CRACK GROWTH,FRACTURE FEATURE AND RUPTURE LIFE DURING CYCLIC CREEP OF SUPERALLOY GH2132

The effects of cyclic loading on crack growth, fracture feature and rupture life of superalloy GH2132 have been studied in the present paper. The crack growth tests were carried out at 550 on compact tension specimens under a wide range of load levels and various periods of hold time, and the fracture surfaces were examined on a scanning electron microscope. The results show that, for both static and cyclic creep, Stage-I of crack growth is related with initial test stress, during which the crack extension is about 0.5mm, and that the final effect of cyclic loading on rupture life depends on the counteraction of its two reversed effects on crack growth rate before and after the point n=0.2.

Fatigue Crack Growth Rate of Ti-6Al-4V Considering the Effects of Fracture Toughness and Crack Closure

Fatigue fracture is one of the main failure modes of Ti-6A1-4V alloy,fracture toughness and crack closure have strong effects on the fatigue crack growth（FCG）rate of Ti-6A1-4V alloy.The FCG rate of Ti-6A1-4V is investigated by using experimental and analytical methods.The effects of stress ratio,crack closure and fracture toughness on the FCG rate are studied and discussed.A modified prediction model of the FCG rate is proposed,and the relationship between the fracture toughness and the stress intensity factor（SIF）range is redefined by introducing a correcting coefficient.Notched plate fatigue tests（including the fracture toughness test and the FCG rate test）are conducted to investigate the influence of affecting factors on the FCG rate.Comparisons between the predicted results of the proposed model,the Paris model,the Walker model,the Sadananda model,and the experimental data show that the proposed model gives the best agreement with the test data particularly in the near-threshold region and the Paris region,and the corresponding calculated fatigue life is also accurate in the same regions.By considering the effects of fracture toughness and crack closure,the novel FCG rate prediction model not only improves the estimating accuracy,but also extends the adaptability of the FCG rate prediction model in engineering.

Finite Element Method Investigation of the Effect of Cold Expansion Process on Fatigue Crack Growth in 6082 Aluminum Alloy

Cold expansion is an efficient way to improve the fatigue life of an open hole. In this paper, three finite element models have been established to crack growth from an expanded hole is simulated. Expansion and its degree influence are studied using a numerical analysis. Stress intensity factors are determined and used to evaluate the fatigue life. The residual stress field is evaluated using a nonlinear analysis and superposed with the applied stress field in order to estimate fatigue crack growth. Experimental test is conducted under constant loading. The results of this investigation indicate expansion and its degree are a benefit of fatigue life and a good agreement was observed between FEM simulations and experimental results.

Fracture analysis of cracked metallic plate repaired with adhesive bonding composite patch

Fatigue crack growth test of cracked metallic plate repaired with adhesive bonding composite patch was conducted to study the fracture behavior of crack patching. The failure mode was that crack grows along with adhesive debonding. The crack length and debonding area were measured at different numbers of cycles. The nonlinear three- dimensional(3D)finite element(FE)model considering adhesive debonding and crack growth simultaneously was developed. The experimental and analytical results were in good agreement with each other.

Effect of Notch Location on Fatigue Life Prediction of Strength Mismatched HSLA Steel Weldments

Welding of high strength low alloy steels (HSLA) involves usage of low, even and high strength filler materials (electrodes) than the parent material depending on the application of the welded structures and the availability of the filler material. In the present investigation, the fatigue crack growth behaviour of weld metal (WM) and heat affected zone (HAZ) regions of under matched (UM), equal matched (EM) and over matched (OM) joints has been studied. The base material used in this investigation is HSLA-80 steel of weldable grade. Shielded metal arc welding (SMAW) process has been used to fabricate the butt joints. Centre cracked tension (CCT) specimen has been used to evaluate the fatigue crack growth behaviour of the welded joints. Fatigue crack growth experiments have been conducted using servo hydraulic controlled fatigue testing machine at constant amplitude loading (R=0).A method has been proposed to predict the fatigue life of HSLA steel welds using fracture mechanics approach by incorporating influences of mismatch ratio (MMR) and notch location.

A two-parameter model to predict fatigue life of high-strength steels in a very high cycle fatigue regime

In this paper, ultrasonic （20 kHz） fatigue tests were performed on specimens of a high-strength steel in very high cycle fatigue （VHCF） regime. Experimental results showed that for most tested specimens failed in a VHCF regime, a fatigue crack originated from the interior of specimen with a fish-eye pattern, which contained a fine granular area （FGA） centered by an inclusion as the crack origin. Then, a two-parameter model is proposed to predict the fatigue life of high-strength steels with fish-eye mode failure in a VHCF regime, which takes into account the inclusion size and the FGA size. The model was verified by the data of present experiments and those in the literature. Furthermore, an analytic formula was obtained for estimating the equivalent crack growth rate within the FGA. The results also indicated that the stress intensity factor range at the front of the FGA varies within a small range, which is irrespective of stress amplitude and fatigue life.

