Micro-strain distribution around a crack tip by electron beam moiré methods

The microscopic deformation around a crack tip in a small tensile specimen of aluminum was measured by using electron beam moiré methods. The tensile test was carried out in a scanning electron microscope(SEM) by using specially designed small tensile testing apparatus for an SEM. A line grating with a pitch of 87 nm was written at the crack tip by electron beam lithography. SEM images of the grating contained(original) moiré fringes at certain magnifications without loadings on the specimen. The displacement and strain in the region 10 to 50 μ m from the crack tip were evaluated by analyzing the (mismatch) moiré fringes. Measured strains normal to loadings(longitudinal strains) near the crack tip were found to be comparable to those estimated using linear elastic fracture mechanics(LEFM), for the lowest load, and elastic-plastic fracture mechanics, at effective crack tip position located within the actual crack tip. The exponent of the strain singularity in the vicinity of the actual crack tip changed with applied stress, ranging between ?0.64 and ?1.0. The measured crack tip opening displacement(CTOD) values disagreed with CTODs based on the Hutchinson-Rice-Rosengren(HRR) field, the Dugdale model, and LEFM. The experimental plastic zones spread from the line of crack extension up to an angle of about 60°, as expected from LEFM theory.     

三向应力度对船用钢三明治板激光焊焊接接头等效断裂应变的影响

为使船用钢CCS-B三明治板激光焊焊接接头在拉伸初期处于不同应力状态,设计了不同尺寸及缺口半径的试样,分别在平面应变、平面应力状态下获得不同的初始三向应力度,进而获得不同应力状态下的力学性能。试验结果表明：在进行拉伸试验时,试样无论是处于平面应力状态下还是平面应变状态下,随着初始三向应力度的减小,等效断裂应变增大,塑性变好;三向应力度与等效断裂应变之间均满足指数关系,即等效断裂应变随着三向应力度的增加呈现指数减小;断口形貌均为韧窝的韧性断裂形貌。     

Novel specimen for the effective measurement of the fracture strain along with stress triaxiality and Lode parameter

A double notched central hole, i.e., DNC specimen, which contains a center hole with a left side notch and a right side notch accompanying the slope α, is proposed to simultaneously achieve dual values of stress triaxiality and Lode parameter from one specimen in the present study. Analytical and numerical approaches are carried out under decent assumptions to characterize the plane strain behavior of DNC specimen along with the slope α. Quasi-static tensile tests with conventional specimens and DNC specimens revealed plastic strains at fracture for each specimen case in accordance with stress triaxiality and Lode parameter by digital image correlation. It is found that one DNC specimen successfully provides dual values of stress triaxiality and Lode parameter at the same time; therefore, it saves up to 50 % of experimental time and labor of conventional specimens.

     

Observation of notch effect in Al6061-T6 specimens under tensile loading using digital image correlation and finite element method

The fracture of ductile materials such as Al6061-T6 usually starts from void nucleation. In this study, we investigated strengthening effect and stress triaxiality behavior in notched Al alloy specimens. Various specimens, one un-notched and two with different U-types of notch, one with large diameter (L-notched) and another with small diameter (S-notched), having the same width were selected. The distribution of strain in the full-field was examined using the digital image correlation (DIC) method. Under the tensile test, S-notched specimens showed a more pronounced strengthening effect than the L-notched specimens. The results of DIC confirmed that the notch tip of the S-notched specimen experienced high strain, while the L-notched specimen experienced high strain at the center. The maximum stress triaxiality moved rapidly from the notch tip to the center with the increase in notch radius over 10 mm. The results of the stress triaxiality analysis by finite element method were in good agreement with the above DIC measurement results and predicted the void generation and fracture sites in L-notched and S-notched specimens.     

