Method for detecting and identifying defects of copper-steel double-material welding joint layer of rotor for airplane

Abstract

The invention relates to the field of aircraft rotor defect identification, in particular to an aircraft rotor copper-steel double-material welding joint layer defect detection and identification method, which comprises the following specific steps of: 1, checking the temperature and the humidity of an environment; 2, checking the state; step 3, visual inspection; step 4, adjusting the size of the opening; 5, inserting a filter disc; step 6, carrying out anti-collision setting; 7, setting an X-ray machine; step 8, setting an area array detector; step 9, setting a mode by an expert; step 10, setting a parameter height; step 11, setting detection parameters according to the gray value; step 12, setting a scanning mode; step 13, adding a CERA reconstruction module; step 14, calibrating the detector; step 15, starting detection; 16, importing data according to the following steps; step 17, adjusting the view; step 18, defect evaluation; defects are accurately recognized and positioned through a method of data reconstruction after a large number of multi-angle X-rays penetrate through the rotor, meanwhile, the sizes and directions of the defects are recognized and positioned in cooperation with a two-dimensional plane and a three-dimensional image, and the effects that the defect distribution state is visually displayed, and defect recognition operation is easy are achieved.

Description

Technical Field

[0001] The invention relates to the field of rotor defect recognition for aircraft, and in particular to a method for detecting and identifying defects in a copper-steel dual-material welded joint layer of an aircraft rotor. Background Art

[0002] In a plunger pump assembly for an aircraft hydraulic pump, the rotor material is bimetallic, the base material is 45# steel, the end face material is tin bronze ZQSn10-2-3, the end face material and the base material are diffusion welded, the end face surface is first nickel plated with 1μm, and then silver plated with 3μm; the oil separator material is 1Cr12MoV, and the hardness requirement is HRC50-55. The plunger rotor shoe end face is processed by a bimetallic diffusion welding process with a steel layer-copper layer structure. Due to welding process and other reasons, the steel-copper joint surface occasionally has faults such as peeling of the copper layer on the shoe end face, abnormal wear of the shoe end face and the rotor end face.

[0003] The main welding mechanism of diffusion welding is the penetration of metal atoms under temperature and pressure. Under a certain temperature and pressure, the welding surfaces of the two metals to be welded are brought into contact with each other, and the physical contact of the surfaces to be welded is expanded through microscopic plastic deformation or the generation of a trace liquid phase through the welding surface, so that the distance is within 1 to 5×10-8cm, and then after a long period of continuous diffusion and mutual penetration between atoms, a welding method is achieved to achieve metallurgical bonding. Since the diffusion bonding base material does not need to be melted, it plays a great role in precision welding, fine connection, special material connection, dissimilar material connection and difficult fusion welding fields, and has become an indispensable technology in advanced technology fields such as aviation and aerospace and the assembly of some industrial products.

[0004] Manufacturers use ultrasonic testing to check the defects of the two metal junction layers of copper-steel dual-material diffusion welding rotors. The detection time is when the rotor blank is in the process, that is, before the end face shoe is processed. After the end face shoe is processed, there is a concave area on the end face of the rotor copper layer. Due to the structural distortion and irregular end face, ultrasonic testing can no longer complete the quality inspection of the copper-steel dual-material diffusion welding junction layer. A new defect detection and identification method that is not affected by the rotor processing structure must be adopted. Summary of the invention

[0005] In order to solve the above problems, the present invention proposes a method for detecting and identifying defects in a copper-steel dual-material welded joint layer of an aircraft rotor.

[0006] A method for detecting and identifying defects in the copper-steel dual-material welding joint layer of an aircraft rotor, the specific steps of which are as follows:

[0007] Step 1. Check the temperature and humidity of the environment: During the operation of the equipment, the ambient temperature range is controlled at 20℃~25℃, the relative air humidity is ≤50%, and there is no condensation;

[0008] Step 2, check the status: log in to the micro-focus X-ray source control software X-COM to check the status of the micro-focus X-ray tube. The filament and cooling indicators are green. The vacuum degree in the tube must reach 10-6 before the micro-focus X-ray source is trained.

