石油钻杆焊缝裂纹成因分析及解决方案

结合实际生产及热处理工艺,对钻杆焊缝生产检测过程中发现的裂纹成因进行了分析。结果表明:裂纹均出现在钻杆熔合线附近接头侧外壁,为淬火过程中内应力较大产生的淬火裂纹。为了解决该问题,把调质处理的淬火温度降低到Ac1~Ac3,即对钻杆进行亚温淬火,再高温回火;工艺调整后,在保证产品性能满足技术要求的基础上,完全避免了焊缝淬火裂纹的产生。     

曲轴主轴颈表面裂纹原因分析

通过对45钢曲轴主轴颈表面裂纹的综合分析,揭示了裂纹产生原因系在调质处理的淬火过程中,网状铁素体沿晶界析出,使晶界严重弱化,最终导致在中频淬火过程中形成以沿晶为主的淬火裂纹。     

GCr15钢轴承滚子冷镦冲头淬火开裂分析

采用宏微观断口分析等方法对轴承滚子冷镦冲头淬火开裂原因进行了分析。结果表明 ,冲头心部存在的粗大液析碳化物和淬火过程中产生的较大拉应力是导致冲头淬火开裂的原因     

某型弹用尾翼片裂纹分析

目的分析弹用尾翼片淬火、回火后表面裂纹产生的原因。方法通过对存在裂纹的尾翼片进行金相检测、化学成分分析、硬度检测、断口检测、力学性能检测,对尾翼片产生的原因进行了分析和讨论。结果确定了尾翼片裂纹的性质和产生原因。结论尾翼片裂纹为淬火裂纹;尾翼片裂纹产生的主要原因是由于原材料钢板剪尾翼片条料过程中,在条料的表面产生了冷变形开裂缺陷,出现了较深的线状缺口,导致淬火热处理时产生了严重的应力集中,诱发了裂纹的萌生,同时,原材料钢板中存在的魏氏组织和硫化物夹杂等材质缺陷,也对促进了淬火裂纹的萌生。     

驱动铲片棘轮断裂分析

针对某型号筑路平地机驱动铲片棘轮发生的断裂事故进行了失效分析,通过对棘轮的材料成分分析、断口分析、金相检验及渗碳层硬度分布检测,判断出棘轮渗碳过程中表面产生了脱碳,在淬火过程中产生淬火裂纹,运行过程中在断裂前由于承受较大的冲击载荷作用,在表面脱碳层形成裂纹,再加上棘轮中心晶粒及晶界较粗大,有过热倾向,最终导致棘轮发生断裂。     

7B04铝合金厚板生产过程优化的数值分析

为了优化7B04铝合金厚板生产过程,对7B04铝合金厚板生产过程中淬火、压光、拉伸过程应力场的变化和分布情况进行了数值分析.结果表明:压光过程可以降低淬火应力并使淬火应力分布均匀化,但这种作用被后续的拉伸过程大大减弱,并且压光过程导致板材两端产生较大的应力集中区域;拉伸是降低铝板材应力和使应力均匀分布的关键环节;当纵向塑性延伸率为2.5%时,拉伸效果最好.     

淬火对V40Ti26Cr26Fe8贮氢合金的影响

淬火工艺被广泛应用于钒基固溶体贮氢合金的热处理过程中,并被认为能够有效改善合金成份均匀性,提高合金的有效放氢量.考察了淬火对V40Ti26Cr26Fe8贮氢合金放氢PCT性能的影响.合金微观结构变化的分析表明,合金在退火态时存在C14 Laves相,淬火后Laves相固溶于BCC主相中,含量下降.成分分析表明,合金BCC主相淬火后Ti含量上升.与退火处理相比,合金放氢量和平台压在淬火后均出现下降.而合金在淬火过程中产生的缺陷及应力,导致了放氢平台倾斜,滞后增大且放氢量下降.     

