Kev soj ntsuam ntawm qhov tsis xws luag kev tshawb nrhiav thev naus laus zis ntawm aero engine siab turbine hniav
Turbine hniav yog ib qho tseem ceeb ntawm lub cav aero, thiab nws cov txheej txheem yog qhov nyuaj, uas yuav tsum tau soj ntsuam zoo heev. Laser direct sau (LDM) yog siv los tsim cov tshuab hluav taws xob hauv tsev siab. Nws muaj cov yam ntxwv ntawm kev ua haujlwm siab, siab ceev thiab siab spectral daws teeb meem, thiab tuaj yeem siv rau kev ntsuas 3D, tsis muaj kev puas tsuaj thiab kev tsim kho 3D ntawm cov khoom 3D. Nrog rau daim ntawv thov ntawm laser direct sau tshuab nyob rau hauv domestic kev kub siab turbine hniav manufacturers, siab siab turbine hniav tau tiav loj lawm. Daim ntawv no qhia txog cov txheej txheem kev sau ntawv ncaj qha laser thiab kuaj pom cov cuab yeej siv hluav taws xob hauv tsev siab siab turbine hniav, thiab tshuaj xyuas cov txheej txheem kuaj xyuas qhov tsis raug thiab software.
Nrog rau txoj kev loj hlob sai ntawm aero-engine technology, aero-engine tso rau pem hauv ntej cov kev xav tau siab dua ntawm cov hniav zoo. Turbine hniav lub zog, qaug zog lub neej thiab nto complexity yog cov cim tseem ceeb los ntsuas nws cov kev ua tau zoo. Vim yog txoj kev tsim cov txheej txheem ntawm high-pressure turbine hniav, feem ntau ntawm cov hniav yog tsim los ntawm laser direct sau. Laser direct sau tshuab siv lub high-power semiconductor laser mus txuas ntxiv irradiate lub laser nyob rau hauv lub cheeb tsam yuav tsum tau ua, thiaj li hais tias nws tsim ib tug uniform faib ntawm laser beams nyob rau hauv lub cheeb tsam yuav tsum tau ua. Cov kev sim tshuaj ib txwm muaj xws li machining thiab kev sim tsis muaj kev puas tsuaj, uas muaj qee qhov teeb meem xws li cov nqi ua haujlwm siab, tsis tshua muaj kev pom zoo thiab yooj yim rau kev cuam tshuam los ntawm tib neeg. Yog li ntawd, txhawm rau xyuas kom meej tias turbine hniav muaj cov khoom siv zoo heev, kev tiv thaiv corrosion thiab qaug zog, lawv yuav tsum raug kuaj kom raug thiab sai sai.
1.LDM txheej txheem qhia
Laser direct sau (LDM) yog ib hom ntawm laser beam nrog qhov sib txawv ntawm qhov sib txawv los siv qhov sib txawv ntawm cov tshuaj tiv thaiv ntawm cov khoom tiv thaiv ntawm lub substrate nto, thiab tsim qhov yuav tsum tau nyem contour ntawm tus tiv thaiv nto tom qab kev loj hlob. Nws cov ntsiab lus tseem ceeb suav nrog: xaiv cov khoom siv ceramic tsim nyog, xaiv cov txheej txheem ua haujlwm tsim nyog, ua kom zoo dua cov txheej txheem laser. LDM thev naus laus zis yog ib txoj hauv kev siv lub zog loj laser los sau cov qauv sib txawv ntawm cov ntaub ntawv ceramic. Nws etched microstructures nyob rau saum npoo ntawm cov ntaub ntawv ceramic kom ua tiav txoj kev morphology, hyperspectral daws teeb meem thiab cov khoom lag luam digital, thiab muab nws nrog LDM txheej txheem los tsim cov ntsiab lus nplua nuj kom tau raws li qhov yuav tsum tau muaj siab precision thiab siab stability ntawm precision khoom xws li aircraft cav. Laser direct sau tshuab yog ib txheej ntawm laser ua, tsis-destructive kuaj, duab ua, CAD/CAM nyob rau hauv ib tug ntawm cov tshiab manufacturing technology, piv nrog rau cov txheej txheem ib txwm, thev naus laus zis muaj qhov zoo hauv qab no: ① kev ua haujlwm siab; ② Kev ua haujlwm ceev ceev; ③ Kev siv cov khoom siv siab; ④ Zoo nto zoo; ⑤ tuaj yeem hloov kho tus kheej. LDM thev naus laus zis siv laser direct sau txoj kev los sau cov saum