金属构件中空间裂纹电磁热止裂技术的研究
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摘要
在现代工业中,金属作为主要原材料被广泛应用于军事、航空、航天、船舶、车辆运输、机械制造等许多工程领域。金属材料构件在制造和使用过程中由于种种原因会出现裂纹,裂纹的扩展导致结构件还远没有达到材料的强度极限就发生断裂破坏,从而给实际生产和生活带来不可估量的损失。利用电磁场的热效应原理对带有裂纹的金属构件进行裂纹止裂,是延长其工作寿命、提高安全性、可靠性的一种新颖而行之有效的方法。关于电磁热裂纹止裂技术,目前国内外研究仅局限于平面问题,对空间问题的理论与实验研究仍属空白。本文正是以此为出发点,结合理论分析、数值模拟和实验三方面开展研究工作。研究内容概括为以下六个部分:
(1)对带有圆型半埋藏裂纹的金属构件进行了脉冲放电瞬间温度场的理论分析:建立了理论分析模型,求得了电流通过裂纹尖端附近的电流密度函数,进而求得电磁热裂纹止裂时裂纹尖端附近温度场和应力场的解析式;建立了数值分析模型,利用Ansys有限元软件模拟了热电耦合过程,求得脉冲放电瞬间的温度场;理论分析与数值模拟的结果有很好的吻合。
(2)对带有深埋椭圆型裂纹的金属构件脉冲放电瞬间的温度场进行了理论分析:利用电流绕流问题与流体力学中流体绕过障碍物问题的相似性,建立了理论分析模型,求得了电磁热裂纹止裂时裂纹前缘附近温度场的解析式。
(3)建立了带有深埋椭圆型裂纹的金属构件进行脉冲放电瞬间的数值模拟分析模型:采用电—热—机械顺次瞬态耦合计算方法,得到非线性过程中瞬态温度场和热应力场的数值解;讨论了止裂中由于放电时间非常短暂,裂纹尖端温度梯度非常巨大,材料特征参数如比热、电阻率、热传导系数等均随温度发生变化而引起的高度非线性问题;模拟计算了理论分析的结果,在验证理论分析的基础上,扩大分析的内容,讨论了含有埋藏椭圆型斜裂纹的金属构件脉冲放电瞬间的温度场与裂纹面倾斜角度的关系,研究了多裂纹的绕流屏蔽效应和局部跨越止裂技术,同时模拟了电流绕流情况。
(4)在自主研制的大型放电止裂装置ZL-2上实现了含空间裂纹金属构件的止裂实验研究。制备了含不同半埋藏裂纹(单个直裂纹、双直裂纹、单个斜裂纹)的多组标准拉伸试件;首先用数值模拟的方法确定了实验放电参数,制定出试验方案;`试验中研究了带有不同形式空间半埋藏裂纹的标准拉伸试件的止裂情况,证实了金属构件中空间裂纹电磁热止裂技术的有效性。
(5)采用对接焊的方法制造了带有埋藏裂纹的金属构件,采用超声波无损探伤的方法确定了焊接结构焊缝中的全埋藏裂纹的位置和形态,对其进行了电磁热止裂实验研究。用脉冲放电的方法实现了焊接结构焊缝中空间埋藏裂纹的电磁热效应止裂,同时提高了焊接接头的强韧性,实现了焊缝处热影响区微观组织的细化、改善了焊接接头的内应力状态,并且不改变焊接结构基体的组织和性能。
(6)对电磁热止裂后的拉伸试件进行了机械性能测试实验。在微机控制拉伸实验机上,对放电前后的试件进行拉伸实验研究,对比研究了其机械性能指标,并对拉断后的试件进行了宏微观断口分析,对放电止裂后裂纹尖端组织进行了微观组织分析,发现围绕裂纹尖端生成了强韧的白亮层组织,提高了止裂后试件的机械性能;采用SPM对电磁热裂纹止裂后的金属构件进行了纳米尺度下的力学性能测试。
本文的研究工作表明:通过强脉冲放电的方法可以实现金属构件中空间半埋藏和埋藏裂纹的电磁热止裂,并且围绕裂纹尖端发生了有利于提高机械性能的组织变化。电磁热止裂技术将成为一项重要的、有发展前景的金属结构损伤修复技术。
In modern industry, metal is widely used in military affairs, aviation, aerospace, shipping, transportation, mechanical productions and many other industrial fields for the main original material. Cracks might be generated due to various reasons when metal components are being made or used, and the crack propagation results in that the fracture in a component takes place before the material intensity limit is come up to, thus this brings immeasurable losses to the practical productions and lives. Making use of electromagnetic heating effect to prevent crack propagation in metal components with cracks is a novel and effective method that can extend its lifetime, improved the security and reliability. Nowadays, for the technology of crack arrest by electromagnetic heating effect, the domestic and overseas studies are only limited in planar problems, but for the theory and experiment research of spatial problems are vacant. The article which is just based on this develops studies in three aspects of theoretical analysis, numerical simulation and experimental study. The content includes six parts as below:
(1)Theoretical analysis of the temperature field is conducted in metal components with half-embedding circular cracks when an impulse current is switched on. The model of theoretical analysis is built, the current density functions around the crack tip is presented when a current is switched on, further more, temperature field and stress field functions are received when crack arrest by electromagnetic heating effect is proceeding. The model of numerical analysis is built, and making use of the software of Ansys the coupling course of thermal and electrical is simulated, in succession the temperature field is received. The results of theoretical analysis and numerical simulation are also compared.
