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Article(id=1243879677186654854, tenantId=1146029695717560320, journalId=1240685776644648972, issueId=1243879674670072443, articleNumber=null, orderNo=null, doi=10.3969/j.issn.1007-7294.2024.07.013, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=null, receivedDate=1705420800000, receivedDateStr=2024-01-17, revisedDate=null, revisedDateStr=null, acceptedDate=null, acceptedDateStr=null, onlineDate=1774493625207, onlineDateStr=2026-03-26, pubDate=1721404800000, pubDateStr=2024-07-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1774493625207, onlineIssueDateStr=2026-03-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1774493625207, creator=13701087609, updateTime=1774493625207, updator=13701087609, issue=Issue{id=1243879674670072443, tenantId=1146029695717560320, journalId=1240685776644648972, year='2024', volume='28', issue='7', pageStart='967', pageEnd='1132', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1774493624607, creator=13701087609, updateTime=1774493869111, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1243880700257087675, tenantId=1146029695717560320, journalId=1240685776644648972, issueId=1243879674670072443, language=EN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1243880700257087676, tenantId=1146029695717560320, journalId=1240685776644648972, issueId=1243879674670072443, language=CN, specialIssueTitle=, coverIllustrator=null, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=1100, endPage=1110, ext={EN=ArticleExt(id=1243879677480256138, articleId=1243879677186654854, tenantId=1146029695717560320, journalId=1240685776644648972, language=EN, title=Fatigue performance tests of Mn25Al7 steel welded joints, columnId=1242129251223274417, journalTitle=Journal of Ship Mechanics, columnName=Structural Mechanics, runingTitle=null, highlight=null, articleAbstract=

Mn25Al7 steel is a new type of lightweight and high-strength marine steel, and the fatigue properties of Mn25Al7 steel have not been studied in relevant experiments. In this paper, the fatigue tests of typical nodes such as base metal, butt welded joint and T-welded joint of Mn25Al7 steel were carried out, and the fatigue grade curve of the typical nodes was obtained based on the nominal stress method and the hot stress method, respectively, and compared with the fatigue grade curve of the existing standard. The fracture morphology of the three samples was observed, and the crack propagation law and fracture mechanism were analyzed. The test results show that the fatigue life of Mn25Al7 steel base metal is higher than that of ordinary steel designed by the specification. The specification underestimates the fatigue life of butt weld joints of base metal and smoothed toes, but can accurately evaluate the fatigue life of T-weld joints. By comparing and analyzing the difference in damage rate of the three specimens, the fracture morphology was further systematically analyzed. It is found that the initial crack source and welding residue will reduce the fatigue strength. This study can provide a theoretical basis and experimental support for the prediction of fatigue life of marine high-strength steel.

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Mn25Al7钢是一种新型的轻质高强船用钢，目前针对Mn25Al7钢的疲劳性能尚未开展相关试验研究。本文对Mn25Al7钢的母材、对接焊接接头及T型焊接接头等典型节点进行疲劳试验研究，分别基于名义应力方法和热点应力方法拟合得到典型节点疲劳等级曲线，并与现有规范的疲劳等级曲线进行对比分析。对三种试样的断口形貌进行观测，分析其裂纹扩展规律和断裂机理。试验结果表明：Mn25Al7钢母材疲劳寿命高于按规范设计的普通钢材；规范低估了母材和磨平焊趾的对接焊缝接头疲劳寿命，但能较好地评估T型焊缝接头的疲劳寿命。通过对比分析三种试件的损伤速率差别，进一步对断口形貌进行了系统分析，发现初始裂纹源和焊接残留物会造成疲劳强度的降低。本研究可为船用高强钢的疲劳寿命预测提供理论依据和试验支撑。

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通讯作者，E-mail：
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张宇（1997-），男，硕士研究生

李晓彬（1971-），男，博士，教授，通讯作者，E-mail：。

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张宇（1997-），男，硕士研究生

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张宇（1997-），男，硕士研究生

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李晓彬（1971-），男，博士，教授，通讯作者，E-mail：。

