An electromagnetic thermal imaging detection device and method for R-zone of additively manufactured metal components

Abstract

The present invention discloses an electromagnetic thermal imaging detection device and method for the R-zone of an additively manufactured metal component. The device includes an excitation coil, an L-shaped double yoke, a displacement sensor, an infrared thermal imager, and a monitoring computer. The excitation coil is wound in the same direction on both L-shaped yokes of the double yoke, with the number of turns and wire diameter of the excitation coil on both L-shaped yokes being the same. The two L-shaped yokes are placed near, but not in contact with, the two side wall panels of the component's R-zone, parallel to the two side wall panels of the component's R-zone. The displacement sensor is fixed to one side of the L-shaped yoke in the direction of movement. The infrared thermal imager is placed diagonally above the component's R-zone, with the infrared thermal imager's imaging direction facing the component's R-zone detection surface within the area surrounded by the L-shaped double yokes. The present invention detects surface and near-surface defects by using temperature distribution information generated on the surface of the component's R-zone, intuitively providing information on the location, orientation, distribution, and shape of the defects on the component's R-zone surface.

Description

Technical Field

[0001] The present invention belongs to the field of non-destructive testing technology, and specifically relates to an electromagnetic thermal imaging detection device and method for the R zone of an additively manufactured metal component. Background Art

[0002] The R transition zone (i.e., corner zone) of aircraft structures is commonly found in structures such as stiffened panels, reinforced frames, I-beams, corner boxes, or joints. The R zone is a stress concentration area of ​​the structural component, and defects are very likely to occur during manufacturing and service. In aircraft structural castings, forgings, machined parts, and additively manufactured metal components, the R zone is a weak area of ​​the structural component. In additively manufactured metal components, in particular, due to various unstable and discontinuous factors during the rapid heating and melting and cooling and solidification during the forming process, metallurgical defects such as pores, unfused components, and cracks are easily generated in the R zone of the component. Defects reduce the mechanical properties of additively manufactured metal components and seriously affect their safety in use. In order to ensure the safe use of additively manufactured metal components in aircraft structures, it is very necessary to use reliable non-destructive testing technology to promptly detect defects in the R zone. Since the R zone of the metal component is a curved surface and has a small spatial size, it brings great difficulties to the existing conventional non-destructive testing technology.

[0003] At present, conventional ultrasonic testing for component R zones has problems such as blind spots, difficulty in making the incident ultrasonic beam perpendicular to the detection surface of the R zone, and inability to achieve full coverage of the entire R zone. Conventional eddy current testing for component R zones has problems such as low detection efficiency and a large lift-off effect of the eddy current detection probe. The existing technology is insufficient in meeting the actual needs of comprehensive, reliable and high-precision defect detection in the R zone of metal components. In order to effectively improve the defect detection efficiency and detection accuracy of the component R zone, and intuitively provide information such as the position, size, orientation, distribution and geometric morphology of surface defects in the component R zone, it has become an urgent need to develop a new type of visual imaging non-destructive testing device and method for additively manufactured metal component R zones. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide an electromagnetic thermal imaging detection device and method for the R zone of an additively manufactured metal component in response to the above-mentioned deficiencies in the prior art.

[0005] In order to achieve the above technical objectives, the technical solution adopted by the present invention is:

[0006] An electromagnetic thermal imaging detection device for the R zone of an additively manufactured metal component, the device comprising an excitation coil, an L-shaped double magnetic yoke, a displacement sensor, an infrared thermal imager, and a monitoring computer;

[0007] The excitation coil is wound in the same direction on the two L-shaped magnetic yokes of the L-shaped double magnetic yoke, and the number of winding turns and wire diameter of the excitation coil on the two L-shaped magnetic yokes are the same;

[0008] The two L-shaped magnetic yokes of the L-shaped double magnetic yoke are respectively placed at positions close to the side wall panels of the component R area but not in contact with the side wall panels, and the two L-shaped magnetic yokes are respectively parallel to the side wall panels of the component R area;

