Reference block for metal glue joint outlet guide vane penetration method ultrasonic detection and detection method
By designing a comparative test block and testing method for ultrasonic testing of metal adhesive-bonded outlet guide vanes using the penetration method, the difficulty of testing caused by the complex structure of the fan outlet guide vanes was solved, enabling a comprehensive and accurate assessment of the adhesive-bonded area and ensuring standardized testing and product safety.
Patent Information
- Application Number
- CN202511535557.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-27
- Publication Date
- 2025-12-26
AI Technical Summary
Due to the complex structure of the fan outlet guide vanes, the narrow bonding area, and the presence of ribs, traditional detection methods struggle to achieve a comprehensive and accurate assessment of the bonding area, particularly in terms of probe placement, path planning, and sensitivity setting.
A comparative test block for ultrasonic testing of metal-bonded outlet guide vanes using the penetration method was designed, including the guide vane body, cover plate, adhesive film, and polytetrafluoroethylene film. Through contour path planning and zonal evaluation, a flat probe with a frequency of 2.5MHz-5MHz was used for testing, and a detection threshold was set to ensure testing standardization and sensitivity.
It enhances the representativeness and consistency of test results, can adapt to complex structures, provides scientific testing basis, and ensures product safety and reliability.
Smart Images
Figure CN121208152A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of nondestructive testing, in particular to a comparison test block and a detection method for penetration method ultrasonic detection of a metal bonded outlet guide vane. BACKGROUND
[0002] With the continuous improvement of the performance requirements of civil aviation engines, the structure of fan outlet guide vanes gradually develops towards lightweight and hollow. In order to achieve the dual goals of structural strength and weight reduction, civil aviation engines use metal bonding structures, that is, the guide vane body and the cover plate are bonded by adhesive film to form a hollow structure.
[0003] However, due to the complex shape of the fan outlet guide vane, the narrow bonding area, the existence of ribs and cavities inside the structure, and the influence of various factors such as uneven curing pressure, blade deformation, improper adhesive film laying, or adhesive surface contamination, etc., defects such as debonding, poor bonding, and porosity may occur. In order to ensure the safety of product use, the bonding quality must be effectively detected.
[0004] As an effective nondestructive testing method, ultrasonic testing is widely used in the quality evaluation of bonded structures. The penetration method is particularly suitable for the detection of such structures due to its sensitivity to debonding defects. However, due to the complex structure of the fan outlet guide vane, the detection has blade surface and cavity, the structure is relatively complex, the bonding area is narrow and there are rib structures, the rib width is narrow, and the traditional detection method has great difficulties in probe arrangement, path planning, sensitivity setting and defect evaluation, making it difficult to achieve comprehensive and accurate evaluation of the bonding area. Therefore, we propose a comparison test block and a detection method for penetration method ultrasonic detection of a metal bonded outlet guide vane. SUMMARY
[0005] The present application relates to the technical field of nondestructive testing, in particular to a comparison test block and a detection method for penetration method ultrasonic detection of a metal bonded outlet guide vane.
[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a comparison test block and a detection method for penetration method ultrasonic detection of a metal bonded outlet guide vane, comprising: a guide vane body; Also include: the inner side of the guide vane body is provided with a vertical stiffener bonding area, the inner side of the guide vane body is provided with a cavity area, the inner side of the guide vane body is provided with an annular bonding area, the inside of the guide vane body is provided with a cover plate, one side of the cover plate is provided with a plastic film, one side of the cover plate is provided with a polytetrafluoroethylene film, the top of the guide vane body is provided with a clamping area, the bottom of the guide vane body is provided with a crown, one side of the guide vane body is provided with a back area.
[0007] Wherein, the guide vane body and the cover plate are made of aluminum alloy material.
[0008] Wherein, the surface of the guide vane body and the cover plate is subjected to anodic oxidation treatment.
[0009] Wherein, the plastic film is selected according to the design drawing requirements.
