渗碳Cr-Ni高强硬度合金钢超高周疲劳寿命预测

为了给渗碳合金钢提供一种有效可行的超高周疲劳寿命预测方法,在应力比为0和0.3两种情况下,对渗碳Cr-Ni高强硬度合金钢展开疲劳试验研究.通过对试样断口的微观组织观测,发现渗碳层与基体材料中均有非金属夹杂的存在;通过对裂纹萌生位置和疲劳断口形貌的观察,将疲劳失效分为带有细晶粒区(Fine Granular Area,F...     

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.     

基于超高周疲劳多元化失效模式的概率S-N曲线模型构建方法EI北大核心CSCD

对渗碳Cr Mn钢开展了超高周疲劳试验,通过观察断口发现其失效模式分为表面裂纹诱发失效、内部夹杂导致的高周疲劳（5×10^4〈N^10^7）失效以及超高周疲劳（N〉10^7）三种。该文假设每一种失效模式的S-N曲线均相互独立,并基于混合Weibull分布以及Basquin和三参数S-N曲线模型,分别构建出了渗碳Cr Mn钢三种失效模式各自的概率S-N曲线及综合反映渗碳Cr Mn钢多元化失效模式的概率S-N曲线。与试验数据相比,99%存活概率的P-S-N曲线在超长寿命区给出了较为安全的寿命预测。     

基于超高周疲劳多元化失效模式的概率S-N曲线模型构建方法

对渗碳Cr Mn钢开展了超高周疲劳试验,通过观察断口发现其失效模式分为表面裂纹诱发失效、内部夹杂导致的高周疲劳(5×104N10~7)失效以及超高周疲劳(N10~7)失效三种。该文假设每一种失效模式的S-N曲线均相互独立,并基于混合Weibull分布以及Basquin和三参数S-N曲线模型,分别构建出了渗碳Cr Mn钢三种失效模式各自的概率S-N曲线及综合反映渗碳Cr Mn钢多元化失效模式的概率S-N曲线。与试验数据相比,99%存活概率的P-S-N曲线在超长寿命区给出了较为安全的寿命预测。     

60Si2CrVA高强度弹簧钢的超高周疲劳破坏行为

进行超声波疲劳和疲劳裂纹扩展速率实验,研究了3种60Si2CrVA弹簧钢的超高周疲劳破坏行为. 结果表明,60Si2CrVA弹簧钢的超高周疲劳性能主要与其中夹杂物的尺寸有关,即随着夹杂物尺寸的减小,钢的疲劳寿命和疲劳强度均逐渐提高.对于内部夹杂物引起的疲劳破坏,在低应力幅、高循环周次(约大于10°cyc)条件下,在夹杂物周围的鱼眼处往往存在粗糙的粒状区域(GBF).对于A-60钢,随着疲劳源夹杂物处应力场强度因子幅的减小,疲劳寿命增加;而GBF处的应力场强度因子幅并不随疲劳寿命变化而变化,基本为一常数(平均值为4.6 Mpa·m1/2),与疲劳裂纹扩展门槛值(4.3 Mpa·m1/2)接近.     

Very High Cycle Fatigue Fracture Behavior of High Strength Spring Steel

进行超声波疲劳和疲劳裂纹扩展速率实验, 研究了3种60Si2CrVA弹簧钢的超高周疲劳破坏行为.结果表明, 60Si2CrVA弹簧钢的超高周疲劳性能主要与其中夹杂物的尺寸有关,即随着夹杂物尺寸的减小, 钢的疲劳寿命和疲劳强度均逐渐提高.对于内部夹杂物引起的疲劳破坏, 在低应力幅、高循环周次(约大于106 cyc)条件下,在夹杂物周围的鱼眼处往往存在粗糙的粒状区域(GBF). 对于A-60钢,随着疲劳源夹杂物处应力场强度因子幅的减小, 疲劳寿命增加;而GBF处的应力场强度因子幅并不随疲劳寿命变化而变化,基本为一常数(平均值为4.6 MPa×m1/2),与疲劳裂纹扩展门槛值(4.3 MPa×m1/2)接近.     

