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Material forming, as a key metal processing technology, encompasses various forms such as casting, welding, forging, additive manufacturing, and powder metallurgy, and it is widely applied in important defence fields such as aerospace. Porosity, inclusions, and voids are the main internal defects, which seriously affect the performance and reliability of high-end equipment. In recent years, with the continuous development of software and hardware, defect detection technology has made significant progress. Based on a brief review of the current status of defect detection technology, this article analyzed the major technical breakthroughs and scientific advancements achieved by various detection methods such as radiography, ultrasound, and fluorescence, discussed the future development trends and research directions of intelligent detection for metal components, and provided policy recommendations from four dimensions: standard system construction, core technology breakthroughs, process flow reengineering, and system platform construction, with the aim of providing theoretical and technical support for high-reliability detection of metal components in high-end equipment.

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材料成形作为一种关键的金属加工工艺,涵盖了铸造、焊接、锻造、增材、粉末冶金等多种形式,广泛应用于航空航天等国防重要领域。气孔、夹杂物、孔隙等是其主要内部缺陷,严重影响高端装备的性能和可靠性。近年来,随着软硬件不断发展,缺陷检测技术也取得了显著进展。文章在简要梳理当前缺陷检测技术现状基础上,分析了射线、超声、荧光等各种检测方法取得的主要技术突破与科学进展,探讨了未来金属构件智能检测的发展趋势与研究方向,并从标准体系构建、核心技术攻关、工艺流程再造、系统平台建设4个维度给出政策建议,以期为高端装备金属构件高可靠检测提供理论与技术支撑。

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周建新,教授,博士研究生导师。国家重点研发计划项目首席科学家、中国铸造学会常务理事、中国铸造协会模具分会常务副理事长兼秘书长、湖北省机械工程学会理事/铸造专业委员会理事长、材料成形与模具技术全国重点实验室首席教授、华铸软件中心负责人。主要从事数字化智能化铸造技术的研发及应用。主持开发的“华铸CAE”、“华铸ERP”等华铸系列软件现已在国内外800多家单位应用。“庆祝中华人民共和国成立70周年”纪念章获得者,荣获“荆楚楷模”“武汉市最美科技工作者”“武汉楷模”称号,入选教育部“新世纪优秀人才支持计划”、国家重大人才工程。获国家科技进步奖二等奖2项(1项第2,1项第4)、省部级科技一等奖5项(均排名第1);发表学术论文200余篇,以第一作者出版著作4部。电子信箱:

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周建新,教授,博士研究生导师。国家重点研发计划项目首席科学家、中国铸造学会常务理事、中国铸造协会模具分会常务副理事长兼秘书长、湖北省机械工程学会理事/铸造专业委员会理事长、材料成形与模具技术全国重点实验室首席教授、华铸软件中心负责人。主要从事数字化智能化铸造技术的研发及应用。主持开发的“华铸CAE”、“华铸ERP”等华铸系列软件现已在国内外800多家单位应用。“庆祝中华人民共和国成立70周年”纪念章获得者,荣获“荆楚楷模”“武汉市最美科技工作者”“武汉楷模”称号,入选教育部“新世纪优秀人才支持计划”、国家重大人才工程。获国家科技进步奖二等奖2项(1项第2,1项第4)、省部级科技一等奖5项(均排名第1);发表学术论文200余篇,以第一作者出版著作4部。电子信箱:

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周建新,教授,博士研究生导师。国家重点研发计划项目首席科学家、中国铸造学会常务理事、中国铸造协会模具分会常务副理事长兼秘书长、湖北省机械工程学会理事/铸造专业委员会理事长、材料成形与模具技术全国重点实验室首席教授、华铸软件中心负责人。主要从事数字化智能化铸造技术的研发及应用。主持开发的“华铸CAE”、“华铸ERP”等华铸系列软件现已在国内外800多家单位应用。“庆祝中华人民共和国成立70周年”纪念章获得者,荣获“荆楚楷模”“武汉市最美科技工作者”“武汉楷模”称号,入选教育部“新世纪优秀人才支持计划”、国家重大人才工程。获国家科技进步奖二等奖2项(1项第2,1项第4)、省部级科技一等奖5项(均排名第1);发表学术论文200余篇,以第一作者出版著作4部。电子信箱:

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refs=[Reference(id=1242114140131627416, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2020, volume=34, issue=增刊1, pageStart=280, pageEnd=282, url=null, language=null, rfNumber=[1], rfOrder=0, authorNames=李毅, 赵永庆, 曾卫东, journalName=材料导报, refType=null, unstructuredReference=李毅, 赵永庆, 曾卫东. 航空钛合金的应用及发展趋势[J]. 材料导报, 2020, 34(增刊1): 280-282., articleTitle=航空钛合金的应用及发展趋势, refAbstract=null), Reference(id=1242114140198736281, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2020, volume=34, issue=Suppl 1, pageStart=280, pageEnd=282, url=null, language=null, rfNumber=[1], rfOrder=1, authorNames=Li Y, Zhao Y Q, Zeng W D, journalName=Materials Reports, refType=null, unstructuredReference=Li Y, Zhao Y Q, Zeng W D. Application and development of aerial titanium alloys[J]. Materials Reports, 2020, 34(Suppl 1): 280-282. (in Chinese), articleTitle=Application and development of aerial titanium alloys, refAbstract=null), Reference(id=1242114140274233754, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2023, volume=72, issue=8, pageStart=947, pageEnd=955, url=null, language=null, rfNumber=[2], rfOrder=2, authorNames=柳建国, 赵刚, 王东生, journalName=铸造, refType=null, unstructuredReference=柳建国, 赵刚, 王东生, . “十四五” 规划期间我国铸造行业发展浅析[J]. 铸造, 2023, 72(8): 947-955., articleTitle=“十四五” 规划期间我国铸造行业发展浅析, refAbstract=null), Reference(id=1242114140341342619, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2023, volume=72, issue=8, pageStart=947, pageEnd=955, url=null, language=null, rfNumber=[2], rfOrder=3, authorNames=Liu J G, Zhao G, Wang D S, journalName=Foundry, refType=null, unstructuredReference=Liu J G, Zhao G, Wang D S, et al. 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(in Chinese), articleTitle=Analysis on development of China’s foundry industry in the“14th Five-Year Plan period”, refAbstract=null), Reference(id=1242114140400062876, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=10.11868/j.issn.1001-4381.2021.000676, pmid=null, pmcid=null, year=2022, volume=50, issue=2, pageStart=50, pageEnd=61, url=null, language=null, rfNumber=[3], rfOrder=4, authorNames=李红, 闫维嘉, 张禹, journalName=材料工程, refType=null, unstructuredReference=李红, 闫维嘉, 张禹, . 先进航空材料焊接过程热裂纹研究进展[J]. 材料工程, 2022, 50(2): 50-61., articleTitle=先进航空材料焊接过程热裂纹研究进展, refAbstract=高焊接热裂纹敏感性是制约新一代合金材料在航空航天领域推广应用的技术瓶颈。本文分别从焊接热裂纹的产生机理和各类合金裂纹敏感性实验的角度梳理该方向的研究进展。焊接热裂纹主要包括凝固裂纹(在焊缝内部产生)和液化裂纹(在焊缝与部分熔化区交界处产生)。影响焊接热裂纹产生的因素包括材料成分、焊接热循环以及接头热应力。在梳理焊接热裂纹机理研究的基础上,分别总结了铝合金、镁合金、先进高强钢以及镍基合金焊接热裂纹的实验研究进展。建立考虑复杂多组元以及结晶形态对裂纹敏感性影响的量化判据,是该领域未来的重要发展方向。针对母材和焊材进行成分优化、添加形核剂或实施辅助工艺措施,是工程应用领域抑制热裂纹缺陷的有效方法。开展焊接热裂纹产生机理及其抑制方法研究,有助于突破新一代合金材料加工技术瓶颈,推进其在航空航天领域的应用。), Reference(id=1242114140462977437, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=10.11868/j.issn.1001-4381.2021.000676, pmid=null, pmcid=null, year=2022, volume=50, issue=2, pageStart=50, pageEnd=61, url=null, language=null, rfNumber=[3], rfOrder=5, authorNames=Li H, Yan W J, Zhang Y, journalName=Journal of Materials Engineering, refType=null, unstructuredReference=Li H, Yan W J, Zhang Y, et al. Research progress of hot crack in fusion welding of advanced aeronautical materials[J]. Journal of Materials Engineering, 2022, 50(2): 50-61. (in Chinese), articleTitle=Research progress of hot crack in fusion welding of advanced aeronautical materials, refAbstract=

