某电厂三通焊接接头开裂原因分析

某电厂主蒸汽管道的三通与上连接管的焊接接头处多次发生开裂。采用无损检测、硬度测试、金相检验、管系应力计算分析、管系推力计算分析和有限元分析等方法对焊接接头开裂的原因进行了分析。结果表明:该管道三通附近管系布置不合理,焊接接头处弯曲应力较大并存在应力集中,最大应力超过了焊接接头的高温持久强度,加之裂纹处显微组织老化,焊接接头的力学性能降低,从而发生蠕变开裂。     

3D机织复合材料卫星桁架接头的抗弯刚度研究

为了研制高性能复合材料卫星桁架接头,采用三维有限元分析技术,分析了三维整体织物增强的碳纤维卫星桁架接头三通制件的等效抗弯刚度和内部应力分布,并与制件的三点弯曲实测结果进行了对比.结果表明:三通制件的等效抗弯刚度可以用有限元软件快速、方便、准确地计算出来,并可提供制件任意部位的应力分布状态,为优化制件结构设计提供理论依据.弯曲破坏实验的破坏载荷未能真实地反映接头的最大抗弯破坏承载能力,3个方管的根部应力尚未达到材料的破坏极限.     

5052-H112铝合金搅拌摩擦焊接头应力腐蚀的研究

采用慢应变速率拉伸法分析了6mm厚5052铝合金及其搅拌摩擦焊接头在大气及海水环境下的应力腐蚀敏感系数,通过OM、SEM、显微硬度仪等分析了接头组织形貌、断口形貌及接头硬度。结果表明:焊核区晶粒由细小的等轴晶粒组成,平均晶粒尺寸约为5μm,为母材的1/10;合金及其接头在应变速率为3.36×10-6 s-1时的应力腐蚀敏感系数分别为1%、2%,应力腐蚀系数小;硬度最小值及接头断口均位于接头返回侧热影响区,为接头的薄弱区;接头断口均由细小、均匀的韧窝组成,呈典型的切断形貌,接头在海水中的断口韧窝较大气中平而浅,这与接头的应力腐蚀倾向有关。     

管道失效判据简析

在外部载荷超过管道所能承受范围时管道即发生失效。通过研究管道在外力作用下的力学性能,有助于确定管道失效时的应力或应变的临界值,根据是取应力还是取应变作为衡量管道失效时的指标,分别有基于应力的失效判据和基于应变的失效判据。合理选用管道失效判据,可以节约管道投资、延长管道使用时间。简介材料应力—应变曲线的一般特征,分析管道基于应力的失效判据和基于应变的失效判据的方法。     

边缘定位胶焊接头的应力应变分布和强度研究

采用强塑性有限元分析和试验研究方法,考察了焊点间距对两种搭接区边缘定位胶焊接头中应力应变分布及接头强度的影响。结果表明：两种接头中两焊点处的应力应变分布基本相同;采用环氧树脂基胶粘剂时,应力变主要分布在搭接区边缘,改变焊点间距基本不影响接头搭接区边缘处的应力应变值;     

制动管一体式法兰接头热镦挤成形工艺仿真分析

目的 针对铁路货车空气管路制动系统中焊接法兰接头连接质量不佳的问题,提出一种制动管一体式法兰接头热镦挤工艺。方法 分析了制动管用AISI321不锈钢的高温变形行为并构建了本构方程,并通过DEFORM–2D软件对制动管件法兰接头热镦挤工艺进行了数值模拟。结果 应力–应变曲线在低应变速率时呈现稳态流动,但在高应变速率下会出现明显的波动。本构方程得到的应力计算值与试验真实值的相关系数为0.986,平均相对误差为6.7%。在热镦挤工艺成形法兰接头过程中,挤压阶段的最大应力位于制动管扩径的圆锥面处;镦粗阶段的最大应力位于法兰接头平面成形处,并最终转移至法兰接头的圆角处。结论 建立的本构方程能够反映AISI 321不锈钢真实应力–真实应变的关系,可用于描述该材料在热镦挤成形工艺中的塑性变形行为。在该制动管一体式法兰接头热镦挤成形过程的镦粗阶段,摩擦因数保持在0.3以下能够有效降低镦粗力。     

