High-cycle Fatigue Fracture Behavior of Ultrahigh Strength Steels

The fatigue fracture behavior of four ultrahigh strength steels with different melting processes and therefore different inclusion sizes were studied by using a rotating bar two-point bending fatigue machine in the high-cycle regime up to 107 cycles of loading. The fracture surfaces were observed by field emission scanning electron microscopy （FESEM）. It was found that the size of inclusion has significant effect on the fatigue behavior. For AtSI 4340 steel in which the inclusion size is smaller than 5.5 μm, all the fatigue cracks except one did not initiated from inclusion but from specimen surface and conventional S-N curve exists. For 65Si2MnWE and Aermet 100 steels in which the average inclusion sizes are 12.2 and 14.9 μm, respectively, fatigue cracks initiated from inclusions at lower stress amplitudes and stepwise S-N curves were observed. The S-N curve displays a continuous decline and fatigue failures originated from large oxide inclusion for 60Si2CrVA steel in which the average inclusion size is 44.4 pro. In the case of internal inclusion-induced fractures at cycles beyond about 1×10^6 for 65Si2MnWE and 60Si2CrVA steels, inclusion was always found inside the fish-eye and a granular bright facet （GBF） was observed in the vicinity around the inclusion. The GBF sizes increase with increasing the number of cycles to failure Nf in the long-life regime. The values of stress intensity factor range at crack initiation site for the GBF are almost constant with Nf, and are almost equal to that for the surface inclusion and the internal inclusion at cycles lower than about 1×10^6. Neither fish-eye nor GBF was observed for Aermet 100 steel in the present study.

High Cycle Fatigue Properties of Die-Cast Magnesium Alloy AZ91D with Addition of Different Concentrations of Cerium

The effect of addition of different concentrations of Ce on high-cycle fatigue behavior of die-cast magnesium alloy AZ91D was investigated. Mechanical fatigue tests were conducted at the stress ratio of R = 0.1, and fatigue strength was evaluated using up-and-down loading method. The results show that the grain size of AZ91D alloy is remarkably refined, and the amount of porosity decreases and evenly distributes with the addition of Ce. The fatigue strength of AZ91D alloy at room temperature increases from 96.7 up to 116.3 MPa （ 1% Ce） and 105.5 MPa （2 % Ce）, respectively, at the number of cycles to failure, Nf = 1 × 10^7. The fatigue crack of AZ91D alloy initiates at porosities and inclusions, and propagates along grain boundaries. The fatigue striations on fractured surface appear with Ce addition. The fatigue fracture surface of test specimens shows mixed-fracture characteristics of quasi-cleavage and dimple.

Fracture of two three-dimensional parallel internal cracks in brittle solid under ultrasonic fracturing

Similar to hydraulic fracturing(HF), the coalescence and fracture of cracks are induced within a rock under the action of an ultrasonic field, known as ultrasonic fracturing(UF). Investigating UF is important in both hard rock drilling and oil and gas recovery. A three-dimensional internal laser-engraved crack(3D-ILC) method was introduced to prefabricate two parallel internal cracks within the samples without any damage to the surface. The samples were subjected to UF. The mechanism of UF was elucidated by analyzing the characteristics of fracture surfaces. The crack propagation path under different ultrasonic parameters was obtained by numerical simulation based on the Paris fatigue model and compared to the experimental results of UF. The results show that the 3D-ILC method is a powerful tool for UF research.Under the action of an ultrasonic field, the fracture surface shows the characteristics of beach marks and contains powder locally, indicating that the UF mechanism includes high-cycle fatigue fracture, shear and friction, and temperature load. The two internal cracks become close under UF. The numerical result obtained by the Paris fatigue model also shows the attraction of the two cracks, consistent with the test results. The 3D-ILC method provides a new tool for the experimental study of UF. Compared to the conventional numerical methods based on the analysis of stress-strain and plastic zone, numerical simulation can be a good alternative method to obtain the crack path under UF.

