3.5%NaCl腐蚀环境下2种航空铝合金材料疲劳性能试验研究

腐蚀环境下的疲劳性能是航空金属结构疲劳寿命设计的重要前提,为此,试验测定了2种航空铝合金材料（2E12-T3、7050-T7451）的光滑试样和缺口试样在干燥大气和3.5%NaCl腐蚀环境下的疲劳性能,在试验数据的基础上进行性能对比,并对试样断口进行扫描电镜（SEM）分析,研究了3.5%NaCl腐蚀环境与载荷联合作用对腐蚀疲劳性能的影响机理,研究结果表明：3.5%NaCl腐蚀环境对2种铝合金材料的疲劳性能均产生不利影响,且腐蚀与疲劳载荷的交互作用随着应力水平的降低而增强,疲劳性能下降更明显;与光滑试样相比,腐蚀环境对铝合金2E12-T3缺口试样疲劳性能的影响更大,但对铝合金7050-T7451缺口试样疲劳性能的影响却变小;在腐蚀环境下,裂纹尖端易发生电化学反应产生腐蚀产物和[H]离子,腐蚀产物的存在会阻碍裂纹闭合,同时,[H]离子导致裂纹尖端的氢脆效应,加快裂纹扩展,使疲劳性能降低。     

钛合金慢应变速率拉伸应力腐蚀行为研究

对TA31和TC4ELI两合金分别在干燥空气、3.5% NaCl环境下进行慢应变速率拉伸试验。结合应力-应变曲线以及断口宏观、微观组织分析两种材料的应力腐蚀敏感性。结果表明:在35℃、3.5%(w,下同) NaCl溶液、应变速率为10^-6/s条件下,TC4ELI合金应力腐蚀敏感性较高,在5×10^-7/s和5×10^-6/s的应变速率下应力腐蚀敏感性较低;TA31合金在上述3种应变速率下应力腐蚀敏感性均较低;在3.5% NaCl环境中,TA31合金断口形貌较空气中试验的断口形貌无明显的变化,TC4ELI则出现较明显的解理面。     

潮湿空气环境对2024-T3铝合金疲劳性能的影响

采用2024-T3铝合金含中心孔试件进行了实验室空气环境和潮湿空气环境下的疲劳寿命实验及升降法实验,研究了潮湿空气环境对2024-T3铝合金疲劳性能的影响.结果表明,潮湿空气环境显著降低了2024-T3铝合金的疲劳性能,潮湿空气环境对其疲劳寿命特征值和疲劳强度均值的影响系数分别为0.6059和0.8722;在潮湿空气环境中疲劳寿命的分散性变大,用疲劳寿命的中值或特征值得到的腐蚀影响系数进行可靠度95%的腐蚀环境下的寿命修正,将得到偏危险的结果.用潮湿空气环境对基本可靠性寿命的影响系数由标准S-N曲线折算得到的对疲劳强度的影响系数与升降法测得的对疲劳强度的影响系数基本一致,在潮湿空气环境下标准S-N曲线参数仍然适用.     

Environmental effects on low cycle fatigue of 2024-T351 and 7075-T651 aluminum alloys

The environmental effects on the low cycle fatigue (LCF) behavior of 2024-T351 and 7075-T651 aluminum alloys were studied at room temperature. The specimens were subjected to identical LCF tests at strain ratio R of −1 and frequency of 5 Hz in three environments: vacuum, air and 1% NaCl solution of pH 2. A separate group of specimens was pre-corroded in 1% NaCl solution and then LCF-tested in air. Their strain–life relations and cyclic stress–strain responses were investigated and compared. Furthermore, the fracture surface morphology was evaluated to find the association of LCF behavior and fractographic features under different environmental conditions.     

LY12CZ、LC4CS铝合金、30CrMnSiA钢在不同介质下的DFR_(cutoff)值EI

对LY12CZ、LC4CS铝合金和30CrMnSiA钢进行了不同环境介质下的“细节疲劳额定强度截止值(DFR_(cutoff))”的试验研究,提供了飞机结构耐久性设计的重要数据。研究表明,不同环境介质对不同材料的寿命影响不同,轻重程度依次是:室温空气,潮湿空气,3.5％NaCl盐水。     

Corrosion fatigue behavior of 7050 aluminum alloys in different tempers

Corrosion fatigue (CF) experiments, including both high-cycle axial fatigue (S–N curve) and fatigue crack growth (FCG), have been performed on 7050 aluminum alloys in a 3.5 wt% NaCl solution as a function of aging treatment. The results of these environmental tests were compared with those obtained in laboratory air to characterize the effect of aging treatment on CF susceptibility. Fatigue resistance in both peak aged (T6) and overaged (T73) tempers was dramatically reduced by the aqueous chloride environment. The FCG rates for T73 condition were lower than the counterparts for T6 condition in both air and saline solution. 7050-T73 alloy exhibited longer fatigue lives in air but shorter ones in the corrosive environment as compared to the T6 temper. This may be attributed to the formation of more extensive and larger corrosion pits acting as crack nuclei to facilitate crack initiation, in the T73 tempered condition. Comparison of CF and stress corrosion cracking (SCC) results reveals that overaging treatments used to improve grain boundary characteristics and increase the intergranular SCC resistance might not guarantee an equivalent improvement in the resistance to transgranular CF cracking.     

