Remaining Useful Life for Heavy-Duty Railway Cast Steel Knuckles Based on Crack Growth Behavior with Hypothetical Distributions

The current research on the integrity of critical structures of rail vehicles mainly focuses on the design stage,which needs an effective method for assessing the service state.This paper proposes a framework for predicting the remaining useful life(RUL)of in-service structures with and without visible cracks.The hypothetical distribution and delay time models were used to apply the equivalent crack growth life data of heavy-duty railway cast steel knuckles,which revealed the evolution characteristics of the crack length and life scores of the knuckle under different fracture failure modes.The results indicate that the method effectively predicts the RUL of service knuckles in different failure modes based on the cumulative failure probability curves for different locations and surface crack lengths.This study proposes an RUL prediction framework that supports the dynamic overhaul and state maintenance of knuckle fatigue cracks.

The Role of Particles in Fatigue Crack Propagation of Aluminum Matrix Composites and Casting Aluminum Alloys

Fatigue crack propagation （FCP） behaviors were studied to understand the role of SiC particles in 10 wt pct SiCp/A2024 composites and Si particles in casting aluminum alloy A356. The results show that a few particles appeared on the fracture surfaces in SiCp/Al composites even at high △K region, which indicates that cracks propagated predominantly within the matrix avoiding SiC particles due to the high strength of the particles and the strong particle/matrix interface. In casting aluminum alloy, Si particle debonding was more prominent.Compared with SiCp/Al composite, the casting aluminum alloy exhibited lower FCP rates, but had a slight steeper slope in the Paris region. Crack deflection and branching were found to be more remarkable in the casting aluminum alloy than that in the SiCp/Al composites, which may be contributed to higher FCP resistance in casting aluminum alloy.

Analysis of cracking phenomena in continuous casting of 1Cr13 stainless steel billets with final electromagnetic stirring

Solidification cracking that occurs during continuous casting of 1Cr13 stainless steel was investigated with and without final elec- tromagnetic stirring （F-EMS）. The results show that cracks initiates and propagates along the grain boundaries where the elements of carbon and sulfur are enriched. The final stirrer should be appropriately placed at a location that is 7.5 m away from the meniscus, and the appropri- ate thickness of the liquid core in the stirring zone is 50 ram. As a stirring current of 250 A is imposed, it can promote colurnnar-equiaxed transition, decrease the secondary dendrite arm spacing, and reduce the segregation of both carbon and sulfur. F-EMS can effectively de- crease the amount of cracks in 1Cr13 stainless steel.

RESEARCH ON THE FORMATION MECHANISM OF INTERNAL CRACK IN THE CONTINUOUS CASTING SLAB

In view of the periodic bending deformation of solid-liquid interface in the solidification process for continuous casting slab, the variation of temperature gradient and dendritic spacing in the front edge of the solid-liquid interface, and the nucleation and propagation process of crack were studied. It is shown that the bending deformation of the interface results in the temperature field change in the front edge of solid-liquid interface, and the occurrence of temperature gradient along drawing direction results in the growth of secondary dendrites. The initial crack formed during the middle and final stage of solidification may extend to the surface of the casting slab and become an internal crack. The results of the theoretical analysis are basically in agreement with that of the experiment.

Longitudinal crack on slab surface at straightening stage during continuous casting using finite element method

Deformation behavior of slab at the straightening stage during continuous casting was simulated by the explicit dynamic finite element method,and the stress distribution along the width direction of the slab and its change regularity at slab center during continuous casting were obtained.The influence of distribution and change of stress on the propagation of longitudinal cracks on slab surface was discussed.The results show that the tensional stress appears on slab surface at the inner arc side and the compressive stress appears on slab surface at the outer arc side at stages 6-8 in straightening zone during continuous casting.Longitudinal cracks generally appear on slab top surface and do not appear on slab bottom surface,which are also observed in industry.

Research on cracking mechanism of the thin shell mould in expendable pattern shell casting during pattern removal process

Aiming at the cracking phenomenon of the thin shell mould in the expendable pattern shell casting during the pattern removing process, some systemic researches are presented.The influence of the pattern removing method and temperature on the pattern removing were investigated.The shell mould cracking mechanism was analyzed by using thermo-gravimetric analysis (TGA), and combining the temperature field and the volume change of the expanded polystyrene (EPS) foam pattern being tested.The results indicated that the shell mould was not easily cracked when the pattern removing process was carried out with the furnace being heated little by little because of the shell slowly shrinking with dehydration and shell strength gradually increasing.The shell mould was soon destroyed when it was set directly into the furnace at above 400 oC because of the thin shell mould rapidly shrinking and the foam pattern hindering.However, the shell mould had no cracking when it had been preheated for a long time even if the furnace temperature was above 400 oC and the shell was put into the furnace directly.Moreover, when the shell mould was directly set into the furnace at lower temperatures, 250 to 300 ℃, the shell would shrink slowly and the foam pattern would stay at the maximum expansion stage temperature of 100 to 110 ℃ for a long time; and the shell mould would experience an expansion force from the foam pattern for a long time.The expansion force is related to the pattern removing temperature, holding time, foam pattern thickness and density.Therefore, the foam pattern with higher density could make the shell crack.

