High-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures

A modified model is developed to characterize and evaluate high-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures by considering the stress ratio effect. The model is informed by the relationship surface between maximum nominal stress, stress ratio and fatigue life. New formulae are derived to deal with the test data for estimating the parameters of the proposed model. Fatigue tests are performed on Co-based superalloy 9Cr Co subjected to constant amplitude loading at four stress ratios of 1, 0.3, 0.5 and 0.9 in three environments of room temperature(i.e., about 25 °C) and elevated temperatures of 530 °C and 620 °C, and the interaction mechanisms between the elevated temperature and stress ratio are deduced and compared with each other from fractographic studies. Finally, the model is applied to experimental data, demonstrating the practical and effective use of the proposed model. It is shown that new model has good correlation with experimental results.     

An inverse strategy to determine constitutive parameters of tubular materials for hydroforming processes

This paper is to determine the flow stress curve of 5049-O aluminium alloy by a tube hydraulic bulging test with fixed end-conditions. During this test, several tubular specimens are bulged under different internal pressures before their bursting, and the corresponding bulging height and wall thickness at the pole are measured. An inverse strategy is developed to determine the constitutive parameters of tubular materials based on experimental data, which combines the finite element method with g...     

New constitutive relation for eddy viscosity models

A new turbulent constitutive relation was directly derived from Boussinesq's hypothesis and mixing length theory, and then implemented in the standard k-ε model. The performance of this constitutive relation was validated in zero pressure gradient flat-plate boundary layer flow, fully-developed turbulent channel flow and separated flow in a plane asymmetric diffuser. The investigation demonstrated that, this new constitutive relation gave very accurate results in the former two basic cases and provided significant improvement in prediction of separated and reattachment points in the plane asymmetric diffuser. Separation and reattachment points at x/H=7.5 and 29 were calculated accurately in comparison to experimental results, and the static pressure coefficient of 0.82 was very close to large eddy simulation calculation. These results are very encouraging but further verification and extensive application of the new constitutive relation to other two-equation eddy viscosity model are needed.      

Cutting tool temperature prediction method using analytical model for end milling

Dramatic tool temperature variation in end milling can cause excessive tool wear and shorten its life, especially in machining of difficult-to-machine materials. In this study, a new analyt-ical model-based method for the prediction of cutting tool temperature in end milling is presented. The cutting cycle is divided into temperature increase and decrease phases. For the temperature increase phase, a temperature prediction model considering real friction state between the chip and tool is proposed, and the heat flux and tool-chip contact length are then obtained through finite element simulation. In the temperature decrease phase, a temperature decrease model based on the one-dimension plate heat convection is proposed. A single wire thermocouple is employed to mea-sure the tool temperature in the conducted milling experiments. Both of the theoretical and experi-mental results are obtained with cutting conditions of the cutting speed ranging from 60 m/min to 100 m/min, feed per tooth from 0.12 mm/z to 0.20 mm/z, and the radial and axial depth of cut respec-tively being 4 mm and 0.5 mm. The comparison results show high agreement between the physical cutting experiments and the proposed cutting tool temperature prediction method.     

Testing and evaluation for fatigue crack propagation of Ti-6Al-4V/ELI and 7050-T7452 alloys at high temperatures

This paper seeks to evaluate crack propagation properties and residual lives of metallic alloys subjected to fatigue loading at room and high temperatures. Fatigue crack growth tests were performed on Ti-6Al-4V/ELI and 7050-T7452 subjected to constant-amplitude and actual randomspectra loading at room temperature of about 25 ℃ and at high temperatures of 250 ℃ and 150 ℃ to determine their crack growth properties and residual lives. The damage mode and mechanisms at high temperature were compared with those at room temperature on the basis of the results of fractographic analysis. Temperature-dependent residual lives under actual random-spectra load history were evaluated based on a modified accumulation damage rule accounting for the load interaction.Good correlation was achieved between the predictions and actual experiments, demonstrating the practical and effective use of the proposed method.     

