陶瓷材料热冲击开裂机理与裂纹间距预报

该文研究陶瓷材料热冲击开裂机理和热冲击裂纹的分布规律。1mm厚的99Al2O3陶瓷薄片的水淬实验显示:裂纹间距随热冲击温差增大而减小,在同一热冲击温差下,5个试件中的各个裂纹间距与平均间距的偏差不超过7%。理论上,结合传热学和力学方法,计算了热冲击过程中试件的瞬态温度场和应力场,阐述了陶瓷材料热冲击条件下的开裂机理。以裂纹间距和深度作为变量,利用最小能量原理,发展了热冲击裂纹间距预报的有限元方法。由于从文献获得的毕渥数数据分散度很大,并且难以直接测量,因此发展了“间接测量法”,逆向估计了实验过程中的毕渥数,并在其他温度点获得了与实验吻合很好的裂纹间距数值预报结果。该文的研究对深入理解陶瓷材料的热冲击失效机制,对陶瓷材料的改性和研制有重要的意义。     

含单侧预制裂纹梁的冲击动态断裂过程试验研究

利用动焦散线试验方法研究了冲击下预制裂纹梁的动态断裂行为,对比分析了冲击荷载作用下单裂纹与双裂纹试件的应力强度因子、扩展轨迹以及速度、加速度等参数的变化规律。试验结果表明:冲击荷载作用下,含双裂纹且主裂纹在冲击点正下方的试件起裂时间最早,裂纹扩展后期朝向次裂纹方向发生较小的偏移;含Ⅰ型单裂纹的试件起裂时间次之,裂纹扩展路径呈直线;含双裂纹且两条裂纹均偏置于冲击点的试件起裂时间最晚,扩展过程中发生明显的曲裂现象。同时,裂纹扩展过程中曲裂现象越严重,裂纹扩展的最大速度就越小。在落锤冲击试件到试件断裂的整个阶段,应力强度因子一直表现出振荡变化。含双裂纹的试件,在主裂纹扩展中期,次裂纹上的应力强度因子有一个快速下降的过程。     

电子束焊接热冲击对GH4133A的微裂纹损伤研究

电子束焊接是一个复杂的强瞬态的热冲击过程,包括发生在表层的热过程和发生在一定深度的应力波与材料的交互作用。本文基于电子束焊接热冲击效应分析了高温合金电子束焊接接头影响区的微裂纹形成原因,研究了微裂纹损伤对GH4133A电子束接头高温力学性能的影响。结果表明,热冲击是高温合金电子束焊接热影响区的微裂纹损伤的主要原因,热冲击损伤效应导致接头力学性能的劣化。     

含不同张开角度裂纹结构的动态断裂试验研究

不同结构的动态断裂行为受多个因素影响,其中裂纹缺陷对其影响最为显著。张开型裂纹是工程结构中十分常见的缺陷,而且张开角度往往并不固定。为研究结构的运动裂纹与不同预制角度裂纹相互作用的规律,以张开角度为单一变量,采用动态焦散线试验系统,在冲击荷载下对含不同张开角度裂纹的有机玻璃试件进行三点弯试验。研究发现：裂纹扩展经过不同张开角度的预制裂纹时,都会先扩展至预制裂纹夹角尖端,再从预制裂纹其中一端重新蓄能起裂,然后偏向落锤点方向扩展,最终贯穿整个试件;开口向上的预制裂纹会增加运动裂纹的扩展时长,而且预制裂纹的开口角度越大,对裂纹扩展产生的迟滞效应越大,裂纹贯穿试件的总时长越大;与预制裂纹相互作用阶段,动态裂纹都会先减速后增速至峰值,预制裂纹角度越大,裂纹扩展速度峰值越小,且当预制裂纹角度为180°时的峰值与无预制裂缝试件的峰值非常接近;运动裂纹再次从预制裂纹尖端处起裂时裂纹尖端应力强度因子迅速大幅增加后又迅速减小直至试件完全断裂。     

仪器化冲击试验结果在SA508 Gr.3-Cl.2钢的韧脆性评价中的应用

采用仪器化冲击试验方法对核电材料用钢SA508Gr.3-Cl.2进行夏比冲击试验,记录冲击过程的力-位移曲线。按GB/T 19748-2005提供的方法计算材料的裂纹形成能量和裂纹扩展能量。结果表明:低于-27℃时材料的裂纹形成能量高于裂纹扩展能量,高于-27℃时情况相反;20℃以上裂纹扩展能量基本保持不变,试样断口为全韧性断口,20~-60℃裂纹扩展能量逐步下降,试样断口由韧性断口向脆性断口转变,-60℃以下裂纹扩展能量进入下平台,试样断口转变为全脆性断口。该结果与采用传统评价方法(剪切断面率)所得到的结果具有良好的一致性。     