[0010] Wherein, the polytetrafluoroethylene film is located or used with copper sheet, and the polytetrafluoroethylene film is commonly used with the copper sheet.
[0011] Wherein, the thickness of the polytetrafluoroethylene film is 0.1-0.3mm, and the diameter size is according to the quality acceptance requirements.
[0012] Wherein, the edge of the polytetrafluoroethylene film is chamfered.
[0013] Wherein, the polytetrafluoroethylene film and the plastic film are connected by local point gluing.
[0014] Wherein, the inside of the guide vane body is provided with a runway corner area, a runway straight line area and a vertical stiffener area, and each typical area contains at least one group of artificial defects, the artificial defects are arranged in the plastic film layer at equal intervals from the center, and the edge distance between adjacent defects is ≥15mm.
[0015] Wherein, the detection method of the metal adhesive outlet guide vane penetration method ultrasonic detection includes the following steps: Step one: material preparation: select aluminum alloy material consistent with the fan outlet guide vane to process the body and the cover plate, and the surface is subjected to anodic oxidation treatment; plastic film laying: select plastic film type and thickness according to design drawing requirements; artificial defect pre-embedding: cut and pre-embed different diameter (such as Φ3mm, Φ6mm, Φ9mm) polytetrafluoroethylene film or copper sheet in the plastic film, thickness control in 0.1-0.3mm; adhesive curing: stack the guide vane body, plastic film and cover plate in order, apply specified pressure and temperature to complete adhesive curing; finished product inspection: check the appearance and size of the test block to ensure no obvious deformation or bubbles; Step two: using a special detection tool to clamp the part, and selecting three easily identifiable and accessible feature points on the part and the numerical model as the three-point positioning reference for matching the numerical model with the actual clamped part; using two 2.5MHz-5MHz flat probes, one transmitting and one receiving, arranged on both sides of the guide vane body; profiling according to the surface profile of the guide vane body, planning the scanning path and detection posture. Adjust the water jet probe arm, angle, etc. to make the water column of the transmitting probe perpendicular to the surface of the cover plate 2, then set the probe water distance to adjust the distance of the receiving probe according to the thickness of the part, and follow the transmitting probe to ensure that the axes of the transmitting probe and the receiving probe are aligned, and the incident ultrasonic probe is always perpendicular to the detection surface; according to the structure characteristics and the sound wave penetration characteristics, the bonding area is divided into runway corner area, runway straight line area and stud area, and the partition evaluation is carried out, the detection sensitivity and defect evaluation threshold of each area are determined by comparing the detection of artificial defects in the contrast test block, and the partition evaluation is carried out according to the C-scan image to judge whether the bonding quality meets the acceptance standard; Step three: using the penetration method, one transmitting and one receiving, arranged on the blade disc side and the back side; profiling the scanning path according to the blade profile to ensure that the sound beam is perpendicular to the incident; dividing the bonding area into runway corner area, runway straight line area and stud area; setting the detection threshold of each area by using the C-scan image of the artificial defects in the contrast test block; carrying out ultrasonic C-scan detection on the guide vane to be detected, and carrying out partition evaluation according to the image; judging whether the bonding quality is qualified according to the defect size, position and area threshold.
