Preliminary experiment on spontaneous ignition performances of cavity-based strut flameholder

The thermal-structural response and low cycle fatigue life of a three-dimensional (3D) channel wall nozzle with regenerative cooling were numerically investigated by coupling the finite volume fluid-thermal method, nonlinear finite element thermal-structural analysis and local strain methods. The nozzle had a high area ratio (nozzle exit area divided by throat area) under cyclic working loads. Parametric studies were carried out to evaluate the effects of channel structural parameters such as channel width, channel height, liner thickness and rib width. Results showed that the integrated effects of three-dimensional channel structure and load distribution caused serious strain, which mainly occurred at the intersectant regions of liner wall on the gas side and the symmetric planes of channel and rib. The cooling effect and channel structural strength were significantly improved as the channel width and height decreased, leading to substantial extension of the nozzle service life. On the other hand, the successive decrease in liner thickness and rib width apparently increased the strain amplitude and residual strain of channel wall nozzle during cyclic work, significantly shortening the service life. The present work is of value for design of the channel wall nozzle to prolong its cyclic service life.      

Thermal-structural analysis of regenerativelycooled thrust chamber wall in reusable LOX/Methane rocket engines

To predict the thermal and structural responses of the thrust chamber wall under cyclic work,a 3-D fluid-structural coupling computational methodology is developed.The thermal and mechanical loads are determined by a validated 3-D finite volume fluid-thermal coupling computational method.With the specified loads,the nonlinear thermal-structural finite element analysis is applied to obtaining the 3-D thermal and structural responses.The Chaboche nonlinear kinematic hardening model calibrated by experimental data is adopted to predict the cyclic plastic behavior of the inner wall.The methodology is further applied to the thrust chamber of LOX/Methane rocket engines.The results show that both the maximum temperature at hot run phase and the maximum circumferential residual strain of the inner wall appear at the convergent part of the chamber.Struc tural analysis for multiple work cycles reveals that the failure of the inner wall may be controlled by the low-cycle fatigue when the Chaboche model parameter γ3 =0,and the damage caused by the thermal-mechanical ratcheting of the inner wall cannot be ignored when γ3 ＞ 0.The results of sen sitivity analysis indicate that mechanical loads have a strong influence on the strains in the inner wall.     

Damage localization effects of the regeneratively-cooled thrust chamber wall in LOX/methane rocket engines

To investigate the damage localization effects of the thrust chamber wall caused by combustions in LOX/methane rocket engines, a fluid-structural coupling computational methodology with a multi-channel model is developed to obtain 3-demensioanl thermal and structural responses. Heat and mechanical loads are calculated by a validated finite volume fluid-thermal coupling numerical method considering non-premixed combustion processes of propellants. The methodology is subsequently performed on an LOX/methane thrust chamber under cyclic operation. Results show that the heat loads of the thrust chamber wall are apparently non-uniform in the circumferential direction. There are noticeable disparities between different cooling channels in terms of temperature and strain distributions at the end of the hot run phase, which in turn leads to different temperature ranges, strain ranges, and residual strains during one cycle. With the work cycle proceeding, the circumferential localization effect of the residual strain would be significantly enhanced. A post-processing damage analysis reveals that the low-cycle fatigue damage accumulated in each cycle is almost unchanged, while the quasi static damage accumulated in a considered cycle declines until stabilized after several cycles. The maximum discrepancy of the predicted lives between different cooling channels is about 30%.     

液体火箭发动机推力室内壁寿命预估

为了分析推力室内壁失效机理及准确预估推力室内壁寿命,对推力室进行流-热-固耦合计算.流-热耦合为热-固耦合提供准确的热和机械载荷,热-固耦合模型对推力室内壁在循环加载下的变形进行非线性平面应变有限元分析.通过计算,得到了推力室内壁在单循环各阶段的应力-应变分布和循环加载下的变形过程,并进行了寿命预估.结果表明:采用的流-固耦合策略能准确地实现流-热耦合模块向热-固耦合模块的载荷传递,能为结构分析提供准确的边界条件.在预冷、后冷和松弛阶段,内壁承受拉应力;在工作阶段,内壁承受压应力.随着循环次数的增加,内壁残余应力和应变不断增大,内壁向燃烧室内鼓起和不断变薄,冷却通道中心最先失效.所采用的分析模型能够模拟内壁在循环热和机械载荷下的变形过程,用于预估推力室内壁的循环寿命.      

