粘接界面特性的超声检测与评价

粘接界面特性的超声检测与评价既是物理学的前沿问题,又是经济建设和国防安全亟需解决的应用问题。高波阻介质下多层低波阻介质界面脱粘检测、滑移界面检测和粘接强度定量评价是粘接质量检测中遇到的三大难题。本文综述了课题组十余年来在攻坚三大难题方面的研究工作：建立了共振匹配理论,发明了六项关键技术并实现了技术集成,研制出全新概念的超声检测设备,解决了第一个难题;成功研制出横波直探头,用纵横波综合判断方法解决了第二个难题;对第三个难题,建立了粘接界面非线性弹簧模型,为利用非线性声学参量评价粘接界面奠定了理论基础,并探索性地利用统计性方法对粘接强度进行了预测,取得较好效果。     

循环温度疲劳作用下粘接界面损伤的非线性超声评价

材料损伤以及性能退化与超声波的非线性效应密切相关.为研究循环温度疲劳作用下粘接界面的损伤情况,本文采用超声波透射法,研究了6061型铝合金/改性丙烯酸酯胶粘接界面的声学非线性系数随高温、低温循环次数的变化情况.结果表明,在高温循环疲劳作用的初始阶段,试件的非线性系数变化不明显,但随着高温循环次数的不断增加,非线性系数随循环次数的变化十分明显;对于低温循环疲劳作用的初始阶段,试件的非线性系数迅速增大,随着循环次数的增加,其值增速减缓.在低温循环疲劳寿命的后期,试件的非线性系数随循环次数的增加而继续增大.进一步的讨论结果表明,胶层三阶弹性常数的变化是造成高温循环疲劳时非线性系数变化的主要原因,而对于低温循环疲劳,粘接界面拉伸刚度的变化是引起非线性系数变化的主要原因.     

板底薄层的超声谐振检测分析

理论上研究了带有薄层的板的超声谐振频率随薄层的厚度或物性改变而发生变化的规律,研究结果表明,在0 ≤ ω<c₂/d₂ arctan (Z₁/Z₂)范围内,板的半波谐振频率因薄层厚度的增加向低频飘移;在一阶近似条件下,飘移量的大小正比于薄层和板的单位面积质量之比。在此基础上,提出了利用板的谐振频率飘移量进行板底薄层厚度检测的方法,并对6.24 mm厚铝板下不同厚度(54-324 μm)的薄层进行了厚度检测,实验得到的厚度相对误差在6%以下。实验结果进一步证实了该规律是正确的,以及基于该规律的板底薄层检测方法是可行的。     

超声在粘接界面的反射和透射

本文讨论了有关超声在两种固体粘接界面上的各种理论模型，介绍了这些模型所假设的界面边界条件以及由此而得到的超声在粘接界面上的反射系数和透射系数。     

粘接界面的非线性弹簧模型及实验验证

研究了纵波及横波垂直入射时在粘接界面处的非线性边界条件。在二阶微扰近似及粘接界面层厚度远小于入射声波长的条件下,给出了严格的界面非线性弹簧模型的表达式。数值计算结果表明,利用该模型得到的透射二次谐波与利用连续性边界条件得到的精确解吻合良好。针对钢(铝)的楔形粘接结构,在纵波垂直入射的条件下对该非线性弹簧模型进行了实验验证。实际测量结果显示该模型具有较高的精度;且被粘物与胶层的阻抗比越大,该模型的误差越小。     

三层介质超声谐振模式随材料和界面粘接性能变化的演变规律

在用超声波谐振对粘接材料的粘接强度进行无损评估时, 不同模式对粘接强度的敏感程度受到众多因素和参数的影响, 对检测结果的可靠性至关重要. 基于多层介质中声传播和界面弱粘接边界条件的理论模型, 将一个上下非对称的金属-粘接剂-金属三层结构的平面波反射系数函数中的谐振模式看作是上下铝金属层各自的Lamb波频散模式通过夹心粘接剂层相互耦合后叠加组成. 改变影响结构粘接强度的因素, 即粘接剂的性能参数(声阻抗、密度、厚度)和界面切向劲度系数k_t来分析三层结构谐振模式耦合方式的变化,得出结论: 粘接结构粘接性能的变化基本上不改变与被粘铝层相关的固有部分的Lamb波模式, 而它们的耦合模式则在谐振频率上产生平移并会与固有模式进行交换和替代; 不同参数的变化引起的模式演变有各自的规律, 大多可彼此区分.     

