航空发动机构件先进热处理技术

热处理技术是发动机制造领域的基础、共性技术,是构件获得服役性能的关键因素.结合近些年的研究和实践,综述了先进热处理技术的发展现状,对真空热处理、化学热处理、特种热处理技术在叶片、涡轮盘、齿轮、轴承、转子等关键构件制造中的应用进行重点讨论,并对未来我国航空发动机热处理技术的研究工作进行了展望.     

航空发动机制造工艺仿真技术体系探索

基于航空发动机仿真工作发展规划,从制造维度对仿真技术的应用需求进行了深入分析。提出了构建航空发动机制造工艺仿真技术体系的思路和建设原则,基于5个环节的应用需求提出了仿真技术体系的初步框架,并对当前需要加快突破的仿真关键技术进行了分析,推进航空发动机制造工艺仿真技术发展和规划的落地。     

航空发动机部件特性自适应计算方法

发展了一种预测发动机部件特性的自适应模型方法,该方法以发动机通用特性为基础,利用单纯型优化方法,将发动机主要性能参数和过程参数的偏差函数最小为优化目标,以部件特性藕合因子为被优参数,此法能较好地预测出不同飞行条件下发动机的风扇、压气机、燃烧室、高、低压涡轮等部件特性.应用于某算例的计算结果表明,发动机主要性能参数和过程参数的计算偏差均在0.5%之内,对发动机各截面总温、总压计算偏差均在1%之内.预测出的部件特性已成功用于发动机故障诊断方程的建立.     

Dynamic performance of a C/C composite finger seal in a tilting mode

The complex operating state of aeroengines has an impact on the performance of finger seals.However,little work has been focused on the issue and the dynamic performance of finger seals is also rarely studied.Therefore,a distributed mass equivalent model considering working conditions is proposed in this paper for solving the existing problems.The effects of the fiber bundle density and the preparation direction of the fiber bundle of a C/C composite on the dynamic performance of a finger seal are investigated in rotor tilt based on the proposed model.The difference between the C/C composite finger seal performances under the rotor precession and nutation tilt cases is also investigated.The results show that the fiber bundle density and the preparation direction of the fiber bundle have an influence on the dynamic performance of the finger seal as rotor tilt is considered,and the dynamic performance of the finger seal is different in the two kinds of tilting modes.In addition,a novel method for design of finger seals is presented based on the contact pressure between finger boots and the rotor.Finger seals with good leakage rates and low wear can be acquired in this method.     

Nonlinear interval analysis of rotor response with joints under uncertainties

The dynamic influence of joints in aero-engine rotor systems is investigated in this paper. Firstly, the tangential stiffness and loss factor are obtained from an isolated lap joint setup with dynamic excitation experiments. Also, the influence of the normal contact pressure and the excitation level are examined, which revel the uncertainty in joints. Then, the updated Thin Layer Elements (TLEs) method with fitted parameters based on the experiments is established to simulate the dynamic properties of joints on the interface. The response of the rotor subjected to unbalance excitation is calculated, and the results illustrate the effectiveness of the proposed method. Meanwhile, using the Chebyshev inclusion function and a direct iteration algorithm, a nonlinear interval analysis method is established to consider the uncertainty of parameters in joints. The accuracy is proved by comparison with results obtained using the Monte-Carlo method. Combined with the updated TLEs, the nonlinear Chebyshev method is successfully applied on a finite model of a rotor. The study shows that substantial attention should be paid to the dynamical design for the joint in rotor systems, the dynamic properties of joints under complex loading and the corresponding interval analysis method need to be intensively studied.     

