粗糙表面高强铝合金导线疲劳寿命预测

doi:10.11900/0412.1961.2021.00049

金属学报

2022, Vol. 58

Issue (8): 1035-1043 DOI: 10.11900/0412.1961.2021.00049

研究论文

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粗糙表面高强铝合金导线疲劳寿命预测

宋文硕¹, 宋竹满², 罗雪梅², 张广平², 张滨¹(

)

^1.东北大学材料科学与工程学院材料各向异性与织构教育部重点实验室沈阳 110819
^2.中国科学院金属研究所沈阳材料科学国家研究中心沈阳 110016

Fatigue Life Prediction of High Strength Aluminum Alloy Conductor Wires with Rough Surface

SONG Wenshuo¹, SONG Zhuman², LUO Xuemei², ZHANG Guangping², ZHANG Bin¹(

)

^1.Key Laboratory for Anisotropy and Texture of Materials, Ministry of Education, School of Materials Science and Engineering, Northeastern University, Shenyang 110819, China
^2.Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

引用本文:

宋文硕, 宋竹满, 罗雪梅, 张广平, 张滨. 粗糙表面高强铝合金导线疲劳寿命预测[J]. 金属学报, 2022, 58(8): 1035-1043.
Wenshuo SONG, Zhuman SONG, Xuemei LUO, Guangping ZHANG, Bin ZHANG. Fatigue Life Prediction of High Strength Aluminum Alloy Conductor Wires with Rough Surface[J]. Acta Metall Sin, 2022, 58(8): 1035-1043.

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摘要:

研究了6101铝合金单股导线的表面粗糙度对其疲劳性能的影响。结果表明,随着表面粗糙度参数(轮廓最大高度R_z)的增加,铝合金导线的疲劳强度逐渐降低,当R_z从57.9 μm增加到161.7 μm时,疲劳极限下降了约36.4%。分析认为,R_z的增加引起理论应力集中系数 $K t$ 的增加,导致疲劳裂纹更易于萌生,致使样品的疲劳强度较低。结合有限元分析研究了R_z对 $K t$ 的影响,将表面粗糙度等效成尺寸为 $a 0$ = $π L R z 2$ (L为平均缺口宽度)的初始裂纹,基于能量理论和Pairs公式提出了不同表面粗糙度铝合金导线疲劳寿命预测模型,有效地预测了铝合金导线疲劳服役可靠性。

关键词 ：铝合金导线, 表面粗糙度, 应力集中, 疲劳寿命

Abstract：

The power industry is changing from rapid growth to high-quality development, and there are urgent demands for the high-quality and high-service reliability of overhead lines. Al-Mg-Si alloys are widely used in the production of long-distance overhead lines owing to their high strength-to-density ratio, good conductivity, and corrosion resistance. In the overhead line service, surface defects reduce their mechanical properties, and surface roughness greatly affects its fatigue properties. A single-strand conductor of 6101 aluminum alloy was employed to investigate the fatigue properties of the conductors with different roughness. The fatigue strength of the alloy wires decreased gradually with an increase in the surface roughness (maximum height of profile, R_z). As R_zincreased from 57.9 to 161.7 μm, the fatigue limit decreased by ~36.4%. The result indicates that an increase of R_z increases the theoretical stress concentration factor $K t$ , which facilitates the initiation of fatigue cracks, and the fatigue strength decreases accordingly. Furthermore, the surface roughness is equivalent to the size of the initial crack $a 0$ = $π L R z 2$ (L is the average value of the arerage width of profile element). A model suitable for predicting the fatigue life of conductors with different surface roughness was obtained.

Key words： aluminum alloy conductor surface roughness stress concentration fatigue life

收稿日期: 2021-01-28

ZTFLH:

TB31

基金资助:国家自然科学基金项目(51671050);国家自然科学基金项目(51971060)

作者简介: 宋文硕,男,1996年生,硕士生

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https://www.ams.org.cn/CN/10.11900/0412.1961.2021.00049 或 https://www.ams.org.cn/CN/Y2022/V58/I8/1035

图1 疲劳样品尺寸示意图

图2 6061铝合金导线样品显微组织的TEM像、STEM像及EDS元素分布图

图3 不同粗糙度6061铝合金导线样品表面形貌照片和表面轮廓曲线

表1 样品的表面粗糙度数据

图4 不同表面粗糙度6061铝合金导线样品的应力幅-疲劳寿命(S-N)曲线

图5 不同表面粗糙度6061铝合金导线样品的断口SEM像

图6 不同粗糙度6061铝合金导线样品的应力幅-粗糙度关系和断口形貌

图7 不同表面粗糙度对应的疲劳断口扩展区面积

图8 不同粗糙度时缺口处的应力分布和等效缺口示意图

表2 模拟计算的理论应力集中系数

图9 不同Rz值对应的理论应力集中系数

图10 不同裂纹尺寸对应的疲劳极限范围

图11 计算结果和实验结果对比

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