[0009] Step 3: Visual inspection: Check the position of the turntable in the lead room and the items placed on the turntable to ensure that there is no interference with the X-ray machine or detector;

[0010] Step 4: Adjust the opening size: insert the carbon fiber rod into the slot of the DM125-200 six-jaw chuck, and use a straight-handled socket wrench to adjust the opening size of the six-jaw chuck;

[0011] Step 5, insert the filter: install the DM125-200 base on the air-floating turntable on the stage, place the DM125-200 six-claw chuck on the base, use the hand operation box to translate the stage to the detection center, and insert the 1mmCu filter in front of the beam exit window of the 300KvX-ray machine;

[0012] Step 6: Anti-collision settings: Log in to the detection operation software FF85 CT and set the anti-collision parameters;

[0013] Step 7, X-ray machine settings: switch the X-ray machine to a micro-focus X-ray source 300KvDirectBeam, and preset the plunger assembly to a tube voltage of 260kV and a tube current of 180μA;

[0014] Step 8: Area array detector settings: switch the detector type to Varex, an area array flat panel detector;

[0015] Step 9, Expert Setting Mode: Select Expert Setting Mode in the Algorithm column, and select 1×12PF VG1 for the plunger component CT detection mode name, 3072×3072 resolution, 4.0Hz maximum frame rate, 1×1 pixel binning, and 4.0Hz frame rate;

[0016] Step 10, set the parameter height: set the horizontal position parameter of the area array detector in the manipulator to 0, the horizontal position of the stage 3 to 0, the height of the synchronous lifting platform of the X-ray source and the area array detector to 340, the Y-axis displacement of the stage to 93, and the Y-axis displacement of the area array detector to 886;

[0017] Step 11. Set the detection parameters according to the grayscale value: observe that the grayscale value in the histogram needs to be evenly distributed between the upper limit line and the lower limit line, and as close to the upper limit line as possible. The plunger assembly CT detection voltage is 265 kV, the current is 180 μA, the mode name is 1×11PF VG1, the resolution is 3072×3072, the maximum frame number is 4.0 Hz, the pixel combination is 1×1, and the frame rate is 4.0 Hz.

[0018] Step 12, set the scanning mode: select the fast circumferential scanning mode, rotate 360°, the number of projections is 2160, and the volume is cropped to retain the observation area;

[0019] Step 13. Add the CERA reconstruction module: Select beam hardening correction, select copper for filter material, steel for main specimen material, and filter thickness 1.0 mm. Select projection spatial noise reduction, select VG Studio as the viewer, and select Generate VGL only for the viewer option;

[0020] Step 14, detector calibration: click the start button, select single-point air calibration, move the workpiece in a standard way, move it out of the field of view, click calibrate, and after the calibration is completed, the workpiece automatically moves back to the calibration center;

[0021] Step 15. Start detection: Click the CERA reconstruction icon for 2S, click Start detection, and observe the detection progress in "System Process". After the scan is completed, the system will automatically rebuild and observe the progress of the reconstruction progress bar;

[0022] Step 16. Follow the steps below to import data: Open VG software - File - VGL - Browse - Flat Data Folder, select data according to time, open - ReconDate - open - CERA folder icon - Next - Histogram, preview and adjust data range - Complete;

[0023] Step 17, adjust the view: adjust the display position and viewing angle of the part in the three view directions of XYZ through the zoom, translation and rotation tools, so that the image can be easily evaluated from the three view directions of the part;

[0024] Step 18, defect assessment: X-rays will be attenuated when passing through the workpiece. Parts with different thicknesses and densities will show different grayscale values ​​in the image. The structural state, shape and material inside the workpiece can be identified based on the different grayscale values.

[0025] The step S1 controls the ambient temperature and humidity through air conditioners and dehumidifiers, and only allows the equipment to be powered on after the requirements are met.