The high fusion welding hot cracking sensibility of the next-generation alloy is the key technological difficulty that hinders its widely application in the aeronautic and astronautic industry. A critical review of the fusion welding hot cracking from the perspective of basic mechanism and the experimental research of typical materials was presented in this article. The fusion welding hot cracking phenomena include solidification cracking (occurs within the fusion zone) and liquidation cracking (occurs at the interface between fusion zone and partial melting zone). The formation factors of the fusion welding hot cracking include alloying composition, welding thermal cycle and thermal stress. Based on the comprehensive understanding of the formation mechanism of the fusion welding hot cracking, the relative research progress in the field of aluminum alloys, magnesium alloys, advanced high strength steel and nickel alloys was summarized. The establishment of the quantitative criterion that involves the effects of complicated multi-component and the morphology of the dendrite on the cracking sensibility is the key development direction. Optimizing the alloying composition of the base metal or filler metal, adding nucleanting agent or auxiliary facilities are the practical method for restraining the fusion welding hot cracking. Conducting the research on the mechanism and restraining method of the fusion welding hot cracking helps to solve the difficulty of the next generation alloys processing, which can realize their application in the field of aeronautic and astronautic industry.

), Reference(id=1242114140534280606, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2020, volume=12, issue=6, pageStart=16, pageEnd=27, url=null, language=null, rfNumber=[4], rfOrder=6, authorNames=赵明杰, 黄亮, 李昌民, journalName=精密成形工程, refType=null, unstructuredReference=赵明杰, 黄亮, 李昌民, . 300M钢的热变形行为及热锻成形工艺研究现状[J]. 精密成形工程, 2020, 12(6): 16-27., articleTitle=300M钢的热变形行为及热锻成形工艺研究现状, refAbstract=null), Reference(id=1242114140605583775, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, doi=null, pmid=null, pmcid=null, year=2020, volume=12, issue=6, pageStart=16, pageEnd=27, url=null, language=null, rfNumber=[4], rfOrder=7, authorNames=Zhao M J, Huang L, Li C M, journalName=Journal of Netshape Forming Engineering, refType=null, unstructuredReference=Zhao M J, Huang L, Li C M, et al. Research status of the hot deformation behaviors and hot forging process of 300M steel[J]. 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Different forming methods and common defects

, figureFileSmall=null, figureFileBig=null, tableContent=
成形方式 常见缺陷
铸造 气孔、缩孔、夹杂、冷隔、粘砂等
焊接 未焊透、咬边、飞溅物残留等
锻造 折叠、过热、氧化皮残留、凹坑、划痕等
增材制造 孔隙、未熔合、阶梯效应、球化效应等
粉末冶金 孔隙、夹杂、成分偏析、烧结不均匀等
), ArticleFig(id=1242114139687031188, tenantId=1146029695717560320, journalId=1146032081894723586, articleId=1148708270489002912, language=CN, label=表1, caption=

不同成形方式和常见缺陷

, figureFileSmall=null, figureFileBig=null, tableContent=
成形方式 常见缺陷
铸造 气孔、缩孔、夹杂、冷隔、粘砂等
焊接 未焊透、咬边、飞溅物残留等
锻造 折叠、过热、氧化皮残留、凹坑、划痕等
增材制造 孔隙、未熔合、阶梯效应、球化效应等
粉末冶金 孔隙、夹杂、成分偏析、烧结不均匀等
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高端装备金属构件成形缺陷智能检测技术进展与展望
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周建新 , 计效园 , 侯明君 , 董淏 , 段浩哲 , 殷亚军 , 沈旭 , 李文
前瞻科技 | 综述与述评 2025,4(1): 108-117
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前瞻科技 | 综述与述评 2025, 4(1): 108-117
高端装备金属构件成形缺陷智能检测技术进展与展望
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周建新 , 计效园, 侯明君, 董淏, 段浩哲, 殷亚军, 沈旭, 李文
作者信息
  • 华中科技大学材料成形与模具技术全国重点实验室,武汉 430074
  • 周建新,教授,博士研究生导师。国家重点研发计划项目首席科学家、中国铸造学会常务理事、中国铸造协会模具分会常务副理事长兼秘书长、湖北省机械工程学会理事/铸造专业委员会理事长、材料成形与模具技术全国重点实验室首席教授、华铸软件中心负责人。主要从事数字化智能化铸造技术的研发及应用。主持开发的“华铸CAE”、“华铸ERP”等华铸系列软件现已在国内外800多家单位应用。“庆祝中华人民共和国成立70周年”纪念章获得者,荣获“荆楚楷模”“武汉市最美科技工作者”“武汉楷模”称号,入选教育部“新世纪优秀人才支持计划”、国家重大人才工程。获国家科技进步奖二等奖2项(1项第2,1项第4)、省部级科技一等奖5项(均排名第1);发表学术论文200余篇,以第一作者出版著作4部。电子信箱:

