Measuring the internal stress of Al alloy forgings accurately is critical for controlling the deformation during the subsequent machine process.In this work,the crack compliance method was used to calculate the intern...Measuring the internal stress of Al alloy forgings accurately is critical for controlling the deformation during the subsequent machine process.In this work,the crack compliance method was used to calculate the internal residual stress of Al-Cu high strength alloys,and the effect of various model parameters of crack compliance method on the calculated precision was studied by combining the numerical simulation and experimental method.The results show that the precision first increased and then decreased with increasing the crack range.The decreased precision when using a high crack range was due to the strain fluctuation during the machining process,and the optimized crack range was 71%of the thickness of forgings.Low orders of Legendre polynomial can result in residual stress curve more smooth,while high orders led to the occurrence of distortion.The Tikhonov regularization method effectively suppressed the distortion of residual stress caused by the fluctuation of strain data,which significantly improved the precision.In addition,The crack compliance method with optimized parameters was used to measure the residual stress of Al-Cu alloy with different quenching methods.The calculated results demonstrated that the distribution of residual stress was obtained accurately.展开更多
In this work,the nickel-based powder metallurgy superalloy FGH95 was selected as experimental material,and the experimental parameters in multiple overlap laser shock processing(LSP)treatment were selected based on or...In this work,the nickel-based powder metallurgy superalloy FGH95 was selected as experimental material,and the experimental parameters in multiple overlap laser shock processing(LSP)treatment were selected based on orthogonal experimental design.The experimental data of residual stress and microhardness were measured in the same depth.The residual stress and microhardness laws were investigated and analyzed.Artificial neural network(ANN)with four layers(4-N-(N-1)-2)was applied to predict the residual stress and microhardness of FGH95 subjected to multiple overlap LSP.The experimental data were divided as training-testing sets in pairs.Laser energy,overlap rate,shocked times and depth were set as inputs,while residual stress and microhardness were set as outputs.The prediction performances with different network configuration of developed ANN models were compared and analyzed.The developed ANN model with network configuration of 4-7-6-2 showed the best predict performance.The predicted values showed a good agreement with the experimental values.In addition,the correlation coefficients among all the parameters and the effect of LSP parameters on materials response were studied.It can be concluded that ANN is a useful method to predict residual stress and microhardness of material subjected to LSP when with limited experimental data.展开更多
Practical experiences gained in the past several years show that the thermal residual stress(TRS)is a main cause leading polycrystalline diamond compacts(PDC)to premature failure.It is the very important to measure th...Practical experiences gained in the past several years show that the thermal residual stress(TRS)is a main cause leading polycrystalline diamond compacts(PDC)to premature failure.It is the very important to measure the TRS accurately for optimizing the interface and improving the service performance of PDC.In this paper,the TRS in 1913 flat-interface PDC was measured using improved stress-release method(ISRM).The TRS on the surface of polycrystalline diamond(PCD)table was obtained,which can be used to calculate the radial thermal residual stress(RTRS)at the interface of PCD table via a refutation process.The obtained results show that there are compressive residual stress at the PCD table interface and in the most region of PCD table surface.The exception occurs near the outer diameter of the PCD table,where the PDC begins to bend and put the PCD table surface into a tension state,an undesirable state for a brittle material.The ISRM has covered the shortage existing in traditional stress-release method,in which only finite points on the surface of PCD table can be tested for one specimen and one time.Simple as the experimental procedures are,the test results are also very accurate and reliable.This method provides the theoretical and experimental basis for testing TRS of PDC accurately.展开更多
The differential thermal expansion of the polycrystalline diamond layer and the tungsten carbide substrate results in large residual stresses as PDC cutters cooling after sintering.The residual stresses on the top sur...The differential thermal expansion of the polycrystalline diamond layer and the tungsten carbide substrate results in large residual stresses as PDC cutters cooling after sintering.The residual stresses on the top surface of the diamond layer of PDC were measured at five points along the radial direction of PDC using X-ray Diffraction Residual Stress Instrument,thus the stresses and their radial distribution were obtained.The results show that the stresses on the diamond surface are compressive,the biggest stress appears at the central point(about 1200 MPa),and that from the center to the edge of PDC,the magnitude of the stress decreases.A finite element analysis(FEA)was made to check the validity of the testing results.The FEA modeling results were found to correlate well with the measured values.Factors leading to the deviation between XRD experimental measurements and the calculations of residual stress by FEA were also analyzed.展开更多
The current paper focuses on the prediction of residual stresses and distortions in the Laser Powder Bed Fusion(LPBF)built Ti6Al4V thin-walled geometries using Ansys Additive Print(AAP)software which employs a layer-b...The current paper focuses on the prediction of residual stresses and distortions in the Laser Powder Bed Fusion(LPBF)built Ti6Al4V thin-walled geometries using Ansys Additive Print(AAP)software which employs a layer-by-layer accumulation of inherent strain to calculate the deformations.Isotropic and anisotropic strain scaling factors were calibrated initially within the APP software for the Ti6Al4V based single cantilever beam geometry.Subsequently,the numerical simulations were performed in APP software and computed the residual stresses and distortions for the varied process parameters including laser power,scan speed and hatch distance while maintaining the layer thickness constant for all the design iterations.The numerical predictions were compared;they were found to match reasonably well with the XRD measurements within the calibrated regime.展开更多