[0009] The L-shaped double magnetic yoke is coupled to the surface layer of the R region of the component through an electromagnetic field;

[0010] The displacement sensor is fixed on one side of the L-shaped double yoke in the moving direction and moves synchronously with the L-shaped double yoke;

[0011] The output end of the displacement sensor is electrically connected to the input end of the monitoring computer;

[0012] The infrared thermal imager is placed above the diagonal of the component R area, and the shooting direction of the infrared thermal imager is facing the component R area detection surface surrounded by the L-shaped double magnetic yoke;

[0013] The output end of the infrared thermal imager is electrically connected to the input end of the monitoring computer.

[0014] Preferably, the L-shaped double magnetic yoke is composed of two L-shaped magnetic yokes of the same material, shape and size, wherein the L-shaped magnetic field is composed of a magnetic conductive material rod and an L-shaped magnetic conductive material bracket connected to both ends of the magnetic conductive material rod, and the L-shaped magnetic conductive material bracket is used to support the magnetic conductive material rod.

[0015] Preferably, the excitation coil is connected to external short-time pulse excitation.

[0016] Preferably, the displacement sensor is used to detect the distance between the L-shaped double magnetic yoke and the starting point of the movement, and the two L-shaped magnetic yokes of the L-shaped double magnetic yoke are at the same distance from the displacement sensor in the moving direction.

[0017] The present invention also discloses a method for electromagnetic thermal imaging detection of the R zone of an additively manufactured metal component, using the above-mentioned device, and the method comprises the following steps:

[0018] S1: The excitation coil is connected to a short-time pulse excitation, which generates a short-time pulse current on the excitation coil. The short-time pulse current flows in the excitation coil to generate a transient excitation magnetic field. The L-shaped double magnetic yoke is close to the component, and the transient excitation magnetic field is transmitted to the surface of the component R region. The transient excitation magnetic field generates eddy currents on the surface of the component R region through electromagnetic induction. The eddy currents induce heating on the surface of the component R region based on the Joule heating effect, causing temperature distribution information. The infrared thermal imager converts the temperature distribution information into a visible thermal image detection signal, which is then transmitted to the monitoring computer through the infrared thermal imager;

[0019] S2: Scan and detect along the radial direction of the R zone of the component. The displacement sensor transmits the spatial position parameters of the detection surface of the R zone of the component to the monitoring computer in real time.

[0020] S3: The monitoring computer draws an electromagnetic thermal imaging detection scan map of the component R area based on the received visual thermal image detection signal and spatial position parameters of the detection surface of the component R area;

[0021] S4: The monitoring computer displays the drawn electromagnetic thermal imaging detection scan map of the component R area on the monitoring display screen in real time.

[0022] The present invention has the following beneficial effects:

[0023] After adopting the electromagnetic thermal imaging detection device and method for the R zone of additively manufactured metal components of the present invention, surface and near-surface defects are detected through the temperature distribution information caused by the electromagnetic thermal multi-physical field on the surface of the R zone of the component. Compared with the existing technology, the efficiency and accuracy of defect detection in the R zone of the component can be improved, and the influence of the arc surface, curvature and probe lift-off effect of the R zone of the component is solved. Non-contact, fast and high-resolution imaging scanning of the R zone of the component can be realized. The obtained detection image can intuitively give the position, orientation, distribution and shape information of the defects on the surface of the R zone of the component, and display it in the form of a visual thermal image.

[0024] The present invention is applicable to, but not limited to, the detection of defects such as pores, lack of fusion, cracks, and inclusions in the R-zone of additively manufactured metal components, and is applicable to the detection of surface defects on the inner and outer surfaces of the R-zone of components with varying curvatures. The present invention is also applicable to the detection of surface and near-surface defects in conventionally manufactured metal components or other conductive materials, including but not limited to castings, forgings, machined parts, or welded parts, such as plates, bars, pipes, and other complex-shaped components. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 This is a schematic diagram of the system composition of an embodiment of an electromagnetic thermal imaging detection device for the R zone of an additively manufactured metal component of the present invention.

