热处理工艺对支撑辊用钢疲劳剥落形式的影响

采用JPM-1型接触疲劳磨损试验机，对450℃、530℃两个回火温度下支撑辊用Cr5钢的线接触滚动疲劳寿命进行了测定；通过扫描电子显微镜（SEM）、X射线（X—ray）和显微组织观察的方法研究了两种热处理工艺下试验用钢的疲劳剥落形式，并对剥落形式及剥落机理进行了初步探讨。结果表明：450℃回火得到硬度为HRC51的试样失效形式主要为棘齿裂纹和深层剥落，疲劳寿命为1．5～3×10^6；530℃回火得到硬度为HRC45的试样失效形式主要为浅层剥落，疲劳寿命为0．5～2×10^5。     

层流等离子体淬火对GCr15轴承钢的滚动接触疲劳及损伤性能的影响

为了提高GCr15轴承钢的滚动接触疲劳(RCF)性能,使用层流等离子体淬火(LPQ)技术对GCr15轴承钢表面进行了四种不同扫描速度(350 mm/min、550 mm/min、750 mm/min、950 mm/min)的等离子体淬火实验。用MJP-30滚动接触疲劳实验机对处理前后的试样进行RCF试验。采用激光共聚焦显微镜(VK-9710)、超景深显微镜(UDM, VHX-1000C, Japan)、扫描电子显微镜分析试样组织结构、成分、微观损伤形貌,对试样进行硬度测试,分析疲劳扩展机理。结果表明：由于LPQ的冷却速率及加热速率较快,试样表面产生淬火硬化区,形成细小的隐晶马氏体组织,表层硬度增大。硬化层厚度影响RCF扩展机理,硬化层厚度越深,疲劳寿命越长,LPQ使RCF寿命延长64%。     

微合金化渗碳齿轮钢的接触疲劳性能

通过滚动接触疲劳试验方法,研究了两种渗碳齿轮钢的接触疲劳性能.结果发现,渗碳齿轮钢接触疲劳试样失效方式主要为渗碳层的点蚀和剥落.氧含量较低的Nb微合金化齿轮钢(含0.04%的Nb)中氧化物夹杂数量少、尺寸小,接触疲劳裂纹起裂较难;同时,Nb微合金化齿轮钢渗碳层晶粒尺寸小、硬度高,提高了疲劳裂纹萌生及扩展阻力,导致Nb微合金化后,齿轮钢的接触疲劳寿命大幅度提高.     

氮等离子体浸没离子注入技术改善轴承钢滚动接触疲劳寿命和机械性能的研究

研究了氮等离子体浸没离子注入(N-PIII)技术处理后GCr15轴承钢表面的滚动接触疲劳特征和机械性能。测试了改性前后试样的滚动接触疲劳寿命和磨痕光学形貌、摩擦磨损行为及纳米压痕硬度。结果表明,处理后试样的最大显微硬度较基体增大近一倍,摩擦系数从0.95下降到0.15。在赫兹接触应力为5.1 GPa,90%置信区间下的L10和L50寿命分别增加了99.6%和236.3%。分析不同处理参数下的Weibull分布曲线和光学显微形貌可知,脉冲偏压、材料内部缺陷、基体表面粗糙度、注入时间和N离子注入剂量对疲劳寿命均有很大影响。疲劳寿命和相关机械性能的改善主要源于N-PIII处理所导致的氮化物强化相和残余压应力的共同作用。     

高强度钢30Cr3SiNiMoVA的疲劳特性研究

为了获得超高强度钢30Cr3SiNiMoVA的疲劳设计数据,对该材料进行了疲劳性能实验。分别对该材料的抛光和未抛光试样进行轴向拉压疲劳实验。用升降试验法测定材料的条件疲劳极限,用成组实验法在四级应力水平下测试其疲劳寿命。结合升降法所得的条件疲劳极限值和成组法实验数据,采用双参数最小二乘法拟合S-N曲线,运用概率方法求得P-S-N曲线。通过对两种试样的S-N曲线分析可知:未抛光试样的疲劳寿命要低于抛光试样的疲劳寿命,并且疲劳载荷级越低,两类试样之间的疲劳寿命差越大,抛光试样的疲劳极限大约是未抛光试样的1.4倍。相关实验现象表明30Cr3SiNiMoVA的疲劳寿命对试样表面粗糙状态非常敏感,建议该类材料在应用过程中要采取有效措施改善构件的表面状态。文中实验数据可为该材料的工程应用提供参考。     