Mechanical properties of CO<Subscript>2</Subscript>/MIG welded structural rolled steel and stainless steel

To accomplish long-term use of specific parts of steel, welding technology is widely applied. In this study, to compare the efficiency in improving mechanical properties, rolled steel (SS400) was welded with stainless steel (STS304) by both CO₂ welding method and MIG (metal inert gas) welding method, respectively. Multi-tests were conducted on the welded specimen, such as X-ray irradiation, Vickers’ Hardness, tensile test, fatigue test and fatigue crack growth test. Based on the fatigue crack growth test performed by two different methods, the relationship of da/dN was analyzed. Although the hardness by the two methods was similar, tensile test and fatigue properties of MIG welded specimen are superior to CO₂ welded one.     

氢对裂纹尖端塑性变形及裂纹扩展影响的TEM观察

利用透射电镜原位动态拉伸方法观察、分析氢对裂纹尖端塑性变形及裂纹扩展过程的影响。结果表明，氢促进裂纹尖端的局部塑性变形，改变裂纹扩展方式，并使裂纹以“Ｚ”字型的途径扩展。     

Deformations of a simplified flip chip structure under thermal testing inspected using a real-time Moiré technique

Deformations of a Si-epoxy-FR4 (simplified flip chip) structure under thermal testing were inspected with a real-time Moiré technique. Specimens without cracks and specimens with a crack at the silicon-epoxy interface were prepared. The measurement results showed that the maximum deformation appeared at the edge. When the specimen was cooled to 20 °C, there was residual plastic deformation in the specimen. The creep effect was more dominant in the FR4-epoxy interface. Upon cooling to 20 °C, the specimen experienced partial strain recovery. To characterize the behavior of the interfacial crack, stress intensity factors K_I and K_II, and the strain energy release rate G in the vicinity of the crack tip were calculated using the measured deformations to conduct a quantitative study. It was observed that a sharp strain gradient occurred at the crack tip. K_I and K_II were dependent on temperature, and G was dominated by K_I for the interfacial crack in the specimen.     

异种钢焊接接头脉冲放电强化与力学性能分析

采用电磁热止裂强化方法对异种材料焊接接头进行强化研究,对含椭圆形埋藏裂纹缺陷的焊接接头进行了脉冲放电数值分析,得到放电瞬间的热应力场和冷却到常温时的残余应力场,结果表明,脉冲放电瞬间焊接接头中的裂纹尖端温升超过材料熔点,裂尖钝化并产生了有利的残余压应力;对Q235和1Cr18Ni9焊接接头进行了电磁热强化试验研究,结果表明,试件通过放电强化,焊接接头的力学性能得到改善,抗拉强度提高19.4%,冲击韧性提高12.07%。     

BGA结构无铅微焊点的低周疲劳行为研究

基于塑性应变能密度概念提出微焊点低周疲劳裂纹萌生、扩展和寿命预测模型,阐明其与连续介质损伤力学的联系,评估应力三轴度对预测模型的影响,并通过试验和数值计算相结合的方法确定出微米尺度球栅阵列(Ball grid array,BGA)结构单颗Sn3.0Ag0.5Cu无铅焊点(高度为500～100 μm,焊盘直径为480 μm)疲劳裂纹萌生和扩展模型中的相关常数。研究结果表明,疲劳裂纹萌生和扩展循环数与每个循环所产生的塑性应变能密度均呈幂函数关系;应力三轴度会影响疲劳裂纹扩展速率,并最终影响焊点的疲劳寿命;应力三轴度与加载方式有关,拉伸载荷下焊点的应力应变行为受异种材料界面和封装结构力学约束作用的影响,应力三轴度随焊点高度降低而明显升高;而剪切载荷作用下焊点中的力学约束十分有限,焊点高度变化对应力三轴度的影响非常小;测得的高度为100 μm焊点的疲劳裂纹扩展相关常数可以很好地用于预测其他不同高度焊点的疲劳寿命,表明所提出的预测模型可以有效地减小由几何结构和体积变化造成的塑性应变能集中现象对焊点疲劳寿命的影响。     

Development of a combined tension–torsion experiment for calibration of ductile fracture models under conditions of low triaxiality

Developments in computational mechanics have given engineers tools to predict the evolution of damage in complex structures. Damage models have been developed that relate failure strain to stress triaxiality and Lode angle. Calibration of these models has traditionally relied on specimens that exhibit high triaxiality and limited Lode angle. This paper presents a specimen that can be tested in combined tension and torsion to achieve low triaxiality over a range of Lode angle. Numerical analysis of the specimen shows that it exhibits uniformity of stress–strain and stable values of triaxiality and Lode angle as plastic strain develops, both of which are desirable characteristics for calibration of ductile failure models. The design of a new displacement and rotation gage is presented that allows non-contact measurement at the gage section. Experimental results are used to develop the failure surface for 5083 aluminum.     

