Ti-6Al-4V超高周疲劳性能研究及可靠性寿命分析

运用超声疲劳试验系统和MTS液压伺服疲劳试验系统开展了Ti-6Al-4V钛合金在不同加载频率下的超高周疲劳试验,使用扫描电镜观察了试样断口形貌并对超高周疲劳试验数据进行了可靠性疲劳寿命分析。结果表明：疲劳循环周数超过107以后,Ti-6Al-4V钛合金试样依然会发生疲劳断裂,不存在传统意义上的疲劳极限。裂纹萌生于试样表面和次表面,随着应力水平降低,萌生位置由表面向次表面转变;试样断口平坦,裂纹源呈现类“鱼眼”特征,裂纹萌生于材料次表面微观组织不均匀处,周围出现黑色颗粒海绵状特征;20Hz和20KHz两种频率下的试验数据吻合良好,加载频率对材料的疲劳性能没有明显影响;Ti-6Al-4V钛合金材料的超高周疲劳寿命服从三参数威布尔分布,采用单侧容限系数法建立了不同置信度和不同存活率下的疲劳寿命模型,给出了p-γ-S-N曲线。     

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对超声疲劳试验技术的特点和应用以及与常规疲劳试验之间的差异进行了阐述,对超声疲劳试验中常见的若干问题,主要是由超声频率产生的热效应、频率效应进行了简单地阐述和探讨。     

负荷频率和试样尺寸对TC4钛合金轴向疲劳性能的影响

本文目的是研究不同负荷频率和不同尺寸试样对TC4合金室温轴向疲劳性能的影响。采用成组对比试验法进行试验。数理统计检验结果证明,所试验的三种频率的平均疲劳寿命和两种尺寸试样的平均疲劳寿命并没有显著差别,即它们对合金的疲劳性能均无显著影响。     

TC17合金超高周疲劳裂纹萌生机理

通过实验研究了2种频率(110 Hz和20 k Hz)循环载荷作用下航空发动机叶片材料TC17合金的超高周疲劳失效行为,分析了不同失效形式下的裂纹萌生机理。结果表明,TC17合金在2种实验载荷频率下均存在表面和内部萌生裂纹诱发疲劳失效2种失效形式,表面萌生裂纹诱发的疲劳失效主要是由加工缺陷和循环载荷作用下试样表面滑移处应力集中引起的横向裂纹所致,内部萌生裂纹诱发的疲劳失效是由循环载荷作用下材料初生α相的滑移断裂所致。失效机理的不同使得材料的应力-疲劳寿命(S-N)曲线呈双线性,载荷频率对TC17合金的裂纹萌生形式和萌生机理的影响不显著。建立了基于薄弱取向晶粒区域尺寸的疲劳强度预测模型,模型预测值与实验值吻合较好。     

含缺陷的TB6钛合金疲劳性能研究和强度评估

为研究航空钛合金TB6在服役过程中因制造缺陷、外物损伤等导致的疲劳失效,通过对光滑试样和含不同尺寸表面缺陷试样开展高周疲劳试验研究,分析了缺陷尺寸对试样高周疲劳性能的影响,并分别使用基于缺口敏感性的Peterson公式和基于断裂力学的修正Murakami疲劳极限预测公式评估带缺陷试样的疲劳极限。结果表明:缺陷会导致钛合金的疲劳性能下降,且下降程度随着缺陷尺寸的增加而增大;光滑试样裂纹萌生于试样表面且为单裂纹源,缺陷试样裂纹萌生于缺陷处且为多裂纹源;基于Peterson公式预测的疲劳极限偏差较大,而修正后的Murakami公式可较准确预测TB6钛合金缺陷试样的疲劳极限。     

不同稀土含量Ti-600合金的高周疲劳性能

研究了不同稀土含量的Ti-600合金光滑试样在应力比R为0.1,加载频率为100 Hz左右时的室温高周轴向应力疲劳性能,并分析了稀土元素对该合金疲劳断裂行为的影响。研究结果表明:10~7周次疲劳后,含0.1%(质量分数)Y和含0.2%(质量分数)Y的Ti-600合金以及Ti-1100基体合金的条件疲劳强度极限分别为537、500、605 MPa。这表明添加稀土元素Y后,合金的疲劳极限降低,且其疲劳极限随稀土元素含量的增多而减小。所形成的稀土氧化物Y_2O_3粒子尺寸差别较大,其椭球长轴尺寸为几百个纳米甚至几个微米,并且Ti-600合金的裂纹萌生与稀土相颗粒的断裂有关。     

