基于非线性超声检测信号的结构件腐蚀疲劳剩余寿命评估方法

苏贤金; 胡剑辉; 李少林; 杨晓光; 石多奇; 齐红宇

doi:10.13224/j.cnki.jasp.20240691

基于非线性超声检测信号的结构件腐蚀疲劳剩余寿命评估方法

doi: 10.13224/j.cnki.jasp.20240691

苏贤金^1,,
胡剑辉¹,
李少林^{1, 2,*, ,},
杨晓光^{1, 2},
石多奇^{1, 2},
齐红宇^{1, 2}

1.
北京航空航天大学能源与动力工程学院，北京 100191
2.
北京航空航天大学航空发动机结构强度北京市重点实验室，北京 100191

基金项目: 国家自然科学基金（51975027）

详细信息

作者简介:
苏贤金（2001-），男，硕士生，主要从事发动机高温结构强度研究。E-mail：suxianjin@buaa.edu.cn

通讯作者:
李少林（1983-），男，副教授、硕士生导师，博士，主要从事发动机高温结构强度研究。E-mail：lishaolin@buaa.edu.cn

中图分类号: V267⁺.2
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出版历程
- 收稿日期: 2024-10-10
- 网络出版日期: 2025-06-10

Evaluation method of corrosion fatigue residual life of structural parts based on nonlinear ultrasonic detection signals

SU Xianjin^1
,,
HU Jianhui¹,
LI Shaolin^{1, 2,*
, ,},
YANG Xiaoguang^{1, 2},
SHI Duoqi^{1, 2},
QI Hongyu^{1, 2}

1.
School of Energy and Power Engineering，Beihang University，Beijing 100191，China
2.
Beijing Key Laboratory of Aero-Engine Structure and Strength，Beihang University，Beijing 100191，China

摘要

摘要:
针对含腐蚀缺陷的叶片结构件，提出了一种基于非线性超声检测信号的寿命评估方法。利用有限元法模拟了腐蚀缺陷试验件的超声无损检测过程，探讨了腐蚀坑对非线性系数和最大应力的影响规律；通过建立单个腐蚀坑试验件的疲劳寿命预测模型，提出了一种基于非线性超声的含腐蚀坑叶片结构的疲劳寿命评估方法；以某压气机叶片为例，介绍了评估方法的详细流程，并对此进行了可行性验证。结果显示：腐蚀坑直径与非线性系数呈正相关关系；在相同的腐蚀条件下，最大应力和非线性系数的变化规律一致；单坑疲劳寿命预测结果均在2倍分散带以内；多腐蚀坑叶片结构件的疲劳寿命预测精度良好，误差范围在25%以内。研究表明：非线性系数可以有效地表征腐蚀坑引起的损伤，非线性超声检测技术可为含腐蚀坑叶片结构件的疲劳寿命评估提供一种可行的手段。
- 腐蚀坑 /
- 非线性超声波 /
- 腐蚀疲劳 /
- 叶片结构 /
- 寿命评估
Abstract:
A life assessment method based on nonlinear ultrasonic detection signals was proposed for blade structures with corrosion defects. The finite element method was used to simulate the ultrasonic non-destructive testing process of the corrosion defect specimens, the influence of corrosion pits on nonlinear coefficient and maximum stress was explored. Then, by establishing a fatigue life prediction model of a single corrosion pit test piece, a fatigue life assessment method for blade structures with corrosion pits based on nonlinear ultrasound was proposed. Taking a compressor blade as an example, the detailed process of the assessment method was introduced, and the feasibility was verified. The results showed that the corrosion pit diameter was positively correlated with the nonlinear coefficient. Under the same corrosion conditions, changes in the maximum stress and nonlinear parameter were consistent. The life prediction results of specimens with single corrosion pit fell in the factor of two scatter band, and the error range of life prediction results of blade structure with corrosion pits was within 25%. The study showed that the nonlinear coefficient could characterize the damage caused by corrosion pits effectively, and the nonlinear ultrasonic detection methodology could provide a feasible means for fatigue life assessment of blade structures with corrosion pits.
- corrosion pits /
- nonlinear ultrasonic /
- corrosion fatigue /
- blade structure /
- life evaluation

