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腐蚀环境下铜薄膜传感器金属结构裂纹监测

谭翔飞 何宇廷 侯波 崔荣洪 冯宇

谭翔飞, 何宇廷, 侯波, 等 . 腐蚀环境下铜薄膜传感器金属结构裂纹监测[J]. 北京航空航天大学学报, 2017, 43(7): 1433-1441. doi: 10.13700/j.bh.1001-5965.2016.0534
引用本文: 谭翔飞, 何宇廷, 侯波, 等 . 腐蚀环境下铜薄膜传感器金属结构裂纹监测[J]. 北京航空航天大学学报, 2017, 43(7): 1433-1441. doi: 10.13700/j.bh.1001-5965.2016.0534
TAN Xiangfei, HE Yuting, HOU Bo, et al. Metal structure crack monitoring based on copper film sensor in corrosion environment[J]. Journal of Beijing University of Aeronautics and Astronautics, 2017, 43(7): 1433-1441. doi: 10.13700/j.bh.1001-5965.2016.0534(in Chinese)
Citation: TAN Xiangfei, HE Yuting, HOU Bo, et al. Metal structure crack monitoring based on copper film sensor in corrosion environment[J]. Journal of Beijing University of Aeronautics and Astronautics, 2017, 43(7): 1433-1441. doi: 10.13700/j.bh.1001-5965.2016.0534(in Chinese)

腐蚀环境下铜薄膜传感器金属结构裂纹监测

doi: 10.13700/j.bh.1001-5965.2016.0534
基金项目: 

国家自然科学基金 51201182

详细信息
    作者简介:

    谭翔飞  男, 硕士研究生。主要研究方向:飞机结构强度与使用寿命

    何宇廷  男, 博士, 教授, 博士生导师。主要研究方向:飞行器结构寿命控制、飞行器结构健康监控、飞行器安全性评估

    通讯作者:

    何宇廷, E-mail:heyut666@126.com

  • 中图分类号: V215.6;TP212.1

Metal structure crack monitoring based on copper film sensor in corrosion environment

Funds: 

National Natural Science Foundation of China 51201182

More Information
  • 摘要:

    铜薄膜传感器在飞机金属结构损伤监测过程中,将长期面临大气腐蚀环境的影响。针对此背景,研究了铜薄膜传感器在腐蚀环境下的耐蚀性能,及腐蚀后的疲劳裂纹监测性能。首先,采用脉冲偏压多弧离子镀技术在不同弧电流和基体负偏压水平下制备了一系列铜薄膜,对其耐蚀性能进行了对比研究。结果表明,在弧电流60 A和基体负偏压250 V时沉积的铜薄膜耐蚀性能最佳。然后,结合耐蚀性能最佳的沉积工艺参数,在2A12-T4铝合金中心孔板试件上制备了同心环状铜薄膜传感器阵列,并开展了盐雾腐蚀试验。最后,对腐蚀试验后的铜薄膜传感器进行了疲劳裂纹监测试验。结果表明:铜薄膜传感器在腐蚀环境下具有良好的耐蚀性能,耐蚀时间达1 000 h;腐蚀试验后的铜薄膜传感器对裂纹变化敏感,能实现对裂纹定量监测,监测精度为1 mm,监测结果具有良好的可重复性。

     

  • 图 1  第1组铜薄膜试件盐雾腐蚀试验形貌

    Figure 1.  The first group copper film morphology after salt-spray corrosion test

    图 2  第2组铜薄膜试件盐雾腐蚀试验形貌

    Figure 2.  The second group copper film morphology after salt-spray corrosion test

    图 3  不同沉积工艺参数组合铜薄膜盐雾腐蚀试验形貌

    Figure 3.  Copper film morphology after salt-spray corrosion test with different deposition process parameter combination

    图 4  铜薄膜传感器示意图

    Figure 4.  Schematic of copper film sensor

    图 5  试件尺寸

    Figure 5.  Specimen dimension

    图 6  制备了同心环状铜薄膜传感器阵列的试件

    Figure 6.  Deposited specimen of concentric ring copper film sensor array

    图 7  盐雾腐蚀试验后试件形貌

    Figure 7.  Specimen morphology after salt-spray corrosion test

    图 8  疲劳裂纹监测试验现场

    Figure 8.  Fatigue crack monitoring test site

    图 9  多通道金属结构实时在线监测系统界面

    Figure 9.  Interface of multi-channel metal structure real-time online monitoring system

    图 10  同心环状铜薄膜传感器输出电位差信号曲线

    Figure 10.  Potential difference signal curves of concentric ring copper film sensor