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Progress and Prospect of Intelligent Detection Technology for Metal Component Forming Defects of High-end Equipment
Jianxin ZHOU , Xiaoyuan JI, Mingjun HOU, Hao DONG, Haozhe DUAN, Yajun YIN, Xu SHEN, Wen LI
Affiliations
  • State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China
出版时间: 2025-03-20 doi: 10.3981/j.issn.2097-0781.2025.01.011
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材料成形作为一种关键的金属加工工艺,涵盖了铸造、焊接、锻造、增材、粉末冶金等多种形式,广泛应用于航空航天等国防重要领域。气孔、夹杂物、孔隙等是其主要内部缺陷,严重影响高端装备的性能和可靠性。近年来,随着软硬件不断发展,缺陷检测技术也取得了显著进展。文章在简要梳理当前缺陷检测技术现状基础上,分析了射线、超声、荧光等各种检测方法取得的主要技术突破与科学进展,探讨了未来金属构件智能检测的发展趋势与研究方向,并从标准体系构建、核心技术攻关、工艺流程再造、系统平台建设4个维度给出政策建议,以期为高端装备金属构件高可靠检测提供理论与技术支撑。

金属构件  /  缺陷  /  检测  /  射线  /  超声  /  荧光

Material forming, as a key metal processing technology, encompasses various forms such as casting, welding, forging, additive manufacturing, and powder metallurgy, and it is widely applied in important defence fields such as aerospace. Porosity, inclusions, and voids are the main internal defects, which seriously affect the performance and reliability of high-end equipment. In recent years, with the continuous development of software and hardware, defect detection technology has made significant progress. Based on a brief review of the current status of defect detection technology, this article analyzed the major technical breakthroughs and scientific advancements achieved by various detection methods such as radiography, ultrasound, and fluorescence, discussed the future development trends and research directions of intelligent detection for metal components, and provided policy recommendations from four dimensions: standard system construction, core technology breakthroughs, process flow reengineering, and system platform construction, with the aim of providing theoretical and technical support for high-reliability detection of metal components in high-end equipment.

