氢对TC4钛合金焊接接头组织与性能影响的研究
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摘要
钛合金材料的焊接方法中,电子束焊接是一种先进的高能束流加工技术,具有其他传统焊接方法无法比拟的优点。由于钛合金电子束焊接构件在使用环境中存在氢和循环应力,焊接构件有发生氢致断裂的可能,因而研究氢对电子束焊接头疲劳性能的影响显得十分重要。作为一种新型的固相连接技术,线性摩擦焊接具有优质、高效、节材、无污染等一系列优点,但线性摩擦焊技术也存在焊机吨位大、设备制造复杂的问题,限制了它的应用范围。钛合金置氢加工工艺是把氢作为一种临时合金化元素,通过改变钛合金的相组成和微观结构,进而达到改善钛合金加工性能的目的。应用这一技术可以允分发挥钛合金材料的加工性能,降低合金对设备成型能力的要求。本文以TC4钛合金为研究对象,首先分析了置氢后TC4钛合金室温组织及亚结构的演变规律,然后研究了氢对TC4钛合金电子束焊接头疲劳性能的影响规律,最后研究了置氢TC4钛合金的线性摩擦焊连接性能,并对置氢钛合金线性摩擦焊过程进行了数值模拟。
钛合金的室温组织是影响其焊接性能以及接头力学性能的主要因索。本文采用光学显微镜、扫描电子显微镜、X射线衍射仪及透射电子显微镜分析了置氢对TC4钛合金室温组织及亚结构的影响规律,并揭示了置氢TC4钛合金中氢化物的析出机制。研究结果表明,随着氢含量的增加,TC4钛合金组织中初生α相的含量逐渐减少,p相的含量逐渐增多,孪晶数量明显增多。当氢含量达到0.25wt%后,在TC4钛合金中观察到了面心立方结构的6氢化物。
采用置氢C(T)试样对TC4钛合金电子束焊接头的室温疲劳裂纹扩展速率进行J’测定。研究结果得出,置氢母材试样在低速扩展区和失稳快速扩展区的da/dN相对于未氢试样有明显的提高,但不同氢含量之间差别不大。在稳态扩展区(Paris区),氧对试样da/dN的影响很小。对于焊缝试样,置氢试样的da/dN在裂纹扩展的全过程均明显于未置氢试样,并且随着氢含量的增加,裂纹扩展速率提高,只是在氢含量0.054wt%增加到0.101wt%时,提高幅度变小。氢对TC4钛合金母材和焊缝试样断口形貌的影响规律基本相同,在预裂区,随着氢含量的增加,二次裂纹的数量增多。在稳态扩展区,随着氢含量的增加,疲劳条带宽度增大,二次裂纹的数量增多、尺寸增大,农明材料脆性增大。在失稳快速扩展区,不同氢含量的试样都为典型韧性断裂,置氢试样的韧窝较浅、较小。
采用统计分析的方法研究了氢对TC4钛合金电子束焊接头疲劳寿命的影响。结果表明,氢显著降低了TC4钛合金电子束焊接头试样的疲劳寿命,氢含量0.028wt%钛合金试样的疲劳寿命仅为未置氢试样的1/2,当氢含量增大到0.120wt%时,疲劳寿命降到了未充氢的1/5。疲劳试样多数断于接头的热影响区,造成这一结果的主要原因是热影响区的组织不均匀性和氢含量相对较高。断口的形貌特征表明,氢促进了疲劳裂纹的萌生和增加了裂纹扩展的速度,导致钛合金电子束焊接头的疲劳寿命显著降低。
本文系统研究了未置氢TC4钛合金的线性摩擦焊连接性能,总结得出,未置氢TC4合金获得成功焊接头并具有优良力学性能的临界工艺参数条件为：f=30Hz,a=2mm,p=4T,t=2s。焊接时需要输入的最小有效功率密度为8×106W/m2。相同焊接工艺参数下置氢TC4钛合金接头的焊合率均高于未置氢钛合金,接头的焊缝宽度也明显小于未置氢钛合金。随着氢含量的增加,置氢钛合金接头的轴向缩短量先显著增加后又稍微降低。氢含量在0.3～0.4wt%之间时,钛合余具有较好的高温塑性,对于提高钛合金的线性摩擦焊连接性能最为有利。置氢-除氢处理过程没有降低TC4钛合金线性摩擦焊接头的室温力学性能。计算得出,置氢TC4钛合金获得成功焊接接头需要要输入的最小有效功率密度为5.5×106W/m2,与未置氢钛合金相比,降低幅度达到了30%。氢主要通过改变钛合金中的两相比例,促进高温变形过程中位错运动和动态再结晶等机制来增加钛合金的高温塑性,从而改善钛合金的线性摩擦焊连接性能。
采用"COSMAP"有限元数值模拟软件,综合考虑线性摩擦焊过程中温度场、应力场、组织场的三场耦合作用,建立了三维弹塑性有限元模型,较好地对置氧TC4钛合金线性摩擦焊过程中的温度场、应力场以及焊缝区的相变过程进行了数值模拟,并对比分析了氢的影响。通过特定节点温度变化曲线的测量,接头表面残余应力的测量以及焊缝区的组织分析对模拟结果进行了试验验证,结果表明,模拟结果与试验结果吻合较好。此数值模拟结果可为钛合金线性摩擦焊的工艺参数优化与接头质量控制提供参考依据。
In the welding methods of titanium alloys, electron beam welding (EBW) is one kind of advanced high energy density beam processing technology, which has many advantages that other traditional welding methods can't compare with. Because there are hydrogen and cyclic stress in the work environment, the possibility exists that hydrogen-induced fracture will take place in the titanium alloy components welded by EBW. So it will be very important to study effects of hydrogen on fatigue properties of titanium alloy EBW joints. As a new solid-phase welding technology, linear friction welding (LFW) has many advantages such as high quality, high efficiency, material saving, pollution free, etc. However, LFW technology also has its disadvantages, i.e. the application of LFW is limited because of the large tonnage of LFW machine and complex technique for manufacturing equipment. The thermohydrogen processing (THP) is a technique in which hydrogen is used as a temporary alloying element in titanium