几种金属材料弯曲微动疲劳试验研究
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摘要
弯曲微动疲劳现象广泛存在于现代工业各领域中,例如火车轮轴、火车牵引电机转轴及小齿轮轴、航空发动机和架空电缆等。弯曲微动疲劳可导致关键零部件的失效甚至灾难性事故,但是目前该问题的研究尚少,且不够系统和深入。因此系统研究弯曲微动疲劳的行为和损伤机理,不仅在揭示微动疲劳损伤机理,完善微动摩擦学理论有重要的科学意义,而且在抗弯曲微动疲劳失效的实际应用中具有重要的工程指导意义。
本研究在自主设计、研制的高精度弯曲微动疲劳试验机上,采用点和线接触方式,在不同弯曲载荷、法向接触载荷和循环周次下,对316L奥氏体不锈钢、7075铝合金、LZ50钢和17CrNiMo6钢等材料进行了系统的弯曲微动疲劳试验,建立了不同材料的常规和微动疲劳S-N曲线。在此基础上,采用光学显微镜(OM)、扫描电子显微镜(SEM)、电子能谱仪(EDS)、透射电子显微镜(TEM)和表面形貌仪等微观分析手段,结合微动疲劳断口分析、微动损伤区分析、剖面分析和显微组织TEM分析,系统研究了四种材料弯曲微动疲劳的损伤机理。获得的主要结论如下：
(1)由于微动作用,弯曲微动疲劳寿命大大低于常规疲劳,寿命可能降到常规疲劳的30%,甚至更低。对于弯曲微动疲劳,交变应力对寿命的影响十分显著,应力水平越高,微动疲劳寿命越低,弯曲微动疲劳的S-N曲线呈“C”曲线型。对应C曲线的鼻子为微动运行的混合区,裂纹最容易萌生、扩展,寿命最低；在C曲线下方为部分滑移区,微动损伤较轻微,寿命较长；在C曲线上方为滑移区,该区域内磨损速率高,表面微裂纹核被磨掉,寿命得以延长。
(2)微动疲劳的损伤区磨损机制主要表现为磨粒磨损、氧化磨损和剥层,损伤过程可总结为：a)在初始阶段,微动损伤区为环状形态,磨损区域有犁沟和少量氧化物磨屑,没有发现形成微观裂纹,磨损机制为轻微磨粒磨损和氧化磨损；b)随着循环次数的增加,损伤变得严重,出现剥落现象,在此阶段也没有发现表面裂纹和疲劳裂纹萌生,此时磨损机制为磨粒磨损、氧化磨损和剥层；c)随着循环周次的进一步作用,损伤继续加剧,表面倾斜裂纹和剖面微观裂纹均已形成,此时磨损机制仍为磨粒磨损、氧化磨损和剥层；d)次表面疲劳裂纹与接触表面呈一定角度方向扩展,在另一方向与表面倾斜裂纹相连,此时磨损机制为磨粒磨损、氧化磨损和剥层,并伴随着开裂。
(3)不同于常规弯曲疲劳,弯曲微动疲劳的裂纹萌生于次表层,裂纹源常伴随杂质颗粒或第二相。影响弯曲微动疲劳过程的主要因素包括：材料性质、交变载荷、接触应力、接触几何、加载速率(频率)等。
(4)微动疲劳裂纹的扩展分为三个阶段,即：阶段Ⅰ—裂纹扩展受接触应力控制,扩展方向与接触表面呈一定角度(-60°),主裂纹同时与独立扩展的表面倾斜裂纹沟通；阶段Ⅱ—裂纹扩展受接触应力和疲劳应力共同控制,扩展角度转向垂直接触表面方向；阶段Ⅲ—裂纹扩展仅受疲劳应力控制,扩展行为与常规疲劳一致,其扩展方向垂直于接触表面。
(5)微动疲劳的损伤区显微组织和亚结构与材料的原始组织关系密切。TEM分析揭示,显微组织和亚结构的演变分两种类型。对于BCC结构的钢铁材料和高层错能FCC结构的铝合金,在交变应力作用下,微动疲劳裂纹的形核以位错胞变形机制形成,而对于低层错能的奥氏体不锈钢,微动疲劳裂纹的形核以孪生机制进行。
Failure phenomena of bending fretting fatigue broadly occur in the modern industrial fields, such as railway wheel-axles, electrical motor shaft and pinion shaft of train traction motors, aircraft engines, overhead conductors, and so on. So far, the bending fretting fatigue, which may lead to the failure of key parts or even cause disastrous accidents, has been rarely studied, and the understanding of its failure mechanism is still not systematical and thorough. Thus, a systematical study on the running behavior and damage characteristics of bending fretting fatigue not only has a great scientific significance to reveal the fretting fatigue damage mechanism and to improve the fretting theory, but also offers some engineering guides for practical applications of anti-failure of bending fretting fatigue.
