Assessment of mechanical properties of aluminium alloy welded joint using small punch test

The small punch test technique （SPT） was used to evaluate the mechanical properties of various materials and the basic method to test material tensile mechanics peqeormance from an inverse finite element （ FE） arithmetic with SPT was put forward. The research shows that specific tensile mechanical behavior and strain-stress distribution of each district of weld seam can be accurately determined by small punch test. Therefore, mechanical behavior of the inhomogeneous joint can be predicted by a numerical model. The simulation comes to good agreement with experimental data.     

带环形裂纹的微试样小冲杆试验法测试材料断裂韧性探讨

火电、核电、石油化工行业中有大量的在役压力容器、管道和构件,准确评价在役设备材料的脆化和结构完整性,对于保证装置的安全运行具有重要意义。为适应这一需求,小冲杆测试技术得到了发展,但对小冲杆试样评估在役容器材料的断裂韧性时,仍然只是依靠经验方法和标准的断裂韧性值进行关联,缺乏理论依据。该文提出了在小冲杆试样上开一环形裂纹,以反映裂纹体的断裂韧性测试要求。     

Calibration of anisotropic yield function by introducing plane strain test instead of equi-biaxial tensile test

The equi-biaxial tensile test is often required for parameter identification of anisotropic yield function and it demands the special testing technique or device. Instead of the equi-biaxial tensile test, the plane strain test carried out with the traditional uniaxial testing machine is suggested to provide the experimental data for calibration of anisotropic yield function. This simplified method by using plane strain test was adopted to identify the parameters of Yld2000-2d yield function for 5xxx aluminum alloy and AlMgSi alloy sheets. The predicted results of yield stresses, anisotropic coefficients and yield loci by the proposed method were very similar with the experimental data and those by the equi-biaxial tensile test. It is validated that the plane strain test is effective to provide experimental data instead of equi-biaxial tensile test for calibration of Yld2000-2d yield function.     

Process design for multi-stage stretch forming of aluminium alloy aircraft skin

A process design approach for multi-stage stretch forming was proposed by combining the strain distribution method and finite element method (FEM) to determine the minimum stage number and deformation amount of each stage. The strain distribution method was used to calculate the deformation amount of each stage and evaluate the formability through a safety criterion. FE simulation was taken as an analysis tool to reveal the deformation behaviour, to predict the strain contour and to determine the process parameters at each stage. To evaluate the effect of heat treatment after pre-strain on occurrence of deformation defects during the subsequent deformation, a multi-stage uniaxial tension test for 2B06 aluminium alloy sheet was carried out. A case study demonstrates that the approach has high reliability and good practicability.     

Assessment of fracture characteristics from revised small punch test using pre-cracked specimen

Small punch (SP) test has been utilized to analyze the neutron irradiation damage of nuclear vessels. Since this technique is easy, simple, and nondestructive, it can be applied to evaluate the mechanical properties and material degradation of in-service components. Conventional SP test has evaluated the ductile-brittle transition temperature and the equivalent fracture strain by the interpretations of load-deflection curve and the change of specimen thickness, respectively. The assumption that fracture occurs at maximum load is, however, not reasonable because the crack initiates at smaller load. In this study, in order to evaluate quantitatively fracture characteristics based on fracture mechanics, the pre-crack is introduced to SP specimen and acoustic emission is used to determine the crack initiation point. Using the load at crack initiation point, the fracture toughness of thin plate is calculated through bending theory. Therefore, the fracture characteristics of thin plate can be evalualed more reliably by using revised SP test.     

小冲杆试验法评价大块非晶合金的超塑性性能

采用小冲杆试验法(SPT)研究了大块非晶合金(Zr41.2Ti13.8Cu12.5Ni10Be22.5)在不同温度和不同压头速度下的变形行为,通过SPT载荷-位移曲线结合理论分析,确定大块非晶(BMG)材料超塑性本构关系.结果表明,BMG材料的SPT载荷-位移曲线对压头速度和实验温度的敏感性较高,而SPT载荷-位移曲线的形状与材料的应变速率敏感系数、粘度、压头速度等因素有关.在应变速率敏感系数和压头速度固定的条件下,SPT最大破裂载荷与粘度成正比;最大破裂位移仅随应变速率敏感系数的增大而增大,而与压头速度和粘度的大小无关.获得了Zr41.25Ti13.75Ni10Cu12.5Be22.5 BMG应变速率敏感系数和表观粘度,确定了该合金的超塑性本构关系.     

