激光喷丸强化铝合金的疲劳裂纹扩展特性及延寿机理研究
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摘要
激光喷丸强化技术利用高能短脉冲激光诱导的高幅冲击波压力实施表面改性,能有效改善金属材料中的应力分布和微观组织结构,从而有效延缓裂纹扩展速率、提高零件的疲劳寿命。目前对于裂纹件的激光喷丸延寿技术主要集中于试验研究,而对共性的机理研究相对匮乏,还未形成系统的激光喷丸诱导残余压应力场下裂纹扩展规律及其延寿机理的基本理论。本文对激光喷丸强化的裂纹扩展特性进行理论探讨,研究典型6061-T6铝合金单联中心孔试样和紧凑拉伸CT试样的激光喷丸强化处理工艺,分析表面完整性对疲劳特性的影响,结合疲劳裂纹扩展的宏观断裂力学性能和微观疲劳断口形貌,依据断裂发展的不同阶段,深入细致地描述激光喷丸强化工艺的延寿机理,且对激光喷丸诱导残余应力场下的疲劳裂纹扩展特性进行数值模拟,本文的主要内容有以下几个方面：
(1)提出了激光喷丸强化后疲劳裂纹扩展寿命的计算方法及其估算式。基于断裂力学的基本理论,探索了激光喷丸工艺对含裂纹件疲劳裂纹扩展特性（包括疲劳裂纹扩展门槛值、应力强度因子、疲劳裂纹扩展速率、裂纹尖端张开位移及裂纹前沿塑性变形区尺寸)的影响；在综合考虑外加载荷及激光喷丸诱导的残余应力相互作用的基础上,基于Paris公式得出了激光喷丸前后疲劳裂纹扩展寿命的估算公式；基于金属物理的方法,通过对疲劳断口形貌特征的定量描述,分析了激光喷丸作用下裂纹件的疲劳应力及疲劳寿命反推的主要方法,为宏微观结合揭示激光喷丸对金属材料的疲劳裂纹扩展特性及其疲劳寿命的增强机制提供理论依据。
(2)系统研究了激光喷丸铝合金表面的完整性及其对疲劳特性的影响。进行了不同激光喷丸工艺参数下铝合金表面及沿深度方向的纳米压痕测试,分析了不同喷丸次数及激光能量对纳米压痕接触深度和接触面积的影响,研究了激光喷丸提高铝合金表层纳米硬度和弹性模量的机制；对激光喷丸后的表面形貌和表面粗糙度进行了测试,分析了表面凹坑形貌、线粗糙度及面粗糙度变化对铝合金疲劳性能的影响；研究了激光喷丸CT试样诱导的残余压应力大小及其分布,分析了不同激光工艺参数对铝合金表面及深度方向残余应力分布规律的影响；测试了不同激光能量下激光喷丸后的显微组织结构,获得了多次激光喷丸6061-T6铝合金的微观强化机制。
(3)探索了激光喷丸强化工艺对工件残余应力和疲劳裂纹扩展的影响。以单联中心孔试样为对象,通过轴向载荷、轴向位移与疲劳寿命的关系曲线,分析了不同激光喷丸次数、喷丸轨迹和激光能量与试样疲劳寿命的关系；在此基础上,研究了含预制裂纹CT试样的激光喷丸强化工艺,通过da/dN-AK及a-N关系曲线,分析了不同激光能量和喷丸轨迹对CT试样疲劳裂纹扩展特性的影响；研究了裂纹尖端张开位移与疲劳裂纹扩展速率、疲劳寿命之间的关系曲线,验证了裂尖张开位移作为表征材料疲劳裂纹扩展特性参量的可行性,为激光喷丸参数的选取和工艺准则的制定提供基础实验数据。
(4)深入分析了激光喷丸强化的疲劳断口形貌特征,实现了疲劳扩展寿命的断口定量反推。以典型单联中心孔试样和CT试样为例,依据断裂过程发展的不同阶段,系统分析了不同激光喷丸次数、激光能量和喷丸轨迹下,试样在疲劳裂纹萌生区、疲劳裂纹扩展早期、裂纹扩展中期、裂纹扩展区与最终瞬断区的过渡区以及最终瞬断区的宏微观疲劳断口形貌特征及其微观强化机制,研究了疲劳裂纹扩展过程中裂纹前端停止-继续微观断口形貌特征的产生机理；根据不同裂纹长度处测得的疲劳条带形貌,对比分析了宏观裂纹扩展速率和微观裂纹扩展速率,采用梯形法进行疲劳扩展寿命的断口定量反推,验证断口定量反推疲劳寿命的可行性；进行了典型试样疲劳断口的三维形貌重建及其粗糙度分析,得到了疲劳断口的高度差、线粗糙度及面粗糙度的变化趋势。
(5)构建了以ABAQUS-MSC.Fatigue软件为平台的疲劳裂纹扩展的数字化分析方法。编制专用ABAQUS/CAE的激光冲击波加载模块,对6061-T6铝合金单联小孔试样及CT试样在不同激光能量和喷丸轨迹作用下产生的残余应力场进行了数值模拟,结合MSC.Fatigue疲劳分析中的数据无缝对接,进行了残余应力场下疲劳裂纹扩展过程的数字化分析,获得了da/dN-△K及a-N的关系曲线；研究了不同激光能量和喷丸轨迹下,疲劳裂纹扩展不同时期驱动力方向上的残余压应力分布对裂纹扩展的抑制性。表明模拟分析与实验结果的一致性较好,为激光喷丸诱导残余应力场下疲劳裂纹扩展特性的预测提供了一种有效的方法。