Large residual stresses would be generated in the laser additive manufactured(LAMed)structures after processing rapid and intense heating and cooling cycles with bad mechanical properties.Scholars have tried many meth...Large residual stresses would be generated in the laser additive manufactured(LAMed)structures after processing rapid and intense heating and cooling cycles with bad mechanical properties.Scholars have tried many methods to decrease the residual stress to prevent the structures from being broken and improve the mechanical properties.In this study,residual stress and mechanical properties of LAMed structures are analyzed,and the advanced measuring method,laser ultrasonic technique,is used to detect the residual stresses accumulated in the samples in time.The results show that when the solution temperature is less than T_(β)(992℃),the residual stress increases gradually with the increase of solution temperature,and when the temperature is more than T_(β)(992℃),Widmanstätten structure will significantly reduce the residual stress;the mechanical properties of the specimen decrease with the increase of the solution temperature,and the different cooling methods do not have much effect on the elastic properties of the specimen.Considering the residual stress and mechanical properties,the HT1 system used in this paper is the best.This study is of great significance for the reasonable suppression of residual stress and the regulation of mechanical properties of TC4 titanium alloy fabricated by laser additive manufacturing.展开更多
The influence of the residual stress in surface of ceramic balls on the fatigue life is large, because the life of silicon nitride ball bearings is more sensitive to the load acted on the bearings than the life of all...The influence of the residual stress in surface of ceramic balls on the fatigue life is large, because the life of silicon nitride ball bearings is more sensitive to the load acted on the bearings than the life of all-steel ball bearings. In this paper, the influence of thermal stress produced in sintering and mechanical stress formed in lapping process on residual stress in surface of silicon nitride ceramic balls was discussed. The residual compress stress will be formed in the surface of silicon nitride ceramic balls after sintering. The residual tensile stress will be formed in surface of silicon nitride ceramic balls in lapping process, and the size of abrasive particle is smaller, such trend is stronger. In this paper the residual stress was measured by the xylometric measurement in which the material in surface was peeled with lapping. The distribution of residual stress in surface can be calculated with the variation in specific volume. The technological parameter with which the material was peeled by lapping was given, for minimizing the extra influence of the residual stress forming in peeling on the original residual stress in surface, the abrasive particle size would not be too small and the load impressed would not be too large. Some experimental researches on residual stress in surface of silicon nitride ceramic balls were made. The surface of silicon nitride ceramic balls presented residual compressive stress after sintering and the influence of the ball size on the residual stress is feeble. It is expected that the size of ball blank is same for achieving the same residual compressive stress in surface on balls after final machining. In lapping process, the surface of silicon nitride ceramic balls presented residual tensile stress, the larger the load which is impressed on single ball, the larger the amplitude of residual tensile stress is; the smaller the abrasive particle, the stronger the trend of plastic deformation is and the larger the amplitude of residual tensile stress is.展开更多
The theoretical model of residual stress of ceramics grinding has been established applying thermal elastoplastic mechanics theory. While grinding at the course of grinding wheel moved along workpiece surface the dist...The theoretical model of residual stress of ceramics grinding has been established applying thermal elastoplastic mechanics theory. While grinding at the course of grinding wheel moved along workpiece surface the distributing regulation of residual stress can be simplified into thermal elastioplastic mechanical issue, under the action of the both moving centralized force and heat source. Calculating and evaluating of surface residual stress using current procedure of finite element analysis which has been reformed is successful. Comparing with X-ray diffraction experiment method, satisfactory precision has been acquired. The results of experiment show the changing regularity of residual stresses after grinding Al 2O 3 using diamond wheel, on condition that alter grinding parameters. The values of residual compress stress are taken place changing at key certain critical point on their figure as follow: When grinding depth a p is lower than 50 μm, the residual compress stresses are increased with grinding depth increasing, on the contrary as a p>50 μm. At V w<8 m/min, the residual compress stresses increased rapidly with feed speed of workpiece increasing, on the contrary at V w>8 m/min.When V s<25 m/s the residual stress increased with wheel speed increasing and keep stable in value at V s>25 m/s.According to grinding mechanism the cause of residual stress transform has been explained.展开更多
High-density AlN ceramics were fabricated without sintering additives at high pressure(5.0 GPa)and temperature(1300~1800℃).The sintered bodies were characterized by XRD,SEM and micro-Raman spectroscopy(MRS).Controlli...High-density AlN ceramics were fabricated without sintering additives at high pressure(5.0 GPa)and temperature(1300~1800℃).The sintered bodies were characterized by XRD,SEM and micro-Raman spectroscopy(MRS).Controlling fracture mode was intragranular when the sintering temperature was as low as 1400℃under 5.0 GPa.The values of residual stresses due to the distortion of the AlN lattice were assessed using the Micro-Raman Spectroscopy(MRS).The residual compression stress of the AlN ceramics sintered at 5.0 GPaand 1700℃for 125 min is 2.0 GPa.The residual compression stress is increased according to the extension of the sintering time.展开更多
