碳纤维复合材料损伤的超声检测与成像方法研究进展

杨红娟; 杨正岩; 杨雷; 单一男; 林奎旭; 武湛君

doi:10.13801/j.cnki.fhclxb.20230318.001

碳纤维复合材料损伤的超声检测与成像方法研究进展

doi: 10.13801/j.cnki.fhclxb.20230318.001

1.
大连理工大学　航空航天学院，大连 116024
2.
大连海事大学　交通运输工程学院，大连 116026
3.
大连交通大学　机车车辆工程学院，大连 116028

基金项目: 国家重点研发计划(2018YFA0702800；2022YFB3402500)；国家自然科学基金(12102075)

详细信息

通讯作者:
武湛君，博士，教授，研究方向为复合材料与结构、结构健康监测、智能/纳米材料与结构　E-mail: wuzhj@dlut.edu.cn

中图分类号: TB553；TB332；TB551；TB552
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- 被引次数: 0
出版历程
- 收稿日期: 2022-12-07
- 修回日期: 2023-03-08
- 录用日期: 2023-03-11
- 网络出版日期: 2023-03-20
- 刊出日期: 2023-08-15

Progress in ultrasonic testing and imaging method for damage of carbon fiber composites

1.
School of Aeronautics and Astronautics, Dalian University of Technology, Dalian 116024, China
2.
College of Transportation Engineering, Dalian Maritime University, Dalian 116026, China
3.
College of Locomotive and Rolling Stock Engineering, Dalian Jiaotong University, Dalian 116028, China

Funds: National Key Research and Development Program of China (2018YFA0702800; 2022YFB3402500); National Natural Science Foundation of China (12102075)

摘要

摘要: 目的碳纤维复合材料具有密度小、弹性高和韧性好等特点，被广泛应用于航空航天和汽车工业等领域。由于碳纤维复合材料制作工艺的复杂性和不稳定性以及服役期间易受环境的影响，易产生分层、孔隙、纤维褶皱等各种类型的损伤。因此，为了防止重大事故的发生，亟需在碳纤维复合材料制造加工和服役阶段及时检测出损伤，以实现碳纤维复合材料的质量控制和安全性能评估。方法针对碳纤维复合材料结构无损检测技术有很多, 如X射线检测法、涡流检测法、磁粉检测法、激光散斑干涉法、红外热成像法和超声无损检测法等。其中，超声无损检测技术因具有技术成熟、检测成本低、准确度高等优势，被广泛应用于碳纤维复合材料的检测。本文介绍了基于体波或导波的C扫描、相控阵、空气耦合、激光超声、光纤超声检测技术的原理、特点以及用于碳纤维复合材料损伤检测的研究现状。本文综述了最具有代表性的损伤诊断成像算法，包括全聚焦成像、三维可视化成像、层析成像、逆时偏移成像和概率成像方法。结果基于体波的检测技术能够实现碳纤维复合材料厚度方向上微小损伤的检测，现有研究检测碳纤维复合材料的样品厚度的范围约为3~6.4 mm，在检测频率为20 MHz时，能够检测到的碳纤维复合材料最小损伤直径约为 0.5 mm。基于导波的检测技术，检测的样品厚度范围一般为2.54~4 mm的碳纤维复合材料层合板，该技术具有检测范围广和检测效率高等优势，能够检测最小损伤直径约为3 mm。成像结果表明五种成像方法能够有效地实现碳纤维复合材料各种类型的损伤形貌图像。然而，这五种成像方法的可靠性都依赖于碳纤维复合材料传播模型的建立和换能器的设计与布局，因此，在实际工业损伤检测诊断成像前，应准确测量各检测样品的各层厚度、弹性常数、密度以及检测换能器的参数等。根据实际损伤诊断需求，选择相应的成像方法。结论超声检测技术是一种可靠的无损检测/结构健康监测手段，在碳纤维复合材料损伤检测领域具有广泛的应用前景。可有效地解决碳纤维复合材料的各种损伤类型的检测，具有操作简单、高效、成本低、检测精度高等特点。总结并对比了超声检测技术结合体波或导波检测的特点以及用于碳纤维复合材料损伤检测的研究现状。各超声检测与成像方法有不同的优缺点，应根据实际检测需求，选择合适的成像方法。从建立复杂构件的碳纤维复合材料层合板的阵列声场模型、优化损伤成像算法、构建智能/高效/实时化的结构健康监测成像系统、建立损伤定量评估标准、结合机器学习和数字孪生技术实施损伤诊断评估和寿命预测等方面进行了展望。
- 超声检测 /
- 超声成像 /
- 损伤检测 /
- 结构健康监测 /
- 碳纤维复合材料
Abstract: Carbon fiber composites are widely used in aerospace and automotive industries due to the characteris-tics of low density, high elasticity, and better toughness. Due to the complexity and instability of the manufacturing process of carbon fiber composites and their vulnerability to environmental impact during service, it is likely to generate delamination, porosity, fiber wrinkle, and other types of damage. In this paper, the principles and characteristics of C-scan, phased array, air-coupled, optical fiber-ultrasound, and laser-ultrasonic testing based on body or guided waves, as well as the research status of these technologies for damage detection of carbon fiber compo-sites, are introduced respectively. The most representative imaging algorithms for damage diagnosis are shown, including total-focus imaging, 3D visualization imaging, tomography, reverse time migration imaging, and probability imaging method, these imaging methods can effectively realize various types of damage morphology in carbon fiber composites. The prospect is made from the following aspects: The establishment of an array acoustic field model of carbon fiber composite laminates, the optimization of damage imaging method, the construction of intelligent/efficient/real-time structural health monitoring imaging system, the establishment of damage quantitative evaluation criteria, and combination of machine learning and digital twin technology for damage diagnosis assessment and life prediction.
- ultrasonic testing /
- ultrasonic imaging /
- damage detection /
- structural health monitoring /
- carbon fiber composites