Laser peening (LP) is a new surface modification technology, during the process of LP, high amplitude shock wave pressure induced by high energy and short pulsed laser can effectively improve the stress distribution and micro-structures of metal materials, thus effectively delay the fatigue crack growth (FCG) rate and improve the fatigue life of metal parts. At present, the study of life-extending technology mainly focus on experiments, but the basic theory of FCG laws and life extension mechanism under residual stress field induced by LP are still pending.
The aim of this paper was to provide some foundational researches on the macro-properties, micro-structure evolution and fatigue properties of6061-T6aluminum(Al) alloy subjected to LP. Base on the theoretical discussion of FCG properties, the LP processes on typical notched and compact tension (CT) samples were studied, and the influence of surface integrity on fatigue properties was analyzed. Combined with the macroscopic FCG performance and microscopic fatigue fracture morphology, thorough descriptions of life extension mechanism induced by LP were performed at the different fracture stages, meanwhile, numerical simulation of FCG properties under residual stress field induced by LP was carried out. The main contents of this paper include the following aspects,
(1) The estimation formulas for FCG life of the untreated and LPed samples were put forward. Based on the fracture mechanics theory, the effects of LP process on FCG properties, including the FCG threshold, stress intensity factor (SIF), FCG rate, crack tip opening displacement(CTOD) and plastic deformation at the crack front were explored. With the comprehensive consideration of the applied load and the residual stress induced by LP, estimation formulas for FCG life of the untreated and LPed samples were obtained based on the Paris formula. Based on the metal physics theory, reverse calculation method for fatigue stress and fatigue life of samples subjected to LP was analyzed by the quantitative description of fatigue fracture morphology. It provided theoretical basis for revealing the enhancement mechanism of FCG properties and fatigue life of metal materials subjected to LP.
