位移幅值对铜镁合金微动磨损行为的影响

在研制的多功能微动磨损试验机上,开展了不同位移幅值下铜镁合金微动磨损试验,以研究位移幅值对铜镁合金微动磨损行为的影响. 微动过程中记录摩擦系数曲线与F_t-D-N曲线,利用光学显微镜(OM)、扫描电镜(SEM)、能量色散X射线光谱仪(EDS)及三维形貌仪对损伤区域进行了微观分析. 结果显示:随着位移幅值的增加,铜镁合金微动运行状态由部分滑移进入完全滑移,未发现混合滑移状态;部分滑移区中呈现由弹性变形协调逐渐向塑性变形协调转变的趋势. 磨损体积随位移幅值的增加而增加,在完全滑移区中体积损失非常严重. 在弹性变形协调的部分滑移状态下,接触表面损伤轻微,而由塑性变形协调的部分滑移状态下,接触中心出现较大切应力,疲劳裂纹扩展至接触表面导致材料剥落,接触边缘有磨粒磨损和氧化磨损的痕迹. 在完全滑移状态下,接触表面损伤主要为疲劳剥层,磨粒磨损和氧化磨损.      

粉末烧结钨合金材料的绝热剪切研究

在分离式霍普金森压杆装置上对斜圆柱粉末烧结钨合金试件进行了冲击实验,由于斜圆柱结构中剪切分量在冲击压缩中的持续作用,实验中观察到了宏观破断现象。利用光学显微镜和扫描电子显微镜分别对试件断面和试件的纵截面进行了分析,观察到了贯通钨颗粒的绝热剪切带这一变形局部化现象。对粉末烧结钨合金绝热剪切破坏机制进行了分析。     

乳、恒牙釉质及本质体外摩擦行为的对比研究

采用往复式滑动摩擦磨损试验考察了人体乳、恒牙牙釉质及牙本质在人工唾液润滑下的摩擦学性能.结果表明:人体牙的摩擦磨损行为同其微观结构密切相关;恒牙釉质磨痕表面存在轻微擦伤迹象;乳牙釉质的磨损表面主要呈现裂纹和轻微犁沟,二者都存在腐蚀磨损的现象;乳牙和恒牙本质的摩擦磨损行为相似,磨损明显加剧,磨斑表面呈现严重犁削和剥落特征.     

成分和组织对衬板钢在腐蚀料浆环境下的冲击磨损性能与机理的影响

利用改造后的MLD-10型冲击磨损试验机研究了3种冶金矿山湿磨衬板钢在铁矿石酸性矿浆中的冲击腐蚀磨损行为;采用扫描电子显微镜观察了试样磨损表面形貌,用光学显微镜分析了垂直于试样磨损表面的亚表层金相组织.结果表明:低碳高合金钢的耐冲击腐蚀磨损性能优于高锰钢及中碳合金钢;低碳高合金钢的冲击腐蚀磨损机制主要为挤出硬化棱剥落、轻微的腐蚀磨损及浅层疲劳剥落,高锰钢的主要冲击腐蚀磨损机制为较深层的累积变形疲劳剥落和严重的腐蚀磨损,而中碳合金钢的主要冲击腐蚀磨损机制为深层脆性剥落和严重的腐蚀磨损.     

Cu/Ni-P多层膜的制备及其摩擦学性能研究

用电沉积方法制备了软硬层交替的Cu／Ni-P多层膜，用原子力显微镜观察分析了多层膜的表面形貌，用X射线衍射仪测定了其相结构；采用动一静摩擦系数精密测量装置考察了多层膜的摩擦学性能和摩擦磨损机制；采用扫描电子显微镜观察分析了其磨损表面形貌．结果表明：Cu／Ni-P多层膜与钢球对摩时具有较好的抗磨减摩性能；在低载荷和低滑动速度下，多层膜的磨痕表面存在擦伤痕迹和较浅的犁沟；在高载荷下多层膜发生严重粘着磨损和剥落。     

D2高速车轮钢在滑动磨损下的白层形成与剥落

通过对不同转数滑动磨损后的D2高速车轮钢进行表面形貌和微观组织观察与分析,研究白层形成、发展与剥落过程以及他们之间的联系.结果表明:随着滑动磨损转数的增加,试块表面磨损方式由黏着磨损逐渐转变为磨粒磨损,同时在磨损表面形成纳米晶白层.该白层由铁素体纳米晶和极少量渗碳体小颗粒组成,其形成机制属于塑性变形机制.从横截面角度观察,白层的形成过程主要分为五个阶段:1)在磨损犁沟内出现月牙形塑性变形层,铁素体发生细化;2)磨损表面形成相对均匀的严重塑性变形层,渗碳体碎化成短棒状甚至是颗粒状;3)犁沟内形成厚度小于1μm的白层,其内组织为纳米级的铁素体和渗碳体小颗粒;4)犁沟内白层增厚成月牙形;5)相邻犁沟内的月牙形白层相互连接,厚度可达10μm.白层剥落过程如下:主要在脊缘处产生裂纹源,表面裂纹沿着与摩擦力成30°~45°方向向犁沟内扩展并交汇,在表层沿着白层与变形层交界处或白层内部扩展,最后使表层金属分层甚至出现金属薄片(含有白层)剥落.     

