用于焊缝缺陷检测的双弧V型EMAT设计与优化
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1.湖北工业大学机械工程学院武汉430068; 2.湖北工业大学现代制造质量工程湖北省重点实验室武汉430068; 3.华中科技大学机械科学与工程学院武汉430074

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TH165+.4TB553

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湖北省重点研发项目 (2024BAB065) 资助


Design and optimization of double arc V-shaped EMAT for weld defect detection
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1.School of Mechanical Engineering, Hubei University of Technology, Wuhan 430068, China; 2.Hubei Key Laboratory of Modern Manufacture Quality Engineering, Hubei University of Technology, Wuhan 430068, China; 3.School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China

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    摘要:

    尽管无损检测技术在工业领域有较广泛的应用,在满足焊缝缺陷的高精度、高分辨率检测需求时仍面临巨大挑战。以核电、船舶等领域的板焊缝为例,其结构通常尺寸紧凑、分布位置复杂,常位于边角、加强筋交汇处或其他难以接近的区域,对检测探头的体积和布置方式提出了严格要求,往往只能在焊缝附近进行检测。现有超声检测多依赖接触式耦合或体积较大的换能器,难以兼顾狭小空间下的激励效率和缺陷识别灵敏度,且在面对小尺寸缺陷时信噪比较低。为此,设计了一种新型双弧V型点聚焦电磁超声换能器,采用双弧曲折线圈与V型对称布局,在限定激励超声能量区域的同时显著提升了激励波束的方向性与聚焦性能。通过建立有限元模型,系统分析了V型夹角、圆心角及近场区对换能器聚焦性能和缺陷响应幅值的影响,并优化了双弧线圈弧度和V型夹角等关键参数,从而增强了对表面及近表面微小缺陷的响应能力。随后搭建实验平台,对焊缝中的裂纹和气孔缺陷进行了检测。研究表明,传统换能器对微裂纹和孔状缺陷的检测效果有限,而所提出的新型换能器不仅能够获取清晰的反射信号,在检测尺寸为10 mm×0.5 mm×0.2 mm的裂纹及直径1 mm的气孔时,最低信噪比达到23.41 dB,显著提升了检测灵敏度,为复杂结构焊缝缺陷检测提供了一种高灵敏度、非接触式检测新方案。

    Abstract:

    Although nondestructive testing technology is widely used in industrial field, it still faces great challenges in meeting the requirements of high-precision and high-resolution detection of weld defects. In particular, plate welds in critical sectors such as nuclear power and shipbuilding are often characterized by compact structural dimensions and complex spatial distributions, frequently located at corners, intersections of stiffeners, or other regions that are difficult to access. These features impose strict requirements on the size and placement of detection probes, which can typically only be deployed in close proximity to the weld. Existing ultrasonic inspection techniques generally rely on contact-based coupling or bulky transducers, making it difficult to simultaneously ensure excitation efficiency and defect detection sensitivity in confined spaces. Furthermore, these approaches often suffer from a low signal-to-noise ratio when detecting small-scale defects. To address these limitations, this study proposes a novel dual-arc V-shaped point-focusing electromagnetic acoustic transducer. The design employs a dual-arc meander-line coil combined with a symmetric V-shaped configuration, which not only confines the excited ultrasonic energy within a specific region but also significantly enhances the beam directivity and focusing performance. A finite element model was established to systematically investigate the influence of V-angle, central angle, and near-field characteristics on the transducer′s focusing capability and defect echo amplitude. The arc curvature of the dual-arc coil and the V-angle were optimized to improve the response to surface and near-surface micro-defects. Then, an experimental platform was built to detect the cracks and porosity defects in the weld. The research shows that the traditional transducer has limited detection effect on micro-cracks and hole-like defects, while the proposed new transducer can not only obtain clear reflected signals, but also achieve a minimum signal-to-noise ratio of 23.41 dB when detecting cracks with a size of 10 mm×0.5 mm×0.2 mm and blowholes with a diameter of 1 mm. This significantly improves the detection sensitivity and provides a high-sensitivity and non-contact detection scheme for weld defects detection of complex structures.

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申鑫,涂君,宋旖旎,张付春,宋小春.用于焊缝缺陷检测的双弧V型EMAT设计与优化[J].仪器仪表学报,2025,46(7):297-306

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  • 在线发布日期: 2025-11-07
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