柔性超声阵列与自适应全聚焦成像在复杂构件无损检测中的应用
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1.天津大学精密测试技术及仪器全国重点实验室天津300072; 2.北京卫星环境工程研究所北京100094

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TH871.7

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国家自然科学基金(12474459)项目资助


Flexible ultrasonic array with adaptive total focusing imaging for nondestructive testing of complex components
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1.State Key Laboratory of Precision Measurement Technology and Instruments, Tianjin University, Tianjin 300072, China; 2.Beijing Institute of Spacecraft Environment Engineering, Beijing 100094, China

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    摘要:

    具有复杂曲面几何特征的关键构件广泛存在于各类工业结构中, 其内部缺陷检测因声束畸变和耦合不稳定而面临显著挑战。为解决这一问题, 提出一种面向复杂曲面构件检测的柔性超声阵列及其自适应成像方法。设计并制备了能够与不规则表面紧密共形的柔性超声传感器阵列。针对柔性阵列贴合曲面后产生的几何形变会引入阵元空间位置偏差, 进而导致全聚焦成像中传播延时计算不准确的问题, 提出了一种基于已知边界特征的自适应全聚焦成像方法。该方法无需外部定位设备, 利用构件底面等几何边界作为参考, 通过归一化互相关计算阵元之间的相对延时, 实现阵列实际形态的重构, 并对全聚焦成像中的延迟法则进行自适应校正, 从而有效补偿阵列共形贴合所引入的相位失配。通过数值仿真与实验验证, 对比分析了自适应校准前后全聚焦成像效果。在整体检测尺度为百毫米量级的曲面试块中, 经自适应校准后, 内部预制缺陷横向最小定位误差2.16 mm, 纵向最小定位误差1.48 mm, 缺陷位置能够被稳定清晰重建。同时, 成像中的几何伪影得到有效抑制, 整体成像信噪比显著提升。结果表明, 提出的柔性超声阵列及其自适应成像方法能够在复杂曲面条件下实现可靠的高精度缺陷定位, 为复杂曲面构件的超声无损检测提供了一种有效的技术途径。

    Abstract:

    Key components with complex curved geometries are widely found in various industrial structures, where internal defect detection faces significant challenges due to acoustic beam distortion and unstable coupling conditions. To address this issue, a flexible ultrasonic array and an adaptive imaging method for the inspection of complex curved components are proposed. A flexible ultrasonic array capable of conformal attachment to irregular surfaces is designed and fabricated. Considering that geometric deformation induced by conformal attachment of the flexible array introduces spatial position deviations of array elements, which consequently lead to inaccuracies in propagation delay calculations in total focusing method (TFM) imaging, an adaptive TFM imaging approach based on known boundary features is developed. The proposed method does not rely on external positioning devices. Instead, geometric boundaries such as the bottom surface of the inspected component are used as internal references. Relative time delays between array elements are estimated using normalized cross-correlation, enabling reconstruction of the actual array geometry and adaptive correction of the delay law in TFM imaging. As a result, phase mismatches caused by conformal attachment of the flexible array are effectively compensated. Numerical simulations and experimental validations are conducted to comparatively analyze TFM imaging performance before and after adaptive calibration. For curved specimens with an overall inspection scale on the order of hundreds of millimeters, the minimum localization errors of internal artificial defects after adaptive calibration are 2.16 mm in the lateral direction and 1.48 mm in the axial direction, respectively, allowing stable and clear reconstruction of defect positions. Meanwhile, geometric imaging artifacts are effectively suppressed, and the overall signal-to-noise ratio is significantly improved. The results demonstrate that the proposed flexible ultrasonic array combined with the adaptive imaging method enables reliable high-accuracy defect localization under complex curved surface conditions, providing an effective approach for ultrasonic nondestructive testing of complex curved components.

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孙贺,高人杰,营笑,綦磊,刘洋.柔性超声阵列与自适应全聚焦成像在复杂构件无损检测中的应用[J].仪器仪表学报,2026,47(1):64-73

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  • 在线发布日期: 2026-03-30
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