残余应力与弹簧的疲劳性能

阐述了残余应力与弹簧高周疲劳极限间的关系,讨论了表层残余应力在改善弹簧疲劳品质的重要性以及制造流程中引入弹簧内残余应力的各种加工工艺,建立了残余压应力场特征参量与弹簧高周疲劳极限间的定量关系。以内部疲劳极限理论为基础,提出了弹簧表层优化喷丸残余应力场的工程计算方法。     

残余应力和粗糙度对叶片振动疲劳性能的影响

为了研究叶片表面完整性对其振动疲劳性能的影响,本文模拟分析了某型高温合金叶片在振动疲劳实验过程中的动力学应力响应,获得叶片共振时应力幅值随时间的变化规律,分析了残余应力和粗糙度对叶片振动疲劳寿命和疲劳极限的影响规律.结果表明:叶片共振过程中的应力响应幅值先增大后减小呈周期性变化,属于"拍"现象,满足关系σ=1 046sin(242.83t)sin(5 828t);叶片的振动疲劳极限和疲劳寿命均随残余应力和粗糙度的增大而减小,振动疲劳极限和残余应力之间的关系满足σfat=510.9-0.31-70.93σrest;而疲劳极限和粗糙度之间的关系则满足σfat=9.67R2roughness-70.93Rroughness+713.23.     

喷丸强化对材料旋转弯曲疲劳强度影响的定量研究

以往的工作已经提出了金属表面及内部疲劳极限的新概念，成功地分析了喷丸对三点弯曲（应力比Ｒ＝０．０５）条件下材料疲劳强度的影响。本文采用３００Ｍ钢研究了喷丸强化对旋转弯曲疲劳强度的影响。结果表明，经适当表面强化后，疲劳裂纹萌生于试样的次表层，萌生疲劳裂纹的；陆界应力（称内部疲劳极限）为未经喷丸强化试样疲劳极限（称表面疲劳极限）的１．３９倍，表明内部疲劳极限理论在旋转弯曲条件下仍然有效。     

残余压应力对45钢疲劳裂纹萌生寿命的影响

本文研究了４５钢不同缺口半径及经预压，喷丸处理后对试样弯曲疲劳裂纹萌生寿命的影响。研究结果表明：随着试样缺口根部半径的增大，试样的弯曲疲劳裂纹萌生寿命增加。     

残余应力对连续拉拔珠光体钢丝力学性能的影响

在残余应力的数值模拟及试验测量基础上,综述了残余应力对以珠光体钢丝为代表的高强度钢丝力学性能的影响,讨论了残余应力在钢丝应用出现的应力松弛、疲劳和环境促进断裂等失效现象中所起的作用。     

残余应力与胶粘剂对ARALL层板疲劳裂纹扩展特性的影响

研究了粘剂性质、含量及残余应力状态对纤维－铝合金胶接层板（ＡＲＡＬＬ）疲劳裂纹扩展特性的影响，分析了裂纹扩展过程中的分层状态的变化，结果表明，ＡＲＡＬＬ层板内富胶层的剪切形变和伴随裂纹扩展的分层区越大，即这两方面耗散能量越多，则疲劳裂纺扩展速率越低；胶粘剂含量的影响不明显，给层板施加预应力极大降低了层板的疲劳裂纹扩展速率，其本质在于裂尖在同样的疲劳载荷下实际所受到的有效应力降低。     

表面冶金复合材料残余应力产生及对热疲劳性能影响

本文通过对基体及焊层材料线膨胀系数及焊层表面应力的测试，阐述了热喷焊层残余应力产生的原因主要与第一、二次冷却过程有关，表面冷却速度是影响焊层表面应力的关键因素，分析了表面应力对焊层热疲劳性能的影响，焊层表面残余压应力对焊层抗热疲劳性有利。     

焊接过程对焊接残余应力及残余变形的影响

采用热弹塑性有限元法，对直通焊和多人同时分段焊两种焊接过程的平板对接焊时焊接应力变形和圆柱壳板环缝的焊接变形进行比较，认为多人同时分段焊直通焊无论在降低焊接残余应力还是焊接残余变形都具有非常显著的效果。     

