An investigation of cavity growth in a superplastic aluminum alloy processed by ECAP

Quantitative measurements were taken to evaluate the significance of cavitation in the tensile testing of a superplastic spray-cast Al-7034 alloy processed by equal-channel angular pressing (ECAP). Samples were processed by ECAP and then tested in tension at 673 K using strain rates from 10⁻³ to 10⁻¹ s⁻¹. For comparison purposes, similar tensile testing was conducted also on samples without ECAP processing. Inspection of polished sections after tensile testing revealed extensive internal cavitation in all samples. Measurements were taken to provide detailed information on the sizes and shapes of the cavities and these measurements were analyzed to determine the dominant cavity growth mechanisms. The results demonstrate the importance of superplastic diffusion growth in ultrafine-grained materials processed by ECAP.     

泄水建筑物的空蚀破坏和处理方法

体型不合理和混凝土表面局部不平整是泄水建筑物表面发生空蚀破坏的主要原因，分析了泄水建筑物空蚀破坏的产生条件和特点，提出了防止和减少空蚀的具体措施。     

The Effects of Stress State and Cavitation on Deformation Stability During Superplastic Forming

The current available models describing superplastic deformation do not account for a number of important characteristics, leading to the current limited predictive capabilities of deformation and failure. In this work, the effects of cavitation and stress state on deformation stability during superplastic forming are investigated using Finite Element simulations. The simulations are performed using constant strain rate forming and using a proposed optimization approach based on a multiscale failure criterion that accounts for stress state, geometrical necking, and microstructural evolution including grain growth and cavitation. The simulations are conducted for the superplastic copper-based alloy Coronze-638 and the superplastic aluminum alloy Al-5083 which are known to develop significant cavitation during deformation. The results clearly show the importance of accounting for microstructural evolution during superplastic forming, especially when the state of stress is biaxial. Furthermore, the results highlight the effectiveness of the proposed optimization technique in reducing the forming time and maintaining the integrity of the formed parts. This article was presented at the AeroMat Conference, International Symposium on Superplasticity and Superplastic Forming (SPF) held in Seattle, WA, June 6-9, 2005.     

聚四氟乙烯软管气蚀引起疲劳损伤的形貌分析

飞机液压系统用聚四氟乙烯软管在使用中先后发生10余起软管内壁穿孔造成的渗漏故障。利用视频显微镜、扫描电镜等对故障软管进行宏观及微观形貌分析。结果表明:故障软管具有相同的失效特征及模式,属于气蚀引起的疲劳损伤;结合软管工作环境,探讨软管气蚀疲劳损伤的机理,总结气蚀引起疲劳损伤的形貌特征,即宏观上损伤区为蜂窝状孔洞形貌,微观上孔洞由多个小疲劳区组成,可见疲劳条带特征;裂纹早期从表面或次表面萌生,基本以平行于表面的疲劳扩展为主;液压软管气蚀疲劳损伤的形成与气蚀的冲击波机制较为吻合。     

Finite element modeling and optimization of superplastic forming using variable strain rate approach

Detailed finite element simulations were carried out to model and optimize the superplastic blow forming process using a microstructure-based constitutive model and a multiscale deformation stability criterion that accounts for both geometrical instabilities and microstructural features. Optimum strain rate forming paths were derived from the multiscale stability analysis and used to develop a variable strain rate forming control scheme. It is shown that the proposed optimization approach captures the characteristics of deformation and failure during superplastic forming and is capable of significantly reducing the forming time without compromising the uniformity of deformation. In addition, the effects of grain evolution and cavitation on the superplastic forming process were investigated, and the results clearly highlight the importance of accounting for these features to prevent premature failure. This paper was presented at the International Symposium on Superplasticity and Superplastic Forming sponsored by the Manufacturing Critical Sector at the ASM International AeroMat 2004 Conference and Exposition, June 8–9, 2004, in Seattle, WA. The symposium was organized by Daniel G. Sanders, The Boeing Company.     