[0026] The step S2 needs to carry out the machine training operation according to the device status prompt, and use a mask to cover the beam output window before the machine training operation.

[0027] The step S3 needs to check the guide rails of each mechanical motion axis to ensure that there are no debris that hinders the movement of each axis of the system, and the surface of the plunger assembly should not have any excess matter that hinders inspection and defect image recognition, such as metal chips, oil stains, and oxide scale.

[0028] The height of the white rubber support of the carbon fiber rod in step S4 is uniformly set to 120 mm, the plunger assembly is placed in the three groups of carbon fiber rods, and the assembly and the end are fixed with tape to keep the plunger rotor end in an inclined state.

[0029] The detection center of step S5 is the horizontal center position of the dust cover, and the dust cover is composed of a horizontal marble platform and two vertical marble platforms.

[0030] The anti-collision parameter in the height direction of step S6 is set to 350 mm, and no value is set in the outer diameter direction.

[0031] The detection parameters of step S11 include voltage, current, mode and exposure time.

[0032] The beneficial effects of the present invention are as follows: the present invention accurately identifies and locates defects by reconstructing data after a large number of multi-angle X-rays penetrate the rotor, and at the same time cooperates with two-dimensional plane and three-dimensional image recognition to locate the size and orientation of the defects, which has the effects of intuitively displaying the defect distribution status and simple defect identification operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0034] Figure 1 is a flow chart of the method of the present invention;

[0035] Figure 2 It is a schematic diagram of the clamping of the plunger rotor of the present invention;

[0036] Figure 3 It is a schematic diagram of the computer tomography detection device of the present invention;

[0037] Figure 4 This is a slice morphology diagram of the copper-steel diffusion welding junction layer of the plunger rotor of the present invention;

[0038] Figure numerals: 1, X-ray source; 2, area array detector; 3, stage; 4, horizontal marble platform; 5, vertical marble platform; 6, air-floating turntable; 7, rotor; 8, carbon fiber rod; 9, six-jaw chuck. DETAILED DESCRIPTION

[0039] In order to make the technical means, creative features, objectives and effects achieved by the present invention easy to understand, the present invention is further described below.

[0040] like Figures 1 to 4 As shown, a method for detecting and identifying defects in the copper-steel dual-material welding interface layer of an aircraft rotor is described, and the specific steps are as follows:

[0041] Step 1. Check the temperature and humidity of the environment: During the operation of the equipment, the ambient temperature range is controlled at 20℃~25℃, the relative air humidity is ≤50%, and there is no condensation;

[0042] Step 2, check the status: log in to the micro-focus X-ray source control software X-COM to check the status of the micro-focus X-ray tube. The filament and cooling indicators are green. The vacuum degree in the tube must reach 10-6 before the micro-focus X-ray source is trained.

[0043] Step 3: Visual inspection: Check the position of the turntable in the lead room and the items placed on the turntable. There should be no interference with the X-ray machine or detector.

[0044] Step 4: Adjust the opening size: insert the carbon fiber rod 8 into the slot of the DM125-200 six-jaw chuck 9, and use a straight-handled socket wrench to adjust the opening size of the six-jaw chuck;

[0045] Step 5, insert the filter: install the DM125-200 base on the air-floating turntable 6 on the stage 3, place the DM125-200 six-claw chuck 9 on the base, use the hand operation box to translate the stage 3 to the detection center, and insert a 1mmCu filter in front of the beam exit window of the 300KvX-ray machine 1;

[0046] Step 6: Anti-collision settings: Log in to the detection operation software FF85 CT and set the anti-collision parameters;

[0047] Step 7, X-ray machine settings: switch the X-ray machine to a micro-focus X-ray source 300KvDirectBeam, and preset the plunger assembly to a tube voltage of 260kV and a tube current of 180μA;

[0048] Step 8, area array detector 2 settings: switch the detector type to the area array flat panel detector Varex;

