Metal magnetic memory testing for early damage assessment in ferromagnetic materials

In order to investigate the physical mechanism of metal magnetic memory testing, both the influences of earth magnetic field and applied stress on magnetic domain structure were discussed. Static tension and fatigue tests for low carbon steel plate specimens were carried out on hydraulic servo testing machine of MTS810 type and magnetic signals were measured during the processes by the type of EMS-2003 instrument. The results indicate that the initial magnetic signals of specimens are different before loading. The magnetic signals curves are transformed from initial random to regular pattern due to the effect of two types of loads. However, the shape and distribution of magnetic signal curves in the elastic region are different from that of plastic region in tension test. While in fatigue test those magnetic signals curves corresponding to different cycles are similar. The H _p(y) value of magnetic signals on the fracture zone increases dramatically at the breaking transient time and positive-negative magnetic poles occur on the two parts of fracture zone. Foundation item: Project(50235030) supported by the National Natural Science Foundation of China     

塑性变形条件下拉伸构件的磁记忆效应

通过对经退磁处理的光滑和切口试件在不同程度拉伸变形下的在线磁信号的测量,研究了塑性变形对磁记忆效应的影响.光滑试件在弹性和均匀塑性流动阶段磁场分布近似为斜直线,仅到颈缩后才在应力集中部位产生明显的磁场畸变;切口试件在屈服以后即出现畸变特征,基于位错理论分析了异常波波高增加的原因,利用磁信号水平线图可定性判断应力集中区破...     

Metal magnetic memory signals from surface of low-carbon steel and low-carbon alloyed steel

In order to investigate the regularity of metal magnetic signals of ferromagnetic materials under the effect of applied load, the static tensile test of Q235 steel and 18CrNiWA steel plate specimens were conducted and metal magnetic memory signals of specimens were measured during the test process. The influencing factors of metal magnetic memory signals and the relationship between axial applied load and signals were analyzed. The fracture and microstructure of the specimens were observed. The results show that the magnetic signals corresponding to the measured points change linearly approximately with increasing axial load. The microstructure of Q235 steel is ferrite and perlite, whereas that of 18CrNiWA steel is bainite and low-carbon martensite. The fracture of these two kinds of specimens is ductile rupture; carbon content of specimen materials and dislocation glide give much contribution to the characteristics of magnetic curves.     

Characteristics of magnetic memory signals for medium carbon steel under static tensile conditions

To test the magnetic signals leaked from the surface of specimens during loading, the experiments of the static tensile of medium carbon 45^# steel were carried out. The results show that the magnetic field strength values rapidly vary when the load began, and the curves of the magnetic field strength change from irregularity to regularity with the increase of the load. Furthermore, by comparing with the state of on-line testing, it is found that the magnetic signals of out-of-line testing has more practicability. In the course of loading, though the dots of passing zero of the magnetic field strength continually changed their positions and quantities, the last rupture places were always approached by the dots of passing zero since the elastic loading phase. Some certain relations should exist between external stress and changing of magnetic signals inside the material, and correlative explanation is made based on dislocation theory and the mechanism of magnetic domain action, which provides the basis for further research of magnetic memory. Foundation item: Project(50235030) supported by the National Natural Science Foundation of China     

高载旋转弯曲疲劳损伤的磁记忆检测

为寻找高载旋转弯曲疲劳破坏前的特征信号,基于磁机械效应及磁场叠加原理进行理论研究,在此基础上,对带环形缺陷的45号钢试件进行高载旋转弯曲疲劳试验,研究疲劳过程中试件表面的磁信号的法向分量的分布变化.理论分析表明,疲劳裂纹附近的磁信号分布随裂纹扩展而变化.实验结果显示在进入裂纹快速扩展前后,缺口两边的磁信号大小顺序发生变化;名义应力及应力集中系数、环境磁场和提离值影响检测效果,但有对应的解决方法.磁记忆技术用于高载旋转弯曲疲劳损伤检测是可行的.     

磁记忆信号与应力之间的关系

为明确磁记忆信号与工作应力和残余应力之间的对应关系,对Q235低碳钢板状试件进行了静载拉伸实验.利用TSC-1M-4型磁检测仪,研究了光滑试件和人工缺陷试件表面法向磁场强度在不同工作载荷下及卸载后的变化规律.结果表明:磁记忆信号与工作应力之间具有较好的相关性,利用相邻两磁信号之间的相关系数可以判断试件是否处于某种临界或极限状态;塑性变形前后的离线磁信号并无明显区别,但断裂后的磁信号及梯度曲线可用于准确识别断裂位置.     

