航空发动机钛合金材料的高周和超高周疲劳性能研究

通过对航空发动机空心风扇叶片用Ti-6Al-4V 随炉试样的高周和超高周疲劳试验研究,揭示了Ti-6Al-4V 材料在107 循环周次以上同样会发生疲劳破坏. 采用三参数幂函数寿命曲线拟合了高周和超高周的疲劳性能数据,发现可以较好地将两种试验下的数据衔接起来,结果显示在此试验条件下基于超声的超高周疲劳试验的频率效应可以忽略. 通过断口分析表明,超高周试样在试样表面没有缺陷的情况下,裂纹大多数是从材料内部或次表面萌生,而高周疲劳试样的裂纹是从材料表面开始萌生.     

航空发动机钛合金材料的高周和超高周疲劳性能研究1）

通过对航空发动机空心风扇叶片用Ti-6Al-4V 随炉试样的高周和超高周疲劳试验研究,揭示了Ti-6Al-4V 材料在10⁷ 循环周次以上同样会发生疲劳破坏. 采用三参数幂函数寿命曲线拟合了高周和超高周的疲劳性能数据,发现可以较好地将两种试验下的数据衔接起来,结果显示在此试验条件下基于超声的超高周疲劳试验的频率效应可以忽略. 通过断口分析表明,超高周试样在试样表面没有缺陷的情况下,裂纹大多数是从材料内部或次表面萌生,而高周疲劳试样的裂纹是从材料表面开始萌生.     

合金材料超高周疲劳的机理与模型综述

在循环载荷作用下, 合金材料发生裂纹萌生、扩展直至断裂的周次在107以上的过程被称为超高周疲劳 (very-high-cycle fatigue, VHCF).本综述将从30年前超高周疲劳的研究起源讲起, 直到近年的最新进展.引言之后的内容包括: 超高周疲劳研究的起源, 超高周疲劳的主要特征, 超高周疲劳裂纹萌生特征区和特征参量, 裂纹萌生特征区的形成机理与模型, 超高周疲劳性能预测模型. 在叙述中, 试图回答下列问题: 什么是超高周疲劳?为什么要研究超高周疲劳?超高周疲劳的关键科学问题是什么?超高周疲劳的S-N曲线趋势为什么发生变化?超高周疲劳裂纹为什么萌生于材料 (试样) 内部?裂纹内部萌生的过程和机理是什么? 上述问题有的可以给出明确的回答, 有的则是现阶段的最新结果, 并有待于对问题的继续探索.      

GCr15钢超声微动疲劳性能研究

由微动产生的裂纹萌生对钢组件的疲劳强度具有重要影响。本文选择GCr15轴承钢,在20kHz超声疲劳试验机提供的循环载荷作用下,测试其超长寿命微动疲劳性能。试验结果显示,在109循环周次下微动疲劳强度影响因子达到0.37。通过电子扫描电镜观察试件磨损面和微动疲劳断口,并分析了高频超长寿命微动疲劳断裂机理。高周疲劳裂纹通常会在磨损面的粘着区与滑移区交界处萌生,超高周疲劳裂纹在粘着区内萌生。微动磨损面的面积以及磨损面的粘着区都随着试件疲劳寿命的增加而增加。     

CrMoW转子钢高温超高周裂纹扩展及疲劳行为研究

本文研究了超超临界汽轮机CrMoW转子钢在常温与600℃条件下的超高周旋转弯曲疲劳行为。实验中利用位移传感器原位监测试件挠度变化,研究裂纹的萌生与扩展特性。研究结果发现,在常温下,疲劳裂纹主要萌生于试样表面,但也发现超高周次疲劳破坏的裂纹萌生于内部的情形。600℃时,S-N曲线呈现直线下降的趋势;大多试样裂纹萌生区和初始扩展区发现非金属夹杂物,其裂纹萌生是表面裂纹起源和亚表面夹杂物相耦合的结果。裂纹萌生寿命占整个疲劳寿命的90%以上,裂纹萌生寿命百分比(Ni/Nf)随疲劳寿命的延长而增大,并且温度对裂纹萌生寿命百分比没有影响。     

