KDP晶体超精密加工技术的研究

通过对KDP晶体等脆性材料的塑性域切削进行理论分析，研究实现脆性材料塑性域切削的条件。激光核聚变KDP晶体的3项主要技术指标是：表面粗糙度、波纹度和透射波前。通过分析影响这3项技术指标的因素。提出了实现KDP晶体精密加工的超精密机床和工艺参数。通过理论分析与实验。研究了晶向、刀具前角、刀具圆弧半径和进给量等参数对表面粗糙度的影响，最终给出KDP晶体精密加工的最佳工艺参数。     

金属塑性成形的晶体塑性学有限元模拟研究进展

综述了金属塑性成形过程中晶体塑性有限元模拟的理论背景和应用方面的研究进展,同时总结了国内研究者该领域的研究现状,指出了晶体塑性有限元模拟所要解决的问题及研究重点。晶体塑性理论起源于20世纪20 年代,包括单晶塑性本构理论和多晶塑性本构理论,能够深刻揭示材料变形的规律。与此同时,开始于30多年前的有限元法也已经日益成为求解材料成形理论公式的有效工具。晶体塑性有限元法作为一个强大的模拟工具将二者有机地结合在一起,已经广泛地用于模拟材料的微观结构和各种力学响应,越来越被材料界和力学界的研究者所重视;然而,无论是在理论方面还是应用方面晶体塑性有限元法都还不尽完善。未来晶体塑性有限元模拟的理论研究重点是建立系统的理论架构用于预测由滑移和孪晶引起塑性变形材料的各种力学响应,应用研究重点是运用各种模型模拟其他与织构相关的性能或参数。晶体塑性有限元模拟不仅能够深化人们对材料成形规律的理解, 而且可以不断推进晶体塑性理论的发展。     

基于晶体塑性理论的钛合金疲劳寿命预测

钛合金是航空航天及船舶制造领域的重要材料。为研究钛合金在拉伸载荷作用下的疲劳寿命,突破传统宏观有限元方法,在介观尺度上基于晶体塑性理论,对钛合金进行仿真。应用Neper与ABAQUS软件,建立Ti-5553钛合金材料的晶体塑性有限元模型,对其应力仿真结果进行分析。结果表明,模型中的最大等效应力为476.6 MPa,最小等效应力为69.95 MPa。将仿真结果导入Fe-safe疲劳分析软件,对钛合金材料的疲劳寿命进行预测,得到疲劳寿命计算结果为229 567次。     

复合材料裂纹尖端塑性区的一种解法

基于Tsai-Hill强度理论,在平面应力条件下,推导正交各向异性复合材料Ⅰ型、Ⅱ型以及Ⅰ-Ⅱ复合型裂纹塑性区方程,得到的结果适用于求解各向同性材料和拉压强度相等的各向异性复合材料的裂尖塑性区;数值算例给出不同材料坐标系与总坐标系夹角θ下的一组复合材料裂尖塑性区结果,讨论参数θ对裂尖塑性区大小和形状的影响,并与各向同性材料的结果进行比较.数值结果表明,参数θ对复合材料裂尖塑性区的影响很明显,各向同性材料具有更大的塑性区.     

工件材料的各向异性对超精密切削变形及已加工表面粗糙度的影响

研究了单晶铜超精密切削时，工件材料的晶体取向对切削变形及表面质量的影响。切削试验结果表明，剪切角、切削力，表面粗糙度随晶体切削方向的不同而有明显的变化。根据超精密切削中切屑形成过程的晶体塑性力学模型，分析了剪切角与切削力随晶体取向的变化规律。理论分析结果与试验结果相符。     

复合型裂纹小范围屈服下裂尖塑性区统一解

采用俞茂宏统一强度理论,推导Ⅰ、Ⅱ复合型裂纹在小范围屈服条件下裂尖塑性区尺寸的统一解析解.给出材料参数在不同拉压比α、泊松比v和中间主应力影响参数b下的一族裂尖塑性区形状与大小的轨迹.讨论以上参数对裂尖塑性区变化的影响,其中拉压比α对塑性区影响较大,α≠1导致塑性区在裂纹上下表面处不连续,b=0和b=1分别对应裂尖塑性区的上限、下限边界.同Tresca准则、Mises准则的解进行比较分析,已有解均是它的特例或线性逼近,该理论解具有理论的统一性和对不同材料的普适性.     

