钢桥面板纵肋与横隔板焊接细节表面缺陷及疲劳效应研究

初始焊接缺陷是影响结构件疲劳性能的关键因素之一。在断裂力学评估框架下引入特征化初始焊接缺陷,结合相互作用积分法与复合断裂准则解决由表面缺陷所导致的复合型疲劳裂纹扩展问题,在此基础上编写裂纹扩展模拟程序,建立表面焊接缺陷效应评价方法,通过分析揭示了不同形态和尺度的初始焊接缺陷对于钢桥面板纵肋与横隔板构造细节裂纹扩展关键性度量指标和疲劳寿命预测的影响。结果表明:所建立的方法可有效用于评估焊趾部位表面焊接缺陷对于疲劳性能的效应;面状缺陷对于裂纹扩展度量指标和疲劳寿命预测结果的影响更为显著,其初始缺陷深度和形态均是影响疲劳性能的关键因素,体积型缺陷对于疲劳寿命的影响主要由深度方向的缺陷尺寸决定;焊接缺陷的形态和几何参数取值应根据工程实际和规范建议值共同确定,直接简化为面状缺陷会低估结构件的疲劳寿命;考虑焊接缺陷不确定性的可靠度评估方法尚需进一步研究。     

船舶工程焊接接头完整性评估与疲劳寿命预测技术综述

介绍了船体结构中含缺陷的焊接接头完整性评估以及疲劳寿命预测方法，对结构完整性评估的K准则、COD准则、J积分准则、SINTAP/FITNET安全性评定方法以及评定流程、国内外标准进行介绍。并对焊接接头的疲劳强度影响因素，如平均应力、残余应力以及接头几何形状应力集中等进行了分析；介绍了焊接接头疲劳寿命预测的常用方法，如基于名义应力的评估方法、基于断裂力学的评估方法、基于损伤力学的评估方法以及其它疲劳评估方法等。此外，还对基于断裂力学法建立的焊接残余应力与疲劳裂纹扩展寿命之间的函数关系进行了介绍，该方法实现了对含残余应力的焊接结构疲劳寿命的精确预测。     

CFRP板加固含裂纹受拉钢板的疲劳性能研究

根据线弹性断裂力学理论,采用“三维块体-弹簧-板”有限元模型对裂纹尖端的应力强度因子幅值进行计算,并基于Paris-Erdogan裂纹扩展模型,提出了CFRP板加固含裂纹受拉钢板的疲劳寿命预测方法。然后对4个CFRP板加固含初始疲劳裂纹钢板的受拉疲劳性能进行了试验研究,考察了碳纤维板加固量、单面和双面加固方式对疲劳性能的影响。试验结果表明,CFRP板加固钢板的疲劳寿命比未加固钢板显著提高,疲劳裂纹扩展的试验结果与预测结果符合较好。     

42CrMo钢疲劳裂纹扩展剩余寿命评估

以高频三点弯曲疲劳试验机为平台,进行42CrMo钢疲劳裂纹扩展试验研究,通过建立裂纹扩展剩余寿命评估模型,实现对存在裂纹的工程机械零部件剩余寿命的评估。采用显微成像测试系统实时采集并测量疲劳扩展裂纹,使用声发射系统监测整个疲劳裂纹扩展过程。结果表明:声发射幅值、能量等特征参数可以实时反应疲劳裂纹萌生、稳定扩展和失稳扩展等各个损伤阶段,并在疲劳断裂时产生急剧的突变;裂纹扩展速率的对数值与应力强度因子幅的对数值具有较高的线性相关性,建立了不同应力工况条件下裂纹扩展剩余寿命评估模型,以双排链轮轴为例进行裂纹扩展剩余寿命评估;随着疲劳应力的增加,裂纹扩展剩余寿命减小。     

