Review of advances in CT detection technology for defects in aero-engine composite materials
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摘要:
综述了计算机断层（CT）技术在航空发动机复合材料构件缺陷检测中的研究进展。针对复合材料在航空发动机应用中产生的跨尺度、多形态缺陷难以精准检测与评估的瓶颈问题，重点从缺陷产生的工艺机理、CT检测的技术原理及智能识别算法的视角展开论述。分析了树脂基、金属基、陶瓷基及碳碳复合材料的核心关键部件典型缺陷，通过梳理CT技术的应用场景，从CT检测典型缺陷特征、结构形态差异切入，对比了微焦点CT、同步辐射CT等不同技术在不同类型缺陷识别中的有效性及局限性。结果表明：基于深度学习的智能识别技术是实现跨尺度缺陷精准表征的有效途径，而多模态融合检测是解决厚壁构件微缺陷检测难题的重要发展方向。综述分类探讨了不同基体复合材料在CT检测中的研究方法，为航空发动机复合材料构件全生命周期智能检测与可靠性评估提供了理论依据和技术支撑。
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关键词:
- 树脂基复合材料（PMC） /
- 金属基复合材料（MMC） /
- 陶瓷基复合材料（CMC） /
- 碳碳复合材料（C/C） /
- 计算机断层（CT）无损检测 /
- 跨尺度缺陷
Abstract:The research progress of computed tomography (CT) technology in defect detection for aero-engine composite components was systematically reviewed. It addressed the bottleneck problem of accurately detecting and evaluating the cross-scale and multi-form defects generated in composites during their application in aero-engines, focusing discussions from the perspectives of the process mechanisms of defect formation, the technical principles of CT detection, and intelligent recognition algorithms. It provided a detailed analysis of typical defects in key components made of resin-based, metal matrix, ceramic matrix, and carbon-carbon composites. By reviewing the application scenarios of CT technology and starting from the typical defect characteristics and structural morphology differences revealed by CT detection, the effectiveness and limitations of different technologies, such as micro-focus CT and synchrotron radiation CT, were compared in identifying various types of defects. The results indicated that intelligent recognition technology based on deep learning is an effective approach for achieving accurate characterization of cross-scale defects, while multi-modal fusion detection is an important development direction for solving the challenge of micro-defect detection in thick-walled components. This review systematically investigated the compatibility of different matrix composites in CT detection, providing a theoretical basis and technical support for the full-lifecycle intelligent detection and reliability assessment of composite components in aero-engines.
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图 1 不同复合材料构件在先进航空发动机中的相关应用
Figure 1. Related applications of different composite components in advanced aero-engines
图 2 超声检测对复合材料内部缺陷识别不足
Figure 2. Insufficient identification of internal defects in composites by ultrasound testing
