Article(id=1148011762177274774, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298831252079541, articleNumber=null, orderNo=null, doi=10.7654/j.issn.2097-1974.20240205, pmid=null, cstr=null, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1615392000000, receivedDateStr=2021-03-11, revisedDate=1621785600000, revisedDateStr=2021-05-24, acceptedDate=null, acceptedDateStr=null, onlineDate=1751636933130, onlineDateStr=2025-07-04, pubDate=1713974400000, pubDateStr=2024-04-25, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1751636933130, onlineIssueDateStr=2025-07-04, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1751636933130, creator=13701087609, updateTime=1751636933130, updator=13701087609, issue=Issue{id=1149298831252079541, tenantId=1146029695717560320, journalId=1146119989267898375, year='2024', volume='47', issue='2', pageStart='1', pageEnd='106', issueExtLink='null', onlineDate='null', pubDate='null', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1751943794309, creator=13701087609, updateTime=1754895895552, updator=13701087609, preIssue=null, nextIssue=null, ext={EN=IssueExt(id=1161680841353552315, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298831252079541, language=EN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=), CN=IssueExt(id=1161680841353552316, tenantId=1146029695717560320, journalId=1146119989267898375, issueId=1149298831252079541, language=CN, specialIssueTitle=, coverIllustrator=, specialIssueEditor=, specialIssueAbout=)}, issueFiles=null}, startPage=32, endPage=41, ext={EN=ArticleExt(id=1148011762361824165, articleId=1148011762177274774, tenantId=1146029695717560320, journalId=1146119989267898375, language=EN, title=Analysis on Turbine Blade Surface Microstructure based on CFD, columnId=1154057566893105509, journalTitle=Missiles and Space Vehicles, columnName=Propulsion, runingTitle=null, highlight=null, articleAbstract=

The flow field simulation and scanning electron microscope observation methods are used to analyze the surface micromorphology of a certain type of turbine blade before and after operation, and the effect of high temperature and high pressure environment on the surface morphology of the blade is investigated. First, in order to improve the calculation efficiency, according to the blade form, a periodic symmetric CFD model of the turbine blade flow field is established, and the temperature and pressure of the flow field are calculated and analyzed by the finite volume method. Then, the surface of the working blade is measured by scanning electron microscope. The morphology is observed to analyze the form of micro-defects on the blade surface. Finally, based on the results of simulation and experimental observations, the reasons for the blade defects and the factors affecting the changes of the blade surface microstructure are analyzed. The results show that the temperature of the leading edge of the blade reaches the highest ${860}\mathrm{\;K}$. Under the combined effect of geometric structure and wave system, the flow characteristics of the flow field near the leading and trailing edge, blade tip, and hub are complicated, and the temperature and pressure distribution in the flow channel is inhomogeneous. The hub near the trailing edge of the blade appears with a cross-grain/inter-grain mixed mode of microcracks about ${180\mu }\mathrm{m}$ in length, and an inclusion crack with a length of about ${30\mu }\mathrm{m}$ appears at the tip of the trailing edge. This is due to the thermal stress of the blade, the metallographic transformation of the blade surface, and the oxidation, hydrogen embrittlement and other effects. According to the actual task of the turbopump, the turbopump ground hot test program should be reasonably arranged, especially in the shutdown stage, consider whether to take atmospheric environmental isolation measures for the cooling of the turbine blades. The current work can provide a reference for the life evaluation of liquid rocket engine turbine blades.

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利用流场仿真和扫描电子显微镜观测的方法,对某型涡轮叶片工作前后的表面微形貌进行了分析,研究了高温高压环境对叶片表面形貌变化的影响。首先为了提高计算效率,根据叶片形式,建立了涡轮叶片流场的周期性对称CFD模型,并利用有限体积法对流场的温度和压力进行计算分析;然后利用扫描电镜对工作叶片的表面形貌进行观测,分析叶片表面微缺陷形式;最后根据仿真与试验观测结果,分析了叶片缺陷产生的原因和影响叶片表面微结构变化的因素。结果表明:叶片前缘温度达到最高的${860}\mathrm{\;K}$,在几何结构和波系的共同作用下,叶片前后缘、叶尖、叶根附近流场流动特性复杂,流道内温度和压力分布不均匀;叶片后缘根部出现长约${180\mu }\mathrm{m}$的穿晶/沿晶混合模式的微裂纹,后缘叶尖处有长约${30\mu }\mathrm{m}$的夹杂物裂纹出现,这是叶片热应力、叶片表面金相转变、氧化、氢脆等共同作用的结果;应根据涡轮泵的实际任务情况对涡轮泵地面热试车程序进行合理的安排,尤其在关机阶段要考虑是否对涡轮叶片的冷却采取大气环境隔离措施。研究可为液体火箭发动机涡轮叶片寿命评估提供参考。

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刘士杰(1985—),男,博士,高级工程师,主要研究方向为液体火箭发动机可重复使用性、疲劳与断裂、金属材料力学本构建模及有限元实现。

李伟(1982—),男,高级工程师,主要研究方向为液体火箭发动机总装设计。

王慧(1973-),女,博士,研究员,主要研究方向为液体火箭发动机强度与振动、故障诊断等。

梁国柱(1966—),男,博士,教授,主要研究方向为火箭发动机设计、仿真与优化集成,火箭发动机点火与燃烧动态过程实验研究,运载器增压输送系统动力学、航天飞行器姿轨控发动机系统总体设计与实验研究。

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刘士杰(1985—),男,博士,高级工程师,主要研究方向为液体火箭发动机可重复使用性、疲劳与断裂、金属材料力学本构建模及有限元实现。

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刘士杰(1985—),男,博士,高级工程师,主要研究方向为液体火箭发动机可重复使用性、疲劳与断裂、金属材料力学本构建模及有限元实现。

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李伟(1982—),男,高级工程师,主要研究方向为液体火箭发动机总装设计。

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李伟(1982—),男,高级工程师,主要研究方向为液体火箭发动机总装设计。

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王慧(1973-),女,博士,研究员,主要研究方向为液体火箭发动机强度与振动、故障诊断等。

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王慧(1973-),女,博士,研究员,主要研究方向为液体火箭发动机强度与振动、故障诊断等。

