基于漫反射法的钢构件塑性变形与损伤检测

从结构损伤识别的需要出发研究能够准确反映钢构件承载过程中发生的塑性变形和损伤过程的量化测试方法.用漫反射法测量了钢构件在变形和损伤过程中表面粗糙度变化的图像,依据记录下来的表面图像进一步处理得到构件表面粗糙度的平均灰度值的变化,据此寻找对构件塑性变形和损伤状态相关并且敏感的参数指标.研究结果表明,基于漫反射法和图像处理得到的钢构件承载过程中表面粗糙度的平均灰度值的变化可以判断金属试样是否发生了塑性变形,并可定量描述试样在塑性变形后期的损伤程度.     

SUS304钢表面粗糙度对红外图像的影响

为提高红外热像仪图像及测温精度,根据红外热像仪的测温原理和红外辐射原理,通过使用红外热像仪、CCD相机以及激光表面形状测量显微镜,研究了SUS304钢在单轴拉伸塑性变形过程中表面粗糙度与目标发射率的关系;并用热电偶和红外热像仪对塑性变形过程中的温度分布进行了测量。研究结果表明,目标发射率随表面粗糙度成比例增大,造成红外热像仪测定的塑性变形区域比实际变形区域大;通过预先设定材料的表面粗糙度,以提高有效目标发射率,能得到较好的红外图像和测温精度。     

一种检测塑性变形的新方法

与仅仅承受弹性变形时不同,当金属试件承受塑性变形或发生疲劳损伤时,内部微观晶粒滑移位错等会导致表面粗糙化。此时其镜面反射能力减弱,漫反射能力增强。据此提出了一种检测试件弹塑性边界和塑性变形程度的新方法。承受均匀拉伸的金属试件被普通光源沿斜向照明,载荷按预定方式逐渐增加。用CCD摄像机沿试件法线方向记录板材试件表面的亮度变化,这些亮度分布摄像机可按一定频率采集以实时图像形式记录下来。我们提出了下述简单直观的方法来分析图像数据。根据实际情况适当选择一个阈值,定义图像中灰度高于阈值的点为亮点,取参数BI为亮点个数的倒数。试验发现在弹性段参数BI基本维持定值;在试件发生屈服时由于表面粗糙化以致漫反射能力增强,图像的亮点数会显著增多,BI参数发生陡然下降的变化,在整个塑性段参数呈单调下降趋势。所以参数BI可以作为描述这一过程的特性参数。由BI的变化可以判断试件塑性变形的发生,也可以作为塑性变形程度的度量。典型的实验结果验证了这一方法,所得结果与用相关搜索方法得到的结果相比较,吻合得相当好。由于这种方法使用白光照明,对环境要求不高,操作过程简单,有望在工程实际中获得广泛的应用。本文还讨论了影响判别精度的阈值选取问题,通过对于所得数据的分析得出阈值选取可以按照误差理论中置信区间的方法来设置,并且置信区间较小时能得到比较好的结果。     

喷丸强化对Cr-Ni-Mo系高强钢的摩擦磨损性能影响

采用喷丸强化对Cr-Ni-Mo系高强钢进行强化处理，利用销盘式摩擦磨损试验机考察了喷丸前后试样的摩擦磨损性能，研究了喷丸强化对Cr-Ni-Mo系高强钢试样的表面形貌、微观结构、显微硬度、残余应力和摩擦磨损特性的影响，进一步揭示了销盘接触摩擦过程中喷丸处理的强化机理.结果表明：喷丸强化在材料表层形成了塑性变形层并产生了位错区域，但提高了表面粗糙度；随着喷丸气压和覆盖率的增加，试样的表层显微硬度和表面残余压应力值显著提高；同时，喷丸试样表面形成的冲击弹坑改善了接触界面润滑效果，喷丸试样的摩擦系数由未处理试样的0.073最大降至0.023，其磨损率由1.25×10^-5 mm³/(N·m)最大降至0.81×10^-5 mm³/(N·m)，平均摩擦系数最大降低68.49%，磨损率最大降低了35.20%；此外，原始试样的磨损机理为犁沟，喷丸试样主要为犁沟、氧化磨损和黏结磨损.     

