服役环境下腐蚀坑等效为表面裂纹的有效性分析

对取自退役飞机机翼蒙皮的光滑试件进行了等幅疲劳试验,通过疲劳断口分析得到了服役环境下飞机主体材料LY12CZ 铝合金蚀坑的拓扑特征.基于飞机结构的实际腐蚀尺寸,将蚀坑的宽度和深度作为等效裂纹的长轴和短轴,并应用 Stress Check 软件对蚀坑等效为裂纹的可行性进行了有限元分析.结果表明:实际蚀坑与等效裂纹对结构应力分布的影响十分相似;应力强度因子在蚀坑等效前后数值大小和变化趋势不大.在分析蚀坑对典型试件疲劳寿命影响时将蚀坑等效成半椭圆形裂纹,选取 Walker 公式作为扩展速率模型,并与试验值进行了对比.结果表明:预测值与试验值比较吻合,最大误差为9.23%,满足工程需求.     

钢轨表面三维疲劳裂纹扩展数值分析

在车轮循环滚动接触载荷作用下,钢轨接触表面裂纹问题频发,严重威胁高速列车运行安全,开展钢轨表面三维滚动接触疲劳裂纹扩展分析意义重大.首先,考虑不同初始裂纹角度,建立钢轨轨头含初始裂纹的三维有限元模型,对钢轨表面施加循环滚动接触载荷,进行轮轨滚动接触计算;然后,基于相互作用积分法计算裂纹前缘的应力强度因子;最后,采用最大周向应力准则和Paris公式计算当前状态下裂纹扩展方向和扩展速率,进而更新下一时刻的裂纹形状和尺寸.通过对上述过程重复实现,从而预测钢轨表面三维裂纹的扩展路径.加载过程中裂纹前缘应力强度因子计算结果表明,随着初始裂纹角度增加,K_Ⅰ的峰值逐渐减小,K_Ⅱ的峰值逐渐增大,裂纹前缘各位置的等效应力强度因子逐渐减小;裂纹前缘节点的位置越靠近钢轨表面,等效应力强度因子越大.疲劳裂纹扩展计算结果表明,随着循环次数的增加,不同初始角度下的裂纹都发生了偏折,逐渐朝着钢轨深度方向扩展,且裂纹的初始角度越大,发生扩展时需要的循环次数越多.对比三种初始裂纹角度下裂纹长度随循环次数的演化曲线可以发现,初始裂纹角度越小,裂纹扩展速率越大.所开发的方法也适用...     

拉伸载荷作用下共面表面裂纹间应力强度因子影响系数的有限元分析

采用参数化有限元方法,结合节点力法和循环迭代算法,对一有限厚矩形板表面有两个相邻共面半椭圆表面裂纹在拉伸载荷作用下进行了求解,得到了两裂纹在不同形状和相隔距离时的应力强度因子的影响系数,计算结果对含三维广布裂纹结构的剩余强度和疲劳寿命有参考意义.     

复合材料修补结构腐蚀扩展特性实验研究

为了研究腐蚀环境对复合材料修补结构疲劳特性的影响,开展以某型飞机加速环境谱为基础的预腐蚀试验,并采用递进式的试验方法分别完成对未修补未腐蚀、修补但未腐蚀、又修补又腐蚀的试样疲劳裂纹扩展试验。利用试验数据计算了复合材料修补构型、腐蚀环境对裂纹尖端应力强度因子影响的修正系数,并确定了通过试验验证的修补结构疲劳裂纹扩展修正模型。该模型预测腐蚀环境下修补结构的疲劳寿命与试验值一致。试验数据和预测模型可为海军飞机复合材料修补结构的损伤容限设计提供参考。     

基于紧凑拉伸剪切结构的复合型疲劳裂纹扩展研究

针对含I-II型复合裂纹的紧凑拉伸剪切(CTS)试样,研究了不同加载角度下的裂纹扩展路径及裂纹扩展寿命,通过实验数据给出了适宜于CTS试样的等效应力强度因子关系式,并基于此提出了一种新的I-II型复合裂纹扩展模型。研究表明,CTS试样的裂纹沿与加载方向近垂直的方向扩展,基于Tanaka公式的等效应力强度因子更适合于本文CTS试件的裂纹扩展寿命评估。当加载角度处于0°~45°之间时,提出的复合型裂纹扩展模型预测误差控制在5.49%之内,验证了分析模型的可行性和准确性。     

