航空发动机低压压气机三级盘裂纹分析

航空发动机在地面试车过程中,出现低压压气机三级盘裂纹故障。通过对故障件进行尺寸复测、性能测试、组织分析和断口观察,分析故障性质和原因。结果发现:断口为多源疲劳断裂,裂纹起始于三级盘排气侧辐板与轴颈转接R表面,向进气边方向扩展,扩展区疲劳条带细密,具有高周疲劳的特征。源区未见明显的冶金缺陷,但裂纹在宏观上与加工接刀痕迹吻合。分析认为故障盘疲劳裂纹的产生与使用过程中特定条件下的振动有关。三级盘辐板与轴颈转接处转接R尺寸偏小,转接不圆滑,存在应力集中,促进裂纹的产生。     

Investigation of fatigue crack initiation in Ti-6Al-4V during tensile-tensile fatigue

Fatigue crack initiation in Ti-6Al-4V has been investigated in high cycle fatigue (HCF) and low cycle fatigue (LCF) regimes at stress ratio R=0.1 using the replication technique. In all four tested α/β microstructures, the crack was initiated by fracture of equiaxed alpha grain. Fractured alpha grains are seen on the fracture surface as flat facets with features characteristics of cleavage fracture. In the regime of low stress amplitudes and in the absence of reverse loading, cleavage fracture contributes to crack initiation and early stages of crack growth in Ti-6Al-4V. This mechanism is discussed in relation to the anomalous mean stress fatigue behavior exhibited by this alloy.     

不锈钢在循环扭转载荷下近门槛值的疲劳裂纹扩展行为

研究了带环状预裂纹不锈钢圆棒试样在循环扭转载荷下、门槛值附近的疲劳裂纹扩展行为,用应力强度因子表征了裂纹扩展开始的门槛值．随着裂纹的扩展,裂纹扩展速率由于裂纹面的滑移接触而减小．通过外插裂纹扩展速率与裂纹长度之间的关系,可近似得到裂纹长度为零时无裂纹面滑移接触影响的裂纹扩展速率．施加的应力强度因子范围可分解为推动裂纹扩展的有效值和由于裂纹面的滑移接触而屏蔽掉的两部分．预测了疲劳裂纹的萌生和断裂极限,预测值和实验值相当一致．     

Fatigue crack growth of titanium alloy joints by electron beam welding

Electron beam welding（EBW） has been widely used in the manufacture of titanium alloy welded blisk for aircraft engines. Based on fatigue crack growth tests on titanium alloy electron beam welding（EBW） joints, mechanism of fracture was investigated under scanning electron microscope（SEM）. The results show that fatigue crack growth rate increases as the experimental load increases under the same stress ratio and stress intensity factor range. At the beginning of crack growth, the extension mechanism of fatigue crack is the typical mechanism of cleavage fracture. In the steady extention stage, crack extends along the weld seam firstly.Then, crack growth direction changes to extend along the base metal. The extension mechanism of fatigue crack in the weld seam is the main mechanism of cleavage fracture and the extension mechanism of fatigue crack in the base metal is the main extension mechanism of fatigue band. In the instantaneous fracture stage, the extension mechanism of fatigue crack is the typical dimple-type static fracture mechanism.Crack growth was simulated by conventional finite element method and extended finite element method.     

BEHAVIOUR OF INITIATION AND GROWTH OF SHORT FATIGUE CRACKS

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840D车轮辐板孔疲劳失效及裂纹容限研究

通过裂纹和断口的观察、理化检验、模拟仿真及其力学计算,分析了840D车轮辐板孔裂纹的特征、机理和原因.结果表明:裂纹属于高低周复合机械疲劳,裂纹主要在制动加机械载荷工况下萌生和扩展.统计分析确定了裂纹扩展速率,结合裂纹发展形态和理论计算给出了临界裂纹长度,进而评估出裂纹容限为20mm.     

