Advances in fabrication of ceramic corundum abrasives based on sol–gel process

Corundum abrasives with good chemical stability can be fabricated into various free abrasives and bonded abrasive tools that are widely used in the precision machining of various parts. However, these abrasives cannot satisfy the machining requirements of difficult-to-machine materials with high hardness, high strength, and strong wearing resistance. Although superhard abrasives can machine the above-mentioned materials, their dressing and manufacturing costs are high. By contrast, ceramic corundum abrasives fabricated by sol–gel method is a cost-effective product between conventional and superhard abrasives. Ceramic corundum abrasives exhibit self-sharpening and high toughness. In this review, the optimization methods of ceramic corundum abrasive properties are introduced from three aspects: precursor synthesis, particle shaping, and sintering. Firstly, the functional mechanism of seeds and additives on the microstructural and mechanical properties of abrasives is analyzed. Specifically, seeds can reduce the phase transition temperature and improve fracture toughness. The grain size and uniformly dense structure can be controlled by applying an appropriate amount of multicomponent additives. Then, the urgent need of engineering application and machinability of special shape ceramic corundum abrasives is reviewed, and three methods of abrasive shaping are summarized. The micromold replication technique is highly advanced and can be used to prepare functional abrasives. Additionally, the influence of a new sintering method, namely, two-step sintering technique, on the microstructural and mechanical performance of ceramic corundum abrasives is summarized. Finally, the challenge and developmental trend of the optimization of ceramic corundum abrasives are prospected.     

Machining of a film-cooling hole in a single-crystal superalloy by high-speed electrochemical discharge drilling

Single-crystal superalloys are typical advanced materials used for manufacturing aeroengine turbine blades. Their unique characteristics of high hardness and strength make them exceedingly difficult to machine. However, a key structure of a turbine blade, the film-cooling hole,needs to be machined in a single-crystal superalloy; such machining is challenging, especially considering the increasing levels of machining efficiency and quality demanded by the aeroengine industry. Tube electrode high-speed electrochemical discharge drilling(TSECDD), a hybrid technique of high-speed electrical discharge drilling and electrochemical machining, provides high machining efficiency and accuracy, as well as eliminating the recast layer. In this study, TSECDD is used to machine a film-cooling hole in a nickel-based single-crystal superalloy(DD6). The Taguchi methods of experiment are used to optimise the machining parameters. Experimental results show that TSECDD can effectively drill the film-cooling hole; the optimum parameters that give the best performance are as follows: pulse duration: 12 ls, pulse interval: 30 ls, peak current:6 A, and salt solution conductivity: 3 m S/cm. Finally, a hole is machined by TSECDD, and the results are compared with those obtained by electrical discharge machining. TSECDD is found to be promising for improving the surface quality and eliminating the recast layer.     

Advances in critical technologies for hypersonic and high-enthalpy wind tunnel

Hypersonic and high-enthalpy wind tunnels and their measurement techniques are the cornerstone of the hypersonic flight era that is a dream for human beings to fly faster, higher and further. The great progress has been achieved during the recent years and their critical technologies are still in an urgent need for further development. There are at least four kinds of hypersonic and high-enthalpy wind tunnels that are widely applied over the world and can be classified according to their operation modes. These wind tunnels are named as air-directly-heated hypersonic wind tunnel, light-gas-heated shock tunnel, free-piston-driven shock tunnel and detonation-driven shock tunnel, respectively. The critical technologies for developing the wind tunnels are introduced in this paper, and their merits and weakness are discussed based on wind tunnel performance evaluation. Measurement techniques especially developed for high-enthalpy flows are a part of the hypersonic wind tunnel technology because the flow is a chemically reacting gas motion and its diagnosis needs specially designed instruments. Three kinds of the measurement techniques considered to be of primary importance are introduced here, including the heat flux sensor, the aerodynamic balance, and optical diagnosis techniques. The techniques are developed usually for conventional wind tunnels, but further improved for hypersonic and high-enthalpy tunnels. The hypersonic ground test facilities have provided us with most of valuable experimental data on high-enthalpy flows and will play a more important role in hypersonic research area in the future. Therefore, several prospects for developing hypersonic and high-enthalpy wind tunnels are presented from our point of view.     

