The shape of aluminum alloy extrudate used in high-speed train is complex, structural noises from the surfaces of the extrudate will be received when using ultrasonic phased array to detect the flaws in FSW. To solve this problem, ultrasonic phased array acoustic field model and propagation simulation of acoustic waves were introduced to simulate the acoustic pressure distribution and the propagation of the acoustic waves. With the methods above, the detection parameters can be optimized and as a result, the experimental process can be simplified and the detection efficiency can be improved. Meanwhile, the echoes in the S-scan images can be predicted, which can help analyze the detection results and judge the defects.
Brazed weldment with lattice structure has been widely used in aerospace industry. The non-destructive testing is often difficult because of the poor inspection accessibility. The present paper illustrates how the plane-like defect lack of brazing can be detected rapidly in this kind of structure by using ultrasonic Lamb wave. Experimental weldments are prepared and weld defect are tested using S2 mode Lamb wave. Acoustic shadow technique is employed based on Lamb wave testing method. The character of the tested D-scan image and A-scan signal is studied. The experimental results show that acoustic shadow based Lamb wave testing method is effective in detecting through-wall lack of brazing. Meanwhile, the D-scan tested data can be rapidly collected and easily interpreted compared with pulse echo bused Lamb wave testing method.
Electron beam welding （EBW） is a fusion welding process in which a beam of high-velocity electrons is applied to two materials to be joined. It is a complex high-temperature metallurgical process, and the quality of welding may deteriorate because of defects caused by improper welding parameters, especially in the EBW of thickened aluminum alloy plate. Ultrasonic phased array（UPA） technology has been applied more widely in the field of nondestructive testing because of its ability of effectively controlling the shape and direction of the emitted ultrasonic beam. In present research, a specimen with EBW seam on thickened aluminum plate was tested with a linear array ultrasonic phased array probe, and a large number of B-scan images of the weld were acquired by electronic scanning in probe combined with the mechanical scanning of the probe along the weld direction. This large number of B-scan images were stacked to construct the volume data, with which the 3D image of the weld discontinuities were reconstructed, and the 3D visualization was realized. More details about weld discontinuities＇ spatial distribution and orientation were revealed, and this approach also made the results of non-destructive ultrasonic testing more easily to understand.