Fatigue cracking criterion of high-strength steels induced by inclusions under high-cycle fatigue

Fatigue properties of high-strength steels become more and more sensitive to inclusions with enhancing the ultimate tensile strength (UTS) because the inclusions often cause a relatively low fatigue strength and a large scatter of fatigue lives. In this work, four S–N curves and more than 200 fatigue fracture morphologies were comprehensively investigated with a special focus on the size and type of inclusions at the fatigue cracking origin in GCr15 steel with a wide strength range by different heat treatments after high-cycle fatigue (HCF). It is found that the percentage of fatigue failure induced by the inclusion including Al2 O3 and TiN gradually increases with increasing the UTS, while the percentage of failure at sample surfaces decreases conversely and the fatigue strength first increases and then decreases. Besides, it is interestingly noted that the inclusion sizes at the cracking origin for TiN are smaller than that for Al2 O3 because the stress concentration factor for TiN is larger than that for Al2 O3 based on the finite element simulation. For the first time, a new fatigue cracking criterion including the isometric inclusion size line in the strength-toughness coordinate system with specific physical meaning was established to reveal the relationship among the UTS, fracture toughness, and the critical inclusion size considering different types of inclusions based on the fracture mechanics. And the critical inclusion size of Al2 O3 is about 1.33 times of TiN. The fatigue cracking criterion could be used to judge whether fatigue fracture occurred at inclusions or not and provides a theoretical basis for controlling the scale of different inclusion types for high-strength steels. Our work may offer a new perspective on the critical inclusion size in terms of the inclusion types, which is of scientific interest and has great merit to industrial metallurgical control for anti-fatigue design.

TC4-DT钛合金的室温高周疲劳断裂特点

在不同应力比(0.5,-1)下对损伤容限型TC4-DT钛合金进行室温高周疲劳试验,对比分析了不同疲劳寿命下光滑试样与缺口试样的典型断口中的宏微观特征。结果表明:光滑试样疲劳断口整体粗糙,类解理特征不明显,但疲劳条带清晰,裂纹源主要为单源,瞬断区多呈月牙形,均位于断口一侧边缘;应力比为0.5下104周次疲劳寿命的断口中无明显平坦疲劳裂纹扩展区,而相近疲劳寿命的应力比为-1的断口中可见平坦疲劳裂纹扩展区;应力比为0.5的疲劳裂纹主要在次表面或内部萌生,而应力比为-1的裂纹基本在表面萌生。缺口试样疲劳断口整体平坦,可见类解理特征,疲劳条带清晰;裂纹起源于缺口根部,多源;随着疲劳寿命由104周次延长到106周次,瞬断区由内部移向缺口边缘,应力比为-1下的瞬断区呈纺锤形,而应力比为0.5下的瞬断区由椭圆向纺锤形变化,且应力比为0.5下的疲劳裂纹扩展区更为光滑平坦,瞬断区的塑性断裂特征更明显。

Fatigue response,fracture characteristic and life modeling of a near-alpha titanium alloy under typical cyclic loadings in service

Experimental investigations on the fatigue behavior of a near-alpha titanium alloy under typical cyclic loadings were carried out to simulate the service loading states applied on the engine blades.The axial stress-controlled tension–tension low-cycle fatigue（LCF） tests were carried out over a range of maximum stresses and stress ratios.The rotary bending tests were conducted using a step-loading procedure to reveal the high-cycle fatigue（HCF） limit stresses.The cyclic softening effect is observed in this material,and the strain ratcheting occurs obviously at the maximum LCF loading of 900 MPa.The LCF resistance is found to be dependent on both the maximum loading and the stress ratio.The HCF limit stresses for 1 9 107 and 1 9 106 cycles are determined as405.7 and 457.6 MPa,respectively.The macroscopic fatigue fracture mode and the failure features on fracture surfaces were analyzed by scanning electron microscope（SEM）.

