SPCC钢滑动摩擦与拉伸声发射信号比较分析

为了将声发射技术应用在金属塑性加工中的摩擦监测中,以SPCC钢在拉伸过程与相对运动速度为100mm/min、正压力为7.5kg的摩擦过程产生的声发射信号特征为研究对象,分别用数据统计、平均值等方法对比分析了两种声发射信号的能量、振铃计数、幅度等参数。实验结果表明:SPCC钢拉伸的声发射能量值要远小于摩擦声发射能量值;拉伸的声发射振铃计数分布范围要略大于摩擦声发射振铃计数分布范围;拉伸的声发射幅度要小于摩擦声发射的幅度。最后对出现该现象的原因进行了探讨。     

基于声发射技术的起重机箱型梁疲劳数据分析

基于声发射技术监测起重机箱型梁疲劳裂纹的扩展,对比Q235B标准试样和箱型梁在疲劳试验中的声发射累积计数/幅值vs.循环周次曲线、声发射累积计数/裂纹扩展速率vs.应力强度因子幅曲线和声发射信号频谱特征。结果表明:箱型梁和标准试样的声发射累积计数/幅值vs.循环周次曲线均呈现基本相似的特征。频谱分析显示,虽然箱型梁和标准试样的声发射累积计数曲线在第二、三阶段产生的主要信号的峰值频率分布范围不尽相同,但是在相应两阶段产生的主要信号的类型(第二阶段2种信号、第三阶段1种信号)、相应频谱的峰数(第二阶段出现单峰和双峰,第三阶段出现多峰)以及两个阶段频谱峰数之间的变化(第三阶段频谱峰数均多于第二阶段)均相似,说明两者的疲劳机制存在着诸多相似之处。因此,一定程度上,能够通过标准试样的疲劳机制来映射箱型梁的疲劳机制,并为大型构件的设计与应用提供指导。     

基于显微CT的泥岩单轴压缩破坏特征的声发射表征

研制了基于实时声发射采集和实时加载CT扫描同步进行的加载控制系统,组建了对岩石损伤、破坏过程进行声发射表征的实验系统和实验方法。研究表明:①在峰值载荷28%前,原生裂纹宽度基本无变化,而后经历先变窄再变宽的过程。在峰值载荷47%前,原生裂纹长度基本无变化,而后开始增长,原生裂纹在宽度上先进行扩展从而引起原生裂纹在长度上的增长;②在峰值载荷65%前,裂纹的延伸发生在裂纹尖端的软弱介质中,而后才是真正的原生裂纹起裂,并快速延伸扩展;③新生裂纹易产生在软硬夹层交界处,新生裂纹产生时的载荷约为峰值载荷的56%～75%,在峰值载荷84%前,裂纹处于稳定扩展阶段,三条裂纹同时各自发展;④裂纹宽度变大、原生裂纹在其尖端软弱介质中延伸、软硬交界处新生裂纹的产生过程中声发射较少,当这些过程连在一起时,便形成了声发射平静期;⑤建立了岩石孔隙率、裂纹长度和宽度与声发射能量、振铃计数之间的表征方程,并提出不同加载阶段岩石状态评价的判据。     

基于声发射和双谱分析的铝合金损伤原位监测研究

以列车车体材料7N01铝合金为研究对象,基于声发射和数字图像技术对7N01铝合金三点弯曲损伤过程进行了监测,采用传统的声发射参数与双谱法分析了7N01铝合金裂纹萌生及失稳扩展的声发射特征。结果表明:声发射能量和质心频率可有效预报7N01铝合金微裂纹的萌生。声发射信号的双谱等高线图显示两个频率成分之间的耦合关系,使得识别7N01铝合金三点弯曲过程中的不同阶段变得相对容易。7N01铝合金试样缺口尖端的损伤演变过程的数字图像监测结果,验证了声发射能量和质心频率对裂纹萌生的预测。实验结果显示声发射监测技术为裂纹演变行为的预测提供了依据。     

