高温结构蠕变裂尖拘束效应

如何对蠕变裂纹扩展寿命进行准确预测和评价是高温结构完整性评定、寿命设计和运行维护中需要解决的核心问题.基于宏观单参数C~*的蠕变断裂行为的评价方法,未有效纳入裂尖拘束效应的影响,因而其评价结果过于保守或非保守.目前国内外还未建立起有效纳入裂尖拘束效应的高温结构蠕变寿命评价的理论体系和技术方法,还没有纳入蠕变拘束效应的高温结构完整性评定规范.本文综述了作者近年来在高温蠕变断裂拘束效应方面的研究工作.主要包括:裂尖拘束对材料蠕变裂纹扩展行为的影响及机理;蠕变裂尖场和拘束参数R的定义和影响因素;载荷无关的蠕变拘束参数R~*的提出及其应用基础;承压管道表面裂纹的拘束参数R~*解及纳入裂尖拘束的蠕变寿命评价方法;试样与管道轴向裂纹蠕变裂尖拘束的关联;基于裂尖等效蠕变应变的面内与面外蠕变裂尖拘束的统一表征参数A_c的研究;材料拘束相关的蠕变裂纹扩展速率的建立;宽范围C~*区蠕变裂纹扩展速率及其拘束效应的数值预测;材料拘束对焊接接头蠕变裂纹扩展行为的影响及机理等.这些研究为建立纳入裂尖拘束效应的高温部件的蠕变裂纹扩展寿命评价方法奠定了理论和技术基础.论文对后续拟开展的工作也进行了展望.     

裂尖曲率对裂纹前缘塑性区的影响

考虑尖端为圆弧形的钝头裂纹模型，在外围取线弹性无裂纹体的解，应用线场分析方法。形成一套估计钝头裂纹前缘塑性区尺寸的方法。对含径向裂纹和圆弧形裂尖的圆盘受均匀张力作用情况，给出了塑性区的裂纹前缘尺寸与裂纹尖端曲率的关系。得到的结论是，塑性区的裂纹前缘尺寸与裂纹尖端曲率有关；对于给定的塑性区的裂纹前缘尺寸，载荷反比于外缘尺寸的平方。前一结论说明了塑性区的裂前尺寸作为裂纹失稳扩展判断的局限性；后一结论说明了裂纹体强度失效的尺寸效应规律：抗断强度与总体线尺寸的平方成反比。     

基于扩展有限元法的裂尖场精度研究

扩展有限元方法基于单元分解的基本思想,通过引入位移加强函数来表征裂纹的不连续性和裂尖的奇异性。在裂尖加强单元与常规单元之间有一层混合单元,当对裂尖特定区域进行加强时,混合单元个数相应增加,混合单元个数与计算精度存在一定联系。本文提出一种正方形裂尖加强区域的选择方式,可得到较单个加强和圆形加强精度更高、更稳定的计算结果。对于不同长度的裂纹,表征裂尖场奇异性所需的裂尖加强范围存在较大差异,以正方形裂尖加强方式进行计算,得到了不同裂纹长度下最优的加强尺寸。     

界面裂纹无摩擦接触裂尖应力场

基于哈密顿原理，通过分离变量及共轭辛本征函数展开法，解析地球解界面裂纹无摩擦接触裂尖的扇形域方程，从另一条途径研究了界面裂尖应力场的特征。     

单边裂纹通电瞬间裂尖处应力场的复变函数解

本文应用复变函数中的Schwarz-Christoffel变换方法，在具单边裂纹的导电薄板通电瞬间温度场复变函数解的基础上，推导出用复变函数表示的应力场的表达式，并且给出算例，通过理论计算得知；当对具有单边裂纹的导电薄板通入适当密度的电流时，裂尖处温度急剧升高并熔化便裂尖变钝。同时，在裂尖周围形成了有利于遏制裂纹扩展的压应力场，有效地防止了裂纹沿其主方向和其它方向延伸。从理论上证明了电磁热效应在裂尖处产生高温形成焊口的同时，压应力场的形成是遏制裂纹扩展的主要因素之一。理论计算结果与实验结果比较吻合，为这一止裂方法的应用打下了理论基础。     

