不同应力状态下6063铝合金断裂机制原位拉伸研究

用SEM-520原位拉伸实验对可以实现不同应力的6063铝合金试件的断裂过程做了详细研究和分析.研究结果表明:不同应力状态下的铝合金试样在拉伸过程在其表面上都产生了大量的滑移带,但断裂机制不同.随着三轴应力度的降低,断裂从正断向剪断过渡,试件断口也由韧窝断裂模式向剪切断裂模式演变;6063铝合金晶界是其最薄弱环节,大量微裂纹产生于晶界,随着载荷的增加,微裂纹长大和扩展,与此同时,在局部变形带中沿晶界和滑移带又产生了新的微裂纹,微裂纹之间通过扩展或剪切而连接导致试样断裂;试样最小截面上的三轴应力度越小,试样断口的2个面上韧窝的取向越明显,而且断口越光滑.     

应力状态对无取向电工钢塑性变形和断裂行为的影响

以晶粒粗大的无取向电工钢为研究对象,通过改装的Arcan夹具和蝶形试样,研究了0°纯拉伸、45°拉伸-剪切复合、90°纯剪切3种应力状态下,应力三轴度Rσ对材料塑性变形和断裂机制的影响。采用万能拉伸试验机多次定点停车、SEM观察晶粒变形和裂纹扩展的试验方法,实现了对变形过程的"准原位跟踪"及其力学响应的动态分析。发现应力三轴度对晶粒的滑移阻力有决定性影响。应力三轴度Rσ越小滑移越容易进行,其断裂形式越接近于无空穴剪切型损伤,断面韧窝特征越少;反之,滑移越难进行,断裂形式越接近拉伸型空穴损伤,断面韧窝密集。对于无取向电工钢,当Rσ≈0时,随着变形损伤的加剧,材料最终发生剪切型断裂;当0Rσ≤0.4时,材料为剪切和韧窝混合型断裂;当Rσ0.4时,材料为韧窝型断裂。     

剪应力状态下6061铝合金的力学性能及断裂行为

对设计的拉伸剪切试样和原位拉伸剪切试样分别进行不同剪应变率下的拉伸剪切试验及原位拉伸剪切试验,研究6061铝合金在剪力状态下的力学性能及断裂行为,并用有限元软件ABAQUS对铝合金在剪应力状态下的断裂行为进行模拟。结果表明:随着剪应变率的增大,6061铝合金的剪切屈服强度和抗剪强度基本保持不变,但剪切断裂应变明显减小;剪应变率对试样的断口形貌没有影响;6061铝合金晶界是其最薄弱环节,在拉伸剪切过程中铝合金试样表面上产生了大量与拉伸方向平行的滑移带;微裂纹在剪应力作用下形核于与拉伸方向平行的滑移带和晶界,随着剪应力的增加,微裂纹长大和扩展;微裂纹之间通过剪切而连接导致试样断裂;6061铝合金剪切断裂行为可以用Johnson-Cook模型进行描述。     

不同应力状态下6061铝合金力学性能及断裂行为的研究

对不同缺口试样进行准静态拉伸,研究了6061铝合金在不同应力状态的力学性能和断裂行为。研究结果表明,随着缺口半径增大,三轴应力度降低。随着三轴应力度降低,合金的峰值载荷降低,断面收缩率和断裂应变均增大,断口上剪切唇区面积逐渐增大,纤维区的山脊状的锯齿数量逐渐减少,但深度增加,显微断口上的韧窝越来越均匀细小。     

SEM原位观察3104铝合金板材的断裂行为

利用原位拉伸扫描电镜,观察并研究了3104铝合金冷轧板动态拉伸过程中裂纹萌生和裂纹扩展情况,讨论了裂纹萌生和扩展与板材微观组织之间的关系。结果表明：在拉伸过程中,裂纹起源于滑移带处,并沿滑移带扩展。裂纹扩展路径受拉伸应力状态以及板材内部晶粒和粗大第二相分布的影响。原位拉伸断裂模式为韧窝断裂和剪切断裂复合断裂模式,断口形貌受裂纹扩展应力状态的影响。     

