铝合金板材疲劳损伤的非线性导波检测

针对传统线性超声检测技术无法检测疲劳微损伤的问题,提出了疲劳微裂纹的非线性超声导波检测技术。首先,通过检测信号时频分布与频散曲线的对比分析,确定了铝板中的Lamb波模态,据此优化试验参数,并在板中激发单一模态的兰姆波;其次,通过试验方法判断该模态Lamb波的非线性响应条件,确定该模态在激励微裂纹疲劳损伤上的实用性;第三,提取了非线性超声检测特征参数,分析了各特征参数随疲劳周数的变化关系。结果表明:铝板中的兰姆波频散特性会导致基频幅值波动较大,非线性系数随基波变化无法反映真实的微裂纹非线性响应;二次谐波幅值在疲劳损伤初期随着疲劳周数的增大而增大,可用于评价缺陷的微观损伤。     

孪晶片层厚度对纳米孪晶Cu疲劳性能的影响

通过恒应力幅控制拉--拉疲劳实验, 比较了脉冲电解沉积制备的不同孪晶片层厚度纯Cu样品的疲劳寿命和疲劳耐久极限. 结果表明: 在应力疲劳下, 样品的疲劳寿命与疲劳耐久极限均随孪晶片层厚度的减小而提高. 疲劳样品的宏观表面变形形貌(SEM观察)和微观结构(TEM观察)表明:
当平均孪晶片层厚度为85 nm时, 材料的塑性形变由位错滑移和剪切带共同承担, 进而疲劳裂纹沿剪切带萌生; 而当平均孪晶片层厚度为32 nm时, 材料的塑性形变由位错--孪晶界交互作用主导, 从而导致疲劳裂纹沿孪晶界形成.     

喷丸处理对7A85-T7452铝合金锻件疲劳性能的影响

研究不同喷丸强度对7A85-T7452铝合金锻件高周疲劳性能的影响,对比喷丸处理前后1×10~7疲劳寿命条件下的疲劳强度,利用扫描电镜(SEM)和透射电镜(TEM)观察了疲劳断口的形貌特征以及强化层微观组织的变化,用X射线(XRD)检测了强化层残余应力的分布。结果表明:喷丸后7A85铝合金试样的疲劳寿命是未喷丸的7.3倍,疲劳强度提高18%。喷丸在材料表面形成了厚度约为0.09 mm的残余压应力层,最大压应力为-231 MPa,该强化层平衡部分外加载荷中的瞬时拉应力,残余压应力层内的高密度位错可以阻碍位错的滑移,导致晶内位错迁移困难,从而阻碍了疲劳裂纹的萌生和扩展。     

基于Tanaka-Mura位错模型的疲劳裂纹萌生寿命预测

为了准确预测材料的疲劳寿命,提高结构疲劳寿命预测精度,对ABAQUS有限元数值模拟预测试样疲劳寿命的方法进行了研究. 基于Tanaka-Mura位错理论,利用python语言对ABAQUS进行二次开发,模拟预测了S960QL马氏体钢和Ti₂AlNb钛合金接头各区域疲劳裂纹萌生寿命. 利用泰森多边形法生成了晶体特征单元建立了微观子模型,考虑了体心立方结构相互垂直的两条滑移带作为潜在的裂纹萌生位置,并对具有相同取向的多条平行滑移带都进行了模拟计算. 通过计算得到的裂纹扩展速率变化,给出了裂纹萌生阶段过渡到裂纹扩展阶段的临界点处的裂纹萌生寿命. 模拟结果表明,除焊缝柱状晶组织外裂纹萌生寿命与试验数据吻合良好.     

ZL702A铝合金构件微动疲劳寿命预测研究

目的探讨ZL702A铝合金的微动损伤机理,寻找适合的微动疲劳寿命预估模型。方法以ZL702A铝合金为研究对象,设计方足桥-试件微动模拟件进行微动疲劳实验,用4XC-PC金相显微镜观察断裂试件表面的磨损形貌,探讨微动损伤机理。建立方足桥-试件有限元模型,编程计算剪应变幅、法向正应力、相对滑移距离等微动特征参数,分别运用FS、KBM、Mc Diarmid以及Ruiz参数预测ZL702A铝合金微动疲劳寿命。结果疲劳裂纹主要在局部塑性区成核,剪切应变可以加速裂纹核的形成,疲劳裂纹增长是裂纹尖端剪切带不断聚合的过程,裂纹面上的法向应力/应变使这种聚合加速。法向载荷保持不变,随着最大轴向力的增大,微动损伤增大。4种微动疲劳寿命预估模型的结果表明,微动损伤在试件接触区边缘最大,容易萌生微动裂纹,与实验值一致。微动疲劳寿命预测结果表明,Ruiz参数预测结果与实验结果误差在2倍公差带因子范围内,最接近实验值。结论微动磨损区分为粘着区、混合区、滑移区,在混合区边界上最容易发生塑性变形,萌生微动疲劳裂纹,用Ruiz参数预测ZL702A铝合金的微动疲劳寿命是可行的。     

