Analysis of Residual-Stress Test Errors via Ultrasonic Method for Aluminium Alloy Used in High-Speed Trains
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摘要: 为了研究超声波残余应力检测技术在高速列车关键部位残余应力检测时，不同误差对测试数据的的影响，以A5083及6005A为研究对象，研究了其织构各向异性与超声传播时间的关系，并分析了频率对测试深度应力系数的影响. 结果表明：在平行与垂直材料轧制方向，A5083材料声波传播在拉压应力状态下应力系数差别相对较小，偏差约为4.26%；6005A材料在拉压应力状态下应力系数差别相对偏大，拉应力和压应力拟合的应力系数偏差率约为13.12%，均需单独标定；不同频率声波探头测试的深度不同，所标定的应力系数值差别较大，焊缝区域在拉压应力状态下应力系数变化最为明显，最大变化率为30.69%，热影响区和母材的变化率分别为14.03%和9.66%.Abstract: To study the influence of different errors incurred during ultrasonic residual-stress detection on test data concerning key components of high-speed trains, the relationship between the anisotropy of A5083 and 6005A materials, in terms of texture and ultrasonic propagation time, was investigated. The stress coefficient corresponding to the measured depth at different frequencies was also investigated. Results demonstrate a relatively small difference between stress coefficients （a deviation of approximately 4.26%） corresponding to the tensile and compressive stress states of sonic-wave propagation along directions parallel and perpendicular to the rolling direction of the A5083 material. Corresponding deviation in the values of tensile and compressive stress states of the 6005A material equals 13.12%. As such, both materials must be calibrated separately. The depth measured by the sonic probe at different frequencies is different, and the stress coefficient calibrated by the probe at different operating frequencies varies greatly from one region to another. Values of the stress coefficient demonstrate obvious changes under tensile and compressive stress states in the weld zone. The maximum rate-of-change observed measured 30.69%. Change rates corresponding to the heat-affected area and base-metal zone measured 14.03% and 9.66%, respectively.
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图 2 铝合金材料在不同方向拉、压应力拟合的K值
Figure 2. Fitting curves of K-values for anisotropic tensile and compressive stresses induced in aluminium alloys.
图 3 不同频率探头LCR波下不同凹槽深度信号图
Figure 3. Signal diagram of LCR waves different groove depth by different frequency probe
图 4 LCR波在不同凹槽深度下的传播路径示意
Figure 4. Sketches of different LCR–waves groove depths measured by different frequency probes
图 5 不同频率探头对不同焊接区域的应力常数K值标定结果
Figure 5. Fitting curves of K-values in different welding zones calibrated by different frequency probes.
表 1 不同频率探头试验深度与国标深度对比
Table 1. Comparison between experimental depths measured by different frequency probes and those prescribed by national standards
项目 探头频率/MHz 2.25 3.50 5.00 10.00 试验深度/mm 3.00～4.00 2.00～3.00 1.50～2.00 1.00～1.50 GB/T 32073—2015深度/mm 2.94 1.92 1.37 0.70 
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