Fatigue tests and life prediction of 16 Mn steel butt welds without crack-like defect

Fatigue test results of 16 Mn steel butt welds without crack-like defect under both constant and variable amplitude loads are reported and new procedures are used to predict fatigue crack initiation (FCI) life, fatigue crack propagation (FCP) life and total life of the butt welds. The results indicate that the FCI life and FCP life should be calculated separately and the total life is the sum of the FCI life and FCP life. For the butt welds investigated, stress cycles to initiate a crack of engineering size may occupy more than 70 percent of the total life of the butt welds and it is more suitable to express the total life as a power function of the equivalent stress amplitude {ie275-1}. In predicting the FCI life, the expression of FCI life obtained from the test results of notched specimens is used but the effects of microstructure, surface condition, macro- and micro-geometrical discontinuities at weld toe should be taken into account. In predicting the FCP life, the formula developed by Zheng and Hirt is used and the stress ratio is taken as 0.6 to account for the residual stresses effect on the FCP rate. Because overload produced by the maximum load in a load spectrum has no effect on the FCI life of 16 Mn steel and weldment of the steel, according to the procedures outlined in the paper, one can use the FCI life expression mentioned and the linear damage accumulation rule proposed by Miner to predict the FCI life of 16 Mn steel butt welds under variable amplitude loads. A good agreement is achieved between the predicted results and the test data.     

Fatigue behaviour of monotectoid-based Zn–Al–Cu alloys in 3.5% NaCl and 1% HCl solutions

One binary Zn–40Al and three Zn–40Al-based ternary alloys containing 1%, 3%, and 5% Cu were produced by permanent mold casting. Their fatigue behavior was investigated in 3.5% NaCl and 1% HCl solutions by a rotary bending fatigue test machine at a frequency of 33.3 Hz. The stress amplitude versus number of cycles to failure (S–N) curves of the alloys was plotted for both environments. Corrosion degradation factors of the alloys were determined. The corrosion environments reduced the fatigue strength and fatigue life of the alloys considerably. However, acid solution was found to be more detrimental for these alloys than the salt water. In addition, copper content was found to be less effective on the fatigue strength and fatigue life of the alloys in both salt water and acid solution than it was in air. Corrosion degradation factor of the alloys increased with increasing copper content up to approximately 3%, above which it decreased as the copper content increased. It was also shown that the fatigue data obtained from the monotectoid-based Zn–Al–Cu alloys in the corrosive environments obey the Basquin's law.     

金属材料低温疲劳性能的预测方法

本文总结了作者近来研究金属低温疲劳取得的进展,主要内容包括:疲劳极限的热激活模型、应变疲劳公式、疲劳始裂寿命和裂纹扩展速率的定量预测方法、疲劳裂纹扩展机制脆转模型。当室温下的疲劳极限和门槛植ΔK_(th)确定后,应用本文的方法可根据拉伸性能定量预测材料在低温下的疲劳极限、应变疲劳寿命、疲劳始裂寿命和裂纹扩展速率,并且不需要低温疲劳试验和经验修正。     

Synergistic effect of environmental media and stress on the fatigue fracture behaviour of aluminium alloys

The present study aims at explaining the synergistic effect of environmental media and stress/strain on fatigue lives of aluminium alloys. Rotating bending fatigue tests were carried out using four different aluminium alloys LY12‐CZ, 2024‐T4, 7475‐T7351 and 7075‐T651, at air state, 3.5% and 5.0% NaCl aqueous solutions. These results indicated that synergistic actions of the environmental media and cyclic loading accelerated the fatigue crack propagation of aluminium alloys. Furthermore, various influence factors (such as solution concentration, cyclic numbers, high (low) strength aluminium alloys etc.) of the fatigue life at synergistic actions of the environmental media and stress were quantificationally discussed in this paper.     