(2) The surface integrity (nano-hardness, elastic modulus, surface roughness, surface profile, residual stress and micro-structure) of6061-T6Al alloy subjected to different LP process parameters was investigated systematically, and the influence of surface integrity on fatigue properties was researched. Nano-indentation test was performed, and the influence of different LP impact times and laser energy on contact depth and contact area of nano-indentation was studied. The improve mechanism of nano hardness and elastic modulus induced by LP was explored. Surface morphology and surface roughness were tested, and the effects of line roughness and surface roughness on fatigue performance were analyzed. Residual stress distribution of CT samples subjected to LP was investigated, and the effects of LP process parameters on the residual stress along surface and depth direction were explored. Micro-structures under different laser energy were observed, and microscopic strengthening mechanism of aluminum samples subjected to multiple LP treatment was obtained.
(3) The effects of LP process on the residual stress and fatigue performance were investigated. The relations between LP impact times, peening paths, laser energy and fatigue life were obtained according to the relation curves of axial load, axial displacement and fatigue life on the notched samples. LP process of pre-crack CT samples was studied, and the FCG properties under different peening paths and laser energy were investigated by the curves of da/dN-ΔK and a-N. The relation curves of CTOD and FCG rate as well as fatigue life were analyzed, in order to verify the feasibility of using CTOD criterion to characterize the FCG performance. The above research can provide experimental datas for optimizing the process parameters and formulating technical criterion during LP.
(4) The fatigue fracture morphology after LP was analyzed, and the fracture quantitative prediction of FCG life was achieved. The macro and micro fatigue fracture morphology and microscopic strengthening mechanism of the notched and CT samples during fatigue crack initiation period, the earlier and medium FCG period, as well as the instantaneous fracture period were systematically analyzed under different LP impact times, peening paths and laser energy. The micro fatigue fracture morphology of the stop-continue crack tip during FCG was investigated. According to the fatigue striations at different crack lengths, the comparison of macro and micro FCG rate was performed, and trapezoidal method was used to predict FCG life based on the quantitative analysis of fatigue fracture. The reconstruction of three dimensional morphology and the analysis of roughness on typical fatigue fracture of CT samples were carried out, and the variation tendency of altitude difference, line roughness and surface roughness were also investigated.
