S30432奥氏体不锈钢喷丸强化及其表征研究
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摘要
S30432奥氏体不锈钢是一种在传统奥氏体不锈钢TP304H基础上应用多元合金强化以及弥散强化理论开发出的一种新型奥氏体不锈钢，该种材质由于具有优异的性能已在国内外超超临界发电设备中得到了广泛应用。喷丸强化是材料表面强化的重要方法之一，可以显著提高材料表面力学性能。为了进一步挖掘S30432奥氏体不锈钢的优良性能，本文优化了S30432奥氏体不锈钢的喷丸工艺，研究了不同喷丸工艺下残余应力分布、组织结构变化、以及残余应力松弛和组织结构的回复与再结晶行为，并且通过表征喷丸层表面力学性能，探讨了其喷丸强化机理。
采用不同的喷丸工艺对S30432奥氏体不锈钢进行喷丸强化处理，结果表明，传统一次喷丸后残余应力在表面呈现各向同性；多步复合喷丸工艺下材料表面残余压应力值以及最大残余压应力值均随喷丸次数增加而增大，当采用优化的三次复合喷丸工艺处理时，S30432奥氏体不锈钢表面残余压应力达到-778MPa，最大残余压应力值及其层深分别为-865MPa和10μm；同时，采用多步复合喷丸工艺不仅可以提高S30432奥氏体不锈钢残余应力值，而且可以提高喷丸表层残余应力的均匀性。应力喷丸残余应力随预应力增加而增大，优化后残余压应力最大值达到-993MPa。
利用X射线应力分析技术研究了S30432奥氏体不锈钢喷丸残余应力在外载荷条件下的松弛行为，结果表明，外载荷越大，松弛越明显，当外载荷接近材料屈服强度时松弛速率最大，且加载方向松弛速率高于垂直加载方向。在不同外加循环载荷作用下，残余应力松弛均发生在循环初始阶段，随着循环次数的增加，残余应力逐渐趋于稳定，外载荷越大，最终残余应力稳定值越小。当外加循环载荷为200，250,300MPa时，分别经过5次，2次，2次循环之后，残余应力即发生剧烈松弛，经过多次循环后，最终喷丸残余应力分别松弛了30%，40%，65%。
S30432喷丸残余应力热松弛行为研究表明，在高温条件下，残余应力热松弛主要发生在退火初期，温度越高残余应力松弛速率越大。利用Zener-Wert-Avrami方程，对残余应力高温松弛随温度与时间的变化规律进行了总结，并计算出其残余应力热松弛激活能为159kJ/mol。
利用X射线衍射线形分析方法分析了S30432奥氏体不锈钢喷丸层的组织结构变化，对各种常用线形分析方法得到的结果进行了对比。将Rietveld全谱拟合分析方法引入喷丸层组织结构的分析中，采用PoPa各向异性模型表征了喷丸层在不同晶向上微观组织结构的变化，并获得了喷丸层晶块尺寸的对数正态分布。对S30432奥氏体不锈钢三次复合喷丸表层组织结构进行表征，结果表明通过喷丸处理后，表层晶块尺寸大小趋于均匀，<111>方向最大为16.3nm。晶块尺寸分布中值随着层深的增加而逐渐增加。预应力喷丸层组织强化效果随着外加载荷增加逐渐增强。
在等温加热过程中，S30432奥氏体不锈钢喷丸组织发生了回复与再结晶行为，显微畸变以及位错密度随着保温温度的提高和保温时间的增加而降低，晶块尺寸随之增大。通过计算S30432奥氏体不锈钢的晶界迁移激活能为259kJ/mol，显微畸变松弛激活能为171kJ/mol。
利用原位X射线应力分析方法表征了S30432奥氏体不锈钢未喷丸试样的表面屈服强度，结果与常规拉伸试验基本一致，其表层屈服强度为268MPa。S30432奥氏体不锈钢经过一次以及二次复合喷丸处理后，其表面σ0.2条件屈服强度分别约为830MPa，940MPa，喷丸强化处理显著提高了S30432奥氏体不锈钢的表层屈服强度。微观结果分析显示喷丸后表层晶块细化与显微畸变增加是其表层屈服强度提高的重要原因。
S30432奥氏体不锈钢喷丸强化机制主要分为残余压应力强化和组织结构强化。残余应力强化主要在于降低材料表面承受的拉应力水平，利用局部疲劳极限模型分析了S30432奥氏体不锈钢喷丸后残余压应力对疲劳极限的影响，发现喷丸后表层材料疲劳极限显著提高。组织结构强化主要在于喷丸使形变层内晶块细化，显微畸变增大，位错密度增加，从而提高了材料表面屈服强度。
S30432austenitic stainless steel, which was developed on the TP304H stainless steel bythe alloying strengthen and dispersion strengthen theories, is widely used in ultra supercritical power plants due to its superior properties. Shot peening is an important surfacetreatment approach to improve the surface properties of metallic materials. In order tooptimize the properties of S30432austenitic stainless steel, in this dissertation the steelwas treated by the optimized shot peening process. The residual stress distribution andmicrostructure change were investigated, the residual stress relaxation and thermalstability of microstructure were also analyzed, furthermore, the shot peening strengthenmechanism was discussed through the characterization of surface mechanical properties ofshot peened surface of S30432austenitic stainless steel.
