WC-Co类硬质合金的疲劳性能及应力分析方法的研究
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摘要
硬质合金被称为工业的牙齿,是现代工业部门和新技术领域不可缺少的工具材料和结构材料。近些年合成人造金刚石行业、线材轧制、精密模具制造业的高速发展拉动了硬质合金制品的研究开发,硬质合金的应用领域不断扩展,需求也越来越高,对新材质的研究与开发的愿望也越来越明显。疲劳和断裂是硬质合金失效的最主要原因,目前国内外有关硬质合金硬度和强度的报道较多而作为最能反映使用状态特性的疲劳方面的研究较少,本文在疲劳机和自行设计的温度冷热循环系统组成的疲劳试验装置上实现了室温疲劳、热疲劳、热-机械疲劳和热-腐蚀疲劳的条件,对硬质合金在单一或耦合疲劳机制下的疲劳寿命和裂纹扩展行为进行了较为系统的研究。
在室温疲劳中,硬质合金材料表现出明显的疲劳效应,即应力水平的降低伴随着疲劳寿命的上升。在高应力区域,材料的疲劳寿命较短,此时合金的疲劳寿命与合金的强度有关,合金的强度越高,其疲劳寿命越长。随着应力幅值的降低,这种强度与疲劳寿命的联系越来越不明显,特别是进入高周疲劳区域(>105)后,高粘结剂含量的合金反而表现出更高的疲劳抗性。疲劳裂纹主要沿晶界和在粘结相中扩展,材料在承受疲劳载荷后,粘结相与WC硬质颗粒之间发生了剥离,这种脱粘造成WC颗粒之间相互错动形成孔隙和微裂纹,这些孔隙和微裂纹相互连接加速了裂纹的扩展并最终导致材料的断裂。粘结相在疲劳过程中产生了大量堆垛层错并发生了相变,同时有析出物产生,Ni-Cr添加剂能有效的升高堆垛层错能,阻碍层错的扩展,使层错宽度变窄,并抑制Co相变的发生
与室温疲劳相比,在热-机械疲劳中,在相同应力幅下,合金的寿命会降低,其原因主要有：(一)在高温作用下试样表面形成一层疏松的氧化层,氧化层的脱落导致试样受力面积减小；(二)合金在高温下的力学性能会下降。这种降低在低应力水平下愈发明显,因为此时疲劳寿命较长,试样承受热循环的次数增多,造成的热损伤也越大。而添加Ni、Cr添加剂能有效提高合金的耐高温疲劳性能,其中YGR60合金在相同应力水平下其疲劳寿命与室温疲劳基本相当,只是在低应力水平下略有降低。
热疲劳裂纹的萌生及扩展包含如下过程：裂纹是经热循环一定次数后才形成,即裂纹的形成有孕育期,裂纹形成后扩展,达到一定尺寸时便停止扩展或者直至断裂。整体上讲硬质合金热裂纹扩展都呈现出先快后慢的趋势,这种热疲劳裂纹的扩展有别于一般的常温疲劳。合金在500。CH20℃均表现出良好的抗裂纹萌生和扩展能力,在700℃-20℃热疲劳条件下,添加Ni、Cr添加剂有利于提高热裂纹萌生的孕育期,而高粘结剂含量的合金则具有好的抗裂纹扩展能力。
在热-腐蚀疲劳中,裂纹扩展机理比较复杂。从本文给出的裂纹扩展速率表达式中可以看到,在热与腐蚀共同作用下,裂纹扩展速率不仅与单纯热疲劳和腐蚀疲劳的控制参数有关,还有两者强烈交互作用对裂纹扩展的贡献。酸性环境中热裂纹萌生和扩展规律与单纯的热疲劳裂纹萌生与扩展的规律类似,即含Ni-Cr添加剂的YGR系列合金的裂纹孕育期的明显大于纯Co粘结剂的YGH系列合金,而从裂纹扩展速率来看,高粘结相含量的合金明显低于低粘结相含量的合金。而碱性环境中孕育期的长短取决于粘结相的含量,即粘结相含量越多,孕育期越长；裂纹扩展速率受粘结相成分的影响较大,两种含Ni-Cr粘结剂的YGR硬质合金的裂纹扩展速率明显慢于纯Co粘结剂的两种YGH合金。
采用深冷处理工艺对硬质合金进行改性,研究了该工艺对包括疲劳性能在内的各种性能的影响并探讨了作用机理。深冷处理通过提高硬质合金表面残余压应力和引起Co的相变达到改性目的。选用适当的深冷处理工艺有效的提高了硬质合金的疲劳性能并改善了其综合力学性能。保温时间是深冷处理最主要的工艺参数,2h是最佳深冷处理时间。
由于硬质合金生产过程中不可避免的产生各种缺陷和残余应力的存在,所以硬质合金制品各部分在承载状态下的应力响应与理论值存在偏差。基于此通过有限元计算和实验应力法对硬质合金制品进行了应力分析,并在此基础上提出了一种硬质合金顶锤的无损在线检测方法。
Cemented carbides, which are called industral tools, are indispensable tool and structural materials in modern industral and new technology field. With the rapid development of the synthetic man-made diamond industry, wire rolling, precision mould manufacturing, the demand for improved performance cemented tungsten carbides is requires. Fatigue and fracture are the major failure mechanisms for cemented carbides. So far, the mechanical behavior is mainly characterized by hardness and bending strength. In practical applications, hard metal components may be subjected to repeated impact or cyclic loading. So dynamic strength propertied are important for hard metal. Therefore knowledge about the behavior of this material under cyclic loads is also required. Although compound mechanical, thermal and environmental condition applies in real service, no much has been reported on the effect of compound testing condition on hard metal life. The aim of the present work is to investigate the fatigue life and the microstructure properties of WC-Co hard metals under compound fatigue conditions.