结构钢焊接接头的超高周疲劳行为研究进展

在传统的认知中,材料在某一应力作用下达到107周次仍然不会断裂,则称材料有无限寿命。但在最新的研究中,在应力循环周次大于107周次时,焊接接头仍会发生断裂,不存在传统意义上的疲劳极限。综述了近年来对于结构钢焊接接头的超高周疲劳性能的研究成果,包括S-N曲线的特征,断口特征与裂纹的萌生机理,超声冲击处理对焊接接头超高周疲劳性能的影响,最后给出了需要进一步的研究方向。     

喷丸强化对TC21高强度钛合金疲劳性能的影响

对TC21疲劳试样进行喷丸,测定未强化试样和喷丸强化试样的旋转弯曲疲劳S-N曲线和采用升降法测定1×107周次下的条件疲劳极限,利用X射线应力仪测定了残余应力,用扫描电镜分析了疲劳断口.试验结果表明,喷丸不仅可显著延长TC21钛合金的疲劳寿命和提高疲劳强度,而且能使疲劳裂纹不再从表面萌生而是从表面强化层下的基体材料处形成并向四周扩展.     

汽车用高强度弹簧钢54SiCrV6和54SiCr6 的超高周疲劳行为

研究了54SiCrV6和54SiCr6两种洁净高强弹簧钢的超高周疲劳行为，并利用FESEM和EPMA对疲劳断口进行了观察．实验结果表明，在高应力幅区，两种弹簧钢的疲劳破坏均起源于表面基体；而在低应力幅长寿命区，疲劳开裂均发生在试样内部．54SiCrV6钢的S-N曲线为典型的台阶式曲线，在10^9循环周次内，其疲劳极限消失；而54SiCr6钢存在疲劳极限．疲劳断口分析表明，54SiCrV6钢内部破坏是由钢中小夹杂物聚集引起的，而在54SiCr6钢中则起源于碳化物的偏聚．临界夹杂物尺寸的估算表明，当高强弹簧钢中的夹杂物尺寸大于临界夹杂物尺寸时，其疲劳极限消失．     

7050铝合金搅拌摩擦焊接头超高周疲劳性能

采用超高周疲劳试验系统研究7050-T7451铝合金搅拌摩擦焊接头的超高周疲劳性能. 试验结果表明,焊接接头在107周次以上仍然会发生疲劳失效,S-N曲线在108周次左右出现转折点,呈折线型下降;通过SEM对超高周疲劳断口形貌进行观察发现,当应力范围较高时,试件的疲劳裂纹往往在表面萌生,随着应力范围的降低,裂纹有亚表面和内部萌生的倾向;裂纹萌生位置取决于表面起裂和内部起裂相互竞争的结果;试件的断裂位置多为焊接接头的热力影响区和热影响区,EBSD和接头硬度的分析结果表明断裂位置与接头组织不均匀密切相关.     

Gigacycle fatigue properties for high-strength low-alloy steel at 100 Hz, 600 Hz,and 20 kHz

Fatigue tests were carried out at frequencies of 100 Hz, 600 Hz, and 20 kHz for low-temperature-tempered JIS SNCM439 steel. Almost all specimens were broken from internal inclusions and frequency effects were not found on the gigacycle fatigue properties. The fatigue limit appeared at over 10⁹ cycles.     

Effect of stress ratio on long life fatigue behavior of Ti-Al alloy under flexural loading

A new ultrasonic three-point bending fatigue test device was introduced to investigate fatigue life ranging up to 10^10 cycles and associated fr＇dcture behavior of Ti-Al alloy. Tests were performed at a frequency of 20 kHz with stress ratio R=0.5 and R=0.7 at ambient temperature in air. Three groups of specimens with different surface roughness were applied to investigate the effect of surface roughness on fatigue life. Furthermore, optical microscopy（OM） and scanning electron microscopy（SEM） were used for microstructure characteristic and fracture surface analysis. The S-N curves obtained show that fatigue failure occurs in the range of 10^5-10^10 cycles, and the asymptote of S-N curve inclines slightly in very high cycle regime, but is not horizontal for R=0.5. Fatigue limit appears after 10s cycles for R=0.7. Surface roughness （the maximum roughness is no more than 3 μm） has no influence on the fatigue properties in the high cycle regime. A detailed investigation on fatigue fracture surface shows that the Ti-Al alloy studied here is a binary alloy in the microstructure composed of α2-Ti3Al and γ-Ti-Al with fully lamellar microstructure. Fractography shows that fatigue failures are mostly initiated on the surface of specimens, also, in very high cycle regime, subsurface fatigue crack initiation can be found. Interlamellar fatigue crack initiation is predominant in the Ti-Al alloy with fully lamellar structure. Fatigue crack growth is mainly in transgranular mode.     