扭力轴三维裂纹扩展寿命仿真研究

对疲劳载荷谱作用下三维表面裂纹,采用双重边界元理论求解裂纹前沿的应力应变场,运用Forman理论、最小应变能密度法和Elber模型,计算裂纹前沿各点的扩展长度、扩展方向和应力强度因子等特征量.根据增量步下裂纹几何形状的改变,对裂纹面进行网格重划分和迭代计算,模拟三维裂纹的扩展,预测裂纹扩展寿命.扭力轴表面裂纹扩展的仿真结果表明该方法合理可行.     

考虑闭合效应和三维应力约束的表面裂纹扩展模拟

假定承受Ⅰ型常幅载荷下的表面裂纹在扩展中的形状保持为半椭圆,利用Newman半椭圆表面裂纹应力强度因子公式计算应力强度因子。提出了等效厚度的概念,利用穿透直裂纹的研究结果,考虑表面裂纹扩展中塑性致闭和三维应力约束效应。基于Elber模型建立了三维表面裂纹扩展模型。数值模拟了表面裂纹扩展过程,研究了裂纹形状变化及规律,计算了裂纹扩展寿命。将计算结果与有关试验结果进行了对比,吻合较好。     

金属结构材料腐蚀疲劳寿命预测模型的研究进展

腐蚀疲劳是工业装备的主要失效模式之一.随着新技术的不断发展,航空航天、轨道交通、海洋设施等重大装备向着高可靠性、长寿命及智能化方向发展,亟需准确、高效的腐蚀疲劳寿命预测方法.论文对金属材料的腐蚀疲劳损伤机理进行了简要总结并对寿命预测模型进行了系统归纳与评述,提出未来的研究趋势与方向.具体地,首先介绍了腐蚀坑的萌生和生长、裂纹萌生及扩展的机理;其次总结了预腐蚀疲劳的断裂力学及损伤力学寿命预测模型,再次归纳了腐蚀疲劳的断裂力学、损伤力学及数据驱动寿命预测模型;进一步地,综合概括了现有寿命预测模型的优点和不足;最后,基于当前的研究指出未来可能的发展方向,一方面可以借助三维成像技术实现蚀坑向裂纹转变阶段和短裂纹扩展阶段的可视化研究,以改进现有的断裂力学模型;另一方面可以建立新型的多尺度多阶段寿命预测模型或利用新兴的数据驱动-物理融合方法实现腐蚀疲劳寿命预测.     

大气预腐蚀下ER8C车轮钢的疲劳寿命评估

随着高速列车车轮服役里程的增加，车轮辐板持续遭受潮湿大气甚至海洋大气环境的考验，点蚀成为车轮失效的主要原因之一.论文首先在大气自然环境下对ER8C车轮钢高周疲劳试样开展为期180天的曝晒(预腐蚀)试验，随后进行表面形貌和疲劳性能表征.结果表明，预腐蚀后车轮钢的疲劳极限为387 MPa,相比光滑试样下降12%;这主要是由于预腐蚀造成的腐蚀坑使试样表面局部应力集中，加速了疲劳裂纹萌生.采用激光共聚焦显微镜统计预腐蚀试样表面蚀坑尺寸，使用由均值蚀坑尺寸计算得到等效初始缺陷尺寸(EIFS),对预腐蚀车轮钢试样的疲劳寿命进行预测，避免腐蚀疲劳裂纹萌生以及短裂纹扩展对疲劳寿命预测的影响；预测结果与实验结果较为符合，证明了该方法的可行性.论文的主要结论是，通过统计试样表面蚀坑尺寸的均值来获得EIFS的方法，可以计算得到大气预腐蚀后车轮钢的剩余寿命，这验证了EIFS方法在大气预腐蚀下材料疲劳寿命研究中的适用性.     