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李晓彬（1971-），男，博士，教授，通讯作者，E-mail：。

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language=EN, label=Tab.1, caption=

Mechanical properties of welding deposited metal

, figureFileSmall=null, figureFileBig=null, tableContent=
焊条类型抗拉强度Rm/MPa屈服强度Rel/MPa断后伸长率A-30 ℃冲击功AK/J
ER80S-G≥600≥48025%62
), ArticleFig(id=1243879689094283453, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表1, caption=

焊条熔覆金属力学性能

, figureFileSmall=null, figureFileBig=null, tableContent=
焊条类型抗拉强度Rm/MPa屈服强度Rel/MPa断后伸长率A-30 ℃冲击功AK/J
ER80S-G≥600≥48025%62
), ArticleFig(id=1243879689178169536, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.2, caption=

Welding parameters

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接方式直径/mm电流/A电压/V焊接速度/（cm·min-1）
手工弧电焊4.0140~18022~2615~25
), ArticleFig(id=1243879689287221448, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表2, caption=

焊接参数

, figureFileSmall=null, figureFileBig=null, tableContent=
焊接方式直径/mm电流/A电压/V焊接速度/（cm·min-1）
手工弧电焊4.0140~18022~2615~25
), ArticleFig(id=1243879689375301836, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.3, caption=

Chemical compositions of Mn25Al7 steel and electrode

, figureFileSmall=null, figureFileBig=null, tableContent=
材料类型CMnPSAlCuMoTi
ER80S-G0.071.750.0130.012/0.210.180.15
Mn25Al70.80~0.9523~27<0.015<0.0156.0~7.5///
), ArticleFig(id=1243879689471770835, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表3, caption=

Mn25Al7钢和焊条的化学成分

, figureFileSmall=null, figureFileBig=null, tableContent=
材料类型CMnPSAlCuMoTi
ER80S-G0.071.750.0130.012/0.210.180.15
Mn25Al70.80~0.9523~27<0.015<0.0156.0~7.5///
), ArticleFig(id=1243879689580822744, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.4, caption=

Test results of tensile strength

, figureFileSmall=null, figureFileBig=null, tableContent=
材料类型屈服强度Rel/MPa抗拉强度Rm/MPa弹性模量E/GPa泊松比
MTS-1514.30835.07149.600.26
MTS-2499.30830.82149.300.28
MTS-3508.17845.09149.100.24
MTS-4515.80833.11146.200.26
MTS-5511.85849.12143.000.23
MTS-6512.83846.90145.500.21
MTS-7498.44826.00143.500.25
Mn25Al7508.67838.015146.60.25
), ArticleFig(id=1243879689668903132, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表4, caption=

拉伸强度试验结果

, figureFileSmall=null, figureFileBig=null, tableContent=
材料类型屈服强度Rel/MPa抗拉强度Rm/MPa弹性模量E/GPa泊松比
MTS-1514.30835.07149.600.26
MTS-2499.30830.82149.300.28
MTS-3508.17845.09149.100.24
MTS-4515.80833.11146.200.26
MTS-5511.85849.12143.000.23
MTS-6512.83846.90145.500.21
MTS-7498.44826.00143.500.25
Mn25Al7508.67838.015146.60.25
), ArticleFig(id=1243879689786343650, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.5, caption=

Values of m、C and σ

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试件类型母材对接T型
m-10.4319-8.2617-2.812
C32.49126.88311.642
C97.7%32.21826.372411.353
C2.3%32.76427.392611.931
σ0.13650.250550.1445
), ArticleFig(id=1243879689878618346, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表5, caption=

m、C和σ值

, figureFileSmall=null, figureFileBig=null, tableContent=
试件类型母材对接T型
m-10.4319-8.2617-2.812
C32.49126.88311.642
C97.7%32.21826.372411.353
C2.3%32.76427.392611.931
σ0.13650.250550.1445
), ArticleFig(id=1243879689975087343, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.6, caption=