超声速变马赫数风洞流场参数线性变化验证

旋转喷管型面使超声速变马赫数风洞在单次运行过程中可连续调节实验区的马赫数,便于研究飞行器的机动过程、进气道起动过程中的气动问题。在控制喷管型面旋转过程中,流场参数能否线性变化是衡量超声速变马赫数风洞性能的一个重要指标。分析变马赫数风洞实验区流场参数的线性变化规律,利用弹簧光顺的动网格技术建立数值仿真模型,验证喷管位于马赫数3.041~3.215 范围所对应的位置时,实验区流场参数是否满足线性变化规律。结果表明：通过对喷管型面旋转的控制实现了风洞实验区流场参数的线性变化,动态计算结果与预期实验区流场参数线性变化规律吻合良好;在不同加速度的流场参数线性变化过程中,各时刻实验区的平均参数与预期参数之间的偏差均小于0.13%。     

基于模型的转子系统不平衡量的估计

采用基于模型的方法对转子系统的不平衡量进行估计,首先记录初始状态下的振动信号,然后根据实时测得的不平衡响应信号,得出差值振动信号,联立转子系统的动力学方程,得出不平衡等效载荷,根据等效载荷,得出不平衡的位置、相位及大小.采用模态扩展技术实现由有限几个点的振动响应获取所需点上的响应.由于噪声的影响,提出了基于高斯小波的降噪方法.仿真与实验结果表明,这一方法能够比较准确地估计出转子系统的不平衡量.      

2.4米跨声速风洞大展弦比飞机测力试验技术研究

针对大展弦比飞机的气动布局特点,在2.4米跨声速风洞中开展了大展弦比飞机测力试验技术研究。该项研究建立了大升阻比高精度天平设计技术和模型支撑系统设计平台,研制了专用大升阻比高精度测力天平和模型支撑系统。在国内高速风洞中建立了大型跨声速风洞模型设计新准则。研究结果表明:所提出和制定的方案是科学合理的,为我国大飞机研制提供了可靠的技术支撑。     

连续离子层吸附反应法制备超薄功能膜及应用

阐述了液相法中制备超薄功能膜的新方法——连续离子层吸附反应法(Successive Ionic Layer Adsorption and Reaction,SILAR)。探究了它的薄膜生长机理、工艺参数影响以及应用现状,指出了尚需深入研究的问题。     

吸气式高超声速技术研究进展

总结了中国空气动力研究与发展中心(CARDC)在吸气式高超声速技术在试验设备、超燃冲压发动机、数值模拟以及机体/推进一体化飞行器等方面的研究进展。介绍了三种类型的高焓设备:脉冲式燃烧加热风洞、连续式燃烧加热风洞和电弧风洞。通过多种尺度的超燃冲压发动机的直连式和自由射流式试验,获得了发动机的基本性能及其随油气比、喷孔位置等的变化规律。对比连续式和脉冲式风洞试验结果,得知工作时间大于100 ms的脉冲式燃烧设备是开展发动机基本性能研究的经济、高效试验手段。成功研制了三维大规模并行数值模拟软件平台AHL3D并广泛应用于发动机研究。在0.6 m风洞中,完成了1.5 m带动力飞行器试验,获得了发动机工作和不工作状态下的飞行器推阻及升力特性。     

对转压气机转差特性试验与数值研究

为了探索对转压气机流场特性,积累相关设计经验,本文进行在前后级转子等转速压比和效率特性试验基础上,着重进行了前后级转子不同转差下的特性实验。同时,借助CFD技术,辅助分析了转差对压气机特性及流场的影响。结果表明,转差变化引起压气机性能与流场结构发生显著变化,是影响压气机性能的主要因素之一。     

超声速PIV示踪粒子布撒技术研究

介绍了上海交通大学高超声速创新技术研究实验室为发展超声速PIV流场测试系统而开发的示踪粒子布撒技术。研究中设计了一套超声速风洞PIV示踪粒子布撒装置,提出了利用发生器罐体内的真空度吸入示踪粒子的加注方式,选定了测试流程时序并得到了较好的粒子布撒效果。通过比较不同的发生器罐注入压力对粒子布撒浓度的影响,得到了效果良好的测试方案。