异型钢轨矫直断裂原因分析

某异型钢轨在经60kg／m热轧钢轨加工至50kg／m过渡轨后出现矫直断裂。经对钢轨断口的宏、微观检验和分析,认为,断裂裂纹起源于轨腰次表层;钢轨发生矫直断裂的原因是在加工异型钢轨的过程中,加热温度偏高,导致轨腰表层部分区域出现沿晶氧化,锻压时因轨腰表层受拉应力作用,沿晶氧化处形成微裂纹,随后矫直时轨腰三点弯曲受力,微裂纹缺陷处产生应力集中致使裂纹扩展,导致钢轨断裂。     

钢轨腰部裂纹原因分析

115RE钢轨在线路上仅使用了6个月就在钢轨轨腰处出现长220mm的纵向裂纹。采用宏观分析以及扫描电镜和光学显微镜进行微观分析和相关的力学性能检验等方法对裂纹出现原因进行了分析。结果表明：钢轨的材质与力学性能无问题,钢轨上的裂纹是由于在轨腰处标识炉号“2”字痕的底部形成较大的应力集中造成的。     

钢轨闪光焊接后轨腰原始裂纹的特征

在U75V钢轨的端部轨腰处采用线切割和高频疲劳预制轨腰裂纹,并进行闪光焊接,在放置7a（天）后对焊接接头试样的裂纹表面形貌和脱碳现象进行了分析和研究。研究表明,预制轨腰裂纹与其他轨腰焊接水平裂纹的宏观和微观区别,为今后焊接接头处的轨腰水平裂纹质量检验和判断提供了依据。     

PG475kg·m^-1钢轨底裂原因分析

PG475kg·m^-1热处理钢轨在焊轨厂的焊接工序前,发现数支钢轨在轨底出现裂纹、掉块伤损。对伤损钢轨取样进行检验、分析,发现钢轨的化学成分、力学性能、显微组织及非金属夹杂物级别均符合相应技术标准要求。根据钢轨裂纹伤损特征,采用MSC·Marc软件对钢轨堆垛中的受力状态进行了仿真计算分析。结果表明：钢轨出现轨底裂纹伤损的原因是,钢轨堆垛时未按要求放平,钢轨出现倾斜,造成一侧轨底角局部受力过大,从而产生裂纹伤损。     

线路钢轨断裂分析

湘桂线发生一起PD3钢轨横向断裂。经对钢轨断口的宏观分析，以及用光学显微镜进行金相分析、电子显微镜的断口微观分析和能谱微区成分测定。结果表明，钢轨轨底下表面中部有一沿钢轨纵向长17mm、宽12mm、深约3mm的外伤凹坑缺陷，凹坑底部有一层厚度不均的、最厚约1．0mm的铜铁合金熔融层，再往里是厚度达1．0mm的马氏体组织层。凹坑缺陷及其凹坑底部的铜铁合金熔融层的产生，是由于钢轨进行接触焊时在电极板与钢轨底面之间接触不良所产生的电打火造成。裂纹就起源于铜铁合金熔融层，然后裂纹快速向轨腰和轨头方向扩展造成钢轨横向断梨．     

钢轨滚动接触疲劳缺陷的特征与发展模式

观察和解剖分析表明,轨头裂纹和隐伤是最主要的RCF缺陷;轨头裂纹在轨头内水平和向下扩展,会在轨面产生凹陷和V形裂纹,然后以水平裂纹为起源形成横向疲劳裂纹,最后引起钢轨断裂.通过对比分析,轨头裂纹在不同强度等级钢轨上都可能出现,但随着钢轨强度等级的提高,出现鱼鳞状、斜线状轨头裂纹和隐伤的可能性依次升高.存在一个合适的轮轨接触力与钢轨强度之比,使几种RCF缺陷出现的可能性都较低.     