基于压电主动传感法的钢管螺纹接头松动监测

针对管道工程中缺乏对接头部位松动监测的相关研究,该文利用压电陶瓷传感技术对城市地下管网中广泛应用的钢管螺纹连接松动进行监测实验。在钢管管道和外接螺纹接头处分别粘贴压电陶瓷传感器,松动发生时,管道和外接头间的相对接触面积减小、相对距离发生变化,最终影响应力波在传感器之间的传播和衰减。基于此,该文从理论上推导螺纹松动程度与应力波信号衰减之间的对应关系,并通过室内实验,验证所提方法的有效性,即压电主动传感法可以较好地实现对管道螺纹接头部位松动病害的监测和分析。此外,5次重复性实验进一步验证所提方法监测效果的一致性和鲁棒性,可为管道工程监测领域提供参考。     

环戊烷进料线三通裂纹原因分析

通过宏观检验、壁厚及硬度测试、化学成分分析和金相检验等方法,对环戊烷进料线三通产生裂纹及补焊后再次开裂的原因进行了分析。结果表明:三通中的裂纹是制造加工时产生的,在安装应力及管系应力的作用下开裂并造成泄漏;补焊后的焊接应力作用于未消除裂纹部位造成了再次开裂。最后对补焊修复和同类型三通检验提出了建议。     

T型三通管道不同流向的数值模拟分析

在管道使用过程中,由于管道介质中夹带微小固体颗粒易产生冲蚀磨损造成管道穿孔而发生泄漏等问题,为此,运用Fluent软件中的DPM冲蚀预测模型,对不同气流方向下的T型三通管的冲蚀、应力和形变量进行数值模拟,从而得出受冲蚀磨损比较严重的区域以及产生最大应力和形变的区域.结果表明:经过分析,三通管在使用过程中易出现冲蚀磨损、应力集中区域和形变部位,因此对三通管材料的力学性能存在着较高要求.分流a工况下的冲蚀速率为5.59×10-9kg/(m2·s),受到的冲蚀磨损最大;汇流b工况下的冲蚀速率为3.03×10-9 kg/(m2·s),受到的冲蚀磨损最小;冲蚀速率较大的工况下的最大应力和形变量也较大.     

兰成渝输油管道东峪沟沉管治理工程应力应变监测技术应用及研究

本研究以沉管区管道的应变监测作为基本出发点,分析了边界点、弯管区、过渡段、最大挠度区管道单元的轴向、环向、45°方向应力及最大主应力变化趋势,并结合弹性破坏理论,对沉管区管道安全状况做出了有效的评价,给出了基于应变测试技术的管道沉降过程力学监测理论。     

Hot deformation behavior and processing map development of AZ110 alloy with and without addition of La-rich Mish Metal

In order to compare the workability of AZ110 alloy with and without addition of La-rich Mish Metal(MM), hot compression tests were performed on a Gleeble-3500 D thermo-mechanical simulator at the deformation temperature range of 473-623 K and strain rate range of 0.001-1 s-1. The flow stress, constitutive relation, DRX kinetic model, processing map and microstructure characterization of the alloys were investigated. The results show that the flow stress is very sensitive to deformation temperature and strain rate, and the peak stress of AZ110 LC(LC = La-rich MM) alloy is higher than that of AZ110 alloy.The hot deformation behavior of the alloys can be accurately predicted by the constitutive relations. The derived constitutive equations show that the calculated activation energy Q and stress exponent n for AZ110 alloy are higher than the calculated values of AZ110 LC alloy. The analysis of DRX kinetic models show that the development of DRX in AZ110 LC alloy is earlier than AZ110 alloy at the same deformation condition. The processing maps show that the workability of AZ110 LC alloy is significantly more excellent than AZ110 alloy and the microstructures are in good agreement with the calculated results.The AZ110 LC alloys can obtain complete DRX microstructure at high strain rate due to its higher stored energy and weak basal texture.     

