2124铝合金板材断裂韧性和高周疲劳特性研究
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摘要
通过MTS测试了不同厚度2124-T851铝合金板材的断裂韧性,并详细考察了合金板材的疲劳性能。此外,通过金相实验方法(OM),X射线物相分析(XRD)以及透射电镜分析(TEM),结合断裂韧性测试以及疲劳性能实验失效样品断口扫描电镜扫描分析(SEM)研究了合金微观组织结构对2124-T851铝合金板材断裂韧性和疲劳性能的影响。结果表明:
(1)2124-T851铝合金板材不同取向的断裂韧性不同,L-T向断裂韧性明显优于T-L向:30mm厚板材断裂韧性最好,L-T向为29.64MPa(?),T-L向为24.31MPa(?)。
(2)2124-T851铝合金板材应力幅值低于243MPa时,疲劳寿命达到10~7;随厚度的增加,疲劳强度下降,疲劳裂纹扩展速率增加。
(3)高周疲劳断裂过程中应力幅值越高,样品疲劳寿命越低,瞬断区面积占总的断面面积的比例也越大。应力幅值对板材疲劳寿命的影响主要在于随着应力幅值的提高,在疲劳辉纹间距略有增大的同时,疲劳裂纹越早进入瞬时断裂阶段。
(4)疲劳裂纹扩展速率计算结果,30mm厚板材为da/dN=2.8×10~(-8)(△K)~(3.5);40mm厚板材为da/dN=4.4×10~(-8)(△K)~(3.4);55mm厚板材为da/dN=5.7×10~(-8)(△K)~(3.3)。由于裂纹闭合效应等因素的影响,循环载荷数会远大于微观可见的疲劳辉纹数目,因此计算结果与断口观察的疲劳辉纹间距有差异。
(5)2124-T851铝合金疲劳裂纹扩展有明显的三阶段特性,疲劳裂纹一般在试样表面萌生,裂纹扩展中产生大量疲劳辉纹,随着裂纹的扩展疲劳辉纹间距会增大,随后发生瞬时断裂,断口呈小韧窝和解理断裂的混合形貌。
(6)Paris描述的应力场强度因子范围与裂纹扩展速率的关系只适用于某一扩展阶段,裂纹在Ⅰ和Ⅲ阶段,其扩展速率都是随△K的增加而急剧上升。疲劳瞬断区的形成和材料的断裂韧性是相关的,当K_(max)大约达到K_(IC)时材料发生断裂。
(7)2124-T851铝合金板材为不完全的再结晶组织,合金主要相有α-Al基体,针状析出相S'(Al_2CuMg)以及大颗粒析出相Al_6(Fe,Mn)。
(8)晶界和亚晶界能有效阻止疲劳裂纹的萌生和扩展,有利于合金的抗疲劳性能和断裂韧性。板材厚度对2124-T851铝合金断裂韧性以及疲劳性能的影响主要源于因板材厚度不同而导致的晶界以及亚晶界情况的差异。
The fracture toughness and high cycle fatigue characteristics of 2124-T851 aluminum alloy plates were investigated using MTS.Meanwhile,the influences of the microstructure on the alloy's fracture toughness and high cycle fatigue characteristics were researched using optical microscopy(OM)、transmission electron microscopy (TEM)and X-ray diffraction(XRD),as well as the fatigue fractography observed by scaning electron microscopy.The results show that:
(1)The fracture toughness of 2124-T851 aluminum alloy plates is anisotropic,and the crack growth resistance in L-T direction is better than the one in T-L direction.The 30mm-thick-plate has the best all-around fracture toughness that 29.64MPam/2 in L-T direction,and 24.31MPam/2 in T-L direction.
(2)The high cycle fatigue strength of 2124-T851 aluminum alloy plates decrease with the increase of the plate thickness.Under the condition of room temperature and stress ratio R=0.1,the fatigue strength at 10~7 cycles of 2124-T851 aluminum alloy with 30mm thickness is 243MPa.