45CrNiMoVA钢的低周疲劳特性和表面疲劳裂纹的在位观测

利用MTS810材料试验机对带中心圆孔的45CrNiMoVA钢低周疲劳特性进行了研究,并借助长焦显微镜和CCD摄像头对试样表面裂纹的演化规律进行了在位停机观测和在位不停机连续观测尝试,试验发现,裂纹均萌生于与拉伸应力垂直的圆孔边缘;疲劳裂纹的萌生与Lueders形变带密切相关,萌生期超过整个疲劳寿命的70%,主裂纹的发展既可以共面扩展的方式向前连续延伸,也可以裂纹连接的方式向前跳跃传播,应力控制的低周疲劳条件下,疲劳寿命与应力面形貌图像,频闪光源照明可以实现表面疲劳裂纹的在位不停机观测。     

微粒子喷丸对等温淬火球墨铸铁超高周疲劳性能的影响

为分析微粒子喷丸工艺对等温淬火球墨铸铁(ADI)超高周疲劳性能的改善情况,利用旋转弯曲疲劳试验机开展了ADI 109循环周次疲劳试验。对比分析了经微粒子喷丸处理前后试样的疲劳性能,并利用扫描电镜对断口表面进行观察,分析了其超高周疲劳破坏行为。结果表明:未喷丸和喷丸处理后ADI的S-N曲线均表现为典型的阶梯下降型,且在超高周区域没有传统疲劳极限。微粒子喷丸可显著提高原始材料高周阶段的疲劳强度,超高周阶段的疲劳强度也有一定程度的提升。断口观察显示,超高周阶段两种试样均起裂于内部的缩孔或石墨球,并且部分断口表面可观察到粒状亮面GBF(granular bright face)区域。微粒子喷丸所引入的硬化层及残余压应力迫使疲劳裂纹萌生位置向内部转移。通过降低裂纹萌生位置的应力可改善旋转弯曲条件下超高周阶段的疲劳强度。     

TC4钛合金超高周次轴向振动疲劳试验

应用基于压电超声疲劳试验技术开发的20kHz轴向振动疲劳试验系统,完成了室温下TC4钛合金超高周疲劳试验,获得了TC4合金在107～109周次范围内的轴向振动疲劳寿命曲线(S-N曲线);运用C.Paris推导公式预测了TC4合金材料的寿命,得到各应力水平下破坏率为50％、95％、99％的安全寿命.结果表明:在疲劳循环大于107周次时,试件仍会发生疲劳断裂,疲劳强度随循环次数的增加而下降,并不存在明显的疲劳极限.TC4合金的S-N曲线在107～109周次的范围内呈连续下降型.在轴向振动超高周疲劳试验中,试件的裂纹扩展寿命只占其在50％破坏率下疲劳安全寿命的一小部分,其疲劳寿命主要由试件的裂纹萌生寿命决定.     

基于修正的局部应力应变法估算连接件疲劳寿命

飞机机体结构疲劳裂纹的萌生与扩展几乎都发生在紧固件连接处,预测结构连接件的疲劳寿命具有重要意义.为了准确计算连接件疲劳寿命,提出了一种修正的局部应力应变法,该方法首先采用应力严重系数法和修正Neuber法分析连接件高应力区的应力、应变,然后利用Manson-Coffin方程计算疲劳寿命,此外考虑到在中、高周疲劳里表面加工和尺寸因素的影响是不能忽略的,对应变-寿命曲线的弹性段作了修正以使其同时适用于高、低周疲劳寿命的估算.以搭接件为算例进行疲劳寿命计算,并使用MTS Landmark试验机对搭接件进行疲劳试验.结果表明,采用此方法估算的连接件疲劳寿命与试验结果相比误差小于16％,证明了此方法的有效性.     

缺口件疲劳寿命分布预测的有效应力法

论文提出了一种由光滑件疲劳寿命试验数据预测缺口件疲劳寿命分布的有效应力法.该方法中缺口件的裂纹可能萌生表面被分解成一个个微元,整个表面可看成是这些微元组成的一个串联模型,按照串联概率失效模型,缺口件的疲劳强度失效概率就可以由各微元的疲劳强度失效概率计算得到,其中微元的疲劳强度失效概率是由光滑件的疲劳强度失效概率通过最弱环节理论计算得到的.在缺口件的疲劳强度失效概率表达式中,引入了有效应力的概念,用它查取光滑件的疲劳寿命试验数据就可以直接得到缺口件的疲劳寿命分布.该方法可以同时考虑到应力梯度和试件尺寸对缺口件疲劳寿命分布的影响.进行了材料LY12CZ的带中心孔缺口件的寿命算例分析,预测结果和试验结果吻合良好,表明该方法是有效的.     

