大气预腐蚀下ER8C车轮钢的疲劳寿命评估

随着高速列车车轮服役里程的增加，车轮辐板持续遭受潮湿大气甚至海洋大气环境的考验，点蚀成为车轮失效的主要原因之一.论文首先在大气自然环境下对ER8C车轮钢高周疲劳试样开展为期180天的曝晒(预腐蚀)试验，随后进行表面形貌和疲劳性能表征.结果表明，预腐蚀后车轮钢的疲劳极限为387 MPa,相比光滑试样下降12%;这主要是由于预腐蚀造成的腐蚀坑使试样表面局部应力集中，加速了疲劳裂纹萌生.采用激光共聚焦显微镜统计预腐蚀试样表面蚀坑尺寸，使用由均值蚀坑尺寸计算得到等效初始缺陷尺寸(EIFS),对预腐蚀车轮钢试样的疲劳寿命进行预测，避免腐蚀疲劳裂纹萌生以及短裂纹扩展对疲劳寿命预测的影响；预测结果与实验结果较为符合，证明了该方法的可行性.论文的主要结论是，通过统计试样表面蚀坑尺寸的均值来获得EIFS的方法，可以计算得到大气预腐蚀后车轮钢的剩余寿命，这验证了EIFS方法在大气预腐蚀下材料疲劳寿命研究中的适用性.     

原始组织对ER9车轮钢滚动接触疲劳性能的影响

利用双盘滚动接触疲劳试验机对原始组织分别为片状珠光体+先共析铁素体(P+PF)和回火索氏体(TS)的ER9车轮钢试样进行滚动接触疲劳试验,并对结果进行了分析。结果表明:在油润滑条件下,原始P+PF试样的滚动接触疲劳寿命是TS试样的2.8倍.?其原因是原始的P+PF的试样表面存在厚约1?μm的机加工细晶层,而TS试样无明显细晶层,在疲劳过程中,P+PF试样会优先在细晶层内萌生浅层裂纹并平行于表面扩展形成浅层剥落,而后在细晶层剥落的区域萌生疲劳裂纹,而TS试样则直接在试样表面萌生疲劳裂纹.?经过1×105周次在空气中的预磨损后,两种不同原始组织的试样表面均被强化,滚动接触疲劳寿命均有大幅度的提升.?但由于P+PF试样预磨损过程中机加工细晶层的剥落以及产生了少量的疲劳磨损,部分疲劳磨损裂纹成为滚动接触疲劳裂纹的裂纹源,而预磨损后的TS试样的表层形成分布更为均匀的细晶层,故预磨损后的TS试样的滚动接触疲劳寿命远高于P+PF试样.      

两种激光熔覆涂层对轮轨材料磨损与损伤性能的影响

选用钴基合金粉末和铁基合金粉末，利用CO₂多模激光器对轮轨材料进行激光熔覆处理. 分析了钴基合金涂层和铁基合金涂层的微观组织、成分、硬度与应力状态. 未处理试样表面残余应力为拉应力，激光熔覆处理后，涂层表面残余应力为压应力. 利用MJP-30A滚动接触疲劳试验机对激光熔覆处理前后轮轨试样进行滚动摩擦磨损试验. 结果表明:激光熔覆处理后轮轨试样磨损率明显降低，其中激光熔覆钴基合金后，轮轨试样磨损率分别降低96.7%和98.9%，激光熔覆铁基合金后，轮轨试样磨损率分别降低81.7%和93.5%. 未处理轮轨试样表面损伤为疲劳损伤；钴基合金涂层表面损伤最轻微，磨痕表面光滑，出现轻微的小块剥落；铁基合金涂层表面出现细小裂纹和犁沟.      

超声冲击对铝合金搅拌摩擦焊接头超高周疲劳性能的影响

本文通过超声疲劳试验方法研究了超声冲击处理对两种铝合金(AA6061和AA7075)搅拌摩擦焊接头超高周疲劳行为(107~109周次)的影响。利用微观组织、显微硬度以及X射线衍等方法对表面处理技术对试样表层材料的作用进行了表征。结果显示,超声冲击处理可以在接头表面形成强化层,使疲劳裂纹源由试样表面转移至内部。对铝合金AA6061,接头处理前后疲劳强度差异不大,但可明显提高AA7075接头的疲劳寿命。最后,对疲劳裂纹萌生的特点和表面强化层以及残余应力对疲劳强度的作用机制进行了分析。     