On a self-designed high-precision bending fretting fatigue test rig with the contact configurations of point and line, the bending fretting fatigue tests of316L austenitic stainless steel,7075aluminum alloy, LZ50steel and17CrNiMo6steel has been carried out under different bending loads, normal contact loads and cycle numbers. The S-N curves of conventional and fretting fatigue for non-identical materials were set up accordingly. Base on this, micro-analysis methods of optical microscope(OM), scanning electron microscopy(SEM), electron energy disperse spectroscopy(EDS), transmission electron microscope(TEM) and surface profile-meter were used to analyze the fracture surface, fretting damage zone, cross-section and microstructure of the bending fretting fatigue. The damage mechanisms of bending fretting fatigue for the four materials have been investigated systematically. The main obtained conclusions are summarized as follows:
(1) The bending fretting fatigue life was much shorter than that of plain fatigue due to the fretting actions, which might decrease to30%, or even lower. The life of bending fretting fatigue was significantly influenced by the alternating stresses. The higher stress level was, the lower fatigue life occurred. The S-N curves of bending fretting fatigue appeared shapes of C type. The nose-shaped part of the C-curve was always corresponding to the mixed fretting regime, where the cracks were easy to initiate and propagate, and the life was the lowest. The partial slip regime located beneath the C-curve, where the fretting damage was slight and the life was longer. Above the C-curve, the slip regime presented higher wear rate, where the surface crack nucleuses were wiped off, resulting in lengthened the life.
(2) The wear mechanisms of the fretting damage zone were abrasive wear, oxidative wear and delamination, and the evolution of fretting damage can be summarized as follows: a) In the initial stage, the damage zone exhibited the annular morphology, and some ploughing grooves, few oxidative debris particles and no crack were found in the wear zone, when the wear mechanisms were slight abrasive and oxidative wear. b) With the increase of the cycles, the damage was aggravated and the delamination also occurred. Also, no surface crack and fatigue crack initiated in this stage. However, the wear mechanisms of fretting damage zone were changed to abrasive wear, oxidative wear and delamination. c) The damage was further aggravated with the further increase of the cycles. The surface incline cracks and cross-section micro-cracks have been formed. The wear mechanisms has been never changed during this stage, d) Finally, the subsurface fatigue crack propagated along a direction with a small angle to the contact surface and linked to the surface incline crack at the another side. The wear mechanisms of this stage were abrasive wear, oxidative wear and delamination accompanied with cracking.
(3) Different from the plain bending fatigue, the bending fretting fatigue cracks initiated at the subsurface usually accompanied with some impurity particles or second phases. The main influencing factors of the bending fretting fatigue process included:material properties, cyclic loads, contact stresses, contact geometries, loading velocity (frequency), and so on.
(4) The fretting fatigue crack propagation can be divided into3stages:Stage Ⅰ—the direction of crack propagation was at a certain angle (～60°) to the contact surface which controlled by the contact stresses, and the main crack linked to the surface incline cracks which propagated alone; Stage Ⅱ—the crack propagation was both dominated by the contact stress and plain bending fatigue stress, and the propagation angle switched towards the direction vertical to the contact surface; Stage Ⅲ—the crack propagation was controlled only by the plain bending fatigue stress, and the propagation direction was perpendicular to the contact surface, its propagation behavior matched the plain fatigue.