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梁国柱(1966—),男,博士,教授,主要研究方向为火箭发动机设计、仿真与优化集成,火箭发动机点火与燃烧动态过程实验研究,运载器增压输送系统动力学、航天飞行器姿轨控发动机系统总体设计与实验研究。

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梁国柱(1966—),男,博士,教授,主要研究方向为火箭发动机设计、仿真与优化集成,火箭发动机点火与燃烧动态过程实验研究,运载器增压输送系统动力学、航天飞行器姿轨控发动机系统总体设计与实验研究。

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方程名称$\phi$扩散系数源项
质量守恒100
$x$-动量守恒$u$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial x}+ \frac{\partial }{\partial x}\left({{\mu }_{\text{eff }}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\text{eff }}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\text{eff }}\frac{\partial w}{\partial x}}\right)+ {S}_{u}$
$y$-动量守恒$v$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial y}+ \frac{\partial }{\partial x}\left({{\mu }_{\text{eff }}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\text{eff }}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\text{eff }}\frac{\partial w}{\partial x}}\right)+ {S}_{v}$
$z$-动量守恒$W$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial z}+ \frac{\partial }{\partial x}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial w}{\partial x}}\right)+ {S}_{w}$
能量守恒$T$$\frac{\mu }{Pr}+ \frac{{\mu }_{\mathrm{t}}}{{\sigma }_{T}}$由特定问题决定
湍动能$k$$\mu +\frac{{\mu }_{\mathrm{t}}}{{\sigma }_{k}}$${\widetilde{P}}_{k}- {\beta }^{* }{\rho \omega k}$
比耗散率$\omega$$\mu +\frac{{\mu }_{\mathrm{t}}}{{\sigma }_{\omega }}$$\frac{\rho \gamma }{{\mu }_{t}}{P}_{k}- {\beta \rho }{\omega }^{2}+ {2\rho }\left({1 -{F}_{1}}\right)\frac{{\sigma }_{\omega 2}}{\omega }\frac{\partial k}{\partial {x}_{j}}\frac{\partial \omega }{\partial {x}_{j}}$
), ArticleFig(id=1197274556424564871, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=CN, label=表1, caption=基于$k -\omega$模型的SST湍流模型的控制方程, figureFileSmall=null, figureFileBig=null, tableContent=
方程名称$\phi$扩散系数源项
质量守恒100
$x$-动量守恒$u$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial x}+ \frac{\partial }{\partial x}\left({{\mu }_{\text{eff }}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\text{eff }}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\text{eff }}\frac{\partial w}{\partial x}}\right)+ {S}_{u}$
$y$-动量守恒$v$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial y}+ \frac{\partial }{\partial x}\left({{\mu }_{\text{eff }}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\text{eff }}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\text{eff }}\frac{\partial w}{\partial x}}\right)+ {S}_{v}$
$z$-动量守恒$W$${\mu }_{\text{eff }}= \mu +{\mu }_{\mathrm{t}}$$-\frac{\partial p}{\partial z}+ \frac{\partial }{\partial x}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial u}{\partial x}}\right)+ \frac{\partial }{\partial y}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial v}{\partial x}}\right)+ \frac{\partial }{\partial z}\left({{\mu }_{\mathrm{{eff}}}\frac{\partial w}{\partial x}}\right)+ {S}_{w}$
能量守恒$T$$\frac{\mu }{Pr}+ \frac{{\mu }_{\mathrm{t}}}{{\sigma }_{T}}$由特定问题决定
湍动能$k$$\mu +\frac{{\mu }_{\mathrm{t}}}{{\sigma }_{k}}$${\widetilde{P}}_{k}- {\beta }^{* }{\rho \omega k}$
比耗散率$\omega$$\mu +\frac{{\mu }_{\mathrm{t}}}{{\sigma }_{\omega }}$$\frac{\rho \gamma }{{\mu }_{t}}{P}_{k}- {\beta \rho }{\omega }^{2}+ {2\rho }\left({1 -{F}_{1}}\right)\frac{{\sigma }_{\omega 2}}{\omega }\frac{\partial k}{\partial {x}_{j}}\frac{\partial \omega }{\partial {x}_{j}}$
), ArticleFig(id=1197274557057904776, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=EN, label=Tab. 2, caption=Constants of $k -\varepsilon$and $k -\omega$model, figureFileSmall=null, figureFileBig=null, tableContent=
${\sigma }_{k1}$${\sigma }_{\omega 1}$$\kappa$${\alpha }_{1}$${\beta }_{1}$${\beta }^{* }$${c}_{1}$
1.1762.0000.410.55320.07500.0910
${\sigma }_{k2}$${\sigma }_{\omega 2}$$\kappa$${a}_{2}$${\beta }_{2}$${\beta }^{* }$-
1.0001.1680.410.44030.090.09-
), ArticleFig(id=1197274557624135817, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=CN, label=表2, caption=${k}- \varepsilon$模型和$k -\omega$模型常数, figureFileSmall=null, figureFileBig=null, tableContent=
${\sigma }_{k1}$${\sigma }_{\omega 1}$$\kappa$${\alpha }_{1}$${\beta }_{1}$${\beta }^{* }$${c}_{1}$
1.1762.0000.410.55320.07500.0910
${\sigma }_{k2}$${\sigma }_{\omega 2}$$\kappa$${a}_{2}$${\beta }_{2}$${\beta }^{* }$-
1.0001.1680.410.44030.090.09-
), ArticleFig(id=1197274558228115594, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=EN, label=Tab. 3, caption=Mass fraction of combustion products per kg, figureFileSmall=null, figureFileBig=null, tableContent=
燃烧产物质量分数燃烧产物质量分数
${\mathrm{H}}_{2}$0.600H0.000
${\mathrm{O}}_{2}$0.000O0.000
${\mathrm{H}}_{2}\mathrm{O}$0.400OH0.000
), ArticleFig(id=1197274558869844107, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=CN, label=表3, caption=每千克燃烧产物的质量分数, figureFileSmall=null, figureFileBig=null, tableContent=
燃烧产物质量分数燃烧产物质量分数
${\mathrm{H}}_{2}$0.600H0.000
${\mathrm{O}}_{2}$0.000O0.000
${\mathrm{H}}_{2}\mathrm{O}$0.400OH0.000
), ArticleFig(id=1197274559465435276, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=EN, label=Tab. 4, caption=Thermodynamic parameters of combustion products, figureFileSmall=null, figureFileBig=null, tableContent=
${T}_{\infty }^{0}/\mathrm{K}$$R/\left\lbrack {\mathrm{{kJ}}\cdot {\left(\mathrm{{mol}}\cdot \mathrm{K}\right)}^{-1}}\right\rbrack$${C}_{\mathrm{p}}/\left\lbrack {\mathrm{J}\cdot {\left(\mathrm{{kg}}\cdot \mathrm{K}\right)}^{-1}}\right\rbrack$${\gamma }_{\mathrm{{pv}}}$
865.6232.6619664.5991.380
), ArticleFig(id=1197274560149106829, tenantId=1146029695717560320, journalId=1146119989267898375, articleId=1148011762177274774, language=CN, label=表4, caption=燃烧产物的热力学参数, figureFileSmall=null, figureFileBig=null, tableContent=
${T}_{\infty }^{0}/\mathrm{K}$$R/\left\lbrack {\mathrm{{kJ}}\cdot {\left(\mathrm{{mol}}\cdot \mathrm{K}\right)}^{-1}}\right\rbrack$${C}_{\mathrm{p}}/\left\lbrack {\mathrm{J}\cdot {\left(\mathrm{{kg}}\cdot \mathrm{K}\right)}^{-1}}\right\rbrack$${\gamma }_{\mathrm{{pv}}}$
865.6232.6619664.5991.380
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基于流场仿真的某型涡轮叶片的表面微结构分析
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刘士杰 1 , 李伟 2 , 王慧 1 , 梁国柱 3
导弹与航天运载技术 | 动力系统 2024,47(2): 32-41
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导弹与航天运载技术 | 动力系统 2024, 47(2): 32-41
基于流场仿真的某型涡轮叶片的表面微结构分析
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刘士杰1, 李伟2, 王慧1, 梁国柱3
作者信息
  • 1北京航天动力研究所低温液体推进技术实验室,北京,100076
  • 2北京航天动力研究所,北京,100076
  • 3北京航空航天大学宇航学院,北京,102206
  • 刘士杰(1985—),男,博士,高级工程师,主要研究方向为液体火箭发动机可重复使用性、疲劳与断裂、金属材料力学本构建模及有限元实现。