基于小冲杆试验的TC4氢脆行为和机理研究

Ti-6Al-4V合金(TC4)广泛应用于海洋和航空领域,其恶劣的使用环境容易引发氢脆(HE)失效而使得TC4的机械性能退化,导致突然的灾难性断裂。为了研究TC4合金的氢脆行为和机理,首先采用小冲孔试验(SPT)测试了TC4合金在不同充氢时间下的力学性能。然后利用原子力显微镜(AFM)和X射线衍射(XRD)技术对TC4合金在不同充氢时间下的氢分布和相转变进行了详细的研究。小冲杆试验（SPT）拟合数据显示,随着充氢时间的增加,TC4合金的强度和伸长率均发生明显的劣化,同时其宏观断口形态由韧性向脆性转变。与此同时,研究还证明了电解充氢后氢化物的生成是导致TC4合金氢脆现象产生的主要原因。本文的研究结果为在役TC4设备的氢脆性能检测提供了一种有效、简便的方法。     

工业AA1200铝合金薄板拉伸成形模拟和实验研究(英文)

对工业AA1200铝合金薄板拉伸成形的模拟和实验结果进行比较和评估。采用单向拉伸试验得到模拟所需输入参数。根据von Mises和Hill-1948屈服准则,采用Abaqus/Explicit有限元软件分析成形过程。将冲压力和应变分布的模拟结果与实验结果进行比较和验证。结果表明:在这两种情况下,使用各向异性屈服准则模拟的结果与实验结果更吻合。     

汽车用铝合金板拉深性能评估参数

为了准确地评估汽车用铝合金板的拉深性能,在单向拉伸试验、平面应变拉伸试验和圆筒件拉深试验获得的样本基础上,采用回归分析方法,全面地分析了汽车用铝合金板各种材料性能参数与其拉深性能之间的对应关系。研究表明:在所给出的材料性能参数中,xb值(平面应变抗拉强度与单向抗拉强度之比)对极限凸模行程的相关性最为显著,其次是硬化指数n及宽度颈缩率ψ等参数,而厚向异性系数r与铝合金的拉深性能并不相关。上述结果表明,在评估汽车用铝合金板的拉深性能时,使用xb值为评价指标最为准确。     

小冲孔能量法评价Q345R的屈服强度

小冲孔试验技术(SPT)是测量在役构件材料力学性能的新方法。文章介绍了基于弹性能量理论预测材料屈服强度的小冲孔能量法,并对试验原理及步骤进行了详细阐述。在验证试验重复性的基础上,对Q345R进行小冲孔能量法试验,并与常规拉伸试验、小冲孔偏移法和双斜率法的结果进行对比。结果表明,能量法测试Q345R屈服强度的误差为5.52%,远小于双斜率法和偏移法试验结果的误差。在此基础上,根据有限元模拟,结合载荷-位移(L-D)曲线与能量-位移(E-D)曲线,分析了试样厚度、压球直径、下模孔径、冲压速度以及试样边缘减薄等因素对小冲孔能量法结果的影响。得出试样厚度0.5mm、压球直径2.4mm、下模孔径4mm为最佳几何尺寸搭配。     

材料力学性能参数对ST07Zn车用钢板拉深成形特性的影响

为了掌握目前在汽车生产中被广泛应用的ST07Zn车用钢板的拉深成形性能,采用计算机数值模拟与物理模拟技术相结合的综合试验研究方法,着重对3种主要力学性能参数(σs、n、γ)对ST07Zn车用钢板拉深成形性能的影响进行相关试验研究.根据试验结果,获得了此3种力学性能参数(σs、n、γ)对ST07Zn车用钢板的成形性能影响的显著性:σs值对最大成形力影响最大,γ值对变形程度的影响最为显著,n值的影响居中,但适当提高这3种力学性能参数能较好地改善板料成形性能.同时,通过试验证明,采用ETA/DYNAFORM软件进行数值模拟试验能有效预测材料力学性能参数对板料拉深成形性能的影响效果.     

轧辊参数对铝合金薄板冷轧过程应力应变的影响

铝合金薄板轧制过程中,研究轧辊参数对板材应力应变分布和影响对于确定轧辊参数合理范围、实现冷轧精确成形及预测具有重要意义.本文基于ABAQUS建立了铝合金3A21O薄板带材(30 mm×2 mm,宽度×厚度)冷轧成形三维非线性有限元模型,分析了轧辊直径、轧辊转速对板材应力应变分布的影响.结果发现:(1)压下量为50％时,不同轧辊参数下板材应力分布变化较小,应变分布变化较大,等效塑性应变波动范围为1.68～2.83; (2)改变轧辊参数下,伸长应变分布存在三种形式:“凹”字形、梯形和抛物线形;(3)改变轧辊直径后,厚向应变、伸长应变发生较大变化,局部点处应变相差可达17.9％,增大直径和轧辊转速有利于提高厚度均匀性.     

涡流法无损检测铝合金管材可靠性的研究

总结了在生产现场的涡流检测过程中如何选择最佳探伤参数,解决管材本底噪声大的问题,提高铝合金薄壁管材涡流检测的准确性和可靠性。     

An evaluation of the statistics of steel material model parameters

In robustness studies, variations of material properties are often represented by simple assumptions, such as scaling of stress-strain relations, often due to lack of knowledge or deeper understanding of the material physics and the material model applied. By performing material characterisation tests on several batches of a DP600 steel and fitting a phenomenological material model to each batch, this paper studies the dispersion of material model parameters, as well as correlations between both experimental and model parameters. It is concluded that some of the characterisation tests may be omitted in the future, due to correlations found between parameters. The results may also be applied in a robustness study by inversely using the retrieved statistics to generate reasonable new sets of material model parameters. The methodology presented may be adopted for any other type of material characterisation process.     