S-N power function expressions

, figureFileSmall=null, figureFileBig=null, tableContent=
试件类型母材对接焊缝接头T型焊缝接头
50%存活率∆S=1301.911N-0.09586∆S=1794.448N-0.12104∆S=13 472.408N-0.35562
97.7%存活率∆S=1225.777N-0.09586∆S=1560.549N-0.12104∆S=10 897.829N-0.35562
GB 50017∆S=5416.89N-0.25∆S=5416.89N-0.25∆S=11 344.472N-0.333
AISC 360∆S=15 804.923N-0.333∆S=11 292.432N-0.333∆S=6749.487N-0.333
BS 7608∆S=5641.245N-0.25∆S=11 496.527N-0.333∆S=8579.593N-0.333
), ArticleFig(id=1243879690075750643, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表6, caption=

S-N幂函数表达式

, figureFileSmall=null, figureFileBig=null, tableContent=
试件类型母材对接焊缝接头T型焊缝接头
50%存活率∆S=1301.911N-0.09586∆S=1794.448N-0.12104∆S=13 472.408N-0.35562
97.7%存活率∆S=1225.777N-0.09586∆S=1560.549N-0.12104∆S=10 897.829N-0.35562
GB 50017∆S=5416.89N-0.25∆S=5416.89N-0.25∆S=11 344.472N-0.333
AISC 360∆S=15 804.923N-0.333∆S=11 292.432N-0.333∆S=6749.487N-0.333
BS 7608∆S=5641.245N-0.25∆S=11 496.527N-0.333∆S=8579.593N-0.333
), ArticleFig(id=1243879690172219640, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.7, caption=

Fatigue ultimate strength values (MPa)

, figureFileSmall=null, figureFileBig=null, tableContent=
试件类型50%存活率97.7%存活率GB 50017AISC 360BS 7608
母材277.69261.4596.3373.76111.40
对接焊缝接头255.05221.8296.3352.7062.67
T型焊缝接头43.6635.3252.6631.5047.09
), ArticleFig(id=1243879690256105724, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表7, caption=

疲劳强度极限值（MPa）

, figureFileSmall=null, figureFileBig=null, tableContent=
试件类型50%存活率97.7%存活率GB 50017AISC 360BS 7608
母材277.69261.4596.3373.76111.40
对接焊缝接头255.05221.8296.3352.7062.67
T型焊缝接头43.6635.3252.6631.5047.09
), ArticleFig(id=1243879690339991809, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=EN, label=Tab.8, caption=

Values of β

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母材对接焊缝接头T型焊缝接头
β9.43197.26171.812
), ArticleFig(id=1243879690428072197, tenantId=1146029695717560320, journalId=1240685776644648972, articleId=1243879677186654854, language=CN, label=表8, caption=

β值

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母材对接焊缝接头T型焊缝接头
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Mn25Al7钢焊接接头的疲劳性能试验研究
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张宇 1 , 李俊 1 , 周俊 2 , 陈威 1 , 谌伟 1 , 李晓彬 1
船舶力学 | 结构力学 2024,28(7): 1100-1110
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船舶力学 | 结构力学 2024, 28(7): 1100-1110
Mn25Al7钢焊接接头的疲劳性能试验研究
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张宇1, 李俊1, 周俊2, 陈威1, 谌伟1, 李晓彬1
作者信息
  • 1.武汉理工大学　船海与能源动力工程学院，武汉　430063
  • 2.中国舰船研究设计中心，武汉　430064

    • 张宇（1997-），男，硕士研究生

    李晓彬（1971-），男，博士，教授，通讯作者，E-mail：。

通讯作者:

通讯作者，E-mail：
Fatigue performance tests of Mn25Al7 steel welded joints
Yu ZHANG1, Jun LI1, Jun ZHOU2, Wei CHEN1, Wei SHEN1, Xiao-bin LI1
Affiliations
  • 1.School of Naval Architecture, Ocean and Energy Power Engineering, Wuhan University of Technology, Wuhan 430063, China
  • 2.China Ship Research and Design Center, Wuhan 430064, China
出版时间: 2024-07-20 doi: 10.3969/j.issn.1007-7294.2024.07.013
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摘要
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Mn25Al7钢是一种新型的轻质高强船用钢，目前针对Mn25Al7钢的疲劳性能尚未开展相关试验研究。本文对Mn25Al7钢的母材、对接焊接接头及T型焊接接头等典型节点进行疲劳试验研究，分别基于名义应力方法和热点应力方法拟合得到典型节点疲劳等级曲线，并与现有规范的疲劳等级曲线进行对比分析。对三种试样的断口形貌进行观测，分析其裂纹扩展规律和断裂机理。试验结果表明：Mn25Al7钢母材疲劳寿命高于按规范设计的普通钢材；规范低估了母材和磨平焊趾的对接焊缝接头疲劳寿命，但能较好地评估T型焊缝接头的疲劳寿命。通过对比分析三种试件的损伤速率差别，进一步对断口形貌进行了系统分析，发现初始裂纹源和焊接残留物会造成疲劳强度的降低。本研究可为船用高强钢的疲劳寿命预测提供理论依据和试验支撑。

高强钢  /  疲劳评估  /  焊接接头  /  断口分析  /  疲劳试验

Mn25Al7 steel is a new type of lightweight and high-strength marine steel, and the fatigue properties of Mn25Al7 steel have not been studied in relevant experiments. In this paper, the fatigue tests of typical nodes such as base metal, butt welded joint and T-welded joint of Mn25Al7 steel were carried out, and the fatigue grade curve of the typical nodes was obtained based on the nominal stress method and the hot stress method, respectively, and compared with the fatigue grade curve of the existing standard. The fracture morphology of the three samples was observed, and the crack propagation law and fracture mechanism were analyzed. The test results show that the fatigue life of Mn25Al7 steel base metal is higher than that of ordinary steel designed by the specification. The specification underestimates the fatigue life of butt weld joints of base metal and smoothed toes, but can accurately evaluate the fatigue life of T-weld joints. By comparing and analyzing the difference in damage rate of the three specimens, the fracture morphology was further systematically analyzed. It is found that the initial crack source and welding residue will reduce the fatigue strength. This study can provide a theoretical basis and experimental support for the prediction of fatigue life of marine high-strength steel.