    李伟(1982—),男,高级工程师,主要研究方向为液体火箭发动机总装设计。

    王慧(1973-),女,博士,研究员,主要研究方向为液体火箭发动机强度与振动、故障诊断等。

    梁国柱(1966—),男,博士,教授,主要研究方向为火箭发动机设计、仿真与优化集成,火箭发动机点火与燃烧动态过程实验研究,运载器增压输送系统动力学、航天飞行器姿轨控发动机系统总体设计与实验研究。

Analysis on Turbine Blade Surface Microstructure based on CFD
Shijie LIU1, Wei LI2, Hui WANG1, Guozhu LIANG3
Affiliations
  • 1Laboratory of Science and Technology on Cryogenic Liquid Propulsion of CASC,Beijing Aerospace Propulsion Institute,Beijing,100076
  • 2Beijing Aerospace Propulsion Institute,Beijing,100076
  • 3School of Astronautics,Beihang University,Beijing,102206
出版时间: 2024-04-25 doi: 10.7654/j.issn.2097-1974.20240205
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利用流场仿真和扫描电子显微镜观测的方法,对某型涡轮叶片工作前后的表面微形貌进行了分析,研究了高温高压环境对叶片表面形貌变化的影响。首先为了提高计算效率,根据叶片形式,建立了涡轮叶片流场的周期性对称CFD模型,并利用有限体积法对流场的温度和压力进行计算分析;然后利用扫描电镜对工作叶片的表面形貌进行观测,分析叶片表面微缺陷形式;最后根据仿真与试验观测结果,分析了叶片缺陷产生的原因和影响叶片表面微结构变化的因素。结果表明:叶片前缘温度达到最高的${860}\mathrm{\;K}$,在几何结构和波系的共同作用下,叶片前后缘、叶尖、叶根附近流场流动特性复杂,流道内温度和压力分布不均匀;叶片后缘根部出现长约${180\mu }\mathrm{m}$的穿晶/沿晶混合模式的微裂纹,后缘叶尖处有长约${30\mu }\mathrm{m}$的夹杂物裂纹出现,这是叶片热应力、叶片表面金相转变、氧化、氢脆等共同作用的结果;应根据涡轮泵的实际任务情况对涡轮泵地面热试车程序进行合理的安排,尤其在关机阶段要考虑是否对涡轮叶片的冷却采取大气环境隔离措施。研究可为液体火箭发动机涡轮叶片寿命评估提供参考。

涡轮叶片  /  扫描电镜  /  表面形貌  /  工作寿命  /  流场仿真

The flow field simulation and scanning electron microscope observation methods are used to analyze the surface micromorphology of a certain type of turbine blade before and after operation, and the effect of high temperature and high pressure environment on the surface morphology of the blade is investigated. First, in order to improve the calculation efficiency, according to the blade form, a periodic symmetric CFD model of the turbine blade flow field is established, and the temperature and pressure of the flow field are calculated and analyzed by the finite volume method. Then, the surface of the working blade is measured by scanning electron microscope. The morphology is observed to analyze the form of micro-defects on the blade surface. Finally, based on the results of simulation and experimental observations, the reasons for the blade defects and the factors affecting the changes of the blade surface microstructure are analyzed. The results show that the temperature of the leading edge of the blade reaches the highest ${860}\mathrm{\;K}$. Under the combined effect of geometric structure and wave system, the flow characteristics of the flow field near the leading and trailing edge, blade tip, and hub are complicated, and the temperature and pressure distribution in the flow channel is inhomogeneous. The hub near the trailing edge of the blade appears with a cross-grain/inter-grain mixed mode of microcracks about ${180\mu }\mathrm{m}$ in length, and an inclusion crack with a length of about ${30\mu }\mathrm{m}$ appears at the tip of the trailing edge. This is due to the thermal stress of the blade, the metallographic transformation of the blade surface, and the oxidation, hydrogen embrittlement and other effects. According to the actual task of the turbopump, the turbopump ground hot test program should be reasonably arranged, especially in the shutdown stage, consider whether to take atmospheric environmental isolation measures for the cooling of the turbine blades. The current work can provide a reference for the life evaluation of liquid rocket engine turbine blades.