(2)The temperature field is analyzed theoretically for metal components with deep embedding elliptical cracks when an impulse current is switched on instantaneously. Using the similarity of current detour problems and fluid detour problems in the hydromechanics, the theoretical analysis model is built, and the functions around the forehead of the crack is gotten when crack arrest by electromagnetic heating effect is carried on. By concrete calculated examples, the effect relations of various parameters to the stress field are discussed. Theoretical analysis problems of spatial crack arrest by electromagnetic heating effect with practical significance are also solved.
(3)The model of numerical simulation analysis is built for metal components with deep embedding elliptical cracks when an impulse current is switched on instantaneously. Using the method of the electric-thermal-mechanical ordinal coupling calculation, the numerical answers of instantaneous temperature field and thermal stress field in the nonlinear course are given. The exceeding unlinear problems result from the instant discharge time, great temperature gradient around the crack tip and material character parameters such as heat consistency, resistivity and heat conduction changing with the temperature in the course of crack arrest are discussed. The results of theoretical analysis are simulated, analytical contents are broadened based on the valid theoretical analysis, the temperature field is calculated when an impulse current is switched on instantaneously in metal components with deep embedding elliptical leaning cracks, the relations of the temperature around the crack tip and the leaning angle are discussed, simultaneously the current detour is simulated.
(4)The crack arrest experimental study in metal components with spatial cracks is conducted on pulse current generator (model ZL-2) developed by the authors. Many standard tension test pieces(single straight crack, double straight cracks, single leaning crack) are produced. Firstly by the method of numerical simulation, the experimental discharge parameters are identified, and the experimental program is established. Experiments study the situation of crack arrest in standard tension test pieces with various spatial cracks, established the validity of the technology of crack arrest by electromagnetic heating effect, which approves the validity of spatial crack arrest in metal components by using elelctromagnetic heating.
(5)By the method of ultrasonic detecting damnification, the position and configuration of the entire embedding crack in weld joint of the jointing structure are conformed, and the crack arrest by electromagnetic heating experimental study is also carried out. The method of pulse current discharge realizes the spatial embedding crack arrest by electromagnetic heating in weld joint, simultaneously the obdurability is improved. Fining microcosmic structure in the heat influence area is realized, the inside stress state of the weld joint is reformed, further more, the structure and performance of the jointing structure don’t change.
(6)The experiments of mechanical performance examination are carried out in standard tension test pieces after crack arrest. Through the PC-control universal tester,the study of stretch experiment is carried out in components before and after crack arrest, mechanical performance index is studied by contrast. Analysis of the macroscopical state and microstructure is carried out in the fracture after the component is snapped.
Microcosmic structure analysis is carried out at the crack tip, the white-right layer which is coriaceous forms around the crack tip. Mechanical performance is improved after crack arrest. Also, Scanning Probe Microscopy is used to finish the mechanical testing for metal component after crack arresting at the nanometer scale.