high-strength steel  /  fatigue assessment  /  welded joint  /  fracture analysis  /  fatigue test
张宇, 李俊, 周俊, 陈威, 谌伟, 李晓彬. Mn25Al7钢焊接接头的疲劳性能试验研究. 船舶力学, 2024 , 28 (7) : 1100 -1110 . DOI: 10.3969/j.issn.1007-7294.2024.07.013
Yu ZHANG, Jun LI, Jun ZHOU, Wei CHEN, Wei SHEN, Xiao-bin LI. Fatigue performance tests of Mn25Al7 steel welded joints[J]. Journal of Ship Mechanics, 2024 , 28 (7) : 1100 -1110 . DOI: 10.3969/j.issn.1007-7294.2024.07.013
正文
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0　引言
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疲劳断裂是钢材失效的主要形式，而船舶裂纹或断裂大部分是由焊接结构引起的。船用高强钢的使用并未明显提高疲劳强度，Mn25Al7钢就是一种新型的轻质高强船用钢，目前针对Mn25Al7钢的疲劳性能尚未有相关试验研究，因此，有必要对Mn25Al7钢展开典型节点疲劳试验研究。
国内外学者早已对船用高强钢展开了系列的疲劳试验研究，如Zhang等[1]对Q345钢在高温冷却后的疲劳性能试验进行了研究，发现高温冷却后Q345钢的疲劳寿命与常温状态下相比明显降低，损伤速率受到高温的明显影响，其宏微观形态也有差异。Hariprasath等[2]探究了焊接工艺对海军级高强度低合金钢的高周疲劳行为的影响，发现母材和焊接接头的S-N曲线在IIW标准曲线之上。Sakai等[3]通过试验观察了金属在正常寿命状态和高周疲劳状态下晶体裂纹、表面夹杂物和加工裂纹等不同的断裂模式。施刚等[4]对Q390GJD钢材展开了疲劳性能试验研究，给出了能够描述其疲劳性能的S-N曲线，发现磨平焊趾的焊缝试件其疲劳强度高于原状焊缝试件，通过对试件断面特征进行微观分析，发现从疲劳断面能观察到明显裂纹，瞬间断裂面能观察到典型的韧窝特征。Yang等[5]对Q420C钢展开了高周疲劳性能试验研究，发现钢板厚度对疲劳性能有着显著影响。郭宏超等[6]对Q690D高强钢展开了母材及焊缝疲劳性能试验研究，拟合了描述其疲劳寿命的S-N曲线，讨论了焊接缺陷对试件疲劳损伤的影响。刘德重等[7]对船用10Ni5CrMoV高强钢的断口进行了微观分析，发现断口呈现韧性断裂的形貌。上述研究均基于名义应力法对多种高强钢的母材及焊缝展开了疲劳性能评估，但由于焊接接头的几何差异，名义应力法无法满足焊接细部结构的疲劳评估要求。常用的焊缝疲劳评估方法还有热点应力法、缺口应力法、结构应力法等，20世纪80年代热点应力法就成为船舶领域研究焊接结构疲劳问题的主流方法，各国学者、国际焊接协会（IIW）和船级社对热点应力法进行了大量的理论研究和试验对比。Niemi[8]建议热点应力插值点取为焊趾到板厚（t）的0.4倍和1.0倍处，对于较粗的网格，插值点建议取为0.5t和1.0t。IIW[9]从2008年将距焊趾的0.4t和1.0t热点应力插值点修订为0.5t和1.5t处进行线性外推，DNV规范（2019）[10]建议使用t×t的20节点实体单元或8节点单元，从0.5t和1.5t两点进行线性外推计算热点应力。经大量理论研究，采用0.5t和1.5t两点作为热点应力插值会更为准确。因此，本文主要通过S-N曲线结合线性累积损伤理论，来评估Mn25Al7钢在裂纹萌生阶段的疲劳性能，使用高频疲劳试验机，分别基于名义应力法和热点应力法得出S-N曲线，再将两种S-N曲线与现有规范分别进行对比来分析试验结果。
基于以上研究，本文对Mn25Al7钢展开疲劳性能试验研究，分析其应力与疲劳寿命之间的关系，并基于名义应力法和热点应力法进行疲劳等级曲线拟合，得到适用于Mn25Al7钢的典型节点S-N曲线，并与现有规范建议的疲劳等级曲线进行对比，评价Mn25Al7钢的疲劳强度；通过断口宏微观形貌分析和损伤分析，观察试验所得试件断口处的疲劳裂纹和细微缺陷，从试验现象来分析造成母材和焊缝试件寿命差异的原因，为船用高强钢的疲劳寿命预测提供理论依据和试验支撑。
