Nondestructive testing method and system for stability of passivation film on surface of high-throwing corrosion-resistant material

Abstract

The present application relates to the technical field of passivation film detection, and particularly relates to a nondestructive testing method and system for the stability of a passivation film on the surface of a high-throwing corrosion-resistant material, the method comprising the following steps: constructing a flow field simulation model to perform flow field coupling analysis on the internal flow field of a hot runner, and evaluating the distribution of the flow state of the rubber in the hot runner; analyzing the disturbance effect of the nozzle release behavior on the local flow field and correcting the distribution of the flow state of the rubber, to generate a contact distribution matrix of the rubber and the passivation film; analyzing the potential corrosion effect of the rubber on the passivation film, and combining the contact distribution matrix to evaluate the disturbance degree of the stability of the passivation film under the coupling influence of flow scouring and corrosion effect; and based on the disturbance degree of the stability of the passivation film by the rubber, combining key processing parameters to evaluate whether the stability of the passivation film meets the processing requirements. The present application improves the accuracy and reliability of the stability detection of the passivation film by quantifying the coupling influence of flow scouring and corrosion effect in the flow channel plate.

Description

Technical Field

[0001] This invention relates to the field of passivation film testing technology, and in particular to a non-destructive testing method and system for the stability of passivation films on the surface of highly polishable corrosion-resistant materials. Background Technology

[0002] Hot runner systems, a key technology in injection molding, are widely used in precision manufacturing industries such as automotive, electronics, and medical devices. Hot runner systems enable efficient distribution and directional transport of molten plastic during injection molding, effectively reducing material waste and improving mold filling uniformity. The runner plate, as the core component of the hot runner system, directly affects the system's production efficiency and product molding quality due to the stability of its surface passivation film.

[0003] In actual processing, the runner plate is subjected to high temperature, high pressure, and cyclic thermal stress for extended periods. Furthermore, the types of molten plastic transported within the runner plate are complex, with some compounds containing corrosive and abrasive additives such as glass fibers, flame retardants, and halogen compounds. These components mechanically erode and chemically corrode the passivation film on the runner plate surface, thereby compromising its stability. When the passivation film experiences localized instability or breakdown under complex flow conditions, the polishing and corrosion resistance of the runner plate decreases. Insufficient polishing performance leads to poor flow of the molten plastic within the runner, causing stagnation and degradation, thus affecting product surface quality. Inadequate corrosion resistance results in the runner plate being eroded over long-term use, shortening the lifespan of the hot runner system and increasing production costs and maintenance frequency.

[0004] Existing passivation film testing methods primarily rely on destructive testing such as electrochemical tests or accelerated corrosion tests, which cannot provide non-destructive assessment of passivation film stability under actual operating conditions. Furthermore, during the long-term use of hot runner systems, significant temperature and pressure differences, as well as uneven flow velocity distribution, exist within the runner. Localized flow dead zones, transient impacts during nozzle switching, and temperature fluctuations all alter the contact characteristics and corrosion intensity between the adhesive and the passivation film, resulting in significant spatial differences and temporal degradation patterns in different regions. Traditional testing methods fail to fully consider the coupled effects of flow erosion and corrosion on passivation film stability, leading to discrepancies between test results and the actual service condition of the passivation film, thus hindering effective guidance for the maintenance and optimization of hot runner systems. Summary of the Invention

[0005] To overcome the defects and shortcomings of existing technologies, this invention provides a non-destructive testing method and system for the stability of passivation films on the surface of highly polishable corrosion-resistant materials. By quantifying the coupling effect of flow scouring and corrosion within the flow channel plate, the accuracy and reliability of passivation film stability testing are improved.

[0006] In order to achieve the above object, the present application adopts the following technical solutions:

[0007] In a first aspect, the present application provides a non-destructive testing method for the stability of a passivated film on the surface of a high-throwing corrosion-resistant material, comprising:

[0008] Obtain the operating parameters of the hot runner, construct a flow field simulation model, and perform flow field coupling analysis on the temperature field, pressure field, and flow velocity field inside the hot runner to evaluate the distribution of the flow state of the rubber inside the hot runner;

[0009] Obtain the operating parameters of the nozzle, analyze the disturbance effect of the nozzle release behavior on the local flow field, and correct the distribution of the flow state of the rubber, to generate a contact distribution matrix of the rubber and the passivated film;

[0010] Obtain the property parameters of the rubber and the passivated film, analyze the potential corrosion effect of the rubber on the passivated film, and combine the contact distribution matrix to evaluate the disturbance degree of the rubber on the stability of the passivated film under the coupling influence of flow scouring and corrosion effect;

[0011] Obtain the key processing parameters, and evaluate whether the stability of the passivated film meets the processing requirements based on the disturbance degree of the rubber on the stability of the passivated film and the key processing parameters.

[0012] Further, the analysis of the disturbance effect of the nozzle release behavior on the local flow field and the correction of the flow state distribution of the rubber comprises:

[0013] Obtain the operating parameters of the nozzle and extract the opening timing parameters, rubber release pressure parameters, rubber release rate parameters, and nozzle outlet temperature parameters of each nozzle;

[0014] Based on the nozzle operating parameters, analyze the pressure wave propagation characteristics and temperature gradient changes formed in the flow channel at the moment of nozzle opening using transient flow field simulation;

[0015] Analyze the flow field interference effect generated when multiple nozzles work cooperatively, and quantitatively evaluate the superposition and cancellation areas of the flow field velocity vector;

[0016] Based on the pressure wave propagation characteristics, temperature gradient changes, and flow field interference effect, dynamically correct the flow state distribution of the rubber, and update the distribution of the flow hysteresis zone and high scouring zone in the flow channel.