metal component  /  defect  /  detection  /  radiography  /  ultrasound  /  fluorescence
周建新, 计效园, 侯明君, 董淏, 段浩哲, 殷亚军, 沈旭, 李文. 高端装备金属构件成形缺陷智能检测技术进展与展望. 前瞻科技, 2025 , 4 (1) : 108 -117 . DOI: 10.3981/j.issn.2097-0781.2025.01.011
Jianxin ZHOU, Xiaoyuan JI, Mingjun HOU, Hao DONG, Haozhe DUAN, Yajun YIN, Xu SHEN, Wen LI. Progress and Prospect of Intelligent Detection Technology for Metal Component Forming Defects of High-end Equipment[J]. Science and Technology Foresight, 2025 , 4 (1) : 108 -117 . DOI: 10.3981/j.issn.2097-0781.2025.01.011
钛合金、镁合金、铝合金、高温合金等广泛用于航空、航天、航海、兵器等国防重要领域,是国家重点发展的高端材料,如歼31战机用钛占比25%[1]。随着国防高端装备对零件的轻质化、整体化、优质化、低成本和短制造周期等要求不断提高,航发机匣、导弹舱体等零件向结构复杂化方向发展。
铸造[2]、焊接[3]、锻造[4]、增材[5]、粉末冶金[6]等作为重要的金属成形工艺,在航空航天等高端制造领域中的应用日益广泛。然而,成形过程中由于材料特性、工艺参数、设备条件等多因素影响,金属构件中容易产生各种缺陷。这些缺陷包括气孔、夹杂、冷隔、飞溅物、孔隙、成分偏析等,如图1表1所示,严重影响装备的性能和安全性。
以精密铸造技术为例,其具有复杂结构的近净成形优势,成为国防高端装备的零件制造的关键成形技术之一。例如,精密铸造成形的某航空发动机钛合金机匣,最小壁厚2.5 mm,该零件集发动机气流通道、基座和承力部件于一体,同时是安装定位的基准,具备加强筋、凸台、径向孔、异型孔、异性槽等复杂结构,具有大尺寸、大壁厚差、薄壁、复杂曲面及内腔等特点,关键质量控制点近千个。类似地,异型薄壁结构的舱体类铸件也极具挑战性。其内壁型面结构多样、形式复杂,内部空间分布有球面、斜面凸台、薄壁框架等,壁厚由3~6 mm突变至40~60 mm。在成形过程中,因合金液补缩较为困难等因素,铸件关键位置易产生各类缺陷。对于高端装备的核心铸件,不允许有超标的气孔、缩孔、夹杂等缺陷,成形难度大,内部质量要求极高。
零件结构复杂化不但导致金属构件成形和内部质量控制难度上升,而且致使其内部、近表面和表面缺陷的无损检测更困难。难以精准高效识别和清除缺陷已经成为铸件等金属构件质量低、成本高、制造周期长的主要原因之一,也是严重制约装备的可靠性与寿命提高的主要瓶颈之一。如某单位对近3年生产的预压泵出口管的质量数据进行统计,平均合格率仅为58.62%。对导致产品报废的缺陷进行统计,结果显示:件构的主要缺陷为疏松缺陷,占比为83.30%,主要分布在小叶片、外环冒口根部、大叶片根部等最后凝固部位。
为保障国防高端装备安全性和可靠性,及时检测和消除缺陷是保障其性能的必要措施。X射线、超声、荧光等检测方法在工业实践中得到了广泛应用,但随着生产需求的不断增长,这些方法在检测效率、精度和自动化水平方面存在一定的局限。近年来,基于机械自动化、人工智能等的智能检测技术迅速发展,为金属构件缺陷检测提供了新的解决思路。
传统的可见光检测精度有限且仅能检测金属构件表面缺陷,已无法满足高精度和深层次缺陷检测的需求。因此,射线检测、超声检测和荧光检测等技术应运而生,能够有效识别金属成形过程中产生的表面、近表面、内部等的各类缺陷,极大提高了检测的精度和可靠性。这些技术的应用为高端装备制造提供了有力支撑。
射线检测技术作为无损检测的重要方法之一,利用X射线穿透材料的特性,通过分析射线在材料内部的衰减和散射情况来识别和评估内部缺陷。这种技术能够有效地检测金属、焊缝、复合材料等多种工件中的微小裂纹、气孔和夹杂物等缺陷,具有高灵敏度和深透视能力。随着科技的进步,射线检测技术正朝着数字化、智能化和高分辨率的方向发展。从传统的X射线检测到数字射线检测技术,再到中子相衬成像技术,这些技术革新显著提升了复杂工件和精密结构中微小缺陷的检测能力,并推动检测设备向自动化与智能化方向的发展。
在全球范围内,射线检测仪器市场规模持续稳定增长,特别是在航空航天合金材料成形领域应用广泛。亚洲、欧洲和北美是主要市场区域,技术发展尤为关键。国际市场上,X射线检测技术正朝精密化和数字化方向进步,尤其是在航空航天领域对X射线源的焦点尺寸要求较高,微焦点X射线源的应用成为实现精密检测的关键。日本滨松光子学株式会社(简称滨松集团)和美国赛默飞世尔科技公司(简称赛默飞世尔)等在射线检测领域占据重要地位,掌握了相关核心技术(图2)。随着市场需求的增长和技术进步,全球射线检测技术正朝着自动化、数字化和智能化方向发展,以提升检测效率和精度。