FAILURES AND THE LIFE OF FURNACE TUBES

It is showed after the furnace tubes serviced for 8-10 years that the density of damage in the HAZ (heat affected zone) of the weld has higher than in parent metals, though the depth of damage is not equal to. By the test of creep crack growth, it is also acquired that under same mechanic parameter C* (t), the rate of creep crack growth in the HAZ is more than twice as fast as in parent metals. Two mechanisms (overheating and thermal shock) of failure occurred in an accident are presented. The stress of thermal shock is analyzed, in which the change of the elasticity modulus with the radius ET = /(r) is considered. Based on it, the safety region of the thermal shock is obtained. Finally, two sets of curves for the safe life are suggested which can facilitate to estimate the remaining life of HK-40 or HP-Nb tubes by their creep rupture data.

STOCHASTIC PROPAGATION OF SEMI-ELLIPTICAL SURFACE CRACK

The semi-elliptical surface crack growth of structural components with uncertain material resistance under random loading is studied by using the stochastic averaging principle.The FPK equation governing the transition probability density function of crack lengths is derived.The analytical solution of the FPK equation for the case of that the equations for the crack growth in the surface and depth directions are uncoupled is obtained.The effects of the parameters of the stress process and of the material property on the behavior of semi-elliptical fatigue crack growth of the components with deterministic resistance to crack growth in the stationary Gaussian stress process are examined.The comparison of the analytical result with digital simulation shows the effectiveness of the present method.

基于运营数据的发动机压气机叶片裂纹扩展规律研究

为研究航空发动机实际服役中转子叶片在复杂载荷作用下的裂纹损伤扩展规律,基于航空发动机运营数据构建叶片的裂纹扩展寿命曲线,同时采用断裂力学理论建立裂纹扩展速率公式。以高压压气机叶片为实例,通过流固耦合方法构建压气机叶片结构的载荷模型,分别采用Paris、Walker、Newman裂纹扩展速率公式对压气机叶尖区域进行三维裂纹扩展分析。仿真结果表明,三种裂纹扩展速率公式在裂纹扩展前期预测结果与发动机运营数据裂纹扩展曲线具有一致性,可较好地描述叶片裂纹扩展规律;在裂纹稳定扩展阶段,Walker和Newman公式预测结果相对危险,Paris公式预测结果吻合度较高,并且能与厂家技术手册中关于其损伤发展控制要求相互印证。

钢桥疲劳裂纹扩展行为研究及可靠度更新分析

疲劳断裂失效一直是导致钢结构桥梁发生破坏的重要原因之一。为了更好地利用断裂力学对此失效行为进行研究,开展桥梁钢板件标准疲劳裂纹扩展试验。利用金属磁记忆无损检测技术监测疲劳裂纹扩展行为,分析疲劳裂纹扩展过程中磁信号的变化情况。从理论及试验两方面探讨疲劳裂纹扩展长度磁信号量化方法,确定磁特征参数与裂纹扩展长度之间定量关系式。随后将所提关系应用于疲劳裂纹扩展剩余寿命预测确定性研究,并通过试验结果对其进行验证。最后考虑疲劳裂纹扩展的随机性及损伤信息更新的必要性,进一步开展疲劳可靠度评估研究。研究结果表明:磁信号梯度最大值可以较好地对裂纹扩展长度进行量化表征,剩余寿命预测结果与试验结果误差均在20%以内,基于磁信号的可靠性评估方法可以配合我们更好地制定桥梁维修及养护策略。

喷丸强化对车辆传动齿轮裂纹扩展影响的研究综述

疲劳断裂是重载车辆传动齿轮的主要失效形式之一,齿轮底部疲劳裂纹的扩展将缩短车辆传动系统的服役寿命,严重时会导致车辆发生安全事故。延缓裂纹扩展的主要方法是在传动齿轮的表面引入一定大小的残余压应力。喷丸技术是一种冷加工表面强化处理工艺,该技术利用高速弹丸冲击材料表面,使零件表层产生塑性应变的同时,在表面和内部引入残余压应力,从而使裂纹闭合的能力得到强化,达到延缓裂纹扩展的强化效果。为了更好地揭示喷丸引入的残余压应力对疲劳裂纹扩展的影响,首先综述了传动齿轮表面疲劳裂纹产生的原因以及疲劳裂纹的扩展行为对重载车辆服役的影响。从强度因子、J积分以及裂纹闭合效应出发,介绍了传动齿轮表面疲劳裂纹扩展的理论以及残余压应力与疲劳裂纹扩展速率之间的关系。其次概述了目前国内外常用的新型有益于将残余拉应力转化为残余压应力的微粒子喷丸、激光喷丸、超声喷丸方法,并与传统机械喷丸技术相比较,阐述了新型喷丸表面强化技术的优缺点。此外,从数值模拟和试验结果两方面,论述了喷丸速度、喷丸角度、弹丸直径、弹丸材质和覆盖率5个工艺参数对在传动齿轮表面引入残余压应力的改善影响。最后对喷丸强化技术在传动齿轮上的多目标参数优化以及多尺度残余压应力与疲劳性能进行了展望,并结合重载车辆的使用需求,强调需要创新设计一种效率高、价格低、适用性广的喷丸技术,以进一步推动喷丸强化在延缓疲劳裂纹扩展方面的持续发展。

