Analysis of Residual-Stress Test Errors via Ultrasonic Method for Aluminium Alloy Used in High-Speed Trains

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.