Grinding-induced residual stress estimation by indentation-fracture method in ground silicon nitrides

An estimating procedure for grinding-induced residual stress based on the indentation-fracture (IF) method was proposed by considering a nonuniform distribution of residual stress in the specimen depth. The proposed procedure was applied to gas pressure sintered and pressureless sintered silicon nitride ceramics, which were ground under different grinding conditions. The estimated residual stress was found to be compressive for both materials. The residual stress was dominantly affected by the grit size of the grinding wheel rather than the cutting depth. Although the dependency of the estimated residual stress on the grit size was different between the two materials, it was revealed that the estimated residual stress in both materials qualitatively corresponded with the stress measured by the x-ray diffraction method. In both materials, the bending strength was reasonably correlated with the estimated residual stress. It was elucidated that the proposed procedure was applicable to a relative evaluation of the grinding-induced residual stress in machined silicon nitride ceramics.     

氮化硅陶瓷的残余应力和抗弯强度特性

利用X射线衍射方法测量了经不同磨削的氮化硅陶瓷表面残余应力及其对抗弯强度的影响。结果表明 ,磨削工艺所引入的残余应力是拉应力 ,显著降低陶瓷抗弯强度。     

Numerical Analysis of Sample-Size Effect on Strength of Alumina

Statistical characteristics of strength distribution in ceramic components should be clarified because of large scatter in ceramics strength. Characteristics of strength distribution, however, depend on sample size, i.e., the number of tested specimens. In this study, a numerical procedure in the framework of fracture mechanics was developed to estimate strength distribution of ceramics by assuming the same statistical distribution of cracks in a material. Experimental results in four-point bending tests of alumina, which were reported in a previous work, were cited to verify the validity of the developed procedure. Smooth specimens of distinct sizes as well as notched specimens with different notch shapes were used in the experiment. Monte Carlo simulations using the developed procedure were carried out to investigate effects of the sample size on strength properties of alumina specimens with various shapes. The simulated result revealed that the experimental strength for various types of specimens was almost covered within a range of upper and lower bounds of strength simulated for the alumina. The experimental mean strength correlated with the effective volume was also included in a band range between the maximum and the minimum of mean strength obtained by the simulation.     

Finite element modelling of brazed residual stress and its influence factor analysis for stainless steel plate-fin structure

This paper presents a finite element modelling of brazed residual stress in a stainless steel plate-fin structure applied to recuperators in microturbines. The effects of nine influence factors on residual stress are investigated. The results show that the brazed joint creates large residual stresses due to the mechanical properties mismatching between base metal and filler metal. Strength in the middle joint is affected mainly by longitudinal stress. The residual stress gradient around the interface between base metal and filler metal is very large, which can have a great effect on interface strength. The material mismatching, brazing gap, pressure loading, fin pitch, fin thickness, fin height and plate thickness significantly affect the residual stress distribution, while the brazing temperature and the number of fin layers have little impact on residual stress. This work provides a reference for optimizing the brazing procedure and decreasing the residual stress for stainless steel plate-fin structures.     

Nondestructively determining local strength and residual stress of glass by Hertzian indentation

Hertzian indentation was used to evaluate the local strength of glasses and to estimate residual stresses in strengthened glasses. It was found that initiation of Hertzian crack in glasses depends on the mean stress within a surface thickness related to material properties, but independent of the peak stress. The maximum mean stress for crack initiation was a constant and was defined as the local strength of the specimen at the contact position. Indentation experiments, using alumina spheres with various sizes as indenters, were performed on unstrengthened and strengthened glasses, respectively. The results showed a good stability in the local strength and a good agreement between the residual stresses measured by the present method and by a polarizing device. In addition, the potential merits of this method are: a) Nondestructive and in-situ measurement of strength can be performed without using a standard specimen and a rupture test; b) Strength proof test and strength comparison can be easily preformed.     

Recent advances in the hole drilling method for residual stress measurement

The main activities in the hole drilling residual stress measurement technique recently developed at the University of Pisa are reviewed and presented. Particular attention was paid to developing tools for increasing the limits indicated by the presently applied standard procedures for residual stress evaluation. For residual stresses that were assumed to be uniform through-thickness, the effect of plasticity was numerically analyzed and results formed the basis for a procedure that allows an increase in the maximum measurable residual stress up to 0.9 of the material yield strength. For nonuniform through-thickness residual stress, accurate analytical influence functions are proposed by which arbitrary interpolation of the influence coefficients is avoided and all the experimentally obtained strains, with no regard to their number, can be used as input for residual stress evaluation.     

坡口形式对SUS304奥氏体不锈钢对接接头残余应力和变形的影响

以ABAQUS软件为平台,开发了热-弹-塑性有限元计算方法用于模拟V形、K形和X形坡口SUS304奥氏体不锈钢多层多道焊对接接头的温度场、残余应力和焊接变形. 同时,采用试验的方法测量了接头的残余应力和角变形. 计算得到的焊接残余应力和角变形与实测结果吻合良好,验证了计算方法的妥当性. 试验和数值结果表明,坡口形式对接头的残余应力和角变形有显著的影响:V形坡口的高拉伸残余应力区和角变形均明显大于K形坡口和X形坡口,而K形坡口则略大于X形坡口; 坡口形式对纵向残余应力的峰值影响较小.     