An investigation about interference fit effect on improving fatigue life of a holed single plate in joints

In this article, the effect of interference fit on fatigue life of holed plate of mechanical joints was investigated both experimentally and numerically. In the experimental part, fatigue tests were carried out on the holed specimens of Al 7075-T6 alloy in which oversized steel pins were force fitted to them. These fatigue tests were conducted on open hole specimen and specimens with 1, 1.5, 2 and 4% nominal interference fit sizes at different cyclic longitudinal loads. From these tests the stress-life (S–N) data for different interference fit sizes were obtained. The results show that interference fit increases fatigue life compared to open hole specimens. In the numerical part of the investigation, 3D finite element simulations have been performed to obtain stress (or strain) histories and distributions around the hole due to interference fit and subsequent cyclic longitudinal loading using FEM package. The stress history from finite element (FE) simulation was used to explain the reason for fatigue life improvement in the interference fitted specimens.     

孔边循环应变与疲劳循环次数相关性实验研究

材料的应变疲劳寿命与裂端的塑性应变有关。研究孔边循环应变与疲劳循环次数的相关性,对于研究材料损伤及微裂纹的产生,预防宏观裂纹的产生及扩展具有十分重要的意义。所以本文对有限宽板中心带孔试件进行了拉伸疲劳试验,用以研究这种相关性。在疲劳试验前首先进行逐级的加、卸载缓慢循环实验,同时利用数字图像相关技术测量孔周的位移场,进而求出孔边应变。在疲劳试验过程中,每当疲劳循环1500次就停机,进行同样的缓慢循环实验,并测量出孔周的位移场及孔边应变。实验研究中获得了一些很重要的结果。     

Experimental and numerical study of residual stresses caused by cold expansion of adjacent holes

Cold expansion is a useful process for imposing compressive residual stresses around the holes in riveted and bolted connections. These stresses increase the fatigue life of holed parts. Distribution and amount of exerted residual stress dependent on various parameters as material, distance of adjacent holes, hole diameter, cold expansion ratio and plate thickness. In this study, experimental and numerical results for two different aluminum alloys and various holes distances are investigated and compared. Effects of mentioned parameters on the residual stress are studied.     

A multiscale approach of fatigue and shakedown for notched structures

The aim of this paper is to analyse the fatigue phenomena in the presence of stress gradients. It is well-known that most fatigue criteria fail to predict the lifetime of components in the presence of high stress concentrations or stress gradients, as it is the case in the neighbourhood of cracks, holes notches and encountered for example in riveted or threaded structures. Proposed is a numerical approach in the framework of the high cycle fatigue domain in order to give a qualitative answer. The work starts from the numerical computation of macroscopic loading corresponding to some fatigue experiments on specimens with an inclusion of metallic grains embedded in a macroscopic matrix. The computed fields are then analysed in terms of the HCF (high cycle fatigue) criterion [1], which is based on the estimation of the shakedown limit at the grain scale. The infinite lifetime prediction is based on the assumption that fatigue occurs if at least one grain fails, i.e. reaches plastic shakedown. The predictions at mesoscopic and macroscopic scales are close if the macroscopic stress distribution is homogeneous. However in the case of the stress gradient, lifetime predicted at the macroscopic scale is underestimated when compared to the predictions made at the mesoscopic scale. Another result is that the gap between microscopic and macroscopic predictions obtained from these numerical computations can roughly be estimated by a diminution of stress of the same order of magnitude as found in the experiments and phenomenological observations.     

薄壁圆管空间结构的热疲劳可靠性分析

针对薄壁圆管的空间结构,分析其在交变热载荷下的疲劳可靠性问题.为同时考虑由截面平均温度和截面温差造成的疲劳损伤,提出了综合利用剩余强度和疲劳累积损伤模型的分析方法.首先根据疲劳累积损伤相等原理,将截面温差造成的多级扰动应力载荷作用频次等效为平均温度下的常幅应力载荷作用次数,从而将两者产生的热应力载荷统一为一常幅载荷,再利用剩余强度模型基于动态应力强度干涉理论对疲劳可靠度进行分析,得到了结构在综合考虑两种热疲劳状态下的动态可靠度.该方法可避免直接利用疲劳累积损伤理论临界损伤值难以确定的问题,且能体现金属疲劳损伤的真实情况.最后以哈勃望远镜为例,分析了其主梁随疲劳热载荷循环作用下的动态可靠度,得出了一些有意义的结论.     

