航空发动机整体叶盘作为发动机构件中的关键部分，其质量是影响发动机性能的关键因素。在整体叶盘的制造和使用过程中，由于工艺条件的不完备以及使用环境的影响，很可能会产生缺陷。为了保证整体叶盘使用的安全可靠，降低意外事故的发生，对其进行质量检测与评价具有重要意义。在实际工程应用中，由于整体叶盘的结构复杂，超声检测多应用于叶盘的坯料阶段，而对后续加工所产生的缺陷检测困难，并对成品叶盘的检测也较难实现。为了补充常规检测方法的不足，论文提出构建航空发动机整体叶盘超声检测系统的方法，重点研究以下内容：针对整体叶盘结构复杂、叶片为变厚度曲面工件的特点，展开对多轴机械联动系统的设计；依据整体叶盘的超声检测要求，展开对高检测精度、高信噪比系统的设计与研究；根据需要对叶片进行自动化表面跟踪检测的要求，展开对电气运动控制系统和基于d-Bezier模型的曲面反求与路径规划算法的设计与研究；设计实验获得检测结果，并对检测结果进行分析与评价。论文设计并研制了结构紧凑、高精度的9轴机电系统，该系统具有5轴联动功能；开发了检测系统的专用软件，实现了超声成像、超声探头参数调整、运动控制、叶盘曲面反求和检测路径规划等功能；开展了相关检测实验。实验表明：论文所研制的9轴机械系统，XYZ轴的绝对定位精度小于±0.05mm，重复定位精度小于±0.025mm，AB轴的绝对定位精度小于±0.1°，重复定位精度小于±0.1°，并可实现5轴联动；论文利用超声测距法结合d-Bezier曲面模型实现了对叶片的曲面反求，曲面拟合平均误差小于0.45mm，满足预期的精度要求，证明了曲面反求算法的精确性；论文实现了对叶片检测的路径规划，并通过5轴联动功能实现了对叶片的检测，验证了路径规划算法的有效性；系统成功检测出标准铝试块中直径为0.3mm的平底孔，证明具有较高的检测精度，达到了实际工程应用的技术指标，还成功检测出了叶盘内环部分与叶片部分的缺陷，证明了系统的性能。

As a key part of aero-engines, the blisk’s quality highly affects engine performance. There may be some flaws such as crack and slag during fabrication and/or operation. In order to secure work efficiency and reduce accidents, the inspection of blisk is significant. Because of complex shape, it is difficult to realize ultrasonic automatic detection and current method only can be used in the manufacturing stage.Based on hereinbefore problem, a new ultrasonic immersed testing system for blisk including hardware and software has been developed. This paper will introduce how to set up such an ultrasonic immersed testing system and emphasize on such topics as the following:Firstly, a novel high precision mechanical testing system equipped with multi-axis motion controlled and high-speed data acquisition card has been developed.Secondly, a surface reconstruction algorithm and a scan trajectory planning algorithm based on STL file have been developed which makes the scan path assignment much more effectively.Thirdly, a blisk has been tested to verify the new system’s functionality and performance, also a 3D imaging algorithm has been designed to describe flaws of blisk.Test result shows that the new system satisfies the requirements of blisk testing in field. The new system can distinguish the flat-bottomed hole whose diameter is 0.3mm in aluminum specimen which fulfills the scale requirement in field. The new system not only can inspect flaws of blisk via A scan and C scan, but also can image the flaws in a 3D way, which is helpful to refine the fabrication technique. The new system can reconstruct the blisk’s surface and assign the scan trajectory via the STL file which is appreciated in field as the blisk in aerospace vary from size. Furthermore, the system can control a probe track a blade’s surface.