Development of multi-physics numerical simulation model to investigate thermo-mechanical fatigue crack propagation in an autofrettaged gun barrel

In this research,a detailed multi-physics study has been carried out by numerically simulating a solid fractured gun barrel for 20 thermo-mechanical cycles.The numerical model is based on thermal effects,mechanical stress fields and fatigue crack mechanics.Elastic-plastic material data of modified AISI 4340 at temperatures ranging from 25 to 1200℃and at strain rates of 4,16,32 and 48 s^(-1) was acquired from high-temperature compression tests.This was used as material property data in the simulation model.The boundary conditions applied are kept similar to the working gun barrel during continuous firing.A methodology has been provided to define thermo-mechanically active surface-to-surface type interface between the crack faces for a better approximation of stresses at the crack tip.Comparison of results from non-autofrettaged and autofrettaged simulation models provide useful information about the evolution of strains and stresses in the barrel at different points under combined thermo-mechanical loading cycles in both cases.The effect of thermal fatigue under already induced compressive yield due to autofrettage and the progressive degradation of the accumulated stresses due to thermo-mechanical cyclic loads on the internal surface of the gun barrel(mimicking the continuous firing scenario)has been analyzed.Comparison between energy release rate at tips of varying crack lengths due to cyclic thermo-mechanical loading in the non-autofrettaged and autofrettaged gun has been carried out.

Numerical simulation of thermo-mechanical fatigue properties for particulate reinforced composites

In this paper, a two dimensional Voronoi cell element, formulated with creep, thermal and plastic strain, is applied for the numerical simulation of thermo-mechanical fatigue behavior for particulate reinforced composites. The relation between mechanical fatigue phases and thermal fatigue phases influences the thermo-mechanical fatigue behavior and cyclic creep damage. The topological features of micro-structure in particulate reinforced composites, such as the orientation, depth-width ratio, distribution and volume fraction of inclusions, have a great influence on thermo-mechanical behavior. Some related conclusions are obtained by examples of numerical simulation.

Review on structural fatigue of NiTi shape memory alloys:Pure mechanical and thermo-mechanical ones

Structural fatigue of NiTi shape memory alloys is a key issue that should be solved in order to promote their engineering applications and utilize their unique shape memory effect and super-elasticity more sufficiently. In this paper, the latest progresses made in experimental and theoretical analyses for the structural fatigue features of NiTi shape memory alloys are reviewed. First, macroscopic experimental observations to the pure mechanical and thermo-mechanical fatigue features of the alloys are summarized; then the state-of-arts in the mechanism analysis of fatigue rupture are addressed; further, advances in the construction of fatigue failure models are provided; finally, summary and future topics are outlined.

Cyclic deformation behaviors of Ti-46Al-2Cr-2Nb-0.15B alloy during thermo-mechanical fatigue tests

Thermo-mechanical fatigue tests were carried out on the gamma-TiAl alloy in the temperature range of 500-800℃ under mechanical strain control m order to evaluate its cyclic deformation behaviors at elevated temperature. Cyclic deformation curves, stress-strain hysteresis loops under different temperature--strain cycles were analyzed and dislocation configurations were also observed by TEM. The mechanisms of cyclic hardening or softening during thermo-mechanical fatigue （TMF） tests were also discussed. Results showed that thermo-mechanical fatigue lives largely depended on the applied mechanical strain amplitudes, applied types of strain and temperature. On the hysteresis loops appeared two apparent asymmetries： one was zero asymmetry and the other was tensile and compressive asymmetry. Dislocations configuration and slip behaviors were contributed to cyclic hardening or cyclic softening.