Defect Recognition in Thermosonic Imaging

This work is aimed at developing an effective method for defect recognition in thermosonic imaging.The heat mechanism of thermosonic imaging is introduced,and the problem for defect recognition is discussed.For this purpose,defect existing in the inner wall of a metal pipeline specimen and defects embedded in a carbon fiber reinforced plastic(CFRP) laminate are tested.The experimental data are processed by pulse phase thermography(PPT) method to show the phase images at different frequencies,and the characteristic of phase angle vs frequency curve of thermal anomalies and sound area is analyzed.A binary image,which is based on the characteristic value of defects,is obtained by a new recognition algorithm to show the defects.Results demonstrate good defect recognition performance for thermosonic imaging,and the reliability of this technique can be improved by the method.     

Investigation on Thermal Contact Conductance Based on Data Analysis Method of Reliability

The method of reliability is proposed for the investigation of thermal contact conductance (TCC) in this study. A new definition is introduced, namely reliability thermal contact conductance (RTCC), which is defined as the TCC value that meets the reliability design requirement of the structural materials under consideration. An experimental apparatus with the compensation heater to test the TCC is introduced here. A practical engineering example is utilized to demonstrate the applicability of the proposed approach. By using a statistical regression model along with experimental data obtained from the interfaces of the structural materials GH4169 and K417 used in aero-engine, the estimate values and the confidence level of TCC and RTCC values are studied and compared. The results show that the testing values of TCC increase with interface pressure and the proposed RTCC model matches the test results better at high interface pressure.     

Periodic Error Compensation for Quartz MEMS Gyroscope Drift of INS

In order to improve the navigation accuracy of an inertial navigation system （INS）, composed of quartz gyroscopes, the existing real-time compensation methods for periodic errors in quartz gyroscope drift and the periodic error term relationship between sampled original data and smoothed data are reviewed. On the base of the results, a new compensation method called using former period characteristics to compensate latter smoothness data （UFCL for short） method is proposed considering the INS working characteristics. This new method uses the original data without smoothing to work out an error conversion formula at the INS initial alignment time and then compensate the smoothed data errors by way of the formula at the navigation time. Both theoretical analysis and experimental results demonstrate that this method is able to cut down on computational time and raise the accuracy which makes it a better real-time compensation approach for periodic error terms of quartz micro electronic mechanical system （MEMS） gyroscope＇s zero drift.     

Cathode design investigation based on iterative correction of predicted profile errors in electrochemical machining of compressor blades

Electrochemical machining (ECM) is an effective and economical manufacturing method for machining hard-to-cut metal materials that are often used in the aerospace field. Cathode design is very complicated in ECM and is a core problem influencing machining accuracy, especially for complex profiles such as compressor blades in aero engines. A new cathode design method based on iterative correction of predicted profile errors in blade ECM is proposed in this paper. A math-ematical model is first built according to the ECM shaping law, and a simulation is then carried out using ANSYS software. A dynamic forming process is obtained and machining gap distributions at different stages are analyzed. Additionally, the simulation deviation between the prediction profile and model is improved by the new method through correcting the initial cathode profile. Further-more, validation experiments are conducted using cathodes designed before and after the simulation correction. Machining accuracy for the optimal cathode is improved markedly compared with that for the initial cathode. The experimental results illustrate the suitability of the new method and that it can also be applied to other complex engine components such as diffusers.     

Dynamic tensile behavior of AZ31B magnesium alloy at ultra-high strain rates

The samples having {0001} parallel to extruding direction(ED) present a typical true stress–true strain curve with concave-down shape under tension at low strain rate. Ultra-rapid tensile tests were conducted at room temperature on a textured AZ31 B magnesium alloy. The dynamic tensile behavior was investigated. The results show that at ultra-high strain rates of 1.93 · 102 s 1and 1.70 · 103 s 1, the alloy behaves with a linear stress–strain response in most strain range and exhibits a brittle fracture. In this case, {10-12} 10-11 extension twinning is basic deformation mode. The brittleness is due to the macroscopic viscosity at ultra-high strain rate, for which the external critical shear stress rapidly gets high to result in a cleavage fracture before large amounts of dislocations are activated. Because {10-12} tension twinning, {10-11} compressive twinning,basal a slip, prismatic a slip and pyramidal c + a slip have different critical shear stresses(CRSS), their contributions to the degree of deformation are very differential. In addition,Schmid factor plays an important role in the activity of various deformation modes and it is the key factor for the samples with different strain rates exhibit various mechanical behavior under dynamic tensile loading.     