HT250刹车盘气体渗氮耐磨性研究

为提高HT250刹车盘耐磨、耐腐蚀性,延长服役寿命,对其进行了气体渗氮表面强化处理.分别对基体和氮化试样进行了微观组织和物相分析,研究了销盘干摩擦的摩擦磨损行为,探讨了HT250渗氮试样的磨损机理.结果表明:采用530℃×10 h气体渗氮时,渗氮层深为0.3 mm,其表层硬度HV_(0.1) 1 140;在20、50和100 N载荷下,渗氮试样摩擦系数均高于基体试样,但磨损率分别降低了11.1%、27.5%和38.3%.基体试样以疲劳剥层磨损为主,伴随着磨粒磨损;渗氮试样以剥层磨损为主,渗氮层的残余压应力抑制了裂纹的扩展,提高了其耐磨性.     

预冷变形对Cu-Ni-Si铜合金疲劳性能和破坏行为影响研究

为了研究预冷变形处理对Cu-Ni-Si铜合金的疲劳性能和破坏行为的影响,对含有预冷变形处理和不含预冷变形处理的Cu-Ni-Si铜合金进行拉伸实验、疲劳实验、裂纹扩展实验等相关实验,并通过扫描电镜对试样疲劳断口进行观察。结果表明,预冷变形处理大幅提高了材料机械强度、降低了材料韧性,同时使疲劳强度降低,其中,107寿命对应疲劳强度下降4.7%。试样的疲劳破坏均萌生自表面的晶体滑移,预冷变形处理的试样在裂纹扩展阶段表现为穿晶破坏,而不含预冷变形处理的试样在裂纹扩展阶段表现为沿晶和穿晶的混合破坏模式。预冷变形处理试样在裂纹稳定扩展阶段,表现为剪切型破坏,而不含预冷变形处理的试样在裂纹萌生后,裂纹转向在最大拉应力面内扩展直到最终的破坏。由上述结果可知,预冷变形改变了Cu-Ni-Si铜合金的疲劳破坏行为,从而影响了其疲劳性能。     

服役后API 5L X56钢腐蚀疲劳裂纹扩展速率试验研究

为研究服役后X56双层海底管道钢的疲劳裂纹扩展速率,对外层管上截取的标准紧凑拉伸试样分别在空气和海水环境下进行不同最大疲劳载荷(P_max=9 kN,10 kN,12 kN)的疲劳裂纹扩展试验。与空气环境中CT试样的疲劳裂纹扩展速率相比,裂纹生长至15.38 mm时,9、10、12 kN载荷下海水环境中CT试样的疲劳裂纹扩展速率分别提高了1.82倍、1.54倍、1.43倍;随着裂纹扩展长度增大,外界载荷起主导作用,海水腐蚀的影响越来越小。综合分析最大疲劳载荷对疲劳裂纹扩展的影响,结果发现相同裂纹长度的前提下,疲劳载荷增加,应力强度因子幅值(ΔK)和疲劳裂纹扩展速率(da/dN)增加,海水腐蚀影响逐渐减小。疲劳裂纹扩展试验中所施加的最大疲劳载荷对CT试样的疲劳寿命具有较大影响,对Paris常数的影响较小。扫描电镜下CT试样的疲劳断口均为穿晶型断裂。海水环境中CT试样的疲劳断口表现出更多的二次裂纹和更高的撕裂脊。随着最大疲劳载荷增加,解理断裂形成的解理台阶晶面面积和高度差逐渐增大,疲劳断口越粗糙,解理特征越明显。     

模拟酸雨腐蚀预应力混凝土T梁重载交通疲劳性能研究

为了研究酸雨腐蚀环境下预应力混凝土T梁重载交通疲劳性能,对6根腐蚀预应力混凝土梁进行静载试验和等幅疲劳试验,利用显微镜观察钢筋疲劳断裂时的破坏形态,从而推出相应条件下钢筋破坏的几何模型。结果表明：腐蚀预应力混凝土梁的疲劳破坏以底部钢筋发生疲劳脆性断裂为标志;在疲劳加载过程中,预应力混凝土梁荷载-挠度曲线、混凝土、钢筋和钢绞线荷载-挠度曲线呈现“疏-密-疏”三段式变化;钢筋疲劳裂纹的发展规律与钢筋应变的变化相对应;相较于未腐蚀试件,腐蚀试件疲劳寿命降低了32.7%;疲劳上限值为0.45和0.6倍极限荷载时,预应力混凝土梁疲劳寿命均小于200万次,且相较于疲劳上限值为0.3倍极限荷载时分别下降69.3%、85.1%。     

