CN112285140A - Quantitative characterization method for early-stage propagation rate of internal crack of single crystal ultrahigh cycle fatigue - Google Patents

Quantitative characterization method for early-stage propagation rate of internal crack of single crystal ultrahigh cycle fatigue Download PDF

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CN112285140A
CN112285140A CN202011128197.9A CN202011128197A CN112285140A CN 112285140 A CN112285140 A CN 112285140A CN 202011128197 A CN202011128197 A CN 202011128197A CN 112285140 A CN112285140 A CN 112285140A
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赵子华
张福禄
李茜
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Beihang University
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Abstract

The invention discloses a method for quantitatively characterizing the early-stage propagation rate of a single-crystal ultra-high cycle fatigue internal crack, which realizes 'fracture nicking' based on an ultrasonic fatigue test of a specific load spectrum and establishes a set of models for quantitatively characterizing the propagation rate of the internal fatigue crack based on fracture back-stepping; the model can quickly calculate the relation between the fatigue crack propagation rate and the stress intensity factor amplitude according to the fatigue fracture and the test conditions without paying attention to the test process, and further analyze the change of the propagation rate in the fatigue crack propagation process.

Description

Quantitative characterization method for early-stage propagation rate of internal crack of single crystal ultrahigh cycle fatigue
Technical Field
The invention belongs to the field of fatigue crack testing, and relates to a quantitative characterization method for the early-stage propagation rate of a single-crystal ultrahigh-cycle fatigue internal crack.
Background
The nickel-based single crystal superalloy has the advantages of high-temperature strength, strong oxidation resistance, excellent fatigue resistance and the like, and is a selected material of the turbine blade of the advanced aircraft engine at the present stage. Ultra-high cycle fatigue failure is a significant problem faced by turbine blades in the mid-to-late stages of service. The ultra-high cycle fatigue cracks of the single crystal superalloy mainly grow from internal defects such as casting pores, loose tissues, carbides, eutectic tissues and the like, and most of the cracks grow along the same plane. Research shows that the initiation stage and the early propagation stage of the ultra-high cycle fatigue crack consume most of the fatigue life, and the quantitative characterization of the propagation rate of the early crack is helpful for reversely deducing the propagation life and the initiation life of the crack. Because the ultra-high cycle fatigue crack of the single crystal superalloy is initiated inside, the conventional surface observation method, potential drop method and flexibility method cannot be applied to measure the crack propagation rate. In addition, the first-stage extension process of the single crystal has no typical characteristics such as fatigue stripes, and a fracture quantitative reverse-estimation method based on the fatigue stripes cannot be used.
Disclosure of Invention
In order to solve the technical problems, the invention provides a quantitative characterization method for the early-stage propagation rate of a single-crystal ultrahigh-cycle fatigue internal crack, which is characterized in that a specific load spectrum is set to realize fracture nicking, the distance from a fatigue arc line to a fatigue source region is measured, the propagation rate of the crack is reversely deduced through the fatigue arc line, the stress intensity factor amplitudes at different arc lines are calculated, the relation between the propagation rate of the crack and the stress intensity factor amplitudes is established, and further the propagation life and the initiation life of the crack are reversely deduced.
In order to achieve the purpose, the invention adopts the following technical scheme.
A quantitative characterization method for the early propagation rate of internal cracks of single crystal ultrahigh cycle fatigue comprises the following steps:
(1) designing and processing an ultrasonic fatigue test piece, and formulating a specific load spectrum: sigma1/τ1+σ2/τ2，σ1And σ2High and low amplitude loads, τ, respectively1And τ2Respectively carrying out fatigue test on the test piece by using an ultrasonic fatigue testing machine for the acting time of the high-amplitude load and the low-amplitude load, and recording the fatigue life of the test piece after the test is finished to obtain a fatigue fracture;
(2) firstly, taking a picture of the macroscopic morphology of the fracture by using a scanning electron microscope, and then taking a picture of the area where the fatigue arc exists;
(3) by means of scanning electron microscopeThe measuring tool measures the distance from each fatigue arc to the source region, namely the length of the fatigue crack, and is marked as ai(ii) a The distance between adjacent fatigue arcs is measured and recorded as delta ai(ii) a Using the above measurement data, the crack growth rate da is calculated by equation (1)i/dN：
Figure BDA0002732272460000021
Calculating the stress intensity factor amplitude delta K at the fatigue arc line by using the formula (2)i：
Figure BDA0002732272460000022
In formula (2), F denotes the form factor, σaCyclic loading stress;
(4) establishing da by using the data calculated in the step (3)idN and Δ KiThe relationship of (1): ordinate is daidN, abscissa Δ Ki。
Further, the low-amplitude load is selected according to the principle that the stress intensity factor amplitude delta K corresponding to the loadiLess than fatigue crack propagation threshold Δ Kth。
Further, the test frequency of the fatigue test is 20 kHz.
Compared with the prior art, the invention has the advantages that: the method introduces fatigue arc lines, but does not influence the crack propagation behavior and the propagation rate, does not need to pay attention to the test process, and does not increase the complexity of the ultrasonic fatigue test device.
