1．5MW风机主轴轴承架残余应力的测量及分析

用“盲孔法”对1．5MW风机主轴轴承架铸态、粗加工态和时效处理前后的残余应力进行了测量。测试结果表明：铸态下的平均残余应力为116．2MPa;粗加工后平均残余应力水平增长了58．17％;人工时效处理后残余应力平均消除率为37．8％;振动时效处理后应力平均消除率为27．6％。振动时效后残余应力的均匀性比人工时效好。     

7075铝合金真空电子束焊接残余应力场数值分析

针对7075铝合金中厚板真空电子束焊接过程，采用非线性有限元法，对焊接接头的残余应力分布进行了数值模拟。结果表明，沿焊缝方向，纵向残余应力均为拉应力，一般在焊缝中间处最大；沿垂直焊缝方向递减。焊缝上表面的横向残余应力多为压应力，沿焊缝方向呈递增趋势。垂直焊缝方向，焊板处的横向残余应力多在零值附近变动。焊缝处沿厚度方向残余应力变化不大。     

7075铝合金真空电子束焊接残余应力场数值分析

针对7075铝合金中厚板真空电子束焊接过程,采用非线性有限元法,对焊接接头的残余应力分布进行了数值模拟。结果表明,沿焊缝方向,纵向残余应力均为拉应力,一般在焊缝中间处最大;沿垂直焊缝方向递减。焊缝上表面的横向残余应力多为压应力,沿焊缝方向呈递增趋势。垂直焊缝方向,焊板处的横向残余应力多在零值附近变动。焊缝处沿厚度方向残余应力变化不大。     

车削残余应力方向性实验

为了了解车削残余应力分布方向性规律,对调质处理和淬火处理的45号钢进行精、粗车削加工,然后测量和观察不同试样的残余应力圆周分布特点,了解材料力学性能和切削条件对残余应力方向性的影响。研究结果显示:残余应力分布具有方向性,车削残余应力轴向最大,切向最小;残余应力方向性主要由机械效应决定,热效应影响不大;残余应力不同方向的大小和变动率受工件材料力学性能和加工条件影响;轴向残余应力对车削工件影响最大。     

工艺过程对散热器电子束钎焊残余应力影响的数值模拟

利用ANSYS软件,建立二维有限元模型,分析了两种不同钎焊工艺对1Cr18Ni9Ti不锈钢散热器电子束钎焊接头残余应力的影响,旨在筛选出一种合适的工艺及参数.结果表明,对于径向残余应力,采用直接加热钎焊工艺,钎焊面上出现明显的应力集中区域;而采用分阶段加热钎焊工艺,钎焊面上没有应力集中区出现,且应力变化曲线比直接加热钎焊工艺平缓得多;对于周向残余应力,分阶段加热与直接加热钎焊工艺相比,拉应力峰值减小了11.2%.两种钎焊工艺的周向残余拉应力峰值均大于径向残余拉应力,钎焊面的危险部位沿圆周方向,即电子束扫描加热的方向.     

Stresses distribution after planing and cutting in welded plates

To forecast the modification and evolution of a residual stress field in a butt-welded plate, the residual stress field was numerically evaluated by a finite element method code. The plate was originated by welding and suffered after chip-forming machining. The residual stress field was taken as a pre-stress condition for the next cutting simulations. Residual stress distribution after machining was then compared to that in the initial residual stress field. Numerical results have been compared to experimental measurements. That shows the potentiality as well as the limitations of numerical techniques. Three major contributions are summarized as follows: Longitudinal residual stress distribution in welded plates is deeply changed by mechanical tooling; Planing and cutting increases peak values of transversal residual stress and in general introduces some unevenness in distribution along X-direction; Comparison of experimental and numerical values is generally satisfactory for longitudinal residual stress.     

有限元分析热—力学参量对焊接残余应力峰值特征的影响

使用随温度变化的材料热—力学参量,采用双椭球热源模型,研究了弹性模量、线膨胀系数、泊松比三个热—力学参量对焊接残余应力的影响.结果表明,弹性模量增加可使焊接残余应力增大,纵向残余应力峰值从双峰特征过渡到单峰特征;线膨胀系数降低可使焊接残余应力峰值降低,纵向残余应力峰值的双峰与波谷差值也逐渐减小;随着泊松比的增加,纵向残余应力峰值逐渐下降.因此,热—力学参量是导致铝合金纵向焊接残余应力峰值比屈服极限低以及焊缝附近呈现双峰分布特征的重要原因.使用切条释放法对材料参量为铝合金2024-T4的平板中纵向焊接残余应力模拟结果进行试验验证,模拟结果与试验结果吻合良好.     

