Corporate Effects of Temperature and Strain Range on the Low Cycle Fatigue Life of a Single-Crystal Superalloy DD10

Low cycle fatigue behavior of a nickel-based single-crystal superalloy DD10 was investigated at 760 and980 °C under different strain ranges. Results show that the fatigue life(Nf) of DD10 alloy exhibits different temperature dependence under various strain ranges. Under low strain range, the alloy exhibits a longer Nfat 760 °C than that at980 °C. However, under high strain range, a reverse result is obtained. This difference can be attributed to the change of dominant damage modes under various test conditions, which is manifested in different modes of crack initiation(crack nucleation and its early propagation). At 760 °C, the crack initiates at pores in subsurface due to local stress concentration.This process is mainly controlled by plastic amplitude and plastic property, but not affected by oxygen-induced damage before the crack propagates to the surface. At 980 °C, the crack initiates at surface instead of pores due to the more homogeneous plastic deformation and the disharmony between the external oxidation layer and the bulk material when the strain amplitude is high. At that temperature, the process is mainly controlled by oxidation damage and strain amplitude simultaneously. Therefore, under high strain range, the crack initiation is much easier at 760 °C due to plastic deformation and the poor plasticity, while under low strain range obvious oxidation damage at 980 °C may accelerate the crack initiation.     

Cr-Mn-Si-Ni高强度钢疲劳裂纹的萌生行为

通过扫描电镜原位疲劳试验,研究Cr-Mn-Si-Ni高强度钢疲劳裂纹的萌生行为,观察并记录从滑移带自然萌生的小裂纹和其发展到宏观裂纹的过程。研究结果表明：在低周疲劳情况下,不是所有萌生的裂纹都会持续扩展,大部分微裂纹在疲劳早期即已萌生,但是裂纹发展很慢,导致失效的裂纹快速扩展在疲劳晚期发生,微裂纹长度与循环数之间也有一定的关系。     

THE CREEP AND FRACTURE BEHAVIOR OF TWO NICKEL-BASED SUPERALLOYS

1.IntroductionTheevolutionofsuperalloyshasbeengreatlymotiVatedbythedevelopmentofmodernjetengines.Somepartsoftheengineareoperatedathightemperaturesandsubjectedtobothstaticanddynamicforcesaswellasthermalgradients.Therefore,creepcanoccuratsignificantratesandthentheestimationofcreepstrainandtheassociateddamageaccumulationbecomethecriticalconsiderationinthedesignoftheenginebladesoperatingathightemperatures.ThepurposeofthisinvestigationwastoexaminethecreeppropertyandfracturebehaviorofthecastK417and…     

气孔对铝合金焊接接头超长疲劳寿命的影响

采用超声疲劳试验方法对铝合金5052-H32焊接接头进行疲劳试验,研究其在超长寿命区间(107~109周次)的疲劳强度及失效机理.结果表明,相同疲劳寿命下焊接接头疲劳强度较母材下降了73.3%,在超高周疲劳区间仍然会发生疲劳破坏;断口观察发现焊接缺陷(气孔)是诱发疲劳裂纹萌生的主要原因.为揭示焊接缺陷对焊接接头疲劳裂纹萌生及扩展的影响,采用有限元技术分析了气孔对应力集中系数和裂纹尖端应力强度因子的影响.最后讨论了焊接缺陷对疲劳寿命的影响机制及裂纹扩展特性.     

Metallurgical control of fatigue crack propagation in superalloys

Low-cycle fatigue life of turbine engine disk alloys is determined by the initiation and propagation of fatigue cracks. Performance improvements can be achieved through the combination of clean melting technology, to reduce the defect size, and a new generation of high-strength superalloys with fatigue cracking resistance. Metallurgical control of fatigue crack propagation in high-strength superalloys becomes feasible only through a clear understanding of the fatigue cracking mechanism, as well as the micro-structure/property relationships. Many metallurgical parameters have been identified to control the fatigue cracking resistance at high temperatures. One of the most effective methods, applicable to all high γ′ content superalloys, is to modify the grain boundary structure by means of a controlled cooling from a supersolvus solutioning. The precipitation reaction occurring on the grain boundaries during cooling generates a serrated structure that exhibits a good stress oxidation resistance for fatigue cracking.     