npoo ntawm cov ntaub ntawv ceramic, thiab cov tshuaj tiv thaiv photochemical tshwm sim nyob rau hauv lub microstructure ntawm cov khoom (xws li atoms, molecules, thiab lwm yam) nyob rau hauv qhov kev txiav txim ntawm laser, yog li hloov cov qauv thiab cov khoom ntawm cov khoom. khoom. Muaj ntau txoj hauv kev kom ua tiav laser ncaj qha sau tshuab, thiab feem ntau yog peb hom rau cov ntaub ntawv ceramic: thawj hom yog cov txheej txheem ib txwm muaj (xws li tshuaj vapor deposition, melting ceev quenching, plasma enhanced CVD, thiab lwm yam); Thib ob, kev siv tshuab siab heev (xws li 3D luam ntawv, laser direct sau, thiab lwm yam); Qhov thib peb yog 3D luam ntawv + laser melting ncej tshuab (xws li: 3D luam ntawv + laser melting ncej hloov tshuab, thiab lwm yam). Muaj peb txoj hauv kev tseem ceeb ntawm laser xaiv melting txoj kev siv tshuab. Ib qho yog siv laser los denude cov ntaub ntawv ceramic los ua kom lawv muaj peb-dimensional morphology. Qhov thib ob yog etching, etching; Qhov thib peb yog siv laser ncaj etching txoj kev nyob rau saum npoo ntawm cov ntaub ntawv ceramic rau graphic processing. Lub laser zog ceev siv nyob rau hauv LDM tshuab yog siab, thiab ib tug siab zog ceev yuav tsum tau rau etch ceramic cov ntaub ntawv. Nyob rau tib lub sijhawm, lub laser ablation qhov tob yuav tsum raug tswj kom raug.
2. Kev kuaj xyuas tsis raug technology
Tam sim no, kev lag luam nrhiav pom ntawm cov hniav tsis xws luag yog X-ray txoj kev, ultrasonic txoj kev thiab X-ray foundations txoj kev. X-ray txoj kev, ultrasonic txoj kev yog ib txoj kev kuaj uas tsis muaj kev puas tsuaj, nws tuaj yeem kuaj xyuas cov khoom tsis xws luag, X-ray txoj kev xav yog kev siv X-ray lossis gamma rays tawm los ntawm qhov chaw los irradiate cov khoom tiav, txhawm rau txhawm rau txheeb xyuas cov teeb meem me me hauv cov khoom siv, tab sis lub peev xwm nkag mus rau hauv txoj kab hluav taws xob yog txwv, tsis tuaj yeem ntes cov teeb meem me me. Yog li ntawd, nyob rau hauv kev siv tswv yim, X-ray txoj kev thiab ultrasonic txoj kev yog lub ntsiab nrhiav kom tau. Txawm li cas los xij, nrog kev txhim kho thev naus laus zis, kev lag luam CT kuaj pom nrog micro-focus tau siv dav hauv kev lag luam turbine hniav vim nws tsis muaj kev puas tsuaj, kev ua haujlwm siab thiab siab precision.
(a) Radiographic transillumination ntawm qhov nkag ntug
(b) Radiographic nkag mus ntawm qhov tso tawm ntug
(c) Cov ntug noj mov yog transilluminated los ntawm digital radiography
2.1 X-ray detection X-ray detection yog siv lub X-ray raj los tso X-rays ntawm qhov chaw ntawm cov khoom nyob rau hauv kev ntsuam xyuas, soj ntsuam qhov tsis xws luag nyob rau saum npoo ntawm cov khoom nyob rau hauv kev sim, thiab ces siv cov duab kaw kom quantity. thiab nrhiav qhov khoom. Raws li qhov sib txawv ntawm qhov tob tob, X-ray tuaj yeem muab faib ua peb txoj hauv kev: qhov tob tob tob, qhov tob tob tob thiab qhov tob tob tob. Txoj kev transillumination siv X-ray raj rau irradiate saum npoo ntawm cov khoom kuaj xyuas kom pom qhov tsis xws luag ntawm cov khoom. Vim muaj kev txwv ntawm cov cuab yeej siv thiab thev naus laus zis, txoj hauv kev yog qhov nyuaj rau kev ua tiav qhov tseeb ntawm qhov tsis xws luag sab hauv ntawm cov txheej txheem nyuaj. Txoj kev no yog tsim nyog rau lub workpiece nrog du nto thiab uniform ntom, tab sis nws tsis muaj peev xwm mus nrhiav tau thiab quantify lub complex sab hauv Cheebtsam.
