电站汽轮机低压转子叶片裂纹形成原因分析

对某电厂汽轮机低压转子末3级含裂纹叶片取样,进行宏观观察、光谱分析、力学性能试验、显微硬度检验、显微组织及能谱等分析。试验结果表明:叶片的合金成分符合相关要求,叶片材料的强度、塑性和韧性等相关指标均符合标准要求;裂纹起源及裂纹尖端未见腐蚀性元素。叶片热处理工艺控制不佳,出汽侧边缘硬度和组织不均匀,存在较大的残余应力,材料的抗疲劳性能降低,塑韧性变差,在离心力和蒸汽压力等周期性交变应力作用下发生疲劳开裂。实现叶片出汽侧边缘硬化层的无损检测是未来发展的一个重要方向。

汽轮机低压转子2Cr13不锈钢叶片断裂分析

通过断口宏观形态分析、扫描电镜(SEM)微观观察、能谱(EDS)分析和显微组织分析以及常规力学性能测试,对电站汽轮机低压转子2Cr13不锈钢叶片断裂失效模式和失效原因进行了全面的分析,并对开裂机制进行了深入探讨。结果表明:该汽轮机低压转子2Cr13不锈钢叶片的失效模式为腐蚀疲劳破坏,叶片材质较差的内部因素和腐蚀疲劳的工况条件共同作用造成了叶片的断裂失效。

K417G低压涡轮转子叶片振动疲劳断裂特征研究

对振动试验开裂的101件发动机低压涡轮转子叶片的裂纹形态、分布、裂纹断口等进行研究。结果表明:所有叶片裂纹均为横向裂纹,其中大部分叶片源区未见缺陷,裂纹位置主要集中在叶根附近进气边前缘或排气边尾缘位置,少数叶片裂纹萌生于疏松,位置随机分布;所有叶片断口均出现3个区域,即源区、沿{111}滑移面扩展的第Ⅰ阶段扩展区和叶片径向垂直的第Ⅱ阶段扩展区;源区主要为单疲劳源,第Ⅰ阶段扩展区发展充分,宏观上可见与叶片径向大致呈45°的反光小平面,微观上断口可见河流花样、滑移台阶和锯齿状断面等特征,第Ⅱ阶段扩展区断面平整,微观上可见间距不足1μm的细密疲劳条带。

叶根前缘倒角对低压涡轮转子叶片强度的影响

针对某型航空发动机低压涡轮转子叶片在叶根前缘倒角处发生应力集中的问题,研究了叶根前缘倒角半径对低压涡轮转子叶片强度的影响。研究结果表明,随着叶根前缘倒角半径的增加,低压涡轮转子叶片根部前缘倒角处应力集中效应降低,可作为减少低压涡轮转子叶片疲劳破坏和断裂失效的措施。叶片表面气动力载荷、离心力载荷是导致低压涡轮转子叶片根部前缘倒角处应力集中的主要原因。其中,气动力载荷引起的应力占总等效应力的78%,离心力载荷引起的应力占总等效应力的22%,温度场载荷引起的应力可忽略。

航空发动机低压涡轮转子叶片动应力测量方案设计

针对发动机结构特点和低压涡轮转子叶片动应力测量要求,提出一种基于应变片和遥测技术的低压涡轮转子叶片动应力测量方案。在不改变发动机振动激振因素的情况下,该方案通过整机结构改装设计,解决了测试系统布置、冷却方案设计、应变片走线和改装转子动力学评估等问题。相比于应变片+引电器测量方案,该动应力测量方案具有改装结构小、冷却方案简单、应变片存活率高、验证成本低等优势。通过在发动机上开展的专项动应力测量试验,验证了设计的动应力测量方案的可行性,为低压涡轮转子叶片动应力和阻尼效果的评估提供了试验数据。可为开展整机环境下低压涡轮转子温度场测量等提供技术支持。