alloys by controlling the microstructure and phase structure to improve the mechanical working properties. By using this technology, the workability of titanium alloy can be given to full play, and the requirement to equipment's forming capability can be lowered. In this paper, TC4alloy is the research object. Firstly, the microstructure and sub-structure evolution of TC4alloy after hydrogenation were analyzed. Secondly, effects of hydrogen on fatigue properties of TC4alloy EBW joints were researched. Finally, linear friction welding performance of hydrogenated TC4alloy was researched, and the numerical simulation of hydrogenated TC4alloy during linear friction welding progress was carried out.
Microstructure of titanium alloys at room temperature has much influence on their welding performance and the mechanical properties of welded joints. Thus optical microscope (OM), scanning electron microscope (SEM), X-ray diffraction analysis (XRD) and Transmission electron microscope (TEM) were used to analyze the influence of hydrogen on the microstructures and substructures of titanium alloy. The precipitation mechanism of titanium hydride in hydrogenated TC4alloy was disclosed. The results show that original α phase fraction decreases gradually, while β phase fraction increases with the increase in hydrogen content. The amounts of twins also increase significantly in the hydrogenated alloy as hydrogen content increasing. When hydrogen content up to0.25wt%,δ titanium hydride having a fee structure can be observed in hydrogenated TC4alloy.
The hydrogenated C(T) specimens were employed to measure the fatigue crack propagation rate (da/dN) of TC4alloy electron beam welded joints at room temperature. The results indicated that the da/dN of hydrogenated base metal specimens were higher than the non-hydrogenated ones in near-threshold stage and rapid rupture stage, but specimens with various hydrogen contents differed little from each other, and hydrogen showed little effects on da/dN in stable crack propagation stage (Paris stage). Thed da/dN of hydrogenated weld bead specimens were obviously enhanced during the whole crack propagation process and increased with the increment of hydrogen content. But the degree of da/dN increasing became small when hydrogen content increased from0.054wt%to0.101wt%. The analysis results of fracture surface morphologies showed that the weld bead specimens had similar surface morphologies with the base metal specimens. The amount of secondary crack increased with the increase of hydrogen content in the pre-crack region. In the stable crack growth region, the width of fatigue striation, amount and size of secondary crack increased when hydrogen content increasing, which indicated the increase of brittleness of titanium alloy. In the rapid cracking region, the surface morphologies of all specimens consisted of dimples, and the dimples of hydrogenated specimens were shallower and smaller.