高速内冷铣孔空蚀机理的数值模拟与实验研究

目的预测高速内冷铣孔过程中空蚀的发生,并初步揭示高速内冷铣削过程中铣刀空蚀失效机理及已加工工件表面的空蚀损伤机理。方法采用三维数值分析与实验相结合的方法,在建立高速内冷铣削封闭流场的基础上进行数值计算,搭建了高速内冷空蚀试验平台并进行实验,通过粗糙度仪对分段后工件样条的已加工表面进行测定,通过电子显微镜对实验后的分段工件样条已加工表面和铣刀形貌进行分析。结果仿真分析发现用40 mm立铣刀以14500 r/min转速铣削60 mm 50 mm孔时,流场中的含气率达到10%左右,预测了高速内冷铣削过程中空蚀现象的存在,空蚀后楔形发散区的孔壁粗糙度Ra为0.311~0.478 m,楔形收缩区的孔壁粗糙度Ra为0.138~0.317 m。工件已加工表面出现麻点和海绵状为主的空蚀针孔,铣刀侧后面出现蜂窝状和鱼鳞状的空蚀坑。结论仿真分析和实验共同验证了高速内冷铣削过程中空蚀现象的存在,空蚀位置可能出现在内冷铣刀侧后刀面及部分工件已加工表面,且铣刀侧后刀面空蚀程度远超工件已加工表面,为高速内冷切削加工过程中空蚀机理的研究提供依据。     

CrMnN双相不锈钢的空泡腐蚀行为研究

利用磁致伸缩空蚀实验机研究了CrMnN双相不锈钢在3％NaCl溶液中的空蚀行为，采用电化学技术测量了静态和空蚀条件下的自腐蚀电位变化和动电位扫描极化曲线．利用扫描电镜(SEM)跟踪观测了试样表面的空蚀形貌．结果表明：CrMnN双相不锈钢的抗空蚀性能优于水轮机的常规用材0Crl3Ni5Mo．CrMnN双相不锈钢的空蚀破坏首先在铁素体相发生．铁素体相的失效方式为脆性失效，而奥氏体相是延性失效．奥氏体相区由滑移和孪生引起的塑性变形消耗了空泡溃灭产生的冲击能量，从而提高CrMnN双相不锈钢的抗空蚀性能．在NaCl溶液中。空蚀使CrMnN不锈钢的自腐蚀电位负移300mV，阳极电流密度增大近3个数量级，但由NaCl引起的失重量对总失重量的贡献很小．     

Quantification of creep cavitation damage around a crack in a stainless steel pressure vessel

In this paper, metallographic sectioning and non-destructive small angle neutron scattering (SANS) are used to map the level of creep cavitation around a surface breaking crack in a stainless steel pressure vessel. The cracking developed during 65,000 h service at an operating temperature of around 525 °C and was promoted by the accumulation of creep strain resulting from relaxation of tensile residual stresses associated with a nozzle attachment weld. The distribution and evolution of the cavities is discussed in terms of existing models of creep cavitation failure based on a ductility exhaustion model in which the corresponding multi-axial creep ductility, expressed as the von Mises strain at failure, is a function of the strain rate and stress state. An empirical approach has been adopted for describing the effects of stress state on ductility, which takes into account cavity nucleation as well as cavity growth by creep deformation, and is similar to local approach models for ductile crack growth. Crack initiation is conceded when the creep damage parameter D_c⩾1. The measured creep cavitation results are found to be in reasonable accordance with such a model.     

1Cr18Mn14N双相不锈钢在腐蚀介质中的抗空蚀性能

利用磁致伸缩空蚀实验机研究了1Cr18Mn14N双相不锈钢在3%NaCl和05 mol/L HCl溶液中的空蚀行为.结果表明：在3%NaCl溶液中，低硬度的Cr18Mn14N双相不锈钢的抗空蚀性能优于高硬度的水轮机常规用材0Cr13Ni5Mo.1Cr18Mn14N双相不锈钢的空蚀破坏首先在铁素体相发生，铁素体相的失效方式为脆性失效，而奥氏体相是延性失效.奥氏体相区由滑移和孪生引起的塑性变形耗散了空泡溃灭产生的冲击能量，从而提高1Cr18Mn14N双相不锈钢的抗空蚀性能.在05 mol/L HCl溶液中，1Cr18Mn14N的抗空蚀性能不如0Cr13Ni5Mo，结果与3%NaCl溶液中的正好相反，这是由于阳极溶解和氢共同作用的结果.     

