CrWMn钢冲孔模具加工过程中开裂分析

某CrWMn钢冲孔模具在磨床磨光后于距边缘较近的圆孔处发生开裂,通过低倍组织检验、显微组织检验、化学成分分析及对开裂模具相关热处理工艺过程分析等方法对模具开裂的原因进行了分析,并进行了验证性试验。结果表明：该模具开裂是由于热处理工艺不当引起的;模具淬火时未预冷,淬火后在未冷透的情况下即用凉水清洗,再加上回火不充分,使材料内应力和组织应力较大,在这两种应力作用下,导致模具在距离边缘较近的圆孔处发生开裂。     

电梯驱动轴断裂原因分析

某电梯公司生产的材料为Q345A钢的电梯驱动轴在短期内发生断裂失效,采用化学成分分析、金相检验、硬度测试、扫描电子显微镜分析等方法对驱动轴断裂原因进行了分析。结果表明:该驱动轴断裂属性为多源旋转弯曲疲劳断裂;断裂源位于驱动轮盘和驱动轴过渡的环焊缝热影响区的应力集中处,加之驱动轴表面加工刀痕明显,且存在硬而脆的马氏体非正常组织,进一步加剧了该处的应力集中,在扭转力作用下萌生多源裂纹,裂纹不断扩展最终导致断裂。     

铁路轴箱弹簧断裂原因分析

某铁路轴箱弹簧在服役过程中发生断裂。采用化学成分分析、非金属夹杂物检验、硬度测试、显微组织及表面脱碳层检验、断口分析等方法,对弹簧断裂的原因进行了分析。结果表明:在服役过程中,弹簧表面存在的不连续凹痕处产生应力集中并形成裂纹源,疲劳裂纹不断扩展,导致弹簧最终发生疲劳断裂。     

双联行星轮断齿原因

某型矿车电动轮上的双联行星轮在运行过程中发生断裂。采用宏观观察、扫描电镜分析、金相检验、硬度测试等方法分析了该行星轮断裂的原因。结果表明：行星轮断齿处呈典型的疲劳断裂特征；裂纹源位于距离齿根次表面约2 mm位置，裂纹源处存在平行于齿宽方向的大尺寸纺锤形氧化铝夹杂物，裂纹从该处萌生并扩展，最终导致行星轮发生断裂。     

压铸模开裂原因分析

某厂压铸模在使用2035次后发现裂纹,采用扫描电镜、金相显微镜、化学分析及硬度测定等方法对模具开裂原因进行分析,发现模具用材料有质量问题,材料的化学成分不均匀,组织呈带状分布以及碳化物液析及非金属夹杂不正常等因素,致使该模具产生附加内应力,当模具在冷热循环及机械循环的环境下服役时,在型腔表面的拐角处应力集中部位率先产生裂纹源,再加上型腔表面脱碳等缺陷降低材料的疲劳强度,使微裂纹得以迅速扩展,最终导致模具早期热机械疲劳失效.     

某宽厚钢板等离子切割开裂原因

在某宽厚板的等离子切割工序中,其板厚1/2处产生中心裂纹。采用宏观观察、化学成分分析、金相检验、扫描电镜及能谱分析、硬度测试等方法分析该钢板开裂的原因。结果表明：在钢板1/2厚度处存在明显的偏析带,基体和偏析带的显微组织分别为回火马氏体和淬火马氏体,在偏析带中分布有长条状夹杂物,裂纹从夹杂物处萌生并扩展;等离子切割后的淬硬层硬度较大,具有很大的淬硬倾向,在热应力和组织应力的作用下,钢板最终开裂。     

高速钢原材料检验方法探讨

针对部分高速钢刀具在热处理过程中及用户使用时，因早期失效而损坏的原因进行了分析研究。结果表明，心部有缺陷的原材料被加工成产品，是因为忽略了对原材料心部热处理金相组织的检验。因此，建议在原材料的1/4直径或1/4厚度处检验纵向碳化物不均匀度的基础上，增加检验横截面1/2直径或1/2厚度处的热处理金相组织。此检验方法能有效地避免某些有显微组织缺陷的原材料流入下道工序，保证高速钢产品的整体质量。     