Residual stress distributions in 7075 aluminum alloy thick plates with different thicknesses and different quenching speeds were measured. A shape function of stress distribution was proposed based on the internal str...Residual stress distributions in 7075 aluminum alloy thick plates with different thicknesses and different quenching speeds were measured. A shape function of stress distribution was proposed based on the internal stress distribution characteristics of aluminum alloy. Using nonlinear regression technology,the function between stress value of key points on internal stress curve and surface stress of the plate was obtained. Based on the measured surface stress,stress value of key points and stress distribution shape,the internal stress distribution can be reconstructed. The experiments show that the model is of good engineering practicality.展开更多
In this study,the cooling rate was manipulated by quenching with water of different temperatures(30,60 and 100℃).Surface and internal residual stresses in the quenched 6061 aluminum alloy samples were measured using ...In this study,the cooling rate was manipulated by quenching with water of different temperatures(30,60 and 100℃).Surface and internal residual stresses in the quenched 6061 aluminum alloy samples were measured using hole-drilling and crack compliance methods,respectively.Then,the processability of the quenched samples was evaluated at cryogenic temperatures.The mechanical properties of the as-aged samples were assessed,and microstructure evolution was analyzed.The surface residual stresses of samples W30℃,W60℃and W100℃is−178.7,−161.7 and−117.2 MPa,respectively along x-direction,respectively;and−191.2,−172.1 and−126.2 MPa,respectively along y-direction.The sample quenched in boiling water displaying the lowest residual stress(~34%and~60%reduction in the surface and core).The generation and distribution of quenching residual stress could be attributed to the lattice distortion gradient.Desirable plasticity was also exhibited in the samples with relatively low quenching cooling rates at cryogenic temperatures.The strengthes of the as-aged samples are 291.2 to 270.1 MPa as the quenching water temperature increase from 30℃to 100℃.Fine and homogeneous β"phases were observed in the as-aged sample quenched with boiling water due to the clusters and Guinier-Preston zones(GP zones)premature precipitated during quenching process.展开更多
By means of XRD, Instron electronic tensile machine and TEM, the dislocation states and strengthening mechanisms of SiC whisker reinforced pure aluminum matrix composites were studied with different annealing treatmen...By means of XRD, Instron electronic tensile machine and TEM, the dislocation states and strengthening mechanisms of SiC whisker reinforced pure aluminum matrix composites were studied with different annealing treatment processes and matrixes. The results showed that the strengthening mechanisms of SiC w/p Al composite and SiC w/6061Al composites are different. For the SiC w/p Al composite, the thermal residual stress plays more important role in strengthening than the high density dislocations in matrix; for the SiC w/6061Al composite, the dislocation strengthening and precipitation are main strengthening factors.展开更多
The effect of strain hardening and strain softening behavior of flow stress changing with temperature on welding residual stress, plastic strain and welding distortion of ATN0 1-T4 aluminum alloy was studied by finite...The effect of strain hardening and strain softening behavior of flow stress changing with temperature on welding residual stress, plastic strain and welding distortion of ATN0 1-T4 aluminum alloy was studied by finite simulation method. The simulation results show that the weld seam undergoes strain hardening in the temperature range of 180-250 ℃, however, it exhibits strain softening at temperature above 250 ℃ during welding heating and cooling process. As a result, the strain hardening and strain softening effects counteract each other, introducing slightly influence on the welding residual stress, residual plastic strain and distortion. The welding longitudinal residual stress was determined by ultrasonic stress measurement method for the flat plates of A7N01-T4 aluminum alloy. The simulation results are well accordant with test ones.展开更多
In this work,the effect of ultrasonic vibration modes on the mechanical properties and relaxation of residual stress in 6061-T6 aluminum alloy was studied.A new ultrasonic vibration Johnson-Cook model was proposed,and...In this work,the effect of ultrasonic vibration modes on the mechanical properties and relaxation of residual stress in 6061-T6 aluminum alloy was studied.A new ultrasonic vibration Johnson-Cook model was proposed,and the relaxation and distribution of residual stress under ultrasonic vibration were predicted and analyzed using the finite element method(FEM).The mechanical properties of 6061-T6 aluminum alloy under different ultrasonic vibration modes were analyzed through experiments involving notched specimen tensile testing and scanning electron microscopy(SEM)analysis.The findings indicate that ultrasonic vibration treatment during deformation,unloading,and load-holding,as well as treatment with its natural ultrasonic frequency,can effectively release residual stress;however,treatment with its natural frequency has the highest rate of release up to 65.4%.Ultrasonic vibration treatment during deformation better inhibits fracture under the same conditions.The FEM results are in good agreement with the experimental results,and it can be used as a valid tool for predicting residual stress release under ultrasonic vibration.展开更多
Carbon fiber-reinforced carbon aerogel(C/CA)composites are one of the most promising candidates for applications requiring both thermal insulation and load bearing capabilities.The preparation of anti-oxidation coatin...Carbon fiber-reinforced carbon aerogel(C/CA)composites are one of the most promising candidates for applications requiring both thermal insulation and load bearing capabilities.The preparation of anti-oxidation coatings on C/CA to address its susceptibility to oxidation is a feasible approach to promote its application in oxidative environments.However,the currently reported coatings on C/CA mainly focus on improving the ablation performance and coating preparation process typically necessitating high-temperature heat treatment.This procedure can increase its thermal conductivity and reduce its thermal insulation ability.In this study,a series of ceramic-resin coatings were fabricated on C/CA through a simple slurry brushing-drying approach at room temperature.The effects of phenolic resin content on the coating structure,residual stress,thermal shock,and oxidation behaviors were investigated.Due to the adhesive properties and curing-induced shrinkage,the PR-7.5 coating(containing 7.5%(in mass)phenolic resin in the slurry)exhibits bonding strength close to fracture strength of the substrate and residual compressive stress of 0.853 GPa,which is beneficial for resisting thermal shock cracking.However,excessive resin content(PR-10.0 containing 10.0%(in mass)phenolic resin in the slurry)induces tensile stress due to uneven curing shrinkage,thereby leading to thermal shock cracking.Meanwhile,oxidation tests reveal significantly reduced weight losses for PR-7.5(17.46%at 800℃/100 min,8.15%at 1000℃/120 min,3.15%at 1200℃/120 min)versus uncoated C/CA’s 44.60%loss at 800℃/20 min.This work provides a brand-new and simple approach to improving the anti-oxidation performance of C/CA and expands its application in mild oxidative environments.展开更多