磨损加疲劳载荷下的协同疲劳行为

自行研制的摩擦磨损装置与轴向疲劳试验机相互配合,实现GDL-1钢试样在疲劳应力(240~280 MPa)及接触载荷(30 N)作用下摩擦磨损疲劳试验.通过对磨损层厚度的分析,研究试样承受摩擦磨损载荷及拉压疲劳载荷双重作用下的疲劳寿命变化,用SEM扫描电镜观察分析次表层内疲劳裂纹扩展的演变过程,并采用Hertz线弹性理论和Smith接触理论计算分析摩擦表面以下切应力值.结果表明:在磨损疲劳载荷作用下,形变层的流变作用将显著影响疲劳小裂纹扩展方向,渐趋于切应力方向,从而提高试样疲劳寿命.在此基础上,建立了在摩擦磨损疲劳载荷下疲劳裂纹扩展模型.此外,计算可知在距表层深度0.03 mm处切应力最大,0.18 mm以内材料产生塑性变形,导致形变层的形成.     

焊接接头超高周疲劳实验研究

本文基于超声疲劳振动技术,设计了三种焊接接头试样(圆形对接焊接试样及其喷丸处理试样和板状十字焊接试样),并利用超声疲劳试验系统测定了其超高周疲劳性能,实验应力比为-1,频率20kHz,实验在室温条件下进行。实验结果表明,圆形对接焊接接头的疲劳性能高于板状十字焊接接头,喷丸处理能提高焊接接头的疲劳强度。将焊接接头的疲劳性能与对应形状的母材进行对比分析,发现焊接接头的疲劳性能远低于母材。在相同疲劳寿命的条件下,圆形焊接接头试件的疲劳强度仅为母材的45%,十字焊接接头试件仅为母材的29%;圆形对接接头在5×106周次以后,试件仍然发生疲劳断裂,而板状十字焊接接头在超高周区域(107～109周次)存在疲劳极限。超声疲劳断口的扫描电子显微镜分析结果显示,圆形焊接接头试件断口位置主要位于熔合区的焊趾处或焊接接头表面几何非连续处,十字接头试件断口位于焊趾处;焊接接头试件裂纹萌生于焊接缺陷、试样表面夹杂或熔合区的不连续处;喷丸处理对焊接接头的裂纹萌生机制没有显著影响。     

Residual stress distribution on surface-treated Ti-6Al-4V by X-ray diffraction

The x-ray diffraction technique has been used to measure surface residual stress in Ti-6Al-4V samples subjected to shot peening (SP), laser shock peening (LSP) and low plasticity burnishing (LPB). The magnitude, spatial and directional dependence and uniformity of the surface residual stresses have been investigated. The results show that residual stresses due to SP are uniform and independent of direction. LSP has been observed to produce non-uniform residual stress varying from one region to another, and also within a single laser shock. In the case of LPB, residual stresses have uniform spatial distribution but have been observed to be direction-dependent. Various components of the residual stress tensor in the LPB sample have been determined following the Dolle-Hauk method. The results of the residual stress due to three surface treatments are compared, and possible reasons for spatial and directional dependence are discussed.     

Grain boundary response of aluminum bicrystal under micro scale laser shock peening

Micro scale laser shock peening (μLSP) is a process in which compressive residual stresses are induced in a material surface to improve fatigue life and wear resistance under cyclic loading. Since the diameter of the laser spot used during the process is the same order of magnitude as grain size, the effects of anisotropy and heterogeneity have to be explicitly taken into account in any model of the process. In this study experimental and numerical studies have been performed in order to investigate the response of an aluminum bicrystal under laser shock peening. The grain boundary is shocked to investigate heterogeneity, and single crystals are shocked to study the effect of anisotropy in the absence of heterogeneity. The orientations of the crystals in the bicrystal as well as the reference single crystals have been chosen such that an approximate plane strain condition is achieved. A finite element model which accounts for the anisotropy, heterogeneity and inertia has also been developed based on single crystal micromechanics. Simulation results are compared with experimental findings. The potential benefit of μLSP as a surface treatment for improvement of fatigue life is also discussed.     

Parametric study on single shot peening by dimensional analysis method incorporated with finite element method

Shot peening is a widely used surface treatment method by generating compressive residual stress near the surface of metallic materials to increase fatigue life and resistance to corrosion fatigue,cracking,etc.Compressive residual stress and dent profile are important factors to evaluate the effectiveness of shot peening process.In this paper,the influence of dimensionless parameters on maximum compressive residual stress and maximum depth of the dent were investigated.Firstly,dimensionless relations of processing parameters that affect the maximum compressive residual stress and the maximum depth of the dent were deduced by dimensional analysis method.Secondly,the influence of each dimensionless parameter on dimensionless variables was investigated by the finite element method.Furthermore,related empirical formulas were given for each dimensionless parameter based on the simulation results.Finally,comparison was made and good agreement was found between the simulation results and the empirical formula,which shows that a useful approach is provided in this paper for analyzing the influence of each individual parameter.     

