钛合金焊接件疲劳寿命估算

基于有限单元法理论，采用ANSYS有限元分析软件，对航空发动机中常用钛合金焊接试件进行应力应变分析，得到了焊接接头的等效应力场和应变场，并确定出试件等效应力集中系数Kf，运用局部应力-应变法对光滑焊接试件估算疲劳寿命，并采用成组试验法对计算结果进行验证和分析。     

焊接工艺方法对6061-T6铝合金焊接接头疲劳性能的影响

通过对6061铝合金MIG焊接头和TIG焊接头在对应的加载应力条件下疲劳寿命的测定,对比分析了两种工艺方法对铝合金焊接接头疲劳性能的影响。结果表明,在加载应力低于焊接接头静载力学性能的90%时,焊接接头的疲劳寿命均能满足需求背景的需要(100000次不破坏)。同样载荷条件下,MIG焊接头的疲劳性能优于TIG焊接头,尤其是在高应力条件下,MIG焊接头的优势更为明显。焊接接头显微组织分析表明,MIG焊接头比TIG焊接头具有更为细小的晶粒和焊接热影响区,有效地提高了接头的滑移形变抗力,抑制了循环滑移带的形成和开裂,从而提高接头的疲劳性能。疲劳断口分析显示,试件的表面缺陷(疏松、气孔、夹杂等)及机械损伤是疲劳裂纹主要的策源地。     

高阶有限元格式研究的一个新途径

 在作者提出的有限差分－有限元混合方法的基础上，将差分法中的三阶无波动、无自由参数的ENN格式较成功地推广应用到有限元法中，为发展高精度有限元格式提供了一个新途径。     

TC4钛合金扩散焊接头的力学性能

在温度为910℃，压力为3.4MPa条件下对TC4钛合金板材进行了扩散焊接，对获得的扩散焊接头取样进行金相观察，仅在接近接头表面材料深度为1mm范围内发现未焊合缺陷，其余部分焊合较好，表明在给定工艺下可获得质量良好的焊接头.随后对TC4扩散焊接头的力学性能进行了试验研究，分别开展了静拉伸试验、断裂韧性试验及焊缝附近区域的纳米压痕试验.试验结果表明，所制得的TC4扩散焊接头屈服强度为887MPa，抗拉强度为948MPa，断裂韧性为101.9MPa·m1/2，均与原材料的性能相差不大.纳米压痕试验的结果显示，接头焊缝区和母材区的显微弹性模量分别为180.2GPa和178.0GPa.      

Effect of beam current on microstructures and mechanical properties of joints of TZM/30CrMnSiA by electron beam welding

Electron beam welding experiments of TZM alloy and 30CrMnSiA steel butt joints were carried out with different beam currents. Microstructures and chemical compositions of typical zones were analyzed by optical microscopy, scanning electron microscopy and X-ray diffraction. The mechanical properties of the joints were evaluated by tensile strength tests. Besides, nanoindentation tests were carried out to compare the brittleness of the reaction layer and other typical microstructures. The results illustrated that the reaction layer at the interface between fusion zone (FZ) and TZM alloy was the weak position of the joint, which was divided into Fe₂Mo layer and a mixture layer of Fe₂Mo and α-Fe phases. As the beam current increased, the thickness of the Fe₂Mo layer decreased, which resulted in the increasing of the tensile strength of the joints. When the beam current exceeded 24 mA, the formation of the joint was poor with a low tensile strength. When the beam current was 24 mA, the joint presented the highest strength of 191.3 MPa and the joint fractured along the Fe₂Mo layer near the TZM alloy side with a brittle fracture mode.     