脆性固体变形响应与裂纹扩展的同步试验观测及其定量分析

通过对砂浆试样的材料变形响应和表面裂纹图象的同步观测实验研究、试样表面细观裂纹萌生和裂纹扩展图象信息的采集和量化方法的研究，探讨脆性固体材料的损伤状态与其宏观力学响应之间的关联。用本文提出的实验及其分析处理方法，可以得到砂浆、混凝土、岩石一类脆性固体材料在承载和变形过程中，表面裂纹扩展的定量结果。试样的表面裂损度代表了砂浆试样在承载和变形过程中表面裂纹扩展的情况，也在一定程度上反映了试样内部的损伤情况。     

基于压电阻抗技术的奥氏体不锈钢力学损伤定量监测

采用压电阻抗(Electro-mechanical impedance,EMI)技术对奥氏体不锈钢在拉伸过程中的力学损伤进行了定量监测实验研究.选择不同损伤状态下阻抗谱谐振峰频率偏移量△f及均方根偏差(Root-mean-square deviation,RMSD)值作为损伤识别指数,结果表明:在试样弹性变形阶段,△f和RMSD值很小,并且在加载过程中基本保持不变或小有波动;试样发生塑性变形以后,二者均明显增加,其中,△f值由0.05kHz随加载应力逐渐增加至1.65kHz时试样发生断裂,而RMSD由1.3％增大至17.6％后逐渐减小.文中对这种差别出现的原因及两参数各自的特点进行了讨论.显微分析结果证实材料弹塑性转变过程中两参数的变化与试样微观损伤具有很好的对应性,表明利用压电阻抗技术监测和评价核电管道用奥氏体不锈钢的力学损伤具有可行性.     

多股螺旋弹簧扭动微动磨损机理研究

基于多股螺旋弹簧工作过程中钢丝表面发生的扭动微动磨损,建立了多股簧受冲击载荷时,各股钢丝间法向接触力及角位移值的数学模型;通过数学模型所得到的试验参数,在新型试验装置上真实模拟了多股簧工作过程中钢丝间发生的柱-柱接触扭动微动;研究了多股簧钢丝在扭动微动条件下的运行行为和损伤机理.结果表明：钢丝间法向接触力大小、角位移幅值及循环次数对扭动微动行为影响很大;扭动微动T-θ曲线在平行四边形状、椭圆状和直线状3种基本类型之间转变;损伤在部分滑移区较轻微,其磨损主要表现为磨粒磨损和轻微氧化磨损;对于混合区和滑移区,损伤加剧,磨痕表面有明显的塑性变形,损伤机制主要为磨粒磨损、氧化磨损和剥层.     

标准超声振动气蚀孕育期内材料响应与表面形貌

材料在气蚀孕育期内仅发生极轻微的磨损,但以弹/塑性变形和晶粒拔出等方式对气蚀做出响应,具体的响应方式则随材料种类而不同.通过对孕育期内材料响应和磨损表面形貌的研究,探索不同材料响应与磨损表面形貌的关系,从而建立以表面粗糙度测量和光学显微镜观察等方式进行材料孕育期的研究.本文在标准超声振动气蚀试验机上进行了纯铜、镍基合金Hastelloy C-276和Sialon陶瓷共三种材料的气蚀试验,着重考察了它们在各自孕育期内的表面粗糙度参数（表面粗糙度R_a和核心粗糙度深度R_k）以及蚀坑面积比的变化.研究结果表明：纯铜和Hastelloy C-276在孕育期内主要以塑性变形为主.R_k不仅可以更好地反映孕育期乃至整个气蚀过程的材料表面形貌变化,还能反映不同金属在孕育期内塑性变形的程度.Sialon陶瓷在孕育期内以新蚀坑的形成为主,伴随着少量蚀坑的长大,蚀坑面积比很好地表征了陶瓷材料孕育期的变化.     

图像维数计算方法及其实质研究

基于颜色单元体模型,本文提出了一种间接量测表面形貌的新方法——真彩图像维数计算方法,并通过激光表面仪扫描实验对此进行了验证。该计算方法的提出,使在表面形貌的实验研究中用拍摄数码照片方法取代激光表面仪扫描成为可能。比较研究显示,该方法具有简单、方便、直观和扫描范围大等优势,是表面形貌实验研究手段上的一大改进。本文还分别探讨了二值化图像,灰度图像,真彩图像的分形特性,剖析了三类图像维数的物理实质。比较研究结果显示,对于同一试样,真彩图像维数最大,灰度图像次之,二值化图像维数最小,其维数在区间[1,2]内。以此说明,二值化图像维数是曲线维数,灰度图像维数仅考虑了颜色明度值的影响,只有真彩图像维数充分考虑了色彩、色饱和度和明度值的"贡献",该维数才是"全局"意义上的图像维数。     