GH536高温合金焊接接头疲劳裂纹萌生与扩展原位试验研究

采用原位疲劳试验方法,实时观察了GH536焊接接头疲劳裂纹的萌生和扩展行为,从而揭示了GH536焊接接头疲劳裂纹的萌生和扩展机制:疲劳加载过程中,位错沿滑移带在晶界前沿塞积,晶界阻碍位错运动,裂纹沿滑移带开裂,萌生疲劳裂纹;疲劳裂纹扩展初期,受单滑移的交替作用,裂纹呈“Z”字型向前扩展,随后裂纹的扩展逐渐以主应力控制为主,垂直于加载方向、平直向前扩展;GH536合金焊接接头组织中的晶界和碳化物会阻碍疲劳裂纹的扩展。     

Study of thermal effects associated with crack propagation during very high cycle fatigue tests

This paper studies the thermal effects associated with the propagation of a fatigue crack in a gigacycle fatigue regime. Ultrasonic fatigue tests were carried out on a high-strength steel. The temperature fields measured by infrared thermography show a significant and very local increase in the temperature just before fracture. In order to better understand these thermal effects and to make a connection with the initiation and the propagation of the fatigue crack, a thermomechanical model is developed. The fatigue crack is modeled by a circular ring heat source whose radius increases with time. The numerical resolution of the thermal problem allows determination of the time evolution of the temperature fields in specimens and shows a good correlation with experiment. These results provide experimental proof that in a very high cycle regime, the propagation stage of the crack constitutes a small part of the lifetime of the specimen.     

ZL101铝合金低周疲劳行为研究

研究了ZL101-T6铝合金的拉压低周疲劳行为,并重点分析了疲劳裂纹在材料中萌生与扩展的过程。通过扫描电镜和金相显微镜的观察分析表明:共晶硅相的断裂是材料低周疲劳裂纹萌生的主要方式,硅颗粒断裂的数量随疲劳循环周次的增加而增加,应变幅值的增加加快了硅颗粒的断裂速率,使疲劳裂纹的萌生速率加快;疲劳裂纹在循环初期主要通过断裂硅颗粒的互相连接进行扩展,随疲劳裂纹的长大,裂纹可穿过铝基体连接形成主裂纹并导致材料破坏,穿晶断裂为最终断裂的主要特征。     

变质处理后Fe-V-W-Mo-Cr合金热疲劳性能的研究

采用自约束热疲劳试验机对Fe-V-W-Mo-Cr合金进行了热疲劳试验,采用金相显微镜对热疲劳裂纹扩展行为进行了研究,同时用RE-Mg对Fe-V-W-Mo-Cr合金进行变质处理。结果表明,经RE—Mg变质处理后,碳化物和基体组织明显细化,并产生较多的小块状和颗粒状碳化物,促使合金的导热系数增加,热膨胀系数减小,热疲劳裂纹萌生所需热循环次数增加,裂纹扩展速率减小,在热循环700周次后的热疲劳裂纹长度减小约49％。     

热力耦合对一种第四代镍基单晶高温合金1100℃蠕变组织演变的影响

以一种第四代镍基单晶高温合金为研究对象,采用变截面蠕变试样,在1100℃、43~96 MPa条件下进行200 h蠕变中断实验,利用SEM和TEM观察了微观组织演变规律,利用同步辐射高能XRD和EPMA分析了高温低应力条件下镍基单晶高温合金的蠕变组织演变。结果表明:随着应力的增大,镍基单晶高温合金的γ′相体积分数降低,筏化程度增大且筏排厚度下降,同时,γ相通道宽度逐渐增大,而γ/γ’两相界面位错网间距逐渐减小。固溶强化元素Re、Mo和Cr等在γ相中的富集导致γ/γ’两相错配度绝对值增大。蠕变过程中γ’相体积分数降低和γ’相筏排厚度减小显著降低了合金的强度。另外,位错在γ′相溶解所导致的弯曲相界处的塞积,使位错易于切入γ′相,也是镍基单晶高温合金室温硬度下降的重要原因。     

结合S-N曲线和断裂力学的焊接结构疲劳寿命分析

针对焊接结构的疲劳裂纹演化过程,将焊接结构的疲劳寿命定义为裂纹萌生寿命N_i和裂纹扩展寿命N_p之和,提出一种结合S-N曲线和断裂力学理论的疲劳寿命分析方法.采用等效结构应力法和99%下限主S-N曲线计算焊接结构的裂纹萌生寿命,并将这一阶段结束时的裂纹看作为半椭圆表面裂纹.采用Paris裂纹扩展模型和半椭圆表面裂纹应力强度因子ΔK计算裂纹扩展寿命N_p.参照某起重机走行梁的疲劳试验结果进行对比和验证研究.结果表明,等效结构应力可以较好地表征复杂焊接结构的裂纹萌生特性,结合S-N曲线和断裂力学的疲劳寿命计算结果与试验结果具有较好的一致性.     

