目的 揭示激光冲击-机械喷丸复合强化工艺对齿轮钢表面微观组织的影响机制。方法 采用X射线衍射线形分析（XRDLPA）方法,对比研究不同强化工艺（渗碳磨削、常规喷丸、激光冲击+常规喷丸、激光冲击+常规喷丸+微粒喷丸）对齿轮钢微观组织（位错密度、位错特性、晶块尺寸、微观应变、相含量）的影响,并通过透射电子显微（TEM）技术及三点弯曲疲劳试验分别验证XRDLPA方法的可行性,以及激光冲击-机械喷丸复合强化工艺对齿轮钢疲劳性能的提升效果。结果 通过复合强化工艺,将齿轮钢表面的位错密度由2.73×1016 m-2增至3.09×1016 m-2,马氏体中位错类型表现为螺型-刃型混合位错,螺型位错发生交滑移,其含量降低,刃型位错含量增加。通过复合强化工艺,促进了齿轮钢表面位错偶极子和位错胞的形成,位错排列参数M由7.3降至5.8;促进了晶块尺寸的均匀分布,平均晶块尺寸由57.1 nm细化至36.7 nm;基于位错增殖分割机制,齿轮钢表面形成了纳米化组织。基于原子滑移程度的不同,(200)晶面晶块尺寸最小,微观应变最大,(222)晶面晶块尺寸最大,微观应变最小。通过复合强化工艺促进了马氏体相变,齿轮钢中马氏体相含量由63.4%增至84%。采用激光冲击-机械喷丸处理后,齿轮钢弯曲疲劳寿命较渗碳磨削态试样提升了33.6倍（540 MPa,应力幅）。结论 基于XRDLPA方法,对激光冲击-机械喷丸复合强化齿轮钢表面微观组织特性进行定量分析是可行的。通过激光冲击-机械喷丸复合强化工艺诱导塑性应变,可促进位错增殖、晶块细化、马氏体相变,多尺度改善了齿轮钢表面微观组织结构,进而有效提升了齿轮钢弯曲疲劳寿命。
Abstract
Heavy-duty gears are subject to alternating loads, high torque as well as harsh service conditions, and bending fatigue is the main failure mode, seriously affecting the comprehensive performance of gears. Conventional shot peening (CSP) is a common method for gear surface strengthening. It introduces high magnitude compressive residual stress, but the induced surface roughness is relatively large, which restricts the manufacturing of high-performance gears. Laser shock peening (LSP) can introduce a deeper compressive stress layer, but the compressive stress level is lower than that of CSP. Fine particle peening (FPP) can improve the surface roughness and enlarge the compressive stress level on the exterior surface of gears, but the compressive stress layer is shallow. Therefore, the existing strengthening methods cannot meet the current technical performance requirements of heavy-duty gears. To address this issue, laser shock-mechanical shot peening compound strengthening method is proposed in this work and the induced microstructural features affecting the bending life of gears are experimentally investigated.
Carburized and ground gear steels made of 20CrMnTi are used in this work, and the dimension of each sample is 30 mm× 50 mm×5 mm. Three kinds of strengthening methods, in terms of CSP (media diameter of 0.8 mm, intensity of 0.52 mmA, coverage of 100%), FPP (media diameter of 0.05 mm, intensity of 0.14 mmN, coverage of 100%), and LSP (pulse energy of 4 J, spot diameter of 2 mm, overlap of 50%, pulse width of 20 ns), are combined to form a laser shock-mechanical shot peening compound strengthening process. Since LSP has strict requirements on the surface roughness of workpieces, this process is arranged before CSP. FPP is often used as the final strengthening process to improve the roughness of workpieces, so it is arranged after LSP and CSP. Considering the processing efficiency, CSP, FPP, and LSP are used for treating gear steels only once. This work aims to reveal the microstructure evolution of gear steels treated by laser shock-mechanical shot peening compound strengthening process. X-ray diffraction line profile analysis (XRDLPA) method is applied to comparatively study the effect of different strengthening processes (carburizing and grinding, conventional shot peening, laser shock peening + conventional shot peening, laser shock peening + conventional shot peening + fine particle peening) on the microstructure (dislocation density, crystallite size, micro-strain and phase fraction) of the gear steels. A three-point bending fatigue test is designed to reveal the effect of the compound strengthening method on the fatigue life of gear steels.