Based on the basic operating principal and the technology characteristic of electron beam physical vapor deposition(EBPVD) technique, EBPVD was used to prepare the micro-layer composites. The effect on the substrate p...Based on the basic operating principal and the technology characteristic of electron beam physical vapor deposition(EBPVD) technique, EBPVD was used to prepare the micro-layer composites. The effect on the substrate preheating temperature was taken into accounts and the finite element analysis package ANSYS was used to simulate the internal stress field and the potential displacement changing tendency. The results show that one of the most important quality factors on the judgment of micro-layer composites is the adhesion between the substrate and the deposition layers as well as among the different deposition layers. Besides the existance of temperature gradient through the thickness of layers, the main reason for the internal stress in micro-layer composites is the mismatch of various properties of the layer and the substrate of different thermal expansions and crystal lattice types. With the increase of substrate preheating temperature, the inter-laminar shear stress also takes on a tendency of increase but the axial residual stress decrease.展开更多
Tungsten inert gas(TIG) welding is the most commonly used joining process for aluminum alloy for AA6061 and AA7075 which are highly demanded in the aerospace engineering and the automobile sector, but there are some d...Tungsten inert gas(TIG) welding is the most commonly used joining process for aluminum alloy for AA6061 and AA7075 which are highly demanded in the aerospace engineering and the automobile sector, but there are some defects occur during TIG welding like micro-crack, coarse grain structure, and porosity. To improve these defects, the TIG welded joint is processed using friction stir processing(FSP).This paper presents the effect of friction stir processing on TIG welding with filler ER4043 and ER 5356 for dissimilar aluminum alloy AA6061 and AA7075. The mechanical characterization, finite element formulation and mathematical equations of heat transfer of TIG + FSP welded joints are investigated using ANSYS Fluent software by adjusting process parameters of FSP. The results show that the maximum compressive residual stress 73 MPa was obtained at the fusion zone(FZ) of the TIG weldment with filler ER4043, whereas minimum compressive residual stress 37 MPa was obtained at stir zone(SZ) of the TIG+ FSP with filler 5356. The maximum heat flux 5.33 × 106 W/m2 and temperature 515C have observed at tool rotation 1600 rpm with a feed rate of 63 mm/min. These results give a satisfactory measure of confidence in the fidelity of the simulation。展开更多
In this research,a detailed multi-physics study has been carried out by numerically simulating a solid fractured gun barrel for 20 thermo-mechanical cycles.The numerical model is based on thermal effects,mechanical st...In this research,a detailed multi-physics study has been carried out by numerically simulating a solid fractured gun barrel for 20 thermo-mechanical cycles.The numerical model is based on thermal effects,mechanical stress fields and fatigue crack mechanics.Elastic-plastic material data of modified AISI 4340 at temperatures ranging from 25 to 1200℃and at strain rates of 4,16,32 and 48 s^(-1) was acquired from high-temperature compression tests.This was used as material property data in the simulation model.The boundary conditions applied are kept similar to the working gun barrel during continuous firing.A methodology has been provided to define thermo-mechanically active surface-to-surface type interface between the crack faces for a better approximation of stresses at the crack tip.Comparison of results from non-autofrettaged and autofrettaged simulation models provide useful information about the evolution of strains and stresses in the barrel at different points under combined thermo-mechanical loading cycles in both cases.The effect of thermal fatigue under already induced compressive yield due to autofrettage and the progressive degradation of the accumulated stresses due to thermo-mechanical cyclic loads on the internal surface of the gun barrel(mimicking the continuous firing scenario)has been analyzed.Comparison between energy release rate at tips of varying crack lengths due to cyclic thermo-mechanical loading in the non-autofrettaged and autofrettaged gun has been carried out.展开更多
In order to prolong the service life of aircraft skin made from AA2524, the effects of laser shock peening(LSP) on fatigue crack growth(FCG) rate and fracture toughness(K_(c)) of AA2524 were investigated. Multiple LSP...In order to prolong the service life of aircraft skin made from AA2524, the effects of laser shock peening(LSP) on fatigue crack growth(FCG) rate and fracture toughness(K_(c)) of AA2524 were investigated. Multiple LSP treatment was performed on compact tension(CT) specimen from single side and double sides. The surface integrity was measured with Vickers hardness tester, X-ray diffractometer and confocal laser scanning microscope, respectively. FCG rate test and fracture toughness test under plane stress were carried out after LSP treatment. The microstructure features of cross-sections were observed with scanning electron microscope. The results showed that the micro-hardness and residual stress of CT specimens were increased dramatically after LSP treatment. Compared to the base metal(BM), the fatigue life was prolonged by 2.4 times and fracture toughness was increased by 22% after multiple LSP.展开更多