加弧辉光离子渗NiCr与喷丸强化复合处理对钛合金微动疲劳性能的影响研究

研究了钛合金表面加弧辉光离子渗NiCr层的相组合和分布,对NiCr渗 层进行喷丸形变强化后处理,以协同提高钛合金耐微动疲劳性能。研究结果表明：利用加弧辉光离子渗技术可以获得由Ni3Ti金属间化合物等组成的渗镀复合层,从而提高钛合金的表面硬度和耐磨性能;NiCr渗层的耐磨性能与喷丸强化引入的表面残余压应力协同作用,使钛合金经加弧辉光离子渗NiCr和喷丸形变强化复合处理后的耐微动疲劳性能较单一喷丸强化处理更好。     

Impact toughness of a gradient hardened layer of Cr5Mo1V steel treated by laser shock peening

Laser shock peening (LSP) is a widely used surface treatment technique that can effectively improve the fatigue life and impact toughness of metal parts. Cr5Mo1V steel exhibits a gradient hardened layer after a LSP process. A new method is proposed to estimate the impact toughness that considers the changing mechanical properties in the gradient hardened layer. Assuming a linearly gradient distribution of impact toughness, the parameters controlling the impact toughness of the gradient hardened layer were given. The influences of laser power densities and the number of laser shots on the impact toughness were investigated. The impact toughness of the laser peened layer improves compared with an untreated specimen, and the impact toughness increases with the laser power densities and decreases with the number of laser shots. Through the fracture morphology analysis by a scanning electron microscope, we established that the Cr5Mo1V steel was fractured by the cleavage fracture mechanism combined with a few dimples. The increase in the impact toughness of the material after LSP is observed because of the decreased dimension and increased fraction of the cleavage fracture in the gradient hardened layer.     

表面纳米化对316L不锈钢低周疲劳性能的影响

超声喷丸(USSP)处理工艺在316L不锈钢表面制备出了纳米表面晶层,对表面纳米化后和未表面纳米化的316L不锈钢试样进行对比拉拉低周疲劳试验,运用数理统计学的方法分析研究了表面纳米化处理对316L不锈钢的低周疲劳性能的影响,并就表面纳米化对疲劳性能的影响机理进行了初步分析探讨.研究结果表明,超声喷丸表面纳米化处理可以有效地提高316L不锈钢的低周疲劳寿命;超声喷丸处理在表面所形成的残余压应力、晶粒细化的纳米强化表层是疲劳寿命提高的主要原因.     

多次激光冲击导致的Ti17合金层裂

为研究激光冲击Ti17合金中厚样品的层裂特性和层裂阈值,对样品（厚5 mm）表面进行单点连续1~8次激光冲击,激光工艺参数为:频率1 Hz,脉宽15 ns,激光能量30 J,方形光斑4 mm×4 mm。采用白光干涉仪、超声波无损检测技术和扫描电镜,分析和检测中厚样品冲击区域的表面形貌、内部损伤以及层裂形貌。实验结果表明,连续从4次到5次激光冲击中厚样品的表面凹坑深度增加值最大为64.5%。连续5次激光冲击为中厚样品层裂阈值,层裂面积随冲击次数增加而增加。连续5~8次激光冲击中厚样品层裂厚度的实验值为280~310 μm。层裂机理为韧性微孔洞的形核、增长和汇合,形成晶界失效和晶内失效。研究结果可为激光冲击强化整体叶盘改性提供工艺参考。     

X-ray diffraction study of residual macrostresses in shot-peened and fatiqued 4130 steel

A study has been made of the effects of shot peening and fatigue cycling on the residual macrostresses determined by X-ray methods in an austenitized and tempered AISI 4130 steel (150–170 ksi). The results show that the effect of shot peening is to produce a residual compressive macrostress layer 0.014-in. deep. The residual-stress profile (stress vs. depth) exhibits a small negative stress gradient at and near the surface and a large positive stress gradient in the interior. Stress relaxation (due to fatique cycling) which occurred early in the fatigue history of the specimen was found greater at the surface than in the subsurface layers. Stress gradients of the stress profile increased with continued cycling and varied with depth. A correlation appears to exist between stress relaxation and stress gradients at the surface.