The results show that it is feasible to conduct a quantitative investigation on the microstructural characteristics of gear steels subject to laser shock-mechanical shot peening compound treatment with XRDLPA method. Laser shock-mechanical shot peening compound strengthening process can promote dislocation multiplication, crystallite refinement and phase transformation, thereby improving the surface microstructure of gear steels on multiple scales. The compound method can effectively enhance the bending fatigue life of gear steels. Specifically, with the application of the compound treatment, the dislocation density for martensite increases from 2.73×1016 to 3.09×1016 m-2 in the form of screw-edge-mixed type. The fraction of screw dislocation decreases due to the occurrence of cross-slip, whereas the fraction of edge dislocation increases. The formation of dislocation dipoles or dislocation cells in the surface layer can be further promoted by the compound strengthening process, and the dislocation arrangement parameter M decreases from 7.3 to 5.8. With the adoption of the compound treatment, the average crystallite size on the surface of gear steels decreases from 57.1 to 36.7 nm, and the uniformity distribution of the crystallite size is improved. Because of dislocation multiplication and division mechanism, nanostructured layers are generated on the surface of gear steels. Due to the different degrees of atomic slip, the (200) crystallographic plane exhibits the smallest crystallite size and highest micro-strain, whereas the (222) plane shows the smallest micro-strain and the largest crystallite size. With the employment of the compound treatment, the martensite fraction of gear steels increases from 63.4% to 84% resulting from martensite transformation. With the use of the compound treatment, the bending fatigue life of gear steels increases by 33.6 times (under the stress amplitude of 540 MPa).
关键词
激光冲击 /
机械喷丸 /
齿轮钢 /
复合强化 /
XRD线形分析 /
微观组织
Key words
laser shock peening /
mechanical shot peening /
gear steel /
compound strengthening /
XRD line profile analysis /
microstructure
{{custom_sec.title}}
{{custom_sec.title}}
{{custom_sec.content}}
参考文献
[1] 刘怀举, 陈地发, 朱才朝, 等. 齿轮弯曲疲劳的研究进展与发展趋势[J]. 机械工程学报, 2024, 60(3): 83-108.
LIU H J, CHEN D F, ZHU C C, et al.State-of-Art and Trend of Gear Bending Fatigue Studies[J]. Journal of Mechanical Engineering, 2024, 60(3): 83-108.
[2] 李彩云, 邢志国, 赵向伟, 等. 强化方法对重载齿轮弯曲疲劳强度影响的研究现状与建议[J]. 材料导报, 2020, 34(21): 21146-21154.
LI C Y, XING Z G, ZHAO X W, et al.Research Status and Suggestions on Influence of Strengthening Methods on Bending Fatigue Strength of Heavy-Duty Gear[J]. Materials Reports, 2020, 34(21): 21146-21154.
[3] 朱鹏飞, 严宏志, 陈志, 等. 齿轮齿面喷丸强化研究现状与展望[J]. 表面技术, 2020, 49(4): 113-131.
ZHU P F, YAN H Z, CHEN Z, et al.Research Status and Prospect of Shot Peening of Gear Tooth Flanks[J]. Surface Technology, 2020, 49(4): 113-131.
[4] IVANOV I V, EMURLAEV K I, LAZURENKO D V, et al.Rearrangements of Dislocations during Continuous Heating of Deformed Β-TiNb Alloy Observed by In-Situ Synchrotron X-Ray Diffraction[J]. Materials Characterization, 2020, 166: 110403.
[5] RAJA M K.XRD Line Profile Analysis for Understanding the Influence of Cold Work on Ageing Behaviour in 304HCu Steel[D]. Mumbai: Homi Bhabha National Institute, 2020: 8-9.
[6] SHINTANI T, MURATA Y.Evaluation of the Dislocation Density and Dislocation Character in Cold Rolled Type 304 Steel Determined by Profile Analysis of X-Ray Diffraction[J]. Acta Materialia, 2011, 59(11): 4314-4322.