不同应力状态下铝合金变形及损伤机理的研究

利用改装的Arcan夹具对铝合金（6063）的蝶形试样进行0°，30°，45°，60°，90°的拉伸及拉伸卸载试验，研究了铝合金在不同应力状态下变形及损伤机理。结果表明：铝合金在不同应力状态下的工程应力一应变曲线明显不同。0°加载时，在蝶形中心产生微孔洞，微孔洞之间剪切，从而产生了微裂纹。随着微裂纹的扩展、连接导致试样断裂。随着试样中三轴应力度的减小，在蝶形试样中心的剪切应力不断增大，同时在蝶形试样中的剪切变形带越来越集中。显微裂纹首先在剪切带中产生，随着微裂纹的扩展导致试样的断裂。90°拉伸时，在蝶形中心形成明显的剪切变形带。90°加载时，在试样中产生的剪切带是形变剪切带而非相变剪切带。利用有限元软件ABAQUS对不同角度拉伸试验进行模拟，从而得出了不同应力状态下的塑性区的形状和大小。     

热处理对7075铝合金应力腐蚀及断口形貌的影响

采用预裂纹双悬臂梁(DCB)试样研究了7075铝合金的应力腐蚀行为.结果表明,四种不同热处理状态合金的应力腐蚀敏感性由高向低的排列顺序为T6>G180>RRA>T7351.不同热处理状态的7075铝合金试样在干燥空气中的SSRT拉伸断口形貌都是由韧窝剪切台阶组成,属于韧窝型延性断裂.在3.5%NaCl溶液中,应力腐蚀敏感性较高的T6状态铝合金,其断口形貌是由塑性韧窝和腐蚀平坦区组成的,而应力腐蚀敏感性较轻微的7075-G180铝合金,属韧性断裂.     

6061铝合金冲击载荷作用下的变形断裂行为

利用常见的落锤冲击试验机和自行设计的夹具装置,研究6061铝合金材料在冲击载荷作用下的变形断裂行为。结果表明:6061铝合金受冲击载荷时的断裂行为与准静态拉伸相比无明显变化,损伤形式仍是由晶界处的微孔洞连接形成微裂纹,宏观上仍产生明显颈缩,试样的断裂面与拉伸轴方向大约成45°角。摆锤高度不同,试样表面的变形带不同,摆锤高度为141°时,出现了"白色变形带"。微观断口是由韧窝组成,冲击速度越大,韧窝越小。     

铝合金在两种应力状态下损伤机理研究

铝合金汽车构件在撞击的过程中,构件的应力状态各点均不相同,而且在撞击的过程中各点的应力状态随着时间变化而变化.为了研究铝合金构件在不同应力状态下损伤机理,采取了两种代表性的三轴应力状态,即缺口拉伸与纯剪切所产生的应力状态.研究结果表明缺口拉伸试验中,缺口根部产生相对较高的三轴应力,而且缺口根部明显产生微孔洞,随着应力的不断升高,微孔洞的体积分数不断增大.当达到材料的临界孔洞体积分数时,试样断裂;纯剪切试验中,三轴应力几乎等于0,在材料内部几乎没有产生微孔洞而产生了剪切带.剪切带在切应力的作用下变形不断增大,当到达材料的等效塑性断裂应变时,试样发生断裂;用Gurson损伤模型和剪切失效分别模拟缺口拉伸和剪切试验,试验的工程应力-应变曲线与模拟的工程应力-应变曲线拟合的很好.     

铝合金在两种应力状态下损伤机理研究

铝合金汽车构件在撞击的过程中,构件的应力状态各点均不相同,而且在撞击的过程中各点的应力状态随着时间变化而变化.为了研究铝合金构件在不同应力状态下损伤机理,采取了两种代表性的三轴应力状态,即缺口拉伸与纯剪切所产生的应力状态.研究结果表明:缺口拉伸试验中,缺口根部产生相对较高的三轴应力,而且缺口根部明显产生微孔洞,随着应力的不断升高,微孔洞的体积分数不断增大.当达到材料的临界孔洞体积分数时,试样断裂;纯剪切试验中,三轴应力几乎等于0,在材料内部几乎没有产生微孔洞而产生了剪切带.剪切带在切应力的作用下变形不断增大,当到达材料的等效塑性断裂应变时,试样发生断裂;用Gurson损伤模型和剪切失效分别模拟缺口拉伸和剪切试验,试验的工程应力-应变曲线与模拟的工程应力-应变曲线拟合的很好.     

Mechanical properties and fracture behaviors on 6061 aluminum alloy under shear stress state

The mechanical properties and fracture behaviors of 6061 aluminum alloy were investigated by the tensile shear tests and in-situ tensile shear tests with tensile shear specimen devised. The results indicate that many slip bands parallel to tensile direction are produced on the surfaces of the specimens. With shear strain rates increasing, the shear yield stress and shear ultimate stress of 6061 aluminum alloy remain constant basically, but the shear fracture strain decreases obviously. The shear strain rates have no influence on the fracture surfaces. The grain boundaries of 6061 aluminum alloy are the weakest area and microcracks initiate at the grain boundaries parallel to tensile direction under shear stress. With the shear stress increasing, the microcracks extend and coalesce. The fracture of specimens is due to coalescence or shearing between the microcracks.     

