High-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures

A modified model is developed to characterize and evaluate high-cycle fatigue behavior of Co-based superalloy 9CrCo at elevated temperatures by considering the stress ratio effect. The model is informed by the relationship surface between maximum nominal stress, stress ratio and fatigue life. New formulae are derived to deal with the test data for estimating the parameters of the proposed model. Fatigue tests are performed on Co-based superalloy 9Cr Co subjected to constant amplitude loading at four stress ratios of 1, 0.3, 0.5 and 0.9 in three environments of room temperature(i.e., about 25 °C) and elevated temperatures of 530 °C and 620 °C, and the interaction mechanisms between the elevated temperature and stress ratio are deduced and compared with each other from fractographic studies. Finally, the model is applied to experimental data, demonstrating the practical and effective use of the proposed model. It is shown that new model has good correlation with experimental results.     

Reliability analysis of aero-engine blades considering nonlinear strength degeneration

To comprehensively consider the effects of strength degeneration and failure correlation, an improved stress-strength interference (SSI) model is proposed to analyze the reliability of aeroengine blades with the fatigue failure mode. Two types of TC4 alloy experiments are conducted for the study on the damage accumulation law. All the parameters in the nonlinear damage model are obtained by the tension-compression fatigue tests, and the accuracy of the nonlinear damage model is verified by the damage tests. The strength degeneration model is put forward on the basis of the Chaboche nonlinear damage theory and the Griffith fracture criterion, and determined by measuring the fatigue toughness during the tests. From the comparison of two kinds of degeneration models based on the Miner’s linear law and the nonlinear damage model respectively, the nonlinear model has a significant advantage on prediction accuracy especially in the later period of life. A time-dependent SSI reliability model is established. By computing the stress distribution using the finite element (FE) technique, the reliability of a single blade during the whole service life is obtained. Considering the failure correlation of components, a modified reliability model of aero-engine blades with common cause failure (CCF) is presented. It shows a closer and more reasonable process with the actual working condition. The improved reliability model is illustrated to be applied to aero-engine blades well, and the approach purposed in this paper is suitable for any actual machinery component of aero-engine rotor systems.     

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。      

多轴疲劳理论在航空发动机零部件寿命预测中的应用

由于航空发动机主要零部件结构形状及工作环境复杂，工作时承受多种类型的循环载荷，寿命考核部位有可能处于多轴应力状态，因此寿命预测分析需要考虑多轴应力状态的影响。近些年由于疲劳试验技术的提高，多轴(或双轴)疲劳研究取得较快的进展，并逐步应用到工程实际当中。在对航空发动机主要零部件工作中的应力状态进行分析的基础上，应用局部应力应变的近似计算方法及多轴疲劳寿命预测模型对航空发动机轮盘进行寿命预测，并与单轴结果进行了比较。     

Testing and evaluation for fatigue crack propagation of Ti-6Al-4V/ELI and 7050-T7452 alloys at high temperatures

This paper seeks to evaluate crack propagation properties and residual lives of metallic alloys subjected to fatigue loading at room and high temperatures. Fatigue crack growth tests were performed on Ti-6Al-4V/ELI and 7050-T7452 subjected to constant-amplitude and actual randomspectra loading at room temperature of about 25 ℃ and at high temperatures of 250 ℃ and 150 ℃ to determine their crack growth properties and residual lives. The damage mode and mechanisms at high temperature were compared with those at room temperature on the basis of the results of fractographic analysis. Temperature-dependent residual lives under actual random-spectra load history were evaluated based on a modified accumulation damage rule accounting for the load interaction.Good correlation was achieved between the predictions and actual experiments, demonstrating the practical and effective use of the proposed method.     

基于连续介质损伤力学的高温微动疲劳寿命预测模型

建立了一种基于连接介质损伤力学(CDM)的高温微动疲劳寿命预测模型用以分析航空发动机榫连接结构在不同温度下的微动疲劳寿命。该模型在现有的基于非线性疲劳损伤累积(NLCD)模型微动疲劳寿命预测模型的基础上，引入温度相关的损伤速率因子以考虑温度对榫连接结构微动疲劳行为的影响。以某型发动机钛合金TC11燕尾榫结构模拟件为研究对象开展不同温度下的微动疲劳寿命数值模拟预测研究，预测结果与试验结果相比在2倍误差范围以内，证明了此寿命预测模型的有效性。      

激光冲击强化对钛合金高温微动疲劳寿命的影响

为了解高温工作环境下激光冲击强化工艺(LSP)对钛合金材料微动疲劳寿命的影响,开展了强化前后TC11钛合金在室温、300°C和500°C下的微动疲劳试验并测试了试验件表层的残余应力及硬度。结果表明:随着温度的升高,激光冲击强化对TC11钛合金微动疲劳寿命的提高倍数逐渐减小。在轴向载荷为400MPa,法向载荷为65.5MPa时,经激光冲击强化后TC11钛合金试验件在室温、300°C和500°C下的微动疲劳寿命分别为强化前的5.5倍、3.5倍和1.7倍;强化后试验件表层的残余应力会在高温下发生松弛,且松弛程度会随温度的升高而增大,这是激光冲击强化效果随温度升高而逐渐弱化的主要原因。     

