热障涂层界面微区域热蠕变应力演化分析

热障涂层热循环载荷下不同界面层蠕变特性是影响界面微区域残余应力变化的关键因素,探究热障涂层蠕变与残余应力的关系有助于提高热障涂层的稳定性。以热弹塑蠕变理论为依据,采用Norton蠕变模型,建立陶瓷层、氧化层、粘接层和基体四层几何分析模型,考虑不同层蠕变和蠕变程度因素,研究热循环载荷作用下涂层界面微区域应力演化规律。结果表明,蠕变参数和蠕变层数的变化影响热障涂层界面残余应力的大小和分布,这对预测热障涂层失效具有指导意义。     

热障涂层氧化残余应力大小与演化过程测试

热障涂层是一种应用广泛的提高高温部件工作效率的技术,在通常的涂层中,粘结层起到过渡和保护基体氧化的作用,在高温环境下,粘结层会发生氧化,而氧化产生的残余应力将引起热障涂层的损伤,表现为涂层的屈曲、起裂和剥落,导致热障涂层失效。研究测试和检测涂层的残余应力,对于评估涂层的安全性和寿命是非常重要的。本文用应力引起光学频谱位移的方法测试了空气等离子喷涂热障涂层中残余应力的大小及分布,并测试了残余应力的大小随氧化时间的演化过程。     

热障涂层弹性模量和残余应力测试研究

采用数字图像相关法实验研究了热喷涂制作的热障涂层的弹性模量和残余应力。首先,采用三点弯测试方法对热障涂层试件进行加载,并利用二维数字图像相关方法对热障涂层试件加装过程中的弯曲变形进行了精确的测量,进而获得了热障涂层在受拉和受压两种状态下的弹性模量,结果表明,受拉时热障涂层试件陶瓷层的弹性模量为31GPa,而受压时其弹性模量为34GPa。其次,基于内力平衡,推导了考虑曲率变化的涂层残余应力计算公式;利用三维数字图像相关法测量了喷涂前后基体曲率的变化,进而获得了涂层残余应力的大小,结果表明,热喷涂后的热障涂层残余应力为压应力,大小为-86^-70MPa。     

热障涂层力学性能的实验测试方法研究进展

涂层-基体体系作为高温热障防护结构被广泛应用于航空、航天、核反应堆等涡轮发动机叶片上, 主要作用是抵抗高温燃气, 保护基体材料. 在服役过程中, 涂层过早出现开裂、脱粘等失效行为直接影响发动机的安全性和可靠性. 长期以来, 热障涂层力学性能的实验测试方法是国内外研究者关注的重点. 首先分析了导致热障涂层失效的失配应力的来源, 重点介绍了热障涂层力学性能研究的实验测试方法、仪器和针对界面脱粘检测的红外热像技术, 接着概述了热障涂层寿命预测方法, 最后分析当前研究中存在的问题, 并对未来的发展的一些方向和有待于进一步研究的问题作了总结.     

SMA复合材料在热载条件下的残余应力分析

本文基于三相复合圆柱模型发展了增量型的分析方法,讨论在ＳＭＡ复合材料中由于ＳＭＡ材料相变以及各相材料热特性随温度变化引起的残余应力。研究基体与过渡恸介面和纤维与过渡界面间的残余应力,同时讨论由于基体相的变化对残余应力的影响。特别研究了涂层和复合材料基体间界面处的残余应力受纤维体积比、涂层厚度、纤维最大相变应以及基体中纤维取向等影响,而且讨论了计及应力对相就运动方程的影响时对ＳＭＡ复合材料相变温度和     

基于圆筒模型的热障涂层安定分析

热载荷作用下,由于热障涂层(thermal barrier coatings, TBCs) 各层材料的热不匹配以及材料参数的温度相关等因素,会使热障涂层界面区域存在复杂的应力应变场,影响系统安定性,并导致涂层开裂和剥落. 将热障涂层外凸和内凹微观界面结构简化为多层圆筒模型,借助经典机动安定定理,利用特雷斯卡(Tresca) 屈服准则和增量破坏准则处理对时间的积分问题,避免了常规安定性分析的数学规划问题,建立了热障涂层安定极限分析方法,将材料屈服强度随温度变化关系简化为双线性关系,利用补偿变换的方法简化求解过程,对典型热障涂层安定性进行了研究. 结果表明,利用基于圆筒的安定极限分析方法,能够方便求解安定极限,便于工程应用;热障涂层安定极限值明显高于弹性设计值,且界面外凸区域安定极限高于内凹区域极限值,结构首先在内凹处失效;圆筒模型基体曲率和涂层厚度越大,结构安定极限越高,分析结果与试验结果一致;所建立的热障涂层安定分析方法,对进一步研究考虑蠕变因素影响的热障涂层安定性具有重要意义.      

