腐蚀疲劳点蚀演化与裂纹扩展机理研究
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摘要
腐蚀疲劳是金属材料在交变应力与腐蚀介质共同作用下发生断裂破坏的过程。工程中存在各种承受循环载荷的结构，如海洋结构、石油化工设备、飞机结构等，其服役环境都具有不同程度的腐蚀性。腐蚀性环境会降低材料的断裂韧性，加快裂纹的萌生与扩展，降低结构服役寿命。腐蚀疲劳已成为工程中各种承受循环载荷结构面临的严重问题，腐蚀疲劳性能研究也成为工程结构耐久性与完整性设计的重要内容。迄今为止，有关腐蚀疲劳的理论与应用都得到了迅速的发展，但由于腐蚀疲劳过程非常复杂，涉及到力学、化学、电化学、金属材料学及冶金学等众多学科内容，还有许多问题没能得到很好的解决，绝大多数研究实际上只停留在实验规律的摸索方面，虽然也有不少关于腐蚀机理分析的研究，但仍缺少基于腐蚀疲劳机理及热力学平衡理论的腐蚀疲劳评价方法。随着航天、海洋工程的飞速发展，结构腐蚀疲劳问题将更为突出，而现有研究成果远不能满足实际工程应用的需要。
本论文结合腐蚀电化学原理、热力学原理，对材料腐蚀疲劳过程中点蚀演化、裂纹成核以及裂纹扩展过程进行机理研究。在此基础上进行腐蚀疲劳损伤研究，并建立合理的腐蚀疲劳损伤演化律。本文主要内容如下：
(1)根据热力学基本原理，结合腐蚀疲劳点蚀演化和裂纹扩展的力学-电化学过程，建立腐蚀疲劳点蚀演化和裂纹扩展过程中的热力学基本方程，获得点蚀演化与裂纹扩展过程的热力学判据。
(2)利用双变量半椭圆点蚀模型，建立腐蚀疲劳点蚀演化及裂纹成核的二维模型。建立点蚀演化过程中体系的热力学势函数，导出点蚀形状参数随点蚀深度的演化规律。根据裂纹成核的应力强度因子准则与位错理论，建立腐蚀疲劳裂纹成核临界条件，对腐蚀疲劳裂纹成核寿命进行定性分析。在此基础上进行腐蚀疲劳点蚀演化以及裂纹成核的三维理论模型分析。
(3)根据腐蚀环境促进疲劳裂纹尖端阳极溶解与降低裂纹表面自由能的机理，建立腐蚀疲劳裂纹扩展过程的能量守恒方程，推导腐蚀疲劳裂纹扩展速率的显式方程。定性分析了阳极溶解、裂尖金属自由能下降以及循环载荷参数对腐蚀疲劳裂纹扩展速率与裂纹扩展寿命的影响。
(4)设计LY12CZ铝合金三点弯曲腐蚀疲劳裂纹扩展试验，研究腐蚀环境、循环载荷频率、应力比以及腐蚀溶液pH值等参数对腐蚀疲劳裂纹扩展速率的影响。
(5)基于损伤力学理论，进行腐蚀疲劳损伤研究。将腐蚀疲劳损伤处理成应力腐蚀损伤与疲劳损伤的非线性累加，利用LY12CZ铝合金试验结果确定相关损伤参数，建立腐蚀疲劳损伤演化律方程，形成基于损伤演化律的腐蚀疲劳寿命评价模型。
The corrosion fatigue is a fracture process of metal material under the combined effect ofthe alternating stress and corrosive medium. A large number of engineering structures, such asmarine structures, petrochemical equipments and aircraft structures, suffer cyclic loadings incorrosive environments. Corrosive environments reduce the fracture toughness, speed up theformation and propagation of cracks, and greatly reduce the service life of metal structure.Corrosion fatigue has now become a serious problem of the structure withstanding cyclicloading, and corrosion fatigue properties research has been updated to an important part of thedesign of the durability and integrity design for engineering structures. Up to now the studiesabout corrosion fatigue in theory and practical applications have been developed rapidly. Butcorrosion fatigue process is very complex and involves many details in mechanics, chemistry,electrochemistry, materials science and metallurgy, there are many issues still could not getgood solutions. The majority of researches actually only stay in trying to find out the laws ofexperimental results, as a result, the evaluation methods based on corrosion fatiguemechanism and thermodynamic equilibrium theory are very scarce, although there are a lot ofrelative studies. Meanwhile, with the rapid development of the aerospace and marineengineering, corrosion fatigue problems become more prominent, while the results of relatedresearches are far to meet the needs of engineering applications.