Drawings
FIG. 1(a) shows fatigue fracture of DD6 single crystal, and FIG. 1(b) shows fatigue arc line near fatigue source region.
FIG. 2 is a relationship between the crack growth rate da/dN of the DD6 single crystal and the stress intensity factor Δ K.
Detailed Description
The idea, specific structure and technical effects of the present invention will be described clearly and completely with reference to the following embodiments, so as to fully understand the objects, features and effects of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all embodiments, and those skilled in the art can obtain other embodiments without inventive effort based on the embodiments of the present invention, and all embodiments are within the protection scope of the present invention.
A quantitative characterization method for the early propagation rate of internal cracks of single crystal ultrahigh cycle fatigue comprises the following steps:
(1) designing and processing an ultrasonic fatigue test piece, and formulating a specific load spectrum: sigma1/τ1+σ2/τ2，σ1And σ2Respectively high-amplitude load and low-amplitude load, and the selection principle of the low-amplitude load is that the stress intensity factor amplitude delta K corresponding to the loadiLess than fatigue crack propagation threshold Δ KthThe fatigue crack overcomes the overload delay effect caused by high load under low-amplitude load, and generates a fatigue arc line; tau is1And τ2The time of action of the high-amplitude load and the low-amplitude load is respectively; carrying out fatigue test on the test piece by using an ultrasonic fatigue testing machine, and recording the fatigue life of the test piece after the test is finished to obtain a fatigue fracture;
(2) firstly, taking a picture of the macroscopic morphology of the fracture by using a scanning electron microscope, and then taking a picture of the area where the fatigue arc exists;
(3) the fatigue crack forms a fatigue arc line under the action of low-amplitude load and expands forwards under the action of high-amplitude load, the distance between adjacent arc lines is the distance of crack expansion under the action of one high-amplitude load, and the ratio of the distance between adjacent arc lines to the cycle frequency of one high-amplitude load is the crack expansion rate. Measuring the distance from each fatigue arc line to the source region, namely the length of the fatigue crack by using a measuring tool of a scanning electron microscope, and recording as ai(ii) a The distance between adjacent fatigue arcs is measured and recorded as delta ai(ii) a Using the above measurement data, the crack growth rate da is calculated by equation (1)i/dN：
Figure BDA0002732272460000031
Calculating the stress intensity factor amplitude delta K at the fatigue arc line by using the formula (2)i：
Figure BDA0002732272460000032
In formula (2), F denotes the form factor, σaCyclic loading stress;
(4) establishing da by using the data calculated in the step (3)idN and Δ KiThe relationship of (1): ordinate is daidN, abscissa Δ Ki。
Example 1
Taking DD6 single crystal as an example, the method for quantitatively characterizing the early propagation rate of the internal crack of the single crystal based on fracture nicking ultrahigh cycle fatigue comprises the following specific steps:
(1) designing and processing a DD6 single crystal ultrasonic fatigue test piece, marking as a test piece 1, and carrying out an ultra-high cycle fatigue test on the test piece 1 by using an ultrasonic fatigue testing machine, wherein the test temperature is 1000 ℃, the test frequency is 20kHz, and the load spectrum is as follows: 200MPa/120ms +20MPa/360ms, and obtaining fatigue life data and a fatigue fracture of the test piece 1 after the test is finished;
(2) observing the fatigue fracture obtained in the step (1) by using a scanning electron microscope, wherein fig. 1(a) shows the overall morphology of the fatigue fracture (a white square box shows a fatigue source region), fatigue cracks are initiated from an internal casting porosity, and a fatigue arc line exists near the fatigue source region, as shown by a white arrow in fig. 1 (b).
(3) Measuring the distance a between each fatigue arc and the source regioniAnd the distance Deltaa between adjacent fatigue arcsiThe measurement results are shown in table 1. The crack propagation rates da at different arc positions are determined by the formula (1)idN, calculating the stress intensity factor amplitude delta K at each arc position by using the formula (2)iThe calculation results are shown in table 1.
TABLE 1 measurement of fatigue arc distance from Source area
Figure BDA0002732272460000041
(4) The results obtained by calculation in step (3) were plotted, and the relationship between da/dN and Δ K was shown in FIG. 2. As can be seen from FIG. 2, da/dN and Δ K have a log-log linear relationship, satisfying the Paris formula da/dN ═ c (Δ K)n。
This gives dN ═ da/c (Δ K)nAnd integrating the two sides to obtain a calculation formula of the early crack propagation life N, wherein the lower limit of the integration is the distance from the first fatigue arc line to the source region, and the upper limit of the integration is the distance from the last fatigue arc line to the source region. The initiation life and the early propagation life of the ultra-high cycle fatigue crack occupy most of the total fatigue life (more than 90%), the late crack propagation life can be ignored, and the crack initiation life can be obtained by subtracting the early crack propagation life from the total fatigue life.
While the preferred embodiments of the present invention have been described in detail, the present invention is also suitable for the characterization of the rate of early propagation cracks in other large planes, such as nickel-based columnar superalloys, for other materials, where the load range and temperature range need to be redefined, and such equivalent applications are intended to be encompassed by the scope of the present claims.