[7] MASUMURA T, INAMI K, MATSUDA K, et al.Quantitative Evaluation of Dislocation Density in As-Quenched Martensite with Tetragonality by X-Ray Line Profile Analysis in a Medium-Carbon Steel[J]. Acta Materialia, 2022, 234: 118052.
[8] MURUGESAN S, KUPPUSAMI P, MOHANDAS E, et al.X-Ray Diffraction Rietveld Analysis of Cold Worked Austenitic Stainless Steel[J]. Materials Letters, 2012, 67(1): 173-176.
[9] FU P, JIANG C H, WU X Y, et al.Surface Modification of 304 Steel Using Triple-Step Shot Peening[J]. Materials and Manufacturing Processes, 2015, 30(6): 693-698.
[10] FUCKS A.Experimental Determination of Dislocation Densities in Martensitic Steels[D]. Graz: Graz University of Technology, 2018: 8-13.
[11] NATH D, SINGH F, DAS R.X-Ray Diffraction Analysis by Williamson-Hall, Halder-Wagner and Size-Strain Plot Methods of CdSe Nanoparticles- a Comparative Study[J]. Materials Chemistry and Physics, 2020, 239: 122021.
[12] YAN H Z, ZHU P F, CHEN Z, et al.Determination of the Optimal Coverage for Heavy-Duty-Axle Gears in Shot Peening[J]. The International Journal of Advanced Manufacturing Technology, 2022, 118(1): 365-376.
[13] MUTHUKUMARAN G, RAI A K, GAUTAM J, et al.A Study on Effect of Multiple Laser Shock Peening on Microstructure, Residual Stress, and Mechanical Strength of 2.5 Ni-Cr-Mo (EN25) Low-Alloy Steel[J]. Journal of Materials Engineering and Performance, 2023, 32(10): 4361-4375.
[14] POUR-ALI S, KIANI-RASHID A R, BABAKHANI A, et al. Correlation between the Surface Coverage of Severe Shot Peening and Surface Microstructural Evolutions in AISI 321: A TEM, FE-SEM and GI-XRD Study[J]. Surface and Coatings Technology, 2018, 334: 461-470.
[15] ZHU P F, YAN H Z, ZHOU J B, et al.Surface Integrity and Transmission Performance of Spiral Bevel Gears Subjected to Shot Peening: A Comparison between Concave and Convex Surfaces[J]. Surface and Coatings Technology, 2022, 445: 128675.
[16] LUAN W Z, JIANG C H, WANG H W, et al.XRD Investigation of Thermostability of TiB2/Al Deformation Layer Introduced by Shot Peening[J]. Materials Science and Engineering: A, 2008, 480(1/2): 1-4.
[17] ZHAN K, WU Y H, LI J L, et al.Investigation on Surface Layer Characteristics of Shot Peened Graphene Reinforced Al Composite by X-Ray Diffraction Method[J]. Applied Surface Science, 2018, 435: 1257-1264.
[18] WU L H, JIANG C H.Effect of Shot Peening on Residual Stress and Microstructure in the Deformed Layer of Inconel 625[J]. Materials Transactions, 2017, 58(2): 164-166.
[19] XIE L C, JIANG C H, LU W J, et al.Investigation on the Surface Layer Characteristics of Shot Peened Titanium Matrix Composite Utilizing X-Ray Diffraction[J]. Surface and Coatings Technology, 2011, 206(2/3): 511-516.
[20] WANG C X, JIANG C H, CAI F, et al.Effect of Shot Peening on the Residual Stresses and Microstructure of Tungsten Cemented Carbide[J]. Materials & Design, 2016, 95: 159-164.
[21] WANG Y M, YANG H P, ZHANG C H, et al.Analysis of the Residual Stress in Zirconium Subjected to Surface Severe Plastic Deformation[J]. Metals and Materials International, 2015, 21(2): 260-269.
[22] HUANG J J, WANG Z, GAN J, et al.X-Ray Diffraction Investigation of Annealing Behavior of Peened Surface Deformation Layer on Precipitation Hardening Stainless Steel[J]. Journal of Materials Engineering and Performance, 2018, 27(5): 2226-2232.