AT道岔钢轨的开裂原因

AT道岔钢轨在加工过程中出现裂纹。采用化学分析、低倍、金相及夹杂物等方法对该钢轨进行了检验。结果表明,化学成分符合标准要求,低倍组织和显微组织正常;而由于感应线圈与道岔钢轨之间的距离设置不当,在进行感应加热时局部区域出现加热温度过高,在该区域形成不同程度的过烧、过热组织和龟裂纹等缺陷;在随后的锻压加工过程中缺陷又进一步扩展,最终形成较大的裂纹而开裂。     

钢轨闪光焊接轨腰横向裂纹产生原因分析

正一、钢轨裂缝概况无缝线路长钢轨焊接技术主要采用闪光对焊方式,目前国内钢轨闪光焊接占轨道运行线路的绝大多数,其比例超过90%。然而钢轨焊接位置由于工艺和现场的状况差异,在列车运行过程中,还是脆弱位置点,容易出现裂纹。本文对一例钢轨焊接位轨腰部位裂纹形成原因进行宏观断口形貌、微观形貌、金相组织等测试分析,试图找出裂纹形成原因。钢轨裂缝样件整体状态如图1所示,为P60型的钢     

U75钢轨闪光焊接头轨腰断后伸长率不合格原因分析

采用化学成分分析、力学性能测试、金相检验和断口分析等方法,分析了U75V钢轨闪光焊接头轨腰拉伸断后伸长率不合格的原因。结果表明:钢轨接头和钢轨母材轨腰大量密集分布MnS夹杂物(评级达到3.0级),长条状的MnS夹杂物经闪光焊顶锻后,随金属流线偏转45°方向,当与拉伸过程中的45°最大剪切应力平行时,相当于MnS夹杂物受到横向拉伸剪切,裂纹容易在夹杂物中开裂和扩展,故断后伸长率很低。     

钢轨万能轧制过程金属横向流动机理研究

为研究钢轨万能轧制过程中轨头、轨底与轨腰断面之间的金属横向流动规律,根据金属横向流动体积与延伸系数的关系,基于钢轨轧制前后体积不变条件推导出轨头、轨底与轨腰之间金属横向体积流动率数学模型.解析计算结果表明:轨头流向轨腰的金属体积流动率与相应轨头综合变形影响因子呈反比关系,与相应轨底综合变形影响因子成正比关系;轨底流向轨腰的金属体积流动率分别与相应轨底综合变形影响因子呈反比关系,与轨头综合变形影响因子呈正比关系;压下系数对轨头及轨底流向轨腰的金属体积流动率的影响比宽展系数大得多.为验证理论模型,完成了钢轨的万能热轧实验,实测了不同轧制规程时钢轨各部分轧制前后断面形状以及体积变化,并与理论计算结果进行了比较.理论计算结果与实验结果误差不超过±16%,可用于钢轨万能轧制实践.     

U75V重轨钢弯曲疲劳裂纹扩展行为EI北大核心

为明确珠光体钢轨的疲劳裂纹扩展行为,测定U75V重轨钢轧态和热处理态两种条件下的三点弯曲疲劳裂纹扩展速率,采用光学显微镜、扫描电镜、EBSD对钢轨的微观组织、片层、断口形貌及裂纹扩展轨迹进行观察。结果表明:轧态和热处理态钢轨的疲劳辉纹平均间距分别为253,215 nm,轧态钢轨的疲劳断口呈现解理台阶与河流花样形貌,且河流花样趋于合并,而热处理态钢轨的疲劳断口呈现大量的解理台阶及较多的微裂纹和撕裂棱,河流花样以支流为主;热处理态钢轨的疲劳裂纹扩展速率远低于轧态,到达裂纹失稳阶段也较滞后;轧态和热处理态钢轨的疲劳裂纹扩展都是以穿晶断裂为主的穿晶断裂和沿晶断裂混合扩展方式进行,轧态和热处理态钢轨的珠光体片层间距分别为272,148 nm,其中热处理态钢轨的珠光体片层细密且方向多样,存在显著的珠光体团簇,裂纹扩展轨迹中出现较多的分支裂纹和裂纹桥接现象,对扩展起到阻碍作用,是热处理态钢轨抗疲劳裂纹扩展能力优于轧态的重要原因。     

轮轨摩擦接触下钢轨多裂纹相互作用研究

利用热机耦合有限元法,建立了轮轨摩擦接触时钢轨表面多裂纹的热弹性平面应变有限元模型。数值模型中,考虑轮轨摩擦温升对轮轨材料参数的影响,通过移动载荷和热源来模拟运动车轮对钢轨的作用。分析了轮轨滑动接触时多裂纹相互作用和表面裂纹数量对钢轨疲劳裂纹扩展特性的影响。计算结果表明:与单个裂纹相比,多裂纹有降低钢轨疲劳裂纹扩展的作用;钢轨裂纹尖端应力强度因子K1和应力强度因子范围?K2均随裂纹数的增多而减小;钢轨表面裂纹数为5条时可以反映更多裂纹时的裂纹扩展特性。     

Beam heating of UO2 thin foils in an electron microscope

Parallel striations in thin foils of UO₂ single crystals introduced by pulse beam heating in the electron microscope have been studied by electron microscopy and electron diffraction. The observations are consistent with the view that both parallel (110) surfaces of the thin foil transform during heating into sets of parallel {111} faces.     

