高强韧中锰钢CO2气体保护焊接头的疲劳性能

采用CO₂气体保护焊对30 mm厚高强韧中锰钢板进行对焊试验,通过圆棒拉压疲劳试验获得中锰钢焊接接头的应力幅-寿命曲线,测定了其高周疲劳极限并观察其断口形貌。结果表明：在应力比为-1、循环次数为10⁷周次条件下,中锰钢焊接接头的高周疲劳极限为353 MPa;当中锰钢焊接接头焊缝中存在明显的焊接缺陷时,疲劳裂纹萌生于微观缺陷处,而当焊缝中无焊接缺陷时,疲劳裂纹萌生于试样表面熔合线位置,疲劳裂纹扩展区表面粗糙,存在着明显的二次裂纹,瞬断区表面存在大量均匀细小的韧窝。     

基于均布临界域本征损伤耗散的疲劳极限等量关系

疲劳极限预测是工程结构件复杂载荷下抗疲劳设计重要基础。应力场强理论,无法给出考虑平均应力的疲劳极限关系,属于临界域准则,而临界点准则无法刻画高周疲劳损伤局部域特点,与高周疲劳损伤特点不相吻合。基于连续介质损伤力学及其不可逆热力学框架,建立一种基于高周疲劳损伤临界域本征损伤耗散的疲劳极限等量关系模型。该等量关系包括考虑拉压异性的含平均应力的拉伸疲劳极限和对称旋转弯曲疲劳极限与对称扭转疲劳极限之比。运用含平均应力的拉伸疲劳极限预测模型,对两种常见铝合金LC4和LC9进行寿命预测,结果表明所提模型优于现有的单一线性(GOODMAN和THORDBERG)和GERBER椭圆疲劳极限等量关系模型,与试验吻合较好,单一线性疲劳极限等量模型无法刻画拉压异性。利用对称旋弯-对称扭转疲劳极限比值预测模型分别对11种常见金属材料疲劳性能进行预测,结果表明所提模型明显优于基于应力场强法导出的比值预测模型。基于均布临界域本征损伤耗散开展疲劳极限预测,为金属材料疲劳强度预测研究提供了新思路。     

汽轮机叶片材料的疲劳板限与疲劳寿命估算

研究了汽轮机叶片材料２Ｃｒ１３马氏休不锈钢在室温到４５０℃之间拉—拉或拉—压疲劳试验过程中平均应力与疲劳极限之间的关系。结果表明,平均应力与疲劳极限之间的关系与Ｇｅｒｂｅｒ关系式吻合。根据室温疲劳极限值导出等效理论疲劳极限与应力疲劳寿命估算公式,并通过引入频率因子对疲劳寿命公式进行修正,推出２Ｃｒ１３钢在不同频率条件下的应力疲劳寿命公式,并进行了试验验证。     

汽轮机叶片材料的疲劳板取与疲劳寿命估算

研究了汽轮机叶片材料２Ｃｒ１３马氏休不锈钢在室温到４５０℃之间拉－拉或拉－压疲劳试验过程中平均应力与疲劳极限之间的关系,结果表明,平均应力与疲劳极限之间的关系与Ｇｅｒｂｅｒ关系式吻合。根据室温疲劳极限值导等效理论疲劳极限与应力疲劳寿命估算公式,并通过引入频率因子对疲劳寿命公式进行修正,推出２Ｃｒ１３钢在不同频率条件下的应力疲劳寿命公式,并进行了试验验证。     

对接结构多部位损伤裂纹发生概率预测

针对飞机结构的多部位损伤问题,本文基于疲劳统计学原理,结合S-N曲线得出了多细节带孔对接板各细节处裂纹疲劳寿命的概率分布,并利用蒙特卡罗模拟方法预测了对接结构孔边出现多部位损伤裂纹的先后顺序.进行了多细节带孔对接板的拉-拉疲劳试验,预测结果和试验结果吻合良好.     

