增材制造Ti-6Al-4V钛合金低周疲劳性能研究进展

金属增材制造技术可用于大型、复杂高性能钛合金结构件的制备,在航空航天等领域具有显著的优势和巨大的发展潜力。虽然增材制造Ti-6Al-4V合金构件的强度已经能够超过锻件,但它仍存在内部孔隙、熔合不良、粗大的柱状晶及残余拉应力等问题,使其在疲劳性能上与锻件具有一定的差距。本文在介绍直接能量沉积、选区激光熔化和电子束选区熔化3种代表性增材制造技术的原理及特点的基础上,简述了3种工艺制备Ti-6Al-4V合金构件的微观组织、静态力学性能及低周疲劳性能的研究进展,重点讨论了打印方向、缺陷、显微组织和表面处理对低周疲劳性能的影响。分析了增材制造Ti-6Al-4V合金构件低周疲劳性能、拉伸性能与微观组织之间的内在关系,并对提高构件低周疲劳性能的方法和推动其广泛应用的发展方向进行展望。     

Effect of microstructural modification on damage tolerance of 34CrMo4 shaft steel

Overall damage tolerances of the heat‐treated 34CrMo4 steels having ferritic‐pearlitic, bainitic, and tempered‐martensitic microstructures were evaluated based on their threshold stress intensity factor prior to small crack propagation, fatigue strength, and fracture toughness under static loading. Kitagawa‐Takahashi diagrams were constructed to determine the limiting size of small crack propagation. The micromechanical effects of carbide morphology and phase distribution on quasi‐static and dynamic mechanical properties were also elaborated. Fractographic investigations were carried out on the notched fatigue test specimens to distinguish deterioration and deformation mechanism of the microstructure under reversed cyclic loads. Finally, improvements in the damage tolerance were discussed to present the advantages and disadvantages of each heat treatment procedure to minimize in‐service fatigue failures.     

Effect of microstructure on the fatigue properties of Ti–6Al–4V titanium alloys

Through an analysis on microstructure and high cycle fatigue (HCF) properties of Ti–6Al–4V alloys which were selected from literature, the effects of microstructure types and microstructure parameters on HCF properties were investigated systematically. The results show that the HCF properties are strongly determined by microstructure types for Ti–6Al–4V. Generally the HCF strengths of different microstructures decrease in the order of bimodal, lamellar and equiaxed microstructure. Additionally, microstructure parameters such as the primary α (α_p) content and the α_p grain size in bimodal microstructures, the α lamellar width in lamellar microstructure and the α grain size in equiaxed microstructures, can influence the HCF properties.     

Fatigue crack growth behaviour of gamma base titanium aluminides under different loading conditions

Static and cyclic fatigue crack growth behaviour of gamma base titanium aluminides with three different microstructures were investigated. Influence of cyclic test frequency on fatigue crack growth behaviour was also studied at room temperature under a controlled humidity condition. The crack growth behaviour both under static and cyclic loading was strongly influenced by the microstructure. The threshold stress intensity and crack growth behaviour under cyclic loading were much inferior than that under static loading indicating the ‘true-cyclic fatigue’ effect exhibited in gamma base titanium aluminides. No significant effect of test frequency on the crack growth behaviour was observed for the equiaxed and duplex microstructure materials.     

A STUDY ON THE CHANGE OF FATIGUE FRACTURE MODE IN TWO TITANIUM ALLOYS

The appearance of the fatigue fracture surface and crack growth curve have been examined for a Ti–2.5Cu alloy with different microstructures (two equiaxed and two lamellar microstructures), and for TIMETAL 1100 with a lamellar microstructure. With increasing Δ K , a slope change in the crack growth curve correlates with a transition in the fracture surface appearance (induced by a fracture mode transition); this being found in each microstructure. The microstructure size that controls the fatigue fracture is found to be the grain size for equiaxed microstructures and the lamella width for lamellar microstructures. The transitional behaviour can be interpreted in terms of a monotonic plastic zone size model in microstructures having a coarse microstructure size and in terms of a cyclic plastic zone size model for microstructures having a fine microstructure size.     

