Sizes effect on the tensile behaviors of H65-IF-H65 laminated metal composites
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摘要:
采用轧制结合退火的方式制备了厚度为0.12 mm、标距宽度为1~9 mm的H65黄铜/IF钢/H65黄铜3层层状复合金属材料(H65-IF-H65)，并借助电子背散射衍射(EBSD)、数字图像相关(DIC)技术、常规拉伸、原位拉伸和SEM等手段分析了试样宽度对复合材料力学行为的影响。研究结果表明：层状复合材料中的H65-IF界面在退火过程中未发生元素扩散，界面结合方式为机械结合。随着标距宽度由9 mm 逐渐降低至1 mm，材料的抗拉强度、屈服强度基本保持不变，但总延伸率、均匀延伸率和不均匀延伸率分别由30.3%、23.4% 和6.9%下降至20.3%、18.8%和1.5%，加工硬化能力迅速减弱。与此同时，材料的应变集中程度逐渐加剧，拉伸断口上的韧窝带宽度变小且带内的韧窝数量和尺寸也明显减小，呈现出显著的尺寸效应。H65-IF-H65层状复合材料的尺寸效应主要源于剪切应力的交互作用随着标距宽度的降低而被抑制，裂纹更易沿单道剪切带快速扩展而导致塑性下降。
Abstract:The H65 brass alloy-interstitial free steel-H65 brass alloy (H65-IF-H65) laminated metal composites (LMCs) of 0.12 mm thickness and 1-9 mm gauge widths were prepared by rolling combined with annealing. The electron back scatter diffraction (EBSD), digital image correlation (DIC) technology, conventional tensile testing, in-situ tensile testing and SEM were used to analysis the effect of specimen width on the mechanical behavior of the H65-IF-H65 LMC. The results show that the H65-IF interface is mechanical bonded without elements diffusion during the annealing process. As the gauge width gradually reduced from 9 mm to 1 mm, the tensile strength and yield strength remain basically unchanged, meanwhile the total, the uniform, and the non-uniform elongations decrease from 30.3%, 23.4% and 6.9% to 20.3%, 18.8% and 1.5%, respectively. The work hardening ability also decreases rapidly. Moreover, the strain of the H65-IF-H65 LMCs is gradually concentrated. On the tensile fracture, the width of the dimple band and the number and size of dimples within it also decrease significantly, which indicates a significant size effect. The main reason of sample sizes effect on the tensile behaviors of H65-IF-H65 LMCs is that the interaction of shear stress is inhibited with the decrease of the gauge width. The cracks are more likely to spread rapidly in the single shear band and result in a decreased ductility.
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Keywords:
- laminated metal composites /
- size effect /
- tensile fracture /
- in-situ tension /
- crack propagation
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图 1 H65-IF-H65层状复合材料的制备流程示意图
Figure 1. Preparation process diagram of the H65-IF-H65 LMCs
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图 2 H65-IF-H65层状复合材料横截面SEM图像(a)及元素分布(b)
Figure 2. SEM image (a) and elements distribution analysis (b) of the cross section of the H65-IF-H65 LMCs
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图 3 H65-IF-H65层状复合材料横截面显微结构EBSD分析(a)及IF层和H65层的反极图(b)及欧拉角φ2=45o的反极图(ODF)截面图(c)
φ1, Φ—Euler angles
Figure 3. EBSD analysis (a) of cross section microstructure of the H65-IF-H65 LMCs, and the inverse pole figures (ODF) (b) and Euler angles φ2=45° orientation distribution function sections (c) of IF layer and H65 layer