表面粗糙度对TC4钛合金柱壳剪切带形成的影响

剪切带是材料在高应变率加载条件下特有的变形和损伤形式之一,关于影响金属材料中剪切带形成的敏感性因素及其机理的研究,一直是科学研究和工程设计中关注的重点问题. 在柱壳高速坍塌过程中,剪切带优先在内表面形核, 其形核及扩展行为受内表面介观状态的影响显著.本文采用爆轰加载厚壁圆筒坍塌实验技术,结合材料表面处理技术、微结构表征技术和剪切带理论模型分析,研究了内表面粗糙度变化对TC4钛合金柱壳剪切带形成影响的细观动力学规律.结果表明, 在爆炸加载形成的高应变率条件下,表面粗糙度对TC4钛合金柱壳中剪切带形成具有明显影响. 在相同的变形条件下,随着试样内表面粗糙度的增大, 剪切带数量、长度和形核速率均增大;表面粗糙度越大, 部分剪切带扩展速率越快, 剪切带长度差异越大,剪切带的屏蔽效应增强. 分析表明,实验获得的剪切带间距与W-O模型和M模型预测结果基本吻合,具体数值受试样内表面粗糙度影响, 随着表面粗糙度的增大,实验结果逐渐小于预测数值.      

An experimental study of inhomogeneous cyclic plastic deformation of 1045 steel under multiaxial cyclic loading

An experimental study was conducted on the inhomogeneous cyclic plastic deformation of 1045 steel under multiaxial cyclic loading. Thin-walled tubular specimens were used and small strain gages were bonded on the specimen surface to characterize the local deformation. The controlled loading paths included cyclic tension–compression, cyclic torsion, proportional axial-torsion, 90°-out-of-phase axial-torsion, and fully reversed torsion with a constant axial stress. The maximum stress in each experiment was lower than the lower yield stress of the material. It was found that the cyclic plastic deformation within the gage section of the specimen under multiaxial stress state followed the three-stage process that was observed from uniaxial loading, namely, incubation, propagation, and saturation. The plastic deformation was significantly inhomogeneous during the propagation stage, and the inhomogeneity continued through the saturation stage. The duration of each stage and the saturated strains were dependent on the cyclic stress amplitude and the loading path. Multiaxial stress state reduced the incubation stage. With identical equivalent stress magnitude, the nonproportional loading path resulted in the shortest incubation and propagation stages, and the saturated equivalent plastic strain magnitude was the smallest. Although the deformation over the gage section was inhomogeneous, the plastic deformation in a given local area was found to be practically isotropic.     

Lüders bands propagation of 1045 steel under multiaxial stress state

Inhomogeneous plastic deformation of 1045 steel under monotonic loading was experimentally studied. Thin-walled tubular specimens were used in the experiments and custom-made small strain gages were bonded on the specimen surface to characterize the local deformation. Experiments were conducted under tension, torsion, and combined tension–torsion. During the propagation of Lüders bands, the local deformation experienced two-stage deformation: an abrupt plastic deformation stage followed by a slower deformation process. In some area of the gage section of the specimen, a small amount of initial plastic deformation occurred before the Lüders front reached. During the propagation of Lüders bands, multiple Lüders fronts can be formed. Under tension, torsion, and combined tension–torsion with a constant axial load, the Lüders front was approximately parallel to the material plane of maximum shear stress. When the combined axial-torsion followed a proportional fashion, the stress–extensometer strain responses were dependent on the axial/torsional loading ratio, and the Lüders fronts were oriented differently and propagated along the specimen axis at a different velocity. The local strain was inhomogeneous even at the work-hardening stage. The relationships between the equivalent stress and the equivalent plastic strain were found to be practically identical for all the loading cases studied.     

低碳钢试件弹塑性边界的白光相关检测

金属试件的弹塑性边界检测对判断该试件是否失效有着重要意义,因此一直是研究人员较感兴趣的研究课题。利用激光和白光作为照明光源的方法都曾被提出以检测金属试件的弹塑性边界以及塑性变形。为避免激光测量的诸多缺点,本文提出一种用白光作为照明光源并结合数字图像处理来检测低碳钢试件弹塑性边界的方法。该方法将数字图像相关和低碳钢试件表面弹塑性变形前后对照明光强的反射特性结合起来以判断试件是否进入塑性屈服。文中通过对加载过程中低碳钢试件表面序列图像的处理,准确地判断了该试件是否进入塑性屈服,验证了该方法的可行性。     

Fatigue damage accumulation around a notch using a digital image measurement system

A digital image measurement (DIM) system is used to study the plastic damage accumulation around a notch under conditions of low-cycle fatigue. This system incorporates a contrast correlation method to evaluation the level of plastic damage at each point of the studied area from two images acquired before and after the introduction of fatigue deformation. A compact tension specimen of 304 stainless steel with a notch radius of 1 mm is analyzed during the stages of fatigue crack initiation and growth. The results obtained using this measurement system are compared with those attained by means of a recrytallization technique.     

