Research on ultrasonic synchronous detection method for material residual stress and thickness

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Abstract

Being limited to the different transmission and reception modes and detection signals of the critical refracted longitudinal wave method for stress measurement and the perpendicular incident echo method for thickness measurement, it is necessary to use different probes and equipments when simultaneously measuring stress and thickness. For this difficulty, the acquisition frequency and the number of bits are taken as the research object to realize the optimization of the echo signal. By combining FEM simulations with Comsol software with experimental research, the effects of probe incidence angle, probe spacing, and temperature on ultrasonic waves are investigated, and the relationship between probe spacing and the stress coefficient of measured component (K) is analyzed. A novel ultrasonic synchronous detection method for residual stress and thickness is proposed. This method is based on an integrated transmit-receive probe with oblique incidence, utilizing critical refracted longitudinal wave (LCR wave) for stress detection and synchronously generated transverse waves for thickness measurement. For the first time, a formula for ultrasonic thickness measurement based on inclined incidence is derived. Using self-developed equipment, ultrasonic testing experiments on step test block and cantilever beam loading device were conducted to verify the accuracy and precision of the proposed synchronous detection method for stress and thickness. This method has significant application prospects in the inspection or online monitoring of pressure vessels concerned with fatigue and corrosion performance.

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About the authors

Wentong Zhao

1Shanghai Institute of Technology

Author for correspondence.
Email: zb521a@sina.com
China, 201418 Shanghai

Bing Zhou

Shanghai Institute of Technology; Suzhou Aisierti Technology Co., Ltd

Email: zb521a@sina.com
China, 201418 Shanghai

Wenrui Bai

Shanghai Institute of Technology

Email: zb521a@sina.com
China, 201418 Shanghai

Zhanyong Wang

Shanghai Institute of Technology

Email: zb521a@sina.com
China, 201418 Shanghai

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Supplementary files

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2. Fig. 1. Model of the ultrasonic testing system: calculated model of the ultrasonic system (a); model of the ultrasonic system (b).

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3. Fig. 2. Experimental equipment.

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4. Fig. 3. Diagram of the simulated state of the ultrasonic wave inside the workpiece at a specific point in time.

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5. Fig. 4. Optimized data from experimental studies of the ultrasonic echo signal: wave during ultrasonic testing of the CSK-1A block (a); wave during ultrasonic testing of the SCK-IB block (b); KPP wave on self-developed equipment with different high-precision data acquisition boards (c); wave after optimization by the developed equipment (d).

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6. Fig. 5. Experimental data on the effect of the distance between the sensors on the echo signal: modeling a wave with different distances between the sensors (a); wave recorded at different distances between the probes (b); calibration of the K value using an approximated curve (c).

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7. Fig. 6. Experimental data on the effect of the probe incidence angle on the echo signal: schematic diagram of the ultrasound propagation envelope (a); wave obtained by modeling for different probe incidence angles (b); wave recorded by the sensor at different incidence angles (c).

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8. Fig. 7. Experimental data on the effect of temperature on stress monitoring: temperature compensation model of the built-in measuring transducer (a); ultrasonic testing of simulated echo signals with different temperatures (b); temperature-acoustic time difference curve (c).

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9. Fig. 8. Ultrasound propagation model corresponding to an incidence angle of 29°.

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10. Fig. 9. Wave recorded on steps with different thicknesses.

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11. Fig. 10. Measured wave with constant beam strength at different applied stresses.

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