[0026] Figure 2 This is a schematic diagram of the detection principle of an electromagnetic thermal imaging detection device and method for the R zone of an additively manufactured metal component of the present invention.

[0027] Figure 3 This is a schematic diagram of the detection results when implementing an electromagnetic thermal imaging detection device and method for the R zone of an additively manufactured metal component according to the present invention.

[0028] In the figure: 1. Excitation coil; 2. L-shaped double yoke; 3. Displacement sensor; 4. Infrared thermal imager; 5. Monitoring computer; 6. Component R area; 7. Discontinuous position; 8. Magnetic lines of force; 9. Eddy currents; 10. Temperature distribution information. DETAILED DESCRIPTION

[0029] The embodiments of the present invention are described in further detail below with reference to the accompanying drawings.

[0030] See also Figure 1 , an electromagnetic thermal imaging detection device for the R zone of an additively manufactured metal component, the device comprising an excitation coil 1, an L-shaped double magnetic yoke 2, a displacement sensor 3, an infrared thermal imager 4 and a monitoring computer 5;

[0031] The excitation coil 1 is wound in the same direction on the two L-shaped yokes of the L-shaped double yoke 2, and the number of winding turns and wire diameter of the excitation coil 1 on the two L-shaped yokes are the same;

[0032] The two L-shaped magnetic yokes of the L-shaped double magnetic yoke 2 are respectively placed in a position close to the side wall panels of the component R area 6 but not in contact with the side wall panels. The two L-shaped magnetic yokes are respectively parallel to the side wall panels of the component R area 6. The two sides of the connecting line of the magnetic poles of the two L-shaped magnetic yokes of the L-shaped double magnetic yoke 2 cover the detection surface of the component R area 6. At the same time, the L-shaped double magnetic yoke 2 and the detection surface of the component R area 6 form multiple closed magnetic field loops.

[0033] The L-shaped double yoke 2 is connected to the component R region 6 through electromagnetic field coupling;

[0034] The displacement sensor 3 is fixed on one side of the L-shaped double yoke 2 in the moving direction, and moves synchronously with the L-shaped double yoke 2;

[0035] The output end of the displacement sensor 3 is electrically connected to the input end of the monitoring computer 5;

[0036] The infrared thermal imager 4 is placed diagonally above the component R region 6, and the shooting direction of the infrared thermal imager 4 faces the detection surface of the component R region 6 in the area surrounded by the L-shaped double magnetic yoke 2;

[0037] The output end of the infrared thermal imager 4 is electrically connected to the input end of the monitoring computer 5 .

[0038] In specific implementation, the L-shaped double magnetic yoke 2 is composed of two L-shaped magnetic yokes of the same material, shape and size, wherein the L-shaped magnetic yoke is composed of a magnetic conductive material rod and an L-shaped magnetic conductive material bracket connected to both ends of the magnetic conductive material rod, and the L-shaped magnetic conductive material bracket is used to support the magnetic conductive material rod.

[0039] During specific implementation, the excitation coil 1 is connected to external short-time pulse excitation.

[0040] In a specific implementation, the displacement sensor 3 is used to detect the distance between the L-shaped double yoke 2 and the starting point of the movement. The two L-shaped yokes of the L-shaped double yoke 2 are at the same distance from the displacement sensor 3 in the moving direction.

[0041] The present invention also discloses an electromagnetic thermal imaging detection method for R zone 6 of an additively manufactured metal component, using the above-mentioned device, and the method comprises the following steps:

[0042] S1: The excitation coil 1 is connected to a short-time pulse excitation, which generates a short-time pulse current on the excitation coil 1. The short-time pulse current flows in the excitation coil 1 to generate a transient excitation magnetic field. The L-shaped double magnetic yoke 2 is close to the component and transmits the transient excitation magnetic field to the surface of the component R region 6. The transient excitation magnetic field generates eddy currents on the surface of the component R region 6 through electromagnetic induction. The eddy currents induce heating on the surface of the component R region 6 based on the Joule heating effect, causing temperature distribution information. The infrared thermal imager 4 converts the temperature distribution information 10 into a visible thermal image detection signal, which is then transmitted to the monitoring computer 5 through the infrared thermal imager 4;