In this paper, based on the principles of corrosion electrochemics and thermodynamics,the pit evolution, corrosion fatigue crack nucleation and corrosion fatigue crack propagationduring corrosion fatigue process of metal materials are discussed. Then corrosion fatiguedamage theory is proposed and corrosion fatigue damage evolution law is established. Themain contents of this paper are as follows:
(1) According to the principles of thermodynamics, the basic thermodynamic equationduring pit evolution and crack propagation is established, from which the thermodynamiccriterion that controls the direction of pit evolution and crack propagation is obtained.
(2) The two-dimensional model of corrosion fatigue pit evolution and crack nucleation is established. According to the two-variable semi-elliptical model of corrosion pit, thethermodynamic potential of the elastic solid with an evolving pit is derived, from which theevolving law of shape parameter with corrosion pit depth is deduced. The critical condition ofcorrosion fatigue crack nucleation is established, according to the stress intensity factorcriterion and dislocation theory of crack nucleation, consequently qualitative analysis of thecorrosion fatigue crack nucleation life is carried on. Similarly, the three-dimensional modelanalysis of pit evolution and crack nucleation is studied.
(3) According to the mechanism that corrosive environment promotes crack propagationby anodic dissolution at crack tip and reduction of free energy at crack surface, the energyconservation equation during corrosion fatigue crack propagation process is established, fromwhich the explicit equation of corrosion fatigue crack propagation rate is derived. Then theeffects of anodic dissolution, free energy reduction at crack surface and cyclic loadingparameters on corrosion fatigue crack propagation rate and crack propagation life arequalitative analyzed.
(4) The three-point bending corrosion fatigue crack propagation experiments of LY12CZaluminum alloy is designed, and the influences of corrosion environment, cyclic loadingfrequency, stress ratio and pH value of solution on the corrosion fatigue crack propagationrate are studied.
(5) Based on the damage mechanics theory, the corrosion fatigue damage is studied.Corrosion fatigue damage is treated as non-linear cumulative outcome of stress corrosiondamage and fatigue damage. The relative damage parameters are determined by theexperimental results of LY12CZ aluminum alloy, and corrosion fatigue damage evolution lawis established. Afterwards, the corrosion fatigue life normalized evaluation based on thedamage evolution law is formed.
本论文结合腐蚀电化学原理、热力学原理，对材料腐蚀疲劳过程中点蚀演化、裂纹成核以及裂纹扩展过程进行机理研究。在此基础上进行腐蚀疲劳损伤研究，并建立合理的腐蚀疲劳损伤演化律。本文主要内容如下：
(1)根据热力学基本原理，结合腐蚀疲劳点蚀演化和裂纹扩展的力学-电化学过程，建立腐蚀疲劳点蚀演化和裂纹扩展过程中的热力学基本方程，获得点蚀演化与裂纹扩展过程的热力学判据。
(2)利用双变量半椭圆点蚀模型，建立腐蚀疲劳点蚀演化及裂纹成核的二维模型。建立点蚀演化过程中体系的热力学势函数，导出点蚀形状参数随点蚀深度的演化规律。根据裂纹成核的应力强度因子准则与位错理论，建立腐蚀疲劳裂纹成核临界条件，对腐蚀疲劳裂纹成核寿命进行定性分析。在此基础上进行腐蚀疲劳点蚀演化以及裂纹成核的三维理论模型分析。
(3)根据腐蚀环境促进疲劳裂纹尖端阳极溶解与降低裂纹表面自由能的机理，建立腐蚀疲劳裂纹扩展过程的能量守恒方程，推导腐蚀疲劳裂纹扩展速率的显式方程。定性分析了阳极溶解、裂尖金属自由能下降以及循环载荷参数对腐蚀疲劳裂纹扩展速率与裂纹扩展寿命的影响。
(4)设计LY12CZ铝合金三点弯曲腐蚀疲劳裂纹扩展试验，研究腐蚀环境、循环载荷频率、应力比以及腐蚀溶液pH值等参数对腐蚀疲劳裂纹扩展速率的影响。
(5)基于损伤力学理论，进行腐蚀疲劳损伤研究。将腐蚀疲劳损伤处理成应力腐蚀损伤与疲劳损伤的非线性累加，利用LY12CZ铝合金试验结果确定相关损伤参数，建立腐蚀疲劳损伤演化律方程，形成基于损伤演化律的腐蚀疲劳寿命评价模型。
