全层状TiAl基合金拉伸试验断裂过程及机理

通过对全层组织TiAl基合金不同缺口试样进行原位拉伸试验,结合数据分析以及断口形貌的观察,研究TiAl基合金拉伸的断裂过程和断裂机理.研究发现在原位拉伸试验中,对于直缺口试样,裂纹起裂于缺口根部,其断裂过程主要是主裂纹(沿层裂纹)首先起裂、扩展、连接,然后形成解理断裂起裂源.这一起裂源形成的同时,在刚好能满足Griffiths脆性解理断裂所需要的临界裂纹尺寸时,引起整个试件发生脆性解理断裂.裂纹首先起裂于层间,层间是薄弱环节,断裂方式是穿层断裂和沿层断裂的混合体,以穿层断裂为主.对于大圆弧和平板试样,这种材料的断裂过程是:首先在较高外加载荷下,在标距范围内比较薄弱的区域沿层开裂,随着外加载荷的进一步增加,这些微裂纹扩展,当微裂纹引起的应力集中和外加载荷共同作用足以引起微裂纹进一步贯穿的瞬间,即能量积累到一定程度时,试样整体发生解理断裂.很多试样的断裂是直接起裂的过程,一旦产生裂纹试样立即解理断裂,即这种材料的强度较高,材料很难产生裂纹,也不易损伤.     

脆性剖分类零件启裂数值分析

裂解槽作为初始裂解源其尖端的应力状态尤其是厚度方向的应力分布直接影响着剖分类零件的裂解性能,是裂解加工成败的关键。文中利用ABAQUS有限元软件,对脆性剖分类零件(轴承座)启裂进行了分析。分析结果表明:裂解槽应力集中效果明显,随着载荷的增加,裂解槽根部的最大正应力逐渐增加,趋近于材料的断裂强度;最大正应力从裂解槽的中间部位向两侧均匀递减;对于脆性材料,最大正应力出现在裂解槽顶端,启裂发生在工件中心对称面裂尖附近,这种启裂位置的唯一性有利于获得高质量的断裂面,减少裂解缺陷。     

Observation of notch effect in Al6061-T6 specimens under tensile loading using digital image correlation and finite element method

The fracture of ductile materials such as Al6061-T6 usually starts from void nucleation. In this study, we investigated strengthening effect and stress triaxiality behavior in notched Al alloy specimens. Various specimens, one un-notched and two with different U-types of notch, one with large diameter (L-notched) and another with small diameter (S-notched), having the same width were selected. The distribution of strain in the full-field was examined using the digital image correlation (DIC) method. Under the tensile test, S-notched specimens showed a more pronounced strengthening effect than the L-notched specimens. The results of DIC confirmed that the notch tip of the S-notched specimen experienced high strain, while the L-notched specimen experienced high strain at the center. The maximum stress triaxiality moved rapidly from the notch tip to the center with the increase in notch radius over 10 mm. The results of the stress triaxiality analysis by finite element method were in good agreement with the above DIC measurement results and predicted the void generation and fracture sites in L-notched and S-notched specimens.     

V形切口复合材料试件拉伸破坏声发射监测

通过对V形切口复合材料试件单向拉伸、分级加卸载拉伸试验及声发射实时监测,研究含切口缺陷复合材料拉伸损伤破坏及其声发射响应特征.结果表明:复合材料切口试件拉伸损伤破坏与声发射特征参量相关;切口尖端的高应力状态导致该区域过早损伤破坏并扩展,且对应较高的声发射相对能量、幅度和急剧增加的撞击数;声发射定位源主要集中在位于试件中部的切口尖端及其扩展区域.     

截面形状对材料微孔洞损伤破坏的影响

为探讨截面形状对金属材料微孔洞损伤破坏的影响,针对圆形、矩形横截面缺口试样进行了拉伸破坏、预拉伸低温冲断试验,断口扫描电镜观察及有限元计算;用细观力学模型计算了缺口试样断裂时微孔洞长大体积率沿断口的分布和断口的起裂位置,并模拟了断口上起裂处微孔洞长大。结果表明：截面形状对材料微孔洞损伤演化有较大的影响,圆形、矩形横截面缺口试样断裂时起裂处微孔洞长大体积率相差较大,微孔洞长大的临界值不是材料常数;用R-T模型、GTN模型模拟非轴对称三轴应力状态下材料微孔洞损伤演化有较大的误差。     

A study on the characteristics of fracture resistance curve of ferritic steels

Fracture resistance (J-R) curves are used for elastic-plastic fracture mechanics analyses. The specimen geometry and the reversed cyclic loading affect the fracture resistance (J-R) curve. On the specimen geometry, The effects of specimen size plane size, specimen thinkness, side grooving and crack length were studied. On the reversed cyclic loading, the effects of load ratio and incremental plastic displacement were studied. The results revealed that theJ-R curves increased with increasing plane size and decreased with increasinga/W and theJ-R curves decreased with decreasing the load ratio and the incremental plastic displacement, respectively.     