In situ observations on effects of hydrogen on deformation and fracture of A533B pressure vessel steel

External hydrogen gas atmospheres enhanced dislocation motion, multiplication of dislocations, and dis-location source activation under applied loading during in situ high-voltage electron microscopy (HVEM) observations of A533B pressure vessel steel. However, in both vacuum and hydrogen atmos-pheres, fracture occurred in a ductile manner in specimen areas transparent in the 1000-keV HVEM. The principal effect of the hydrogen atmosphere was to decrease the stress required for deformation near the crack tip and for crack propagation. Deformation at the crack tip was highly localized in both atmos-pheres, and a yielding strip plastic zone, analogous to the Dugdale-Barenblatt model for crack growth, formed ahead of the crack tip. The crack tip plasticity was confined to this strip. Inside the yielding strip, final cracking occurred through a sliding-off mechanism in the thin areas of the HVEM specimen. In the thicker areas of the specimen, where the yielding strip ahead of the crack was no longer transparent, crack tip blunting and void/microcrack formation ahead of the main crack tip could be observed directly. Crack tip blunting occurred by a two-corner mechanism, and further crack growth initiated by strain lo-calization at one of the crack tip vertices. Also void/microcrack formation ahead of the main crack tip was operative and resulted in coalescence into the main crack tip along the anticipated shear bands. Frac-tography of the thicker areas showed a ductile, dimpled fracture mechanism both in vacuum and hydro-gen atmospheres. Technical Research Centre of Finland, Metals Labo-ratory, SF-02150 Espoo, Finland     

A537钢在3.5%NaCl溶液中低周腐蚀疲劳的裂纹萌生

利用三电极技术研究了Ａ５３７低合金钢在３．５％ＮａＣｌ活化体系中的低周腐蚀疲劳的裂纹萌生行为．结果表明，应变速率越小，或者应变幅越大，裂纹萌生寿命越短；阳极极化和强阴极极化可以大大缩短裂纹萌生寿命，阴极保护条件下的裂纹萌生寿命与空气中的相似．裂纹主要在软的铁素体内萌生，然后穿过珠光体连接．剧烈的阳极溶解破坏了表面形变形貌，阴极析氢导致表面产生许多小裂纹．     

淬态晶相对块状Zr-Al-Ni-Cu非晶合金疲劳断裂的影响

研究了带有淬态晶相块体非晶合金的对称循环疲劳断裂。结果表明，粗大的晶相促进疲劳裂纹的萌生，而完全非晶试样及带有细小晶相试样的裂纹萌生于样品的表层。非晶基体断口为典型的非晶疲劳条纹。在晶相处为典型的瞬断断口形貌，非晶基体疲劳条纹的间距远大于晶体疲劳条纹的间距。     

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  846 mm轮箍发生崩裂，为确定轮箍失效原因，对其进行解剖检验分析。低倍酸洗后发现轮缘表面有多条热裂纹。金相检验可知其表面存在马氏体组织。断裂起源于轮缘表面的热裂纹，为典型的疲劳断口。结果表明：轮箍崩裂由轮缘处热裂纹引起。轮缘处热裂纹的产生与其使用、路况等因素有关。     

Ф846mm轮箍崩裂原因分析

Ф846 mm轮箍发生崩裂,为确定轮箍失效原因,对其进行解剖检验分析。低倍酸洗后发现轮缘表面有多条热裂纹。金相检验可知其表面存在马氏体组织。断裂起源于轮缘表面的热裂纹,为典型的疲劳断口。结果表明：轮箍崩裂由轮缘处热裂纹引起。轮缘处热裂纹的产生与其使用、路况等因素有关。     