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图 4 H65-IF-H65层状复合材料中的IF层(a)和H65层(b)的晶粒尺寸分布
Figure 4. Grain size distributions of IF layer (a) and H65 layer (b) in the H65-IF-H65 LMCs
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图 5 (a)不同标距宽度H65-IF-H65层状复合材料工程应力-应变曲线；(b)标距宽度1 mm、3 mm和9 mm试样的真应力、应变硬化率-真应变曲线
Figure 5. (a) Engineering stress-strain curves of H65-IF-H65 LMCs with different gauge widths; (b) True stress and strain hardening rate vs. true strain curves of samples with gauge widths of 1 mm, 3 mm and 9 mm
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图 6 H65-IF-H65层状复合材料各类延伸率(a)及强度(b)随标距宽度的变化关系
Figure 6. Variation of different elongations (a) and strengths (b) of H65-IF-H65 LMCs with the change of the gauge widths
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图 7 ((a)~(c))标距宽度为1 mm的H65-IF-H65层状复合材料试样拉伸至工程应变约为10%、18.8%(颈缩点)和20%(即将断裂)的应变分布图；((d)~(f))标距宽度为9 mm试样拉伸至工程应变约为10%、29.3%(颈缩点)和37.3%(即将断裂)的应变分布图
Figure 7. Strain distributions of the H65-IF-H65 LMCs specimens with gauge width of 1 mm at the strains of 10%, 18.8% (necking point) and 20% (about to break) ((a)-(c)), and 9 mm at the strains of 10%, 29.3% (necking point) and 37.3% (about to break) ((d)-(f)), respectively
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图 8 标距宽度为1 mm (a)和9 mm (b)的H65-IF-H65层状复合材料拉伸至工程应变18.8%(颈缩点)和29.3%(颈缩点)时的表面形貌及相应的粗糙度曲线(c)
Figure 8. Surface morphologies of the H65-IF-H65 LMCs specimens with gauge widths of 1 mm (a) and 9 mm (b) at the strains of 18.8% (necking point) and 29.3% (necking point) and their surface roughness curves (c)
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图 9 标距宽度为1 mm ((a)~(d))和9 mm ((e)~(h))的H65-IF-H65层状复合材料试样在裂纹扩展过程中的侧面SEM图像(图9(i)和图9(j)为图9(f)中裂纹前端放大图与EDS分析；图9(k)和图9(l)为图9(f)和图9(h)在电镜下拍摄的宏观照片)
Figure 9. Side SEM images during the crack growth of the H65-IF-H65 LMCs samples with gauge widths of 1 mm ((a)-(d)) and 9 mm ((e)-(h)) (Fig. 9(i) and Fig. 9(j) are the enlarged image and EDS analysis of the crack front in Fig. 9(f); Fig. 9(k) and Fig. 9(l) are the macroscopic photographs of Fig. 9(f) and Fig. 9(h) under electron microscope)
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图 10 标距宽度1 mm (a)和9 mm (d)的H65-IF-H65层状复合材料试样断口正面SEM图像：((b), (c))图10(a)中左侧和右侧框位置放大图；((e), (f))图10(d)中左侧和右侧框位置放大图
Figure 10. SEM images of the front side of the H65-IF-H65 LMCs specimen with gauge width of 1 mm (a) and 9 mm (d): ((b), (c)) Enlarged images of the left and right frames in Fig. 10(a); ((e), (f)) Enlarged images of the left and right frames in Fig. 10(d)
表 1 H65黄铜-IF钢-H65黄铜(H65-IF-H65)层状复合材料(LMCs)中H65黄铜和IF钢成分(单位：wt%)
Table 1 Compositions of H65 brass and IF steel in the H65 brass-IF steel-H65 brass (H65-IF-H65) laminated metal composites (LMCs) (Unit: wt%)
Material Element H65 Cu Zn P Fe Impurities 64.524 Bal. ≤0.01 0.016 <0.2 IF Fe C Mn Cu Ni Cr P S Bal. 0.003 0.18 0.01 0.01 0.01 0.03 0.004 Note: Bal.—Banlance. 