汽轮机转子钢常温与600℃超高周疲劳行为研究

利用自主研发的高温超声疲劳实验系统,开展Cr Mo W转子钢常温及600℃下的超高周疲劳实验。为新型超超临界汽轮机转子提供高温超高周疲劳数据,实验结果表明高温会极大降低转子钢的疲劳强度。S-N曲线在常温及600℃下均呈现连续下降型,且600℃下S-N曲线在整个疲劳寿命周次内保持一定下降趋势。断口分析发现,常温下疲劳寿命107周次试件的疲劳裂纹以内部萌生为主,600℃下疲劳破坏的内部夹杂萌生方式与表面萌生方式均分布于整个疲劳寿命。夹杂物尺寸分析表明,高温降低疲劳裂纹内部萌生夹杂物的临界尺寸。     

基于均方误差修正的渗碳12CrNi3钢疲劳强度预测模型

为对渗碳12CrNi₃合金钢提供一种安全可靠的高周疲劳强度预测方法,本文利用高频疲劳测试机,在10⁴～10⁸循环周次内对渗碳12CrNi₃合金钢疲劳试样开展应力比为-1的高周疲劳实验。采用灰色估计法对渗碳12CrNi₃钢疲劳数据的威布尔W(α,β,γ)参数进行评估,并通过估算的威布尔参数,进一步确定渗碳12CrNi₃合金钢强度预测模型的参数。考虑应力-寿命关系,结合疲劳数据的威布尔分布规律,建立了失效概率为1%时的渗碳12CrNi₃合金钢高周疲劳强度预测模型。从预测疲劳强度安全可靠性出发,通过均方误差(MSE)方法对模型进行修正,并将修正后模型99%MSE下界线与渗碳12CrNi₃合金钢疲劳寿命P-S-N曲线(不同存活率P的S-N曲线)进行对比,研究发现12CrNi₃合金钢疲劳寿命数据点均位于模型99%MSE下界线内,预测结果很好。研究表明,在以渗碳12CrNi₃合金钢...     

残余奥氏体对渗碳处理钢疲劳强度的影响

为了评定残余奥氏体对渗碳处理钢疲劳强度的影响,对船舶推进装置齿轮用钢进行了旋转弯曲疲劳试验。在有效渗碳层深度的试样中,发现了残余奥氏体量为某一定最时疲劳强度具有最大值。根据渗碳表面层的残余应力、显微结构和断口表面研究了出现最佳残余奥氏体量的原因。     

风电渗碳齿轮内部疲劳断裂可靠性研究

齿轮内部疲劳断裂作为风电渗碳齿轮典型失效形式，是限制风电齿轮箱服役性能提升的瓶颈之一。基于应力强度模糊干涉函数和齿轮材料强度退化理论，结合风电LDD载荷与Dang Van多轴疲劳准则建立渗碳齿轮内部疲劳断裂可靠度分析模型，通过与某2 MW风电齿轮失效样本进行对比验证了模型的适用性。采用因子试验设计方法分析齿轮硬度梯度和微观修形对内部疲劳断裂失效的影响，通过材料暴露系数回归方程进行望小优化设计获得主因子最佳参数匹配。研究结果表明心部硬度、齿向鼓形对内部疲劳断裂失效影响权重最大，通过优化设计将该齿轮副内部疲劳断裂可靠度由0.968 399提高至0.972 678。     

Fatigue strength prediction of carburized 12Cr steel alloy: Effects of evaluation of maximum crack sizes and residual stress distribution

Axial loading fatigue tests of carburized 12Cr steel alloy in long‐life regime were performed under stress ratios of ?1 and 0. Fatigue fracture can be divided into surface failure, interior failure without fine granular area (FGA), and interior failure with FGA. By considering the effects of the tensile limit, the evaluation of maximum crack sizes (inclusion sizes and FGA sizes), and residual stress distribution, the fatigue strength prediction model of carburized 12Cr steel alloy for inclusion‐FGA‐fisheye induced failure in low stress level region can be established. By comparing the predicted results evaluated by generalized extreme values (GEV) with generalized Pareto (GP), the GP distribution is more suitable to predict the fatigue limit of the carburized 12Cr steel alloy. Furthermore, by using the relationship between inclusion sizes and FGA sizes, the fatigue limit prediction model for the design of components can be established, and the result is extremely accurate for the carburized 12Cr steel alloy.     

