等离子喷熔修形提高焊接接头疲劳性能研究
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摘要
等离子喷熔修形(Modification of Plasma Spurt Spraying---MPSS)作为一种新的提高焊接接头疲劳强度的方法被提出，在焊缝表面覆盖一层完全冶金结合的高曲率半径且表面光滑的喷熔涂层，使其在焊趾处形成圆滑的过渡，降低了应力集中，从而显著提高焊接接头的疲劳性能。
本文以Q235B钢十字焊接接头为研究对象，对比分析了TIG熔修接头、超声冲击处理接头、氧-乙炔火焰喷熔修形(Modification of Oxygen-acetylene SpurtSpraying---MOSS)接头和等离子喷熔修形接头的疲劳性能。观察了氧-乙炔火焰喷熔和等离子喷熔涂层的显微组织及涂层与焊缝的结合情况。采用纳米压痕技术分析了喷熔涂层及过渡区域材料的力学性能。研制了能够在接头表面形成残余压缩应力的低相变点等离子喷熔粉末。采用通用有限元分析软件ANSYS对原始焊态接头、常规粉末喷熔修形接头、低相变点合金粉末熔修接头及低相变点合金粉末喷熔修形接头进行了温度场和应力场的模拟。
性能试验表明：正交试验设计获得了等离子喷熔修形的最优工艺参数，保证了等离子喷熔涂层与焊缝的冶金结合。Ni65Cr16B3.1Si4.5粉末等离子喷熔涂层中存在硬度高、韧性差的硬质相，硬质相上的纳米压痕点出现了裂纹，根据裂纹的尺寸确定了硬质相的断裂韧性值。同时，获得了等离子喷熔涂层与焊缝过渡区域材料的本构方程。
高周疲劳试验表明：Ni65Cr16B3.1Si4.5粉末氧-乙炔火焰喷熔修形接头在2×10~6循环周次下的疲劳强度为217MPa,与原始焊态接头相比提高了60.7%。等离子喷熔修形接头在2×10~6循环周次下的疲劳强度为220MPa,与原始焊态接头相比提高了62.96%。低周疲劳试验表明：相同应力水平下，氧-乙炔火焰喷熔修形接头的低周疲劳寿命为1.0×10~4至1.3×10~4循环周次，等离子喷熔修形接头的低周疲劳寿命相比氧-乙炔火焰喷熔修形接头又有所提高，达到了1.5×10~4至1.7×10~4循环周次。
通过对自制的三种低相变点等离子喷熔粉末喷熔层残余应力、冲击韧性、硬度、相组织的分析，获得了主要成分为5Cr-8Ni，同时外加Cu及稀土元素的低相变点合金系统。
采用模拟焊接温度场及应力场的方法模拟了低相变点等离子喷熔修形接头的温度场和残余应力场分布。结果表明，低相变点等离子喷熔修形接头焊趾区存在一定范围的残余压缩应力，这一残余压缩应力的存在使得低相变点等离子喷熔修形接头的疲劳强度进一步提高，与疲劳测试结果相符合。
Modification of Plasma Spurt Spraying (MPSS), which is a new method, wasused to improve the fatigue strength of welded joint. The basic principle of MPSS isto spray fusing a complete metallurgical bonding layer of high curvature appearanceon the surface of the whole welded joint, which can greatly reduce the stressconcentration of welded joint. As a result, fatigue strength of welded joint will besubstantially improved.
Take as-supplied, cross-shaped welded joints of Q235B steel as testing object.The comparative analysis of fatigue behavior for TIG-dressing joint, welded jointstreated by ultrasonic peening treatment (UPT) and spraying fused joint. The bondinglayer between coating and weld was studied by optical microscopy, scanning electronmicroscopy (SEM). Material properties of metallurgy bonding zone were performedat room temperature using a nano-indentation device equipped with a Berkovich tip.In order to gain compressive residual stress, the low transformation temperature (LTT)alloy powder was developed. The temperature field and stress field of spraying fusedjoint were simulated by ANSYS software.
Performance tests show that: the orthogonal experiment design won the optimalparameters of MPSS. The hard phase exists in the coating spray fused byNi65Cr16B3.1Si4.5alloy powder. There is the existence of a crack in the hard phase,and the fracture toughness of hard phase was determined according to the size ofcrack. The constitutive equation of metallurgy bonding zone was founded accordingto Reverse Analysis Algorithms.
High cycle fatigue test results indicate that fatigue strength of MOSS-joint andMPSS-joint corresponding to2×10~6cycles is217MPa and220MPa, respectively.Compared with as-welded joints, Fatigue strength increases by60.7%and62.96%,respectively. Low cycle fatigue test results show that fatigue life of MOSS-joint islower than MPSS-joint.
Through the analysis of residual stress, impact toughness and hardness of plasmaspurt spraying coating, LTT alloy powder system of5Cr-8Ni was determined.
