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2022 Vol. 65, No. 17
Published: 2022-09-01
FEATURE
FORUM
C0NTENTS
COVER STORY
Blisk Polishing
High-Temperature Protective Coating
1
COVER
2022 Vol. 65 (17): 1-1 [
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82
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C0NTENTS
6
CONTENTS
2022 Vol. 65 (17): 6-10 [
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71
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FEATURE
14
Research Status of Laser Additive Manufacturing of Titanium-Aluminum Intermetallic Compounds
WANG Jiang, CAO Tingwei, CHEN Chaoyue, ZHAO Ruixin, XU Songzhe, HU Tao, SHUAI Sansan, REN Zhongming
DOI: 10.16080/j.issn1671-833x.2022.17.014
With the development of China’s industrial technology, engine materials have become a barrier to the development of aviation technology. TiAl alloy has the advantages of low density, good oxidation resistance and high specific strength, and it is a promising alternative material for low-pressure turbine blades. In order to explore the application prospects of TiAl alloy prepared by laser additive manufacturing technology in aero-engines, this paper introduces in detail the TiAl powder required for laser additive manufacturing and related laser additive manufacturing technology, as well as the current research status. The advantages and drawbacks of using laser additive manufacturing technology for TiAl alloy are analyzed, and the problems that still need to be studied are proposed.
2022 Vol. 65 (17): 14-32 [
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250
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COVER STORY
34
Application and Prospect of Digital Twin in Design Phase of Aero-Engine Combustion Chambers
REN Zhuyin, ZHOU Hua, ZHANG Jian, ZHANG Qi
DOI: 10.16080/j.issn1671-833x.2022.17.034
With the ever-increasing requirements for the better performance of aero-engines, and the increasing complexity of the aero-engine system, digital twin is becoming an important tool to support the management of the whole life cycle of aero-engines. Being the heart of an aero-engine, the design phase of the combustion chamber is known for its difficulty, as well as its high cost in time and money. The digital-twin based design process can significantly reduce the time and cost of the design phase of the combustion chamber by predicting its performance, evaluating its reliability, as well as pre-evaluating and optimizing the testing protocol. In this work, the challenges faced by aero-engine combustion chambers in the design phase are briefly described, a brief review and outlook on the application and key issues of digital twins in the design phase of aero-engine combustion chambers are provided.
2022 Vol. 65 (17): 34-39 [
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336
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FORUM
42
Study on Stepwise Pulsant Precision Electrochemical Machining Method for Aero-Engine Blade
XU Zhengyang, WANG Jingtao, LIU Jia, ZHU Dong, WEI Haodi
DOI: 10.16080/j.issn1671-833x.2022.17.042
Electrochemical machining (ECM) has played an important role in the efficient and precise manufacturing of core components such as aero-engine blades or blisks in Europe and the United States. Using the traditional ECM, the cathode tools for machining blade concave and convex surfaces move towards each other, and the profile of the blade and the contour of the leading and trailing edges are processed at the same time. At this time, the accuracy of blade profile is easy to ensure, while the accuracy of leading and trailing edges is low. In this paper, a stepwise pulsant precision ECM method for blade is proposed, which aims to further improve the profile accuracy of blade and the contour accuracy of leading and trailing edges. The method is divided into two different stages. Firstly, the blade surface is machined precisely by pulsant dynamic variable parameter ECM mode, and then the leading and trailing edges are machined by micro pulse ECM mode. The research of the above two stages in machining mechanism and processing experiment are described in detail. Aiming at the problem of passive diversion in the traditional radial flow field, an active diversion axial flow field is proposed. The experimental results indicate that this method shows favorable process effects. The machining error of the concave surface and convex surface is – 0.013 – 0.025 mm and – 0.003 – 0.030 mm, respectively. The machining error of leading edge is – 0.034 – 0.041 mm, the machining error of trailing edge is – 0.038 – 0.034 mm, and the surface roughness of the concave profile and the convex profile are respectively
R
a
0.333 μm and
R
a
0.287 μm. The proposed method provides a new solution for the realization of high-precision manufacturing of aero-engine blades, and can be used for machining of other complex-shaped components.
2022 Vol. 65 (17): 42-48/64 [
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121
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49
Application Prospect of Integral CaO-Based Ceramic Mold in Investment Casting of Turbine Blades
YANG Qiang，LU Zhongliang，WANG Fu，LI Dichen
DOI: 10.16080/j.issn1671-833x.2022.17.049
The manufacturing technology of turbine blade, which is the first key component of aero-engine, has become an important indicator of a country’s manufacturing level. Ceramic mold preparation is a key step of blade manufacturing because the mold materials and preparation processes have a direct effect on the quality of blade manufacturing. The fabrication technology of core/shell integral ceramic mold based on stereolithography provides a new process for rapid fabrication of complex hollow turbine blades. Calcium oxide (CaO) is an ideal casting mold material with the advantages of high service temperature, good chemical stability at high temperature, similar thermal expansion coefficient to superalloy, easy removal, low price, etc. The advantages and problems of CaO-based ceramic mold in turbine blade investment casting are investigated in this paper, the research progress of the preparation of integral CaO-based ceramic casting is introduced, and the application prospect of integral CaO-based ceramic casting in turbine blade investment casting is discussed.
