金属表面渗镀复合改性层接触力学行为探讨
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摘要
表而渗镀复合改性层,不但具备表面完全改性,而且由于成分梯度分布的中间扩散层的存在,使其在钛及不锈钢等软基材农而承载过程中具备较单一匀质涂层更好的协调变形性能。也正是由于中间梯度扩散层的存在,使渗镀复合改性层力学性能的表征远较匀质改性层复杂。本文借助纳米压入、微米压入、小能量多冲测试并结合有限元模拟,对渗镀复合改性层的弹塑性性能参数及典型静、动态接触载荷下的变形及火效行为进行初步分析。研究结果可为渗镀复合改性层的设计及工程应用提供理论参考。
正向分析是本文研究的基础,本文先期对性能已知的钛/不锈钢(Ti/SS)及铬/不锈钢(Cr/SS)两种膜/基体系进行正向分析。然后,基于正向分析及代农性应力和代表性应变的概念,建立求解渗镀复合改性层塑性性能参数的反演分析方案。最后,针对Mo改性Ti进行纳米压入测试和反演分析,微米压入测试和正向分析,小能量多冲测试和正向分析。主要研究工作和结论如下：
(1)对软膜硬基Ti/SS以及硬膜软基Cr/SS体系进行正向分析,发现弹性模量比硬度对基体效应更为敏感,10%准则不具有通用性；软膜硬基在受压过程中产生膜层的堆积,使得垂直于压头棱边的方向存在环向拉应力，因此沿着压头棱边的方向易于产生径向裂纹；硬膜软基在受压过程中，发生膜、基的沉陷,使得压头与试样表而接触圆周附近存在径向弯曲拉应力,导致该区域易于产生环向裂纹。
(2)采取分层处理的思路,基于正向分析、代表性应力和代表性应变的概念,建立了两种求解渗镀复合改性层塑性性能参数的反演分析方案(Ⅰ和Ⅱ)。两种反演分析方案的主要区别是：方案Ⅱ选用的代表性应变为塑性应变,具有一定的物理意义；应变强化指数不是通过无量纲函数求得,而是依赖于反复的模拟修正。
(3)利用等离子表面合金化技术,在纯Ti表面制备了Mo渗镀复合改性层,对其表面及横截面进行了纳米压入测试,并对改性前后的纯Ti基体也进行了对比纳米压入测试。考虑纳米压入测试尺寸效应的情况下,利用反演分析方案Ⅱ求解了Mo改性层的塑性性能参数。由Mo改性层的弹塑性性能参数可知,经过等离子表而合金化处理,Ti表面的硬度及弹性模量大幅升高,但依然保有较好的塑性性能指标。
(4)选用5N、10N和15N三种载荷,通过单次力加载的方式对Mo改性层的表面进行了微米压入测试,发现Mo改性Ti具有硬膜/软基体系的失效形式。针对5N载荷情况,通过循环力加载的方式进行测试,得到了和纳米压入测试相衔接的结果。结合试验及正向分析,得出微米压入过程中环向裂纹产生的规律：随着施加载荷的增大,在压头的正下方,裂纹宽度逐渐增大,当达到最大载荷时,在接触圆周附近产生最大宽度的裂纹,且随着拉应力沿着接触表面向外的扩展,在接触圆周外围继续产生裂纹,但宽度呈逐渐减小的趋势。
(5)采用100N、300N、500N和700N四种冲击载荷,对Mo改性层的表面进行了小能量多次冲击测试及分析。动态接触载荷下Mo改性层的典型失效过程表现为：首先,冲击球与试样表面接触圆周刷的附近,由于存在较大的塑性变形而产生环向裂纹；其次,由于冲击疲劳的作用,上述区域产生垂直于环向裂纹的径向裂纹；最后是在该区域发生内聚失效。上述失效过程中伴有一定程度的冲击磨损,尤其是在高冲击载荷下,冲击磨损作用不可忽略,应当加以考虑。结合试验及正向分析,提出了较高载荷理想冲击状态下Mo改性层的失效模型。
A diffusion and deposition duplex modified layer (DDDML) with high hardness and high resistance of wear and corrosion can be obtained by using the plasma surface alloying technique after selecting reasonable diffusion elements. DDDML contains a homogeneous deposition layer and a gradient diffusion layer. Compared to homogeneous films, DDDML belongs to metallurgical bonding and its diffusion part can coordinate the deformation between the deposition layer and the substrate. Because the diffusion layer is not only gradient in composition but in elasto-plastic properties, it is difficult to quantificationally determine its mechanical properties. Based on nano/microindentation, low energy repeat impact test and finite element simulation, this paper seeks to determine the elasto-plastic properties of DDDML and investigate its deformation and failure behavior corresponding static and dynamic contact conditions.The research results could provide theoretical references for the design and application of DDDML.