The results of shot peening experiments on S30432austenitic stainless steel revealedthat the residual stress distribution in the deformed layer was isotropic. The compressiveresidual stress on the surface and the maximum compressive residual stress aftermulti-step shot peening method was increased by adding the step of shot peening. Whenthe sample was treated by triple shot peening process, the compressive residual stress was-778MPa, the maximum value was-865MPa at the depth of10μm. besides, themulti-step shot peening method can not only increase the residual stress value but alsomake the stress distribution more uniform on the surface. The residual stress values wereincreased as increasing the pre-stress in stress peening. A maximum residual stress of-993MPa was observed with the optimized stress peening parameters.
The residual stress relaxation of S30432austenitic stainless steel after shot peeningunder the static loading showed that the larger the applied loading was, the more obviousthe relaxation was, and when the applied loading reached the yield strength of the steel, the rate of relaxation was the largest, and it was larger in the direction of applied loadingthan that in the direction vertical to the applied loading. Under cyclic loading conditions,with the cycling number increased, it began to relax and the fast rate of compressiveresidual stress relaxation took place in the initial stage, gradually, the residual stressbecome stable. The larger of the applied loading, the lower of the stable stress value.When under the applied cyclic loading of200,250and300MPa, the drastic relaxationtook place during the first5times,2times,2times cycling. Then the residual stress wererelaxed about30%,40%and65%, respectively.
The results of thermal relaxation of residual stress showed that the relaxation took placein the initial period of annealing. the higher temperature resulted faster relaxation rate. Theeffect of annealing time and temperature on the relaxation was described byZener-Wert-Avrami function, and the activation energy of the residual stress relaxationwas159kJ/mol.
X-ray diffraction line profile analysis methods were used for the microstructure analysis,and the results were discussed. The Rietveld method was introduced to analyze of themicrostructure after shot peening. the PoPa anisotropic model can not only characterizethe change of microstructure in different crystalline direction but also the lognormaldistribution of domain size. the results of S30432austenitic stainless steel after three stepshot peening showed the domain size on the surface was trend to isotropic. In <111>direction, it was16.3nm which was the largest. The average domain size was increased asthe depth increasing. For stress peening, with the applied stress increased, themicrostructure refinement was more obvious.
In the isothermal annealing process, the domain size increased, while micro-strain anddislocation density reduced. The activation energy of grain boundary migration of S30432austenitic stainless steel is259kJ/mol, the activation energy of microstrain is171kJ/mol.
The surface yield strength of S30432austenitic stainless steel without shotpeening,which was characterized by X-ray stress analyzing method, is268MPa thesame as the tensile testing experiment. The yield strength σ0.2of S30432austenitic stainless steel after traditional and dual shot peening were about830MPa,940MPa,respectively. Shot peening treatment can greatly improve the yield strength of S30432austenitic stainless steel. The microstructure refinement was the main reason for theimproved surface yield strength.