Coupling damage and reliability model of low-cycle fatigue and high energy impact based on the local stress–strain approach

Fatigue induced products generally bear fatigue loads accompanied by impact processes,which reduces their reliable life rapidly. This paper introduces a reliability assessment model based on a local stress–strain approach considering both low-cycle fatigue and high energy impact loads.Two coupling relationships between fatigue and impact are given with effects of an impact process on fatigue damage and effects of fatigue damage on impact performance. The analysis of the former modifies the fatigue parameters and the Manson–Coffin equation for fatigue life based on material theories. On the other hand, the latter proposes the coupling variables and the difference of fracture toughness caused by accumulative fatigue damage. To form an overall reliability model including both fatigue failure and impact failure, a competing risk model is developed. A case study of an actuator cylinder is given to validate this method.     

可重复使用复合材料气瓶设计及试验验证

为了适应未来重复使用运载器更高的重复使用性能要求,设计了一种航天用轻质高压可重复使用复合材料气瓶,采用金属内胆/复合材料层结构形式。复合材料采用T700碳纤维复合材料,金属内衬采用铝合金。采用有限元仿真和试验验证的方法对气瓶的强度和重复使用性能进行了分析和验证,其仿真爆破强度为81 MPa,试验爆破强度84 MPa,仿真与试验疲劳失效次数均大于1 200次。结果表明,所设计的重复使用复合材料气瓶满足23 MPa工作压力重复使用300次要求。     

液体火箭发动机推力室可重复使用技术

为了验证液体火箭发动机推力室可重复使用技术,采用流-固耦合方法对推力室内壁材料、外壁厚度、冷却通道高宽比等影响推力室内壁寿命的因素进行了数值模拟.通过计算,得到了推力室内壁在不同内壁材料、不同外套厚度、不同冷却通道高宽比下单循环各阶段的应力、应变分布,对计算结果进行后处理,得到了内壁损伤.结果表明,采用高强度及延展性内壁材料、低刚性外套、大冷却通道高宽比可以减小推力室内壁损伤,延长推力室内壁使用寿命.      

材料循环应力-应变行为及循环应变寿命的研究

材料的循环应力-应变行为以及循环应变与寿命的关系是材料的主要疲劳特性,用局部应力 -应变法计算构件疲劳裂纹形成寿命时要用到它们。使用这些疲劳特性的不同描述方法给寿命计算带来的误差差别很大。依据试验结果对目前的一些描述方法作出比较,并指出较为合理的选择。     

用等效平均损伤模型计算剩余寿命方法的研究

分析了复杂载荷下材料的损伤累积过程和疲劳寿命计自身材料疲劳损伤与其不可逆电阻变化响应的联系。疲劳寿命计自身材料疲劳损伤演变、损伤累积过程以电阻变化速率和变化量显示了其全貌。假设其等效平均损伤等一般规律与金属材料的疲劳情况相类似,结合本文给出拟合精度很好的材料应力寿命曲线,得出随机载荷下剩余寿命计算的简便方法,具有较高可信度。初步实验验证很令人满意。     

考虑耦合损伤的燃气轮机叶片材料高低周复合疲劳寿命研究

燃气轮机叶片在实际工作过程中,受到高低周载荷共同作用而易发生疲劳失效.针对高低周复合疲劳损伤演化和寿命预测比较复杂这一问题,考虑高低周载荷叠加形成的耦合损伤,建立了一种新的高低周复合疲劳寿命预测模型,在此基础之上,引入弱化函数描述某些低幅高周载荷对复合损伤的弱化作用,建立了具有低载强化寿命效应的高低周复合疲劳寿命预测模...     

