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基于晶体塑性理论的P91钢高温低周疲劳行为与裂纹萌生寿命预测研究

HIGH-TEMPERATURE LOW-CYCLE FATIGUE BEHAVIOR AND CRACK INITIATION LIFE PREDICTION OF P91 STEEL BASED ON CRYSTAL PLASTICITY THEORY

  • 摘要: P91钢因其在高温环境下的优异性能,被广泛应用于关键结构部件。然而,其循环软化行为和疲劳裂纹的萌生行为尚未得到全面理解,限制了材料的可靠性设计与寿命预测。为此,本文提出了一种基于物理机制的晶体塑性本构模型,系统考虑了背应力演化、马氏体板条粗化和位错滑移/攀移机制,并对模型进行了有限元实现。模拟结果成功再现了P91钢在高温循环加载下的实验现象,验证了模型的准确性和适用性。研究表明,P91钢在高温下的循环软化行为主要源于马氏体板条粗化和位错密度下降等微观结构的恢复过程,而疲劳裂纹则倾向于在晶界或三晶交汇区域优先萌生。通过累积塑性滑移和累积能量耗散的两种疲劳指标因子(Fatigue Indicator Parameters, FIP)进行裂纹萌生寿命预测,结果显示,两种FIPs均表现出良好的预测能力,其预测数据点全部分布在二倍误差带内。在高应变幅值条件下,基于累积能量耗散的疲劳寿命预测精度更高,凸显其在高温疲劳行为研究中的应用潜力。本研究为深入揭示P91钢的循环塑性行为及疲劳裂纹萌生规律提供了科学依据,也为高温材料的可靠性设计提供了方法框架。

     

    Abstract: P91 steel is widely utilized in critical structural components due to its outstanding performance in high-temperature environments. However, its cyclic softening behavior and the initiation mechanisms of fatigue cracks are not yet fully understood, which hinders the reliability design and lifespan prediction of the material. In this context, the present study proposes a crystal plasticity-based constitutive model grounded in physical mechanisms. The model systematically accounts for the evolution of back stress, martensitic lath coarsening, and dislocation slip/climb mechanisms, and is implemented using the finite element method. The simulation results effectively replicate the experimental observations of P91 steel under high-temperature cyclic loading, thereby validating the accuracy and applicability of the model. The findings indicate that the cyclic softening behavior of P91 steel at elevated temperatures is primarily driven by microstructural recovery processes, including martensitic lath coarsening and a reduction in dislocation density. Fatigue cracks are observed to preferentially initiate at grain boundaries or triple-junctions. The crack initiation life is predicted using two fatigue indicator parameters (FIPs): cumulative plastic slip and cumulative energy dissipation. The results demonstrate that both FIPs exhibit strong predictive capability, with all predicted data points falling within the two-fold error band. Under high strain amplitude conditions, the fatigue life prediction based on cumulative energy dissipation provides higher accuracy, underscoring its potential for application in high-temperature fatigue behavior research. This study provides a comprehensive scientific foundation for understanding the cyclic plasticity behavior and fatigue crack initiation mechanisms in P91 steel, and offers a robust methodological framework for the reliability design of high-temperature materials.

     

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