The strength mechanism of shot peening can ascribe to compressive residual stressstrength and microstructure strength. The compressive residual stress can weaken thetensile stress of the surface. The local fatigue limit model was applied to analyze theinfluence of compressive residual stress to fatigue limit of S30432shot peening sample.The result revealed that the compressive residual stress can enhance the fatigue limit. themicrostructure strength mechanism was that the refined domain size and highermicro-strain and dislocation density after shot peening improved the surface yieldstrength.
采用不同的喷丸工艺对S30432奥氏体不锈钢进行喷丸强化处理，结果表明，传统一次喷丸后残余应力在表面呈现各向同性；多步复合喷丸工艺下材料表面残余压应力值以及最大残余压应力值均随喷丸次数增加而增大，当采用优化的三次复合喷丸工艺处理时，S30432奥氏体不锈钢表面残余压应力达到-778MPa，最大残余压应力值及其层深分别为-865MPa和10μm；同时，采用多步复合喷丸工艺不仅可以提高S30432奥氏体不锈钢残余应力值，而且可以提高喷丸表层残余应力的均匀性。应力喷丸残余应力随预应力增加而增大，优化后残余压应力最大值达到-993MPa。
利用X射线应力分析技术研究了S30432奥氏体不锈钢喷丸残余应力在外载荷条件下的松弛行为，结果表明，外载荷越大，松弛越明显，当外载荷接近材料屈服强度时松弛速率最大，且加载方向松弛速率高于垂直加载方向。在不同外加循环载荷作用下，残余应力松弛均发生在循环初始阶段，随着循环次数的增加，残余应力逐渐趋于稳定，外载荷越大，最终残余应力稳定值越小。当外加循环载荷为200，250,300MPa时，分别经过5次，2次，2次循环之后，残余应力即发生剧烈松弛，经过多次循环后，最终喷丸残余应力分别松弛了30%，40%，65%。
S30432喷丸残余应力热松弛行为研究表明，在高温条件下，残余应力热松弛主要发生在退火初期，温度越高残余应力松弛速率越大。利用Zener-Wert-Avrami方程，对残余应力高温松弛随温度与时间的变化规律进行了总结，并计算出其残余应力热松弛激活能为159kJ/mol。
利用X射线衍射线形分析方法分析了S30432奥氏体不锈钢喷丸层的组织结构变化，对各种常用线形分析方法得到的结果进行了对比。将Rietveld全谱拟合分析方法引入喷丸层组织结构的分析中，采用PoPa各向异性模型表征了喷丸层在不同晶向上微观组织结构的变化，并获得了喷丸层晶块尺寸的对数正态分布。对S30432奥氏体不锈钢三次复合喷丸表层组织结构进行表征，结果表明通过喷丸处理后，表层晶块尺寸大小趋于均匀，<111>方向最大为16.3nm。晶块尺寸分布中值随着层深的增加而逐渐增加。预应力喷丸层组织强化效果随着外加载荷增加逐渐增强。
在等温加热过程中，S30432奥氏体不锈钢喷丸组织发生了回复与再结晶行为，显微畸变以及位错密度随着保温温度的提高和保温时间的增加而降低，晶块尺寸随之增大。通过计算S30432奥氏体不锈钢的晶界迁移激活能为259kJ/mol，显微畸变松弛激活能为171kJ/mol。
利用原位X射线应力分析方法表征了S30432奥氏体不锈钢未喷丸试样的表面屈服强度，结果与常规拉伸试验基本一致，其表层屈服强度为268MPa。S30432奥氏体不锈钢经过一次以及二次复合喷丸处理后，其表面σ0.2条件屈服强度分别约为830MPa，940MPa，喷丸强化处理显著提高了S30432奥氏体不锈钢的表层屈服强度。微观结果分析显示喷丸后表层晶块细化与显微畸变增加是其表层屈服强度提高的重要原因。
S30432奥氏体不锈钢喷丸强化机制主要分为残余压应力强化和组织结构强化。残余应力强化主要在于降低材料表面承受的拉应力水平，利用局部疲劳极限模型分析了S30432奥氏体不锈钢喷丸后残余压应力对疲劳极限的影响，发现喷丸后表层材料疲劳极限显著提高。组织结构强化主要在于喷丸使形变层内晶块细化，显微畸变增大，位错密度增加，从而提高了材料表面屈服强度。
S30432austenitic stainless steel, which was developed on the TP304H stainless steel bythe alloying strengthen and dispersion strengthen theories, is widely used in ultra supercritical power plants due to its superior properties. Shot peening is an important surfacetreatment approach to improve the surface properties of metallic materials. In order tooptimize the properties of S30432austenitic stainless steel, in this dissertation the steelwas treated by the optimized shot peening process. The residual stress distribution andmicrostructure change were investigated, the residual stress relaxation and thermalstability of microstructure were also analyzed, furthermore, the shot peening strengthenmechanism was discussed through the characterization of surface mechanical properties ofshot peened surface of S30432austenitic stainless steel.
