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.     

Evaluation of Residual Stresses Induced by Robotized Hammer Peening by the Contour Method

Welded components suffer from high tensile residual stresses close to the weld beads. These stresses seem to be the origin of premature cracking which could result in a catastrophic rupture during operation and a reduction of the lifespan of these components. In this context, the Hydro-Québec’s Research Institute (IREQ) developed a technique of residual stresses relaxation by robotized hammer peening which makes it possible to release stresses close to surface and preserve the mechanical and dimensional properties of manufactured components. Robotized hammer peening was used to induce compressive residual stresses on initially stress free samples of austenitic stainless steel 304L. Hammer peening layers from one to nine were performed and the resulting residual stresses were evaluated thanks to the contour technique. Complete 2D residual stress fields on samples cross sections were obtained. The ability of hammer peening to relax residual stresses within welded plates was then quantified on austenitic stainless steel 304L plates welded with a 308 steel and hammer peened. These tests show the efficiency of hammer peening as a method to relax tensile residual stresses and induce compressive ones to a depth of a few millimetres. Process parameters were optimized such as the number of hammer peening layers to be applied to reduce processing time and maximization of the intensity and spatial distribution of the compressive residual stresses.     

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.     

激光冲击修复后压力容器钢Q345R耐腐蚀及抗疲劳性能研究

对激光冲击强化后的压力容器材料Q345R钢的耐腐蚀性能和抗疲劳性能进行研究。通过电化学实验,并结合扫描电子显微镜分析其耐腐蚀性。结果显示,有吸收层保护和无吸收层保护激光冲击后,相较于原试样,耐腐蚀性分别提升5.8倍和2.6倍;微观实验结果表明经过激光冲击后腐蚀试样表面裂纹明显少于未处理试样。但随着冲击次数增加,耐腐蚀性有所下降。疲劳试验结果显示,相同应力条件下,腐蚀1和2 h的疲劳寿命相较于原试样降低36.8%和56.4%,经过一次或三次激光冲击后试件的疲劳寿命分别提升43.8%和198.2%,经XRD检测,激光冲击能在表面形成一定深度的残余压应力层并抑制裂纹扩展。     

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。     

航空薄壁弧形结构件喷丸强化变形预测

喷丸强化是一种有效提高工件抗疲劳性能的表面处理工艺，经喷丸强化处理后的航空薄壁弧形结构件发生变形是航空制造领域的共性难题．本文基于变截面曲梁平面弯曲理论，建立了弧形件喷丸诱导应力与变形方程，将得到的构件最大变形与有限元方法计算结果进行对比，所建立理论模型能有效预测弧形件喷丸强化后的变形．讨论了喷丸压力和喷丸区域对喷丸变形的影响，结果表明：喷丸强化工艺仅作用于弧形件腹板表面时，弧形件变形以径向收缩为主；喷丸强化工艺仅作用于弧形件筋板表面时，弧形件变形以径向扩张为主；与局部喷丸相比，对弧形件所有表面喷丸强化时，弧形件弯曲变形减小，轴向伸长增大．     

残余应力测定的围箍压痕法模拟

本文从同工量测方法得到启发，提出了一种新型的残余应力测试方法－围箍压痕法。采用轴对称弹塑性有限元计算模拟了围箍压痕法测量结构残余应力的力学过程，得到了围箍压痕时不同残余应力程度下材料的变形，塑性区和接触应力分布。     

汽轮机轮盘热处理残余应力分析

百万核电汽轮机红套低压转子工作环境的蒸汽参数较低,各级轮盘均处于湿度较大的工作区域,易产生应力腐蚀,引起裂纹萌生和扩展．为提高轮盘的抗腐蚀能力,降低工作应力是一个有效的方法．通过热处理方法,在轮盘表面形成预压应力以抵消部分旋转拉应力是可行的方法,而产生适当深度和大小的预压应力则需对热处理过程进行谨慎的设计．本文以汽轮机轮盘为研究对象,建立轴对称有限元模型,通过对ABAQUS软件的二次开发,实现对轮盘热处理过程的温度场及应力场进行数值模拟．计算综合考虑了非线性的材料热物性参数、力学性能参数、表面换热系数及不同材料组织转变的相变潜热、热物性参数和力学参数,通过对不同热处理方法得到的残余应力场的比较,获得了较合理的水冷方式,为热处理工艺确定提供参考．     