[0016] The present application has at least the following beneficial effects: 1. The contrast test block is consistent with the structure of the part, which ensures that the detection results of the contrast test block are representative, and thus the structural matching is enhanced; 2. The detection sensitivity and evaluation threshold of the contrast test block are unified, the detection standard is unified, the detection consistency is improved, and the detection standardization is ensured; 3. The artificial defect simulation simulates typical bonding defects, enhances the recognition ability of the detection system, and can simulate real defects; 4. Based on the profiled path planning, the ultrasonic detection is suitable for complex curved surfaces, cavities and rib structures, and thus the complex structure can be adapted; 5. The fan outlet guide vane bonding quality provides scientific and quantifiable detection basis, ensures the safety of product use, and improves the reliability. BRIEF DESCRIPTION OF DRAWINGS
[0017] Figure 1 It is a front view of the structure of the present application; Figure 2 It is a rear view of the structure of the present application; Figure 3 It is a bottom view of the structure of the present application; Figure 4 The rear perspective structure schematic diagram of the fan outlet guide vane of the present application; Figure 5 The front perspective structure schematic diagram of the fan outlet guide vane of the present application; Figure 6 The front perspective structure schematic diagram of the cover plate of the present application; Figure 7 The rear perspective structure schematic diagram of the cover plate of the present application; Figure 8 The structure schematic diagram of the ultrasonic contrast test block (including polytetrafluoroethylene film and copper sheet) of the fan outlet guide vane assembly of the present application; Figure 9 The structure schematic diagram of the ultrasonic contrast test block (only including polytetrafluoroethylene film) of the fan outlet guide vane assembly of the present application; Figure 10 The structure schematic diagram of the fan outlet guide vane penetration method ultrasonic detection of the present application; Figure 11 The structure schematic diagram of the fan outlet guide vane bonding area evaluation partition of the present application; Figure 12 The structure schematic diagram of the fan outlet guide vane contrast test block penetration method ultrasonic detection C scan of the present application; Figure 13 The structure schematic diagram of the fan outlet guide vane part penetration method ultrasonic detection C scan of the present application.
[0018] In the figure: 1, guide vane body; 2, cover plate; 3, adhesive film; 4, polytetrafluoroethylene film; 5, vertical rib bonding area; 6, cavity area; 7, shroud; 8, clamping area; 9, back area; 10, annular bonding area. DETAILED DESCRIPTION
[0019] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.
[0020] Embodiment one Please refer to Figures 1 to 13 The present application provides a technical solution: metal bonded outlet guide vane penetration method ultrasonic detection contrast test block and detection method, comprising: guide vane body 1; Further comprising: the inner side of the guide vane body 1 is provided with a vertical rib bonding area 5, the inner side of the guide vane body 1 is provided with a cavity area 6, the inner side of the guide vane body 1 is provided with an annular bonding area 10, the inside of the guide vane body 1 is provided with a cover plate 2, one side of the cover plate 2 is provided with a glue film 3, one side of the cover plate 2 is provided with a polytetrafluoroethylene film 4, the top of the guide vane body 1 is provided with a clamping area 8, the bottom of the guide vane body 1 is provided with a shroud 7, and one side of the guide vane body 1 is provided with a back area 9.
[0021] Example two As Figures 1 to 13 In this embodiment two, other structures remain unchanged, and different from example one is: The guide vane body 1 and the cover plate 2 are both made of aluminum alloy material; in use, it can ensure that the contrast test block and the actual inspected part remain highly consistent in acoustic characteristics.
[0022] The surface of the guide vane body 1 and the cover plate 2 is subjected to anodizing treatment; in use, it can truly restore the surface state before actual part gluing.
[0023] The glue film 3 is selected according to the design drawing requirements; in use, it can accurately simulate the bonding layer characteristics in the actual gluing process.
[0024] The polytetrafluoroethylene film 4 is positioned or used with a copper sheet, and the polytetrafluoroethylene film 4 and the copper sheet are universal; in use, it can simulate different types and acoustic response characteristics of the gluing defects.
[0025] The thickness of the polytetrafluoroethylene film 4 is 0.1-0.3mm, and the diameter size is according to the quality acceptance requirements; in use, it can accurately simulate the minimum detectable and minimum rejected defect size that may occur in actual production.
[0026] The edge of the polytetrafluoroethylene film 4 is chamfered; in use, it can prevent the film edge from being raised, torn or producing micro cracks due to stress concentration in the process of hot pressing and curing.
