基于超声相控阵全聚焦成像的焊接结构表面裂纹扩展寿命研究

doi:10.3901/JME.2025.22.069

摘要/Abstract

摘要： 面向服役焊接结构完整性评估的需求，焊接接头表面疲劳裂纹演化的状态对其疲劳寿命的评估至为重要。当前尚未建立有效监测焊接结构表面裂纹扩展的方法，难以表征裂纹形态演化对其疲劳寿命的影响。创新性地提出一种基于超声相控阵全聚焦成像技术的焊接结构表面三维疲劳裂纹扩展状态监测方法。采用该成像技术对8 mm厚铝合金足尺寸对接接头进行疲劳试验，通过实时成像获取焊趾部位表面疲劳裂纹的形态演化过程。将裂纹扩展的成像结果与断口形貌特征进行对比分析，验证所提出状态监测方法的有效性。通过将裂纹深度a与长度c的监测数据拟合为分段函数引入到以a/c和a/t为参数的BS7910解析函数中，对裂纹前缘的应力强度因子进行了优化计算。研究结果表明，基于超声相控阵全聚焦成像的状态监测方法能够有效捕捉焊趾处疲劳裂纹深度a与长度c的动态演化过程，完整揭示贯穿厚度失效模式下表面裂纹形态的演化规律。此外，动态裂纹形态特征解析函数的引入，显著提升了焊接结构疲劳裂纹扩展寿命评估的准确性。该方法为焊接结构疲劳裂纹扩展的状态监测与寿命预测提供了一种全新的思路，具有重要的理论意义与工程应用价值。

关键词: 超声相控阵, 全聚焦成像, 裂纹扩展演化, BS 7910标准, 应力强度因子

Abstract: Facing the needs of integrity assessment of welded structures in service, the state of fatigue crack evolution on the surface of welded joints is of paramount importance for the assessment of their fatigue life. Currently, the method for effective monitoring of fatigue crack propagation on the surface of welded structures has not been established, and it is difficult to characterize the effect of crack morphology evolution on the fatigue life of welded structures. An innovative method for monitoring the three-dimensional fatigue crack propagation state on the surface of welded structures based on ultrasonic total focus phased array imaging is proposed. First, the imaging technique is used to perform fatigue tests on 8 mm thick aluminium alloy full-size butt joints, and the morphological evolution of surface fatigue cracks in the weld toe area is obtained by real-time imaging. Then, the imaging results of crack propagation were compared and analysed with the fracture morphology characteristics to verify the effectiveness of the proposed condition monitoring method. Finally, the stress intensity factor at the crack leading edge was optimized by fitting the monitoring data of crack depth a and length c into the segmented function introduced into the BS7910 analytical function with a/c and a/t as parameters. The results show that the condition monitoring method based on ultrasonic total focus phased array imaging can effectively capture the dynamic evolution of the fatigue crack depth a and length c at the weld toe. The evolution law of surface crack morphology under through-thickness failure mode is completely revealed. In addition, the dynamic crack morphology feature analysis function is introduced to significantly improve the accuracy of fatigue crack propagation life assessment of welded structures. The method provides a new way of reflection for the condition monitoring of fatigue crack propagation and life prediction of welded structures, which has important theoretical significance and engineering application value.

Key words: ultrasonic phased array, total focus imaging, crack propagation evolution, BS 7910 standard, stress intensity factor

中图分类号:

TG405

王超, 杨冰, 朱涛, 阳光武, 肖守讷. 基于超声相控阵全聚焦成像的焊接结构表面裂纹扩展寿命研究[J]. 机械工程学报, 2025, 61(22): 69-79.

WANG Chao, YANG Bing, ZHU Tao, YANG Guangwu, XIAO Shoune. Surface Crack Propagation Life Study of Welded Structures Using Phased-array Ultrasonic Total Focusing Imaging[J]. Journal of Mechanical Engineering, 2025, 61(22): 69-79.

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