LC4CS铝合金的超高周疲劳寿命分布

采用超声高频疲劳试验机进行了LC4CS铝合金实验样本容量为66的超高周疲劳寿命实验.结果表明,超高周疲劳寿命具有双峰分布特征,这一特征与疲劳裂纹的萌生点有关:较短疲劳寿命的样品的裂纹萌生于夹杂等缺陷处,而较长疲劳寿命的样品的裂纹萌生于表面.寿命分布的双峰特征使得传统的升降法不能用于确定材料的超高周疲劳的条件疲劳极限,超高周疲劳寿命的分散性远大于低周和高周疲劳寿命的分散性.     

GH4720合金涡轮盘榫槽模拟件疲劳性能研究(英文)

基于航空发动机涡轮盘榫槽结构特点及其工作状态,采用榫槽模拟件对GH4720合金的疲劳失效机理和裂纹扩展寿命进行了实验研究和理论分析。研究结果表明:GH4720合金榫槽模拟件的疲劳失效表现为3个阶段:(i)模拟涡轮盘榫槽处由于较高的应力集中而产生滑移,进而萌生裂纹;(ii)随着应力集中和循环载荷的持续,相邻晶粒间位错开动、发生滑移,裂纹在晶粒间传递;(iii)随着应力强度因子范围增大,剪应力和主应力交互作用、滑移系开动及位错在不同滑移系间的运动,裂纹快速扩展。在实验基础上建立了GH4720合金的疲劳裂纹扩展寿命模型,基于有限元分析的榫槽处的应力和裂纹扩展寿命模型得到的裂纹扩展寿命与实验结果相符,表明该裂纹扩展寿命模型可用于工程中预测涡轮盘的剩余寿命。     

Study on Fatigue Properties of Turbine Disk Groove Modeling Specimens of GH4720 Alloy

基于航空发动机涡轮盘榫槽结构特点及其工作状态,采用榫槽模拟件对GH4720合金的疲劳失效机理和裂纹扩展寿命进行了实验研究和理论分析。研究结果表明:GH4720合金榫槽模拟件的疲劳失效表现为3个阶段:(i)模拟涡轮盘榫槽处由于较高的应力集中而产生滑移,进而萌生裂纹;(ii)随着应力集中和循环载荷的持续,相邻晶粒间位错开动、发生滑移,裂纹在晶粒间传递;(iii)随着应力强度因子范围增大,剪应力和主应力交互作用、滑移系开动及位错在不同滑移系间的运动,裂纹快速扩展。在实验基础上建立了GH4720合金的疲劳裂纹扩展寿命模型,基于有限元分析的榫槽处的应力和裂纹扩展寿命模型得到的裂纹扩展寿命与实验结果相符,表明该裂纹扩展寿命模型可用于工程中预测涡轮盘的剩余寿命。     

超声冲击改善MB8镁合金焊接接头超高周疲劳性能的机理

通过超声疲劳试验探究超声冲击对MB8镁合金焊接接头超高周疲劳性能的影响。同时,从应力集中、残余应力、晶粒细化等3个因素来探究超声冲击改善MB8镁合金焊接接头超高周疲劳性能的机理。结果表明:在1.0×108疲劳寿命下,焊态试样疲劳强度为31.62 MPa,冲击态试样疲劳强度为39.81 MPa,冲击态试样疲劳强度相较于焊态提高了26%。这说明超声冲击可以明显提高MB8镁合金焊接接头超高周疲劳性能。焊态试样焊趾处应力集中系数K_(t1)=1.95,冲击态试样焊趾处应力集中系数K_(t2)=1.67,应力集中系数降低了14.4%,所以超声冲击可以降低焊趾处的应力集中程度。超声冲击后试样焊趾处的应力由残余拉应力转变成残余压应力。超声冲击细化了焊趾表面晶粒从而改善了MB8镁合金焊接接头的超高周疲劳性能。     

