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3D Ultrasonic Non-destructive Evaluation of Spot Welds Using an Enhanced Total Focusing Method

机译:使用增强的总聚焦方法对点焊进行3D超声波无损评估

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摘要

Spot welds are used to join sheets of metals in the automotive industry. When spot weld quality is evaluated using conventional ultrasonic manual pulse-echo method, the reliability of the inspection is affected by selection of the probe diameter and the positioning of the probe in the weld center. The application of a 2D matrix array is a potential solution to the aforementioned problems. The objective of this work was to develop a signal processing algorithm to reconstruct the 3D spot weld volume showing the size of the nugget and the defects in it. In order to achieve this, the conventional total focusing method was enhanced by taking into account the directivities of the single elements of the array and the divergence of the ultrasonic beam due to the propagation distance. Enhancements enabled a reduction in the background noise and uniform sensitivity at different depths to be obtained. The proposed algorithm was verified using a finite element model of ultrasonic wave propagation simulating three common spot weld conditions: a good weld, an undersized weld, and a weld containing a pore. The investigations have demonstrated that proposed method enables the determination of the size of the nugget and detection of discontinuities.
机译:点焊在汽车工业中用于连接金属板。当使用常规的超声波手动脉冲回波法评估点焊质量时,检查的可靠性会受到探头直径的选择以及探头在焊接中心位置的影响。 2D矩阵阵列的应用是上述问题的潜在解决方案。这项工作的目的是开发一种信号处理算法,以重建3D点焊量,以显示出熔核的大小和其中的缺陷。为了实现这一点,通过考虑阵列的单个元件的方向性以及由于传播距离引起的超声波束的发散,增强了常规的总聚焦方法。通过增强功能,可以减少背景噪声并获得不同深度的均匀灵敏度。使用模拟的三种常见点焊条件的超声波传播有限元模型对提出的算法进行了验证,该条件模拟了一种良好的焊缝,一种尺寸较小的焊缝和一种包含气孔的焊缝。研究表明,所提出的方法能够确定熔核的大小并检测不连续性。

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