高速冲击表面处理对金属材料力学性能和组织结构的影响

高玉魁; 陶雪菲

doi:10.11883/bzycj-2020-0342

高速冲击表面处理对金属材料力学性能和组织结构的影响

doi: 10.11883/bzycj-2020-0342

高玉魁^{1, 2,},
陶雪菲³

1.
同济大学材料科学与工程学院，上海 201804
2.
上海市金属功能材料开发应用重点实验室，上海 201804
3.
同济大学航空航天与力学学院，上海 200092

详细信息

作者简介:
高玉魁（1973－　），男，博士，教授，ykgao12088@126.com

中图分类号: O347.3; TB31
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- 文章访问数: 1302
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- 被引次数: 0
出版历程
- 收稿日期: 2020-09-22
- 修回日期: 2020-11-21
- 网络出版日期: 2021-03-18
- 刊出日期: 2021-04-14

A review on the influences of high speed impact surface treatments on mechanical properties and microstructures of metallic materials

GAO Yukui^{1, 2
,},
TAO Xuefei³

1.
School of Materials Science and Engineering, Tongji University, Shanghai 201804, China
2.
Shanghai Key Laboratory od R&D for Metallic Function Materials, Shanghai 201804, China
3.
School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai 200092, China

摘要

摘要: 高速冲击表面处理过程中的应变率对金属材料的宏观力学性能和微观组织结构都具有重要影响。根据当前应变率效应的研究成果，从宏观与微观相结合的角度出发，综述了高速冲击表面处理过程中应变率对金属材料强度和塑性的影响规律，并重点阐述了不同应变率下金属材料内部微观组织结构的演变规律，主要包括晶粒结构、绝热剪切带、相变、位错组态和析出相以及变形孪晶等。此外，还分析了组织结构随应变率的演化和微观变形机制的转变对材料力学性能的强化和弱化机理。最后，对高速冲击表面处理梯度组织的变形特点进行了总结。提出了不同组织结构对材料性能影响的综合效应模型，以期为应变率效应的深入研究奠定基础。
- 高速冲击表面处理 /
- 金属材料 /
- 应变率效应 /
- 力学性能 /
- 微观组织结构
Abstract: The strain rate during the process of high speed impact surface treatments has a significant effect on the mechanical properties as well as the microstructures of metallic materials. In this paper, the effects of strain rate during the process of high speed impact surface treatments on the variation of both strength and ductility of metallic materials are reviewed from macroscopic and microscopic prospective based on the current research achievements. The emphases are concentrated on the microstructural evolution under various strain rates, including grain structures, adiabatic shear bands, phases, dislocation structures, precipitates and deformation twins. At relatively low strain rates, grains tend to be elongated with respect to the loading direction, and they may be refined when the strain increases to a certain extent. In comparison, with the increment of strain rates, the free path of dislocation motion is remarkably reduced so that grains can be further refined to consume the impact energy and dislocations are multiplied significantly. However, the relatively high strain rates may also bring about adiabatic temperature rise and frictional heat, which may give rise to dynamic recovery and recrystallization in some materials so that the dislocation density would in turn be reduced. Moreover, precipitates can be formed and they may interact with dislocations owing to the combined effects of high strain rates and temperature rise. When the strain rates increase to the extremely high level, the movement of dislocations may be inhibited and deformation twins can be triggered to coordinate the deformation. As a result, the strain rate effects are complicated phenomena which comprehensively affect the microstructural strengthening and softening effects. Based on these, the influences of both microstructural evolution and the transition of microscopic deformation mechanisms with strain rates on the enhancement and deterioration of mechanical properties are analyzed. Finally, the characteristics of deformation mechanisms of the gradient microstructures derived from high velocity impact surface treatments are concluded. Furthermore, a comprehensive model embodying the influences of different microstructures is proposed, which can provide a foundation for the further researches of strain rate effects.
- high speed impact surface treatment /
- metallic materials /
- strain rate effects /
- mechanical properties /
- microstructures

