Detecting recrystallization in a single crystal Ni-base alloy using resonant ultrasound spectroscopy

The use of resonant ultrasound spectroscopy (RUS) as a nondestructive evaluation (NDE) technique for Ni-base single crystal superalloys has been investigated. Manufacture of single crystal superalloys can be challenging due to the prevalence of defects induced during single crystal growth or subsequent processing. Common defects involve the presence of misoriented (non-single crystal) material that change the bulk elastic properties and, as a result, are detectable by RUS. To control the extent of misoriented material, recrystallization induced by shot peening the surface of the single crystal has been studied. RUS was then used to determine the presence and depth of misoriented material due to recrystallization. Recrystallization of shot peened cylindrical single crystal specimens occurred to a depth of 80 μm and 178  μm during subsequent heat treatments. Experimental average resonance frequency shifts of 1.835% ±1.704% and 2.380% ±2.910%, respectively, were measured over a frequency range from 20–200 kHz when compared to the baseline shot peened condition. Finite element (FE) models using the ABAQUS Lanczos Eigen frequency solver assessed the influence of recrystallization as a function of depth from the surface and showed good agreement with the measured resonance frequency shifts. For the greatest NDE sensitivity on production-scale turbine blades and other gas turbine components, a coupled RUS measurement and FE modeling approach is essential, and has the potential to improve single crystal processing approaches and manufacturing yields.     

Enhanced Sliding Wear Resistance of Technical Alloys by Hard Particle Reinforcement Using Machine Hammer Peening

Machine hammer peening is a surface treatment technique originally developed for smoothening tools and mold surfaces. Treated surfaces are locally cold-worked, which results in a hardness increase and the induction of compressive residual stresses. In the present work, the feasibility of using this technique as a tool for embedding tungsten carbide hard particles on engineering-relevant substrate materials is systematically investigated. Tungsten carbide particles of three different sizes were embedded onto selected substrates using machine hammer peening. The particle embedment quality of the engineered surfaces was evaluated and correlated to the substrates' mechanical properties. The resulting tribological performance was investigated under reciprocating sliding conditions and the dominant wear mechanisms were correlated with the diameter of the embedded particles. The results show that machine hammer peening is a suitable technique for embedding hard particles in substrates of various materials, which additionally results in an enhancement in wear resistance, thus opening up a wide range of potential applications in tribologically loaded surfaces.     

Probabilistic prediction of high cycle fatigue reliability of high strength steel butt‐welded joints

The aim of this paper is to develop a probabilistic approach of high cycle fatigue (HCF) behaviour prediction of welded joints taking into account the surface modifications induced by welding and the post‐welding shot peening treatment. In this work, the HCF Crossland criterion has been used and adopted to the case of welded and shot peened welded parts, by taking into account the surface modifications which are classified as follows: (i) the compressive residual stresses, (ii) the surface work‐hardening, (iii) the geometrical irregularities and (iv) the superficial defects. The random effects due to the dispersions of: (i) the HCF Crossland criterion material characteristics (ii) the applied loading and (iii) the surface modifications parameters are introduced in the proposed model. The HCF reliability has been computed by using the ‘strength load’ method with Monte Carlo simulation. The reliability computation results lead to obtain interesting and useful iso‐probabilistic Crossland diagrams (PCD) for different welding and shot peening surface conditions. To validate the proposed method, the approach has been applied to a butt‐welded joint made of S550MC high strength steel (HSS). Four types of specimens are investigated: (i) base metal (BM), (ii) machined and grooved (MG) condition, (iii) As welded (AW) condition and (iv) as welded and shot peened (AWSP) condition. The comparison between the computed reliabilities and the experimental investigations reveals good agreement leading to validate the proposed approach. The effects of the different welded and post‐weld shot peened specimen's surface properties are analysed and discussed using the design of experiments (DoE) techniques.     

球铁轧辊材料的热疲劳断裂及强化

通过试验和断口分析分析了球铁材料的热疲劳机理,研究了热轧轧辊破坏的行为和规律。对试样进行了喷丸处理,进而探讨了球铁材料的强化机制和抗疲劳技术。     

电火花表面强化与喷丸复合处理对Ti811合金高温微动疲劳性能的影响

研究了Ti811钛合金表面电火花强化层的界面成分分布、耐磨和微动疲劳性能.研究结果表明:以0Cr18Ni9合金为电极材料在Ti811钛合金表面进行电火花处理可以形成合金层,显著提高了钛合金表面硬度和耐磨性能.但由于合金层硬度高,韧性较低,在微动疲劳(FF)过程中易萌生裂纹并快速扩展进入基体,致使高温下钛合金FF抗力降低.对电火花强化层进行喷丸强化(SP)后处理能够使钛合金FF抗力恢复到裸件的水平.     