Considering that forward analysis is the basis of this paper, it was firstly launched corresponding nanoindentation tests on Ti/SS and Cr/SS systems. Then, based on forward analysis, representative stress and representative strain, this paper sought to present inverse analysis approaches to determine the plastic properties of DDDML. Finally, nanoindentation, microindentation and low energy impact tests were performed. What is more, inverse analysis corresponding nanoindentation test and forward analysis correspongding microindentation and low energy impact tests were lauched. The main results are as follows:
(1) According to the forward analysis corresponding nanoindentation tests on the Ti/SS and Ti/SS systems, it can be founded that the elastic modulus is more sensitive than the hardness and the10%rule is not universally true. In the nanoindentation process of soft film/hard substrate system,"pile up" presented, which made the hoop tensile stress exist in the direction perpendicular to the pyramidal edge. Therefore, along the pyramidal edge direction, radial cracks are easy to produce. For the hard film/soft substrate system,"sink in" exhibited in the nanoindentation process, which caused radial tensile stress around the contact circle between the indenter and the sample. Thus ring cracks are easy to form in this area.
(2) Based on forward analysis, representative stress and representative strain, two inverse analysis approaches were built (Ⅰ and Ⅱ). The main differences between them are the representative strain of the inverse analysis approach II is of plastic strain and the strain hardening exponent of the inverse analysis approach II was not obtained by a dimensionless function but by repeated simulation modifications.
(3) Nanoindentation tests were performed on the cross section and surface of the Mo modified layer. For the purpose of comparison, nanoindentation tests were also performed on the treated and untreated Ti substrates. With the consideration of size effects, the plastic properties of every sub-layer of the Mo modified layer were obtained. Experimental and inverse analysis results indicate that the whole Mo modified layer possesses higher hardness, elastic modulus and retains relatively fine plasticity. Through comparing nanoindentation test results of the treated and untreated Ti substrates, it is concluded that the alloying treatment temperature of900℃has no effect on the mechanical properties of the Ti substrate.
(4) Microindentation tests were performed on the surface of the Mo modified layer using the CSM Micro-Hardness Tester (CSM Instruments, Switzerland) with a Vickers diamond tip. Two loading types were adopted, i.e. the linear loading type with three different maximum loads of5N, ION and15N, and the continuous multi-cycle (CMC) loading type with the maximum load of5N reached by30cycles. Linear loading test results indicate that the Mo modified Ti has the same failure mode as the hard film/soft substrate system. CMC loading test results could link with the nanonindentation results. According to the experimental and forward analysis results, the occurrence rule of the ring cracks was concluded. With the increase of the applied load, cracks become bigger and bigger under the indenter. When the load reaches the maximum value, the biggest crack appears around the contact circle. Owing to the expanding of the radial tensile stress, ring cracks continue to propagate at the periphery of the contact circle, but become weaker and weaker.