2Cr13钢高周疲劳微塑性损伤特性研究

研究了２Ｃｒ１３马氏体不锈钢高周疲劳载荷作用下微观塑性变形的演变过程。在三种选定循环载荷作用下,在疲劳裂纹萌生前试样一直处于弹性变形阶段,而且弹性模量基本不变。在１／２寿命时,普遍观察到局部微观塑性变形特征。有些板条内存在含扭折对的平行螺位错束或十字交叉网状位错组态,一些细长碳化物周围塞积了棱柱或滑移型位错环。达到疲劳寿命时,有些区域内形成位错胞状结构。经过高周疲劳实验的薄膜试样在透射电镜下进行动态拉伸原位观察结果表明,微裂纹易在细长碳化物处萌生,沿位错胞壁或板条界扩展后与主裂纹汇合。高周疲劳过程中局部微观塑性耗散造成一定程度的微观结构损伤,裂纹穿过这些区域只需消耗很少的塑性功     

Nondestructive sizing and localization of internal microcracks in fatigue samples

A large number of fatigue experiments on standardized samples is required for the development of databases of the fatigue properties of specific material systems. To facilitate such studies, different visual monitoring methods for surface fatigue cracks have been used; however, the problem of monitoring internal fatigue crack initiating during cold dwell fatigue of Ti is much more complicated. This paper describes the development and integration of several nondestructive evaluation methods for monitoring and sizing microcracks in titanium fatigue samples. For in situ monitoring of crack initiation and evolution ultrasonic Lamb wave signals are excited and acquired in the sample continuously during fatigue tests at different levels of fatigue load using a high-speed data acquisition system. Localization of the secondary cracks is done by both the in situ ultrasonic method and an ultrasonic immersion scanning method here referred to as “vertical C-scan” (VC-scan). The VC-scan is developed for imaging small cracks aligned normal to the fatigue sample axis. Microradiography has been performed on fatigue samples to confirm the localization and sizing of the detected cracks with other ultrasonic NDE techniques. The fusion of data from different NDE techniques provides useful information on the initiation, location, shape, size and growth history of fatigue cracks.     

304不锈钢钎焊板翅结构疲劳断裂机理分析

对304不锈钢板翅结构进行疲劳试验,分析疲劳断裂机理.疲劳裂纹从上钎角萌生,然后向翅片扩展,最终导致失效.在钎焊过程中,钎角处生成了较多的脆性化合物,且钎角处应力高度集中,使得裂纹从钎角萌生.疲劳裂纹的扩展经历了4个阶段:(1)裂纹在循环载荷作用下,在钎角脆性化合物启裂;(2)裂纹启裂后,在循环载荷作用下,沿钎角扩展;(3)裂纹跨越钎角和固溶体组织的界面,沿固溶体组织扩展;(4)裂纹跨越翅片和固溶体的界面,进入翅片区域扩展,直至完全断裂.     

Research Progress on the Crack Formation Mechanism and Cracking-Free Design of gamma' Phase Strengthened Nickel-Based Superalloys Fabricated by Selective Laser MeltingEI北大核心CSCD

传统牌号高强镍基高温合金具有较宽的凝固温度区间、较高比例的低熔点共晶相,在增材制造快速非平衡凝固过程中易产生裂纹等缺陷;同时,热处理过程中残余应力释放和γ’相快速析出导致应变时效裂纹的形成,严重限制了其在激光增材制造领域的应用与推广。基于此,本文综述了近年来国内外研究组及作者团队在选区激光熔化高强镍基高温合金裂纹形成机理与抗裂纹设计(成形工艺参数优化、热处理制度调控以及合金成分设计)领域相关的研究进展,并对激光增材制造γ’相强化镍基高温合金裂纹调控的研究进行了展望。     