[0027] The polytetrafluoroethylene film 4 and the glue film 3 are connected by local point gluing; in use, it can fix the position of artificial defects without affecting the overall gluing process, preventing displacement, shifting or floating during the gluing layer assembly and hot pressing and curing process.
[0028] The inside of the guide vane body 1 is provided with a runway corner area, a runway straight line area and a vertical rib area, and each typical area contains at least one set of artificial defects, the artificial defects are arranged in the glue film layer with equal intervals from the center, and the edge distance between adjacent defects is ≥15mm; in use, it can avoid mutual interference of ultrasonic field, and can fully cover the key gluing area in the complex structure of the fan outlet guide vane, realizing partition detection and evaluation.
[0029] Example Two As Figures 1 to 13 In this Example Two, other structures remain unchanged, and different from Example One is: The detection method of the metal bonding outlet guide vane penetration method ultrasonic detection, comprising the following steps: Step one: material preparation: select the same aluminum alloy material as the fan outlet guide vane to process the body and cover plate, and perform anodic treatment on the surface; adhesive film laying: select the film type and thickness according to the design drawing requirements; artificial defect pre-embedding: cut and pre-embed tetrafluoroethylene film 4 or copper sheet of different diameters (such as Φ3mm, Φ6mm, Φ9mm) in the film, with a thickness of 0.1-0.3mm; adhesive curing: stack the guide vane body 1, adhesive film 3 and cover plate 2 in order, apply the specified pressure and temperature to complete the adhesive curing; finished product inspection: check the appearance and size of the test block to ensure that there is no obvious deformation or bubbles; Step two: use a special detection tool to clamp the part, and select three easily identifiable and accessible feature points on the part and the numerical model as the three-point positioning reference for matching the numerical model with the actual clamped part; use two 2.5MHz-5MHz flat probes, one transmitting and one receiving, arranged on both sides of the guide vane body 1; profile according to the surface profile of the guide vane body 1, plan the scanning path and detection posture. Adjust the water jet probe arm, angle, etc. to make the water column of the transmitting probe perpendicular to the surface of the cover plate 2, then set the probe water distance to adjust the distance between the receiving probe and the transmitting probe, and follow the transmitting probe to ensure that the axes of the transmitting probe and the receiving probe are aligned, and the incident ultrasonic probe is always perpendicular to the detection surface. According to the structural characteristics and the sound wave penetration characteristics, divide the bonding area into runway corner area, runway straight line area and stud area, and evaluate by area. By comparing the detection of artificial defects in the test block, determine the detection sensitivity and defect evaluation threshold of each area. According to the C-scan image, evaluate by area to determine whether the bonding quality meets the acceptance standard; Step three: use penetration method, one transmitting and one receiving, arranged on the blade disc side and the back side; profile according to the blade profile to design the scanning path, ensure that the sound beam is perpendicular to the incident; divide the bonding area into runway corner area, runway straight line area and stud area; use the C-scan image of the artificial defects in the comparison test block to set the detection threshold of each area; perform ultrasonic C-scan detection on the guide vane to be detected, and evaluate by area according to the image; judge whether the bonding quality is qualified according to the defect size, position and area threshold.
[0030] It is to be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting; it is not intended to exclude myriad other embodiments of the present application that other inventors can develop based on the same general inventive concepts embodied by the described embodiments. That is, although the present application is described in terms of particular embodiments and illustrative figures, it should be apparent that the scope of the present application is not limited to these specific embodiments.
[0031] While the embodiments of the application have been shown and described herein, it will be understood by those skilled in the art that many changes, modifications, substitutions and alterations to these embodiments can be made without departing from the principles and spirits of the application, the scope of which is defined by the appended claims and their equivalents.
