Impact of Porosity Defects on High-Cycle Fatigue Life of Steel Pipe Weldments
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摘要: 以钢管为构件的焊接结构在焊接过程中,易形成气孔这类典型体积型焊接缺陷,导致结构在幅值较低的循环荷载作用下发生高周疲劳破坏。因此,基于试验和数值模拟相结合,研究了气孔缺陷对钢管焊接试件高周疲劳寿命的影响。首先,设计焊接完好和有气孔缺陷的两组钢管焊接试件进行高周疲劳试验;接着建立有气孔焊接试件的仿真模型,并基于试验结果验证模型的正确性;最后分析气孔缺陷轴向、周向、径向不同尺寸对钢管焊接试件应力集中系数和高周疲劳寿命的影响。结果表明:气孔缺陷三维尺寸对钢管焊接试件的应力集中和高周疲劳寿命的影响呈现不同机理,由于焊接试件管壁尺寸较其他两个方向小得多,因此缺陷径向尺寸对应力集中和高周疲劳寿命影响最为敏感,使得应力集中系数变化剧烈,高周疲劳寿命下降幅度大;由于缺陷轴向尺寸增大不会削弱截面有效承载面积,反而降低了缺陷处形状的特异性,使得应力集中系数随缺陷轴向尺寸增加而下降,且能保持较长的高周疲劳寿命;由于缺陷周向尺寸增加会减小截面有效承载面积,使得应力集中系数随缺陷周向尺寸增加而有所增加,高周疲劳寿命出现一定下降。Abstract: During the welding process of welded structures composed of steel pipes, typical volumetric welding defects such as porosity are easily formed, which may result in high-cycle fatigue failure of the structure under low-amplitude cyclic loads. Therefore, based on a combination of experimental and numerical simulations, the paper studied the effect of porosity defects on the high-cycle fatigue life of welded steel pipe specimens. First, two groups of steel pipe weldments with intact welding and porosity defects were designed for high-cycle fatigue tests; then a simulation model of porosity weldments was established and verified based on the test results; finally, the influence of different axial directions, circumferential directions, and radial dimensions of porosity defects on the stress concentration factor and high-cycle fatigue life of steel pipe weldments was analyzed using the simulation model. The results showed that the three-dimensional size of porosity defects exhibited different influence mechanisms on the stress concentration and high-cycle fatigue life of steel pipe weldments. Since the size of the welded pipe wall was much smaller than the other two directions, the stress concentration and high-cycle fatigue life were most sensitive to the radial size of the defect, casuing drastic variations in stress concentration and significant reductions in high-cycle fatigue life; because the increase in the axial size of the defect did not reduce the effective bearing area of the section but decreased the specificity of the defect shape, the stress concentration factor decreased with the increase of the axial size of the defect, thereby maintaining a long high-cycle fatigue life; since the increased circumferential size of the defect reduced the effective bearing area of the section, the stress concentration factor increased with the increase of the defect's circumferential size, thereby decreasing the high-cycle fatigue life to a certain extent.
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