Wang Baichuan,Jia Haiwen.Study on high-speed water-based abrasive two-phase flow finishing of high-temperature alloy gas film holes Wang Bingkun1, Hao Juan 2*, Wu Dong1, Mi Tianjian 2, Jiao Xudong1,[J].Plating & Finishing,2024,(10):1-8.
高温合金气膜孔的高速水基磨粒两相流光整研究
- Title:
- Study on high-speed water-based abrasive two-phase flow finishing of high-temperature alloy gas film holes Wang Bingkun1, Hao Juan 2*, Wu Dong1, Mi Tianjian 2, Jiao Xudong1,
- Keywords:
- gas film hole; remelted layer; two-phase flow; surface roughness
- 分类号:
- TQ 43
- 文献标志码:
- A
- 摘要:
- 随着先进航空发动机对涡轮前燃气温度需求不断提升，气膜孔冷却作为涡轮叶片高效冷却的核心技术，对激光加工气膜孔的粗糙表面进行光整处理对于涡轮叶片的冷却性能和使用寿命具有重要意义，然而现有常见的磨粒流抛光、磨料水射流抛光、磁力抛光、化学抛光等光整方法均存在一定的局限性。研究基于新型高速水基磨粒两相流技术，通过调控磨抛压力、加工时间对激光加工的DD6镍基单晶高温合金叶片圆型气膜孔进行光整探索，采用金相显微镜、扫描电子显微镜、激光共聚焦扫描显微镜等表征手段对比分析磨抛前后气膜孔的端口孔型尺寸、内壁微观形貌及表面粗糙度。结果表明：磨抛压力是影响气膜孔尺寸精度与质量的第一核心因素，磨抛压力过小则磨抛效果不明显，磨抛压力过大则极易诱发微裂纹并向基体内部蔓延而最终导致片状剥离或崩口，使得气膜孔尺寸精度及内壁质量下降。当磨抛压力为6 MPa、磨抛时间为90 min时，气膜孔内壁重熔层已基本完全去除，孔径扩大尺寸为0.024 mm，圆度最佳、倒角最大为0.1 mm，表面粗糙度由原始孔4.85 μm显著降低至0.80 μm，尺寸精度控制与内壁质量提升均较为理想。
- Abstract:
- With the increasing demand for turbine gas temperature in advanced aero-engines, film hole cooling is the core technology for efficient cooling of turbine blades. The rough surface finishing of laser-processed film holes is of great significance for the cooling performance and service life of turbine blades. However, the existing common finishing methods such as abrasive flow polishing, water jet polishing, magnetic polishing, and chemical polishing have certain limitations. Based on the new high-speed water-based abrasive two-phase flow technology, the laser-processed circular film holes of DD6 nickel-based single crystal superalloy blade were explored by adjusting the grinding and polishing pressure and processing time. The port hole size, inner wall morphology and surface roughness of the film holes before and after grinding and polishing were compared and analyzed by means of metallographic microscope, scanning electron microscope, laser confocal scanning microscope and other characterization methods. The results show that the polishing pressure is the first core factor affecting the dimensional accuracy and quality of the gas film hole. If the polishing pressure is too small, the polishing effect is not obvious. If the polishing pressure is too large, it is easy to induce microcracks and spread to the interior of the matrix, which eventually leads to flake peeling or chipping, resulting in the decrease of the dimensional accuracy of the gas film hole and the quality of the inner wall. When the polishing pressure is 6 MPa and the polishing time is 90 min, the remelted layer on the inner wall of the gas film hole has been basically completely removed. The aperture expansion size is 0.024 mm, the roundness is the best, the chamfering is 0.1 mm, and the surface roughness is significantly reduced from the original hole 4.85 μm to 0.80 μm. The dimensional accuracy control and the inner wall quality improvement are ideal
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