Fatigue crack growth behavior and mechanism of aluminum alloy welded joints under overloads

XU Lianyong; ZHAO Lei; HUANG Jinchao; SUN Quanwei; LIANG Wenzhou

doi:DOI：10.16579/j.issn.1001.9669.2025.09.005

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Fatigue crack growth behavior and mechanism of aluminum alloy welded joints under overloads

更新时间：2025-09-22

- Fatigue crack growth behavior and mechanism of aluminum alloy welded joints under overloads
- Journal of Mechanical Strength Vol. 47, Issue 9, Pages: 62-71(2025)
- 作者机构：
  
  1.天津大学材料科学与工程学院，天津 300350
  2.高性能轧辊材料与复合成形全国重点实验室，天津 300350
  3.天津市现代连接技术重点实验室，天津 300350
  4.南通中集能源装备有限公司，南通 226000
  5.中海油研究总院有限责任公司，北京 100020
- 作者简介：
  
  ZHAO Lei, E-mail:zhaolei85@tju.edu.cn
- 基金信息：
  
  National Natural Science Foundation of China(52025052)
- DOI：DOI：10.16579/j.issn.1001.9669.2025.09.005
  CLC：
- Received：05 July 2025，
  
  Revised：2025-07-21，
  
  Published：15 September 2025
- 稿件说明：
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徐连勇，赵雷，黄金超，等. 铝合金焊接接头在过载下疲劳裂纹扩展行为和机制研究［J］. 机械强度，2025，47（9）：62-71.

XU Lianyong，ZHAO Lei，HUANG Jinchao，et al. Fatigue crack growth behavior and mechanism of aluminum alloy welded joints under overloads［J］. Journal of Mechanical Strength，2025，47（9）：62-71.
徐连勇，赵雷，黄金超，等. 铝合金焊接接头在过载下疲劳裂纹扩展行为和机制研究［J］. 机械强度，2025，47（9）：62-71. DOI： DOI：10.16579/j.issn.1001.9669.2025.09.005.

XU Lianyong，ZHAO Lei，HUANG Jinchao，et al. Fatigue crack growth behavior and mechanism of aluminum alloy welded joints under overloads［J］. Journal of Mechanical Strength，2025，47（9）：62-71. DOI： DOI：10.16579/j.issn.1001.9669.2025.09.005.

摘要

高速列车转向架不同部位常采用不同强度铝合金材料进行设计，且采用焊接方式连接不同部件。当高速列车行驶在复杂路况时，转向架将承受拉伸过载作用，该拉伸过载会与焊接接头强度差异产生耦合叠加作用。因此，对转向架焊接结构件进行拉伸过载试验，研究拉伸过载作用下不同强度铝合金焊接接头的疲劳裂纹扩展行为和内在机制。采用柔度法测量拉伸过载作用下的裂纹扩展速率；用数字图像相关（Digital Image Correlation

DIC）技术分析了拉伸过载施加前后裂纹尖端塑性区的尺寸变化规律；采用扫描电子显微镜（Scanning Electron Microscope

SEM）观测了不同铝合金拉伸过载作用区域的断口形貌特征，用裂纹尖端塑性区尺寸变化和对应断口形貌特征解释了拉伸过载作用下的裂纹扩展行为和内在机制。结果表明，单次拉伸过载能降低疲劳裂纹扩展速率，延长疲劳寿命。分析结果表明，拉伸过载过程增大裂纹尖端塑性区，并钝化裂纹尖端，从而使疲劳裂纹扩展速率降低。材料强度越低，相同拉伸过载作用下，裂纹尖端变形越严重，迟滞效应越明显。焊接接头在拉伸过载作用下与母材试验结果保持一致，迟滞效应的强弱只取决于材料本身强度。

Abstract

Different parts of high-speed train bogies are usually designed with aluminum alloy materials of varying strengths

and welding is adopted to connect these different parts. When high-speed trains operate under complex road conditions

the bogies will be subjected to tensile overload

which will produce a coupled superposition effect with the strength difference of welded joints. Therefore

tensile overload tests were carried out on the welded structural components of bogies to study the fatigue crack growth behavior and intrinsic mechanism of aluminum alloy welded joints with different strengths under the action of tensile overload. The compliance method was used to measure the crack growth rate under tensile overload; the digital image correlation (DIC) technology was applied to analyze the change in the size of the plastic zone at the crack tip before and after the application of tensile overload; the scanning electron microscope (SEM) was employed to observe the fracture morphology characteristics of different aluminum alloys in the region affected by tensile overload. The crack growth behavior and intrinsic mechanism under tensile overload were explained based on the change in the size of the plastic zone at the crack tip and the corresponding fracture morphology characteristics. The results show that a single tensile overload can reduce the fatigue crack growth rate and extend the fatigue life. Further analysis indicates that during the tensile overload process

the plastic zone at the crack tip expands and the crack tip is blunted

which together lead to the reduction of the fatigue crack growth rate. The lower the material strength

the more severe the deformation at the crack tip and the more obvious the hysteresis effect under the same tensile overload. The test results of welded joints under tensile overload are consistent with those of the base metal

suggesting that the strength of the hysteresis effect depends only on the inherent strength of the material itself.

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references

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