This paper concentrates on simulating fracture in thin walled single-lap joints connected by resistance spot-welding(RSW)process which were subjected to tensile loading.For this purpose,three sets of lap-joints with d...This paper concentrates on simulating fracture in thin walled single-lap joints connected by resistance spot-welding(RSW)process which were subjected to tensile loading.For this purpose,three sets of lap-joints with different spot configurations were tested to achieve the joints’tensile behavior.To simulate the joints tensile behavior,firstly a 2D axisymmetric finite element(FE)model was used to calculate residual stresses induced during the welding process.Then the results were transferred to 3D models as pre-stress.In this step,cohesive zone model(CZM)technique was used to simulate fracture in the models under tensile load.Cohesive zone parameters were extracted using coach-peel and shear lap specimens.The results were employed to simulate deformation and failure in single lap spot weld samples.It has been shown that considering the residual stresses in simulating deformation and fracture load enables quite accurate predictions.展开更多
基金Project(51875583)supported by the National Natural Science Foundation of ChinaProject(zzyjkt2018-03)supported by the State Key Laboratory of High Performance Complex Manufacturing,China。
文摘Measuring the internal stress of Al alloy forgings accurately is critical for controlling the deformation during the subsequent machine process.In this work,the crack compliance method was used to calculate the internal residual stress of Al-Cu high strength alloys,and the effect of various model parameters of crack compliance method on the calculated precision was studied by combining the numerical simulation and experimental method.The results show that the precision first increased and then decreased with increasing the crack range.The decreased precision when using a high crack range was due to the strain fluctuation during the machining process,and the optimized crack range was 71%of the thickness of forgings.Low orders of Legendre polynomial can result in residual stress curve more smooth,while high orders led to the occurrence of distortion.The Tikhonov regularization method effectively suppressed the distortion of residual stress caused by the fluctuation of strain data,which significantly improved the precision.In addition,The crack compliance method with optimized parameters was used to measure the residual stress of Al-Cu alloy with different quenching methods.The calculated results demonstrated that the distribution of residual stress was obtained accurately.
基金Projects(51875558,51471176)supported by the National Natural Science Foundation of ChinaProject(2017YFB1302802)supported by the National Key R&D Program of China。
文摘In this work,the nickel-based powder metallurgy superalloy FGH95 was selected as experimental material,and the experimental parameters in multiple overlap laser shock processing(LSP)treatment were selected based on orthogonal experimental design.The experimental data of residual stress and microhardness were measured in the same depth.The residual stress and microhardness laws were investigated and analyzed.Artificial neural network(ANN)with four layers(4-N-(N-1)-2)was applied to predict the residual stress and microhardness of FGH95 subjected to multiple overlap LSP.The experimental data were divided as training-testing sets in pairs.Laser energy,overlap rate,shocked times and depth were set as inputs,while residual stress and microhardness were set as outputs.The prediction performances with different network configuration of developed ANN models were compared and analyzed.The developed ANN model with network configuration of 4-7-6-2 showed the best predict performance.The predicted values showed a good agreement with the experimental values.In addition,the correlation coefficients among all the parameters and the effect of LSP parameters on materials response were studied.It can be concluded that ANN is a useful method to predict residual stress and microhardness of material subjected to LSP when with limited experimental data.
基金supported by the Natural Science of Hunan(06JJ4062)
文摘Practical experiences gained in the past several years show that the thermal residual stress(TRS)is a main cause leading polycrystalline diamond compacts(PDC)to premature failure.It is the very important to measure the TRS accurately for optimizing the interface and improving the service performance of PDC.In this paper,the TRS in 1913 flat-interface PDC was measured using improved stress-release method(ISRM).The TRS on the surface of polycrystalline diamond(PCD)table was obtained,which can be used to calculate the radial thermal residual stress(RTRS)at the interface of PCD table via a refutation process.The obtained results show that there are compressive residual stress at the PCD table interface and in the most region of PCD table surface.The exception occurs near the outer diameter of the PCD table,where the PDC begins to bend and put the PCD table surface into a tension state,an undesirable state for a brittle material.The ISRM has covered the shortage existing in traditional stress-release method,in which only finite points on the surface of PCD table can be tested for one specimen and one time.Simple as the experimental procedures are,the test results are also very accurate and reliable.This method provides the theoretical and experimental basis for testing TRS of PDC accurately.
文摘The differential thermal expansion of the polycrystalline diamond layer and the tungsten carbide substrate results in large residual stresses as PDC cutters cooling after sintering.The residual stresses on the top surface of the diamond layer of PDC were measured at five points along the radial direction of PDC using X-ray Diffraction Residual Stress Instrument,thus the stresses and their radial distribution were obtained.The results show that the stresses on the diamond surface are compressive,the biggest stress appears at the central point(about 1200 MPa),and that from the center to the edge of PDC,the magnitude of the stress decreases.A finite element analysis(FEA)was made to check the validity of the testing results.The FEA modeling results were found to correlate well with the measured values.Factors leading to the deviation between XRD experimental measurements and the calculations of residual stress by FEA were also analyzed.
文摘The current paper focuses on the prediction of residual stresses and distortions in the Laser Powder Bed Fusion(LPBF)built Ti6Al4V thin-walled geometries using Ansys Additive Print(AAP)software which employs a layer-by-layer accumulation of inherent strain to calculate the deformations.Isotropic and anisotropic strain scaling factors were calibrated initially within the APP software for the Ti6Al4V based single cantilever beam geometry.Subsequently,the numerical simulations were performed in APP software and computed the residual stresses and distortions for the varied process parameters including laser power,scan speed and hatch distance while maintaining the layer thickness constant for all the design iterations.The numerical predictions were compared;they were found to match reasonably well with the XRD measurements within the calibrated regime.
