ITER 718合金螺栓断裂原因分析及工艺改进

通过化学成分检测、金相组织分析、氢含量的测定、断口的宏微观观察、大直径高强螺栓的原型件拉伸试验以及有限元分析等手段从材料、结构、制造工艺三个方面上探究了ITER 磁体支撑718 螺栓低强度断裂的原因。材料分析结果表明,国产718 螺栓材料的性能满足要求。工艺分析结果表明,螺栓低强度断裂的主要原因为滚压螺纹后的热处理导致螺纹根部脆性。结构分析结果表明,由于应力集中的影响,718 螺栓的强度低于原材料强度,而且随着螺栓直径的增大而降低。基于以上分析结论,提出了能显著提高718 螺栓强度的新工艺。通过原型件的拉伸试验,新工艺螺栓可以有效地提高螺栓的强度160MPa,达到1230MPa。     

基于Ansys的螺栓应力数值仿真及失效机理分析

针对某液氮输送管路低温工况下的螺栓断裂问题,首先进行了基于Ansys软件的应力仿真计算,对低温工况下螺栓的应力状态及分布等力学特性进行了分析。同时,采用宏观检测、微观检测和能谱分析、化学成分分析等方法,对螺栓断口进行了实效分析。结果表明,导致螺栓断裂的主要原因为应力腐蚀,断裂位置与Ansys仿真确定的最大应力区域相一致。     

核电堆内构件围板螺栓超声检测优化有限元仿真研究*

围板螺栓是核电堆内构件的关键紧固部件,典型的围板螺栓主要为外六角形式。在长期辐照和震动等恶劣环境服役过程中,其断裂韧性下降,脆性增加,最终导致螺栓退化开裂或断裂脱落,需要对其进行定期无损检测。然而由于其结构的复杂性,现有超声检测方法仍难以对其进行有效检测。为进一步提高超声检测方法对于围板螺栓内部缺陷的检测能力,针对堆内构件围板螺栓典型缺陷失效形式,通过有限元数值仿真技术开展适用于围板螺栓不同区域(螺栓过渡区域、螺杆区域和螺纹区域)的超声检测方法和工艺研究,对超声探头激励频率、晶片尺寸及超声波入射角度等进行优化,实现对不同区域15%缺陷横截面积占比的检测目标。为研发具有高度匹配性和高灵敏度的堆内构件围板螺栓超声传感器、实现对围板螺栓敏感区域的高精度检测提供理论指导。     

HL–2M装置真空室设计与分析

HL–2M装置真空室为D型截面,双侧薄壁为全焊接结构,内环直径为2m,外环直径为5.22m,环高3.02m,真空室由内壳、外壳、加强筋以及各种形式的窗口组成。整个真空室由20个扇形段焊接而成,材料采用Inconel 625、Inconel 718与316L组合形式。运用有限元法对真空室进行了结构强度评估,通过对危险工况进行分析计算得知真空室满足工程设计要求。     

微机化超声螺栓轴向应力仪的原理与误差分析

本文提出用沿轴向纵波声时差以测螺栓的轴向应力，推导了声时差与应力的关系．利用声时差测螺栓轴向应力，能克服耦会误差”“，同时还能克服温度引起的伸缩及波速变化的声时误差·本文还导出并且从实验上测出了，只与螺栓材料有关，而与螺栓的夹紧长度，直径，总长无关的常数，简化了测量过程．经实验测定，在夹紧长度大于30mm，应力低于240MPa时，应力最大误差小于±4MPa．本文还分析了声时，夹紧长度测量误差所导致的应力误差．     

螺栓强度的随机与模糊可靠性分析

螺栓结构的强度可靠性不仅与自身材料和结构有关，还与被连接件的材料和结构及承载状况有关。已有的螺栓结构设计基本都基于确定性分析的结果而进行，考虑不确定性因素的随机或模糊可靠性设计几乎没有，特别是模糊可靠性设计，目前还处于理论探索阶段。     

