复合材料结构中θ-胶接界面非对称频率超声表征与脱粘评估

Characterization of θ-bonding interface and delamination evaluation in composite structures using asymmetrical-frequency ultrasonic technique

  • 摘要: 胶接是复合材料中一种重要的连接形式,胶接界面质量好坏影响复合材料结构的整体性能,通常需要对胶接界面进行100%无损检测,垂直入射超声纵波反射法是一种有效的检测方法,但当胶接界面与零件表面呈现一定的夹角θ,形成θ-胶接界面时,因得不到理想的超声入射界面,会导致复合材料结构中θ-胶接界面超声检测与缺陷评估变得困难。针对碳纤维树脂基复合材料层压结构中θ-胶接界面检测,研究了一种非对称频超声(Asymmetric-frequency ultrasonic,AU)检测方法,构建了不同频率模式的超声检测系统,设计制备了复合材料结构θ-胶接界面试件,研究了不同频率模式超声波在θ-胶接界面区产生的超声信号时域行为和断面成像特征。实验结果表明:在AU模式下,回波信号质量、时域可分辨性均比对称频率超声(Symmetric-frequency ultrasonic,SU)方法明显好,AU断面成像质量、空间分辨率明显得到改善;根据成像灰度分布特征,可以非常有效地识别出θ-胶接界面区及其大小、θ-胶接界面区形貌特征、θ-胶接界面及其界面脱粘、θ-胶接界面区厚度、θ-胶接界面区周围的几何特征变化等界面行为;对于4.5 mm厚复合材料试件,局部厚度评估结果与实际机械测量厚度4.60 mm(均值)相差小至0.10 mm,倾斜的θ-胶接连接界面对脱粘的检出能力没有影响,从而为复合材料结构中θ-胶接界面及冲击凹坑提供了一种非常有效的无损表征和缺陷评估方法,取得了很好的实际检测应用效果。

     

    Abstract: Adhesive bonding is an important form of joint in composite structure. Joint quality of bonding interface directly affects the overall performance of the composite structures. Therefore, it is usually required to conduct 100% non-destructive testing and evaluation (NDT&E) on bonding quality. The normal incidence ultrasonic longitudinal wave reflection method is an effective detection technique. When there is a θ angle between the bonding interface and the surface of the part to be tested, a θ-bonding interface is formed. Because of the lack of ideal ultrasonic incident angle at the θ-bonding interface, it is difficult to detect and evaluate quality of θ-bonding interface. An asymmetric-frequency ultrasonic (AU) method was studied for the NDT&E of θ-bonding interface in carbon fiber laminate structures. An ultrasonic detection system with different frequency modes was developed, and θ-bonding specimens were designed and manufactured. The time-domain behavior and cross-sectional imaging characteristics from different frequency mode ultrasonic waves at θ-bonding interfaces are studied. The experiments demonstrated that the quality and time-domain resolution of the echo signal under AU mode are obviously better than those of the symmetric-frequency ultrasonic (SU) method, and the imaging quality and spatial resolution of the AU cross-section are obviously improved. According to the imaging gray-scale distribution characteristics, the interface behavior of θ-bonding interface region and its size, θ-bonding interface topography, θ-bonding interface and disbands in it, θ-bonding interface thickness, and the change of geometric features around θ-bonding interface region can be effectively identified. The minimum deviation between the ultrasonically estimated and mechanical measured average thicknesses reaches to 0.10 mm for 4.5 mm thick carbon-fiber composite specimen. The tilted bonding interface has no effect on disbands detectability using the AU technique. Thus, it provides an effective nondestructive characterization and reliable defect evaluation method for θ-bonding interface and impact pits in composite structures. A very good practical application has been achieved in composite structures.

     

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