压缩机连杆断裂失效分析

某炼油厂焦化装置富气压缩机连杆发生断裂。采用化学成分分析、金相检验、力学性能测试和断口分析等方法对断裂连杆进行了分析。结果表明,在交变栽荷的作用下,连杆的小头孔内应力集中处产生微裂纹并成为裂纹源,然后发生裂纹扩展,最终导致连杆小头处发生疲劳断裂。     

安全阀配对法兰焊口裂纹产生原因分析

某集气装置原料气放空安全阀配对法兰焊口处出现裂纹,通过宏观以及微观检验、化学成分分析、力学性能测试等方法对裂纹产生的原因进行了分析。结果表明：该裂纹为硫化物应力腐蚀开裂所致,焊接工艺不当或焊后冷却速度过快导致焊接接头区域出现硫化物应力腐蚀开裂敏感性组织是该焊口产生裂纹的主要原因。     

铸钢件摇臂裂纹原因分析及改进

在对内燃机气门摇臂进行磁粉探伤时发现有裂纹存在。通过化学成分分析及金相检验分析了裂纹产生的原因。结果表明:该裂纹为铸造过程的热裂纹;通过加大模具过渡区的圆角及减小内浇口尺寸,可消除铸件热裂纹的产生。     

Damage in aligned-fibre SiC/Al quantified using a laboratory X-ray tomographic microscope

A first-generation laboratory X-ray tomographic microscope is used to non-destructively ‘section’ a continuous, aligned-fibre SiC/Al metal-matrix composite (MMC). Damage in the MMC associated with mechanical deformation is the principal focus of the study. Two types of deformation are examined: wedge loading (with and without load) and three-point bending. Quantification of crack opening and fibre fracture detection is found to be practical down to one-tenth of a pixel in the reconstructed sections     

架桥机移动模架销轴断裂分析

通过断口分析、化学成分分析、非金属夹杂物检验、力学性能测试、金相检验以及销轴受力及焊接工艺分析,对移动模架销轴的断裂原因进行了分析。结果表明:焊接接头结构设计或焊接工艺不当,形成粗大马氏体组织缺陷或裂纹,是造成该轴脆性断裂的主要原因,并提出了预防措施。     

Effect of bending moment on the dynamic fracture of a beam or plate under tensile loading

The dynamic fracture response of a long beam of brittle elastic material under tensile loading is studied. If the magnitude of the applied loading is increased to a critical value, a crack is assumed to propagate across the beam cross section. As an extension of previous work, an induced bending moment generated during fracture is incorporated into the analysis and this improved formulation is presented. The crack length, crack tip speed, axial force and bending moment on the fracturing section are determined as functions of time after crack initiation. It is found that the bending moment has a significant effect on the fracture process in that it tends to retard fracture and causes a drastic change in the slope of the loading curve for large crack depths. Finally, by appropriate change of the elastic modulus, the results may be applied to plane strain fracture of a plate in pure tensile loading.     

Dynamic fracture of a beam or plate under tensile loading

The dynamic fracture response of a long beam of brittle elastic material under tensile loading is studied. If the magnitude of the applied loading is increased to a critical value, a crack is assumed to propagate across the beam cross section. In a parallel analysis to [t] the crack length and applied loading at the fracture face are determined as functions of time measured from fracture initiation. The results of the analysis are shown in graphs of crack length, crack tip speed and fracturing section tensile loading vs time. As found in [1], the crack tip accelerates very quickly to a speed near the characteristic terminal speed for the material, travels at this speed through most of the beam thickness, and then decelerates rapidly in the final stage of the process. Finally, by appropriate change of the elastic modulus, the results may be applied to plane strain fracture of a plate under pure tensile loading.     

On the symmetric dynamic fracture of a beam under tensile loading

The dynamic fracture response of a long beam of brittle elastic material under tensile loading is studied by means of two different one-dimensional models. If the magnitude of the applied loading is increased quasi-statically to a critical value, two coplanar edge cracks are assumed to propagate across the beam's cross section. The first model parallels that of [6] with the crack length, crack speed and the loading on the fracturing section being determined as functions of time after fracture initiation. The second model is derived by means of energy considerations in the vicinity of the fracturing section. The results obtained from both models are similar except during the final phase of the fracture process.     