延性材料断裂准则与平面应变断裂韧度

延性材料的临界断裂规律对结构完整性评价和金属塑性成形分析具有重要意义,但相关的弹塑性断裂强度研究长期存在瓶颈。本文针对30Cr2Ni4MoV低压转子钢和3Cr13不锈钢,完成了不同应力三轴度的4类试样拉伸破坏试验,基于FAT （Finite-element-analysis Aided Testing）方法,通过有限元迭代分析实现试样的载荷-位移关系逼近,进而获得材料直至断裂的全程等效应力-应变关系,并以此通过有限元正向分析获取4种试样的临界断裂阈值和临界应力三轴度,提出了基于临界断裂单元的应力三轴度与第一主应力阈值之间的对数型断裂强度准则。结果表明,2种材料、4类试样的FAT阈值分析结果与断裂强度准则符合良好。最后,基于断裂强度准则提出了依据I型裂纹尖端的应力分布预测材料平面应变启裂断裂韧度的新方法,并获得了30Cr2Ni4MoV低压转子钢和3Cr13不锈钢的平面应变启裂断裂韧度,结合临界断裂准则和裂纹静态扩展机理,提出了I型裂纹的材料J阻力曲线的理论预测方法,并给出了30Cr材料的预测结果。     

描述1Cr18Ni9Ti不锈钢单轴棘轮行为的黏塑性本构模型

在室温下对1Cr18Ni9Ti不锈钢进行了单轴棘轮实验研究,提出了一种新的分离型黏塑性本构模型。引入了能记忆最大塑性应变的记忆面,在记忆面内和面上采用不同形式的塑性应变流动律和背应力演化律,将单调拉伸和循环行为分别独立描述。将模型应用于1Cr18Ni9Ti不锈钢单轴棘轮行为的描述中,模拟结果和实验结果吻合较好。     

基于漏斗试样的C250钢高温扭转低周疲劳行为

C250钢的扭转疲劳破坏是其主要失效形式之一。为了获得航空材料C250钢的扭转疲劳特性,并消除等直圆棒试样在扭转试验中产生的弊端,依据漏斗试样完成了C250钢在3种高温(150、200、350℃)环境下的扭转低周疲劳试验,获得了在扭转低周疲劳下的扭矩-名义扭转角曲线。基于试验结果,利用FAT方法分析得到了C250钢在3种高温环境下的材料循环本构关系,利用该循环本构关系对漏斗试样进行三维扭转有限元分析,获得漏斗根部剪切应力与扭矩之间的转换公式及漏斗根部剪切应变与名义扭转角之间的转换公式。基于以上试验与分析方法,得到了材料的剪切应变幅-倍循环次数曲线、剪切应力幅-循环分数曲线以及剪切应力-剪切应变的稳定滞回线,发现材料呈现出循环软化特性,并基于Manson-Coffin模型对材料寿命进行了分析。     

棘轮和蠕变条件下材料的附加塑性变形行为研究

针对316L不锈钢进行大量单轴棘轮和蠕变试验研究,对材料在棘轮和蠕变作用下的塑性变形行为以及变形量进行比较和分析.分析发现,材料棘轮和蠕变变形行为之间存在一些相似规律,而且相同试验时间下蠕变变形高于棘轮变形.在持续应力作用下,材料的附加塑性变形与作用应力间体现出上凸的抛物线规律,附加塑性变形先随应力的增长而升高,达到峰值后又逐渐减小.最后,根据这种上凸的抛物线规律提出相应的本构描述方程.     

Theoretical model and testing method for ball indentation based on the proportional superposition of energy in pure elasticity and pure plasticity

For a homogeneous, continuous, and isotropic material whose constitutive relationships meets with the Ramberg-Osgood law(R-O law), the energy in the elastoplastic indentation with a ball indenter was theoretically analyzed, and the proportional superposition of energy in pure elasticity and pure plasticity during indentation was considered based on the equivalence of energy density. Subsequently, a Proportional Superposition-based Elasto Plastic Model(PS-EPM) was developed to describe the relati...     

