Abstract
An analysis method for the detectability of defects on the TC4 (Ti-6Al-4V) diffusion bonding interface was proposed in this study. First, a semi-analytical model of the liquid–solid coupling acoustic field with attenuation characteristics was constructed. Based on this, a method for the selection of transducer parameters was investigated for effective focus on the diffusion bonding interface. Second, according to the characteristics of defects on the diffusion bonding interface, an acoustic response model for diffusion bonding defects was established based on Kirchhoff approximation. The detectability of defects on the diffusion bonding interface was analyzed using transducers of different frequencies with different diffusion bonding interface gaps. Finally, an experiment was conducted to verify the reliability of the simulation. The analysis method proposed shows the advantages in the selection of suitable parameters for detecting specific diffusion bonding interface gaps, providing theoretical predictions of the detectability of diffusion bonding interface defects.
Highlights
Diffusion bonding is a solid-phase welding process, by which two prepared surfaces are joined at elevated temperatures under applied pressure [1]
The ultrasonic C-scan inspection technology is the most widely used in the nondestructive evaluation of diffusion bonding [7]
Analysis of3.Characteristics of the Acoustic Field Radiated by Focusing Transducer
Summary
Diffusion bonding is a solid-phase welding process, by which two prepared surfaces are joined at elevated temperatures under applied pressure [1]. Due to the complexity of the diffusion bonding process, factors such as surface roughness of the workpiece material and contamination or improper selection of the diffusion joining process parameters will cause defects in the diffusion bonding interface. These defects, such as unbonded and interfacial microvoids, seriously reduce the mechanical properties of TC4 alloy diffusion bonding components [2], such as those of the hollow blades of aeroengines [3–5]. The ultrasonic C-scan inspection technology is the most widely used in the nondestructive evaluation of diffusion bonding [7]. Liu et al [10] used a high-frequency ultrasonic transducer
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