氟化钡晶体超精密切削材料去除机理研究

氟化钡晶体在红外成像与激光系统有着广泛而重要的应用,作为典型的萤石型离子晶体,其材料去除机理目前尚不清晰,获得超光滑表面仍极具挑战.本研究采用槽切法研究氟化钡晶体脆塑转变临界深度、脆塑转变机制及表面缺陷形成机理.通过分析最大未变形切屑厚度随切削参数的变化规律,提出实现氟化钡晶体塑性域切削的理论模型.对氟化钡晶体进行了端...     

晶体塑性疲劳指示因子研究方法综述

金属材料与结构的疲劳失效被视为工程领域的“癌症”,是微观结构逐渐劣化的结果,因此从微观角度准确预测材料与结构的疲劳裂纹萌生就显得极为必要与迫切。基于晶体塑性有限元的疲劳指示因子(Fatigue indicator parameters, FIP)能从微观角度较好地表征剪应变主导的疲劳裂纹驱动力,目前已经形成了累积塑性滑移类、应变能耗散类与多轴疲劳寿命预测准则改进的FIP等。累积塑性滑移类FIP是基于位错滑移与应力集中理论所建立,多个应用案例也表明能较好地描述疲劳驻留滑移带与三叉晶界应力集中等现象,具有形式简单、参数少等优点;应变能耗散类FIP是基于能量理论,不区分载荷模式与裂纹扩展优先方向,在高应变幅或复杂载荷状况下较累积塑性滑移类FIP更可靠;多轴疲劳寿命预测准则改进的FIP主要有基于Fatemi-Socie准则、Dang Van准则与Tanaka-Mura准则等修正的FIP,虽工程应用广泛,但是由于经验模型需要大量试验确定参数且临界平面与位错滑移平面的关系不明。为此,指出研究多轴疲劳损伤的临界平面与晶体塑性的滑移平面的物理一致性、以晶粒旋转数据直接构建晶体塑性FIP模型以及采用模糊...     

KDP晶体塑性域切削技术研究

通过对KDP晶体等脆性材料压痕实验中的塑性行为分析,说明了实现KDP晶体等脆性材料塑性域切削的可行性.通过对脆性材料的切削模型进行分析,阐明了刀具几何尺寸以及切削用量对KDP晶体切削过程的影响.分析已有模型的不足,同时提出了从微观角度建立材料脆性断裂判据,以完善KDP晶体塑性域切削机理的研究思路.     

基于全局优化算法的超塑性本构模型参数的识别

考虑晶粒长大的超塑性本构模型能否成功模拟成形过程依赖于参数选取的好坏,由于该模型涉及多个物理过程且每个过程都很难同其他过程区别开来,同时模型中包含多个材料参数,因此很难通过试验直接识别模型中的材料参数。模型中材料参数通过反分析方法进行。给出需要识别参数的超塑性本构模型,以使晶粒尺寸—时间关系和应力—应变关系计算值和试验值差值的加权平方和最小化为目标,构造目标函数;基于参数物理意义和数值结果给出参数取值范围。基于目标函数特性构造一全局优化算法,该算法吸收遗传算法能进行全局搜索的优点和Levenberg-Marquardt算法和增广Gauss-Newton算法收敛速度比较快的优点。针对某些参数取值范围比较大的特点,设计出同时使用指数编码和传统实型编码的混合编码的遗传算子。最后以Ti-6Al-4V为例,应用构造的算法识别超塑性本构模型中的材料参数,计算结果和试验结果符合较好。     

