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基于水浸超声C扫描技术的微蜂窝钎焊复合材料钎着率检测方法探讨

Discussion on brazed rate testing of micro-honeycomb brazed composites based on water-immersion ultrasonic C-scan technology

  • 摘要: 微蜂窝钎焊复合材料钎着率是其钎焊工艺优化、质量检测与产品验收的重要依据,其无损检测方法一直是相关领域的研究热点。本文以直径为300 mm、厚度为20 mm的高温合金环内表面钎焊六边型蜂窝(单个蜂窝直径为0.55 mm)环件作为考察对象,通过对超声C扫描探头频率、焦距、步进、焦点尺寸等参数进行优化,探讨了采用水浸超声C扫描技术量化表征微蜂窝钎焊复合材料钎着率的可行性。基于频率梯度设计与参数匹配优化的经验,分别选用10、20、30 MHz共3种频率探头,并匹配相应焦距、步进与焦点尺寸开展试验,结果表明,当探头频率为30 MHz,焦距为31.75 mm,焦点尺寸为0.16 mm, 步进为0.05 mm的条件下,可获得相对清晰蜂窝图像,最小分辨特征尺寸达0.05 mm。对图像进行了等比例放大处理,测得这些结构的直径为0.56 mm,该测定值与部件实际的微蜂窝直径0.55 mm吻合。结合钎着率定义(钎焊接头内实际有效冶金结合钎缝面积与设计钎焊总面积之比),本文提出采用水浸超声 C 扫描技术,通过获取清晰蜂窝图像面积与工件总扫查面积的比值,可实现对钎着率的定量计算

     

    Abstract: The brazed rate of micro-honeycomb brazed composites is an important basis for optimizing the brazing process, quality inspection and product acceptance, and its non-destructive testing methods have always been a research hotspot in related fields. In this paper, a hexagonal honeycomb ring (with a single honeycomb diameter of 0.55 mm) that was brazed on the inner surface of high-temperature alloy ring with diameter of 300 mm and thickness of 20 mm was seclected as the research object. Through optimizing the parameters of ultrasonic C-scan probe, such as frequency, focal length, step size and focus size, the feasibility of quantitatively characterizing the brazed rate of micro-honeycomb brazed composites was explored by water-immersion ultrasonic C-scan technology. Based on the experience of frequency gradient design and parameter matching optimization, three types of probes with frequencies of 10, 20 and 30 MHz were selected respectively, and the corresponding focal lengths, step sizes and focus sizes were matched for experiments. The results showed that a relatively clear honeycomb image could be obtained with probe frequency of 30 MHz, the focal length of 31.75 mm, the focus size of 0.16 mm, and the step size of 0.05 mm, and the minimum resolution feature size reached 0.05 mm. The images were proportionally enlarged, and the diameters of these structures were measured to be 0.56 mm, which was consistent with the actual micro-honeycomb diameter of 0.55 mm. Combined with the definition of brazed rate (the ratio of the actual effective metallurgical bonding brazing seam area of the brazed joint to the total brazed area designed), water-immersion ultrasonic C-scan technology was adopted to calculate quantitatively the brazed rate by obtaining the ratio of the clear honeycomb image area to the total scanning area of the workpiece.

     

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