CHARACTERIZATION OF THERMO-MECHANICAL FATIGUE PROPERTIES FOR PARTICULATE REINFORCED COMPOSITES

A Voronoi cell dement, formulated with creep, thermal and plastic strain was applied for investigation of thermo-mechanical fatigue behavior for particulate reinforced composites. Under the in-phase fatigue loading, the maximum of tensile deformation at the maximum given loading are larger than that at the same maximum under the out-phase fatigue. The stiffness decreases nonlinearly with the increasing of the phase angle, which results in increasing of the area of fatigue loop curve and the decrease in fatigue life. The spatially centralizing of inclusions results in decreasing of the plastic strain amplitude and the area of fatigue loop curve, which will also reduce the consumption of single-circle plastic strain energy and prolong the fatigue life.

Thermo-mechanical fatigue behavior of nickel-base powder metallurgy superalloy FGH96 under tension-tension loading

Thermo-mechanical fatigue （TMF） behavior of FGH96, a nickel-base powder metallurgy superalloy, has been studied under tension-tension loading at the temperature range from 550 to 720 ℃. The results show that TMF fracture mode is intergranular for the in-phase （IP）, but transgranular cleavage-like for the out-of-phase （OP） samples. The total content of Al, Ti and Nb in the γ＇ phases for the IP or OP samples and the partitioning ratio of γ＇/γin these elements for the IP samples are relatively higher at the lower strain amplitude, which is consistent with the case of the γ＇ size that is larger at the lower strain amplitude, the lattice parameter misfit is negative and the absolute value is lower at the lower strain amplitude that is correlative with the change of the γ＇ morphology. The deformation at the lower strain amplitude is mainly dominated by the dislocation lines and dislocation pairs in the matrix channels, at the higher strain amplitude dominated by the large numbers of superlattice stacking faults within the γ＇ phases.

Novel Crystallization Behaviors of Zr-Based Metallic Glass Under Thermo-Mechanical Coupled Fatigue Loading Condition

Novel crystallization behaviors of Zr55Cu30Al10Ni5 bulk metallic glass are investigated. On the one hand, mixed oxides, including CuO, CuAlO2, CuA12O4 and ZrO2, show sequential oxidation process determined by coupling effects of specific cyclic load and temperature. On the other hand, at a temperature (100℃) by far lower than Tg of 412 ℃, under cyclic loading condition, non-oxidized binary alloy CuZr2 is precipitated;the thermo-mechanical coupled effects of temperature below Tg, and fatigue accumulation on the non-oxidized crystallization behaviors are revealed. Meanwhile, at a constant temperature of 400 ℃, by comparing among the XRD patterns, respectively, obtained from tensile, creep and fatigue fractures, the dominating effect of cyclic load on the generation of non-oxidized CuZr2 is verified. Furthermore, the crystallization behavior of amorphous phases under cyclic loading condition is observed through TEM micrograph and diffraction pattern at 100℃.

镍基高温合金的热机械疲劳寿命预测模型研究

针对发动机热端部件常用材料镍基高温合金GH4169进行了200~450℃及400~650℃条件下的同相位热机械疲劳(TMF)试验,考虑TMF条件下多晶材料在弹性阶段产生的微观损伤应变能,提出一种适用于多晶材料的TMF寿命预测模型,并结合试验数据确定模型参数;采用GH4169、IN718、DD8三种高温合金对该模型的TMF寿命预测能力进行评估,结果表明,提出的寿命模型预测精度高于TMF寿命预测常用的Manson-Coffin模型和Ostergren模型。

压铸模具钢热机械疲劳损伤机制研究

热机械疲劳(Thermal Mechanical Fatigue,TMF)是压铸模具钢在高温和机械应力下的重要损伤形式。通过分析TMF加载条件下的疲劳断口特征,揭示其与传统低周疲劳不同的疲劳断口特征。研究发现:TMF的疲劳断口具有疲劳源区、裂纹扩展区和断裂区3个明显区域,其中裂纹扩展区面积最大;在不同加载条件下,断裂区的特征存在一定变化趋势。此外,在TMF过程中观察到断口表面的氧化现象在不同相位下呈现不同特征,这与加载条件及材料性质有关。研究还发现,在TMF过程中存在预缩现象,尤其在外部压力-热机械疲劳(External Pressure-Thermal Mechanical Fatigue,EP-TMF)条件下更为显著,这与低温半周塑性变形有关。

