基于单轴缺口试样的一种低周疲劳测试方法与应用

对于漏斗式小曲率半径的缺口圆棒与缺口薄片试样提出了一种采用轴向测量应变的低周疲劳测试方法.通过有限元分析建立小曲率半径的漏斗式缺口圆棒或薄片试样的轴向测试应变到缺口根部Tresca等效应变的应变转换模型,并由疲劳损伤等效假设建立基于缺口试样疲劳实验数据的材料低周疲劳寿命估算模型;完成了大曲率半径漏斗光滑试样和小曲率半径缺口试样的Ti-4Al-2V合金低周疲劳试验,基于缺口试样的疲劳试验所建立的材料低周疲劳寿命估算模型与基于大曲率半径漏斗试样的低周疲劳寿命估算模型有良好的符合度.新方法也方便应用于N18锫合金缺口薄片试样的材料高温单轴低周疲劳行为试验研究,可推荐于材料低周疲劳测试规范修订采用.文中获得的Ti-4Al-2V合金和N18锆合金的不同温度下单轴低周疲劳行为试验数据与寿命估算模型有宜于工程应用.     

TA17合金薄片材料毫小试样疲劳性能研究

关键工程结构、小尺寸零部件和焊接区的疲劳寿命评估中往往无法采用传统大试样进行疲劳试验,因此本文提出了一种采用毫米级别薄片试样获取材料循环本构关系和低周疲劳寿命的新方法。在Care原位试验机上完成毫米级别薄片漏斗试样的加载工装和低周疲劳试验的基础上,通过变幅对称循环试验和等辐循环试验分别实现了材料循环本构关系和低周疲劳性能的获取。该文提出了一种对不同幂律材料和不同几何尺寸构型均具有良好普适性的材料循环本构关系预测模型,并通过有限元实现了模型准确性的正反向预测验证。将循环本构关系用于有限元计算中,给出了薄片漏斗试样漏斗两侧名义应力、名义应变和漏斗根部真实应力、真实应变的转换方程,进而预测材料的低周疲劳寿命。该文完成了TA17合金等直圆棒试样和1.2 mm厚度薄片漏斗试样的对称变幅循环试验和多级等辐循环试验。由模型预测获得的TA17合金循环本构关系与等直圆棒试样的试验结果比较表明:两种曲线的弹性段和0.009 mm/mm~0.011 mm/mm应变段吻合良好,在弹塑性过渡段（0.004 mm/mm~0.009 mm/mm）模型预测结果最大相对误差小于9%。根据两组应力和应变转换方程获得的漏斗试样材料代表性体积单元疲劳寿命和Manson-Coffin寿命预测模型与等直圆棒试样试验结果均吻合良好。     

基于毫小薄片漏斗试样的材料弹塑性循环应力应变关系测试方法研究

为获取毫小尺寸试样疲劳性能,针对厚度为0.5~2.5 mm的薄板材料,该文提出一种应用毫小薄片漏斗试样完成等幅低循环试验的新方法。该方法实现毫小尺寸薄片漏斗试样的设计、加工和加载,提出一种能量分离函数并由此给出毫小薄片漏斗试样循环应力-应变关系的预测模型。针对不同材料完成的有限元分析表明,该模型对不同几何尺寸和不同幂律材料具有良好普适性。以316 L不锈钢为例,完成等直圆棒试样和包括厚度为0.7 mm的6种不同几何尺寸小尺寸薄片漏斗试样的变幅应变对称循环试验,结果表明:基于漏斗薄片小试样的载荷-位移稳定试验曲线,新方法预测的材料循环应力-应变关系与传统等直圆棒试样的试验结果吻合良好。     

基于等效全程单轴本构关系的应力三轴度分析

该文利用有限元辅助测试(Finite element Aided Testing,FAT)方法测得了四种工程材料的等效全程单轴本构关系,基于此全程本构关系对拉伸过程中漏斗试样的应力三轴度演化进行了有限元分析,并同基于Bridgman应力修正后的单轴本构关系得到的漏斗试样漏斗根部截面中心处应力三轴度计算公式结果进行了比较。得到了四种材料的等效全程单轴本构关系、破断应变、破断应力和漏斗根部截面上应力三轴度分布随截面中心Von-Mises等效应变的变化规律。同时基于三轴度理论还讨论了漏斗型试样的拉伸破断机理以及断口的形貌。     

