精铸热锻模具的主要失效形式和分析

对新型精铸模具钢制热锻模具的失效进行了分析，并对不同形式下模具的失效原因作了探讨。结果表明，精铸热锻模的主要失效形式为热磨损、塑性变形、热疲劳裂纹、冲击疲劳破断和脆性断裂。     

Study of the fracture of ferritic ductile cast iron under different loading conditions

This work is a continuation of the studies presented in a recent paper by the authors, where the fracture surfaces of pearlitic ductile cast iron under different loading conditions were exhaustively analysed. In this study, fracture surfaces of ferritic ductile cast iron (or ferritic spheroidal graphite cast iron) generated under impact, bending and fatigue loading conditions were characterised and compared. The fracture surfaces were characterised qualitatively and quantitatively from the observation under a scanning electron microscope. The fracture mechanisms in each case were identified. For impact tests, as test temperature increases, the dominant fracture mechanism changes from brittle to ductile. For bending tests, a fully ductile fracture micromechanism dominates the surface. In fatigue tests, the surface shows a mix of flat facets that appear to be cleavage facets and ductile striations, but the typical fatigue striations are not easily found on the fracture surface. Methodologies for the determination of the macroscopic direction of main crack propagation in both ductile and brittle failure modes are proposed. These allow identifying main crack propagation direction with good approximation. The results are potentially useful to identify the nature of loading conditions in a fractured specimen of ferritic spheroidal graphite cast iron. The authors believe that it is necessary to extend the methodologies proposed in samples with different geometry and size, before they can be used to provide additional information to the classical fractographic analysis.     

氢处理对铸造钛合金低周疲劳寿命及断裂韧性的影响

本文研究了氢处理对铸造钛合金的低周疲劳寿命及断裂韧性的影响,发现经氢处理后铸造钛合金粗大的魏氏组织转变成细小的等轴组织,其应变低周疲劳寿命大大延长,在低周疲劳过程中,应变量较小时,试样出现循环硬化现象,而在应变量较大时,出现循环软化现象,氢处理后材料的断裂形式由脆性断裂转为韧性断裂;断裂韧性提高。     

Fracture life prediction and sensitivity analysis for hollow extrusion dies

It has been reported in literature that extrusion dies most often fail by fatigue fracture. Experimental studies have shown that cracks pre‐exist in dies because of various factors including machining, heat treatment and surface hardening. High levels of repeated mechanical and thermal loads result in crack propagation leading to ultimate fracture failure. In an earlier work by the authors, a simplified approach of plate‐with‐edge‐crack was used to develop a fracture mechanics based fatigue life prediction model for tube dies. In the current work, extrusion die is modeled as a pressurized‐cylinder‐with‐internal‐crack, a more realistic approach for a hollow (tube) die. Stochastic nature of various fatigue‐related die parameters has been used to reflect their variability. Monte Carlo simulation has been performed to forecast fracture failure of extrusion dies under a given set of operating conditions and mechanical properties. Predicted mean‐time‐to‐failure is quite close to actual average extrusion die life data from the industry. Using tube die as a basis, fracture life of other hollow profiles can be estimated through their shape complexity values. Analysis has also been carried out to evaluate how sensitive fracture life of hollow extrusion dies is to material and process parameters. Major findings are that die life is highly sensitive to initial crack size, wall thickness, profile outer diameter and billet length; moderately sensitive to Paris constant and extrusion ratio; and only slightly sensitive to fracture toughness and ram speed. These results can contribute to a deeper understanding of the factors responsible for fracture failure of an extrusion die exposed to thermo‐mechanical fatigue environment.     

氢处理对铸造钛合金低周疲劳寿命及断裂韧性的影响

本文研究了氢处理对铸造钛合金的低周疲劳寿命及断裂韧性的影响,发现经氢处理后铸造钛合金粗大的魏氏组织转变成细小的等轴组织,其应变低周疲劳寿命大大延长。在低周疲劳过程中,应变量较小时,试样出现循环硬化现象;而在应变量较大时,出现循环软化现象。氢处理后材料的断裂形式由脆性断裂转为韧性断裂;断裂韧性提高。     

5CrNiMo钢的强度水平和表面强化对冲击疲劳性能的影响

本文探讨了用冲击疫劳试验测定的疲劳寿命和疲劳裂纹扩展速率衡量热锤锻模材料疲劳抗力的合理性。研究了5CrNiMo钢在热锻模要求的硬度范围内,材料强度水平和表面强化对冲击疲劳性能的影响。试验结果表明,在相当小型锻模受载的低冲击能量作用下,适当提高材料强度可延长疲劳寿命;在相当大型锻模受载的高冲击能量作用下,提高材料塑性、韧性可提高疲劳寿命。软氮化并磨去脆性白层可显著提高低冲击能量下的冲击疲劳寿命。     