分段退焊对角接接头焊接残余应力及变形的影响

基于热-弹塑性有限元理论,以Abaqus软件为平台进行角接接头焊后残余应力及变形的分析,采用分段移动热源模型并利用Fortran语言开发热源子程序,分别采用直通焊和分段退焊两种方式进行角接接头焊接温度场、残余应力及变形的数值模拟分析。结果表明:横向变形是角接接头最主要的变形;角接接头焊接在焊缝端口处的残余应力为压应力,而在中间部位的残余应力为拉应力;分段退焊对横向残余应力的减弱作用较为明显,可以有效降低焊接后的变形及其应力。     

HT250冷焊表面残余应力试验

利用亚激光瞬间熔冷焊机对柴油发动机缸体所用材料HT250表面缺陷进行修复,并用x射线法测定焊缝两侧表面残余应力,以此研究冷焊残余应力分布规律以及与不同工艺参数间的关系．结果表明,靠近焊缝处为拉应力,远离焊缝处为压应力：冷焊残余应力范围很小,峰值主要分布在离焊缝中心5mm的范围内,离焊缝中心20mm处,残余应力接近为零;时间参数对残余应力峰值的影响较小,而能量参数对残余应力峰值的影响较大;通过改变时间与能量参数组合,可以得到较小的残余应力峰值,满足发动机再制造零部件表面损伤的修复要求．     

基于弹性模量变化的7A52铝合金VPPA-MIG复合焊接残余应力测试

采用虚拟仪器和NI数据采集卡搭建了一种以小孔法为核心的残余应力测试系统,分析了7A52铝合金VPPA-MIG复合焊后残余应力的分布情况. 为降低弹性模量误差对最终测量结果的影响,通过实测复合焊接接头不同区域的弹性模量,拟合弹性模量随测量点位置变化的曲线来修正弹性模量误差. 针对10 mm厚7A52铝合金板材,完成了VPPA-MIG复合焊接残余应力测试试验. 结果表明,焊缝两侧各区域上的残余应力分布基本关于焊缝对称,熔合区出现最大拉应力,最大横向残余应力σ_y与纵向残余应力σ_x分别为118和223 MPa. 从熔合区至热影响区,残余应力均为拉应力,逐渐减小且高于焊缝中心的残余应力. 与单MIG焊相比,复合焊的最大横向残余应力与纵向残余应力大于MIG焊,但高应力区比MIG焊窄.     

Effect of Cold Rolling Parameters on the Longitudinal Residual Stress Distribution of GH4169 Alloy Sheet

For plastic deformed parts, the dimensional accuracy is significantly affected by residual stresses and so does the performance in service. Therefore, the rolling process of GH4169 alloy sheet at room temperature was investigated by finite element method. The effects of rolling reduction, friction coefficient, rolling velocity and initial stress on the longitudinal residual stress distribution over the thickness of GH4169 alloy sheet were analyzed. The results show that the values of longitudinal residual stress can be slightly reduced by increasing the rolling reduction and velocity. The longitudinal residual stress over the thickness distributes as ‘‘V' type or weak ‘‘W' type. The initial stress mainly has an effect on the longitudinal stress in the backward slip area. But the friction coefficient has remarkable influence on longitudinal residual stress. With the friction coefficient increasing from 0.1 to 0.5, the value of longitudinal residual stress on the sheet surface is reduced by 282 MPa. Simultaneously, the tensile stress turns into compressive stress with a strong‘‘W' type distribution.     

GH742高温合金激光冲击强化和喷丸强化残余应力

对GH742高温合金进行激光冲击强化和喷丸强化,利用X射线应力分析仪测定强化层的残余应力,对比分析2种残余应力的差异和特征,并采用不同的退火温度进行退火,研究表面残余应力在高温下的稳定性。结果表明,2种表面强化方法都可以在GH742高温合金表层引入残余压应力,但激光冲击强化试样比喷丸强化试样具有更深的残余压应力层和较好的稳定性,且残余压应力最大值在表面;与激光冲击强化的试样相比,喷丸强化试样的残余压应力较浅,而且随着喷丸强度的增加,最大残余压应力也由表面移向了次表面。     

2195-F态铝锂合金TIG焊和FSW焊后残余应力分析

采用盲孔法和压痕法,分别对2195-F态铝锂合金手工TIG焊和FSW焊后残余应力进行测量. 结果表明,盲孔法的测量值普遍高于压痕法. 两种焊接方法,近焊缝区的纵向应力均高于横向应力;横向应力整体表现为压应力或小于50 MPa的拉应力;纵向应力在热影响区附近表现为大于焊缝的拉应力. 焊缝区附近,手工TIG焊纵向残余应力大于FSW,且纵向残余应力表现为较大的拉应力,最大值接近于接头的屈服强度;焊缝区外,手工TIG焊和FSW残余应力值相差不大,其横向残余应力基本表现为很小的拉应力或者压应力.     