某超硬不锈钢的接触疲劳P-S-N曲线的测定

测定某超硬不锈钢的接触疲劳P S N曲线,估计出试验应力S与试样寿命N之间函数关系式N=CS-m中的待定参数C和m,得出不同破坏概率(1%,5%,10%,50%)下试验应力S与寿命N的关系,为材料的使用和产品设计提供试验依据。     

疲劳损伤件中温热等静压后的疲劳性能试验研究

对40Cr调质试样先进行了0.6N(N为全寿命）拉-拉疲劳试验，再中温热等静压，在随后的继续拉-拉疲劳试验中，发现其数据分散度降低，疲劳寿命大幅度提高，经分析，认为其主要原因是，中温热等静压使试样表面硬度增加，残余压应力提高，约束并减缓了随后继续疲劳试验时损伤区微裂纹的发展。     

航空GH2036合金硬度热处理优化及疲劳性能DIC分析

为探究热处理工艺参数对GH2036合金硬度及疲劳性能的影响,基于四因素三水平正交热处理实验,对GH2036铁基高温合金的硬度性能进行优化,并分析热处理后的显微组织;同时利用疲劳实验与DIC(digital image correlation)非接触全场应变测量相结合的方法,利用Y方向应变-疲劳寿命比的云图,直观地分析热处理后GH2036合金疲劳失效过程。结果表明:固溶温度对合金硬度性能的影响最大,其次是固溶时间、时效时间、时效温度,极差分析所得的最优热处理工艺为960℃/60 min+水冷+560℃/2 h;正交试验中最高显微维氏硬度(HV305.34)较未处理试样(HV260.41)提高17.3%;热处理后金相组织基体为奥氏体,增强相为第二相碳化物,显微硬度值随着奥氏体中的第二相碳化物含量的增加而升高;热处理后平均疲劳寿命(942372次循环)较未处理试样(450800次循环)提高109%,疲劳性能明显优化。     

高周疲劳过程中45钢表面显微硬度变化规律的研究

应用显微硬度计对高周疲劳不同循环周次下正火45钢光滑圆试样进行了表面显微硬度测量。使用数理统计的方法对显微硬度测试值进行了处理。研究结果表明，不同疲劳阶段，试样表面显微硬度测试值呈正态分布，显微硬度方差在整个疲劳过程中始终呈现较大的离散性。在三级应力水平下显微硬度统计均值随循环周数的不同变化规律基本相同，表现出明显的阶段性，即显微硬度先升高，后下降，再上升并逐渐趋于稳定，其中在寿命的20％～30％阶段是一个活跃时期。随着应力水平的提高，表面硬度达到稳定状态所需时间有缩短趋势。疲劳后期，随着应力水平的提高，试样表面显微硬度有明显降低。     

喷丸处理对6151-T6铝合金旋转弯曲疲劳性能的影响

对经过电解抛光、喷丸处理和喷丸处理再抛光的三种6151-T6铝合金试样的表面粗糙度及喷丸处理后试样表面硬化层的硬度进行测试。对三种表面状态不同的铝合金材料进行旋转弯曲疲劳实验。研究喷丸处理试样表面残余应力随疲劳实验的变化情况,以及喷丸处理对该铝合金疲劳性能的影响。结果表明:喷丸处理对材料疲劳性能的影响与加载的压应力水平有关。当加载的压应力与表面残余压应力之和不超过材料表面硬化层的循环屈服强度时,硬化层中的残余压应力在疲劳过程中不发生应力松弛,疲劳寿命得到大幅度提高;反之,将发生应力松弛现象,疲劳寿命的提高程度受残余压应力松弛程度的影响。此外,喷丸处理造成的材料表面粗糙度的增加,在全应力幅范围,使材料的疲劳寿命略有降低。     

Weld arrangement effects on the fatigue behavior of multi friction stir spot welded joints

In this study, the effects of friction stir spot weld arrangements as multi type on fatigue behavior of friction stir spot welded joints is investigated. The joints that are considered with five different styles for friction stir spot welded joints: one-row four joints parallel to loading direction, two-row four-joint specimen, one-row four joints perpendicular to the loading axis, three-row as diamond shape with four joints in each edge and five friction stir spot welded specimen in three rows that middle row consist three joints. The correlation between micro hardness, cyclic material constants and mechanical strength of different zones around the friction stir spot welds are assumed to be proportional to base material hardness. A non-linear finite element analysis was carried out for simulating tensile shear multi friction stir spot welded joints with ANSYS software by considering gap effects. Using the local stress and strain calculated with finite element analysis, fatigue lives of specimens were predicted with Morrow, modified Morrow and Smith–Watson–Topper (SWT) damage equations. Experimental fatigue tests of welded specimens have been carried out using constant amplitude load control servo-hydraulic fatigue testing machine. The results reveal that there is relatively good agreement between fatigue life predictions and experimental data in reasonable fatigue life regime.     