锌漆薄膜/2Cr13钢基体系统薄膜裂纹试验与模拟

本文采用试验和数值模拟方法研究锌漆薄膜/2Cr13钢基体系统薄膜开裂和裂纹扩展情况。创新性地使用三点弯曲试验结合声发射技术监测到薄膜裂纹萌生时刻,并计算薄膜断裂韧性。采用扩展有限元法研究三点弯曲作用下薄膜裂纹扩展过程,发现模拟得到的荷载-位移曲线与试验曲线相吻合。模拟结果表明,薄膜裂纹尖端区域存在应力峰值,当该值达到损伤判据临界应力时,裂纹发生扩展。同时,对多种因素影响下薄膜周期裂纹无量纲能量释放率进行分析,发现薄膜厚度一定时,薄膜相对于基体刚度越大,半无限基体上薄膜裂纹前缘达到稳定状态时对应的基体厚度与裂纹间距越大。      

带有槽缺陷游乐设施用Q235圆管构件弯曲破坏声发射特性

为研究带有槽缺陷游乐设施用Q235圆管构件破坏时声发射特性,利用声发射技术监测其三点弯曲破坏过程。通过对载荷时间曲线与声发射相对能量、幅度、振铃计数特征参数历程图的综合分析,可将其破坏过程划分为3个阶段。该过程声发射信号幅值主要集中在40～70 dB之间,且随缺陷长度增加,超过70 dB信号振铃计数明显增多,典型阶段特征参数峰值增大。相对能量—持续时间历程图中高持续时间、低能量信号来自于加载过程中的噪声干扰。声发射特征参数将缺陷微小变化对构件整体性能的影响量化,历程图变化与力学行为一一对应,建立声发射特征信号与弯曲力学性能和缺陷长度的联系,为声发射监测游乐设施损伤的判定提供依据。     

花岗岩热损伤抗拉强度和声发射特征试验研究

针对核废料处置库、地热开采工程、煤炭地下气化等地下工程围岩结构高温稳定性问题,研究花岗岩在25～700℃加热后的抗拉强度变化和声发射特征,并分析花岗岩的微裂纹损伤特征和宏观破坏模式。试验结果表明：试样的应力时间曲线表现为明显的近线性增长和迅速破坏特征,应力近线性增长速率随温度增加先缓慢上升后下降;花岗岩的抗拉强度随温度增加不断减小,其中在300～400℃抗拉强度下降最快;随温度增加声发射b值波动更为剧烈,声发射累计振铃计数在不同温度下也表现出差异性增长特征,声发射能量随温度总体上是不断减小的,声发射事件数水平和出现频率在高温条件下显著增大;随温度增长裂纹出现越早,裂纹损伤应力门槛比值则是先减小后增大;花岗岩破坏模式在不同温度下均是以主裂纹为主,断裂面的粗糙度、不平整度随温度不断增大。     

蜂窝夹层复合材料压缩损伤声发射特征研究

应用声发射技术对蜂窝夹层复合材料压缩损伤过程进行了实验研究。分析载荷与声发射信号经历图,依据其损伤过程和声发射特征,发现随着加载载荷的增加,复合材料的损伤逐步增大。在加载初始阶段,仅有少量声发射信号,各种表征信号量小幅度增加;在加载中期,声发射信号增多,各种表征信号量不断增大;在加载后期,声发射信号明显突增,各种表征信号量急剧增加。复合材料压缩损伤破坏与声发射的幅值、能量、撞击、上升时间、持续时间和计数等参量相关。蜂窝夹层复合材料试件的应力-应变曲线近似为直线,应变速率与声发射信号特征相互对应。     

SUS304不锈钢拉伸过程中的声-热像特征

测量了含有Ⅰ型裂纹的SUS304不锈钢试样的单轴拉伸过程中的塑性变形和断裂。分析了裂纹尖端区域的塑性变形和断裂过程。结果表明:SUS304的各向异性在断裂阶段对声发射信号影响较大;红外热图像中的温度分布与塑性应变率有关;通过声发射参数和红外热图像可以从微观和宏观两方面分析裂纹尖端区域的塑性变形和断裂。     

