Research on accelerated thermal fatigue testing and life prediction of Al-Si alloy pistons under start-stop cycles

IF 5.7 2区 材料科学 Q1 ENGINEERING, MECHANICAL International Journal of Fatigue Pub Date : 2024-10-30 DOI:10.1016/j.ijfatigue.2024.108677
Jie Yan, Qipei Tong, Weizheng Zhang, Yanpeng Yuan, Shuang Jin, Zhenyao Guo, Haonan Zhang, Yunle Yu, Zicong Cao
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Abstract

As one of the most critical components in the combustion chamber of diesel engines, pistons operate under high temperature and pressure conditions for extended periods, which increases the likelihood of failures such as thermal fatigue. This paper first utilizes finite element simulation to obtain the temperature and stress field distribution of an Al-Si alloy piston under actual engine conditions. The results indicate that the throat area of the piston is the most susceptible to fatigue failure. Based on this, accelerated thermal fatigue tests were conducted to study the influence of various experimental factors on piston life, as well as to analyze the weight of each factor. Results from macroscopic and microscopic analyses of cracks using a scanning electron microscope show that fatigue cracks originate at the interface between the aluminum matrix and the detached hard particles. The cracking at the piston throat exhibits clear characteristics of ductile fracture, which is the result of cumulative fatigue damage. Therefore, from the perspective of continuum damage mechanics, it is considered to characterize the equivalent stress using the average loading rate during the loading phase and the maximum axial temperature gradient, establishing an experimental life prediction model for Al-Si alloy pistons.
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铝硅合金活塞在启停循环下的加速热疲劳测试和寿命预测研究
作为柴油发动机燃烧室中最关键的部件之一,活塞长期在高温高压条件下工作,这增加了发生热疲劳等故障的可能性。本文首先利用有限元模拟获得了铝硅合金活塞在实际发动机工况下的温度和应力场分布。结果表明,活塞的喉部区域最容易发生疲劳失效。在此基础上,进行了加速热疲劳试验,以研究各种试验因素对活塞寿命的影响,并分析各因素的权重。使用扫描电子显微镜对裂纹进行宏观和微观分析的结果表明,疲劳裂纹起源于铝基体和分离的硬颗粒之间的界面。活塞喉部的裂纹具有明显的韧性断裂特征,是累积疲劳损伤的结果。因此,从连续损伤力学的角度出发,考虑利用加载阶段的平均加载速率和最大轴向温度梯度来表征等效应力,建立铝硅合金活塞的实验寿命预测模型。
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来源期刊
International Journal of Fatigue
International Journal of Fatigue 工程技术-材料科学:综合
CiteScore
10.70
自引率
21.70%
发文量
619
审稿时长
58 days
期刊介绍: Typical subjects discussed in International Journal of Fatigue address: Novel fatigue testing and characterization methods (new kinds of fatigue tests, critical evaluation of existing methods, in situ measurement of fatigue degradation, non-contact field measurements) Multiaxial fatigue and complex loading effects of materials and structures, exploring state-of-the-art concepts in degradation under cyclic loading Fatigue in the very high cycle regime, including failure mode transitions from surface to subsurface, effects of surface treatment, processing, and loading conditions Modeling (including degradation processes and related driving forces, multiscale/multi-resolution methods, computational hierarchical and concurrent methods for coupled component and material responses, novel methods for notch root analysis, fracture mechanics, damage mechanics, crack growth kinetics, life prediction and durability, and prediction of stochastic fatigue behavior reflecting microstructure and service conditions) Models for early stages of fatigue crack formation and growth that explicitly consider microstructure and relevant materials science aspects Understanding the influence or manufacturing and processing route on fatigue degradation, and embedding this understanding in more predictive schemes for mitigation and design against fatigue Prognosis and damage state awareness (including sensors, monitoring, methodology, interactive control, accelerated methods, data interpretation) Applications of technologies associated with fatigue and their implications for structural integrity and reliability. This includes issues related to design, operation and maintenance, i.e., life cycle engineering Smart materials and structures that can sense and mitigate fatigue degradation Fatigue of devices and structures at small scales, including effects of process route and surfaces/interfaces.
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