(5) Based on the software platform of ABAUQS-MSC.Fatigue, a digital analysis method of FCG properties was established. Special loading module of laser shock wave was established in ABAQUS/CAE, and the residual stresses of the notched and CT6061-T6Al alloy samples subjected to different laser energy and coverage areas were simulated. Combined with MSC.Fatigue, the FCG performance under residual stress field was simulated, and the curves of da/dN-ΔK and a-N were obtained. The FCG inhibition induced by LP along the driving force direction during different FCG stages was investigated. It indicated that the simulation results were consistent with the experimental results, therefore, an effective method for predicting the FCG properties under the residual stress field induced by LP was provided.
(1)提出了激光喷丸强化后疲劳裂纹扩展寿命的计算方法及其估算式。基于断裂力学的基本理论,探索了激光喷丸工艺对含裂纹件疲劳裂纹扩展特性（包括疲劳裂纹扩展门槛值、应力强度因子、疲劳裂纹扩展速率、裂纹尖端张开位移及裂纹前沿塑性变形区尺寸)的影响；在综合考虑外加载荷及激光喷丸诱导的残余应力相互作用的基础上,基于Paris公式得出了激光喷丸前后疲劳裂纹扩展寿命的估算公式；基于金属物理的方法,通过对疲劳断口形貌特征的定量描述,分析了激光喷丸作用下裂纹件的疲劳应力及疲劳寿命反推的主要方法,为宏微观结合揭示激光喷丸对金属材料的疲劳裂纹扩展特性及其疲劳寿命的增强机制提供理论依据。
(2)系统研究了激光喷丸铝合金表面的完整性及其对疲劳特性的影响。进行了不同激光喷丸工艺参数下铝合金表面及沿深度方向的纳米压痕测试,分析了不同喷丸次数及激光能量对纳米压痕接触深度和接触面积的影响,研究了激光喷丸提高铝合金表层纳米硬度和弹性模量的机制；对激光喷丸后的表面形貌和表面粗糙度进行了测试,分析了表面凹坑形貌、线粗糙度及面粗糙度变化对铝合金疲劳性能的影响；研究了激光喷丸CT试样诱导的残余压应力大小及其分布,分析了不同激光工艺参数对铝合金表面及深度方向残余应力分布规律的影响；测试了不同激光能量下激光喷丸后的显微组织结构,获得了多次激光喷丸6061-T6铝合金的微观强化机制。
(3)探索了激光喷丸强化工艺对工件残余应力和疲劳裂纹扩展的影响。以单联中心孔试样为对象,通过轴向载荷、轴向位移与疲劳寿命的关系曲线,分析了不同激光喷丸次数、喷丸轨迹和激光能量与试样疲劳寿命的关系；在此基础上,研究了含预制裂纹CT试样的激光喷丸强化工艺,通过da/dN-AK及a-N关系曲线,分析了不同激光能量和喷丸轨迹对CT试样疲劳裂纹扩展特性的影响；研究了裂纹尖端张开位移与疲劳裂纹扩展速率、疲劳寿命之间的关系曲线,验证了裂尖张开位移作为表征材料疲劳裂纹扩展特性参量的可行性,为激光喷丸参数的选取和工艺准则的制定提供基础实验数据。
(4)深入分析了激光喷丸强化的疲劳断口形貌特征,实现了疲劳扩展寿命的断口定量反推。以典型单联中心孔试样和CT试样为例,依据断裂过程发展的不同阶段,系统分析了不同激光喷丸次数、激光能量和喷丸轨迹下,试样在疲劳裂纹萌生区、疲劳裂纹扩展早期、裂纹扩展中期、裂纹扩展区与最终瞬断区的过渡区以及最终瞬断区的宏微观疲劳断口形貌特征及其微观强化机制,研究了疲劳裂纹扩展过程中裂纹前端停止-继续微观断口形貌特征的产生机理；根据不同裂纹长度处测得的疲劳条带形貌,对比分析了宏观裂纹扩展速率和微观裂纹扩展速率,采用梯形法进行疲劳扩展寿命的断口定量反推,验证断口定量反推疲劳寿命的可行性；进行了典型试样疲劳断口的三维形貌重建及其粗糙度分析,得到了疲劳断口的高度差、线粗糙度及面粗糙度的变化趋势。
(5)构建了以ABAQUS-MSC.Fatigue软件为平台的疲劳裂纹扩展的数字化分析方法。编制专用ABAQUS/CAE的激光冲击波加载模块,对6061-T6铝合金单联小孔试样及CT试样在不同激光能量和喷丸轨迹作用下产生的残余应力场进行了数值模拟,结合MSC.Fatigue疲劳分析中的数据无缝对接,进行了残余应力场下疲劳裂纹扩展过程的数字化分析,获得了da/dN-△K及a-N的关系曲线；研究了不同激光能量和喷丸轨迹下,疲劳裂纹扩展不同时期驱动力方向上的残余压应力分布对裂纹扩展的抑制性。表明模拟分析与实验结果的一致性较好,为激光喷丸诱导残余应力场下疲劳裂纹扩展特性的预测提供了一种有效的方法。
Laser peening (LP) is a new surface modification technology, during the process of LP, high amplitude shock wave pressure induced by high energy and short pulsed laser can effectively improve the stress distribution and micro-structures of metal materials, thus effectively delay the fatigue crack growth (FCG) rate and improve the fatigue life of metal parts. At present, the study of life-extending technology mainly focus on experiments, but the basic theory of FCG laws and life extension mechanism under residual stress field induced by LP are still pending.