亚稳奥氏体金属抗空蚀性能及其主要控制因素

用旋转圆盘实验机对5种亚稳奥氏体金属的抗空蚀性能和水轮机叶片用0Cr13Ni5Mo不锈钢进行了对比研究。结果表明，2种应力诱发马氏体Fe-Mn-Si-Cr形状记忆合金的抗空蚀性能远高于3种应变诱发马氏体相变奥氏体不锈钢和0Cr13Ni5Mo不锈钢。高的局域弹性性质he是Fe-Mn-Si-Cr形状记忆合金具有高抗空蚀性能的主要原因。he是影响亚稳奥氏体金属抗空蚀性能的首要控制因素，空蚀诱发马氏体耗散能量，空蚀表层硬度及加工硬化能力是影响亚稳奥氏体金属抗空蚀性能的第二控制因素。     

铁基块体非晶合金的空泡腐蚀研究

通过对超声空化作用过程中试样表面物相组成变化和试样失重的实验研究,分析了Fe74Al4Ga2P12B4Si4铁基块体非晶合金的空蚀过程。分别采用处于晶态和非晶态的铁基块体合金,在自来水中进行超声空化实验,确定了材料特性对空蚀过程的影响。结合已有的空泡形成和溃灭理论,初步提出了铁基块体非晶合金的耐空蚀机理。     

SUPERPLASTICITY OF A RAPIDLY SOLIDIFIED AI-Li ALLOY

A rapidly solidified microcrystalline Al-Li-Cu-Mg-Zr alloy and its superplasicity have beeninvestigated.An optimum tensile elongation of 585% was obtained at 540℃ and strain rate1.67×10~(-2)s~(-1).The superplastic Al-Li alloy is manufaetured using thermomechanical pro-cessing:solution,overaging,warm rolling and recrystallization.Microstructural changes inthermomechanical processing and cavitation occurred during superplastic deformation havebeen observed.The superplastic failure of alloy may be caused mainly by nucleation andgrowth of cavities as well as the linkage around grains.     

微/纳米力学技术对金属空泡腐蚀表层力学性质的定量表征

采用微/纳米力学测试技术,在研究奥氏体不锈钢空泡腐蚀规律的基础上,对奥氏体不锈钢受到空化作用后其金属表层的纵向截面微米硬度和腐蚀表层的纳米力学性能进行定量表征,研究奥氏体不锈钢腐蚀表层力学性能参数及其空间分布,并初步探讨腐蚀表层力学性质劣化与金属空泡腐蚀间的关系。结果表明,奥氏体不锈钢在空泡腐蚀过程中,表层中由硬度较小的腐蚀表层、硬度较大的硬化层和机体层构成。在空化作用下,因空化与介质腐蚀交互作用引起奥氏体不锈钢空泡腐蚀表层力学性质劣化,使得奥氏体不锈钢发生严重腐蚀,并存在空泡腐蚀表层力学性质劣化的阈值。其中,奥氏体不锈钢的空泡腐蚀表层纳米硬度起主要作用。无量纲函数--空泡腐蚀表层纳米硬度与弹性模量之比, 可用于描述金属空泡腐蚀表层力学性质劣化程度,并可与金属空泡腐蚀评价深度相关联。     

低碳钢与304不锈钢的超声空蚀机理对比研究

目的研究低碳钢及304不锈钢在蒸馏水中的超声空蚀行为及损伤机理,并评价低碳钢及304不锈钢的抗空蚀能力,为抗空蚀材料的选择提供依据。方法采用符合ASTM国际标准的超声空蚀实验装置,开展低碳钢及304不锈钢在蒸馏水中不同时间的超声空蚀实验,从累积质量损失(失重)、累积质量损失率(失重率)、试样表面形貌和残余应力等方面对两种材料的超声空蚀行为进行描述和对比分析。结果低碳钢试样空蚀开始15 min后进入空蚀加速期,在90 min左右存在较短的空蚀稳定期,而后迅速进入空蚀衰减期;304不锈钢试样在空蚀30min内累积失重率变化缓慢,之后随着空蚀时间的延长而急剧增加,在120min后进入空蚀衰减期。低碳钢与304不锈钢的空蚀变形机制以滑移为主。随着空蚀的发展,低碳钢晶粒经历了晶粒取向→晶粒细化→晶界开裂→晶粒碎化→剥落的变化过程。而在同等实验条件下,304不锈钢试样的变化相对滞后,且残余应力值较大。结论由于空蚀裂纹在304不锈钢中的深层扩展受到奥氏体相的阻碍,从而对空蚀的发展产生关键的抑制作用,使得304不锈钢的抗空蚀能力较强。     

