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    基于双晶面阵的厚壁奥氏体不锈钢焊缝稀疏全聚焦成像分析

    Analysis of sparse total focusing method of thick-walled austenitic stainless steel welds based on dual matrix array

    • 摘要: 针对厚壁奥氏体不锈钢焊缝超声全聚焦成像效率低、一发一收纵波(TRL)双晶面阵探头声场复杂和阵列稀疏影响因素多的难题,提出遗传算法(GA)优化的TRL稀疏全聚焦方法。根据探头二维阵列结构和声束伪聚焦特性,结合声源辐射理论分析主动轴、从动轴阵列稀疏情况对声束指向性的影响。建立以指向函数旁瓣水平、主瓣宽度为目标的数学优化模型,利用GA在16×4(行×列)的约束栅格上设计TRL探头的阵元排布方式。检测对象为厚度76 mm的奥氏体不锈钢焊缝试块上深度为10 ~70 mm、直径为3.2 mm的横通孔缺陷,采集相控阵检测信号进行稀疏全聚焦成像。试验结果表明,相比于满阵,25% GA稀疏成像的缺陷检测信噪比最多下降3.29 dB,图像阵列性能参数(API)仅增加1.26,成像耗时从512.93 s减少至56.63 s,效率提升了近9倍。

       

      Abstract: A genetic algorithm (GA) optimized TRL sparse total focusing method was proposed to address the challenges of low efficiency in ultrasonic total focusing method of thick-walled austenitic stainless steel welds, complex acoustic field of transmitter-receiver longitudinal wave (TRL) dual matrix array probe, and multiple factors affecting array sparsity. Based on the 2D array structure of the probe and the pseudo-focusing characteristics of the sound beam, combined with the acoustic radiation theory, this study analyzed the impact of sparse conditions along the active and passive axes on the directivity of the sound beam. A mathematical optimization model was established with the objectives of pointing function side-lobe level and main lobe width, and GA was used to design the array element layout of TRL probe on a 16×4 (row×column)constrained grid. The detection object was transverse through-hole defects with depth range of 10~70 mm and diameter of 3.2 mm on a 76 mm thick austenitic stainless steel weld test block. The phased array detection signals were collected for sparse total focusing method. The results showed that compared to full array, the defects detection signal-to-noise ratio of GA sparse imaging with 25% sparsity decreased by up to 3.29 dB, the image API only increased by 1.26, the imaging time decreased from 512.93 s to 56.63 s, and the efficiency improved by nearly 9 times.

       

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