中速定向凝固K10高温合金的组织和偏析的研究

本文利用最新研制的ZMLMC（区域熔化液态金属冷却）超高温度梯度定向凝固装置研究了钴基高温合金K10在中等冷却速率下定向凝固时的微观组织变化和枝晶偏析及其与凝固参数的关系。结果表明,钴基高温合金K10在中速定向凝固后,其一次枝晶间距比传统的HRS法定向凝固组织细化5倍以上,并在一定的冷却速率下获得了二次分枝被强烈抑制、一次轴呈平行排列的定向凝固超细柱晶组织,在所研究的冷却速率范围内,合金元素Cr、Mo和Ni在枝晶干与枝晶间的偏析比均随冷却速率的增大而趋于1,枝晶偏析得到抑制甚至消除。     

A dynamic surface topography model for the prediction of nano-surface generation in ultra-precision machining

Materials induced vibration has its origin in the variation of micro-cutting forces caused by the changing crystallographic orientation of the material being cut. It is a kind of self-excited vibration which is inherent in a cutting system for crystalline materials. The captioned vibration results in a local variation of surface roughness of a diamond turned surface. In this paper, a dynamic surface topography model is proposed to predict the materials induced vibration and its effect on the surface generation in ultra-precision machining. The model takes into account the effect of machining parameters, the tool geometry, the relative tool–work motion as well as the crystallographic orientation of the materials being cut. A series of cutting experiments was performed to verify the performance of the model and good correlation has been found between the experimental and simulation results.     

Structure and mechanical properties of NiAl and Ni3Al-based alloys

The investigation of Ni–Al–Fe–Ti–B alloys was carried out to determine the influence of iron and small titanium and boron additions on the phase composition, microstructure and mechanical characteristic, particularly with respect to high-temperature deformation conditions. These alloys, containing Al 35.8 at% and Fe 3.6–8.6–17.6 at% were prepared from high-purity components and Al master alloy containing Ti₂B particles. The influence of alloying additions of chromium and iron on the mechanical properties of directionally solidified Ni–Al–Cr–Fe alloy was investigated. Additions of both Cr 8 at% and Fe 2 at% result in higher strength than exhibited by unalloyed Ni₃Al. However, the ductility is reduced by the formation of the β′ phase. The typical, lamellar structure of Ni–20Al–8Cr–2Fe alloy undergoes coagulation during a high-temperature deformation process. The sequence of structural changes of NiAl and Ni₃Al-based alloys has been correlated with mechanical characteristics of high-temperature deformation process, determined in uni-axial compression tests. Two ranges of work hardening have been identified on the stress–strain curves of these alloys. It has been found that the first range of the deformation of Ni–Al–Fe–Ti–B alloys corresponds to the intergranular slip system operating within individual grains, while the second one is connected with transgranular slip. In the directionally solidified Ni–20Al–8Cr–2Fe alloy similar work hardening curves were observed in relation to the microstructural evolution from the lamellae shape, through elliptical shape into circular shape.     

Crystallographic analysis of freeze-fracture electron micrographs: application to the structure determination of cubic lipid–water phases

An original approach combining freeze-fracture electron microscopy and quantitative image processing has been developed as an alternative to X-ray analysis. It has been applied to the crystallographic study of different lipid–water cubic phases [bicontinuous or micellar and of type I (oil-in-water) or type II (water-in-oil)] and has enabled significant advances in the study of these phases. Freeze-fracture electron microscopy has revealed that the cubic phases fracture preferentially along a few crystallographic directions which appeared on the images as noisy planar fracture surfaces containing periodic information. The visibility of the corresponding unit cells has been considerably improved by image-filtering techniques based on correlation averaging, allowing a quantitative analysis of the fracture images to be made. This analysis yielded faithful information on the symmetries of the cubic structure (rotation axes and mirror planes) as well as on the structure of the cubic phase itself. Eventually, the different parameters that determine the most favourable fracture pathways within the structures were established. This novel approach constitutes a powerful tool of general interest, complementary to X-ray diffraction, for solving complex ordered macromolecular structures at low resolution.     