In mechanical fatigue conditions, the fatigue effect is strongly dependent on the stress amplitude. At high stress level, material's fatigue life is more corresponding to its hardness, however, at low stress level, the fatigue life increases with increasing binder content. Fatigue cracks grow alone grain boundaries and in binding phases. After cyclic loading, WC particles and binders separate, this debonding causes pore and micro.cracks formed. The pore and crackle connected to accelerate the crack growth and eventually lead to material fracture. In Co binders, stacking fault and phase transformation occurred during fatigue process, precipitated phases are also found. Ni-Cr additive in Co binder can effectively increase the stacking fault, hinder the expansion, and suppress the occurrence of Co phase transformation.
Compared with mechanical fatigue, in thermal-mechanical fatigue conditions, fatigue life reduces in the same stress amplitude. The main reasons are:(1) a loose oxide layer forms on the sample surface, which reduce applied force area of samples;(2) in high temperature, mechanical properties of alloy will decline. This reduction is more obvious at low stress level. This is because sample suffers more temperature damage when its fatigue life is longer. YGR alloys show almost the same fatigue life in thermal-mechanical fatigue conditions as well as just mechanical fatigue conditions. Only in the case of low stress level fatigue life reduces slightly. Which cofirms that Ni and Cr additions can increase the high temperature fatigue resistance.
Typical thermal fatigue crack incluse three stages:crack initiation, crack propagation and fracture. And the crack appears first quick back slow trend, which is different with crack in mechanical fatigue condition. High binder content alloys express lower crack propagation rate, compared with corresponding low binder content alloys. Cemented carbides show better fatigue resistance in500℃(?)20℃ranges compared with700℃(?)20℃. Add Ni and Cr in the Co binder is helpful way to improve the crack initiation life.
During thermo-corrosion fatigue, mechanisms account for the influence of the corrosive environment on the fatigue response of the cemented carbides is complex. It can be seen from the given formula that many factors interactions contribute simultaneously to crack propagation. High binder content alloys exhibit lower crack propagation rate, compared with corresponding low binder content alloys. Low binder content alloys conduct better crack propagation resistance in acid environment than in neuter and alkali solution. Co-Ni-Cr binder alloys show better crack propagation resistance in corrosion environment.