2.2 Ultrasonic detection Lub hauv paus ntsiab lus ntawm kev kuaj xyuas ultrasonic yog siv lub tshuab kuaj ultrasonic thiab sojntsuam kom emit ultrasonic tsis, thiab qhov kev sojntsuam tau txais lub ncha rau qhov chaw. Ultrasonic detection technology yog dav siv nyob rau hauv industrial teb vim nws qhov zoo ntawm rhiab heev, siab nkag, siab precision thiab nruam nrhiav. Rau cov ntaub ntawv hlau, feem ntau yog siv lub taub hau ncaj thiab oblique taub hau ob txoj kev, ncaj taub hau nrhiav kom pom qhov tob yog feem ntau 1 hli, inclined taub hau nrhiav kom pom qhov tob yog feem ntau 5 hli, nyob rau hauv cov ntaub ntawv siv, ultrasonic nrhiav kom tau ntaus ntawv raws li cov khoom sib txawv yuav tsum tau ntsuas, siv txawv probes. Lub thermal conductivity ntawm turbine hniav khoom yog siab, yog li cov kev sojntsuam nrog zoo thermal kev ua tau zoo yuav tsum tau xaiv rau ultrasonic nrhiav. Rau qis siv ultrasonic teeb liab, xws li chav tsev kub iav ceramic pas nrig, vim nws cov thermal zoo, tuaj yeem ua tau raws li qhov xav tau. Rau cov ntaub ntawv uas muaj qhov tsis xws luag lossis kev suav nrog, ib qho kev sojntsuam uas muaj kev nkag mus tau zoo thiab muaj kev nkag siab zoo yuav tsum raug xaiv, thiab rau cov ntaub ntawv uas muaj qhov tsis xws luag loj, txoj kev emission txuas ntxiv thiab cov txheej txheem pulse reflection tuaj yeem siv los kuaj xyuas. Hauv kev siv tswv yim, txoj kev sib txuas ntawm ib leeg ntev yoj, ob chav shear yoj thiab longitudinal nthwv dej tuaj yeem siv tau, thiab nws muaj peev xwm siv tib lub sijhawm ntev yoj nrhiav kom tau cov khoom uas muaj cov kab nrib pleb thiab lwm yam tsis xws luag. Tam sim no, cov cuab yeej kuaj ultrasonic tau siv dav, tab sis vim nws cov khoom siv ntsuas kim, nws tsis haum rau kev sim teb.
2.3 Microfocus Industrial CT detection Microfocus industrial CT nrhiav tau tsuas yog siv X-ray lossis gamma ray kis tau tus mob thiab kev xav hauv cov khoom los tsim cov kab hluav taws xob, thiab tom qab ntawd tus ntes tau txais cov kab hluav taws xob irradiation ntawm cov khoom kuaj pom kom nqus tau lub zog, hloov mus rau X- rays los yog gamma rays, thiab tom qab ntawd lub detector hloov lub zog mus rau hauv hluav taws xob teeb liab, thiab tom qab ntawd cov qauv duab ntawm cov khoom tuaj yeem tau txais tom qab ua tiav. Thaum lub sijhawm kuaj pom, cov khoom yog thawj zaug tso rau ntawm qhov chaw X-ray, thiab tom qab ntawd cov teeb liab tsim los ntawm X-ray beam dhau los ntawm cov khoom tau txais los ntawm txoj kev scanning. Thaum cov khoom kuaj pom nyob rau hauv lub xeev tsis muaj pob tshab, lub teeb liab tau txais los ntawm lub ntes yuav pom; Speckle yog tsim los ntawm lub teeb liab tau txais los ntawm tus ntes thaum cov khoom kuaj pom tau kis. Thaum qhov chaw qhov chaw loj, nws qhia tau hais tias muaj qhov tsis xws luag loj hauv cov khoom kuaj pom. Thaum qhov chaw me me, nws qhia tau hais tias muaj qhov tsis xws luag hauv qhov khoom kuaj pom. Txhawm rau tshem tawm cov nyhuv speckle ntawm cov duab zoo, cov txheej txheem tshwj xeeb tuaj yeem siv los tshem tawm cov nyhuv speckle thiab txhim kho cov duab zoo. Piv txwv li, cov xim lim tuaj yeem muab ntxiv rau pem hauv ntej ntawm lub tshuab ntes kom tshem tawm cov pob, ntxiv rau, speckle tuaj yeem cuam tshuam los ntawm kev hloov cov ntsuas ntsuas, thiab cov kab ntawv luam tawm tuaj yeem ua rau qhov tsis xws luag; Rau qhov loj me tsis xws luag, qhov chaw scanning yog ua tau. Txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau muaj kev kub ntxhov, cov txheej txheem kev sim tsim nyog yuav tsum raug xaiv. Multi-beam teeb pom kev yog feem ntau tau txais, thiab cov kab hluav taws xob array detectors yog siv los ua qhov tseem ceeb hauv kev nrhiav kom tau cov duab. X-ray thiab gamma rays yog siv los kuaj xyuas raws li cov ntaub ntawv sib txawv.