高速切削强化表面（HSMS）的摩擦学性能试验研究

借助X射线衍射应力分析仪、球-盘式滑动摩擦磨损试验机以及扫描电子显微镜等工具,考察了已加工表面的残余应力场与X射线衍射线半高宽分布特征,研究了高强度钢工件高速切削强化表面的摩擦学性能,探讨了强化表面的摩擦学性能与表面强化特征指标间的相关性.结果表明：合理的高速切削强化工艺能够有效提高高强度钢材料的滑动摩擦学性能;残余压应力场的作用深度是决定加工表面摩擦学性能的关键强化特征指标;位错密度增加和晶粒细化是提高强化表面耐磨性能的主要因素;高速切削强化表面的主要磨损机理为磨粒磨损、塑变磨损以及疲劳磨损等磨损机理.     

经不同表面改性处理的钛合金的微动疲劳和微动磨损行为对比研究

对比研究了钛合金微动疲劳(FF)和微动磨损(FW)失效行为,考察了表面喷丸强化和氮化等表面处理对钛合金微动疲劳和微动磨损性能的影响,探讨了钛合金微动磨损和微动疲劳性能的相关性.结果表明,钛合金微动疲劳和微动磨损损伤表面形貌特征相似;当微动位移幅较大、微动区发生整体滑动时,微动接触区磨损有利于延缓微动疲劳裂纹萌生;而在小位移幅、部分滑移情况下,局部磨损促进微动疲劳裂纹萌生.利用喷丸强化在钛合金表面引入残余压应力,可以在降低摩擦系数的同时,提高钛合金抗微动疲劳和微动磨损失效的能力;氮化处理后钛合金表面硬度提高,有利于改善其微动磨损性能,但表面韧性降低导致抗微动疲劳能力降低.因此,在提高表面硬度的同时,不应忽视表层韧性的降低对钛合金微动疲劳性能的不利影响.     

Influence of Residual Stresses Introduced by Shot Peening Upon the Fatigue Life of Materials

Strain hardening by shot peening is an operation which broadly increases the fatigue resistance of a mechanical part. This increase is particularly due to the compressive residual stresses induced in the surface layers of the material. This article demonstrates the resulting improved fatigue resistance of three types of mechanical parts (helical springs, chain links, and lifting hooks.     

Intralaboratory Repeatability of Residual Stress Determined by the Slitting Method

This paper presents repeated slitting method measurements of the residual stress versus depth profile through the thickness of identically prepared samples, which were made to assess repeatability of the method. Measurements were made in five 17.8 mm thick blocks cut from a single plate of 316L stainless steel which had been uniformly laser peened to induce a deep residual stress field. Typical slitting method techniques were employed with a single metallic foil strain gage on the back face of the coupon and incremental cutting by wire EDM. Measured residual stress profiles were analyzed to assess variability of residual stress as a function of depth from the surface. The average depth profile had a maximum magnitude of −668 MPa at the peened surface. The maximum variability also occurred at the surface and had a standard deviation of 15 MPa and an absolute maximum deviation of 26 MPa. Since measured residual stress exceeded yield strength of the untreated plate, microhardness versus depth profiling and elastic–plastic finite element analysis were combined to bound measurement error from inelastic deformation.     

X-ray diffraction study of the fatigue behavior of a shot-peened aluminum-lithium alloy

The effect of different shot-peening treatments on the cyclic fluctuating bending fatigue behavior of a new aluminum-lithium alloy (the 2091) has been investigated. The residual-stresses in-depth profiles have been defined just after the shot peening using mainly the X-ray diffraction method. To reach a given depth inside the material, the surface layer was removed by electro-polishing. The acquired data had to be then corrected in order to account for the redistribution of the stresses during the polishing. Furthermore, this alloy contains up to 15-percent intermetallic precipitates. Moreover, the X-rays penetrate deeply inside the material (23 m). For these reasons, a special procedure, based on a self-consistent micromechanical scheme, has been developed to correct the acquired data. The stress profiles obtained by this procedure are compared to those obtained by other mechanical experimental methods and those calculated by a theoretical shot-peening method. Shot peening improves the life of the material but the surface residual stresses are partially released during the first cycles of fatigue and are then quickly stabilized.Paper was presented at the 1994 SEM International Conference on Residual Stresses (ICRS4) held in Baltimore, MD on June 8–10.     