CONSIDERATIONS OF THE EFFECT OF RESIDUAL STRESSES ON FATIGUE OF WELDED ALUMINIUM ALLOY STRUCTURES

A new class of large, high-speed seagoing ferry-boat is under development for service around the world. The ships, which are built entirely of aluminium-alloy plate and stiffeners, show a propensity for fatigue cracking of the welded structure. Cracks may occur in both the hulls and the superstructure early in their 20-year service life. Early appearance of fatigue cracks is shown to result from the combined stress and strain fields set up in weld zones by the static residual stresses and cyclic loads, beyond the effects of weld and detail geometry.  A numerical example demonstrates that conventional methods of fatigue analysis overestimate the lifetime of the welded aluminium structure, while damage tolerance analysis based on fracture mechanics leads to improved prediction.     

THE EFFECT OF UNDERCUT, MISALIGNMENT AND RESIDUAL STRESSES ON THE FATIGUE BEHAVIOUR OF BUTT WELDED JOINTS

Abstract— A mathematical model is developed to predict the effect of weld toe undercut, misalignment and residual stresses on the fatigue behaviour of butt welded joints subjected to zero-to-tensile loading. Linear Elastic Fracture Mechanics (LEFM), Finite Element Analysis (FEA) and superposition approaches have been used for the modelling. It has been found that an undercut at the toes of welded joints is one of the most important weld geometry parameters. The reduction of fatigue strength of welded joints with a weld toe undercut is at least twice that of joints without an undercut in comparison with flush-ground welded plate. A misalignment of 5% of plate thickness and an undercut of 2% of plate thickness are fairly representative for the lower boundary of S-N curves of butt joints. The improvement of fatigue limits by means of surface treatments is shown to be effective for both undercut and misaligned joints. This approach is practical for a "Fitness-for-Purpose" assessment of welded joints subject to fatigue conditions.     

残余应力测定的基本知识——第五讲 金属材料与零件的表面完整性与疲劳断裂抗力间的关系

论述了金属材料/零件的表面完整性与其疲劳断裂抗力之间的关系.试验结果表明,表面完整性中的残余应力、组织结构与表面粗糙度这三个因素对疲劳断裂抗力是最有影响力的三个因素.     

RELAXATION OF RESIDUAL STRESSES AT COLD-WORKED FASTENER HOLES DUE TO FATIGUE LOADING

Abstract— Cold-expansion of fastener holes is now commonly used within the aerospace industry to increase the fatigue endurance of airframes. Although a number of methods of cold expansion are possible, the split-sleeve cold-expansion process is the most widely accepted and is frequently used in the repair and manufacture stages of both military and civil aircraft. In the present work, the redistribution of residual hoop stresses due to the application of constant amplitude fatigue loading at 4% cold-expanded holes has been studied. A modified Sachs method was adopted to evaluate the residual stress profiles and a replication technique was used to quantify crack growth. It was found that the decay of the residual hoop stress profile near the bore of the hole was due to the initiation and growth of small fatigue cracks. Cracks were found to initiate both near and below the fatigue limit, but subsequently arrested so stabilising the overall residual stress profile.     

EFFECT OF RESIDUAL STRESSES OF SHOT PEENING ON THE FATIGUE BEHAVIOUR OF A HIGH STRENGTH STEEL*

Abstract— The effects of shot-peening residual stresses on bending fatigue behaviour of welded plate and surface-flawed plate were investigated. The results show that shot peening residual stresses may significantly increase fatigue strength as well as the threshold stress- intensity factor range of a surface-flawed plate. This paper presents a simple analytical method for determining the residual stresses. The calculated values are essentially in agreement with the experimental results.     