Residual stress indentation model based on material equivalence

A novel residual stress indentation model for conical indentation loading is proposed to describe the relationship between the residual stress, material constitutive parameters, load, and displacement for materials with a uniaxial constitutive relationship that obeys Hollomon’s power law (H-law). The novel model was established based on the principle that the equivalent material without residual stress corresponds to the original material with residual stress, conical indentation theoretical model based on energy density equivalence, and an assumed power-law relationship between the dimensionless residual stress and relative difference of the yield stresses of the equivalent material and original material. Sixty imaginary H-law materials with ten equibiaxial and ten uniaxial residual stresses were investigated by Finite Element Analysis (FEA). The residual stresses predicted by the novel model from the indentation load–displacement curves simulated for the imaginary materials are in close agreement with those applied by the FEA. Finally, indentation tests for Cr12MoV steel, 45 steel, and 6061-T6511 aluminum alloy were carried out on their specimens without residual stress and their bending specimens with equibiaxial and uniaxial residual stresses. The residual stresses predicted by the novel model according to the indentation load–displacement test curves are in good agreement with those applied by the tests.     

激光选区熔化成型316L不锈钢工艺参数研究

针对激光选区熔化成型316L不锈钢工艺参数选择问题,采用单因素条件变量分析法,在激光选区熔化过程中,分析了激光功率、扫描速度对316L不锈钢成型零件表面粗糙度、致密度、硬度和尺寸偏差的影响规律。结果表明:当激光功率降低或者扫描速度提高时,内部能量密度减小,粉末熔化量减少,试样表面球化效应增强,孔隙缺陷增多,试样致密度减小、硬度降低;当激光功率提高或者扫描速度降低时,内部能量密度增大,粉末被过度烧蚀,产生较大的尺寸偏差,所形成熔道易塌陷,导致层间结合较差,试样性能降低。当激光功率为300 W、扫描速度为1000 mm/s时,能量密度适中,形成了较好的冶金结合,抗拉强度可达753 MPa,上表面硬度HRB能达到97.22。该项研究为316L不锈钢激光选区熔化工艺参数的合理选择提供了参考。     

应力作用下316L不锈钢塑性变形行为研究

 对316L不锈钢进行了大量的单轴高周次棘轮和蠕变试验，讨论了在长达20 000周应力循环中材料的棘轮变形演化与饱和棘轮变形的规律，以及棘轮幅值应力对峰值控制规律的影响；基于材料棘轮效应和蠕变迁为之间相互联系的系统研究提示出：材料的棘轮变形本质上源于应力循环过程中材料的黏塑性。     

A novel method of utilizing static mixer to obtain mixing homogeneity of multi-species powders in laser metal deposition

Real-time mixing of multi-species powder challenges Laser Metal Deposition (LMD) of Functionally Graded Materials (FGMs). The current work proposes a novel method of using a static mixer to realize rapid, uniform multi-species powder mixing. Firstly, copper powder and 316L stainless steel powder are selected to complete the powder mixing observation experiment with Scanning Electron Microscope (SEM) and Energy Dispersive Spectrometer (EDS). Secondly, computational fluid dynamics and particle mixing simulation models are used to analyze the flow field and particle motion characteristics in the static mixer. Finally, LMD experiment and metallographic observation are carried out with 316L stainless steel powder and WC powder to verify the feasibility of the static mixer. This study provides a theoretical and practical basis for powder mixing in laser processing with a static mixer. The conclusions can also be applied to other processing fields requiring real-time and uniform mixing of multi-species powders.     

316L 不锈钢的单轴棘轮效应

对316L不锈钢进行了单轴应变控制和应力控制下的系统循环试验。对316L不锈钢在应变循环下的循环应变幅值、应变幅值历史、平均应变对循环特性的影响进行了揭示;对该材料在应力循环下的应力幅值、平均应力及其历史对循环蠕变（棘轮效应）的影响进行了分析。发现无论单轴应变循环特性还是非对称单轴应力下的棘轮效应不但依赖于当前加载状态,而且依赖于其加载历史。得到了316L单轴循环行为的一些有意义的结果。