颗粒增强复合材料中微观热应力和残余应力分析

运用空间配位体密堆模型和球对称分析单元，分析计算了颗粒增强复合材料经历温度变化后产生的微观热应力和残余应力。分析结果表明，温度升高时界面产生径向张应力，降温时产生压应力。存在一个基体开始发生塑性变形的临界温差ｔ＿ｐ，其值随增强体体积分数Ｖ＿ｐ增加而降低。除组元间热膨胀系数差和弹性常数外，基体材料本构关系和屈服强度对热应力和残余应力均有很大影响。随Ｖ＿ｐ增加，微观应力和水静宏观应力幅值上升。但粒子周围塑性区尺寸近似与Ｖ＿ｐ无关。给出了不同变温条件下残余应力的确定方法。     

耐磨胶粘涂层固化残余应力的测试分析

将多根电阻丝平行于界面预埋在耐磨涂层中不同深度处，通过半桥电路测定了相应深度处涂层的固化残余应力。结果表明，紧接界面处耐磨胶粘涂层的残余应力最高，自界面开始处外约０．５ｍｍ层厚范围内的残余应力逐渐减小，可见涂层的固化残余应力主要来自底材表面对其固化收缩的阻碍效应。用适量的橡胶增韧是减小耐磨胶粘涂层固化残余应力的可行途径。     

用显微云纹干涉法研究SiC/Ti-15-3界面热残余应力场

SiC/Ti-15-3复合材料基体与增强体之间的热膨胀系数存在显著差异。在复合材料制造过程中经高温冷却后,在基体与增强体的界面会产生热残余应力场。此残余应力场对复合材料的力学性能会产生重要的影响。本文运用纤维推出法推出部分SiC纤维后,采用显微云纹干涉法在细观尺度研究了上述界面处的热残余应力,得到了分辨率较高的云纹图,并由此计算出了孔边处的残余应力。用有限元软件对界面热残余应力进行了数值模拟分析。实验结果表明,显微云纹干涉法可以用来测量直径为0.1 mm左右的纤维界面附近的残余应力场,在此尺度下,使用显微云纹干涉法比用电子束云纹法更方便。     

干摩擦条件下3Cr13 涂层的加速磨损机理研究

在MM200摩擦磨损试验机上对高速电弧喷涂3Cr13涂层在干摩擦条件下的加速磨损机理进行了研究.涂层在加速磨损过程中经历了跑合磨损、稳定磨损、剧烈磨损这三个不同的阶段.采用扫描电镜、X射线衍射仪、显微硬度仪和纳米压痕仪对涂层磨损各阶段的截面形貌、残余应力、硬度和纳米力学性能进行了表征.结果表明:在加速磨损寿命3个阶段中,涂层的磨损机制和影响残余应力的主导因素是动态变化的,过分的冷作硬化加剧了涂层的失效,涂层磨损寿命长短关键在于稳定磨损时间的长短.     

Stress intensity factors and crack initiation directions for ceramic/metal joint

Four points bending tests for Si₃N₄/Cu/S45C joint specimen showed that the bending strengths depend on the residual stresses that originated from joining process. The residual thermal stresses caused an edge sub-interface crack to initiate in the ceramic. The stress intensity factors (SIFs) of the edge sub-interface crack located at distance h from the interface with or without interlayer metal were calculated by the Green's function obtained from a finite element analysis. The crack path at the joint specimen under four points bending loading with the influence of residual stresses was also evaluated by the maximum tensile stress criterion. Finally the effect of residual stress on the crack path was found numerically; the interlayer metal decreases the deflection angle of crack from interface by reducing the residual stress.     

Thermo–elasto–plastic stresses in functionally graded materials under consideration of the fabrication process

Summary  The present study analyzes elasto–plastic thermal stresses in some particle-reinforced functionally graded material plates (FGP) by taking into consideration residual stresses of the fabrication process. For the FGP, the region near the cooling metal surface consists of distributed ceramic particles in a metal matrix, while the region near the heating ceramic surface contains distributed metal particles in a ceramic matrix. We use the thermo–elasto–plastic constitutive equation of a particle-reinforced composite, taking into consideration temperature changes and damage as well as the reinforcing effect of particles. Elasto–plastic thermal stresses are discussed here with the goal of reducing the thermal stresses. Two kinds of particle-reinforced FGP are considered: the first kind (FGP1) represents distributed ceramic particles in the metal matrix, and the second one (FGP2) represents distributed metal particles in the ceramic matrix. We modify the thermo–elasto–plastic constitutive equation of a particle-reinforced composite for the FGP2 by taking into consideration temperature changes and damage as well as the reinforcing effect of particles. Using the temperature-dependent material properties, three cases of temperature conditions are studied. The first one is the cooling from the fabrication temperature to the room temperature, the second one is the heating from the room temperature, and the last one is the heating after cooling from the fabrication temperature. The particle volume fraction is assumed to vary according to a power function in the thickness direction of the FGPs. Using the finite element method, the effects of the distribution parameter of the composition on the macroscopic stress, the stress in the matrix and the stress in the particle in the FGPs are discussed. Also, the effects of the particle volume fraction and the fabrication temperature on the maximum tensile matrix stress are discussed. Received 22 November 2000; accepted for publication 24 April 2001     