高体分SiC_p/Al复合材料螺纹性能的测试

从SiCp/Al复合材料性能分析着手,讨论了预置件法、焊接法和粘接法等在空间遥感器研制中常用的联接方法的优缺点,提出了在高体积分数(体分)SiCp/Al复合材料上直接加工螺纹,并加装钢丝螺套的方法来改善螺纹联接性能。对在某高体分SiCp/Al复合材料上加工的M4、M5螺纹进行了拉伸测试,结果表明:加装钢丝螺套前,复合材料螺纹有被拉脱现象;加装钢丝螺套后,M4螺纹、螺杆在3 000～4 000 N被拉断;M5螺纹、螺杆在8 000～9 000 N被拉断,测试后两种规格的螺纹状态良好,可以满足实际应用对该材料拉伸强度的要求,其已应用于工程项目中。     

高体分SiC_p/Al复合材料螺纹性能的测试

从SiCp/Al复合材料性能分析着手,讨论了预置件法、焊接法和粘接法等在空间遥感器研制中常用的联接方法的优缺点,提出了在高体积分数（体分）SiCp/Al复合材料上直接加工螺纹,并加装钢丝螺套的方法来改善螺纹联接性能。对在某高体分SiCp/Al复合材料上加工的M4、M5螺纹进行了拉伸测试,结果表明：加装钢丝螺套前,复合材料螺纹有被拉脱现象;加装钢丝螺套后,M4螺纹、螺杆在3 000～4 000 N被拉断;M5螺纹、螺杆在8 000～9 000 N被拉断,测试后两种规格的螺纹状态良好,可以满足实际应用对该材料拉伸强度的要求,其已应用于工程项目中。     

可折叠展开式伞状龙骨聚光器的聚光性能

针对可折叠展开式伞状龙骨聚光器具有自重低、功率高、比冲高、推力适中的特点,利用ANSYS和ZEMAX软件对功率为100 kW的可折叠展开式伞状龙骨聚光器在太空环境中的聚光性能进行模拟分析。在太阳风及衬底薄膜表面张力的影响下,伞面最大应力为1.66 MPa,远小于Kevlar材料及Ti-6Al-4V龙骨材料的阈值强度,伞面最大形变仅为0.941 mm,焦斑半径为6.37 cm,几何聚光比可达5 917,比标准抛物面仅减小了1.25%。结果表明:将材质轻、抗拉伸强度高的伞状龙骨结构引入可折叠展开式聚光器的设计方案,在很大程度上抵消了衬底薄膜材料表面张力及太阳风对聚光器工作形态的影响,可消除褶皱,提高可折叠展开式伞状龙骨聚光器的结构稳定性及可展开度,同时证明了伞状龙骨结构及Kevlar材料的选择是合理的。     

含有断裂缺陷的复合材料壳体的力学行为

利用湿法缠绕制备了玻璃纤维增强环氧树脂基复合材料壳体,通过拉伸、双悬臂梁和三点端部开口弯曲试验对该复合材料层合板进行基本力学性能评估,得到强度和刚度参数并用于有限元模拟中。同时,在Abaqus中建立了含有不同深度断裂缺陷复合材料壳体的三维渐进损伤有限元模型,预测内压作用下壳体的力学响应。试验和模拟结果表明:复合材料主向拉伸强度为(222.7±18)MPa,弹性模量为39.39 GPa,Ⅰ型和Ⅱ型断裂韧性层间强度分别为(4.67±0.24)和(4.98±0.26)kJ/m~2。随着内压增大,Mises应力也不断增大;当断裂缺陷在最深层(接近内压的第一层,深度为18 mm)时,Mises应力最大;当内压为0.3 MPa时,Mises应力高达28.8 MPa,且周向应变小于纵向应变。     