[0049] Step 9, Expert Setting Mode: Select Expert Setting Mode in the Algorithm column, and select 1×12PF VG1 for the plunger component CT detection mode name, 3072×3072 resolution, 4.0Hz maximum frame rate, 1×1 pixel binning, and 4.0Hz frame rate;

[0050] Step 10, setting parameter height: set the horizontal position parameter of the area array detector 2 in the manipulator to 0, the horizontal position of the stage 3 to 0, the height of the synchronous lifting platform of the X-ray source 1 and the area array detector 2 to 340, the Y-axis displacement of the stage 3 to 93, and the Y-axis displacement of the area array detector 3 to 886;

[0051] Step 11. Set the detection parameters according to the grayscale value: observe that the grayscale value in the histogram needs to be evenly distributed between the upper limit line and the lower limit line, and as close to the upper limit line as possible. The plunger assembly CT detection voltage is 265 kV, the current is 180 μA, the mode name is 1×11PF VG1, the resolution is 3072×3072, the maximum frame number is 4.0 Hz, the pixel combination is 1×1, and the frame rate is 4.0 Hz.

[0052] Step 12, set the scanning mode: select the fast circumferential scanning mode, rotate 360°, the number of projections is 2160, and the volume is cropped to retain the observation area;

[0053] Step 13. Add the CERA reconstruction module: Select beam hardening correction, select copper for filter material, steel for main specimen material, and filter thickness 1.0 mm. Select projection spatial noise reduction, select VG Studio as the viewer, and select Generate VGL only for the viewer option;

[0054] Step 14, detector calibration: click the start button, select single-point air calibration, move the workpiece in a standard way, move it out of the field of view, click calibrate, and after the calibration is completed, the workpiece automatically moves back to the calibration center;

[0055] Step 15. Start detection: Click the CERA reconstruction icon for 2S, click Start detection, and observe the detection progress in "System Process". After the scan is completed, the system will automatically rebuild and observe the progress of the reconstruction progress bar;

[0056] Step 16. Follow the steps below to import data: Open VG software - File - VGL - Browse - Flatbed data folder ConeBeamCtScan, select data according to time, open - ReconDate - open - CERA folder icon - Next - Histogram, preview and adjust data range - Complete;

[0057] Step 17, adjust the view: adjust the display position and viewing angle of the part in the three view directions of XYZ through the zoom, translation and rotation tools, so that the image can be easily evaluated from the three view directions of the part;

[0058] Step 18, defect assessment: X-rays will be attenuated when passing through the workpiece. Parts with different thicknesses and densities will show different grayscale values ​​in the image. The structural state, shape and material inside the workpiece can be identified based on the different grayscale values.

[0059] The step S1 controls the ambient temperature and humidity through air conditioners and dehumidifiers, and only allows the equipment to be powered on after the requirements are met.

[0060] The defects are accurately identified and located by reconstructing the data after a large number of multi-angle X-rays penetrate the rotor. At the same time, the size and orientation of the defects are located by cooperating with two-dimensional plane and three-dimensional images. The defect distribution status is intuitively displayed and the defect identification operation is simple.

[0061] The step S2 needs to carry out the machine training operation according to the device status prompt, and use a mask to cover the beam output window before the machine training operation.

[0062] The step S3 needs to check the guide rails of each mechanical motion axis to ensure that there are no debris that hinders the movement of each axis of the system, and the surface of the plunger assembly should not have any excess matter that hinders inspection and defect image recognition, such as metal chips, oil stains, and oxide scale.

[0063] The height of the white rubber support of the carbon fiber rod 8 in step S4 is uniformly set to 120 mm. The plunger assembly is placed in the three groups of carbon fiber rods 8. The assembly and the end are fixed with adhesive tape. The end of the plunger rotor 7 is kept in an inclined state. Figure 1 shown.