On the expression of fatigue crack initiation life considering the factor of overloading effect

In the present study attempts are made to give an expression of the fatigue crack initiation life of notched elements with the consideration of overloading effects. This expression may be used to predict the fatigue crack initiation life of notched element under variable amplitude loading. Experimental work on LY12CZ alloy show that the test results of fatigue crack initiation life after tension overloading can be well fitted by the formula developed before for fatigue crack initiation life. Tension overloading increases the fatigue crack initiation threshold but has no effect on the coefficient of the resistance to fatigue crack initiation. The overloading ratio has no markable effect on crack initiation life. The increase of the crack initiation threshold results in the increase of crack initiation life, in particular, in long life range. The same results are also obtained by reanalysing some existing test results of overloading effect on crack initiation life given in literature. Consequently, the expression of the fatigue crack initiation life can be obtained by the method given in this paper. However, the overloading stress should be determined from the theoretical stress concentration factor of notched element and the maximum nominal stress in the load spectrum of elements.     

新型铝合金阳极电化学性能与组织研究

研制了两种新型铝合金阳极材料；用恒电流方法和动电位方法测定了铝合金阳极在碱性氯化钠（25％KOH＋3．5％NaCl）介质中的电化学性能；用金相显微镜、扫描电子显微镜观察了新型铝合金的微观组织和阳级溶解后的表面腐蚀状态。结果表明：固溶于铝基体的微量合金化元素Ga、In及其适量均匀分布的第二相，可以破坏铝氧化膜的致密结构，促使铝基体的正常溶解，减少铝阳极极化，使铝合金阳极的稳定电极电位变得更负；加入能改变铝基体中杂质的存在状态和降低杂质含量的合金化元素Mg等，可以改善铝阳极的腐蚀均匀性，降低自腐蚀速度，提高阳极利用率。     

Experimental study on very high cycle fatigue of martensitic steel of 2Cr13 under corrosive environment

Rotating bending fatigue test at very high cycle regimes was carried out on martensitic steel of 2Cr13 in air and 3.5% NaCl environment. The result showed that the S–N curve presents a stepwise tendency over the range of 10⁶–10⁸ cycles in both air and 3.5% NaCl environment. In air fatigue, cracks initiated from the sample surface and inclusions at subsurface and no typical fish eye feature in very high cycle fatigue were observed for all samples tested up to 6 × 10⁸ cycles. In 3.5% NaCl solution, a fatigue limit over the range of 10⁶–10⁸ cycles exhibited with the corrosion fatigue strength reduced by 47% compared to the air fatigue. Multiple cracks initiated from surface and the number of crack origins increased with increasing stress level and surface proportion of fatigue propagation increased as number of cycles increased.     

Corrosion fatigue behavior of extruded AZ80, AZ61, and AM60 magnesium alloys in distilled water

Rotary bending fatigue tests were conducted in laboratory air and distilled water using three extruded magnesium (Mg) alloys AZ80, AZ61, and AM60 with different chemical compositions. In laboratory air, the fatigue strengths at high stress levels were similar in all alloys because cracks initiated at Al-Mg intermetallic compounds, whereas AZ80 with the largest Al content exhibited the highest fatigue strength at low stress levels, which was attributed to the crack initiation due to cyclic slip deformation in the matrix microstructure. In distilled water, fatigue strengths were considerably decreased due to the formation of corrosion pits in all alloys, and the difference of fatigue strength at low stress levels among the alloys disappeared, indicating that the addition of Al that improved the fatigue strength in laboratory air was detrimental to corrosion fatigue. __________ Translated from Problemy Prochnosti, No. 1, pp. 141–145, January–February, 2008.     

Acoustic emission study of corrosion fatigue crack propagation mechanism for LY12CZ and 7075-T6 aluminum alloys

Acoustic emission signals were continuously monitored during fatigue crack propagation for LY12CZ and 7075-T6 aluminum alloys in laboratory air and 3.5% NaCl solution. The results showed that the acoustic emission count rate was as a linear function of crack propagation rate during fatigue and corrosion fatigue. The acoustic emission activity for LY12CZ was smaller in solution than that in air; but for 7075-T6, greater in solution than that in air. The acoustic emission waveform parameter, the frequency centroid ratio, was tried to use as a criterion to distinguish the corrosion fatigue crack propagation mechanism for anodic dissolution of LY12CZ and hydrogen embrittlement of 7075-T6.     