1　疲劳试验
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1.1　试件设计
根据GB/T2975—2018《钢及钢产品力学性能试验取样位置及试样制备》[11]，本试验设计了三组试件，分别为母材试件（33件）、对接焊接试件（25件）和T型焊接试件（22件）。试验用钢为Mn25Al7钢，采用全板厚取样方式，疲劳试件如图1所示。
1.2　材料参数
母材试件保留原始表面尺寸，对接焊接接头及T型焊接接头的构造设计、焊接工艺及焊缝质量满足GB/T 13816-2009《焊接接头脉动拉伸疲劳试验方法》[12]，对接焊接接头磨平焊趾，T型焊接接头试件采用角焊缝连接，焊趾尺寸为2~3 mm。焊条型号为ER80S-G，采用手工电弧焊，常温下进行焊接，钢板和焊条化学成分如表1~3。
为得到Mn25Al7钢的材料参数，根据GB/T 208.1-2010《金属材料拉伸试验第一部分：室温实验方法》[13]规定，制作7个试样，拉伸试件如图2所示，进行了准静态拉伸试验，测得Mn25Al7钢的应力-应变曲线，结果如图3所示，材料性能如表4所示。
1.3　加载方法
本次试验使用JXG-200高频疲劳试验机，加载方法如图4所示。根据GB/T 3075-2008《金属材料疲劳试验轴向力控制方法》[14]要求进行试验。试验的应力比为R=Smin/Smax，即循环加载过程中试件截面最小应力Smin和最大应力Smax的比值，为避免试件受压屈曲，取R=0.1。幅值Δσ=（Smin-Smax）/2，平均应力σm=（Smin+Smax）/2。试件厚度均小于25 mm，不考虑厚度影响。
实验采用的机器为JXG-200高频疲劳试验机，其加载频率范围为60~300 Hz，最大平均试验力为±200 kN，最大动态试验力为100 kN。为防止试件在高频率时产生过大的热量而影响试件的疲劳性能，故选择频率120~140 Hz进行疲劳试验。试验最大应力范围为0.70~0.90 Pe，Pe为母材屈服强度，最小应力范围为试件在循环载荷107次时的对应值。加载系数为K=Smax/Pe（Smax为对应最大应力），初始加载系数为0.5，利用升降法找到无限寿命区间，即循环载荷为107次时对应的应力范围。试件的最大应力范围和最小应力范围之间应有5个等级划分区间，根据试件类型的不同，最大和最小应力范围也有所区别。
2　疲劳寿命评估
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2.1　名义应力S-N曲线与现行规范对比
名义应力法适用于高周疲劳寿命的分析，其以S-N曲线为基础进行寿命预测，其对数形式如下：
97.7%存活率的计算公式为
式中，m和C为材料常数，σ为标准差，经线性回归后的参数如表5所示。
将试验结果和GB 50017、AISC360及BS 7608三种规范[15-17]进行对比，试验及各规范的幂函数表达式如表6所示，在疲劳寿命107次时对应的疲劳强度极限值对比如表7所示。
如图5~7所示，将疲劳试验结果所得的S-N对数曲线与各规范中的设计曲线进行对比，发现拟合的S-N对数曲线与试验结果吻合。其中母材的离散性较大，但符合应力水平越低、疲劳寿命就越高的趋势；对接焊缝和T型焊缝的试验数据分布广泛，但都符合正常趋势。
由图5~7可知，在50%存活率下，母材的疲劳强度极限值是277.69 MPa；对接焊接接头的疲劳强度极限值为255.05 MPa；是母材的91.85%；T型焊接接头的疲劳强度极限值为43.66 MPa，是对接焊接接头的17.12%。在97.7%存活率下，母材的疲劳强度极限值为261.45 MPa，是GB 50017理论计算值的2.717倍、AISC 360理论计算值的3.765倍、BS 7608理论计算值的2.347倍，说明Mn25Al7钢的疲劳性能明显优于按照上述规范所设计的普通钢材。对接焊接接头的疲劳强度极限值为221.82 MPa，是GB 50017理论计算值的2.303倍、AISC 360理论计算值的4.209倍、BS 7608理论计算值的3.539倍。