Effect of hardness on multiaxial fatigue behaviour and some simple approximations for steels

Constant-amplitude in-phase and 90° out-of-phase axial-torsional fatigue tests were conducted on tubular specimens made from a medium-carbon steel with three hardness levels obtained from normalizing, quenching and tempering and induction hardening to find the effect of hardness on multiaxial fatigue behaviour. In addition, the same loadings were applied on the normalized solid specimens to investigate the effect of specimen geometry on multiaxial fatigue life. Similar fatigue life variation as a function of hardness was found for in-phase and out-of-phase loadings, with higher ductility beneficial in low-cycle fatigue (LCF) and higher strength beneficial in high-cycle fatigue (HCF). Multiaxial fatigue data were satisfactorily correlated for all hardness levels with the Fatemi–Socie parameter. Furthermore, in order to predict multiaxial fatigue life of steels in the absence of any fatigue data, the Roessle–Fatemi hardness method was used. Multiaxial fatigue lives were predicted fairly accurately using the Fatemi–Socie multiaxial model based on only the hardness level of the material. The applicability of the prediction method based on hardness was also examined for Inconel 718 and a stainless steel under a wide range of loading conditions. The great majority of the observed fatigue lives were found to be in good agreement with predicted lives.     

Residual stress influence on fatigue lifetimes of electroplated AISI 4340 high strength steel

Residual stresses play an important role in the fatigue lives of structural engineering components. In the case of near surface tensile residual stresses, the initiation and propagation phases of fatigue process are accelerated; on the other hand, compressive residual stresses close to the surface may increase fatigue life. In both decorative and functional applications, chromium electroplating results in excellent wear and corrosion resistance. However, it is well known that it reduces the fatigue strength of a component. This is due to high tensile internal stresses and microcrack density. Efforts to improve hard chromium properties have increased in recent years. In this study, the effect of a nickel layer sulphamate process, as simple layer and interlayer, on fatigue strength of hard chromium electroplated AISI 4340 steel hardness – HRc 53, was analysed. The analysis was performed by rotating bending fatigue tests on AISI 4340 steel specimens with the following experimental groups: base material, hard chromium electroplated, sulphamate nickel electroplated, sulphamate nickel interlayer on hard chromium electroplated and electroless nickel interlayer on hard chromium electroplated. Results showed a decrease in fatigue strength in coated specimens and that both nickel plating interlayers were responsible for the increase in fatigue life of AISI 4340 chromium electroplated steel. The shot peening pre-treatment was efficient in reducing fatigue loss in the alternatives studied.     

塔机提升系统输入齿轮失效分析

通过宏观检验、化学成分分析、非金属夹杂物检验、硬度测试以及金相检验等方法,对塔机提升系统输入齿轮失效的原因进行了分析。结果表明：该输入齿轮损坏属于接触疲劳失效,趋网状分布的铁素体降低了材料的硬度、耐磨性和疲劳寿命,是造成齿轮早期失效的主要原因。同时提出了预防控制措施。     

The research on failure analysis of fluid cylinder and fatigue life prediction

To analyze the reasons of fluid cylinders’ rupture, macro-analysis, SEM, composition inspection, metallographic analysis, hardness test and mechanics performance test of fluid cylinders materials were implemented. Two different kinds of fatigue life prediction methods have been proposed which are based on total life analysis and strain–life methodology. The results indicate that: the failure cylinders’ material quality is satisfactory. Fatigue damage caused by high working, stress and corrosion is the main reason of cracking. The fatigue life prediction illustrates that strain–life methodology is well adapted to fluid cylinders.     

Enhancing torsion fatigue behaviour of a martensitic stainless steel by generating gradient nanograined layer via surface mechanical grinding treatment

Abstract

A gradient nanograined (GNG) surface layer was formed on a martensitic stainless steel bar sample by means of the surface mechanical grinding treatment (SMGT). The average grain size is ～25 nm on the topmost surface layer and increases gradually with increasing depth. The torsion fatigue strength is elevated by 38% with the GNG surface layer compared with the original material. An additional 8% increment in fatigue strength is achieved after a post-annealing treatment of the SMGT sample. By analysing the microstructure, hardness, surface roughness and residual stress distribution in the SMGT samples, we believe that the enhanced fatigue resistances originate from the GNG structure with a hard surface layer and a high structural homogeneity.     