Effects of continuous casting mould fluxes on reducing longitudinal and star cracks on a slab surface

In the continuous casting production of medium carbon steel (whose mass fraction of carbon is 0.09 % to 0.16 %) and high strength low alloy steel (whose mass fraction of Mn is 0.90 % to 1.40 %), flecks occurring the most often are usually longitudinal and star cracks. In additional to the employment of a galvanized plate mould, two kinds of fluxes with special properties were studied and used to harmonize the conflicts between the function of heat transfer and lubrication. An industrial application revealed that the crystallizing temperature (Tc) and crystal ratio (R) of fluxes have a crucible effect on impeding the occurrence of above defects on a slab surface. In the case of slab section (180 to 240) mm(1000 to 1400) mm and casting speed Vc of (0.7 to 1.2) m/min, the optimized parameters of fluxes are Tc of (1170 to 1190) ℃, R of 80 % to 95 % for medium carbon steel, and Tc of (1100 to 1150) ℃, plus R of 40 % to 60 % for high strength low alloy steel.

Growth of Casting Microcrack and Micropore in Single-crystal Superalloys Analysed by Three-Dimensional Unit Cell

Finite element （FE） analysis was employed to investigate the casting microcrack and micropore growth in nickel-base single-crystal superalloys DD3. Based on the finite deformation rate-dependent crystallographic constitutive equation, the simulations of casting microcrack and micropore growth in three-dimensional unit cell model were carried out in a range of parameters including stress triaxiality, Lode parameter and type of activated slip systems. The FE results show that the stress triaxiality has profound effects on growth behavior, and the Lode parameter is also important for the casting microcrack and micropore growth. The type of operative slip systems has remarkable effect on casting microcrack and micropore growth, so the life of single- crystal component is associated with the type of activated slip systems, which is related to Schmid factor and the number of activated slip systems. The growth comparison between microcrack and micropore reveals that when the material is subjected to large deformation, the growth rate of microcrack is faster than that of micropore, i.e. microcrack is more dangerous than micropore; the microcrack is easier to result in brittle fracture than micropore. The stress triaxiality and Lode parameter have strong influence on the growth of microcrack and micropore.

The mechanism of hot crack formation in Ti-6Al-4V during cold crucible continuous casting

Hot crack is one of common defects in castings, which often results in failure of castings. This work studies the formation of hot crack during cold crucible continuous casting by means of experiments and theoretical analysis. The results show that hot crack occurs on the surface and in the circumference of ingots, where the solidified shell and the solidification front meet each other. The tendency of hot cracking decreases with the increase of withdrawal velocities in some extent. The hot crack is caused mainly by the friction force between the shell and the crucible inner wall, and it takes place when the stress resulting from friction exceeds the tensile strength of the shell. The factors of μ_m, η_t, η_s and η_m, affecting hot cracks are analyzed and verified. In order to decrease the tendency of hot cracks, technical parameters should be optimized by decreasing μ_m, η_t, η_s and η_m.

Investigation of longitudinal surface cracks in a continuous casting slab of high-carbon steel

Based on a series of related investigations, a mechanism for the formation of longitudinal surface cracks on a continuous casting slab of high-carbon steel was investigated. High-temperature tensile tests performed on slab samples,metallographic and scanning electron microscopy studies, as well as heat flux and shell thickness in continuous casting predicted on the basis of a mathematical model were conducted. The results showed that high- carbon steel exhibited a much lower liquidus temperature and a wider brittle temperature range immediately after solidification compared with those of low-carbon steel. Concentrations of elements K and Na, which are contained in the mold fluxes, were not observed in the cracks during this study. The calculated results showed that the heat flux and the shell thickness were uneven along the mold width and that the shell was thinner and close to the center line of the slab surface. The longitudinal cracks were observed in situ using confocal laser scanning microscopy, to first occur close to the solidification front,where the ductility was extremely low;in addition ,the shell growth was slower than in other regions, which led to a thinner shell and depressed shrinkage owing to a lack of lubrication by the mold fluxes below the meniscus. Furthermore, the pouring temperature of high-carbon steel is - 100 ~C lower than that of low-carbon steel,so the formation of a stable liquid flux near the meniscus within a short time at the beginning of casting is difficult. The amounts of liquid slag film and crystalline slag film were insufficient to provide adequate lubrication between the shell and the mold, which resulted in greater friction force that induced or aggravated cracks. Therefore, the homogeneity of mold fluxes and initial solidification in the mold should be improved to reduce the concentration of slab surface defects.