轴对称构件疲劳寿命预测的损伤力学-附加载荷-有限元法

 提出了一种实用有效的弹塑性损伤应力 -应变本构方程与损伤演化方程。针对中高周疲劳问题,发展了轴对称疲劳寿命预测的损伤力学 -附加载荷 -有限元法计算格式。通过引入塑性附加载荷,考虑了构件应力集中区域塑性变形对构件疲劳寿命的影响。预估了30 Cr Mn Si Ni2A材料含沟槽轴对称试件的疲劳裂纹形成寿命,并分析了疲劳裂纹的扩展情况。疲劳寿命理论预测结果与实验结果吻合良好。     

轮盘低周疲劳寿命的可靠性研究

利用R.W.Landgraf的低周疲劳寿命公式, 建立累积损伤的低周疲劳寿命的失效方程, 以此方程为基础利用H-L方法求其可靠度。推导了在非线性的弹塑性状况下的随机有限元法, 从而使低周疲劳寿命可靠性得以计算。      

复杂载荷下疲劳寿命估算

 本文给出了LY12CZ铝合金板材的循环硬化规律;以材料在循环载荷作用下累积的塑性滞后能作为疲劳损伤准则,证明了应力控制等幅循环加载条件下损伤累积随循环次数变化的非线性,导出了材料瞬态塑性应变能的计算公式,算出了破坏发生时材料耗散的总塑性应变能,并给出了它与应力变程的关系。文中把疲劳损伤分为静拉伸损伤与循环损伤两部分,给出了损伤累积模型。以该模型为基础,计算了两级加载、4级加载和程序加载下光滑试件的疲劳寿命。计算结果与试验结果符合很好。     

单晶高温疲劳损伤参量的选取与寿命建模

高温疲劳损伤是引起单晶涡轮叶片破坏的主要因素之一。利用不同试验条件下DD6标准试件的低周疲劳和蠕变-疲劳试验结果,结合基于滑移系的黏塑性应力-应变分析,分别研究了晶体取向、应变范围、平均应变以及保载时间等对单晶高温疲劳损伤的影响机制。进而采用滑移剪应变最大的滑移系作为临界滑移系,选取临界滑移系上的最大Schmid应力、最大滑移剪应变率、循环Schmid应力比以及滑移剪应变范围等细观参量作为损伤参量,建立了一种新的基于临界平面的循环损伤累积（CDA）模型。结果表明,该模型对于DD6高温疲劳寿命预测精度基本在3倍分散带内。     

燃烧室火焰筒结构在随机噪声作用下的振动响应分析

针对航空发动机燃烧室火焰筒结构声疲劳问题,建立了某型航空发动机燃烧室火焰筒有限元计算模型。采用耦合的边界元和有限元方法对该结构进行声激励载荷作用下的响应进行计算,获得该结构在不同声压级下的振动位移和应力响应结果,对燃烧室火焰筒结构疲劳故障分析和抗声疲劳结构设计具有一定参考价值。     

用塑性滞后能原理估算随机载荷下的疲劳寿命

 材料的疲劳损伤包括静力损伤和循环损伤,静力损伤为第一次静力加载引起的塑性应变能与静力韧性之比；循环损伤由循环塑性滞后能与疲劳韧性之比来计算,计算中计及了材料循环硬化（或软化）引起的屈服应力增大（或减小）的影响。为了简化计算,假设在循环加载时应力一应变曲线均按迟滞回线规律变化；不同应力变程下材料疲劳韧性可由对称循环的应力控制疲劳试验确定。本文提出了一种比较合理又便于工程应用的、用塑性滞后能原理估算随机载荷下疲劳寿命的新方法,初步的试验验证是令人满意的。     

带保载平面应变塑性诱发裂纹闭合效应

用黏塑性有限元法模拟含中心裂纹试件在等幅循环拉伸加载和保载作用下的裂纹扩展规律.试件采用涡轮盘材料Udimet720 Li(low inclusion)、恒温700℃和平面应变假设,通过逐步释放裂纹尖端节点约束来模拟裂纹扩展.计算了在应力比R=0,不同最大循环载荷、不同保载时间对平面应变下无量纲裂纹张开应力强度因子的影响.平面应变情况下,无量纲裂纹张开应力强度因子随最大载荷的变化而趋于分散,并随着裂纹的扩展,会存在先上升后下降并趋于一个稳定值的趋势;载荷相同时,保载时间的增加使裂纹张开应力强度因子增加.高温保载情况下,蠕变会影响裂纹扩展速率.      

