超声波Fractography在测试裂纹尖端动态剪切模量中的应用

介绍用超声波Fractography技术测量高速扩展裂纹尖端准微观区域内材料的剪切模量的实验原理和方法.本方法目前尚限于在脆性高分子材料中应用,在其它材料中的应用以及实验方法本身都期待着进一步完善和发展.

MICROFRACTOGRAPHY OF NEAR-THRESHOLD FATIGUE CRACK GROWTH

The fracture surface micromorphology in the near-threshold FCG region was studied in LD-10 aluminum alloy and Ti-6Al-4V allov.The SEM examinations reveal that the frac- ture surface of both alloys at low crack growth rates(1×10^(-7)-1×10^(-5)mm/cycle)takes on a cyclic facet appearance.The typical morphologies were either sawtoothedfacets or terraced facets for LD-10 aluminum alloy and isolated island facets for Ti-6Al-4V alloy.The mech- anism of near-threshold fatigue crack growth is explicated on the basis of experimental ob- servations.

Flex Fatigue Property and Fractography of High Performance Fibers

The effects of pre-stress and bending angle on the flex fatigue lifetimes of para-aramids have been studied choosing the Twaron 2000 high performance filament as the studying subject by use of the self-developed flex fatigue apparatus. The fractography of the fatigue-breaking end of the single filaments has been obtained and the fatigue-breaking mechanisms have been analyzed using the LM and SEM. The differences of the fatigue properties and fractography of a variety of high performance fibers such as Kevlar 129, Kevlar 29 and UHMW PE have been discussed.

STUDY ON FRACTOGRAPHY OF TRANSGRANULAR SCC OF 70Cu-3OZn IN AN AMMONIACAL SOLUTION

The microfractography of transgranular stress corrosion cracking (TSCC) of 70Cu-30Zn a-brass in ammoniacal solution was studied. The observations indicate that on a very microscale, the crack path of TSCC of or-brass follows {111} planes. The crack path very often alternates between {111} Planes to result in 'cleavage-like'facet, the usual average orientation of which is {110} with preferential microscopic crack propagation in (100) and (112) directions. The average orientation of wide secondary facets is often close to {100}. The size of {111} microfacets increases with incrmsing stress intensity K, which indicates that the microscopic crack path follows {111} planes on which some localized slip has occurred. Possible TSCC mechanisms which appear to be consistent with the microfraphic features observed in the present study are also discussed.

Fractography Analysis of Monolithic Epoxy with Tailored Topography

The topographical features of fractured tensile, flexural, K1C, and impact specimens of monolithic epoxy have been studied and correlated with mechanical properties and surface features of samples before fracture. The topographical features studied include waviness (Wa), roughness average (Ra), root mean square value (Rq), and maximum roughness height (Rmax or Rz). As surface notches generate triaxial state of stress, therefore, the crack propagation is precipitated resulting in catastrophic failure. Although surfaces can be examined before fracture for any deleterious topographical elements, however, fractured surfaces can reveal finer details about the topography. It is because, as discussed in this article, surfaces with specific topography produce fracture patterns of peculiar aesthetics, and if delved deeper, they can further be used to estimate about the topography of surfaces before fracture. In addition, treating the samples with surfaces of specific topography can help improve the mechanical properties of monolithic epoxy.

Fractography Analysis with Topographical Features of Multi-Layer Graphene Reinforced Epoxy Nanocomposites

The stiff and fragile structure of thermosetting polymers, such as epoxy, accomplices the innate cracks to cause fracture and therefore the applications of monolithic epoxy are not ubiquitous. However, it is well established that when reinforced especially by nano-fillers, its ability to withstand crack propagation is propitiously improved. The crack is either deflected or bifurcated when interacting with strong nano-filler such as Multi-Layer Graphene (MLG). Due to the deflection and bifurcation of cracks, specific fracture patterns are observed. Although these fracture patterns seem aesthetically appealing, however, if delved deeper, they can further be used to estimate the influence of nano-filler on the mechanical properties. Here we show that, by a meticulous examination of topographical features of fractured patterns, various important aspects related to fillers can be approximated such as dispersion state, interfacial interactions, presence of agglomerates, and overall influence of the incorporation of filler on the mechanical properties of nanocomposites.