基金Project(51771051)supported by the National Natural Science Foundation of ChinaProject(2021-MS-102)supported by the Natural Science Foundation of Liaoning Province,China+1 种基金Project(N2105021)supported by the Fundamental Research Funds for the Central Universities,ChinaProject(230032)supported by the National Training Program of Innovation and Entrepreneurship for Undergraduates,China。
文摘Large residual stresses would be generated in the laser additive manufactured(LAMed)structures after processing rapid and intense heating and cooling cycles with bad mechanical properties.Scholars have tried many methods to decrease the residual stress to prevent the structures from being broken and improve the mechanical properties.In this study,residual stress and mechanical properties of LAMed structures are analyzed,and the advanced measuring method,laser ultrasonic technique,is used to detect the residual stresses accumulated in the samples in time.The results show that when the solution temperature is less than T_(β)(992℃),the residual stress increases gradually with the increase of solution temperature,and when the temperature is more than T_(β)(992℃),Widmanstätten structure will significantly reduce the residual stress;the mechanical properties of the specimen decrease with the increase of the solution temperature,and the different cooling methods do not have much effect on the elastic properties of the specimen.Considering the residual stress and mechanical properties,the HT1 system used in this paper is the best.This study is of great significance for the reasonable suppression of residual stress and the regulation of mechanical properties of TC4 titanium alloy fabricated by laser additive manufacturing.
文摘The influence of the residual stress in surface of ceramic balls on the fatigue life is large, because the life of silicon nitride ball bearings is more sensitive to the load acted on the bearings than the life of all-steel ball bearings. In this paper, the influence of thermal stress produced in sintering and mechanical stress formed in lapping process on residual stress in surface of silicon nitride ceramic balls was discussed. The residual compress stress will be formed in the surface of silicon nitride ceramic balls after sintering. The residual tensile stress will be formed in surface of silicon nitride ceramic balls in lapping process, and the size of abrasive particle is smaller, such trend is stronger. In this paper the residual stress was measured by the xylometric measurement in which the material in surface was peeled with lapping. The distribution of residual stress in surface can be calculated with the variation in specific volume. The technological parameter with which the material was peeled by lapping was given, for minimizing the extra influence of the residual stress forming in peeling on the original residual stress in surface, the abrasive particle size would not be too small and the load impressed would not be too large. Some experimental researches on residual stress in surface of silicon nitride ceramic balls were made. The surface of silicon nitride ceramic balls presented residual compressive stress after sintering and the influence of the ball size on the residual stress is feeble. It is expected that the size of ball blank is same for achieving the same residual compressive stress in surface on balls after final machining. In lapping process, the surface of silicon nitride ceramic balls presented residual tensile stress, the larger the load which is impressed on single ball, the larger the amplitude of residual tensile stress is; the smaller the abrasive particle, the stronger the trend of plastic deformation is and the larger the amplitude of residual tensile stress is.
文摘The theoretical model of residual stress of ceramics grinding has been established applying thermal elastoplastic mechanics theory. While grinding at the course of grinding wheel moved along workpiece surface the distributing regulation of residual stress can be simplified into thermal elastioplastic mechanical issue, under the action of the both moving centralized force and heat source. Calculating and evaluating of surface residual stress using current procedure of finite element analysis which has been reformed is successful. Comparing with X-ray diffraction experiment method, satisfactory precision has been acquired. The results of experiment show the changing regularity of residual stresses after grinding Al 2O 3 using diamond wheel, on condition that alter grinding parameters. The values of residual compress stress are taken place changing at key certain critical point on their figure as follow: When grinding depth a p is lower than 50 μm, the residual compress stresses are increased with grinding depth increasing, on the contrary as a p>50 μm. At V w<8 m/min, the residual compress stresses increased rapidly with feed speed of workpiece increasing, on the contrary at V w>8 m/min.When V s<25 m/s the residual stress increased with wheel speed increasing and keep stable in value at V s>25 m/s.According to grinding mechanism the cause of residual stress transform has been explained.
基金Supported by the National Natural Science Foundation of China(50572032)
文摘High-density AlN ceramics were fabricated without sintering additives at high pressure(5.0 GPa)and temperature(1300~1800℃).The sintered bodies were characterized by XRD,SEM and micro-Raman spectroscopy(MRS).Controlling fracture mode was intragranular when the sintering temperature was as low as 1400℃under 5.0 GPa.The values of residual stresses due to the distortion of the AlN lattice were assessed using the Micro-Raman Spectroscopy(MRS).The residual compression stress of the AlN ceramics sintered at 5.0 GPaand 1700℃for 125 min is 2.0 GPa.The residual compression stress is increased according to the extension of the sintering time.
基金Projects(2005CB623708, 2010CB731703) supported by the National Basic Research Program of China
文摘Residual stress distributions in 7075 aluminum alloy thick plates with different thicknesses and different quenching speeds were measured. A shape function of stress distribution was proposed based on the internal stress distribution characteristics of aluminum alloy. Using nonlinear regression technology,the function between stress value of key points on internal stress curve and surface stress of the plate was obtained. Based on the measured surface stress,stress value of key points and stress distribution shape,the internal stress distribution can be reconstructed. The experiments show that the model is of good engineering practicality.
