Thermal Analysis of Turbine Blades with Thermal Barrier Coatings Using Virtual Wall Thickness Method

Avirtual wall thicknessmethod is developed to simulate the temperature field of turbine bladeswith thermal barrier coatings(TBCs),to simplify the modeling process and improve the calculation efficiency.The results show that the virtualwall thickness method can improve themesh quality by 20%,reduce the number ofmeshes by 76.7%and save the calculation time by 35.5%,compared with the traditional real wall thickness method.The average calculation error of the two methods is between 0.21%and 0.93%.Furthermore,the temperature at the blade leading edge is the highest and the average temperature of the blade pressure surface is higher than that of the suction surface under a certain service condition.The blade surface temperature presents a high temperature at both ends and a low temperature in themiddle height when the temperature of incoming gas is uniformand constant.The thermal insulation effect of TBCs is the worst near the air film hole,and the best at the blade leading edge.According to the calculated temperature field of the substrate-coating system,the highest thermal insulation temperature of the TC layer is 172.01 K,and the thermal insulation proportions of TC,TGO and BC are 93.55%,1.54%and 4.91%,respectively.

Experimental investigation on fatigue of blade specimen subjected to resonance and effect of a damping hard coating treatment

Failures due to high-cycle fatigue have led to a high cost in aerospace engineering over the past few decades.In this paper,the experimental results of the fatigue behavior of compressor blade specimen subjected to resonance and the effects of a damping hard coating on relieving the fatigue progress are presented.The crack initiation and propagation processes were observed under resonance of the first bending mode by using the resonant frequencies as the indicator.Significant nonlinear features were observed in the spectrum of the blade with a fatigue crack.The finite element model considering the breathing crack was established with nonlinear contact based on the crack localization and size,which was obtained by ultrasonic phased array technology.The simulation results of the vibration behavior of the cracked blade were obtained and consistent with the experimental results.A NiCrAlY coating was deposited on the blade,and increases in the fatigue life were observed under the same condition.The results of this paper can help to better understand the fatigue of a compressor blade subjected to resonance and provide a preference for the application of a damping hard coating on compressor blades.

Biopolymer passivation for high-performance perovskite solar cells by blade coating

Thin films of perovskite deposited from solution inevitably introduce large number of defects,which serve as recombination centers and are detrimental for solar cell performance.Although many small molecules and polymers have been delicately designed to migrate defects of perovskite films,exploiting credible passivation agents based on natural materials would offer an alternative approach.Here,an ecofriendly and cost-effective biomaterial,ploy-L-lysine(PLL),is identified to effectively passivate the defects of perovskite films prepared by blade-coating.It is found that incorporation of a small amount(2.5 mg mL^(-1))of PLL significantly boosts the performance of printed devices,yielding a high efficiency of 19.45% with an increase in open-circuit voltage by up to 100 mV.Density functional theory calculations combined with X-ray photoelectron spectroscopy reveal that the functional groups(-NH2,-COOH)of PLL effectively migrate the Pb-I antisite defects via Pb-N coordination and suppress the formation of metallic Pb in the blade-coated perovskite film.This work suggests a viable avenue to exploit passivation agents from natural materials for preparation of high-quality perovskite layers for optoelectronic applications.

Improvement on the performance of perovskite solar cells by doctor-blade coating under ambient condition with hole-transporting material optimization

Numerous fabrication methods have been developed for high-efficiency perovskite solar cells(PSCs). However, these are limited to spin-coating processes in a glove box and are yet to be commercialized. Therefore, there is a need to develop a controllable and scalable deposition technique that can be carried out under ambient conditions. Even though the doctor-blade coating technique has been widely used to prepare PSCs, it is yet to be applied to high-efficiency PSCs under ambient conditions(RH ~45%, RT ~25 °C). In this study, we conducted blade-coating fabrication of modified high-efficiency PSCs under such conditions. We controlled the substrate temperature to ensure phase transition of perovskite and added dimethyl sulfoxide(DMSO) to the perovskite precursor solution to delay crystallization, which can facilitate the formation of uniform perovskite films by doctor-blade coating. The as-prepared perovskite films had large crystal domains measuring up to 100 μm. Solar cells prepared from these films exhibited a current density that was enhanced from 17.22 to 19.98 m A/cm^2 and an efficiency that was increased from 10.98% to 13.83%. However, the open-circuit voltage was only 0.908 V, probably due to issues with the hole-transporting layer. Subsequently, we replaced poly(3,4-ethylenedioxythiophene) polystyrene sulfonate(PEDOT:PSS) with Ni O x as the hole-transporting material and then prepared higher-quality perovskite films by blade-coating under ambient conditions. The as-prepared perovskite films were preferably orientated and had large crystal domains measuring up to 200 μm;The open-circuit voltage of the resulting PSCs was enhanced from 0.908 to 1.123 V, while the efficiency increased from 13.83% to 15.34%.