铝合金粘接件界面层超声检测的进展

本文简述了检测铝合金粘接件界面层质量的超声反射法中有关理论和实验技术.介绍了粘接件中多孔Al_2O_3薄层有效弹性常数的确定方法和Al_2O_3/有机涂层之间界面的粘弹体模型.对五层媒质组成的粘接件声反射系数的理论值和实验值进行了比较.指出了粘接件界面层超声检测中一些尚待解决的问题。     

粗糙接触界面超声非线性效应的概率模型

提出描述粗糙接触界面超声非线性效应的概率模型,利用分段均匀概率函数描述粗糙接触界面劲度系数变化,结合表面粗糙峰的几何分布特征,得到界面粗糙度和两侧表面相对运动对声波的非线性调制作用。实验观测了铝合金材料的粗糙接触界面的高次谐波现象和阈值现象,进一步分析了归一化非线性参数与界面加载压力、粗糙度之间的关系。实验测量结果与概率模型的理论预测一致,证明了该模型的正确性,为利用超声非线性效应评价粗糙接触界面提供了理论依据。     

金属基复合结构粘接强度的非线性超声混频检测

采用非线性超声混频方法对金属基复合结构的粘接强度进行表征研究。以不同固化剂含量的铝合金丙烯酸酯粘接结构作为检测对象,基于非线性超声混频的共振条件及其作用机制,并结合粘接固化机理,开展了非线性超声混频实验。非线性超声混频模式选取两列横波生成和频纵波的方式,实验测量并计算不同基频周期数下的超声非线性参量。通过拉伸实验标定粘接结构的粘接强度,并采用扫描电镜分析拉伸断面微观结构,进而分析超声非线性参量与粘接强度的关系。从实验结果可以看出在不同周期的基频信号激励下,超声非线性参量随着粘接强度的增大均呈现出减小的趋势。研究表明非线性超声混频信号对金属基复合结构粘接强度的变化比较敏感,可以适用于类似结构件粘接强度状态弱化的表征。     

各向异性固体板中的非线性超声导波

将超声导波的非线性视为线性波动响应的一个二阶微扰,采用二阶微扰近似和导波的模式展开分析方法,从理论上研究了各向异性固体板中超声导波的二次谐波发生效应,给出了超声导波二次谐波声场的一般形式解。板材的各向异性可从多个方面对二次谐波发生效应产生影响,尤其是板材各向异性引起的导波模式相速度的改变,可显著地影响到构成导波二次谐波声场的二倍频导波模式随传播距离的积累增长程度。根据理论分析和数值计算结果可知,在不同传播方向上超声导波的非线性效应存在较显著的差异,伴随基频导波模式的传播所发生的二次谐波对固体板材的各向异性表现出更为敏感的性质,这一结果可为准确定征板材的弹性各向异性提供一种理论依据。     

Ultrasonic field characteristics in resonant standing waves

The application of high performance ultrasound in resonant standing waves recently has obtained some new technical applications as the ultrasonic-standing-wave-atomization (USWA) of liquids. In this application a resonant ultrasonic wave field is generated by means of two oscillating transducers facing each other on a common axis. Characterization of the wave field formation in this resonant, high-amplitude case of ultrasonic standing wave fields is of significant importance for understanding and optimization of such processes. Computational simulation of the sound field provides insight in the complex gas behaviour and atomization process. The numerical simulation of the ultrasonic field characteristics is based on the fundamental hydrodynamic conservation equations including nonlinear and viscous effects. The numerical calculation procedure and boundary conditions will be outlined. Results for the ultrasonic wave field characteristics in standard geometric arrangements as well as possibilities for energy density enhancement will be discussed.     

Helmholtz solitons at nonlinear interfaces

Reflection and refraction of spatial solitons at dielectric interfaces, accommodating arbitrarily angles of incidence, is studied. Analysis is based on Helmholtz soliton theory, which eliminates the angular restriction associated with the paraxial approximation. A novel generalization of Snell's law is discovered that is valid for collimated light beams and the entire angular domain. Our new theoretical predictions are shown to be in excellent agreement with full numerical simulations. New qualitative features of soliton refraction and limitations of previous paraxial analyses are highlighted.     