Fracture of high carbon high strength anchor rods

During a heavy windstorm, there was failure of anchors supporting transmission towers. We were given the mandate to examine the reasons for the failure of the anchor rods and suggest measures to prevent such failures from occurring. The study involved the in-depth examination of the chemical composition, microstructures, mechanical properties and fracture morphologies of specimens from failed anchors. Results indicated that the chemical composition, yield and tensile strengths of the anchor rods are within the norm of ASTM standard A722. The chemical composition corresponds to that of AISI 1070 with slightly higher manganese and silicon levels. Microstructure is ferrite–pearlite with dominance of pearlite due to the relatively high carbon content. Fracture surfaces of failed anchor rods exhibited pronounced cleavage facets (cleavage steps and river pattern) indicating that failure mode is brittle and the mechanism of fracture is cleavage. There were no signs for the occurrence of fatigue – any beach mark or striations. Final area of fracture showed traces of ductility (small shallow dimples). To prevent brittle failure of anchor rods, their toughness has to be improved. To achieve this, the potentiality of applying HSLA steel technology of micro alloying and TMCP (thermo mechanical control process) has been suggested.     

Regression-based CVN–KIC Models for hot work tool steels

Dies and tools used in hot metal forming (extrusion, forging, rolling, etc.) are exposed to high pressures, elevated temperatures, and thermo-mechanical fatigue. The most common mode of in-service die failure is fatigue fracture (brittle failure through crack propagation). Reliable determination of fracture toughness of the die material is thus critically important. However, as die steels have a combination of high-hardness and high-strength, and are used at elevated temperatures, standard plane-strain fracture toughness (K_IC) testing methods become impracticable. Alternate testing procedures such as the Charpy impact energy (CVN), together with empirical/semi-empirical correlations of K_IC to other data, are then more viable and economical. Experimental data (values of K_IC, CVN, and HRC) of H13 steels have been collected through an exhaustive literature search. This data set has been augmented through in-house experimentation: samples variously heat treated (different tempering temperatures and times, and both air-cooling and oil-quenching), and tested at different working temperatures. Linear and quadratic models are proposed for determination of fracture toughness, based on experimental (in-house) and published values of Charpy impact energy (CVN) and Rockwell hardness (HRC), both at room and at elevated temperatures.     

Bruchzähigkeit und Ermüdungs-Rißwachstum von Gußeisen

Fracture Toughness and Fatigue Crack Growth of Cast Irons Fracture toughness, elastic moduli and fatigue crack growth rates in air and in vacuum were measured for 17 different cast irons. The graphite shape in the cast irons varied from flakes to nodules, the matrix varied from ferrite to pearlite to martensite. In the fatigue crack growth rate tests, using fracture mechanics methods, it was observed that the fatigue crack growth rate increases significantly as the cyclic stress intensity range approaches the critical value for stable crack growth. This phenomenon was used to determine the fracture toughness of the cast irons. Such toughness data agree well with literature data on the fracture toughness of cast irons. An extensive review of the effects of strength on the fracture toughness of commercial cast irons is presented. In cast irons with flake graphite, cyclic loading results in a reduced modulus of elasticity. This is attributed to the rupture of the graphite flakes under cyclic loading.     

Reinforcement of Hadfield steel matrix by oriented high‐chromium cast iron bars

To attain a wear‐resistant material compatible with high hardness and high toughness, Hadfield steel matrix was reinforced by oriented high chromium cast iron bars, through inserting high chromium alloys flux‐cored welding wires into Hadfield steel melt at 1500 ± 10 °C. The obtained composites were investigated by XRD, SEM, micro‐hardness, three‐body abrasion wear and impact toughness testers. The results show that the alloy powders inside the flux‐cored welding wires can be melted by the heat capacity of Hadfield steel melt and in situ solidified into high chromium cast iron bar reinforcements tightly embedded in the matrix. The micro‐hardness of reinforcements of the water‐quenched composite is about four times higher than that of the matrix. The impact toughness of the water‐quenched composite is higher than that of the as‐cast composite and lower than that of Hadfield steel, and its fracture mechanism is very complicated and refers to brittle and ductile mixture fracture mode. The excellent impact toughness and better wear resistance of the water‐quenched composite are attributed to combine fully the advantages and avoid the drawbacks of both Hadfield steel and high chromium cast iron. Additionally, in industrial application, the pulverizer plate produced by this composite, has also better wear resistance compared to the reference Hadfield steel pulverizer plate.     