Highly oriented MXene/polyvinyl alcohol films prepared by scalable layer-by-layer blade coating for efficient electromagnetic interference shielding and infrared stealth

Controlling the orientation of two-dimensional MXene within layered films is essential to optimize or tune their mechanical properties and electromagnetic interference shielding(EMI)performance,but achieving the high orientation MXene layers on an industrial scale remains a challenging goal.In this paper,a scalable layer-by-layer blade coating(LbLBC)method was employed to fabricate highly oriented MXene/polyvinyl alcohol(PVA)films.During the LbLBC process,MXene/PVA colloid suffered a strong shearing effect,which induced the ordered alignment of MXene nanosheets along the direction of the blade movement.The orientation of MXene can be effectively adjusted by changing the scraping gap of LbLBC,achieving a maximum Herman orientation factor f of 0.81.As a result,the mechanical properties and EMI performance of the as-prepared MXene/PVA films are in direct proportion to their orientation,with the optimal values of tensile strength of 145.5 MPa,fracture strain of 19.6%,toughness of 17.7 MJ·m^(−3),and EMI shielding effectiveness of 36.7 dB.Furthermore,the inherently low mid-infrared(mid-IR)emissivity of MXene,combined with the densely oriented structure affords the composite films with IR stealth,resulting in a substantial decrease from 150 to 66.1℃in the radiative temperature of a surface.Conclusively,these scalable MXene/PVA films exhibit remarkable potential for integration into the next generation of multifunctional protective camouflage materials.

Comparative Study on Different Methods for Prediction of Thermal Insulation Performance of Thermal Barrier Coating Used on Turbine Blades

As turbine inlet temperature gets higher and higher,thermal barrier coating(TBC) is more and more widely used in turbine blades.For turbine blades with TBC,it is of great significance to evaluate the temperature distribution of its substrate metal quickly and accurately,especially during the design stage.With different degrees of simplification such as whether to consider the change of the geometric size of the fluid domain by TBC and whether to consider the planar heat conduction in TBC,three different methods used in conjugate heat transfer(CHT) simulation to model the TBC of the turbine blades have been developed and widely used by researchers.However,little research has been conducted to investigate the influence of the three methods on the temperature distribution of turbine blade.To fill this gap,three geometric models were designed.They are a solid conduction model with a substrate metal layer and a TBC layer,a transonic turbine vane with internal cooling and TBC,and a plate cylindrical film hole cooling model with TBC.Different methods were used in these geometric models and their differences were carefully analyzed and discussed.The result shows that for the conduction model used in this paper,with the same TBC surface temperature distribution,the difference between the three methods is very small and can be ignored.For a transonic turbine vane with internal cooling,regarding the local maximum temperature of the substrate-TBC interface,the largest difference between the method in which TBC is considered as a thermal resistance or a virtual layer of cells and the method in which three-dimensional heat conduction equation of TBC is solved occurs at the trailing edge.The difference near the leading edge is below 2K.When employed to the film cooling model,the difference of the laterally averaged temperature of the substrate-TBC interface can be 8 K which is mainly due to the change of the length to diameter ratio of the film cooling hole by TBC.If the substrate thickness is reduced by the thickness of TBC when three-dimensional heat conduction equation of TBC is solved,the temperature difference between the three methods will be quite limited.

Microstructure design to improve the efficiency of thermal barrier coatings

The insulation effect of ceramic coating in a turbine blade is of great importance for the service of engine in the field of aviation industry. Fabricating microstructure in the thermal barrier coatings(TBCs) is considered to be able to enhance the thermal insulation effect. In this study, the traditional three-layer structure, containing ceramic top coat, bonding coat and substrate, is firstly simplified into a double-layer structure, where only ceramic layer and substrate are left, for analyzing the thermal insulation. Afterwards, the thermal insulation effect of the designed microstructure in the bonding coat of the three-layer structure is further studied. Column-like microstructures, filled with hollow ceramic microspheres in the interspace, are designed to improve the thermal insulation effect. The size parameters of the designed microstructure were optimized. The existence of the designed microstructure can significantly prolong the efficiency of thermal barrier coatings. The insulation temperature between the heating surface and lower surface of the substrate can exceed 300℃ and the thermal balance time has a big improvement of 240 s, more than 50%, than the traditional TBCs structure. Compared with the TBCs structure without microstructure, the designed microstructure can significantly improve the insulation temperature of more than 110℃.