Interior induced fatigue of surface‐strengthened steel under constant and variable loading: Failure mechanism and damage modeling

Pulsating tension tests with constant amplitude (CA) and variable amplitude (VA) were conducted to investigate the interior failure mechanisms of a carburized Cr steel, and a cumulative damage model with the fine granular area (FGA) formation process was proposed in this study. Such a steel represents the continuously descending S‐N (stress‐number of cycles) curve characteristics associated with inclusion‐FGA‐fisheye induced failure even under variable amplitude. Due to crack growth retardations and accelerations resulted from the interaction effect between stepwise resets of the applied stress, the crack morphology under variable amplitude loading is much rougher. The interior failure mechanism was elucidated in combination with the determination of stress intensity factor values at different crack tips. Based on proposed damage model, the agreement between the predicted and experimental results is fairly good within the factor‐of‐two range.     

A cumulative damage model for fatigue life estimation of high‐strength steels in high‐cycle and very‐high‐cycle fatigue regimes

A cumulative fatigue damage model is presented to estimate fatigue life for high‐strength steels in high‐cycle and very‐high‐cycle fatigue regimes with fish‐eye mode failure, and a simple formula is obtained. The model takes into account the inclusion size, fine granular area (FGA) size, and tensile strength of materials. Then, the ‘equivalent crack growth rate’ of FGA is proposed. The model is used to estimate the fatigue life and equivalent crack growth rate for a bearing steel (GCr15) of present investigation and four high‐strength steels in the literature. The equivalent crack growth rate of FGA is calculated to be of the order of magnitude of 10^?14–10^?11 m/cycle. The estimated results accord well with the present experimental results and prior predictions and experimental results in the literature. Moreover, the effect of inclusion size on fatigue life is discussed. It is indicated that the inclusion size has an important influence on the fatigue life, and the effect is related to the relative size of inclusion for FGA. For the inclusion size close to the FGA size, the former has a substantial effect on the fatigue life. While for the relatively large value of FGA size to inclusion size, it has little effect on the fatigue life.     

Interior micro-defect induced cracking mechanism and life prediction of carburized Cr−Ni steel based on double nonlinear damage under variable amplitude loading

The constant/variable amplitude loading fatigue test with interior inclusion-fine granular area-fisheye induced failure under R=0 were carried out on carburized Cr−Ni steel. The results showed that the fatigue life under variable amplitude loading is longer than that under constant amplitude loading in very-high-cycle fatigue regime under same maximum stress level, and the surface morphology of fine granular area under variable amplitude loading is coarser than that under constant amplitude loading under same order of magnitude of fatigue life. Simultaneously, it can be determined that the formation micro-mechanism of fine granular area is caused by the continuous deboning due to stress concentration around interior micro-defects. Furthermore, the life prediction model based on double nonlinear fatigue damage, which considers the coupling effect of local equivalent stress (surface residual stress and local stress concentration effect), loading sequence, failure mechanism and nonlinear characteristics of fatigue damage under constant/variable amplitude loading is established, and predicted life has good accuracy within the factor-of-three lines.     

Interior failure mechanism and life prediction of surface‐treated 17Cr‐Ni steel under high and very high cycle fatigue

The understanding of very high cycle fatigue (VHCF) mechanisms is critical to the development of life prediction approach. For this purpose, high cycle fatigue (HCF) and VHCF properties of a surface‐treated 17Cr‐Ni steel were investigated under axial loading with stress ratio of 0. This steel exhibits the constantly decreasing S‐N characteristics associated with the inclusion‐fisheye induced failure under the HCF and the inclusion‐FGA (fine granular area)‐fisheye induced failure under the VHCF. The cyclic pressing plays an important role in the FGA formation process, but the FGA still can be observed for the stress ratio of zero due to the slight crack closure effect. Two life modelling approaches associated with related failure mechanisms in the HCF and VHCF regimes are proposed based on the agreement between experimental and predicted results.     

Effect of loading type on fatigue properties of high strength bearing steel in very high cycle regime

Very high cycle fatigue tests under axial loading at frequencies of 95 Hz and 20 kHz were performed to clarify the effect of loading type on fatigue properties of a high strength bearing steel in combination with experimental result of this steel under rotating bending. As a result, this steel represents the single P-S-N (probabilistic-stress-life) curve characteristics for surface-induced fracture and interior inclusion-induced fracture, just like that under rotating bending. However, fatigue strength is lower, where the run-out stress at 10⁹ cycles is evaluated to be 588 MPa, less than that under rotating bending with about 858 MPa. Occurrence probability of larger and deeper inclusion-induced fracture is much higher than that under rotating bending. Furthermore, the formation process of fine granular area (FGA) is independent of the type and frequency of loading, which is very slow and is explained as the crack nucleation process under the special dislocation mechanism. The stress intensity factor range at the front of FGA, ΔK_FGA, is approximately regarded as the threshold value controlling the stable propagation of interior crack. For the control volume of specimen under axial loading, the estimated value of fatigue limit by FGA is similar to experimental run-out stress value at 10⁹ cycles, but that by inclusion is larger. However, the corresponding estimated results under rotating bending are all conservative.     

