CN111323478A - Method for manufacturing corrosion comparison test block and method for determining corrosion damage by using test block - Google Patents
Method for manufacturing corrosion comparison test block and method for determining corrosion damage by using test block Download PDFInfo
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- CN111323478A CN111323478A CN202010304880.7A CN202010304880A CN111323478A CN 111323478 A CN111323478 A CN 111323478A CN 202010304880 A CN202010304880 A CN 202010304880A CN 111323478 A CN111323478 A CN 111323478A
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- 230000007797 corrosion Effects 0.000 title claims abstract description 199
- 238000005260 corrosion Methods 0.000 title claims abstract description 199
- 238000000034 method Methods 0.000 title claims abstract description 45
- 238000012360 testing method Methods 0.000 title claims abstract description 23
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 230000007547 defect Effects 0.000 claims abstract description 55
- 238000001514 detection method Methods 0.000 claims abstract description 45
- 239000011229 interlayer Substances 0.000 claims abstract description 26
- 230000035945 sensitivity Effects 0.000 claims abstract description 18
- 238000012545 processing Methods 0.000 claims abstract description 7
- 239000000843 powder Substances 0.000 claims description 20
- 229910044991 metal oxide Inorganic materials 0.000 claims description 18
- 150000004706 metal oxides Chemical class 0.000 claims description 18
- 239000002253 acid Substances 0.000 claims description 10
- 238000003754 machining Methods 0.000 claims description 9
- 238000004140 cleaning Methods 0.000 claims description 7
- 239000003292 glue Substances 0.000 claims description 6
- 230000001788 irregular Effects 0.000 claims description 6
- 238000001035 drying Methods 0.000 claims description 5
- 238000010892 electric spark Methods 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 3
- 239000011159 matrix material Substances 0.000 claims description 2
- 238000012876 topography Methods 0.000 claims description 2
- 230000003628 erosive effect Effects 0.000 claims 2
- 230000004888 barrier function Effects 0.000 claims 1
- 238000011002 quantification Methods 0.000 abstract description 7
- 239000000047 product Substances 0.000 description 10
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000011160 research Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 3
- 238000005336 cracking Methods 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000005674 electromagnetic induction Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 239000013558 reference substance Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N27/00—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means
- G01N27/72—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables
- G01N27/82—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws
- G01N27/90—Investigating or analysing materials by the use of electric, electrochemical, or magnetic means by investigating magnetic variables for investigating the presence of flaws using eddy currents
- G01N27/9006—Details, e.g. in the structure or functioning of sensors
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Abstract
The invention belongs to the technical field of processing and detection, and particularly relates to a method for manufacturing a corrosion comparison test block for eddy current detection and a method for determining corrosion damage by using the test block. The method comprises the steps of obtaining interlayer corrosion defects on the aircraft and determining common characteristics of the interlayer corrosion defects; determining the structural form of the corrosion reference block and the characteristics of the corrosion defects to be processed according to detection requirements based on the interlayer corrosion defects and the common characteristics of the interlayer corrosion defects; forming corrosion defects on the first plate according to the characteristics of the corrosion defects to be processed to obtain a corrosion plate; and assembling the second plate and the corrosion plate together according to the structural form of the corrosion reference block to form the corrosion reference block. The test block obtained by the method is used for corrosion damage detection, so that the sensitivity and accuracy of interlayer corrosion damage detection are improved, the damage degree can be effectively determined, and the defects are prevented from being missed and inaccurate in quantification.
Description
Technical Field
The invention belongs to the technical field of processing and detection, and particularly relates to a method for manufacturing a corrosion comparison test block for eddy current detection and a method for determining corrosion damage by using the test block.
