基于超声相控阵的轨头缺陷检测研究
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华东交通大学机电与车辆工程学院、华东交通大学轨道车辆智能运维技术与装备江西省重点实验室

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国家自然科学基金(52065021);江西省领军人才项目(S2021GDKX1442);江西省基金项目(20242BAB26086,20224BAB204042, 20252BAC240051);国铁集团科技研究开发计划课题(2024YJ081,N2024G028)


Research on Rail Head Defects Based on Ultrasonic Phased Array
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    摘要:

    针对钢轨轨头内部隐性缺陷检测中成像分辨率及深度定量精度受限的问题,提出面向轨头缺陷的超声相控阵检测与成像优化流程。基于COMSOL建立轨头二维声场模型,分析阵列参数对聚焦声束分布的影响并优选探头参数组合;采用全矩阵捕获获取检测数据,结合全聚焦成像,提出归一化降噪、Hilbert变换与TF-PCF加权结合的成像优化策略;在P60钢轨试块轨头区域预制平底孔缺陷开展试验,并与仿真结果进行对比验证。结果表明:32阵元、阵元间距与波长比为0.5、阵元宽度与阵元间距比小于0.5、偏转角不超过45°时成像效果较优;优化后的成像结果可以抑制噪声与伪像,实现缺陷定位及定量测量,其中孔长误差不超过10%,垂向深度误差不超过5%。该研究可为轨头缺陷超声相控阵检测的高分辨成像与缺陷定量评估提供理论依据。

    Abstract:

    To address the limited imaging resolution and depth-quantification accuracy in the detection of hidden defects within the rail head, an ultrasonic phased-array detection and imaging-optimization procedure for rail-head defects is proposed. A two-dimensional acoustic-field model of the rail head is established in COMSOL to investigate the influence of array parameters on the focused beam distribution and to optimize the probe-parameter set. Inspection data are acquired using Full Matrix Capture (FMC) and reconstructed by the Total Focusing Method (TFM), and an imaging-optimization strategy combining normalization-based denoising, the Hilbert transform, and TF-PCF weighting is introduced. Experiments are conducted on a P60 rail test block with prefabricated flat-bottom-hole defects in the rail head, and the results are validated by comparison with simulations. The results show that improved imaging performance is obtained with 32 elements, an element-pitch-to-wavelength ratio of 0.5, an element-width-to-pitch ratio below 0.5, and a steering angle not exceeding 45°. The optimized imaging suppresses noise and artifacts and enables defect localization and quantitative measurement, with a hole-length error within 10% and a depth error within 5%. This study provides a theoretical basis for high-resolution imaging and quantitative evaluation of rail-head defects in ultrasonic phased-array inspection.

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  • 收稿日期:2025-11-28
  • 最后修改日期:2026-01-27
  • 录用日期:2026-02-15
  • 在线发布日期: 2026-03-20
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