[0017] Further, the generation of the contact distribution matrix of the rubber and the passivated film comprises:

[0018] Based on the corrected flow state distribution results of the rubber, extract the shear rate, contact pressure, and residence time of the rubber in each microelement region on the inner surface of the flow channel plate;

[0019] Based on the shear rate, contact pressure, and residence time of the rubber, determine the local scouring energy density of each microelement region;

[0020] Determine the contact angle factor based on the flow channel geometry, and geometrically correct the contact intensity of the flow dead angle and elbow area;

[0021] Based on the contact angle factor, the local erosion energy density is weighted to obtain the comprehensive contact coefficient of each micro-element area, and a contact distribution matrix indexed by spatial coordinates is constructed.

[0022] Further, the analysis of the potential corrosion effect of the compound on the passivation film includes:

[0023] Obtain the compound attribute parameters and the passivation film attribute parameters, the compound attribute parameters including the compound flame retardant type, halogen content, acid group concentration and oxidizing substance content, and the passivation film attribute parameters including the breakdown potential and passivation current density of the passivation film in the simulated hot runner environment;

[0024] Based on the compound attribute parameters and the passivation film attribute parameters, a response surface of temperature-concentration-corrosion rate is constructed to quantify the activity change law of the corrosion medium in different temperature intervals;

[0025] Based on the response surface and the Arrhenius equation, a corrosion rate prediction model under the influence of temperature effect is constructed to quantify the potential chemical corrosion effect of different compound components on the stability of the passivation film.

[0026] Further, the evaluation of the disturbance degree of the compound on the stability of the passivation film under the coupling influence of flow erosion and corrosion effect includes:

[0027] Obtain the comprehensive contact coefficient of each micro-element area of the contact distribution matrix and the corrosion rate prediction result of the corresponding micro-element area;

[0028] Based on the comprehensive contact coefficient and the corrosion rate prediction result, a corrosion contact synergistic effect model is constructed to calculate the synergistic amplification coefficient of flow erosion and chemical corrosion;

[0029] Using damage accumulation algorithm to calculate the film layer damage degree and film layer damage area of each micro-element area in the preset process period, and quantitatively evaluate the overall disturbance degree of the stability of the passivation film.

[0030] Further, the disturbance degree of the compound on the stability of the passivation film is combined with the key processing parameters to evaluate whether the stability of the passivation film meets the processing requirements, including:

[0031] Obtain the key processing parameters and the film layer damage degree and film layer damage area of each micro-element area in the preset process period, and the key processing parameters include the safety thickness threshold of the passivation film, the maximum maintenance interval requirement and the planned production cycle;

[0032] Based on the film layer damage degree and the film layer damage area of each micro-element region in the preset process cycle, thickness attenuation trend and failure risk evolution of the passivation film in the planned production cycle are evaluated;

[0033] The thickness attenuation trend is compared with the safety thickness threshold of the passivation film, and the failure risk evolution is matched with the maximum maintenance interval requirement, when the predicted thickness in the planned production cycle is always greater than the safety thickness threshold and the failure risk evolution meets the maximum maintenance interval requirement, it is determined that the passivation film stability meets the process requirement, otherwise, it is determined that it does not meet.

[0034] In the second aspect, the application provides a nondestructive testing system for passivation film stability of high-throwing corrosion-resistant material surface, comprising:

[0035] The glue flow state evaluation module is used for acquiring hot runner operation parameters, constructing a flow field simulation model to perform flow field coupling analysis on the temperature field, pressure field and flow velocity field inside the hot runner, and evaluating the glue flow state distribution in the hot runner.

[0036] The contact distribution matrix generation module is used for acquiring nozzle operation parameters, analyzing the disturbance effect of the nozzle release behavior on the local flow field and correcting the glue flow state distribution, and generating a contact distribution matrix of the glue and the passivation film.

[0037] The disturbance degree evaluation module is used for acquiring glue attribute parameters and passivation film attribute parameters, analyzing the potential corrosion effect of the glue on the passivation film, and combining the contact distribution matrix to evaluate the disturbance degree of the glue on the passivation film stability under the coupling influence of flow scouring and corrosion effect.

[0038] The passivation film stability evaluation module is used for acquiring key processing parameters, and evaluating whether the passivation film stability meets the processing requirement based on the disturbance degree of the glue on the passivation film stability and the key processing parameters.

[0039] In the third aspect, the application provides an electronic device, comprising a processor and a memory, wherein the memory stores a computer program that can be called by the processor, and the processor executes a nondestructive testing method for passivation film stability of high-throwing corrosion-resistant material surface by calling the computer program stored in the memory.

[0040] In the fourth aspect, the application provides a computer readable storage medium storing instructions, when the instructions run on a computer, the computer executes a nondestructive testing method for passivation film stability of high-throwing corrosion-resistant material surface.

[0041] Compared with the prior art, the application has the following advantages and beneficial effects:

[0042] (1) The present application builds a multi-physical field coupling simulation model of the temperature field, pressure field and flow field inside the hot runner, evaluates the glue flow state of the hot runner system under the operating condition, and then accurately identifies the high erosion area and stagnation area in the flow channel by combining the influence of nozzle transient disturbance on the local flow field, establishes the contact distribution matrix of the glue and the passivation film, and realizes the accurate positioning and quantitative analysis of local instability.