地球磁场对磁记忆检测信号的影响研究

对一轴类铁磁性材料进行磁记忆检测实验,研究不同检测方法对磁记忆检测信号参数的影响。研究结果显示,不同的检测方法,检测得到的试件磁记忆信号差别较大。试件上下放置时,地磁场的影响程度最大;南北向放置时,地磁场的影响程度次之;东西向放置时,地磁场的影响程度最小。     

开孔Q460高强钢板在低周疲劳加载下的力学性能试验研究

为探讨单调拉伸及低周疲劳荷载下开孔Q460高强钢板的力学性能,对33个开孔材性试件进行试验测试,通过分析试件的应力-应变曲线、骨架曲线和耗能能力对比图,探讨了试件设计尺寸、开孔数量及加载模式等因素对开孔材性试件的强度、刚度、延性和耗能能力等力学性能的影响规律。在此基础上,使用ANSYS有限元分析软件建立了疲劳加载作用下开孔材性试件的精细有限元模型,并与材性试验结果进行了对比分析,验证了模型的正确性和可靠性。试验结果表明,开孔对Q460高强钢试件的力学性能有不利影响,导致应力集中加剧;在疲劳荷载作用下,增加试件轴向的开孔数量有利于提高试件的延性,但对钢材的耗能能力产生不利影响。开孔试件在低周反复荷载下易在开孔位置发生应力集中导致裂缝产生,且孔洞四周存在鼓曲现象,断后试件整体呈马鞍形。试件厚度对高强钢的破坏模式及力学性能影响显著,在低周疲劳荷载下,开孔试件的破坏形态与未开孔试件差别较大,且随厚度增加呈现两种不同的断口形态,随着试件设计厚度增加,断口截面与试件横截面呈约45°夹角和锯齿形交错相嵌两种断口类型;且随着钢材厚度的增加,试件的抗拉强度、延性和耗能能力均有所提高。加载模式对开孔Q460高强钢的抗拉强度影响较小,随着荷载循环圈数的增加,Q460高强钢的延性降低,耗能能力提高。     

Anisotropy of Fatigue Behavior and Tensile Behavior of 5A06 Aluminum Alloy Based on Infrared Thermography

The fatigue behavior during high cycle fatigue testing and the tensile behavior of 5A06 aluminum alloy considering the anisotropy were studied.Two types of specimens including longitudinal specimen(parallel to the rolling direction) and transverse specimen(perpendicular to the rolling direction) were prepared.Infrared thermography was employed to monitor the temperature evolution during the fatigue and tensile tests.The temperature evolution curves in the two directions were contrastively analyzed.It is found that the temperature evolution during fatigue process possesses four stages:initial temperature rise stage,slow temperature decline stage,rapid temperature rise stage,and finial temperature decline stage.The heat generating mechanisms of the four stages are discussed.Obvious differences can be found between the longitudinal specimen and transverse specimen in fatigue strength and fatigue life.The fatigue strength and fatigue life of longitudinal specimen are higher than those of transverse specimen.During the tensile and fatigue testing process,the fracture temperature in the transverse direction are higher than that in the longitudinal direction.The fatigue strength prediction by means of infrared thermography has a good consistency with that by the traditional method.     

环境磁场对磁记忆检测信号的影响

通过对一铁磁性试件进行磁记忆检测实验,选择手机信号作为干扰源,研究不同环境磁场下试件磁记忆检测信号的变化情况.同时,对试验过程中的环境磁场对磁场强度变化的影响进行了机理分析.研究结果表明:对不同程度的环境磁场干扰,检测得到的试件磁记忆信号差别显著;周围有放置手机但不通话时,环境磁场的干扰程度不大;随着周围环境的通话手机数量逐渐增多,环境磁场的干扰程度不断加大直至足以影响检测精度.     