The effect of cryogenic treatment on the fatigue and mechanical properties of cemented carbides has been investigated in this paper. The results show that after cryogenic treatment, the samples are characteristics of the enhanced mechanical properties, wear resistance and fatigue resistance. The change of the properties is highly dependent on the soaking time, and2h is the best process parameter, which could be ascribed to the change of residual stressed and martensitic phase transformation of Co binder during the cryogenic treatment.
This paper introduced a method of detecting the quality of anvils made of cemented tungsten carbide used in cubic high-press apparatus. The qualitative standard of anvils was established by means of the finite element method, and subsequent it was being used in batches.
在室温疲劳中,硬质合金材料表现出明显的疲劳效应,即应力水平的降低伴随着疲劳寿命的上升。在高应力区域,材料的疲劳寿命较短,此时合金的疲劳寿命与合金的强度有关,合金的强度越高,其疲劳寿命越长。随着应力幅值的降低,这种强度与疲劳寿命的联系越来越不明显,特别是进入高周疲劳区域(>105)后,高粘结剂含量的合金反而表现出更高的疲劳抗性。疲劳裂纹主要沿晶界和在粘结相中扩展,材料在承受疲劳载荷后,粘结相与WC硬质颗粒之间发生了剥离,这种脱粘造成WC颗粒之间相互错动形成孔隙和微裂纹,这些孔隙和微裂纹相互连接加速了裂纹的扩展并最终导致材料的断裂。粘结相在疲劳过程中产生了大量堆垛层错并发生了相变,同时有析出物产生,Ni-Cr添加剂能有效的升高堆垛层错能,阻碍层错的扩展,使层错宽度变窄,并抑制Co相变的发生
与室温疲劳相比,在热-机械疲劳中,在相同应力幅下,合金的寿命会降低,其原因主要有：(一)在高温作用下试样表面形成一层疏松的氧化层,氧化层的脱落导致试样受力面积减小；(二)合金在高温下的力学性能会下降。这种降低在低应力水平下愈发明显,因为此时疲劳寿命较长,试样承受热循环的次数增多,造成的热损伤也越大。而添加Ni、Cr添加剂能有效提高合金的耐高温疲劳性能,其中YGR60合金在相同应力水平下其疲劳寿命与室温疲劳基本相当,只是在低应力水平下略有降低。
热疲劳裂纹的萌生及扩展包含如下过程：裂纹是经热循环一定次数后才形成,即裂纹的形成有孕育期,裂纹形成后扩展,达到一定尺寸时便停止扩展或者直至断裂。整体上讲硬质合金热裂纹扩展都呈现出先快后慢的趋势,这种热疲劳裂纹的扩展有别于一般的常温疲劳。合金在500。CH20℃均表现出良好的抗裂纹萌生和扩展能力,在700℃-20℃热疲劳条件下,添加Ni、Cr添加剂有利于提高热裂纹萌生的孕育期,而高粘结剂含量的合金则具有好的抗裂纹扩展能力。
在热-腐蚀疲劳中,裂纹扩展机理比较复杂。从本文给出的裂纹扩展速率表达式中可以看到,在热与腐蚀共同作用下,裂纹扩展速率不仅与单纯热疲劳和腐蚀疲劳的控制参数有关,还有两者强烈交互作用对裂纹扩展的贡献。酸性环境中热裂纹萌生和扩展规律与单纯的热疲劳裂纹萌生与扩展的规律类似,即含Ni-Cr添加剂的YGR系列合金的裂纹孕育期的明显大于纯Co粘结剂的YGH系列合金,而从裂纹扩展速率来看,高粘结相含量的合金明显低于低粘结相含量的合金。而碱性环境中孕育期的长短取决于粘结相的含量,即粘结相含量越多,孕育期越长；裂纹扩展速率受粘结相成分的影响较大,两种含Ni-Cr粘结剂的YGR硬质合金的裂纹扩展速率明显慢于纯Co粘结剂的两种YGH合金。
采用深冷处理工艺对硬质合金进行改性,研究了该工艺对包括疲劳性能在内的各种性能的影响并探讨了作用机理。深冷处理通过提高硬质合金表面残余压应力和引起Co的相变达到改性目的。选用适当的深冷处理工艺有效的提高了硬质合金的疲劳性能并改善了其综合力学性能。保温时间是深冷处理最主要的工艺参数,2h是最佳深冷处理时间。
由于硬质合金生产过程中不可避免的产生各种缺陷和残余应力的存在,所以硬质合金制品各部分在承载状态下的应力响应与理论值存在偏差。基于此通过有限元计算和实验应力法对硬质合金制品进行了应力分析,并在此基础上提出了一种硬质合金顶锤的无损在线检测方法。
Cemented carbides, which are called industral tools, are indispensable tool and structural materials in modern industral and new technology field. With the rapid development of the synthetic man-made diamond industry, wire rolling, precision mould manufacturing, the demand for improved performance cemented tungsten carbides is requires. Fatigue and fracture are the major failure mechanisms for cemented carbides. So far, the mechanical behavior is mainly characterized by hardness and bending strength. In practical applications, hard metal components may be subjected to repeated impact or cyclic loading. So dynamic strength propertied are important for hard metal. Therefore knowledge about the behavior of this material under cyclic loads is also required. Although compound mechanical, thermal and environmental condition applies in real service, no much has been reported on the effect of compound testing condition on hard metal life. The aim of the present work is to investigate the fatigue life and the microstructure properties of WC-Co hard metals under compound fatigue conditions.