基于疲劳热响应的高强钢疲劳剩余寿命预测

为了在不破坏材料的情况下估算服役结构材料的使用寿命,尤其是估算承受过未知周次循环载荷（已受损）的材料剩余疲劳寿命,提出一种预测高强钢试件剩余疲劳寿命的方法。以300M钢为研究对象,在不同的循环应力水平下进行疲劳试验,所有的试验过程使用红外成像仪对试件进行全程温度监控,记录了试件在不同损伤阶段的受激温升斜率以构造包含金属疲劳热响应和疲劳寿命对应关系的“参考斜率曲面系”,并以此为依据估算剩余疲劳寿命。试验结果表明受激温升斜率与疲劳损伤状况,即试件的累计受载周次存在明显的线性关系。经试验验证,发现剩余寿命预测的误差不超过5%,说明该线性关系可作为估算剩余疲劳寿命的指标。     

TMF本构和寿命模型:从光棒到涡轮叶片

针对空心涡轮叶片，发展了考虑瞬态变温效应的热机械疲劳（TMF）本构模型和寿命预测方法。第一，以某涡轮叶片用定向凝固合金DZ125为对象，开展了光棒、缺口TMF试验，结合已有的高温疲劳试验数据，获得了相位、温度范围、应力集中等因素对TMF寿命影响规律；第二，利用材料微观组织分析手段，揭示了导致光棒和缺口TMF失效的疲劳裂纹萌生机理；第三，借助于Chaboche本构模型，进行了各向异性、变温、蠕变损伤修正，建立了考虑变温效应的循环-蠕变本构模型，实现了DZ125合金拉伸、等温循环、蠕变、疲劳-蠕变以及TMF应力应变响应的统一建模和预测；第四，发展了疲劳-蠕变-氧化损伤累积的TMF寿命模型，利用简单纯疲劳和蠕变基础数据获得了寿命模型参数，并进一步发展了名义应力法预测了缺口模拟件的TMF寿命；最后，以某涡轮叶片为对象，进行了模拟飞行载荷谱条件下的瞬态变形响应计算和叶片TMF寿命预测。     

高温环境下薄壁结构声激励响应及疲劳分析与试验验证

针对航空发动机薄壁结构热声疲劳问题,采用耦合的有限元/边界元法,对GH188薄壁结构进行动力学响应计算,采用改进的雨流计数法和Morrow平均应力模型,结合Miner线性累积损伤理论对薄壁结构疲劳寿命进行了预估。基于高温行波管试验器开展了GH188薄壁结构高温声激振疲劳试验研究,获取了薄壁结构在不同温度和声载荷作用下的模态频率、应力/应变响应和疲劳寿命结果。仿真计算结果与试验结果对比分析表明:数值仿真对结构破坏位置判断准确,破坏位置均为结构根部,结构1阶热模态频率具有一致性,误差0.49%~2.09%之间,X方向应力响应峰值集中在基频附近,随温度升高,结构发生软化刚度下降,响应峰值向左发生偏移,且预测水平与试验一致,误差在1%~3%之间,验证了薄壁结构热声响应计算方法与计算模型的准确性。结构疲劳寿命随温度和声压级的上升而均呈现下降趋势,疲劳破坏时间的预估值与试验结果在一个量级之内,误差在3~3.5倍之间,满足工程级寿命预测要求,验证了薄壁结构热声疲劳寿命预估方法的有效性。