表面淬火等离子体束温度及宽度测量方法

等离子体表面淬火技术是一种新型表面处理技术。该技术通过等离子体发生器产生高能等离子体束作用于金属材料表面,使材料表面温度快速升高超过相变温度,再依靠自身快速冷却达到淬火效果。目前在缺少对淬火过程中等离子体束温度的测量方法。本文研究出一种数字图像处理与双色比色法相结合的方法能够测量出等离子体束在表面淬火过程中的温度。实验结果显示本方法可以有效观测到淬火过程中的等离子体束温度与宽度及其变化,为等离子体表面淬火技术提供了支持。     

淬火过程数值模拟技术的研究进展

淬火是使工件获得预期的组织和性能的一种重要热处理工艺。由于淬火试验存在高温作业、在线测量困难、成本高等问题,淬火过程的数值模拟成为目前淬火技术研究的重要手段。综述了淬火过程数值模拟技术的发展历程,分阶段地介绍了淬火过程中工件、冷却介质、工件和冷却介质耦合的数值模拟技术的研究现状,提出了今后一段时间内淬火过程数值模拟技术的发展方向。     

20CrMnMo钢渗碳齿轮磨削裂纹成因分析

采用化学成分分析、金相分析、显微硬度测试以及残余应力测定等方法对某20CrMnMo钢渗碳齿轮磨削裂纹产生原因进行了分析。结果表明:该齿轮产生磨削裂纹主要是由于磨削过程中表面产生严重的二次淬火烧伤和回火烧伤,二次淬火烧伤的次表面及边缘回火烧伤区硬度大幅下降及表面受拉应力,两者共同作用下产生了磨削裂纹;另外,渗碳层中存在针状马氏体和大量残余奥氏体,增加了齿轮磨削开裂的敏感性,这是齿轮产生磨削裂纹的另一个重要原因。     

淬火应力场对铝合金厚板固有频率的影响

建立7075铝合金厚板淬火残余应力场数学模型,理论与实验探讨振动时效中淬火残余应力场对板固有频率的影响。结果表明,板尺寸、密度、均匀性等物理材料特性确定时,其固有频率主要受到残余应力场的分布状态影响,且高阶固有频率受残余应力的影响比低阶固有频率大。淬火残余应力场总是增大板的固有频率,振动时效消减或均匀化残余应力的同时,也将降低各阶次固有频率。     

Stress field simulation of carburized specimens with different carbon content during quenching process

This study focuses on the numerical model simulation of stress and temperature fields of carburized specimens with different carbon content during the quenching process. In the models the coupling between thermal field, phase transformation field and stress field was considered. The changes of the thermomechanical parameters of the material, as a function of carbon content and thermal field, were considered in the stress simulations. The residual stress fields of 20CrMnTi specimens with different carbon content of 0.8% and 1.0% were measured using an X-ray stress analyzer. Finite element model (FEM) was built for simulating the residual stress field after quenching. Meanwhile, the temperature and stress fields during quenching were simulated. The measured and simulated results are in good agreement.     

Stress–phase-transformation interactions – basic principles,modelling, and calculation of internal stresses

Abstract

The two main effects of stress on phase transformation, kinetics modification and transformation plasticity, are reviewed for both diffusional and non-diffusional transformations. Results for these interactions during the pearlitic and martensitic transformation of steels under uniaxial tensile stress are analysed from a metallurgical point of view. These results are used to produce a model for a triaxial stress state, and in a finite element program for calculating internal stresses during quenching. Transformation plasticity is introduced in the calculation of internal stresses as an additional strain related to the stress state and to the progress of transformation, and the kinetics of martensitic transformation are also related to the stress state. The calculated results show that these phenomena have important consequences on the stress and plastic strain histories during quenching.

MST/9     

Deformation twinning in alloys of low stacking-fault energy

A High Voltage Electron Microscopy (HVEM) examination of quenched and strained alloys of low stacking-fault energy has indicated a high incidence of deformation twins at second phase particles. Deformation twins are produced at NbC particles during quenching of 20/25/Nb steel and following approximately 1% strain in the case of Ni₃Al particles in PE-16 alloy.The association of twins and particles in these alloys is a direct result of the development of large stresses at the particle-matrix interface, due to differential contraction rates during quenching. At NbC particles of the order 10³ nm diameter, the twinning stress is exceeded on quenching from the solution treatment temperature. In the case of PE-16 alloy the thermal stress set up at the Ni₃Al particle is smaller, necessitating a further external applied stress in order to nucleate such twins.     

