材料微观结构和试样厚度对小冲杆试验的影响
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摘要
小冲杆微试样试验技术由于具有使用极少量材料评估宏观块状材料力学性能的特点,近年来逐渐成为研究的热点。但是小尺寸材料和大尺寸材料在力学和物理化学性质方面均存在着一定程度的尺度效应差异,小冲杆试验得到的材料力学性能能否准确的衡量宏观在役设备材料的力学性能还没有进行深入系统的研究。本文对比分析了目前存在的小冲杆试验结果和常规拉伸试验的ReL和Rm值进行合理回归的问题,结合试验及有限元数值模拟结果详细研究了小冲杆试验中试样在不同变形阶段的受力状态；以力学性能各向异性的A350锻件为研究对象,通过对比小冲杆试验与常规拉伸试验的结果,对各向异性材料中存在的试样取样方向对应问题进行了研究；通过单向轧制和多步交叉轧制,获得具有不同织构的奥氏体不锈钢316L样品,以及通过轧制和热处理手段制备25种具有相同织构不同晶粒度不同厚度的不锈钢316L试样,并进行小冲杆试验,系统地研究试样厚度和晶粒尺寸对于小冲杆试验结果的影响。主要的研究结论和创新如下：
(1)首次阐明了试样变形过程中的应力状态从弹性弯曲应力占主导并逐步出现薄膜应力,再转化为以薄膜应力为主导而弯曲应力不断减小的演化过程。阐明了小冲杆试验数据中屈服载荷转化为单轴拉伸试验中屈服强度值ReL的关联式中采用试样原始厚度h2参数,以及最大载荷转化为抗拉强度Rm值时采用h参数的理论依据,并极大地提高了线性回归精度。
(2)A350锻件宏观上纵向拉伸试样呈脆性断裂,而周向拉伸试样呈韧性断裂。对应方向的小冲杆试样均为韧性断裂,表明小冲杆试样在试验中表现出比常规拉伸试验中更好的塑性。对比试验结果发现,两个方向取样的小冲杆试验结果差别不大。
(3)小冲杆试验对于奥氏体不锈钢316L试样的厚度和晶粒度变化具有很好的敏感性。试验得到的试样屈服强度、抗拉强度和试样的厚度(h)以及厚度-晶粒度比(h/dg)都有很好的相关性。结果表明,除了试样厚度,小试样的厚度-晶粒度比会极大的影响小冲杆试验得到的材料强度。
(4)通过数据分析,首次提出了小冲杆试验中奥氏体不锈钢316L试样的尺度效应判断准则：当奥氏体不锈钢小冲杆试样的厚度-晶粒度比值h/dg>-8,厚度h>200μm时,得到的材料屈服强度和抗拉强度趋近于定值,由小冲杆试验数据关联得到的材料的力学性能不受材料尺度效应的影响。
Small punch test (SPT) technique which is used for quantifying the properties of bulk materials with greatly reduced volume has been extensively studied recently. However, some size effects on mechanical, physical and chemical properties of material have been observed at small scale (or microscale) and macroscale. So far very few studies have been devoted to verify if the miniature specimen SPT is able to measure the mechanical properties of in-service component correctly and appropriately due to observed mechanical size effects. In this study, the existing correlation equations for correlating yield load Fp, maximum load Fm in SPT to yield strength ReL and ultimate tensile strength Rm in conventional tensile test (CTT) were compared and the rationalities of them were discussed. Evolution of stress state of specimen during SPT was analyzed through finite element model and stress linearization method. CTT and SPT were carried out on A350forging flange, which has anisotropic mechanical properties, to study specimen size effect on mechanical behavior at different scales and to study the corresponding sampling direction that is able to adopted to evaluate the properties of anisotropic material with different specimen orientation and different specimen sizes between SPT and CTT. Additionally, two kinds of316L austenitic stainless steel (ASS) SPT specimens with same thickness but distinct texture were prepared by means of unidirectional rolling and multi-step cross rolling, and25sorts of316L ASS samples with nearly the same crystallographic texture but different thickness and grain size were prepared using different thermo-mechanical process. SPT is used to evaluate the effects of specimen thickness, grain size and ratio of thickness to grain size on mechanical properties of316L ASS. The present work provided a critical ratio of thickness to grain size of SPT sample for engineering application, as well as its mechanism and a basic understanding of the size effect of specimen on SPT, based on which the reliability of SPT in relating the mechanical properties of small specimens to those of bulk counterparts was enhanced. The conclusions obtained in this study are as follows.
(1) The evolution of stress state of deformation process of specimen in SPT was clarified. The results showed that at initial stage the elastic bending stress is predominant and then the stress state dominated by membrane stress with the decreasing of elastic bending stress and the increasing of punch displacement. The reason for introducing the specimen thickness h2to the equation for correlating Fp with ReL, and the reason for introducing h to equation for correlating Fm with Rm were provided respectively. As a result, the coefficients of determination of linear regression between Fp and ReL, as well as Fm and Rm, were improved.
(2) The fractographic features of CTT specimens machined along different orientations of anisotropic A350forging flange are different. The CTT longitudinal specimen showed brittle fracture mode, while CTT circumferential specimen showed ductile fracture mode. The results revealed that SPT samples showed more ductile features compared with CTT samples and the SPT is not sensitive to the difference of properties between specimens along different sampling orientation in the anisotropic material.