(3)At high cycle fatigue condition,the higher the stress amplitude, the lower the fatigue life,and the greater the ratio between the intermittent fracture area and the whole fracture area.The influence of the stress amplitude on the fatigue life of alloy plates dues to the aggrandizement of space between fatigue striations and advance of fatigue crack developing into the intermittent fracture area.So the fatigue resistance can be improved effectively with the increase of alloy's fracture toughness.
(4)The calculated fatigue crack growth rate results of 2124-T851 aluminum alloy plates with 30mm、40mm and 55mm thickness are da/dN=2.8×10~(-8)(△K)~(3.5);da/dN=4.4×10~(-8)(△K)~(3.4);and da/dN=5.7×10~(-8)(△K)~(3.3),respectively.Because of the crack closure effect,the time of cyclic loads is more than the number of fatigue striations which can be observed using SUM,so the results of estimation do not tally with the observed separation of fatigue striations well.
(5)The fatigue crack growth of 2124-T851 aluminum alloy can be divided into three regions obviously.Generally,the fatigue crack initiates at the surface of the samples,then a number of fatigue striations form during the process of fatigue crack propagation,and the separation of them becomes larger.Lastly,the rapid fracture happens,and the mixed fractography of little dimples and cleavage fracture can be observed.
(6)The relationship between the stress intensity factor D-value and the fatigue crack developing rate can be described using Paris equation just during the process of theⅡstage of crack propagation. And during theⅠandⅢstage,the fatigue crack growth rate speeds rapidly with the enhancement of△K.Because the rapid fracture stage forms relating with the fracture toughness of alloy,when the K_(max)reaches to the K_(IC)the fracture happens.
(7)The microstructure of the 2124-T851 aluminum alloy is partially recrystallized.The grain size in normal of rolling plane augments with the increase of plate thickness.The main phases of the as-received alloy includeα-Al、S'(Al_2CuMg)and Al_6(Fe, Mn)
(8)The grain boundary,and sub-boundary can effectively restrain the initiation and propagation of fatigue crack,so they are propitious to the fatigue resistance and fracture toughness.The effect of thickness on the fracture toughness is primarily due to the differences of alloy's grain boundary and sub-boundary owing to the differrent thickness.
(1)2124-T851铝合金板材不同取向的断裂韧性不同,L-T向断裂韧性明显优于T-L向:30mm厚板材断裂韧性最好,L-T向为29.64MPa(?),T-L向为24.31MPa(?)。
(2)2124-T851铝合金板材应力幅值低于243MPa时,疲劳寿命达到10~7;随厚度的增加,疲劳强度下降,疲劳裂纹扩展速率增加。
(3)高周疲劳断裂过程中应力幅值越高,样品疲劳寿命越低,瞬断区面积占总的断面面积的比例也越大。应力幅值对板材疲劳寿命的影响主要在于随着应力幅值的提高,在疲劳辉纹间距略有增大的同时,疲劳裂纹越早进入瞬时断裂阶段。
(4)疲劳裂纹扩展速率计算结果,30mm厚板材为da/dN=2.8×10~(-8)(△K)~(3.5);40mm厚板材为da/dN=4.4×10~(-8)(△K)~(3.4);55mm厚板材为da/dN=5.7×10~(-8)(△K)~(3.3)。由于裂纹闭合效应等因素的影响,循环载荷数会远大于微观可见的疲劳辉纹数目,因此计算结果与断口观察的疲劳辉纹间距有差异。
(5)2124-T851铝合金疲劳裂纹扩展有明显的三阶段特性,疲劳裂纹一般在试样表面萌生,裂纹扩展中产生大量疲劳辉纹,随着裂纹的扩展疲劳辉纹间距会增大,随后发生瞬时断裂,断口呈小韧窝和解理断裂的混合形貌。
(6)Paris描述的应力场强度因子范围与裂纹扩展速率的关系只适用于某一扩展阶段,裂纹在Ⅰ和Ⅲ阶段,其扩展速率都是随△K的增加而急剧上升。疲劳瞬断区的形成和材料的断裂韧性是相关的,当K_(max)大约达到K_(IC)时材料发生断裂。
(7)2124-T851铝合金板材为不完全的再结晶组织,合金主要相有α-Al基体,针状析出相S'(Al_2CuMg)以及大颗粒析出相Al_6(Fe,Mn)。
(8)晶界和亚晶界能有效阻止疲劳裂纹的萌生和扩展,有利于合金的抗疲劳性能和断裂韧性。板材厚度对2124-T851铝合金断裂韧性以及疲劳性能的影响主要源于因板材厚度不同而导致的晶界以及亚晶界情况的差异。