HTML

图 1 试验件有限元模型（单位：mm）

Figure 1. Finite element model of specimen （unit：mm）

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图 2 不同缺陷的表面波频域响应信号

Figure 2. Frequency domain response signals of surface wave at different defects

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图 3 缺陷直径d与非线性系数β的关系

Figure 3. Relationship between corrosion pit diameter d and nonlinear coefficient β

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图 4 最大应力σ_max和非线性系数β的变化趋势对比（d=180 μm）

Figure 4. Comparison of changing trends in maximum stress σ_max and nonlinear coefficient β （d=180 μm）

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图 5 400 ℃下不同腐蚀坑直径TC4试验件的疲劳寿命

Figure 5. Fatigue life results of TC4 specimens with different corrosion pits at 400 ℃

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图 6 基于非线性系数的单腐蚀坑TC4试验件的疲劳寿命预测结果

Figure 6. Fatigue life prediction results based on nonlinear coefficient of TC4 specimens with single corrosion pit

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图 7 某发动机叶片腐蚀坑数量分布

Figure 7. Statistics of corrosion pits on an engine blade

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图 8 基于超声的多腐蚀坑叶片结构件寿命评估框架

Figure 8. Life assessment process for blade structures with multiple corrosion pits based on the ultrasonic signal

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图 9 某型发动机压气机叶片几何模型（单位：mm）

Figure 9. Geometric model of an engine compressor blade（unit：mm）

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图 10 叶片的边界条件

Figure 10. Boundary conditions of blade

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图 11 某型发动机工作状态转速-时间占比曲线^[28]

Figure 11. Speed-time ratio curve of a certain type of engine working state^[28]

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图 12 压气机叶片应力分布云图

Figure 12. Compressor blade stress distribution cloud diagram

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图 13 叶片上腐蚀坑的分布位置（单位：μm）

Figure 13. Location of corrosion pits on blades （unit：μm）

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图 14 超声信号激励及接收位置（单位：mm）

Figure 14. Ultrasonic signal excitation and receiving position （unit：mm）

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图 15 无腐蚀坑叶片结构在评估区域的应力分布云图

Figure 15. Stress distribution cloud diagram of the blade structure without corrosion pits in the assessment area

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图 16 TC4叶片结构的非线性超声时域响应信号

Figure 16. Nonlinear ultrasonic time-domain response signal of TC4 blade structure

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图 17 0Cr16Ni叶片结构的非线性超声时域响应信号

Figure 17. Nonlinear ultrasonic frequency-time domain response signal of 0Cr16Ni blade structure

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图 18 当量预腐蚀损伤对0Cr16Ni叶片疲劳性能的影响^[31]

Figure 18. Effect of equivalent pre-corrosion damage on fatigue properties of 0Cr16Ni blades^[31]

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表 1 TC4试验件疲劳试验矩阵（400 ℃）

Table 1. Fatigue test matrix of TC4 specimens （400 ℃）

应力比	加载频率/Hz	腐蚀坑直径d/μm	组别
0.1	0.5	0	参数验证
		180	参数验证
		200	模型验证
		250	参数验证

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表 2 模型参数

Table 2. Model parameters

模型	参数	取值
疲劳损伤模型	γ	−0.9292
	a/10⁻⁴	−4.3975
	σ_f/MPa	321
	b/10⁻³	4.3823
	M₀	−7.7738
	D_0,180/10⁻³	2.2457
	D_0,250/10⁻²	8.6364
腐蚀坑初始损伤模型/10⁻¹¹	ζ	1.2708
腐蚀坑初始损伤模型/10⁻¹¹	ε	4.1003
基于非线性系数的腐蚀坑损伤模型	n	0.8417
	m	0.2263
	c	0.4489

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表 3 随机腐蚀坑分布尺寸

Table 3. Random corrosion pit distribution size

腐蚀坑编号	直径/μm	间距/μm
1	593
2	423	955
3	624	578
4	345	746
5	274	840

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