Multiscale topology optimization using feature-driven method

This paper presents a multiscale design method for simultaneous topology optimization of both macrostructures and microstructures. Geometric features are extended as design primitives at both macro and micro scales and represented by Level Set Functions (LSFs). Parameters related to the locations, sizes, and orientations of macro and micro features are considered as design variables and optimized simultaneously. In the overlapping areas of different macro features, embedded microstructures are optimally figured out as the solution of the corresponding sub-optimization problem. In this study, the eXtended Finite Element Method (XFEM) is implemented for structural and sensitivity analyses with respect to design variables. This method has the advantage of using a fixed grid independent of the topology optimization process. The homogenization procedure is applied to calculate the effective properties of considered microstructures in each macro feature. Numerical examples are presented to illustrate the effectiveness of the proposed method. Results depict that the multiscale design cannot obviously improve structural stiffness compared with a solid-material design under the linear elastic condition.     

微纳米压痕测试技术:发展与应用

近年来,具有高精度、高通量的微纳米压痕测试技术,已被广泛应用于研究微/纳米尺度下材料力学性能演化规律和变形行为中。然而,在航空航天材料试验测试领域,令研究人员更感兴趣的往往是如何更好地揭示材料工程性能,更好地理解材料在服役环境下变形损伤机制。因此,接近材料真实服役环境（如高/低温、电/磁场）下的微纳米压痕测试系统更具应用潜力。首先对传统的微纳米压痕测试技术进行回顾总结,涉及测试系统的组成、经典分析理论方法及其面临的尺度/尺寸效应。然后,简要描述典型磁电弹性材料在力-电-热-磁多场耦合环境下接触力学行为的解析模型,并着重阐述面向材料实际服役环境下的压痕测试技术的典型应用,包括高/低温纳米压痕测试和电/磁场耦合条件下的纳米压痕测试应用。最后,讨论了目前发展所面临的主要问题和挑战,这对微纳米压痕测试技术的进一步发展和先进应用具有重要意义。     

基于能量有限元法和虚拟模态综合法的高频冲击响应分析方法

为了分析结构受到高频冲击载荷激励后的瞬态响应,提出了一种基于能量有限元法（EFEM）和虚拟模态综合（VMSS）法的高频冲击响应分析方法。通过能量有限元法进行高频稳态分析,获得结构频响函数（FRF）的频段平均值,然后结合虚拟模态综合法得到虚拟模态振型系数,最后通过Duhamel积分获得结构在高频冲击载荷作用下的瞬态响应。对一简支梁模型进行算例分析,将本文方法的结果与传统有限元法（FEM）和统计能量法（SEA）的分析结果进行对比,验证了所提方法的有效性,也表明该方法具有模型简单、分析速度快等优点。     

Semi-analytical model for flat indentation of metal materials and its applications

The increasing use of small material components in a wide range of industrial fields necessitates the development of an accurate and robust indentation testing method. To this end, this paper proposes an Energy-density-equivalence for a Flat Indentation (E-FI) model based on the energy density equivalent principle. The proposed model describes the relationships among the material parameters of Hollomon’s power law (H-law), flat indenter diameter, energy, and indentation displacement. An E-FI Method (E-FIM) that determines the H-law parameters of materials through the indentation test is also developed. The energy-displacement curves forward-predicted by the E-FI model (based on known H-law parameters of materials) and the H-law parameters of materials given by the E-FIM (based on known energy-displacement curves) are consistent with the results of Finite Element Analysis (FEA) and the H-law parameters of materials used as the input for FEA, respectively. Using E-FIM, the goodness of fit for both stress–strain curves with H-law, predicted based on the displacement with 2% signal interference, and that for stress–strain curves without interference is more than 0.98. The stress–strain relations predicted by E-FIM were consistent with the results obtained via uniaxial tensile tests of ten ductile materials.     

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...     