Evaluation of crack growth behavior and probabilistic S–N characteristics of carburized Cr–Mn–Si steel with multiple failure modes

The unexpected failures of case-hardened steels in long life regime have been a critical issue in modern engineering design. In this study, the failure behavior of a carburized Cr–Mn–Si steel under very high cycle fatigue (VHCF) was investigated, and a model for evaluating the probabilistic S–N curve associated with multiple failure modes was developed. Results show that the carburized Cr–Mn–Si steel exhibits three failure modes including the surface flaw-induced failure, the interior inclusion-induced failure without the fine granular area (FGA) and the interior inclusion-induced failure with the FGA. As the predominant failure mode in the VHCF regime, the interior failure process can be divided into four stages: (i) the small crack growth around the inclusion, (ii) the stable macroscopic crack growth outside the FGA, (iii) the unstable crack growth outside the fish-eye and (iv) the momentary fracture outside the final crack growth zone. The threshold values are successively evaluated to be 2.33 MPa m^1/2, 4.13 MPa m^1/2, 18.51 MPa m^1/2 and 29.26 MPa m^1/2. The distribution characteristics of the test data in transition failure region can be well characterized by the mixed two-parameter Weibull distribution function. The developed probabilistic S–N curve model is in good agreement with the test data with multiple failure modes. Although the result is somewhat conservative in the VHCF regime, it is acceptable for safety considerations.     

The fatigue limit of bearing steels – Part I: A pragmatic approach to predict very high cycle fatigue strength

Bearing steels and other high strength steels exhibit complex fatigue behavior in excess of 10⁷ cycles due to their sensitivity to defects like inclusions. Failure occurring in the very high cycle fatigue regime and the lack of an asymptote in the measured S–N data raise the questions as to the existence of fatigue limit and prediction of the fatigue strength of the high strength steel components. A series of two papers are written to discuss on the characteristics of the very high cycle fatigue and their implication for engineering applications. In the present paper (Part I) a deterministic defect model is developed to describe the fatigue crack growth from de-bonded hard inclusions. The model is shown to provide a unified prediction of fatigue behavior in different regimes, i.e. low cycle fatigue regime dictated by the tensile strength, high cycle fatigue regime obeying Basquin’s law and the very high cycle fatigue regime featured by the fish-eye and ODA (optically dark area) surrounding an interior fatigue-initiating inclusion on the fracture surface. The model predictions agree well with experiments. A combination of the deterministic model with a stochastic model that describes the inclusion size distribution allows prediction of fatigue strength and fatigue limit associated with certain reliability of a steel component. It is found that very high cycle fatigue, associated with interior inclusions, is attributed to the very slow crack propagation in vacuum condition, and that an asymptote for fatigue limit observed for mild steels also exists for high strength steels such as bearing steels, but extends beyond the very high cycle fatigue regime normally measured to-date. Monte Carlo simulation shows that such a fatigue limit asymptote becomes clearly visible in excess of 10¹² cycles, which is difficult to measure with today’s testing devices. Furthermore, the effects of steel cleanliness and specimen type and shape are studied by means of Monte Carlo simulations.     

Failure Analysis of the 18CrNi3Mo Steel for Drilling Bit

The failure cause of the 18CrNi3Mo steel for drilling bit, including inclusions, prior austenite grain size, carburized layers, and morphology of the fatigue fracture, was investigated by optical microscope, quantitative metallography, and scanning electron microscope. Results show that the failure of the drill bit is not related to interior inclusions or the inhomogeneity of the prior austenite grain size distribution. The failure is related to geometrical discontinuities causing stress concentration along the tooth profiles while under effect of continuous twisting and axial impact. Thus, the crack initiates in these areas, and the microstructures of the carburized layer, the transitive layer, and the matrix are all tempered martensite such that the crack propagation cannot be effectively restrained and the crack propagates quickly, causing premature failure of the drilling bit.