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图 1 碳纤维复合材料常见损伤^[4-5]

Figure 1. Common damage in carbon fiber composite materials^[4-5]

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图 2 损伤检测与成像的主要环节

Figure 2. Main links of damage detection and imaging

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图 3 基于体波检测的碳纤维复合材料各向同性声学模型

Figure 3. Isotropic acoustic model for carbon fiber composites based on body wave detection

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图 4 均质化声学模型示意图(a)^[6]和速度分布曲线(b)^[7]

Figure 4. Schematic diagram of the homogenization acoustic model (a)^[6] and velocity distribution curve (b)^[7]

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图 5 基于体波的碳纤维复合材料各向异性声学模型

Figure 5. Anisotropic acoustic model for carbon fiber composites based on body wave

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图 6 基于导波的碳纤维复合材料各向异性声学模型^[13]

Figure 6. Anisotropic acoustic model for carbon fiber composites based on guided wave^[13]

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图 7 B扫描和C扫描检测技术

Figure 7. B-scan and C-scan detection technology

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图 8 超声C扫描检测系统^[24]

Figure 8. Ultrasonic C-scan detection system^[24]

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图 9 检测复合材料中的冲击损伤：(a)超声波C扫描技术；(b) X射线技术^[44]

Figure 9. Detection of impact damage in composites: (a) Ultrasonic C-scan technology; (b) X-ray technology^[44]

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图 10 激光超声检测复合材料的结果^[46]

Figure 10. Results of the composite by the laser ultrasound^[46]

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图 11 光纤超声检测系统示意图^[88]

Figure 11. Schematic diagram of optical fiber ultrasonic testing system^[88]

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图 12 碳纤维复合材料中褶皱损伤的TFM成像^[32]

Figure 12. TFM imaging of wrinkle defects in carbon fiber composites^[32]

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图 13 碳纤维复合材料损伤的三维可视化成像^[110]

Figure 13. Three-dimensional visualization imaging of carbon fiber composite damage^[110]

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图 14 三维相控阵扫描示意图^[113]

Figure 14. Schematic image of a scanning of 3D phased arrays^[113]

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图 15 碳纤维复合材料的损伤层析成像结果^[118]

Figure 15. Tomography results of damage in carbon fibre composites^[118]

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图 16 碳纤维复合材料不同形状的损伤概率成像结果^[137]

Figure 16. Probability imaging results of damage in carbon fiber composites with different shapes^[137]

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表 1 检测碳纤维复合材料的线性换能器阵列参数

Table 1. Linear transducer array parameters for carbon fiber composites

Element pitch/ mm	Number of element	Centre frequency/ MHz	Ref.
0.6	64	5	[7]
0.75	64	2.25	[7]
1.4	32	2.25	[27]
1	64	5	[28]
0.63	64	5	[29]
0.6	16	7	[30]
1.0	32	5	[31]
0.3	128	10	[32]
0.6	32	5	[33-34]

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表 2 用于碳纤维复合材料损伤的检测技术的比较

Table 2. Comparison of damage detection techniques for carbon fiber composites

Detection technique	Wave type	Damage type	Feature
C-scan	Body wave	Hole^[25], delamination^[37], impact damage^[42], debonding defect^[43]	Intuitive display and high detection efficiency
Phased array	Body wave	Delamination^{[30, 35, 51]}, fiber wrinkle defect^[32]	Acoustic beam focusing, high detection accuracy, high detection sensitivity
Phased array	Guided wave	Delamination^[90], drill hole^[59], multiple surface damage^[63]
Air-coupled	Body wave	Delamination^[40], square hole^[41], impact damage^[42], debonding defect^[43]	Contactless, no coupling agent, no effect on material properties
Air-coupled	Guided wave	Circular defect^[69]
Laser ultrasonic	Body wave	Circular defect^[46], delamination^[45]	Long-distance, contactless, high-resolution, wide-range detection
Laser ultrasonic	Guided wave	Impact damage^[70]
Optical fiber ultrasonic	Guided wave	Impact damage^[88]	Anti-electromagnetic interference, corrosion resistant

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表 3 三维图像重构的两种数据采集方式的优劣

Table 3. Advantages and disadvantages of two data acquisition methods for 3D image reconstruction

Data acquisition method	Advantage	Disadvantage
1D linear array	Low cost	Complex detection process and slow detection speed^[111], low resolution^[112]
2D array	Fast detection speed, high imaging spatial resolution^[111]	High cost, complex acoustic beam control algorithm

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表 4 5种成像方法用于碳纤维复合材料损伤的优劣

Table 4. Advantages and disadvantages of five imaging methods for carbon fiber composite damage

Imaging method	Wave type	Advantage	Disadvantage	Application
Total focus method	Body wave	Simple algorithm	Artifacts	Hole^[51], fiber wrinkle defect^[32]
3D visualization imaging	Body wave	3D damage image	Large amount of data, complex process	Impact damage^[110]
Tomography	Guided wave	No media prior knowledge required	Large amount of calculation	Delamination^[116]
Reverse time migration	Guided wave	High accuracy	Large amount of calculation and storage space	Damage of thin plate of complex structure^[133-134]
Probability-based diagnostic imaging	Guided wave	No media prior knowledge required	Vulnerable to environmental impact	Debonding damage^[142-143]

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