Electromagnetic ultrasonic on-line monitoring method and failure mechanism of carbon fiber reinforced resin matrix composite material gas cylinder
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摘要: 氢能具有来源广泛、清洁无碳等优点，随着氢能源的广泛应用，氢能储运逐渐成为研究热点。目前，国家大力发展的碳纤维增强树脂基复合材料气瓶已被广泛应用于氢能储运领域，然而气瓶在使用和运输过程中，容易出现纤维断裂、划伤，严重影响使用安全，故亟需发展碳纤维增强树脂基复合材料气瓶在线监测技术。针对复合材料气瓶的纤维断裂、划伤缺陷在长期、多次充放气过程中发生扩展的问题，采用电磁超声换能器(Electromagnetic acoustic transducer，EMAT)在线监测方法，并结合90TJ3-140 MPa水压疲劳系统，分别采用超声导波反射式和透射式方法，分析了纤维损伤对导波幅值的影响，并研究了含纤维损伤的气瓶在不同疲劳状态下的导波信号特征的变化规律。结果表明：纤维损伤会降低透射波幅值，且幅值减少量由纤维损伤程度决定；随着气瓶内压的增加，超声导波的声速和中心频率逐渐减小；长20 mm、宽0.5 mm和深1 mm的裂纹对应的缺陷波幅值呈先增大后减小的趋势，经过110 MPa、80次循环后，缺陷波幅值由19.33 mV减小至8.02 mV，声速减小了6.6%，中心频率从0.24 MHz减小至0.17 MHz，纤维完全分层；针对长20 mm、宽0.5 mm和深0.5 mm的裂纹，当气瓶内压由0 MPa增加至105 MPa时，直达波幅值由80.17 mV减小至20.08 mV，降低了75%；采用的电磁超声技术能够很好地解决碳纤维增强树脂基复合材料气瓶在线监测技术难题。Abstract: Hydrogen energy has the advantages of wide source, clean and carbon-free. With the wide application of hydrogen energy, hydrogen energy storage and transportation has gradually become a research hotspot. At present, the carbon fiber reinforced resin matrix composite material gas cylinder vigorously developed by the country has been widely used in the field of hydrogen energy storage and transportation, but the gas cylinder is prone to fiber breakage and scratches during use and transportation, which seriously affects the safety of use, so it is urgent to develop the carbon fiber reinforced resin matrix composite material gas cylinder online monitoring technology. In order to solve the problem that fiber fracture and scratch defects of composite material gas cylinders will expand during long-term and multiple filling and venting, an online monitoring method using electromagnetic acoustic transducer (EMAT) was adopted. Combined with the 90TJ3-140 MPa hydraulic pressure fatigue system, the influence of fiber damage on the amplitude of guided wave was analyzed by ultrasonic guided wave reflection method and ultrasonic guided wave transmission method, and the variation of guided wave signal characteristics of gas cylinders with fiber damage under different fatigue conditions was studied. The results show that fiber damage can reduce the amplitude of transmission wave, and the amplitude reduction is determined by the degree of fiber damage. With the increase of the pressure inside the cylinder, the sound velocity and center frequency of ultrasonic guided wave decrease gradually. For cracks with length 20 mm, width 0.5 mm and depth 1 mm, the amplitude of the defect wave increases first and then decreases. After 110 MPa and 80 cycles, the amplitude of the defect wave decreases from 19.33 mV to 8.02 mV, the sound velocity decreases by 6.6%, and the center frequency decreases from 0.24 MHz to 0.17 MHz, the fibers are completely layered. For cracks with a length of 20 mm, a width of 0.5 mm and a depth of 0.5 mm, when the internal pressure of the cylinder increases from 0 MPa to 105 MPa, the direct wave amplitude decreases from 80.17 mV to 20.08 mV, which decreases by 75%. The electromagnetic ultrasonic technology can effectively solve the difficult problem of on-line monitoring of carbon fiber reinforced resin matrix composite material gas cylinder.
