Chen Changhong, Xu Chunguang, Yang Guangcan, Ma Yongjiang, Yang Shuangxu
School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China.
Sensors (Basel). 2025 Aug 21;25(16):5205. doi: 10.3390/s25165205.
Accurate stress evaluation of structural components during manufacturing and operation is essential for ensuring the safety and reliability of advanced equipment in aerospace, defense, and other high-performance fields. However, existing electromagnetic ultrasonic stress detection methods are often limited by low signal amplitude and limited adaptability to complex environments, hindering their practical deployment for in situ testing. This study proposes a novel surface wave transducer structure for stress detection based on acoustoelastic theory combined with electromagnetic ultrasonic technology. It innovatively designs a surface wave transducer composed of multiple proportionally scaled dislocation meandering coils. This innovative configuration significantly enhances the Lorentz force distribution and coupling efficiency, which accurately measure the stress of components through acoustic time delays and present an experimental method for applying electromagnetic ultrasonic technology to in situ stress detection. Finite element simulations confirmed the optimized acoustic field characteristics, and experimental validation on 6061 aluminum alloy specimens demonstrated a 111.1% improvement in signal amplitude compared to conventional designs. Through multiple experiments and curve fitting, the average relative error of the measurement results is less than 4.53%, verifying the accuracy of the detection method. Further testing under random stress conditions validated the transducer's feasibility for in situ testing in production and service environments. Owing to its enhanced signal strength, compact structure, and suitability for integration with automated inspection systems, the proposed transducer shows strong potential for in situ stress monitoring in demanding industrial environments.
在制造和运行过程中对结构部件进行精确的应力评估，对于确保航空航天、国防和其他高性能领域先进设备的安全性和可靠性至关重要。然而，现有的电磁超声应力检测方法往往受到信号幅度低和对复杂环境适应性有限的限制，阻碍了它们在原位检测中的实际应用。本研究提出了一种基于声弹性理论并结合电磁超声技术的新型表面波换能器结构用于应力检测。它创新性地设计了一种由多个按比例缩放的位错曲折线圈组成的表面波换能器。这种创新配置显著增强了洛伦兹力分布和耦合效率，通过声时延精确测量部件应力，并提出了一种将电磁超声技术应用于原位应力检测的实验方法。有限元模拟证实了优化后的声场特性，在6061铝合金试样上的实验验证表明，与传统设计相比，信号幅度提高了111.1%。通过多次实验和曲线拟合，测量结果的平均相对误差小于4.53%，验证了检测方法的准确性。在随机应力条件下的进一步测试验证了该换能器在生产和使用环境中进行原位测试的可行性。由于其增强的信号强度、紧凑的结构以及适合与自动化检测系统集成，所提出的换能器在苛刻的工业环境中进行原位应力监测显示出强大的潜力。
