A new monitoring system for piping systems in fossil fired power plants

A CEC-funded project has been performed to tackle the problem of producing an advanced Life Monitoring System (LMS) which would calculate the creep and fatigue damage experienced by high temperature pipework components. Four areas were identified where existing Life Monitoring System technology could be improved:

1. 1. the inclusion of creep relaxation

2. 2. the inclusion of external loads on components

3. 3. a more accurate method of calculating thermal stresses due to temperature transients

4. 4. the inclusion of high cycle fatigue terms.

The creep relaxation problem was solved using stress reduction factors in an analytical in-elastic stress calculation. The stress reduction factors were produced for a number of common geometries and materials by means of non-linear finite element analysis. External loads were catered for by producing influence coefficients from in-elastic analysis of the particular piping system and using them to calculate bending moments at critical positions on the pipework from load and displacement measurements made at the convenient points at the pipework. The thermal stress problem was solved by producing a completely new solution based on Green's Function and Fast Fourier transforms. This allowed the thermal stress in a complex component to be calculated from simple non-intrusive thermocouple measurements made on the outside of the component. The high-cycle fatigue problem was dealt with precalculating the fatigue damage associated with standard transients and adding this damage to cumulative total when a transient occurred.

The site testing provided good practical experience and showed up problems which would not otherwise have been detected.     

Processing of Yttria-Alumina Coated Silicon Nitride Slips by Slip Casting

Si₃N₄powders coated with 6 wt% Y₂O₃and 4 wt% Al₂O₃were prepared by coprecipitation. The resulting powders were dispersed in water at different pH values and with addition of various amounts of ammonium polyacrylate (NH₄PA) to produce 32 vol% slips. The influence of the amount of NH₄PA solution added and pH on the rheological properties of 32 vol% coated Si₃N₄slips were studied. In addition, the sintered density of cast samples was determined and related to the degree of slip dispersion. The adsorption of the NH₄PA on the coated particle surface was rather high and the surface became saturated near 0.86 mg/m²at pH 9.2. High NH₄PA concentrations (1.7–3 wt%) were necessary to obtain well dispersed 32 vol% coated Si₃N₄slips at pH 9.2. The best stabilization was obtained with the addition of 2.3 wt% NH₄PA; in this condition, the viscosity reached a minimum value of 35 mPa.s at 100 s^–1. The slip viscosity increased with increasing pH from 9.2 to 10.2. Slips with low viscosities gave a more dense packing of cast samples and consequently higher sintered density values.     

工艺因素对金属封装外引线弯曲疲劳的影响

考察了金属封装外壳制造工艺对外引线弯曲疲劳的影响,发现电镀镍是导致外引线弯曲次数明显减少的最主要工艺步骤,且随镀镍层厚度的增加,弯曲次数减少。此外还讨论了外引线的氢含量和晶粒度对引线抗疲劳能力的影响。     

复相材料的循环变形行为

对三种组织状态的F-M复相钢进行了对称和非对称循环加载条件下的形变研究.结果表明,双相钢的循环变形行为,不仅与组织中位错组态的演变过程有关,同时也受循环载荷大小、类型以及加载方式所影响.分析表明,双相钢的循环硬化、软化行为主要受控于两个基本过程,即循环变形时位错组态演变的物理过程和相间分载应力的转嫁、相间残余应力变化的力学过程.     

重载齿轮齿面疲劳损坏及预防

点蚀和剥落是重载齿轮齿面疲劳损坏最普遍的形式.根据齿轮失效分析实例,对齿面初始点蚀、破坏性点蚀和齿面剥落等三种主要疲劳损坏的特征、发生部位及破损危害程度进行了分析研究,较系统地论述了齿轮接触疲劳破坏机理,影响因素及其产生原因,并对有关的齿面破坏提出了相应的预防措施.     

X60管线钢疲劳特性的研究

利用2、4和14mm的X60钢紧凑拉伸试样进行同样应力水平、固定应力比（R＝0．1）的疲劳裂纹扩展试验，揭示出高韧性管道钢的疲劳裂纹扩展存在显著的厚度效应。由于应力水平低，相应的离面应力也低，不足以导致分层开裂，因此，裂纹端部的三维应力约束随厚度增加而增大。4mm试样的疲劳裂纹速率远高于2mm试样，但厚度再增大，裂纹扩展速率不再有显著变化。进一步对表面裂纹试样进行疲劳裂纹扩展试验，并用勾线法纪录裂纹扩展情况，利用穿透裂纹的da/dN-ΔK曲线预测表面裂纹扩展，用2mm厚试样的数据控制裂纹表面长度的扩展，用14mm厚试样的数据控制裂纹底部沿厚度方面的扩展，得到了与表面裂纹扩展实验吻合很好的预测结果。     

The effect of a solid additive on rolling fatigue life

Behaviour of a series of lubricant oils and the effect of a non stoichiometric inorganic compound, as solid extreme pressure additive, on rolling fatigue life are studied using the rolling four-ball accelerated service simulation test proposed by Barwell and Scott. The results show, in all tested cases, the remarkable efficacy of this type of additive. The Total Acidity Number (tan) was found to increase with performance time for the case of the base lubricant, while for the oils with additives, it remained at its constant low value. This led to a proposal of a possible mechanism of the additive performance in the rolling process.     

Microscopic and Macroscopic Growth Rates of Fatigue Cracks in Steels and Alloys under the Influence of Crack Closure

On the basis of the experimental data, we show that the difference between the macroscopic and microscopic fatigue crack growth rates in the second section of the kinetic diagram of fatigue fracture is caused by the effect of crack closure within the limits of its existence. We establish the relationships between the macroscopic and microscopic fatigue crack growth rates and the structure of the material in the second section of the diagram for various values of the load ratio with regard for the effect of crack closure and propose a procedure of examination of the fracture processes in structural materials based on the analysis of microscopic and macroscopic fatigue crack growth rates.     

Effects of solidification structure on fatigue crack initiation and fatigue strength in Al−Si−Mg cast alloys

Rotating-bending uniaxial fatigue tests and micro-fatigue crack initiation tests were carried out using a permanent mold cast (PMC) and semi-solid die cast (SDC) with Al−7%Si−0.35%Mg composition in order to examine the relationship between solidification structures and fatigue behaviors. The crack length was measured using a replication method. Fatigue strength was improved in SDC, which was almost consistent with the predicted fatigue strength using the size of Si particle cluster. Resistance to fatigue crack initiation and fatigue strength were improved in SDC owing to the finer Si cluster and to higher ultimate tensile strength. Fatigue crack in PMC was preferentially initiated at pores. For SDC, the fatigue crack was initiated at the Si particle/matrix interface, and then sucessively grew along eutectic cell boundaries.     

基于相关性的人机系统可靠性模型

本文在剖析人机系统中操作者行为特征的基础上,考虑到操作者行为的自适应性、自学习能力及其行为形成主因子,着重结合操作者行为的相关性-感知作用于判断决策后影响到动作,建立了人机系统中操作者行为模式,并推导出计算操作者可靠度的公式,求出了相应参数.最后进行了实例量度,同时定量辨识了行为相关性对人可靠性的制约程度,以期从人机系统可靠性角度为人机系统的优化设计提供新的依据.