载荷方向和焊缝余高对氩弧焊缝疲劳性能的影响

采用疲劳寿命测试和观测断口方法,研究焊接方向和焊缝余高对TC2钛合金氩弧焊缝疲劳性能的影响。结果表明:同种焊接方向,保留焊高试件的疲劳寿命低于去焊高试件;同种焊缝余高处理方式,斜焊试件的疲劳寿命高于直焊试件。去焊高试件于气孔缺陷处萌生裂纹,保留焊高试件疲劳裂纹起源于焊趾。裂纹扩展初期,裂纹均在焊缝内扩展,有明显的疲劳条带;扩展后期,斜焊试件裂纹穿过焊缝进入母材,存在典型的韧性疲劳条带。直焊试件疲劳瞬断区韧窝少而浅;斜焊试件在母材瞬断,韧窝多且密。     

镍基合金超声疲劳裂纹扩展寿命预测研究

针对发动机结构材料承受高频循环载荷的特点,应用超声疲劳试验技术开展了镍基合金材料的疲劳裂纹扩展试验研究。考虑高频载荷下疲劳裂纹扩展过程中的温升效应,测试了超声疲劳裂纹扩展过程中的温度变化,基于温度变化对材料弹性模量的影响和热膨胀效应,数值计算了疲劳裂纹扩展应力强度因子。研究了温度变化对超声疲劳裂纹扩展的影响机制,并在现有模型基础上,建立了考虑温度影响的超声疲劳裂纹扩展模型,完善疲劳裂纹扩展寿命预测方法。     

基于Beach Marking方法的钢结构疲劳裂纹检测研究

研究裂纹的形成和扩展规律是钢结构疲劳断裂的一个重要课题。该文讨论了一种十分经济有效的检测钢结构疲劳裂纹萌生与扩展的方法,即Beach Marking方法。首先简要总结了该方法的发展历史和研究现状,并系统归纳了其基本原理和关键问题。同时,通过焊接H型钢梁的试验案例,探索该方法应用在大尺寸构件上的实际效果,并具体展示该方法的设计步骤和应用过程。试验表明,Beach Marking方法简单实用,关键在于设计合理的疲劳荷载序列;通过分析疲劳断口上留下的疲劳弧线,并结合断裂力学理论,可以获得疲劳裂纹的扩展规律和参数,为钢结构疲劳寿命数值分析提供科学依据。     

随机荷载下疲劳裂纹扩展寿命的统计模型

根据断裂力学和随机过程理论,提出了一个随机荷载作用下疲劳裂纹扩展的统计模型。在基于应变能密度因子变程的确定性疲劳裂纹扩展速率公式中引入材料内在的分散性和外部荷载的随机性,将疲劳裂纹扩展近似为连续型马尔可夫过程。应用随机平均法导出了裂纹扩展过程转移概率满足的向后Fokker-Planck方程,并得出相应的边界条件。采用本征函数法进行求解,以收敛的无穷级数表示出疲劳裂纹扩展寿命的分布函数。作为一个算例,具体计算出疲劳裂纹扩展寿命的分布密度曲线。     

基于模态频率的缺口梁疲劳裂纹扩展寿命预测

从试验出发,研究了含V型缺口悬臂梁在循环载荷作用下的疲劳裂纹扩展特性及其模态频率变化规律,分析了模态频率与裂纹扩展增量间的关联性。将裂纹扩展增量作为损伤参量,建立了基于模态频率下降率与损伤参量的关系。基于损伤力学,建立了裂纹损伤与循环加载次数的演化模型。结合模态频率下降率与裂纹损伤参量的关系,提出了一种基于模态频率下降率的缺口梁疲劳裂纹扩展寿命预测方法,实现了基于当前裂纹损伤和对应循环次数的疲劳裂纹扩展剩余寿命预测。结果表明,模态频率下降率对缺口梁的疲劳裂纹扩展寿命敏感,该方法预测的疲劳裂纹扩展寿命与实测的疲劳裂纹扩展寿命基本吻合。     