(3) The results of study of size effects observed in SPT specimens with different grain size and thickness showed that the SPT is sensitive not only to thickness (h), but also to the ratio of thickness to grain size (h/dg), though a size effect exists between SPT and standard-sized samples. Such an effect becomes more significant especially for the samples with relative larger grain size and smaller specimen thickness.
(4) A size effect criteria on SPT and critical thickness-grain size-ratio and thickness for AISI316L ASS was provided through data analysis. The yield strength and ultimate tensile strength correlated from the SPT results of ASS316L showed the grain size, thickness and specimen size dependencies significantly in the SPT. When the value of h/dg is larger than～8and h≥200μm, the yield strength and ultimate tensile strength correlated with yield load and maximum load respectively in SPT tend to be constants.
(1)首次阐明了试样变形过程中的应力状态从弹性弯曲应力占主导并逐步出现薄膜应力,再转化为以薄膜应力为主导而弯曲应力不断减小的演化过程。阐明了小冲杆试验数据中屈服载荷转化为单轴拉伸试验中屈服强度值ReL的关联式中采用试样原始厚度h2参数,以及最大载荷转化为抗拉强度Rm值时采用h参数的理论依据,并极大地提高了线性回归精度。
(2)A350锻件宏观上纵向拉伸试样呈脆性断裂,而周向拉伸试样呈韧性断裂。对应方向的小冲杆试样均为韧性断裂,表明小冲杆试样在试验中表现出比常规拉伸试验中更好的塑性。对比试验结果发现,两个方向取样的小冲杆试验结果差别不大。
(3)小冲杆试验对于奥氏体不锈钢316L试样的厚度和晶粒度变化具有很好的敏感性。试验得到的试样屈服强度、抗拉强度和试样的厚度(h)以及厚度-晶粒度比(h/dg)都有很好的相关性。结果表明,除了试样厚度,小试样的厚度-晶粒度比会极大的影响小冲杆试验得到的材料强度。
(4)通过数据分析,首次提出了小冲杆试验中奥氏体不锈钢316L试样的尺度效应判断准则：当奥氏体不锈钢小冲杆试样的厚度-晶粒度比值h/dg>-8,厚度h>200μm时,得到的材料屈服强度和抗拉强度趋近于定值,由小冲杆试验数据关联得到的材料的力学性能不受材料尺度效应的影响。
Small punch test (SPT) technique which is used for quantifying the properties of bulk materials with greatly reduced volume has been extensively studied recently. However, some size effects on mechanical, physical and chemical properties of material have been observed at small scale (or microscale) and macroscale. So far very few studies have been devoted to verify if the miniature specimen SPT is able to measure the mechanical properties of in-service component correctly and appropriately due to observed mechanical size effects. In this study, the existing correlation equations for correlating yield load Fp, maximum load Fm in SPT to yield strength ReL and ultimate tensile strength Rm in conventional tensile test (CTT) were compared and the rationalities of them were discussed. Evolution of stress state of specimen during SPT was analyzed through finite element model and stress linearization method. CTT and SPT were carried out on A350forging flange, which has anisotropic mechanical properties, to study specimen size effect on mechanical behavior at different scales and to study the corresponding sampling direction that is able to adopted to evaluate the properties of anisotropic material with different specimen orientation and different specimen sizes between SPT and CTT. Additionally, two kinds of316L austenitic stainless steel (ASS) SPT specimens with same thickness but distinct texture were prepared by means of unidirectional rolling and multi-step cross rolling, and25sorts of316L ASS samples with nearly the same crystallographic texture but different thickness and grain size were prepared using different thermo-mechanical process. SPT is used to evaluate the effects of specimen thickness, grain size and ratio of thickness to grain size on mechanical properties of316L ASS. The present work provided a critical ratio of thickness to grain size of SPT sample for engineering application, as well as its mechanism and a basic understanding of the size effect of specimen on SPT, based on which the reliability of SPT in relating the mechanical properties of small specimens to those of bulk counterparts was enhanced. The conclusions obtained in this study are as follows.
(1) The evolution of stress state of deformation process of specimen in SPT was clarified. The results showed that at initial stage the elastic bending stress is predominant and then the stress state dominated by membrane stress with the decreasing of elastic bending stress and the increasing of punch displacement. The reason for introducing the specimen thickness h2to the equation for correlating Fp with ReL, and the reason for introducing h to equation for correlating Fm with Rm were provided respectively. As a result, the coefficients of determination of linear regression between Fp and ReL, as well as Fm and Rm, were improved.
(2) The fractographic features of CTT specimens machined along different orientations of anisotropic A350forging flange are different. The CTT longitudinal specimen showed brittle fracture mode, while CTT circumferential specimen showed ductile fracture mode. The results revealed that SPT samples showed more ductile features compared with CTT samples and the SPT is not sensitive to the difference of properties between specimens along different sampling orientation in the anisotropic material.
(3) The results of study of size effects observed in SPT specimens with different grain size and thickness showed that the SPT is sensitive not only to thickness (h), but also to the ratio of thickness to grain size (h/dg), though a size effect exists between SPT and standard-sized samples. Such an effect becomes more significant especially for the samples with relative larger grain size and smaller specimen thickness.
(4) A size effect criteria on SPT and critical thickness-grain size-ratio and thickness for AISI316L ASS was provided through data analysis. The yield strength and ultimate tensile strength correlated from the SPT results of ASS316L showed the grain size, thickness and specimen size dependencies significantly in the SPT. When the value of h/dg is larger than～8and h≥200μm, the yield strength and ultimate tensile strength correlated with yield load and maximum load respectively in SPT tend to be constants.
引文
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