金属材料内裂纹愈合过程的物理模拟与计算机模拟
摘要
对金属材料内部裂纹愈合的机理、行为和规律进行深入研究,是改善金属材料性能、提高品质和延长使用寿命的重要基础性工作,对丰富材料学理论具有十分重要的意义,在材料设计、材料成形和材料使用指导方面有广泛的工程应用背景和潜在的经济和社会效益。本文选题结合国家自然科学基金重点项目“金属材料内部裂纹愈合研究”的主要研究工作,采用物理模拟和数值模拟分析方法对金属材料内部裂纹愈合规律进行了研究,并在此基础上进行了裂纹愈合过程的扩散热力学分析及裂纹愈合内变量分析。
在物理模拟研究方面:对于用平板撞击和钻孔压缩两种方法制备的试样,平板撞击铜试样中的层状内部裂纹由微孔洞连接形成的裂纹及临域离散分布的显微孔洞组成;钻孔压缩纯铁、20 钢、45 钢、16Mn 和5CrMnMo 钢试样中的内部裂纹由预置孔洞演化形成的一次裂纹及临域放射状二次裂纹组成。通过高温显微镜裂纹愈合的原位动态观察发现:在平板撞击纯铜试样剖分面上,10~100μm 级孔洞在温度为750℃时开始愈合,在900℃时明显愈合;扫描电镜观察发现:愈合孔洞的精细结构由μm 级团状颗粒与nm 级颗粒组成。基于上述观察研究认为,对于试样观察面上的开放式孔洞,其愈合过程是由位于基体内部的孔洞内表面向观察面进行的;由此推之对于封闭在试样内部的孔洞,其愈合过程的发生将会是从孔洞的内表面向孔洞的中心部位进行的。对纯铁、20 钢、45钢、16Mn 和5CrMnMo 钢钻孔压缩试样内部裂纹进行了热愈合处理,并对愈合区域进行了形态、组织结构、化学成分和力学性能的观察与分析。扫描电镜分析确定,愈合区内精细组织主要为铁素体,并存在许多大小为数百nm 级的多边晶块和析出颗粒。X 射线能谱分析结果表明,基体区、愈合区及析出颗粒中的主体元素均为Fe、Mn、S 和Si,各元素在不同区域的相对含量接近。出现析出颗粒说明愈合区是过饱和区,即愈合过程必须有原子的长距离扩散以满足成分上的需要。成分趋于一致说明在随后的保温过程中,发生了成分均匀化的扩散过程。维氏硬度测试结果显示,出现在愈合区的铁素体组织维氏硬度高于基体区铁素体组织,可能原因是愈合区中出现的多边晶块结构所引发的强化。
在数值模拟研究方面:利用分子动力学方法,对Cu 单晶中心贯穿裂纹的愈合形态演化过程进行了模拟,结果表明裂纹形态演化与建立在大量实验观察基础上所获得的形态演化物理模型类似。用ANSYS 有限元分析软件,模拟了压缩过程中45 钢圆柱试样中心孔洞的闭合过程,分析了孔洞的闭合规律及闭合过程中孔洞周围的应力状态。
The Research on the mechanism of the internal crack healing in metals is an important basic work for improving metal quality and prolonging its lifetime, and it is very significant for developing the theory of materials. There is a broad engineering application background and potential benefits of economic and social as the main work of the key project “Inner crack healing in metal”supported by National Natural Sciences Foundation of China, physical and mathematic simulation were taken to study the internal crack healing in metals. On this basis diffusion thermodynamics and inner variable analysis in crack healing processing have been discussed.
Physical simulation: sample preparation, in situ observation of inner crack healing, experiment research on inner crack healing process.
Two methods were adopted to obtain the samples containing internal pre-cracks. One is plate impacting and the other is compressing drilled hole in column sample. It were found that the internal cracks in the samples of pure copper made by plate impacting consist of the micro-voids connected by micro-cracks and many dispersed micro-voids, while the internal cracks made by compressing drilled hole in the samples of pure iron, 20, 45, 16Mn and 5CrMnMo steel consist of lentoid primary cracks and spokewise secondary cracks.
In situ observation of the internal crack healing on the section of pure copper sample under high temperature metallograph showed that the micro-voids of 10-100μm begin to be healed at the temperature of 750℃, and obviously healed at the temperature of 900℃. SEM analyze showed that the healed micro-voids consist of some agglomerate particles at the scale of micrometer and much smaller particles on these agglomerate particles. According to the above observation, the healing processing is proceeded from inner surface of holes in matrix to observation plane for opening holes of the sample. Conclusion can be drawn that the healing processing of closed holes in the sample will be done from inner surface to the center.
