铝合金材料的应力腐蚀及腐蚀疲劳特性实验研究
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摘要
盐溶液环境下金属材料的腐蚀力学是一门涉及到电化学、金属物理学、冶金学和力学等多门学科的新兴学科，虽然已经进行了大量的研究工作，也积累了不少实际经验，但由于涉及多种因素且各因素间的耦合作用复杂，因此尚未形成该力学过程的基本理论规律。在实际应用中，目前人们难以精确地确定和使用环境谱、载荷谱以及选择特定的腐蚀力学试验来获得可靠的实验数据，用以指导工程设计应用。因此本论文期望发展一种以力学为基础的可靠工具以预测和跟踪腐蚀环境中的裂纹形成与扩展直至失效行为。
本文选择对环境十分敏感的铝合金材料作为研究对象，该材料的腐蚀问题更是一个很早就困扰航空、汽车等领域的难点，每年因腐蚀造成的经济损失数字庞大，引发的事故灾难屡见不鲜。应力腐蚀和腐蚀疲劳是铝合金材料失效破坏行为的多发领域，亟待人们去深入研究、解决设计和优化问题。目前在研究铝合金材料的腐蚀力学问题时，通常将荷载因素与腐蚀条件分别考虑，特别是实验测试中对于荷载与腐蚀环境两种因素的耦合作用规律还缺乏深入研究，因此造成所获得的实验数据局限性很大。而工程中铝合金材料有很多情况是同时受到荷载因素和腐蚀因素作用而最终导致失效破坏的，因此对铝合金材料在盐溶液环境下的腐蚀力学过程和规律进行系统的研究与阐述，具有重要的科学意义和实际应用价值。
本论文提出以盐溶液中腐蚀电流作为腐蚀环境的特征参量，结合常规环境下铝合金材料的腐蚀力学理论，提出了使用寿命的预测模型，以及易于应用的断裂准则。本论文提出的模型系统地考虑了铝合金的常见力学参数在可控腐蚀条件和荷载的耦合作用下的趋势和规律。本论文的研究内容和创新点描述如下：
1.本文首先提出了用腐蚀电极的电流强度衡量腐蚀速率的方法，并搭建了测量模型。选用工程中常用的2024铝合金材料，通过在实验过程中调整人工腐蚀溶液配比方案（包含浓度、酸碱度和温度等）实现了对该种材料的腐蚀速率的有效控制。该铝合金在溶液1%HCl+3.5%NaCl中经预腐蚀后，再进行材料抗冲击性能实验测试，应用扫描电镜等显微测量设备观察端口形貌，以及腐蚀边界与腐蚀孔的形貌特征等参量，研究分析了不同预腐蚀时间和腐蚀速率下材料的标准试验吸收能的衰减规律和腐蚀电流的关系，验证了用腐蚀电流表征腐蚀环境作用的可行性，并能同时判断腐蚀模式。
2.本文研究了在拉压状态下应力腐蚀开裂行为，得到裂纹起裂时间的评价公式，并发现了受压状态下的开裂新行为。在获得了有效控制腐蚀速率方法的基础上，设计合适的实验方案，使用减薄的WOL试样进行应力腐蚀试验，通过应变片测量的方法得到了距预裂纹前端5mm处应变的变化规律，并通过数值模拟的方法得到了验证。论文还研究了初始应力对于应力腐蚀的影响，分析初始应力与起裂时间的关系，并以实验数据为基础，将疲劳领域中的S-N曲线公式引入到应力腐蚀领域，提出了初始应力强度因子与起裂时间的关系式
3.本文还进一步提出了“腐蚀速率-时间-频率”的等效假设，并且以腐蚀速率和荷载频率为参量提出腐蚀疲劳寿命评价模型。该预测模型使用ZL101和7075两种光滑铝合金试件进行腐蚀疲劳寿命研究试验，拟合了S-N曲线，提出了腐蚀条件下应力-疲劳寿命的改进模型N_if(i_(cor))~n(△σ)~m=C。然后通过等比率地降低腐蚀速率和加载频率的方法再次测试材料的断裂破坏寿命，数据结果与原寿命预测曲线对比，结果未超出工程要求的误差范围，验证了等效假设的合理性。同时，本文还探索了腐蚀溶液如何与承受荷载条件的材料实现有效、可控接触的方法。
4.本文发展了使用非耐腐蚀测量设备记录腐蚀条件下的裂纹扩展过程的方法，并基于实验结果和端口形貌分析提出了Paris公式的修正模型。在实验中我们分别实现了在1、5、10Hz频率，20℃、60℃、80℃温度和pH=3、7、10时的腐蚀溶液的条件下材料的疲劳裂纹扩展行为。温度和pH值的改变引起了腐蚀电流的改变，通过对腐蚀疲劳裂纹扩展速率测量结果与常温常态下的曲线作对比，得到腐蚀裂纹扩展的一般规律和速率变化趋势。分析了决定材料腐蚀疲劳裂纹扩展速率的多种因素，并对它们的变化范围和影响程度进行预测分析。提出了Paris公式的修正模型模型中引入影响因子α与速率偏置因子β，讨论频率、腐蚀电流参量参与表达腐蚀疲劳裂纹扩展预测模型的实用性和科学性。
Corrosion mechanics is an emerging discipline related to electrochemistry,metal physics and metallurgy. Continuous eforts have been made in this feld.However, scientists fail to extract reliable experiment data due to the difcultiesin determining corrosion fatigue test with proper environmental and loading con-ditions. The dilemma also lies in precisely predicting initiation or propagationof fatigue crack under corrosion environment since widely accepted mechanicalcriteria are still absent. Specifcally, corrosion of aluminum alloy has drawn theattention of aeronautics and automobile communities for decades. The factorsof fatigue, such as load condition and corrosion efects, are taken into accountseparately in traditional studies. Such a methodology results in signifcant er-ror regarding load and corrosion not coupled with material properties as long asfailure is normally resulted from the combined efects of load condition and cor-rosion environment. Hence, further detailed study and comprehensive analysisare necessary in this feld.