HTML全文

爆炸焊接是一种以炸药爆炸能量驱动，通过飞板加速碰撞基板，结合而直接焊接两层或多层异种金属的复合技术^[1]。这种焊接的强度往往是其他技术所不能达到的，爆炸复合板广泛应用于化工、造船、核工业、航空航天等工业领域。

爆炸焊接的最大优势在于大尺寸、异种金属的焊接复合。由于炸药爆炸产生的瞬时高温高压，对一些厚度很薄的金属箔材(特别是厚度在1 mm以下的薄板)和变形性很差的脆性材料、超硬材料，在焊接时通常要进行许多特殊的处理，而且焊接效果不太理想，复合板整体或局部断裂、薄片屈曲、复合率不高等缺点限制了爆炸焊接在此类特殊材料上的应用。近年来，开发了水下爆炸焊接方法，并且成功应用于铝箔(0.1 mm)与ZrO₂陶瓷^[2]、不锈钢与非晶薄板(38 μm) ^[3]、铜板与钨箔(0.5 mm)^[4]、NiTi形状记忆合金与铜箔(0.5 mm)^[5]等特殊难焊材料的焊接实验。对比水下冲击波和空气冲击波各自的特点，可以发现：(1)水的可压缩性小，消耗本身的变形能少，传压性稳定，水中爆炸所产生的初始冲击波压力比空气中大很多；(2)密度差异会导致惯性大，水下爆轰产物膨胀过程比空气中慢，产生多次膨胀和压缩；(3)水的声速(1 500 m/s)比空气的声速(334 m/s)大，在相同药量和距离下，水下冲击波对目标体作用的时间短、冲量大。这些特点表明，水下冲击波将在一些特殊领域完善对传统空气爆炸加工的应用。水下爆炸焊接的优点，可以概括为：(1)当炸药爆轰波直接作用于待焊板材，很容易导致此类材料的破碎，而水下爆炸焊接法由于以水为传压介质，可以得到均匀的水下冲击波加载压力，且压力在炸药爆轰压力下可调，便于寻找最优焊接参数，实现均匀完整的焊接复合；(2)使用传统爆炸焊接对金属箔材焊接时，往往需要通过添加介质缓冲层、固定或镶嵌金属箔材等特殊处理，来实现复合。在水下爆炸焊接中，由于基、复板上下都有水层保护，能够有效缓冲压力波，防止大变形，保持焊接材料的完整性。

本文中，利用水下爆炸焊接方法开展合金工具钢与铜箔的焊接复合实验。其中，合金工具钢JIS SKS3为高硬度脆性材料，铜箔为薄材。传统爆炸焊接中炸药直接加载飞板，可以利用格尼(Gurney)公式^[6]、Aziz一维飞板驱动公式^[7]等估算飞板的加速过程以及基复板的碰撞速度。但是，在水下爆炸焊接中，由于炸药和复板之间水层的存在，爆轰波先在水中传播，形成水下冲击波，然后在水下冲击波的驱动下加速飞板，形成焊接。所以，现有的飞板运动(加速过程、终速大小)计算规律不能直接应用于水下爆炸焊接，需对水下爆炸焊接进行数值模拟。利用数值模拟，可以分析炸药爆轰后冲击波在水下的传播过程、飞板的加速过程以及飞板与基板的碰撞变形过程，可以计算基复板的碰撞速度，保证碰撞速度满足爆炸焊接窗口理论。