如图5~6所示，三种规范与试验所得结果的斜率差距过大的原因有两点：一是在GB 50017规范中，对磨平焊趾试件的疲劳性能评估仅比未磨平焊趾试件的疲劳寿命增加30%，而AISC 360和BS 7608两规范并未考虑磨平焊趾对试件造成的影响，说明这些规范明显低估了磨平焊趾后的Mn25Al7钢对接焊接试件的疲劳寿命；二是未考虑试验的实际情况，磨平焊趾只能将试件整体厚度磨平，一些初始缺陷也会被处理，从而提高了试件的疲劳寿命，在文献[4]中也有类似情况。在97.7%存活率下，T型焊接试件的疲劳强度极限值为35.32 MPa，与AISC 360疲劳强度极限值相比约低10.81%，有足够的安全储备，而GB 50017和BS 7608均处于置信区间内，说明规范可以较好地预测Mn25Al7钢T型焊接接头的疲劳寿命。
2.2　热点应力S-N曲线与现行规范对比
如图8所示，焊接接头结构的热点指的是结构表面上容易发生应力集中的焊趾。焊头区域产生的所有应力都属于热点应力范畴，局部焊缝产生的应力除外。IIW[9]仅定义了热点应力法的两个FAT类别，即用于承载载荷的FAT90和非承载的FAT100，且其S-N曲线仅由其在200万次循环中的疲劳强度定义。这两个FAT类别明显低估了钢结构的疲劳评估。
热点应力定义为
式中，σ0.5t为距焊趾0.5倍板厚处的计算应力，σ1.5t为距焊趾1.5倍板厚处的计算应力。
根据试件的实际焊接变形对母材试件、对接焊缝试件和T型焊缝接头试件的有限元模型进行建模，采用如图9所示的尺寸为t×t粗网格的20节点的C3D20R单元，横向载荷以节点均布载荷的形式施加到加载位置，主板左端固支约束，右端施加均布荷载。考虑焊接变形对应力集中有较大影响，实际的有限元模型应考虑焊接变形。采用计算焊接拐角处热点应力，外插得到热点应力集中系数，其中母材和磨平焊趾后的对接焊缝试件的热点应力与名义应力相同。
如图10所示，在考虑焊接结构后的热点应力S-N曲线中，50%存活率下的Mn25Al7钢的T型焊接接头的疲劳强度极限值为87.63 MPa，是对接焊接接头的疲劳强度极限值的33.516%；在97.7%存活率下的疲劳强度极限值为68.55 MPa，是对接焊接接头的疲劳强度极限值的30.904%。其中IIW规范中对应热点应力的FAT 100的疲劳强度极限值为58.50 MPa，与97.7%存活率下的T型焊接接头的疲劳强度极限值相比低14.661%，表明IIW规范能较好地评估Mn25Al7钢T型焊接接头的疲劳寿命，有足够的安全储备。
3　疲劳试验现象分析
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3.1　疲劳损伤分析
在高周疲劳中，只产生微小的塑形变形。为了观察疲劳试验结果的准确率，令耗散势函数中塑形累积应变率为0，可得疲劳损伤D的周变化率[18]为
将式（4）积分后，在边界条件N=0时，D0=0；N=Nf，D=1时，可得疲劳损伤量D的演化方程[6]：
式中：B为材料常数；Smax、Smin分别为最大和最小应力；Nf为疲劳寿命；N为疲劳次数；D为疲劳损伤量；β值根据试验所得S-N对数曲线公式可得，如表8所示。
由图11可知，随着疲劳次数的增加，损伤曲线斜率不断增大，损伤速率越来越快，在接近1时瞬间增大，说明试件由于损伤累积断裂，剩余截面不足以应对外载荷产生的应力，发生瞬时断裂。其中母材和对接焊缝接头试件的损伤速率趋势一致，对接焊缝略高，与试验所得疲劳寿命结果一致，说明对接焊缝虽有初始缺陷，但经过焊趾打磨后，缺陷减少，增加了疲劳强度。图中T型焊缝接头的损伤速率明显高于母材和对接焊缝接头，这也与试验所得结果相符合。
3.2　疲劳断口形貌分析
为进一步分析疲劳损伤原因，对试件断口进行形貌观测，分析其断裂过程，发现在裂纹萌生区中，图12（a）所示的母材断口平坦、光滑；图12（b）所示对接焊缝试件的焊缝处有明显的凹陷区域；图12（c）所示T型焊缝试件焊缝处有裂纹向扩展区延展。疲劳裂纹扩展区中，三种试件由于裂纹表面在扩展过程中反复张开与闭合磨损，断面平坦呈撕裂状，且伴有明暗相间的条纹。裂纹瞬断区的断面较粗糙，有剪切唇，与拉伸断口类似。