[0043] (2) The present application analyzes the chemical corrosion effect of glue and passivation film by introducing glue attribute parameters and passivation film material attribute parameters, and builds a synergistic effect model of flow scouring and chemical corrosion by combining flow scouring energy density, quantifies the coupling relationship between glue composition, flow characteristics and film layer failure, and effectively improves the accuracy and reliability of passivation film stability detection. BRIEF DESCRIPTION OF DRAWINGS

[0044] Other features, objects and advantages of the present application will become more apparent from the following detailed description of non-limiting embodiments made with reference to the accompanying drawings:

[0045] Figure 1 is a flowchart of the non-destructive testing method for the stability of the passivation film on the surface of the high-throwing corrosion-resistant material provided by the embodiment of the present application;

[0046] Figure 2 is a schematic diagram of a flow field simulation model provided by the embodiment of the present application;

[0047] Figure 3 is a structural schematic diagram of the non-destructive testing system for the stability of the passivation film on the surface of the high-throwing corrosion-resistant material provided by the embodiment of the present application;

[0048] Figure 4 is a structural schematic diagram of the electronic device provided by the embodiment of the present application. DETAILED DESCRIPTION

[0049] The technical solutions of the present application will be described in detail below by means of the accompanying drawings and specific embodiments. It should be understood that the specific features in the embodiments and the specific features in the embodiments are detailed descriptions of the technical solutions of the present application, and are not limitations of the technical solutions of the present application. In the case of no conflict, the technical features in the embodiments and the embodiments can be combined with each other.

[0050] Please refer to Figure 1 , Figure 1 is a whole flowchart of the non-destructive testing method for the stability of the passivation film on the surface of the high-throwing corrosion-resistant material provided by the embodiment of the present application, which specifically comprises the following steps:

[0051] S100, obtain hot runner operating parameters, construct a flow field simulation model to analyze the flow field coupling of the temperature field, pressure field and flow velocity field inside the hot runner, and evaluate the distribution of the flow state of the rubber in the hot runner. Please refer to Figure 2 , Figure 2 The flow field simulation model schematic diagram provided by the embodiment of the present application, the hot runner operating parameters include the flow channel geometric dimensions, nozzle layout and heater position extracted through the three-dimensional CAD model, and the melt temperature, injection pressure, holding pressure curve and heating power collected in real time through the injection molding machine PLC system, a three-dimensional non-isothermal flow field simulation model including control equations of energy conservation, momentum conservation and mass conservation is established by using the finite volume method, and the boundary conditions including the flow channel wall surface condition, inlet pressure condition and temperature control condition are set, the Navier-Stokes equation and the energy equation are coupled and solved, the synchronous calculation of the non-uniform distribution of the temperature field, the gradient change of the pressure field and the vector characteristics of the flow velocity field inside the hot runner is realized, and the flow line distribution, shear rate field and residence time cloud chart are analyzed to quantitatively evaluate the distribution of the flow state of the rubber in the flow channel;

[0052] S200, obtain nozzle operating parameters, analyze the disturbance effect of nozzle release behavior on local flow field and correct the flow state distribution of the rubber, and generate a contact distribution matrix of the rubber and the passivation film;

[0053] In the hot runner system, the nozzle is a key transition node before the plastic melt enters the mold cavity, and its opening time sequence, release pressure and release rate directly affect the transient flow field distribution inside the flow channel. Due to the differences in opening time, melt temperature and release rate of different nozzles, complex pressure wave propagation and temperature gradient change will occur in the nozzle area in a short time, thereby disturbing the stability of the original flow field. If this nozzle disturbance effect is not considered, the flow field simulation result will deviate from the actual operating state, resulting in errors in identifying the flow state distribution, flow dead angle and high scouring area of the rubber, and further affecting the accuracy of the evaluation of the contact characteristics and stability of the passivation film. By analyzing the disturbance effect of the nozzle release behavior on the local flow field and correcting it in combination with the transient flow field simulation, the flow state distribution of the rubber can be more consistent with the actual working condition, and the local flow evolution characteristics of different nozzle areas under high pressure impact can be truly reflected, thereby providing accurate basic data support for subsequent passivation film contact and corrosion coupling analysis. The analysis of the disturbance effect of the nozzle release behavior on the local flow field and the correction of the flow state distribution of the rubber include:

[0054] Obtain nozzle operating parameters and extract the opening time sequence parameters, rubber release pressure parameters, rubber release rate parameters and nozzle outlet temperature parameters of each nozzle;

[0055] The pressure wave propagation characteristics and temperature gradient changes formed in the flow channel at the nozzle opening moment are analyzed based on nozzle operating parameters. Specifically, by setting the nozzle operating parameters as the dynamic boundary conditions of the transient flow field simulation, the time step method is used to solve the unsteady Navier-Stokes equation and energy equation. During the simulation process, the pressure jump at the nozzle opening moment is modeled as a transient excitation. By calculating the rate of change of pressure at each point in the flow channel with time and the propagation speed, the reflection, superposition and attenuation characteristics of the pressure wave in the flow channel network are analyzed. At the same time, based on the temperature difference between the nozzle outlet temperature and the main fluid, the transient process of heat convection and heat conduction is calculated, so as to accurately capture the local temperature sudden change region caused by the injection of the rubber compound and its diffusion path in the flow channel, and quantitatively analyze the instantaneous impact effect of nozzle action on the internal pressure field and temperature field of the hot runner;

[0056] The flow field interference effect generated when multiple nozzles work cooperatively is analyzed, and the superposition and cancellation areas of the flow field velocity vector are quantitatively evaluated. Specifically, based on the transient flow field simulation, for the working condition of multiple nozzles working cooperatively in a specific time sequence, the velocity vector field of each point in the flow channel at the same time is extracted for superposition analysis. Using the vector synthesis principle in computational fluid dynamics, the velocity vector field generated by the action of each nozzle is vector superimposed in space, so as to identify the velocity enhancement area caused by phase synchronization and the flow velocity reduction area caused by opposite phase. By calculating the divergence and curl of the synthesized velocity field, the flow energy concentration degree and vortex intensity are quantitatively evaluated, and the complex flow field interference mode and uneven energy distribution phenomenon existing in the multiple nozzle system are revealed.

