Fatigue crack initiation behavior of additive manufacturing components based on dislocation model
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摘要: 选区激光熔化的制造过程不可避免地会在构件内部和表面产生缺陷，如何从“合于使用”的角度评价缺陷微观尺度扩展行为对结构寿命周期服役完整性的影响是目前亟需解决的主要问题之一. 为了定量揭示疲劳裂纹萌生行为，借助Tanaka-Mura位错模型描述选区激光熔化成形GH3536合金的疲劳裂纹萌生及短裂纹扩展情况，分析由于缺陷位置、缺陷尺寸和缺陷类型等导致疲劳裂纹的表面和内部萌生的竞争情况. 结果表明，随着缺陷距表面距离的减小或等效缺陷尺寸的增加，疲劳失效模式由表面变为内部失效；选区激光熔化成形GH3536存在对应条件下的损伤容限，当缺陷尺寸较小时，构件的裂纹萌生模式不发生变化，但随着缺陷数量增多，疲劳短裂纹的扩展路径发生多次偏转且萌生寿命明显降低.Abstract: During selective laser melting (SLM) process, defects will be formed inevitably inside and on the surface of the additive manufacturing component. Therefore, it is important to evaluate the impact of crack propagation at the microscale on service integrity of structures throughout their life cycle from the perspective of fitness for service. In order to quantitatively reveal the initiation behavior of fatigue cracks, the Tanaka-Mura dislocation model was used to explain the fatigue crack initiation and short crack propagation of SLM formed GH3536 alloy. The competition mechanism between the surface and internal initiation of fatigue cracks caused by defect location, defect size, and defect type was analyzed. The results indicate that as the distance from the defect to the surface decreases or the equivalent defect size increases, the fatigue failure mode changes from surface failure to internal failure. SLM formed GH3536 exhibits damage tolerance under corresponding conditions: when the defect size is small, the crack initiation mode of the additive manufacturing component remains the same; while with the rising number of defects, the fatigue short crack propagation path deflects several times and the initiation life decreases significantly.
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图 3 SLM成形GH3536的EBSD图和晶粒尺寸分布
Figure 3. EBSD map and grain size distribution of SLM formed GH3536. (a) EBSD map; (b) grain size distribution
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图 5 x = 0.1, 0.2, 0.35 mm时裂纹萌生扩展路径
Figure 5. Crack initiation and propagation path at x = 0.1, 0.2, 0.35 mm. (a) 3 cracks(x = 0.1 mm); (b) 15 cracks(x = 0.1 mm); (c) 50 cracks(x = 0.1 mm); (d) 10 cracks(x = 0.2 mm); (e) 60 cracks(x = 0.2 mm); (f) 10 cracks(x = 0.35 mm); (g) 60 cracks (x = 0.35 mm)
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图 6 不同尺寸夹杂下裂纹萌生扩展路径
Figure 6. Crack initiation and propagation path under different size of inclusions. (a) R = 10 μm; (b) R = 20 μm; (c) R = 40 μm; (d) R = 60 μm
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图 7 多孔缺陷裂纹萌生扩展路径
Figure 7. Crack initiation and propagation path of multiple pore defects. (a) single pore; (b) 0° direction of two pores; (c) 45° direction of two pores; (d) three pores
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图 8 两孔缺陷的Mises应力云图
Figure 8. Mises stress nephogram of two pores defects. (a) 0° direction；(b) 45° direction
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图 9 不同数量缺陷下疲劳寿命与裂纹萌生数量关系
Figure 9. Relationship between fatigue life and crack initiation with different number of defects
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图 10 预置裂纹模型剪切应力分布
Figure 10. Shear stress distribution of preset crack model. (a) longitudinal crack; (b) transverse crack
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图 11 不同应力下裂纹萌生扩展路径
Figure 11. Crack initiation and propagation paths under different stresses. (a) preset longitudinal cracks(140 MPa); (b) preset transverse cracks(140 MPa); (c) preset longitudinal cracks with pore(140 MPa); (d) preset longitudinal cracks(160 MPa); (e) preset transverse cracks(160 MPa); (f) preset longitudinal cracks with pore(160 MPa)
表 1 正交各向异性弹性刚度矩阵各分量
Table 1 Components of orthotropic elastic stiffness matrix MPa
C11/C22/C33 C12/C13/C23 C44/C55/C66 285 613 122 405 81 603 
下载: 导出CSV
表 2 Tanaka-Mura位错模型参数
Table 2 Parameters of Tanaka-Mura dislocation model
临界剪切应力
CRSS /MPa单位面积起裂能
ws /(kJ·m−2)泊松比νA 231 2 0.3
下载: 导出CSV
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