（F＋M＋A）三相钢低周疲劳的扫描电镜动态研究SCIEI

用扫描电子显微镜疲劳加载台进行动态原位观察，研究了奥氏体（Ａ）在（Ｆ＋Ｍ＋Ａ）三相钢低周疲劳裂纹萌生和扩展过程中的作用．结果表明，在低周疲劳裂纹的萌生和早期扩展阶段，三相钢中的奥氏体会降低疲劳缺口敏感性，延长裂纹萌生期，使裂纹路径弯折并降低扩展速率．在高应变疲劳阶段，因奥氏体应变诱发相变生成马氏体，其边界是裂纹扩展的低能通道，从而加速裂纹的扩展．并提出了一个能量判据：当裂尖扩展功小于Ａ→Ｍ转变的能量时，奥氏体会提高材料的疲劳抗力，反之奥氏体会加速疲劳裂纹的萌生和扩展．     

Research Progress on Surface Impact Strengthening Mechanisms and Application of Nickel-Based SuperalloysEI北大核心CSCD

为满足不断攀升的两机涡轮动力系统的快速发展,表面冲击强化技术在涡轮转子用高温合金表面强化的应用及相应机制的研究受到了广泛关注。然而,高温合金表面硬化层在高温服役环境下的回复、再结晶行为难以避免,由此引起的表面强韧化、抗疲劳效果的退化,成为制约表面冲击强化技术在先进高温合金关键部件深入应用的瓶颈。本文总结了近年来镍基高温合金表面冲击强化机制及应用研究进展,分析了表面冲击强化对镍基高温合金表面强韧性及抗疲劳的作用规律,探究了高温合金表面冲击硬化层在高温及长期时效过程中的显微组织、微结构演化及其对高温稳定性的作用机理。以期为发展镍基高温合金表面冲击强化、提高两机涡轮转子疲劳抗力提供基础。     

A concept for the EQ coating system for nickel-based superalloys

Nickel-based single-crystal superalloys with high concentrations of refractory elements are prone to generate a diffusion layer called a secondary reaction zone (SRZ) beneath their bond coating during long exposure to high temperatures. The SRZ causes a reduction of the load-bearing cross section and it is detrimental to the creep properties of thin-walled turbine airfoils. In this study, a new bond coat system, “EQ coating,” which is thermodynamically stable and suppresses SRZ has been proposed. Diffusion couples of coating materials and substrate alloys were made and heat treated at 1,100°C for 300 h and 1,000 h. Cyclic oxidation examinations were carried out at 1,100°C in air and the oxidation properties of EQ coating materials were discussed. High-velocity frame-sprayed EQ coatings designed for second-generation nickel-based superalloys were deposited on fourth-and fifth-generation nickel-based superalloys, and the stability of the microstructure at the interface and creep property of the coating system were investigated.     

Effect of Stress Ratio on the Fatigue Crack Propagation Behavior of the Nickel-based GH4169 Alloy

The fatigue crack growth behavior of the newly developed GH4169 nickel-based alloy at a maximum stress of700 MPa and different stress ratios was investigated in the present work employing the specimens with a single micronotch at a frequency of 129 Hz at room temperature. The results demonstrate a typical three-stage process of fatigue crack propagation processing from the microstructurally small crack(MSC) stage to the physically small crack(PSC) stage, and finally to the long crack stage. The crack growth rate in the MSC stage is relatively high, while the crack growth rate in the PSC stage is relatively low. A linear function of crack-tip reversible plastic zone size was proposed to predict the crack growth rate, indicating an adequate prediction solution.     

拉保持对316L奥氏体不锈钢焊接接头低周疲劳循环应力响应及损伤机制的影响

在873 K温度下对316L奥氏体不锈钢母材和焊缝分别进行连续和拉保持低周疲劳试验,使用光学显微镜(OM)和透射电镜(TEM)对试样位错微观结构和裂纹扩展形貌进行观察,分析拉保持对母材和焊缝低周疲劳循环应力响应及损伤机制的影响.结果表明,母材在连续和拉保持低周疲劳试验初期都发生循环硬化,焊缝在连续低周疲劳试验中发生连续循环软化,而在拉保持试验后期则出现明显循环稳定阶段;母材和焊缝试样拉保持低周疲劳寿命低于其连续低周疲劳寿命;母材和焊缝在连续低周疲劳试验中裂纹主要以穿晶方式扩展,而在拉保持试验中焊缝是以沿晶或混合方式扩展.