Claims
1. A comparative test block for ultrasonic testing of metal-bonded outlet guide vanes using the penetration method, characterized in that: include: Guide vane body; It also includes: a vertical rib bonding area on the inner side of the guide vane body, a cavity area on the inner side of the guide vane body, an annular bonding area on the inner side of the guide vane body, a cover plate inside the guide vane body, an adhesive film on one side of the cover plate, a polytetrafluoroethylene film on one side of the cover plate, a clamping area on the top of the guide vane body, a leaf crown on the bottom of the guide vane body, and a leaf back area on one side of the guide vane body.
2. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: Both the guide vane body and the cover plate are made of aluminum alloy.
3. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: Both the guide vane body and the cover plate are anodized.
4. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The adhesive film is selected according to the corresponding model and thickness as required by the design drawings.
5. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The polytetrafluoroethylene film may be placed on a copper sheet, and the polytetrafluoroethylene film and the copper sheet are interchangeable.
6. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The thickness of the polytetrafluoroethylene film is 0.1-0.3 mm, and the diameter is determined according to the quality acceptance requirements.
7. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The edges of the polytetrafluoroethylene film are chamfered.
8. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The polytetrafluoroethylene film and the adhesive film are connected by localized dispensing of adhesive.
9. The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to claim 1, characterized in that: The guide vane body has a runway corner area, a runway straight area, and a rib area inside. Each typical area contains at least one set of artificial defects. The artificial defects are arranged at equal intervals with the center in the film layer, and the distance between the edges of adjacent defects is ≥15mm.
10. A method for ultrasonic testing of metal-bonded outlet guide vanes using the penetration method, characterized in that: The comparative test block for ultrasonic testing of the metal-bonded outlet guide vane using the penetration method according to any one of claims 1-9 includes the following steps: Step 1: Material Preparation: Select aluminum alloy material consistent with the fan outlet guide vane to process and manufacture the body and cover plate, and perform anodizing treatment on the surface; Adhesive Film Laying: Select the adhesive film type and thickness according to the design drawings; Artificial Defect Pre-embedding: Cut and pre-embed PTFE films or copper sheets of different diameters in the adhesive film, with the thickness controlled between 0.1–0.3 mm; Adhesive Bonding and Curing: Stack the guide vane body, adhesive film, and cover plate in sequence, and apply the specified pressure and temperature to complete the adhesive bonding and curing; Finished Product Inspection: Inspect the appearance and dimensions of the test block to ensure that there is no obvious deformation or air bubbles; Step 2: Clamp the part using a dedicated testing fixture, and select three easily identifiable and reachable feature points on the part and the digital model as three-point positioning references for matching the digital model with the actual clamped part; use two 2.5MHz-5MHz flat probes, one transmitting and one receiving, respectively arranged on both sides of the guide vane body; perform contouring based on the surface profile of the guide vane body, plan the scanning path and testing posture, adjust the support arm and angle of the water spray probe, etc., so that the water column of the transmitting probe is perpendicular to the surface of the cover plate, and then set the probe water distance so that the receiving probe adjusts the distance according to the thickness of the part and follows the transmitting probe, ensuring that the axes of the transmitting probe and the receiving probe are aligned, and always keeping the incident ultrasonic probe perpendicular to the incident detection surface. Based on the structural characteristics and sound wave penetration characteristics, divide the bonding area into the runway corner area, the runway straight area, and the vertical rib area, and evaluate each area. By comparing the detection of artificial defects in the test block, determine the detection sensitivity and defect evaluation threshold of each area, and perform regional evaluation based on the C-scan image to determine whether the bonding quality meets the acceptance standard; Step 3: Using the penetration method, one transmitter and one receiver are positioned on the blade disk side and the blade back side, respectively; a contour scanning path is designed based on the blade profile to ensure that the sound beam is incident perpendicularly; the bonding area is divided into the runway corner area, the runway straight area, and the vertical rib area; using the C-scan images of artificial defects in the comparison test block, the detection threshold for each area is set; ultrasonic C-scan inspection is performed on the guide vanes of the fan under inspection, and the area is evaluated based on the images; the bonding quality is judged to be qualified based on the defect size, location, and area threshold.