深窄腔体异型承载件铸造缺陷原位全体积检测及其在役容限反算

针对大型武器装备异型承载件铸造质量的原位无损检测及其评价的重大需求，本申请拟开展“深窄腔体异型承载件铸造缺陷原位全体积检测及其在役容限反算”研究，通过分析机械臂辅助超声相控阵检测的同步协调机制及动态耦合瓶颈，重点突破适用于极端深窄柱腔结构的机械臂辅助超声相控阵动态局部水浸检测同步协调方法，以此消除检测时序失步、检测位姿失调及耦合特性对检测精度的影响，进而结合对匹配深窄腔体异型承载件结构、型面和材料特性的超声相控阵检测方法、定制化工艺及缺陷超声相控阵检测数据空间拼接算法的研究，实现深窄腔体异型承载件铸造缺陷的原位全体积检测及缺陷的三维可视化显示；进一步通过对铸造缺陷超声相控阵检测的智能定性分类与定量分级方法的探索，在缺陷检测快速定性分类与定量分级的基础上，研究预期服役寿命下深窄腔体异型承载件铸造缺陷超声相控阵检测评价的在役容限反算方法，最终实现其铸造缺陷超声相控阵检测的分区、分类精准评价。

Aiming at the significant demands for the in-situ nondestructive testing and evaluation on the casting quality of irregular load-bearing part in large weapons, this proposal is going to the research topic of “in-situ full volume testing and in-service tolerance inverse calculation of casting defects in irregular load-bearing part with deep and narrow cavities”. Through analyzing the synchronous coordination mechanism and dynamic coupling problem of the robot-assisted ultrasonic phased-array ultrasonic testing (PAUT), a new robot-assisted PAUT method with dynamic local water immersion is proposed to weaken the effect of out-of-sequence testing, testing pose error and coupling property on the testing accuracy. Meanwhile, the PAUT scheme and customized testing process are matched with structure feature, shape and material characteristics of irregular load-bearing part with deep and narrow cavities, and then combining with the space-mapping algorithm study on the PAUT image, to realize the in-situ full volume testing and three-dimensional visualization of the casting defects in irregular load-bearing part. Furthermore, based on the exploration on the intelligent qualitative classification and quantitative grading method for the PAUT image, the in-service tolerance inverse algorithm of the different types of casting defect in the irregular load-bearing part are further proposed according to its expected service life, on the basis of which to realize the accurate evaluation for the PAUT on the different casting defects locating in the variable fields of the irregular load-bearing part.