基于键基近场动力学理论的单裂纹圆孔板冲击破坏研究

基于键基近场动力学理论,建立分离式霍普金森杆冲击单裂纹圆孔板动力学模型,其中霍普金森杆用一维PD模型、单裂纹圆孔板用二维PD模型描述,采用短程斥力模型描述碰撞过程,模拟冲击压缩条件下单裂纹圆孔板动态破坏行为。通过试样端面受力分析得到端面载荷的V形分布规律,解决了传统实验-数值研究法在端面加载上的局限性。研究不同入射速度下试件裂纹的扩展过程和破坏模式,准确捕获了裂纹起裂、止裂及二次起裂时间。根据键基近场动力学理论下材料动态应力强度因子计算方法,求得裂纹的起裂韧度,为材料动态断裂韧度计算提供了新的途径。     

X70管道钢裂纹尖端张开角的试验研究

高压富气输送管道要求发展管道钢的裂纹尖端张开角(CTOA)的测试方法。采用准静态的撕裂过程和长裂纹扩展长度试件,进行了X70管道钢的裂纹扩展试验,用摄像机跟踪拍摄裂纹扩展全过程,从获得的照片上直接测量出裂纹扩展全过程的CTOA值,分析了裂纹扩展中的断裂力学行为。试验结果表明:试件的韧带厚度越小,越容易获得稳定的扩展过程,且稳态裂纹扩展的CTOA值随试件韧带厚度的增加而增大,太厚的试件不易得到稳态扩展过程。韧带厚度为4mm、8mm试件的稳态的裂纹扩展阶段分别为7.6°、11.3°,裂纹扩展长度与韧带厚度比在4―25、4―10之间。     

热力载荷下多材料构件连接区的界面断裂分析

应用改进的虚裂纹闭合技术对热、力载荷作用下多材料构件连接区界面进行断裂分析。首先,通过对含橡胶夹层的复合材料层合板单腿弯曲（SLB）试件断裂分析,研究了在不同温度载荷作用下,橡胶夹层对试件能量释放率及其各型分量的影响。其次,对具有热流边界下,典型复合材料-橡胶-金属组成的多材料圆柱壳体连接裙结构进行了热力耦合断裂分析,结果表明裂纹总能量释放率随温度升高而增大。最后,针对该连接裙结构讨论了裂纹位置和橡胶层厚度对裂纹能量释放率的影响,指出适当增加橡胶层厚度可以降低裂纹能量释放率,但橡胶厚层度与界面韧性之间存在尺寸效应。     

两种钢夏比V型冲击试验裂纹形成能量与扩展能量之间的关系

采用仪器化冲击试验方法对两种承压设备用钢Q245R钢和13MnNiMoR钢进行系列温度下的夏比V型冲击试验,对比研究了两种钢裂纹形成能量W_i与裂纹扩展能量W_p之间的关系。结果表明:两种钢在韧脆转变K_(V2)-t曲线的上平台以及紧邻转变区的温度范围内,裂纹形成能量W_i不随温度变化而变化,基本恒定,但13MnNiMoR钢的值高于Q245R钢的;材料的韧脆转变,始于裂纹扩展能量W_p转变,其是主导材料由韧向脆的关键。     

冲击载荷下双预置裂纹三点弯曲梁动态断裂实验

采用数字激光焦散线实验系统,对双预置裂纹三点弯曲梁进行了动态冲击实验,分析了双预置裂纹对试件裂纹尖端扩展速率和动态应力强度因子值的影响。实验结果表明:1双预置裂纹三点弯曲梁在动态冲击实验中,B裂纹作为开裂裂纹,其起裂时间和扩展速率峰值受到冲击载荷加载点与其预置位置之间水平距离值的影响,距离越小,起裂越快,扩展速率峰值越大;2试件开裂后,裂纹的裂纹扩展速度和动态应力强度因子值随时间的变化曲线均具有快速上升然后波动下降的规律;3B裂纹起裂所需能量随着A、B裂纹间距a值减小而增大。     