[0057] Based on the pressure wave propagation characteristics, temperature gradient changes and flow field interference effect, the rubber flow state distribution is dynamically corrected, and the distribution of flow lag area and high scouring area in the flow channel is updated. Specifically, according to the instantaneous high pressure area and low pressure area identified by the pressure wave propagation characteristics, the pressure field distribution is corrected to reflect the transient influence of pressure wave on the compressibility and flow velocity of the rubber compound. The viscosity and density parameters of each area in the flow channel are updated in combination with the temperature gradient change analysis results. Temperature unevenness will change the rheological properties of the rubber compound. The velocity vector superposition and cancellation areas revealed by the superposition flow field interference effect analysis are superimposed to redefine the main flow path, secondary flow area and vortex core position of the rubber compound in the flow channel. The new flow lag area and high scouring area generated by transient disturbance are corrected and updated by coupling.

[0058] The flow state of plastic melt in the runner plate is not uniformly distributed, and is affected by factors such as nozzle opening time, runner geometry and temperature gradient. There are generally flow velocity mutation zones, flow dead angle zones and high scouring zones in the runner. The contact characteristics between the rubber and the passivation film in different areas are significantly different, and the contact characteristic difference directly determines the mechanical scouring stress and chemical corrosion intensity borne by the passivation film. If the stability of the passivation film is analyzed by overall average parameters, the real service state of the local film layer cannot be reflected, and the detection result deviates from the actual operation risk. Therefore, by constructing the contact distribution matrix of the rubber and the passivation film, the local action relationship between the rubber and the passivation film can be finely described in the spatial scale, the complex flow scouring process can be quantified into a calculable spatial data model, the scouring energy density, contact strength and contact frequency of each microelement area on the surface of the runner can be comprehensively represented, and the contact distribution matrix of the rubber and the passivation film is generated, including:

[0059] Based on the modified flow state distribution of the rubber, the shear rate, contact pressure and residence time of each microelement area on the inner surface of the runner plate are extracted;

[0060] Based on the shear rate, contact pressure and residence time of the rubber, the local scouring energy density of each microelement area is determined. The shear rate and contact pressure of the rubber together constitute a quantitative description of the unit area mechanical action force on the passivation film. At the same time, since longer action time means continuous accumulation of energy input, by introducing residence time as a time accumulation factor, multiplying the normalized shear rate and contact pressure of the rubber, and integrating the residence time representing the cumulative effect, the total mechanical scouring energy borne by each microelement area on the unit area is calculated, and the local scouring energy density is obtained, which converts the transient flow field parameters into a scalar index reflecting the long-term scouring damage potential;

[0061] Based on the geometric characteristics of the runner, the contact angle factor is determined to geometrically correct the contact strength of the flow dead angle and the elbow area. The contact angle factor is the sine value of the angle between the normal vector of each microelement unit on the inner surface of the runner plate and the corresponding position rubber main flow direction vector;

[0062] Based on the contact angle factor, the local scouring energy density is weighted to obtain the comprehensive contact coefficient of each microelement area, and the contact distribution matrix indexed by spatial coordinates is constructed.

[0063] S300, obtain the rubber property parameters and the passivation film property parameters, analyze the potential corrosion effect of the rubber on the passivation film, and evaluate the disturbance degree of the rubber on the stability of the passivation film under the coupling influence of flow scouring and corrosion effect in combination with the contact distribution matrix;

[0064] There are significant differences in the chemical corrosion of different rubber components in the hot runner system, especially the rubber containing flame retardants, halogen compounds and oxidizing additives, which can decompose under high temperature and high pressure conditions to produce chemically active substances with strong corrosive properties, such as hydrogen halide, acidic groups or free radicals. The chemical active substances can react with the metal oxides in the passivation film, causing the film to dissolve or locally fail. The stability of the passivation film cannot be fully evaluated by analyzing the flushing of fluid mechanics alone, and the dominant factors of the potential corrosion behavior of the rubber must be identified from the perspective of chemical reaction kinetics. By systematically analyzing the properties of the rubber and the electrochemical characteristics of the passivation film, a response surface model of temperature-concentration-corrosion rate can be constructed, which can quantitatively reveal the variation of the corrosion activity of different chemical components at different temperature intervals. Coupling the composition of the rubber with the material properties of the passivation film provides a quantitative basis for subsequent corrosion rate prediction and film failure risk assessment, and realizes the transition from empirical judgment to mechanism-driven corrosion analysis. The potential corrosion of the rubber on the passivation film includes:

[0065] Obtain the rubber property parameters and the passivation film property parameters. The rubber property parameters include the type of flame retardant, halogen content, acidic group concentration and oxidizing substance content. The passivation film property parameters include the breakdown potential and the passivation current density of the passivation film in the simulated hot runner environment.

[0066] Based on the rubber property parameters and the passivation film property parameters, a response surface of temperature-concentration-corrosion rate is constructed to quantify the variation of the corrosion medium activity in different temperature intervals. Specifically, the rubber property parameters are used as independent variables, and the corrosion rate quantified by the passivation film property parameters is used as the response variable. The central composite design or Box-Behnken design method is used to arrange the simulation experiment points, and the corrosion current density data of the passivation film under different temperature and concentration combinations is obtained through electrochemical simulation calculation. The kriging interpolation method is used to fit the surface of the discrete data, and a mathematical model is established to continuously represent the variation of the corrosion rate under different corrosion medium concentrations within the hot runner working temperature interval, revealing the influence mechanism of the interaction between temperature and concentration on the corrosion process.

[0067] Based on the response surface and the Arrhenius equation, a corrosion rate prediction model is constructed to quantify the potential chemical corrosion of different rubber components on the stability of the passivation film. Specifically, on the basis of the response surface, the temperature-corrosion rate relationship curve under fixed concentration conditions is extracted. According to the chemical kinetics theory, the temperature dependence of the corrosion process follows the Arrhenius relationship, i.e. the corrosion rate and the inverse of the temperature are exponentially related. By fitting the response surface data with the Arrhenius equation, the characteristic parameter reflecting the activation energy of the corrosion reaction is calculated, which improves the empirical response surface model to a mechanism-based model with physical significance. The corrosion rate prediction model can predict the instantaneous corrosion rate under specific temperature and concentration combinations.