缺口圆棒低温断裂的局部法研究

对A508-Ⅲ钢两种缺口尺寸的缺口圆棒拉伸试样进行有限元数值模拟分析及低温断裂试验研究,研究结果表明,对于低温下脆断的缺口圆棒试样(断口呈解理断裂),起裂并非发生于弹性应力分布最大的缺口根部,而是在离开缺口根部有一定距离处,断裂时构件内部应力已非线弹性分布,而为弹塑性分布,采用基于线弹性有限元分析的应力场很难解释试验现象,而基于弹塑性有限元分析的应力场则能较好解释试验结果。基于解理断裂局部法理论,采用数值模拟方法预测不同缺口半径的缺口圆棒试样的解理断裂概率－载荷曲线,提出44%的解理断裂概率所对应的预测载荷值与实际的平均解理断裂载荷值基本相等,在此基础上预测不同缺口半径的解理断裂载荷随缺口半径变化的趋势,并得到试验验证。     

单试样测试材料JId值方法的比较

利用示波冲击试验，以小角度多试样冲击试验结果为标准，对几种单试样测试材料动态弹塑性断裂韧度JId值的方法进行了比较。结果表明：最大载荷前能量方法只适用于测试启裂后无显著形变强化的高强钢；柔度变化率方法不宜于测试撕裂阻力较高的材料；而对于裂尖钝化时近似呈半圆形的材料，利用饱和伸张区宽度方法可以方便地得到材料的JId值。     

Micro-strain distribution around a crack tip by electron beam moiré methods

The microscopic deformation around a crack tip in a small tensile specimen of aluminum was measured by using electron beam moiré methods. The tensile test was carried out in a scanning electron microscope(SEM) by using specially designed small tensile testing apparatus for an SEM. A line grating with a pitch of 87 nm was written at the crack tip by electron beam lithography. SEM images of the grating contained(original) moiré fringes at certain magnifications without loadings on the specimen. The displacement and strain in the region 10 to 50 μ m from the crack tip were evaluated by analyzing the (mismatch) moiré fringes. Measured strains normal to loadings(longitudinal strains) near the crack tip were found to be comparable to those estimated using linear elastic fracture mechanics(LEFM), for the lowest load, and elastic-plastic fracture mechanics, at effective crack tip position located within the actual crack tip. The exponent of the strain singularity in the vicinity of the actual crack tip changed with applied stress, ranging between ?0.64 and ?1.0. The measured crack tip opening displacement(CTOD) values disagreed with CTODs based on the Hutchinson-Rice-Rosengren(HRR) field, the Dugdale model, and LEFM. The experimental plastic zones spread from the line of crack extension up to an angle of about 60°, as expected from LEFM theory.     

Recent development in low-constraint fracture toughness testing for structural integrity assessment of pipelines

Fracture toughness measurement is an integral part of structural integrity assessment of pipelines. Traditionally, a single-edge-notched bend (SE(B)) specimen with a deep crack is recommended in many existing pipeline structural integrity assessment procedures. Such a test provides high constraint and therefore conservative fracture toughness results. However, for girth welds in service, defects are usually subjected to primarily tensile loading where the constraint is usually much lower than in the three-point bend case. Moreover, there is increasing use of strain-based design of pipelines that allows applied strains above yield. Low-constraint toughness tests represent more realistic loading conditions for girth weld defects, and the corresponding increased toughness can minimize unnecessary conservatism in assessments. In this review, we present recent developments in low-constraint fracture toughness testing, specifically using single-edge-notched tension specimens, SENT or SE(T). We focus our review on the test procedure development and automation, round-robin test results and some common concerns such as the effect of crack tip, crack size monitoring techniques, and testing at low temperatures. Examples are also given of the integration of fracture toughness data from SE(T) tests into structural integrity assessment.     

