单晶空心涡轮叶片排气窗开裂制造影响因素分析

李青; 程荣辉; 丛佩红; 马世岩; 张倩

doi:10.13224/j.cnki.jasp.20240730

单晶空心涡轮叶片排气窗开裂制造影响因素分析

doi: 10.13224/j.cnki.jasp.20240730

中国航发沈阳发动机研究所，沈阳 110015

基金项目: 国家科技重大专项（J2019-Ⅵ-0022-0138）

详细信息

作者简介:
李青（1982-），男，高级工程师，硕士生，主要从事发动机零部件失效分析方面的研究。E-mail：114915889@qq.com

中图分类号: V232.4
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出版历程
- 收稿日期: 2024-10-25
- 网络出版日期: 2025-01-09

Analysis on manufacturing factors influencing exhaust window cracking of hollow single crystal turbine blade

Shenyang Engine Research Institute，Aero Engine Corporation of China，Shenyang 110015，China

摘要

摘要:
为了解决目前带劈缝结构的单晶涡轮叶片工程应用中出现的排气窗开裂问题，通过视频显微镜、扫描电镜（SEM）和能谱分析等手段开展排气窗裂纹断口宏、微观分析，明确裂纹断口性质，归纳出导致排气窗过早开裂的多种制造影响因素。结果表明：排气窗裂纹均起源于尾缘排气窗的间隔墙。间隔墙表面沟状缺陷是陶瓷型芯局部未打磨存在毛刺所致；间隔墙表面再结晶主要是由于陶瓷型芯强度过高，退让性不足，铸造应力无法释放所致；间隔墙表面原始“沟纹”主要是由腐蚀检验酸溶液对单晶枝晶干和枝晶间腐蚀速率不同引起的；间隔墙表面铸造缺陷主要是由于型芯和合金的界面反应所致；锯齿冠磨削过程中缺少辅助支撑会导致间隔墙表面产生疲劳裂纹。
- 单晶 /
- 涡轮叶片 /
- 工程失效 /
- 冶金缺陷 /
- 疲劳开裂
Abstract:
In order to solve the crack failure of the single crystal alloy turbine blade in practical project application, multiple manufacturing factors leading to premature cracking of exhaust windows were summarized. The crack fracture properties were identified by macro and micro observation utilizing video microscope, scanning electron microscope (SEM) and energy spectrum analysis. The results showed that the exhaust window cracks were originated from the partition wall. The groove defect on the partition wall was due to the ceramic core which was not polished before casting. The higher strength of ceramic core had a strong impact on the recrystallization grain of the partition wall, which was related to the excessive casting residual stress. The “groove crack” on the partition wall was resulted from the corrosion liquid attacking the interdendritic region. The difference in surface potential between the dendrite and interdendritic region played a critical role on the surface morphology and corrosion mechanism. Casting flaw on the partition wall was due to the interface reaction between superalloy and ceramic core. The fatigue crack was produced due to lack of auxiliary support during the grinding process of the saw tooth shaped shroud.
- single crystal alloy /
- turbine blade /
- engineering failure /
- metallurgical defects /
- fatigue crack

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图 1 涡轮叶片尾缘排气窗裂纹部位宏观图像

Figure 1. Macromorphology of exhaust window cracking of hollow turbine blade

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图 2 裂纹断口宏观图像

Figure 2. Macromorphology of crack fracture

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图 3 8#～9#排气窗间的间隔墙断口微观形貌

Figure 3. Micromorphology of fracture surface of the partition wall between the 8#—9# exhaust window

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图 4 间隔墙沟状缺陷宏观图像

Figure 4. Macromorphology of linear defect of the partition wall

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图 5 陶瓷型芯排气窗口毛刺

Figure 5. Burrs of exhaust window of ceramic core sueface

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图 6 再结晶引起排气窗裂纹断口图像

Figure 6. Fracture surface image of crack originated from the recrystallization boundary of the partition wall

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图 7 间隔墙表面及截面组织图像

Figure 7. Image of the partition wall and appearance of the section organization

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图 8 叶片间隔墙微观形貌

Figure 8. Micromorphology of the partition wall

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图 9 叶片间隔墙微裂纹断口形貌

Figure 9. Fracture surface image of micro-crack of partition wall

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图 10 起源于间隔墙腐蚀“沟纹”断口微观形貌

Figure 10. Fracture surface image of micro-crack originated from the corrosion “groove crack” of partition wall

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图 11 新叶片间隔墙裂纹形貌

Figure 11. Micromorphology of the partition wall of the new turbine blade

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图 12 裂纹尖端区域面扫描分析

Figure 12. Plane scan analysis of the crak tip area

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图 13 裂纹前端区域能谱分析

Figure 13. Energy spectrum analysis of the crak tip area

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图 14 新叶片间隔墙裂纹断口形貌

Figure 14. Fracture surface image of the crack of partition wall

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图 15 铸造裂纹和再结晶裂纹宏观对比图像

Figure 15. Macro-image contrast between casting crack and crystal crack

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图 16 铸造裂纹和再结晶裂纹断口对比图像

Figure 16. Fracture surface image contrast between casting crack and crystal crack

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图 17 新叶片间隔墙微裂纹断口宏观形貌

Figure 17. Fracture surface image contrast between casting crack and crystal crack

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