DZ125高温合金超高周疲劳裂纹萌生与扩展

裂纹的萌生与扩展是研究合金材料超高周疲劳行为的重要方面。本研究分析与探讨了温度和表面状态对DZ125合金的超高周疲劳裂纹萌生与扩展特征的影响。不同温度下,DZ125合金的超高周疲劳裂纹萌生位置和扩展方式不同。室温下,裂纹均沿表面起源,裂纹扩展以拉伸模式为主;700℃下,裂纹均沿亚表面起源,裂纹扩展以剪切模式为主。室温下,DZ125合金经激光冲击处理前后的超高周疲劳裂纹萌生位置和扩展方式均存在差异。经过激光冲击处理后,裂纹萌生于合金的内部孔洞缺陷,裂纹扩展完全以剪切模式进行。     

航空发动机风扇叶片裂纹失效分析

航空发动机风扇叶片产生了裂纹故障。通过对故障叶片进行外观检查、断口分析、叶尖端面检查、化学成分分析、硬度检测及金相组织分析,确定了风扇叶片裂纹的性质和产生原因。结果表明:风扇叶片裂纹为高周疲劳裂纹;钛合金风扇叶片与镍包石墨涂层摩擦相容性差,叶片与机匣镍包石墨涂层发生严重摩擦是导致叶片产生早期疲劳开裂的主要原因;同时,结构的应力集中以及振动应力也会引起疲劳裂纹的萌生及扩展;并提出了相应的改进建议,避免类似故障的发生。     

Monte Carlo simulation of stress corrosion cracking on a smooth surface of sensitized stainless steel type 304

Stress corrosion cracking (SCC) on a smooth surface of structural metal materials occurs by initiation and coalescence of micro cracks, subcritical crack propagation and multiple large crack formation or final failure under combination of material, stress and corrosive environment. In this paper, a Monte Carlo simulation of the SCC process is proposed based on stochastic properties for micro crack initiation and concepts in fracture mechanics for crack coalescence and propagation. The procedure is as follows: The possible number of grain-sized micro cracks which can be initiated is set for a given space and initiation times for all cracks are assigned by random numbers based on exponential distribution. Sites and sizes of cracks are assigned by uniform random numbers and normal random numbers, respectively. Coalescence and propagation of cracks are determined based on fracture mechanics. The emphasis in the model is put on the influence of semi-elliptical surface cracks. Numerical simulations are carried out based on the results of creviced-bent-beam tests for sensitized stainless steel type 304 under high-temperature and high-purity water containing dissolved oxygen and the influence of micro crack initiation rate and coalescence condition on the simulation results is discussed.     

BEHAVIOR OF SHORT FATIGUE CRACKS AT BLUNT NOTCHESIN A MEDIUM CARBON STEEL

1.IntroductionTheinitiati0nandpropagation0ffatiguec=acksatn0tchesareofgreatpracticalim-portancesincethemaj0rity0ffatiguefailuresinengineeringc0mponentsandstructuresoccurduetol0calstressconcentrationsatnotches.Thefatiguelifeisusuallyseparatedintotwoparts:0neportion0flifespentincrackinitiationandtheotherp0rti0nspentinpropagati0n.However,t0talfatiguelifecannotbeevaluatedbecausetherearepresentlyn0proceduresf0revaluatingthecrackinitiati0nlength.Crackinitiati0nisusuallydefinedasthepr0cessesofl0calpl…     

喷丸对H13钢单边带缺口试样疲劳裂纹扩展行为的影响

喷丸工艺通过改变试件的表面形貌、微观组织及残余应力等表面完整性可以影响裂纹的萌生和扩展;对于存在缺陷的试件,喷丸的作用机制和影响结果有所不同。采用白光干涉仪、SEM、XRD及显微硬度计等对单边带缺口的H13钢薄板试样喷丸前后的表面完整性进行了测定。并借助原位SEM开展了系列裂纹扩展试验,分析了喷丸对试样疲劳寿命、裂纹扩展速率以及疲劳断口特征的影响。研究结果表明,虽然残余压应力诱发裂纹闭合,但由于喷丸后表面粗糙度的大幅提高增强了缺口效应,表面加工硬化使得韧性有所降低,以及残余应力在加载过程中发生松弛等因素,喷丸后单边带缺口试样的裂纹萌生过程缩短,疲劳寿命降低,且裂纹扩展速率的变化较小。喷丸前后疲劳断口形貌均为准解理特征,喷丸后断口近表面处的撕裂棱特征消失。     