自20世纪初以来,中国射线检测技术在国家重大战略任务中的应用,如航空航天和核工业等领域,展现了积极的发展态势。近年来,随着国家对工业自动化和现代化重视程度的提高,射线检测技术得到了快速的发展,满足了高端制造业对检测精度和效率的严苛要求。在国家《智能检测装备产业发展行动计划》等政策支持下,射线检测技术正朝向核心零部件国产化、整机装备自动化、专用软件智能化方向发展,展现出强大的发展潜力和市场竞争力,为国家在关键核心技术领域的自主创新提供了有力支持。
超声无损检测技术自20世纪20年代开始发展,苏联科学家在1929年首次提出使用超声波检测金属内部缺陷的方法。然而,由于初期穿透式检测仪器的灵敏度低、应用范围有限,该技术很快被更先进的脉冲反射法取代。脉冲反射法及其相应仪器的出现,特别是在20世纪四五十年代,为超声检测技术注入了新的活力,使其能够更准确地定位和测量小缺陷。随后的技术进步,如20世纪60年代超声检测仪性能上的突破、70年代集成电路技术的发展,以及80年代末—90年代初计算机和信号处理技术的进步,推动了超声检测技术从模拟向数字转变,并催生了如超声衍射声时技术和相控阵技术等创新方法。
在全球范围内,超声无损检测技术由多家领先企业主导,包括日本奥林巴斯株式会社(简称奥林巴斯)、美国贝克休斯公司(简称贝克休斯)、英国声纳Sonatest公司(简称Sonatest公司)、美国捷特公司、法国M2M-Eddyfi Technologies集团等,相关超声探伤仪产品见图3。这些公司专注于研发、生产和销售高性能的超声检测设备,提供广泛的产品线覆盖多个工业领域。例如,贝克休斯以其全面的无损检测解决方案服务于全球石油开发和加工行业;Sonatest公司则因其高质量的超声波探伤仪、测厚仪和相控阵探伤仪而闻名。近年来,随着超声相控阵技术的引入,国外企业如美国通用电气(GE)传感与检测技术公司、西门子股份公司已成功商业化便携式及大型超声相控阵检测系统,极大提高了缺陷检测的效率和准确性。
中国自20世纪60年代起开展超声无损检测技术的研究与应用,经过几十年的发展,在理论研究和技术创新方面取得了显著成就,缩小了与国际先进水平的差距。目前,中国的超声检测技术应用几乎涵盖了所有主要工业领域,包括钢铁、机械制造、锅炉压力容器、石油化工、铁路运输、造船、航空航天和电力核电等。在技术创新方面,中国超声数字信号处理技术已取得显著进展,部分领域达到或接近国际先进水平。例如,在人工智能(Artificial Intelligence, AI)、神经网络、模式识别及多种扫描成像技术的应用上。
荧光检测技术主要用于金属构件表面和近表面裂纹、气孔等缺陷检测。其原理是通过荧光渗透剂在缺陷处的富集,在紫外光激发下发射可见荧光,从而实现对缺陷的可视化检测。该技术具有高灵敏度、非破坏性和操作简便等特点,广泛应用于航空航天、汽车制造等高端制造领域。近年来,随着高分辨率成像和自动化技术的引入,荧光检测在金属构件缺陷检测中的精度和效率显著提升。
国际上,欧盟、美国等国家和地区在金属构件缺陷荧光检测领域处于领先地位,已形成成熟的技术体系和高精度检测设备。例如,美国、德国等国家开发的自动化荧光检测系统结合了机器视觉和AI算法,能够实现复杂金属构件的高效、精准检测。此外,国外企业在荧光渗透剂配方、高灵敏度紫外光源及成像系统等核心技术上具有显著优势,主导了全球高端市场。
中国在金属构件缺陷荧光检测领域已实现中低端设备的国产化,并在部分应用场景中达到国际水平。例如,国内企业开发的便携式荧光检测设备在中小型金属构件检测中具有成本优势。然而,高端设备核心部件(如高灵敏度紫外光源和成像系统)仍依赖进口,检测精度和自动化水平与国外存在一定差距。未来,需加强核心技术的自主研发,推动高端设备的国产替代,并提升检测标准的国际化水平,以缩小与国外的技术差距。
在金属构件成形智能检测技术领域,国际发展态势呈现出显著的技术革新和市场扩张趋势。国际研究不断推动射线检测技术的进步,提供了新的技术路径和材料选择,显著提升了射线检测技术在灵敏度、分辨率和材料适用性方面的表现[7]。全球范围内,X射线智能检测装备正从离线型向在线型发展,以满足高效、实时检测的需求。
在中国,射线检测技术领域近年来的研究进展体现在多个理论和技术的发展上[8],射线检测行业的发展态势呈现出快速增长和技术进步的特点。随着产业数字化程度的加深,X射线检测设备与大数据、AI算法等技术紧密结合,检测精度逐渐提高,检测过程也逐渐向自动化方向发展。中国企业如无锡日联科技股份有限公司(简称日联)、丹东奥龙射线仪器集团有限公司(简称奥龙)在射线源及影像软件方面实现了自主研发生产,相关产品见图4。未来核心部件的全面国产化将进一步降低设备成本,实现设备供应链的安全和稳定。