Formation and control of the surface defect in hypo-peritectic steel during continuous casting:A review

Hypo-peritectic steels are widely used in various industrial fields because of their high strength,high toughness,high processability,high weldability,and low material cost.However,surface defects are liable to occur during continuous casting,which includes depression,longitudinal cracks,deep oscillation marks,and severe level fluctuation with slag entrapment.The high-efficiency production of hypo-peritectic steels by continuous casting is still a great challenge due to the limited understanding of the mechanism of peritectic solidification.This work reviews the definition and classification of hypo-peritectic steels and introduces the formation tendency of common surface defects related to peritectic solidification.New achievements in the mechanism of peritectic reaction and transformation have been listed.Finally,countermeasures to avoiding surface defects of hypo-peritectic steels duiring continuous casting are summarized.Enlightening certain points in the continuous casting of hypo-peritectic steels and the development of new techniques to overcome the present problems will be a great aid to researchers.

氮元素对高钛含铌钢裂纹影响的定量研究

应用试验、热力学计算及统计,定量研究了氮(N)对高钛(Ti)含铌(Nb)钢连铸横裂纹的影响,提出N控定量标准。结果表明:高钛含铌钢的高温塑性与氮化物形成具有强相关性;凝固末期TiN的析出影响第一脆性区,第二脆性区与Nb(C,N)的析出有关,温度区间为从Nb(C,N)析出到其析出速率开始缓和的温度,第三脆性区与铁素体或AlN析出有关,温度区间为从铁素体或AlN析出到渗碳体开始析出的温度。高钛含铌钢的N控瓶颈在于TiN在凝固末期的析出,根据Ti、N积建立控N标准,Ti、N积为4×10-5~7×10-5(%•%)。

超大规格2024铝合金扁锭开裂行为研究

随着航空航天大型结构件尺寸的增大,高强铝合金铸锭的尺寸也要增大,铸锭成型难度也随之增大。通过铸造过程数值模拟研究了铸造速度和刮水器位置对500 mm×2300 mm和600 mm×2500 mm规格2024铝合金扁铸锭温度场及应力场的影响规律。结果表明,铸造速度对液穴深度影响最大,提升铸造速度能够大幅降低铸锭内应力,但是大幅增加了液穴深度,不利于减轻铸锭疏松和热裂;提升刮水器位置可以大幅降低铸锭的应力。提出了降低铸造速度的同时提升刮水器位置的工艺优化方向,该工艺可以制备超大规格2024铝合金扁铸锭。

马鞍山长江公铁大桥主航道桥中塔下横梁施工关键技术

马鞍山长江公铁大桥主航道桥Z4号中塔采用空间四肢A形钢-混组合塔,横向两塔肢间设下横梁,下横梁间设3道系梁,纵向两塔肢间不设置横梁。下横梁采用支架法分层浇筑施工。下横梁施工支架采用落地式钢管支架配套模板体系,受力性能满足要求;通过有限元计算比选下横梁混凝土分层浇筑方案并进行优化,采取(5.5+2.5)m分层方案,上、下层混凝土分别分为2块、3块分层分块浇筑;通过低温升、易泵送、高抗裂的C60混凝土研制、下横梁与塔柱倒弧结合面抗裂措施优化、分块间接缝构造形式及施工工艺优化、下横梁与系梁混凝土浇筑施工组织优化、混凝土温度智能化监控、预应力束张拉时机控制等混凝土防裂措施,有效解决了下横梁大体积混凝土易开裂的难题。

超宽鱼腹式现浇箱梁混凝土裂缝控制

近年来,国内站城综合体TOD开发成为一种新型建筑模式,地铁、市政道路、商业综合体等多种大体量建筑形态交叉同步施工成为工程实践难题。基于此,结合已经实施的成都博览城综合交通枢纽工程,解析福州路桥鱼腹式多幅四箱室闭合型超宽箱梁,采取优化混凝土配合比、U形冷却管布置、后浇带布置、支架沉降控制、箱梁浇筑顺序等5种措施,解决大体积C60梁体混凝土防开裂难题,并取得明显实践成果,获得国家优质工程奖和土木工程詹天佑奖。

Production of super-high strength aluminum alloy billets by low frequency electromagnetic casting

The effects of low frequency electromagnetic field on the macro-physical fields in the semi-continuous casting process of aluminum alloys and the microstructure and crack in the billets were studied and analyzed by the numerical and experimental methods.Comparison of the results for the macro-physical fields in the low frequency electromagnetic casting（LFEC） process with the conventional DC casting process indicates the following characters due to the application of electromagnetic field：an entirely changed direction and remarkably increased velocity of melt flow;a uniform distribution and a decreased gradient of temperature;elevated isothermal lines;a reduced sump depth;decreased stress and plastic deformation.Further,the microstructure of the billets is refined remarkably and the crack in the billets is eliminated in LFEC process because of modification of the macro-physical fields induced by the application of low frequency electromagnetic field.