EBSD: a powerful microstructure analysis technique in the field of solidification

This paper presents a few examples of the application of electron back-scatter diffraction (EBSD) to solidification problems. For directionally solidified Al–Zn samples, this technique could reveal the change in dendrite growth directions from <100> to <110> as the composition of zinc increases from 5 to 90 wt%. The corresponding texture evolution and grain selection mechanisms were also examined. Twinned dendrites that form under certain solidification conditions in Al–X specimens (with X = Zn, Mg, Ni, Cu) were clearly identified as <110> dendrite trunks split in their centre by a (111) twin plane. In Zn–0.2 wt% Al hot-dip galvanized coatings on steel sheets, EBSD clearly revealed the preferential basal orientation distribution of the nuclei as well as the reinforcement of this distribution by the faster growth of <10 1 0> dendrites. Moreover, in Al–Zn–Si coatings, misorientations as large as 10° mm⁻¹ have been measured within individual grains. Finally, the complex band and lamellae microstructures that form in the Cu–Sn peritectic system at low growth rate could be shown to constitute a continuous network initiated from a single nucleus. EBSD also showed that the α and β phases had a Kurdjumov–Sachs crystallographic relationship.     

Process variables determining the dimensional and metallurgical properties of directionally solidified,cored turbine blades produced by investment casting of super-alloys

The investment casting process for the manufacture of directionally solidified, cored turbine blades is described. The dimensional and metallurgical properties of blades produced by this process is subject to variations which can result in long lead times in development and scrap during production. The process variables that determine the dimensional and metallurgical properties have been identified and classified in order of importance. The objective of the research is the formation of a database of process variables that can be used as a basis for control of the casting process and for predicting the final geometry as a result of the process.     

脉冲电流对金属材料塑性变形和组织结构与性能的影响

脉冲电流对金属材料的塑性变形、组织结构和力学性能有显著影响。利用高强脉冲电流可显著改善金属材料的加工性能及力学性能；能改变疲劳损伤金属材料的位错组态，提高其疲劳寿命；能促进一些冷变形合金的再结晶过程；能减少合金凝固组织中的缩孔、缩松。由于利用脉冲电流可改善金属材料加工性能及力学性能，并促进组织结构转变，因此在金属材料加工和组织结构调整等领域有着广阔的应用前景。     

The influences of macrosegregation, intermetallic particles, and dendritic spacing on the electrochemical behavior of hypoeutectic Al-Cu alloys

The purpose of this research is (1) to investigate the influence of Al(2)Cu intermetallic particles associated with the dendritic arm spacing on the corrosion resistance of different hypoeutectic Al-Cu alloys and (2) to evaluate the electrochemical behavior of a hypoeutectic Al-Cu alloy directionally solidified under unsteady-state heat flow. The as-cast samples were produced using vacuum arc remelting and vertical upward water-cooled solidification. Microscopic examinations were carried out with optical microscopy and scanning electron microscopy + energy dispersiveX-ray analyses. To evaluate the surface corrosion behavior of such alloys, all corrosion tests were performed in a 0.5-M NaCl solution at 25 degrees C using an electrochemical impedance spectroscopy technique and potentiodynamic polarization curve analysis. Based on the tests, corrosion rate and impedance parameters were obtained. The present research has underlined the use of appropriate techniques of characterization for determining Al(2)Cu distribution, morphology, and fraction within the typical microstructures of Al-Cu alloys. The experimental results have established correlations between the Al-rich phase dendritic arm size, the intermetallic particles distribution in the eutectic mixture, the macrosegregation profile, and the resulting corrosion resistance.     

A CAD/CAM system for die design and manufacture

The manufacture of directionally solidified cast turbine blades relies on the precise casting of wax patterns of the actual turbine blade. This, in turn, requires the design and manufacture of a complex die. A CAD/CAM system is presented specifically for producing manufacturing information for dies based on basic data defining the shape of a turbine blade. The system is based around a UNIX graphics workstation which forms part of a CIM system being developed as part of an SERC Teaching Company based at Rolls-Royce plc, Derby.     

定向凝固合金叶片的裂纹与再结晶研究

对定向凝固合金叶片的裂纹进行分析，在断口观察与金相组织分析的基础上，对叶片的失效模式与失效原因进行研究，并提出预防该类故障发生的措施。研究结果表明，定向凝固合金叶片的裂纹是由于叶片表面的再结晶而导致的。叶片表面的再结晶在叶片使用之前就已存在，是由于固溶热处理前叶片的表面存在塑性变形，在固溶热处理过程中形成的。