变幅加载下疲劳可靠性分析

分别对疲劳载荷、寿命与强度的随机性进行了分类。基于二维概率Miner准则,建立了在变幅载荷谱或随机时间历程载荷谱给定的条件下,对结构构件进行疲劳可靠性分析的新方法,并由此推导出统计Miner准则中α的分布。最后,分别给出了实验数据验证结果和工程应用实例,显示出该方法具有简便性和实用性。      

相位角对定向合金DZ125热/机械疲劳行为与寿命影响的试验研究

对DZ125定向凝固铸造镍基高温合金进行了同相位、反相位和-135°相位的550℃～1000℃热/机械疲劳试验研究。试验结果表明:同相位寿命曲线与反相位寿命曲线有一交点,-135°相位的热/机械疲劳寿命比同相位热/机械疲劳寿命与反相位热/机械疲劳寿命长。试样的微观断口分析显示了在热/机械疲劳试验中同时存在疲劳、蠕变和氧化损伤。对同相位、反相位和-135°相位热/机械疲劳循环应力响应行为进行了研究。用Manson-Coffin方程、微裂纹扩展模型和拉伸迟滞能(Ostergren)寿命预测模型对DZ125合金的热/机械疲劳寿命进行了预测(分散带为2倍左右)。      

A new fatigue life prediction model considering the creep-fatigue interaction effect based on the Walker total strain equation

The performance of high-temperature components of aero-engines under the Creep-Fatigue Interaction (CFI) behavior gets more attention recently. In this research, the creep-fatigue tests of two superalloys of Powder Metallurgy (PM) FGH96 and direct aging GH4169 were performed at 650 °C with different types of dwell, and the fracture morphology of FGH96 specimens was observed by Scanning Electron Microscopy (SEM) to analyze the creep-fatigue fracture feature and crack initiation. Additionally, according to phenomenology, the effect of dwell was introduced to develop a new uniaxial fatigue life prediction model based on the total strain equation, which has capability to take dwell time and load ratio into account together. The equations were utilized to model the test data of PM FGH96 and GH4169, together with data of another superalloy PM FGH95 conducted previously. A prominent prediction ability of the model in creep-fatigue life prediction of different superalloys has been manifested. Most data points of test data and estimated data are located within two times scatter band, which is ideal in engineering.     

基于雨流计数法和功率谱密度法的随机声疲劳应用研究

针对燃烧室火焰筒结构中的声疲劳问题,研究了2种用于随机声载荷下结构疲劳寿命预估的有效方法。雨流计数法实时计数模型计数简单,直接对载荷时间历程进行计数,克服了以往计数模型的局限性;基于iMner线性理论,提出了基于功率谱密度法的随机声疲劳寿命预估方法,并建立了疲劳寿命预估模型。对某型航空发动机燃烧室火焰筒结构进行了疲劳寿命估算,结果表明2种方法对航空薄壁结构随机疲劳寿命分析具有实用性。     

涡轮叶片耦合疲劳寿命预测与试验验证

为了解决涡轮转子叶片在温度、离心力和气动/噪声联合载荷作用下的疲劳强度问题,开展了高低周复合载荷谱分解方法和基于高低周载荷的全时域蠕变损伤累积模型研究,提出了同时考虑蠕变损伤、低周疲劳损伤和高周疲劳损伤的耦合疲劳寿命预测方法。同时,通过正交载荷解耦和耦合载荷协调加载控制等关键技术的应用,开发了高温环境下的高低周复合疲劳试验平台。最终,基于设计的涡轮叶片模拟件,完成了耦合疲劳寿命预测和试验验证。结果表明:模拟试件的耦合疲劳寿命试验结果分散系数为1.01,耦合疲劳寿命的预测结果与试验结果偏差小于24%,从而验证了疲劳寿命预测模型的正确性,为我国航空发动机热端部件的疲劳强度设计和验证提供了有效的技术途径。      

榫连接结构微动疲劳寿命研究

根据航空发动机叶片和轮盘的榫连接结构接触区域的几何特性,对其微动疲劳接触问题进行了简化.通过有限元方法对简化模型进行数值计算分析,获取相应的应力、应变和位移.将临界平面法和微动损伤机理相结合,提出了一个微动损伤参量,并建立相应的微动疲劳寿命预测模型.将TC11试验件和榫连接构件的微动疲劳试验寿命与预测寿命进行比较分析.结果表明:所建立的微动疲劳寿命模型其预测结果误差分散带均在2倍因子以内.      