3.Defect nrhiav tau software qhia
Daim ntawv no qhia txog microfocal CT scanning software tsim nyog rau kev kub siab turbine blade defect detection. Lub software feem ntau ua cov haujlwm hauv qab no: (1) scan cov ntaub ntawv nyeem; ② Kev ntsuas duab thiab kev tsom xam; ③ Tsis siv neeg tshawb pom qhov tsis xws luag; ④ Kev tswj cov ntaub ntawv; ⑤ Tswj kom zoo; ⑥ Peb-dimensional reconstruction. Ntawm lawv, kev nyeem cov ntaub ntawv scan yog cov ntaub ntawv tseem ceeb, uas txiav txim siab tus lej, txoj haujlwm, cov duab, qhov loj me thiab lwm yam ntaub ntawv ntawm cov duab nruab nrab. Raws li cov txiaj ntsig tshawb pom, CT scan cov txiaj ntsig tuaj yeem hloov kho raws li qhov xav tau sib txawv. Rau kev luam theej duab cov ntaub ntawv, cov software muaj qhov tsis xws luag kev faib tawm, kev lim dej tsis raug, kev sau npe tsis raug, kho qhov tsis xws luag, kev tsim kho tsis raug thiab lwm yam haujlwm. Table 1 CT scan parameters.
4.LDM hniav kuaj kev tshawb nrhiav
Cov ntaub ntawv ua haujlwm tiag tiag ua ntej thiab tom qab sib xyaw yog qhia hauv Table 6. Nws tuaj yeem pom los ntawm Table 6 tias nyob rau hauv kev sim, thaum 100% cov roj hluav taws xob raug hlawv, lub zog tso zis ntawm cov roj turbine yog 179.8MW thiab efficiency yog 35.49%. Lub zog tso zis ntawm cov roj turbine yog 169.0MW thiab qhov ua tau zoo yog 35.81%, uas yog qhov tseem ceeb raws li tus nqi suav.
4.1 Secondary processing defects Secondary processing yog hais txog kev kho hniav, sib tsoo, polishing thiab lwm yam txheej txheem, nyob rau hauv cov txheej txheem thib ob yuav tshwm sim cov teeb meem hauv qab no: (1) deg roughness tsis yog raws li tus qauv: nyob rau hauv cov txheej txheem polishing khoom yuav tsim. ib lub suab nrov, kom lub ntsej muag roughness tom qab polishing tsis tuaj yeem ua tau raws li qhov yuav tsum tau ua. Txhawm rau tshem tawm cov suab nrov zoo li no, cov tuam ntxhab feem ntau siv ultrasonic, electrolysis thiab lwm txoj hauv kev los tshem tawm nws, ultrasonic, electrolysis tuaj yeem tshem tawm qhov roughness, tab sis ultrasonic yog qhov cuam tshuam rau cov hmoov av lossis roj ntawm cov hniav, Yog li ntawd, txawm tias ultrasonic los yog electrolysis, tsis haum rau tshem tawm qhov roughness ntawm cov hniav. Hauv kev tsim khoom tiag tiag, thaum lub ntsej muag roughness ntawm cov hniav tsis ua raws li qhov yuav tsum tau ua, kev sib tsoo tuaj yeem siv tau. Txawm hais tias qhov tsis xws luag tuaj yeem tshem tawm tau zoo, kev ua haujlwm thib ob tseem xav tau tom qab sib tsoo. (2) Tsis tsim nyog qhov chaw zoo: Nyob rau hauv cov txheej txheem ntawm high-pressure turbine hniav, yog hais tias lub nto zoo ntawm cov hniav tsis ua raws li tus qauv, kev ntsuas xws li polishing thiab polishing yuav raug coj los daws qhov teeb meem. Txawm hais tias txoj kev no tuaj yeem tshem tawm qhov tsis xws luag, nws txo qis kev ua haujlwm ntawm cov hniav. Txhawm rau txhim kho nws cov kev ua tau zoo, cov tuam ntxhab feem ntau polish thiab polish nws ntau zaus hauv cov txheej txheem ntau lawm, tab sis thaum sib tsoo thiab polishing, nws yog ib qho yooj yim los tsim cov kev ua haujlwm thib ob.
