显微组织与微量氢对钛合金电子束焊接接头疲劳特性的影响
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摘要
由于具有优良的拉伸、疲劳强度与耐腐蚀性能的优点,钛合金在航空、化学工程及医学等领域广泛应用。对于航天用钛合金,疲劳性能是一个重要的参数,特别是用作结构材料,焊接是一种必不可少的手段,焊接后焊接接头中存在较大组织与力学性能的不均匀性,对其疲劳性能也有深刻的影响。钛与氢具有很好的结合力,焊接接头中微量氢的存在,对焊接接头的性能将产生深刻的影响,许多研究都致力于找出氢对钛合金性能影响的机理。本文对TC4与TA15两种钛合金电子束焊接接头的分区疲劳扩展差异,结合裂纹尖端微区形态分析,探讨了显微组织对合金疲劳行为的影响;并对微量的氢元素对钛合金的疲劳性能进行研究,为钛合金的应用提供理论基础。
本文的主要研究内容及成果为:
①疲劳裂纹扩展速率试验表明:距焊缝上表面5/6处裂纹扩展速率最快,1/6处速率次之,3/6处裂纹扩展最慢,且研究中硬度梯度越大处,裂纹扩展速率越高;焊接接头分区裂纹扩展试验表明:热影响区裂纹扩展速率最高,其次为焊缝区,母材区裂纹扩展最缓慢。母材等轴组织裂纹扩展抗力最大;焊缝区马氏体成束分布且取向各异,导致裂纹扩展路径曲折,裂纹扩展抗力居中;热影响区硬度梯度最大,疲劳过程中,α相与马氏体变形不匹配,裂纹扩展抗力最低。
②疲劳裂纹尖端的微区形态研究表明:经历疲劳循环后,位错密度大大增加,α/β相界面位错密度高,易成为位错形核的源区。焊缝区马氏体板条之间的细碎相细碎相易成为疲劳裂纹形核的“软点”,焊缝区较窄的马氏体板条,易成为疲劳裂纹萌生的源区。热影响区软质α相与硬质马氏体相变形不匹配,大大降低了裂纹的扩展抗力。此外,通过分区TEM对比研究,发现了焊缝区相对于母材更易萌生裂纹的相关证据。
③微量氢对TC4疲劳性能影响的研究表明:在置氢含量低于0.120 wt.%,氢以固溶形态存在于TC4中,疲劳寿命随平均氢含量增加而急剧下降。氢的加入在一定程度上粗化了β相,β相粗化造成α与β相界面的协调能力下降,缺陷将沿α与β相界面聚集,从而成为二次裂纹源。在应力作用下裂纹尖端聚积了原子氢,加速了裂纹扩展。氢含量的提高在增加TC4硬度的同时,减少了TC4的塑性与韧性。显微组织分析表明,位错在次生的α、β相区聚集,且α/β相界往往是裂纹萌生的根源。固溶的原子氢导致驻留滑移带软化,降低了裂纹扩展的门槛值,从而增加了裂纹的扩展速率。
④微量氢对TA15疲劳性能影响的研究表明:置氢含量低于0.105wt.%,氢以固溶形态存在于TA15焊缝中,疲劳寿命及扩展寿命随平均氢含量增加剧烈下降。这是由于氢降低了合金的韧性并增加了裂纹扩展速率。母材比焊接接头具有更高的裂纹扩展抗力。组织分析表明,电子束焊接TA15钛合金生成马氏体α'相,由于马氏体片束取向分布导致扩展后期形成团簇结构;氢沿相界聚集,加速了裂纹沿马氏体团的扩展速率,在断口上留下了“胞状”形态。马氏体团作为一个单元共同承受变形,固溶氢有加速裂纹沿“胞状”组织边界扩展的作用。
⑤TA15小裂纹尖端微区形态研究中,测定了TA15的△K-da/dN曲线,拟合得到曲线方程为:da/dN=6.93×10~(-10)(△K)~(2.61),并通过计算得到裂纹尖端循环塑性区尺寸为166.17μm,研究发现TA15α相分布取向接近,加速了疲劳裂纹扩展。对小裂纹阶段的尖端形态进行了研究,发现了裂纹尖端塑性区及滑移带特征;裂纹尖端塑性区对疲劳裂纹扩展影响深刻。裂纹扩展通过尖端锐化-粗化-再锐化的过程实现的,其过程伴随着裂纹尖端位错运动、聚集及滑移带形成,滑移在相界处发生一定角度的偏折,而由于TA15中α相分布取向接近,弱化了相界对裂纹扩展的阻碍作用。
Because of its excellent specific tensile, fatigue strengths and corrosion resistance, Titanium alloy have been mainly used for aircraft structural and engine parts, materials for a petrochemical plants and surgical implants. Since excellent fatigue properties are required from investment titanium alloy to be used for airplane parts, fatigue properties should be taken into critical consideration. Particularly, the fatigue behavior of airplane parts containing welded regions should be closely examined and evaluated before the parts are actually applied, because there were unhomogeneities of microstructure and mechanical property in welded joints. Therefore, it is essentially required to investigate fatigue properties of the welded region which differ in microstructures.