Background
Corrosion defects are a type of structural damage often found in aircraft that severely affects the structural strength and life of the aircraft. Many aircraft structural components are damaged by corrosion, including spars, door frames, landing gear outer barrels, propeller hubs, wing fractures, etc., and even aircraft crashes. Whether these structures are safe or not is related to the flight and test safety of the whole airplane. The more serious consequences caused by corrosion damage can be reduced to the maximum extent by carrying out corrosion detection, discovery and treatment on the in-service aircraft structure. In the aspect of corrosion damage detection and evaluation: current research has become relatively mature for the visual corrosion of aircraft surfaces. With the increasing complexity of airplane structures, the corrosion damage of the inner surfaces or inner hole walls and inner side walls of structures such as multilayer board connecting structures, joint structures and the like can be easily found only during disassembly and inspection. The in-situ nondestructive detection of the structures without disassembly is a difficult point of the current technical research. In order to improve the safety better, the corrosion damage of the inner surface or the inner hole wall and the inner side wall of the structure such as a multilayer board connecting structure, a joint structure and the like needs to be detected timely and accurately. However, the currently effective means is few, only the improvement CN104730144A in the aspect of the eddy current sensor is found through search, and no improvement is related to the reference block, so that the problems of difficulty in detection, low accuracy, easy defect omission and inaccurate quantification exist.
Disclosure of Invention
The purpose of the invention is as follows: the method for manufacturing the corrosion comparison test block for eddy current detection and the method for determining the corrosion damage by using the test block are provided to improve the sensitivity of interlayer corrosion damage detection, thereby accurately detecting interlayer corrosion and preventing defects from missing detection and inaccurate quantification.
The technical scheme of the invention is as follows:
in a first aspect, a method for manufacturing a corrosion reference block for eddy current testing is provided, the corrosion reference block including a first plate and a second plate, including:
acquiring interlayer corrosion defects on an aircraft and determining common characteristics of the interlayer corrosion defects;
determining the structural form of the corrosion reference block and the characteristics of the corrosion defects to be processed according to detection requirements based on the interlayer corrosion defects and the common characteristics of the interlayer corrosion defects;
forming corrosion defects on the first plate according to the characteristics of the corrosion defects to be processed to obtain a corrosion plate;
and assembling the second plate and the corrosion plate together according to the structural form of the corrosion reference block to form the corrosion reference block.
Further, according to the characteristics of the corrosion defect to be processed, forming a corrosion defect on the first plate to obtain a corrosion plate specifically includes:
processing irregular lineation on the appearance of the corrosion pit and the inner surface of the corrosion pit to form a rugged bottom surface;
dripping strong acid into the corrosion pit, and cleaning and drying after the corrosion is carried out for a preset time;
fully mixing metal oxide powder which is the same as the plate matrix with insulating glue according to a preset proportion to simulate a corrosion product;
injecting the simulated corrosion product into the corrosion pit, filling and compacting for 2-4 hours to ensure that the simulated corrosion product is firmly bonded;
the powder-filled surface was modified to follow the true corrosion topography.
Further, the processing of the etch pit profile and the etch pit inner surface irregularity marking line specifically comprises:
the shape of the corrosion pit and the irregular scribing of the inner surface of the corrosion pit are processed by a numerical control machining and electric spark machining method to form a rugged bottom surface.
Further, dropping a strong acid into the etch pit specifically includes:
and dropping strong acid with a certain concentration into the corrosion pit, and controlling the corrosion amount according to the corrosion time to enable the inner surface of the corrosion pit to be closer to a real corroded surface.
Further, dropping strong acid into the corrosion pit, and cleaning after corroding for a preset time, specifically comprising:
and cleaning the inner surface of the corrosion pit and drying.
Further, the common features include:
the corrosion morphology of the corrosion defects on the corrosion side and the products of the corrosion defects on the corrosion side.
Further, the characteristics of the corrosion defect to be processed include the shape, size, depth and gradient of the corrosion defect.
In a second aspect, a method for determining interlayer corrosion damage is provided, wherein the method utilizes the corrosion reference block formed by the method to determine corrosion damage.
Furthermore, before interlayer corrosion damage is determined, the method also comprises the step of adjusting sensitivity, namely detecting a corrosion defect area of a corrosion reference block by using an eddy current method, and adjusting the amplitude of a gain signal to reach 40% of full screen to serve as detection sensitivity.
The invention has the beneficial effects that: the manufacturing method of the eddy current detection reference block obtains the reference block which is closer to the real corrosion state, and the reference block is used for interlayer corrosion damage detection of the invention, so that the sensitivity and the accuracy of interlayer corrosion damage detection are improved, the damage degree can be effectively determined, the defects are prevented from being missed and inaccurate in quantification, and measures are taken in time to prevent the defects from happening in the bud.