MECHANISM MAP OF TORSIONAL FATIGUE FRACTURE

Studies have been made of the torsional fatigue fracture life of notched specimens,the macroscopic fractography and microscopic fracture mechanism of steel 40Cr after various tempering treatments under different stresses,With the increase of stress,the fracture model changes from normal stress fracture to longitudinal shear one,and then transversal shear one. Under same stress,with the increase of strength,the fracture mode transfers from shear to normal stress fracture.The mechanism of normal stress fracture may be:transgranular frac- ture→striation+intergranular fracture→dimple+intergranular fracture,and of shear fracture may be:transgranular fracture→shear trace→dimple.Based on the experimental results,a fracture mechanism map of torsional fatigue has been drawn up.     

40CrNiMo钢高温拉伸变形行为和组织演变规律

采用光滑和缺口拉伸试样进行不同温度(950、1050和1150 ℃)和不同应变速率(0.5、1.0和5.0 s^-1)的高温拉伸试验,研究了40CrNiMo钢在高温拉伸时的力学性能变化、微观组织演变以及塑性损伤形成机理,分析了不同应力三轴度对高温塑性损伤的影响。结果表明,提高变形温度或降低应变速率会降低峰值应力;应变速率从0.5 s^-1增大至5 s^-1,晶粒大小不均匀程度增加,材料更容易产生塑性损伤;变形温度从950 ℃提高到1150 ℃,晶粒尺寸增大近3倍;损伤经历形核、长大并形成微裂纹3个步骤,应力三轴度与缺口半径成负相关关系,应力三轴度的增大会加剧塑性损伤的发生,使得拉伸试件的断裂应变值降低。在车轴实际轧制过程中,在保证一定生产效率的前提下,可以通过尽可能减小楔横轧模具的成形角,并适当增大展宽角的方法,来降低材料塑性变形时内部各处的动态应力三轴度值,降低损伤发生的概率。     

7075铝合金搅拌摩擦焊接头变形及失效行为

使用搅拌摩擦焊（FSW）设备对厚度为6mm的7075高强度铝合金平板进行对接试验。设计出双径试样,采用液压伺服试验机对7075铝合金搅拌摩擦焊接头进行拉伸试验,并借助奥林巴斯显微镜和扫描电镜观察接头的变形及失效过程。结果表明,7075铝合金搅拌摩擦焊接头在拉伸过程中出现双颈缩现象,颈缩首先在后退侧出现,随着加载的进行,前进侧也出现颈缩现象。微裂纹在接头中的前进侧和后退侧颈缩区内晶界处由微孔洞聚集产生。随着应变的增加,微孔洞数量明显增加,当应变足够大时,微孔洞连接形成微裂纹。微裂纹沿着与加载方向成45°向焊核区进行扩展,导致接头断裂,断裂位置位于接头中的焊核区,断裂方式为剪切断裂混合着微孔聚集型断裂。     

Damage and fracture mechanism of 6063 aluminum alloy under three kinds of stress states

To study the damage and fracture mechanism of 6063 aluminum alloy under different stress states,three kinds of representative triaxial stress states have been adopted,namely smooth tensile,notch tensile,and pure shear.The results of the study indicate the following.During the notch tensile test,a relatively higher stress triaxiality appears in the root of the notch.With the applied loading increasing,the volume fraction of microvoids in the root of the notch increases continuously.When it reaches the critical volume fraction of microvoids,the specimen fractures.During the pure shear test,the stress triaxiality almost equals to zero,and there is almost no microvoids but a shear band at the center of the butterfly specimen.The shear band results from nonuniform deformation constantly under the shear stress.With stress concentration,cracks are produced within the shear band and are later coalesced.When the equivalent plastic strain reaches the critical value（equivalent plastic fracture strain）,the butterfly specimen fractures.During the smooth tensile test,the stress triaxiality in the gauge of the specimen remains constant at 0.33.Thus,the volume of microvoids of the smooth tensile test is less than that of the notch tensile test and the smooth specimen fractures due to shearing between microvoids.The G-T-N damage model and Johnson-Cook model are used to simulate the notch tensile and shear test,respectively.The simulated engineering stress-strain curves fit the measured engineering stress-strain curves very well.In addition,the empirical damage evolution equation for the notch specimen is obtained from the experimental data and FEM simulations.     