拉应力对不同厚度Q345钢磁记忆信号的影响

为明确磁记忆信号与拉应力之间的对应关系和几何尺寸对试件表面磁场的影响,对Q345低合金钢不同厚度板状试件进行静载拉伸实验.利用TSC-1M-4型磁检测仪,研究3种厚度的光滑试件表面磁记忆信号在不同拉应力下的变化规律.结果表明:弹性阶段磁记忆信号与拉应力之间有较好的相关性,塑性阶段两者相关性较弱;切向磁记忆信号对试件局部屈服的表征比法向磁记忆信号更敏感,利用切向磁场的畸变性可预判试件的早期塑性变形和应力集中区;同一应力水平下,试件表面磁场强度随厚度增加而减小,但不影响其变化规律.     

高温后混凝土断裂全过程的裂缝扩展阻力曲线

采用楔入劈拉法试验,设置20～600 ℃共10组温度,试件尺寸统一采用230 mm×200 mm×200 mm,初始缝高比为0.4.根据试验得到的荷载-开口位移曲线（P-CMOD）求得应力强度因子曲线（K曲线）.基于虚拟裂缝黏聚应力,对高温后混凝土断裂全过程的裂缝扩展阻力曲线进行求解.将混凝土断裂全过程划分为4个部分,裂缝黏聚应力呈Petersson双线性软化曲线分布.计算表明,在某一特定温度下,裂缝扩展阻力曲线随裂缝扩展长度的增加而增长;阻力曲线随温度的上升呈下降趋势.对应力强度因子曲线与裂缝扩展阻力曲线进行裂缝扩展的稳定性分析.结果表明,当裂缝扩展阻力曲线位于应力强度因子曲线上方时,裂缝稳定发展;反之,裂缝将失稳发展.该判据可以等同于双K断裂准则,起裂韧度、失稳韧度是裂缝扩展阻力曲线上的2个关键点.     

GH80A镍合金电子束焊接接头旋转弯曲高周疲劳行为研究

随着镍合金电子束焊接在工业中的大量应用,尤其是在航空发动机和燃气轮机等关键长寿命服役设备中的使用,有必要对镍合金电子束焊接接头的高周疲劳属性和断裂机理进行系统的分析研究。本文利用旋转弯曲高周疲劳试验机进行疲劳试验,获得了母材和焊接接头的应力-寿命(S-N)曲线和疲劳断口,同时利用扫描电镜（Scanning Electron Microscope,SEM）对疲劳断口进行了微观特征分析,确定了母材和焊接接头在不同应力幅下的疲劳裂纹萌生区和扩展区,分析了裂纹萌生区位置与应力幅的相互关系。最后,利用有限元分析了焊接接头热影响区微裂纹位置与大小对材料疲劳性能的影响。从现有的试验和模拟结果可以得到：1)母材和电子束焊接接头应力-寿命(S-N)曲线分布趋势一致,但焊接接头疲劳强度要低于母材,在靠近107周次时,两者疲劳强度差距最小;2)在高应力幅（低周疲劳寿命阶段）母材和焊接接头的疲劳裂纹均起源于试件表面并且都是多点萌生断裂,焊接接头疲劳断口位置位于焊接熔合区或热影响区;3)在低应力幅（高周疲劳寿命阶段）疲劳裂纹在试件次表面萌生,焊接接头疲劳断口位于热影响区或焊接母材靠近热影响区处;4) 通过有限元模拟发现微裂纹的存在有利于裂纹的扩展。在拉应力作用下,横向微裂纹更优于纵向裂纹沿着应力方向进行裂纹扩展;随着微裂纹尺寸增大,微裂纹间更易于相互贯通,形成更长的裂纹,从而降低了材料的疲劳性能。综上可知,电子束焊接仅仅影响材料的疲劳强度。疲劳断裂机理和母材一致都为穿晶解理断裂,疲劳裂纹萌生区域位置也和母材一样都受应力幅的直接影响。     

超高强钢焊点的S-N对数正态分布

为了研究超高强钢焊点的疲劳性能,以22Mn B5点焊结构为研究对象,采用中频伺服点焊设备对2 mm厚试件进行了焊接.利用高频疲劳试验机、激光补焊设备和光学显微镜,研究了不同焊接工艺参数下试件的S-N曲线.结果表明,焊接时间与电流参数会对高应力等级焊点的疲劳寿命产生明显影响,而其对低应力区焊点的疲劳寿命影响较小.合理的工艺参数可以有效提高焊点的疲劳寿命.利用激光工艺对焊点的微小圆周薄弱区进行补焊后,可以有效增强焊点的结构强度.     

