再制造抽油杆疲劳寿命评估的磁记忆检测实验研究

废旧零部件寿命评估一直是再制造工程的技术难点之一。通过对预制沟槽抽油杆试件的拉-拉疲劳实验,利用磁记忆检测仪在线测量试件表面在不同循环次数下的磁记忆信号,研究抽油杆疲劳损伤演化的切向幅值和法向峰峰值变化规律。通过引入李萨如图,表明随着循环的进行所围成的面积由变大到最大后又逐步减小,而非闭合图形面积达到最大时正好对应着宏观裂纹即将发生失稳扩展的临界状态。在此基础上,提出切向法向合成磁场梯度最大值作为预测疲劳寿命的指标,结果表明该特征参数与疲劳循环发展的不同阶段相对应,基于高斯函数拟合建立了其与归一化寿命之间的定量关系模型,可用于抽油杆的疲劳寿命预测。     

疲劳损伤磁性无损评估技术研究现状及发展前景

磁性无损检测技术是评估铁磁材料疲劳损伤以及重要结构件可靠性的重要检测手段。针对铁磁材料的疲劳损伤,介绍了几种典型的磁性无损检测技术,如磁巴克豪森噪声(MBN)、磁声发射(MAE)、漏磁(MFL)和金属磁记忆(MMM)等,对其产生机理及应用特点进行了概述;对几种磁性检测技术在疲劳损伤评估领域的研究现状以及取得的主要研究成果进行了综述;最后指出几种技术尚存的问题和进一步的研究方向,并对其发展前景进行预测。     

提高漏磁法检测抽油杆疲劳裂纹灵敏度的新方法

采用漏磁法可检测抽油杆表面存在的各种缺陷,但对于在现场检测的抽油杆表面却存在油污(虽然经过清洗)、表面粗糙及直线度低(虽然经过矫直)等问题,使得检测过程中的检测探头与被检测的抽油杆接触不严密,造成对微小缺陷特别是疲劳裂纹的检测信号不敏感.研制了拉伸式管/杆漏磁无损检测实验台,对拉伸实验杆预制疲劳裂纹并对其进行了检测试验,结果采集到了更大的疲劳裂纹信号,因此用该方法提高了漏磁法检测抽油杆疲劳裂纹的灵敏度.     

基于统计学方法的热喷涂层滚动接触疲劳寿命研究现状

热喷涂层是对可再制造零件进行修复,并恢复其性能的一种重要手段。通过热喷涂技术获取的再制造零件,其表面接触疲劳主要表现为热喷涂层的滚动接触疲劳问题。目前,依据统计学方法常被用于热喷涂层滚动接触疲劳寿命研究的模型主要有:Weibull模型、疲劳曲线模型、理论预测模型和回归分析模型。从统计学理论及应用的角度出发,总结了各种方法研究和应用现状,对基于统计学方法提高热喷涂层滚动接触疲劳寿命预测的精确度和可靠性进行了展望。     

SA335-P22钢主蒸汽管道非破坏性剩余寿命评估方法

通过宏观检验、多种无损检测方法以及现场硬度测试和金相覆膜方法,对累计运行已超过113 000h的SA335-P22钢主蒸汽管道进行了检测,并结合Larson-Miller公式预测法和蠕变损伤级别分类法共同对该主蒸汽管道进行了非破坏性剩余寿命评估,得出该管道的剩余寿命不超过105 937h。该试验结果可为电厂运行人员提供参考。     

多轴载荷下缺口件的疲劳寿命估算方法

提出了一种多轴载荷下缺口件的疲劳寿命估算方法。该方法基于临界平面理论,计算出缺口件各部位的多轴疲劳损伤参数,以损伤参数最大的部位为缺口件的多轴疲劳危险点。根据临界距离思想,提出了热点法和线法的临界距离的计算方法,采用热点法和线法考虑缺口件疲劳危险点附近损伤梯度的影响,以临界距离修正的损伤参数计算多轴载荷下缺口件的疲劳寿命。采用SAE1045钢缺口件的多轴疲劳试验对该文提出的寿命估算方法进行评估和验证,结果表明:该文所建立的寿命预测方法具有较好的预测能力,预测结果大部分分布在试验结果的3倍分散带之内。     

