激光增材制造金属材料疲劳寿命研究

廖宇; 钟贵勇; 舒茂盛; 柏林; 江旭来

doi:10.21656/1000-0887.430319

激光增材制造金属材料疲劳寿命研究

doi: 10.21656/1000-0887.430319

航空工业成都飞机设计研究所，成都 610091

详细信息

作者简介:
廖宇（1990—），男，工程师，硕士（通讯作者. E-mail：610746336@qq.com）

中图分类号: O346.2
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- 被引次数: 0
出版历程
- 收稿日期: 2022-10-11
- 修回日期: 2023-01-13
- 网络出版日期: 2023-02-04
- 刊出日期: 2023-02-15

A Study on the Fatigue Life of the Laser Additive Manufactured Metallic Material

AVIC Chengdu Aircraft Design & Research Institute, Chengdu 610091, P.R.China

摘要

摘要:
随着军用飞机上越来越多的结构件使用增材制造（AM）技术成形，对增材制造材料和结构疲劳特性的研究就变得十分迫切。为了研究激光增材制造（选区激光熔化成形，SLM）铝合金以及钛合金的疲劳寿命特性，设计了一系列带各种结构细节的模拟试验件，进行常幅谱和随机谱下的试验，统计分析了各组试验的基本可靠性寿命，并得到了可靠度安全寿命曲线。断口分析发现铝合金试验件缺陷较多，存在混合失效特征，而钛合金试验件疲劳分散性较锻件大。
- 增材制造 /
- 疲劳特性 /
- 结构细节 /
- 钛合金 /
- 可靠性寿命
Abstract:
As more and more structural parts of military aircraft are formed with the additive manufacturing (AM) technology, it is very urgent to study the fatigue characteristics of the additive manufactured materials and structures. To investigate the fatigue life characteristics of the aluminum alloy and the titanium alloy manufactured with the selective laser melting (SLM) technology, a series of specimens with various structural details were designed and tested under the constant amplitude spectrum and the random spectrum. The basic reliable life of each test specimen was statistically analyzed and the reliable safety life curve was obtained. The fractography analysis shows that, more defects and mixed failure characteristics exist in the aluminum alloy specimens, while the fatigue scatter of the titanium alloy specimens is larger than that of forge pieces.
- additive manufacturing /
- fatigue characteristics /
- structural details /
- titanium alloy /
- reliable fatigue life

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图 1 试验件形式（单位：mm）：（a）试件类型1；（b）试件类型2；（c）试件类型3；（d）试件类型4

Figure 1. The shapes and dimensions of the specimens (unit: mm): （a）specimen type 1; （b） specimen type 2;（c） specimen type 3; （d） specimen type 4

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图 2 可靠度安全寿命曲线：（a）铝合金；（b）钛合金

注　为了解释图中的颜色，读者可以参考本文的电子网页版本，后同。

Figure 2. Safety life curves with certain reliabilities: （a） AlSi10Mg; （b） TC4 ELI

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图 3 SLMed试件与TC4-DT锻件对比

Figure 3. Comparison of the SLMed TC4 ELI specimen and the TC4-DT forging specimen

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图 4 工业CT扫描缺陷（软件模拟计算截图）：（a）试件类型4，08号件；（b）试件类型4，09号件

Figure 4. Scan defects by the industrial CT (screenshots of software simulation): （a） No.08 of specimen type 4; （b） No.09 of specimen type 4

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图 5 部分试件断口示意图：（a）试件类型3正常起裂；（b）试件类型1缺陷起裂；（c）试件类型4正常起裂；（d）试件类型3多裂纹源

Figure 5. Fractography of some specimens: （a） normal initiation in type 3; （b） defect initiation in type 1; （c） normal initiation in type 4; （d） multiple crack initiation in type 3

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表 1 AlSi10Mg粉末和TC4 ELI粉末的主要化学成分

Table 1. Main chemical compositions of the AlSi10Mg powder and the TC4 ELI powder

AlSi10Mg	element	Al	Si	Mg	Fe	Mn	Ti
AlSi10Mg	mass fraction	balance	9.0% ~ 11.0%	0.2% ~ 0.5%	< 0.55%	< 0.45%	< 0.15%
TC4 ELI	ellement	Ti	V	Al	Sn	Mo	Cu	Mn
	mass fraction	balance	3.4% ~ 4.5%	5.5% ~ 6.5%	< 0.1%	< 0.1%	< 0.1%	< 0.1%
	mass fraction	balance	3.4% ~ 4.5%	5.5% ~ 6.5%	no more than 0.2% in total

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表 2 试验矩阵

Table 2. The test matrix

material	specimen	test spectrum	structural detail
AlSi10Mg	type 1	constant amplitude/	L_T=20%
AlSi10Mg	type 3	random spectrum	K_t=1.37
TC4 ELI	type 2	constant amplitude/	L_T=20%
TC4 ELI	type 4	random spectrum	K_t=5.10

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表 3 试验结果

Table 3. Test results

	AlSi10Mg			TC4 ELI
	specimen	σ_max/MPa	N_99.9/90	specimen	σ_max/MPa	N_99.9/90
constant amplitude spectrum (N_99.9/90 in cycles)	type 1	121	35 635	type 2	314	47 214
	type 1	110	76 232	type 2	280	84 662
	type 3	200	44 799	type 4	607	23 346
	type 3	196	42 044	type 4	552	39 926
random spectrum (N_99.9/90 in flight hour)	type 1	171	1 683	type 2	572	2 924
		155	5 461		520	4 563
		140	7 449		468	8 238
	type 3	252	2 629	type 4	933	2 959
		230	5 281		877	4 205
		220	7 282		786	5 239

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表 4 拟合结果

Table 4. Fitting results

material	specimen	structural detail	fitting equation
AlSi10Mg	type 1	L_T=20%	σ^7.334= 5×10¹⁹ N
AlSi10Mg	type 3	K_t=1.37	σ^7.522= 3×10²¹ N
TC4 ELI	type 2	L_T=20%	σ^5.170= 5×10¹⁷ N
TC4 ELI	type 4	K_t=5.10	σ^3.173= 8×10¹² N

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表 5 试件1疲劳分散性对比

Table 5. Comparison of fatigue scatter for specimen type 1

material	AlSi10Mg	7475-T7351	7050-T7651
logarithmic standard deviation	0.116	0.115	0.201
	0.116	0.230	0.117
	0.167	0.131	0.209
average	0.133	0.159	0.176

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表 6 试件4疲劳分散性对比

Table 6. Comparison of the fatigue scatter for specimen type 4

material	spectrum	σ_max/MPa	number	fatigue life (cycles)	number of defects
TC4 ELI	constant amplitude	524	05	>100 0000	0
			08	>400 000 (uncracked)	4
			09	72 000	5
			13	36 000	0

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表 7 试验件断口反推结果

Table 7. The inference results from the fractography of the specimens

specimen	material	total life (cycles)	life of crack initiation (cycles)	life of crack growth (cycles)	growth life to total life
fig. 5(a)	AlSi10Mg	115 000	108 000	7 000	6.10%
fig. 5(c)	TC4 ELI	455 000	437 000	18 000	4.00%

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