分缝护栏致空心板梁桥L型裂缝预应力控制方法研究

为提高护栏分缝桥梁的耐久性和承载力,以台金高速公路杨司高架桥预制空心板梁桥为背景,研究通过施加预应力控制因护栏分缝引起L型裂缝的有效性,并针对既有桥梁加固和新建桥梁设计提出通用的有效方法。采用Abaqus软件建立既有桥梁和新建桥梁的有限元模型,研究车道荷载作用产生的应力放大效应;分析预应力筋布置高度和长度对边梁梁底应力的影响及对既有桥梁护栏分缝导致的预应力损失;在此基础上,提出L型裂缝的预应力控制方法。结果表明:边梁应力放大系数随桥梁跨径和护栏高度的增加而增大,其取值范围为[1.42,2.14];预应力筋布置高度越低,边梁跨中梁底应力越大;预应力筋布置长度越短,既有桥梁梁底应力越大,对新建桥梁应力没有影响;分缝护栏对既有桥梁施加预应力产生损失,对新建桥梁不会产生预应力损失;在边梁跨中施加相应的预应力,可有效抵消跨中的应力集中效应,防止主梁跨中产生L型裂缝。

江阴靖江长江隧道现浇大体积混凝土的抗裂技术与应用

在原材料优选和配合比优化的基础上,通过协同调控水化速率与膨胀历程,设计制备了低温升高抗裂混凝土(M0不掺抗裂剂、M1和M2掺抗裂剂),对比研究了其力学性能、绝热温升和自生体积变形。在此基础上,依托江阴靖江长江隧道现浇大体积C40混凝土工程,采用基于水化-温度-湿度-约束多场耦合机制的收缩模型对该工程不同结构部位的开裂风险进行了定量评估。试验结果表明:掺入适量抗裂剂能有效改善混凝土的绝热温升和自生体积变形,且对抗压强度影响不大。开裂风险评估计算结果表明:底板、侧墙可选择M1配合比,并控制入模温度不大于28℃,同时在侧墙中心布置冷却水管;顶板可选择M2配合比,并控制倒角处和其他部位的入模温度分别不大于28℃和32℃。工程现场持续跟踪监测6个月,未发现混凝土出现开裂、渗漏,达到预期目标。

明挖法超长节段现浇混凝土隧道早期开裂机制现场试验研究

为研究超长节段明挖隧道混凝土早期开裂机制,依托实际工程,根据隧道前期已浇筑节段开裂情况调查结果,在隧道侧墙和顶板结构的中心线处埋置温度、湿度、应变传感器,对混凝土早龄期的温度、湿度、应变进行连续监测,并结合温度应力理论和现场裂缝调查对隧道混凝土早期开裂机制进行分析。分析结果表明:1)隧道侧墙和顶板结构浇筑后产生的水化热温升可达40℃以上,隧道顶板结构应变的变化趋势主要与温度相关。2)结构温度下降引起的收缩变形在受到下部旧混凝土的约束作用后产生的拉应力是引起开裂的主要原因;长度方向上的应变差、里表温差产生的不均匀收缩和湿度下降产生的干燥收缩会进一步加大开裂风险。3)结构中心与外表面的最大温差高出与内表面的最大温差12℃以上,因而结构外表面更容易出现开裂。4)在连续式的外约束作用下,浇筑段中部开裂的可能性更大。5)结构表面与内部的裂缝会逐渐沿裂缝走向扩展导致风险较低的区域也出现开裂。

770 MPa级调质铸钢液态金属致脆失效原因及相应防护对策

采用金相显微镜、电子扫描显微镜等对某大型截面铸钢工件裂纹成因进行了分析。结果表明:开裂高强度调质铸钢,在热浸锌过程中,基体产生了垂直于表面的裂纹,裂纹长度约为3 mm,且裂纹沿晶开裂。能谱结果表明,裂纹中富含大量锌,为典型的液态金属致脆现象。针对此情况,在热浸锌工艺、焊接工艺、成型工艺、涂装体系等方面给出了避免产生液态金属致脆的防护对策。