Drawings
FIG. 1 is a true corrosion map;
FIG. 2 is a schematic view of a flat bottom hole reference block;
FIG. 3 is a schematic view of a manually simulated etch pit according to the present invention;
FIG. 4 is a schematic illustration of a manually simulated corrosion according to the present invention;
FIG. 5 is a schematic diagram of an eddy current test signal.
Detailed Description
It has been found that cracking and corrosion are the predominant damage forms in each type of damage, whereas corrosion pits, corrosion zones (fig. 1) are often the primary cause of cracking, and stress corrosion, like corrosion fatigue, is the primary cause of crack propagation.
In the conventional detection of corrosion damage by the eddy current method, the eddy current detection is actually a detection method based on signal comparison, and a signal of a reference object is required as a reference. The reference block is a reference substance for determining a detection reference in a nondestructive detection process, and researches show that the reference block plays an important role in determining detection parameters, adjusting detection sensitivity, judging a detection result and the like. Therefore, the simulated corrosion damage of the reference block plays a decisive role in the final result and damage assessment of the corrosion detection. The existing method for simulating the corrosion damage of the reference block can adopt a mechanical or electric spark drilling method to manufacture a flat-bottom hole to approximately simulate corrosion. The obtained detection body is a hollow cylinder, as shown in fig. 2, the depth of the flat bottom hole is also the depth of artificial corrosion to be detected, and the flat bottom hole is a detection reflector during detection.
However, the actual corrosion pit shape is a surface gradually changing from deep to shallow, the bottom surface of the test block of the flat-bottom hole is suddenly changed, the detection sensitivity of the test block of the flat-bottom hole is difficult to meet the requirement, the defects are easy to leak and the quantification is not accurate, and the sensitivity depends on the reference test block.
In addition, researches show that the reason of low sensitivity is that natural corrosion defects are different from those of a hollow cylinder, but a solid body is formed by a corrosion interface and a metal corrosion product, and the corrosion interface and the metal corrosion product can influence an eddy current field during eddy current corrosion detection, so that the required detection sensitivity is different. The detection sensitivity is determined by the artificial defects on the reference block during detection. The degree of similarity of the artificial defect to the true corrosion determines the reliability of the detection. The sensitivity is too low, which causes that some small cracks are not easy to be found, and random improvement of the sensitivity influences the qualitative judgment of the cracks and the judgment of the sizes of the cracks. The eddy current signal amplitude formed by the flat bottom hole is different from the real corrosion signal amplitude, so that the defects are missed to be detected and the quantification is inaccurate. There is a need for a reference block that more truly reflects corrosion.
Based on the research, the invention provides a method for manufacturing a reference test block as follows:
two metal plates (as intact plates and corroded plates) of the same size and thickness (or different) are first machined and assembly holes are drilled. The corrosion defect is simulated on a required metal plate (corrosion plate).
Designing the structural form of the corrosion reference block and the position, size and form of the corrosion defect according to the detection requirement; in particular, for interlayer corrosion defects found on an aircraft, common characteristics of such corrosion defects, namely corrosion surfaces, products formed, morphology and the like, are found. And designing the shape, size, depth, gradient and the like of the artificial simulated corrosion according to the size of the corrosion defect to be detected.
And (3) making corrosion defects on the corrosion plate, specifically, processing irregular lineation on the appearance of the corrosion pit and the inner surface of the corrosion pit to form an uneven bottom surface. Wherein, the simulated corrosion defect can be processed into the shape of the corrosion pit by a numerical control machining and electric spark machining method. And processing irregular cross scribing lines in the corrosion pits by using a numerical control machining method, so that the inner surfaces of the corrosion pits become convex and concave.
Dropping strong acid into the corrosion pit to make the inner surface of the corrosion pit closer to a real corroded surface; specifically, strong acid with a certain concentration is dripped into the corrosion pit, and the corrosion amount is controlled according to the corrosion time, so that the inner surface of the corrosion pit is closer to the real corroded surface as shown in figure 3. Etching for 1-2 minutes followed by cleaning the etch pit inner surface and drying.
