.0
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表 3 疲劳试验参数
Table 3 Fatigue testing parameter
板厚
t/mm加载宽度
b/mm名义应力
σ /MPa应力比
R最小加载力
Fmin/kN最大加载力
Fmax/kN疲劳寿命
N/次10 80 195 0. 1 21. 6 216 371 557
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