基金Project(2021GK1040)supported by the Major Projects of Scientific and Technology Innovation of Hunan Province,ChinaProject(52375398)supported by the National Natural Science Foundation of China。
文摘In this study,the cooling rate was manipulated by quenching with water of different temperatures(30,60 and 100℃).Surface and internal residual stresses in the quenched 6061 aluminum alloy samples were measured using hole-drilling and crack compliance methods,respectively.Then,the processability of the quenched samples was evaluated at cryogenic temperatures.The mechanical properties of the as-aged samples were assessed,and microstructure evolution was analyzed.The surface residual stresses of samples W30℃,W60℃and W100℃is−178.7,−161.7 and−117.2 MPa,respectively along x-direction,respectively;and−191.2,−172.1 and−126.2 MPa,respectively along y-direction.The sample quenched in boiling water displaying the lowest residual stress(~34%and~60%reduction in the surface and core).The generation and distribution of quenching residual stress could be attributed to the lattice distortion gradient.Desirable plasticity was also exhibited in the samples with relatively low quenching cooling rates at cryogenic temperatures.The strengthes of the as-aged samples are 291.2 to 270.1 MPa as the quenching water temperature increase from 30℃to 100℃.Fine and homogeneous β"phases were observed in the as-aged sample quenched with boiling water due to the clusters and Guinier-Preston zones(GP zones)premature precipitated during quenching process.
文摘By means of XRD, Instron electronic tensile machine and TEM, the dislocation states and strengthening mechanisms of SiC whisker reinforced pure aluminum matrix composites were studied with different annealing treatment processes and matrixes. The results showed that the strengthening mechanisms of SiC w/p Al composite and SiC w/6061Al composites are different. For the SiC w/p Al composite, the thermal residual stress plays more important role in strengthening than the high density dislocations in matrix; for the SiC w/6061Al composite, the dislocation strengthening and precipitation are main strengthening factors.
基金Project(2007DFR70070) supported by China-Russia Government-to-Government Scientific and Technical Cooperation Foundation
文摘The effect of strain hardening and strain softening behavior of flow stress changing with temperature on welding residual stress, plastic strain and welding distortion of ATN0 1-T4 aluminum alloy was studied by finite simulation method. The simulation results show that the weld seam undergoes strain hardening in the temperature range of 180-250 ℃, however, it exhibits strain softening at temperature above 250 ℃ during welding heating and cooling process. As a result, the strain hardening and strain softening effects counteract each other, introducing slightly influence on the welding residual stress, residual plastic strain and distortion. The welding longitudinal residual stress was determined by ultrasonic stress measurement method for the flat plates of A7N01-T4 aluminum alloy. The simulation results are well accordant with test ones.
基金Project(51775480)supported by the National Natural Science Foundation of ChinaProjects(E2018203143,E2022203050)supported by the Natural Science Foundation of Hebei Province,China。
文摘In this work,the effect of ultrasonic vibration modes on the mechanical properties and relaxation of residual stress in 6061-T6 aluminum alloy was studied.A new ultrasonic vibration Johnson-Cook model was proposed,and the relaxation and distribution of residual stress under ultrasonic vibration were predicted and analyzed using the finite element method(FEM).The mechanical properties of 6061-T6 aluminum alloy under different ultrasonic vibration modes were analyzed through experiments involving notched specimen tensile testing and scanning electron microscopy(SEM)analysis.The findings indicate that ultrasonic vibration treatment during deformation,unloading,and load-holding,as well as treatment with its natural ultrasonic frequency,can effectively release residual stress;however,treatment with its natural frequency has the highest rate of release up to 65.4%.Ultrasonic vibration treatment during deformation better inhibits fracture under the same conditions.The FEM results are in good agreement with the experimental results,and it can be used as a valid tool for predicting residual stress release under ultrasonic vibration.
基金National Natural Science Foundation of China(52272075,52472053)Research Fund of Youth Innovation Promotion Association of CAS,China(2021190)Defense Industrial Technology Development Program(JCKY2021130B007)。
文摘Carbon fiber-reinforced carbon aerogel(C/CA)composites are one of the most promising candidates for applications requiring both thermal insulation and load bearing capabilities.The preparation of anti-oxidation coatings on C/CA to address its susceptibility to oxidation is a feasible approach to promote its application in oxidative environments.However,the currently reported coatings on C/CA mainly focus on improving the ablation performance and coating preparation process typically necessitating high-temperature heat treatment.This procedure can increase its thermal conductivity and reduce its thermal insulation ability.In this study,a series of ceramic-resin coatings were fabricated on C/CA through a simple slurry brushing-drying approach at room temperature.The effects of phenolic resin content on the coating structure,residual stress,thermal shock,and oxidation behaviors were investigated.Due to the adhesive properties and curing-induced shrinkage,the PR-7.5 coating(containing 7.5%(in mass)phenolic resin in the slurry)exhibits bonding strength close to fracture strength of the substrate and residual compressive stress of 0.853 GPa,which is beneficial for resisting thermal shock cracking.However,excessive resin content(PR-10.0 containing 10.0%(in mass)phenolic resin in the slurry)induces tensile stress due to uneven curing shrinkage,thereby leading to thermal shock cracking.Meanwhile,oxidation tests reveal significantly reduced weight losses for PR-7.5(17.46%at 800℃/100 min,8.15%at 1000℃/120 min,3.15%at 1200℃/120 min)versus uncoated C/CA’s 44.60%loss at 800℃/20 min.This work provides a brand-new and simple approach to improving the anti-oxidation performance of C/CA and expands its application in mild oxidative environments.