[23] MALEKI E, FARRAHI G H, REZA KASHYZADEH K, et al.Effects of Conventional and Severe Shot Peening on Residual Stress and Fatigue Strength of Steel AISI 1060 and Residual Stress Relaxation Due to Fatigue Loading: Experimental and Numerical Simulation[J]. Metals and Materials International, 2021, 27(8): 2575-2591.
[24] MALEKI E, UNAL O, REZA KASHYZADEH K.Surface Layer Nanocrystallization of Carbon Steels Subjected to Severe Shot Peening: Analysis and Optimization[J]. Materials Characterization, 2019, 157: 109877.
[25] LIU H F, WEI Y F, TAN C K I, et al. XRD and EBSD Studies of Severe Shot Peening Induced Martensite Transformation and Grain Refinements in Austenitic Stainless Steel[J]. Materials Characterization, 2020, 168: 110574.
[26] YAN H Z, ZHU P F, CHEN Z, et al.Effect of Shot Peening on the Surface Properties and Wear Behavior of Heavy-Duty-Axle Gear Steels[J]. Journal of Materials Research and Technology, 2022, 17: 22-32.
[27] AKAMA D, TSUCHIYAMA T, TAKAKI S.Change in Dislocation Characteristics with Cold Working in Ultralow-Carbon Martensitic Steel[J]. ISIJ International, 2016, 56(9): 1675-1680.
[28] TAKEBAYASHI S, KUNIEDA T, YOSHINAGA N, et al.Comparison of the Dislocation Density in Martensitic Steels Evaluated by Some X-Ray Diffraction Methods[J]. ISIJ International, 2010, 50(6): 875-882.
[29] GUBICZA J.X-Ray Line Profile Analysis in Materials Science[M]. Pennsylvania: IGI Global, 2014: 171-180.
[30] KUMAGAI M, IMAFUKU M, OHYA S I.Microstructural Features of Cold-Rolled Carbon Steel Evaluated by X-Ray Diffraction Line Profile Analysis and Their Correlation with Mechanical Properties[J]. ISIJ International, 2014, 54(1): 206-211.
[31] JIANG F Q, TANG L, HUANG J W, et al.Influence of Equal Channel Angular Pressing on the Evolution of Microstructures, Aging Behavior and Mechanical Properties of As-Quenched Al-6.6Zn-1.25Mg Alloy[J]. Materials Characterization, 2019, 153: 1-13.
[32] MASUMURA T, SETO Y, TSUCHIYAMA T, et al.Work-Hardening Mechanism in High-Nitrogen Austenitic Stainless Steel[J]. Materials Transactions, 2020, 61(4): 678-684.
[33] KHELIFA N, BEY K, MZAD H.Study of Mechanical Behaviour in Three-Point Bending of Fatigue-Stressed Composite Laminates[J]. Composites Theory and Practice, 2021, 21(3): 107-113.
[34] UNGÁR T, BORBÉLY A. The Effect of Dislocation Contrast on X-Ray Line Broadening: A New Approach to Line Profile Analysis[J]. Applied Physics Letters, 1996, 69(21): 3173-3175.
[35] UNGÁR T, DRAGOMIR I, RÉVÉSZ Á, et al. The Contrast Factors of Dislocations in Cubic Crystals: The Dislocation Model of Strain Anisotropy in Practice[J]. Journal of Applied Crystallography, 1999, 32(5): 992-1002.
[36] ZHU P F, YAN H Z, ZHOU J B, et al.Microstructure of Gear Steels Treated by Shot Peening by X-Ray Line Profile Analysis Method[J]. Metals and Materials International, 2023, 29(10): 2926-2939.
[37] ARECHABALETA Z, VAN LIEMPT P, SIETSMA J.Quantification of Dislocation Structures from Anelastic Deformation Behaviour[J]. Acta Materialia, 2016, 115: 314-323.
[38] IVANOV I V, LAZURENKO D V, STARK A, et al.Application of Different Diffraction Peak Profile Analysis Methods to Study the Structure Evolution of Cold-Rolled Hexagonal Α-Titanium[J]. Metals and Materials International, 2020, 26(1): 83-93.