表面压应力对10Ni5CrMoV钢疲劳性能的影响

分别采用精磨和冲击加工在IONi5CrMoV钢试样表面形成不同的残余压应力,对具有不同表面压应力的试样进行高周和低周疲劳试验,采用扫描电子显微镜对疲劳断口进行分析,并测试经不同周次高应变幅循环加载后的试样表面应力。结果表明,较高的表面压应力能有效抑制小应力幅下疲劳裂纹在表面的起裂,从而有效的提高了高周疲劳性能;在高应变幅作用下,初始的表面压应力迅速发生松弛而失去对疲劳裂纹在表面起裂的抑制作用,因而对低周疲劳性能无明显影响。     

7050-T7451铝合金低周疲劳平均应力松弛规律

为了研究平均应变对7050-T7451铝合金低周疲劳力学行为的影响,开展了不同应变比(R=-1、-0.06、0.06和0.5)下的室温恒幅低周疲劳试验。结果表明:在对称循环应变下,材料总体表现为循环软化特征;而在非对称循环应变下,材料表现为初始硬化后的循环稳定行为。非对称循环应变导致了材料出现与应变幅相关的平均应力松弛现象。采用Landgraf模型和非线性Maxwell模型分别研究了7050-T7451铝合金的平均应力松弛规律。结果表明:Maxwell模型能够较准确地描述材料的平均应力循环松弛特征,而Landgraf模型更适用于低应变幅下的平均应力松弛描述。     

Al-5.4Zn-2.6Mg-1.4Cu合金板材的低周疲劳行为

进行Al-5.4Zn-2.6Mg-1.4Cu合金板材的室温低周疲劳实验,对比研究了轴向平行于轧制方向(RD方向)和垂直于轧制方向(TD方向)试样的低周疲劳行为。结果表明：对于0.4%~0.8%的外加总应变幅,RD和TD方向合金试样的循环应力响应行为均呈现出循环稳定;对于相同的外加总应变幅,TD方向合金的循环应力幅值高于RD方向,而RD方向合金的疲劳寿命高于TD方向。对于RD和TD方向,Al-5.4Zn-2.6Mg-1.4Cu合金的塑性应变幅、弹性应变幅与载荷反向周次均呈线性关系。在低周疲劳加载条件下,裂纹在疲劳试样的自由表面以穿晶方式萌生和扩展。     

高温对核电工程材料低循环行为的影响研究

对核电工程材料（钛合金T42NG与T225NG和主螺栓材料18Cr2NiWA)开展了室温与350度高温下的低周疲劳性能试验研究,获得了各材料单调R－O本构模型和M－C寿命估算模型,基于这些模型,研究了材料的循环强化与软化规律,了温度系数λσ,λΔσ,和λNf对钛合金静强度,循环强度和低周疲劳规律的影响效应;根据温度对寿命的影响系数λNf与应变幅Δε/2呈线性规律的重要发现,提出了考虑温度效应的用于高温低周疲劳寿命估算的λ－M－C模型,进而总结出一种现行方法更简便的高温疲劳试验方法。     

OCr18Ni24Mo6N奥氏体焊缝金属循环塑性变形的力学本构关系

针对OCr18Ni24Mo6N奥氏体焊缝金属开展了系列应变幅的循环加载试验,并分析了循环应力应变特性.结果表明:循环塑性变形条件下表观弹性模量随应变幅的增大呈线性降低特点;循环塑性应变显著降低屈服强度,且屈服强度随应变幅的增大呈线性降低特点;塑性变形段的真应力和真应变塑性分量满足单对数强化弹塑性本构关系,并建立了OCr18Ni24 Mo6N奥氏体焊缝金属循环应力应变本构方程.     