Fracture mechanics approaches in the analysis of strains and fractures of bodies with notches and scotches

Fracture mechanics models and criteria for bodies with cracks have been developed to analyze strains and fractures of bodies with notches and scotches. Criterion equations and corresponding crack growth resistance diagrams for a body with a notch taking into account the changes in the degree of strain constraint at the notch apex due to finiteness of its apex radius rounding and a nonsingular stress component (T-stresses) have been considered. Analytical relations for calculating the J-integral in the case of bodies with blunt U-and V-notches under elastic and plastoelastic loading have been given. Capabilities of the method of separable functions for the experimental study of plastoelastic crack growth resistance for nonstandard samples with scotches have been presented.     

基于统一强度理论的断裂准则

基于统一强度理论,在小范围屈服条件下,推导Ⅰ、Ⅱ复合型裂纹裂尖塑性区范围的统一解析解。给出不同拉压比α、泊松比υ、中间主应力影响参数b以及裂纹倾角β下的一族塑性区形状与大小的轨迹,讨论以上参数对裂尖塑性区变化的影响。最后基于裂纹尖端塑性区的解析解,提出了一种复合型裂纹断裂准则,分析了裂纹倾角与初始断裂角的关系。结果表明,该准则预测结果比其它准则更精确,与试验结果吻合得非常好。     

In-situ crack propagation observation of a particle reinforced polymer composite using the double cleavage drilled compression specimens

In this study, we investigate the feasibility of in-situ crack propagation by using a double cleavage drilled compression (DCDC) specimen showing a slow crack velocity down to 0.03 mm/s under 0.01 mm/s of displacement control. Finite element analysis predicted that the DCDC specimens would show at least 4.3 fold delayed crack initiation time than conventional tensile fracture specimens under a constant loading speed. Using DCDC specimens, we were able to observe the in-situ crack propagation process in a particle reinforced transparent polymer composite. Our results confirmed that the DCDC specimen would be a good candidate for the in-situ observation of the behavior of particle reinforced composites with slow crack velocity, such as the self-healing process of micro-particle reinforced composites.     

钢的回火与强度塑性的配合

淬火后回火是最常用的热处理工艺之一。然而,钢的强度与塑性常常随回火温度——时间参量的发言改变而向相反的方向变化。必须指出,这些强度与塑性值通常是由光滑试样单向拉力试验得来的,一个机械零件的实际承载能力或寿命往往既不单纯取决于材料的强度,也不单纯取决于塑性,而是根据服役条件决定于两者的合理配合。本文提供了几种结构钢淬火成为金属马氏体后回火对某些机械性能参量影响的研究结果。这些参量更接近于表征一些典型钢种的实际承载能力或服役寿命。它们包括：一次加载时的失效抗力：带有不同应力集中直至一个实际裂纹的极限拉伸强度,缺口敏感度,断裂韧性和冲击韧性。循环加载下的失效抗力：光滑与缺口试样的疲劳极限,过载持久寿命,重复冲击持久寿命,裂纹产生的应力循环次数及裂纹扩展速率。试验结果表明,几乎所有这些参量均在一定的回火温度下出现高峰、低谷或饱和拐点,它们反映了给定材料的强度与塑性之间的一种适当的配合关系,当服役条件改变时这些转折回火温度则向一定的方向转移,要求新的配合。从而为选择回火温度提供一些依据。通过回火转变的高压电镜薄膜透射研究,显示了不同回火温度下所发生的组织变化,为这些表征参量的变化提供了部分内在的联系数。     

基于ANSYS的V型切口模型应力强度因子计算

基于ANSYS有限元软件,给出了含有切口尖端应力奇异场模型的有限元建模和分析方法,利用有限元模型的分析结果,分别采用多种方法,计算和分析了V型切口平面模型的切口参数对其应力强度因子的影响,并对所采用的不同方法进行了对比和讨论。结果表明,当利用预制切口对材料进行拉伸断裂的机械加工时,应尽可能加大预制切口的长度和减小切口的张角。     