[0068] In the long-term operation of the hot runner system, the environment of the passivation film is complex and changeable, which is not only subjected to the high-speed flow scouring of the plastic melt, but also subjected to the chemical corrosion of the corrosion component. Single analysis of flow scouring or chemical corrosion cannot truly reflect the degradation mechanism of the passivation film. By evaluating the disturbance degree of the compound of the flow scouring and the corrosion effect on the stability of the passivation film, the comprehensive damage process of the film layer in the service state can be described from the perspective of energy superposition and chemical reaction synergy, so as to realize the quantitative evaluation of the stability of the film layer. The disturbance degree of the compound of the flow scouring and the corrosion effect on the stability of the passivation film includes:

[0069] Obtaining the comprehensive contact coefficient of each microelement area of the contact distribution matrix and the corrosion rate prediction result of the corresponding microelement area;

[0070] Based on the comprehensive contact coefficient and the corrosion rate prediction result, a corrosion contact synergy effect model is constructed to calculate the synergistic amplification coefficient of the flow scouring and the chemical corrosion. Specifically, the synergistic amplification coefficient of the flow scouring and the chemical corrosion , is the comprehensive contact coefficient, is the corrosion rate prediction result, and are material-related synergy effect parameters, which are determined by fitting the corrosion wear test data. The natural logarithmic function is used to simulate the sensitivity and nonlinear growth in the initial stage and the saturation trend of the synergistic amplification effect growth. The slope of the natural logarithmic function in the initial stage is large, which is used to represent the beginning of the passivation film surface to appear small damage or defects. The corrosion medium will immediately use these channels to accelerate the penetration, resulting in that the synergistic effect is very sensitive and grows rapidly in the initial stage. With the continuous increase of the scouring and corrosion intensity, the synergistic damage effect is not infinitely linearly enhanced. Due to the physical and chemical limitations such as reaction rate and mass transfer, the synergistic effect will gradually tend to be saturated. Only when the synergistic amplification coefficient is greater than 1, it indicates that the scouring and corrosion promote the enhancement effect.

[0071] The damage accumulation algorithm is used to calculate the film layer damage degree and the film layer damage area of each microelement area in the preset process period, and the overall disturbance degree of the stability of the passivation film is quantitatively evaluated. Specifically, the damage accumulation algorithm regards the corrosion damage in each process cycle modified by the synergistic amplification coefficient as an independent damage increment. In the preset complete process period, the damage increments generated by all cycles are accumulated, so as to calculate the total film layer damage degree of each microelement area. The total damage degree is compared with the critical damage threshold value determined by the material experiment. The connected microelement areas with the damage degree greater than the critical damage threshold value are determined as the failure area, and the total area of the failure area is calculated as the film layer damage area of the inner surface of the entire runner plate.

[0072] S400, obtain a key processing process parameter, and evaluate whether the passivation film stability meets the processing process requirement based on the disturbance degree of the rubber compound on the passivation film stability and the key processing process parameter.

[0073] In the long-term operation process of the hot runner system, the stability of the passivation film is not only affected by the coupling of the rubber compound composition, flow scouring and corrosion, but also affected by the continuous cumulative effect of specific processing process conditions, such as production cycle, maintenance interval and other factors. If the film layer performance is evaluated only from the single flow condition or single corrosion characteristic, the degradation law and life boundary of the passivation film in the actual production cycle cannot be truly reflected. Therefore, by combining the disturbance degree of the rubber compound on the passivation film stability with the key processing process parameter, a dynamic degradation model of the film layer performance is established in the time dimension, the multi-dimensional coupling analysis of the thickness attenuation trend, damage accumulation rate and failure risk of the passivation film is realized, the service stability of the passivation film under different rubber compound systems, different production tempos and maintenance cycles is quantitatively reflected, the long-term reliable operation of the hot runner system is supported, whether the passivation film stability meets the processing process requirement is evaluated based on the disturbance degree of the rubber compound on the passivation film stability and the key processing process parameter, including:

[0074] Obtaining the key processing process parameter and the film layer damage degree and the film layer damage area of each microelement region in the preset process cycle, the key processing process parameter including the safety thickness threshold of the passivation film, the maximum maintenance interval requirement and the planned production cycle.

[0075] Based on the film layer damage degree and the film layer damage area of each microelement region in the preset process cycle, the thickness attenuation trend and the failure risk evolution of the passivation film in the planned production cycle are evaluated. Specifically, the film layer damage degree of each microelement region is converted into the corresponding thickness loss, and the thickness attenuation curve in the time dimension is established based on the material corrosion kinetics characteristics. The damage concentration area is identified according to the spatial distribution characteristics of the damage area, the damage degree growth rate and the damage concentration area are analyzed to predict the failure risk evolution law, and the thickness attenuation trend and the corresponding failure risk development process of the passivation film in the entire planned production cycle are quantitatively evaluated by comprehensively considering the slope of the thickness attenuation curve and the expansion speed of the damage area.

[0076] The thickness attenuation trend is compared with the safety thickness threshold of the passivation film, and the failure risk evolution is matched with the maximum maintenance interval requirement. When the predicted thickness in the planned production cycle is always greater than the safety thickness threshold and the failure risk evolution meets the maximum maintenance interval requirement, it is determined that the passivation film stability meets the processing process requirement, otherwise, it is determined that it does not meet the requirement.