聚乙二醇对环氧胶衣温度冲击开裂性能的影响

为开发一种满足航空环境要求的新型环氧胶衣,首先,研究了不同分子量、不同含量的聚乙二醇(PEG)改性环氧胶衣在室温下的冲击韧性及冲击断面形貌;然后,采用一种简单温度冲击试样模型,着重研究了PEG改性环氧胶衣在温度冲击(-50℃/30 min+90℃/30 min)下的开裂性能,并通过分析热膨胀及储能模量等的变化趋势对其进行了验证。结果表明:5wt% PEG-1000改性环氧胶衣的冲击强度比未改性环氧胶衣的提高了31.8%,达到最高值4.97 kJ·m-2;PEG-1000和PEG-2000改性环氧胶衣的冲击断面呈现出更明显的塑性变形形貌,胶衣的冲击韧性得到提高;15wt% PEG-400改性环氧胶衣在温度冲击下的宏观初始开裂性能达到最佳,平均初始开裂需要进行10.4次循环;改性环氧胶衣的耐开裂扩散性能基本上随着PEG分子量和含量的增加而提高,但裂纹宽度也会随PEG分子量的增加而扩大。      

Stellite12钴基合金热循环冲击前后拉伸断裂机理研究

对不同缺口的Stellite12钴基合金试样(700℃/20℃进行不同次数的热循环冲击和未冲击)进行原位拉伸,并结合试验数据的分析以及断口形貌的扫描电镜观察,分析了Stellite12钴基合金热循环冲击前后的拉伸断裂过程和断裂机理。结果发现:热循环冲击后不同半径试样的断裂过程略有不同,热循环冲击后的小圆弧缺口试样在缺口根部产生表面微裂纹,试样边缘及微裂纹两侧产生氧化微孔;原位拉伸时,该试样热冲击过程产生的裂纹先向试样厚度方向扩展,待厚度方向贯通,然后裂纹尖端的基体发生变形、黑相(白相)穿晶开裂、少量沿氧化微孔裂开,试样瞬间发生断裂;而经历热循环冲击后的大圆弧试样表面并未产生明显的裂纹,拉伸加载过程经历大圆弧根部基体变形、黑白相内开裂、边缘氧化微孔张开,试样突然断裂;对于未冲击试样,在加载过程中,试样的断裂过程经历基体变形、黑白相内部开裂,能量聚集到一定程度试样突然断裂。对于未热冲击的三种不同试样其断裂过程基本类似,仅仅是由于小圆弧半径的试样应力集中程度更大,从而使得其断裂应力低于平板以及大圆弧试样。     

Effects of microstructural through‐thickness non‐uniformity and crack size on fatigue crack propagation and fracture of rolled Al‐7075 alloy

Some of the fatigue tests performed using the standard compact tension (CT) and a non‐standard specimen made of rolled 7075 aluminium alloy exhibit fatigue crack growth (FCG) lagging in a small region along the crack front. Through‐thickness microstructural evaluation shows that material grains in this region did not flatten as much as other regions. In the non‐standard specimen, surface cracks are either grown under fatigue loading or broken under monotonically increasing quasi‐static loads at different crack sizes. The aforementioned lagging also exists in a narrow region of 3‐D FCG for specimens with microstructural through‐thickness non‐uniformity. A more important feature for this type of specimen with surface crack is the deflection of fast fracture direction into the grain interfaces, namely from L‐T orientation to S‐L and S‐T directions. It is proved that this is due to significant levels of second principal stresses near the free surface for small cracks and lower fracture toughness of the material in S‐L and S‐T directions.     

Ultimate Bearing Capacity Analysis and Sizing Optimization of a Cracked Reactor Pressure Vessel in the Coupled Thermo-Mechanical Field

Pressurized thermal shock (PTS) can subject a crack surface to a very high tensile stress. Also the material toughness is obviously decreased in the cooling process, so it is necessary to study the influence of PTS on the ultimate bearing capacity of a reactor pressure vessel with defects. A 3-D finite element model is established for the beltline region around an inner crack. The FEM is used to reveal the transient temperature field and stress field, and the XFEM is adopted to simulate the ductile crack propagation. To ensure that the strength requirement is satisfied, the ultimate internal pressures of vessels with different crack sizes and different wall thicknesses are obtained. The result shows that the ultimate bearing capacity of the base wall with shallow surface cracks at high temperature is mainly controlled by tensile strength, while it is also affected by the fracture toughness of the material under the severe PTS. The stress in the early stage of the PTS is mainly the thermal stress, and later is the thermo-mechanical coupling stress. The impact of the crack depth on the bearing capacity of the structure is much greater than that of the crack length.     