Fatigue Life Prediction of Gray Cast Iron for Cylinder Head Based on Microstructure and Machine Learning

Conventional fatigue tests on complex components are difficult to sample,time-consuming and expensive.To avoid such problems,several popular machine learning(ML)algorithms were used and compared to predict fatigue life of gray cast iron(GCI)with the complex microstructures.The feature analysis shows that the fatigue life of GCI is mainly influenced by the external environment such as the stress amplitude,and the internal microstructure parameters such as the percentage of graphite,graphite length,stress concentration factor at the graphite tip,matrix microhardness and Brinell hardness.For simplicity,collected datasets with some of the above features were used to train ML models including back-propagation neural network(BPNN),random forest(RF)and eXtreme gradient boosting(XGBoost).The comparison results suggest that the three models could predict the fatigue lives of GCI,while the implemented RF algorithm is the best performing model.Moreover,the S–N curves fitted by the Basquin relation in the predicted data have a mean relative error of 15%compared to the measured data.The results have demonstrated the advantages of ML,which provides a generic way to predict the fatigue life of GCI for reducing time and cost.

国产P92钢低周疲劳性能与断裂特征研究

采用疲劳性能测试方法研究了应变控制下国产P92钢室温和600℃高温下的低周疲劳性能,并采用扫描电子显微镜对疲劳试样断口形貌进行了观察.结果表明:国产P92钢具有循环软化特征,应变幅和温度的提高是造成材料单轴疲劳寿命降低的主要原因;2种温度下疲劳裂纹均起源于表面,裂纹扩展为条纹机制;高温下具有较低的疲劳寿命是与氧化损伤、裂纹萌生扩展速率和材料的塑性变形密切相关的.

P91钢蠕变—疲劳交互作用下断裂特性研究

在546℃下,对电厂用关键材料P91钢进行应力控制的蠕变—疲劳交互作用下试验。分别讨论平均应力和应力幅对断裂时间的影响,分析断口形貌与韧窝脱粒成分,断口裂纹金相,获得P91钢蠕变—疲劳交互作用下断裂机制与断裂特性。研究结果表明,由于微观裂纹的闭合,P91钢蠕变—疲劳交互作用寿命随着下保载的时间增加而增加。当平均应力远小于应力幅时,试样主要表现为疲劳断裂,当平均应力与应力幅相等时,试样为蠕变疲劳共同作用下的断裂特征,当平均应力远大于应力幅时,断裂特征为蠕变断裂。通过断口金相分析,试样断口裂纹均为穿晶断裂。对断口韧窝的脱粒成分研究,脱粒为氧化物。研究结果为P91钢蠕变—疲劳断裂机制分析提供理论和实验基础。

单晶高温合金断裂特征

对单晶高温合金高温拉伸、低周疲劳、高周疲劳和持久断裂特征进行试验研究。结果表明:单晶高温合金高温拉伸断口具有类解理断裂与韧窝断裂的混合特征,断裂机制为中心微孔聚集型断裂。低周疲劳断裂在高应变幅下为多疲劳源,裂纹扩展初期断口与主应力方向垂直,随后疲劳裂纹沿特定晶体学平面扩展;在低应变幅下为单疲劳源,疲劳裂纹沿特定晶体学平面扩展。高周疲劳断裂为单疲劳源,在大应力下断口由多个相交的特定晶体学平面组成,应力较小时,断口由一个大的晶体学平面和瞬断区组成。疲劳裂纹在晶体学平面上扩展形成的疲劳条带间距很宽。高温持久断裂机制为微孔聚集型断裂,显微缩孔成为持久断裂的主要裂纹源。表面再结晶对高温持久断裂机制影响较小,但会使持久性能降低。

S135钻杆钢扭转疲劳寿命及断裂特征

针对钻杆在循环应力下的疲劳问题,通过室内试验测定了S135钻杆钢的扭转疲劳寿命,得到了扭转疲劳的Δ-τN曲线,应用统计分析方法得到扭转疲劳寿命公式,并采用扫描电镜(SEM)对疲劳断口进行了观察和分析。结果表明,扭转疲劳裂纹形成于光滑试样表面,且疲劳源的大小随切应力幅值的增加而增加;在疲劳源与疲劳裂纹扩展处的微观形貌特征为典型纯滑移型断裂,在裂纹扩展处涟波状花样区域的大小随切应力幅值的增加而增大。