Correlation of crack growth rate and stress ratio for fatigue damage containing very high cycle fatigue regime

A model is proposed to correlate the crack growth rate and stress ratio containing very high cycle fatigue regime. The model is verified by the experimental data in literature. Then a formula is derived for the effect of mean stress on fatigue strength, and it is used to estimate the fatigue strength of a bearing steel in very high cycle fatigue regime at different stress ratios. The estimated results are also compared with those by Goodman formula.     

Minimizing stress concentrations around circular holes in uniaxially loaded plates

The problem of determining stress distributions and reducing stress concentrations around holes in plates occurs in numerous design situations. One method for reducing the stress concentration around a central circular hole in a uniaxially loaded plate was demonstrated by Heywood. With this approach, smaller holes are introduced on either side of the original hole to help smooth the flow of the tensile principal-stress trajectories past the original hole. For the one case reported by Heywood (which did not produce the greatest reduction possible), the maximum stress was reduced to 84 percent of that due to a single hole. In the present program, a systematic study was undertaken using two-dimensional photoelasticity method to determine the optimum sizes and locations for the auxiliary holes for a number of plates with different central-hole diameter-to-plate width ratios. Maximum stress reductions from 13 to 21 percent were demonstrated for plates with hole diameter-to-plate width ratios between 0.1 and 0.6. With such reductions in maximum stress level, the improvement in fatigue life of a part can be very significant.     

The behaviour of a self-piercing riveted connection under quasi-static loading conditions

The behaviour of a self-piercing riveted connection was investigated experimentally and numerically. An extensive experimental programme was conducted on elementary riveted joints in aluminium alloy AA6060 in two different tempers, T4 and T6. The experimental programme was focused on the influence of important model parameters such as thickness of the plates, geometry of the specimens, material properties of the plates and loading conditions. An accurate 3D numerical model of different types of riveted connections subjected to various loading conditions was generated based on the results of the numerical simulation of the riveting process. A new algorithm was generated in order to transfer all the information from the 2D numerical model of the riveting process to the 3D numerical model of the connection. Thus, the 3D model was initialized with the proper deformed shape and the current post-riveting stress–strain state. The residual stresses and the local changes in material properties due to the riveting process were an important factor in order to get the correct structural behaviour of the model. The simulations have been carried out using the explicit finite element code LS-DYNA. The model was validated against the experimental results in order to get the correct deformation modes and the force–displacement characteristics. The numerical force–displacement curves fitted the experimental ones with reasonable accuracy. Furthermore, the model seemed to be able to describe the correct structural behaviour and thus the failure mechanisms of the self-piercing riveted connections.     

Very high cycle fatigue for GCr15 steel with smooth and hole-defect specimens

Very high cycle fatigue (VHCF) properties of a low temperature tempering bearing steel GCr15 with smooth and hole-defect specimens are studied by employing a rotary bending test machine with frequency of 52.5 Hz. Both smooth and hole-defect specimens break in VHCF regime with some difference in fatigue crack initiation. For smooth specimens, a fine granular area (FGA) is observed near the grain boundary in the fracture surface of the specimens broken after 10⁷ cycles. But no FGA is observed in the hole-defect specimens broken in VHCF regime, and the VHCF crack does not initiate from the small hole at the surface as it does at low or high cycle fatigue regime. Internal stress is employed to explain the VHCF behavior of these two types of specimens. At last, an advanced dislocation model based on Tanaka and Mura model is proposed to illustrate the internal stress process and to predict fatigue crack initiation life with FGA observed in the fracture region.     

循环载荷下冷挤压孔宏观残余应力的松弛效应

本文对应用云纹干涉法测量冷挤压孔周残余应力分布作了简要的论述，并应用该技术研究了冷挤压孔周残余应力在循环应力作用下的松弛问题，还探讨了残余应力的构件疲劳过程的相互作用，最后绘出不同循环应力次数作用后残余应力高周疲劳效应的几组实验结果。