Kugelstrahlen von Spaltbiegeprofilen mit ultrafeinkörnigen Gradientengefügen

Linear bend splitting and linear flow splitting are innovative methods to produce bifurcated profiles with ultrafine grained (UFG) microstructures in an integral style. Linear bend split profiles exhibit high potential for lightweight applications, due to their bifurcations and the high strength of the ultrafine grained microstructures, which develop at the surface of the work piece. The presence of the ultrafine grained microstructure is accompanied by a duplication of hardness and strength and a markedly increase of the fatigue properties, compared to the untreated material. Because of their high strength, ultrafine grained materials exhibit increased potential for the formation of compressive residual stresses. Therefore, shot peening of ultrafine grained microstructures could result in an increased fatigue resistance. The results clearly show that shot peening, despite optimized shot peening parameters, does not lead to an increase of the fatigue resistance. Compared to the untreated ultrafine grained microstructure, the fatigue resistance of shot peened material is even lower. The lower fatigue resistance is probably caused by the roughness of the shot peened surface, which overcompensates the compressive residual stresses.     

Fatigue damage of high performance concrete through a 2D mesoscopic lattice model

Based on high-resolution digital images of High Performance Concrete (HPC) microstructures, a two-dimensional mesoscopic lattice model which accounts for fatigue damage is proposed. Fatigue damage is introduced by considering the coupled effects of loading cycles and tensile strain on stiffness degradation of microstructural lattice elements under fatigue loading. The ultimate tensile strain is defined as the failure threshold value for microstructural lattice elements. Further, the effects of the lattice element properties (i.e. size and finite element type) and fatigue loading parameters (i.e. stress levels) on the damage mechanisms of the HPC microstructure are investigated and discussed. It is found that lattice truss elements 1 mm long are satisfactory, giving also their smaller computational requirements in comparison to beam counterparts, to investigate fatigue damage in the HPC microstructure. The numerical results of the present model are consistent with experimental observations.     

Fracture toughness and fatigue crack growth in Ti‐6Al‐4V friction stir welds

Friction stir welding of titanium holds the promise for producing joints with microstructures and mechanical properties that are more comparable to wrought material than traditional fusion welding processes. Extensive data exist on the microstructure and static mechanical properties of titanium friction stir welds, but very little are available on the durability (fatigue) and even less on the damage tolerance (fracture toughness and fatigue crack growth). This paper presents the results of an investigation into the damage tolerance of friction stir welds made in 6 mm thick Ti‐6Al‐4V after a post‐weld heat treatment. It was found that the apparent fracture toughness was lower than the wrought base material, 7–25% depending on the crack orientation relative to the weld, but the crack growth performance (ΔK vs. da/dN) of the weld in the absence of weld‐induced residual stresses was identical to the base material.     

Hydrogen Treatment of Cast Ti-6Al-4V Alloy

This paper presents the results of an investiga-tion of the effect of hydrogen treatment onmicrostructures and tensile and low cycle fatigueproperties of a Ti-6Al-4V cast alloy.The phasetransformation and the refining mechanism of thecast microstructure during the process of hydrogentreatment were studied.It was found that afterhydrogen treatment,the coarse Widmanstttenstructure of the as-cast Ti alloy was transformedinto a very fine and equiaxed α+β microstructurewithout any GBα phase.The tensile strength andductility and the low cycle fatigue life of thehydrogen treated specimens were significantly im-proved.     

Microstructural effect on tensile and fatigue behaviour of C–Mn steel

Stress–strain behaviour in tension and in torsion was studied in ferrite–pearlite and ferrite–bainite microstructures of C–Mn steel. The fatigue tests were performed under reverse torsional loading on hour-glass shape specimens. The cyclic plasticity in torsion was found at about 37% of the monotonic yield stress in both ferrite–pearlite and ferrite–bainite microstructures. The ferrite phase in the direction of maximum shear stress was the preferable site for crack nucleation. The ferrite–bainite microstructure showed better fatigue properties than the ferrite–pearlite microstructure.     