2Cr13钢汽轮机叶片的开裂原因分析

在电厂机组启停和运行参数变化时,汽轮机低压转子末级叶片易受到交变应力作用而发生开裂,影响汽轮机的安全运行。对某汽轮机发生开裂的叶片进行了金相检验、硬度测试、断口分析和能谱分析,以确定叶片开裂的原因。结果表明:该开裂叶片材质状态正常,叶片开裂的原因为腐蚀疲劳,是由腐蚀环境和交变应力的共同作用导致的。

Detection of Blade Mistuning in a Low Pressure Turbine Rotor Resulting from Manufacturing Tolerances and Differences in Blade Mounting

For a serious prediction of vibration characteristics of any structure, a detailed knowledge of the modal characteristic is essential. This is especially important for bladed turbine rotors. Mistuning of the blading of a turbine rotor can appear due to manufacturing tolerances or because of the blading process itself due to unequal mounting of the blades into the disk. This paper investigates the mistuning of the individual blades of a low pressure turbine with respect to the effects mentioned above. Two different rotors with different aerodynamic design of the blades were investigated. The blades were mounted to the disk with a so-called hammer head root which is especially prone to mounting irregularities. For detailed investigations, the rotor was excited with a shaker system to detect the forced response behavior of the individual blades. The measurements were done with a laser vibrometer system. As the excitation of rotor structure was held constant during measurement, it was possible to detect the line of nodes and mode shapes as well. It could be shown that the assembly process has an influence on the mistuning. The data were analyzed and compared with numerical results. For this, different contact models and boundary conditions were used. The above described characterization of modal behavior of the rotor is the basis for the upcoming aeroelastic investigations and especially for the blade vibration measurements of the rotor, turning with design and off-design speeds.

Effects of Nozzle-Strut Integrated Design Concepton on the Subsonic Turbine Stage Flowfield

In order to shorten aero-engine axial length,substituting the traditional long chord thick strut design accompanied with the traditional low pressure(LP) stage nozzle,LP turbine is integrated with intermediate turbine duct(ITD).In the current paper,five vanes of the first stage LP turbine nozzle is replaced with loaded struts for supporting the engine shaft,and providing oil pipes circumferentially which fulfilled the areo-engine structure requirement.However,their bulky geometric size represents a more effective obstacle to flow from high pressure(HP) turbine rotor.These five struts give obvious influence for not only the LP turbine nozzle but also the flowfield within the ITD,and hence cause higher loss.Numerical investigation has been undertaken to observe the influence of the Nozzle-Strut integrated design concept on the flowfield within the ITD and the nearby nozzle blades.According to the computational results,three main conclusions are finally obtained.Firstly,a noticeable low speed area is formed near the strut's leading edge,which is no doubt caused by the potential flow effects.Secondly,more severe radial migration of boundary layer flow adjacent to the strut's pressure side have been found near the nozzle's trailing edge.Such boundary layer migration is obvious,especially close to the shroud domain.Meanwhile,radial pressure gradient aggravates this phenomenon.Thirdly,velocity distribution along the strut's pressure side on nozzle's suction surface differs,which means loading variation of the nozzle.And it will no doubt cause nonuniform flowfield faced by the downstream rotor blade.

Numerical Investigation of Influence of Rotor/Stator Interaction on Blade Boundary Layer Flow in a Low Speed Compressor

Numerical method was applied to the unsteady flow simulation at the mid span of a two-stage low speed compressor,and the blade boundary layer flow under rotor/stator interaction was investigated.By the model of wake/boundary layer interaction provided in this paper,the simulated blade frictional force and the boundary layer turbulent kinetic energy,the influence of wake/potential flow interaction on the blade boundary layer flow was analyzed in detail.The results show that under the condition of rotor/stator interaction,the wake is able to induce the stator laminar boundary layer flow to develop into turbulent flow within a certain range of wake interaction.In the stator suction boundary layer,an undisturbed region occurs behind the rotor wake,which extends the laminar flow range,and the wake with high turbulent intensity has the capability to control the boundary layer separation under adverse pressure gradient.