2205双相不锈钢在NaCl溶液中的疲劳裂纹扩展行为

为提高2205双相不锈钢的使用安全性,采用光学显微镜和力学性能测试等方法,研究了2205双相不锈钢在NaCl溶液中的疲劳裂纹扩展行为。结果表明:与空气中相比,2205双相不锈钢在NaCl溶液中的疲劳裂纹扩展门槛值有降低的趋势,近门槛区的裂纹扩展速率有所提高,并且裂纹扩展由近门槛区向稳态扩展区转变的临界ΔK提高;在稳态扩展阶段,NaCl溶液使裂纹扩展速率显著提高,导致疲劳寿命显著降低;当NaCl浓度在0.5%~26.6%范围内时,随着浓度的增大,稳态扩展阶段的Pairs方程参数m值呈增大趋势,C值呈减小趋势;NaCl溶液中力学和环境因素的交互作用,加速了疲劳裂纹扩展,材料一旦进入稳态扩展就更容易进入高速扩展区并最终发生断裂。     

Fatigue Crack Growth of Al-Li Alloy 2091 in 3.5% NaCl Solution and at 130℃

A study has been made of the fatigue crackgrowth in an Al-Li alloy 2091 in 3.5%NaCl solu-tion and at an elevated temperature of 130℃.Theaging and environmental effects on the crackgrowth behaviour were examined.It is shown thatthe fatigue crack growth resistance decreases withaging.The specimen with underaged structuresshows the highest resistance to fatigue crack growthdue to more deflected crack paths and the resultinghigh crack closure levels.As compared to laborato-ry air,both 3.5% NaCl solution and elevated tem-perature of 130℃ cause an increase of near-thresh-old crack growth rates and a decrease of thresholdlevels.The elevated temperature is more effective.The effect of elevated temperature is mainly due tothe precipitate coarsening which results in anenhancement of slip irreversibility.Hydrogenembritttlement is supposed to be responsible for thedegradation of fatigue crack growth resistance in3.5%NaCl solution     

Effect of hold time and environment on Fatigue Crack Growth Rate in Ti Alloys

In titanium alloys an effect of hold time at maximum load in a cyclic test is observed if K_max exceeds the threshold for crack propagation at a constant load test. For tests in air it is possible to predict crack growth rate for a hold time cycle from the crack growth rates from a cyclic test with triangular wave form and a constant load test. In 3.5% NaCl solution the measured crack growth rate is lower than the predicted.     

Probabilistic prediction of minimum fatigue life behaviour in α + β titanium alloys

The objective of this work was to develop and demonstrate a probabilistic life prediction method for the prediction of minimum fatigue lives that are typically used in the design of fracture critical rotating turbine engine components. A Monte Carlo analysis was used to predict the variability in fatigue lives based on the distribution of microstructural features that lead to early crack initiation as well as the variability in small fatigue crack growth rates. Two titanium alloys, both with bimodal microstructures, were tested and analysed in this study. The distribution of critical microstructural features was calibrated based on test results and understanding of microstructure neighbourhood effects. Testing was conducted on both alloys and included both smooth and notched specimens. The predictions are presented and compared with the data for smooth and notch geometries for the various loading conditions. A parametric study was performed to identify the importance of several model inputs and to identify areas for future improvement.     

Evaluation of stress corrosion resistance and corrosion fatigue fracture behavior of ultra-high-strength P/M Al–Zn–Mg alloy

Quasi-static tensile tests in air and slow strain rate tests (SSRTs) in a 3.5% NaCl solution were conducted in an ultra-high-strength P/M Al–Zn–Mg alloy fabricated through powder metallurgy. Attention is also paid to fatigue strength and fatigue crack growth behavior in laboratory air and in a 3.5% NaCl solution. The alloy has extremely high strength of about 800 MPa. However, elongation at break remains small, at about 1.3%. The final fracture occurs by a macroscopically flat crack normal to the tensile axis, with little reduction in area and little shear lip on the periphery of a smooth sample. However, it fails microscopically in a ductile manner, with dimples. Dimple size is less than 1 μm, because the grain size of the alloy is extremely small. Strengthening mechanisms operating in the alloy are: small grains, sufficient metastable η′ phase in a matrix, and intermetallic compound acting as a fiber reinforcement. The SSRT strength in a 3.5% NaCl solution decreases slightly at a very low strain rate, that is smaller than those observed in aluminum alloys sensitive to stress corrosion. This means that the crack initiation resistance to stress corrosion is superior. However, under cyclic loading, the corrosion fatigue strength becomes lower than that conducted in air, because pitting corrosion on a sample surface acts as a stress concentrator. Crack initiation site of quasi-static and fatigue failure of the alloy is at inclusions, and hence, it is essential to decrease inclusions in the alloy for the improvement of the mechanical properties. Fatigue crack resistance of the alloy is inferior to conventional Al–Zn–Mg alloys fabricated by ingot metallurgy, because the fatigue fracture toughness, or ductility, of the alloy is inferior to other Al alloys, and intergranular cracking promotes crack growth. However, no influence of 3.5% NaCl solution on corrosion fatigue crack growth is observed, although an investigation is required into whether stress corrosion crack growth occurs or not, and at the same time, and of corrosion fatigue crack growth behavior at lower stress intensity. The fracture surface and crack initiation sites are closely examined using a high-resolution field emission type scanning electron microscope, and the fracture mechanisms of the alloy are discussed.