残余应力的超声横纵波检测方法

基于声弹性原理,研究板材厚度方向、螺栓轴向方向(以下简称z轴方向)宏观残余应力分布的超声无损检测方法。针对被测构件厚度不均匀对应力检测精度的影响非常大、检测原理繁杂不适合工程应用、拉伸实验中拉伸形变对应力系数测量精度的影响很大等问题,采取超声横波、纵波相结合的方法重新推导检测公式,并提出采用一发一收模式进行拉伸实验,通过对实验数据进行拟合,由公式计算出声弹性系数代替应力系数。然后结合插值、互相关等算法,采用VC++编制z轴方向残余应力超声检测软件并搭建检测系统。分别对性能为A2-70,4.8,8.8,长度依次为135 mm,100 mm,100mm的M20的螺栓进行拉伸实验,比对计算拉伸应力与检测拉伸应力,结果表明,该测量系统的绝对误差限为20 MPa,相对误差小于25%,且应力值较大时,相对误差有所减小,当应力值大于100 MPa时,相对误差小于5%,非常实用。      

纵横波测已紧固螺栓轴向应力

本提出了用纵横波声时测已紧固螺栓轴向应力的一种新方法,解决了用超声精确地测已紧固螺栓应力问题,并且利用超声波沿轴向传播的波速同轴向应力以及三阶弹性常数的关系导出了螺栓应力同其材料声速特性、夹紧距离、温度及纵、横波声时的一种新关系,考虑了受应力作用时温度对声速的影响,简化了测量及计算过程,本还介绍了材料的声速特性实验及测量方法;实验结果表明应力低于２５０ＭＰａ,夹紧距离大于３０ｍｍ时,应力超声测     

Characterizing and modeling the free recovery and constrained recovery behavior of a polyurethane shape memory polymer

In this work, tensile tests and one-dimensional constitutive modeling are performed on a high recovery force polyurethane shape memory polymer that is being considered for biomedical applications. The tensile tests investigate the free recovery (zero load) response as well as the constrained displacement recovery (stress recovery) response at extension values up to 25%, and two consecutive cycles are performed during each test. The material is observed to recover 100% of the applied deformation when heated at zero load in the second thermomechanical cycle, and a stress recovery of 1.5 MPa to 4.2 MPa is observed for the constrained displacement recovery experiments.After performing the experiments, the Chen and Lagoudas model is used to simulate and predict the experimental results. The material properties used in the constitutive model - namely the coefficients of thermal expansion, shear moduli, and frozen volume fraction - are calibrated from a single 10% extension free recovery experiment. The model is then used to predict the material response for the remaining free recovery and constrained displacement recovery experiments. The model predictions match well with the experimental data.     

ITER校正场底部线圈结构的有限元分析

采用有限元法(FEM)研究了ITER装置中超导校正场底部线圈 (BCC)结构的力学性能。针对BCC结构各组合部件三个方向尺寸的巨大差异,将BCC结构均匀化模型和局部细化模型分步组合,通过有限元分析获得了整体结构和薄弱部位各材料的位移场和应力场。针对BCC结构提出了支撑部位螺栓中预紧力的确定方法,用有限元法得出合理的螺栓预紧力,可用于指导BCC结构的安装。     

Comparison of microstructure and mechanical properties of ultra-narrow gap laser and gas-metal-arc welded S960 high strength steel

The microstructural characteristics and mechanical properties, including micro-hardness, tensile properties, three-point bending properties and Charpy impact toughness at different test temperatures of 8 mm thick S960 high strength steel plates were investigated following their joining by multi-pass ultra-narrow gap laser welding (NGLW) and gas metal arc welding (GMAW) techniques. It was found that the microstructure in the fusion zone (FZ) for the ultra-NGLW joint was predominantly martensite mixed with some tempered martensite, while the FZ for the GMAW joint was mainly consisted of ferrite with some martensite. The strength of the ultra-NGLW specimens was comparable to that of the base material (BM), with all welded specimens failed in the BM in the tensile tests. The tensile strength of the GMAW specimens was reduced approximately by 100 MPa when compared with the base material by a broad and soft heat affected zone (HAZ) with failure located in the soft HAZ. Both the ultra-NGLW and GMAW specimens performed well in three-point bending tests. The GMAW joints exhibited better impact toughness than the ultra-NGLW joints.     