[0064] The detection center of step S5 is the horizontal center position of the dust cover. The dust cover is composed of a horizontal marble platform 4 and two vertical marble platforms 5, which mainly constitute the base of the detection equipment. The marble material is conducive to maintaining the stability of the equipment.

[0065] The X-ray source 1 is mainly used to emit X-rays under high voltage. After penetrating the rotor workpiece, the X-rays are received by the area array detector. The area array detector 2 converts the energy of the structural parts into electrical signals and transmits them to the reconstruction software for background data processing.

[0066] The stage 3 is mainly used to carry rotor-type workpieces. When the air-floating turntable rotates 6N×360°, the area array detector 2 can receive energy passing through the workpiece at different angles.

[0067] The anti-collision parameter in the height direction of step S6 is set to 350 mm, and no value is set in the outer diameter direction.

[0068] The step S10 needs to turn on the X-ray source 1 and observe whether the plunger assembly image appears on the signal acquisition screen of the area array detector 2. If not, use a manipulator to adjust the position of the plunger assembly.

[0069] The detection parameters of step S11 include voltage, current, mode and exposure time.

[0070] The step S17 needs to adjust the image contrast and brightness according to the state of the defect to be observed, and the defective parts found should be labeled. The selected three views and the volume view should be able to reflect the location of the defect and the defect morphology characteristics.

[0071] In step S18, in the copper-steel diffusion welding junction layer, there are differences in thickness due to reasons such as copper layer peeling, and the grayscale values ​​of the slices are different. Figure 4 The white patches shown are the defect locations and shapes.

[0072] When scanning the sample, the sample is usually placed vertically, with the radiation source and detector located on both sides of the test workpiece. The required parameters, voltage, current, integration time, and required data volume are set. During the test, the sample is rotated according to the set angle, and the two-dimensional slice data acquisition system automatically obtains photos, which will be automatically saved together with the position information. The size and rotation accuracy of each fixed rotation angle will directly determine the data volume and clarity of the two-dimensional slice.

[0073] When the ray beam passes through the object being inspected, the transmission energy received by the detector is different depending on the different attenuation coefficients of the object material in each transmission direction.

[0074] According to the image reconstruction algorithm, a thin layer of tomographic scanning image without image overlap of the cross section of the inspected workpiece can be obtained. By repeating the above process, a new tomographic image can be obtained. After collecting enough two-dimensional data at various positions, a three-dimensional image can be reconstructed through a 3D image data processing and analysis system.