Addition of hydrogen has a considerable effect on the mechanical properties of titanium alloys because that titanium alloys have a high affinity for hydrogen, hydrogen can be detrimental to the mechanical properties of titanium alloys, especially for the titanium alloy with welded joints. Much work has been done concerning the effects of hydrogen as an alloying element and its corresponding mechanism. In present study, the fatigue growth behavior and micro-morphologies at crack tips of the welded joints in different region and the effects of small amounts of hydrogen on the fatigue properties of electron beam welded TC4 and TA15 alloys were investigated, which is expected to contribute to fundamental understanding of the fatigue mechanism and the role of hydrogen.
The important outcomes are as follows:
①The results of fatigue crack growth revealed that: the fatigue crack growth rate of 5/6 from the welded joint surface was highest, followed by the 1/6 from the surface, the lowest rate was 3/6 from the surface which was the middle of the welded joint. The experiment of fatigue growth in different region of welded joints was based on the fatigue crack growth of micro-hardness, the results also revealed that the gradients of micro-hardness have some relationship with the fatigue crack growth: the bigger of the gradient, the faster of the fatigue growth rate. The base metal whose microstructure was exquilax plasticαphase had best crack growth resistance; the orientation of martensite packets in fusion zone differ with each other, which makes the crack growth tortuously. The heat affected zone whose hardness gradient was the highest of the three groups showed the lowest resistance to cyclic crack growth. Theαphase and martensite lash in heat affact zone deformation dismatched during the fatigue cycle, which induced the resistance to the crack growth decreased.
②The research on the micro-morphologies at the crack tips of TC4 welded joints revealed that: experiencing from fatigue crack growth, the dislocations which emitted fromα/βinterfaces reached so densely that they inclined to become a source of the fatigue cracks, from which these dislocations were diverged radioactively under the cyclic stress. Dislocations accumulated badly among the small fatigue phases which lay between two martensite lathes, indicating that these small fatigue phases tended to become the source of fatigue crack. What is more, the more narrow the width of martensite lathes, the easier dislocations accumulated and became the fatigue source. The plasticαphase and martensite lash mixed structure in heat affected zone deformation dismatched which decreased the resistance of fatigue crack growth. By comparing the TEM morphologies of different regions, the corresponding evidence that welded joints were more liable to become the source fatigue cracks than the base metal was found.
③The influences of hydrogen on fatigue behaviors of electron beam welded TC4 experiment revealed that: no hydride formed when less than 0.120 wt% hydrogen charged in TC4, and the fatigue lives drop evidently with median hydrogen content increase. The compatible deformation ability of the phase boundaries was decreased because of theβphase became coarser after hydrogen charged, and the defects were accumulated at the phase boundaries, then became a source of second crack. Hydrogen atoms accumulated at the phase boundaries because of the cyclic stress, which accelerate the crack growth. With the increase of the hydrogen content, the micro-hardness of TC4 became higher, while the toughness and plasticity was drop badly. The microstructure analysis revealed that: dislocations accumulated in secondaryα/βphase region, which could be suspected of developing a source of crack. Hydrogen atoms soften the PSB at crack tips, which resulted fatigue threshold of the crack growth was decreased, while the crack growth rate was increased.
④The influences of hydrogen on fatigue behaviors of electron beam welded TA15 experiment revealed that: no hydride formed when less than 0.105wt. % hydrogen was charged in TA15 welded joints. Fatigue results revealed that: with hydrogen content increasing, the fatigue life in the welded joints was drop remarkably, because the existed hydrogen reduced the toughness remarkably of the TA15 alloy in the welded joint, and increased the fatigue crack growth rates. The substrates presented better fatigue cracking resistance than the welded joint. The morphology analysis of the fatigue fracture demonstrated that, the hydrogen accumulated along the boundaries, and accelerated crack propagation along the martensite packets in the welded joints, resulting of“colony structure”on the fracture surface, the martensite packets performed as a unit, and hydrogen had some effects on the martensite packet during the crack propagation.