基于裂纹扩展尺寸概率密度演化法的疲劳可靠性预测方法研究

疲劳破坏是金属构件的一种主要破坏形式。该文提出一种新的疲劳可靠性预测方法—裂纹扩展尺寸概率密度演化法,该方法通过求解裂纹扩展尺寸时变概率密度函数来预测疲劳寿命可靠性。首先建立随机裂纹扩展模型,然后根据此模型建立概率密度演化方程,并运用数值方法进行求解。最后的算例证明了裂纹扩展尺寸的概率密度函数具有演化特征,新方法计算结果与蒙特卡罗法的结果符合较好。     

Life Prediction of Ball Grid Array Soldered Joints under Thermal Cycling Loading by Fracture Mechanics Method

［1］J.J.Wang, M.F.Lu, D.Q.Zou and S.Liu: IEEE-CPMT(B), 1998, 21, 79. ［2］Y.H.Pao, E.Jih and V.Siddapureddy: J. of Electronic Packaging, 1996, 118, 235. ［3］H.U.Akay, N.H.Paydar and A.Bilgic: J. of Electronic Packaging, 1997, 119, 228. ［4］D.J.Xie, Y.C.Chan and J.K.Lai: IEEE-CPMT(B),1996, 19, 669.     

Influence of defects on fatigue crack propagation in laser hybrid welded eccentric fillet joint

Fatigue cracking of laser hybrid welded eccentric fillet joints has been studied for stainless steel. Two-dimensional linear elastic fracture mechanics analysis was carried out for this joint geometry for four point bending load. The numerical simulations explain for the experimental observations why the crack propagates from the lower weld toe and why the crack gradually bends towards the root. Lack of fusion turned out to be uncritical for the initiation of cracks due to its compressive stress conditions. The linear elastic fracture mechanics analysis has demonstrated in good qualitative agreement with fatigue test results that lack of fusion slightly (<10%) reduces the fatigue life by accelerating the crack propagation. For the geometrical conditions studied here improved understanding of the crack propagation was obtained and in turn illustrated. The elaborated design curves turned out to be above the standard recommendations.     

Fatigue behavior prediction of welded joints by using an integrated fracture mechanics approach

Current fracture mechanics methods for fatigue assessment of welded joints are based on long crack behavior. The present work introduces a method to predict the fatigue strength of welded joints by means of an integrated fracture mechanics approach (IFMA) that takes into account the fatigue behavior of short cracks. This methodology estimates the fatigue crack propagation rate as a function of the difference between the applied driving force and the material threshold for crack propagation, function of crack length. Firstly, the proposed fracture mechanic method is introduced and compared with the traditional fracture mechanic approach, used mainly for fitness for purpose assessment of welded joints with cracks or other crack-like defects. Then, the method is used for several theoretical and parametric applications to show its ability to predict the influence of different mechanical, geometrical and microstructural parameters in the definition of the fatigue resistance of welded joints. The influence of plate thickness, initial crack length and reinforcement angle on fatigue strength of butt-welded joints has been analysed and results show good agreement with experimental trends. Finally, the method is applied to predict and analyze the fatigue behavior of butt welded and non-load-carrying transverse fillet welded joints, and estimated and experimental results are analysed and compared.     

Analysis of fatigue crack behaviour based on dynamic response simulations and experiments for tensile-shear spot-welded joints

Fatigue crack initiation and propagation behaviours were studied based on the dynamic response simulation by the three‐dimensional finite‐element analysis (FEA) and dynamic response experiments for tensile‐shear spot‐welded joints. The entire fatigue propagation behaviour from the surface elliptical cracks at the initiation stage to the through thickness cracks at the final stage was taken into consideration during the three‐dimensional FEA dynamic response simulations. The results of the simulations and experiments found that the fatigue cracks of spot‐welded joint from initial detectable crack sizes to crack propagation behaviour could be described by three stages. Approximately one‐half of the total fatigue life was taken in stage I, which includes micro‐crack nucleation and the small crack growth process; 20% of the total fatigue life in stage II, in which the existing surface crack propagates through the thickness of sheet and 30% of the total fatigue life in stage III, during which the through thickness crack propagates along the direction of plate width to the final failure. According to the relationship between the crack length and depth and the dynamic response frequency during the simulated fatigue damage process, the definition of fatigue crack initiation and propagation stages was proposed. The analysis will provide some information for the fatigue life prediction of the spot‐welded structures.     