The aim of this paper was to provide some foundational researches on the macro-properties, micro-structure evolution and fatigue properties of6061-T6aluminum(Al) alloy subjected to LP. Base on the theoretical discussion of FCG properties, the LP processes on typical notched and compact tension (CT) samples were studied, and the influence of surface integrity on fatigue properties was analyzed. Combined with the macroscopic FCG performance and microscopic fatigue fracture morphology, thorough descriptions of life extension mechanism induced by LP were performed at the different fracture stages, meanwhile, numerical simulation of FCG properties under residual stress field induced by LP was carried out. The main contents of this paper include the following aspects,
(1) The estimation formulas for FCG life of the untreated and LPed samples were put forward. Based on the fracture mechanics theory, the effects of LP process on FCG properties, including the FCG threshold, stress intensity factor (SIF), FCG rate, crack tip opening displacement(CTOD) and plastic deformation at the crack front were explored. With the comprehensive consideration of the applied load and the residual stress induced by LP, estimation formulas for FCG life of the untreated and LPed samples were obtained based on the Paris formula. Based on the metal physics theory, reverse calculation method for fatigue stress and fatigue life of samples subjected to LP was analyzed by the quantitative description of fatigue fracture morphology. It provided theoretical basis for revealing the enhancement mechanism of FCG properties and fatigue life of metal materials subjected to LP.
(2) The surface integrity (nano-hardness, elastic modulus, surface roughness, surface profile, residual stress and micro-structure) of6061-T6Al alloy subjected to different LP process parameters was investigated systematically, and the influence of surface integrity on fatigue properties was researched. Nano-indentation test was performed, and the influence of different LP impact times and laser energy on contact depth and contact area of nano-indentation was studied. The improve mechanism of nano hardness and elastic modulus induced by LP was explored. Surface morphology and surface roughness were tested, and the effects of line roughness and surface roughness on fatigue performance were analyzed. Residual stress distribution of CT samples subjected to LP was investigated, and the effects of LP process parameters on the residual stress along surface and depth direction were explored. Micro-structures under different laser energy were observed, and microscopic strengthening mechanism of aluminum samples subjected to multiple LP treatment was obtained.
(3) The effects of LP process on the residual stress and fatigue performance were investigated. The relations between LP impact times, peening paths, laser energy and fatigue life were obtained according to the relation curves of axial load, axial displacement and fatigue life on the notched samples. LP process of pre-crack CT samples was studied, and the FCG properties under different peening paths and laser energy were investigated by the curves of da/dN-ΔK and a-N. The relation curves of CTOD and FCG rate as well as fatigue life were analyzed, in order to verify the feasibility of using CTOD criterion to characterize the FCG performance. The above research can provide experimental datas for optimizing the process parameters and formulating technical criterion during LP.
(4) The fatigue fracture morphology after LP was analyzed, and the fracture quantitative prediction of FCG life was achieved. The macro and micro fatigue fracture morphology and microscopic strengthening mechanism of the notched and CT samples during fatigue crack initiation period, the earlier and medium FCG period, as well as the instantaneous fracture period were systematically analyzed under different LP impact times, peening paths and laser energy. The micro fatigue fracture morphology of the stop-continue crack tip during FCG was investigated. According to the fatigue striations at different crack lengths, the comparison of macro and micro FCG rate was performed, and trapezoidal method was used to predict FCG life based on the quantitative analysis of fatigue fracture. The reconstruction of three dimensional morphology and the analysis of roughness on typical fatigue fracture of CT samples were carried out, and the variation tendency of altitude difference, line roughness and surface roughness were also investigated.
(5) Based on the software platform of ABAUQS-MSC.Fatigue, a digital analysis method of FCG properties was established. Special loading module of laser shock wave was established in ABAQUS/CAE, and the residual stresses of the notched and CT6061-T6Al alloy samples subjected to different laser energy and coverage areas were simulated. Combined with MSC.Fatigue, the FCG performance under residual stress field was simulated, and the curves of da/dN-ΔK and a-N were obtained. The FCG inhibition induced by LP along the driving force direction during different FCG stages was investigated. It indicated that the simulation results were consistent with the experimental results, therefore, an effective method for predicting the FCG properties under the residual stress field induced by LP was provided.
引文
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