[0077] Please refer to Figure 3 , Figure 3 is a structure schematic diagram of a nondestructive testing system for the stability of the passivation film of the high-throwing corrosion-resistant material surface provided by the embodiment of the present application, comprising:

[0078] The glue flow state evaluation module 210 is configured to obtain the hot runner operation parameters, construct a flow field simulation model, perform flow field coupling analysis on the temperature field, pressure field and flow velocity field inside the hot runner, and evaluate the glue flow state distribution in the hot runner;

[0079] The contact distribution matrix generation module 220 is configured to obtain the nozzle operation parameters, analyze the disturbance effect of the nozzle release behavior on the local flow field and correct the glue flow state distribution, and generate the contact distribution matrix of the glue and the passivation film.

[0080] The disturbance degree evaluation module 230 is configured to obtain the glue attribute parameters and the passivation film attribute parameters, analyze the potential corrosion effect of the glue on the passivation film, and evaluate the disturbance degree of the glue on the stability of the passivation film under the coupling influence of flow scouring and corrosion effect in combination with the contact distribution matrix.

[0081] The passivation film stability evaluation module 240 is configured to obtain the key processing parameters, evaluate whether the passivation film stability meets the processing requirements in combination with the key processing parameters based on the disturbance degree of the glue on the passivation film stability.

[0082] In the embodiment of the present application, the contact distribution matrix generation module 220 is configured to obtain the nozzle operation parameters, analyze the disturbance effect of the nozzle release behavior on the local flow field and correct the glue flow state distribution, and generate the contact distribution matrix of the glue and the passivation film.

[0083] The nozzle operation parameters are obtained, and the opening timing parameters, glue release pressure parameters, glue release rate parameters and nozzle outlet temperature parameters of each nozzle are extracted.

[0084] Based on the nozzle operation parameters, the pressure wave propagation characteristics and temperature gradient changes formed in the flow channel at the moment of nozzle opening are analyzed by using transient flow field simulation.

[0085] The flow field interference effect generated when multiple nozzles work cooperatively is analyzed, and the superposition and offset regions of the flow field velocity vectors are quantitatively evaluated.

[0086] Based on the pressure wave propagation characteristics, temperature gradient changes and flow field interference effect, the glue flow state distribution is dynamically corrected, and the distribution of flow lag zones and high scouring zones in the flow channel is updated.

[0087] The contact distribution matrix of the glue and the passivation film is generated, including:

[0088] Based on the corrected glue flow state distribution results, the glue shear rate, contact pressure and residence time of each microelement region on the inner surface of the flow channel plate are extracted.

[0089] Determine the local erosion energy density of each microelement region based on the shear rate, contact pressure and residence time of the rubber compound;

[0090] Determine the contact angle factor based on the geometric characteristics of the flow channel, and geometrically correct the contact intensity of the flow dead angle and elbow region;

[0091] Weight the local erosion energy density based on the contact angle factor to obtain the comprehensive contact coefficient of each microelement region, and construct a contact distribution matrix indexed by spatial coordinates.

[0092] In the embodiment of the present application, the disturbance degree evaluation module 230 is used to obtain the rubber compound attribute parameters and the passivation film attribute parameters, analyze the potential corrosion effect of the rubber compound on the passivation film, and evaluate the disturbance degree of the rubber compound on the stability of the passivation film under the coupling influence of flow erosion and corrosion effect in combination with the contact distribution matrix, wherein the analysis of the potential corrosion effect of the rubber compound on the passivation film comprises:

[0093] Obtain the rubber compound attribute parameters and the passivation film attribute parameters, the rubber compound attribute parameters including the types of rubber compound flame retardants, halogen content, acid group concentration and oxidizing substance content, and the passivation film attribute parameters including the breakdown potential and passivation current density of the passivation film in the simulated hot runner environment;

[0094] Construct a response surface of temperature-concentration-corrosion rate based on the rubber compound attribute parameters and the passivation film attribute parameters to quantify the activity variation law of the corrosion medium in different temperature intervals;

[0095] Construct a corrosion rate prediction model under the influence of temperature effect based on the response surface and the Arrhenius equation to quantify the potential chemical corrosion effect of different rubber compound components on the stability of the passivation film;

[0096] Wherein, the evaluation of the disturbance degree of the rubber compound on the stability of the passivation film under the coupling influence of flow erosion and corrosion effect comprises:

[0097] Obtain the comprehensive contact coefficient of each microelement region of the contact distribution matrix and the corrosion rate prediction result of the corresponding microelement region;

[0098] Construct a corrosion contact synergistic effect model based on the comprehensive contact coefficient and the corrosion rate prediction result to calculate the synergistic amplification coefficient of flow erosion and chemical corrosion;

[0099] Calculate the film layer damage degree and film layer damage area of each microelement region in a preset process period by using damage accumulation algorithm, and quantify and evaluate the overall disturbance degree of the stability of the passivation film.

[0100] In the embodiment of the present application, the passivation film stability evaluation module 240 is used to obtain the key processing parameters, evaluate whether the stability of the passivation film meets the processing requirements based on the disturbance degree of the rubber compound on the stability of the passivation film in combination with the key processing parameters, comprising:

[0101] obtaining a key processing parameter, and a film layer damage degree and a film layer damage area of each microelement region in a preset process period, the key processing parameter including a safe thickness threshold of the passivation film, a maximum maintenance interval requirement, and a planned production period;

[0102] evaluating a thickness attenuation trend and a failure risk evolution of the passivation film in the planned production period based on the film layer damage degree and the film layer damage area of each microelement region in the preset process period;

[0103] comparing the thickness attenuation trend with the safe thickness threshold of the passivation film and performing matching analysis on the failure risk evolution and the maximum maintenance interval requirement, when a predicted thickness in the planned production period is always greater than the safe thickness threshold and the failure risk evolution meets the maximum maintenance interval requirement, determining that the passivation film stability meets the processing process requirement, otherwise, determining that the passivation film stability does not meet the processing process requirement.