带台阶厚壁管类工件水淬的计算机模拟

本文以金属淬火冷却过程的连续过冷沸腾换热理论为基础,利用热分析和热结构耦合分析的有限元算法,以有限元分析软件ANSYS为分析工具,对45钢带台阶厚壁管类工件水淬过程进了计算机模拟,得到瞬态温度场、瞬态应力场以及残余应力场分布,并对计算结果进行分析.     

Stresses and phase transformations occurring in quenching of carburized steel gear wheel

Abstract

A method for analysing temperature, metallic structures, stress and strain, and carbon content during the carburized quenching of a steel gear is presented, and the results of calculations using the finite element method are compared with experimentally measured data. Since carburization precedes quenching, a diffusion equation is solved in order to determine the carbon content. Calculated profiles of temperature, stresses, and martensite and pearlite volume fractions during quenching are presented, and the effects of coupling between them are also considered.

MST/19     

SDC99钢淬火过程中应力和组织演变的有限元模拟

为了研究钢铁材料在淬火过程中内部组织和应力的变化,以自主研发的SDC99钢为研究对象,考虑相变潜热的影响,采用有限元方法对偏心圆环的淬火过程进行模拟仿真,并对淬火过程中模型的温度场、应力场和组织场的变化进行分析和研究.结果表明:经实验测定淬火过程中温度场及残余应力的分布与模拟结果吻合较好,偏心圆环上最大残余应力出现在45°及315°位置;模型硬度的分布与其马氏体含量分布趋势一致,模拟的硬度值略小于实测值.     

Numerical calculations of residual–stress relaxation in quenched plates

Abstract

Methods of thermal stress relief such as stretching and compression are compared for different thermal and mechanical properties during quenching. The heat equation for a simple geometric model, such as an infinite plate, is solved with an experimental surface conductance and a step–by–step method of determining the temperature field in the thickness of the plate. This field is introduced as data for the uncoupled thermal elastic–plastic model for quenching. In the calculation of the plastic–strain path, the thermal and mechanical properties are considered as temperature dependent for a homogeneous and isotropic material. Good agreement is found between the calculated residual stresses and experimental values for an aluminium alloy and a stainless steel. The predicted residual–stress distributions and strain history are then used as data for the numerical simulation of stress–relief methods with an incremental integration of the Prandtl–Reuss equation. This analysis allows the observation of the effects of small variations in mechanical properties during quenching on the residual–stress field after mechanical stress relief and the theoretical comparison of different processes.

MST/6     

Numerical Simulation and Technological Parameter Optimization for Quenching Process of a Gas Turbine Compressor Disk Based on Metallo-Thermo-Mechanics

Thermal, mechanical and microstructural phenomena are involved in the process of steel quenching. Based on the coupled metallo-thermo-mechanics theory, a calculation model has been developed in this study to simulate the quenching process of a gas turbine compressor disk by finite element method. The thermal physical and mechanical properties were treated as a functions of temperature. Moreover, a series of subroutines were developed on the MARC software platform. Consequently, simulated results on temperature, internal stress and distortion during the quenching were illustrated. With the aid of the simulated results, an optimum quenching scheme was proposed. The quenching process simulated in this study appears to be a promising tool in design of heat-treatment processing parameters for gas turbine compressor disks.     

Design of the multi-stage quenching process for 7050 aluminum alloy

In order to attain good hardenability in the single-stage quenching process of Al–Zn–Mg–Cu alloys, rapid cooling rate is often desirable. But this would inevitably increase the residual stress. Therefore, the aim of this study is to achieve coupling control of the cooling rate and the residual stress by using the multi-stage quenching process. First, a series of single-stage quenching tests were conducted based on the end quenching equipment. Then in the double-stage quenching tests, a higher cooling rate was obtained comparing to the single-stage quenching. Based on this discovery, three kinds of multi-stage quenching processes were designed based on the experimental results of the single-stage quenching tests. The mechanism of the multi-stage quenching has been analyzed by comparing the cooling curves, the microstructure, the hardening depth, and the maximum residual stress. Furthermore the optimal multi-stage quenching process for 7050 aluminum alloy plate was obtained.