Crack Propagation of Rolling Contact Fatigue in Ball Bearing Steel Due to Tensile Strain

Crack propagations or failure modes in rolling element bearings, which had been difficult to explain via conventional crack propagation mechanisms such as the orthogonal shear stress mechanism, were discussed from the viewpoint of a tensile strain mechanism. Contact stresses are compressive in three axes, whose values differ from each other; then strain can be tensile in one of these directions, acting at a right angle to the direction of maximum compressive stress. A crack is considered to propagate by this tensile strain. When contact stress is small, a crack produced by some cause can propagate by this elastic tensile strain. When contact stress is large, residual tensile strain is produced by plastic deformation, which can also influence the crack propagation. Several failure modes of rolling element bearings, which had been difficult to explain, were explained by tensile strain.     

非均质焊接接头裂纹尖端塑性区

采用平面应力弹塑性大应变有限元法分析了非均质焊接接头裂纹尖端塑性区的扩展规律，指出在非均质焊接接头中存在着塑性变形的不同时性与不均匀性，且焊缝金属强度匹配、材料本构关系以及裂纹长度（韧带长度）对塑性区的发生发展均有重要影响。     

裂纹位置对焊接接头断裂参量的影响

结合焊接结构的工程安全评定,针对焊接接头熔合线上容易出现缺陷的问题,本文利用有限元计算方法,编写了断裂参量J积分计算的有限元程序,并对裂纹位置不同时的焊接接头进行了有限元计算。结果表明,无论是平面应变还是平面应力条件下,焊接接头J积分值都与全母材和全焊缝材料不同;与此同时,裂纹位于熔合线上和裂纹处于焊缝中,焊接接头的J积分值也是有所差异的,并且,这种差异在平面应变状态下表现得更加明显。在实际工作中,对焊接接头的断裂参量的计算必须考虑裂纹所处位置的影响。     

980MPa级低碳贝氏体高强钢MAG焊接接头不同试样的拉伸断裂机理

在980MPa级深海用低碳贝氏体高强钢MAG焊接接头上,制取5种不同形状和缺口位置的试样进行拉伸试验,原位观察了每种试样的动态断裂过程,并对其断裂机理进行了分析,确定了焊接接头的薄弱部位。结果表明:直缺口试样的断裂经历了塑性变形、裂纹起裂、裂纹扩展、裂纹尖端钝化,直至断裂的过程,并且在裂纹扩展过程中,裂纹尖端重复钝化、扩展、新裂纹产生、再钝化、再扩展;圆弧和平板试样以剪切方式断裂,经历了塑性变形、颈缩、出现微裂纹、微裂纹扩展,直至瞬间断裂的过程;所有试样的薄弱部位都为焊缝金属。     

Shear deformation of voids with contact modelled by internal pressure

The behaviour of voids in a ductile material subject to simple shear or to a shear-dominated stress state is analyzed numerically. Here the stress triaxiality is so low that instead of void volume growth to coalescence there is void closure leading to micro-cracks that rotate in the shear field. At some stage of the deformation, the void surfaces will come in contact so that sliding with or without friction will start to occur. To avoid problems with strong mesh distortion in the large strain field around the deforming void and with mesh resolution at the tip of the crack, an internal pressure is applied as an approximate representation of void surfaces pressed together in frictionless sliding, and also remeshing is applied. This micromechanical model for a strain hardening elastic–plastic material shows that a maximum overall shear stress is reached, at which localization of plastic flow occurs, leading to final failure in the material.     