[0104] Please refer to Figure 4 The embodiment of the present application also provides an electronic device 300, comprising a memory 320 configured to store a computer program 322, and a processor 310 configured to execute the computer program 322 to implement the nondestructive testing method for passivation film stability of high-throwing corrosion-resistant material surface according to any one of the above embodiments.

[0105] It should be noted that the above-mentioned Figure 4 is a structural diagram of the electronic device 300 according to an exemplary embodiment, and the contents in the diagram should not be considered as any limitation on the use range of the present application.

[0106] Specifically, the electronic device 300 can specifically include at least one processor 310, at least one memory 320, a power supply 330, a communication interface 340, an input / output interface 350, and a communication bus 360. The memory 320 is configured to store a computer program 322, and the processor 310 is configured to load and execute the computer program 322 to implement the related steps in the nondestructive testing method for passivation film stability of high-throwing corrosion-resistant material surface disclosed in any one of the above embodiments. In addition, the electronic device 300 in the embodiment of the present application can specifically be an electronic computer.

[0107] In the embodiment of the present application, the power supply 330 is configured to provide working voltage for each hardware device on the electronic device 300, the communication interface 340 is capable of creating a data transmission channel between the electronic device 300 and external devices, and the communication protocol followed by the communication interface 340 is any communication protocol applicable to the technical solution of the present application, which is not specifically limited here; the input / output interface 350 is configured to obtain external input data or output data to the outside, and the specific interface type can be selected according to the specific application needs, which is not specifically limited here.

[0108] In addition, the memory 320, as a carrier for storing resources, can be a read-only memory, a random access memory, a magnetic disk or an optical disk, etc., and the resources stored thereon can include an operating system 321, a computer program 322, etc., and the storage mode can be temporary storage or permanent storage.

[0109] The operating system 321 is used to manage and control various hardware devices and computer programs on the electronic device 300, and can be Windows Server, Netware, Unix, Linux, etc. In addition to the computer program 322 capable of completing the non-destructive testing method for the stability of the passivated film on the surface of the high-throwing corrosion-resistant material executed by the electronic device 300 disclosed in any of the above embodiments, the computer program 322 can further include computer programs 322 capable of completing other specific work.

[0110] The embodiments of the present application also provide a computer readable storage medium for storing the computer program 322, which is executed by the processor 310 to implement the non-destructive testing method for the stability of the passivated film on the surface of the high-throwing corrosion-resistant material in any of the above embodiments.

[0111] For example, the computer readable storage medium can be a read-only memory (ROM), a random access memory (RAM), a compact disc read-only memory (CD-ROM), a magnetic tape, a floppy disk, an optical data storage device, etc.

[0112] The term "comprising" or "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that the process, method, article or device including a series of elements not only includes those elements, but also includes other elements not explicitly listed, or further includes elements inherent to such process, method, article or device.

[0113] The above description is only the preferred embodiments of the present application and the explanation of the applied technical principles. Those skilled in the art should understand that the scope of the application involved in the present application is not limited to the technical solutions formed by the specific combinations of the above technical features, and should also cover other technical solutions formed by any combination of the above technical features or their equivalent features without departing from the above application concept. For example, the above features and the technical features applied in the present application (but not limited to) with similar functions are replaced with each other to form a technical solution.

Claims

1. A non-destructive testing method for the stability of the passivation film on the surface of a high-polish corrosion-resistant material, characterized in that, include: Obtain the operating parameters of the hot runner, construct a flow field simulation model, perform flow field coupling analysis on the temperature field, pressure field and flow velocity field inside the hot runner, and evaluate the distribution of the rubber flow state inside the hot runner; Obtain nozzle operating parameters, analyze the disturbance effect of nozzle release behavior on local flow field and correct the flow state distribution of rubber, and generate the contact distribution matrix between rubber and passivation film. Obtain the property parameters of the adhesive and the passivation film, analyze the potential corrosive effect of the adhesive on the passivation film, and combine the contact distribution matrix to evaluate the degree of disturbance of the stability of the passivation film by the adhesive under the coupled influence of flow erosion and corrosion. Obtain key processing parameters, and evaluate whether the stability of the passivation film meets the processing requirements based on the degree of disturbance of the adhesive to the stability of the passivation film in combination with the key processing parameters. The potential corrosive effect of the analyzed adhesive on the passivation film includes: Obtain the property parameters of the rubber compound and the property parameters of the passivation film. The property parameters of the rubber compound include the type of flame retardant, halogen content, concentration of acidic groups and content of oxidizing substances. The property parameters of the passivation film include the breakdown potential and passivation current density of the passivation film under simulated hot runner environment. Based on the property parameters of the adhesive and the property parameters of the passivation film, a response surface of temperature-concentration-corrosion rate is constructed to quantify the activity change law of the corrosive medium in different temperature ranges. Based on response surface methodology and the Arrhenius equation, a corrosion rate prediction model under the influence of temperature effect was constructed to quantify the potential chemical erosion effect of different adhesive components on the stability of the passivation film. The evaluation assesses the degree to which the adhesive material disturbs the stability of the passivation film under the coupled effects of flow erosion and corrosion, including: Obtain the comprehensive contact coefficient of each micro-region of the contact distribution matrix and the corresponding corrosion rate prediction results of the micro-region; A corrosion contact synergy effect model was constructed based on the comprehensive contact coefficient and corrosion rate prediction results, and the synergistic amplification factor of flow erosion and chemical corrosion was calculated. The damage accumulation algorithm is used to calculate the film damage degree and film damage area of ​​each micro-element region within a preset process cycle, and to quantitatively evaluate the overall disturbance degree of passivation film stability.