在多数生产车间,射线探伤在整个生产流程中的智能化程度较低,难以真正融入“智能制造”流程。例如,探伤装备在进行图像采集时仍需人工依据经验控制机器进行拍片规划,智能化程度较低。为此,未来可针对大型金属构件开展智能拍片路径研究,通过分析金属构件三维模型特征并提取记录,根据铸造知识寻找缺陷频发部位,生成探伤路径规划程序,控制机械臂自动运作,解决人工依据经验拍片效率低下、关键部位易漏拍等问题。
此外,现有内部缺陷定位修复方式依赖于人工判断和操作,导致效率低且易伤害金属构件本体,如图5所示。未来可开展基于多角度X射线探伤图像的金属构件缺陷三维智能定位研究,揭示二维与三维坐标间的转换规律,解决依赖人工多次拍片探索的问题。
近年来,随着图像处理[9]、机器学习[10]、深度学习[11]等技术的快速发展,以及数字图像采集设备、图形处理器等硬件性能的不断提升,基于深度学习的缺陷检测技术已成为工业质检领域的研究热点。在金属构件内部缺陷检测方向,研究者围绕样本增广、定位分割、分类评级3个核心环节开展了系统性研究,为构建智能评片系统奠定了技术基础。
首先,在样本增广方面,深度学习模型的泛化能力与训练样本规模显著正相关。针对金属构件X射线图像数据稀缺的行业痛点,研究者通过数据扩增技术[12-14]有效提升了缺陷检测模型的鲁棒性。其次,在定位分割环节,早期研究多采用基于图像底层特征的阈值分割、边缘检测等传统算法[15-16],而自2017年起,基于深度学习的语义分割方法逐渐成为主流[17-18],其通过生成掩模图像或包围框实现缺陷的精准定位,为后续评级提供空间维度信息。最后,在分类评级阶段,研究范式已从人工特征设计[19-20]转向深度神经网络结构优化[21-22],通过改进卷积神经网络(Convolutional Neural Networks, CNN)的层级结构与注意力机制,显著提升了孔松、夹杂等复杂缺陷的识别准确率。
以华中科技大学华铸团队为例,针对样本增广[23]、缺陷检测开展研究,提出一种结合过滤选择性搜索和均布式CNN的铸造缺陷检测与识别方法[24],以及一种基于改进教与学算法的缺陷图像阈值分割方法[25],可实现轻合金铸件典型缺陷的自动检测识别,验证了自动评片的可行性,并开发了轻合金复杂铸件X射线探伤自动评片系统——华铸FDI(InteCAST Flaw Detection and Identification),如图6所示。值得注意的是,当前X射线检测仍存在技术代际差异:传统胶片成像凭借高分辨率和直观影像优势,仍是缺陷判读的主要依据;而数字成像技术虽具有实时性优势,但在图像评片稳定性方面仍需突破。
为实现全流程数字化升级,未来研究可从3个维度展开:① 研制X射线胶片冲扫一体化装置,通过集成胶片冲洗与数字化扫描环节直接生成DCM(Digital Imaging and Communications in Medicine, DICOM)格式图像,如图7所示;② 开发基于强化学习的自适应调窗算法,动态优化窗宽/窗位参数以增强图像特征表现;③ 建立无参考质量评估体系,通过量化指标客观评价图像增强效果。该技术路径将有效贯通“物理胶片-数字图像-智能分析”的全链条,为铸造缺陷的全自动智能评级提供高质数据支撑。
在制造业智能化转型的驱动下,以超声、荧光为代表的先进无损检测技术正加速与人工智能、物联网等技术深度融合。这种技术协同效应不仅提升了检测精度与效率,更为航空航天等提供了关键质量保障手段,有力支撑着中国产业升级与高质量发展。
以超声检测为例,其技术演进呈现“算法突破”与“设备创新”双轮驱动格局[26-29]。算法层面,自适应波束形成等新型信号处理技术,结合机器学习驱动的缺陷特征提取方法,显著提升了检测效率与可靠性。设备研发方面,国内企业已突破关键技术壁垒:如图8所示,广东汕头超声电子股份有限公司超声仪器分公司研发的CTS-PA322T型相控阵全聚焦实时3D超声成像系统实现了实时3D全聚焦成像检测;西安金波科技有限责任公司推出的激光超声波可视化检测仪(Laser Ultrasonic Visualizing Inspector, LUVI)系列产品首创超声波传播过程的可视化监测,其缺陷识别精度达国际领先水平。尽管国内已涌现出广州多浦乐电子科技股份有限公司、武汉中科创新技术股份有限公司等代表性企业,但相比奥林巴斯、贝克休斯等国际巨头,国产设备在自动化集成度方面仍存在提升空间。
当前,超声、荧光等无损检测与AI标记系统的协同自动化水平较射线检测仍显不足。这种技术差距主要体现在两方面:一方面,检测数据的智能解析能力有待加强,现有系统多依赖人工经验进行缺陷判定;另一方面,检测-反馈-优化的闭环控制尚未完全实现。因此,未来需重点突破缺陷自动识别、多模态数据融合等关键技术,同时加强行业标准体系建设。通过将全聚焦技术、激光超声等创新成果与具体工程场景深度耦合,中国有望在无损检测智能化领域实现弯道超车,进而提升在全球高端检测装备市场的话语权。