The effects of hydrogen on fatigue life values of TC4titanium alloy electron beam welded joints were evaluated by statistic approach. The fatigue fracture positions of joints as well as the fracture surface morphologies of specimens were observed and analyzed. It was found that the fatigue life was evidently reduced by hydrogen charging. The fatigue life of joint with0.028wt%hydrogen was just half of the hydrogen-free joint. When hydrogen content was0.120wt%, the fatigue life of hydrogen-charged joint decreased to one fifth of the hydrogen-free joint. The fracture occurred at heat affected zone (HAZ) of most fatigue specimens. This was due to the structure inhomogeneity and the higher hydrogen content of materials at HAZ. The fractographic observation results indicate that hydrogen accelerates the fatigue crack initiation and increases the speed of crack propagation, which leads to the obvious decrease of fatigues lives of TC4titanium alloy joints welded by electron beam welding.
Systematic researches on linear friction welding performance of TC4alloy were carried out.The results show that the critical parameters for unhydrogenated TC4alloy to obtain a successful LFW joint having excellent mechanical properties are:f=30Hz, a=2mm, p=4T, t=2s. The minimum effective power density needed is8.0×106W/m2. Under the same welding parameters condition, the bonding rates of all hydrogenated TC4alloy LFW joints are higher than the unhydrogenated alloy joints, and the widths of weld bead of hydrogenated TC4alloy joints are narrower than the unhydrogenated joints. As hydrogen content increases, the axial shortening of hydrogenated TC4alloy first increases obviously and then decreases slightly. It can be concluded that TC4alloy containing0.3～0.4wt%hydrogen has better high temperature plasticity, which resultes in the optimum welding performance improvement of LFW. The THP process doesn't reduce the mechanical properties of TC4alloy LFW joints. The minimum effective power density needed for hydrogenated TC4alloy to obtain a success LFW joint is calculated to be5.5×106W/m2. Comparing with the unhydrogenated TC4alloy, the reduce rate is up to30%. The high temperature plasticity of titanium alloy is enhanced by hydrogen mainly through mechanisms:changing phase proportion of α and β, promoting dislocation movement and dynamic recrystallization. As a result, the linear friction welding performance is improved by hydrogenation.
By use of finite clement simulation (FHM) code COSMAP, the mathematical model synthetically concerning the coupled effects of temperature field, stress field and phase structure was established. Moreover, a three-dimensional elastic-plastic FHM model was established. Then the linear friction welding process of hydrogenated TC4alloy was well simulated, and the law of variation and distribution of temperature and stress fields as well as phase structure was obtained. Furthermore, the effects of hydrogen on the three fields were analyzed by comparative analysis method. By performing the measurement of temperature variation of a specific node and residual stress distribution at surface of the joint as well as observation of microstructure at weld bead zone, the simulation results were experimentally verified. By comparison, the calculation data obtained from this numerical simulation work was in good agreement with the experimental data. This numerical simulation result can be used to provide a reference for parameters optimization and joint quality control of titanium alloy in linear friction welding technology.
钛合金的室温组织是影响其焊接性能以及接头力学性能的主要因索。本文采用光学显微镜、扫描电子显微镜、X射线衍射仪及透射电子显微镜分析了置氢对TC4钛合金室温组织及亚结构的影响规律,并揭示了置氢TC4钛合金中氢化物的析出机制。研究结果表明,随着氢含量的增加,TC4钛合金组织中初生α相的含量逐渐减少,p相的含量逐渐增多,孪晶数量明显增多。当氢含量达到0.25wt%后,在TC4钛合金中观察到了面心立方结构的6氢化物。