[0043] S2: Moving radially along the R region 6 of the component to perform scanning detection, the displacement sensor 3 transmits the spatial position parameters of the detection surface of the R region 6 of the component to the monitoring computer 5 in real time;

[0044] S3: The monitoring computer 5 draws an electromagnetic thermal imaging detection scan map of the component R region 6 based on the received visual thermal image detection signal and spatial position parameters of the detection surface of the component R region 6;

[0045] S4: The monitoring computer 5 displays the drawn electromagnetic thermal imaging detection scan map of the component R area 6 on the monitoring display screen in real time.

[0046] Detection principle and operation process:

[0047] Assume that there is a discontinuity 7 in the surface layer of the component R region 6 of the additively manufactured metal component;

[0048] See also Figure 2 , is a schematic diagram of the detection principle of the present device. The direction of the magnetic lines of force 8 of the transient excitation magnetic field transmitted to the surface of the component R zone 6 through the L-shaped double magnetic yoke 2 is parallel to the radial direction of the component R zone 6. The direction of the eddy current 9 generated by the electromagnetic induction of the transient excitation magnetic field lines 8 on the surface of the component R zone 6 is orthogonal to the magnetic lines of force 8. The direction of the induced eddy current 9 is orthogonal to the radial direction of the component R zone 6. When a discontinuity 7 appears on the surface of the component R zone 6, the discontinuity 7 hinders and changes the direction and distribution of the induced eddy current 9. The induced eddy current 9 causes temperature distribution information 10 near the discontinuity 7 on the surface of the component R zone 6.

[0049] See also Figure 3 Due to the interaction between the electromagnetic thermal multi-physics field and the discontinuity 7, the temperature distribution information 10 caused near the discontinuity 7 on the surface of the component R zone 6 can reflect the position, orientation, distribution and shape information of the discontinuity 7.

[0050] When a discontinuity 7 appears on the surface of the component R area 6, the visible thermal image detection signal detected by the device will be different from the visible thermal image detection signal detected previously when there was no discontinuity 7 on the surface of the component R area 6. This difference will be synchronously displayed in the electromagnetic thermal imaging detection scan map of the component R area drawn by the monitoring computer 5, and the monitoring computer 5 will output an alarm at the same time; the monitoring computer 5 will also intercept and save the visible thermal image detection signal and spatial position parameters of the detection surface of the component R area 6 at that time for observation and evaluation by the detection personnel.

[0051] The present invention provides an electromagnetic thermal imaging detection device and method for the R zone of an additively manufactured metal component. Surface and near-surface defects are detected by using the temperature distribution information caused by the electromagnetic thermal multi-physics field on the surface of the R zone of the component. Compared with the existing technology, the device and method can improve the efficiency and accuracy of defect detection in the R zone of the component, solve the influence of the arc surface, curvature and probe lift-off effect of the R zone of the component, and realize non-contact, fast, high-resolution imaging scanning of the R zone of the component. The obtained detection image can intuitively provide the position, orientation, distribution and shape information of the defects on the surface of the R zone of the component, and display it in the form of a visual thermal image.

[0052] The present invention is applicable to, but not limited to, the detection of defects such as pores, lack of fusion, cracks, and inclusions in the R-zone of additively manufactured metal components, and is applicable to the detection of surface defects on the inner and outer surfaces of the R-zone of components with varying curvatures. The present invention is also applicable to the detection of surface and near-surface defects in conventionally manufactured metal components or other conductive materials, including but not limited to castings, forgings, machined parts, or welded parts, such as plates, bars, pipes, and other complex-shaped components.

[0053] Although the present invention has been described in detail above using general descriptions and specific embodiments, it will be apparent to those skilled in the art that modifications and improvements may be made thereto. Therefore, such modifications and improvements, without departing from the spirit of the present invention, are intended to fall within the scope of the present invention.

