航空发动机增材制造结构强度、寿命评估与设计：研究现状及展望

胡殿印; 潘锦超; 米栋; 闫成; 王荣桥

doi:10.13224/j.cnki.jasp.20220465

航空发动机增材制造结构强度、寿命评估与设计：研究现状及展望

doi: 10.13224/j.cnki.jasp.20220465

胡殿印^{1, 2, 3,},
潘锦超⁴,
米栋^{3, 5},
闫成^{5, 6},
王荣桥^{2, 3, 4}

1.
北京航空航天大学航空发动机研究院，北京 100191
2.
北京航空航天大学航空发动机结构强度北京市重点实验室，北京 100191
3.
中小型航空发动机联合研究中心，北京 100191
4.
北京航空航天大学能源与动力工程学院，北京 100191
5.
中国航发湖南动力机械研究所，湖南株洲 412002
6.
厦门大学航空航天学院，福建厦门 361102

基金项目: 国家自然科学基金（52022007）

详细信息

作者简介:
胡殿印（1980-），女，教授、博士生导师，博士，研究方向为发动机结构强度及疲劳可靠性。E-mail：hdy@buaa.edu.cn

中图分类号: V252.2
计量
- 文章访问数: 439
- HTML浏览量: 194
- PDF量: 229
- 被引次数: 0
出版历程
- 收稿日期: 2022-06-28
- 网络出版日期: 2022-09-21

Strength and lifetime assessment and design for additive manufacturing structures in aero-engine: review and prospects

HU Dianyin^{1, 2, 3
,},
PAN Jinchao⁴,
MI Dong^{3, 5},
YAN Cheng^{5, 6},
WANG Rongqiao^{2, 3, 4}

1.
Research Institute of Aero-Engine，Beihang University，Beijing 100191，China
2.
Beijing Key Laboratory of Aero-Engine Structure and Strength，Beihang University，Beijing 100191，China
3.
United Research Center of Mid-Small Aero-Engine，Beijing 100191，China
4.
School of Energy and Power Engineering，Beihang University，Beijing 100191，China
5.
Hunan Aviation Powerplant Research Institute， Aero Engine Corporation of China，Zhuzhou Hunan 412002，China
6.
School of Aerospace Engineering，Xiamen University，Xiamen Fujian 361102，China

摘要

摘要:
介绍了增材制造技术在航空发动机中的应用现状，重点论述航空发动机中增材制造结构强度、寿命评估与设计等关键技术的研究进展。分别从增材制造缺陷的无损检测方法与等效准则、考虑缺陷影响的关重件强度与寿命预测方法，以及创新结构一体化设计技术等方面探讨了现有研究进展、存在不足，以及发展趋势。结果表明：航空发动机中增材制造结构强度、寿命评估处于起步阶段，大多针对增材制造材料及简单结构的单一失效模式，仍需在复合疲劳失效、“结构特征-广布缺陷-表面形貌”多因素耦合失效等方面开展研究，从而发展适用于航空发动机增材制造结构的数据驱动评估方法、损伤容限设计方法以及专用试验技术。
- 增材制造 /
- 缺陷表征 /
- 损伤机制 /
- 强度与寿命评估 /
- 一体化设计
Abstract:
The application status of additive manufacturing technology in aero-engine was introduced, and the key technologies of strength, lifetime assessment and design methods for additive manufacturing structures in aero-engine were emphatically reviewed. The shortcomings and development trends of existing research were discussed in terms of nondestructive detection methods and equivalence criteria for additive manufacturing defects, strength and lifetime prediction methods considering the effects of defects, and the integrated innovative structure design technology of aero-engine additive manufacturing structures, respectively. The results showed that strength and life assessment of additive manufacturing structures in aero-engine was at the initial stage. Most of them were geared for the additive manufacturing materials and simple structures under a single failure mode, making it necessary to conduct research on compound fatigue failure, multi-factor failure coupled of structural characteristics-widespread defects-surface morphology, so as to develop data-driven evaluation methods, damage tolerance design methods and special test techniques for aero-engine additive manufacturing structures.
- additive manufacturing /
- defect characterization /
- damage mechanism /
- strength and lifetime prediction /
- integrated design

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图 1 裂纹等效准则^[24]

Figure 1. Crack equivalence criterion^[24]

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图 2 电弧增材制造成形Al-Mg4.5Mn铝合金缺陷形貌^[27]

Figure 2. Defect morphologies of Al-Mg4.5Mn aluminum alloy formed by wire arc additive manufacturing^[27]

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图 3 PBF成形Ti-6Al-4V中缺陷等效直径与球度间关联

Figure 3. Relationship between defect equivalent diameter and sphericity in Ti-6Al-4V formed by PBF

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图 4 基于主成分分析的椭球等效准则^[34]

Figure 4. Ellipsoidal equivalence criterion based on principal component analysis^[34]

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图 5 多球等效准则^[36]

Figure 5. Multi-sphere equivalence criterion^[36]

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图 6 SLM成形AlSi10Mg铝合金试样内部的缺陷演化^[42]

Figure 6. Defect evolution in AlSi10Mg aluminum alloy specimen formed by SLM

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图 7 结合损伤模型对不同工艺参数LENS成形316L不锈钢单轴拉伸曲线预测^[50]

Figure 7. Damage model prediction of uniaxial tensile curve of 316L stainless steel formed by LENS with different process parameters^[50]

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图 8 SLM成形2070A铝合金离心叶轮^[51]

Figure 8. SLM formed 2070A aluminum centrifugal impeller^[51]

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图 9 不同成形方向PBF AlSi10Mg铝合金试样疲劳极限预测^[33]

Figure 9. Fatigue limit prediction of PBF AlSi10Mg aluminum alloy samples in different forming directions^[33]

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图 10 考虑表面粗糙度与表面/亚表面缺陷互相作用时的有效缺陷参量等效方法

Figure 10. Effective defect parameter equivalence method considering the interaction between surface roughness and surface/sub surface defects

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图 11 SLM成形AlSi10Mg试样疲劳试验数据及预测结果^[57]

Figure 11. Fatigue test data and prediction results of AlSi10Mg specimen formed by SLM^[57]

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图 12 激光直接沉积316L不锈钢多阶段疲劳寿命预测^[64]

Figure 12. Multi-stage fatigue lifetime prediction of 316L stainless steel formed by laser directly deposited^[64]

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图 13 考虑连通性约束前后的涡轮盘拓扑优化结果^[70]

Figure 13. Results of topology optimization of turbine disk before and after considering connectivity constraints^[70]

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图 14 拓扑优化后增材制造航空发动机泄压门铰链^[73]

Figure 14. Aero-engine pressure relief door hinge formed byadditive manufacturing after topology optimization^[73]

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图 15 拓扑优化后航空发动机齿轮箱壳体结构^[81]

Figure 15. Aero-engine gearbox shell structure after topology optimization^[81]

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图 16 基于点阵结构的空心风扇叶片设计^[88]

Figure 16. Design of hollow fan blade based on lattice structure^[88]

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图 17 拓扑优化及多学科优化后的离心叶轮

Figure 17. Centrifugal impeller after topology optimization and multidisciplinary optimization

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图 18 拓扑优化及多学科优化后的涡轮叶盘

Figure 18. Turbine disk after topology optimization and multidisciplinary optimization

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