Study on Fatigue Lifetimes and Their Variation of Mg Alloy AZ61 at Various Stress Ratios

In this study, fatigue tests under different R ratios were conducted on the AZ61 Mg alloy to investigate its fatigue lifetimes and fatigue crack growth (FCG) behavior. The fracture surface of the failed specimens was investigated using a scanning electron microscope to study the size of the intermetallic compounds from which the pioneer fatigue crack initiated and led to the final failure of the specimen. To determine the maximum size of the intermetallic compounds existing within the cross section of the specimen at higher risk, Gumbel’s extreme-value statistics were utilized. In the present study, the intermetallic compounds contained within the specimen were assumed to be the initial cracks existing in the material before the fatigue tests. A modified linear elastic fracture-mechanics parameter, M, proposed by McEvily et al., was used to analyze the short FCG behavior under different stress ratios, R. The relation between the rate of FCG and M parameter was found to be useful and appropriate for predicting the fatigue lifetimes under different R ratios. Moreover, the probabilistic stress-fatigue life (P-S-N) curve of the material under different R ratios could be predicted with this method, which utilizes both the FCG law and a statistical distribution of sizes of the most dangerous intermetallic compounds. The evaluated results were in good agreement with the experimental ones. This correspondence indicates that the estimation method proposed in the present study is effective for evaluation of the probabilistic stress-fatigue life (P-S-N) curve of the material under different R ratios.

高温高压水管道热疲劳试验设计与数值模拟

核电厂压力容器启停堆和正常运行时,温度压力会在一定范围内发生波动,随着波动次数的增加,会对设备和管道造成严重疲劳损伤。依托北京某高校高温高压腐蚀实验站亚临界水汽环境结构材料试验装置双回路,设计了一种承压管道高通量热疲劳试验方法。基于该试验方法,完成了瞬态水温变化对管道疲劳裂纹扩展的影响研究。结果表明,疲劳裂纹扩展速率随冷却速率降低而逐渐降低。结合有限元数值模拟和三维裂纹扩展分析软件建立了阶梯管道结构的热疲劳裂纹扩展速率模型,并用试验结果对模型进行了修正。

高速缓冲液压缸内表面裂纹扩展特性研究

由于制造缺陷、疲劳及腐蚀等原因,缓冲液压缸在服役过程中内壁会产生轴向裂纹,严重影响液压缸的结构强度、缓冲性能和使用寿命。通过AMESim液压仿真平台建立缓冲系统模型来模拟实际工况,将缓冲油压作为有限元分析的初始载荷,建立缓冲缸有限元模型和裂纹扩展模型,研究不同初始裂纹形状、裂纹位置对疲劳寿命的影响,并分析裂纹前缘动态应力强度因子和裂纹形貌的变化。结果表明:无缺陷的油缸完全能承受缓冲压力;裂纹初始长度一定时,随着深长比增大,裂纹前缘应力强度因子会整体增大,裂纹扩展速度加快;不同深长比的初始裂纹经过多次循环载荷后都更倾向于在长度方向快速扩展;缸体内不同位置的裂纹疲劳寿命存在较大差异,在壁厚较小的边角位置,疲劳裂纹扩展寿命最短。

氢环境下金属材料的疲劳寿命预测:从裂纹的角度

随着氢能技术的快速发展,金属设备在氢环境下的运用越发广泛。然而,氢脆效应可显著削弱金属材料的疲劳性能,为相关设备的安全性埋下了隐患。因此,精准预测氢环境下金属材料的疲劳寿命具有重要意义。本文系统分析了氢环境下金属材料的疲劳裂纹扩展行为,总结了氢脆效应下各参数对疲劳裂纹扩展速率的影响。同时,调研并分析了氢环境下金属材料疲劳性能的研究及寿命预测方法的应用。氢环境下金属材料的疲劳裂纹扩展速率测算结果可作为输入进行计算材料的疲劳寿命,但研究发现疲劳裂纹扩展速率受多种参数的综合影响。尽管断裂力学的方法是疲劳裂纹扩展阶段常用的方法,也是氢环境下疲劳寿命预测的常用理论,但其求解效率尚有待提高。机器学习凭借其高效准确的预测性能,被广泛应用于各类疲劳问题的寿命预测中,但其在氢环境下金属材料的疲劳寿命预测领域尚少见。若能采用相关数据增强的方法扩充氢环境下的疲劳寿命数据,进而采用机器学习的方法进行寿命预测,将有望显著提升氢环境下金属材料疲劳寿命预测的效率。