Deformation dynamics at low and ambient temperatures

The variation of tensile yield stress at a constant strain rate as a function of temperature for well-annealed pure metals show, with increasing temperatures, a rather sharp drop in yield stress (low temperature regime), followed by the intermediate temperature regime where yield stress decreases more slowly (and the ratio of yield stress to shear modulus remains more or less constant), which in turn is followed by the high temperature regime where the yield stress drops again rather sharply. The paper discusses the phenomenological framework for studying deformation dynamics in the low and intermediate temperature regimes. The approach adopted is the well-known state variable approach, where the evolutionary nature of deformation structure is described by one or more structure variables such that the current values of mechanical variables and structure variables together completely define the current state of deformation. A critical analysis of experimental results available suggest that at least for deformation at low strain rates, stress-rate is probably not a state variable of deformation. Thus deformation is most conveniently studied in terms of TASRA (thermally activated strain rate analysis) where the stress, plastic strain rate, temperature and structure are interrelated through a Gibb’s free energy for thermal activation by an Arrhenius equation. The stress-dependence of Gibb’s free energy and its maximum value then form the basis of identifying the rate-controlling obstacles. The need for careful experimentation and systematic analysis is illustrated by the example of low temperature deformation of hard hep metals. Modelling for the evolution of deformation structure is also touched upon.     

高模量涤纶纤维的结构弱节特征及力学行为

采用断面形态特征与纤维对应拉伸曲线组合的对比分析方法,讨论了歼雉的结构弱节及拉伸行为。结果表明,涤纶纤维的弱节主要是表层缺陷及其扩展所引起的,其力学性能为低应力、低应变、低断裂功特征。     

Constitutive modeling and prediction of hot deformation flow stress under dynamic recrystallization conditions

Simple modeling approaches based on the Hollomon equation, the Johnson–Cook equation, and the Arrhenius constitutive equation with strain-dependent material’s constants were used for modeling and prediction of flow stress for the single-peak dynamic recrystallization (DRX) flow curves of a stainless steel alloy. It was shown that the representation of a master normalized stress–normalized strain flow curve by simple constitutive analysis is successful in modeling of high temperature flow curves, in which the coupled effect of temperature and strain rate in the form of the Zener–Hollomon parameter is considered through incorporation of the peak stress and the peak strain into the formula. Moreover, the Johnson–Cook equation failed to appropriately predict the hot flow stress, which was ascribed to its inability in representation of both strain hardening and work softening stages and also to its completely uncoupled nature, i.e. dealing separately with the strain, strain rate, and temperature effects. It was also shown that the change in the microstructure of the material at a given strain for different deformation conditions during high-temperature deformation is responsible for the failure of the conventional strain compensation approach that is based on the Arrhenius equation. Subsequently, a simplified approach was proposed, in which by correct implementation of the hyperbolic sine law, significantly better consistency with the experiments were obtained. Moreover, good prediction abilities were achieved by implementation of a proposed physically-based approach for strain compensation, which accounts for the dependence of Young’s modulus and the self-diffusion coefficient on temperature and sets the theoretical values in Garofalo’s type constitutive equation based on the operating deformation mechanism. It was concluded that for flow stress modeling by the strain compensation techniques, the deformation activation energy should not be considered as a function of strain.     

特大跨缆索桥钢箱梁疲劳应力特性对比性研究

疲劳应力监测是特大跨缆索桥结构健康监测和安全评估的关键环节。研究发现,对于结构健康监测系统采集的海量应变数据,局部时段不能反映出应变的整体特性,且交通载荷和环境载荷在不同类型的大跨缆索桥如斜拉桥和悬索桥结构中产生的响应是不同的。为了对桥梁的实际运营状态和应力水平有总体而全面的认识,需要对采集数据进行统计分析。本文以润扬悬索桥和斜拉桥钢箱梁应变时程数据为基础,分析了半年内两桥疲劳应力谱的特征;拟合了各自的疲劳损伤增量的概率密度函数。研究表明：对半年样本容量的参数估计显示,润扬悬索桥和斜拉桥的相对累积损伤均不拒绝对数正态分布,且前者均值均高于后者。在相同的环境和车辆载荷下,由车辆和变温载荷所引起的总疲劳损伤增量,悬索桥高于斜拉桥,且前者为后者的两倍以上。考虑了噪声影响的应变时程比去除噪声后的应变时程所造成的损伤增量高出一倍。而耦合了引起材料热胀冷缩的温度变形的影响,其应变时程造成的累积损伤增量比不考虑其影响所造成的损伤增量高出30%。因此,需要严格控制随机干扰和温度变形的影响,将真实的动态应变信息加以提取后才能进行大跨缆索桥的疲劳状态评估。     