The method of simulating welding was used to simulate temperature field andresidual stress field of joint spray fused by LTT powder. Results show that, thereexists a certain range of residual compression stress at weld toe of joint spray fused by LTT powder. The existence of residual compression stress will improve fatiguestrength of welded joint further.
本文以Q235B钢十字焊接接头为研究对象，对比分析了TIG熔修接头、超声冲击处理接头、氧-乙炔火焰喷熔修形(Modification of Oxygen-acetylene SpurtSpraying---MOSS)接头和等离子喷熔修形接头的疲劳性能。观察了氧-乙炔火焰喷熔和等离子喷熔涂层的显微组织及涂层与焊缝的结合情况。采用纳米压痕技术分析了喷熔涂层及过渡区域材料的力学性能。研制了能够在接头表面形成残余压缩应力的低相变点等离子喷熔粉末。采用通用有限元分析软件ANSYS对原始焊态接头、常规粉末喷熔修形接头、低相变点合金粉末熔修接头及低相变点合金粉末喷熔修形接头进行了温度场和应力场的模拟。
性能试验表明：正交试验设计获得了等离子喷熔修形的最优工艺参数，保证了等离子喷熔涂层与焊缝的冶金结合。Ni65Cr16B3.1Si4.5粉末等离子喷熔涂层中存在硬度高、韧性差的硬质相，硬质相上的纳米压痕点出现了裂纹，根据裂纹的尺寸确定了硬质相的断裂韧性值。同时，获得了等离子喷熔涂层与焊缝过渡区域材料的本构方程。
高周疲劳试验表明：Ni65Cr16B3.1Si4.5粉末氧-乙炔火焰喷熔修形接头在2×10~6循环周次下的疲劳强度为217MPa,与原始焊态接头相比提高了60.7%。等离子喷熔修形接头在2×10~6循环周次下的疲劳强度为220MPa,与原始焊态接头相比提高了62.96%。低周疲劳试验表明：相同应力水平下，氧-乙炔火焰喷熔修形接头的低周疲劳寿命为1.0×10~4至1.3×10~4循环周次，等离子喷熔修形接头的低周疲劳寿命相比氧-乙炔火焰喷熔修形接头又有所提高，达到了1.5×10~4至1.7×10~4循环周次。
通过对自制的三种低相变点等离子喷熔粉末喷熔层残余应力、冲击韧性、硬度、相组织的分析，获得了主要成分为5Cr-8Ni，同时外加Cu及稀土元素的低相变点合金系统。
采用模拟焊接温度场及应力场的方法模拟了低相变点等离子喷熔修形接头的温度场和残余应力场分布。结果表明，低相变点等离子喷熔修形接头焊趾区存在一定范围的残余压缩应力，这一残余压缩应力的存在使得低相变点等离子喷熔修形接头的疲劳强度进一步提高，与疲劳测试结果相符合。
Modification of Plasma Spurt Spraying (MPSS), which is a new method, wasused to improve the fatigue strength of welded joint. The basic principle of MPSS isto spray fusing a complete metallurgical bonding layer of high curvature appearanceon the surface of the whole welded joint, which can greatly reduce the stressconcentration of welded joint. As a result, fatigue strength of welded joint will besubstantially improved.
Take as-supplied, cross-shaped welded joints of Q235B steel as testing object.The comparative analysis of fatigue behavior for TIG-dressing joint, welded jointstreated by ultrasonic peening treatment (UPT) and spraying fused joint. The bondinglayer between coating and weld was studied by optical microscopy, scanning electronmicroscopy (SEM). Material properties of metallurgy bonding zone were performedat room temperature using a nano-indentation device equipped with a Berkovich tip.In order to gain compressive residual stress, the low transformation temperature (LTT)alloy powder was developed. The temperature field and stress field of spraying fusedjoint were simulated by ANSYS software.
Performance tests show that: the orthogonal experiment design won the optimalparameters of MPSS. The hard phase exists in the coating spray fused byNi65Cr16B3.1Si4.5alloy powder. There is the existence of a crack in the hard phase,and the fracture toughness of hard phase was determined according to the size ofcrack. The constitutive equation of metallurgy bonding zone was founded accordingto Reverse Analysis Algorithms.
High cycle fatigue test results indicate that fatigue strength of MOSS-joint andMPSS-joint corresponding to2×10~6cycles is217MPa and220MPa, respectively.Compared with as-welded joints, Fatigue strength increases by60.7%and62.96%,respectively. Low cycle fatigue test results show that fatigue life of MOSS-joint islower than MPSS-joint.
Through the analysis of residual stress, impact toughness and hardness of plasmaspurt spraying coating, LTT alloy powder system of5Cr-8Ni was determined.
The method of simulating welding was used to simulate temperature field andresidual stress field of joint spray fused by LTT powder. Results show that, thereexists a certain range of residual compression stress at weld toe of joint spray fused by LTT powder. The existence of residual compression stress will improve fatiguestrength of welded joint further.
引文
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