Microstructure,static properties,and fatigue crack growth mechanisms in Ti-6Al-4V fabricated by additive manufacturing: LENS and EBM

Additive manufacturing (AM) technology is capable of building 3D near-net-shaped functional parts directly from computer models using unit materials, such as powder or wire. Additive manufacturing's computer-aided design offers superior geometrical flexibility. The near-net-shaping capability also significantly reduces materials waste. These benefits make AM desirable for critical applications, such as aerospace, ground transportation, and medical. Confident utilization of the technology requires thorough understanding of the AM materials, ensuring that structural integrity and performance requirements are met or exceeded. In this study, Ti-6Al-4V fabricated by two AM techniques: Laser Engineered Net Shaping (LENS) and Electron Beam Melting (EBM) were investigated and critically compared. Samples were built using various processing parameters and heat treated under different conditions, which resulted in different microstructures and mechanical properties. Characteristic microstructures were determined for all cases. Room temperature tensile and fatigue crack growth properties were also evaluated and compared in different orientations with respect to the building direction. The effects of post-AM heat treatments on microstructure and properties were also studied. The results are systematically presented and discussed from the material/process optimization, structural design, and fatigue life prediction perspectives.     

Relation between fatigue crack initiation and propagation,toughness and microstructure in large steel blooms for automotive plastic molds

Molds for plastic automotive components such as bumpers and dashboards are usually machined from large pre-hardened steel blocks. Due to their dimensions, the heat treatment produces mixed microstructures, continuously varying with the distance from the quenched surface, at which fracture toughness and fatigue behavior are not well known; fracture toughness is generally lower than that corresponding to a fully quenched and tempered condition. The response of the mold to defects and stresses applied during service depends on steel properties, that in turn depend upon the heat treatment and the microstructure.A survey of the mechanical properties of some commercial blooms was carried out by using three point fatigue bending tests on notched samples to evaluate the threshold behavior and the crack growth behavior by ΔK-decreasing and ΔK-increasing methods. The samples were obtained from different depths of the blooms. The relationship between mechanical properties, fracture surfaces and microstructure was also investigated.     

High-cycle fatigue bending strength of rapidly solidified and plastic consolidated RS442 aluminium alloy

Grain refinement in metallic materials down to submicro and nano scale results in improvement of mechanical properties. However, increase in strength under static load is not always accompanied by improved fatigue behaviour. In the current studies microstructure and mechanical properties of the submicrocrystalline RS442 aluminium alloy (chemical composition corresponds to conventional 442 cast alloy) were investigated. The alloy was subjected to rapid solidification followed by the extrusion process (variant 1) and additional annealing at 450 °C (variant 2). Rapidly solidified alloy was also consolidated with addition of graphite (variant 3). As the reference material conventionally cast and extruded alloy was also tested (variant 4). For all material variants strength properties were tested in static tensile test and high-cycle stress-controlled fatigue bending tests. It was found that rapid solidification and plastic consolidations led to increase of static mechanical properties of 442 alloy but reduced its fatigue strength.     

LIFE PREDICTION BY SIMULATION OF CRACK GROWTH IN NOTCHED COMPONENTS WITH DIFFERENT MICROSTRUCTURES AND UNDER MULTIAXIAL FATIGUE

A modelling procedure was developed which is applicable to crack growth in notched components subjected to multiaxial fatigue for materials with different microstructures. An algorithm for crack growth, in a microstructure that was modelled as hexagons, was established as a competition between growth by crack linkages during the crack initiation and propagation stages and the propagation of a dominant crack as a single crack. Analytical results simulated by using the developed model were compared with experimental results from fatigue tests which had been conducted using notched specimens of pure copper, carbon steel and two kinds of titanium alloy. Cracking morphology, which was experimentally observed to depend on the microstructure and the loading mode, was well simulated using the present model. The fatigue failure life of a notched specimen was statistically estimated by a Monte Carlo procedure based on the model. The simulated life with a statistical scatter-band almost coincided with the experimental data.     