海洋柔性立管用钢的疲劳断裂行为

采用GPS100高频疲劳试验机研究了海洋柔性立管用钢在温轧工艺下的疲劳断裂行为。结果表明,海洋柔性立管用钢疲劳寿命随加载应力幅的升高而不断下降;疲劳裂纹产生于试样表面,裂纹源区可见变形带及河流花样,裂纹扩展区存在大量二次裂纹,瞬断区疲劳裂纹呈韧性断裂特征。在疲劳裂纹扩展过程中,裂纹的扩展能力因大角度晶界的铁素体和高强度贝氏体的相互作用而受到限制,同时在晶界处形成的二次裂纹同样可减缓扩展速率,达到提高疲劳寿命的效果。     

单晶高温合金损伤与断裂特征研究

研究了单晶高温合金在持久、拉伸和低周疲劳条件下的损伤与断裂特征。结果表明:单晶合金高温持久微观断裂方式为沿原始微孔洞扩展的微孔聚集型断裂,中温持久微观断裂方式为微孔聚集型断裂与滑移剪切断裂共存的混合型断裂;高温拉伸首先在内部以微孔聚集型模式开裂,最后阶段以滑移剪切的方式发生断裂,微孔聚集型断裂过程占主要地位,中温拉伸以纯滑移剪切的方式发生断裂,断口由一个平面组成;低周疲劳断裂由裂纹萌生、裂纹稳定扩展和裂纹失稳扩展3个阶段组成。断口呈现多源开裂特征,疲劳裂纹一般萌生于表面。疲劳裂纹扩展初期断口基本与主应力方向垂直,随着疲劳裂纹扩展,断口表现为与主应力约成45°的平面特征。     

粗晶纯Al多晶材料的循环形变——Ⅱ.断口形貌

对粗晶纯Al多晶体的疲劳断口进行了扫描电镜分析,在应变控制循环形变下,晶粒粗大而延性很好的金属的疲劳断口具有某些特征:断裂源少而集中,断裂源附近裂纹呈扇形扩展,疲劳条纹为循环解理刻面,每一条纹由较宽的解理刻面和窄的解理台阶两部分组成,台阶往往由于塑性形变而钝化;在裂纹扩展第Ⅱ阶段的疲劳条纹清晰、连续,布满裂纹扩展第Ⅱ阶段的整个区域,不同水平面形成的条纹间以“麻花形”的条带连接;多处观察到沿条纹形成的二次微裂纹,有些已发展成二次宏观裂纹,并有二次疲劳条纹;在断口上可观察到解理小舌台;断口上无最后拉断的静断区,对疲劳条纹的形成机制进行了初步的探讨。     

CYCLIC DEFORMATION OF COARSE GRAINED POLYCRYSTALLINE PURE Al Ⅱ. FRACTURE SURFACE MORPHOLOGY

对粗晶纯Al多晶体的疲劳断口进行了扫描电镜分析,在应变控制循环形变下,晶粒粗大而延性很好的金属的疲劳断口具有某些特征:断裂源少而集中,断裂源附近裂纹呈扇形扩展,疲劳条纹为循环解理刻面,每一条纹由较宽的解理刻面和窄的解理台阶两部分组成,台阶往往由于塑性形变而钝化;在裂纹扩展第Ⅱ阶段的疲劳条纹清晰、连续,布满裂纹扩展第Ⅱ阶段的整个区域,不同水平面形成的条纹间以“麻花形”的条带连接;多处观察到沿条纹形成的二次微裂纹,有些已发展成二次宏观裂纹,并有二次疲劳条纹;在断口上可观察到解理小舌台;断口上无最后拉断的静断区,对疲劳条纹的形成机制进行了初步的探讨。