(5) The microstructure and sub-structure of fretting fatigue damage zone was close related to the original microstructure of the materials. The TEM analysis indicated that there were two types of microstructure and sub-structure evolution laws. For the steels with BCC structure and aluminum alloys with FCC structure and high-level stacking fault energy, the nucleation of fretting fatigue cracks accorded the mechanism of dislocation cell deformation. However, for the austenitic stainless steel with low-level stacking fault energy, its nucleation of fretting fatigue cracks deferred to the twinning mechanism.
本研究在自主设计、研制的高精度弯曲微动疲劳试验机上,采用点和线接触方式,在不同弯曲载荷、法向接触载荷和循环周次下,对316L奥氏体不锈钢、7075铝合金、LZ50钢和17CrNiMo6钢等材料进行了系统的弯曲微动疲劳试验,建立了不同材料的常规和微动疲劳S-N曲线。在此基础上,采用光学显微镜(OM)、扫描电子显微镜(SEM)、电子能谱仪(EDS)、透射电子显微镜(TEM)和表面形貌仪等微观分析手段,结合微动疲劳断口分析、微动损伤区分析、剖面分析和显微组织TEM分析,系统研究了四种材料弯曲微动疲劳的损伤机理。获得的主要结论如下：
(1)由于微动作用,弯曲微动疲劳寿命大大低于常规疲劳,寿命可能降到常规疲劳的30%,甚至更低。对于弯曲微动疲劳,交变应力对寿命的影响十分显著,应力水平越高,微动疲劳寿命越低,弯曲微动疲劳的S-N曲线呈“C”曲线型。对应C曲线的鼻子为微动运行的混合区,裂纹最容易萌生、扩展,寿命最低；在C曲线下方为部分滑移区,微动损伤较轻微,寿命较长；在C曲线上方为滑移区,该区域内磨损速率高,表面微裂纹核被磨掉,寿命得以延长。
(2)微动疲劳的损伤区磨损机制主要表现为磨粒磨损、氧化磨损和剥层,损伤过程可总结为：a)在初始阶段,微动损伤区为环状形态,磨损区域有犁沟和少量氧化物磨屑,没有发现形成微观裂纹,磨损机制为轻微磨粒磨损和氧化磨损；b)随着循环次数的增加,损伤变得严重,出现剥落现象,在此阶段也没有发现表面裂纹和疲劳裂纹萌生,此时磨损机制为磨粒磨损、氧化磨损和剥层；c)随着循环周次的进一步作用,损伤继续加剧,表面倾斜裂纹和剖面微观裂纹均已形成,此时磨损机制仍为磨粒磨损、氧化磨损和剥层；d)次表面疲劳裂纹与接触表面呈一定角度方向扩展,在另一方向与表面倾斜裂纹相连,此时磨损机制为磨粒磨损、氧化磨损和剥层,并伴随着开裂。
(3)不同于常规弯曲疲劳,弯曲微动疲劳的裂纹萌生于次表层,裂纹源常伴随杂质颗粒或第二相。影响弯曲微动疲劳过程的主要因素包括：材料性质、交变载荷、接触应力、接触几何、加载速率(频率)等。
(4)微动疲劳裂纹的扩展分为三个阶段,即：阶段Ⅰ—裂纹扩展受接触应力控制,扩展方向与接触表面呈一定角度(-60°),主裂纹同时与独立扩展的表面倾斜裂纹沟通；阶段Ⅱ—裂纹扩展受接触应力和疲劳应力共同控制,扩展角度转向垂直接触表面方向；阶段Ⅲ—裂纹扩展仅受疲劳应力控制,扩展行为与常规疲劳一致,其扩展方向垂直于接触表面。
(5)微动疲劳的损伤区显微组织和亚结构与材料的原始组织关系密切。TEM分析揭示,显微组织和亚结构的演变分两种类型。对于BCC结构的钢铁材料和高层错能FCC结构的铝合金,在交变应力作用下,微动疲劳裂纹的形核以位错胞变形机制形成,而对于低层错能的奥氏体不锈钢,微动疲劳裂纹的形核以孪生机制进行。
Failure phenomena of bending fretting fatigue broadly occur in the modern industrial fields, such as railway wheel-axles, electrical motor shaft and pinion shaft of train traction motors, aircraft engines, overhead conductors, and so on. So far, the bending fretting fatigue, which may lead to the failure of key parts or even cause disastrous accidents, has been rarely studied, and the understanding of its failure mechanism is still not systematical and thorough. Thus, a systematical study on the running behavior and damage characteristics of bending fretting fatigue not only has a great scientific significance to reveal the fretting fatigue damage mechanism and to improve the fretting theory, but also offers some engineering guides for practical applications of anti-failure of bending fretting fatigue.