A numerical and experimental investigation into residual stress in thermally sprayed coatings

This paper is concerned with an investigation into the thermal spray process and is particularly concerned with the residual stresses that arise when a steel-alloy coating is sprayed onto a copper-alloy substrate. This material combination was used recently to enhance the thermal and mechanical efficiency of the pressure die casting process. A difficulty with the spraying of steel on copper is the attainment of appreciable thickness of the coating due to debonding during the thermal spraying process. Prominent among possible causes of debonding is residual stress, which is the focus of the research presented in the paper. An investigation into the thermal spray process is performed using experimentation, simplified numerical modelling and finite element modelling. The development of residual stress for a range of process parameters, i.e. deposited layer thickness, interval of layer deposition and the number of layers in a coating (i.e. block deposition versus multilayer deposition for a desired coating thickness) is recorded. The results from the three investigation methods agreeably indicate a progressive change in average interfacial residual stress from compressive towards tensile with increase in thickness of deposited layer; and a tensile interfacial stress in a two-layer coating, which increases with increase in interval of deposition between the two layers. On the whole, the observations from the results suggest an increase in potential for coating debonding with increase in both deposited layer thickness and layer deposition interval. The results further suggest higher potential for coating debonding with block deposition compared to multilayer deposition for a desired coating thickness.     

Thermal stresses in functionally graded materials caused by a laser thermal shock

 Mathematical simulation of a thermal shock method for reliability testing of functionally graded material (FGM) is performed with the end to determine operating parameters of the testing device (power of a laser, laser beam radius, duration of heating) and to investigate the effect of the composition of FGM on a magnitude of thermal stresses in a coating. An analytical method for solution of the thermal elasticity problem is developed whereby the approach of a multilayer plate is used for determining temperature and thermal stresses distributions in a coating. We considered the limiting case of the obtained solution when the thickness of a layer is infinitesimally small and the number of layers tends to infinity. This procedure allowed us to obtain the thermal stresses distribution in a FGM coating. The results for the FGM coating composed of WC (tungsten carbide) ceramics and HS-steel are presented. It is showed that variation of the volume content of ceramics strongly affects thermal stresses in a coating and they decrease significantly in the case of the uniform spatial distribution of ceramics. Received on 21 November 2000 / Published online: 29 November 2001     

应用增量理论考虑应变硬化效应包辛格效应和温度对机械性质影响的自增强厚壁圆筒分析

本文提出的采用增量理论的分析模型和方法可以定量分析应变硬化、包辛格效应和材料机械性质随温度变化等因素对自增强厚壁圆筒中残余应力和操作应力分布的影响.厚壁圆筒看成由N个同轴薄壁圆筒套在一起组成的构件;采用包括弹性、塑性和温度应变的增量型本构关系和相容条件导出了自增强圆筒的基本方程;设计了计算机程序并给出了分析实例。分析结果表明,应变硬化会减小塑性区并降低残余应力;包辛格效应使反向屈服容易出现;温度升高将使残余应力和热应力松驰.     

Residual Stress-Related Common Intersection Points in the Mechanical Behavior of Ceramic Matrix Composites Undergoing Cyclic Loading

The mechanical response of SiC-fiber reinforced barium osumilite ceramic matrix composites tested in tension with unloading/reloading cycles was very recently reported to exhibit self-assembling common intersection points (CIP) of unloading/reloading loops in the tensile domain which relate exactly to the thermal residual stress state of reinforcing fibers in a matrix of a lower coefficient of thermal expansion (Dassios et al. Compos A: Appl Sci Manuf 44:105–113, 2013). Knowledge of the experimentally-exact residual stress state enables, herein, examination of the validity of the conventional compliance-based methodology for indirectly calculating residual stresses from projected/extrapolated CIPs. The efficiency of two prominent residual stress prediction models is also tested across the experimentally-established value of thermal residual stress (TRS). The significance of the CIP as the TRS-free origin of the stress-strain curve is discussed in view of the importance in calculating accurate material property values from mechanical testing data of materials under residual stress.     

涂层/基体体系的界面应力分析

针对热防护涂层的承载特征,建立了涂层、基体体系的平面应变模型.以均匀应变差比拟热膨胀失配,基于最小功原理,推导了完整涂层/基体界面应力的级数解.分析结果表明,在自由端面附近,界面应力集中明显,其峰值达到了与涂层内拉应力相当的量级.涂层膨胀或收缩,界面正应力分别呈现压应力或拉应力状态,界面剪应力也发生方向交变.     

复相陶瓷中颗粒桥联与相变协同增韧作用的力学分析

本文对复相陶瓷内延性金属颗粒和相变颗粒的协同增韧作用进行了力学分析，其中颗粒桥联效应还考虑了桥联颗粒与基体间工艺残余应力的影响，相变效应考虑了相变体膨胀和剪切塑性对增韧的共同贡献。数值计算结果与Ａｍａｚｉｇｏ－Ｂｕｄｉａｎｓｋｙ的结果及２Ｙ－ＴＺＰ／２０ＶＯＬ％Ｎｉ的实验结果作了比较。