目的 揭示超声滚挤压过程中表层晶粒等微观组织的演变规律,为高强度42CrMo钢表层性能的精准调控提供理论支撑,并为其他高强度钢及金属材料的表层性能优化提供新的思路。方法 利用EBSD分析手段,分别对超声滚挤压强化前后的淬火态42CrMo钢的晶界、位错及织构等演变规律进行深入分析。结果 在超声滚挤压的强化作用下,42CrMo钢的表层力学性能和表面形貌得到明显改善,其表面的残余拉应力转化为残余压应力,且最大残余压应力达到了-1 030 MPa,表层硬度升至697HV,表面粗糙度降至0.179 μm。由EBSD分析结果可知,由超声滚挤压造成的剧烈塑性变形诱导42CrMo钢表层晶粒发生明显取向演化,由原来以<101>为主的取向逐渐转变为以<001><111>为主的择优取向,小角度晶界占比从18.9%升至37.5%,晶粒尺寸从40 μm左右降至10 μm以下。在此过程中发现形成了{112}<110>织构,同时在超声滚挤压过程中发生动态再结晶现象。结论 在超声滚挤压强化过程中,超声能与高频机械动能共同作用于材料表层,诱导晶粒内部产生大量位错和孪晶结构。随着塑性变形的持续进行,位错与孪生相互作用,在晶界及孪晶界处发生缠结与塞积,导致小角度晶界数量增加、晶粒细化现象增强。高应变率变形与局部热积累为动态再结晶的发生创造了有利条件,晶粒取向重排和新晶粒形核在一定程度上表征了动态再结晶行为的演化趋势。动态再结晶进一步优化了材料的组织结构和力学性能,是超声滚挤压显著提升零件表层性能的重要机制之一。
Abstract
To reveal the microstructural evolution, including grain refinement, dislocation structures, and texture changes, during the surface strengthening process of ultrasonic surface rolling process (USRP), an in-depth analysis is conducted through electron backscatter diffraction (EBSD), to provide a theoretical basis for precise surface performance control of high-strength 42CrMo steel while establishing a novel guideline for optimizing surface properties in other high-strength steel and metallic materials. USRP, as a high-frequency vibration-assisted mechanical treatment, introduces severe plastic deformation (SPD) into the material surface, significantly altering the microstructure of the surface and enhancing the mechanical performance of the surface. To analyze these effects, quenched 42CrMo steel samples are subject to USRP under optimized parameters, and their grain boundary characteristics, dislocation structures, and crystallographic texture evolution are examined before and after USRP. The results indicate that USRP markedly improves the surface integrity of 42CrMo steel by converting residual tensile stress into residual compressive stress, with a maximum compressive stress of -1 030 MPa. Additionally, the surface hardness increases from its initial value to 697HV, while the surface roughness decreases to 0.179 μm, demonstrating enhanced wear resistance and fatigue performance. EBSD analysis reveals that the severe plastic deformation induced by USRP leads to significant grain orientation evolution in the surface layer of 42CrMo steel, characterized by a preferential transformation from the initial <101> orientation to <001> and <111> orientations. The fraction of low-angle grain boundaries (LAGBs) increases significantly from 18.9% to 37.5%, and the average grain size is refined from approximately 40 μm to below 10 μm. Moreover, the formation of a {112}<110> texture is observed, along with clear evidence of dynamic recrystallization occurring during USRP. The strengthening mechanism of USRP can be attributed to the combined action of ultrasonic energy and high-frequency mechanical vibrations on the material surface, which induces a high density of dislocations and twin structures within the grains. As plastic deformation progresses, the interaction between dislocations and twins leads to entanglement and accumulation at grain and twin boundaries, promoting the formation of low-angle grain boundaries and enhancing grain refinement. The high strain rate and localized thermal accumulation create favorable conditions for dynamic recrystallization, as evidenced by grain orientation rearrangement and the nucleation of new grains. Dynamic recrystallization further refines the microstructure and enhances the mechanical properties of the material, representing a key mechanism by which USRP significantly improves the surface performance of components. These findings confirm that USRP is an effective surface enhancement technique for high-strength steel, offering substantial improvements in fatigue strength, wear resistance, and overall surface integrity. Compared with conventional mechanical surface treatments such as shot peening and deep rolling, USRP provides superior microstructural refinement and stress redistribution due to its unique ultrasonic vibration-assisted mechanism. These results provide valuable insights into the role of microstructural evolution in surface strengthening and offer practical guidance for optimizing USRP parameters to achieve superior surface properties in engineering applications. The methodology and findings of this study also hold promise for broader applications in aerospace, automotive, and precision manufacturing industries, where high-performance surface-treated components are critical for reliability and durability. Future research should focus on further refining the USRP through numerical modeling and experimental validation to optimize the balance between microstructural refinement, residual stress distribution, and mechanical performance enhancement.
关键词
高强度钢 /
微观强化机制 /
超声滚挤压 /
晶粒变化 /
动态再结晶
Key words
high-strength steel /
microstructural strengthening mechanism /
USRP /
grain evolution /
DRX
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基金
国家自然科学基金（U1804145）; 国家重点研发计划（2018YFB2000405, 2022YFC2805702）
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