超声冲击改善MB8镁合金焊接接头超高周疲劳性能机理探究

通过超声疲劳试验探究超声冲击对MB8镁合金焊接接头超高周疲劳性能的影响。同时,从应力集中、残余应力、晶粒细化等三个因素来探究超声冲击改善MB8镁合金焊接接头超高周疲劳性能的机理。结果表明：在1.0×108寿命下,焊态试样疲劳强度为31.62MPa,冲击态试样疲劳强度为39.81MPa,冲击态试样疲劳强度相较于焊态提高了26%。这说明超声冲击可以明显提高MB8镁合金焊接接头超高周疲劳性能。焊态试样焊趾处应力集中系数Kt1=1.95,冲击态试样焊趾处应力集中系数Kt2=1.67,应力集中系数降低了14.4%,所以超声冲击可以降低焊趾处的应力集中程度。超声冲击后试样焊趾处的应力由残余拉应力转变成残余压应力。超声冲击细化焊趾表面晶粒改善MB8镁合金焊接接头的超高周疲劳性能。     

微弧表面处理对AZ31B镁合金耐腐蚀及耐腐蚀疲劳性能的影响

采用微弧表面处理技术(微弧氧化MAO和微弧复合MCC)在AZ31B镁合金基体上制备出不同断面结构的防护涂层。通过电化学腐蚀及腐蚀疲劳测试方法,研究了MAO、MCC涂层的电化学腐蚀及腐蚀疲劳性能。结果表明,生长10 min的MAO涂层具有较好的耐电化学腐蚀性能。MAO涂层表面存在微孔和微裂纹,在应力条件下微孔和微裂纹作为疲劳断裂的裂纹萌生点,可加速裂纹的萌生与扩展,使其腐蚀疲劳寿命相较AZ31B合金基体降低了55%。而具有MCC涂层的AZ31B合金试样腐蚀疲劳极限为(64.0±5.4) MPa,比AZ31B合金基体提高了59%。在低应力载荷下(＜80 MPa),微弧复合涂层试样的腐蚀疲劳强度得到明显提高。     

高碳铬轴承钢超长寿命疲劳破坏过程的研究

研究了高碳铬轴承钢超长寿命疲劳的破坏过程．结果表明，在超长寿命区，约在疲劳寿命的5％-10％时疲劳裂纹首先在内部夹杂物处萌生，由于夹杂物周围的球形碳化物开始从基体剥离，在夹杂物周围形成许多不连续的微小裂纹．然后，相邻的微小裂纹相互连接，直到疲劳寿命的90％以上，裂纹开始连续扩展．     

高密度脉冲电流对Cu单晶体驻留滑移带的影响

对含驻留滑移带（ＰＳＢ）的「１２３」取向的疲劳Ｃｕ单晶体,进行了高密度脉冲电流处理,结果表明,高密度脉冲电流处理产生的热压应力改善了ＰＳＢ－基体界面的应力集中状态,使驻留滑移带局部消失,理论计算同时表明,高密度脉冲电流处理能提高Ｃｕ单晶疲劳寿命。     

Effect of crystallographic orientation and grain boundary character on fatigue cracking behaviors of coaxial copper bicrystals

Four coaxial copper bicrystals were employed to study the slip morphologies and fatigue cracking behaviors during cyclic deformation. Three of them had high-angle grain boundaries (GBs) with nearly the same misorientation and one bicrystal had a twin boundary (TB). Different slip bands (SBs) operated near the GBs and TB, generating different dislocation arrangements, which are mainly determined by the crystallographic orientations of the component grains. The GBs suffered impingement or shear damage caused by slip difference from both sides. It is suggested that there is an energy increase in the interfaces between matrix and persistent slip bands (PSBs), GBs and TBs per cycle during cyclic deformation due to the accumulation of lattice defects, which would make the interface unstable. After a certain number of cycles, fatigue cracks initiated firstly at GBs for some bicrystals while fatigue cracking occurred preferentially at PSBs for the others. It is confirmed that the energy growth rate is an increasing function of the shear stress, strain amplitude and strain incompatibility, which results from slip differences on both sides of the interfaces. Interfaces with different energies and strain incompatibilities have different fatigue cracking resistance. It is found that GBs with defective and complex structure, and hence high interfacial energy accompanied by high modulus of the residual GB dislocation (GBD), are preferential sites for fatigue cracking, while the fatigue cracking appeared predominantly at PSBs when the modulus of the residual GBD is lower than that of a perfect dislocation with simple GB structure and low interfacial energy. The present model for the energy can predict well which kind of interface would form cracks preferentially during cyclic deformation in one coaxial bicrystal and which GB would need more cycles to initiate fatigue cracking between coaxial bicrystals with different GB characters.     

