Fretting fatigue properties and life prediction of additively manufactured GH4169 superalloys
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摘要:
为了探究增材制造高温合金微动疲劳性能，设计了微动疲劳实验件，开展了不同工况下的增材制造高温合金宏观微动疲劳实验，获得了不同打印方向和载荷下试件的微动疲劳寿命。在不同打印方向下，增材制造高温合金试件微动疲劳寿命都随着峰值载荷的增大而减小，沿打印方向的微动疲劳寿命高于垂直打印方向。为了建立不同打印方向下增材制造高温合金微动疲劳寿命模型，对不同工况下的微动疲劳实验进行了有限元模拟，获得了应力、应变分布。发现最大Mises应力及最大应变均出现在微动疲劳接触区域，与裂纹萌生位置相吻合。进一步使用临界平面法建立了微动疲劳寿命预测模型，结果表明不同打印方向试件的SWT（Smith-Watson-Topper）和 FS（Fatemi-Socie）参量的预测寿命均在2倍误差带内。
Abstract:To investigate the fretting fatigue performance of additively manufactured superalloys, fretting fatigue test specimens were designed, macro fretting fatigue tests on additively manufactured superalloys under various conditions were conducted, and the fretting fatigue life of specimens under different printing directions and loads was obtained. The fretting fatigue life of additively manufactured superalloy specimens decreased with the increase of peak load in different printing directions, and the fretting fatigue life along the printing direction was higher than that perpendicular to the printing direction. To establish a fretting fatigue life model for additively manufactured superalloys in different printing directions, finite element simulations of fretting fatigue tests under different conditions were performed, and the stress and strain distributions were obtained. It was found that the maximum Mises stress and maximum strain both occurred in the fretting fatigue contact area, which coincided with the crack initiation position. Furthermore, a fretting fatigue life prediction model was established using the critical plane method. The results showed that the predicted life of SWT （Smith-Watson-Topper） and FS （Fatemi-Socie） parameters for specimens in different printing directions was within 2 fatigue scatter band.
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Key words:
- fretting fatigue /
- additive manufacturing /
- superalloys /
- fractography /
- life prediction
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图 1 宏观微动疲劳实验夹具及试件装配图
Figure 1. Macroscopic fretting fatigue test fixture and specimen assembly image
图 3 600 ℃下BD、VD向试件宏观微动疲劳寿命与峰值载荷变化趋势
Figure 3. Variation trend of macroscopic fretting fatigue life and peak load of BD and VD specimens at 600 ℃
图 6 BD方向试件（BD-7-1）断口扫描电镜图像
Figure 6. SEM fracture observation of BD direction（specimen BD-7-1）
图 7 VD方向试件（VD-7-1）断口扫描电镜图
Figure 7. SEM fracture observation of VD direction （specimen VD-7-1）
图 8 宏观微动疲劳试样EBSD表征选区及标记
Figure 8. EBSD characterization selection and label of macroscopic fretting fatigue specimen
图 14 最大Mises应力随接触区网格尺寸变化图
Figure 14. Maximum Mises stress variation with contact area mesh size
图 15 BD与VD向试件拉伸应力应变曲线
Figure 15. Tensile stress-strain curves of specimens in BD and VD
图 16 不同载荷下BD向试件的模拟结果
Figure 16. Simulation results of the BD condition under different loads
图 17 不同载荷下VD向试件的模拟结果
Figure 17. Simulation results of the VD condition under different loads
图 18 基于临界平面参量的不同打印方向试件微动疲劳寿命预测结果
Figure 18. Prediction results of fretting fatigue life for specimens in different printing directions based on critical plane parameters
表 1 600 ℃宏观微动疲劳实验工况及寿命结果
Table 1. Test condition and life of macroscopic fretting fatigue at 600 ℃
峰值载荷/kN 试件编号 实验寿命/循环数 平均寿命/循环数 7 BD-7-1 233 813+ 243 719 BD-7-2 253 625+ VD-7-1 213 398+ 236 951 VD-7-2 260 504+ 9 BD-9-1 34 388 37 344 BD-9-2 40 300 VD-9-1 38 149 30 525 VD-9-2 22 901 11 BD-11-1 23 530 21 765 BD-11-2 20 000 VD-11-1 17 905 17 196 VD-11-2 16 486 
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