船舶工程焊接接头完整性评估与疲劳寿命预测技术综述

介绍了船体结构中含缺陷的焊接接头完整性评估以及疲劳寿命预测方法，对结构完整性评估的K准则、COD准则、J积分准则、SINTAP/FITNET安全性评定方法以及评定流程、国内外标准进行介绍。并对焊接接头的疲劳强度影响因素，如平均应力、残余应力以及接头几何形状应力集中等进行了分析；介绍了焊接接头疲劳寿命预测的常用方法，如基于名义应力的评估方法、基于断裂力学的评估方法、基于损伤力学的评估方法以及其它疲劳评估方法等。此外，还对基于断裂力学法建立的焊接残余应力与疲劳裂纹扩展寿命之间的函数关系进行了介绍，该方法实现了对含残余应力的焊接结构疲劳寿命的精确预测。     

基于声发射技术的热障涂层损伤行为

热障涂层以优异的隔热、耐磨和耐蚀性而被广泛应用于航空涡轮发动机中。由于热障涂层体系内部结构复杂,服役环境苛刻,导致其失效不可预测。热障涂层系统内的表面开裂和界面分层是限制热障涂层长时间使用的瓶颈问题,且热障涂层的过早剥落失效会导致合金基体暴露在高温燃气中,这可能引起灾难性的后果。针对涂层的裂纹扩展行为,最重要也最直接的研究方法就是对热障涂层的整个失效过程进行实时无损检测,为寿命预测提供最直接的证据。声发射技术是一种实时动态的无损检测方法,可直接检测热障涂层失效过程中的裂纹扩展行为,因此在热障涂层失效检测领域得到了广泛的应用。然而,造成热障涂层损伤失效的因素较多,如失效机理复杂、失效形式多样,以及声发射信号本身的随机性和不可逆性,使得利用声发射技术检测热障涂层失效整个过程的研究还不够全面。目前,已通过声发射技术的参数分析和波形分析实现了对热障涂层损伤失效的定性、定量和定位分析,并对涂层寿命进行了预测。参数分析是以多个简化的波形特征参数来表示声发射信号的特征,即对一些特征量进行统计的过程,如能量、频率、幅度等。采用声发射特征参数法可定量评估热障涂层的损伤程度并对涂层的寿命进行预测。目前人们从连续损伤累计、某一特定参量变化等多个角度预测热障涂层的寿命,但是各种寿命预测模型主要是根据实验结果的经验或半经验公式,随着热障涂层的发展以及对热障涂层失效机理认识的不断加深,寿命预测模型也在不断发展与完善。波形分析是通过对声发射信号的时域波形或频谱特征分析来获取缺陷信息的一种信号处理方法。从理论上讲,波形分析应当能给出任何所需的信息,因而波形也是表达声发射源特征最精确的方法,目前主要通过小波变换把声发射波形信号从时域变换到频域,进而识别其损伤模式并实现声发射源的定位。本文对声发射技术进行了简要的介绍,总结了声发射技术参数分析和波形分析在热障涂层损伤模式识别、损伤位置的定位、损伤程度的定量评估和剩余寿命预测方面的研究进展,指出了当前研究中存在的问题并对其下一步的发展进行了展望。     

Lamb波的交叉递归分析在金属板损伤量化中的应用EI北大核心CSCD

针对金属板疲劳损伤演变的非线性动力学特性,提出了基于Lamb波交叉递归分析的疲劳裂纹量化检测方法。该方法首先从结构动力学角度采用交叉递归图分析了损伤信号与无损信号在相空间中的非线性相关性,并在此基础上采用了交叉递归量化分析(cross-recurrence quantification analysis, CRQA)特征对Lamb波信号中的裂纹损伤进行表征。接着,结合CRQA特征的状态相关性、单调性、鲁棒性及特征间的关联性进行特征的优化选择,采用支持向量描述模型对优选特征进行了融合,构建了金属板疲劳损伤的统一量化指数。最后,采用铝板随机裂纹仿真试验与铝板弯折试验对该研究提出方法进行了验证。结果表明,基于Lamb波交叉递归分析的损伤评估方法突破了Lamb波的多模态性、散射性、损伤波包的微弱性造成的损伤特征提取困难的问题,不仅能够对金属板疲劳损伤进行有效的量化评估,还具有较好的噪声鲁棒性,在复杂结构疲劳损伤检测与评估领域具有较好的应用前景。     