基于子模型法的带有表面裂纹钢丝应力强度因子研究

钢丝裂纹应力强度因子是进行钢丝疲劳断裂寿命评估、疲劳裂纹扩展分析和钢丝断裂强度评估等工作的重要参数。本文首先介绍了裂纹扩展分析软件FRANC3D,然后基于子模型法模拟研究了拉伸荷载作用下带有表面裂纹钢丝的应力强度因子,裂纹种类包括直线形裂纹和半圆形裂纹,最后拟合得到拉伸荷载作用下带表面裂纹钢丝的应力强度因子形状修正系数表达式,分析了利用该公式进行承载力评估时产生误差的原因。研究结果表明,利用子模型模拟分析拉伸荷载作用下带有表面裂纹的钢丝应力强度因子时计算精度高,计算速度快,对计算机硬件要求低;利用该方法得到的钢丝裂纹应力强度因子,在进行索承式桥梁吊索安全性能评估时,评估结果更精确。     

滚压强化的残余应力的数值仿真及工艺分析

表面滚压强化,由于在表层引起加工硬化和残余压应力,可以十分有效地提高构件、零件疲劳强度,而滚压强化的有限元数值仿真,将成为分析优化滚压强化工艺的重要手段.本文建立了连续多、圈滚压工艺的有限元数值仿真模型,获得了比较合理的滚压变形与残余应力结果.在此基础上对滚压工艺做了进一步分析.结果表明,滚压变形的进给量太大.滚压的转速太快都容易造成工件表层残余应力分布的不均匀甚至形成残余拉应力;在滚压与未滚压的过度区域,从表面到心部的近1mm范围内,均未出现人们通常所担心的残余拉应力.这将在工程生产实践中,为滚压工艺制订提供重要的依据.     

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.     

Dependence of stress intensity factors on elastic constants for cracks in an orthotropic bimaterial with a thin film

An interface crack and a subinterface crack in an orthotropic bimaterial structure consisting of a thin film and a half plane substrate are analyzed. The orthotropic bimaterial structure is subjected to compressive load and bending moment per unit thickness. Complete expressions of stress intensity factors for the two cracks are obtained based on the path independence of the J integral, apart from one dimensionless parameter undetermined each. The dependence of the dimensionless parameters on material constants is examined. A reduction of the number of necessary material parameters for the parameters is made based upon the modified Stroh formalism. The explicit dependence of the dimensionless parameters on one orthotropic parameter for the film is determined by using the orthotropy rescaling technique. Variations of the dimensionless parameters with the other material parameters are also obtained through numerical computations.     

基于多因素的焊接结构疲劳裂纹扩展速率分析

以Donahue等提出的疲劳裂纹扩展速率计算模型为基础,通过引入形状系数、张开比和残余应力等参数,建立了适用于焊接结构的疲劳裂纹扩展速率计算模型,分析了多种因素对焊接结构疲劳裂纹扩展速率的影响规律。结果表明,焊板厚度和焊缝余高的变化均会对焊接结构疲劳裂纹的扩展速率产生影响,在对焊接结构表面形状进行设计时应保有一定的焊缝余高;有效应力比的增大会降低焊接结构疲劳裂纹的扩展速率,且裂纹深度的变化不会改变有效应力比对焊接结构疲劳裂纹扩展速率的影响;残余应力的增大会提高焊接结构疲劳裂纹的扩展速率,且残余应力对疲劳裂纹扩展速率的促进作用随着裂纹深度的增加而增大,在对焊接结构的疲劳性能进行设计时须考虑残余应力对结构性能的影响。     

孔径尺寸对干涉配合铆接件超高周疲劳性能的影响

合理的干涉配合铆接工艺可以有效提高构件疲劳性能,本文通过试验研究与数值模拟相结合分析孔径尺寸对干涉配合铆接件超高周疲劳性能的影响。利用20kHz超声疲劳试验系统测试了三种不同孔径尺寸下干涉配合铆接件的超高周疲劳性能;基于ABAQUS模拟分析了铆接工艺过程以及孔径尺寸对干涉量和孔边残余应力的影响,通过分析高频低幅加载下孔边应力分布,结合超高周疲劳试验及断口形貌观察,分析了孔径尺寸对铆接件超高周疲劳性能的影响。结果表明:不同孔径尺寸铆接件的裂纹萌生扩展方式类似,疲劳裂纹萌生均发生在孔边距表面1.5mm最大残余拉应力处;适当减小孔径尺寸所形成的合理干涉量可以提高铆接件疲劳寿命,φ4.10mm的孔径可以形成0.66%的孔边平均干涉量,铆接件疲劳寿命最高达到3.63×108周。