煤制天然气中氢对X80钢螺旋焊管力学性能的影响

近年来,我国多项煤制天然气示范工程投入运行,X80钢螺旋焊管常用于天然气长输管道建设,其与煤制天然气的相容性直接影响了长输管道的服役寿命和安全可靠性。为研究煤制天然气对国产X80钢螺旋焊管的力学性能影响,分别从埋弧螺旋焊管的母材和螺旋焊缝处取样,在总压为12 MPa,氢气分数为0,1vol%,2.2vol%,5vol%的模拟环境中分别进行慢应变速率拉伸试验和疲劳裂纹扩展速率试验。试验结果表明:含氢量5vol%以下时,煤制天然气对国产X80管线钢强度性能影响很小,但对塑性性能有一定影响,对疲劳裂纹扩展性能影响很大,煤制天然气中氢对母材的疲劳裂纹扩展性能劣化影响比螺旋焊缝严重。     

垫板导热能力对钛合金薄板焊接残余应力的影响

针对钛合金TC4薄板钨极氩弧焊(GTAW)分别在试件背面衬以铜垫板与覆盖石棉的垫板两种情况下所焊的对接试件,采用切条应力释放法测量了其中纵向残余应力和纵向残余塑性应变的分布,比较研究了不同导热能力的垫板对钛合金薄板焊接残余应力及纵向残余塑性应变的影响。测量结果表明:钛合金GTAW焊接过程中垫板不仅提供了对焊缝背面的保护,也影响了焊接纵向残余应力与纵向残余塑性应变的分布与大小。不同导热能力的垫板控制应力与变形的效果不同。铜垫板控制应力与变形的效果好于覆盖石棉的垫板。     

25 Cr2 Ni2 MoV钢焊接接头循环变形行为的有限元模拟与分析

以25Cr2Ni2MoV汽轮机转子钢V形平板焊接接头为研究对象,考虑不同热影响区材料与母材的弹性模量比值、坡口角度及载荷特性（包括不同应力比、平均应力和应力幅值）等因素的影响,采用大型有限元软件ABAQUS和Chaboche循环本构模型对接头的循环变形行为、局部塑性变形分布及其随循环周次的演化特性进行了有限元模拟与分析。结果表明,随着热影响区材料与母材的弹性模量比值的增大,焊接接头整体抗拉和抗棘轮变形能力增强,发生局部破坏的可能性也随之增大;随着坡口角度的增加,焊接接头的抗拉性能和抗棘轮变形能力降低;应力比、平均应力和应力幅值越大,焊接接头越容易发生破坏。研究成果实现了对平板焊接接头结构及性能的初步优化,为提高该类焊接接头的设计水平提供了参考。     

加载速率对焊接接头断裂行为的影响

在不同温度、不同加载速率下，对典型建筑结构用钢及其焊缝进行拉伸试验，测试其基本力学性能。采用能综合考虑加载速率及高加载速率下材料温度变化的R参量，确定本构关系。通过断裂力学试验，测试不同温度及加载速率下供试钢材及其焊接接头的断裂韧度值。随加载速率的增大，断裂韧度降低，但存在有较大的分散性。不同加载速率下裂纹尖端应力场数值分析结果表明，裂纹尖端最大主应力随加载速率的增大而升高。最后基于局部法，研究不同加载速率下母材及接头的断裂行为。局部断裂参量－－威布尔应力不受温度、加载速率的影响，可有效地描述材料的断裂行为。     

Analysis of short and long crack behavior and single overload effect by crack opening stress

The study analyzed the behaviors of short and long crack as well as the effect of single tensile overload on the crack behaviors by using fatigue crack opening behavior. Crack opening stress is measured by an elastic compliance method which may precisely and continuously provide many data using strain gages during experiment. The unusual growth behaviors of short crack and crack after the single tensile overload applied, was explained by the variations of crack opening stress. In addition, fatigue crack growth rate was expressed as a linear form for short crack as for long crack by using effective stress intensity factor range as fracture mechanical parameter, which is based on crack closure concept. And investigation is performed with respect to the relation between plastic zone size formed at the crack tip and crack retardation, crack length and the number of cycles promoted or retarded, and the overload effect on the fatigue life.