工业CT技术应用介绍及其在再制造中的展望

主要介绍了工业CT系统的基本组成部件和影响工业CT检测的关键性能指标,及工业CT在物品检测、地质研究、疲劳裂纹检测、快速成型和逆向工程等实际工程方面的应用情况,展望了工业CT在再制造零部件寿命预测、再制造产品的安全验证和再制造产品的推广前景.     

基于磁记忆方法的抽油杆裂纹扩展监测

基于拉-拉疲劳实验,利用磁记忆检测仪监测了抽油杆试件疲劳裂纹扩展的整个过程,提取了表征应力集中程度的磁信号合成梯度极限状态系数指标;并结合有限元方法计算了裂纹尖端的断裂力学参量,得到不同裂纹长度所对应的应力强度因子。结果表明:基于实验数据和仿真结果所建立的磁记忆信号特征指标与应力强度因子之间具有很好的一致性,可以有效反映疲劳裂纹的扩展过程以及累积损伤,为再制造前的毛坯筛选提供理论依据。     

Non-destructive evaluation of fatigue and creep-fatigue damage by means of the induced-current focused potential drop technique

Quantitative evaluation of damage accumulation including crack initiation and propagation is one of the major concerns of industrial plant management and plant licence renewal. In order to develop a novel non-destructive testing (NDT) and non-destructive evaluation (NDE) technique for damage evaluation, the induced-current focused potential drop (ICFPD), originally proposed for a defect inspection, was employed. In this study, ICFPD was successfully applied to a non-destructive damage evaluation based on crack measurements. The measurements were taken on fatigued specimens with various degrees of fatigue damage. The ICFPD can clearly detect and differentiate the damage accumulation processes including crack initiation, small crack growth and subsequent macroscopic crack growth. In order to demonstrate the applicability of damage evaluation assessments based on small crack measurements, ICFPD has also been applied to creep–fatigue loading where damage evaluation of a fusion reactor material is based on small crack measurements by the ICFPD technique and a novel methodology is proposed.     

Effects of local fibre waviness on damage mechanisms and fatigue behaviour of biaxially loaded tube specimens

Damage development in and final failure process of glass fibre winding specimens during biaxial fatigue loading are investigated. The phenomena in nominally defect-free tubes and specimens exhibiting local fibre waviness in one layer are compared. A subset of wound tubes is analysed using non-destructive testing methods, i.e. air-coupled guided waves, thermography, optical fracture analysis by a high-speed camera, and discrete damage monitoring. Air-coupled guided waves are employed for detection of fibre waviness and for monitoring the failure progress initiated by this waviness. Stiffness degradation due to fatigue damage corresponds to a decline in guided wave velocity. Using infrared inspection, the fibre waviness can be detected in an early stage of fatigue life. Non-destructive evaluation reveals that initiation of final failure in the specimens is caused by local fibre waviness. Finally, the effect of local fibre waviness on the S–N curves of the specimens is illustrated.     

Fatigue limit evaluation of metals using an infrared thermographic technique

The paper aims to illustrate three advantages of infrared thermography as a non-destructive, real-time and non-contact technique. It permits first observation of the physical processes of damage and failure in metals, and in particular, automotive components subjected to fatigue loading, second detection of the occurrence of intrinsic dissipation, and third evaluation of the fatigue strength in a very short time, compared to traditional testing techniques. In addition, infrared thermography readily describes the damage location and the evolution of structural failure.     

电阻点焊质量检测技术研究现状

电阻点焊过程由于受到各种因素的影响,熔核区域容易出现裂纹、缩孔、未熔合等缺陷,焊点质量直接影响焊接部件的使用寿命,因此对焊点的缺陷检测与质量评定非常重要.对电阻点焊原理进行概述,总结了电阻点焊质量检测技术最新研究成果及应用,分析了焊接过程参数监控方法、焊后无损检测方法的检测机理、质量评定方法及其在实际应用中的优缺点,对...     