INFLUENCE OF LOW-INTENSITY SHOT PEENING ON THE FATIGUE STRENGTH OF AN Al/Al

Metal matrix composites are increasingly utilized in engineering applications because of their favourable strength/weight ratio. However, their applications are still limited because of their relatively poor fatigue resistance, which could be improved by using some appropriate surface treatment. In this paper, an Al/Al₂ O₃ (20%) composite material is considered. In particular its fatigue strength is examined to verify if, how and when shot peening can be used to improve the performances of MMC components that are cyclically loaded. Fatigue tests allow one to evaluate the influence of shot peening on the fatigue limit of both smooth and notched specimens. Residual stress measurements, fracture surface analyses and metallographic examinations allow one to evaluate the role of residual stresses, hardening and grain distortion on the improvement that can be achieved with this treatment. On the basis of these results, some guidelines are drawn on how to optimize the choice of peening parameters.     

DESIGN OF EXPERIMENTS TO INVESTIGATE RESIDUAL STRESSES AND FATIGUE LIFE IMPROVEMENT BY A SURFACE TREATMENT

Abstract— The careful design of experiment (DOE) technique has been utilized to analyze the residual stress state and to investigate the fatigue life improvement of a material (nitriding steel) subjected to thermal and mechanical treatment.
Nitriding treatments have been performed on several specimens which have been subsequently shot- peened, varying the main parameters controlling the process. The design of experiment method has been accomplished in order to evaluate the influence of the main shot-peening parameters on the distribution and values of the residual stresses close to the surface, and also in order to estimate the influence of these parameters on fatigue resistance.     

FATIGUE STRENGTH OF NON-LOAD-CARRYING FILLET WELDED JOINTS: EFFECTS OF WELD RESIDUAL STRESSES AND STRESS CONCENTRATION

The fatigue strength of non-load-carrying fillet welded joints of KE36(TMCP) steel was studied. Both residual stress measurements and fatigue tests were carried out, with the plate thickness, the plate width and the heat input being varied. Specimens given a Post Weld Heat Treatment (PWHT) were also prepared. The plate width had no effect on the fatigue strength, because it hardly affected the transverse residual stresses at the weld toe. However, the heat input influenced the transverse residual stress distribution, and a significant difference in fatigue strength due to the heat input was observed, especially when N≥ 10⁶ cycles. It was also found that PWHT removed almost all the residual stresses at the weld toe, improving the fatigue strength drastically. In this study, the values of stress concentration factor K₂ were estimated by Machida's method and it was concluded that the thickness effect resulted from a combination of both stress concentration and residual stresses with the contribution of the latter being particularly significant for N≥ 10⁶ cycles.     

EFFECTS OF DRAWING STRAIN AND BLUING ON THE FATIGUE STRENGTH OF EUTECTOID STEEL WIRES

Abstract— The effects of bluing, associated with drawing strain, on the fatigue strength of eutectoid steel wires have been investigated. The fatigue limit increases by bluing and the increase is more significant with higher drawing strain. The peak in the fatigue limit with regard to the drawing strain in the wires, at a strain of 2.5, disappears after bluing. On the other hand, in the ferritic steel wires investigated for comparison, the fatigue limit gradually increases with the drawing strain up to 7.7. Furthermore, no appreciable change in the fatigue limit due to bluing is found. Based on the results of hardness tests on fatigue specimens with- and without-bluing, it is deduced that the decrease of the fatigue limit beyond the peak drawing strain in the eutectoid steel wire can partly be attributed to insufficient locking of the high-density dislocations by solute atoms. The effect of relaxation of residual stress during bluing is also briefly discussed.     

A STUDY OF RESIDUAL CAUSTICS GENERATED FROM FATIGUE CRACKS

Abstract— The method of caustics was used to determine the stress intensity factor of fatigue cracks in steel compact tension specimens. Under zero load a residual caustic was observed at the tip of a fatigue crack indicating the presence of a residual stress field. Caustics were generated at increasing static loads and the stress intensity factors were compared with those predicted by theory. It was found that the difference between each measured stress intensity factor and its corresponding theoretical value was a constant for the range of loads. This difference was shown statistically to be equal to the stress intensity factor determined from the residual caustic. The proposed mechanism for the formation of this residual caustic was probably due to crack tip plasticity effects and not due to crack closure. It was concluded that residual caustics can be measured to quantify crack tip behaviour in fatigue cracks and have been shown to be a useful tool in the measurement of residual stress fields.