Effect of inclusions on size of surface flaws in glass-crystal composites

Indentation fracture studies were conducted on three sodium borosilicate glasses containing a dispersed phase of alumina inclusions with different degrees of thermal expansion mismatch between the glass matrices and the alumina. The alumina inclusions were found to cause a significant decrease in the size of the indentation cracks compared to those in the glass. This effect was greatest at the higher values of indentation load, which resulted in cracks of dimensions of sufficient size that their propagation was impeded by the tougher alumina dispersions. The fracture toughness for the composite samples calculated from the indentation data showed a significant increase with increasing crack size. For the smallest cracks in these composites, the value for fracture toughness was well below the value obtained in an earlier study by the single-edge notch-beam technique. The fracture toughness for the larger crack sizes which interacted with the alumina dispersions showed excellent agreement with the notch-beam data. The residual stresses due to the thermal expansion mismatch appeared to lead to a slight increase in the mean crack size regardless of the direction of thermal expansion mismatch.     

Fracture toughness of transverse cracks in graphite/epoxy laminates at cryogenic conditions

Stress singularity of a transverse crack normal to ply-interface in a composite laminate is investigated using analytical and finite element methods. Four-point bending tests were performed on single-notch bend specimens of graphite/epoxy laminates containing a transverse crack perpendicular to the ply-interface. The experimentally determined fracture loads were applied to the finite element model to estimate the fracture toughness. The procedures were repeated for specimens under cryogenic conditions. Although the fracture loads varied with specimen thickness, the critical stress intensity factor was constant for all the specimens indicating that the measured fracture toughness can be used to predict delamination initiation from transverse cracks. For a given crack length and laminate configuration, the fracture load at cryogenic temperature was significantly lower. The results indicate that fracture toughness does not change significantly at cryogenic temperatures, but the thermal stresses play a major role in fracture and initiation of delaminations from transverse cracks.     

Strength recovery of machined Al2O3/SiC composite ceramics by crack healing

Alumina is used in various fields as a machine component. However, it has a low fracture toughness, which is a weakness. Thus, countless cracks may be initiated randomly by machining, and these cracks decrease the component's mechanical properties and reliability. To overcome this problem, a crack‐healing ability could be a very useful technology. In this study, Al₂O₃/SiC composite was sintered. This alumina exhibits excellent crack‐healing ability. Small specimens for a bending test were made from the Al₂O₃/SiC. A semicircular groove was machined using a diamond ball‐drill. The machining reduced the local fracture stress from approximately 820–300 MPa. The machined specimens were crack‐healed under various conditions. The fracture stress of these specimens after crack healing was evaluated systematically from room temperature (RT) to 1573 K. It was found that the local fracture stress of the machined specimen recovered almost completely after crack healing. Therefore, it was concluded that crack healing could be an effective method for improving the structural integrity of machined alumina and reducing machining costs.     

Dynamic fracture mechanics—A scientific tool for the prevention of catastrophic failure

The major area of research in dynamic fracture has been the extension of the concept of static fracture toughness to predict crack arrest for a propagating crack. In this work crack propagation due to a ductile (microvoid) mechanism and cleavage (brittle) mechanism, as well as transition from one mode to another, has been analysed theoretically. Dynamic fracture toughness as a function of crack velocity has been determined. Temperature distribution near a propagating crack tip has been predicted for plane stress condition. The effect of reflected stress wave in a single edge notch specimen under transient crack growth conditions has also been analysed.     

压痕-淬冷技术表征氧化锆/铁铝复合材料的抗热震性能

采用压痕-淬冷技术研究了单相 ZrO₂(3Y)及ZrO₂(3Y)/Fe₃Al复合材料的抗热震性能。研究表明: 单相ZrO₂(3Y)及ZrO₂(3Y)/Fe₃Al复合材料的压痕裂纹在热震作用下具有相似的扩展模式: 当△T<△T_U时, 裂纹扩展量较低, 且进行稳态扩展; 当△T>△T_</em>U时, 裂纹发生失稳扩展。 复合材料的△T_U明显高于单相ZrO₂(3Y)。ZrO₂(3Y)/Fe₃Al复合材料较高的断裂韧性和导热率、 较低的弹性模量和泊松比是导致△T_U升高的主要原因。