应变能—内应力干涉模型的多轴高周疲劳研究

塑性应变能使材料微观组织结构发生不可逆变化而引起等效宏观应力,该应力随循环加载而增大。假定该应力的一种分布函数,将疲劳极限以上加载等效为塑性应变,建立了塑性应变与加载应力成线性关系的表达式,由此得到循环加载的塑性应变能。导出其最大应力与外加应力叠加达到材料本征断裂应力时的裂纹成核寿命,并由微裂纹引起上述两部分应力变化,得到继续加载直至宏观裂纹出现的疲劳寿命。所建立的多轴疲劳寿命公式由三个材料参数表达,并通过单轴疲劳试验数据确定。初步研究表明,该模型对所引用的多轴疲劳试验数据有很好的预测能力。     

冷轧钢压印接头拉伸-剪切和疲劳性能研究

对冷轧钢圆形连接点和矩形连接点的压印接头进行拉伸-剪切试验,研究连接点形状对接头拉伸-剪切性能的影响.并对圆形连接点压印接头进行疲劳试验.试验结果表明,两种接头拉伸-剪切强度和刚度相当.圆形连接点拉伸-剪切过程中的能量吸收值大于矩形连接点,矩形连接点的失效形式为上板拉脱失效.应力比R=0.5,当最大疲劳载荷为接头强度的95％时,接头循环寿命可以达到137万次,为80％时,可以达到疲劳极限500万次.疲劳失效形式为上板接头处产生裂纹,裂纹方向与加载方向大致呈90°.提出了圆形点压印接头的拉伸-剪切强度预测公式和疲劳寿命计算公式,拉伸-剪切强度公式的误差为6.9％.     

X56管线钢的腐蚀疲劳寿命试验研究

采用不同应力比在不同环境下对Ｘ５６管线钢进行了疲劳试验。结果表明，对称循环时腐蚀环境下的Ｓ－Ｎ曲线的斜率要比空气中的大，低应力下腐蚀劳寿命比在空气中低得多，应力越低降低幅度越大。在空气中有疲劳极限存在，而在腐蚀环境中存在疲劳极限。在高应力区两曲线有相交点，广交会劳寿命甚至比空气中时还要长。当应力比为０．２时，两曲线的斜率几乎相同。所不同的仅是有无疲劳极限之分。即在较高频率下腐蚀损伤只在低应力区有效     

基于模糊理论的疲劳寿命估算方法

对疲劳寿命估算中存在的模糊现象,引入模糊理论中的隶属函数来描述疲劳极限附近的应力对构件造成损伤的模糊性,提出了应力模糊带的概念,并根据疲劳极限与应力模糊带边界的位置关系,将模糊带类型分为安全型、经济型和兼顾型.算例证明,将模糊理论应用于疲劳寿命分析中可以大大提高疲劳寿命估算的精确度.     

疲劳寿命估算中的模糊性研究

针对工程中构件疲劳寿命估算存在的模糊现象,引入模糊理论中的隶属函数来描述疲劳极限附近的应力对构件造成损伤的模糊性,提出了应力模糊带的概念。并根据疲劳极限与应力模糊带边界的位置关系,将模糊带类型分为安全型、经济型和兼顾型。算例证明:将模糊理论应用于疲劳寿命分析中可以大大提高疲劳寿命预测的精度;选用安全型模糊带和升半正态分布隶属函数,且a=0.6σr,k=0.5时,与忽略模糊性的传统疲劳寿命预测方法相比误差可以减小38.7%。     

The effect of rubber contact on the fretting fatigue strength of railway wheel tire