Cr4Mo4V轴承钢滚动接触疲劳和磨损性能研究

通过球棒滚动接触疲劳(RCF)试验机,研究了Cr4Mo4V轴承钢在4050润滑油润滑和0.18滑滚比条件下的滚动接触疲劳和磨损性能.结果表明:Cr4Mo4V钢的应力-寿命(S-N)曲线数据分散性较大,疲劳寿命随着应力增加呈下降趋势.Cr4Mo4V钢滚动接触磨损主要为磨料磨损,黏着磨损和疲劳磨损,随着应力和时间增加磨损体积增加,滚道凹槽深度达到17μm.通过光学显微镜(OM)和扫描电子显微镜(SEM)观察试样棒剖面与滚道交界处疲劳裂纹,发现疲劳破坏类型主要有两种:起源于表面的剥落(SOF)和起源于白蚀区的剥落(WSF).通过滚道径向切割抛光酸蚀显示Cr4Mo4V钢滚动接触疲劳影响区,随着应力和循环接触次数的增加,在次表层依次发现黑蚀区(DER)、白蚀区(WEA)和蝴蝶组织(BW).表面碳化物的剥落坑,黏着磨损和疲劳磨损的凹坑导致了表面起裂、白蚀区和蝴蝶组织中的碳化物和夹杂导致微裂纹的产生,链状碳化物使裂纹往深处扩展.     

等离子喷涂层接触疲劳失效模式及失效机理的研究

研究了等离子喷涂层在不同应力水平下的接触疲劳失效模式与声发射幅值的对应关系,并分析了涂层的接触疲劳失效机理.结果表明:声发射幅值与接触应力的大小无明显的关系,根据疲劳失效时的声发射幅值可以判断涂层接触疲劳失效模式,幅值为87～93 dB时易发生剥落或分层失效,幅值为78～83 dB易发生点蚀失效.涂层表面微凸体与轴承球滚压接触产生黏着磨损以及涂层、磨粒、轴承球三者形成的三体磨料磨损是点蚀失效产生的主要原因.剥落失效主要与涂层表面微观缺陷处裂纹的萌生、扩展以及表面磨损行为有关.层内分层失效是由涂层内部最大剪切应力控制的,而界面分层失效主要是由涂层与基体的低结合强度、热失配以及界面剪切应力造成的.     

690合金传热管在不同摩擦副条件下的微动磨损性能研究

采用MFF-3000电磁振动微动疲劳与磨损试验机，研究两种抗振条材料(退火405不锈钢和淬火回火06Cr13)对690合金传热管的微动磨损性能的影响，试验采用块/管线接触方式，即线接触. 试验结束后，采用OM、SEM、EDX和EPMA和三维光学显微镜对磨痕微观形貌和成分等进行分析，对比分析两种摩擦副的微动摩擦行为. 结果表明:当配副材料为405不锈钢时，690合金的磨损相对严重；工况相同时，06Cr13的磨损比405不锈钢严重，且405不锈钢的磨屑尺寸较小，06Cr13磨痕表面存在大量的剥层裂纹. 随着温度增加，磨屑增加，氧化程度加剧，磨损加剧，主要的磨损机制为磨粒磨损和剥层.      

轮胎磨损颗粒物形貌及产生机理的实验研究

采用自行设计的磨损试验机采集轮胎-路面摩擦副产生的轮胎磨损颗粒物,通过光学显微镜和扫描电子显微镜(SEM)分析和讨论了不同负载、速度和胎压工况影响下磨损颗粒物的表面形貌、粒度及磨损胎面形貌,建立了磨损颗粒物与胎面磨损形态的关系.结果表明:轮胎磨损颗粒物的粒度和数量类似正态分布,粒度主要集中在100~300μm.轮胎磨损颗粒物的主要产生机理是胎面疲劳剥落,形式主要为片状剥落和卷曲磨损共存,卷曲磨损会导致更多的磨损颗粒物脱离.载荷可使两种磨损形式的主导地位发生转变.接触界面应力提高会使团絮状胎面磨损颗粒物增多,速度增大会明显减小磨损颗粒物粒度.对小于10μm颗粒物来说,工况对其数量影响的主次顺序依次为速度、胎压和载荷.本研究可以为减少因轮胎磨损而导致的磨屑次生危害提供可供借鉴的理论指导.     