The microstructure,mechanical, and fatigue behaviours of MAG welded G20Mn5 cast steel

The microstructure, mechanical strength, and fatigue response of metal active gas (MAG) butt‐welded G20Mn5 cast steel was thoroughly investigated for exploring the service safety and reliability of new‐generation railway bogie frames. The fatigue properties of the matrix and welded joints were determined by both low‐ and high‐cycle service regimes. On the basis of nanoindentation testing, the fatigue crack growth (FCG) was derived by correlating with cyclic plastic response of microdomain materials across the MAG joint. The results show that the MAG induces considerable changes in microstructures and hardness of the G20Mn5 matrix and resultantly produces an overmatching welded joint but show comparatively low‐ and high‐cycle fatigue properties to as‐received material. The calculated threshold FCG range based on the Murakami model indicates that the maximum 1.5‐mm defect might be the cracking site subjected to fatigue loading from the structural integrity viewpoint.     

6005A铝合金挤压型材搅拌摩擦焊接头的疲劳性能

对6005A-T6铝合金挤压型材进行焊速为1000 mm/min的搅拌摩擦高焊速焊接,研究了对接面机械打磨对接头组织和力学性能的影响.结果 表明,与生产中常用的焊前打磨处理相比,尽管对接面未机械打磨的接头焊核区的"S"线更明显,但是两种接头的硬度分布和拉伸性能相当,拉伸时都在最低硬度区即热影响区断裂.高周疲劳实验结果表...     

Microstructural influence on the intrinsic fatigue properties of Al---Li 8090 alloy

A study has been made to investigate the influence of microstructure on the extrinsic and intrinsic fatigue properties of the Al---Li alloy, 8090. Two types of microstructure have been produced to compare the relative fatigue properties, one with a δ′ phase dominant microstructure and the other with a S′ + δ′ microstructure. Crack closure loads measured by the crack-opening displacement method have been used to obtain intrinsic fatigue resistance of the δ′ and S′ + δ′ microstructures. Results have shown that the extrinsic fatigue resistance of the δ′ microstructure was considerably higher than that of the S′ + δ′ microstructure, especially at lower growth rate, which was mainly due to the more severe crack path tortuosity and associated high levels of crack closure. In addition, the intrinsic fatigue resistance of the δ′ microstructure was also observed to be higher than that of the S′ + δ′ microstructure, presumably due to greater slip reversibility in the δ′ microstructure.     

The effect of the microstructure on the static fatigue behaviour of Si3N4

The effect of the microstructure on the static fatigue behaviour of two Si3N4 samples containing different sintering aids has been studied. The results show that the static fatigue behaviours of the two samples are consistent with each other in various media, i.e. the rate of crack growth of both materials is greatest in water, followed by air, and then kerosene. A distinctive microstructure endows one of the samples with a higher fracture toughness. In turn this results in a higher crack propagation resistance and a longer service life at the same stress level. This revised version was published online in November 2006 with corrections to the Cover Date.     

Effect of crystalline morphology on fatigue crack propagation in polyethylene

An investigation of the influence of crystalline morphology on fatigue crack propagation (FCP) resistance in a slightly branched polyethylene is presented. Various thermal histories have been utilized to generate samples with different crystalline microstructures and the samples were characterized thoroughly using standard methods. Estimation of tie molecule densities was obtained from measurements of brittle fracture stress. Differences in FCP behaviour for the quenched and annealed samples were shown to be dictated by a competing effect between the degree of crystallinity and tie molecule density. Further, larger spherulite size and distribution appeared to have a deleterious effect on fatigue properties. In general, crystalline microstructure is shown to have a significant influence on fatigue crack propagation behaviour.