基于光波反射行为的复合材料孔隙率跨模态智能评估方法

The cross-mode artificial intelligent method for evaluation of porosity in composites based on reflection behavior of light waves

  • 摘要: 气孔或孔隙或空隙(统称“孔隙”)是树脂基复合材料结构在固化成型过程中容易产生的一种具有显微分布特征的弥散性缺陷,影响复合材料结构力学性能。采用传统光学人工观察或纯灰度统计方法,难以准确进行复合材料孔隙率量化评估,且效率低,影响构建复合材料制件超声孔隙率评估模型的准确性,增加了漏检误判风险,不利于复合材料关键结构件的质量控制。针对碳纤维增强树脂基复合材料(Carbon fiber-reinforced resin-matrix composites, CFC)复杂多向层压结构界面特点和孔隙特征,研究了一种基于可见光在 CFC表面反射行为的孔隙率跨模态人工智能(Cross-mode Artificial Intelligent,CAI)评估方法。分析了光波在纤维、基体树脂、孔隙部位的反射行为。构建了CFC孔隙CAI评估实验系统。利用设计制备的真实工艺条件下不同CFC孔隙试样,研究了不同取向纤维、树脂区、孔隙、层间界面的光学反射信号变化规律。构建了CAI评估模型。分析了CAI量化评估结果与效果。实验结果表明:基于CFC表面光学反射行为产生的信号变化规律及其成像特征,利用所构建的CAI模型和方法,可以准确地进行孔隙量化评估。双帧信号的孔隙率评估正确性达到100%。完成孔隙的智能识别、标注和量化结果列表等耗时约0.14秒,即不超过0.5秒,孔隙率评估效率得到极大地提升。在20 μm2 识别阈值时,最小可准确识别出的孔隙大小达 5.5 μm×6.5 μm、孔隙最小取向尺寸达 4.5 μm。从而为CFC提供了一种快速智能可视化孔隙率表征和量化评估方法。

     

    Abstract: Voids, porosity or pores (Collectively referred to as "porosity") are the defects with microscopic distribution characteristics that are prone to occur during the curing process of resin-matrix composites. Porosity influences mechanical properties of composite structures. Using traditional optical man-observation or pure gray-scale statistical methods, it is difficult to accurately perform a quantitative evaluation of porosity, and the testing efficiency is very low, thus affecting the accuracy of constructing an ultrasonic porosity evaluation model for composite parts, and increasing the risk of missed detection and misjudgment. It is detrimental to the quality control and safety of key composite components. In view of the complex multi-directional lay-up structure characteristics and porosity features in carbon fiber-reinforced resin-matrix composites (CFCs), a cross-modal artificial intelligent (CAI) porosity evaluation method based on the light reflection behavior in their surfaces was studied. The reflection behavior of optical waves on the areas of fibers, matrix resin, and porosity was analyzed. A CFC porosity CAI evaluation experimental system was constructed. Using different CFC porosity samples prepared under the real manufacturing process condition, the variation characterization of optical reflection signals at the surfaces of different directional fiber, resin, porosity, and interfaces were studied. The CAI evaluation model was constructed. The CAI quantitative evaluation results and effects were analyzed. The experimental results show that: Based on the signal variations and their imaging characteristics from the optical reflection behavior at the CFC surface, using the constructed CAI model and method, the porosity quantitative evaluation can be accurately carried out. The accuracy of porosity evaluation from the two frame signals reaches up to 100%. The intelligent recognition, annotation, and quantitative results list of measured porosity are completed within 0.5 second, approximately 0.14 second. The porosity testing efficiency has been greatly improved using the CAI evaluation method. The minimum porosity that can be accurately identified reaches to 5.5 μm × 6.5 μm in size and 4.5 μm in orientation width at 20 μm2 porosity discrimination threshold, thus providing a fast, intelligent visual characterization, and quantitative evaluation method for CFC porosity testing.

     

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