钢丝绳动载荷疲劳时的磁记忆信号研究

建立了模拟钢丝绳动载荷疲劳的实际工作状态的实验装置,确定了钢丝绳上三个检测段.通过磁记忆检测方法检测不同检测段的磁场分布,然后对发生疲劳断裂的检测段的磁场强度变化进行分析,从而得到钢丝绳动疲劳时磁记忆信号的特点.     

MMM testing and failure analysis of fastening bolts on reciprocating compressor cylinder cover

To avoid the serious accidents caused by the failure fastening bolts on reciprocating compressor cylinder cover,a new nondestructive testing(NDT) technology,metal magnetic memory(MMM) testing,was applied to safety evaluating and failure analyzing for the fastening bolts.Based on the dynamic stress calculation of the failure bolts,MMM testing was carried out at workshop.Given are the MMM stress distribution characteristics of the failure bolts and fracture faces.It has been found that the MMM signal variation amplitude of the crack transition zone in the fracture surface is minimal,that of the crack initiation zone is in the middle,and that of the tear fracture zone is maximal.The failure reasons were analyzed with MMM effect.The results of the metallographic examination showed that the validity and feasibility of MMM testing and failure analysis.This means MMM technology is a new,fast and validity method of failure analysis.     

长江三峡大坝混凝土双K断裂参数试验研究

对长江三峡工程泄洪坝段原材料制成的大坝混凝土及其湿筛混凝土试件做直接拉伸试验,得到大坝混凝土及其湿筛混凝土断裂过程区的本构关系.结合标准三点弯曲切口梁试验,运用双K断裂模型,得到大坝混凝土和湿筛混凝土的双K断裂参数.试验结果表明,三峡大坝混凝土的起裂和失稳韧度均大于其湿筛混凝土,前者分别为后者的1.14和1.19倍.     

锈蚀对钢材低周疲劳性能的影响分析

以我国钢桥结构中使用较多的Q345钢材为例,对人工加速锈蚀试样进行2种应变幅下的低周疲劳试验研究.应用精细的有限元模型分析,基于微观断裂判据--循环空穴扩张模型（CVGM）,对锈蚀钢材的低周疲劳断裂机理进行分析,讨论蚀坑对钢材低周疲劳（LDF）寿命的影响机理,并验证方法的有效性.结果表明,质量损失率约为6%的锈蚀Q345钢材试样的低周疲劳寿命比无锈蚀钢材减少约30%;完好试样与锈蚀试样的稳定滞回环形状几乎相同,锈蚀对钢材承载能力影响较小;在1%应变幅作用下,试样破坏现象为脆性的低周疲劳破坏,而在2.5%应变幅作用的循环荷载下,试样发生延性的超低周疲劳破坏.锈蚀引起钢材超低周疲劳寿命下降程度与蚀坑位置的应变集中有关,随着应变集中程度的增加,疲劳寿命的下降增大.     

Influences of magnetic treatment on microstructure densification of diamond saw segments

The heated test pieces were treated with alternating magnetic field by self-made experimental facility firstly. And influences of magnetic treatment on microstructure densification of Diamond Saw Segments were studied through hardness testing, ultrasonic testing, metallurgical structure and fracture pattern analysis by comparative method. The mechanism of magnetic treatment is analyzed and discussed in the end. The results show that the hardness of test pieces after magnetized are harder than before, that HRB hardness is improved by 3.58 on average. The sound path and amplitude of echo wave both decrease in test pieces after magnetized. The relative pad value of echo wave is regularly related with the microstructure densification, what is profound to further establish the regularity studying the degree of matrices densification using ultrasonic testing. The pores become few and pore shape gradually spheroidizing with the magnetic treatment, and matrices are more homogeneous and compact than the without by metallographic microscope. The degree of matrices densification is further improved after magnetized. The average crystal grain size is finer than the without, and the reason of grain refining is that densification of diamond saw blade improved. Magnetic treatment can act as one kind of effective technique to improve the microstructure densification of diamond saw segments.     

拉—拉变幅载荷下45钢切口件疲劳寿命的分布及其模拟

根据45钢切口件疲劳寿命表达式中疲劳抗力系数和疲劳门槛值物理意义及概率分布,提出了一种新的模拟45钢切口件变幅载荷下疲劳寿命实验及其分布的方法,并与拉－拉变幅载荷下的实验结果进行了比较,结果表明,45钢切口件在变幅载荷下的疲劳寿命分布的模拟结果服从对数正态分布,并与实验结果符合得很好。