Fretting fatigue behaviour of hard anodizing coated 2014‐T6 aluminium alloy with dissimilar mating materials under plane bending loading

The effect of hard anodizing coated 2014‐T6 aluminium alloy test samples with dissimilar mating materials on fretting fatigue was investigated. Fretting fatigue configuration involved bridge‐type pads on the flat specimen. Bridge‐type pads were made of AISI 4140 steel. All the fretting fatigue tests were conducted under plane bending loading with a stress ratio of R=?1. Coated and uncoated specimens were compared for microhardness, surface roughness, tangential force. The specimens were tested under both plain fatigue and fretting fatigue loading at ambient temperature. Micrographs obtained from scanning electron microscope showed that hard anodizing coating had tiny cracks through the thickness of the anodized layer. The hardness of hard anodized coating was higher than that of uncoated specimens and they also exhibited lower tangential force. However, the fretted region of the hard anodizing coated specimens was rougher than that of uncoated samples and despite lower tangential forces, fatigue lives of hard anodizing coated samples were inferior to those of uncoated samples. As the hard anodizing coating had pre‐existing tiny cracks and tension residual stress, cracks propagated from the hard anodizing coating through the interface into the substrate. We conclude that these may be the main reasons for inferior fretting fatigue lives compared with uncoated samples.     

Fatigue and fracture behavior of laser clad repair of AerMet® 100 ultra-high strength steel

The effect of laser cladding on the fatigue and fracture behavior under variable amplitude loading is a major consideration for the development of laser cladding process to repair high value complex fatigue critical aerospace military components, that otherwise would be replaced. The selected material, AerMet®100, is a widely used ultra-high strength steel in current and next generation aerospace components, such as landing gears. Laser cladding was performed using AerMet® 100 powder on AerMet® 100 fatigue substrate specimens. No micro-cracking and very little porosity were observed in the clad layer. The fatigue tests were performed under variable amplitude loading with a maximum stress of 1000 MPa. Residual stress, microstructure, and hardness, was also evaluated. Both the as-clad and post-heat treated (PHT) samples were compared to a baseline sample with an artificial notch to simulate damaged condition. Results show that laser cladding significantly improves fatigue life, as compared to the baseline sample with a notch. However, the fatigue life of the as-clad sample is lower as compared to a baseline sample without a notch. A compressive residual stress of 300–500 MPa was observed in the clad region and HAZ. The fracture modes in the as-clad specimen consisted mainly of tearing topology surface and some regions of decohesive rupture through the columnar austenite grains. The PHT condition however was not effective in improving the fatigue life. The fracture modes showed mainly decohesive rupture, and as a consequence, reduced the fatigue life.     

Failure modes of liquid nitrocarburized and heat treated tool steel under monotonic loading conditions

The tensile properties and failure mode of heat treated and liquid nitrocarburized tool steels were studied. The tested steels are used as die and tool materials for plastic molds and punching/blanking dies, where wear resistance is required. In addition to intense friction, the main die block and other die components are subjected to tensile and repetitive stresses during operation (tension and fatigue loading). Therefore, hardness, tensile, and fatigue resistance are also critical quality parameters that contribute to material reliability and tool life. However, this study is an initial component of research and does not include fatigue data.     

Einfluß von Schweißen und Kaltumformung auf das Kurzzeitschwingfestigkeitsverhalten von austenitischem Stahl

Influence of Welding and Cold Forming on the Low-Cycle-Fatigue Behaviour of Austenitic Steel The low-cycle-fatigue behaviour of the austenitic steel X 10 CrNiTi 189, as received and welded, was investigated after cold forming up to 10 per cent by strain controlled tests. The fatigue life to crack initiation of the unwelded material is 10 times higher than the fatigue life of the butt-welded and unfinished material. The grinding of the butt-welds however leads to an increase of the fatigue life by a factor of 4 in comparison to the unfinished state. In comparison to these results obtained under 1 Hz the reduction of the frequency to 0.1 Hz causes a significant cyclic hardening and decrease of the fatigue life. The cold forming remains in all cases without influence. This hardening is a result of the diffusionless transformation of the austenitic microstructure into ferromagnetic α′-martensite under the lower frequency. The increase of the hardness caused also by the cold forming makes the stainless material more sensitive to corrosion.