铝和不锈钢FSW对搭接接头界面结构及性能研究

采用搅拌摩擦焊接方法,设计了基于“差高 偏置”的对搭接接头,对厚度为4　mm的 5A06铝合金和厚度为2　mm的316L不锈钢进行了搅拌摩擦焊接(Friction stir welding, FSW)焊接试验。通过观察焊缝金相形貌发现,焊接界面光滑平整,没有形成Hook钩,在焊缝靠近界面位置形成了钢颗粒增强铝基复合组织和河流状花样组织结构。通过SEM观察,铝 钢之间形成了一层厚度约为3　μm的中间过渡层。显微硬度及拉伸测试结果表明,过渡层的显微硬度较高,接头的拉伸强度达到了铝合金母材强度的89.7%。     

航天领域常用聚四氟乙烯性能试验研究

聚四氟乙烯因其具有优异的特性,在航天领域有着广泛的应用。文章对SFB-2、M-12、M-111、4FT-6这4种航天领域常用聚四氟乙烯材料的摩擦性能和压缩变形特性进行试验研究:50 N载荷下它们的磨损率分别为1.21×10-4、1.39×10-4、1.32×10-4、1.19×10-6 mm3/(N·m);而13.7 MPa压缩载荷作用下的压缩变形量依次为7.0%、6.1%、3.3%、3.3%。表明不同厂家、不同牌号聚四氟乙烯的摩擦性能和压缩变形特性存在显著差异,在进行产品设计、材料选型时必须因材施用。     

连铸连轧镁合金AZ41微观结构与摩擦磨损性能

为研究铸轧镁合金AZ41板材的摩擦磨损性能,通过连铸连轧制备出镁合金AZ41板材,并观察其铸轧态和热处理态的微观组织结构特点。研究了滑动干摩擦条件下滑动速度和载荷对AZ41镁合金板材摩擦磨损性能的影响,采用扫描电镜观察磨损表面形貌,探讨了其磨损机制,并利用有限元方法模拟了其磨损时的应力分布。结果表明：制备的镁合金AZ41在（1012）上出现了大量压缩孪晶,经热处理后晶粒变为等轴晶;摩擦系数随着转速的增加而升高,在一定范围内随载荷的增加而降低;磨损量随着载荷和转速的增加而增加,低载时磨损机制为磨粒磨损,伴有氧化磨损的发生,高载时其磨损以粘着磨损为主。     

微吹减阻技术影响因素的数值模拟

以NASA格伦中心的PN3和PN23型微孔壁板为原形建立"1排微孔"、"4排微孔"、"8排微孔"和"16排微孔"4种计算模型,针对不同的几何、物理参数进行了微吹技术MBT(Micro-Blowing Technique)降低平板摩擦阻力的数值模拟参数研究.结果显示:微量吹气使主流边界层近壁面流动减速,从而改变了壁面局部摩擦力的分布;不同几何、物理参数对MBT技术减阻能力的影响满足一定的规律.参数研究的结果可为该技术的减阻应用提供一定的指导.     

铝合金搅拌摩擦加工原位反应生成物颗粒增强机制

在1100-H14铝合金基体表面开凹槽添加Ni粉进行搅拌摩擦加工(Friction Stir Processing,FSP),利用Ni粉在搅拌过程中的碎化及其与基体的原位反应生成的高强、高硬的金属间化合物制备强化的表面复合层。结果表明,不同于添加陶瓷颗粒的FSP工艺,Ni颗粒能在搅拌过程中充分碎化,并与铝基体原位合成金属间化合物,原位自生的增强体颗粒与基体是以金属键合的方式结合在一起,因此与基体金属间具有良好的界面相容性和界面结构,能够很大程度上改善颗粒的强化效果。增强颗粒与基体结合界面的性质对复合层硬度的影响非常显著,为了提高复合层硬度,提出了通过原位反应获得颗粒/基体的高强界面的模型。     

摩擦堆焊过程中耗材热力过程数值模拟

采用刚粘塑性材料模型,借助有限元软件对摩擦堆焊过程耗材三维温度场与变形场进行了耦合计算,分析了耗材的温度变化及变形情况,讨论了影响温度变化的因素,并用热电偶测量了耗材的温度变化情况.模拟结果显示,耗材摩擦界面处温度的升高先急后缓,待系统进入准稳态,摩擦界面上温度也基本恒定,耗材端部存在一定温度梯度.耗材端部摩擦界面处最先进入热塑性状态并发生变形.模拟结果与试验结果吻合良好,再现了摩擦堆焊过程中耗材的温度变化及变形.模拟结果可为摩擦堆焊机理研究及确定关键工艺参数提供理论指导.     