一种基于混合硬化本构模型的汽轮机轮盘榫槽疲劳寿命预测方法

针对汽轮机转子轮盘的受力特点,以非对称载荷下材料的瞬态应力应变响应为基础,在内变量理论框架下,建立起某型汽轮机轮盘材料的率无关循环塑性本构模型;并结合局部应力应变法,进一步建立了基于混合硬化本构模型(N-5L1)描述平均应力松弛行为的汽轮机轮盘榫槽疲劳寿命预测方法。通过与实验结果相比较,表明混合硬化本构模型能够较好地模拟脉动加载下转子轮盘材料的循环应力应变响应及平均应力松弛行为,由此建立的寿命预测方法可对轮盘榫槽进行较为准确的疲劳寿命预测(与试验寿命误差总体落在1.5倍分散带以内),明显优于基于平均应力松弛经验公式的疲劳寿命预测值。     

BIAXIAL HIGH STRAIN FATIGUE TESTING OF 1Cr-Mo-V STEEL

Abstract— A test facility has been developed in which a thin walled tube can be subjected to fully reversed fatigue cycles for all biaxial stress or strain ratios. Twin loop servo-control allied to high resolution gauge length extensometry, load and pressure transducers permits stress or strain controlled testing. The rig is unique in that cyclic stress-strain hysteresis loops can be obtained for both axial and circumferential directions during a test. Results from a strain controlled series of low cycle fatigue tests on a ferritic 1Cr-Mo-V steel obeyed the Manson-Coffin relationship with the exponent being sensibly constant for all strain ratios. For a given maximum principal biaxial strain, the damaging effect increased as the strain ratio φ increased from –1 to +1. By comparing results from solid and hollow cylindrical specimens, geometry effects on fatigue life were revealed. Data on shakedown and cyclic softening under biaxial strain conditions were also obtained.     

Fatigue life evaluation of tension‐compression asymmetric material using local stress–strain method

In this paper, the low‐cycle fatigue characteristics of cold‐drawn steel were investigated under strain‐controlled uniaxial fatigue load. Cyclic softening was observed throughout fatigue life except for the initial relatively short period which exhibited cyclic hardening. Positive mean stress was found under fully reversed strain loading, indicating that there was a significant cyclic asymmetry. A modified local stress–strain method was proposed to estimate fatigue life of notched tension‐compression asymmetric material. In order to verify this method, fatigue experiments on two kinds of notched specimens with different notch radius were carried out under constant and block load spectrum. It was found that the modified local stress–strain method was more accurate than the traditional ones, the maximum relative error between predicted and experimental fatigue life was less than 6%.     

Torsional fatigue with axial constant stress of oligo‐crystalline 316L stainless steel thin wire

A series of symmetric torsional fatigue with axial constant stress tests, a kind of multiaxial fatigue test, was conducted on oligo‐crystalline 316L stainless steel thin wire, which was less than 3.5 grains across diameter of 200 μm. The material presents significant cyclic hardening under symmetric torsion cycling, and hardening is more obvious with the increasing shear strain amplitude. However, symmetric torsional cycle with constant axial stresses tests characterize rapid initial hardening and then gradually softening until fatigue failure. The axial stress has a great effect on torsional fatigue life. Fractography observation shows a mixed failure mode combined torsional fatigue with tensile strain because of axial tensile stress. A newly proposed model with axial stress damage parameter is used to predict the torsional fatigue life with constant axial stress of small scale thin wire.     

MEAN STRESS EFFECTS ON LOW CYCLE FATIGUE FOR A HIGH STRENGTH STEEL

Abstract— ASTM A723 Q & T steel with a yield strength and ultimate strength of 1170 and 1262 MPa respectively was evaluated for mean stress-strain effects under smooth specimen axial strain controlled low cycle fatigue conditions with strain ratios R of −2, −1, 0, 0.5 and 0.75. Cycles to failure ranged from 15 to 10⁵. Cyclic stress-strain response based upon half-life hysteresis loop peaks were similar for all R ratios. Mean stress relaxation occurred for R ≠−1 only when plastic strain amplitudes were present and this occurred above total strain amplitudes of 0.005. Thus, mean stress relaxation was completely dependent upon cyclic plasticity. Mean strains did not affect low cycle fatigue life unless accompanied by half-life mean stress. Tensile mean stress was detrimental and compressive mean stress was beneficial and these effects only occurred at strain ampltidues below 0.005. Three different mean stress models were used to evaluate the low cycle fatigue data and the SWT log-log linear model best represented the data. These results can be used with the local notch strain fatigue life prediction methodology.     