铜/镍箔中间层对铝/钢激光焊接接头组织与力学性能的影响

研究以Ni、Ni/Cu箔片为中间层的铝/钢异种金属激光焊接行为,系统考察Cu/Ni箔片复合中间层的添加对铝/钢异种激光焊接接头组织与性能的影响。利用扫描电子显微镜和能谱仪对焊缝横截面的组织形貌和各区域的元素分布进行观察分析,利用X射线衍射仪对焊接接头的主要物相进行分析,并利用电子万能试验机对焊接接头进行拉伸实验以表征其力学性能,结果表明:Cu/Ni箔片做复合中间层加入时,其中加入0.02 mm厚Cu箔片时焊接接头的最大剪切力提高至1754.72 N;加入0.05 mm厚Cu箔片时的最大剪切力为734.97 N,相比只添加Ni箔片时焊接接头的最大剪切力反而下降。Cu箔片的添加使得铝/钢界面的物相组成、元素分布和微观组织形态发生改变,同时增加了熔池的流动性。在靠近不锈钢侧的Fe-Al脆性相中的部分Fe原子被Cu原子取代生成新的二元韧性相,从而抑制Fe-Al二元脆性金属间化合物的生成,有效改善铝/钢的焊接性。因此,Cu/Ni箔片复合中间层的加入,可以有效地改善铝/钢异种激光焊接过程中的冶金反应,进而提高焊接接头的力学性能。     

2524与7150铝合金激光焊T型接头的组织与性能

介绍了2524与7150铝合金激光焊T型接头优化的工艺参数,并研究了T型接头在优化工艺下的显微组织与力学性能,进行金相分析、显微硬度测试与接头拉伸试验。结果表明:优化工艺下焊缝没有裂纹、气孔,金相组织晶粒细小、致密,焊缝区域的硬度最低;T型接头x方向的拉伸强度达到384 MPa,z方向的拉伸强度为236 MPa。     

微量元素C和Mg对一种镍基高温合金组织和力学性能的影响

通过对微量元素C,Mg含量的调整,来研究C,Mg元素对一种镍基合金组织及性能的影响,结果表明:C含量不足时,合金组织中碳化物数量少,在合金组织中分布不均匀,合金持久性能较低;而适量提高C含量,碳化物均匀分布,持久寿命明显提高.Mg元素含量低时,不影响合金的组织,合金的力学性能没有明显改变;而当Mg含量过高时,晶界碳化物粗大,合金冲击韧性aK值较低,拉伸塑性也降低;当加入最佳Mg含量时,碳化物得到充分细化,晶界碳化物呈粒状分布,合金的aK值和拉伸延伸率δ值显著提高.     

基于Tanaka-Mura模型的电子束焊接头疲劳裂纹萌生模拟

为揭示高温合金电子束焊接头的疲劳特性,对其开展了疲劳裂纹萌生数值模拟研究。考虑焊缝区微观组织特性,对Voronoi图法进行改进,建立了焊缝区包含柱状晶、细等轴晶及粗等轴晶的混合晶区微观组织模型;对ABAQUS进行二次开发,考虑晶粒随机取向,生成晶粒多滑移带模型。基于Tanaka-Mura位错滑移模型,编写了疲劳裂纹萌生算法,考虑晶界处裂纹的连接与合并,对算法进行了改进,并结合有限元计算建立了电子束焊接头疲劳裂纹萌生数值模拟方法。基于上述方法对GH4169电子束焊接头不同载荷大小的疲劳裂纹萌生进行数值模拟,分析了裂纹萌生过程及萌生寿命,并与试验结果进行对比验证;还探讨了不同热影响区晶粒尺寸对焊接接头疲劳裂纹萌生的影响规律。结果表明,电子束焊接头疲劳裂纹均萌生于热影响区,但随着载荷水平的提高,萌生位置向熔合区一侧靠近;当热影响区晶粒尺寸与母材区晶粒尺寸越接近时,接头疲劳寿命越长。     

燕尾形榫联接修形的数值研究

将边界元法用于榫联接修形的数值分析研究。对分析具有摩擦接触问题的边界元法的理论及实现方法作了讨论;将边界元分析应用于航空发动机轮盘榫槽与叶片样头联接的计算,并与激光散斑法的实测结果进行比较;对修形的榫联接进行了计算分析,初步揭示了修形榫联接接触边界上力学参数的变化规律,与试验结果相符合。     

A novel surrogate modeling strategy of the mechanical properties of 3D braided composites