And (3) taking metal oxide powder, and fully mixing the metal oxide powder with the insulating glue in proportion, wherein the metal oxide powder is the same as the metal oxide powder of the plate substrate, such as aluminum oxide for aluminum alloy and ferric oxide for steel). Injecting and bonding metal oxide powder into the corrosion pits by using a powder filling technology, filling and compacting for 2 to 4 hours for solidification so as to ensure that the metal oxide powder is firmly bonded, and forming a corrosion-like product shown in figure 4; finishing the powder filling surface to make the filling surface form similar to the real corrosion surface form;
assembling the intact board and the simulated corrosion board together by using a connecting piece according to a determined structural form to form a multilayer corrosion reference block;
the test block can be used for detecting corrosion of the bottom of a single plate and corrosion of the upper bottom plate and the lower top plate of an interlayer.
The method for manufacturing the test block can also be used for manufacturing the reference test block in other detection methods.
The corrosion reference block manufactured by the method can be used for interlayer corrosion damage detection, and the sensitivity of interlayer corrosion damage detection is improved, so that interlayer corrosion is accurately detected, and the defects are prevented from being missed and inaccurate in quantification. The method specifically comprises the following steps: and detecting the corrosion area of the reference block by using an eddy current method, observing the signal amplitude, adjusting the gain to enable the signal amplitude to reach 40% of the full screen as detection sensitivity, detecting the aircraft sandwich structure by using the sensitivity, and judging that the corrosion is shown in figure 5 if the signal amplitude reaches more than 20% of the full screen.
The principle of the invention is as follows:
the metal oxide powder is filled into a corrosion pit of simulated machining by utilizing the fact that the shape and the electrical property of the metal oxide powder are similar to those of a corrosion product, so that a corrosion comparison test block which is close to the real corrosion shape and the electrical property and artificially simulates corrosion damage is obtained.
When the metal oxide powder is filled, the insulating glue is mixed with the metal oxide powder, namely the metal oxide powder is ensured to be combined with the corrosion pit, the glue layer on the metal oxide powder is very thin and is close to a natural corrosion product, and meanwhile, the glue layer has very small change on the electrical property of the metal oxide powder and hardly influences an eddy current field detected by an eddy current method.
The detection principle of the low-frequency eddy current method used by the method is electromagnetic induction, an eddy current field permeates from the upper surface of an intact metal plate to the inside and under the interlayer, when the material is subjected to corrosion damage such as corrosion change of material form and electrical property, the impedance of the material changes, so that a detection signal changes and is displayed on a fluorescent screen, and whether defect information exists or not can be obtained by analyzing a reflection signal. The degree of eddy current signals depends mainly on the electrical properties, volume morphology and size of the formed interface and the metal oxide. The larger the interface and the metal oxide volume formed, the stronger the reflected signal, and conversely, the weaker the reflected signal.
The metal oxide is adhered in the corrosion pit by adopting a powder filling technology, the electrical property is similar to that of natural corrosion, and the impedance change which is more consistent with that of the natural corrosion can be obtained, so that the aim of correctly reflecting the true corrosion condition is fulfilled.
Claims (9)
1. A method of making an erosion control block for eddy current testing, the erosion control block comprising a first plate and a second plate, comprising:
acquiring interlayer corrosion defects on an aircraft and determining common characteristics of the interlayer corrosion defects;
determining the structural form of the corrosion reference block and the characteristics of the corrosion defects to be processed according to detection requirements based on the interlayer corrosion defects and the common characteristics of the interlayer corrosion defects;
forming corrosion defects on the first plate according to the characteristics of the corrosion defects to be processed to obtain a corrosion plate;
and assembling the second plate and the corrosion plate together according to the structural form of the corrosion reference block to form the corrosion reference block.
2. The method according to claim 1, wherein forming corrosion defects on the first plate according to the characteristics of the corrosion defects to be processed to obtain a corrosion plate comprises:
processing irregular lineation on the appearance of the corrosion pit and the inner surface of the corrosion pit to form a rugged bottom surface;
dripping strong acid into the corrosion pit, and cleaning and drying after the corrosion is carried out for a preset time;
fully mixing metal oxide powder which is the same as the plate matrix with insulating glue according to a preset proportion to simulate a corrosion product;
injecting the simulated corrosion product into the corrosion pit, filling and compacting for 2-4 hours to ensure that the simulated corrosion product is firmly bonded;
the powder-filled surface was modified to follow the true corrosion topography.