B5后桥A356铝合金支承座早期断裂失效分析

针对某B5后桥A356铝合金支承座台架试验早期断裂的问题,采用宏观分析、化学成分分析和扫描电镜断口观察等方法对支承座的断裂原因进行了分析.结果表明:由于该支承座受到意外挤压而造成其在加强筋处表面产生一较小的凹坑,由此形成的应力集中使零件在随后的台架试验中很快在此处萌生裂纹源;同时由于该支承座在裂纹源附近存在大面积的疏松...     

Comparison of fatigue life assessment by analytical,experimental and damage accumulation modelling approach for steel SAE 1045

Fatigue life assessment for two‐phase steel SAE 1045 has been carried out by experimental and simulation techniques. Analytical approach, termed as fatigue lifetime calculation, was employed making use of a load increase testing procedure and constant amplitude tests equipped with measurement techniques – plastic strain amplitude, change in temperature and change in electrical potential difference. The predicted fatigue life has been validated by constant amplitude tests and compared with fatigue life estimation by microstructure‐based simulation. Simulation has been carried out over the complete cross section of the specimen. The simulation uses damage accumulation in the gage section of the specimen culminating in the macro‐crack propagation, taking into account the inhomogeneous fatigue resistance of the material element. The results show that at the initial intervals of high cycle fatigue range at relatively higher stress amplitudes, the experimental and simulation results are in agreement; whereas in the (high cycle fatigue) region at relatively low stress amplitudes, the simulation results were found more optimistic and the corresponding fatigue scatter is also increased. Each scatter is attributed to the relatively small number of analysed models of the material structure. Scanning electron microscope was used to determine volume fraction of the microstructure for simulation. Fatigue fracture surface analysis shows that crack initiated from internal defect of material and crack propagation is driven by silicon oxide inclusion.     

Effect of rare-earth treatment on the banded microstructure and fracture properties of a 16 Mn steel

The two treatments, namely rare-earth (RE) additions to the mould and Ca-Si injection into the ladle, were used to control the MnS inclusion shape in a 16 Mn steel. The critical crack opening displacement, δ_c, method and tensile testing were used to determine the fracture properties of the steel sheets. Scanning electron microscope (SEM) fractography of the fracture surface of tensile specimens tested at room temperature clearly showed the banded structure of the steel sheets in all, even modified, steels. The RE treatment improved the fracture properties both by sulphide inclusion shape control and by reducing microstructural heterogeneity.     

55CrSi弹簧钢失效分析与研究

本文利用扫描电镜对弹簧钢的金相组织、断口及表面进行观察分析,研究其失效原因,结果表明此弹簧钢断裂为早期疲劳断裂,裂纹源萌生于并圈处,由于该处间隙过小,一则不能保证喷丸的效果,二则增加疲劳过程的接触疲劳应力及加重表面损伤,另外该处喷丸微细粒子未清洗干净,相当于表面有一夹杂在运行时遗留在并圈处表层,导致表面损伤,并诱发微裂纹而导致弹簧早期疲劳断裂。     

Predictive models for stable tearing crack growth due to overloading in fatigue

Stable tearing is a recurring process in which fatigue crack growth is interspersed by substantial jumps of crack growth, commonly at the central cross‐section of the component while the crack front nearer the surface lags behind. These tearing bands have been observed to start very early during fatigue life and can make up the majority of the fatigue fracture surface. This paper presents the development of predictive models, in which the tongue‐shaped stable tearing band is first idealised as trapezoidal shape, and then two alternative fracture criteria are formulated with the aid of the finite element (FE) method and the Forsyth stable tearing concept. Parametric solutions of the stress intensity factor at the front of the trapezoidal crack front are obtained using the FE method. Comparisons between the model predictions and experimental results indicate that both models produce satisfactory prediction of the stable tearing crack jump length in aluminium alloy coupons of varying cross‐sectional thickness.