Unusual plastic deformation and damage features in titanium: Experimental tests and constitutive modeling

In this paper, we present an experimental study on plastic deformation and damage of polycrystalline pure HCP Ti, as well as modeling of the observed behavior. Mechanical characterization data were conducted, which indicate that the material is orthotropic and displays tension-compression asymmetry. The ex-situ and in-situ X-ray tomography measurements conducted reveal that damage distribution and evolution in this HCP Ti material is markedly different than in a typical FCC material such as copper. Stewart and Cazacu (2011) anisotropic elastic/plastic damage model is used to describe the behavior. All the parameters involved in this model have a clear physical significance, being related to plastic properties, and are determined from very few simple mechanical tests. It is shown that this model predicts correctly the anisotropy in plastic deformation, and its strong influence on damage distribution and damage accumulation. Specifically, for a smooth axisymmetric specimen subject to uniaxial tension, damage initiates at the center of the specimen, and is diffuse; the level of damage close to failure being very low. On the other hand, for a notched specimen subject to the same loading the model predicts that damage initiates at the outer surface of the specimen, and further grows from the outer surface to the center of the specimen, which corroborates with the in-situ tomography data.     

复杂加载下混凝土的弹塑性本构模型

混凝土材料在不同应力路径下或复杂加载条件下会表现出差异性显著的应力应变关系,在小幅循环加载条件下,其应力应变关系会表现出类似于弹性变形的滞回曲线.在不同应力水平下,混凝土的应力应变关系以及破坏特性都具有静水压力相关特点,即随着静水压力增大,各向异性强度特性弱化.此外,混凝土受压及受拉破坏机理不同,因而对应于混凝土硬化损伤亦有不同,即可分为受压硬化损伤,受拉硬化损伤及两者的混合硬化损伤类型.基于Hsieh模型,对该模型进行了三点改进.（1）针对小幅循环加载下混凝土无塑性变形的试验规律,而模型中在应力水平较低的循环加载条件下始终存在塑性变形的预测问题,采用在边界面模型框架下,设置了应力空间的弹性域,初始屈服面与后续临界状态屈服面几何相似的假定.（2）基于广义非线性强度准则将原模型采用变换应力方法将其推广为三维弹塑性本构模型,采用变换后模型可合理的考虑不同应力路径对于子午面以及偏平面上静水压力效应形成的影响,并避免了边界面应力点奇异问题.（3）分别对拉压两种加载损伤模式建议了相应的硬化参数表达式,可分别用于描述上述加载中产生的应变软化及强度退化行为.基于多种加载路径模拟表明:所建立的三维弹塑性本构模型可合理地用于描述混凝土的一般应力应变关系特性.      

软化Mohr-Coulomb材料强度参数的测定方法

为了得到试件的粘聚力和内摩擦角随轴向塑性压应变变化的曲线提出本方法。试件的弹塑性本构关系遵循相关联的Mohr-Coulomb强度准则;对常规三轴试验,试件受力进入塑性状态后,处在棱椎状屈服面的棱上,加载过程遵循Koiter流动法则。按经典塑性力学理论,推导得到轴向塑性压应变与轴向应力与轴向应变的关系;在常规三轴试验机上获得不同围压下试件的全程应力-应变曲线,进而可得到各自围压下轴向塑性压应变随加载过程的变化曲线;把来自不同围压下对应同一轴向塑性压应变的应力分别代入屈服面方程,即可求得对应的粘聚力和内摩擦角。结果表明,Mohr-Coulomb材料的两个强度参数的变化由轴向塑性压应变确定。轴向塑性压应变可以作为塑性变形的状态参数,它和试件的受力过程可以唯一确定试件的变形过程。     

Onset of Surface Damage in Modular Orthopedic Implants: Influence of Normal Contact Loading and Stress-assisted Dissolution

Surface damage at interfaces of modular implants results from repeated fretting contacts between metallic surfaces in a corrosive environment. As a first step in understanding this complex process, multi-asperity contact experiments were conducted to characterize roughness evolution due to action of contact loads and exposure to a reactive environment. Cobalt–chromium specimens with surface roughness similar to modular implant were first subjected to only contact loading and subsequently, to alternating contact loads and exposure to reactive environment. During repeated normal contact loading, amplitude of surface roughness reached a steady value after decreasing during the first few cycles. However during the second phase surface roughness amplitude continuously evolved—decreasing during contact loading and increasing on exposure to corrosive environment. The increase in roughness amplitude during surface reaction depended on the magnitude of applied contact loads. A damage mechanism that incorporates contact-induced residual stress development and stress-assisted dissolution is proposed to elucidate the measured surface roughness evolution.