The main focuses of this study are aiming at corrosion mechanics of alu-minum alloys, for example, initiation of stress fatigue crack under tension-compressionload, and characteristics of curve of corrosion fatigue life/propagation of corro-sion fatigue crack under uni-axial tension-compression load. Then an applicablefailure criterion is proposed to predict fatigue life of aluminum alloys under com-plex corrosion condition coupled with load. Highlights of this study are listed asfollows.
First, a new method is employed to measure corrosion rate through currentintensity, which is gauged by a new established model. Experiments are con-ducted to study characteristics of aluminum alloy, for examples, corrosion rateafected by artifcial corrosion solution ratio, resistance to impact of pre-corroded sample, corrosion mode on cross-section and attenuation law of energy absorptionunder diferent corrosion time or corrosion rate.
Secondly, this study uncovers the stress corrosion cracking(SCC) behav-ior under tension-compression load and that stress corrosion may occur undercompression for aluminum alloy. With controllable corrosion rate, variationof strain near crack front in stress corrosion fatigue test is obtained throughmeasuring strain with thin WOL samples. The result is verifed by numeri-cal simulation. The efects of initial stress to stress corrosion are also studied.The KISCCand the relationship of initial stress to time of initiation of crackingare yielded from the former step. Thirdly, the research introduces a corrosionrate/time/frequency assumption, based on which an estimation law of life on cor-rosion fatigue N_i=f(i_(cor))~n(△σ)~m is proposed with corrosion rate and frequencyof load as parameters. During this step, smooth aluminum alloy specimens,subjected to corrosion and cyclic tension, are tested to extract S-N curves inconsideration of corrosion environment and cyclic tension at the same time. Inaddition, the frequency efect is studied. Discussions are present to uncover theapplicable conditions for high-frequency equipment in terms of studying corrosionfatigue. Attempts are also made to study how to get efective contact betweencorrosion solution and specimens.