3. The method of claim 2, wherein machining the etch pit profile and the etch pit interior surface irregularities comprises:
the shape of the corrosion pit and the irregular scribing of the inner surface of the corrosion pit are processed by a numerical control machining and electric spark machining method to form a rugged bottom surface.
4. The method according to claim 2, wherein dropping a strong acid into the etch pits comprises:
and dropping strong acid with a certain concentration into the corrosion pit, and controlling the corrosion amount according to the corrosion time to enable the inner surface of the corrosion pit to be closer to a real corroded surface.
5. The method according to claim 2, wherein dropping a strong acid into the etch pit to etch for a predetermined time and then cleaning the etch pit, specifically comprises:
and cleaning the inner surface of the corrosion pit and drying.
6. The method of claim 1, wherein the common characteristic comprises:
the corrosion morphology of the corrosion defects on the corrosion side and the products of the corrosion defects on the corrosion side.
7. The method of claim 1, wherein the characteristics of the corrosion defect to be machined include shape, size, depth, and slope of the corrosion defect.
8. A method of determining interlayer corrosion damage, wherein corrosion damage is determined using a corrosion control block formed according to the method of any one of claims 1 to 7.
9. The method of claim 8, further comprising adjusting the sensitivity of the eddy current method to detect the corrosion defect area of the corrosion reference block before determining the barrier corrosion damage, wherein the sensitivity of the eddy current method is adjusted to a gain signal amplitude of 40% of full screen.
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| CN202010304880.7A CN111323478A (en) | 2020-04-17 | 2020-04-17 | Method for manufacturing corrosion comparison test block and method for determining corrosion damage by using test block |
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| CN202010304880.7A CN111323478A (en) | 2020-04-17 | 2020-04-17 | Method for manufacturing corrosion comparison test block and method for determining corrosion damage by using test block |
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102901777A (en) * | 2012-10-18 | 2013-01-30 | 镇江出入境检验检疫局检验检疫综合技术中心 | Manufacturing method of metal sheet manual damage based on aciding |
| CN105823661A (en) * | 2016-03-21 | 2016-08-03 | 西安交通大学 | Method for preparing simulated stress corrosion crack with controllable crack size and conductivity |
| US20170176391A1 (en) * | 2015-07-16 | 2017-06-22 | Ningbo Yinzhou Cital Electronic Technology Co., Ltd. | Micro-magnetic Detecting Method and Micro-magnetic Detecting Device |
| CN109959706A (en) * | 2019-04-23 | 2019-07-02 | 华能国际电力股份有限公司 | TBCs interlayer crack eddy current testing reference block and manufacturing method thereof |
-
2020
- 2020-04-17 CN CN202010304880.7A patent/CN111323478A/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102901777A (en) * | 2012-10-18 | 2013-01-30 | 镇江出入境检验检疫局检验检疫综合技术中心 | Manufacturing method of metal sheet manual damage based on aciding |
| US20170176391A1 (en) * | 2015-07-16 | 2017-06-22 | Ningbo Yinzhou Cital Electronic Technology Co., Ltd. | Micro-magnetic Detecting Method and Micro-magnetic Detecting Device |
| CN105823661A (en) * | 2016-03-21 | 2016-08-03 | 西安交通大学 | Method for preparing simulated stress corrosion crack with controllable crack size and conductivity |
| CN109959706A (en) * | 2019-04-23 | 2019-07-02 | 华能国际电力股份有限公司 | TBCs interlayer crack eddy current testing reference block and manufacturing method thereof |
Non-Patent Citations (2)
| Title |
|---|
| 全国金属与非金属覆盖层标准化技术委员会编著: "覆盖层标准应用手册 下", vol. 978, 中国石油大学出版社, pages: 169 - 171 * |
| 李正龙: "飞机多层结构内层腐蚀涡流检测技术研究", 《中国优秀硕士学位论文全文数据库工程科技Ⅱ辑》, no. 04, pages 031 - 65 * |
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