陶瓷/金属钎焊接头强度研究现状

陶瓷与金属钎焊是当前工程领域研究的热点,由于陶瓷与金属的热膨胀系数与弹性模量等性能不匹配,造成接头存在较大的残余应力,这已成为影响钎焊接头强度的主要因素.因此,降低接头残余应力,提高接头强度是陶瓷与金属钎焊的主要研究内容之一.分别对氧化物陶瓷、氮化物陶瓷、碳化物陶瓷、碳氮化物陶瓷与金属钎焊接头强度的研究现状进行了综述.     

Temperature and energy partition for grinding of mixed oxide ceramics

Mixed oxide ceramics show high potential for widespread utilization due to the transformation toughening effect of these ceramics. During grinding, the stress-induced transformation from the tetragonal to the monoclinic phase of ZrO₂ particles ensures a high strength in combination with a high fracture toughness even after processing with unavoidable surface and subsurface damage due to micro-cracks. The thermal impact during grinding can be one of the main limitations of this transformation toughening effect in case of exceeding the temperature of retransformation back to the tetragonal phase. Thus, the technological basis for a reliable grinding process of mixed oxide ceramics requires a fundamental understanding of the grinding temperatures to maintain workpiece quality and strength requirements. This paper presents an analytical method to calculate the maximum grinding temperatures beneath a single abrasive grain and show their effect on the bending strength of ground mixed oxide ceramics as well as on the monoclinic phase content and on the residual stresses.     

Improvement mechanism of fatigue strength of weld joints by hammer peening on base metal

New peening technology is proposed to improve the fatigue strength of welded joints. By using this technology, compressive residual stress is introduced at weld toe by the developed peening procedure which plastic deformation is only applied to the base material near the weld toe. In this study, improvement mechanism of fatigue strength of weld joints by hammer peening on base metal was clarified by FEA. It was clarified that increasing of stress at weld toe is controlled by depression formed near the weld toe. Not only compressive residual stress at weld toe but also decreasing stress concentration at weld toe by plastic deformation on base metal was indicated as the factor of improving fatigue strength of weld joints.     

固态相变对P91钢焊接残余应力的影响

基于SYSWELD软件,首先模拟了P91的Satoh试验,得到加热、冷却过程中的温度-应力曲线. 通过Satoh试验探讨了因固态相变引起的体积变化、屈服强度的变化和相变过程中的超塑性对残余应力形成过程的影响. 随后,以平板TIG重熔模型为研究对象,系统讨论了固态相变对焊接残余应力分布和大小的影响. 结果表明,体积膨胀对焊接残余应力的形成过程和最终应力的大小与分布有显著影响,它不仅可改变焊缝及HAZ处的应力大小,甚至可能改变应力的符号. 相变引起的屈服强度变化对残余应力的形成及最终应力值的大小也有较明显的影响. 相变塑性的影响比前两者小,它在相变过程中有一定的"应力松弛"效应.     

RPV顶盖和CRDM管座焊接残余应力三维数值模拟

制造了反应堆压力容器顶盖和控制杆驱动机构(CRDM)管座贯穿件J形密封焊模拟件,测试了焊接过程温度和焊后残余应力;采用分段移动温度热源模型和热力耦合方法实现了三维焊接温度场和应力场的高效计算,并与试验结果进行了比较;基于模拟的三维残余应力场研究了J形密封焊的应力分布特征. 结果表明,采用的模型和方法能实现J形密封焊残余应力的高效数值计算,计算和试验结果符合较好;J形密封焊缝上的纵向应力大于轴向应力,贯穿件内外壁应力不均匀,焊缝和贯穿件坡上和坡下区域的应力大于侧坡区域应力.     

Effect of prior machining deformation on the development of tensile residual stresses in weld-fabricated nuclear components

Austenitic alloy weldments in nuclear systems may be subject to stress- corrosion cracking (SCC) failure if the sum of residual and applied stresses exceeds a critical threshold. Residual stresses developed by prior machining and welding may either accelerate or retard SCC, depending on their magnitude and sign. A combined x- ray diffraction and mechanical procedure was used to determine the axial and hoop residual stress and yield strength distributions into the inside- diameter surface of a simulated Alloy 600 penetration J- welded into a reactor pressure vessel. The degree of cold working and the resulting yield strength increase caused by prior machining and weld shrinkage were calculated from the line- broadening distributions. Tensile residual stresses on the order of +700 MPa were observed in both the axial and the hoop directions at the inside- diameter surface in a narrow region adjacent to the weld heat- affected zone. Stresses exceeding the bulk yield strength were found to develop due to the combined effects of cold working of the surface layers during initial machining and subsequent weld shrinkage. The residual stress and cold work distributions produced by prior machining were found to influence strongly the final residual stress state developed after welding.     