Claims (3)

1. A quantitative characterization method for the early propagation rate of internal cracks of single crystal ultrahigh cycle fatigue is characterized by comprising the following steps:
(1) designing and processing an ultrasonic fatigue test piece, and formulating a specific load spectrum: sigma1/τ1+σ2/τ2，σ1And σ2High and low amplitude loads, τ, respectively1And τ2Respectively carrying out fatigue test on the test piece by using an ultrasonic fatigue testing machine for the acting time of the high-amplitude load and the low-amplitude load, and recording the fatigue life of the test piece after the test is finished to obtain a fatigue fracture;
(2) firstly, taking a picture of the macroscopic morphology of the fracture by using a scanning electron microscope, and then taking a picture of the area where the fatigue arc exists;
(3) measuring the distance from each fatigue arc line to the source region, namely the length of the fatigue crack by using a measuring tool of a scanning electron microscope, and recording as ai(ii) a The distance between adjacent fatigue arcs is measured and recorded as delta ai(ii) a Using the above measurement data, the crack growth rate da is calculated by equation (1)i/dN：
Figure FDA0002732272450000011
Calculating the stress intensity factor amplitude delta K at the fatigue arc line by using the formula (2)i：
Figure FDA0002732272450000012
In formula (2), F denotes the form factor, σaCyclic loading stress;
(4) establishing da by using the data calculated in the step (3)idN and Δ KiThe relationship of (1): ordinate is daidN, abscissa Δ Ki。
2. The method for quantitatively characterizing the early propagation rate of the internal crack of the single crystal ultra-high cycle fatigue as claimed in claim 1, wherein the low-amplitude load is selected based on the stress intensity factor amplitude Δ K corresponding to the loadiLess than fatigue crack propagation threshold Δ Kth。
3. The method for quantitatively characterizing the early propagation rate of internal cracks of single crystal ultrahigh cycle fatigue as claimed in claim 1, wherein the test frequency of the fatigue test is 20 kHz.
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