The cause of the ICE train derailment, which occurred in 1998 at Eschede, was fatigue failure originating on the inside of the wheel tire. Rubber-sprung resilient wheels were used for the trailer cars. The wheel tire is mounted on the wheel disc. Thirty-four rubber pads were arranged between the wheel disc and the wheel tire. It was postulated that fretting fatigue between the rubber block and the inner side of the tire might have an influence on the initiation of the incipient crack. In order to clarify the influence of the rubber contact on the fatigue strength of the tire, fretting fatigue experiments under rubber contact conditions were performed. During the fundamental fretting fatigue test using bridge pads and small size carbon steel specimens, no typical fretting damage such as fretting wear and minute cracks were observed due to contact of the rubber. Stress conditions of the rubber-sprung wheel under vertical and lateral wheel loads were evaluated by a three-dimensional elastic stress analysis. Since the rubber is a super-elastic material, the Mooney-Rivlin model was used in the FEM calculation. It was found that the wheel tire is subjected to a cyclic stress during one revolution of the wheel and the maximum stress occurred at the center of the inner surface of the tire where the fatigue crack initiated. Fatigue strength of the wheel tire was determined by the rotating bending fatigue testing of specimens taken from the tire. It was found that the tire with an 862 mm diameter at a wheel load of 80 kN had a safety factor more than 3.5 from a fatigue limit diagram with a failure probability of 0.01. To confirm the fretting damage under the rubber contact and the result of the fatigue strength evaluation, fatigue tests of a full size wheel were made. After 20 million cycles at the wheel load of 280 kN, which was just below the endurance limit estimated by the endurance limit diagram, no fretting damage and no fatigue cracks were observed. The wheel was, however, fractured at 1.56 million cycles under the maximum load of 308 kN, which was just above the endurance limit. The estimation of the safety factor of 3.5 estimated from the endurance diagram was confirmed by the full size fatigue testing. It was concluded that there was no effect of fretting due to the rubber contact on the fatigue strength of the rubber-sprung single-ring railway wheel.     

基于二元疲劳失效判据的非线性疲劳损伤累积模型及其强度退化研究

二元疲劳失效判据认为疲劳破坏是由损伤程度和当前作用应力这两个量共同决定的,由此观点出发定义了非线性损伤,并建立了与载荷状态有关的非线性损伤累积模型,推导了在多级加载下的递推公式。经两种金属材料的疲劳试验数据验证表明,用该模型预测疲劳寿命,其结果是令人满意的。从疲劳过程本质上是材料静强度不断退化的过程的观点出发,建立了基于二元疲劳失效判据的非线性强度退化模型,将模型应用于两级及多级载荷下的剩余寿命估算,结果表明,所提出的剩余强度退化模型是合理可行的。

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Modal characteristics and fatigue strength of compressor blades

High-cycle fatigue (HCF) has been identified as one of the primary causes of gas turbine engine failure. The modal characteristics and endurance strength of a 5 MW gas turbine engine blade developed by Doosan Heavy Industries & Construction Co., Ltd. in HCF fracture were verified through analysis and tests to determine the reliability of the compressor blade. A compressor blade design procedure that considers HCF life was performed in the following order: airfoil and blade profile design, modal analysis, stress distribution test, stress endurance limit test, and fatigue life verification. This study analyzed the Campbell diagram and estimated resonance risk on the basis of the natural frequency analysis and modal test of the compressor blade to guarantee safe and operational reliability. In addition, the maximum stress point of the compressor blade was determined through stress distribution analysis and test. The bonding point of the strain gage was determined by using fatigue test. Stress endurance limit test was performed based on the results of these tests. This research compared and verified the modal characteristics and endurance strengths of the compressor blades to prevent HCF fracture, which is among the major causes of gas turbine engine damage. A fatigue life design procedure of compressor blades was established. The 5 MW class gas turbine compressor blade is well designed in terms of resonance stability and fatigue endurance limit.     

Study of Growth of Fatigue Cracks in Metallic Samples Using Methods of Acoustic Emission and Strain Measurement

Results of cyclic stress tests of planar samples from the D16T duralumin 2 and 6 mm thick performed with the help of the methods of acoustic emission (AE) and strain measurements are reported. The variables recorded in the tests were the applied load, number of loading cycles, length of a fatigue crack, strain in sample material, and parameters of AE signals. In addition, in tests of samples 3 mm thick the stress intensity factor was maintained constant as fatigue cracks grew over fixed intervals of lengths, and information was derived from total counts of AE pulses, their energy distributions and spectral characteristics.     