Ti-25Al-10Nb-3V-1Mo合金的高周疲劳性能及断裂特征

实验测定了 Ti- 2 5 Al- 10 Nb- 3V - 1Mo合金 6 5 0℃下高周疲劳 S- N曲线及热暴露后合金的疲劳性能。结果表明 ,Ti- 2 5 Al- 10 Nb- 3V- 1Mo合金具有较高的疲劳强度 ,可以满足转子零件的要求。对比光滑和缺口试样的高周疲劳性能 ,可以看出该合金缺口敏感程度高 ,且随着应力水平的增加而增大。应用 SEM对疲劳变形后的断口进行了观察 ,详细分析了疲劳裂纹的起源与扩展 ,以及裂纹扩展时的微观应力状态。

FGH97粉末高温合金的断裂特征

对FGH97粉末高温合金低周疲劳、高周疲劳和持久断裂特征进行了研究。结果表明:低周疲劳断裂在小应变条件下的裂纹源为单裂纹源,疲劳裂纹稳定扩展第一阶段为类解理小平面特征;在大应变条件下,裂纹源转变为多源,疲劳扩展第一阶段即可见疲劳条带特征;高周疲劳裂纹稳定扩展第一阶段有较大区域的类解理断裂小平面,疲劳扩展第二阶段为疲劳条带特征;持久试验温度为500℃时,断口为穿晶特征,表现为类解理形貌;在500℃以上时,其断裂机制为晶内发生单取向和双取向滑移,随蠕变进行位错在晶界处塞积,进而引起应力集中,致使裂纹在晶界处萌生并扩展。

铝锂合金T型自冲铆接头疲劳特性及失效机理

为研究T型自冲铆接头的疲劳特性,以铝锂合金(AL1420)同种及其与铜合金(H62)和不锈钢(410)异种组合制备的AA、HA和SA三组T型自冲铆接头为研究对象,基于其静力学试验采用正弦波进行拉-拉加载疲劳试验,用二参数威布尔分布对所得疲劳数据的有效性进行验证,采用最小二乘拟合直线得到拟合的F-N曲线,并采用SEM扫描电镜对各组典型疲劳失效断口进行微观分析。结果表明:SA组疲劳寿命对载荷变化最敏感,并且疲劳寿命随相对滑移量的增加而减小;由三组T型接头失效形式可看出接头薄弱环节有由铆钉向板材转移的趋势;从微观分析疲劳断口可知裂纹萌生区多为形貌特征较为平坦的准解理,裂纹瞬断区形貌更加突出,多为沿晶断裂或韧窝形貌。

DD6单晶高温合金低周疲劳断裂特征的研究

对DD6单晶高温合金在高温低周(980℃、760℃)及疲劳/蠕变交互作用的断裂特征进行了研究。结果表明:DD6单晶高温合金高温低周疲劳断口往往呈多源开裂特征,裂纹萌生于试样的表面或亚表面,疲劳裂纹在刚萌生时沿着一定的小平面进行扩展,扩展区主要由垂直于裂纹扩展方向的疲劳条带和河流花样组成,瞬断区为类解理台阶形貌,裂纹扩展初期断口基本与主应力方向垂直,随着疲劳裂纹的扩展,断口呈现与主应力约成45°的平面特征;低周疲劳/蠕变交互作用的断裂特征与相同应变条件下低周疲劳断口总体形貌相似,但也一些不同之处,如断口整体氧化严重、疲劳扩展区面积明显减小。