硬质合金磁头壳体拉伸模质量分析

通过化学成分、显微组织及断口分析等试验方法，对进口及国产硬质合金磁头壳体拉伸模，进行了质量分析，探讨了国产硬质合金模具发生早期失效的原因．结果表明：该拉伸冲头继裂的住质属疲劳断裂．本文对改进国产硬质合金的冶金质量及模具的合理选材提出建议．     

Dynamic fracture toughness testing of epoxy resin filled with sio2 particles

The fracture behavior of epoxy resin used as one of electrical insulation materials is generally brittle compared with that of metals. Therefore, when epoxy resin is used as a structural material, the effect of impact loading must be taken into consideration in design. In the present study, the dynamic fracture toughness of epoxy resin filled with SiO₂ particles has been evaluated both by the absorbed energy method and by the impact load obtained from the instrumented Charpy type impact test. Therefore, the absorbed energy has been analysed to evaluate the real fracture toughness. Moreover, the influence of inertial loading on the impact load must be also considered; therefore, the dynamic fracture toughness has been evaluated by the formula taking the inertial loading effect into consideration. Thus both fracture toughness values evaluated from absorbed energy and from impact load have been compared; as a result, a good agreement has been ascertained.It is common to perform impact test on specimens with blunt notches since they are easy to be prepared. However, variation of fracture toughness with notch root radius in the brittle material cannot be ignored. Therefore, the influence of notch root radius on the fracture toughness has been examined. As a result, it has been ascertained that the variation of fracture toughness with notch root radius follows the formula presented by Williams.     

Fracture toughness and shear behavior of composite bonded joints based on a novel aerospace adhesive

In this paper, the mechanical performance of the newly developed LMB aerospace structural adhesive has been characterized experimentally. To this end, a comparison has been performed with the Epibond 1590 A/B adhesive on the basis of the effects of thermal aging, wet aging and adhesive thickness on the fracture toughness and shear behavior (static and fatigue) of bonded joints between CFRP laminates. Mode-I and -II fracture toughness was measured through tensile and 3-point bending tests on double-cantilever beam specimen, respectively, while the shear behavior of the joints was assessed through static and fatigue double-lap shear tests. A fractographic analysis of the fracture surfaces was performed in order to detect the failure mode of the bonded joint. The experimental results show a higher fracture toughness and improved fatigue behavior for the LMB adhesive.     

49MnVS3非调质易切削钢汽车曲轴的失效分析

49MnVS3非调质易切削钢汽车曲轴在进行发动机例行工况试验时发生断裂。对失效曲轴进行了化学成分、金相组织、力学性能和断口分析。发现该曲轴材料晶粒粗大，铁素体大都呈网状沿晶分布；材料的韧性差；宏观下，裂纹源区萌生于断口边缘部位，该处未发现刀痕及外伤；断口微观形貌为沿晶断裂和穿晶断裂，有较明显的脆性特征。结论：曲轴断裂是始、终锻温度偏高所致。     

Microstructure and toughness of CuNiMo austempered ductile iron

The effect of austempering on the microstructure and toughness of nodular cast iron (designated as CuNiMoSG) alloyed with molybdenum, copper, nickel, and manganese has been studied. Light microscopy (LM), scanning electron microscopy (SEM), and X-ray diffraction technique were performed for microstructural characterization, whereas impact energy test was applied for toughness measurement. Specimens were austenitised at 860 °C, then austempered for various times at 320 and 400 °C, followed by ice-water quenching. Austempering at 320 °C produces a microstructure consisting of a mixture of acicular bainitic ferrite and the stable carbon-enriched austenite. In this microstructure ε-carbides are also identified after austempering up to 5 h. Fracture mode is changed from ductile to brittle with the prolonged time of austempering at 320 °C. The highest impact energy (115 kJ) corresponds not only to ductile fracture, but also to the maximum value of the volume fraction of retained austenite. Only martensitic structure was observed during austempering at 400 °C, inducing brittle fracture and significantly low-impact energy (10–12 kJ).     

Failure analysis of a cast steel railway wheel

The failure analysis of a broken railway pearlitic cast steel railway wheel, which was involved in a train derailment, has been investigated. The fractographic results near the fracture origin of the wheel have been compared to the regions of stable (fatigue) and unstable crack propagation of cast steel fracture toughness samples. The macro and microfractographic features of the broken wheel did not show any evidence of the occurrence of a fatigue mechanism, indicating that its fracture was caused by transgranular cleavage fracture, as a consequence of the train derailment.     

