含腐蚀损伤金属材料剩余寿命与剩余强度研究
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摘要
工程上常用的金属材料如铝合金、钢，对腐蚀介质十分敏感，腐蚀与疲劳共同作用严重影响金属结构的完整性和安全性。如何根据含腐蚀损伤金属结构表面形貌得到其剩余寿命和剩余强度，而无需进行大量试验，成为急需解决的问题。
本文针对金属材料预腐蚀疲劳损伤形式，从局部和整体两个方面深入研究预腐蚀损伤对剩余寿命的影响，分别基于断裂力学理论和分形理论建立了根据腐蚀形貌预测预腐蚀疲劳剩余寿命的理论模型，并对模型的合理性及其预测能力进行深入分析和试验验证。基于试验数据和机理分析给出预腐蚀疲劳剩余强度概率分布模型，统一了前人研究得到的矛盾观点。本文主要工作和创新成果如下：
(1)完成了预腐蚀疲劳剩余寿命及剩余强度试验，共227件试验件。在实验室环境条件下，对LC4CS铝合金及钢材进行了预腐蚀疲劳剩余寿命和剩余强度试验，为后续剩余寿命和剩余强度模型研究提供试验观测数据。
(2)提出了危险蚀坑新的评判标准—张开角。针对现有CM-EIFS方法中无法合理地确定裂纹萌生蚀坑问题，使用三维显微镜拍摄大量腐蚀形貌并结合文献中SEM图像分析影响裂纹萌生的形貌细节，给出张开角定义。通过张开角筛选得到萌生裂纹蚀坑，采用CM-EIFS方法计算得到剩余寿命，结果表明张开角定义明确合理，计算结果准确，改进了CM-EIFS方法。
(3)提出了初始裂纹尺寸的等效面积法及裂纹扩展模型。以蚀坑投影面积为参量将蚀坑等效为半椭圆表面初始裂纹，使其与裂纹扩展寿命最关键的因素-应力强度因子相关联且初始裂纹形貌与试验结果相一致。在张开角筛选得到危险蚀坑基础之上，得到等效初始裂纹尺寸。给出新的裂纹扩展模型，构成了新的CM-EIFS计算体系，与试验结果对比表明该模型计算结果准确。
(4)提出了光滑试件预腐蚀疲劳剩余寿命估算的分形维数方法。根据分形维数能够在整体上描述形貌复杂程度且不会忽略任何细节形貌的特性，创新性地提出用分形维数描述腐蚀形貌并找到其与剩余寿命之间规律。提出新的三维腐蚀形貌分形维数计算方法并以此预测剩余寿命。剩余寿命预测结果与试验结果吻合良好，表明该方法可以在仅有腐蚀形貌和未腐蚀S-N曲线条件下很好的预测剩余寿命而无需任何预腐蚀疲劳实验数据，大大节省了试验时间和试验经费。
(5)提出了预腐蚀疲劳缺口系数定义及其随预腐蚀时间变化的经验公式。定义预腐蚀疲劳缺口系数并由实验数据得到预腐蚀疲劳缺口系数随预腐蚀时间变化规律经验公式。由此公式结合预腐蚀光滑试件剩余寿命可以计算得到缺口件剩余寿命。
(6)提出了缺口试件预腐蚀疲劳剩余寿命估算的分形维数方法。给出预腐蚀应力集中系数定义及其物理意义，由分形维数特性，计算预腐蚀疲劳缺口系数。剩余寿命预测结果与试验结果吻合良好，表明该方法可以在仅有腐蚀形貌与缺口几何尺寸条件下计算得到预腐蚀疲劳缺口系数，继而得到缺口件预腐蚀疲劳剩余寿命。
(7)对预腐蚀疲劳剩余强度进行实验研究，给出含腐蚀疲劳损伤金属材料剩余强度概率分布模型。在实验室环境下，对国产LC4CS铝合金试件进行预腐蚀剩余强度试验，并对某在实际环境中使用30余年钢材进行剩余强度试验(共44件试验件)，提出剩余强度分布的双峰模型。该模型很好的解释了前人和本人实验中一些结论的矛盾之处，为今后剩余强度校核提供参考。
Metallic material such as aluminum, steel, is sensitive to corrosive environment. Corrosiondamage and fatigue damage together seriously affect the integrity and security of the metal structure.How to calculate residual life and residual strength of metal structure contained the corrosion damageby surface morphology of metal structure without large number of tests become ankey problem.