缺口悬臂梁振动疲劳裂纹扩展行为研究

航空飞行器在服役过程中会经受大量复杂的随机振动载荷,其结构易发生振动疲劳进而导致损伤甚至失效,造成严重损失。以铝合金悬臂梁结构件为对象,开展振动疲劳试验与理论分析,研究随机振动载荷下含裂纹梁的应力强度因子求解方法,提出一种基于Hudson理论的时域法,结合经典的Paris公式估算振动疲劳裂纹扩展寿命。结果表明:本文提出的基于Hudson理论的时域法的寿命预测结果优于试验对比估算结果,验证了该方法能够有效描述随机振动裂纹扩展行为。

激光沉积TA15钛合金的裂纹扩展行为

采用标准CT试样测定了激光沉积TA15钛合金疲劳裂纹扩展速率,结合微观组织、裂纹扩展路径以及断口形貌分析疲劳裂纹扩展机理;并基于ABAQUS与FRANC 3D联合仿真的方法,模拟裂纹尖端应力强度因子并进行寿命预测。结果表明,激光沉积制造态的裂纹扩展速率低于锻造态,裂纹主要穿过片状α相(αl),少量沿αl扩展,稳定扩展区清晰可见疲劳条纹,并伴随大量的二次裂纹,瞬断区为典型的韧性断裂。另一方面,ABAQUS与FRANC 3D联合仿真计算的应力强度因子与理论值吻合较好,预测寿命相对误差低于5%,且证实了预测结果保守,验证了模拟分析的可靠性,确保了工程应用中的安全性。

苯基硅橡胶的低温疲劳寿命研究

研究了苯基硅橡胶在-40~20℃时的动态刚度、应变能密度和疲劳寿命,并验证了实验结果与基于裂缝生长理论的疲劳寿命计算式的符合程度。结果表明,随着温度的升高,苯基硅橡胶的动态刚度、应变能密度下降,疲劳寿命增加,且疲劳特性满足基于裂缝生长理论的疲劳寿命模型预测。

汽轮机老化热部件剩余寿命评估方法研究

随着国内大批火电机组达到设计寿命或寿命提前耗尽,如何系统、全面地评估老化机组的安全性与剩余寿命已成为目前亟待解决的问题。通过运行数据分析和理论计算对某电厂联合循环汽轮机中压内缸进行了剩余寿命预测,考虑了蠕变和低周疲劳2种损伤失效机理,分别利用损伤累积理论和断裂力学理论计算了汽缸的裂纹萌生寿命和裂纹扩展寿命。同时,基于金相检查结果评定材料的剩余寿命,现场硬度测试结果也可作为评估的重要补充。研究成果可为汽轮机部件寿命管理和检修周期的确定提供参考。

滚动轴承内圈不同曲率初始次表面裂纹的扩展仿真研究

滚动轴承内圈次表面裂纹的动态扩展将影响轴承工作的稳定性,继而影响轴承的剩余使用寿命。针对这一问题,研究了滚动轴承内圈上不同曲率的初始次表面裂纹对应力分布和裂纹扩展的影响规律。首先,基于扩展有限元方法,构建了承受径向载荷的圆柱滚子轴承有限元模型;然后,基于滚动轴承次表面裂纹的形态特征,模拟了滚道次表面不同曲率的初始裂纹在径向载荷下的动态扩展过程;最后,基于模拟结果,在相同工况下,分析并讨论了次表面裂纹尖端应力随裂纹曲率的变化规律,以及裂纹尖端应力对裂纹扩展的影响。研究结果表明:在径向载荷作用下,次表面裂纹尖端出现应力集中现象;裂纹的扩展主要受水平方向应力(S_(11))的影响;相同工况下,0.25 mm^(-1)~1.67 mm^(-1)曲率范围内的次表面裂纹,曲率较大的裂纹两端的应力较小;次表面裂纹的曲率越大,裂纹的扩展长度和角度均越小;通过比较相同径向载荷下不同曲率次表面裂纹的扩展长度、扩展角度等,发现曲率较大的次表面裂纹对轴承的损伤程度以及寿命的影响较小。这些研究结果可以为更好地理解和预防轴承损伤提供理论依据和参考。