某空心风扇叶尖进气道封焊疲劳失效研究-航空制造技术.PDF

RESEARCH 研究论文 某空心风扇叶尖进气道封焊疲劳失效研究 刘晓锋，李  迪，廖连芳，陈云永 （中国航发商用航空发动机有限责任公司设计研发中心，上海 201108） [摘要]  针对某空心风扇叶片叶尖在高循环疲劳试验中异常失效的现象，应力分布测试和振动仿真分析表明应力集 中部位与失效位置不符，断口分析结果表明裂纹萌生于叶尖的通气孔封焊部位，磨除进气道封焊层的叶片试验验证 表明失效源于叶尖进气道焊接缺陷。基于失效机理分析及验证，确定失效源于加工环节焊接工艺选择不当且焊接控 制不良，因此制定了更换封焊工艺为电子束焊和 CT 检测环节的改进措施。 关键词：空心风扇叶片；高循环疲劳；焊接；断口分析 Research on Hollow Fan Blade Tip Welding Failure in HCF Test LIU Xiaofeng, LI Di, LIAO Lianfang, CHEN Yunyong ( Design, Research Development Center, AECC Commerical Aircraft Engine Co., Ltd., Shanghai 201108, China ) [ABSTRACT] For the unexpected tip failure of hollow fan blade HCF test, the stress distribution test, vibration simulation and crack analysis were done. The test results indicate that the failure region is not the high stress region, and fracture anal- ysis indicates that the crack initiates from the welding area of the duct in the blade tip. Validation test on the blades without the tip welding shows that the failure is induced by the welding defect in the blade tip duct. Based on the fatigue analysis and test validation, the failure occurs by improper welding method selection and welding process control in the manu- facturing process. Consequently, the improved process is applying the EB welding in manufacturing and CT inspection. Keywords: Hollow fan blade; High cycle fatigue; Welding; Crack analysis DOI: 10.16080/j.issn1671-833x.2017.17.075 商用大涵道比钛合金空心风扇叶片尺寸大，展弦比 小，具有大扭角、复合弯掠的设计特征 [1-3] ，内部空心瓦伦 1  试验过程及失效描述 结构通常采用扩散焊接 / 超塑成型等特种工艺 [4-7] 。为 某 TC4 空心风扇叶片振动疲劳试验目标循环数为 7 实现空心叶片的成型，一般通过在超塑成形环节高温环 1×10 ，试验考核振型为一阶弯曲振型，试验设备为希 境下冲入高压气体的方法来实现，通气孔通常选择在叶 尔 8T 电磁振动台，试验装置如图 1 所示。 尖型面上，具体位置则基于充气的易于实现性来考虑。 图 1 中空心风扇叶片试验件通过圆弧形榫连结构 在叶片塑性成形环节完成