涡轮盘榫槽裂纹失效分析及喷丸强化改进
|
摘要
对航空发动机涡轮盘服役后产生的榫槽裂纹进行失效分析,并通过喷丸强化改进。通过断口分析对故障涡轮盘进行失效原因确定;针对该种材料(GH2132)开展喷丸强化工艺试验,并在表面残余压应力、高温疲劳寿命及断口和显微组织等方面进行分析。结果表明故障涡轮盘属于疲劳断裂,疲劳裂纹并不是材料本身原因引起的,而是与应力集中和加工过程有关;实施表面喷丸强化工艺后,形成很高的表面残余压应力,高温疲劳寿命较喷丸前提高1～2个数量级,断口分析显示为单一疲劳源,显微组织显示晶粒明显细化。即涡轮盘榫槽裂纹为表面加工缺陷引起的疲劳断裂;喷丸强化则能够提高其高温疲劳强度极限,而喷丸强化层内的残余压应力和精细的亚晶粒是提高疲劳强度的主要因素。
Failure cracks found in the aero-engine turbine disc mortise after service were analyzed,and shot peening was introduced as an improvement measure. The failure causes of the disc were confirmed by fracture analysis. After shot peening treatment,the residual compressive stress; high temperature fatigue life,fracture and microstructure of the GH2132 alloy were analyzed. The results show that the cracks are due to fatigue fracture,while the fatigue cracks are not caused by material itself but related to the stress concentration and prior machining process. After shot peening process,higher residual compressive stress is formed,high temperature fatigue life is increased by 1-2 order of magnitude,the fracture begins from a single fatigue source,and the grains get fined obviously. That is,the turbine disc mortise cracks are fatigue fracture caused by surface machining defects,and shot peening process increases the high temperature fatigue strength limit of the mortise by forming higher residual compressive stress and refining grains.
Failure cracks found in the aero-engine turbine disc mortise after service were analyzed,and shot peening was introduced as an improvement measure. The failure causes of the disc were confirmed by fracture analysis. After shot peening treatment,the residual compressive stress; high temperature fatigue life,fracture and microstructure of the GH2132 alloy were analyzed. The results show that the cracks are due to fatigue fracture,while the fatigue cracks are not caused by material itself but related to the stress concentration and prior machining process. After shot peening process,higher residual compressive stress is formed,high temperature fatigue life is increased by 1-2 order of magnitude,the fracture begins from a single fatigue source,and the grains get fined obviously. That is,the turbine disc mortise cracks are fatigue fracture caused by surface machining defects,and shot peening process increases the high temperature fatigue strength limit of the mortise by forming higher residual compressive stress and refining grains.
引文
[1]陶春虎,钟培道,王仁智,等.航空发动机转动部件的失效与预防[M].北京:国防工业出版社,1999:102-107.
[2]刘长福,邓明.航空发动机结构分析[M].西安:西北工业大学出版社,2006:114-117.
[3]张津,洪杰,陈光.现代航空发动机技术与发展[M].北京:北京航空航天大学出版社,2006:22-23.
[4]《中国航空材料手册》编辑委员会.中国航空材料手册,变形高温合金铸造高温合金[M].北京:中国标准出版社,2002:293.
[5]钟群鹏,赵子华.断口学[M].北京:高等教育出版社,2006:270-273.
[6]邢誉峰,诸德超.航空发动机涡轮盘榫槽的形状优化设计[J].航空学报,1995,16(4):488-491.Xing Yufeng,Zhu Dechao.Shape optimization of aero-engine disc groove[J].Journal of Aeronautics,1995,16(4):488-491.
[7]Meguid S A.Finite element analysis of fir-tree region in turbine discs[J].Finite Element Analysis and Design,2000,35:305-317.
[8]何柏林,张枝森,谢学涛,等.加载环境对合金超高周疲劳行为的影响[J].华东交通大学学报,2016(5):51-57.He Bolin,Zhang Zhisen,Xie Xuetao,et al.Influence of loading environment on ultra-high-cycle fatigue of alloy material[J].Journal of East China Jiaotong University,2016(5):51-57.
[9]顾玉丽,陶春虎,佘力,等.DZ125高温合金超高周疲劳裂纹萌生与扩展[J].失效分析与防护,2014,9(6):323-329.Gu Yuli,Tao Chunhu,She Li,et al.Analysis on ultra-high cycle fatigue crack initiation and propagation characteristics of DZ125superalloy[J].Failure Analysis and Prevention,2014,9(6):323-329.
[10]Mughrabi H.On the life-controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime[J].Fatigue and Fracture of Engineering Materials and Structures,1999,22:633-641.
[11]Bathias C.There is no infinite fatigue life in metallic materials[J].Fatigue and Fracture of Engineering Materials and Structures,1999,22:559-565.