After healing processing of the samples of pure iron, 20, 45, 16Mn and 5CrMnMo steel, the healing area of internal cracks made by compressing drilled hole was observed and analyzed. SEM analysis displayed that the fine structure exists in healing area is mostly ferrite and there exists many polyangular grains of several hundreds nanometer and precipitated particles which means that bulk diffusion resulted in the supersaturated healing area. X-ray analyze showed that the content of main elements Fe、Mn、S and Si in matrix, healing area and precipitated
在物理模拟研究方面:对于用平板撞击和钻孔压缩两种方法制备的试样,平板撞击铜试样中的层状内部裂纹由微孔洞连接形成的裂纹及临域离散分布的显微孔洞组成;钻孔压缩纯铁、20 钢、45 钢、16Mn 和5CrMnMo 钢试样中的内部裂纹由预置孔洞演化形成的一次裂纹及临域放射状二次裂纹组成。通过高温显微镜裂纹愈合的原位动态观察发现:在平板撞击纯铜试样剖分面上,10~100μm 级孔洞在温度为750℃时开始愈合,在900℃时明显愈合;扫描电镜观察发现:愈合孔洞的精细结构由μm 级团状颗粒与nm 级颗粒组成。基于上述观察研究认为,对于试样观察面上的开放式孔洞,其愈合过程是由位于基体内部的孔洞内表面向观察面进行的;由此推之对于封闭在试样内部的孔洞,其愈合过程的发生将会是从孔洞的内表面向孔洞的中心部位进行的。对纯铁、20 钢、45钢、16Mn 和5CrMnMo 钢钻孔压缩试样内部裂纹进行了热愈合处理,并对愈合区域进行了形态、组织结构、化学成分和力学性能的观察与分析。扫描电镜分析确定,愈合区内精细组织主要为铁素体,并存在许多大小为数百nm 级的多边晶块和析出颗粒。X 射线能谱分析结果表明,基体区、愈合区及析出颗粒中的主体元素均为Fe、Mn、S 和Si,各元素在不同区域的相对含量接近。出现析出颗粒说明愈合区是过饱和区,即愈合过程必须有原子的长距离扩散以满足成分上的需要。成分趋于一致说明在随后的保温过程中,发生了成分均匀化的扩散过程。维氏硬度测试结果显示,出现在愈合区的铁素体组织维氏硬度高于基体区铁素体组织,可能原因是愈合区中出现的多边晶块结构所引发的强化。
在数值模拟研究方面:利用分子动力学方法,对Cu 单晶中心贯穿裂纹的愈合形态演化过程进行了模拟,结果表明裂纹形态演化与建立在大量实验观察基础上所获得的形态演化物理模型类似。用ANSYS 有限元分析软件,模拟了压缩过程中45 钢圆柱试样中心孔洞的闭合过程,分析了孔洞的闭合规律及闭合过程中孔洞周围的应力状态。
The Research on the mechanism of the internal crack healing in metals is an important basic work for improving metal quality and prolonging its lifetime, and it is very significant for developing the theory of materials. There is a broad engineering application background and potential benefits of economic and social as the main work of the key project “Inner crack healing in metal”supported by National Natural Sciences Foundation of China, physical and mathematic simulation were taken to study the internal crack healing in metals. On this basis diffusion thermodynamics and inner variable analysis in crack healing processing have been discussed.
Physical simulation: sample preparation, in situ observation of inner crack healing, experiment research on inner crack healing process.
Two methods were adopted to obtain the samples containing internal pre-cracks. One is plate impacting and the other is compressing drilled hole in column sample. It were found that the internal cracks in the samples of pure copper made by plate impacting consist of the micro-voids connected by micro-cracks and many dispersed micro-voids, while the internal cracks made by compressing drilled hole in the samples of pure iron, 20, 45, 16Mn and 5CrMnMo steel consist of lentoid primary cracks and spokewise secondary cracks.
In situ observation of the internal crack healing on the section of pure copper sample under high temperature metallograph showed that the micro-voids of 10-100μm begin to be healed at the temperature of 750℃, and obviously healed at the temperature of 900℃. SEM analyze showed that the healed micro-voids consist of some agglomerate particles at the scale of micrometer and much smaller particles on these agglomerate particles. According to the above observation, the healing processing is proceeded from inner surface of holes in matrix to observation plane for opening holes of the sample. Conclusion can be drawn that the healing processing of closed holes in the sample will be done from inner surface to the center.
After healing processing of the samples of pure iron, 20, 45, 16Mn and 5CrMnMo steel, the healing area of internal cracks made by compressing drilled hole was observed and analyzed. SEM analysis displayed that the fine structure exists in healing area is mostly ferrite and there exists many polyangular grains of several hundreds nanometer and precipitated particles which means that bulk diffusion resulted in the supersaturated healing area. X-ray analyze showed that the content of main elements Fe、Mn、S and Si in matrix, healing area and precipitated
引文
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