2022 Vol. 65 (17): 49-57 [
Abstract
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59
)
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58
Research on Array Polishing Path Adjustment for Aero-Engine Blade
ZHANG Yun，CHEN Zhitong，ZHU Zhengqing
DOI: 10.16080/j.issn1671-833x.2022.17.058
High efficiency automatic polishing of aero-engine blade is an important means to replace manual polishing and ensure the quality of finish machined profile. In this paper, blade measurement analysis and polishing experiment for leading/trailing edge are carried out on the array machining machine tool. Therefore, the array polishing path adjustment algorithm with the objective function of minimum polishing removal difference and the constraint condition of surface roughness is established, and the coordinate transformation function of NC system is used to realize the automatic adjustment of G-code. On the premise of ensuring the polishing accuracy and surface roughness, the purpose of high-efficiency multi-spindle synchronous polishing is achieved. Four typical blades are used for array polishing verification, their linear profile is no more than 0.032 mm and the surface roughness is
R
a
<0.4 μm. The average polishing time of a single blade is 2.75 min.
2022 Vol. 65 (17): 58-64 [
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] (
71
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65
Research on Twist-Bend Forming and Performance Control of Titanium Alloy Wide-Chord Hollow Fan Blade Under High Temperature
CHEN Minghe，FENG Rui，WANG Ning，SHI Wenxiang，XIE Lansheng，MA Guanglu，XU Yanqiang，MEI Han
DOI: 10.16080/j.issn1671-833x.2022.17.065
The thermal deformation behavior of TC4 titanium alloy was studied by using UTM 5504X electronic universal testing machine at 650 – 850 ℃ and strain rate 10
–3
– 1 s
–1
. The modified Misiolek hardening model was established and the flow stress of the material under different deformation conditions can be predicted accurately by this model. At the same time, the finite element model of high temperature twist-bend forming of TC4 titanium alloy hollow blade was established. Considering the simulation results, the optimal process parameters of twist-bend forming of TC4 titanium alloy hollow blade were determined as follows: twist forming temperature 750 ℃, twist forming section 550 mm and twist angular velocity 1.938°/min. The result is found that the content of α phase decreases and the content of β phase continues to increase under the condition of high temperature deformation, and the material has high elongation and plastic forming property. Finally, the hollow blade prepared by bending and torsional forming has a smooth overall transition, no surface defects and has good forming quality. The research results can provide guidance for the mass manufacturing of TC4 titanium alloy wide-string hollow fan blade.
2022 Vol. 65 (17): 65-73 [
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104
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74
Experimental Investigation on Eutectic Fraction in Single Crystal Castings of Superalloy CMSX– 4 and DD419
ZHAO Yunxing，YUAN Yingying，MA Dexin，XU Weitai，XU Fuze，WEI Bing
DOI: 10.16080/j.issn1671-833x.2022.17.074
Using two types of the second generation superalloys CMSX– 4 and DD419, the single crystal blades and plates with the same shape were produced under the same process conditions. The as-cast and solution heat treated microstructures of the blade castings were detected and analyzed. It was found that the γ/γ ′ eutectic fraction in as-cast structure of CMSX– 4 alloy is about 39% higher than that in alloy DD419, in spite of the similar chemical compositions of the both alloys. After solution heat treatment, the residual eutectic in CMSX– 4 alloy was observed to be higher than that of DD419 alloy, revealing more risk to exceed the technical standard. Besides the significant higher eutectic fraction, CMSX–4 exhibits also more non-uniform distribution of eutectic in different blade positions, so that the mechanical properties of the CMSX–4 castings is further negatively influenced.
2022 Vol. 65 (17): 74-80 [
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96
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81
Experimental Investigation on Vibration Frequency of DD5 Superalloy Single Crystal Blades
SUN Hongyuan, MA Dexin, GONG Xiaoyi,ZHAO Yunxing, YUAN Yingying, WEI Bing
DOI: 10.16080/j.issn1671-833x.2022.17.081
In the present work, two types of single crystal (SC) blades using second generation superalloys DD5 were directionally solidified under industrial conditions. As one of the important material properties, the vibration frequency of the blades were measured and analyzed. It was found that clearly higher vibration frequency was exhibited in the blades with larger primary orientation deviation. In comparison, it was little affected by secondary orientation deviation. Another important factor influencing the vibration frequency is the airfoil constitution, instead of the total weight of a blade. In order to strictly control the blade vibration frequency, the airfoil constitution should be further optimized in the design, and the deviation of the primary crystal orientation of the blades should be minimized during the casting process.