⑤In the research on micro-morphologies of the fatigue crack tip in TA15, the△K-da/dN curve of TA15 alloy was determined, the curve equation through regression fitting was: da/dN=6.93×10~(-10)(△K)~(2.61). Through calculation it was found that the size of the plastic zone of the crack tip is 166.17μm. According to findings, the conclusion was finally reached thatαphases of similarly aligned accelerate the crack propagation. Furthermore, the small-crack stage and the micro-morphologies plastic zone of the crack tip was studied by transmission electron microscopy (TEM), indicating that the plastic zone of the crack tip have profound effects on the crack propagation behavior. While the crack propagate through the sharp - blunt - resharp process of the crack tip, the motion and accumulation of dislocation as well as the formation of the slip band were displayed. The slip bands are deflected at the phase or grain boundaries, and the orientation of theαphases of similarly aligned weakes the hindering effects of the phase boundaries.
本文的主要研究内容及成果为:
①疲劳裂纹扩展速率试验表明:距焊缝上表面5/6处裂纹扩展速率最快,1/6处速率次之,3/6处裂纹扩展最慢,且研究中硬度梯度越大处,裂纹扩展速率越高;焊接接头分区裂纹扩展试验表明:热影响区裂纹扩展速率最高,其次为焊缝区,母材区裂纹扩展最缓慢。母材等轴组织裂纹扩展抗力最大;焊缝区马氏体成束分布且取向各异,导致裂纹扩展路径曲折,裂纹扩展抗力居中;热影响区硬度梯度最大,疲劳过程中,α相与马氏体变形不匹配,裂纹扩展抗力最低。
②疲劳裂纹尖端的微区形态研究表明:经历疲劳循环后,位错密度大大增加,α/β相界面位错密度高,易成为位错形核的源区。焊缝区马氏体板条之间的细碎相细碎相易成为疲劳裂纹形核的“软点”,焊缝区较窄的马氏体板条,易成为疲劳裂纹萌生的源区。热影响区软质α相与硬质马氏体相变形不匹配,大大降低了裂纹的扩展抗力。此外,通过分区TEM对比研究,发现了焊缝区相对于母材更易萌生裂纹的相关证据。
③微量氢对TC4疲劳性能影响的研究表明:在置氢含量低于0.120 wt.%,氢以固溶形态存在于TC4中,疲劳寿命随平均氢含量增加而急剧下降。氢的加入在一定程度上粗化了β相,β相粗化造成α与β相界面的协调能力下降,缺陷将沿α与β相界面聚集,从而成为二次裂纹源。在应力作用下裂纹尖端聚积了原子氢,加速了裂纹扩展。氢含量的提高在增加TC4硬度的同时,减少了TC4的塑性与韧性。显微组织分析表明,位错在次生的α、β相区聚集,且α/β相界往往是裂纹萌生的根源。固溶的原子氢导致驻留滑移带软化,降低了裂纹扩展的门槛值,从而增加了裂纹的扩展速率。
④微量氢对TA15疲劳性能影响的研究表明:置氢含量低于0.105wt.%,氢以固溶形态存在于TA15焊缝中,疲劳寿命及扩展寿命随平均氢含量增加剧烈下降。这是由于氢降低了合金的韧性并增加了裂纹扩展速率。母材比焊接接头具有更高的裂纹扩展抗力。组织分析表明,电子束焊接TA15钛合金生成马氏体α'相,由于马氏体片束取向分布导致扩展后期形成团簇结构;氢沿相界聚集,加速了裂纹沿马氏体团的扩展速率,在断口上留下了“胞状”形态。马氏体团作为一个单元共同承受变形,固溶氢有加速裂纹沿“胞状”组织边界扩展的作用。
⑤TA15小裂纹尖端微区形态研究中,测定了TA15的△K-da/dN曲线,拟合得到曲线方程为:da/dN=6.93×10~(-10)(△K)~(2.61),并通过计算得到裂纹尖端循环塑性区尺寸为166.17μm,研究发现TA15α相分布取向接近,加速了疲劳裂纹扩展。对小裂纹阶段的尖端形态进行了研究,发现了裂纹尖端塑性区及滑移带特征;裂纹尖端塑性区对疲劳裂纹扩展影响深刻。裂纹扩展通过尖端锐化-粗化-再锐化的过程实现的,其过程伴随着裂纹尖端位错运动、聚集及滑移带形成,滑移在相界处发生一定角度的偏折,而由于TA15中α相分布取向接近,弱化了相界对裂纹扩展的阻碍作用。
Because of its excellent specific tensile, fatigue strengths and corrosion resistance, Titanium alloy have been mainly used for aircraft structural and engine parts, materials for a petrochemical plants and surgical implants. Since excellent fatigue properties are required from investment titanium alloy to be used for airplane parts, fatigue properties should be taken into critical consideration. Particularly, the fatigue behavior of airplane parts containing welded regions should be closely examined and evaluated before the parts are actually applied, because there were unhomogeneities of microstructure and mechanical property in welded joints. Therefore, it is essentially required to investigate fatigue properties of the welded region which differ in microstructures.