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目的
H65/IF/H65层状复合材料不仅具有外层H65铜良好的导电、导热和耐蚀性能，还可兼具芯部IF钢优异的强度、塑性及成形性能。鉴于H65/IF/H65层状复合材料在微型电子元器件方面的巨大应用潜力，其势必会面临微拉伸和微冲压等工艺所带来的外在尺寸效应，故本文旨在研究试样宽度对已优化层厚及层厚比的H65/IF/H65层状复合材料力学性能的影响及其机理。
方法H65/IF/H65层状复合材料为三层商用H65、IF、H65金属薄板通过轧制结合退火复合而成。用线切割沿轧制方向切割出标距宽度分别为1、2、3、4、5、9mm、标距长度为25 mm的拉伸试样。采用配置非接触式视频引伸计AVE 2的Instron3369台式电子万能机进行常规拉伸测试。利用数字图像相关技术DIC对拉伸过程中的应变场进行分析。采用配置(EBSD, HKL/Channel 5 system)的FEI Nova Nano SEM 450扫描显微镜对两侧H65层和中间IF层进行晶粒度统计、取向观测。利用配置有EDS装置和3D roughness软件的phenom XL扫描电镜对H65/IF/H65层状复合材料成分分布、断口形貌和拉伸过程中的表面粗糙度进行表征。利用1kN载荷的原位拉伸台对样品裂纹萌生和扩展情况进行分析。
结果(1)H65/IF/H65层状复合材料厚度约为120 μm，其中芯部IF层与单侧H65层平均层厚为100 μm和10 μm左右，IF层与H65层平均晶粒尺寸分别为20.9 μm和9.6 μm。H65/IF界面无元素扩散，结合方式为机械结合。(2)标距宽度为9 mm时，H65/IF/H65层状复合材料的总延伸率、屈服强度和抗拉强度分别为37.5 %、218.9 MPa 和302.0 MPa。随着标距宽度不断下降，材料的总延伸率呈现单调下降趋势。当标距宽度为1 mm时，总延伸率、屈服强度和抗拉强度分别为20.2 %、209.8 MPa 和287.5 MPa。层状复合材料抵抗塑性失稳的能力随着试样标距宽度的减小而降低，相较于强度，H65/IF/H65层状复合材料的塑性变形能力更易受到标距宽度的影响。(3)随着标距宽度由9 mm逐渐降低至1 mm，H65/IF/H65层状复合材料标距段内的形变不均匀程度愈发明显，其拉伸至颈缩点时的样品表面粗糙度Ra也由1.84 μm下降至1.45 μm。当标距宽度为9 mm时，H65/IF/H65层状复合材料的剪切应力交互作用更强，裂纹于试样内部沿剪切带萌生并在数对交错的剪切带结构影响下形成台阶状扩展。当标距宽度为1 mm时，剪切应力交互作用被抑制，数对交错的剪切带结构合并为单道剪切带，裂纹于剪切带一侧萌生并沿单道剪切带进行无台阶偏转的快速扩展。(4)H65层在断口附近区域发生剥离和脱落。随着标距宽度由9 mm逐渐降低至1 mm，断口韧窝带宽度以及韧窝带内部韧窝的尺寸与数量均显著减小，并在断口局部区域形成了较为尖锐的劈尖。
结论随着标距宽度由9 mm 逐渐降低至1 mm，H65/IF/H65层状复合材料的力学性能呈现出显著的尺寸效应。该尺寸效应主要源于剪切应力的交互作用随着标距宽度的降低而被抑制。当标距宽度较小时，裂纹更易沿单道剪切带快速扩展而导致塑性下降。
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H65黄铜-IF钢-H65黄铜层状金属复合材料不仅具有外层铜材质良好的导电、导热和耐蚀性能，还可兼具芯部IF钢优异的强度、塑性及成形性能，可以广泛应用于新能源、通讯、电力电气等诸多领域。然而，随着电子元器件逐渐向微型化的方向发展，H65-IF-H65层状复合金属材料的力学性能随着成型工件尺寸的减小而表现出愈发显著的尺寸效应。
本文通过对H65-IF-H65层状复合金属材料的显微组织进行分析，并对标距宽度分别为9、5、4、3、2和1 mm 的H65-IF-H65层状复合金属材料进行力学性能、应变分布、裂纹扩展行为和断口形貌等进行分析。结果显示，随着标距宽度由9 mm 逐渐降低至1 mm，材料的抗拉强度、屈服强度基本保持不变，但总延伸率、均匀延伸率和不均匀延伸率分别由30.3%、23.4% 和6.9%下降至20.3%、18.8%和1.5%，加工硬化能力迅速减弱。与此同时，材料的应变集中程度逐渐加剧，拉伸断口上的韧窝带宽度变小且带内的韧窝数量和尺寸也明显减小，呈现出显著的尺寸效应。H65-IF-H65层状复合材料的尺寸效应主要源于剪切应力的交互作用随着标距宽度的降低而被抑制，裂纹更易沿单道剪切带内快速扩展而导致塑性下降。
(a)不同标距宽度H65-IF-H65层状复合材料工程应力-应变曲线，(b)标距宽度1mm、3mm和9mm试样的真应力、应变硬化率Vs真应变曲线
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