The research results in the dissertation demonstrated that the spatial half-embedding crack and embedding crack can be prevented in metal component by pulse current discharged using electromagnetic heating effect, and the super fine metal structure appears around the crack tip for improving the mechanical performance of metal component after crack arrest, and it is reasonable to anticipate that the crack arrest by using electromagnetic heating will be developed to repair the damage and fracture of metal component.
(1)对带有圆型半埋藏裂纹的金属构件进行了脉冲放电瞬间温度场的理论分析:建立了理论分析模型,求得了电流通过裂纹尖端附近的电流密度函数,进而求得电磁热裂纹止裂时裂纹尖端附近温度场和应力场的解析式;建立了数值分析模型,利用Ansys有限元软件模拟了热电耦合过程,求得脉冲放电瞬间的温度场;理论分析与数值模拟的结果有很好的吻合。
(2)对带有深埋椭圆型裂纹的金属构件脉冲放电瞬间的温度场进行了理论分析:利用电流绕流问题与流体力学中流体绕过障碍物问题的相似性,建立了理论分析模型,求得了电磁热裂纹止裂时裂纹前缘附近温度场的解析式。
(3)建立了带有深埋椭圆型裂纹的金属构件进行脉冲放电瞬间的数值模拟分析模型:采用电—热—机械顺次瞬态耦合计算方法,得到非线性过程中瞬态温度场和热应力场的数值解;讨论了止裂中由于放电时间非常短暂,裂纹尖端温度梯度非常巨大,材料特征参数如比热、电阻率、热传导系数等均随温度发生变化而引起的高度非线性问题;模拟计算了理论分析的结果,在验证理论分析的基础上,扩大分析的内容,讨论了含有埋藏椭圆型斜裂纹的金属构件脉冲放电瞬间的温度场与裂纹面倾斜角度的关系,研究了多裂纹的绕流屏蔽效应和局部跨越止裂技术,同时模拟了电流绕流情况。
(4)在自主研制的大型放电止裂装置ZL-2上实现了含空间裂纹金属构件的止裂实验研究。制备了含不同半埋藏裂纹(单个直裂纹、双直裂纹、单个斜裂纹)的多组标准拉伸试件;首先用数值模拟的方法确定了实验放电参数,制定出试验方案;`试验中研究了带有不同形式空间半埋藏裂纹的标准拉伸试件的止裂情况,证实了金属构件中空间裂纹电磁热止裂技术的有效性。
(5)采用对接焊的方法制造了带有埋藏裂纹的金属构件,采用超声波无损探伤的方法确定了焊接结构焊缝中的全埋藏裂纹的位置和形态,对其进行了电磁热止裂实验研究。用脉冲放电的方法实现了焊接结构焊缝中空间埋藏裂纹的电磁热效应止裂,同时提高了焊接接头的强韧性,实现了焊缝处热影响区微观组织的细化、改善了焊接接头的内应力状态,并且不改变焊接结构基体的组织和性能。
(6)对电磁热止裂后的拉伸试件进行了机械性能测试实验。在微机控制拉伸实验机上,对放电前后的试件进行拉伸实验研究,对比研究了其机械性能指标,并对拉断后的试件进行了宏微观断口分析,对放电止裂后裂纹尖端组织进行了微观组织分析,发现围绕裂纹尖端生成了强韧的白亮层组织,提高了止裂后试件的机械性能;采用SPM对电磁热裂纹止裂后的金属构件进行了纳米尺度下的力学性能测试。
本文的研究工作表明:通过强脉冲放电的方法可以实现金属构件中空间半埋藏和埋藏裂纹的电磁热止裂,并且围绕裂纹尖端发生了有利于提高机械性能的组织变化。电磁热止裂技术将成为一项重要的、有发展前景的金属结构损伤修复技术。
In modern industry, metal is widely used in military affairs, aviation, aerospace, shipping, transportation, mechanical productions and many other industrial fields for the main original material. Cracks might be generated due to various reasons when metal components are being made or used, and the crack propagation results in that the fracture in a component takes place before the material intensity limit is come up to, thus this brings immeasurable losses to the practical productions and lives. Making use of electromagnetic heating effect to prevent crack propagation in metal components with cracks is a novel and effective method that can extend its lifetime, improved the security and reliability. Nowadays, for the technology of crack arrest by electromagnetic heating effect, the domestic and overseas studies are only limited in planar problems, but for the theory and experiment research of spatial problems are vacant. The article which is just based on this develops studies in three aspects of theoretical analysis, numerical simulation and experimental study. The content includes six parts as below:
(1)Theoretical analysis of the temperature field is conducted in metal components with half-embedding circular cracks when an impulse current is switched on. The model of theoretical analysis is built, the current density functions around the crack tip is presented when a current is switched on, further more, temperature field and stress field functions are received when crack arrest by electromagnetic heating effect is proceeding. The model of numerical analysis is built, and making use of the software of Ansys the coupling course of thermal and electrical is simulated, in succession the temperature field is received. The results of theoretical analysis and numerical simulation are also compared.