为推动高端装备金属构件检测技术向智能化、数字化转型升级,建议从标准体系构建、核心技术攻关、工艺流程再造、系统平台建设4个维度完善政策支持体系。通过制定智能检测技术路线图、设立产业共性技术研发专项、搭建产学研用协同创新平台等政策组合拳,重点突破检测路径规划、缺陷三维定位、胶片数字化处理、多模态数据融合等关键技术瓶颈,加速形成覆盖“工艺研发-装备研制-系统集成-应用示范”全链条的智能检测创新生态。
针对大型复杂金属构件人工拍片效率低、覆盖率不足等问题,建议由工业和信息化部牵头制定智能射线检测路径规划技术规范,引导行业开展以下攻关。
(1)质量关键点搜寻:构建基于数值模拟、大数据分析的缺陷概率分布图谱,并结合三维结构确定质量关键点,建立其与检测路径的映射关系;
(2)机械臂轨迹优化:研发强化学习驱动的多轴协同运动规划算法,实现曲面、盲孔、大壁厚差等复杂结构自适应扫描覆盖;
(3)工艺知识库建设:整合历史缺陷数据库与专家经验规则,开发可解释的路径决策支持系统。
通过标准试点示范项目,在航发机匣、航天舱体等典型产品中验证路径规划算法,3年内实现新品检测效率提升30%、漏检率降低至0.5%以下。
为解决二维DR图像定位精度低、损伤构件本体等问题,建议科技部设立“金属构件缺陷智能三维定位”重点研发计划,鼓励从多视角成像技术、三维重建算法、无损验证系统等角度开展攻关,研制可编程多角度射线源阵列,开发投影几何参数自标定算法;构建领域知识与深度学习驱动的缺陷三维重建模型,实现亚毫米级定位精度;开发机械臂自动打标记录装置,验证缺陷位置信息并建立缺陷三维信息数字化档案库。
专项实施周期内,以航空航天领域为示范,应完成5类典型构件的工程验证,定位误差控制在±5 mm以内,减少90%以上破坏性验证操作。
为突破传统胶片处理效率低瓶颈,实现胶片图像缺陷智能检测和数字化归档,建议工业和信息化部将“射线胶片全流程数字化装备”纳入首台套重大技术装备目录,支持研制暗室环境自适应冲扫一体机,集成化学药液循环系统和扫描模块,并开发胶片降噪增强算法和质量量化评价体系,制定数字化胶片处理工艺规范,实现从显影定影到数据分析的闭环管控。
通过财政补贴支持航空航天等重点单位进行设备升级,推动胶片数字化处理速度提升3倍,图像可用率达99%。
建议组建“智能检测技术与装备创新联盟”,将智能检测技术与DeepSeek等大模型结合,重点建设多源数据融合、智能算法研发、应用示范验证平台,构建集成X射线、超声、荧光等检测方法的百万级缺陷特征数据库,建立多模态缺陷自动识别评价算法。利用自监督和无监督学习方法,减少对标注数据的依赖,提升多模态数据融合的灵活性和适应性。同时,可探索跨模态迁移学习技术,将一种模态的学习成果迁移到另一种模态,提升多模态检测的协同效果。
金属构件缺陷检测是确保零件质量的重要环节,随着检测技术的不断进步,已取得显著的研究成果。传统的无损检测技术,尤其是射线检测和超声检测,仍在工业实践中发挥着重要作用。而新兴的X射线图像技术与深度学习驱动的缺陷自动检测,展现出了强大的发展潜力,特别是在自动化、智能化和多模态检测方面。未来,随着探伤路径规划、缺陷三维定位、胶片冲扫一体化、多模态融合与数据驱动检测等技术的进一步发展,构件缺陷检测将朝着更加高效、精准和智能化的方向发展。持续的技术创新和跨学科研究,将为构件质量控制提供更加坚实的理论基础,进而有力支持航空航天等高端装备复杂金属构件的高质量研制与高可靠检测。
  • 国家自然科学基金(52275337)
  • 国家自然科学基金(52090042)
  • 国家重点研发计划(2020YFB1710100)
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doi: 10.3981/j.issn.2097-0781.2025.01.011
  • 接收时间:2024-12-23
  • 出版时间:2025-03-20
  • 发布时间:2025-03-27
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  • 收稿日期:2024-12-23
  • 修回日期:2025-02-28
基金
国家自然科学基金(52275337)
国家自然科学基金(52090042)
国家重点研发计划(2020YFB1710100)
作者信息
    华中科技大学材料成形与模具技术全国重点实验室,武汉 430074

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表12种不同金属材料的力学参数

Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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