一种镍基单晶高温合金的热机械疲劳行为

采用热机械疲劳试验、扫描电镜、透射电镜等方法研究了一种镍基单晶高温合金在600-900℃的同相位热机械疲劳行为。结果表明：该合金在试验中承受的平均应力表现为压应力；随着机械应变幅的增大，疲劳寿命逐渐下降，应力范围和塑性应变量逐渐增大；合金在试验中表现为高温半周循环软化、低温半周循环硬化；合金热机械疲劳的主要变形机制为a／2（110）{111}型位错在基体内的滑移和交滑移运动；合金的断裂方式为微孔聚集型断裂，拉应力对合金的断裂起到了主导作用。

DD8单晶镍基高温合金的热机械疲劳

对DD8合金进行了同位相(IP)与反位相(DP)热机械疲劳(TMF)实验.结果表明:当以机械应变幅作为参量时,在高应变幅下,IP疲劳寿命均低于OP的寿命;随着应变幅的降低,IP疲劳寿命有向OP寿命靠近的趋势.扫描电镜观察表明,IP和OP TMF试样的断口形貌有明显的不同.在IP实验中,裂纹萌生于试样内的铸造孔洞,垂直于加载轴方向扩展;而OP裂纹则是萌生于试样的自由表面,沿着{111}晶面扩展.不同的裂纹萌生和扩展机制是导致IP和OP TMF寿命差异的主要原因.

Ni_3Al合金热/机械疲劳裂纹扩展行为研究

对 IC10定向凝固高温合金进行了 45 0～ 990℃热 /机械疲劳裂纹扩展行为的试验研究。分别研究了相位角、保持时间、温度、频率对 IC10合金裂纹扩展行为的影响 ,并建立了热 /机械疲劳裂纹扩展速率预测模型。研究发现 :温度的升高和频率的降低均会加速裂纹扩展 ;同相位热 /机械疲劳裂纹扩展速率大于反相位热 /机械疲劳裂纹扩展速率 ,而且它们两者介于最大温度和最小温度的等温疲劳裂纹扩展速率之间 ;

镍基单晶超合金中孔洞长大的试验和有限元分析(英文)

在高温状态下,镍基单晶超合金的变形、损伤及断裂分析中,孔洞的长大都起着主要的作用。本研究进行了系列的蠕变、疲劳及热机械疲劳(TMF)试验。对试件的断面进行的 SEM 观察表明,所有的断面都是有许多小断面构成,在断面的中心,至少有一个孔洞。孔洞的尺寸与加载的条件相关。使用晶体塑性有限元程序对单胞模型进行分析,模拟孔洞的长大规律。给出了蠕变和弹塑性两种条件下的模拟结果及不同的晶体取向对孔穴长大的影响结果。对孔洞长大的有限元分析有助于对实验结果的理解。

纤维增强金属基复合材料层板热/机械疲劳性能试验研究

进行了B/Al层板250～350℃温度循环范围内的同相位、反相位的热/机械疲劳寿命试验以及250℃和350℃下的等温疲劳试验与宏微观分析研究。结果表明:同相位与反相位的热/机械疲劳S-N曲线出现相交,以交点做应力水平线FPF,在FPF以上,同相位的热/机械疲劳(TMF)比反相位的要短;而在FPF以下,同相位的TMF寿命比反相位的要长;无论是同相位,还是反相位的TMF寿命,均低于250℃和350℃下的等温疲劳寿命;疲劳裂纹起源于纤维与基体界面,并随着基体的横向开裂而扩展,但最终的疲劳损伤机理不仅取决于应力水平,还取决于试验环境条件;纤维与基体之间界面反应区在TMF的损伤扩展方面起了主要作用。