某钢结构梁高温切割全过程的监测与分析

为保证某大型生产车间钢框架平台梁在设备荷载作用下改造过程中的安全性,采用ANSYS软件对改造方案进行了有限元分析,并采用光纤光栅传感器对其改造全过程进行了实时可视化监测。通过钢梁的有限元结构分析以及高温切割过程中钢梁温度场分析,确定了钢梁的切割方案,同时为相应高温环境下的结构实时监测方案设计、传感器的布设以及实时监测预警阀值的设定提供了依据。监测过程中实时获取了现场钢梁的工作状态,并对实时监测数据进行了快速分析和评价,从而判断钢梁的安全性,以保证钢梁切割过程的顺利进行。监测结果表明,根据监测方案可以快速评价钢梁的受力状态,为切割机的前进速度提供指导,同时表明光纤光栅应变和温度传感器完全满足高温环境下的测量要求。可视化监测方案在快速预警方面的成功应用可为类似的结构改造提供结构健康监测依据。     

超高分子量聚乙烯人工髋臼材料压缩性能的红外辐射研究

采用先进的试验设备和方法对超高分子量聚乙烯(UHMW PE)人工髋臼材料在不同的加载速度下进行压缩力学性能试验的同时,对其压缩变形过程进行了热红外辐射温度的监测。对超高分子量聚乙烯人工髋臼材料试验过程中的应力与应变、平均红外辐射温度与应变、平均红外辐射温度与机械功之间的关系进行了分析。试验结果为超高分子量聚乙烯人工髋臼材料在特殊的人体环境中的应用提供了参考。     

火灾下平行钢丝束温度膨胀及高温蠕变试验研究

采用非接触式应变视频测量系统,对常用于实际工程的1670级平行钢丝束进行了15个温度水平下的温度膨胀试验以及多应力水平下的高温蠕变试验,并对历经2 h高温蠕变试验后冷却至室温的平行钢丝束试件进行了抗拉强度测试,获取了平行钢丝束热膨胀应变历程及高温蠕变应变历程曲线。试验结果表明:平行钢丝束热膨胀应变随着温度升高呈非线性增长,且在750 ℃附近材料微结构发生相变;温度和应力水平对高温蠕变历程均会产生显著影响;蠕变试验温度愈高,应力水平对历经高温后平行钢丝束的剩余抗拉强度的影响愈显著;与1860级预应力钢绞线相比,1670级平行钢丝束具有较小的高温蠕变应变。基于试验数据,建议了平行钢丝束热膨胀系数关于温度的函数式及高温蠕变模型。该文所建议的平行钢丝束热膨胀系数及高温蠕变模型有利于预应力钢结构火灾高温下的力学响应分析。     

Transient strain of self-compacting concrete loaded in compression heated to 700 °C

Self-compacting concrete (SCC) tends to spall when subject to high temperature in case of an accidental fire. Proper understanding its deformation properties at elevated temperatures is necessary in avoiding detrimental effects. This paper presents the experimental results carried out on SCC specimens subjected to high temperatures when they are loaded. The transient strain and load induced thermal strain of SCC are measured under the variation of temperature level, heating rate, stress level, strength grade of SCC, and content of polypropylene fibres. Furthermore, measurements with differential thermal analysis, SEM and mercury intrusion porosimetry had been conducted on samples taken from thermal-loading tests to investigate the mechanism that induces transient strain.     

Remaining Life Evaluation Based on Strain Deformation Monitoring

The operating conditions of a power plant affect its structural integrity due to many degradation mechanisms, among which is creep. Strain measurements constitute a relatively simple and reliable method of obtaining accurate data regarding the capability of engineering materials to withstand loads and of determining stress distribution in all manner of structural components. This work carried out a critical evaluation of the application of a high-temperature strain gage on a strain and stress analysis. The sensor was undergoing a group of long-term creep tests whose results were compared with the creep machine’s acquisition system. The same strain gage was part of a monitoring system and its out some used on the remaining life evaluation a power plant’s pipeline. The methodology consists of online strain monitoring of those components or regions more susceptible to creep failure, which were identified by finite element analysis. The long-term creep tests using high-temperature strain gages showed that the relative position between sensor and the sample necking region exercises great influence on the measured results. Linear relationship between minimum creep rate obtained by strain gages and rupture time values was observed. The power plant pipeline analysis showed that thermomechanical fatigue is the predominant degradation mechanism.