同心环状薄膜传感器阵列及其飞机金属结构裂纹监测研究

机械工程学报 ›› 2015, Vol. 51 ›› Issue (24): 9-14.

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同心环状薄膜传感器阵列及其飞机金属结构裂纹监测研究

侯波, 崔荣洪, 何宇廷, 高潮, 张腾

空军工程大学航空航天工程学院西安 710038

收稿日期:2014-12-15 修回日期:2015-06-25 出版日期:2015-12-15 发布日期:2015-12-15
通讯作者: 何宇廷，男，1966年出生，博士，教授，博士研究生导师。主要研究方向为飞行器结构寿命控制、飞行器结构健康监控、飞行器安全性评估。 E-mail：hyt666@tom.com
作者简介:侯波，男，1986年出生，博士研究生。主要研究方向为飞行器使用可靠性、安全性与故障诊断。 E-mail：bohr_h@163.com
基金资助:
国家自然科学基金资助项目(51201182)

Concentric Ring Film Sensor Array and Its Experimental Research on Crack Monitoring for Aircraft Metallic Structure

HOU Bo, CUI Ronghong, HE Yuting, GAO Chao, ZHANG Teng

Aeronautics and Astronautics Engineering College, Air Force Engineering University, Xi’an 710038

Received:2014-12-15 Revised:2015-06-25 Online:2015-12-15 Published:2015-12-15

摘要/Abstract

摘要： 飞机金属部件在服役过程中的疲劳损伤严重威胁飞行安全。针对飞机金属结构疲劳裂纹实时监测需求，提出一种与结构基体一体化集成的同心环状薄膜传感器阵列及其裂纹监测方案。对同心环状薄膜传感器阵列进行了设计与优化。应用表面处理技术对基体表面进行绝缘处理，应用脉冲偏压电弧离子镀技术制备同心环状薄膜传感器阵列。应用同心环状薄膜传感器阵列开展结构模拟件疲劳损伤监测试验。监测试验结果表明：薄膜传感器对裂纹非常敏感；当结构起裂或裂纹前缘扩展至薄膜传感器监测区域时，相应薄膜传感器的监测电压信号快速增加；当裂纹扩展穿越监测区域时，相应薄膜传感器的监测信号阶跃上升，监测通道失效；将薄膜传感器监测数据变化特征作为结构起裂、裂纹前缘扩展至相应监测区域以及扩展出监测区域的判断标准，同心环状薄膜传感器阵列可以实现疲劳裂纹的定量监测，监测精度为1 mm；根据内侧薄膜传感器监测数据变化，还可以定性分析结构疲劳累积损伤程度。

关键词: 薄膜传感器, 电弧离子镀, 电位法, 结构健康监测, 裂纹

Abstract: Fatigue damage of aero metal components causes serious threat to flight security. According to the requirement of metallic structural fatigue crack monitoring in real time, a concentric ring film sensor array integrated with structural substrate and corresponding monitoring method are proposed. The concentric ring film sensor array is designed and optimized. Surface treatment technology is introduced for surface insulation treatment of the substrate, and then pulsed bias arc ion plating technology is introduced to deposit concentric ring film sensor array. Fatigue damage monitoring experiment of structural simulating sample is carried out with the concentric ring film sensor array. Monitoring experimental result shows that the sensor is very sensitive to structural crack, monitoring signal of voltage increased rapidly when structural cracking begin to appear or crack front expands into monitoring area of the corresponding film sensor, and monitoring signal of voltage experiences a step rise and failure of the monitoring channel occurs when crack front expands out of the monitoring area of the corresponding film sensor. Taking variation characteristics of monitoring data as judgment criterions of structural crack initiation, crack front’s entering corresponding monitoring area, crack front’s crossing corresponding monitoring area, concentric ring film sensor array can realize quantitative monitoring of fatigue crack, and monitoring precision is 1 mm. Besides, the degree of structural fatigue accumulation damage can also be analyzed qualitatively through monitoring data variation of inner ring film sensor.

Key words: arc ion plating, crack, electrical potential difference method, film sensor, structural health monitoring

侯波, 崔荣洪, 何宇廷, 高潮, 张腾. 同心环状薄膜传感器阵列及其飞机金属结构裂纹监测研究[J]. 机械工程学报, 2015, 51(24): 9-14.

HOU Bo, CUI Ronghong, HE Yuting, GAO Chao, ZHANG Teng. Concentric Ring Film Sensor Array and Its Experimental Research on Crack Monitoring for Aircraft Metallic Structure[J]. Journal of Mechanical Engineering, 2015, 51(24): 9-14.

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同心环状薄膜传感器阵列及其飞机金属结构裂纹监测研究

Concentric Ring Film Sensor Array and Its Experimental Research on Crack Monitoring for Aircraft Metallic Structure

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