    表  1  铜薄膜沉积工艺参数

    Table  1.   Copper film deposition process parameters

    参数 数值
    基体负偏压/V 依据设计参数
    氩气气压/Pa 2.2~2.4
    沉积时间/min 12~15
    弧电流/A 依据设计参数
    下载: 导出CSV

    表  2  盐雾腐蚀试验条件

    Table  2.   Salt-spray corrosion test condition

    参数 数值
    盐雾沉积速度/(mL·h-1·80 cm-2) 1~2
    NaCl溶液浓度/(g·L-1) 50±5
    喷雾气源压力/Pa 100~140
    相对湿度/% ≥90
    温度/℃ 40±2
    pH 4±0.2
    下载: 导出CSV

    表  3  腐蚀率与评定等级的关系[19]

    Table  3.   Relationship between corrosion rate and grade estimation[19]

    腐蚀率范围 腐蚀评级
    无腐蚀 10
    0 < A≤0.1 9
    0.1 < A≤0.25 8
    0.25 < A≤0.5 7
    0.5 < A≤1.0 6
    1.0 < A≤2.5 5
    2.5 < A≤5.0 4
    5.0 < A≤10 3
    10 < A≤25 2
    25 < A≤50 1
    50 < A 0
    下载: 导出CSV

    表  4  外观评级与外观变化对应关系[19]

    Table  4.   Relationship between appearance rating and appearance change[19]

    外观评级 试样表面外观的变化
    A 无变化
    B 轻微到中度的变色
    C 严重变色到极轻微的失光
    D 轻微的失光或出现极轻微的腐蚀产物
    E 严重的失光,或在试样局部表面上布有薄层的腐蚀产物或点蚀
    F 有腐蚀物或点蚀,且其中之一集中斑布在整个试样表面上
    G 整个表面上布有厚的腐蚀产物层或点蚀,并有深的点蚀
    H 整个表面上布有非常厚的腐蚀产物或点蚀,并有深的点蚀
    下载: 导出CSV

    表  5  第1组铜薄膜试件盐雾腐蚀试验结果

    Table  5.   Results of the first group copper filmafter salt-spray corrosion test

    参数组合(弧电流,A/基体负偏压,V) 腐蚀等级(腐蚀评级/外观评级)
    腐蚀12 h 腐蚀24 h 腐蚀36 h 腐蚀48 h
    40/100 10/C 5/E 2/F
    50/100 10/C 5/E 2/F
    60/100 10/C 5/E 2/F
    70/100 10/A 4/D 3/E 2/F
    80/100 10/B 5/D 3/E 2/F
    下载: 导出CSV

    表  6  第2组铜薄膜试件盐雾腐蚀试验结果

    Table  6.   Results of the second group copper film after salt-spray corrosion test

    参数组合(弧电流,A/基体负偏压,V) 腐蚀等级(腐蚀评级/外观评级)
    腐蚀12 h 腐蚀24 h 腐蚀36 h 腐蚀48 h 腐蚀60 h 腐蚀72 h 腐蚀84 h
    60/20 5/D 5/E 2/G
    60/60 10/C 5/E 2/G
    60/100 10/C 5/E 2/F
    60/140 10/B 6/D 5/D 5/D 3/E 3/E 2/F
    60/180 10/B 6/D 3/F 2/F
    下载: 导出CSV

    表  7  铜薄膜耐蚀性最佳的沉积工艺参数组合

    Table  7.   Deposition process parameter combination for optimal corrosion resistance of copper film

    参数组合(弧电流,A/基体负偏压,V) 腐蚀等级(腐蚀评级/外观评级)
    腐蚀12 h 腐蚀24 h 腐蚀36 h 腐蚀48 h 腐蚀60 h 腐蚀84 h 腐蚀204 h
    60/250 10/A 10/A 10/B 10/C 10/D 9/E 9/E
    70/150 10/B 5/D 4/D 3/E 2/E
    70/200 6/D 6/D 4/D 3/E 2/E
    80/100 10/B 5/D 3/E 2/F
    下载: 导出CSV

    表  8  硫酸-硼酸阳极氧化工艺参数

    Table  8.   Sulfuric acid/boric acid anodic oxidation process parameters

    参数 溶液浓度/(g·L-1) 温度/℃ 直流电压/V 时间/min
    H2SO4 H3B3 Al3+
    数值 40~60 10~15 < 5.5 20~30 15~20 30~40
    下载: 导出CSV
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  • 收稿日期:  2016-06-21
  • 录用日期:  2016-07-01
  • 刊出日期:  2017-07-20

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