1. 实验

实验材料为日本产JIS SKS3合金工具钢，主要成分为Fe，其他成分含量为：w(C)=1.0%，w(Si)=0.3%，w(Mn)=1.0%，w(Cr)=0.8%，w(W)=0.8%。工具钢尺寸为60 mm× 60 mm × 25 mm，作为基板，铜箔尺寸为60 mm × 60 mm × 0.5 mm，作为飞板。日本产高爆速防水SEP炸药成分为w(PETN)=65%、w(石蜡)=35%，密度约1 300 kg/m³、爆速约7 000 m/s。爆炸焊接的焊接速度小于材料的声速，本实验采用倾斜装药，倾角预设为20°，整体装置模型如图 1所示。药厚为5 mm，铜箔与合金工具钢的间距设为0.2 mm，用防水胶布密封飞板和基板。实验在水中完成，使用电雷管从左端起爆炸药。

图 1 水下爆炸焊接装置图

Figure 1. Underwater explosive welding setup

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2. 数值模拟

利用有限元软件ANASYS/LS-DYNA对炸药爆轰、水下冲击波传播以及驱动飞板与基板碰撞过程进行模拟，炸药、水、基复板各模型如图 2所示。炸药尺寸12 cm×0.5 cm，倾斜角20°，飞板6 cm×0.5 cm，基板6 cm×2.5 cm，飞板与基板间隔0.02 cm。网格划分为0.05 cm×0.05 cm。

图 2 水下爆炸焊接的数值模型

Figure 2. Numerical model ofunderwater explosive welding

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炸药采用高爆燃材料模型和JWL状态方程。JWL方程的形式为：

$p=A\left( 1-\frac{\omega }{{{R}_{1}}V} \right){{\text{e}}^{-{{R}_{1}}V}}+B\left( 1-\frac{\omega }{{{R}_{2}}V} \right){{\text{e}}^{-{{R}_{2}}V}}+\frac{\omega E}{V}$

式中：A、B、R₁、R₂和ω为炸药参数，相对体积V=v/v₀，v为体积，v₀为初始体积，E为单位体积内能。

SEP炸药状态方程参数如下：ρ=1.310 g/m³, D=6 970 m/s，A=365.0 GPa，B=2.310 GPa，R₁=4.30，R₂=1.0，ω=0.280，p_CJ=15.9 GPa^[8]。

水的密度为1 g/cm³，采用空材料模型和Grüneisen状态方程。材料压缩和膨胀的Grüneisen状态方程形式分别为：

${{p}_{\text{pre}}}=\frac{{{\rho }_{0}}{{c}^{2}}\mu \left[ 1+\left( 1-{{\gamma }_{0}}/2 \right)\mu -\alpha {{\mu }^{2}}/2 \right]}{{{\left[ 1-\left( {{S}_{1}}-1 \right)\mu -{{S}_{2}}{{\mu }^{2}}/(\mu +1)-{{S}_{3}}{{\mu }^{3}}/{{(\mu +1)}^{2}} \right]}^{2}}}+\left( {{\gamma }_{0}}+\alpha \mu \right)E$

${{p}_{\text{exp}}}={{\rho }_{0}}{{c}^{2}}\mu +\left( {{\gamma }_{0}}+\alpha \mu \right)E$

式中：c为v_s-v_p曲线的截距，S₁、S₂、S₃为v_s-v_p曲线的斜率参数，γ₀为Grüneisen常数，α为Grüneisen常数γ₀的修正系数，μ=ρ/ρ₀-1，ρ为密度，ρ₀为初始密度，E为单位体积内能。

飞板与基板均选用Johnson-Cook材料模型^[9]和Grüneisen状态方程^[10]。Johnson-Cook材料模型的形式为：

${{\sigma }_{\text{y}}}=\left( A+B\bar{\varepsilon }_{\text{p}}^{n} \right)\left( 1+C\ln {{{\dot{\varepsilon }}}^{*}} \right)\left( 1-{{T}^{*m}} \right)$

式中：A、B、C、m和n为材料常数，ε_p为等效塑性应变， $\dot{\varepsilon}$ 为等效应变率，T^*=(T－T_r)/(T_m－T_r)，T为温度，T_r为实验初始温度，T_m为熔点温度。