PG4热处理钢轨落锤断裂原因分析

采用体视显微镜、光学显微镜和扫描电镜等仪器分析了PG4热处理钢轨母材落锤试验不合格的原因。结果表明:落锤断裂钢轨的断裂均起源于轨底角圆弧过渡处的表面薄层马氏体组织区域;由于钢轨在输送过程中其轨底角与输送辊道轮缘根部磨损台阶接触形成滑动摩擦,摩擦热导致局部金属温度瞬时升高并达到奥氏体化温度,随后快速冷却生成了硬而脆的马氏体组织,致使钢轨母材在锤重1000kg和锤高6.4m条件下落锤1锤即发生断裂。     

PROCESSING AND FRACTURE TOUGHNESS OF SINTERED FIBER REINFORCED CERAMIC MATRIX COMPOSITES

ABSTRACT

The paper discusses the processing and the resulting mechanical properties of sintered fiber reinforced ceramic matrix composites. In situ observations of the sintering process revealed that stresses which develop due to the differential shrinkage between the fibers and the matrix initiate already during the heating cycle and are of sufficient magnitude and duration that crack like damage forms. Successful methods were employed for reducing and avoiding these stresses during the sintering process. Coarse grained alumina coatings deposited onto the fibers with a coating thickness of up to 10 µm delayed and reduced the stress development. Polymer coated fibers produced fully dense composites on which fracture toughness measurements were performed. Crack propagation and crack/fiber interaction was observed in situ inside a scanning electron microscope. The importance of studying both the crack front and the crack wake phenomena in fiber reinforced composites is illustrated. In specimens where the cracks are already bridged by 10% area fraction of fibers a toughness of 7 MPa √m was obtained. However, in samples where the cracks are not bridged yet by fibers, the crack becomes unstable before reaching the fiber positions and the fibers had no effect in resisting the crack propagation.     

New insights into the crystallization of cordierite from a stoichiometric glass by in situ high-temperature SEM

The crystallization of cordierite from stoichiometric glass is observed in situ in the scanning electron microscope. A heating stage was, therefore, operated at 1000 and 1100 °C. The surface crystallization of well-separated crystals was recorded. Surprisingly, at the late stage of crystallization, the formation of cracks as well as a squeezing out of a low viscous phase took place. To our knowledge, this has not been reported before and gives rise to new considerations of the crystallization mechanism of cordierite from glasses.     

PROCESSING AND FRACTURE TOUGHNESS OF SINTERED FIBER REINFORCED CERAMIC MATRIX COMPOSITES

The paper discusses the processing and the resulting mechanical properties of sintered fiber reinforced ceramic matrix composites. In situ observations of the sintering process revealed that stresses which develop due to the differential shrinkage between the fibers and the matrix initiate already during the heating cycle and are of sufficient magnitude and duration that crack like damage forms. Successful methods were employed for reducing and avoiding these stresses during the sintering process. Coarse grained alumina coatings deposited onto the fibers with a coating thickness of up to 10 µm delayed and reduced the stress development. Polymer coated fibers produced fully dense composites on which fracture toughness measurements were performed. Crack propagation and crack/fiber interaction was observed in situ inside a scanning electron microscope. The importance of studying both the crack front and the crack wake phenomena in fiber reinforced composites is illustrated. In specimens where the cracks are already bridged by 10% area fraction of fibers a toughness of 7 MPa √m was obtained. However, in samples where the cracks are not bridged yet by fibers, the crack becomes unstable before reaching the fiber positions and the fibers had no effect in resisting the crack propagation.     

Mg-0.4Zn镁合金挤压板拉伸变形组织的演变

用电子背散射衍射(EBSD)技术结合原位拉伸,研究了在0％～20％应变条件下,Mg-0.4％Zn二元镁合金晶界、织构和裂纹的变化.结果 表明,在拉伸应变从0％增加到20％的过程中,随着应变量的增大材料微观组织中的孪晶逐渐增加.孪晶的类型以{10-12}拉伸孪晶为主;这种孪生使材料的组织织构类型发生了显著的变化,随着应变...