In this paper, a surrogate-based modeling methodology is developed and presented to predict the elastic properties of three dimensional (3D) four-directional braided composites. Using this approach, the prediction process becomes feasible with only a limited number of training points. The surrogate models constructed using Finite Element (FE) method and Diffuse Approximation, reduce the computational time and cost for preparing experimental samples. In the FE model, multiscale method is applied to couple the computations of elastic properties at microscale and mesoscale. Subsequently, a parametric study is performed to analyze the effects of the three design parameters on the elastic properties. Satisfactory results are obtained via the surrogate-based modeling predictions, which are compared with the experimental measurements. Moreover, the predictions obtained from surrogate models concur well with the FE predictions. This study orients a new direction for predicting the mechanical properties based on surrogate models which can effectively reduce the sample preparation cost and computational efforts.     

纳米压痕实验微米级深度硬度下降现象的研究(英文)

本文针对均匀材料微米级压痕深度,分析接触深度、接触面积、载荷以及加载时间几种因素对实验数据的影响,结合有限元数值模拟,说明压头几何缺陷、接触深度与接触面积的处理并不是造成微米级压痕硬度随压深增大而下降的主要原因,最可能的原因是材料的蠕变特性。进行了不同最大压深实验显示连续刚度法(CSM)将强化蠕变特性对硬度曲线的影响,证明造成该现象的重要原因是纳米压痕实验的实验方法问题。     

Theoretical aspects of selecting repeated unit cell model in micromechanical analysis using displacement-based finite element method

Repeated Unit Cell(RUC)is a useful tool in micromechanical analysis of composites using Displacement-based Finite Element(DFE)method,and merely applying Periodic Displacement Boundary Conditions(PDBCs)to RUC is almost a standard practice to conduct such analysis.Two basic questions arising from this practice are whether Periodic Traction Boundary Conditions(PTBCs,also known as traction continuity conditions)are guaranteed and whether the solution is independent of selection of RUCs.This paper presents the theoretical aspects to tackle these questions,which unify the strong form,weak form and DFE method of the micromechanical problem together.Specifically,the solution’s independence of selection of RUCs is dealt with on the strong form side,PTBCs are derived from the weak form as natural boundary conditions,and the validity of merely applying PDBCs in micromechanical Finite Element(FE)analysis is proved by referring to its intrinsic connection to the strong form and weak form.Key points in the theoretical aspects are demonstrated by illustrative examples,and the merits of setting micromechanical FE analysis under the background of a clear theoretical framework are highlighted in the efficient selection of RUCs for Uni Directional(UD)fiber-reinforced composites.     

Multi-layered plate finite element models with node-dependent kinematics for smart structures with piezoelectric components

This article presents a type of plate Finite Element (FE) models with adaptive mathematical refinement capabilities for modeling laminated smart structures with piezoelectric layers or distributed patches. The p-version shape functions are used in combination with the higher-order Layer-Wise (LW) kinematics adopting hierarchical Legendre polynomials. Node-Dependent Kinematics (NDK) is employed to implement local LW models in the regions with piezoelectric components and simulate the global substrate structure with the Equivalent Single-Layer (ESL) approach. Through the proposed NDK FE models, the electro-mechanical behavior of smart structures can be predicted with high fidelity and numerical efficiency, and various patch configurations can be conveniently modeled through one set of mesh grids. Moreover, the effectiveness and efficiency of the NDK FE approach are assessed through numerical examples and its application is demonstrated.     

DZ40M合金缺陷试样TLP-DB接头力学性能研究

开展定向凝固钴基高温合金DZ40M的过渡液相扩散焊试验,研究不同界面缺陷率DZ40M合金TLP-DB接头的高温力学性能。结果表明:采用1260℃/0.5h+1200℃/6h规范可实现DZ40M合金过渡液相扩散焊的良好结合;接头高温持久强度达到等条件下母材的70%以上;当界面缺陷率达15%时,接头高温持久强度仍达到母材的70%以上;但随着缺陷比例的增大,断裂位置由母材转移到焊缝。