图 3为水下爆炸焊接过程中飞板与基板在水下冲击波作用下的变形过程以及压力分布情况。炸药爆轰后，冲击波传入水中，形成水下冲击波，飞板在水下冲击波作用下向下加速与基板碰撞，碰撞点附近压力剧增，同时向水中形成反射波。因此，在飞板与基板的焊接过程中，可以观察到反射波和碰撞点压力分布显现出两个峰值。图 4为水下爆炸焊接过程中复板随时间的变形过程。可以看到，复板从左端开始向基板碰撞，直到复板与基板完成焊接，大约需要20 μs。

图 3 14 μs时基复板压力分布

Figure 3. Pressure distribution of flyerand base plate at 14 μs

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图 4 水下爆炸焊接过程

Figure 4. Process of underwater explosive welding

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在炸药稳定爆轰后，分别选取飞板各段节点进行分析，绘制速度时程曲线如图 5。在飞板前段，速度大约为400 m/s。沿着爆轰方向，速度逐渐减小，在后端速度大约为300 m/s。对照文献[11]的双金属爆炸焊接下限条件，可以看出，300~400 m/s可以满足大多数金属材料的飞板速度下限要求。

图 5 飞板垂直方向的速度

Figure 5. Vertical velocity distribution ofthe flyer plate along the welding direction

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3. 实验结果分析

3.1 界面形貌观察

工具合金钢SKS 3与铜箔界面形貌如图 6。从图 6可以看出，焊接区域结合紧密，呈现规律和连续的正弦波状结合形态，没有产生明显孔洞和脆性金属间化合物，获得优良的结合强度。典型的波状界面表明，焊接参数的正确性和焊接强度的可靠性。沿着爆轰方向，焊接界面在开始阶段5 cm处，波纹振幅大约为16 μm，然后逐渐减小，在后端表现为平直界面。由于采用了倾斜安置法进行水下爆炸焊接，飞板从前端到后端与炸药的距离逐渐增大，导致爆轰能量随着焊接方向逐渐减小。在爆炸焊接中，随着爆炸能量的增大，焊接板材受影响的深度增加，而射流层的厚度增厚，爆炸焊接界面会由平直界面逐渐转变为波状界面^[12-17]。反之，用倾斜安置法进行爆炸焊接实验时，各个位置的能量不同，导致界面形态的变化。一组实验可以得到不同的实验结果，这有益于爆炸焊接的研究。

图 6 初始态工具钢与铜箔的界面形态

Figure 6. Interface of tool steel and copper foil

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3.2 界面显微硬度分析

在载荷10 g的HM-102上进行显微硬度分析，基覆板显微硬度与界面距离的变化关系曲线如图 7。铜层与合金钢SKS3硬度分布变化平稳，靠近界面处硬度稍微增加。爆炸焊接中，由于界面处金属强烈的塑性变形，细晶强化、冷作硬化、位错增加等原因导致硬度在靠近界面处达到峰值，随着远离界面而减小，在基体中达到稳定。在界面上，由于两种金属的混合，硬度值介于两种金属之间。

图 7 工具钢与铜箔界面的显微硬度分布

Figure 7. Micro hardness distributionat the interface of tool steel and copper foil

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4. 结论

高硬度合金工具钢JIS SKS3和铜箔，可通过水下爆炸焊接成功复合。可以看出，水下爆炸焊接高硬度、薄板材料具有很好的焊接效果，这正是传统焊接方法的难点。

(1) 利用有限元软件ANASYS/LS-DYNA预测水下爆炸焊接过程，得到基覆板的变形和焊接过程中的压力分布以及速度分布，弥补传统经验公式在水下爆炸焊接中的不足。

(2) 典型的波状界面表明焊接参数的合理性和焊接强度的可靠性。

(3) 倾斜爆炸焊接装置导致的界面形态的变化，与模拟结果预测一致。

(4) 显微硬度显示基复板在靠近界面处硬度值达到峰值。

图 1 材料性能的影响因素示意图^[3]