屈服强度参数对10Ni5CrMoV钢焊接残余应力数值计算结果的影响

为了研究低合金高强钢在焊接过程中屈服强度参数变化对焊接数值计算结果的影响,测定了在稳态和冷却条件下10Ni5CrMoV钢在不同温度时的屈服强度和焊接接头的焊接残余应力,并采用有限元软件分别根据两种条件下所测屈服强度参数对10Ni5CrMoV钢焊接接头的焊接残余应力进行了数值计算.结果表明,冷却条件下不同温度的屈服强度测试值低于稳态条件下相应温度屈服强度测定值,根据冷却条件下测定的屈服强度曲线计算所得焊接残余应力分布与实测值具有更好的吻合度.     

核电SA508-3钢大型筒体环焊残余应力分析

为了准确地预测核电SA508-3钢的大型筒体环焊温度和残余应力变化规律,基于ANSYS有限元软件,引入子结构法优化焊接模拟过程,并比较模拟结果与试验数据.结果表明,文中采用的计算方法成功地模拟了更加接近真实的筒体环焊过程,且模拟结果与实测值基本吻合;焊缝上所有节点的热循环曲线相似,热影响区的模拟宽度为4 mm左右;筒体外表面焊缝中心线上任意节点的残余应力大小相近,仅在靠近筒体外表面焊缝中心线附近存在一定的轴向压应力,其它区域大部分为拉应力,环向保持较高的拉应力;筒体焊后产生内凹残余变形;结果可为分析大型筒体环焊残余应力提供参考数据.     

An estimation of factors influencing residual stress characteristics of fillet welded lap joints

The residual stress behaviours in fillet welded lap joints of sheet metal have been researched in a systematic testing procedure with varied steel types, steel thicknesses and welding wires having different transformation points. Consequently, under the simulated fabrication welding conditions (with a constant amount of deposited metal), the transverse residual stress at the weld toe, which is deemed critical in fatigue strength, has been found almost invariable to a change in steel type and thickness, but it has been clarified to become compressive to a greater extent as the wire’s transformation point is lower. Moreover, as for the residual stress inside the weld metal, the compressive residual stress area has been found to expand as the welding wire’s transformation point reduces, from the results of the thermo-elastic-plastic analysis.     

微粒子喷丸中碳钢疲劳性能分析

使用旋转弯曲疲劳试验机进行了中碳钢10~9cyc的疲劳实验,分析了直径100μm的钢球和陶瓷球喷丸处理后材料的疲劳性能及实验过程中残余应力的稳定性.与未喷丸试样相比,2种微粒子喷丸试样的疲劳极限分别提高了35%和23%.根据实验过程中对残余应力的跟踪测试,详细分析了残余应力松弛的过程及机理,阐述了疲劳极限提高机理及其控制因素.     

纳米掺杂Al2O3基等离子喷涂涂层残余应力分析

利用逐层剥离X射线衍射法,测定了纳米粒子掺杂对Al2O3 13%TiO2(AT13)等离子喷涂涂层残余应力的影响.结果证明AT13等离子喷涂涂层残余应力分布为:陶瓷涂层部分为压应力;Al/Ni过渡层由陶瓷涂层到钢基体,由压应力过渡到拉应力;在距钢基体0.05mm处现拉应力峰值.随着纳米掺杂量的增大,陶瓷涂层及Ni/Al过渡层残余应力绝对值降低,这对改善陶瓷涂层性质是十分有益的.     

Preparation of porous hydroxyapatite ceramics with starch additives

Porous ceramics prepared from nano-sized hydroxyapatite powders by adding water soluble starch and insoluble starch were investigated. The results show that small pores of several micrometers or less can be produced by adding water soluble starch as a pore former. Two kinds of starch have different pore forming mechanisms. The permeability of the porous ceramics can be greatly improved by adding the insoluble starch to channel the small pores rather than solely using water soluble starch. The control of permeability can be achieved by adjusting the content ratio of water soluble starch to insoluble starch. Strength tests show the ceramics have rather high strength. Therefore a kind of porous filtering material with small pores, controllable permeability and good strength can be prepared by using starch additives.     

多层陶瓷电容器的黏聚力有限元模型及失效分析

通过施加一定的边界条件,建立了一种新颖的零厚度黏聚力有限元单层简化模型。该简化模型可避免薄介质层、高层数和三维建模引起的高计算量问题。基于提出的简化模型,模拟了多层陶瓷电容器(MLCCs)由于过大的残余应力而导致的损伤起始和扩展的整个过程,结果表明:相比于沿长度方向的电极/陶瓷界面,沿厚度方向的界面更容易失效,贯穿的裂纹将导致MLCCs整体失效。同时分析了不同电极/陶瓷层厚比的界面失效开始时间和黏聚力界面单元单位体积能量耗散随时间的变化趋势,分析表明:电极层和陶瓷层相对厚度比值越大单位体积能量耗散的越大,器件越容易失效。