基金Project(50304007) supported by the National Natural Science Foundation of China
文摘Based on the basic operating principal and the technology characteristic of electron beam physical vapor deposition(EBPVD) technique, EBPVD was used to prepare the micro-layer composites. The effect on the substrate preheating temperature was taken into accounts and the finite element analysis package ANSYS was used to simulate the internal stress field and the potential displacement changing tendency. The results show that one of the most important quality factors on the judgment of micro-layer composites is the adhesion between the substrate and the deposition layers as well as among the different deposition layers. Besides the existance of temperature gradient through the thickness of layers, the main reason for the internal stress in micro-layer composites is the mismatch of various properties of the layer and the substrate of different thermal expansions and crystal lattice types. With the increase of substrate preheating temperature, the inter-laminar shear stress also takes on a tendency of increase but the axial residual stress decrease.
文摘Tungsten inert gas(TIG) welding is the most commonly used joining process for aluminum alloy for AA6061 and AA7075 which are highly demanded in the aerospace engineering and the automobile sector, but there are some defects occur during TIG welding like micro-crack, coarse grain structure, and porosity. To improve these defects, the TIG welded joint is processed using friction stir processing(FSP).This paper presents the effect of friction stir processing on TIG welding with filler ER4043 and ER 5356 for dissimilar aluminum alloy AA6061 and AA7075. The mechanical characterization, finite element formulation and mathematical equations of heat transfer of TIG + FSP welded joints are investigated using ANSYS Fluent software by adjusting process parameters of FSP. The results show that the maximum compressive residual stress 73 MPa was obtained at the fusion zone(FZ) of the TIG weldment with filler ER4043, whereas minimum compressive residual stress 37 MPa was obtained at stir zone(SZ) of the TIG+ FSP with filler 5356. The maximum heat flux 5.33 × 106 W/m2 and temperature 515C have observed at tool rotation 1600 rpm with a feed rate of 63 mm/min. These results give a satisfactory measure of confidence in the fidelity of the simulation。
基金the DAAD Faculty Development for Ph.D.Candidates(Balochistan)2016(57245990)-HRDI-UESTP’s/UET’s funding scheme in cooperation with the Higher Education Commission of Pakistan(HEC)for sponsoring the stay at IMF TU Freiberg,Germany.
文摘In this research,a detailed multi-physics study has been carried out by numerically simulating a solid fractured gun barrel for 20 thermo-mechanical cycles.The numerical model is based on thermal effects,mechanical stress fields and fatigue crack mechanics.Elastic-plastic material data of modified AISI 4340 at temperatures ranging from 25 to 1200℃and at strain rates of 4,16,32 and 48 s^(-1) was acquired from high-temperature compression tests.This was used as material property data in the simulation model.The boundary conditions applied are kept similar to the working gun barrel during continuous firing.A methodology has been provided to define thermo-mechanically active surface-to-surface type interface between the crack faces for a better approximation of stresses at the crack tip.Comparison of results from non-autofrettaged and autofrettaged simulation models provide useful information about the evolution of strains and stresses in the barrel at different points under combined thermo-mechanical loading cycles in both cases.The effect of thermal fatigue under already induced compressive yield due to autofrettage and the progressive degradation of the accumulated stresses due to thermo-mechanical cyclic loads on the internal surface of the gun barrel(mimicking the continuous firing scenario)has been analyzed.Comparison between energy release rate at tips of varying crack lengths due to cyclic thermo-mechanical loading in the non-autofrettaged and autofrettaged gun has been carried out.
基金Project(52075552) supported by the National Natural Science Foundation of ChinaProject(kq2007085) supported by Changsha Municipal Natural Science Foundation,China。
文摘In order to prolong the service life of aircraft skin made from AA2524, the effects of laser shock peening(LSP) on fatigue crack growth(FCG) rate and fracture toughness(K_(c)) of AA2524 were investigated. Multiple LSP treatment was performed on compact tension(CT) specimen from single side and double sides. The surface integrity was measured with Vickers hardness tester, X-ray diffractometer and confocal laser scanning microscope, respectively. FCG rate test and fracture toughness test under plane stress were carried out after LSP treatment. The microstructure features of cross-sections were observed with scanning electron microscope. The results showed that the micro-hardness and residual stress of CT specimens were increased dramatically after LSP treatment. Compared to the base metal(BM), the fatigue life was prolonged by 2.4 times and fracture toughness was increased by 22% after multiple LSP.
文摘This paper concentrates on simulating fracture in thin walled single-lap joints connected by resistance spot-welding(RSW)process which were subjected to tensile loading.For this purpose,three sets of lap-joints with different spot configurations were tested to achieve the joints’tensile behavior.To simulate the joints tensile behavior,firstly a 2D axisymmetric finite element(FE)model was used to calculate residual stresses induced during the welding process.Then the results were transferred to 3D models as pre-stress.In this step,cohesive zone model(CZM)technique was used to simulate fracture in the models under tensile load.Cohesive zone parameters were extracted using coach-peel and shear lap specimens.The results were employed to simulate deformation and failure in single lap spot weld samples.It has been shown that considering the residual stresses in simulating deformation and fracture load enables quite accurate predictions.