(5) On the surface of the Mo modified layer, low energy impact tests were conducted at four loads of100N,300N,500N and700N with10000impact cycles. The failure process was obtained. Firstly, ring cracks occurred around the contact circle between the impact ball and the sample due to the large plastic deformation. Secondly, radial cracks perpendicular to the ring cracks presented because of impact fatigue. Finally, cohesion failure occurs near the contact circle. During the failure process, there existed the impact wear, especially under the higher impact load. According to the experimental and forward analysis results, the failure model under the ideal impact condition and the higher impact load was established.
正向分析是本文研究的基础,本文先期对性能已知的钛/不锈钢(Ti/SS)及铬/不锈钢(Cr/SS)两种膜/基体系进行正向分析。然后,基于正向分析及代农性应力和代表性应变的概念,建立求解渗镀复合改性层塑性性能参数的反演分析方案。最后,针对Mo改性Ti进行纳米压入测试和反演分析,微米压入测试和正向分析,小能量多冲测试和正向分析。主要研究工作和结论如下：
(1)对软膜硬基Ti/SS以及硬膜软基Cr/SS体系进行正向分析,发现弹性模量比硬度对基体效应更为敏感,10%准则不具有通用性；软膜硬基在受压过程中产生膜层的堆积,使得垂直于压头棱边的方向存在环向拉应力，因此沿着压头棱边的方向易于产生径向裂纹；硬膜软基在受压过程中，发生膜、基的沉陷,使得压头与试样表而接触圆周附近存在径向弯曲拉应力,导致该区域易于产生环向裂纹。
(2)采取分层处理的思路,基于正向分析、代表性应力和代表性应变的概念,建立了两种求解渗镀复合改性层塑性性能参数的反演分析方案(Ⅰ和Ⅱ)。两种反演分析方案的主要区别是：方案Ⅱ选用的代表性应变为塑性应变,具有一定的物理意义；应变强化指数不是通过无量纲函数求得,而是依赖于反复的模拟修正。
(3)利用等离子表面合金化技术,在纯Ti表面制备了Mo渗镀复合改性层,对其表面及横截面进行了纳米压入测试,并对改性前后的纯Ti基体也进行了对比纳米压入测试。考虑纳米压入测试尺寸效应的情况下,利用反演分析方案Ⅱ求解了Mo改性层的塑性性能参数。由Mo改性层的弹塑性性能参数可知,经过等离子表而合金化处理,Ti表面的硬度及弹性模量大幅升高,但依然保有较好的塑性性能指标。
(4)选用5N、10N和15N三种载荷,通过单次力加载的方式对Mo改性层的表面进行了微米压入测试,发现Mo改性Ti具有硬膜/软基体系的失效形式。针对5N载荷情况,通过循环力加载的方式进行测试,得到了和纳米压入测试相衔接的结果。结合试验及正向分析,得出微米压入过程中环向裂纹产生的规律：随着施加载荷的增大,在压头的正下方,裂纹宽度逐渐增大,当达到最大载荷时,在接触圆周附近产生最大宽度的裂纹,且随着拉应力沿着接触表面向外的扩展,在接触圆周外围继续产生裂纹,但宽度呈逐渐减小的趋势。
(5)采用100N、300N、500N和700N四种冲击载荷,对Mo改性层的表面进行了小能量多次冲击测试及分析。动态接触载荷下Mo改性层的典型失效过程表现为：首先,冲击球与试样表面接触圆周刷的附近,由于存在较大的塑性变形而产生环向裂纹；其次,由于冲击疲劳的作用,上述区域产生垂直于环向裂纹的径向裂纹；最后是在该区域发生内聚失效。上述失效过程中伴有一定程度的冲击磨损,尤其是在高冲击载荷下,冲击磨损作用不可忽略,应当加以考虑。结合试验及正向分析,提出了较高载荷理想冲击状态下Mo改性层的失效模型。
A diffusion and deposition duplex modified layer (DDDML) with high hardness and high resistance of wear and corrosion can be obtained by using the plasma surface alloying technique after selecting reasonable diffusion elements. DDDML contains a homogeneous deposition layer and a gradient diffusion layer. Compared to homogeneous films, DDDML belongs to metallurgical bonding and its diffusion part can coordinate the deformation between the deposition layer and the substrate. Because the diffusion layer is not only gradient in composition but in elasto-plastic properties, it is difficult to quantificationally determine its mechanical properties. Based on nano/microindentation, low energy repeat impact test and finite element simulation, this paper seeks to determine the elasto-plastic properties of DDDML and investigate its deformation and failure behavior corresponding static and dynamic contact conditions.The research results could provide theoretical references for the design and application of DDDML.