Delamination of an elastic film from an elastic–plastic substrate during adhesive contact loading and unloading

Adhesive contact between a rigid sphere and an elastic film on an elastic–perfectly plastic substrate was examined in the context of finite element simulation results. Surface adhesion was modeled by nonlinear springs obeying a force-displacement relationship governed by the Lennard–Jones potential. A bilinear cohesive zone law with prescribed cohesive strength and work of adhesion was used to simulate crack initiation and growth at the film/substrate interface. It is shown that the unloading response consists of five sequential stages: elastic recovery, interface damage (crack) initiation, damage evolution (delamination), film elastic bending, and abrupt surface separation (jump-out), with plastic deformation in the substrate occurring only during damage initiation. Substrate plasticity produces partial closure of the cohesive zone upon full unloading (jump-out), residual tensile stresses at the front of the crack tip, and irreversible downward bending of the elastic film. Finite element simulations illustrate the effects of minimum surface separation (i.e., maximum compressive surface force), work of adhesion and cohesive strength of the film/substrate interface, substrate yield strength, and initial crack size on the evolution of the surface force, residual deflection of the elastic film, film-substrate separation (debonding), crack-tip opening displacement, and contact instabilities (jump-in and jump-out) during a full load–unload cycle. The results of this study provide insight into the interdependence of contact instabilities and interfacial damage (cracking) encountered in layered media during adhesive contact loading and unloading.     

接触应力对轮轨材料滚动摩擦磨损性能影响

利用MMS-2A型微机控制摩擦磨损试验机研究了接触应力对轮轨材料的滚动摩擦磨损性能影响.结果表明：随接触应力的增加,滚动摩擦系数呈增加趋势,车轮和钢轨试样磨损加剧;相同接触应力水平下,车轮试样磨损量大于钢轨试样,表面损伤严重;随接触应力的增加,车轮试样表面从犁沟且轻微剥落向严重剥落损伤转变,钢轨试样表面损伤主要表现为犁沟效应并伴随有剥落现象,但相比车轮试样的剥离损伤要轻微.     

列车车轮滚动接触疲劳裂纹评价研究

列车车轮踏面表层金属滚动接触疲劳是影响列车运行安全性和舒适性的核心科学问题. 借助金相显微镜、扫描电镜、透射电镜和显微硬度计，通过开展列车车轮材料的标准滚动接触疲劳试验，将标准接触疲劳样品的损伤行为与实际服役车轮的损伤行为对比分析，研究了列车车轮的滚动接触疲劳裂纹评价方法. 结果表明:车轮表层金属接触疲劳开裂是表层金属累积塑性变形损伤的结果；标准滚动接触疲劳样品剥离坑的深度恰好等于硬化层的深度，实际服役车轮剥离坑的深度小于硬化层的深度；将车轮表面的滚动接触疲劳裂纹命名为“三角形指向性裂纹”；初步建立了车轮表面滚动接触疲劳损伤程度的定量评价方法.      

Surface Residual Stress Measurement Using Curvature Interferometry

Surface roughness plays an important role in the delamination wear caused by rough surface contact. A recent dislocation model analysis predicts that nano-scale contacts of surface steps induce nucleation of dislocations leading to pro-load and anti-load dislocation segregation near the contact surface. Such dislocation segregation generates a sub-layer of tensile residual stress in a much thicker layer of compressive residual stress near the surface. The tensile sub-layer thickness is expected to be about 50 to 100 times the step height. In order to verify the predictions of the model analysis, contact experiments are carried out on polycrystalline aluminum surface to determine the existence of the tensile sub-layer. The variation of the residual stress along the thickness direction is measured using a newly developed high sensitivity curvature-measurement interferometer. The residual stress distribution measured with sub-nanometer spatial resolution indicates that contact loading leads to formation of a highly stressed sub-layer of tensile residual stress within a much thicker layer of compressive residual stress. Implications of tensile residual stress for delamination wear are discussed.     

A novel technique for time-resolved detection and tracking of interfacial and matrix fracture in layered materials

A novel experimental technique is developed for time-resolved detection and tracking of damage in the forms of delamination and matrix cracking in layered materials such as composite laminates. The technique is non-contact in nature and uses dual or quadruple laser interferometers for high temporal resolution. Simultaneous measurements of differential displacement and velocity at individual locations are obtained to analyze the initiation and progression of interfacial fracture and/or matrix cracking/delamination in a polymer matrix composite laminate system reinforced by graphite fibers. The measurements at multiple locations allow the speeds at which interfacial crack front (mode-I) or matrix cracking/delamination front (mode-II dominated) propagates to be determined. Experiments carried out use three-point bend configurations. Impact loading is achieved using a modified Kolsky bar apparatus with a complete set of diagnostics for load, deformation, deformation rate, and input energy measurement. This technique is used to characterize the full process of damage initiation and growth. The experiments also focused on the quantification of the speed at which delamination or damage propagates under primarily mode-I and mode-II conditions. The results show that the speed of delamination (mode-I) or the speed of matrix cracking/delamination (primarily mode-II) increases linearly with impact velocity. Furthermore, speeds of matrix failure/delamination under primarily mode-II conditions are much higher than the speeds of mode-I crack induced delamination under mode-I conditions.     