Evaluation of vibration stress of TA11 titanium alloy blade by quantitative fractography

Vibration fatigue is the main failure mode of compressor blade. Evaluating the vibration stress of blade that leads to cracking is very useful for analysis of vibration fatigue. In this paper, fatigue stress estimation methods by quantitative fractography were studied through experimental blade and in-service first-stage compressor blade in order to evaluate the initiation vibration stress of in-service blade. The analysis process of initiation vibration stress was established. The evaluating result of vibration stress of in-service blade subjected to centrifugal force and bending vibration stress agrees with aero engine test result. It is shown that the evaluation method can not only evaluate the equivalent fatigue stresses of different crack depths but also yield the initiation equivalent fatigue stress.

Fractography and morphology of shear bands of a Zr-based bulk metallic glass

Bulk metallic glasses（BMGs）have attracted considerable attention in the last few decades particularly triggered by their potential applications as novel structural and/or functional materials,owing to their superior strength,large elastic strain limit and relatively low Young′s modulus etc.compared to their crystalline counterparts.Here,a 3Dreconstruction application to the fractography and the morphology of shear bands was reported for a ductile Zr_（56）Co_（28）Al_（16）（at.%）BMG through a Phenom series desktop scanning electron microscope.The results of the 3Dreconstruction and the following contour analysis indicate a typical shear fracture mode for the investigated alloy.It is inferred that the fractography and the morphology of shear bands might be dependent on their composition,structure states,and loading conditions for BMGs.

Low-cycle fatigue behaviour of Mg-9Gd-4Y-2Zn-0.5Zr alloys with different structures

The strain-controlled cyclic deformation behaviour of Mg-9Gd-4Y-2Zn-0.5Zr with different structures was investigated. Alloys were prepared by solution, extrusion and pre-ageing extrusion, and the microstructures before and after the fatigue tests were characterized.Experimental results indicated that the bimodal structure owned the better performance in fatigue test, which was attributed to the higher yield strength. For the equiaxed structure, cyclic hardening induced stress concentration until the failure. Stable cyclic deformation and persistent cyclic softening played an important role at the low and high strain amplitudes, respectively. This was attributed to the formation of fine grains relieving the stress concentration during cyclic loading. In addition, residual twins were observed in equiaxed structure to induce crack, and the bimodal structure effectively restrain it.

Revealing effect of aluminum alloying on work hardening and impact behaviors of low-density Fe-18Mn-1.3C-2Cr-(4,11)Al casting steel

The present study designed two kinds of Fe-18Mn-1.3C-2Cr-(4,11)Al(wt.%)low-density steels.Tensile and impact tests were carried out to evaluate the work hardening and impact toughness properties via aluminum(Al)alloying control.Meanwhile,microstructure evolution and fracture morphology were investigated by X-ray diffraction(XRD),a scanning electron microscope(SEM)equipped with electron backscatter diffraction(EBSD),a transmission electron microscope(TEM),and a stereo-optical microscope(OM).It is found that the Al addition obviously promotes the dislocation planar slipping,resulting in cleavage and brittle impact fracture in 11wt.%Al steel.Besides,the microband-induced plasticity(MBIP)mechanism is found in 4wt.%Al containing steel,introducing considerable work hardening capacity and impact toughness of 156.8±17.4 J.The present study provides a direct illustration of the relationship between work hardening and impact toughness behaviors of these two low-density steels for potential application as impact-resistant components.

Experimental and numerical study of failure behavior and mechanism of coal under dynamic compressive loads

A comprehensive understanding of the failure behavior and mechanism of coal is a prerequisite for dealing with dynamic problems in mining space.In this study,the failure behavior and mechanism of coal under uniaxial dynamic compressive loads were experimentally and numerically investigated.The experiments were conducted using a split Hopkinson pressure bar(SHPB)system.The results indicated that the typical failure of coal is lateral and axial at lower loading rates and totally smashed at higher loading rates.The further fractography analysis of lateral and axial fracture fragments indicated that the coal failure under dynamic compressive load is caused by tensile brittle fracture.In addition,the typical failure modes of coal under dynamic load were numerically reproduced.The numerical results indicated that the axial fracture is caused directly by the incident compressive stress wave and the lateral fracture is caused by the tensile stress wave reflected from the interface between coal specimen and transmitted bar.Potential application was further conducted to interpret dynamic problems in underground coal mine and it manifested that the lateral and axial fractures of coal constitute the parallel cracks in the coal mass under roof fall and blasting in mining space.