绕裂尖白亮层的形成及其止裂作用分析

应用电磁热效应对带有裂纹的金属导体通入脉冲电流进行止裂，在裂纹尖端处熔化形成钝化焊口的同时，围绕裂尖的很小范围内形成一白亮层．分析表明：白亮层的形成对裂纹的扩展起到了屏蔽和防止应力腐蚀的作用，进一步提高了钝化止裂的效果．     

含裂纹结构时间相关的疲劳断裂理论与剩余寿命评价技术

高温结构的疲劳失效是与时间相关的, 建立这一失效机制下的断裂理论和寿命评价技术, 进而控制结构失效是人们多年来努力的目标. 从裂纹扩展控制参量、裂纹扩展规律和寿命评价技术、材料老化与环境因素影响和结构完整性评定工程方法等几个方面, 对近年来这一领域的研究进展进行了总结, 并对今后该领域的发展方向进行了预测.      

一种XFEM断裂分析的裂尖单元新型改进函数

提出了一种适用于裂尖改进单元的新型改进函数, 基于三角变换的方法, 保留裂纹尖端场的应力奇异性和裂纹上、下表面的位移不连续性, 将常规扩展有限元法裂尖改进单元的4 项改进函数缩减为2 项, 裂尖改进单元的结点由常规的8 个改进自由度减少为4 个. 采用2 个正交的水平集函数表征材料内部裂纹面, 详细阐述了改进单元类型的判别方法, 给出一种改进单元的分区域积分方案. 最后, 若干断裂力学问题经典算例的数值计算结果表明:建议的裂尖改进函数具有较高的数值精度, 该方法是十分有效的.     

压电界面裂纹裂尖强度因子的显式计算公式

对常见横观各向同性压电材料(TIP)中界面裂纹的裂纹面与压电材料的极化方向成任意夹角的一般情况进行了研究,通过推导得到了计算裂尖强度因子的显式外推公式,同时给出了裂纹面与极化方向垂直的典型情况下的外推公式.这些显式计算公式为常见数值方法如有限元法及边界元法在压电材料断裂力学中的应用提供了便利.     

基于裂纹扩展的疲劳-蠕变寿命预测

为了提高疲劳-蠕变寿命的预测精度,首次从裂纹扩展角度出发引入有效应变能密度增量,利用应力-应变迟滞回线所围图形的正值面积对其进行了定义和计算。计算表明,有效应变能密度增量与加载的应力、速率、保载时间、材料性质及疲劳-蠕变的速率相关,且随压应力增加而增大。通过将有效应变能密度增量与裂纹的长度之积定义为裂纹扩展的控制参量,建立了疲劳-蠕变下的裂纹扩展速率方程,并由此导出了疲劳-蠕变寿命与有效应变能密度增量之间的关系式。该式中的疲劳与蠕变有效应变能密度增量交叉项恰好反映了疲劳与蠕变的交互作用。最后,采用该式对1.25Cr0.5Mo钢在540℃时不同应力控制下的疲劳-蠕变寿命进行了预测,发现83.3%的预测值在实验值的1.3倍分散带以内,预测结果良好。     

Creep crack-tip constraint effect in high temperature structures

如何对蠕变裂纹扩展寿命进行准确预测和评价是高温结构完整性评定、寿命设计和运行维护中需要解决的核心问题.基于宏观单参数C^*的蠕变断裂行为的评价方法,未有效纳入裂尖拘束效应的影响,因而其评价结果过于保守或非保守.目前国内外还未建立起有效纳入裂尖拘束效应的高温结构蠕变寿命评价的理论体系和技术方法,还没有纳入蠕变拘束效应的高温结构完整性评定规范.本文综述了作者近年来在高温蠕变断裂拘束效应方面的研究工作.主要包括：裂尖拘束对材料蠕变裂纹扩展行为的影响及机理;蠕变裂尖场和拘束参数R的定义和影响因素;载荷无关的蠕变拘束参数R^*的提出及其应用基础;承压管道表面裂纹的拘束参数R^*解及纳入裂尖拘束的蠕变寿命评价方法;试样与管道轴向裂纹蠕变裂尖拘束的关联;基于裂尖等效蠕变应变的面内与面外蠕变裂尖拘束的统一表征参数A_c的研究;材料拘束相关的蠕变裂纹扩展速率的建立;宽范围C^*区蠕变裂纹扩展速率及其拘束效应的数值预测;材料拘束对焊接接头蠕变裂纹扩展行为的影响及机理等.这些研究为建立纳入裂尖拘束效应的高温部件的蠕变裂纹扩展寿命评价方法奠定了理论和技术基础.论文对后续拟开展的工作也进行了展望.     