The results of shot peening experiments on S30432austenitic stainless steel revealedthat the residual stress distribution in the deformed layer was isotropic. The compressiveresidual stress on the surface and the maximum compressive residual stress aftermulti-step shot peening method was increased by adding the step of shot peening. Whenthe sample was treated by triple shot peening process, the compressive residual stress was-778MPa, the maximum value was-865MPa at the depth of10μm. besides, themulti-step shot peening method can not only increase the residual stress value but alsomake the stress distribution more uniform on the surface. The residual stress values wereincreased as increasing the pre-stress in stress peening. A maximum residual stress of-993MPa was observed with the optimized stress peening parameters.
The residual stress relaxation of S30432austenitic stainless steel after shot peeningunder the static loading showed that the larger the applied loading was, the more obviousthe relaxation was, and when the applied loading reached the yield strength of the steel, the rate of relaxation was the largest, and it was larger in the direction of applied loadingthan that in the direction vertical to the applied loading. Under cyclic loading conditions,with the cycling number increased, it began to relax and the fast rate of compressiveresidual stress relaxation took place in the initial stage, gradually, the residual stressbecome stable. The larger of the applied loading, the lower of the stable stress value.When under the applied cyclic loading of200,250and300MPa, the drastic relaxationtook place during the first5times,2times,2times cycling. Then the residual stress wererelaxed about30%,40%and65%, respectively.
The results of thermal relaxation of residual stress showed that the relaxation took placein the initial period of annealing. the higher temperature resulted faster relaxation rate. Theeffect of annealing time and temperature on the relaxation was described byZener-Wert-Avrami function, and the activation energy of the residual stress relaxationwas159kJ/mol.
X-ray diffraction line profile analysis methods were used for the microstructure analysis,and the results were discussed. The Rietveld method was introduced to analyze of themicrostructure after shot peening. the PoPa anisotropic model can not only characterizethe change of microstructure in different crystalline direction but also the lognormaldistribution of domain size. the results of S30432austenitic stainless steel after three stepshot peening showed the domain size on the surface was trend to isotropic. In <111>direction, it was16.3nm which was the largest. The average domain size was increased asthe depth increasing. For stress peening, with the applied stress increased, themicrostructure refinement was more obvious.
In the isothermal annealing process, the domain size increased, while micro-strain anddislocation density reduced. The activation energy of grain boundary migration of S30432austenitic stainless steel is259kJ/mol, the activation energy of microstrain is171kJ/mol.
The surface yield strength of S30432austenitic stainless steel without shotpeening,which was characterized by X-ray stress analyzing method, is268MPa thesame as the tensile testing experiment. The yield strength σ0.2of S30432austenitic stainless steel after traditional and dual shot peening were about830MPa,940MPa,respectively. Shot peening treatment can greatly improve the yield strength of S30432austenitic stainless steel. The microstructure refinement was the main reason for theimproved surface yield strength.
The strength mechanism of shot peening can ascribe to compressive residual stressstrength and microstructure strength. The compressive residual stress can weaken thetensile stress of the surface. The local fatigue limit model was applied to analyze theinfluence of compressive residual stress to fatigue limit of S30432shot peening sample.The result revealed that the compressive residual stress can enhance the fatigue limit. themicrostructure strength mechanism was that the refined domain size and highermicro-strain and dislocation density after shot peening improved the surface yieldstrength.
引文
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