Addition of hydrogen has a considerable effect on the mechanical properties of titanium alloys because that titanium alloys have a high affinity for hydrogen, hydrogen can be detrimental to the mechanical properties of titanium alloys, especially for the titanium alloy with welded joints. Much work has been done concerning the effects of hydrogen as an alloying element and its corresponding mechanism. In present study, the fatigue growth behavior and micro-morphologies at crack tips of the welded joints in different region and the effects of small amounts of hydrogen on the fatigue properties of electron beam welded TC4 and TA15 alloys were investigated, which is expected to contribute to fundamental understanding of the fatigue mechanism and the role of hydrogen.
The important outcomes are as follows:
①The results of fatigue crack growth revealed that: the fatigue crack growth rate of 5/6 from the welded joint surface was highest, followed by the 1/6 from the surface, the lowest rate was 3/6 from the surface which was the middle of the welded joint. The experiment of fatigue growth in different region of welded joints was based on the fatigue crack growth of micro-hardness, the results also revealed that the gradients of micro-hardness have some relationship with the fatigue crack growth: the bigger of the gradient, the faster of the fatigue growth rate. The base metal whose microstructure was exquilax plasticαphase had best crack growth resistance; the orientation of martensite packets in fusion zone differ with each other, which makes the crack growth tortuously. The heat affected zone whose hardness gradient was the highest of the three groups showed the lowest resistance to cyclic crack growth. Theαphase and martensite lash in heat affact zone deformation dismatched during the fatigue cycle, which induced the resistance to the crack growth decreased.
②The research on the micro-morphologies at the crack tips of TC4 welded joints revealed that: experiencing from fatigue crack growth, the dislocations which emitted fromα/βinterfaces reached so densely that they inclined to become a source of the fatigue cracks, from which these dislocations were diverged radioactively under the cyclic stress. Dislocations accumulated badly among the small fatigue phases which lay between two martensite lathes, indicating that these small fatigue phases tended to become the source of fatigue crack. What is more, the more narrow the width of martensite lathes, the easier dislocations accumulated and became the fatigue source. The plasticαphase and martensite lash mixed structure in heat affected zone deformation dismatched which decreased the resistance of fatigue crack growth. By comparing the TEM morphologies of different regions, the corresponding evidence that welded joints were more liable to become the source fatigue cracks than the base metal was found.
③The influences of hydrogen on fatigue behaviors of electron beam welded TC4 experiment revealed that: no hydride formed when less than 0.120 wt% hydrogen charged in TC4, and the fatigue lives drop evidently with median hydrogen content increase. The compatible deformation ability of the phase boundaries was decreased because of theβphase became coarser after hydrogen charged, and the defects were accumulated at the phase boundaries, then became a source of second crack. Hydrogen atoms accumulated at the phase boundaries because of the cyclic stress, which accelerate the crack growth. With the increase of the hydrogen content, the micro-hardness of TC4 became higher, while the toughness and plasticity was drop badly. The microstructure analysis revealed that: dislocations accumulated in secondaryα/βphase region, which could be suspected of developing a source of crack. Hydrogen atoms soften the PSB at crack tips, which resulted fatigue threshold of the crack growth was decreased, while the crack growth rate was increased.
④The influences of hydrogen on fatigue behaviors of electron beam welded TA15 experiment revealed that: no hydride formed when less than 0.105wt. % hydrogen was charged in TA15 welded joints. Fatigue results revealed that: with hydrogen content increasing, the fatigue life in the welded joints was drop remarkably, because the existed hydrogen reduced the toughness remarkably of the TA15 alloy in the welded joint, and increased the fatigue crack growth rates. The substrates presented better fatigue cracking resistance than the welded joint. The morphology analysis of the fatigue fracture demonstrated that, the hydrogen accumulated along the boundaries, and accelerated crack propagation along the martensite packets in the welded joints, resulting of“colony structure”on the fracture surface, the martensite packets performed as a unit, and hydrogen had some effects on the martensite packet during the crack propagation.
⑤In the research on micro-morphologies of the fatigue crack tip in TA15, the△K-da/dN curve of TA15 alloy was determined, the curve equation through regression fitting was: da/dN=6.93×10~(-10)(△K)~(2.61). Through calculation it was found that the size of the plastic zone of the crack tip is 166.17μm. According to findings, the conclusion was finally reached thatαphases of similarly aligned accelerate the crack propagation. Furthermore, the small-crack stage and the micro-morphologies plastic zone of the crack tip was studied by transmission electron microscopy (TEM), indicating that the plastic zone of the crack tip have profound effects on the crack propagation behavior. While the crack propagate through the sharp - blunt - resharp process of the crack tip, the motion and accumulation of dislocation as well as the formation of the slip band were displayed. The slip bands are deflected at the phase or grain boundaries, and the orientation of theαphases of similarly aligned weakes the hindering effects of the phase boundaries.
引文
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