turbine blade  /  scanning electron microscopy  /  surface morphology  /  working life  /  flow field simulation
刘士杰, 李伟, 王慧, 梁国柱. 基于流场仿真的某型涡轮叶片的表面微结构分析. 导弹与航天运载技术, 2024 , 47 (2) : 32 -41 . DOI: 10.7654/j.issn.2097-1974.20240205
Shijie LIU, Wei LI, Hui WANG, Guozhu LIANG. Analysis on Turbine Blade Surface Microstructure based on CFD[J]. Missiles and Space Vehicles, 2024 , 47 (2) : 32 -41 . DOI: 10.7654/j.issn.2097-1974.20240205
涡轮叶片是液体火箭发动机涡轮的重要部件, 它长时间在高温、高压、高转速的极端环境下工作, 实际应用中, 会发生叶片的腐蚀和疲劳断裂。究其原因是工作环境导致叶片表面产生明显缺陷, 而后诱发叶片疲劳破坏。因此,研究涡轮叶片表面微结构在工作环境中的变化可为涡轮叶片工作寿命分析提供参考。
国内外开展了大量涡轮叶片疲劳寿命研究工作。 沈道贵[1]指出,叶片根部裂纹和叶片断裂是涡轮转子的典型失效模式, 起动关机导致低周疲劳, 振动引起高周疲劳,二者的复合作用引起了叶片的疲劳断裂。 从损伤机理出发揭示叶片的失效原因, 可以直接为叶片设计提供指导。Kaufman等[2]以航天飞机主发动机(Space Shuttle Main Engine, SSME)高压液氢涡轮泵(High Pressure Fuel Tubopump, HPFTP)一级动叶为对象, 结合试验结果对非弹性有限元程序和力学行为简化计算方法进行了分析。Abdul-Aziz[3]利用MARC软件对SSME HPFTP一级涡轮叶片进行了仿真分析, 计算了涡轮叶片裂纹端应力强度因子和带裂纹叶片裂纹的扩展情况,研究表明,涡轮叶片${0.127}\mathrm{\;{mm}}$裂纹对应的应力强度因子大约是${14.52}\mathrm{{MPa}}\cdot {\mathrm{m}}^{\frac{1}{2}}$,裂纹扩展速度很快。需要指出的是尽管叶片裂纹扩展理论的研究早已开展, 但目前中国实际工程中涡轮叶片不允许采用损伤容限设计, 即涡轮叶片使用中不允许出现裂纹扩展,一旦发现裂纹就立即更换。刘士杰等[4]对SSME HPFTP的故障模式进行了综述分析, 指出涡轮叶片故障类型多样且危害严重。以上研究工作可为涡轮叶片疲劳寿命分析提供参考。文献[5]指出裂纹萌生和小裂纹扩展占据该类合金65%~90% 的疲劳寿命。叶片表面质量对叶片疲劳寿命的影响特别明显, 相关研究文献也较多, 比如Wassim等[6]利用力学、 金相学和化学分析的方法对某燃气涡轮发电机的第一级压气机叶片的失效模式和失效机理进行了分析, 研究了表面微结构特性对疲劳寿命的影响。Mokaber等[7]研究了在离心载荷和振动载荷作用下压气机叶片的疲劳裂纹扩展问题, 研究表明叶片的断裂是由前缘处的腐蚀坑引起的。Ernst等[8]利用金相分析、有限元分析、断裂力学分析方法并结合试验数据对某低压蒸汽涡轮的第三级叶片根部裂纹扩展情况进行了评估, 研究表明叶根部位的腐蚀坑产生了局部应力集中, 形成了表面微裂纹, 该裂纹在离心力与气动弯矩的叠加作用下加速扩展。目前, 航天涡轮叶片多为小尺寸冲击式涡轮叶片,叶片材料是高温合金钢GH4169, Lu等[9]对GH4169结构组织的高温稳定性问题进行了研究,在650 °C下对GH4169进行了200~${1000}\mathrm{\;h}$的无应力自由状态热处理,处理后观察到强化相${\gamma }^{\prime }$${\gamma }^{\prime \prime }$的粗大化,随着热处理时间的增加,室温和650 °C下的强度极限下降,应力断裂寿命显著降低。 Deng等[10]的研究表明,疲劳裂纹多萌生于氧化夹杂物处, 并且这个萌生的潜伏期占据了90% 的疲劳寿命。通过以上分析表明,涡轮叶片的表面微结构质量对叶片的疲劳特性的研究非常重要, 表面缺陷是裂纹形成的诱导源, 而叶片材料的抗裂纹扩展能力一般都比较弱, 这就很容易造成叶片的突然断裂。刘士杰等[11]利用电火花加工方法制备了某型$\mathrm{{GH}}{4169}$航天涡轮叶片, 并通过几何形貌观测、表面微结构分析对叶片的抗疲劳特性进行了分析, 这为叶片疲劳寿命考核试验奠定了研究基础。
综上所述, 叶片表面质量对疲劳寿命具有显著影响, 因此本文开展了叶片流场的CFD仿真分析和叶片表面微结构的观察分析。具体的研究内容如下:a)叶片流场仿真分析, 包括物理模型和数学计算模型介绍、网格划分、计算设置和计算结果分析; b)叶片表面微结构观测;c)结合流场分析结果和微结构观测结果, 分析叶片表面微结构变化的原因, 给出研究结论。
某型液体火箭发动机涡轮动叶是整体加工成形的小尺寸冲击式涡轮叶片, 其中, 单个叶片三维模型如图1所示。 本文基于该叶片模型建立叶片流场仿真模型。
流场计算所采用的主要数学模型可由雷诺输运方程表示, 其中, 在直角坐标系下的通用控制方程如式(1)所示:
$\frac{\partial \left({\rho \phi }\right)}{\partial t}+ \operatorname{div}\left({\rho \underline{v}\phi }\right)= \operatorname{div}\left({\Gamma \operatorname{grad}\phi }\right)+ S $
式中$\phi$为对应不同控制方程的守恒变量;$\underline{v}$为速度矢量。因为SST湍流模型能够较好地模拟逆压梯度引起的流动分离问题, 在旋转机械的流场仿真中被广泛应用。本文采用基于$k -\omega$的SST湍流模型对叶片流场进行仿真分析。基于$k -\omega$模型的SST湍流模型的控制方程形式如表1所示。
SST湍流模型因为拥有$k -\varepsilon$模型和$k -\omega$模型的优点而被广泛应用在涡轮机械的流场仿真中。这样的优点应归因于混合函数${F}_{1}$的引入,它在靠近固体壁面处等于1,则使用$k -\omega$模型求解湍流特性,而在远离固体壁面的流场区处等于0,则使用$k -\varepsilon$模型。它的定义如下:
${F}_{1}= \tanh \left({\arg }_{1}^{4}\right)$
${\arg }_{1}= \min \left({\max \left({\frac{\sqrt{k}}{{\beta }^{* }{\omega d}};\frac{500v}{{d}^{2}\omega }}\right);\frac{{4\rho }{\sigma }_{\omega 2}k}{C{D}_{k\omega }{d}^{2}}}\right)$
$ C{D}_{k\omega }= \max \left({{2\rho }{\sigma }_{\omega 2}\frac{1}{\omega }\frac{\partial k}{\partial {x}_{j}}\frac{\partial \omega }{\partial {x}_{j}};{1.0}{\mathrm{e}}^{-{10}}}\right)$
式中$v$为运动粘度;$d$为距壁面最近的一层网格到壁面的距离。
除此以外, SST模型还定义了湍流涡粘度${\mu }_{1}$:
${\mu }_{\mathrm{t}}= \frac{\rho {a}_{1}\kappa }{\max \left({{a}_{1}\omega ,\Omega {F}_{2}}\right)} $
式中$\Omega$为涡量;${a}_{1}$取0.31; 混合函数${F}_{2}$定义如下:
${F}_{2}= \tanh \left({\arg }_{2}^{2}\right)$
${\arg }_{2}= \max \left({2\frac{\sqrt{k}}{{\beta }^{* }{\omega d}};\frac{500v}{{d}^{2}\omega }}\right)$
常系数$\theta$为混合函数${F}_{1}$的函数:
$\theta ={F}_{1}{\theta }_{1}+ \left({1 -{F}_{1}}\right){\theta }_{2}$
${\theta }_{1}$${\theta }_{2}$分别为$k -\omega$$k -\varepsilon$的常数。相关的参数值见表2
其中两个常数未列于上表, 分别是:
${\gamma }_{1}= \frac{{\beta }_{1}}{{\beta }^{* }}- \frac{{\sigma }_{\omega 1}{\kappa }^{2}}{\sqrt{{\beta }^{* }}}\text{ 和 }{\gamma }_{2}= \frac{{\beta }_{2}}{{\beta }^{* }}- \frac{{\sigma }_{\omega 2}{\kappa }^{2}}{\sqrt{{\beta }^{* }}}$
总能形式的能量方程一般被用在马赫数大于0.2 、 在边界层具有黏性传热效应的高速流动中, 因为在这样的流动中动能效应变得很重要, 表示为
$\frac{\partial \left({\rho {h}_{\text{tot }}}\right)}{\partial t}- \frac{\partial p}{\partial t}+ \nabla \cdot \left({\rho \underline{\mathbf{v}}{h}_{\text{tot }}}\right)= \nabla \cdot \left({\lambda \nabla T}\right)+ \nabla \cdot \left({\underline{\mathbf{v}}\cdot \underline{\underline{\tau }}}\right)$
式中${h}_{\text{tot }}$为总焓,与静焓$H\left({T, p}\right)$的关系为:${h}_{\text{tot }}= h +$$\frac{1}{2}\parallel \underline{v}{\parallel }^{2};\nabla \cdot \left({\underline{v}\cdot \underline{\tau }}\right)$为黏性应力$\underline{\tau }$所作的功。
以上便是本文CFD仿真中所使用到的控制方程。
根据所研究涡轮燃气发生器的工作状况, 基于最小Gibbs自由能法,利用Matlab编程计算在${6.2}\mathrm{{MPa}}$绝压下液氧液氢$\left({{\mathrm{{LO}}}_{2}/{\mathrm{{LH}}}_{2}}\right)$混合比为0.85的推进剂燃烧产物的平衡组分。采用高斯消主元的方法来求解燃烧产物的平衡组分线性方程组, 当相邻两次求解结果差值绝对值的最大值达到$1 \times {10}^{-8}$时即得到6种假定燃烧产物的摩尔数。表3是计算得到的燃烧产物的质量分数。
由计算可知,富氢燃烧条件下,燃烧产物只有${\mathrm{H}}_{2}$${\mathrm{H}}_{2}\mathrm{O}$表4是计算得到的燃烧产物的热力学参数。
计算得到的绝热燃烧温度是${865.623}\mathrm{\;K}$,与实际温度${860}\mathrm{\;K}$很接近。燃烧产物的输运参数为: 动力黏度${\mu }_{\mathrm{d}}= {2.118}\times {10}^{-5}\mathrm{\;{kg}}/\left({\mathrm{m}\cdot \mathrm{s}}\right)$; 热导率$k ={1.451}\times {10}^{-1}$W/(m·K)。
该型涡轮由94个动叶和21个喷嘴组成, 按照节距等于1的原则, 选取4个涡轮动叶和1个喷嘴来进行流场仿真分析。为了使仿真顺利进行, 在动叶和喷嘴之间添加了一个过渡段。图2给出了本文所采用的计算区域形式。
利用ICEM软件划分计算区域的六面体网格。利用$\mathrm{{OH}}$型网格划分涡轮叶片流道,叶片由$\mathrm{O}$型网格包围,保证网格线尽可能地正交,其中, 在靠近叶片壁面的区域进行了网格加密。总共使用32个块来对叶片流道计算区域进行网格划分。最终,每个叶片流道生成240 260个网格节点。图3给出了单个叶片流道计算区域划分的网格结果。