铝合金型材疲劳实验研究

研究铝合金型材的疲劳持久极限,为产品设计提供疲劳性能指标。按相关标准规定将铝合金型材加工成标准试样,在高频疲劳试验机上,分别对表面光滑和表面粗糙2组试样在相同应力作用下进行疲劳实验,并得出了2组试样的循环次数,结果表明表面粗糙试样循环次数显著低于表面光滑组试样。     

基于构件S-N曲线的波纹管速度外压耦合加载下疲劳寿命研究

真空灭弧室用波纹管服役工况复杂,采用传统的理论计算方法和试验手段难以准确预测其疲劳寿命,一定程度上制约波纹管的设计与选用。本文利用数字图像相关技术,基于拉伸试验、疲劳试验,精细化获得了波纹管构件的S-N曲线,基于ANSYS有限元分析软件,建立波纹管弹塑性变形有限元模型,通过XTDIC验证了模型的准确性,结合nCode DesignLife对波纹管疲劳寿命进行了预测,并验证其准确性。研究了关键工艺参数(压力、位移、速度)对波纹管波峰、波谷等关键特征区域应力、应变和疲劳寿命的分布演变规律。研究表明：波纹管在只施加外压的工况下,波峰内壁处更容易产生疲劳损伤,位移载荷对波纹管应力应变分布影响更为显著,位移越大,波纹管更容易产生应力集中。在加载位移不变时,速度越大,波纹管等效应力越大,此时耦合0.2 MPa外压,抵消部分应力集中。在0.2 MPa外压下,当压缩速度由0.5 m/s增加到4 m/s,最大等效应力由378.89 MPa增加到424.27 MPa,疲劳寿命由49 540次减小到3 064次。     

超声疲劳试验方法在铸铝疲劳试验中的应用

应用20kHz频率下的超声疲劳设备完成亿周次疲劳试验，获得铸铝AS5U3G-Y35超高周疲劳特性。通过20kHz频率下的超声疲劳试验和35Hz频率下的常规试验，完成10^4～10^10周的S-N曲线。试验结果表明，在10^7周以上试件仍会发生疲劳断裂。在10^7～10^10周之间，当应力比R=-1时，疲劳强度随循环数的增加而下降；当应力比r=0．1时，在循环数超过10^8周时，疲劳强度不再下降，S-N曲线出现平台。比较20kHz和35Hz两种频率下的试验结果，在10^4～10^7周之间没有明显差别，即铸铝AS5U3G-Y35在超声疲劳试验中不存在频率效应。扫描电镜观察试件疲劳断裂面发现材料中分布许多小的缩孔，而且大多数试件的疲劳破坏都发生在试件表面或接近表面的缩孔处。     

Incipient damage detection and its propagation monitoring of rolling contact fatigue by acoustic emission

The acoustic emission (AE) technique was applied to rolling contact fatigue tests using a test-rig running under constant load and speed for detecting the incipient damage and damage location. This incipiently-damaged roller was investigated in detail and monitored by further running to determine the damage severity and to understand the surface damage propagation process by applying the AE techniques. The conventional AE parameters and AE signal features were studied, and their relation with the AE source locator hit count rate were correlated. The results demonstrated the successful use of the AE measurement unit, which is principally, consists of the AE data analyzer and the AE source locator as a new system for detecting incipient damage produced by fatigue. Moreover, the system is able to forecast the position of the damage in the roller, capable of providing an indication of the severity of damage i.e. damage size, and thus it could allow the user to monitor the rate of further degradation of the rolling elements.     

基于声发射技术的金属高频疲劳监测

采用声发射技术监测高频疲劳条件下金属材料裂纹的扩展。介绍了如何运用软硬件处理的方法，从采集到的信号中分离出裂纹扩展的声发射信号。从处理后的声发射信号与观察得到的裂纹扩展对比来看，声发射参数的变化能够有效地反映材料疲劳裂纹扩展的过程，并且能更早地发现试样内部微小裂纹的变化。通过试验，得出了紧凑拉伸试样在裂纹稳定扩展阶段声发射信号能量率与应力强度因子幅值之间的关系式。     

三维编织C/SiC复合材料拉伸损伤演化

利用声发射技术,对三维编织C/SiC复合材料在拉伸过程中损伤发展、演化进行了实验研究。实验采集了三维编织C/SiC复合材料拉伸过程的声发射信号。运用多参数分析法,分析了三维编织C/SiC复合材料拉伸损伤的声发射特性,宏观上揭示了材料拉伸损伤的发展、演化过程和规律。研究结果表明三维编织C/SiC复合材料拉伸损伤演化可被分为两个主要阶段,损伤初始阶段和损伤严重阶段。