Experimental correlation development for thermal contact resistance of IN718 alloy
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摘要:
针对航空发动机涡轮轴和叶片的接触传热问题，以IN718高温合金为研究对象，基于稳态热流法搭建了新的接触热阻（TCR）实验平台。首先，采用单点接触热阻标定法对设备不确定度进行评估，结果表明无量纲单点TCR的相对误差可控制在18%以内。其次，通过实验测量研究了IN718样件两种界面粗糙度、界面压力（0.05～10 MPa）及平均温度（20～160 ℃）对TCR的影响规律。结果表明：TCR随界面压力和平均温度的升高而减小，随表面粗糙度的增大而增大。最后，将实验结果与经典半经验关联式对比发现，现有接触热阻模型及实验关联式在特定压力与粗糙度区间存在显著失效现象。综合考虑表面粗糙轮廓曲线的高斯与非高斯分布特征，提出了一个新的无量纲TCR经验关联式，该公式预测值与实验数据的平均误差小于10%。
Abstract:Thermal contact resistance (TCR) at the interfaces of turbine shafts and blades is critical for the thermal analysis and durability design of aero-engines. To address this, a novel experimental apparatus based on the steady-state heat flux method was developed to measure TCR in IN718 superalloy contacts. The measurement uncertainty of the setup was first evaluated using a single-point TCR method, which demonstrated that the relative errors for dimensionless single-point TCR were within 18%. Subsequently, experimental investigations were conducted to examine the effects of two levels of surface roughness, interface pressure (0.05—10 MPa), and mean interface temperature (20—160 ℃) on the TCR of IN718 specimens. The results indicate that TCR decreases with increasing pressure and temperature, but increases with higher surface roughness. A comparison of the experimental data with existing classical semi-empirical models revealed significant prediction inaccuracies, particularly within specific pressure and roughness ranges. Consequently, by accounting for both the Gaussian and non-Gaussian distribution characteristics of the surface profile, a new dimensionless empirical correlation was proposed. The average error between the predicted values from this correlation and the experimental data is less than 10%.
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图 6 单点样件尺寸及标定结果
Figure 6. Dimensions and calibration results of the single-point specimen
图 10 文献结果对比
Figure 10. Comparison of present experimental TCR results with literatures results
图 11 实验无量纲TCC与无量纲TCC关联式对比
Figure 11. Comparison between experimental dimensionless TCC and dimensionless correlation for TCC
图 12 无量纲TCC预测值与实验值对比
Figure 12. Comparison of dimensionless predicted and experimental TCC values
表 1 接触表面形貌表征参数
Table 1. Contact surface topography characterization parameters
试验组号 样件编号 Ra/μm $ \sigma $/μm m $ \sigma ' $ $ \sigma '' $ Rsk Rku A 1 0.23 0.40 0.063 0.082 38.580 −0.919 3.395 2 0.24 0.35 0.072 0.092 49.566 −0.336 3.596 B 3 3.53 4.09 0.112 0.141 44.996 0.231 1.931 4 3.39 4.03 0.108 0.130 35.839 0.267 1.792 
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表 2 接触热阻预测关联式
Table 2. Predicted correlation of TCR
文献 形式 A0 B0 C0 [23] $ {h}^{*}={A}_{0}{ （{{p}^{*}}） }^{{{B}_{0}}} $ 1.45 0.985 [34] $ {h}^{*}={A}_{0}{ （\sqrt{2}p/{{E}_{\text{e}}}{{m}_{\text{e}}}） }^{{{B}_{0}}} $ 1.55 0.94 [35] $ {h}^{*}={A}_{0}{ （{{p}^{*}}） }^{{{B}_{0}}} $ 0.55 0.693 [1] $ {h}^{*}={A}_{0}{ （{{p}^{*}}） }^{{{B}_{0}}}{\left({t}^{*}\right)}^{{{C}_{0}}} $ 0.2417 0.5698 0.3772 [20] $ {R}_{\text{c}}={A}_{0}{ （{{p}^{*}}） }^{{{B}_{0}}}{ （{{t}^{*}}） }^{{{C}_{0}}} $ 1.8×10−4 −0.355 −1.12
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