由于喷嘴和过渡段网格划分比较容易, 此处不再叙述。
利用CFX软件通过求解雷诺时均N-S方程完成叶片流道内流场稳态特性的仿真计算。首先,利用1.2节的${\mathrm{{LO}}}_{2}/{\mathrm{{LH}}}_{2}$热力学计算结果建立新的材料模型; 然后, 利用有限体积法离散求解流场控制方程和湍流控制方程。使用高分辨率格式来离散对流项、扩散项以及黏性项。能量方程采用总能模型, 使用SST湍流模型来模拟湍流流动特性,并且使用$\mathrm{{CFX}}$的自动壁面处理方法来实现近壁与远壁区域计算模型的转换, 壁面均采用无滑移绝热边界条件。喷嘴段出口与过渡段进口为内部交接面, 过渡段出口与动叶通道进口为固定转子交接面。最后,设置监控变量(动量与能量)的平均残差小于$1 \times {10}^{-5}$或最大迭代次数超过1000次作为收敛判别准则。除此以外, 设置动叶流场区域转速为${2073}\mathrm{r}/\mathrm{s}\left({{19800}\mathrm{r}/\mathrm{{min}}}\right)$,在叶片流场周向两侧设置旋转周期性边界,喷嘴入口总温设为${860}\mathrm{\;K}$,总压为${6.2}\mathrm{{MPa}}$,出口设置成考虑回流效果的敞口边界, 出口静压设为${0.3}\mathrm{{MPa}}$。过渡段周向两侧设定为旋转周期边界。图4是设置的边界条件情况。
本文主要分析叶片附近的流场特性, 对喷嘴和过渡段的流动在此不做分析。马赫数可以很好地反映流场流动特性,图5给出了叶片中径截面上流场马赫数分布云图。图6给出了中径截面上叶片表面静压的分布情况, 其中, 横坐标是以叶片前缘为原点的叶片轴向距离与弦长的比值。
图5可以看出,${Ma}= {1.8}$超声速气流在叶尖前端入口受到吸力面的阻挡流动速度减小,压力升高形成一束压缩波, 遇到该压缩波的气流马赫数降至1.3左右,然后气流在扩张型的叶盆入口段继续加速, 在大约30% 的弦长位置(大约是入口直线段与圆弧段的转接位置)上气流马赫数在叶盆处达到2.3左右, 同时在该部位出现气流分离。分离的气流使得叶片流道表现为收敛扩张型,超声速气流在${50}\%$弦长之后(扩张段)加速。当超声速气流$\left({{Ma}\approx {1.3}}\right)$遇到突然开放式扩张的叶盆出口时便在该部位形成一组膨胀波, 气流马赫数达到2.3左右。压力面侧的超声速气流同样在入口受到圆弧段叶盆的阻挡, 气体流速下降, 形成压缩波束,但这些波束强度较小,不会形成激波。气流马赫数的变化在很大程度上反映出叶片附近压力的变化, 这在图6所示的压力变化中有所反映。来流受到叶片前缘的直接阻挡, 压力在叶片前缘最大。由于前缘压缩波的缘故, 在10% 弦长位置前气体压力缓慢升高, 随后叶盆侧压力变化较平缓, 直到在50% 弦长位置, 压力面侧的气流再次受到压缩, 形成压缩波, 使得叶盆附近气流压力升高。而叶背侧由于气流加速, 出现气流分离,压力在30% 弦长位置达到最低,随后变化较平缓。
图7是几个区域的流场温度分布情况。由温度分布云图可知, 温度在3个截面上的变化趋势不太相同。10% 叶高截面上的温度普遍高于50% 和90% 叶高截面上的温度。为了定量地观察温度的变化,图8给出了这3个截面上从叶片前缘沿叶片表面至叶片后缘的温度变化情况。
图7图8可知, 在靠近围带的10% 到40% 的弦长范围内的截面上温度变化最大,在40% 至80% 的弦长范围内较稳定, 随后在靠近后缘的位置温度急剧下降。通过比较这3个截面上叶片后缘附近的温度变化情况发现, 截面上靠近轮毂处温度的变化较快。于是, 此处临近区域的温度梯度会较大, 因此该区域的热应力引起的损伤问题可能比较突出。
除此以外, 叶片-叶片流道之间的压力梯度(叶盆与叶背之间的压力不相等)会引起二次流, 这使得温度沿径向分布变得不均匀。图9是相邻叶片之间压力面一侧与吸力面一侧的流线图。由图9可知, 在靠近轮毂位置有明显的涡流, 这些涡流会加剧壁面附近的物质交换, 增大传热效率并带来不均匀的温度分布, 从而产生局部热机械应力。这样就有必要研究温度由轮毂沿径向到围带的变化情况, 有助于分析叶片表面温度分布, 以此分析微结构变化的诱因。图10给出了叶片前、后缘径向温度变化情况。
图10可知, 温度在前、后缘沿径向表现出明显不同的变化规律。但是, 温度差异在靠近轮毂或围带的位置都较大, 这会造成相对明显的热机械应力, 表面微结构质量会因该热应力的作用而下降。
由前文可知, 在轮毂、围带与叶身的连接部位流场比较复杂, 且这些部位的流场参数变化大。本节利用$\mathrm{S}- {3400}\mathrm{\;N}$型扫描电子显微镜对工作(试车)后叶片的表面形貌进行了观察, 以研究流场特性对叶片表面微结构质量的影响, 奠定叶片疲劳寿命分析的基础。
图11给出了经过多次热试车后的涡轮叶片表面微结构情况。
图11可知, 叶片不同部位的微结构表现出明显的不同。Lu等[12]$\mathrm{{GH}}{4169}$合金的高温结构稳定特性的研究表明,在${650}^{\circ }\mathrm{C}$下强化相${\gamma }^{\prime }$${\gamma }^{\prime \prime }$会发生粗化, 而前文得到的叶片前缘温度为${860}\mathrm{\;K}\left({ \sim {586.85}^{\circ }\mathrm{C}}\right)$左右,这表示图11所示的微结构可能是对强化相粗化的反映。由于叶片前、后缘流动特性变化较快且前、后缘处几何尺寸变化明显, 这使得在涡轮起动/关机阶段前、后缘处温度梯度较大, 较大的温度梯度带来了较高的热应力。因此, 叶片前、后缘的损伤往往是由瞬态阶段的热应力腐蚀引起的, 这也是航空涡轮叶片中一种常见的故障模式。图12是叶片前、后缘部分的微结构观察结果。
图12可以发现, 叶片前、后缘的表面存在腐蚀坑, 且有表面崩出现象。这可能是表面氧化物和/ 或碳氢化物在工作环境作用下从表面脱离而形成的腐蚀坑, 这些腐蚀坑经过足够次数的工作循环后便会萌生成表面微裂纹, 在高、低周复合载荷的作用下裂纹会快速扩展引起叶片断裂。图12的微结构形貌与文献[13]所观察到的微结构情形类似,$\mathrm{{Cr}}$元素在局部的反应消耗引起了文献[13]中的腐蚀, 需要进一步的分析才可确定是何种元素引起图12所示的腐蚀。由于试验条件的限制, 本文未对该微结构成分做进一步的分析。