聚氨酯改性TDE-85/ MeTHPA环氧树脂的力学性能研究

 采用自制的聚氨酯预聚体(PUP)制备聚氨酯(PU)改性TDE-85/ MeTHPA环氧树脂体系，探讨了聚醚二元醇(PPG)分子量的大小、PUP加入量等因素对PU改性TDE-85/ MeTHPA环氧树脂体系力学性能的影响。研究结果表明，PU改性TDE-85/ MeTHPA环氧树脂的拉伸强度和冲击强度随着合成的PUP加入量的增加先呈上升趋势，达到最大值后又开始下降。采用的PPG分子量不同，得到的改性材料的力学性能相差悬殊。当PPG分子量为1 000，PUP质量分数为15%时，改性材料的拉伸强度达到69.39 MPa，冲击强度达到23.56 kJ/m²，力学综合性能显著提高。     

Effect of matrix yield properties on fragmentation behavior of single fiber composites

Experimental and theoretical investigations have been conducted to study the dependence of fiber fragmentation behavior on matrix yielding properties. The cured Epikote 828 resins with two types of curing agents have almost similar elastic moduli, but different tensile yield strengths. The interfacial chemistry between fiber and epoxy resin is unchanged due to the same constituent of the epoxy resin. The experimental results indicate that the fragmentation behavior of the fibers embedded in the matrix is significantly different for the tested glass fiber treated by γ-glycidoxypropyltrimethoxysilane. The average fragment length decreased with increasing tensile yield strength of resin, which suggests that the interfacial shear strength determined in the fragmentation test should be different depending on the tensile yield strength of resin used. The important phenomenon observed is the transition of the micro-damage mode from matrix crack to interfacial debonding. An elastoplastic shear-lag model was used to calculate the shear stress and fiber tensile stress distributions considering different plastic behaviors of the matrices. The theoretical results indicate that the plastic behavior of the matrix has a large influence on stress transfer. Based on elastic and plastic properties of the matrix, the fiber fragmentation behavior in the matrix is predicted. Experimental and theoretical results are favorably compared.     

Bolt axial stress measurement based on a mode-converted ultrasound method using an electromagnetic acoustic transducer

A method is proposed to measure the stress on a tightened bolt using an electromagnetic acoustic transducer (EMAT). A shear wave is generated by the EMAT, and a longitudinal wave is obtained from the reflection of the shear wave due to the mode conversion. The ray paths of the longitudinal and the shear wave are analyzed, and the relationship between the bolt axial stress and the ratio of time of flight between two mode waves is then formulated. Based on the above outcomes, an EMAT is developed to measure the bolt axial stress without loosening the bolt, which is required in the conventional EMAT test method. The experimental results from the measurement of the bolt tension show that the shear and the mode-converted longitudinal waves can be received successfully, and the ratio of the times of flight of the shear and the mode-converted longitudinal waves is linearly proportional to the bolt axial tension. The non-contact characteristic of EMAT eliminates the effect of the couplant and also makes the measurement more convenient than the measurement performed using the piezoelectric transducer. This method provides a promising way to measure the stress on tightened bolts.     

预应力对熔石英损伤的影响

采用ANSYS进行形变-应力模拟。对不同应力状态下的熔石英表面进行三倍频激光损伤测试,结果发现,预加压应力为0~50 MPa时损伤阈值有明显提高的趋势,用应力耦合作用对此给出了解释:0~50 MPa的预加压应力可以降低和抵消激光辐照产生的张应力破坏,大于50 MPa预应力的耦合作用会使得该处机械性能下降,另外,损伤增长在预应力存在时更容易发生。因此,0~50 MPa预加压应力时的表面预应力可以提高熔石英的抗激光辐照能力。