工艺过程对固体氧化物燃料电池材料力学性能的影响

固体氧化物燃料电池在生产过程中采用不同的加工手段,加工过程会产生一定的损伤,同时材料烧结过程产生比较大的残余应力,这些因素都会影响电池的使用寿命和完整性.本文通过实验测试,研究了不同加工过程对材料性能的影响,其中包括直接冲剪,激光切割以及切割后研磨等方法,并测试了这些加工手段对应的试件的强度.结果显示,直接冲剪法造成性能的分散性比较大,激光切割的性能较好,而研磨加工法对材料的性能影响最小;受残余应力或各层有效应力的作用,单层阳极材料的强度要高于双层电池结构材料的强度;利用弯曲法测试了半电池结构中的残余应力和不同薄膜对应的厚度残余应力,测试的结果和热弹性力学计算结果进行了对比.由于在高温时阳极材料有应力松弛现象,计算得出的残余应力高于实验测试结果.     

基于轮廓法测量钛合金激光熔覆中的残余应力

由于激光熔覆过程中有温度变化快、局部温度梯度大和伴随固液相快速转化等特性，在熔池和热影响区会产生很大的残余应力和变形，不利于金属增材制造和局部修复的精确可控。本文对Ti-6Al-4V(TC4)合金开展激光熔覆实验，采用轮廓法测量了激光熔覆所产生的残余应力；通过三维热力耦合有限元模型计算了温度场和残余应力场，仿真计算结果与轮廓法测量的残余应力趋势一致。结果表明，残余应力在熔覆位置有最大拉伸应力，随着远离焊缝急剧变成压缩应力并逐渐减小。上述工作有利于研究熔覆过程中的温度分布规律及残余应力的生成机制，可为熔覆过程的工艺控制提供参考。     

考虑塑性和刚度不匹配的焊接残余应力估算

现有残余应力计算方法未能考虑材料塑性变形和焊接接头刚度不匹配的影响,使得焊接残余应力计算结果和实际残余应力存在较大偏差.在2219-T87铝合金钨极氩弧焊焊接头残余应力测试基础上,提出一种基于非线性有限元和材料弹性模量分区的残余应力—释放应变曲线的残余应力计算方法,研究了材料塑性变形和接头刚度不匹配对焊接残余应力计算的影响.结果表明,焊接接头中非均质材料塑性不匹配可以引起对于残余应力计算的较大误差;材料塑性变形对残余应力的影响大于接头刚度不匹配对残余应力的影响.所提出方法修正了传统方法在焊接接头的残余应力计算中由于未考虑接头非均质材料塑性不匹配而引起的误差.     

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。     

对“钻孔偏心对松弛应变和残余应力的影响”一文的讨论

关于松弛应变-残余应力关系式,即[1]中(11)式,由于其中之释放系数 B′不是常数,它不仅与几何-弹性参数有关,而且夹进了未知的应力状态参数(?),这必然会给以后残余应力以求解带来困难.事实上文献[2]已成功地把未知应力参数σ_1、σ_2、(?)与几何-弹性常数彻底地分开,即把松弛应变表为     

基于弹性理论的残余应力反演和变形计算

毛坯在制造过程中,材料力学性能的非均匀性导致其内部产生残余应力.残余应力会造成结构破坏,在工件的切削去除过程中,残余应力会逐渐释放并引起变形.采用有限元的“生死单元”技术模拟材料的切削去除过程,并转化为残余应力的释放,基于板壳理论、小变形理论、弹性理论和叠加原理,将径向基函数插值法与几何方程、物理方程相结合,开发出一种新的解析方法,反演残余应力场并计算变形.结果表明解析方法的理论解与有限元解高度吻合,能够用于判断残余应力分布并计算残余应力弹性释放引起的变形.     

焊管的残余应力测试与研究

通过小孔法与分割法对φ272mm螺旋埋弧焊管和φ380mm对接焊管的残余应力测试,分析探讨了螺旋焊缝、环焊缝以及焊缝热影响区的残余应力分布。研究结果表明,不同工艺焊接成型的圆管,其焊缝纵向均匀为拉应力分布,焊缝横向均为压应力分布,焊缝热影响区的残余应力分布各异。     

聚晶金刚石复合片热残余应力分布规律实验研究

利用改进的应力释放法、X射线衍射法以及Raman光谱,对平面界面结构金刚石复合片表面热残余应力分别进行了实验研究,得到了金刚石层表面热残余应力值及其分布规律,同时得到了基体厚度与热残余应力的相关关系.研究结果表明,采用应力释放法、X射线衍射法及Raman光谱法测试PDC表面热残余应力,其测试结果均与有限元分析结果相吻合,证明了这三种方法的有效性.其中,X射线衍射法测试结果的误差最大,应力释放法其次,Raman光谱法最为精确.由于应力释放法应变片尺寸及X射线衍射法光斑照射范围的限制,无法在试样表面上取较多的测试点,因此难以得到理想的热残余应力分布曲线.而Raman光谱法中所采用的激光光斑仅5μm,可以取更多的测试点,因此其结果更能真实的反映金刚石层表面热残余应力的分布规律.本文的研究结果为精确测试PDC热残余应力,从而为优化PDC界面结构、提高PDC使用性能提供了理论和实验依据.     