超声冲击处理钛合金焊接接头的性能研究

采用超声冲击工艺,处理了钛合金两种型式的焊接接头。试验结果表明:超声冲击处理可显著降低接头焊接残余应力,并可提高接头的疲劳强度和疲劳寿命。其中对于Ti80合金的对接接头和十字接头,疲劳极限分别提高22.7%和64.5%,疲劳寿命分别提高5.4倍和13.5倍;对于TA2和Ti75合金的对接接头,焊接残余应力分别降低68%和65%。     

外施应力与表面残余应力作用下圆柱螺旋压缩弹簧任意截面的受力分析

在对承受扭转与表面残余应力的圆柱螺旋压缩弹簧任意截面所作的应力分析的基础上得出,与弹簧线材轴线成α=135°斜截面上的为最大正应力.因此这类弹簧的疲劳开裂大多起裂于内圆表面,沿α=135°斜截面扩展并导致疲劳断裂.但表面形变强化引入表面α=45°方向的残余压应力σr,α,能有效地降低外施扭转切应力在斜截面上(α=135°)的最大正应力水平,从而使弹簧的疲劳断裂抗力得以提高.     

Influence of surface integrity on fatigue strength of 40CrNi2Si2MoVA steel

Influence of surface integrity (including surface roughness, residual stresses, and microstructure in surface) on fatigue limit of 40CrNi2Si2MoVA steel specimens is investigated comprehensively in this work according to a systematic consideration. The surface integrity of specimens is changed due to several widely used manufacturing procedures: heat-treatment, grinding, electro-polishing, hard chromium plating and shot peening. In comparison with specimen electro-polished after grinding, the specimen without polishing has 10% lower fatigue limit due to higher surface roughness; while shot peening improves the fatigue limit for about 36% due to inducing of compressive residual stress field in the surface and transferring the fatigue crack source from surface to interior. The fatigue limit of specimen with decarburized layer after grinding is lower about 13%, but the shot peening can eliminate its detrimental effect. Hard chromium plating decreases the fatigue limit dramatically. The shot peening carried before plating can improve the fatigue limit of specimen and cause it to get to a level even higher than that of specimen without plating.     

激光窄条喷丸成形的实验研究

利用短脉冲激光对LY12CZ航空铝合金进行了窄条激光喷丸(LP)成形。激光脉冲参数:波长为1.06μm,脉冲宽度为23 ns,光斑直径为7 mm,输出能量为22 J。试样外形尺寸为100 mm×25 mm×2 mm,喷丸窄条宽度为7 mm,条带内相邻光斑的距离为4 mm,相邻喷丸条带中心间距为15 mm。利用弧高仪测试样变形后的变形量,用X-350A残余应力测试仪测其残余应力,用HVS-1000硬度计测其显微硬度和用Taylor Hobson-5M测表面粗糙度。实验结果表明,试样经激光喷丸后,变成了曲率半径为1.87 m的单曲率件,冲击硬度得到提高,喷丸条带内的表面粗糙度值增大,但仍然保持光滑,试样上下表面的残余应力均有显著提高,其激光喷丸面的残余应力平均增加了250%,下表面平均增加了75%,喷丸条带内的硬度平均值增加约40%。     

激光喷丸成形中的残余应力

通过对激光喷丸成形(LPF)中残余应力场分布的研究,找出单点喷丸残余应力分布形式,以及单点多次、多点不同路径喷丸中后续冲击对前次冲击残余应力分布的影响规律。对准确控制残余应力分布,获得激光喷丸后所需的板料形状具有指导意义。利用钕玻璃高功率脉冲激光对厚度为1.2 mm的LY12CZ硬铝合金进行了单点激光喷丸,用X衍射应力测定仪考察了单点冲击后材料表面及深度方向的残余应力,用厚度为2 mm 的6061-T6铝合金板料进行三列窄条激光喷丸变形实验。以ANSYS/LS-DYNA有限元分析软件为平台,建立了具有一定精度的激光喷丸过程中冲击波压力的加载模型,对板料的变形过程进行了数值模拟, 分别考察了不同激光能量,板料尺寸,冲击路径等工艺参数对残余应力场分布的影响。实验结合数值模拟探索激光喷丸的主要参数和残余应力场之间的相互关系。