In mechanical fatigue conditions, the fatigue effect is strongly dependent on the stress amplitude. At high stress level, material's fatigue life is more corresponding to its hardness, however, at low stress level, the fatigue life increases with increasing binder content. Fatigue cracks grow alone grain boundaries and in binding phases. After cyclic loading, WC particles and binders separate, this debonding causes pore and micro.cracks formed. The pore and crackle connected to accelerate the crack growth and eventually lead to material fracture. In Co binders, stacking fault and phase transformation occurred during fatigue process, precipitated phases are also found. Ni-Cr additive in Co binder can effectively increase the stacking fault, hinder the expansion, and suppress the occurrence of Co phase transformation.
Compared with mechanical fatigue, in thermal-mechanical fatigue conditions, fatigue life reduces in the same stress amplitude. The main reasons are:(1) a loose oxide layer forms on the sample surface, which reduce applied force area of samples;(2) in high temperature, mechanical properties of alloy will decline. This reduction is more obvious at low stress level. This is because sample suffers more temperature damage when its fatigue life is longer. YGR alloys show almost the same fatigue life in thermal-mechanical fatigue conditions as well as just mechanical fatigue conditions. Only in the case of low stress level fatigue life reduces slightly. Which cofirms that Ni and Cr additions can increase the high temperature fatigue resistance.
Typical thermal fatigue crack incluse three stages:crack initiation, crack propagation and fracture. And the crack appears first quick back slow trend, which is different with crack in mechanical fatigue condition. High binder content alloys express lower crack propagation rate, compared with corresponding low binder content alloys. Cemented carbides show better fatigue resistance in500℃(?)20℃ranges compared with700℃(?)20℃. Add Ni and Cr in the Co binder is helpful way to improve the crack initiation life.
During thermo-corrosion fatigue, mechanisms account for the influence of the corrosive environment on the fatigue response of the cemented carbides is complex. It can be seen from the given formula that many factors interactions contribute simultaneously to crack propagation. High binder content alloys exhibit lower crack propagation rate, compared with corresponding low binder content alloys. Low binder content alloys conduct better crack propagation resistance in acid environment than in neuter and alkali solution. Co-Ni-Cr binder alloys show better crack propagation resistance in corrosion environment.
The effect of cryogenic treatment on the fatigue and mechanical properties of cemented carbides has been investigated in this paper. The results show that after cryogenic treatment, the samples are characteristics of the enhanced mechanical properties, wear resistance and fatigue resistance. The change of the properties is highly dependent on the soaking time, and2h is the best process parameter, which could be ascribed to the change of residual stressed and martensitic phase transformation of Co binder during the cryogenic treatment.
This paper introduced a method of detecting the quality of anvils made of cemented tungsten carbide used in cubic high-press apparatus. The qualitative standard of anvils was established by means of the finite element method, and subsequent it was being used in batches.
引文
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