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。     

Damage Accumulation in Aluminum Alloys under Plastic Deformation and Creep

The accumulation of local and bulk damage in D16 AT and 1201 T1 aluminum alloys used in aircraft engineering is studied. The local damage level is calculated from data of thermoactivation analysis of the residual life of D16 AT alloy specimens after preliminary plastic deformation. The bulk damage level is determined from the elastic-modulus defect by measuring the natural frequency of 1201 T1 alloy specimens. Life tests of the specimens were performed at constant tensile loads and elevated temperatures. The dependence of the local damage on preliminary plastic strain at room temperature is obtained. The residual life of the specimens is calculated with allowance for the damage to the material in the initial stage of failure and compared with experimental results. Data are given on the kinetics of bulk-damage accumulation in various test regimes. __________ Translated from Prikladnaya Mekhanika i Tekhnicheskaya Fizika, Vol. 47, No. 1, pp. 172–182, January–February, 2006.     

Quick assessment methodology for reliability of solder joints in ball grid array (BGA) assembly—Part I: Creep constitutive relation and fatigue model

In this study, a new unified creep constitutive relation and a modified energy-based fatigue model have been established respectively to describe the creep flow and predict the fatigue life of Sn−Pb solders. It is found that the relation successfully elucidates the creep mechanism related to current constitutive relations. The model can be used to describe the temperature and frequency dependent low cycle fatigue behavior of the solder. The relation and the model are further employed in part II to develop the numerical simulation approach for the long-term reliability assessment of the plastic ball grid array (BGA) assembly. The project supported by the National Natural Science Foundation of China (59705008)     

Predicting the fatigue life and crack aspect ratio evolution in complex structures

This paper discusses a computationally efficient method for determining the behaviour of complex structures containing three-dimensional cracks. A simple method is presented for calculating the mode I stress intensities for semi-elliptical cracks emanating from the saddle point of two intersecting tubular members. This method, which gives results in good agreement with published values, uses the finite element technique, but does not require the crack to be modelled explicitly. The technique is then used, in conjunction with FASTRAN II, to study fatigue crack growth and the results are compared to experimental data. Good agreement is achieved between both the predicted and measured fatigue crack growth and the evolution of the crack aspect ratios.     

Plastic constraint considerations at the prediction of wide plate failure behaviour from small scale testing, like c.o.d. determinations in s.e.n.b.-specimens

The stress intensity factor, crack opening displacement, J-integral, etc. will depend, besides on load, reduced (physical) cracklength and dimensions also on the plastic constraint situation near the crack tip. Assumedly their critical values are also dependent on this, which can imply an appreciable quantitative consequence for uniaxial gross stresses larger than (2/3) Y, as elaborated. This might interfere when trying to predict large sale behaviour of notched plates from small scale behaviour of specimens with the same thickness, as this presumbly does not guarantee equal plastic constraint. An average plastic constraint factor (p.c.f.) estimate for contained plastic flow can be indicated from simultaneous readings of s.i.f. or c.o.d. and gross stress during loading and its decrease followed. This allows to predict the failure conditions at the end of the experiment, provided the dependence of critical c.o.d. on this p.c.f. was previously determined. For arbitrary notched specimens a priori predictions of failure from the known critical c.o.d./p.c.f.-curve can be envisaged, using analytical and numerical evaluations of p.c.f. development at loading. The transition temperature concept is discussed with respect to the p.c.f. The failure prognosis for wide plate testing from small scale testing is reconsidered for deformation controlled loading: for contained plastic flow an alternative for the design-curve is suggested, using the deformation of the gauge length of the specimen defined as the distance between the localisations of load application. Finally the allowable deformation of plates, indicated for the required load in absence of a defect, is analysed for plates with a defect present.     