2. The non-destructive testing method for the stability of the passivation film on the surface of a high-polish corrosion-resistant material according to claim 1, characterized in that, The analysis of the nozzle release behavior's disturbance effect on the local flow field and the correction of the rubber compound flow state distribution include: Obtain nozzle operating parameters and extract the opening timing parameters, rubber release pressure parameters, rubber release rate parameters, and nozzle outlet temperature parameters for each nozzle; Based on nozzle operating parameters, transient flow field simulation was used to analyze the propagation characteristics of pressure waves and temperature gradient changes formed in the flow channel at the moment the nozzle opens. The flow field interference effect generated when multiple nozzles work together is analyzed, and the superposition and cancellation regions of flow field velocity vectors are quantitatively evaluated. The flow state distribution of the rubber compound is dynamically corrected based on the propagation characteristics of pressure waves, temperature gradient changes, and flow field interference effects, and the distribution of the flow lag zone and high scouring zone in the flow channel is updated.

3. The non-destructive testing method for the stability of the passivation film on the surface of a high-polish corrosion-resistant material according to claim 1, characterized in that, The contact distribution matrix between the generated adhesive and the passivation film includes: Based on the corrected rubber flow state distribution results, the shear rate, contact pressure and residence time of the rubber in each micro-element region on the inner surface of the flow channel plate are extracted. The local scouring energy density of each micro-element region is determined based on the shear rate of the rubber compound, the contact pressure, and the residence time. The contact angle factor is determined based on the flow channel geometry, and the contact strength in the dead flow angle and bend region is geometrically corrected. The comprehensive contact coefficient of each micro-element region is obtained by weighting the local scour energy density based on the contact angle factor, and a contact distribution matrix indexed by spatial coordinates is constructed.

4. The non-destructive testing method for the stability of the passivation film on the surface of a high-polish corrosion-resistant material according to claim 1, characterized in that, The assessment of whether the passivation film stability meets the processing requirements based on the degree of disturbance of the adhesive to the passivation film stability in conjunction with key processing parameters includes: Obtain key processing parameters and the degree and area of ​​film damage in each micro-element region within the preset process cycle. Key processing parameters include the safe thickness threshold of the passivation film, the maximum maintenance interval requirement, and the planned production cycle. Based on the degree of film damage and the area of ​​film damage in each micro-element region within the preset process cycle, the thickness decay trend of the passivation film and the evolution of failure risk within the planned production cycle are assessed. The thickness decay trend is compared with the safe thickness threshold of the passivation film, and the failure risk evolution is matched with the maximum maintenance interval requirement. If the predicted thickness during the planned production cycle is always greater than the safe thickness threshold and the failure risk evolution meets the maximum maintenance interval requirement, then the passivation film stability is determined to meet the processing requirements; otherwise, it is determined not to meet the requirements.

5. A non-destructive testing system for the stability of the passivation film on the surface of a high-polish corrosion-resistant material, used to implement the non-destructive testing method for the stability of the passivation film on the surface of a high-polish corrosion-resistant material as described in any one of claims 1-4, characterized in that, The system includes: The rubber flow state assessment module is used to obtain the operating parameters of the hot runner, construct a flow field simulation model to perform flow field coupling analysis on the temperature field, pressure field and flow velocity field inside the hot runner, and evaluate the distribution of the rubber flow state inside the hot runner. The contact distribution matrix generation module is used to obtain nozzle operating parameters, analyze the disturbance effect of nozzle release behavior on the local flow field and correct the flow state distribution of the rubber material, and generate the contact distribution matrix between the rubber material and the passivation film. The disturbance degree assessment module is used to obtain the property parameters of the adhesive and the property parameters of the passivation film, analyze the potential corrosive effect of the adhesive on the passivation film, and combine the contact distribution matrix to assess the degree of disturbance of the adhesive on the stability of the passivation film under the coupled influence of flow erosion and corrosion. The passivation film stability assessment module is used to obtain key processing parameters and assess whether the passivation film stability meets the processing requirements based on the degree of disturbance of the adhesive to the passivation film stability and the key processing parameters. The potential corrosive effect of the analyzed adhesive on the passivation film includes: Obtain the property parameters of the rubber compound and the property parameters of the passivation film. The property parameters of the rubber compound include the type of flame retardant, halogen content, concentration of acidic groups and content of oxidizing substances. The property parameters of the passivation film include the breakdown potential and passivation current density of the passivation film under simulated hot runner environment. Based on the property parameters of the adhesive and the property parameters of the passivation film, a response surface of temperature-concentration-corrosion rate is constructed to quantify the activity change law of the corrosive medium in different temperature ranges. Based on response surface methodology and the Arrhenius equation, a corrosion rate prediction model under the influence of temperature effect was constructed to quantify the potential chemical erosion effect of different adhesive components on the stability of the passivation film. The evaluation assesses the degree to which the adhesive material disturbs the stability of the passivation film under the coupled effects of flow erosion and corrosion, including: Obtain the comprehensive contact coefficient of each micro-region of the contact distribution matrix and the corresponding corrosion rate prediction results of the micro-region; A corrosion contact synergy effect model was constructed based on the comprehensive contact coefficient and corrosion rate prediction results, and the synergistic amplification factor of flow erosion and chemical corrosion was calculated. The damage accumulation algorithm is used to calculate the film damage degree and film damage area of ​​each micro-element region within a preset process cycle, and to quantitatively evaluate the overall disturbance degree of passivation film stability.

6. An electronic device, comprising: A processor and a memory, wherein the memory stores a computer program that can be called by the processor; characterized in that the processor executes a non-destructive testing method for the stability of the passivation film on the surface of a highly polishable corrosion-resistant material as described in any one of claims 1-4 by calling the computer program stored in the memory.

7. A computer-readable storage medium, characterized in that, The device stores instructions that, when executed on a computer, cause the computer to perform a non-destructive testing method for the stability of the passivation film on the surface of a highly polishable corrosion-resistant material as described in any one of claims 1-4.

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