Considering that forward analysis is the basis of this paper, it was firstly launched corresponding nanoindentation tests on Ti/SS and Cr/SS systems. Then, based on forward analysis, representative stress and representative strain, this paper sought to present inverse analysis approaches to determine the plastic properties of DDDML. Finally, nanoindentation, microindentation and low energy impact tests were performed. What is more, inverse analysis corresponding nanoindentation test and forward analysis correspongding microindentation and low energy impact tests were lauched. The main results are as follows:
(1) According to the forward analysis corresponding nanoindentation tests on the Ti/SS and Ti/SS systems, it can be founded that the elastic modulus is more sensitive than the hardness and the10%rule is not universally true. In the nanoindentation process of soft film/hard substrate system,"pile up" presented, which made the hoop tensile stress exist in the direction perpendicular to the pyramidal edge. Therefore, along the pyramidal edge direction, radial cracks are easy to produce. For the hard film/soft substrate system,"sink in" exhibited in the nanoindentation process, which caused radial tensile stress around the contact circle between the indenter and the sample. Thus ring cracks are easy to form in this area.
(2) Based on forward analysis, representative stress and representative strain, two inverse analysis approaches were built (Ⅰ and Ⅱ). The main differences between them are the representative strain of the inverse analysis approach II is of plastic strain and the strain hardening exponent of the inverse analysis approach II was not obtained by a dimensionless function but by repeated simulation modifications.
(3) Nanoindentation tests were performed on the cross section and surface of the Mo modified layer. For the purpose of comparison, nanoindentation tests were also performed on the treated and untreated Ti substrates. With the consideration of size effects, the plastic properties of every sub-layer of the Mo modified layer were obtained. Experimental and inverse analysis results indicate that the whole Mo modified layer possesses higher hardness, elastic modulus and retains relatively fine plasticity. Through comparing nanoindentation test results of the treated and untreated Ti substrates, it is concluded that the alloying treatment temperature of900℃has no effect on the mechanical properties of the Ti substrate.
(4) Microindentation tests were performed on the surface of the Mo modified layer using the CSM Micro-Hardness Tester (CSM Instruments, Switzerland) with a Vickers diamond tip. Two loading types were adopted, i.e. the linear loading type with three different maximum loads of5N, ION and15N, and the continuous multi-cycle (CMC) loading type with the maximum load of5N reached by30cycles. Linear loading test results indicate that the Mo modified Ti has the same failure mode as the hard film/soft substrate system. CMC loading test results could link with the nanonindentation results. According to the experimental and forward analysis results, the occurrence rule of the ring cracks was concluded. With the increase of the applied load, cracks become bigger and bigger under the indenter. When the load reaches the maximum value, the biggest crack appears around the contact circle. Owing to the expanding of the radial tensile stress, ring cracks continue to propagate at the periphery of the contact circle, but become weaker and weaker.
(5) On the surface of the Mo modified layer, low energy impact tests were conducted at four loads of100N,300N,500N and700N with10000impact cycles. The failure process was obtained. Firstly, ring cracks occurred around the contact circle between the impact ball and the sample due to the large plastic deformation. Secondly, radial cracks perpendicular to the ring cracks presented because of impact fatigue. Finally, cohesion failure occurs near the contact circle. During the failure process, there existed the impact wear, especially under the higher impact load. According to the experimental and forward analysis results, the failure model under the ideal impact condition and the higher impact load was established.
引文
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