铸造Ti-48Al-2Cr-2Nb合金的热机械疲劳行为

采用应变控制的方法,研究了铸造Ti-48Al-2Cr-2Nb合金400℃~800℃循环温度下的同相位热机械疲劳行为,并与400℃和800℃恒温低周疲劳结果进行了对比分析。结果表明,该合金的400℃~800℃同相位热机械疲劳性能在大应变短寿命区优于400℃和800℃恒温低周疲劳;在小应变长寿命区略低于400℃低周疲劳,介于800℃低周疲劳数据分散带内;在热机械疲劳试验条件下,合金不表现明显循环硬化或软化现象,疲劳试样断口可观察到层片间、层片内断裂和穿层片撕裂3种开裂方式。

In-phase thermal–mechanical fatigue investigation on hollow single crystal turbine blades

Thermal-mechanical fatigue（TMF）is the primary cause of failure of nickel-based single crystal turbine blades.TMF experiments have been performed on the critical section which is subjected to the most serious damage and determined by numerical calculation combined with service failure experience.An experimental system including the loading,heating,air cooling,water cooling,and control subsystems,is constructed to satisfy the TMF experimental requirements.This experimental system can simulate the stress feld,temperature feld,air cooling process,and TMF spectrum on the critical section under service conditions in a laboratory environment.A metal loading device and a new induction coil are developed to achieve the required stress and temperature distributions on the critical section,respectively.TMF experimental results have indicated that cracks initiated at the trailing edge of the suction surface on the critical section.Based on these experiments,life prediction and failure analysis of hollow single crystal turbine blades can be investigated.

汽车排气歧管热机械疲劳CAE分析方法

通过研究一种应用于发动机歧管设计的CFD与FEA耦合分析技术方法,模拟分析发动机歧管在特定工况下的热-机械疲劳特性,依据一个直列四缸发动机排气歧管热-机械疲劳分析结果,合理改善热机械疲劳强度风险较高地方的结构设计,有效提升产品热机械疲劳强度和开发效率,降低产品设计中的耐久试验次数与成本。

某型汽车排气催化器开裂原因分析

针对某型汽车催化器端盖开裂问题,通过材料金相分析和模拟仿真分析,考虑排气系统的高温影响,发现在高温工况下材料的力学性能下降,导致了零件热疲劳强度降低,零件的等效塑性应变增量超过推荐值1%,并找到了构件断裂的主要原因。因此温度对排气系统的排气系统设计的影响不可忽视,热疲劳分析能够有效的提升重要零件的开发效率。

一种单晶涡轮叶片热机械疲劳寿命评估方法

针对单晶涡轮叶片热机械疲劳(TMF)问题,围绕单晶涡轮叶片TMF试验,结合单晶变形、损伤理论及数值模拟,建立了一套单晶涡轮叶片TMF寿命评估方法.利用空心气冷涡轮叶片TMF试验系统,对单晶涡轮片考核截面在服役条件下所产生的交变应力场和交变温度场进行模拟,确定了裂纹萌生部位及其TMF寿命.考虑单晶涡轮叶片变形和损伤行为的特征,分别建立了基于滑移系的Walker黏塑性本构模型和基于临界平面的循环损伤累积(CDA)模型.利用上述本构和寿命模型,完成了单晶涡轮叶片TMF试验的数值模拟.结果表明:叶片理论危险点与试验结果一致,且计算寿命基本落在试验寿命的3倍分散带内.

弹片热机械疲劳试验方法研究及设计

针对弹片的热机械疲劳(TMF)试验要求,采用机械设计技术、机电技术、冷却技术、计算机技术和数据采集技术,提出了压力载荷和热载荷的加载方法,建立了2种载荷5个试验件的并联试验控制系统,并设计了弹片热机械疲劳试验器。试验结果表明:该系统能够同时模拟服役环境下弹片的压力载荷和热载荷。利用该试验系统进行了弹片的热机械疲劳试验,试验结果再现了弹片在服役状态下的失效模式。试验系统具有良好的重复度、较高的加载频率和加载精度。压力载荷最大相对误差为2.4%,绝对误差小于0.5N。温度载荷最大相对误差为3.55%,最大绝对误差为3.89℃。