微构件自由弯曲回弹的数值模拟

回弹是影响弯曲成形精度的一个重要因素,由于尺度效应的存在,微构件的弯曲回弹问题更复杂.利用动态显式与静态隐式算法相结合的方法数值模拟了C1200黄铜V形微构件的自由弯曲,与其超薄板三点弯曲的实验结果吻合度很好,验证了该方法模拟微构件弯曲回弹的可行性.分析了板厚t、晶粒大小d、t/d(板厚与晶粒大小比值)和残余应力对回弹的影响,结果显示t/d可以作为表征回弹的重要参数,回弹量随着t/d减小而增大;随着t和d的增大,工件的残余应力也增大,会影响工件的质量.可以采用适当热处理工艺增大材料的晶粒尺寸来减少回弹,当然也要兼顾残余应力对工件质量的影响.     

超短激光脉冲加热薄板的广义热弹扩散问题

由于超短激光脉冲具有功率密度高、持续时间短、加工精度高等优势, 近年来被广泛应用于超精细加工、光学储存和微电子器件制造等领域. 本文基于L-S型广义热弹扩散理论, 建立了考虑材料记忆依赖效应和空间非局部效应的记忆依赖型非局部广义热弹扩散耦合理论, 它能够准确预测几何尺寸与内部特征尺寸相近结构的热弹扩散瞬态响应. 推导了所建理论的控制方程, 并基于拉普拉斯积分变换获得了控制方程的解. 作为算例, 利用所建理论和求解方法研究了半无限大薄板受非高斯激光脉冲加热和化学冲击联合作用下的热弹扩散瞬态响应问题, 得到了薄板的温度、化学势、位移、应力和浓度等随非局部参数、热时间迟滞因子和扩散时间迟滞因子等参数变化的分布规律. 结果表明: 传热对传质影响显著, 传质对传热影响甚微; 非局部参数对位移、应力影响显著, 对温度、化学势和浓度几乎没有影响. 该理论及求解方法的建立, 旨在实现材料在机械、热、化学势等冲击作用下传热传质瞬态响应的准确预测.      

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.     

短脉冲激光加热分数阶导热及其热应力研究

短脉冲激光加热引起材料内部复杂的传热过程及热变形,现有的以Fourier定律或Cattaneo-Vernotte松弛方程结合弹性理论为框架建立起来热应力理论在刻画其热物理过程存在严重缺陷. 本文基于分数阶微积分理论, 以半空间为研究对象, 建立了分数阶Cattaneo热传导方程和相应的热应力方程, 给出了问题的初始条件和边界条件, 采用拉普拉斯变换方法, 给出了非高斯时间分布激光热源辐射下温度场和热应力场的解析解, 研究了短脉冲激光加热的温度场及热应力场的热物理行为. 数值计算中, 首先对理论解进行数值验证, 然后取分数阶变量$p=0.5$研究温度场和热应力场的变化特点及激光参数对温度和热应力的影响,最后数值计算分数阶参数对温度和热应力场的影响. 计算结果表明, 分数阶Cattaneo传热方程和热应力方程描述的温度和热应力任然具有波动特性,与经典的Fourier传热模型和标准的Cattaneo传热模型相比, 分数阶阶次越大, 热波波速越小, 热波波动性越明显; 反之, 则热波波速越大, 热扩散性越强.激光加热和冷却的速度越快, 温度上升和下降的速度越快, 压应力和拉应力交替变化越快, 温度变化幅值越小, 热应力幅值影响不明显.      