喷丸对DZ4合金旋转弯曲疲劳断裂特征的影响

对喷丸前后DZ4高温合金旋转弯曲高周疲劳断口的断裂特征进行了观察。结果表明,室温和高温(820℃)时,未喷丸的DZ4合金高周疲劳裂纹均萌生于试样表面以及与表面相连的铸造缺陷或碳化物处。Kt=1时,疲劳断口为点源,源区存在滑移平面和滑移台阶;随着应力集中水平的升高(Kt=2,Kt=3),疲劳断口向多源和线源发展,源区滑移面变小甚至消失;随着温度的升高,断口源区滑移特征明显。喷丸后,疲劳裂纹源内移,裂纹萌生于试样次表面的晶体内部或铸造缺陷处。带缺口试样裂纹源减少,起源区域缩小,出现明显的主、次疲劳源。实验证明,喷丸可降低DZ4合金表面和缺口敏感性,对裂纹萌生有抑制作用,可提高材料的疲劳性能,随着温度升高,喷丸的强化作用逐渐减弱,但在820℃仍有强化作用。

中强和高强铝锂合金的疲劳特性

研究了８０９０中强铝锂合金和２０９０高强铝锂合金的疲劳特性，包括疲劳裂纹扩展速率、名义和本征门槛值、裂纹闭合效应、尾迹效应、无裂纹疲劳寿命。８０９０合金在近门槛值区有优良的名义疲劳裂纹扩展抗力和名义门槛值，归因于高的裂纹闭合效应；同时，显露出强的短裂纹效应，系因裂纹闭合效应的尾迹依赖性。无裂纹疲劳寿命以２０９０合金为佳，与其高的屈服强度和细的扁平未再结晶晶粒相对应。两合金的本征疲劳裂纹扩展抗力、本征门槛值以及在Ⅲ区的名义疲劳裂纹扩展抗力差别甚微。在断口上，８０９０合金的塑变特征明显，２０９０合金的分层倾向更强。重点探索了疲劳特性与断裂特征的关系。

一种改进的遗传算法在疲劳断口图像鉴别中的应用

特征选择是疲劳断口图像鉴别中的重要问题之一。针对高维的断口图像特征,特征选择一方面可以提高分类精度和效率,另一方面可以确定富含信息的特征子集。针对此问题,提出一种改进的遗传算法,并用于疲劳断口的特征选择:首先,引入线性预测对简单遗传算法SGA(simple genetic algorithm)进行修正,在每一代较优的个体附近,采用线性预测的方法预测出新的个体,提高遗传算法的局部搜索能力;其次,把特征选择转化为目标优化问题,确定目标函数,并利用改进的遗传算法进行断口图像特征选择,得到精简的特征子集;最后,在特征子集上进行断口图像分类鉴别。结果表明:改进的遗传算法可找到有效的特征子集,从而实现降维并提高分类精度。

8090铝锂合金的外韧化机制

本文研究了８０９０铝锂合金的疲劳裂纹扩展特性、短裂纹效应、裂纹闭合效应、断裂待亚等，并与２０２４铝合金相对比，证实该合金优良的疲劳长裂纹扩展抗力主要源于外韧化效应，且在近门槛值区、Ｐａｒｉｓ区和Ⅲ区有着不同的断裂机制和外韧化机制。近门槛值区和Ⅲ区的外韧化效应分别为裂纹闭合效应和分层韧化效应，而在Ｐａｒｉｓ区系上述两种效应的耦合。

铝锂合金8090+Ce的疲劳断裂特征

研究了铝锂合金8090+Ce的疲劳寿命和断裂特征,并与2024铝合金相对比。结果表明,铝锂合金8090+Ce各应力水平的疲劳寿命均低于2024铝合金;其早期沿晶萌生的微小裂纹一般沿晶纵向扩展,而发展成为非扩展短裂纹,不构成对疲劳寿命的危害;其主断裂面上的短裂纹沿粗滑移带扩展,显示宽而平直的典型脆性疲劳条带;其瞬断方式为穿晶粗滑移带开裂+穿晶和沿晶撕裂的混合型,对应于较小的失稳扩展临界尺寸。