An inverse analysis using a finite element model for identification of rheological parameters

In order to reduce the discrepency between experimental and numerical development, a parameter automatic identification procedure from rheological test is formulated as an inverse problem. The direct model which permits to simulate the large strain behaviour during the rheological test is a Finite Element Code. The inverse problem is formulated as finding a set of rheological parameters starting from a known constitutive equation. The goal is to compute the parameter vector which minimizes an objective function representing, in the least square sense, the difference between experimental and numerical data. The high nonlinearity of the problem to be solved, requires the use of an accurate evaluation of the sensitivity matrix by analytical differentiation of governing equations with respect to the parameters. Thus the optimisation algorithm is strongly coupled with the finite element simulation. This method, namely a Computer Aided Rheology (CAR) methodology is possible in principle for all tests able to be simulated. This paper concerns the thermoviscoplastic deformation during torsion and tension tests.     

3104铝合金热变形的试验研究

采用G leeb le-3500热模拟实验机,对3104铝合金在变形温度为350℃~500℃、应变速率为0.001 s-1~1s-1、变形程度为50%的条件下进行热压缩试验。结果表明,流变应力随应变的增加而显著增大,到达峰值后逐渐降低并趋于稳定,具有明显的稳态流变特征。变形温度和应变速率对流变应力影响较大,并用包含Arrhen iues项的本构方程描述了3104铝合金的高温变形行为。     

具有焊接残余应力的矩形薄板固有频率计算方法研究

为避免残余应力对焊接结构的不利影响,保证其可靠性,需要探究残余应力分布. 模态试验法因具有快速和无损的特点,逐渐应用于残余应力测试. 为实现模态试验法测试焊接残余应力,通过振动理论分析了模态试验法的机理,获得了薄板焊件中残余应力与固有频率的关系;薄板焊件中的残余拉应力使固有频率减小,残余压应力使固有频率增大. 在此基础上,将钻孔法和模态试验相结合,借助数据拟合的方法,估计了模态试验法测试6 mm 7A52铝合金试板 VPPA-MIG(variable polarity plasma arc-metal inert gas)复合焊接残余应力的模型参数,确立了固有频率与残余应力的数值关系. 依据确立的数值关系,测得了7A52铝合金试板在不同复合焊接参数下的纵向残余应力分布. 结果表明,接头各区域的残余应力分布特征与钻孔法测得的结果基本一致,偏差在4%范围之内,估计出的模型参数能够保证模态试验法测试结果的可靠性,实现了焊接残余应力的快速和无损测试.     

等离子弧焊熔敷Ti-6Al-4V合金原位拉伸过程中显微组织及应变响应的电子背散射衍射表征

航天级钛合金的新型叠层制造技术（ALM）的优势体现在较低的制造成本等方面,并可替代传统加工成型工艺。由等离子弧焊熔敷叠层制造技术制备Ti-6Al-4V合金的显微组织由定向凝固生长的β柱状晶及在其晶内生长的细小的α片层组织构成。在原位拉伸过程中结合应用高速离线电子背散射衍射表征（Offline EBSD）可快速获取试样显微组织和形变特征之间的关系。揭示出不均匀变形的发生取决于柱状晶界间的应变响应。柱状滑移和基面滑移系统被激活进而导致最后出现形变滑移线,即在某些柱状晶中滑移扩展至整个晶粒;而在另一些晶粒中表现为存在应变梯度和应力集中的地方发生形变失配。形变的扩展习性受制于定向凝固生长的柱状晶生长方向及其之间的界面取向关系。在垂直于柱状晶方向的拉伸试验揭示存在剧烈的变形局域化。基于原位拉伸观测及高速的离线电子背散射衍射表征结果,本文作者提出从微观到宏观形变扩展的控制机制。     

Microscopic Phase-Field Simulation of the Structure Transformation from DO22 to L10(M=1) Phase in Ni64Al21V15 Alloy

基于微观相场模型,研究了Ni64Al21V15合金在1150K时效过程中相结构演化。结合微观组织演化图像和各个格点上原子占位几率的演化,分析了DO22结构向L10(M=1)结构转变机制。合金沉淀中期,在相界处析出L10(M=1)结构。研究发现,L10(M=1)结构形成可分为3类:在DO22与L12相界处形核,沿[001]方向排列,向DO22相扩张;在DO22结构90°有序畴界处形核,沿[001]方向排列,向DO22扩张;在2个[100]向排列的DO22结构交界处形核,沿[100]方向排列,向DO22结构扩张。DO22相中,V主要占据β位,Ni主要占据α2和α3位,Al主要占据α1位;随后,V向α2位跃迁,在(002)面富聚且发生有序化,逐渐占据β和α2位,Ni原子发生面间跃迁,由α2位跃迁至α1位,逐渐占据α1和α3位,Al原子向相外扩散。DO22结构最终转变为高度有序的L10(M=1)结构。