[39] SAHU P, DE M, S, et al. Microstructural Characterization of Fe-Mn-C Martensites Athermally Transformed at Low Temperature by Rietveld Method[J]. Materials Science and Engineering: A, 2002, 333(1/2): 10-23.
[40] POPA N C, BALZAR D.An Analytical Approximation for a Size-Broadened Profile Given by the Lognormal and Gamma Distributions[J]. Journal of Applied Crystallography, 2002, 35(3): 338-346.
[41] LI T T, ZHENG L W, ZHANG W G, et al.Determining the Preferred Orientation of Silver-Plating via X-Ray Diffraction Profile[J]. Nanomaterials, 2021, 11(9): 2417.
[42] ZHANG H, WANG W R, YUAN L H, et al.Quantitative Phase Analysis of Ti-3Al-5Mo-4.5 V Dual Phase Titanium Alloy by XRD Whole Pattern Fitting Method[J]. Materials Characterization, 2022, 187: 111854.
[43] 付鹏. 高强双相钢喷丸强化及其XRD表征[D]. 上海: 上海交通大学, 2015: 90-91.
FU P.Shot Peening Strengthening and XRD Characterization of High Strength Dual-Phase Steel[D]. Shanghai: Shanghai Jiao Tong University, 2015: 90-91.
[44] ZHU K Y, JIANG C H, LI Z Q, et al.Residual Stress and Microstructure of the CNT/6061 Composite after Shot Peening[J]. Materials & Design, 2016, 107: 333-340.
[45] YANG S, ZHANG M, YU P H, et al.Effect of Laser Shock Peening Overlap Rate on Microstructure and Wear Resistance of M50 Steel[J]. Optics & Laser Technology, 2025, 184: 112548.
[46] ZHANG Y T, ZHANG K, HU Z, et al.The Synergetic Effects of Shot Peening and Laser-Shot Peening on the Microstructural Evolution and Fatigue Performance of a Medium Carbon Steel[J]. International Journal of Fatigue, 2023, 166: 107246.
[47] WANG D F, DANG J Q, LI Y G, et al.Study on the Surface Integrity Distribution of 300M Ultrahigh Strength Steel Subjected to Different Surface Modification Treatments[J]. Surface and Coatings Technology, 2022, 451: 129033.
[48] ZHANG H P, CAI Z Y, CHI J X, et al.Microstructural Evolution, Mechanical Behaviors and Strengthening Mechanism of 300 M Steel Subjected to Multi-Pass Laser Shock Peening[J]. Optics & Laser Technology, 2022, 148: 107726.
[49] LV L L, SHAO W, TANG J Y, et al.Gradient Microstructure Evolution of High-Strength Alloy Steel Induced by Shot Peening[J]. Mechanics of Materials, 2025, 210: 105472.
[50] DENG W W, WANG C Y, LU H F, et al.Progressive Developments, Challenges and Future Trends in Laser Shock Peening of Metallic Materials and Alloys: A Comprehensive Review[J]. International Journal of Machine Tools and Manufacture, 2023, 191: 104061.
[51] QU S G, DUAN C F, HU X F, et al.Effect of Shot Peening on Microstructure and Contact Fatigue Crack Growth Mechanism of Shaft Steel[J]. Materials Chemistry and Physics, 2021, 274: 125116.
[52] PAN H J, TAO W Y, ZHANG B, et al.Effect of Shot Peening Strengths on Microstructure and Mechanical Properties of 316L Stainless Steel Prepared by 3D Printing[J]. Advanced Engineering Materials, 2023, 25(11): 2201675.
[53] AN H J, WANG Z, ZHANG B, et al.Effect of Shot Peening on Microstructure and Mechanical Properties of 316L Stainless Steel Prepared by 3D Printing with Different Forming Angles[J]. Journal of Materials Engineering and Performance, 2024, 33(16): 8226-8235.
基金
国家自然科学基金（52405609, 52305081）; 湖南省自然科学基金（2023JJ40049）; 湖南省重点研发计划（2025JK2012）
PDF(4854 KB)
渝公网安备 50010702501715号 渝ICP备15012534号-3