图 4 基于工业CT扫描的复合材料缺陷特征获取
Figure 4. Acquisition of composite defect characteristics based on Industrial CT scanning
图 8 复合材料试样Micro-CT路径检测分析[49]
Figure 8. Micro-CT path detection and analysis of composite samples
图 12 复合材料原位CT灰度图像缺陷表征
Figure 12. Defect characterization of composite materials in CT grayscale images
表 1 航空发动机复合材料不同种类缺陷比较
Table 1. Comparison of different types of defects in aero-engine composites
缺陷类型 形成因素 图像表现 主要特征 分层 制造工艺把控不到位，固化参数不合理、使用加工等环节
遭受外力冲击产生损伤
层间开裂、脱胶、大面积间隙等 脱黏 使用或加工时承受的应力超出合理范围，以及受到外力冲击、
摩擦等损伤
胶接面间分离 夹杂 混入了原本不应存在的杂质或者外界异物进入或造成材料误操作 
金属或非金属夹杂物 孔洞 工艺环节出现诸如模具设计不合理、树脂填充不充分、固化条件失控 
空穴 孔隙 浸渍过程未能充分渗透，或层合铺层间空气未通过真空辅助、
加压排气未彻底排出
扁圆形孔隙 基体开裂 遭受外力冲击、长期承受交变载荷，或是处于极端温度环境下
产生应力集中
基体内纵向断裂 纤维断裂 受到外部冲击，或是承受较高拉伸载荷，或长期疲劳循环作用 
纤维丝/束断裂 纤维褶皱 材料之间热膨胀系数不匹配，或温度和压力控制不合理，
或铺层顺序不合理
褶皱 
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表 2 常用的内部缺陷无损检测方法对比
Table 2. Comparison of common nondestructive testing methods for internal defects
常用手段 方法优点 方法缺点 主要应用 图像表现 
检测速度快 形状或厚度不均匀导致
结果不准确中小复合材料部件 
检测快速、操作简单 受环境、温度影响较大，难以识别微小缺陷 表面缺陷和热性能评估，复合材料涂层和黏合 
高分辨率，识别内部缺陷 分层缺陷不敏感，
对比度不足复杂航空航天复合材料
孔隙、夹杂
微小缺陷精确定位，
检测速度快扫描时间较长，效率低， 设备成本高 复杂形状和结构
复合材料及零件
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表 3 不同成像检测技术的性能
Table 3. Performance of different imaging detection technologies
检测手段 激励方式 成像模式 缺陷（损伤）类型 成像最小缺陷尺寸/mm 超声波检测 超声波 液体耦合剂 冲击凹痕、分层、脱黏 5×10−2～100 红外热成像 热辐射/振动 非接触 分层损伤、基体开裂、纤维断裂 >100 X射线检测 X射线 非接触 孔隙、孔洞、分层、脱黏 10−1～2×10−1 工业CT技术 X射线 非接触 孔隙、孔洞、分层、脱黏、疏松、基体开裂 3×10−2～5×10−2
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表 4 CT技术类型分类比较
Table 4. Classification and comparison of CT technology types
技术类型 核心原理 空间分辨率/mm 优势 局限 典型应用场景 案例 工业CT X射线穿透成像 +
三维重建3×10−2～10−1 适配大尺寸构件、检测范围广 微小缺陷（<5×
10−2 mm）对比度低树脂基复合材料风扇叶片宏观缺陷检测、金属基
复合材料压气机叶片
裂纹定位图7 显微CT
（Micro-CT）微焦点 X 射线+
高分辨率探测器10−3～5×10−2 捕捉微米级缺陷、三维结构重构
精度高仅适配小尺寸样品（<102 mm）、扫描
效率低树脂基复合材料微观孔隙率计算、碳基复合材料
编织结构分析图8 同步辐射
（SR-CT）同步辐射光源+
快速成像系统10−4～10−3 动态观测缺陷演化、对比度高 依赖同步辐射装置
（资源稀缺）、成本高陶瓷基复合材料涡轮叶片高温损伤动态检测、金属基复合材料半固态压缩
孔隙演变图10 原位CT CT扫描+
力/热加载装置10−2～5×10−2 关联载荷-缺陷演化关系（如拉伸下
裂纹扩展）加载装置对扫描
视野有遮挡树脂基复合材料拉伸损伤机制、陶瓷基复合材料
弯曲缺陷扩展图12
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表 5 不同基体复合材料特点及缺陷表现
Table 5. Characteristics and defect performance of different matrix composites
基体类型 材料特点 常见产品 实物图片 CT图像 缺陷表现 树脂基 通常以纤维增强（如碳纤维或玻璃纤维）为主要组成，强度
和刚度较高风扇机匣、风扇
叶片、进气道
消声衬板
孔隙、孔洞、分层、脱黏、疏松、
基体开裂金属基 由钨、铅、镍铝金属间化合物构成，承载能力和导热性优异 压气机叶片、
密封元件
裂纹、气孔 陶瓷基 基体为氧化铝、氧化硅、碳、硼、碳化硅等高温结构陶瓷，
适合极端环境火焰筒、涡轮导叶、调节片 
裂纹、分层、孔隙 碳碳基 基体以碳纤维为增强相，适合在极端
磨损环境尾喷管、喷油杆、隔热屏 
孔洞、分层、裂纹
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