(2)The temperature field is analyzed theoretically for metal components with deep embedding elliptical cracks when an impulse current is switched on instantaneously. Using the similarity of current detour problems and fluid detour problems in the hydromechanics, the theoretical analysis model is built, and the functions around the forehead of the crack is gotten when crack arrest by electromagnetic heating effect is carried on. By concrete calculated examples, the effect relations of various parameters to the stress field are discussed. Theoretical analysis problems of spatial crack arrest by electromagnetic heating effect with practical significance are also solved.
(3)The model of numerical simulation analysis is built for metal components with deep embedding elliptical cracks when an impulse current is switched on instantaneously. Using the method of the electric-thermal-mechanical ordinal coupling calculation, the numerical answers of instantaneous temperature field and thermal stress field in the nonlinear course are given. The exceeding unlinear problems result from the instant discharge time, great temperature gradient around the crack tip and material character parameters such as heat consistency, resistivity and heat conduction changing with the temperature in the course of crack arrest are discussed. The results of theoretical analysis are simulated, analytical contents are broadened based on the valid theoretical analysis, the temperature field is calculated when an impulse current is switched on instantaneously in metal components with deep embedding elliptical leaning cracks, the relations of the temperature around the crack tip and the leaning angle are discussed, simultaneously the current detour is simulated.
(4)The crack arrest experimental study in metal components with spatial cracks is conducted on pulse current generator (model ZL-2) developed by the authors. Many standard tension test pieces(single straight crack, double straight cracks, single leaning crack) are produced. Firstly by the method of numerical simulation, the experimental discharge parameters are identified, and the experimental program is established. Experiments study the situation of crack arrest in standard tension test pieces with various spatial cracks, established the validity of the technology of crack arrest by electromagnetic heating effect, which approves the validity of spatial crack arrest in metal components by using elelctromagnetic heating.
(5)By the method of ultrasonic detecting damnification, the position and configuration of the entire embedding crack in weld joint of the jointing structure are conformed, and the crack arrest by electromagnetic heating experimental study is also carried out. The method of pulse current discharge realizes the spatial embedding crack arrest by electromagnetic heating in weld joint, simultaneously the obdurability is improved. Fining microcosmic structure in the heat influence area is realized, the inside stress state of the weld joint is reformed, further more, the structure and performance of the jointing structure don’t change.
(6)The experiments of mechanical performance examination are carried out in standard tension test pieces after crack arrest. Through the PC-control universal tester,the study of stretch experiment is carried out in components before and after crack arrest, mechanical performance index is studied by contrast. Analysis of the macroscopical state and microstructure is carried out in the fracture after the component is snapped.
Microcosmic structure analysis is carried out at the crack tip, the white-right layer which is coriaceous forms around the crack tip. Mechanical performance is improved after crack arrest. Also, Scanning Probe Microscopy is used to finish the mechanical testing for metal component after crack arresting at the nanometer scale.
The research results in the dissertation demonstrated that the spatial half-embedding crack and embedding crack can be prevented in metal component by pulse current discharged using electromagnetic heating effect, and the super fine metal structure appears around the crack tip for improving the mechanical performance of metal component after crack arrest, and it is reasonable to anticipate that the crack arrest by using electromagnetic heating will be developed to repair the damage and fracture of metal component.
引文
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