充氢Cr-Mo钢变形过程的声发射特征

对电化学充氢后的2.25Cr-1Mo钢进行拉伸实验,并在实时拉伸过程中采集声发射信号。结果表明:充氢后2.25Cr-1Mo钢抗拉强度为536.30MPa,下降约57MPa;断面收缩率为43.62%,下降约7%。拉伸断口上出现由氢脆引起的"白点"特征与准解理断裂形貌。充氢后试样拉伸过程弹性阶段的声发射信号活动增强,而屈服阶段的声发射信号活动减弱,变形过程的声发射信号累积绝对能量值要比未充氢试样低约1个数量级。充氢试样拉伸产生的声发射信号比未充氢试样的信号幅值降低约0.33mV,频宽降低0.06MHz。通过对声发射信号的分析发现,充氢试样变形的微观机制为氢促进位错发射与运动,而交叉滑移受到抑制。     

带缺口塑性材料的声发射特性研究

以带线切割加工缺口的碳钢在拉伸试验时的断裂过程为研究对象,通过对其产生的声发射信号进行检测和分析,研究其开裂时的声发射特性。试验结果表明:带缺口塑性材料在拉伸断裂过程中会产生幅值在47dB￣90dB范围内的声发射信号;信号的振铃累计数在材料的塑性变形段与裂纹稳态扩展段均与应变成线性关系,但后者斜率大于前者;试样缺口深度越大,材料开裂时间越早,振铃计数率越高,且信号能量累计数与应变成线性关系。     

基于声发射技术的30CrMnSi钢断裂机理研究

采用三点弯曲试样加载过程声发射监测实验,结合断口SEM观察及X射线能谱分析,考察了30CrMnSi合金钢延性断裂的整个物理过程.结果表明:30CrMnSi钢的断裂过程从宏观上可以分为裂尖塑性变形、裂纹亚临界扩展和裂纹失稳扩展三个阶段.其机理如下:裂尖塑性变形过程是位错的滑移、堆积而引起的孔洞形核和长大;裂纹亚临界扩展过...     

Failure assessment of a hard brittle coating on a ductile substrate subjected to cyclic contact loading

Hard brittle films and coatings are often employed as a protective coating for metallic ductile substrates. In use, such coatings are generally subjected to cyclic/repeated contact loading and sliding over long periods of time. This study investigated the monotonic and cyclic contact fracture mechanism of hard coatings on ductile substrates (an electroplated Ni–P coating on a stainless steel substrate, SUS304) in order to evaluate their mechanical durability. In the experiment, both monotonic and cyclic indentation tests using a ball indenter with large contact force were performed. The fracture nucleation process was identified using the acoustic emission method. For monotonic contact loading (single indentation), coating cracks are produced by the excessive plastic deformation of the substrate, itself caused by contact loading, which makes the bending curvature of a coating a critical moment. Subsequently, cyclic contact loading (cyclic indentation) was applied to the coating in order to investigate the cycle number of film cracking. It was found that the critical contact force for coating fracture decreases, compared with that of monotonic loading. This critical force is dependent on the number of loading cycles. This may be due to the fact that cyclic contact loading encourages large plastic deformation of the SUS304 substrate owing to cyclic plasticity. Therefore, the cyclic plastic deformation behavior of the substrate was investigated using cyclic microindentation tests and the finite element method. In the computation, the Chaboche model was employed to compute the cyclic plastic deformation of the substrate, since it simulates cyclic plasticity. We clarified the cyclic contact fracture mechanism of electroplated Ni–P coating on an SUS304 substrate. Based on this, we finally predicted the coating lifetime (i.e., mechanical durability) under cyclic contact loading. Therefore, the present study is useful for obtaining information about film/coating fracture properties under both monotonic and cyclic contact loadings.     

Acoustic emission behaviour during stage II fatigue crack growth in an AISI type 316 austenitic stainless steel

Acoustic emission (AE) behaviour during fatigue crack growth (FCG) in a ductile AISI type 316 austenitic stainless steel is reported. The two substages in the stage II Paris regime of FCG could be distinguished by a change in the rate of acoustic activity with increase in crack growth rate. The transition point in the cumulative ringdown count plot coincides with that in the da/dn plot. The AE activity increases with increase in ΔK during stage IIa and decreases during stage IIb. The major source of AE during stage IIa is found to be the plastic deformation within the cyclic plastic zone (CPZ) as compared to the phenomena such as monotonic plastic zone (MPZ) expansion, ductile crack growth, crack closure, etc. The increase in AE activity with increase in ΔK during stage IIa is attributed to the increase in the size of the CPZ which is generated and developed only under plane strain conditions. The decrease in AE activity during stage IIb is attributed to the decrease in the size of the CPZ under plane stress condition. The high acoustic activity during the substage IIa is attributed to irreversible cyclic plasticity with extensive multiplication and rearrangement of dislocations taking place within the CPZ. The AE activity is found to strongly depend on the optimum combination of the volume of the CPZ, average plastic strain range and the number of cycles before each crack extension. Based on this, an empirical relationship between the cumulative RDC and ΔK has been proposed and is found to agree well with experimentally observed values.     