Investigation of Fatigue Growth Behavior of an Inclined Crack in Aluminum Alloy Plate

In the present paper, fatigue tensile tests are carried out on a servo-hydraulic fatigue testing machine to study the whole propagation process of the inclined crack. And the scanning electron microscope is employed to observe the micromorphology of the fracture surface to further probe the crack growth rate from a microscopic point of view. Meanwhile, the finite element method has also been applied to predict the crack propagation trajectory and the fatigue life of the sample with two finite element analysis codes. The fatigue tensile tests indicate the inclined crack propagates along the direction perpendicular to the external loading and the crack growth rate increases continuously based on the micromorphology of the fracture surface. The numerical analysis results reveal the variation of the stress distribution at the crack tip as well as the crack trajectory at different extension steps. Moreover, the stress intensity factor values are discussed in detail. And the computed results, the inclined crack propagation path and fatigue life of the sample, agree well with the experimental ones, which provide certain referential significance for the prediction of the inclined crack propagation in thin plate.     

3D fracture mechanics investigation on surface fatigue crack propagation

Surface fatigue crack propagation is the typical failure mode of engineering structures. In this study, the experiment on surface fatigue crack propagation in 15MnVN steel plate is carried out, and the crack shape and propagation life are obtained. With the concept of ‘equivalent thickness’ brought into the latest three‐dimensional (3D) fracture mechanics theory, one closure model applicable to 3D fatigue crack is put forward. By using the above 3D crack‐closure model, the shape and propagation life of surface fatigue crack in 15MnVN plates are predicted. The simulative results show that the 3D fracture mechanics‐based closure model for 3D fatigue crack is effective.     

Predicting fatigue S-N (stress-number of cycles to fail) behavior of reinforced plastics using fracture mechanics theory

The present study describes a model to predict fatigue S-N behavior, and thus fatigue life, of glass fiber reinforced thermoplastics by using a fracture mechanics approach. The model assumes the presence of an inherent initial flaw in the molded plastic parts and thus ignores crack initiation contributions. In this paper we describe how fatigue crack propagation rate data were obtained for the same three glass fiber reinforced plastics whose S-N behavior was previously described in detail. Using the measured constants from the crack growth data, and corresponding S-N data for uncracked specimens, the validity of the single initial flaw hypothesis was evaluated. From the analyzed results it is concluded that accurate S-N predictions are possible using this simple fracture mechanics model for some materials. The best results are obtained for glass filled polyamide, PA (nylon 66) and polycarbonate, PC; however, with polybutylene terephthalate, PBT, predictions were poor. It is also shown that S-N data for different glass fiber orientations can be predicted by combining the single flaw model with predicted fatigue crack propagation rate measurements. The latter are calculated from a generalized crack growth rate expression utilizing the strain energy release rate fracture mechanics parameter, which was previously described.     

Fatigue life prediction for stainless steel welded plate CCT geometry based on Lawrence''s local-stress approach

In the present study, the effect of welding process and procedure on fatigue crack initiation from notches and fatigue crack propagation in AISI 304L stainless steel welds was experimentally investigated. Full penetration, double-vee butt welds have been fabricated and CCT type specimens were used. Lawrence's local-stress approach (a two-stage model) is used to predict the fatigue life. The notch-root stress method was applied to calculate the fatigue crack initiation life, while the fatigue crack propagation life was estimated using fracture mechanics concepts. The fatigue notch factor is calculated using Lawrence's approach. Constant amplitude fatigue tests with stress ratio, R=0 were carried out using 100 kN servo-hydraulic DARTEC universal testing machine with a frequency of 30 Hz. The predicted lives were compared with the experimental values. A good agreement has been reached. It is found that the weld procedure has a stronger effect on lives to initiation than on propagation lives.