In this thesis, metal material pre-corrosion fatigue damage was concerned, from both local andglobal perspective, the impact on the residual life of metal material by pre-corrosion damage wasin-depth studied. Based on the fracture mechanic and fractal dimension, theoretical models to predictthe pre-corrosion fatigue residual life which were only need the data of corrosion morphology wereestablished. The rationality and predictive ability of the models were analyzed and experimentalverified. The probability distribution of the pre-corrosion fatigue residual strength was also given byexperimental analysis. This model unified conflicting views of previous studies. The main work andinnovations in this paper are as follows:
(1) Pre-corrosion fatigue residual life and residual strength tests (227specimens) were done. Inthe laboratory ambient conditions, pre-corrosion fatigue residual life and residual strength tests onaluminum alloy LC4CS and steel were completed. Provided observational data for the follow-upstudy and experimental verification of predicted results of residual life and residual strength.
(2) Proposed new criteria for critical pits-opening angle. For existing CM-EIFS method cannotreasonably determine crack initiation pit, the definition of opening angle was proposed by analyzed alot of corrosion morphology observed by three-dimensional microscopy and topography details ofSEM image which influenced crack initiation. Through filtering crack initiation pits by opening angle,remaining life was calculated by CM-EIFS method. The predicted results showed that the openingangle definition was reasonable. Predicted results were accurate, so the CM-EIFS method wasimproved.
(3) Proposed an equivalent area method to calculate the initial crack size and crack propagationmodel. The pit is equivalent to a semi-elliptical surface initial crack by projected area of the pit. Thismethod associated initial crack size with the most critical factors of crack propagation life-stressintensity factorand the morphology of initial crack was consistent with experimental results. Based onfiltering the critical pits by opening angle, the equivalent initial crack size could be gotten by equivalent area method. A new crack growth model was also given in this paper, and constituted anew, complete CM-EIFS calculation system. Compared with the experimental results showed that themethod was accurate enough.
(4) Proposed a new method to estimate pre-corrosion fatigue residual life of smooth specimenbased on fractal dimension.Because fractal dimension can describe the complexity of overallmorphology and will not ignore any details, an innovative method based on fractal dimension todescribe corrosion morphology and the relationship between fractal dimension and residual life wasproposed. Proposed a new three-dimensional fractal dimension calculation method to predict residuallife. Predicted results with the experimental results were in good agreement and showed that thismethod could well predict the residual life in the only corrosion morphology and pristine S-N curveconditions, saved test time and expenses.
(5) Pre-corrosion fatigue notch factor was defined and its empirical formula with pre-corrosiontime change was given. This formula combined with pre-corrosion residual life of smooth specimencould calculate residual life of notched specimen.
(6) Proposed a new method to estimate pre-corrosion fatigue residual life of notched specimenbased on fractal dimension. Defined pre-corrosion stress concentration factor and discussed itsphysical meaning. Given the method to calculate pre-corrosion fatigue notch factor by fractaldimension. Predicted results with the experimental results were in good agreement and showed thatthis method could well predict pre-corrosion fatigue notch factor in the only corrosion morphologyand geometry size of notch conditions, and then calculated residual life of notch specimen.
(7) Experimental study of pre-corrosion fatigue residual strength was completed, probabilitydistribution model of residual strength of metallic materials containing corrosion fatigue damage wasproposed. In a laboratory environment, residual strength test of the domestic LC4CS aluminum alloyand steel used more than30years in a real environment was implemented (49specimens). A bimodaldistribution model of residual strength was proposed and it provided a good explanation for theinconsistency of experiment results of residual strength in literatures and this thesis. This modelprovided reference for future residual strength check.