4.2 Cov khoom siv stratification Nyob rau hauv cov txheej txheem ntawm high-pressure turbine hniav, vim tsis sib haum ntawm cov txheej txheem tsis, ib los yog ntau tshaj raw cov ntaub ntawv los yog impurities nkag mus rau hauv lub hniav, ua rau cov khoom stratification. Hauv qhov kev sim tiag tiag, lub siab siab turbine hniav nrog delamination tsis xws luag tuaj yeem muab tso rau ntawm cov qauv disk, thiab cov qauv disk tuaj yeem muab piv nrog cov qauv zoo tib yam disk kom pom qhov delamination delamination ntawm cov khoom. Yog tias muaj teeb meem thaum lub sij hawm muab tso rau hauv txoj kev, yuav tsum tau soj ntsuam ntxiv los txiav txim seb nws qhov chaw tshwj xeeb, thiaj li txiav txim siab seb hom kev puas tsuaj.
4.3 Porosity thiab Slag inclusion defects xws li porosity thiab slag inclusion yog ib qho teeb meem zoo nyob rau hauv zus tau tej cov high-pressure turbine hniav. Porosity defect yog lub ntsiab ua rau cov khoom siv zog poob, uas muaj kev cuam tshuam tseem ceeb ntawm kev ua haujlwm ntawm lub tshuab hluav taws xob siab. Hauv kev tsim khoom tiag tiag, qhov tsis xws luag feem ntau tshwm sim los ntawm cov npuas me me hauv. Piv nrog rau lwm yam khoom, qhov loj ntawm lub npuas yog me me heev piv nrog rau lwm yam khoom, thaum lub puab phab ntsa ntawm lub npuas yog raug kev nyuaj siab heev, cov kab nrib pleb yuav tshwm sim, ntxiv rau, lub puab phab ntsa ntawm lub npuas yog kuj tsis muaj zog, yooj yim rau rupture nyob rau hauv qhov kev txiav txim ntawm sab nraud kev nyuaj siab. Muaj qee qhov teeb meem hloov hluav taws xob hauv kev ua haujlwm ntawm cov tshuab hluav taws xob siab, uas yuav ua rau muaj qhov tshwm sim kub hnyiab rau qee yam. Yog tias qhov ablation tsis raug tshem tawm raws sijhawm, kev suav nrog yuav raug tsim. Slag inclusions yog ib hom kev sib koom ua ke, thiab cov slag suav nrog qhov tsis xws luag yog qhov hnyav dua li qhov tsis xws luag, uas tsis yog tsuas yog cuam tshuam rau kev ua haujlwm thiab lub neej ntawm lub tshuab hluav taws xob siab, tab sis kuj tuaj yeem ua rau cov hniav poob qis lossis txawm tias tsis ua haujlwm. Nyob rau hauv qhov tseeb ntau lawm, yog hais tias lub slag inclusion cheeb tsam ntawm high-pressure turbine hniav tsis loj, cov pa muaj CT txoj kev yuav siv tau los ntes nws; Yog tias thaj tsam slag loj lossis muaj qhov tsis xws luag, microcoke industrial CT yuav tsum tau siv los kuaj xyuas thiab tshuaj xyuas. Nyob rau hauv tus txheej txheem ntawm microfocus industrial CT nrhiav kom tau, txhawm rau tiv thaiv cov duab plooj, cov duab tuaj yeem ua ntej thiab segmented kom tau txais cov ntaub ntawv meej thiab raug.
Hauv cov ntsiab lus, nrog rau kev txhim kho txuas ntxiv ntawm aero-engine thev naus laus zis, kev tshawb pom zoo ntawm cov tshuab hluav taws xob siab siab tau dhau los ua qhov tseem ceeb. Daim ntawv no qhia txog ntau yam kev kub siab turbine blade defect detection technologies. Hauv kev siv cov tswv yim, cov cuab yeej sib txawv ntawm kev kuaj pom muaj qhov sib txawv. Thaum siv cov thev naus laus zis txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau txhawm rau nws, nws yog ib qho tsim nyog yuav tsum xaiv cov txheej txheem sib txawv, nws yog qhov yuav tsum tau xaiv thiab sib xyaw ua ke raws li cov xwm txheej tshwj xeeb ntawm cov hniav. Txoj kev loj hlob ntawm kev kub siab turbine blade defect detection technology tseem ntsib ntau yam teeb meem thiab teeb meem. Nyob rau hauv lub neej yav tom ntej, cov cuab yeej raug, cov ntaub ntawv muaj peev xwm ua tau thiab algorithm kev ua tau zoo yuav tsum tau txhim kho ntxiv kom ua tau raws li qhov yuav tsum tau ua ntawm aero-engine high pressure turbine blade defect detection.