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图 1 贴附式周期性永磁体序列电磁超声换能器(PPM-EMAT)的结构示意图及换能机制
Figure 1. Structure diagram and energy exchange mechanism of attached periodic permanent magnet electromagnetic acoustic transducer (PPM-EMAT)
SH—Shear horizontal
图 3 电磁超声在线监测系统及碳纤维增强树脂基复合材料高压气瓶
Figure 3. Electromagnetic ultrasonic on-line monitoring system and carbon fiber reinforced resin matrix composite high pressure gas cylinder
图 4 碳纤维增强树脂基复合材料高压气瓶的结构
Figure 4. Structure of carbon fiber reinforced resin matrix composite high pressure gas cylinder
图 7 不同疲劳状态下的超声A扫信号
Figure 7. Ultrasonic A scanning signal under different fatigue conditions
图 8 不同疲劳状态下的反射水平剪切(SH)导波幅值
Figure 8. Amplitude of reflected shear horizontal (SH) guide wave under different fatigue states
图 9 不同疲劳状态下的碳纤维分层情况：(a) 50 MPa-15次； (b) 60 MPa-15次；(c) 100 MPa-30次；(d) 110 MPa-80次
Figure 9. Stratification of carbon fiber under different fatigue conditions: (a) 50 MPa-15 cycles; (b) 60 MPa-15 cycles; (c) 100 MPa-30 cycles; (d) 110 MPa-80 cycles
图 10 碳纤维增强树脂基复合材料高压气瓶的SH导波频谱
Figure 10. SH guided wave spectrum of carbon fiber reinforced resin matrix composite high pressure gas cylinder
图 11 不同损伤状态下碳纤维增强树脂基复合材料高压气瓶SH导波的中心频率
Figure 11. Center frequency of SH guided wave of carbon fiber reinforced resin matrix composite high pressure gas cylinder under different damage states
图 12 碳纤维增强树脂基复合材料高压气瓶有无缺陷时的超声A扫信号
Figure 12. Ultrasonic A scanning signal with and without defect of carbon fiber reinforced resin matrix composite high pressure gas cylinder
图 13 碳纤维增强树脂基复合材料高压气瓶透射式不同损伤状态下的超声A扫信号
Figure 13. Transmission type ultrasonic A scanning signal of carbon fiber reinforced resin matrix composite high pressure gas cylinder under different damage states
图 14 15次循环下碳纤维增强树脂基复合材料高压气瓶不同损伤状态下的透射SH导波幅值
Figure 14. Amplitude of transmitted SH guide wave of carbon fiber reinforced resin matrix composite high pressure gas cylinder under different damage states with 15 cycles
图 15 碳纤维增强树脂基复合材料高压气瓶不同疲劳状态下的纤维分层情况：(a) 0 MPa；(b) 50 MPa；(c) 60 MPa；(d) 70 MPa；(e) 87.5 MPa；(f) 105 MPa
Figure 15. Fiber delamination of carbon fiber reinforced resin matrix composite high pressure gas cylinder under different fatigue conditions: (a) 0 MPa; (b) 50 MPa; (c) 60 MPa; (d) 70 MPa; (e) 87.5 MPa; (f) 105 MPa
表 1 水压疲劳试验参数
Table 1. Hydraulic fatigue test parameters
Parameter Value High pressure holding deviation setting/MPa 4 High pressure holding time setting/s 2 Low pressure holding deviation setting/MPa 1 Low pressure holding time setting/s 2 Unloading proportional valve close setting 80.0 Pressure relief proportional valve close setting 80.0 Pressure relief proportional valve close minimum 0.2 Pressure relief proportional valve close extreme
dead zone value0.2 Step-down time increment setting/s 1 
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表 2 不同损伤状态下的碳纤维增强树脂基复合材料声速
Table 2. Sound velocity of carbon fiber reinforced resin matrix composites under different damage states
Fatigue state Velocity of sound/(m·s−1) 0 MPa 1833.07 20 MPa-15 cycles 1828.60 30 MPa-15 cycles 1827.49 40 MPa-15 cycles 1827.15 50 MPa-15 cycles 1767.83 60 MPa-15 cycles 1718.21 70 MPa-15 cycles 1713.31 80 MPa-15 cycles 1713.30 90 MPa-15 cycles 1718.21 100 MPa-30 cycles 1718.21 110 MPa-30 cycles 1711.74 110 MPa-80 cycles 1711.74
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