Finally, an innovative application of recording equipment, not build for cor-rosion tests, is adopted to record fatigue crack propagation. A modifed Paris-with interaction factor α, deviation factor βand corrosion rate, is proposed to analyze practicality and feasibility of the fa-tigue model. During the experiment, three diferent frequencies, three temper-ature levels and solutions with three diferent ratios are successfully applied tofatigue cracking. Then the trend of fatigue-crack-propagation is obtained throughcomparing our experiment result to the propagation rate at room temperature.The dominant factors on fatigue-crack-propagation rate are analyzed to uncovertheir variation range and efects.
本文选择对环境十分敏感的铝合金材料作为研究对象，该材料的腐蚀问题更是一个很早就困扰航空、汽车等领域的难点，每年因腐蚀造成的经济损失数字庞大，引发的事故灾难屡见不鲜。应力腐蚀和腐蚀疲劳是铝合金材料失效破坏行为的多发领域，亟待人们去深入研究、解决设计和优化问题。目前在研究铝合金材料的腐蚀力学问题时，通常将荷载因素与腐蚀条件分别考虑，特别是实验测试中对于荷载与腐蚀环境两种因素的耦合作用规律还缺乏深入研究，因此造成所获得的实验数据局限性很大。而工程中铝合金材料有很多情况是同时受到荷载因素和腐蚀因素作用而最终导致失效破坏的，因此对铝合金材料在盐溶液环境下的腐蚀力学过程和规律进行系统的研究与阐述，具有重要的科学意义和实际应用价值。
本论文提出以盐溶液中腐蚀电流作为腐蚀环境的特征参量，结合常规环境下铝合金材料的腐蚀力学理论，提出了使用寿命的预测模型，以及易于应用的断裂准则。本论文提出的模型系统地考虑了铝合金的常见力学参数在可控腐蚀条件和荷载的耦合作用下的趋势和规律。本论文的研究内容和创新点描述如下：
1.本文首先提出了用腐蚀电极的电流强度衡量腐蚀速率的方法，并搭建了测量模型。选用工程中常用的2024铝合金材料，通过在实验过程中调整人工腐蚀溶液配比方案（包含浓度、酸碱度和温度等）实现了对该种材料的腐蚀速率的有效控制。该铝合金在溶液1%HCl+3.5%NaCl中经预腐蚀后，再进行材料抗冲击性能实验测试，应用扫描电镜等显微测量设备观察端口形貌，以及腐蚀边界与腐蚀孔的形貌特征等参量，研究分析了不同预腐蚀时间和腐蚀速率下材料的标准试验吸收能的衰减规律和腐蚀电流的关系，验证了用腐蚀电流表征腐蚀环境作用的可行性，并能同时判断腐蚀模式。
2.本文研究了在拉压状态下应力腐蚀开裂行为，得到裂纹起裂时间的评价公式，并发现了受压状态下的开裂新行为。在获得了有效控制腐蚀速率方法的基础上，设计合适的实验方案，使用减薄的WOL试样进行应力腐蚀试验，通过应变片测量的方法得到了距预裂纹前端5mm处应变的变化规律，并通过数值模拟的方法得到了验证。论文还研究了初始应力对于应力腐蚀的影响，分析初始应力与起裂时间的关系，并以实验数据为基础，将疲劳领域中的S-N曲线公式引入到应力腐蚀领域，提出了初始应力强度因子与起裂时间的关系式
3.本文还进一步提出了“腐蚀速率-时间-频率”的等效假设，并且以腐蚀速率和荷载频率为参量提出腐蚀疲劳寿命评价模型。该预测模型使用ZL101和7075两种光滑铝合金试件进行腐蚀疲劳寿命研究试验，拟合了S-N曲线，提出了腐蚀条件下应力-疲劳寿命的改进模型N_if(i_(cor))~n(△σ)~m=C。然后通过等比率地降低腐蚀速率和加载频率的方法再次测试材料的断裂破坏寿命，数据结果与原寿命预测曲线对比，结果未超出工程要求的误差范围，验证了等效假设的合理性。同时，本文还探索了腐蚀溶液如何与承受荷载条件的材料实现有效、可控接触的方法。
4.本文发展了使用非耐腐蚀测量设备记录腐蚀条件下的裂纹扩展过程的方法，并基于实验结果和端口形貌分析提出了Paris公式的修正模型。在实验中我们分别实现了在1、5、10Hz频率，20℃、60℃、80℃温度和pH=3、7、10时的腐蚀溶液的条件下材料的疲劳裂纹扩展行为。温度和pH值的改变引起了腐蚀电流的改变，通过对腐蚀疲劳裂纹扩展速率测量结果与常温常态下的曲线作对比，得到腐蚀裂纹扩展的一般规律和速率变化趋势。分析了决定材料腐蚀疲劳裂纹扩展速率的多种因素，并对它们的变化范围和影响程度进行预测分析。提出了Paris公式的修正模型模型中引入影响因子α与速率偏置因子β，讨论频率、腐蚀电流参量参与表达腐蚀疲劳裂纹扩展预测模型的实用性和科学性。
Corrosion mechanics is an emerging discipline related to electrochemistry,metal physics and metallurgy. Continuous eforts have been made in this feld.However, scientists fail to extract reliable experiment data due to the difcultiesin determining corrosion fatigue test with proper environmental and loading con-ditions. The dilemma also lies in precisely predicting initiation or propagationof fatigue crack under corrosion environment since widely accepted mechanicalcriteria are still absent. Specifcally, corrosion of aluminum alloy has drawn theattention of aeronautics and automobile communities for decades. The factorsof fatigue, such as load condition and corrosion efects, are taken into accountseparately in traditional studies. Such a methodology results in signifcant er-ror regarding load and corrosion not coupled with material properties as long asfailure is normally resulted from the combined efects of load condition and cor-rosion environment. Hence, further detailed study and comprehensive analysisare necessary in this feld.