Effect of surface-grafted molecular brushes on the adhesion performance of bonded polymers and composite interfaces

This paper reviews the theoretical principles of the macromolecular design of polymer interface/interphase systems for obtaining maximum adhesion and fracture performance of composite materials and adhesively bonded assemblies. Subsequently, a relatively simple and industry-feasible technology for surface grafting molecular brushes is discussed in detail and supported by a range of experimental examples. It is shown, in agreement with contemporary theory, that the use of chemically attached graft chemicals of controlled spatial geometry and chemical functionality enables a significant increase in the strength and fracture energy of the interphase, to the point of cohesive fracture of the substrate, or that of an adjacent medium such as adhesive, elastomer or matrix material. This occurs even after prolonged exposure of investigated systems to adverse environments such as hot water.     

Theoretical study of adhesion at the metal-zirconium dioxide interfaces

The atomic and electronic structure of the interfaces between metals with body-centered cubic (bcc) and face-centered cubic (fcc) structures and zirconium dioxide is studied systematically using the ab initio methods of the electron density functional theory (DFT). It is shown that high adhesion properties can be attained at the nonstoichiometric polar Me(001)/ZrO₂(001) interface with bcc metals from the middle of the 4d–5d periods (Mo, Ta, W, and Nb). Charge transfer from the metal to the oxide substrate ensures the strong ionic chemical bond on the metal-ceramic interfaces. The structural and electronic factors responsible for lowering of adhesion at differently oriented interfaces are analyzed. It is shown that a decrease of adhesion at the (110) nonpolar stoichiometric interface is due to an increase in the interfacial spacing as well as a decrease in the number of metal-oxygen bonds. The effect of doping with oxides (CaO, MgO, and Y₂O₃) stabilizing zirconium dioxide at low temperatures on the adhesion energy at the Me(001)/ZrO₂(001) interface is analyzed.     

Propagation behaviors of thickness-twist modes in an inhomogeneous piezoelectric plate with two imperfectly bonded interfaces

The thickness-twist modes in an inhomogeneous piezoelectric plate with two imperfectly bonded interfaces are analyzed, and an exact solution is obtained according to the spring-type relation from the equations of the linear theory of piezoelectricity. The frequency shift, the displacement and the stress components are all obtained and plotted. Both theoretical analysis and numerical examples show that the effect of mechanical imperfection is more evident than that of the electrical imperfection on the thickness-twist modes. Results show that the displacement and the stress components all change obviously due to the imperfectly bonded interfaces. The relationship between the frequency shift Δω and the non-dimensional number γ that is related to the imperfect interfaces is linear, which can be used to provide the foundation for a new experimental procedure for measuring the level of the interface bonding.     

Vector soliton fission by reflection at nonlinear interfaces

We address the reflection of vector solitons, comprising several components that exhibit multiple field oscillations, at the interface between two nonlinear media. We reveal that reflection causes fission of the input signal into sets of solitons propagating at different angles. We find that the maximum number of solitons that arises upon fission is given by the number of field oscillations in the highest-order input vector soliton.     

Observation of nonlinear acoustic effects at isotropic solid-solid interfaces

The second harmonic generation of SV shear waves at isotropic solid-solid interfaces is experimentally studied. The amplitude of shear waves is measured for the interfaces of glass-air, glass-iron, glass-copper, and glass-aluminum. The measured angular relation of amplitude of the second harmonic wave is compared with theory and the agreement is reasonably good. The influence of the physical state of the interface on second harmonic generation is also observed. It is found that the second harmonic generation is sensitive to the interface state.     

Bi-directional spatial soliton emission at engineered nonlinear waveguide interfaces

We observed tunable bi-directional emission of spatial solitons at a quadratically nonlinear interface in periodically poled lithium niobate planar waveguides. The interface consists of the boundary between two quasi-phase-matched regions with a different poling period. We show the intensity and phase-mismatch (temperature or wavelength) dependence of the phenomena.     

双层压电结构超声波传感器的研究

为获得三频或宽频超声波传感器，本文提出了一种新型双层压电结构超声波传感器，文中从理论上分析研究了电容对其频率特性控制的原理，同时，在２ＭＨｚ频率范围进行了实测验证，理论与实测结果吻合较好。