Claims

1. An electromagnetic thermal imaging detection device for the R zone of an additively manufactured metal component, characterized by: The device comprises an excitation coil (1), an L-shaped double magnetic yoke (2), a displacement sensor (3), an infrared thermal imager (4) and a monitoring computer (5); The excitation coil (1) is wound in the same direction on two L-shaped magnetic yokes of the L-shaped double magnetic yoke (2), and the number of winding turns and wire diameter of the excitation coil (1) on the two L-shaped magnetic yokes are the same; The L-shaped double magnetic yoke (2) is composed of two L-shaped magnetic yokes of the same material, shape and size, wherein the L-shaped magnetic yoke is composed of a magnetic conductive material rod and an L-shaped magnetic conductive material bracket connected to both ends of the magnetic conductive material rod, and the L-shaped magnetic conductive material bracket is used to support the magnetic conductive material rod; The two L-shaped magnetic yokes of the L-shaped double magnetic yoke (2) are respectively placed at positions close to the side wall panels of the component R region (6) but not in contact with the side wall panels. The two L-shaped magnetic yokes are respectively parallel to the side wall panels of the component R region (6). The direction of the transient excitation magnetic field lines (8) transmitted to the surface of the component R region (6) through the L-shaped double magnetic yoke (2) is parallel to the radial direction of the component R region (6). The L-shaped double magnetic yoke (2) is coupled to the surface layer of the component R region (6) through an electromagnetic field; The displacement sensor (3) is fixed on one side of the L-shaped double yoke (2) in the moving direction, and moves synchronously with the L-shaped double yoke (2); The displacement sensor (3) is used to detect the distance between the L-shaped double magnetic yoke (2) and the starting point of the movement, and the two L-shaped magnetic yokes of the L-shaped double magnetic yoke (2) are at the same distance from the displacement sensor (3) in the moving direction; The output end of the displacement sensor (3) is electrically connected to the input end of the monitoring computer (5); The infrared thermal imager (4) is placed diagonally above the component R region (6), and the shooting direction of the infrared thermal imager (4) faces the detection surface of the component R region (6) in the area surrounded by the L-shaped double magnetic yoke (2); The output end of the infrared thermal imager (4) is electrically connected to the input end of the monitoring computer (5).

2. The electromagnetic thermal imaging detection device for the R zone of an additively manufactured metal component according to claim 1, characterized in that: The excitation coil (1) is connected to external short-time pulse excitation.

3. A method for electromagnetic thermal imaging detection of the R zone of an additively manufactured metal component, characterized by: Using the device according to claim 1, the method comprises the following steps: S1: The excitation coil (1) is connected to an external short-time pulse excitation, and the short-time pulse excitation generates a short-time pulse current on the excitation coil (1). The short-time pulse current flows in the excitation coil (1) to generate a transient excitation magnetic field. The L-shaped double magnetic yoke (2) is close to the component and transmits the transient excitation magnetic field to the surface of the component R region (6). The transient excitation magnetic field generates eddy currents on the surface of the component R region (6) through electromagnetic induction. The eddy currents induce heating on the surface of the component R region (6) based on the Joule heating effect, causing temperature distribution information. The infrared thermal imager (4) converts the temperature distribution information (10) into a visible thermal image detection signal, and the visible thermal image detection signal is then transmitted to the monitoring computer (5) through the infrared thermal imager (4); S2: Moving radially along the component R region (6) to perform scanning detection, the displacement sensor (3) transmits the spatial position parameters of the detection surface of the component R region (6) to the monitoring computer (5) in real time; S3: The monitoring computer (5) draws an electromagnetic thermal imaging detection scan map of the component R region (6) based on the received visual thermal image detection signal and spatial position parameters of the detection surface of the component R region (6); S4: The monitoring computer (5) displays the drawn electromagnetic thermal imaging detection scan map of the detection surface of the component R area (6) in real time on the monitoring display screen.

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