The main focuses of this study are aiming at corrosion mechanics of alu-minum alloys, for example, initiation of stress fatigue crack under tension-compressionload, and characteristics of curve of corrosion fatigue life/propagation of corro-sion fatigue crack under uni-axial tension-compression load. Then an applicablefailure criterion is proposed to predict fatigue life of aluminum alloys under com-plex corrosion condition coupled with load. Highlights of this study are listed asfollows.
First, a new method is employed to measure corrosion rate through currentintensity, which is gauged by a new established model. Experiments are con-ducted to study characteristics of aluminum alloy, for examples, corrosion rateafected by artifcial corrosion solution ratio, resistance to impact of pre-corroded sample, corrosion mode on cross-section and attenuation law of energy absorptionunder diferent corrosion time or corrosion rate.
Secondly, this study uncovers the stress corrosion cracking(SCC) behav-ior under tension-compression load and that stress corrosion may occur undercompression for aluminum alloy. With controllable corrosion rate, variationof strain near crack front in stress corrosion fatigue test is obtained throughmeasuring strain with thin WOL samples. The result is verifed by numeri-cal simulation. The efects of initial stress to stress corrosion are also studied.The KISCCand the relationship of initial stress to time of initiation of crackingare yielded from the former step. Thirdly, the research introduces a corrosionrate/time/frequency assumption, based on which an estimation law of life on cor-rosion fatigue N_i=f(i_(cor))~n(△σ)~m is proposed with corrosion rate and frequencyof load as parameters. During this step, smooth aluminum alloy specimens,subjected to corrosion and cyclic tension, are tested to extract S-N curves inconsideration of corrosion environment and cyclic tension at the same time. Inaddition, the frequency efect is studied. Discussions are present to uncover theapplicable conditions for high-frequency equipment in terms of studying corrosionfatigue. Attempts are also made to study how to get efective contact betweencorrosion solution and specimens.
Finally, an innovative application of recording equipment, not build for cor-rosion tests, is adopted to record fatigue crack propagation. A modifed Paris-with interaction factor α, deviation factor βand corrosion rate, is proposed to analyze practicality and feasibility of the fa-tigue model. During the experiment, three diferent frequencies, three temper-ature levels and solutions with three diferent ratios are successfully applied tofatigue cracking. Then the trend of fatigue-crack-propagation is obtained throughcomparing our experiment result to the propagation rate at room temperature.The dominant factors on fatigue-crack-propagation rate are analyzed to uncovertheir variation range and efects.
引文
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