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基于数字图像相关的增材制造GH4169薄壁件锯齿流变温度效应研究

TEMPERATURE EFFECT ON SERRATED FLOW IN ADDITIVELY MANUFACTURED GH4169 THIN-WALLED PARTS BASED ON DIGITAL IMAGE CORRELATION

  • 摘要: 激光粉末床熔融(Laser Powder Bed Fusion, LPBF)成形GH4169薄壁件在航空发动机热端部件中具有重要应用前景, 然而其在高温环境下的锯齿流变(Portevin-Le Chatelier, PLC)行为机理仍不清晰. 本文采用基于双棱镜的单镜头三维数字图像相关技术(Bi-Prism-based Single-lens 3D Digital Image Correlation, BSL 3D DIC), 以LPBF成形GH4169航空发动机燃烧室机匣薄壁结构模拟件为对象, 系统研究了其在25 °C ~ 750 °C宽温域内的动态应变时效(Dynamic Strain Aging, DSA)特性. 研究明确了该材料PLC效应(应变率10−3 s−1)的温度窗口为250 °C ~ 650 °C, 定量表征了窗口内锯齿数量、幅值、周期及塑性应变增量的温度相关性. 结果表明: 在本试验条件下, 锯齿数量在350 °C呈现单峰峰值, 平均幅值随温度升高单调递增, 表现出从“高频低幅”向“低频高幅”的错峰转变. 塑性应变增量(临界应变与屈服应变差值)在450 °C时取得最小值. 通过全场应变演化分析, 揭示了550 °C变形带在试样上下两端之间的反复迁移与竞争规律; 25 °C无PLC对比试验及横截面积演化分析表明, PLC效应通过诱导变形带的时空演化, 调控了局部损伤累积的空间分布, 进而与最终断裂位置相关联. 同时, 研究发现250 °C锯齿周期呈现显著离散, 而650 °C锯齿在变形后期完全消失. 本研究系统揭示了LPBF成形GH4169薄壁结构模拟件在10−3 s−1应变率下的锯齿流变行为的温度调控规律, 为增材制造镍基高温合金材料和结构的塑性失稳分析提供了实验依据.

     

    Abstract: Laser powder bed fused (LPBF) GH4169 thin-walled components hold significant promise for hot-section parts in aero-engines; however, the underlying mechanism of their serrated flow (Portevin-Le Chatelier, PLC) behavior at high temperatures remains unclear. In this study, a bi-prism-based single-lens three-dimensional digital image correlation (BSL 3D DIC) technique was employed to systematically investigate the dynamic strain aging (DSA) characteristics of an LPBF-fabricated GH4169 thin-walled structural simulation part (aero-engine combustion chamber casing) over a wide temperature range from 25 °C to 750 °C. The temperature window for the PLC effect under a strain rate of 10−3 s−1 has been identified as 250 °C to 650 °C. Within this window, the temperature dependences of serration number, amplitude, period, and plastic strain increment were quantitatively characterized in detail. The obtained results clearly show that the serration number exhibits a unimodal peak at 350 °C, while the average serration amplitude increases monotonically with temperature, revealing a transition from “high-frequency low-amplitude” to “low-frequency high-amplitude”. Under the present test conditions, the plastic strain increment (the difference between the critical strain and the yield strain) reaches its minimum at 450 °C. Full-field strain evolution analysis reveals repeated migration and competition of deformation bands between the upper and lower ends of the specimen at 550 °C. The 25 °C PLC-free comparative test, together with cross-sectional area evolution analysis, demonstrates that the PLC effect, by mediating the spatio-temporal evolution of deformation bands, modulates the spatial distribution of local damage accumulation and thereby correlates with the final fracture location. Concurrently, the serration periods at 250 °C exhibit significant discreteness, while serrations at 650 °C disappear completely in the later stage of deformation. This study systematically reveals the temperature-dependent regulation of serrated flow behavior in LPBF-fabricated GH4169 thin-walled structural simulation parts at a strain rate of 10−3 s−1, thus providing solid experimental evidence for the analysis of plastic instability in additively manufactured nickel-based superalloy materials and structures.

     

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