Microstructure and mechanical properties of Al/Cu/Mg laminated composite sheets produced by the ARB proces

In the present study, an Al/Cu/Mg multi-layered composite was produced by accumulative roll bonding(ARB) through seven passes, and its microstructure and mechanical properties were evaluated. The microstructure investigations show that plastic instability occurred in both the copper and magnesium reinforcements in the primary sandwich. In addition, a composite with a perfectly uniform distribution of copper and magnesium reinforcing layers was produced during the last pass. By increasing the number of ARB cycles, the microhardness of the layers including aluminum, copper, and magnesium was significantly increased. The ultimate tensile strength of the sandwich was enhanced continually and reached a maximum value of 355.5 MPa. This strength value was about 3.2, 2, and 2.1 times higher than the initial strength values for the aluminum, copper, and magnesium sheets, respectively. Investigation of tensile fracture surfaces during the ARB process indicated that the fracture mechanism changed to shear ductile at the seventh pass.

Evaluation of physical and mechanical properties of AZ91D/SiC composites by two step stir casting process

Magnesium alloy(AZ91D)composites reinforced with silicon carbide particle with different volume percentage were fabricated by two step stir casting process.The effect of changes in particle size and volume fraction of SiC particles on physical and mechanical properties of composites were evaluated under as cast and heat treated(T6)conditions.The experimental results were compared with the standard theoretical models.The results reveal that the mechanical properties of composites increased with increasing SiC particles and decrease with increasing particle size.Distribution of particles and fractured surface were studied through SEM and the presence of elements is revealed by EDS study.

Effect of inclusion size on the high cycle fatigue strength and failure mode of a high V alloyed powder metallurgy tool steel

The fatigue strength of a high V alloyed powder metallurgy tool steel with two different inclusion size levels, tempered at different temperatures, was investigated by a series of high cycle fatigue tests. It was shown that brittle inclusions with large sizes above 30μm prompted the occurrence of subsurface crack initiation and the reduction in fatigue strength. The fracture toughness and the stress amplitude both exerted a significant influence on the fish-eye size. A larger fish-eye area would form in the sample with a higher fracture toughness subjected to a lower stress amplitude. The stress intensity factor of the inclusion was found to lie above a typical value of the threshold stress intensity factor of 4 MPa.m^1/2. The fracture toughness of the sample with a hardness above HRC 56 could be estimated by the mean value of the stress intensity factor of the fish-eye. According to fractographic evaluation, the critical inclusion size can be calculated by linear fracture mechanics.

Effects of thermomechanical treatments on the microstructures and mechanical properties of GTA-welded AZ31B magnesium alloy

Thermomechanical treatments were carried out to improve the properties of AZ31B joints prepared by gas tungsten arc welding. The microstructures of the joints were studied by optical microscopy and scanning electron microscopy with energy-dispersive spectrometry. Tensile tests and hardness tests were performed to investigate the effects of thermomechanical treatments on the mechanical properties of the joints. It is found that the thermomechanical-treated joints show superior mechanical properties against the as-welded joints, and their ultimate tensile strength can reach more than 92% of the base material. This mainly attributes to the formation of fine equiaxed grains in the fusion zone. ARer thermomechanical treatments the dendrites are transformed to fine spherical grains, and the dendritic segregation can be effectively eliminated.

Fractographic analysis of the overload effect on fatigue crack growth in 2024-T3 and 7075-T6 Al alloys

The effect of single overload on the fatigue crack growth in 2024-T3 and 7075-T6 Al alloys was analyzed.Fatigue tests under constantamplitude loading with overload peak were carried out on V-notched specimens.Fractographic analysis was used as a principal approach to explain the crack growth retardation due to the overload.Scanning electron microscopy(SEM)analyses were conducted on the fractured surface of failed specimens to study the retardation effect.The obtained results show that the overload application generates a plastic zone in both aluminum alloys.The generated plastic zone is three times larger in the case of 2024-T3 compared to 7075-T6,and thus,a significant crack retardation was induced for 2024-T3.The retardation effect due to the overload for 2024-T3 and 7075-T6 lasted for about 10 mm and 1 mm,respectively,from the point of overload application.