粘性耗散对微管内部液体温升影响的实验研究

以去离子水为工质,流经内径分别为19.6μm和44.2μm石英管,实验研究了粘性耗散对微管内部流动的影响.采用微区热成像技术,使用红外成像仪加特种放大镜头测量了微管内部由于粘性耗散导致的温升△T,同时测量到相应的压降与流量,从而获得摩擦因子f、△T及雷诺数Re的关系.研究表明,在低Re数下,f的值与HagenPoiseuille理论预测值几乎一致;随着Re数的增大,工质与微管为壁面之间高的速度梯度引起粘性耗散导致工质温升,进而使得f的实验值增加.f的实验值与Hagen-Poiseuille理论预测的最大偏差达到15%~20%.     

带冠涡轮叶片干摩擦阻尼减振试验研究

为验证某型真实带冠涡轮叶片叶冠干摩擦阻尼减振效果,本文建立了可实现正压力连续调节的非旋转状态涡轮叶片试验系统,对不同接触紧度、不同接触角度的真实带冠涡轮叶片的振动响应进行了测试。通过试验分析了叶冠接触面紧度、接触角度等重要参数对带冠叶片振动特性和减振效果的影响规律,结果表明：带冠涡轮叶片出现了明显的非线性现象,同时存在一个最优的接触紧度使得该带冠涡轮叶片的减振效果最佳。接触角度的选取应综合考虑叶冠振动能量的消耗能力和带冠涡轮叶片共振频率的稳定性。     

Minimizing airfoil drag at low angles of attack with DBD-based turbulent drag reduction methods

Dielectric Barrier Discharge (DBD) based turbulent drag reduction methods are used to reduce the total drag on a NACA 0012 airfoil at low angels of attack. The interaction of DBD with turbulent boundary layer was investigated, based on which the drag reduction experiments were conducted. The results show that unidirectional steady discharge is more effective than oscillating discharge in terms of drag reduction, while steady impinging discharge fails to finish the mission (i.e. drag increase). In the best scenario, a maximum relative drag reduction as high as 64 % is achieved at the freestream velocity of 5 m/s, and a drag reduction of 13.7 % keeps existing at the freestream velocity of 20 m/s. For unidirectional discharge, the jet velocity ratio and the dimensionless actuator spacing are the two key parameters affecting the effectiveness. The drag reduction magnitude varies inversely with the dimensionless spacing, and a threshold value of the dimensionless actuator spacing of 540 (approximately five times of the low-speed streak spacing) exists, above which the drag increases. When the jet velocity ratio smaller than 0.05, marginal drag variation is observed. In contrast, when the jet velocity ratio larger than 0.05, the experimental data bifurcates, one into the drag increase zone and the other into the drag reduction zone, depending on the value of dimensionless actuator spacing. In both zones, the drag variation magnitude increases with the jet velocity ratio. The total drag reduction can be divided into the reduction in pressure drag and turbulent friction drag, as well as the increase in friction drag brought by transition promotion. The reduction in turbulent friction drag plays an important role in the total drag reduction.     

Mechanism of interconnected synchronized switch damping for vibration control of blades

The Synchronized Switch Damping (SSD) is regarded as a promising alternative to mitigate the vibration of thin-walled structures in aero-engines, especially for blades or bladed disks. The common manner is to shunt the switch circuit independently to a single piezoelectric structure. This paper is aimed at exploring a novel way of using the SSD, i.e., the SSD is interconnected between two piezoelectric structures or substructures. The damping mechanism, performance, and effective range of the interconnected SSD are studied numerically and experimentally. First, based on a dual cantilever beam finite element model, the time domain and frequency domain modeling and solving methods of the interconnected SSD are deduced and validated. Then, the influence of the amplitude and phase relationship on the damping effect of the interconnected SSD is numerically studied and compared with the shunted SSD. A self-sensing SSD control board is developed, and experimental studies are carried out. The results show that the interconnected SSD establishes an additional energy channel between the corresponding piezoelectric structures. When the amplitudes of the two cantilever beams are different, the interconnected SSD balances the vibration level of each beam. When the amplitudes of the two cantilever beams are the same, if the appropriate interconnection manner is selected according to the phase, the resonance peak can be reduced by more than 30%. When the vibration is in-phase/out-of-phase, the damping generated by the interconnected SSD in a cross/parallel manner is even more significant than the shunted SSD. Furthermore, this novel connection scheme reduces the number of SSD circuits in half. Finally, for engineering applications, we implement the proposed damping technology to the finite element model of a typical dummy bladed disk. A piezoelectric damping ratio of 13.7% is achieved when the amount of piezo material is only 10% of blade mass. Compared with traditional friction dampers, the major advancements of the interconnected SSD are: (A) it can reduce the vibration level of blades without friction interface; (B) the space constraint is overcome, i.e., the vibration energy is not necessarily dissipated independently in one sector or through physically adjacent blades, and instead, the dissipation and transfer of vibrational energy can be realized between any blade pair. If a specific gating circuit is adopted to adjust the interconnection manner of the SSD, vibration mitigation under variable working conditions with different engine orders will be expected; (C) designers do not need to worry about the annoying nonlinearities related to working conditions anymore.