不同拉伸速率下钢材损伤的声发射监测评价

钢材已成为生产的基本材料,被广泛应用于各行业,目前还没有对其进行损伤动态监测的有效方法。采用声发射技术对钢材Q235在不同的拉伸速率下进行损伤动态监测试验研究,首先通过试验获取了不同拉伸速率时材料的弹性、屈服、强化、颈缩和断裂各个力学行为阶段声发射信号并提取各个特征参数;然后通过各个特征参数累积量历程图归一化曲线对钢材拉伸损伤过程进行评价,发现特征参数累积量历程图归一化曲线可以明显反映出钢材拉伸整体演变过程及各个力学行为阶段特征,并且随着拉伸速率的减小,在屈服阶段的结束端点出现更为明显的突增量,可作为表征屈服阶段和强化阶段的重要转折点。结合拉伸力学,对各个力学行为阶段声发射信号的产生机制和特征进行总结,可为钢材后期声发射信号源的产生机制以及后期损伤定量、寿命预测的研究提供参考了依据。     

An experimental methodology for characterizing fracture of hard thin films under cyclic contact loading

Hard thin films are often employed as protective coatings for metal substrates and their fatigue/fracture property (especially that under contact) needs to be sufficiently understood. In this study, we present a combined experimental/computational framework for exploring the fracture characteristics of hard thin films upon both monotonic and cyclic contacts. The techniques of acoustic emission and corrosion potential fluctuation are combined to monitor the mode and initiation of crack, and numerical simulations based on the finite element method provide further information on the criterion of film fracture. For a model system of a TiN film physical vapor deposited onto a stainless steel substrate, ring cracks are produced when the stress in the film exceeds critical — such a critical moment arrives when the substrate undergoes excessive deformation, which makes the curvature of film bending critical just outside the contact zone. Since cyclic contact loading encourages large plastic deformation of substrate due to ratcheting plasticity, it is found that the critical contact force degrades, compared with monotonic loading. The present experimental/computational methodology is useful for obtaining the information of film fracture property under both monotonic and cyclic contact loads.     

铁素体/贝氏体双相钢的变形和断裂特性

对一种低碳硅锰钢进行TMCP实验,获得了不同铁素体形态的铁素体/贝氏体双相钢(FB钢),研究了FB钢在单轴拉伸下的变形行为及断裂特性,结果表明:在均匀塑性变形阶段,FB钢的瞬时加工硬化指数n*值与真应变ε的关系曲线可分为n*值较高、n*值随ε缓慢下降以及n*值随ε迅速下降三个阶段,与等轴铁素体/贝氏体双相钢相比,准多边形铁素体/贝氏体双相钢的强度和低应变区的n*值均比较高,FB钢拉伸试样颈缩区的孔洞或微裂纹产生在F-B相界面附近和铁素体内,有助于减弱裂纹尖端附近的局部应力集中,改善钢材的抗裂纹扩展性能.     

基于声发射技术的Si-Cr-Ti高温抗氧化涂层弯曲失效机理研究

本研究借助声发射技术对铌基高温抗氧化涂层在常温下的弯曲失效过程进行了研究。利用k均值聚类方法对信号进行了分类, 结合截面扫描电镜观测结果确定高温抗氧化涂层在弯曲载荷下的信号分别对应基体变形、表面垂直裂纹、滑动型界面裂纹和张开型界面裂纹, 通过快速傅里叶变换得到了各类信号的主频分别为100、310、590和450 kHz, 借助小波分析得到了各信号的小波能量系数。涂层弯曲失效过程主要包括四个阶段, 分别为受拉侧表面垂直裂纹萌生的初始损伤阶段、表面垂直裂纹增殖阶段、两侧界面裂纹快速扩展的损伤积累阶段和受压侧涂层明显剥落的宏观剥落阶段。