The effect of processing temperature and time on the structure and fracture characteristics of self-reinforced composite poly(methyl methacrylate)

A novel material, self-reinforced composite poly(methyl methacrylate) (SRC-PMMA) has been previously developed in this laboratory. It consists of high-strength PMMA fibers embedded in a matrix of PMMA derived from the fibers. As a composite material, uniaxial SRC-PMMA has been shown to have greatly improved flexural, tensile, fracture toughness and fatigue properties when compared to unreinforced PMMA. Previous work examined one empirically defined processing condition. This work systematically examines the effect of processing time and temperature on the thermal properties, fracture toughness and fracture morphology of SRC-PMMA produced by a hot compaction method. Differential scanning calorimetry (DSC) shows that composites containing high amounts of retained molecular orientation exhibit both endothermic and exothermic peaks which depend on processing times and temperatures. An exothermic release of energy just above T_g is related to the release of retained molecular orientation in the composites. This release of energy decreases linearly with increasing processing temperature or time for the range investigated. Fracture toughness results show a maximum fracture toughness of 3.18 MPa m1/2 for samples processed for 65 min at 128°C. Optimal structure and fracture toughness are obtained in composites which have maximum interfiber bonding and minimal loss of molecular orientation. Composite fracture mechanisms are highly dependent on processing. Low processing times and temperatures result in more interfiber/matrix fracture, while higher processing times and temperatures result in higher ductility and more transfiber fracture. Excessive processing times result in brittle failure.     

复合材料微细杆增强复合材料研究进展

纤维增强树脂基复合材料具有轻质高强的特点,但复合材料层合板层间韧性和抗冲击性能差,复合材料微细杆(Z-pin)增强技术极大地改善了这一不足,被广泛应用于各工业制造领域。近年来,Z-pin增强复合材料的制备工艺不断发展,目前主要有热压罐法和超声植入法(UAZ)。Z-pin增强复合材料的层间增韧和抗冲击性能提高效果显著,但其面内拉伸性能、面内压缩性能和疲劳性能稍有下降。文中从Z-pin增强复合材料的性能特点出发,针对其层间韧性、抗冲击性、面内力学性能和疲劳性能进行了综述。指出Z-pin在Ⅰ型断裂模式、Ⅱ型断裂模式和混合断裂模式下的增韧机制;总结了Z-pin在提高复合材料低能量冲击后剩余压缩性能方面的作用;介绍了Z-pin增强复合材料在平面拉伸和压缩载荷下的破坏模式,从纤维损伤角度归纳了其面内拉伸及压缩性能下降的原因;总结了Z-pin增强复合材料在循环压缩载荷下的破坏模式。最后从材料体系和工艺优化两方面出发,为降低纤维损伤提供了建议。对Z-pin增强技术的进一步应用进行了展望。     

Abnormal manifestation of the high-temperature degradation of the weld metal of a low-alloy steel welded joint

We have shown that hardness, impact toughness, mechanical properties in tension, and the local parameters of fracture mechanics (static and cyclic crack resistance) are sensitive to the operating degradation of weld metal of steam pipelines of thermal power plants made of 15Kh1M1F steel. The simultaneous decrease in the resistance to brittle and plastic fracture (hardness, strength, and impact toughness) represents a phenomenon of the operating degradation of weld metal. We have established a specific correlation between the characteristics of plasticity and other mechanical parameters of operated metal: the increase in °₅ of operated weld metal is in good agreement with the decrease in its strength, whereas the reduction of Ψ correlates with the lowering of resistance to brittle fracture. Electrolytic hydrogenation decreases the characteristics of strength and plasticity of operated weld metal much stronger than in the initial state. The absence of ferritic edgings on the boundaries of primary austenitic grains makes for a low resistance to brittle fracture, and the change in acicular ferrite deteriorates the mechanical properties. The ductile fracture of nonoperated metal is replaced by brittle intercrystalline failure in operated metal. __________ Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 43, No. 1, pp. 73–79, January–February, 2007.     

A criterion for brittle fracture in U-notched components under mixed mode loading

A failure criterion is proposed for brittle fracture in U-notched components under mixed-mode static loading. The criterion, called UMTS, is developed based on the maximum tangential stress criterion and also a criterion proposed in the past for mode I failure of rounded V-shaped notches [Gomez FJ, Elices M. A fracture criterion for blunted V-notched samples. Int J Fracture 2004;127:239-64]. Using the UMTS criterion, a set of fracture curves are derived in terms of the notch stress intensity factors. These curves can be used to predict the mixed mode fracture toughness and the crack initiation angle at the notch tip. An expression is also obtained from this criterion for predicting fracture toughness of U-notched components in pure mode II loading. It is shown that there is a good agreement between the results of UMTS criterion and the experimental data obtained by other authors from three-point bend specimens.