The corrosion fatigue is a fracture process of metal material under the combined effect ofthe alternating stress and corrosive medium. A large number of engineering structures, such asmarine structures, petrochemical equipments and aircraft structures, suffer cyclic loadings incorrosive environments. Corrosive environments reduce the fracture toughness, speed up theformation and propagation of cracks, and greatly reduce the service life of metal structure.Corrosion fatigue has now become a serious problem of the structure withstanding cyclicloading, and corrosion fatigue properties research has been updated to an important part of thedesign of the durability and integrity design for engineering structures. Up to now the studiesabout corrosion fatigue in theory and practical applications have been developed rapidly. Butcorrosion fatigue process is very complex and involves many details in mechanics, chemistry,electrochemistry, materials science and metallurgy, there are many issues still could not getgood solutions. The majority of researches actually only stay in trying to find out the laws ofexperimental results, as a result, the evaluation methods based on corrosion fatiguemechanism and thermodynamic equilibrium theory are very scarce, although there are a lot ofrelative studies. Meanwhile, with the rapid development of the aerospace and marineengineering, corrosion fatigue problems become more prominent, while the results of relatedresearches are far to meet the needs of engineering applications.
In this paper, based on the principles of corrosion electrochemics and thermodynamics,the pit evolution, corrosion fatigue crack nucleation and corrosion fatigue crack propagationduring corrosion fatigue process of metal materials are discussed. Then corrosion fatiguedamage theory is proposed and corrosion fatigue damage evolution law is established. Themain contents of this paper are as follows:
(1) According to the principles of thermodynamics, the basic thermodynamic equationduring pit evolution and crack propagation is established, from which the thermodynamiccriterion that controls the direction of pit evolution and crack propagation is obtained.
(2) The two-dimensional model of corrosion fatigue pit evolution and crack nucleation is established. According to the two-variable semi-elliptical model of corrosion pit, thethermodynamic potential of the elastic solid with an evolving pit is derived, from which theevolving law of shape parameter with corrosion pit depth is deduced. The critical condition ofcorrosion fatigue crack nucleation is established, according to the stress intensity factorcriterion and dislocation theory of crack nucleation, consequently qualitative analysis of thecorrosion fatigue crack nucleation life is carried on. Similarly, the three-dimensional modelanalysis of pit evolution and crack nucleation is studied.
(3) According to the mechanism that corrosive environment promotes crack propagationby anodic dissolution at crack tip and reduction of free energy at crack surface, the energyconservation equation during corrosion fatigue crack propagation process is established, fromwhich the explicit equation of corrosion fatigue crack propagation rate is derived. Then theeffects of anodic dissolution, free energy reduction at crack surface and cyclic loadingparameters on corrosion fatigue crack propagation rate and crack propagation life arequalitative analyzed.
(4) The three-point bending corrosion fatigue crack propagation experiments of LY12CZaluminum alloy is designed, and the influences of corrosion environment, cyclic loadingfrequency, stress ratio and pH value of solution on the corrosion fatigue crack propagationrate are studied.
(5) Based on the damage mechanics theory, the corrosion fatigue damage is studied.Corrosion fatigue damage is treated as non-linear cumulative outcome of stress corrosiondamage and fatigue damage. The relative damage parameters are determined by theexperimental results of LY12CZ aluminum alloy, and corrosion fatigue damage evolution lawis established. Afterwards, the corrosion fatigue life normalized evaluation based on thedamage evolution law is formed.
引文
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