材料重复冲击损伤模型与数值计算方法研究

基于连续介质损伤力学,将有效应力概念和应变等效假设应用于Johnson-Cook本构模型中,建立了重复冲击载荷作用下材料力学性能退化的损伤模型,以及考虑材料性能退化对冲击应力应变响应影响的数值计算方法。首先,推导了基于损伤耦合J-C本构模型的应力应变数值计算关系式,并在ABAQUS中进行二次开发,采用两种方法实现了考虑损伤影响的应力应变数值计算。进一步,建立了试件在重复冲击下损伤累积的计算方法,并采用所建方法对含缺口三点弯试件的重复冲击损伤进行了数值计算,研究了缺口根部应力应变及损伤度,并对试件整体损伤规律进行了分析。进一步开展了缺口三点弯试件的重复冲击试验,通过计算结果与试验结果的对比验证了建立的数值计算方法的可行性和适用性。与无损伤耦合模型计算结果相比,损伤耦合模型更能合理反映出缺口根部材料的力学性能退化过程以及损伤累积与冲击响应之间的相互影响。     

Computer simulations of the dynamic behavior of three point bend specimens

Computer simulations of the mechanical behavior of a three point bend specimen with a quarter notch under impact load are performed. Two cases with different load application points at the side and at the middle of the specimen are considered. An elastic-plastic von Mises material model is chosen. Three phases such as impact, bouncing and bending phases are found to be identified during the period from the moment of impact to the estimated time for crack initiation. The quasi static case is compared with the above two cases. It is clearly shown that no plastic deformation near the crack tip is appeared at the impact phase. However, it is confirmed that the plastic zone near the crack tip emerges in the second phase and the plastic hinge has been formed in the third phase i.e., at the end of which a quasi static state is reached.     

Surface wear characteristics of some hard carbons

The surface resistance to damage of homogeneous hard carbons such as glassy low temperature isotropic pyrolytic (LTI) and Ceraphite carbons have been determined by the falling abrasive particle test using SiC grit. Surfaces prepared from within the bulk of the glassy carbon specimens exhibit wear resistance proportional to their microindentation hardness but material near their virgin surfaces shows a lower resistance to this low velocity impact wear. Both pure and silicon-alloyed LTI carbons and Ceraphite material show considerably greater wear than the bulk glassy carbons of the same hardness. However, all of the hard carbons exhibit much greater surface damage resistance than other materials of comparable hardness such as mild steel or soda-lime glass. Microscopic surface examination indicates that brittle fracture is the main wear mode of the hard carbons in this test and the results are interpreted in terms of the microstructural features and characteristic elasticity properties of these solids.     

6061铝合金断裂机理的原位拉伸研究

用SEM-520原位拉伸试验对不同应力状态下6061铝合金试件的断裂过程进行研究.结果表明,不同应力状态下的铝合金试样在拉伸过程中其表面均产生了大量的滑移带,但断裂机理不同.随着三轴应力度的降低,断裂从韧窝聚合型混合剪切机制向纯剪切断裂机制过渡,试件断口也由韧窝断裂模式向剪切断裂模式演变;6061铝合金晶界处为最薄弱环节,微裂纹形核于晶界,随载荷的增加,微裂纹长大和扩展.微裂纹之间通过扩展或剪切而连接导致试样断裂;试样最小断面上的三轴应力度越小,试样断口的两个面上韧窝的取向就越明显,断口越光滑.     

An Investigation into the Effect of Normal Load Frequency on Fretting Fatigue Behavior of Al7075-T6

Most previous studies on fretting fatigue have been accomplished under constant normal loading and less attention has been paid to cyclic normal loading. An innovative test apparatus was specially designed and manufactured for fretting fatigue tests under cyclic loading in this work and the fretting fatigue behavior of Al7075-T6 was investigated at different normal load frequencies. A finite element model was developed to study the effect of normal load frequency on the contact stress distribution. It was found that the cyclic normal load has a more damaging effect on fretting fatigue life compared to constant normal load, particularly at lower frequencies. The results showed that at the normal load frequency of f = 1 Hz, fatigue life decreased by 52% in the high cycle fatigue regime and 28% in the low cycle fatigue regime. The experimental results also indicated that at the normal load frequency of 80 Hz, the fretting fatigue life converged to its corresponding life under constant normal load condition. The fracture surface and the fretting area of the specimens were examined using both optical and scanning electron microscopy (SEM). The experimental observations showed that the dominant partial slip condition with a wider slip region compared to constant normal loading, severe delamination, and higher oxidation rate due to the normal load release at each cycle, are the most important reasons for significant reductions in fretting fatigue life, under cyclic normal loading, especially for low normal load frequencies.