Damage mechanism of a nodular cast iron under the very high cycle fatigue regime

Fatigue behaviour in the very high cycle regime (VHCF) of 10¹⁰ cycles were investigated with a cast iron (GS51) under ultrasonic fatigue test system (20 kHz) in ambient air at room temperature with a stress ratio R = −1.

The influence of frequency was examined by comparing similar data generated on conventional servo hydraulic test systems. An advanced, high-speed, and high-sensitivity infrared imaging system was used to measure the temperature changes during ultrasonic fatigue test at various load levels caused by internal damping due to a very high frequency cycling. The temperature field on the surface specimen was determined by using a non-destructive measurement technique called infrared pyrometer. An infrared camera made up of a matrix of 320 × 240 detectors was used.

The S-N curves obtained show that fatigue failure occurred beyond 10⁹ cycles, fatigue limit does not exist for the cast iron and there is no evidence of frequency effect on the test results. A detailed study on fatigue specimens subjected to ultrasonic frequency shows that the temperature evolution of the cast iron specimen is very evident, the temperature increased just at the beginning of the test, the temperature increased depending on the maximum stress amplitude. Under the current test conditions, the high cycle fatigue (VHCF) behaviour of the cast iron exhibited a typical fatigue crack growth process, that is, fatigue initiation takes place always at the surface graphite or subsurface void; the distinctive stable fatigue crack growth zone can be found around the fatigue crack initiation site, the change of fatigue initiation site from surface to subsurface is associated with the complex effects of applied maximum stress level, surface condition.

Under lower stress amplitude and high cycle condition, surface graphite fatigue initiation is predominantly depended on cyclic stress amplitude; subsurface void fatigue initiation is determined by maximum cyclic stress.

In the process of small crack propagation, the temperature in local plastic zone increase very sharply. The temperature field of ultrasonic fatigue specimen can be changed with the cooling condition; internal heating can accelerate surface fatigue crack initiation and propagation.

Fatigue properties in VHCF regime were studied for cast iron (GS51) at 20 kHz frequency and for the first time, crack initiation and propagation stages were analyzed using a high-sensitivity infrared camera. The new Paris's model for fish eye formation in the gigacycle fatigue were also confirmed by this study.     

DZ125定向凝固高温合金的超声疲劳行为研究

利用超声疲劳试验方法研究DZ125合金在105～109循环周次范围内的疲劳性能,其载荷频率为20kHz.结果表明:DZ125合金疲劳断裂寿命在105～108循环周次范围内;扫描电镜观察表明,DZ125合金的超声疲劳裂纹均起源于表面,疲劳断口的起源区由多个斜面组成,存在明显的滑移台阶形貌特征,从合金的超声疲劳裂纹扩展形态...     

表面完整性对40Cr钢性能的影响

采用电火花表面强化和喷丸强化改变40Cr钢的表面完整性,用升降法测定了10^7循环周次下试样的疲劳极限,用滚动磨损试验评定了试样的耐磨性。结果表明,两种表面强化方法均使试样的表面粗糙度发生变化并且产生残余压应力。喷丸强化使疲劳极限提高12％,电火花表面强化使疲劳极限提高20％;电火花表面强化试样的耐磨性明显高于磨加工、喷丸强化试样的耐磨性。     