2022 Vol. 65 (17): 81-87 [
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90
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Blisk Polishing
88
Research Status and Development Trend of Blisk Polishing Technology
LI Wenhui，WEN Xuejie，LI Xiuhong，ZHANG Yan
DOI: 10.16080/j.issn1671-833x.2022.17.088
The surface integrity of the blisk has a great influence on the engine performance and service life, and the polishing technology is the key technology to realize the blisk performance manufacturing. In view of the problem that the blisk does not meet the use requirements after forming and manufacturing, the characteristics of polishing were analyzed from three aspects of material characteristics, structural characteristics and processing requirements. The development history, research status and polishing effect of polishing technology were introduced from the aspects of manual polishing, numerical control polishing, abrasive flow polishing, magnetic abrasive finishing and barrel finishing. And the advantages and limitations of each polishing technology were compared and analyzed. On this basis, the development trend of the blisk polishing technology was put forward, to explore the precision and performance coordination type and multi-process combination type of polishing technology, to realize the intelligent decision making of the polishing process, and to the direction of green environmental protection.
2022 Vol. 65 (17): 88-102 [
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119
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103
Subregional Polishing Technology for Root and Hub Area of Blisk
YE Huan，CHEN Zhitong，SI Chuanrui，LI Xiancai，ZHENG Qiang，CHAI Jinfeng
DOI: 10.16080/j.issn1671-833x.2022.17.103
Aiming at the problems of severe tool wear and low polishing efficiency in polishing the root and hub area of blisk, a study was carried out based on the idea of subregional polishing from the aspects of tool selection, toolpath optimization, area overlapping and division. Based on the idea of subregional machining, the polishing tool and toolpath are optimized; An optimization model for the overlapping problem between subregions is established and analyzed. After that, the root and hub area is divided based on the method of subregional polishing. Experiments in engineering environment show that the tool wear is reduced by about 30% and the polishing efficiency is increased by about 30%, which promotes the engineering application of automatic polishing technology in blisk.
2022 Vol. 65 (17): 103-109 [
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112
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High-Temperature Protective Coating
110
Damage Behavior of SiC f /SiC Composites With BSAS Environmental Barrier Coating by Plasma Spraying During Sector Combustor Test
HONG Zhiliang，CUI Yongjing，GUO Hongbao，ZHOU Chen，HOU Jingtong，JIANG Ting，WANG Ziyuan，CHEN Chao，FENG Xiaoxing
DOI: 10.16080/j.issn1671-833x.2022.17.110
SiC
f
/SiC composites combustor liner which consists of inner liner, outer liner, left and right plate prepared by chemical vapour infiltration process (CVI), was exposed to simulated aero-engine service environment by sector combustor rig. A three-layer BSAS/Mullite/Si environmental barrier coating (EBC) was deposited on the flow surface of the combustor liner by atmospheric plasma spraying. The evolution of the defect, mechanical property, microstructure and surface phase composition of the composite liner subjected to combustion environment were evaluated by mechanical test, scanning electron microscope and X-ray diffraction, respectively. The results indicate that the as-sprayed coating is mainly composed of monoclinic celsian BSAS phase and BaAl
2
O
4
phase; After the sector combustor test, the core ablation area is mainly composed of orthorhombic mullite phase Al
2
（Al
2.8
Si
1.2
）O
9.6
, cubic Si, and BaAl
2
O
4
phases. Meanwhile, silicon droplets and holes can also be observed on the surface. In addition, the results of mechanical properties after the burner rig test show that the tensile strength of SiC
f
/SiC composites in the coating integrity area is not affected, while that of the core ablation area decreased significantly. The high-temperature ablation mechanism of the coating was discussed at final.
2022 Vol. 65 (17): 110-116 [
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100
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117
Modification Mechanism and Thermal Cycling Oxidation Behavior of Arc Ion Plated NiCoCrAlYSiHf Coating Irradiated via High-Current Pulsed Electron Beam
CAI Jie，YAO Yiming，GAO Jie，GUAN Qingfeng
DOI: 10.16080/j.issn1671-833x.2022.17.117
The NiCoCrAlYSiHf coatings were modified via high-current pulsed electron beam (HCPEB) in this contribution. The surface state (surface roughness and macro morphology) and microstructures (phase composition, crystal defects, and reactive element distribution) of the original and irradiated coatings were comparatively characterized. Thermal cycling tests at 1100 ℃ were also performed. Microstructural characterization results show that preparation defects of the original coating are eliminated, and the irradiated coating surface becomes smooth and dense. In addition, abundant plastic deformation structures and uniformly distributed reactive element precipitates (nano-sized) can be observed. These irradiated effects can ensure the chemical stability of the thermally grown oxide (TGO) during the cycling process and significantly delay the cracking and spallation of TGO. The thermal cycling resistance of the irradiated coatings is improved significantly.
2022 Vol. 65 (17): 117-126 [
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82
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