CTS试件中复合型疲劳裂纹扩展

针对复合型循环载荷作用下的金属构件中的裂纹扩展问题进行了实验分析和理论建模. 首先 采用紧凑拉剪试件(CTS)和 Richard研制的复合型载荷加载装置，对承受复合型循环载荷的裂纹进行了实验研究. 实验选择了两种金属材料试件，分别承受3种形式的复合型循环载荷的作用，在裂纹尖端具 有相同的初始应力场强度的条件下考察复合型循环载荷对裂纹扩展规律的影响. 实验结果表明，疲劳裂纹的扩展速率与加载角度有关. 对于同样金属材料的试件，当裂尖处 初始应力场强度相等时，载荷越接近于II型，裂纹增长速率越快. 采用等效应力强度 因子(I型和II型应力强度因子的组合)、裂纹扩展速率及复合强度等参数，以实验数据为 基础，建立了一个疲劳裂纹扩展模型，用来预测裂纹在不同模式疲劳载荷作用下的扩展速率. 为验证其有效性，该模型被应用于钢制试件的数值模拟计算中. 实验结果与模拟计算曲线保 持一致，表明该模型可以用来估算带裂纹金属构件的寿命.     

Environmentally assisted initiation and growth of multiple surface cracks

The initial stages of stress corrosion on an amorphous polymer is investigated. This is done by exposing stressed specimens of polycarbonate to an acetone and water solution. The surface develops two distinct features of degradation that appear on different length scales when subjected to tensile stress. Small pits form on the surface and make it rough. These pits are in the order of micrometers, and are found to be randomly distributed. They occur even without load and seem to slightly increase in number with increasing stress. In the millimeter domain, visible to the bare eye, surface cracks are formed transverse to the direction of loading. The occurrence of cracks is seen to have a positive stress threshold value, exceeding which, a linear increase of number of cracks with stress is found. The manners in which the cracks grow and coalesce on the surface are examined. It is seen that they do not meet crack tip to crack tip. Instead, they avoid each other initially and coalesce crack tip to crack side. The results are discussed in the light of mechanical considerations. A stress analysis for a few configurations of meeting cracks supports the experimental observations. With assumptions of stress corrosion crack growth and coalescence, a simulation of cracks growing from randomly distributed initiation sites is performed. Similar crack patterns as obtained in the experiments are found.     

Strain-induced passivity breakdown in corrosion crack initiation

Corrosion crack nucleation and growth are modelled as a moving boundary problem. The model incorporates three physical processes––dissolution, passivation and straining––into a continuum mechanical framework. The dissolution triggers surface advance; the passivation restrains the access of the environment to bare metal; the deformation causes for passivity breakdown. Plane cracks nucleating from surface pits in an elastic–plastic material body under fatigue load are considered. The problem is solved using a FEM program and a moving boundary tracking procedure. The model simulates how cracks form and grow in a single continuous course. The geometry of the developed cracks is found independent of the initial pit size. Plasticity is found to influence the curvature at the tip of the nucleated corrosion cracks. The most important evolution length parameter, the width of the corrosion crack, is found to depend on the size constraints of the tracking procedure. It is concluded that the model is deficient for determining all length scales observed in reality. Physical processes to be considered in an advanced model are proposed and discussed.     

Evolution of fatigue crack corrosion from surface irregularities

A moving boundary model is presented for crack nucleation and growth from surface flaws. It concerns with chemical attack that results in material dissolution. A controlling mechanism for evolution is the rupture of a brittle corrosion-protective film that is built up along the corroding surface. The evolution rate is a function of the degree of protective film damage caused by the surface straining. The problem is formulated for an elastic body containing a single and double pits. Low-frequency cyclic loading is considered. Numerical solution is proposed. The behaviours of a growing crack and of two competing cracks are described. Stages of incubation, blunting and steady-state growth characterise a single crack evolution. The steady-state growth rate is found independent of the initial geometry. Stages of independent growth, interactive growth and arrest of one crack characterise the evolution of two competing cracks. The lengths of the arrested cracks are presented as functions of the ratio between the pit depth for a series of different distances between the pits. It is emphasized that the solutions correspond to a homogeneous material. Further work is required to account for the material microstructure.     