Repair Effect of Hot Work Tool Steel by Laser-Melting Process

Both wear and crack due to heat checking in hot work tool steel are major failure modes. It is desirable to find amethod to lengthen the tool life while reducing manufacturing cost. This paper suggests a method to improve toollife for hot work tool steel (SKD6) with crack by laser-melting process. The method has been evaluated using theimpact and fatigue test results. It is demonstrated that a repair of the crack by a laser-melting process is effectivefor life extension of the damaged tool.

Effects of mechanical vibration on the physical,metallurgical and mechanical properties of cast A308(LM21)aluminum alloy

This study investigated the microstructure,physical,and mechanical properties of die-cast A308 alloy subjected to mechanical vibration during solidification.Different frequencies(0,20,30,40,and 50 Hz)at constant amplitude(31μm)were employed using a power amplifier as the power input device.X-ray diffraction,optical microscopy,and scanning electron microscopy were used to examine the morphological changes in the cast samples under stationary and vibratory conditions.Metallurgical features of the castings were evaluated using Image J software.The average values of metallurgical features,including primaryα-Al grain size,dendrite arm spacing,average area of eutectic silicon,aspect ratio,and percentage porosity,reduced by 34%,59%,56%,22%,and 62%,respectively,at 30 Hz frequency compared with stationary casting.Mechanical tests of the cast samples showed that the yield strength(YS),ultimate tensile strength(UTS),percentage elongation(%EL),and microhardness(HV)increased by 8%,13%,17%,and 16%,respectively,at 30 Hz frequency compared with stationary casting.The fractured surface of the tensile specimens exhibited mixed-mode fracture behavior because of brittle facets,cleavage facets,ductile tearing,and dimple morphologies.The presence of small dimples showed that plastic deformation occurred before fracture.

Effect of Reduction on Bonding Interface of Hot-rolled Wear-resistant Steel BTW1/Q345R Cladding Plate

Wear-resistant cladding plates consisting of a substrate（Q345 R） and a clad layer（BTW1） were bonded through hot rolling at the temperature of 1 200 ℃ and a rolling speed of 0.5 m/s. The microhardness of the cladding plate was also tested after being heat treated. The microstructure evolution on the interface of BTW1/Q345 R sheets under various reduction rates was investigated with a scanning electron microscope（SEM） and EBSD. It is found that the micro-cracks and oxide films on the interface disappear when the reduction is 80%, whereas the maximum uniform diffusion distance reaches 10 μm. As a result, a wide range of metallurgical bonding layers forms, which indicates an improved combination between the BTW1 and the Q345 R. Additionally, it is discovered that the unbroken oxide films on the interface are composed of Mn, Si or Cr at the reductions of 50% and 65%. The SEM fractography of tensile specimen demonstrates that the BTW1 has significant dimple characteristics and possesses lower-sized dimples with the increment in reduction, suggesting that the toughness and bonding strength of the cladding plates would be improved by the increase of reduction. The results reveal that a high rolling reduction causes the interfacial oxide film broken and further forms a higher-sized composite metallurgical bonding interface. The peak microhardness is achieved near the interface.

Preparation and Performance of Short Carbon Fiber and Flake Graphene Reinforced Polycarbonate Composites: Effects of Different Tougheners

Different tougheners including methyl methacrylate-butadiene-styrene terpolymer (MBS, core-shell type), maleic anhydride (MAH) grafted ethylene-octene copolymer (EOM), and MAH grafted polyethylene wax (PEM) were investigated for toughening the polycarbonate (PC) composites reinforced by short carbon fiber (SCF) and flake graphene (FG). The effects of tougheners on the preparation, thermal conductivity and mechanical properties of PC composites were studied. Scanning electron microscopy was used for characterizing the impact fracture surfaces of the composites. The results showed that introducing tougheners into the carbon reinforced PC composites was beneficial to improving the processability, and PEM was more effective than EOM and MBS. Meanwhile, the through-thickness and the in-plan thermal conductivity decreased to some degree due to the isolated island effects of tougheners. Moreover, the brittle PC composites with high flexural stress could be easily toughened by tougheners. In contrast, PEM had better toughening function than EOM and MBS, and correspondingly, the stiffness of the composites was the lowest for the PEM toughened systems. The fractography revealed that dense and uniformly distributed carbon fillers dispersed in matrix PC and circular cavities coexisted in the composites. The naked fiber length gradually increased as the ductility of composite materials improved.