涡轮叶片气膜孔制造及检测技术发展与展望  

Development and Prospect of the Drilling and Detection of Film Cooling Holes on Turbine Blades and Vaves

作　　者：杨泽南 查海勇 黄子婴 许骏杰 梁威 张朕 王振栋 黄魁东[4] YANG Ze-nan;ZHA Hai-yong;HUANG Zi-ying;XU Jun-jie;LIANG Wei;ZHANG Zhen;WANG Zhen-dong;HUANG Kui-dong(Science and Technology on Advanced High Temperature Structural Materials Laboratory,AECC Beijing Institute of Aeronautical Materials,Beijing 100095,China;AECC Sichuan Gas Turbine Research Establishment,Chengdu,610500,China;State Key Laboratory of Rolling and Automation,School of Materials Science and Engineering,Northeastern University,Shenyang 110819,China;The Key Laboratory of High Performance Manufacturing for Aero Engine(Northwestern Polytechnical University),Ministry of Industry and Information Technology,Xi’an 710072,China)

机构地区：[1]中国航发北京航空材料研究院先进高温结构材料重点实验室,北京100095 [2]中国航发四川燃气涡轮研究院,成都610500 [3]东北大学轧制技术及连轧自动化国家重点实验室,沈阳110819 [4]西北工业大学航空发动机高性能制造工信部重点实验室,西安710072

出　　处：《失效分析与预防》2023年第1期14-20,共7页Failure Analysis and Prevention

基　　金：中国科协青年托举人才工程项目(YESS20200408);财政部稳定支持项目(KZ90220107);国家科技重大专项项目(J2019-VII-0013-0153);航发产学研合作项目(HFZL2020CXY014-1)。

摘　　要：涡轮叶片作为航空发动机最核心的热端部件,在叶身加工气膜冷却孔是提高叶片承温能力的必然趋势。目前主流制孔工艺方法包括电火花加工(EDM)、电化学加工(ECM)与激光加工。其中,电火花制孔工艺最成熟,成本效率优势最为明显,广泛应用于多种型号叶片;电化学制孔可以满足“无重熔层、无微裂纹、无热影响区”的孔壁质量验收要求,但对异型孔加工能力不足限制其应用前景;长脉冲激光主要应用于静子件及燃机叶片的制孔,近些年随着超快激光技术的迅猛发展,孔壁加工精度及质量得到显著提升,使其在叶片转子件的制孔中也获得应用。此外,采用磨粒流、磁力研磨等气膜孔后处理工艺可消除孔口相贯线锐边,避免应力集中效应导致锐边起裂。目前,气膜孔检测技术的工程化应用滞后于加工技术,但对于叶片制孔质量控制与验收标准制定具有重要意义,亟需建立相关标准将先进测试表征方法应用于工程生产中,并长期助力智能制造技术发展。Turbine blades are the core hot-end components for aeroengines,and machining film cooling holes on the blade body is essential for improving the temperature capability of turbine components.At present,the mainstream hole-drilling methods include electrical-discharged machining(EDM),electrochemical machining(ECM)and laser machining.Among them,the EDM hole-drilling process is the most mature and has the most obvious advantages in cost efficiency,which is widely used in various types of blades.ECM method satisfies the requirement of‘no recast layer,no microcrack,no heat affected zone’,but the incapability of diffusor machining restricts its application.Long pulse laser was mainly used in hole drilling of stator and gas turbine blades.Recent years,with the rapid development of ultra-fast laser technology,the machining accuracy and quality of the hole wall have been significantly improved,making it also used in the hole making of blade rotor parts.Moreover,adopting abrasive flow,magnetic grinding and other film hole post-treatment processes could eliminate the sharp edge of the orifice intersecting line,and avoid the sharp edge cracking caused by the stress concentration effect.The engineering application of air film hole detection technology lags behind the processing technology,but it is of great significance for the quality control and the establishment of acceptance criterions for blade hole drilling.It is urgent to establish relevant standards to apply the advanced test and characterization methods to the engineering production,and to help the development of intelligent manufacturing technology in the long run.

关 键 词：气膜冷却孔 电火花加工 电化学加工 超快激光加工 磨粒流处理 

分 类 号：TG661[金属学及工艺—金属切削加工及机床] TG662[电子电信—物理电子学] TG665TN249