高速列车车轴用EA4T钢腐蚀疲劳性能研究

目的 研究腐蚀环境中EA4T车轴钢疲劳性能,为车轴的腐蚀检测和使用寿命评估提供依据.方法 采用旋转弯曲疲劳试验机,在人造雨水模拟的腐蚀环境和空气环境中,对EA4T车轴钢试样进行疲劳试验,以获得不同环境下试样的疲劳S-N曲线、表面损伤以及裂纹扩展规律.然后对扩展裂纹进行概率统计,通过扫描电镜对疲劳失效的断口进行观察,并分析对比不同环境中裂纹扩展门槛值的变化.结果 空气环境中,试样的疲劳极限为355 MPa,而在腐蚀环境中,试样不存在疲劳极限,107循环周次对应的疲劳强度降低到245 MPa,相比空气环境中降低了31％.Gumbel分布统计与Weibull双参数分布统计相比,更适合描述EA4T车轴钢试样表面腐蚀裂纹长度随加载次数的变化.腐蚀环境中,疲劳裂纹萌生于表面腐蚀坑,并存在多个裂纹源.腐蚀环境显著降低了试样裂纹扩展门槛值,空气环境下,该值为6.29 MPa·m1/2,腐蚀环境下降低到4.1 MPa·m1/2.结论 腐蚀环境降低EA4T钢疲劳寿命的主要原因是,腐蚀环境降低了裂纹扩展门槛值,加快了裂纹萌生以及短裂纹扩展.而当裂纹达到一定长度时,腐蚀环境对裂纹扩展几乎没有影响.     

超长寿命区间16Mn钢焊接接头疲劳性能

使用自行研制的TJU-HJ-Ⅰ型超声疲劳试验系统装置进行了16 Mn钢母材和焊接接头试件的超声疲劳性能试验,以探索其在超长疲劳寿命区间的疲劳行为.结果表明,无论母材还是焊接接头,其S-N曲线都是一条连续下降的曲线;在106～107循环周次范围内焊接接头不存在传统概念上的疲劳极限,载荷循环周次超过107甚至109以后,试件依然发生疲劳断裂.在超长寿命区间,焊接接头疲劳强度远低于母材的疲劳强度.使用现有疲劳极限数据去设计工作在超长寿命区间的焊接结构件是很危险的.     

42CrMoVNb细晶高强钢的疲劳行为

研究了不同热处理制度下得到的3种晶粒尺寸的42CrMoVNb细晶高强钢的疲劳性能.结果表明，它们的光滑疲劳试样S-N曲线在10^6—10^7周期范围内无平台出现，疲劳极限消失．SEM断口观察表明，光滑试样疲劳裂纹起源位置与寿命长短密切相关，测量了长寿命试样疲劳断裂源夹杂物的位置及尺寸．通过对实验数据的初步分析，给出了夹杂物及奥氏体晶粒尺寸应控制的水平．     

Effect of corrosion on mass loss, and high and low cycle fatigue of reinforcing steel

The effect of various levels of corrosion on the mass loss, and the high and low cycle fatigue of BSt500_s steel reinforcement were experimentally investigated. The mass loss, the fatigue limit, and the life expectancy were reduced by 1.5 to 2.9%, 20 to 40%, and 56 to 76%, respectively, according to the corrosion level. Low cycle strain-controlled fatigue testing under a ±1% constant amplitude strain showed that the corroded steel bars exhibit a gradual reduction in the load-bearing ability, the available energy, and the number of cycles to failure. The considerable reduction in the fatigue limit took place because the mass loss led to a reduction of the exterior hard layer of martensite and a drastic drop in the energy density of the corroded specimens, thus developing stress concentration points that are highly localized at imperfections, and especially in the pits and notches of the rib bases of the corroded steel. Because corrosion and cycle fatigue are time-dependent, it seems that steel reliability is also time-dependent.     

稀土元素La对300M钢疲劳性能的影响

采用力学性能测试、疲劳断口形貌及裂纹源非金属夹杂物扫描电镜分析等方法,研究了稀土元素La对300M钢常规力学及高周疲劳性能的影响,以及稀土La对300M钢非金属夹杂物形态及尺寸的改性作用。结果表明:添加0.006%(质量分数)的稀土La对300M钢的常规力学性能影响较小,却显著提高300M钢的高周疲劳性能;300M钢加入稀土La后,其疲劳极限σ_-1由867 MPa提高至940 MPa;添加稀土La改性后的钢中夹杂物尺寸变大,并转变为含S、O的稀土夹杂物,其硬度、弹性模量、膨胀系数与钢基体更接近,有效减小了夹杂处的应力集中,有利于提高钢的高周疲劳性能。