本文针对金属材料预腐蚀疲劳损伤形式，从局部和整体两个方面深入研究预腐蚀损伤对剩余寿命的影响，分别基于断裂力学理论和分形理论建立了根据腐蚀形貌预测预腐蚀疲劳剩余寿命的理论模型，并对模型的合理性及其预测能力进行深入分析和试验验证。基于试验数据和机理分析给出预腐蚀疲劳剩余强度概率分布模型，统一了前人研究得到的矛盾观点。本文主要工作和创新成果如下：
(1)完成了预腐蚀疲劳剩余寿命及剩余强度试验，共227件试验件。在实验室环境条件下，对LC4CS铝合金及钢材进行了预腐蚀疲劳剩余寿命和剩余强度试验，为后续剩余寿命和剩余强度模型研究提供试验观测数据。
(2)提出了危险蚀坑新的评判标准—张开角。针对现有CM-EIFS方法中无法合理地确定裂纹萌生蚀坑问题，使用三维显微镜拍摄大量腐蚀形貌并结合文献中SEM图像分析影响裂纹萌生的形貌细节，给出张开角定义。通过张开角筛选得到萌生裂纹蚀坑，采用CM-EIFS方法计算得到剩余寿命，结果表明张开角定义明确合理，计算结果准确，改进了CM-EIFS方法。
(3)提出了初始裂纹尺寸的等效面积法及裂纹扩展模型。以蚀坑投影面积为参量将蚀坑等效为半椭圆表面初始裂纹，使其与裂纹扩展寿命最关键的因素-应力强度因子相关联且初始裂纹形貌与试验结果相一致。在张开角筛选得到危险蚀坑基础之上，得到等效初始裂纹尺寸。给出新的裂纹扩展模型，构成了新的CM-EIFS计算体系，与试验结果对比表明该模型计算结果准确。
(4)提出了光滑试件预腐蚀疲劳剩余寿命估算的分形维数方法。根据分形维数能够在整体上描述形貌复杂程度且不会忽略任何细节形貌的特性，创新性地提出用分形维数描述腐蚀形貌并找到其与剩余寿命之间规律。提出新的三维腐蚀形貌分形维数计算方法并以此预测剩余寿命。剩余寿命预测结果与试验结果吻合良好，表明该方法可以在仅有腐蚀形貌和未腐蚀S-N曲线条件下很好的预测剩余寿命而无需任何预腐蚀疲劳实验数据，大大节省了试验时间和试验经费。
(5)提出了预腐蚀疲劳缺口系数定义及其随预腐蚀时间变化的经验公式。定义预腐蚀疲劳缺口系数并由实验数据得到预腐蚀疲劳缺口系数随预腐蚀时间变化规律经验公式。由此公式结合预腐蚀光滑试件剩余寿命可以计算得到缺口件剩余寿命。
(6)提出了缺口试件预腐蚀疲劳剩余寿命估算的分形维数方法。给出预腐蚀应力集中系数定义及其物理意义，由分形维数特性，计算预腐蚀疲劳缺口系数。剩余寿命预测结果与试验结果吻合良好，表明该方法可以在仅有腐蚀形貌与缺口几何尺寸条件下计算得到预腐蚀疲劳缺口系数，继而得到缺口件预腐蚀疲劳剩余寿命。
(7)对预腐蚀疲劳剩余强度进行实验研究，给出含腐蚀疲劳损伤金属材料剩余强度概率分布模型。在实验室环境下，对国产LC4CS铝合金试件进行预腐蚀剩余强度试验，并对某在实际环境中使用30余年钢材进行剩余强度试验(共44件试验件)，提出剩余强度分布的双峰模型。该模型很好的解释了前人和本人实验中一些结论的矛盾之处，为今后剩余强度校核提供参考。
Metallic material such as aluminum, steel, is sensitive to corrosive environment. Corrosiondamage and fatigue damage together seriously affect the integrity and security of the metal structure.How to calculate residual life and residual strength of metal structure contained the corrosion damageby surface morphology of metal structure without large number of tests become ankey problem.