On a self-designed high-precision bending fretting fatigue test rig with the contact configurations of point and line, the bending fretting fatigue tests of316L austenitic stainless steel,7075aluminum alloy, LZ50steel and17CrNiMo6steel has been carried out under different bending loads, normal contact loads and cycle numbers. The S-N curves of conventional and fretting fatigue for non-identical materials were set up accordingly. Base on this, micro-analysis methods of optical microscope(OM), scanning electron microscopy(SEM), electron energy disperse spectroscopy(EDS), transmission electron microscope(TEM) and surface profile-meter were used to analyze the fracture surface, fretting damage zone, cross-section and microstructure of the bending fretting fatigue. The damage mechanisms of bending fretting fatigue for the four materials have been investigated systematically. The main obtained conclusions are summarized as follows:
(1) The bending fretting fatigue life was much shorter than that of plain fatigue due to the fretting actions, which might decrease to30%, or even lower. The life of bending fretting fatigue was significantly influenced by the alternating stresses. The higher stress level was, the lower fatigue life occurred. The S-N curves of bending fretting fatigue appeared shapes of C type. The nose-shaped part of the C-curve was always corresponding to the mixed fretting regime, where the cracks were easy to initiate and propagate, and the life was the lowest. The partial slip regime located beneath the C-curve, where the fretting damage was slight and the life was longer. Above the C-curve, the slip regime presented higher wear rate, where the surface crack nucleuses were wiped off, resulting in lengthened the life.
(2) The wear mechanisms of the fretting damage zone were abrasive wear, oxidative wear and delamination, and the evolution of fretting damage can be summarized as follows: a) In the initial stage, the damage zone exhibited the annular morphology, and some ploughing grooves, few oxidative debris particles and no crack were found in the wear zone, when the wear mechanisms were slight abrasive and oxidative wear. b) With the increase of the cycles, the damage was aggravated and the delamination also occurred. Also, no surface crack and fatigue crack initiated in this stage. However, the wear mechanisms of fretting damage zone were changed to abrasive wear, oxidative wear and delamination. c) The damage was further aggravated with the further increase of the cycles. The surface incline cracks and cross-section micro-cracks have been formed. The wear mechanisms has been never changed during this stage, d) Finally, the subsurface fatigue crack propagated along a direction with a small angle to the contact surface and linked to the surface incline crack at the another side. The wear mechanisms of this stage were abrasive wear, oxidative wear and delamination accompanied with cracking.
(3) Different from the plain bending fatigue, the bending fretting fatigue cracks initiated at the subsurface usually accompanied with some impurity particles or second phases. The main influencing factors of the bending fretting fatigue process included:material properties, cyclic loads, contact stresses, contact geometries, loading velocity (frequency), and so on.
(4) The fretting fatigue crack propagation can be divided into3stages:Stage Ⅰ—the direction of crack propagation was at a certain angle (～60°) to the contact surface which controlled by the contact stresses, and the main crack linked to the surface incline cracks which propagated alone; Stage Ⅱ—the crack propagation was both dominated by the contact stress and plain bending fatigue stress, and the propagation angle switched towards the direction vertical to the contact surface; Stage Ⅲ—the crack propagation was controlled only by the plain bending fatigue stress, and the propagation direction was perpendicular to the contact surface, its propagation behavior matched the plain fatigue.
(5) The microstructure and sub-structure of fretting fatigue damage zone was close related to the original microstructure of the materials. The TEM analysis indicated that there were two types of microstructure and sub-structure evolution laws. For the steels with BCC structure and aluminum alloys with FCC structure and high-level stacking fault energy, the nucleation of fretting fatigue cracks accorded the mechanism of dislocation cell deformation. However, for the austenitic stainless steel with low-level stacking fault energy, its nucleation of fretting fatigue cracks deferred to the twinning mechanism.
引文
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