应力三轴度和罗德参数对铝合金材料韧性断裂的影响

大量研究表明应力三轴度对韧性断裂有重要影响。然而,最新研究表明,与应力偏张量第三不变量相关的罗德参数也是影响韧性断裂的重要因素。采用7075铝合金制成的缺口圆棒和凹槽平板试样分析了应力三轴度和罗德参数对韧性断裂的影响及相应的微观机理。通过准静态拉伸试验和数值模拟得到应力三轴度、罗德参数及失效轨迹,同时利用扫描电镜分析了试样不同应力状态下的空穴演化规律。结果表明,应力三轴度和罗德参数对破坏应变有重要影响,并且罗德参数的影响随应力三轴度的增加而降低。断口分析表明,孔洞的尺寸随着应力三轴度的增大而减小,不同罗德参数的空穴形态明显不同。二级孔洞的成核速率和生长程度也受罗德参数的影响。     

MECHANISM ANALYSIS OF THICKNESS EFFECT ON MIXED MODE I／II FRACTURE OF LC4-CS ALUMINUM ALLOY

Mixed mode I//II fracture experiments of LC4-CS aluminum alloy were conducted by using tension-shear specimens with thicknesses of 2, 4, 8 and 14mm. Fracture mechanisms of thickness effect on mixed mode I//II fracture were first examined from fracture surface morphology to correlate with the macroscopic fracture behavior and stress state. It is found that specimen thickness has a strong influence on mixed mode fracture. As thickness varies from thin to thick the macroscopic fracture surfaces appear the characteristics of plane stress state (2mm, 4mm-thick specimen), three-dimensional stress state (8ram-thick specimens), and plane strain state (14mm-thick specimens), respectively. The specimens of all kinds of thicknesses are typical of tensile type failure under mode I loading condition and shear type failure under mode II loading condition. Two distinct features coexist on the fracture surfaces under mixed mode loading conditions, and the corresponding proportion varies with loading mixity. Void-growth processes are the failure mechanism in both predominately tensile and shear-type fractures. The size and depth of dimples on the fracture surface vary greatly with thickness. Therefore, it is extraordinary necessary to take into account the thickness effect when a mixed mode fracture criterion is being established.     

MECHANISM ANALYSIS OF THICKNESS EFFECT ON MIXED MODE Ⅰ/Ⅱ FRACTURE OF LC4-CS ALUMINUM ALLOY

Mixed mode Ⅰ/Ⅱ fracture experiments of LC4-CS aluminum alloy were conducted by using tension-shear specimens with thicknesses of 2, 4, 8 and 14mm. Fracture mechanisms of thickness effect on mixed mode Ⅰ/Ⅱ fracture were first examined from fracture surface morphology to correlate with the macroscopic fracture behavior and stress state. It is found that specimen thickness has a strong influence on mixed mode fracture. As thickness varies from thin to thick the macroscopic fracture surfaces appear the characteristics of plane stress state (2mm, 4mm-thick specimen), threedimensional stress state (8mm-thick specimens), and plane strain state (14mm-thick specimens), respectively. The specimens of all kinds of thicknesses are typical of tensile type failure under mode I loading condition and shear type failure under mode Ⅱloading condition. Two distinct features coexist on the fracture surfaces under mixed mode loading conditions, and the corresponding proportion varies with loading mixity. Void-growth processes are the failure mechanism in both predominately tensileand shear-type fractures. The size and depth of dimples on the fracture surface vary greatly with thickness. Therefore, it is extraordinary necessary to take into account the thickness effect when a mixed mode fracture criterion is being established.     

Ti-6Al-4V合金中的绝热剪切断裂

利用分离式霍普金森压杆（SHPB）装置在3900s-1应变率条件下对Ti-6Al-4V合金进行动态加载,获得完全分离的断裂试样。使用扫描电子显微镜对试样的断裂特征进行观察。结果表明：试样中出现绝热剪切断裂,试样断口上交替分布着两个不同特征的典型区域（韧窝区及平滑区）。其中,韧窝区由微孔洞形核、长大并最终连接形成,表现出韧性断裂特征。在平滑区观察到超细晶粒（UFGs）,且晶粒间可观察到微裂纹,说明平滑区由微裂纹沿晶界扩展形成,表现出脆性断裂特征。由此可知,Ti-6Al-4V合金在动态加载过程中沿绝热剪切带发生的断裂失效过程不均匀,韧性及脆性两种断裂模式的共同作用导致该合金样品的最终断裂。