采用置氢C(T)试样对TC4钛合金电子束焊接头的室温疲劳裂纹扩展速率进行J’测定。研究结果得出,置氢母材试样在低速扩展区和失稳快速扩展区的da/dN相对于未氢试样有明显的提高,但不同氢含量之间差别不大。在稳态扩展区(Paris区),氧对试样da/dN的影响很小。对于焊缝试样,置氢试样的da/dN在裂纹扩展的全过程均明显于未置氢试样,并且随着氢含量的增加,裂纹扩展速率提高,只是在氢含量0.054wt%增加到0.101wt%时,提高幅度变小。氢对TC4钛合金母材和焊缝试样断口形貌的影响规律基本相同,在预裂区,随着氢含量的增加,二次裂纹的数量增多。在稳态扩展区,随着氢含量的增加,疲劳条带宽度增大,二次裂纹的数量增多、尺寸增大,农明材料脆性增大。在失稳快速扩展区,不同氢含量的试样都为典型韧性断裂,置氢试样的韧窝较浅、较小。
采用统计分析的方法研究了氢对TC4钛合金电子束焊接头疲劳寿命的影响。结果表明,氢显著降低了TC4钛合金电子束焊接头试样的疲劳寿命,氢含量0.028wt%钛合金试样的疲劳寿命仅为未置氢试样的1/2,当氢含量增大到0.120wt%时,疲劳寿命降到了未充氢的1/5。疲劳试样多数断于接头的热影响区,造成这一结果的主要原因是热影响区的组织不均匀性和氢含量相对较高。断口的形貌特征表明,氢促进了疲劳裂纹的萌生和增加了裂纹扩展的速度,导致钛合金电子束焊接头的疲劳寿命显著降低。
本文系统研究了未置氢TC4钛合金的线性摩擦焊连接性能,总结得出,未置氢TC4合金获得成功焊接头并具有优良力学性能的临界工艺参数条件为：f=30Hz,a=2mm,p=4T,t=2s。焊接时需要输入的最小有效功率密度为8×106W/m2。相同焊接工艺参数下置氢TC4钛合金接头的焊合率均高于未置氢钛合金,接头的焊缝宽度也明显小于未置氢钛合金。随着氢含量的增加,置氢钛合金接头的轴向缩短量先显著增加后又稍微降低。氢含量在0.3～0.4wt%之间时,钛合余具有较好的高温塑性,对于提高钛合金的线性摩擦焊连接性能最为有利。置氢-除氢处理过程没有降低TC4钛合金线性摩擦焊接头的室温力学性能。计算得出,置氢TC4钛合金获得成功焊接接头需要要输入的最小有效功率密度为5.5×106W/m2,与未置氢钛合金相比,降低幅度达到了30%。氢主要通过改变钛合金中的两相比例,促进高温变形过程中位错运动和动态再结晶等机制来增加钛合金的高温塑性,从而改善钛合金的线性摩擦焊连接性能。
采用"COSMAP"有限元数值模拟软件,综合考虑线性摩擦焊过程中温度场、应力场、组织场的三场耦合作用,建立了三维弹塑性有限元模型,较好地对置氧TC4钛合金线性摩擦焊过程中的温度场、应力场以及焊缝区的相变过程进行了数值模拟,并对比分析了氢的影响。通过特定节点温度变化曲线的测量,接头表面残余应力的测量以及焊缝区的组织分析对模拟结果进行了试验验证,结果表明,模拟结果与试验结果吻合较好。此数值模拟结果可为钛合金线性摩擦焊的工艺参数优化与接头质量控制提供参考依据。
In the welding methods of titanium alloys, electron beam welding (EBW) is one kind of advanced high energy density beam processing technology, which has many advantages that other traditional welding methods can't compare with. Because there are hydrogen and cyclic stress in the work environment, the possibility exists that hydrogen-induced fracture will take place in the titanium alloy components welded by EBW. So it will be very important to study effects of hydrogen on fatigue properties of titanium alloy EBW joints. As a new solid-phase welding technology, linear friction welding (LFW) has many advantages such as high quality, high efficiency, material saving, pollution free, etc. However, LFW technology also has its disadvantages, i.e. the application of LFW is limited because of the large tonnage of LFW machine and complex technique for manufacturing equipment. The thermohydrogen processing (THP) is a technique in which hydrogen is used as a temporary alloying element in titanium alloys by controlling the microstructure and phase structure to improve the mechanical working properties. By using this technology, the workability of titanium alloy can be given to full play, and the requirement to equipment's forming capability can be lowered. In this paper, TC4alloy is the research object. Firstly, the microstructure and sub-structure evolution of TC4alloy after hydrogenation were analyzed. Secondly, effects of hydrogen on fatigue properties of TC4alloy EBW joints were researched. Finally, linear friction welding performance of hydrogenated TC4alloy was researched, and the numerical simulation of hydrogenated TC4alloy during linear friction welding progress was carried out.
Microstructure of titanium alloys at room temperature has much influence on their welding performance and the mechanical properties of welded joints. Thus optical microscope (OM), scanning electron microscope (SEM), X-ray diffraction analysis (XRD) and Transmission electron microscope (TEM) were used to analyze the influence of hydrogen on the microstructures and substructures of titanium alloy. The precipitation mechanism of titanium hydride in hydrogenated TC4alloy was disclosed. The results show that original α phase fraction decreases gradually, while β phase fraction increases with the increase in hydrogen content. The amounts of twins also increase significantly in the hydrogenated alloy as hydrogen content increasing. When hydrogen content up to0.25wt%,δ titanium hydride having a fee structure can be observed in hydrogenated TC4alloy.