In this thesis, metal material pre-corrosion fatigue damage was concerned, from both local andglobal perspective, the impact on the residual life of metal material by pre-corrosion damage wasin-depth studied. Based on the fracture mechanic and fractal dimension, theoretical models to predictthe pre-corrosion fatigue residual life which were only need the data of corrosion morphology wereestablished. The rationality and predictive ability of the models were analyzed and experimentalverified. The probability distribution of the pre-corrosion fatigue residual strength was also given byexperimental analysis. This model unified conflicting views of previous studies. The main work andinnovations in this paper are as follows:
(1) Pre-corrosion fatigue residual life and residual strength tests (227specimens) were done. Inthe laboratory ambient conditions, pre-corrosion fatigue residual life and residual strength tests onaluminum alloy LC4CS and steel were completed. Provided observational data for the follow-upstudy and experimental verification of predicted results of residual life and residual strength.
(2) Proposed new criteria for critical pits-opening angle. For existing CM-EIFS method cannotreasonably determine crack initiation pit, the definition of opening angle was proposed by analyzed alot of corrosion morphology observed by three-dimensional microscopy and topography details ofSEM image which influenced crack initiation. Through filtering crack initiation pits by opening angle,remaining life was calculated by CM-EIFS method. The predicted results showed that the openingangle definition was reasonable. Predicted results were accurate, so the CM-EIFS method wasimproved.
(3) Proposed an equivalent area method to calculate the initial crack size and crack propagationmodel. The pit is equivalent to a semi-elliptical surface initial crack by projected area of the pit. Thismethod associated initial crack size with the most critical factors of crack propagation life-stressintensity factorand the morphology of initial crack was consistent with experimental results. Based onfiltering the critical pits by opening angle, the equivalent initial crack size could be gotten by equivalent area method. A new crack growth model was also given in this paper, and constituted anew, complete CM-EIFS calculation system. Compared with the experimental results showed that themethod was accurate enough.
(4) Proposed a new method to estimate pre-corrosion fatigue residual life of smooth specimenbased on fractal dimension.Because fractal dimension can describe the complexity of overallmorphology and will not ignore any details, an innovative method based on fractal dimension todescribe corrosion morphology and the relationship between fractal dimension and residual life wasproposed. Proposed a new three-dimensional fractal dimension calculation method to predict residuallife. Predicted results with the experimental results were in good agreement and showed that thismethod could well predict the residual life in the only corrosion morphology and pristine S-N curveconditions, saved test time and expenses.
(5) Pre-corrosion fatigue notch factor was defined and its empirical formula with pre-corrosiontime change was given. This formula combined with pre-corrosion residual life of smooth specimencould calculate residual life of notched specimen.
(6) Proposed a new method to estimate pre-corrosion fatigue residual life of notched specimenbased on fractal dimension. Defined pre-corrosion stress concentration factor and discussed itsphysical meaning. Given the method to calculate pre-corrosion fatigue notch factor by fractaldimension. Predicted results with the experimental results were in good agreement and showed thatthis method could well predict pre-corrosion fatigue notch factor in the only corrosion morphologyand geometry size of notch conditions, and then calculated residual life of notch specimen.
(7) Experimental study of pre-corrosion fatigue residual strength was completed, probabilitydistribution model of residual strength of metallic materials containing corrosion fatigue damage wasproposed. In a laboratory environment, residual strength test of the domestic LC4CS aluminum alloyand steel used more than30years in a real environment was implemented (49specimens). A bimodaldistribution model of residual strength was proposed and it provided a good explanation for theinconsistency of experiment results of residual strength in literatures and this thesis. This modelprovided reference for future residual strength check.
引文
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