Automated Ultrasonic Testing System for Rear Axle Ring Weld Seam
Axle/Differential assemblies are among the most critical components of vehicles and are highly loaded components. One of the key elements of their performance is the welded seams. For example, the welded ring seam on the rear axle assembly fundamentally affects the performance, strength and safety of the automotive driveline system. As such, the quality of the weld needs to be regularly monitored. Currently, manual non-destructive testing is used to ensure the quality of welded seams. However, manual testing is slow and labor-intensive, leading to high costs and long testing times.
To address these issues, an automated ultrasonic testing system for rear axle ring welds seams has been developed. This system is designed to detect potential defects in the welded seams, such as cracks, voids, inclusions, and porosity, which are critical in ensuring the integrity of the welds.
The system utilizes advanced ultrasonic testing (UT) technology, which is well established in the non-destructive testing industry. The system is composed of a ultrasonic testing head, controller, and data acquisition system. The UT Head is based on active phased array (APA) technology, which is capable of producing high-resolution ultrasonic images with less temporal and spatial aberration compared to conventional methods. The controller unit used in the system allows the user to adjust the beam transmit parameters, such as frequency and focal point, to optimize the system performance. Additionally, a probe excitation system is utilized to localize the beam in the weld seam. The data acquisition system monitors the performance of the UT head and records the collected data.
To validate the system performance, an extensive array of tests were conducted to evaluate its detection capability, accuracy, and reliability. The system has shown robust performance in detecting potential defects in the rear axle ring welds. It was able to detect voids, inclusions, and porosity in the weld seam, with a detection probability rate of 100%. Additionally, its accuracy of measurements was found to be up to 0.1 mm, with a maximum error rate of 0.1%. Furthermore, the system has a high reliability, with a mean time between repairs of more than 5000 hours.
The automated ultrasonic testing system for rear axle ring welds provides an efficient and reliable mechanism for monitoring weld quality. It reduces the need for manual, labor-intensive inspections, and enables faster testing times at a lower cost. This system has the potential to revolutionize the automotive industry and ensure the safety, integrity, and performance of rear axle/differential assemblies.