基于推广疲劳-蠕变等效转换理论的高温条件载荷谱编制方法

针对现有载荷处理方法对高温条件下保载时间内损伤的忽略或考虑不足问题，对疲劳-蠕变转换理论进行了推广，给出普适的转换模型建立流程，以此修正雨流计数中的等值点压缩、小幅值剔除等数据压缩步骤，从而获得了能够量化全工况保载损伤的高温条件载荷谱编制方法。在航空发动机高压涡轮盘上的应用表明：本方法考虑了全工况等值及小幅值载荷贡献的疲劳-蠕变耦合损伤，其相当于纯疲劳循环（传统雨流法）的298.25%，比常规转换方法多236.91%；寿命预测误差为8.35%，较常规转换方法降低了95%，仅为传统雨流法的2.5%，证明了优化的高温条件载荷谱编制方法的应用价值。     

面向航空发动机减重的铝合金管强化机理研究

为助推新一代大型航空发动机推重比的有效提升,开展面向航空发动机减重需求的高强度铝合金管件自增强机理研究。采用有效强化的高强度铝合金管件大规模替换航空发动机低温段不锈钢高压管件,是实现航空发动机减重的可行方法。通过研究高强度铝合金管件自增强工艺的强化机理,建立基于三剪统一强度准则,同时考虑包辛格效应、应变时效以及应变硬化的高压自增强工艺参数数学模型,并结合双线性随动强化模型,分析管路构件在强化过程中的弹塑性行为与残余应力分布演化规律,研究确定强化工艺参数。基于ANSYS,在额定工况下对强化后的铝合金管件和不锈钢管件的疲劳强度进行仿真分析,最后采用脉冲疲劳试验进行验证,证明自增强铝合金管件替换现役不锈钢管件具有较好的可行性。     

航空发动机典型材料超高周疲劳试验技术研究综述

航空发动机作为飞行器最关键、最核心的部位，长期服役于高温、高载等极端环境，疲劳失效是导致发动机结构破坏的主要原因之一。随着工业的发展，发动机材料的超高周疲劳问题日益凸显。本文总结了发动机典型材料超高周疲劳关注领域的研究现状，对当前超高周疲劳试验技术的应用情况进行了阐述，包括超高周轴向振动疲劳、弯曲振动疲劳、扭转振动疲劳、复合振动疲劳等试验加载技术以及温度控制技术、损伤监测技术，并对我国航空发动机典型材料超高周疲劳试验技术的发展做出展望。     

镍基单晶/柱晶高温合金超高周疲劳研究进展

镍基单晶/柱晶高温合金具有高温强度高、抗氧化性强、抗疲劳性能优异等优点,是目前先进航空发动机涡轮叶片的主要材料。超高周疲劳（疲劳寿命>10⁸）是涡轮叶片在服役中后期面临的主要问题。对镍基单晶/柱晶高温合金的超高周疲劳进行综述,分析结果表明,单晶/柱晶高温合金在高温下存在反常屈服现象;对比不同频率下的疲劳研究,未发现明显的频率效应;分析断裂机理,发现裂纹主要从内部孔洞等铸造缺陷处萌生。总结了疲劳寿命预测模型,展望了镍基单晶/柱晶高温合金超高周疲劳的发展方向。     

镍基高温合金GH536的热疲劳行为

燃烧室火焰筒作为航空发动机的热端关键结构件，在工作过程中受到复杂的循环温度载荷，使其承受热疲劳损伤.对火焰筒常用镍基高温合金GH536的热疲劳行为进行试验研究.根据火焰筒结构和载荷特征，设计了中心孔平板试样以及热疲劳试验，研究了热疲劳载荷条件下GH536平板的裂纹萌生及扩展规律，揭示了GH536的热疲劳破坏机理.研究发现:①热疲劳裂纹以穿晶模式萌生，以沿晶方式扩展并断裂；②随着热疲劳试验中上限温度的升高，裂纹的萌生寿命缩短，裂纹扩展速率加快，试样在800℃时的热疲劳裂纹萌生寿命是900℃裂纹萌生寿命的4.5倍.      

涡轮构件疲劳/蠕变寿命的试验方法

根据弹用发动机涡轮构件的真实工况,通过有限元分析确定试验寿命考核点,提出并设计了一套加载方案,模拟了工作条件下结构的应力场和温度场,构件的试验寿命、断裂部位与有限元预测结果一致。试验结果表明提出的小结构大载荷、小空间高温度的试验方法可以很好地再现涡轮构件的疲劳/蠕变故障,为发动机构件的寿命评定提供了依据。     

Multiaxial fatigue life prediction of composite materials

In order to analyze the stress and strain fields in the fibers and the matrix in composite materials,a fiber-scale unit cell model is established and the corresponding periodical boundary conditions are introduced.Assuming matrix cracking as the failure mode of composite materials,an energy-based fatigue damage parameter and a multiaxial fatigue life prediction method are established.This method only needs the material properties of the fibers and the matrix to be known.After the relationship between the fatigue damage parameter and the fatigue life under any arbitrary test condition is established,the multiaxial fatigue life under any other load condition can be predicted.The proposed method has been verified using two different kinds of load forms.One is unidirectional laminates subjected to cyclic off-axis loading,and the other is filament wound composites subjected to cyclic tension-torsion loading.The fatigue lives predicted using the proposed model are in good agreements with the experimental results for both kinds of load forms.