Fatigue crack/residual stress field interactions and their implications for damage-tolerant design

Residual stress fields are now widely accepted to have significant influence on fatigue crack growth. Tensile stresses have detrimental effects on fatigue lives, whereas compressive residual stresses can be beneficial. Control of fatigue lives via residual stress is now established in many industrial applications, using techniques such as shot peening or cold expansion. However, knowledge of the processes that occur when a fatigue crack grows through a pre-existing stress field is far from complete. Although the residual stress field will clearly have an effect on crack growth, the crack will equally have an effect on the residual stress field. The determination of this effect is not trivial, and direct measurement may be the designer’s best safeguard. This article outlines the complementary effects that a growing fatigue crack and a residual stress field have on each other. Two types of residual stress field are considered: mechanically induced and thermally induced. The results are discussed in terms of the implications that residual stress interactions have for damage-tolerant-based design.     

Internal residual stress measurement on linear friction welding of titanium alloy plates with contour method

The internal residual stress within a TC17 titanium alloy joint welded by linear friction welding (LFW) was measured by the contour method, which is a relatively new and destructive technique to obtain a full map of internal residual stress. The specimen was first cut into two parts; the out-of-plane displacement contour formed by the release of the residual stress was then measured; finally, taking the measured contour of the cut plane as the boundary conditions, a linear elastic finite element analysis was carried out to calculate the corresponding distribution of residual stress normal to the cut plane. The internal stress distribution of the TC17 titanium alloy LFW joint was also analyzed. The results show that the tensile residual stress in the TC17 LFW weld is mainly present within a region about 12 mm from the weld centerline; the peak tensile residual stress occurs at the weld centerline and reaches 360 MPa (about one third of the yield strength of TC17 alloy); within the weld zone of the TC17 LFW weld, the through-thickness stress is not uniform, and the internal stress is larger than that near the top or bottom surface.     

LD10铝合金残余应力测试及分析

对ＬＤ１０铝合金加工后的去应力处理工艺的残余应力用小孔释放法进行了测试，对不同热处理工艺和加工后的去应力处理工艺对残余应力的影响进行了分析。结果表明：加工以后使应力重新分布和使残余应力降低或均匀化，冷热循环去应力处理效果很小。     

Evaluation of residual stress distribution in Ni base alloy clad welds by numerical simulation and X-ray stress measurement

Abstract

Dissimilar material components such as clad welds are important to achieve both performance, and economic and ecological efficiency. The evaluation of the residual stress distribution in such components is needed to assess and assure the integrity of structures components. In this study, the residual stress distribution in clad welds of Ni base alloy over low alloy steel was investigated. A clad welded mock-up was fabricated, and the residual stress distribution was evaluated by X-ray stress measurement method and finite element simulation. The residual stress was measured with high accuracy even in coarsened Ni base alloy clad weld metal by X-ray stress measurement method utilising a two-dimensional detector and multiaxial rocking technique. The residual stress distribution was well reproduced by the finite element simulation considering the redistribution due to cutting off of the specimen from the fabricated mock-up.     

基于快速面探测方法的碳化硅表面残余应力测量

陶瓷加工后表面残余应力的测量通常采用一维X射线衍射线探测法,该方法存在测量过程烦琐、效率低、成本高等问题,因此采用新型快速二维面探测X射线衍射残余应力测量方法,对碳化硅陶瓷表面的残余应力进行测量,实验中测量了3种不同品牌碳化硅工件的初始表面和抛光后表面的残余应力。结果表明:此新方法单次测量即可获得样品500点的衍射信息,特别适用于陶瓷材料的应力测量。同时还发现:对于被加工表面的残余压应力,抛光加工最高能够消除近80%的残余应力,但不能改变工件的残余应力分布。      

Analysis of residual stress in carbon steel weldment incorporating phase transformations

Abstract

The welding process, incorporating rapid heating and cooling, generates distortion and residual stress in weldments. Welding distortion and residual stress in welded structures can result in problems such as dimensional inaccuracies during assembly and raise concerns regarding safety during service. Therefore, accurate prediction and reduction of residual stress are critical in improving the quality of a weldment. In the present paper a new method of analysis is proposed to predict welding residual stress by considering solid phase transformations during the welding process. This method is applied to two cases, involving medium carbon steel and low carbon steel respectively. The analysis of medium carbon steel revealed the presence of compressive residual stress due to martensite formation when phase transformation was considered. However, in low carbon steel the residual stress obtained considering the effect of phase transformation did not differ significantly from that obtained when phase transformation was ignored.     

基于轮廓法测试镍基高温合金惯性摩擦焊接头内部残余应力

采用轮廓法(contour method)测试小直径FGH96镍基高温合金惯性摩擦焊接接头的内部环向应力。详细介绍了轮廓法测试步骤,包括试样切割、切割面轮廓测试、数据处理和有限元分析;获得了FGH96镍基高温合金惯性摩擦焊接接头内部环向应力分布全貌并分析其分布特征。测试结果表明:镍基高温合金惯性摩擦焊接接头的焊缝中心位置环向应力为非常大的拉应力,峰值拉应力为1200 MPa,达到材料室温时的屈服强度;焊缝区域(距焊缝中心±5 mm区域)近内壁区域的环向应力大于外壁区域环向应力,垂直焊缝方向的环向应力变化梯度非常大;远离焊缝区域,焊缝两侧的环向应力不对称。