[12]Paris P,Erdogan F.A critical analysis of crack propagation laws[J].Journal of Fluids Engineering,1963,85(4):528-533.
[13]Jr Newman J C,Raju I S.An empirical stress-intensity factor equation for surface crack[J].Engineering Fracture Mechanics,1985,15(S1/2):185-192.
[14]Caton M,John R,Porter W,et al.Stress ratio effects on small fatigue crack growth in Ti-6Al-4V[J].International Journal of Fatigue,2012,38(5):36-45.
[15]徐岩,张川.拉刀设计对航空发动机涡轮盘榫槽型面的影响[J].航空制造技术,2010(15):50-52.Xu Yan,Zhang Chuan.Influence of broach design on aero-engine turbine disk fir tree groove[J].Aeronautical Manufacturing Technology,2010(15):50-52.
[16]徐岩,张川,曹祖安.涡轮盘枞树形榫槽拉刀的改进设计[J].航空制造技术,2008(S1):85-87.Xu Yan,Zhang Chuan,Cao Zu’an.Improved design of turbine disc fire-tree mortise broach[J].Aeronautical Manufacturing Technology,2008(S1):85-87.
[17]Paris P,Erdogan F.A critical analysis of crack growth laws[J].Journal of Basic Engineering,Transaction of the ASME,1963,85:528-534.
[2]刘长福,邓明.航空发动机结构分析[M].西安:西北工业大学出版社,2006:114-117.
[3]张津,洪杰,陈光.现代航空发动机技术与发展[M].北京:北京航空航天大学出版社,2006:22-23.
[4]《中国航空材料手册》编辑委员会.中国航空材料手册,变形高温合金铸造高温合金[M].北京:中国标准出版社,2002:293.
[5]钟群鹏,赵子华.断口学[M].北京:高等教育出版社,2006:270-273.
[6]邢誉峰,诸德超.航空发动机涡轮盘榫槽的形状优化设计[J].航空学报,1995,16(4):488-491.Xing Yufeng,Zhu Dechao.Shape optimization of aero-engine disc groove[J].Journal of Aeronautics,1995,16(4):488-491.
[7]Meguid S A.Finite element analysis of fir-tree region in turbine discs[J].Finite Element Analysis and Design,2000,35:305-317.
[8]何柏林,张枝森,谢学涛,等.加载环境对合金超高周疲劳行为的影响[J].华东交通大学学报,2016(5):51-57.He Bolin,Zhang Zhisen,Xie Xuetao,et al.Influence of loading environment on ultra-high-cycle fatigue of alloy material[J].Journal of East China Jiaotong University,2016(5):51-57.
[9]顾玉丽,陶春虎,佘力,等.DZ125高温合金超高周疲劳裂纹萌生与扩展[J].失效分析与防护,2014,9(6):323-329.Gu Yuli,Tao Chunhu,She Li,et al.Analysis on ultra-high cycle fatigue crack initiation and propagation characteristics of DZ125superalloy[J].Failure Analysis and Prevention,2014,9(6):323-329.
[10]Mughrabi H.On the life-controlling microstructural fatigue mechanisms in ductile metals and alloys in the gigacycle regime[J].Fatigue and Fracture of Engineering Materials and Structures,1999,22:633-641.
[11]Bathias C.There is no infinite fatigue life in metallic materials[J].Fatigue and Fracture of Engineering Materials and Structures,1999,22:559-565.
[12]Paris P,Erdogan F.A critical analysis of crack propagation laws[J].Journal of Fluids Engineering,1963,85(4):528-533.
[13]Jr Newman J C,Raju I S.An empirical stress-intensity factor equation for surface crack[J].Engineering Fracture Mechanics,1985,15(S1/2):185-192.
[14]Caton M,John R,Porter W,et al.Stress ratio effects on small fatigue crack growth in Ti-6Al-4V[J].International Journal of Fatigue,2012,38(5):36-45.
[15]徐岩,张川.拉刀设计对航空发动机涡轮盘榫槽型面的影响[J].航空制造技术,2010(15):50-52.Xu Yan,Zhang Chuan.Influence of broach design on aero-engine turbine disk fir tree groove[J].Aeronautical Manufacturing Technology,2010(15):50-52.
[16]徐岩,张川,曹祖安.涡轮盘枞树形榫槽拉刀的改进设计[J].航空制造技术,2008(S1):85-87.Xu Yan,Zhang Chuan,Cao Zu’an.Improved design of turbine disc fire-tree mortise broach[J].Aeronautical Manufacturing Technology,2008(S1):85-87.
[17]Paris P,Erdogan F.A critical analysis of crack growth laws[J].Journal of Basic Engineering,Transaction of the ASME,1963,85:528-534.