基于空化特性的高速轴向柱塞泵配流盘优化设计

以某型号高速轴向柱塞泵为研究对象，搭建其带空化模块的CFD数值仿真模型，并以此为基础，对柱塞泵在旋转过程中的空化情况进行分析。结果表明：空化主要发生在柱塞腔内，充液率不足及射流角过大是发生空化的主要原因。针对空化的产生机制，利用仿真数据与理论数据相结合的方法，对配流盘开口角度进行优化。根据流场情况，提出一种两端具有一定斜度的配流盘结构，并对该结构进行优化。在配流盘开口角度和结构优化后，柱塞腔内的整体空化程度下降了74.2%，对空化具有明显的抑制效果。     

A novel method to control electrical-discharge nonlinear bulk cavitation

Experimental results from the study of cavitation generated in a liquid during underwater synchronous parallel discharges are presented. It is shown that only synchronous discharges permit the productions of large cavitation regions in a free liquid. The cavitation parameters may be controlled through variation of operational tensile stresses.     

Evaluation of cavitation erosion–corrosion degradation of mild steel by means of dynamic impedance spectroscopy in galvanostatic mode

Cavitation erosion and corrosion of mild steel was studied by means of a vibratory facility in 3% w/w NaCl solution. Dynamic Electrochemical Impedance Spectroscopy (DEIS) measurements were carried out in the galvanostatic mode to allow on-line monitoring of impedance parameters in cavitation failure. The results, based on an analysis of instantaneous impedance spectra, correspond to degradation under the influence of cavitation erosion–corrosion. It has been shown that a change of pseudo-capacitance corresponds to an increase in sample roughness, while the charge-transfer resistance determines changes in the corrosion rate under the combined mechanical and electrochemical factors.     

A quick-quench technique for the study of creep cavitation in metals

A quick-quench technique has been developed for the study of creep cavitation in metals and alloys. With such a technique, the specimen could be quenched from the test temperature to 50 °C within 5 minutes. Couple with standard metallographic techniques, the above quick-quench technique has been successfully applied to investigate the evolution of creep cavities in pure and OFHC copper, especially during the early stage of creep deformation. The result shows that a threshold strain of about 0.1 to 0.5% is required for cavitation in pure copper, while it is negligible for cavitation at inclusion sites at grain boundaries in OFHC copper. It also shows that for metals and alloys containing low to moderate amounts of inclusions or second-phase particles, although the second-phase particles provide easy cavitation sites at grain boundaries during the initial stage of creep deformation, the creep cavitation behaviour at large strains is controlled by cavitation at ‘normal’ sites at grain boundaries. Works in the literature show that such ‘normal’ sites are probably the intersections of subboundaries at grain boundaries [12,14–16].     

注塑齿轮及其模具设计

介绍了塑料齿轮常用材料的特性。分析了塑料齿轮的3种失效形式-断齿、点蚀和热软化。以模数m=3，齿数z=30，齿宽b=20的齿轮为例，研究了该齿轮的注塑模的设计要素及型腔尺寸的计算方法。总结认为，注塑模具宜选择单型腔，设计注塑模具的关键是确定收缩率，计算型腔的工作尺寸。     

Cavitation Erosion in Hydraulic Turbine Components and Mitigation by Coatings: Current Status and Future Needs

Cavitation erosion is a frequently observed phenomenon in underwater engineering materials and is the primary reason for component failure. The damage due to cavitation erosion is not yet fully understood, as it is influenced by several parameters, such as hydrodynamics, component design, environment, and material chemistry. This article gives an overview of the current state of understanding of cavitation erosion of materials used in hydroturbines, coatings and coating methodologies for combating cavitation erosion, and methods to characterize cavitation erosion. No single material property fully characterizes the resistance to cavitation erosion. The combination of ultimate resilience, hardness, and toughness rather may be useful to estimate the cavitation erosion resistance of material. Improved hydrodynamic design and appropriate surface engineering practices reduce damage due to cavitation erosion. The coatings suggested for combating the cavitation erosion encompasses carbides (WC Cr₂C₃, Cr₃C₂, 20CrC-80WC), cermets of different compositions (e.g., 56W₂C/Ni/Cr, 41WC/Ni/Cr/Co), intermetallic composites, intermetallic matrix composites with TiC reinforcement, composite nitrides such as TiAlN and elastomers. A few of them have also been used commercially. Thermal spraying, arc plasma spraying, and high velocity oxy-fuel (HVOF) processes have been used commercially to apply the coatings. Boronizing, laser surface hardening and cladding, chemical vapor deposition, physical vapor deposition, and plasma nitriding have been tried for surface treatments at laboratory levels and have shown promise to be used on actual components.