在多轴载荷下45钢的循环特性

通过多轴疲劳试验，研究了在多轴加载条件下45钢的循环特性变化规律，分析了非比例附加强化、多轴循环软化/硬化特性及疲劳寿命对加载路径参数的依赖性，结果表明，相位角主要影响非比例附加强化程度，幅值比主要影响多轴循环软化/硬化特性，二者都影响多轴疲劳寿命。     

Low cycle fatigue behavior of thermo-mechanically treated rebar

The strain and stress controlled low cycle fatigue behavior of thermo-mechanically treated rebar are examined in this current work at room temperature. Severe cyclic softening is observed in all applied strain amplitudes during strain controlled low cycle fatigue. Cyclic softening deteriorates the seismic resistance property of the rebar. Decrease in the cyclic yield stress (linear portion of the hysteresis loop) is responsible for cyclic softening. Cyclic softening results progressive opening up the hysteresis loop during stress controlled low cycle fatigue. It is experimentally observed that irrespective of control mode (stress/strain) and loading conditions, fatigue crack initiates form the transverse rib root and propagate along the same region. Finite element simulation result reveal that stress concentration takes place at the root of the transverse rib and stress triaxiality become higher in the same region. Tensile strain accumulation at the transverse rib root is detected in simulation. Simulation result explains the experimental fact that fatigue crack initiate and propagate along the transverse rib root.     

Simulation of cyclic stress/strain evolutions for multiaxial fatigue life prediction

This study deals with simulation for cyclic stress/strain evolutions and redistributions, and evaluation of fatigue parameters suitable for estimating fatigue lives under multiaxial loadings. The local cyclic elastic–plastic stress–strain responses were analyzed using the incremental plasticity procedures of ABAQUS finite element code for both smooth and notched specimens made of three materials: a medium carbon steel in the normalized condition, an alloy steel quenched and tempered and a stainless steel, respectively. Emphasis is on the studying of ‘intelligent’ material behaviors to resist fracture, such as stress redistribution and relaxation through plastic deformations, etc. For experimental verifications, a series of tests of biaxial low cycle fatigue composed of tension/compression with static and cyclic torsion were carried out on a biaxial servo-hydraulic testing machine (Instron 8800). Different multiaxial loading paths were used to verify their effects on the additional cyclic hardening. The comparisons between numerical simulations and experimental observations show that the FEM simulations allow better understanding on the evolutions of the local cyclic stress–strain and it is shown that strong interactions exist between the most stressed material element and its neighboring material elements in the plastic deformations and stress redistributions. Based on the local cyclic elastic–plastic stress–strain responses, the energy-based multiaxial fatigue damage parameters are applied to correlating the experimentally obtained lives. Improved correlations between the predicted and the experimental results are shown. It is concluded that the improvement of fatigue life prediction depends not only on the fatigue damage models, but also on the accurate evaluations of the cyclic elasto-plastic stress/strain responses.     

Evaluation of fatigue crack initiation life from a notch

Local strain at the notch-root and its effect on fatigue crack initiation was investigated in four metals by the real-time, fine-grid method. Special attention was focused on local notch-root strain behaviour until crack initiation. From the application of strain hysteresis at the notch root, the maximum strain under loading conditions during each cycle was investigated in detail. One of the main results was that the maximum strain value at the first cycle of the fatigue test coincided with that at crack initiation. Maximum strain defined from the cyclic strain changes at the notch root was proposed as one possible parameter for estimating fatigue crack initiation life. Based on the curvilinear relationship between maximum strain and number of cycles to crack initiation, a new life evaluation method for fatigue crack initiation is proposed. This approach differs fundamentally from the usual fracture mechanics method based on the stress intensity factor.