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在空气和腐蚀介质中对低合金钢分别的进行疲劳试验,获得了S-N曲线,并对疲劳试样表面和断口形貌进行了观察。结果表明：与空气相比,腐蚀介质使低合金钢的疲劳强度显著降低;空气中疲劳试样只有一个萌生于试样表面基体的裂纹源,而腐蚀介质中的疲劳试样一般有多个裂纹源,多数裂纹源均萌生于点蚀坑;空气中疲劳裂纹扩展区以疲劳辉纹为主,而腐蚀疲劳则以沿晶开裂等脆性特征为主;此外还对空气中的疲劳极限进行了预测,预测值与试验值比较吻合     

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采用有限元方法对表面含有两个不同大小半椭圆裂纹的有限厚矩形板在拉伸载荷作用下 进行参数化求解，得到两裂纹取不同尺寸和位置坐标时附属裂纹(尺寸较小裂纹)对主 导裂纹(尺寸较大裂纹)前沿参考点($\theta= 0, \pi/2, \pi $)处的应力强 度因子的影响系数$\beta$, 然后结合神经网络技术建立了相邻裂纹尺寸和位置参 数到主导裂纹前沿点处$\beta$的多变量非线性映射关系.     

巴西圆盘泥岩试件裂纹扩展及应变演化实验研究

为了研究准静态加载条件下岩石试件巴西劈裂裂纹扩展规律,采用MTS试验机进行准静态加载,同时用高速摄像机记录裂纹扩展过程。采用白光数字散斑处理软件对摄像机记录的照片进行处理,得到试件裂纹扩展过程中应变场的演化情况。通过实验和分析可以看出,由于端部效应及加载方式的原因,因此裂纹起裂点在底部加载部位;泥岩试件表面裂纹的平均扩展速度为252m/s;岩石的非均质性即内部微缺陷、微裂纹使得泥岩试样的开裂并不是沿着中心直径方向,而是偏离一定的角度,初始偏离角度约为17°。裂纹扩展过程可以划分为三个阶段:泥岩试件宏观变形阶段(宏观无裂纹)、宏观裂纹稳定扩展阶段、宏观裂纹动态张裂阶段。同时,在裂纹扩展过程中,表面第一主应变场、水平位移场等变化明显,在开裂部位第一主应变最大。通过对圆盘泥岩试件裂纹扩展实验研究,可为研究岩石破裂及其演化规律提供依据。     

Fracture Mechanics of Corrosion Cracking in Concrete by Acoustic Emission

Nucleation of microcracks can be detected and analyzed by acoustic emission (AE), by which crack kinematics of locations, types and rientations are quantitatively estimated. The procedure was applied to clarify mechanisms of corrosion cracking. Based on fracture mechanics, numerical analysis was conducted by the boundary element method (BEM). Relations between the stress intensity factors and crack types were investigated by BEM solutions. In experiments, four types of crack patterns were nucleated by employing expansive agent. Following the surface crack, the diagonal crack and/or the horizontal crack propagated. The internal crack extended after the surface crack was terminated. Depending on the crack types, contributions of mode-I and mode-II were varied. According to AE results, four crack patterns observed differently consisted of tensile, mixed-mode and shear cracks. It is demonstrated that mechanisms of corrosion cracking in concrete are dominantly of mode-I failure along with a minor contribution of mixed-mode and mode-II.     

16Mn钢在不同条件下的疲劳行为研究

对截面为3 mm×3mm的16Mn钢试件在空气和3.5%NaCl溶液中分别进行疲劳试验,获得了S-N曲线,并对疲劳试样表面和断口形貌进行了观察.结果表明:与空气相比,3.5%NaCl腐蚀溶液使16Mn钢的疲劳强度显著降低;在空气中疲劳试样只有一个萌生于试样表面基体的裂纹源,而在3.5%NaCl溶液中一般有多个裂纹源,而...     

Closed-form weight function for edge crack problems

An accurate crack surface opening displacement formula for edge cracks in finite bodies has been derived, and was subsequently used to develop wide-range closed-form weight functions for edge cracks. The analytical weight function is general and can be easily used to determine accurate stress intensity factors and crack surface opening displacements for arbitrarily loaded edge cracks with high efficiency. Examples have been given for problems of edge crack(s) with a number of typical load conditions for illustration.     

Interactive effect of multiple crack growth on fatigue

Interaction of multiple cracks are found in mud when drying and crazing, thin film varnishes or coatings of aeroengine turbine blades. A two-dimensional multiple crack interaction model is developed to simulate the growth of interacting parallel surface cracks. Density and the initial distribution of the microcracks are accounted for in analyzing the growth of a crack to a pre-determined length. Analytical predictions are discussed with reference to experimental observations of fatigue cracks on coated turbine blades. Introduction of a large density of similar cracks can enhance the fatigue life of structural components.