Role of microstructure in sucker rod string failures in oil well production

Sucker-rod pumps are operating in very aggressive environments in oil well production. The combined effect of a corrosive environment and significant mechanical loads contribute to frequent cases of failure of the rod string during operation. Standards and recommendations have been developed to control and avoid those failures. This study presents various failure cases of sucker rods in different applications. The heat treatment of the steel material and the resulting microstructure are an important factor in the behavior of the sucker rod. A spheroidized microstructure presents a weaker resistance to corrosion affecting the rod life. Non-metallic inclusions are a pitting preferential site leading to fatigue crack initiation. Heterogenous microstructure as banded martensite and ferrite/pearlite decreases the ductility of the material affecting the fatigue propagation resistance.     

Non-destructive fatigue damage characterization of laminated thermosetting fibrous composites

The fatigue behaviour of the laminated thermosetting Fiberdux 6376-HTA composite material is studied experimentally for both constant and variable amplitude stress reversal loading. The fatigue-induced material degradation is correlated to non-destructive evaluation data obtained from C-scan graphs through the concept of the damage severity factor ( DSF ). The DSF is able to account for the varying severity of damage at the different specimen locations and is used to quantify the fatigue-induced damage. The concept of the DSF , introduced earlier by the authors for constant amplitude fatigue loading of thermoplastic fibrous composites, is applied to characterize fatigue damage of thermosetting fibrous composites and is extended to account for variable amplitude loading. Constant amplitude fatigue tests at various stress levels were performed to correlate fatigue damage to the change of mechanical properties, such as axial stiffness, residual tensile strength and interlaminar shear strength, and to develop expressions to relate DSF to the degradation of the mechanical properties with increasing fatigue damage. Correlation between DSF evolution and consumed fatigue life is made and fatigue damage functions involving stress amplitude dependency are formulated. These expressions together with a modified rainflow method are then used to assess fatigue life under variable amplitude fatigue loading; computed fatigue lives are compared against experimental results.     

Failure Analysis and Design Optimization of the Steady Rest Hanger Rod Pipe Assembly

This article investigates the failure of the steady rest hanger rod pipe assembly weld joints of an automotive exhaust system. Rig testing of the exhaust system showed the presence of crack at the steady rest hanger rod and brace weld joints. Metallurgical investigation was performed in order to determine the root case of failure and contribution factors. Metallurgical analysis methods included visual examination, thickness measurements, optical and scanning electron microscopy, chemical analysis of the material and weld evaluation. A CAE analysis was performed to simulate the rig test. Finite element simulation of the system also showed high damage at the steady rest hanger and brace weld locations. A DOE study was conducted to identify the design variables that could impact the dynamic response of the system like the thickness of the parts, the weld characteristics of joints, etc. Design changes were proposed; to improve the fatigue life of steady rest hanger rod pipe assembly based on the results of DOE-based study. The new design was analyzed using finite element analysis and compared with the original design for fatigue life, which showed a considerable improvement in the durability of the joint.     

Beitrag zum Lebensdauerverhalten und zur zerstörungsfreien Bewertung geschweißter und fehlerbehafteter ultrafester Stähle

Relationship between fatigue behaviour and non-destructive assessment of weld defects of TIG-welded ultra-high strength steels With respect to the influence of welding defects on the fatigue properties of welded high strength special steels and on the dynamic load carrying capacity of joints in welded constructions, a minimum of information is available. For this reason, the preparation of an assessment standard for classifying weld defects was considered practical, whereby the character of the defects was to be determined using non-destructive testing methods. The investigations were concerned with a special method of producing specimens containing defined and reproducable defects, with the characterization of the defects using X-ray and ultrasonic techniques, and with the determination of the influence of the weld defects on the fatigue strength of TIG-welded joints. As a result of the investigations, a relationship between allowable and critical defect size with respect to an assessment standard has been sought. By introducing weighting factors for various types and sizes of defects occurring in welds the efficiency of non-destructive testing methods for the assessment of weld defects is considerably increased.