Experimental and Finite Element Simulation Study of Thermal Relaxation of Residual Stresses in Laser Shock Peened IN718 SPF Superalloy

An integrated experimental and modeling/simulation approach was developed to investigate and secure a quantified knowledge of the impact of high temperature exposures on the stability of residual stresses in a laser shock peened (LSP) high temperature aero-engine alloy, IN718 SPF (super-plastically formed). Single dimple LSP and overlap LSP treatments were carried out utilizing a Nd:Glass laser (λ?=?1.052 μm), and subsequent heat treatments on the LSP-treated coupons were conducted at different temperatures between 550 and 700 °C. A 3-D nonlinear finite element (FE) computational model and the rate-dependent Johnson-Cook material model were calibrated using the experimental results of residual stress from the single dimple LSP and thermal relaxation treatments, and were further extended to the overlap LSP treatment case. Both experimental and FE simulations show that: a) a high level of compressive residual stress (~700 MPa at surface) and residual stress depth (~0.4–0.6 mm) were achieved following LSP, and b) the overlap LSP treatment gave higher residual stress and greater depth. The magnitudes of the initial residual stress (and plastic strain), heating temperature and exposure time were identified as the key parameters controlling the thermal relaxation behavior. The stress relaxation mainly occurs initially before 20 min exposure and the extent of relaxation increases with an increase in temperature and a higher magnitude of the initial as-peened residual stress. In addition, in regions deeper than ~300 μm or after initial thermal exposure where the residual stress was lower than ~300 MPa, stress relaxation was found to be negligible. Kinetic analysis of the experimental thermal relaxation data based on Zener-Wert-Avrami model gave an activation enthalpy of 2.87 to 3.77 eV, which is near that reported in the literatures for volume and/or substitutional solute diffusion in Nickel. These results suggest that thermal relaxation of the LSP-induced residual stress occurs by a creep-like mechanism involving recovery, rearrangement and annihilation of dislocations by climb.     

Properties and appropriate conditions of stress reduction factor and thermal shock resistance parameters for ceramics

Through introducing the analytical solution of the transient heat conduction problem of the plate with convection into the thermal stress field model of the elastic plate, the stress reduction factor is presented explicitly in its dimensionless form. A new stress reduction factor is introduced for the purpose of comparison. The properties and appropriate conditions of the stress reduction factor, the first and second thermal shock resistance (TSR) parameters for the high and low Biot numbers, respectively, and the approximation formulas for the intermediate Biot number-interval are discussed. To investigate the TSR of ceramics more accurately, it is recommended to combine the heat transfer theory with the theory of thermoelasticity or fracture mechanics or use a numerical method. The critical rupture temperature difference and the critical rup- ture dimensionless time can be used to characterize the TSR of ceramics intuitively and legibly.     

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．     

Influence of laser pulse shape both on temperature profile and hardened layer depth

This paper presents a mathematical modelling and numerical calculations of heat conduction problems where laser generated heat is assumed as a surface heat source. Also the effect of a laser time structure on a hardened layer depth is examined. Temperature profiles for different laser pulse shapes are determined from the solution of a linear one-dimensional heat conduction equation for semi-infinite medium and discussed in terms of the parameters evolution such as dimensionless: temperature, heat flux, hardening depth, laser impulse duration and increasing time of triangular pulse shape.     

A partially insulated interface crack between a graded orthotropic coating and a homogeneous orthotropic substrate under heat flux supply

In this paper, thermal response of an orthotropic functionally graded coating-substrate structure with a partially insulated interface crack under heat flux supply is considered. It is assumed that there exists thermal resistance to heat conduction through the crack region. The mixed boundary value problems are reduced to a system of singular integral equations and solved numerically. Higher order asymptotic terms for the singular integral kernels are considered to improve the accuracy and the convergence efficiency of the numerical integrals. Numerical results are presented to show the effects of the orthotropy parameters, thermo-elastic nonhomogeneity parameters, and dimensionless thermal resistance on the temperature distribution and the thermal stress intensity factors (SIFs).     

直接有限元法求解广义磁热弹二维旋转问题

为了验证直接有限元法求解广义磁热弹耦合旋转问题的有效性及准确性,该文基于Lord和Shulman(L-S)广义热弹性理论,采用直接有限元方法,求解了置于磁场中的旋转半无限大体受热冲击作用的动态响应问题.文中给出了L-S型广义磁热弹耦合旋转问题的控制方程,建立了L-S型广义磁热弹旋转问题的虚位移原理,推导得到了相应的有限...     

Unsteady numerical simulation of double diffusive convection heat transfer in a pulsating horizontal heating annulus

A numerical study is conducted on time-dependent double-diffusive natural convection heat transfer in a horizontal annulus. The inner cylinder is heated with sinusoidally-varying temperature while the outer cylinder is maintained at a cold constant temperature. The numerical procedure used in the present work is based on the Galerkin weighted residual method of finite-element formulation by incorporating a non-uniform mesh size. Comparisons with previous studies are performed and the results show excellent agreement. In addition, the effects of pertinent dimensionless parameters such as the thermal Rayleigh number, Buoyancy ratio, Lewis number, and the amplitude of the thermal forcing on the flow and heat transfer characteristics are considered in the present study. Furthermore, the amplitude and frequency of the heated inner cylinder is found to cause significant augmentation in heat transfer rate. The predictions of the temporal variation of Nusselt and Sherwood numbers are obtained and discussed.