The fracture toughness and high cycle fatigue characteristics of 2124-T851 aluminum alloy plates were investigated using MTS.Meanwhile,the influences of the microstructure on the alloy's fracture toughness and high cycle fatigue characteristics were researched using optical microscopy(OM)、transmission electron microscopy (TEM)and X-ray diffraction(XRD),as well as the fatigue fractography observed by scaning electron microscopy.The results show that:
(1)The fracture toughness of 2124-T851 aluminum alloy plates is anisotropic,and the crack growth resistance in L-T direction is better than the one in T-L direction.The 30mm-thick-plate has the best all-around fracture toughness that 29.64MPam/2 in L-T direction,and 24.31MPam/2 in T-L direction.
(2)The high cycle fatigue strength of 2124-T851 aluminum alloy plates decrease with the increase of the plate thickness.Under the condition of room temperature and stress ratio R=0.1,the fatigue strength at 10~7 cycles of 2124-T851 aluminum alloy with 30mm thickness is 243MPa.
(3)At high cycle fatigue condition,the higher the stress amplitude, the lower the fatigue life,and the greater the ratio between the intermittent fracture area and the whole fracture area.The influence of the stress amplitude on the fatigue life of alloy plates dues to the aggrandizement of space between fatigue striations and advance of fatigue crack developing into the intermittent fracture area.So the fatigue resistance can be improved effectively with the increase of alloy's fracture toughness.
(4)The calculated fatigue crack growth rate results of 2124-T851 aluminum alloy plates with 30mm、40mm and 55mm thickness are da/dN=2.8×10~(-8)(△K)~(3.5);da/dN=4.4×10~(-8)(△K)~(3.4);and da/dN=5.7×10~(-8)(△K)~(3.3),respectively.Because of the crack closure effect,the time of cyclic loads is more than the number of fatigue striations which can be observed using SUM,so the results of estimation do not tally with the observed separation of fatigue striations well.
(5)The fatigue crack growth of 2124-T851 aluminum alloy can be divided into three regions obviously.Generally,the fatigue crack initiates at the surface of the samples,then a number of fatigue striations form during the process of fatigue crack propagation,and the separation of them becomes larger.Lastly,the rapid fracture happens,and the mixed fractography of little dimples and cleavage fracture can be observed.
(6)The relationship between the stress intensity factor D-value and the fatigue crack developing rate can be described using Paris equation just during the process of theⅡstage of crack propagation. And during theⅠandⅢstage,the fatigue crack growth rate speeds rapidly with the enhancement of△K.Because the rapid fracture stage forms relating with the fracture toughness of alloy,when the K_(max)reaches to the K_(IC)the fracture happens.
(7)The microstructure of the 2124-T851 aluminum alloy is partially recrystallized.The grain size in normal of rolling plane augments with the increase of plate thickness.The main phases of the as-received alloy includeα-Al、S'(Al_2CuMg)and Al_6(Fe, Mn)
(8)The grain boundary,and sub-boundary can effectively restrain the initiation and propagation of fatigue crack,so they are propitious to the fatigue resistance and fracture toughness.The effect of thickness on the fracture toughness is primarily due to the differences of alloy's grain boundary and sub-boundary owing to the differrent thickness.
引文
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