中央传动锥齿轮行波共振特征精准识别试验研究

为了精准监测复杂工作环境下航空发动机中央传动锥齿轮行波共振特征,并满足对试验器改装小和测试装置易安装的技术要求。建立了基于刚性壁声波导管技术的导出式噪声测量方法和基于替代法原理的动态特性标定方法,研制了导出式噪声测量系统和数字式闭环控制声喇叭行波管装置动态标定系统,解决了复杂环境下的齿轮行波共振声信号测量与数据修正的问题。完成了基于噪声和应力同步测试的某航空发动机中央传动锥齿轮行波共振特性试验,对从动锥齿轮的行波共振频率、共振转速及节径振动声辐射量级进行了分析。研究结果表明：导出式噪声测量方法及系统和动态标定方法及系统有效提高了齿轮行波共振特性的测量精度,可实现高温高油雾环境下齿轮行波共振频率和共振转速的精准识别和有效监测,行波共振频率误差小于0.04%,共振转速误差小于0.005%。四节径后行波共振时的齿轮辐板振动辐射的声压能量是三节径前行波共振时的4.5倍,说明齿轮在高转速发生行波共振会更危险。     

基于复合推进系统动态模型-状态变量模型的航空发动机直接推力预测控制

直接推力控制可以有效改善推力控制的品质,针对航空发动机直接推力控制问题,进行了模型预测控制(Model Predictive Control, MPC)研究。为了提升航空发动机推力控制的精度,提出了基于复合推进系统动态模型-状态变量模型(Compact Propulsion System Dynamic Model-State Variable Model-State Variable Model, CPSDM-SVM)的航空发动机直接推力预测控制方法。CPSDM实时估计出不可测参数（推力、喘振裕度等）的基准值,SVM则根据未来输入实时预测发动机未来响应。由于CPSDM将发动机分为进气道、核心机、喷管、喘振裕度、推力等进行建模,在兼顾精度的同时,提高机载模型的实时性。CPSDM-SVM作为MPC算法中的预测模型,具有较高的精度和实时性。仿真结果表明,在与基于分段线化模型的传统模型预测控制方法实时性基本相同的情况下,所提出方法控制效果有明显的提升,调节时间减小了1.17s。所提出方法稳态控制精度为0.08%,传统方法稳态精度为2.58%。因此,所提出方法在保证实时性的条件下,提升了控制精度和控制效果。     

耐海洋环境腐蚀的航空发动机封严涂层技术及其发展

对耐海洋腐蚀热喷涂可磨耗封严涂层在航空发动机领域的应用进行了论述,重点介绍航空发动机用热喷涂涂层的海洋气氛电化学腐蚀机理及相应涂层结构与材料设计等防护方法,提出了未来航空发动机用耐海洋腐蚀热喷涂封严涂层的发展方向.     

FPGA-Based Independent Backup ControlSystem of Aero-Engine

An independent backup control system based on Field Programmable Gate Array (FPGA) is used to ensure air safety when the master control system of aero-engine breaks down. It can realize a smooth transition from the master control system to the backup control system, control the fuel flow and airscrew speed by setting the programmable logic in FPGA. This system can improve the reliability and safety of aero-engine. This paper proposed the general plan, operating principle, control algorithm, switching logic, channel synchronization and Built-In Test (BIT) of the backup control system. The research has been applied in a certain type of aero-engine control system and passed the rig test. Speed control error is less than 0.2% and fuel flow control error is less than 0.35%. During the channel switching, the fluctuation of the fuel flow control is within 1.5%. It turns out that the system works stably and meets the design requirements.     

航空发动机陶瓷基复合材料无损表征技术研究进展

随着陶瓷基复合材料在先进航空发动机热端部件中的推广应用,对其在工艺研发、制备加工、试验考核以及使用服役等阶段形成的缺陷/损伤进行高效准确的无损表征就变得尤为重要。由于陶瓷基复合材料复杂的制备成型工艺及多相复合引起的高度非均质和各向异性,导致传统基于整体均质化假设的无损检测技术面临诸多挑战。本文结合陶瓷基复合材料在航空发动机领域的应用情况,分析了其在制备、加工及服役等阶段的典型缺陷/损伤类型及特征,重点回顾了近年来陶瓷基复合材料无损表征技术的研究进展及应用情况,总结了现有无损表征技术面临的主要挑战,并对未来的发展趋势进行了展望。