GH4169材料中不可避免地会有碳化物存在, 在这样的工作环境下,$\mathrm{{MC}}$的比例会逐渐的降低,而${\mathrm{M}}_{22}{\mathrm{C}}_{6}$的比例会增加,可以通过分解反应式(10)来解释:
$\mathrm{{MC}}+ \gamma \rightarrow {\mathrm{M}}_{23}{\mathrm{C}}_{6}+ {\gamma }^{\prime }$
还有其他类型的碳化物分解反应会在晶界处发生, 但是由于受工作时间的影响, 式(10)所示的反应是最主要的碳化物分解反应, 这一结论可以参见文献[14]。除此以外, 碳氮化合物也会通过以下反应增加${\mathrm{M}}_{22}{\mathrm{C}}_{6}$的比例:
$\mathrm{M}\left(\mathrm{{CN}}\right)+ \gamma \rightarrow {\mathrm{M}}_{23}{\mathrm{C}}_{6}+ {\gamma }^{\prime }+ \mathrm{N}$
除此以外, 叶片过渡段(指的是叶根与轮毂、叶尖与围带的连接过渡区)的微结构形貌与文献[15]中的研究结果很相似, 但是没有明显的证据表明二者具有相同的损伤机理。
叶片流场CFD仿真分析指出, 在叶根与叶尖附近存在复杂的二次流, 加剧了该区域的物质交换, 加速了热量向叶片内部的传输, 且该区域存在的温度梯度会造成局部的热应力不匹配, 导致这些部位的表面微结构质量变差。图14是叶根和叶尖部位的表面微结构观察结果。
通过比较图14图12发现, 高温与高压环境并不是这些区域表面质量恶化的最主要原因, 因为微结构从叶根沿叶身方向至叶尖部位表现出明显的差异, 而在这些区域压力与温度(相差$1 \sim {3}^{\circ }\mathrm{C}$)的差异很小。经过分析认为, 在起动/关机阶段, 叶片端壁处的温度梯度要比叶身远离端壁的区域变化快, 从而在端壁处受到的热应力冲击会更加明显, 这为腐蚀坑的形成提供了良好的条件。一旦腐蚀坑形成,在高温、高压环境下氢原子将会沿着晶界进入叶片内部引起“氢脆”现象。同时, 在热试车的停机阶段, 高温叶片会暴露在大气环境下逐渐冷却,从而使叶片表面氧化,这可能是导致表面微结构质量下降的主要原因。
图11中未给出叶身中间部位的微结构分布情况, 该部位的微结构也需要进行观察分析。图15是压力面叶身中部区域的表面微结构观察结果。
定性来看,图15所示的黑色区域容易引起应力集中从而萌生小裂纹。但一般来说, 这些部位(叶身中间部位)与叶根、叶尖和叶片前后缘相比, 承载能力比较富余, 在其他部位发展出危险裂纹前还可以继续安全工作。所以, 该区域引起的叶片断裂未见相关报道。通过调研发现, 这些沿晶界分布黑色区域一般是由碳氢化合物和/或碳化物组成的, 比如铬、镍和钛的碳化物。
在观察过程中发现两处明显的微裂纹。其中, 靠近叶根的微裂纹长约${180\mu }\mathrm{m}$,是明显的穿晶/沿晶型裂纹。另一个是在叶尖黑色夹杂物上长约${30\mu }\mathrm{m}$的微裂纹。图16是裂纹观测结果。
图16a可以发现, 叶根部位的裂纹是以夹杂物为裂纹萌生源的, 微裂纹首先以穿晶的形式进行扩展,随后遇到晶界$\delta$相的阻隔,使得穿晶形式终止, 而以沿晶形式继续进行扩展。图16b中出现在黑色夹杂物上的微裂纹可能是由于晶相之间应力不匹配造成的, 这种应力的不匹配将会使微裂纹沿滑移面方向萌生和扩展。
CFD仿真结果显示该型涡轮叶片的工作环境温度并不是很高, 应该不会引起特别恶劣的表面微结构质量下降。但是通过上面的观察发现, 在叶片表面存在微结构缺陷。因此, 应当考虑其他可能引起叶片表面微结构变化的因素, 比如机械载荷、氢脆和氧化诱导的裂纹萌生等。
由前文燃气发生器燃烧产物热力学计算结果可知,该涡轮的环境温度大约是${600}^{\circ }\mathrm{C}$,燃烧产物的主要成分是${\mathrm{H}}_{2}$${\mathrm{H}}_{2}\mathrm{O}$。在这样的环境下,可能存在氢脆引起的损伤。在涡轮泵中, 氢脆是常见的导致结构损坏的诱因, 文献[16]对环境氢脆引起的航天飞机主发动机(SSME)高压液氢涡轮泵(HPFTP)的微结构变化情况进行了讨论。
通常,氢气很容易被相间界面(如$\gamma$基体与$\mathrm{{MC}}$,${\gamma }^{\prime \prime }$相和$\delta$相的界面)所俘获,被俘获的氢气会分解为氢原子。氢原子会沿着晶界或空隙渗入到合金内部, 然后再次生成氢气引起氢脆。在本文的分析中, 假设涡轮叶片完全暴露在外部热氢环境中且不考虑由于冶炼与热处理等工序带入的内部氢。叶片表面的二次相颗粒可以捕获氢气引起位错, 并进一步产生微裂纹。 需要注意的是,(Nb, Ti)CN相对氢气的结合能量的门槛值大约是${58}\mathrm{\;{kJ}}/\mathrm{{mol}}$,这些颗粒位置捕获氢气的能力强且属于不可逆的氢气捕获点。除此以外, 其他相也可以捕获氢气, 比如文献[17]研究表明氢脆会受${\gamma }^{\prime }\text{、}{\gamma }^{\prime \prime }$$\delta$相的影响,文献[18]的研究发现氢脆的敏感性随着${\gamma }^{\prime }$相的增多而增强,$\delta$相对抗氢脆有不利影响。${\gamma }^{\prime }+ {\gamma }^{\prime \prime }$相的结合能的门槛值大约是${23}\sim {27}\mathrm{\;{kJ}}/\mathrm{{mol}}$, 属于弱的可逆结合位置。$\delta$相的结合能量大约是${30}\mathrm{\;{kJ}}/\mathrm{{mol}}$,也属于弱的结合位置,不过它对氢脆影响显著。文献[19]指出氢的稳态通量(steady-state flux)${J}_{\infty }$与渗透系数(permeability coefficient)$\Phi$存在的关系如式(12)所示:
${J}_{\infty }= \frac{\Phi }{l}{p}^{1/2}$
式中$p$为作用于叶片上的燃气压力;$l$为叶片厚度。
由式(12)可知, 氢脆应该与压力的平方根成正比例关系。因此, 工作在高温、高压环境下的涡轮叶片的氢脆问题会变得比较突出。