The hydrogenated C(T) specimens were employed to measure the fatigue crack propagation rate (da/dN) of TC4alloy electron beam welded joints at room temperature. The results indicated that the da/dN of hydrogenated base metal specimens were higher than the non-hydrogenated ones in near-threshold stage and rapid rupture stage, but specimens with various hydrogen contents differed little from each other, and hydrogen showed little effects on da/dN in stable crack propagation stage (Paris stage). Thed da/dN of hydrogenated weld bead specimens were obviously enhanced during the whole crack propagation process and increased with the increment of hydrogen content. But the degree of da/dN increasing became small when hydrogen content increased from0.054wt%to0.101wt%. The analysis results of fracture surface morphologies showed that the weld bead specimens had similar surface morphologies with the base metal specimens. The amount of secondary crack increased with the increase of hydrogen content in the pre-crack region. In the stable crack growth region, the width of fatigue striation, amount and size of secondary crack increased when hydrogen content increasing, which indicated the increase of brittleness of titanium alloy. In the rapid cracking region, the surface morphologies of all specimens consisted of dimples, and the dimples of hydrogenated specimens were shallower and smaller.
The effects of hydrogen on fatigue life values of TC4titanium alloy electron beam welded joints were evaluated by statistic approach. The fatigue fracture positions of joints as well as the fracture surface morphologies of specimens were observed and analyzed. It was found that the fatigue life was evidently reduced by hydrogen charging. The fatigue life of joint with0.028wt%hydrogen was just half of the hydrogen-free joint. When hydrogen content was0.120wt%, the fatigue life of hydrogen-charged joint decreased to one fifth of the hydrogen-free joint. The fracture occurred at heat affected zone (HAZ) of most fatigue specimens. This was due to the structure inhomogeneity and the higher hydrogen content of materials at HAZ. The fractographic observation results indicate that hydrogen accelerates the fatigue crack initiation and increases the speed of crack propagation, which leads to the obvious decrease of fatigues lives of TC4titanium alloy joints welded by electron beam welding.
Systematic researches on linear friction welding performance of TC4alloy were carried out.The results show that the critical parameters for unhydrogenated TC4alloy to obtain a successful LFW joint having excellent mechanical properties are:f=30Hz, a=2mm, p=4T, t=2s. The minimum effective power density needed is8.0×106W/m2. Under the same welding parameters condition, the bonding rates of all hydrogenated TC4alloy LFW joints are higher than the unhydrogenated alloy joints, and the widths of weld bead of hydrogenated TC4alloy joints are narrower than the unhydrogenated joints. As hydrogen content increases, the axial shortening of hydrogenated TC4alloy first increases obviously and then decreases slightly. It can be concluded that TC4alloy containing0.3～0.4wt%hydrogen has better high temperature plasticity, which resultes in the optimum welding performance improvement of LFW. The THP process doesn't reduce the mechanical properties of TC4alloy LFW joints. The minimum effective power density needed for hydrogenated TC4alloy to obtain a success LFW joint is calculated to be5.5×106W/m2. Comparing with the unhydrogenated TC4alloy, the reduce rate is up to30%. The high temperature plasticity of titanium alloy is enhanced by hydrogen mainly through mechanisms:changing phase proportion of α and β, promoting dislocation movement and dynamic recrystallization. As a result, the linear friction welding performance is improved by hydrogenation.
By use of finite clement simulation (FHM) code COSMAP, the mathematical model synthetically concerning the coupled effects of temperature field, stress field and phase structure was established. Moreover, a three-dimensional elastic-plastic FHM model was established. Then the linear friction welding process of hydrogenated TC4alloy was well simulated, and the law of variation and distribution of temperature and stress fields as well as phase structure was obtained. Furthermore, the effects of hydrogen on the three fields were analyzed by comparative analysis method. By performing the measurement of temperature variation of a specific node and residual stress distribution at surface of the joint as well as observation of microstructure at weld bead zone, the simulation results were experimentally verified. By comparison, the calculation data obtained from this numerical simulation work was in good agreement with the experimental data. This numerical simulation result can be used to provide a reference for parameters optimization and joint quality control of titanium alloy in linear friction welding technology.
引文
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