Figure 1. Schematic diagram of the influencing factors of mechanical properties^[3]

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图 2 根据应变率的加载模式分类^[7]

Figure 2. Classifications of loads with reference to strain rate^[7]

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图 3 不同材料高速冲击表面处理前后力学性能变化^{[21, 23]}

Figure 3. Mechanical properties of different materials processed by various high velocity impact surface treatments^{[21, 23]}

FSW: Friction stir welding; LW: laser-welded; HAZ: heat affected zone; FZ: fusion zone

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图 4 不同材料经高速冲击表面处理后的塑性变化^[24-26]

Figure 4. The plastic changes of different materials processed by high velocity impact surface treatments^[24-26]

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图 5 不同材料经高速冲击表面处理后的拉伸断口^[27-28]

Figure 5. Tensile fracture morphologies of different materials after high speed impact surface treatment^[27-28]

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图 6 不同梯度材料的应力应变曲线^[30-31]

Figure 6. The stress-strain curves of different gradient materials^[30-31]

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图 7 低应变率表面处理后的晶粒形貌^[34-35]

Figure 7. Grain structure of materials processed by low-strain-rate surface treatments^[34-35]

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图 8 表面形变处理横截面梯度形貌^[37-39]

Figure 8. The cross section morphologies of the specimen processed by surface mechanical treatment^[37-39]

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图 9 AA2060铝锂合金喷丸过程中的动态回复再结晶^[46]

Figure 9. Dynamic recovery and recrystallization of AA2060 Al-Li alloy induced by shot peening^[46]

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图 10 AA2060铝锂合金喷丸前后晶粒取向图^[46]

Figure 10. Grain orientation map of AA2060 Al-Li alloy before and after shot peening^[46]

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图 11 304奥氏体不锈钢的冲击相变^[57]

Figure 11. Phase transformation of 304 austenite stainless steel by impact deformation^[57]

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图 12 不同材料在不同高速冲击表面处理下的形变诱发相变^[60-62]

Figure 12. Deformation induced phase transformation of different materials under different high velocity impact surface treatments^[60-62]

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图 13 位错组态随应变量和应变率的演变规律示意图^[66-67]

Figure 13. Proposed diagram of dislocation evolution with the increment of plastic strain and strain rates^[66-67]

(LGs: large grains; DLs: dislocation lines; DWs: dislocation walls; DTs: dislocation tangles; UFGs: ultrafine-grains; NGs: nano-grains)

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图 14 高速冲击表面处理后不同深度处的位错组态^[68-70]

Figure 14. Dislocations at different depths after high velocity impact surface treatments^[68-70]

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图 15 不同材料在不同高速冲击表面处理变形时析出相变化^[72-74]

Figure 15. The variation of precipitates of different materials deformed under different high velocity impact surface treatments^[72-74]

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图 16 位错运动通过强化相方式^[77]

Figure 16. The ways of dislocation moving through strengthening phases^[77]

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图 17 应变率对位错与析出相之间相互作用的影响^[77]

Figure 17. Effects of strain rate on the interaction of dislocations and precipitates^[77]

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图 18 位错到变形孪晶的演变规律示意图^[68]

Figure 18. Schematic diagram of the transformation from dislocations to deformation twins with the increment of plastic strain and strain rates^[68]

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图 19 高应变率下变形孪晶^[85-86]

Figure 19. Deformation twins occurred under high strain rates^[85-86]

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图 20 纳米晶铝TEM图像^[41]

Figure 20. TEM micrographs of nanocrystalline aluminum deformed by manually grinding^[41]

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图 21 Thompson双四面体与纳米孪晶片层的相对位向关系^[89]

Figure 21. A schematics showing the relative orientation between a double Thompson tetrahedra and twin lamellae^[89]

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图 22 试样变形示意图

Figure 22. Schematic diagram of sample deformation

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