三体介质温成形界面接触换热特性的试验研究

温成形摩擦界面模具与工件之间的传热特性对工件质量和模具寿命有重要影响,固体粉末介质导入该摩擦副可实现高温润滑,但其传热特性与传统加工方式的有很大不同.采用稳态法自行设计了三体界面的传热特性试验,研究和分析了界面温度、接触载荷、层厚对带有石墨粉和氧化铝粉润滑层的H62铜合金和45钢之间的三体界面接触换热系数的影响.结果表明:带有石墨粉润滑层的三体界面接触换热系数随温度的增加先升高后降低,随载荷和层厚的增加先缓慢增加后迅速增加;带有氧化铝粉润滑层的三体界面接触换热系数随温度的变化缓慢升高,与载荷基本成线性关系,随层厚的增加而降低.温度改变了固体润滑剂的材料热阻和上下试样表面硬度及氧化层厚度,载荷改变了三体界面实际接触面积和接触属性,层厚决定能否完全隔开上下试样,不同物性固体润滑剂决定了其材料热阻在三体界面接触热阻中的主次关系.     

From Damage to Delamination in Nonlinearly Elastic Materials at Small Strains

Brittle Griffith-type delamination of compounds is deduced by means of ??-convergence from partial, isotropic damage of three-specimen-sandwich-structures by flattening the middle component to the thickness 0. The models used here allow for nonlinearly elastic materials at small strains and consider the processes to be unidirectional and rate-independent. The limit passage is performed via a double limit: first, we gain a delamination model involving the gradient of the delamination variable, which is essential to overcome the lack of a uniform coercivity arising from the passage from partial damage to delamination. Second, the delamination gradient is suppressed. Noninterpenetration- and transmission-conditions along the interface are obtained.     

The effects of bridging in a 3D composite on buckling, postbuckling and growth of delamination

Summary Buckling and postbuckling solutions to circular delamination constrained by transversal restoring forces, which occur extensively in stitched or woven composites with three-dimensional (3D) reinforcement, are obtained by using von Karman's geometrically nonlinear thin plate theory by means of Taylor's series expansion. The through-thickness tows are assumed to provide continuous and linear restoring tractions, opposing the deflection of the annular delaminated region adjacent to a penny-shaped crack. When the end of the delaminated layer is clamped, and the deflection is permitted in the positive direction of the z-axis only, there exists a characteristic delamination radius a _* for initial buckling. In the case that the initial delamination radius a ₀ exceeds a _*, it will consist of waves whose sizes decrease gradually, as they are apart from the delamination center with larger distances, and will usually not span the whole crack region. Therefore, buckling profiles can be divided into two types: (1) lacking contact phenomena between the delaminated layer and the base plate; (2) having contact surfaces inside the delamination region. In this paper, growth laws of buckling, postbuckling and growth of delamination at lacking contact surface are discussed. The corresponding stability of the delamination growth under fixed boundary load is studied, and the dependence of stable scope upon the fracture toughness of the composite and the elastic constant of bridging fiber is summarized. It follows from the analysis that bridging can increase the load-bearing capacity of composite structure, improve its mechanical performances and restrain the growth of delamination. Received 23 November 1998; accepted for publication on 13 January 1999     

Non-linear behavior of delaminated unidirectional sandwich panels with partial contact and a transversely flexible core

The paper presents the results of an investigation of the non-linear behavior of delaminated sandwich panels with a compressible core. The delaminated zone, at one of the face-core interfaces, consists of through-the-width crack, which is free of shear stresses but is capable of accommodating partial contact with compressive stresses only within the debonded zone. The governing non-linear equations along with the appropriate boundary conditions and the continuity conditions are derived through variational principles. The governing equations include moderate deformations type of kinematic relations, and include the high-order effects due to the transverse flexibility of the core. The governing equations along with the stress and displacements fields for the core and the appropriate continuity conditions are presented. The effects of the non-linear response and the partial contact are described through some numerical cases of three points bending typical sandwich panels with inner delaminations in the vicinity of a concentrated load, in the vicinity of a stiffened core and, finally, far from the load. Numerical results in the form of displacements, bending moments, shear stresses in the core and vertical interfacial normal stresses at the upper and lower face-core interfaces along the panel length and at the delamination crack tips are presented. Buckling curves of load versus various extreme structural parameters are included. The analyses show that a full contact type of delamination transforms into a partial contact area with buckling of the compressed face sheet, as the load is increased and it is associated with extreme large displacements and stresses.