[0075] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions only describe the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A method for detecting and identifying defects in the copper-steel dual-material welding interface of an aircraft rotor, characterized in that: The specific steps are as follows: Step 1. Check the temperature and humidity of the environment: During the operation of the equipment, the ambient temperature range is controlled at 20℃~25℃, the relative air humidity is ≤50%, and there is no condensation; Step 2, check the status: log in to the micro-focus X-ray source control software X-COM to check the status of the micro-focus X-ray tube. The filament and cooling indicators are green. The vacuum degree in the tube must reach 10-6 before the micro-focus X-ray source is trained. Step 3: Visual inspection: Check the position of the turntable in the lead room and the items placed on the turntable to ensure that there is no interference with the X-ray machine or detector; Step 4, adjusting the opening size: insert the carbon fiber rod (8) into the slot of the DM125-200 six-jaw chuck (9), and use a straight-handled socket wrench to adjust the opening size of the six-jaw chuck; Step 5, inserting the filter: the DM125-200 base is mounted on the air-floating turntable (6) on the stage (3), the DM125-200 six-jaw chuck (9) is placed on the base, the stage (3) is translated to the detection center using the hand operation box, and a 1mm Cu filter is inserted in front of the beam exit window of the 300Kv X-ray machine; Step 6: Anti-collision settings: Log in to the detection operation software FF85 CT and set the anti-collision parameters; Step 7, X-ray machine settings: switch the X-ray machine to a micro-focus X-ray source 300KvDirectBeam, and preset the plunger assembly to a tube voltage of 260kV and a tube current of 180μA; Step 8, area array detector (2) setting: switch the detector type to the area array flat panel detector Varex; Step 9, Expert Setting Mode: Select Expert Setting Mode in the Algorithm column, and select 1×12PF VG1 for the plunger component CT detection mode name, 3072×3072 resolution, 4.0Hz maximum frame rate, 1×1 pixel binning, and 4.0Hz frame rate; Step 10, setting parameter height: the horizontal position parameter of the area array detector (2) in the manipulator is set to 0, the horizontal position of the stage (3) is set to 0, the height of the synchronous lifting platform of the X-ray source (1) and the area array detector (2) is set to 340, the Y-axis displacement of the stage (3) is set to 93, and the Y-axis displacement of the area array detector (3) is set to 886; Step 11. Set the detection parameters according to the grayscale value: observe that the grayscale value in the histogram needs to be evenly distributed between the upper limit line and the lower limit line, and as close to the upper limit line as possible. The plunger assembly CT detection voltage is 265 kV, the current is 180 μA, the mode name is 1×11PF VG1, the resolution is 3072×3072, the maximum frame number is 4.0 Hz, the pixel combination is 1×1, and the frame rate is 4.0 Hz. Step 12, set the scanning mode: select the fast circumferential scanning mode, rotate 360°, the number of projections is 2160, and the volume is cropped to retain the observation area; Step 13. Add the CERA reconstruction module: select beam hardening correction, copper for filter material, steel for main specimen material, and filter thickness of 1.0 mm; select projection spatial noise reduction, select VG Studio as the viewer, and select GenerateVGL only for the viewer option; Step 14, detector calibration: click the start button, select single-point air calibration, move the workpiece in a standard way, move it out of the field of view, click calibrate, and after the calibration is completed, the workpiece automatically moves back to the calibration center; Step 15. Start detection: Click the CERA reconstruction icon for 2S, click Start detection, and observe the detection progress in "System Process". After the scan is completed, the system will automatically rebuild, and observe the progress of the reconstruction progress bar; Step 16. Follow the steps below to import data: Open VG software - File - VGL - Browse - Flat Data Folder, select data according to time, open - ReconDate - open - CERA folder icon - Next - Histogram, preview and adjust data range - Complete; Step 17, adjust the view: adjust the display position and viewing angle of the part in the three view directions of XYZ through the zoom, translation and rotation tools, so that the image can be easily evaluated from the three view directions of the part; Step 18, defect assessment: X-rays will be attenuated when passing through the workpiece. Parts with different thicknesses and densities will show different grayscale values ​​in the image. The structural state, shape and material inside the workpiece can be identified based on the different grayscale values.

2. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The step S1 controls the ambient temperature and humidity through air conditioners and dehumidifiers, and only allows the equipment to be powered on after the requirements are met.

3. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The step S2 needs to carry out the machine training operation according to the device status prompt, and use a mask to cover the beam output window before the machine training operation.

4. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The step S3 needs to check the guide rails of each mechanical motion axis to ensure that there are no debris that hinders the movement of each axis of the system, and the surface of the plunger assembly should not have any excess matter that hinders inspection and defect image recognition, such as metal chips, oil stains, and oxide scale.

5. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The height of the white rubber support of the carbon fiber rod (8) in step S4 is uniformly set to 120 mm, the plunger assembly is placed in the three groups of carbon fiber rods (8), and the assembly and the end are fixed with adhesive tape, and the end of the plunger rotor (7) is kept in an inclined state.

6. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The detection center of step S5 is the horizontal center position of the dust cover, and the dust cover is composed of a horizontal marble platform (4) and two vertical marble platforms (5).

7. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The anti-collision parameter in the height direction of step S6 is set to 350 mm, and no value is set in the outer diameter direction.

8. The method for detecting and identifying defects in the copper-steel dual-material welded joint layer of an aircraft rotor according to claim 1, characterized in that: The detection parameters of step S11 include voltage, current, mode and exposure time.

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