为进一步观察断口形貌，观测导致三种试件疲劳强度不同的因素，采用JSM-IT300扫描电子显微镜对断面进行扫描。图13（a）中，母材的裂纹萌生区平坦且存在以裂纹源向外扩散的河流状条纹；图14（a）中，对接焊缝接头的裂纹源处有少许焊接缺陷；图15（a）中，T型焊缝试件存在明显的焊接凹陷区和焊接残留颗粒[19]。图13（b）、14（b）和15（b）裂纹扩展区的特征为疲劳条纹和二次裂纹沿着晶体扩展[20]，局部存在具有大量撕裂岭的断裂面，疲劳条纹较短且条纹间距不断扩大，垂直于裂纹扩展方向[21]，整个疲劳裂纹扩展区呈现穿晶断裂的特点，断裂模式为准解理断裂[22]。图13（c）瞬断区主要特征为韧窝和撕裂岭，且存在不规则的疲劳条纹带，说明母材在快速扩展过程中不易发生滑移；瞬断区的主要特征为韧窝和显微孔穴，图14（c）中对接焊缝接头的韧窝多且小，并含有少量解理面；图15（c）T型焊缝接头含有少量解理面和大量显微孔穴和少数韧窝。
由上述现象说明，母材需要在循环载荷作用下产生裂纹源，焊缝试件含有初始裂纹源，故而母材断口较焊缝试件更为平坦。裂纹扩展区的穿晶断裂特征在焊缝试件中更为明显，这显然与焊接残留颗粒的影响、大量疲劳条纹的存在、材料的塑性较强有关。瞬断区中母材韧窝相比焊缝试件较大，是因为母材疲劳强度更高，韧窝由显微孔穴成形，而焊缝试件疲劳强度低于母材，断裂更快，显微孔穴只有少数成形的大韧窝，其余为小韧窝。T型焊缝试件的成形韧窝较对接焊缝试件更少，显微孔穴多于对接焊缝试件，符合试验中T型焊缝试件的疲劳强度低于对接焊缝试件的结果，与损伤曲线观察结果一致，说明成形韧窝越少，试件的疲劳强度越低，未成形韧窝呈现为小韧窝和显微孔穴。
4　结论
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本文对Mn25Al7钢母材、对接焊缝接头和T型焊缝接头三种试件的疲劳性能进行了试验研究，并基于名义应力法和热点应力法与相关规范进行了对比分析，进一步对试件断口进行了形貌分析，得到如下结论：
（1）母材在97.7%存活率下的疲劳强度为261.45 MPa，是GB 50017理论计算值的2.717倍、AISC 360理论计算值的3.765倍、BS 7608理论计算值的2.347倍，故Mn25Al7钢母材的疲劳性能明显优于上述规范中所设计的普通钢材。
（2）磨平焊趾的对接焊接接头试件在97.7%存活率下的疲劳强度极限值为221.82 MPa，远高于各规范的设计值，表明规范低估了磨平焊趾后的Mn25Al7钢对接焊接接头试件的疲劳性能。
（3）T型焊接接头的S-N曲线与GB 50017和BS 7608更吻合，可以更准确地预测T型焊缝接头的疲劳性能，AISC 360有更多的安全储备。
（4）基于热点应力法的S-N曲线与IIW规范中的FAT 100设计曲线较吻合，能较好地评估Mn25Al7钢T型焊接接头的疲劳寿命，有足够的安全储备。
（5）断口形貌分析与损伤曲线结果一致，焊接试件的初始裂纹源越多，疲劳强度越低。母材试件裂纹源始于循环载荷累积，对接焊接接头和T型焊接接头试件可观察到明显的初始裂纹源。
基金
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  • 国家自然科学基金资助项目(51979213)
文献
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2024年第28卷第7期
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doi: 10.3969/j.issn.1007-7294.2024.07.013
  • 接收时间：2024-01-17
  • 首发时间：2026-03-26
  • 出版时间：2024-07-20
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  • 收稿日期：2024-01-17
基金
国家自然科学基金资助项目(51979213)
作者信息
    1.武汉理工大学　船海与能源动力工程学院，武汉　430063
    2.中国舰船研究设计中心，武汉　430064

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2种不同金属材料的力学参数
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