Cyclic saturation behavior of tungsten monofilament-reinforced monocrystalline copper matrix composites

Studies on saturation behavior produced by cyclic deformation have been conducted on tungsten monofilament-reinforced monocrystalline copper composites. The effect of the fiber on strain localization has been investigated using interferometry. For a given applied strain amplitude, local strain and volume fraction of the persistent slip bands (PSBs) in the composite appeared no different from those observed in monolithic copper single crystals. However, the distribution of the PSBs was observed to be more uniform, and the total number of PSBs is substantially higher than that in monolithic crystals. The PSBs appeared mostly in the form of micro-PSBs or macro-PSBs with very limited width. Instead of expanding existing PSBs, new PSBs were more likely to nucleate at new locations during cyclic deformation. The volume fraction and width of the PSBs were observed to increase during saturation, which indicates that some of the PSBs become aged and new PSBs form in order to continue to carry the plastic strain. A rule of mixtures model was established to link the cyclic stress–strain response of the monocrystalline composites to the behavior of monolithic single crystals and fibers. The results calculated from the model show very good agreement with the experimental data.     

微弧氧化处理LD10铝合金的疲劳特性

利用旋转弯曲疲劳试验机研究了三种膜厚(10μm、15μm、20μm)的微弧氧化处理LD10铝合金的疲劳性能;采用SEM观察微弧氧化试样的表面、截面以及断口形貌;利用XRD分析微弧氧化试样的表面相组成和表面残余应力。结果表明:微弧氧化膜层由AlSi0.5O2.5非晶相组成,膜层中的微裂纹起源于放电通道(微孔),终止在通道附近区域;膜层附近基体中存在残余拉应力,促使疲劳裂纹在此形成和扩展,导致10μm、15μm、20μm三种膜厚的微弧氧化处理铝合金的疲劳寿命分别下降了63%、75%和65%,疲劳极限分别下降了9.5%、7.9%和9.9%。     

氢对Ti-2Al-2.5Zr钛合金疲劳性能的影响

研究了4种含量的氢对Ti-2Al-2.5Zr钛合金疲劳性能的影响。结果表明，自然含氢量的材料具有最好的疲劳性能。而当疲劳载荷大于材料的屈服强度时，氢含量对疲劳寿命基本没有影响；低于屈服强度后，疲劳寿命随着氢含量的升高而和。认为固溶的原子氢导致驻留滑移带软化，裂纹萌生提前，造成在较大△σ时充氢试样的疲劳寿命降低；而材料中氢化物对驻留滑移带（PSB）的阻碍作用导致氢化物与基体分离 而成为裂纹源，是小△σ下疲劳寿命降低扩要原因。     

2A97铝锂合金的疲劳裂纹萌生及早期扩展行为(英文)

研究2A97铝锂合金的疲劳裂纹萌生及早期扩展行为。在室温条件下,采用光滑试样进行疲劳测试,其中最大应力为恒定值,应力比R为0.1,频率f为40 Hz。利用金相显微镜、透射电镜、扫描电镜及电子背散射衍射等手段对合金的微观组织进行分析,研究合金的疲劳裂纹萌生及早期扩展行为与其微观组织的关系。结果表明:2A97合金的疲劳裂纹主要萌生于试样表面的杂质相和粗大第二相处;其疲劳裂纹的早期扩展行为主要受晶粒结构与位错或滑移带共同作用的影响。当相邻晶粒的错配度接近于其晶内的最优滑移面的位向差时,大角度晶界强烈阻碍滑移带的运动,从而导致裂纹分叉和偏折。     

调质态40Cr钢旋转弯曲疲劳寿命与显微组织的关系*

文中对调质态的40Cr钢进行了旋转弯曲疲劳试验,采用透射电镜对经过不同的旋转弯曲疲劳试验阶段的试样进行微观分析,并测定了不同疲劳阶段试样内部的位错密度。结果表明:开始时位错从晶界萌生,向晶内扩展,形成亚晶粒组织。随着旋转弯曲疲劳循环次数增加,位错密度逐渐增加,晶内碳化物也发生明显变形以至破裂。建立位错密度与旋转弯曲疲劳之间的数学方程式,旋转弯曲疲劳所引起的位错密度增殖与疲劳循环次数呈线性正比关系,函数公式为ρ=2.0108×108 N-1.914×108,R2=0.98193。研究结果可供无损检测法制订再制造毛坯剩余寿命判据参考。     

Fatigue of metallic microdevices and the role of fatigue-induced surface oxides

A new method for fatigue testing of metallic micro-electro-mechanical systems has been developed and applied to characterize the high-cycle fatigue behavior of nickel microspecimens formed by the LIGA process. Cantilever microbeams with a cross-section of 26 × 250 μm were tested under fully reversed loading conditions at 20 Hz. The observed stress-life curve and fatigue limit was similar to what has typically been reported for conventional bulk nickel. SEM inspection of the fatigue surface revealed that failure initiated in zones of localized extrusions and intrusions associated with persistent slip bands (PSBs). Focused ion beam machining was used to extract a cross-sectional TEM foil from the deformation zone, revealing an unexpected thick (up to 400 nm) oxide on the surface of the PSBs. This PSB oxide thickening mechanism appears to be the source of crack initiation.