尽管涡轮的工作环境中氧气和氧原子几乎是不存在的, 但在试车的关机冷却阶段涡轮叶片会与外界空气充分接触, 会引起叶片表面氧化。
对于Inconel718 (中国对应牌号GH4169), Con-nolley[20]研究发现,无受力状态下的试样表面的(Nb, Ti)C这类碳化物在${550}^{\circ }\mathrm{C}$${600}^{\circ }\mathrm{C}$下更容易发生氧化。因此,图12所示的表面崩出现象可能是由碳化物的氧化引起的。文献[21]指出, 富含镍的$\mathrm{{Nb}}$$\mathrm{{NbC}}$${\mathrm{{Ni}}}_{3}\mathrm{\;{Nb}}$相与不含镍的${\mathrm{{Ni}}}_{3}\mathrm{{Ti}}$${\mathrm{{Ni}}}_{3}\mathrm{{Al}}$相相比,更容易发生氧化。一旦发生氧化,脆性氧化物膜就会沿晶界分布, 更加有利于裂纹的萌生和扩展, 最终导致叶片失效。
晶粒尺寸对结构表面微结构质量有重要影响, 尤其在高温下,晶粒尺寸对疲劳裂纹的扩展有重要作用。Alexandre等[22]研究发现当晶粒尺寸在$5 \sim {10\mu }\mathrm{m}$时疲劳裂纹易萌生于二次相颗粒处, 当晶粒尺寸较大时典型的穿晶裂纹会沿着密集的滑移带萌生。Qin等[5]对不同晶粒度且带有缺口的$\mathrm{{GH}}{4169}$试样进行了裂纹扩展机理的研究, 研究发现, 粗晶结构的试样具有较长的疲劳寿命, 细晶试样的疲劳寿命主要受小裂纹的影响。在低裂纹扩展速率或蠕变载荷作用下,粗大晶粒的构件表现出更好的抗氧化特性, 这是由于细小的晶粒更加有利于氧的渗透。而且, 粗大晶粒的晶界会阻挡裂纹的进一步扩展。文献[23]中, Li研究了不同加工方法和不同热处理工艺下的GH4169的蠕变特性,结果表明$\delta$相对应力断裂寿命和蠕变寿命具有不利的影响。因此, 为了获得更好的材料力学性能, 本文所研究的涡轮叶片材料经过了标准热处理。 固溶处理:${960}{}^{\circ }\mathrm{C}\times 1\mathrm{\;h}$,空冷; 时效处理:${720}{}^{\circ }\mathrm{C}\times$$8\mathrm{\;h}$,以${50}^{\circ }\mathrm{C}/\mathrm{h}$炉冷至${620}^{\circ }\mathrm{C}\times 8\mathrm{\;h}$,空冷。$\mathrm{{GH}}{4169}$有3种热处理工艺, 热处理的主要作用是控制金属相的生成比例和分布。
综上可知, 涡轮热试车程序应当根据实际工作情况进行合理安排。比如, 在实际的应用中SSME涡轮叶片的冷却是处于高空无氧环境, 而Falcon 9一级可回收火箭发动机的涡轮叶片会在高温状态下与大气充分接触。因此, 在地面试车时, 就SSME涡轮叶片而言, 停机阶段的冷却环境应当保证无氧, 而Falcon 9可以在大气环境下直接冷却。至于两种试车程序对叶片实际寿命的影响有多大, 还需要做进一步的研究。
为了分析某型涡轮叶片的疲劳寿命, 本文对工作环境引起的涡轮叶片表面微结构变化进行了分析。首先, 对燃气发生器进行了热力学计算, 获取了燃气热力学参数和输运参数; 然后, 利用CFX软件对该型冲击式涡轮叶片流场进行了仿真分析, 并且通过扫描电子显微镜对叶片的表面微结构情况进行了观察; 最后, 结合流场仿真结果研究了工作环境对叶片表面形貌变化的影响。通过本文的研究可以得出如下结论:
a)叶片前缘温度达到${860}\mathrm{\;K}$,相对其他区域,叶片前、后缘, 叶片与轮毂和围带连接区的温度梯度较大。叶尖和叶根部位、相邻叶片流道之间存在复杂的二次流, 这些流动特性是由波系特性引起的, 造成了叶片表面的温度和压力分布不均匀。
b)多次试车后,叶片后缘的根部位出现长约${180\mu }\mathrm{m}$的穿晶/沿晶混合模式的微裂纹,另有长约${30\mu }\mathrm{m}$的裂纹出现在后缘叶尖部位的夹杂物上,这是金相之间的转变、氧化、氢脆和恶劣的工作环境共同作用的结果。
c)应根据涡轮泵的实际任务情况, 合理安排涡轮泵地面热试车程序, 尤其在关机阶段要考虑是否对涡轮叶片的冷却采取大气环境隔离措施, 这在一定程度上保证了涡轮泵地面试车测试结果的准确性。
本文的研究可为航天冲击式涡轮叶片的疲劳寿命分析提供参考。
  • 国家高新技术发展计划
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2024年第47卷第2期
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doi: 10.7654/j.issn.2097-1974.20240205
  • 接收时间:2021-03-11
  • 首发时间:2025-07-04
  • 出版时间:2024-04-25
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  • 收稿日期:2021-03-11
  • 修回日期:2021-05-24
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国家高新技术发展计划
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    1北京航天动力研究所低温液体推进技术实验室,北京,100076
    2北京航天动力研究所,北京,100076
    3北京航空航天大学宇航学院,北京,102206
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2种不同金属材料的力学参数

Family
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种数
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占总种数比例
Percentage of
total species (%)

Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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