THE ANALYSES OF THE THREE-DIMENSIONAL STRESS STRUCTURE NEAR THE CRACK TIP OF MODE I CT SPECIMENS IN ELASTICPLASTIC STATE(Ⅰ)—THE ANALYSES OF CONSTRAINT PARAMETERS AND FRACTURE PARAMETERS

In the present paper, three dimensional analyses of some general constraint parameters and fracture parameters near the crack tip. of Mode I CT specimens in two different thicknesses are carried out by employing ADINA program. The results reveal that the constraints along the thickness direction are obviously separated into two parts: the keeping similar high constraint field (Z₁) and rapid reducing constraints one (Z₂). The two fields are experimentally confiremed to correspond to the smooth region and the shear lip on the fracture face respectively. So the three dimensional stress structure of Mode I specimens can be derived through discussing the two fields respectively. The distribution of the Crack Tip Opening Displacement (CTOD) along the thickness direction and the three dimensional distribution of the void growth ratio (V_g) near the crack tip are also obtained. The two fracture parameters are in similar trends along the thickness direction, and both of them can reflect the effect of thickness and that of the loading level to a certain degree.     

Subcritical Growth of an Internal Circular Crack in an Aging Viscoelastic Laminated Composite

Delayed fracture of a laminated composite under tensile loads applied at infinity is studied. The composite consists of alternating elastic and aging viscoelastic layers and contains an internal penny-shaped mode I macrocrack located in parallel to the layers. A modified Leonov–Panasyuk–Dugdale crack model and the critical crack-tip opening criterion constitute a fracture model. The subcritical crack growth equations are derived using the Volterra principle and the method of operator continued fractions. The laws governing delayed fracture are studied for a specific composite material     

Fatigue crack growth of cable steel wires in a suspension bridge: Multiscaling and mesoscopic fracture mechanics

Intrinsically, fatigue failure problem is a typical multiscale problem because a fatigue failure process deals with the fatigue crack growth from microscale to macroscale that passes two different scales. Both the microscopic and macroscopic effects in geometry and material property would affect the fatigue behaviors of structural components. Classical continuum mechanics has inability to treat such a multiscale problem since it excludes the scale effect from the beginning by introducing the continuity and homogeneity assumptions which blot out the discontinuity and inhomogeneity of materials at the microscopic scale. The main obstacle here is the link between the microscopic and macroscopic scale. It has to divide a continuous fatigue process into two parts which are analyzed respectively by different approaches. The first is so called as the fatigue crack initiation period and the second as the fatigue crack propagation period. Now the problem can be solved by application of the mesoscopic fracture mechanics theories developed in the recent years which focus on the link between different scales such as nano-, micro- and macro-scale.On the physical background of the problem, a restraining stress zone that can describe the material damaging process from micro to macro is then introduced and a macro/micro dual scale edge crack model is thus established. The expression of the macro/micro dual scale strain energy density factor is obtained which serves as a governing quantity for the fatigue crack growth. A multiscaling formulation for the fatigue crack growth is systematically developed. This is a main contribution to the fundamental theories for fatigue problem in this work. There prevail three basic parameters μ^∗, σ^∗ and d^∗ in the proposed approach. They can take both the microscopic and macroscopic factors in geometry and material property into account. Note that μ^∗, σ^∗ and d^∗ stand respectively for the ratio of microscopic to macroscopic shear modulus, the ratio of restraining stress to applied stress and the ratio of microvoid size ahead of crack tip to the characteristic length of material microstructure.To illustrate the proposed multiscale approach, Hangzhou Jiangdong Bridge is selected to perform the numerical computations. The bridge locates at Hangzhou, the capital of Zhejiang Province of China. It is a self-anchored suspension bridge on the Qiantang River. The cables are made of 109 parallel steel wires in the diameter of 7 mm. Cable forces are calculated by finite element method in the service period with and without traffic load. Two parameters α and β are introduced to account for the additional tightening and loosening effects of cables in two different ways. The fatigue crack growth rate coefficient C₀ is determined from the fatigue experimental result. It can be concluded from numerical results that the size of initial microscopic defects is a dominant factor for the fatigue life of steel wires. In general, the tightening effect of cables would decrease the fatigue life while the loosening effect would impede the fatigue crack growth. However, the result can be reversed in some particular conditions. Moreover, the different evolution modes of three basic parameters μ^∗, σ^∗ and d^∗ actually have the different influences on the fatigue crack growth behavior of steel wires. Finally the methodology developed in this work can apply to all cracking-induced failure problems of polycrystal materials, not only fatigue, but also creep rupture and cracking under both static and dynamic load and so on.