热障涂层在航空发动机涡轮叶片上的应用、失效与维护

航空发动机涡轮叶片热障涂层对延长涡轮叶片的使用寿命具有至关重要的作用。首先概述了航空发动机热障涂层的重要性,其次归纳了航空发动机涡轮叶片热障涂层的制备技术及应用特点,主要对大气等离子、电子束物理气相沉积、等离子喷涂-物理气相沉积等3种热障涂层进行了论述。在此基础上,重点阐述了热障涂层在航空发动机涡轮叶片中的典型失效形式,包括高温氧化失效、热腐蚀失效及颗粒物冲击,对以上失效形式的失效机理进行了重点论述。最后结合发动机状态监控及涡轮叶片孔探技术,对涡轮叶片热障涂层的常见典型失效给出了工程案例分析与建议。

风机叶片新型耐磨超疏水涂层的防覆冰性能研究

风力发电机叶片在服役过程中经常会受到覆冰影响,超疏水材料由于其特殊的湿润性,在防冰领域具有较大的应用潜力。基于此,以风力发电机叶片为基底,在其表面旋涂由环氧树脂(EP)、聚二甲基硅氧烷(PDMS)和改性的SiO2等配制的无氟悬浮液,固化后制得耐磨防冰的超疏水试样。采用扫描电镜、红外光谱仪和接触角测量仪分别对超疏水涂层的微观形貌、成分组成和疏水性能进行研究。结果表明:超疏水涂层的接触角为166.65°,滚动角为2.5°。相比于无涂层风机叶片,涂层在-10℃和-15℃延长结冰时间40%左右,并且涂层结冰后冰层的粘结强度明显小于风机叶片的。涂层在800目砂纸上磨损10 m后接触角为150.5°。制备的耐磨超疏水涂层具有超疏水效果和良好的防冰性能。

激光能量密度对65Mn钢表面Ni60A/WC复合涂层摩擦磨损性能的影响规律

目的改善旋耕刀65Mn钢的摩擦磨损性能,提高农机触土零部件的使用寿命。方法采用激光熔覆技术在65Mn钢基体表面制备Ni60A/WC复合涂层。通过改变激光功率调节激光能量密度,在不同能量密度下制备Ni60A/WC复合涂层,观察并测试不同参数下复合涂层试样的宏观形貌、微观结构、物相组成、元素分布、显微硬度及摩擦磨损特性,研究激光能量密度对Ni60A/WC复合涂层组织演变及摩擦磨损性能的影响规律和机理。结果Ni60A/WC复合熔覆层顶部主要有胞状晶和树枝晶,分布较紧密,熔覆层中部主要有树枝状晶,熔覆层底部主要为胞状晶和垂直交界面生长的枝晶,且分布均匀致密。随着激光能量密度的升高,熔覆层的熔高和熔深增加显著,WC硬质相颗粒发生分解,硬质相的数量明显减少,涂层的平均显微硬度降低。在激光能量密度为120 J/mm^(2)时,熔覆层的平均显微硬度为587.1HV1.0,相较于基体,提升了约1.8倍。此时熔覆层的平均摩擦因数最小,为0.312,相较于基体,得到显著提升,摩擦磨损机制为轻微的磨粒磨损。经田间试验测试发现,在激光能量密度为120 J/mm^(2)时制备的带有熔覆层的旋耕刀相较于无熔覆层的旋耕刀,其磨损质量降低了63%。结论通过控制激光能量密度,可以有效调控Ni60A/WC熔覆层的硬度和耐磨性,可为农机触土易磨损件的减摩耐磨表面强化改性提供理论指导。

旋耕刀表面硬质WC合金涂层的电弧热喷涂工艺研究

目的旋耕刀是重要的农机土壤部件,“表硬芯韧”是制造高性能旋耕刀的关键。尝试利用电弧热喷涂方法在旋耕刀表面直接制备含硬质碳化钨(WC)的合金涂层,以提高其综合力学性能。方法以旋耕刀常用制造材料65Mn为基材,以含WC的合金材料为电极丝材,搭建电弧喷涂实验平台,开展三因素两水平工艺实验。重点探讨喷涂电压、送丝速度、扫描速度对涂层制备的影响。结果所制备的涂层表面光滑、平整,无宏观裂纹或可见缺陷。在喷涂电压30V、送丝速度40mm/s、扫描速度30mm/s时,电弧热喷涂的涂层沉积速率为174.7g/min,其平均硬度可达HRC51,表面粗糙度Ra为2.366μm。扫描电镜(SEM)、能谱仪(EDS)等测试结果表明,WC合金涂层具有典型的层状结构,结构均匀致密,涂层与基体之间形成了良好的机械结合。结论在基础工艺研究基础上,成功制备了表面含有硬质WC合金涂层的旋耕刀样件,进一步验证了工艺可行性,为高性能旋耕刀制备提供了新的思路和方法。

金刚石耐磨涂层在水轮机叶片上的应用研究进展

水轮机中的过流部件,如水轮机叶片的磨损是影响水轮机性能和寿命的重要因素之一。为了克服水轮机叶片在工作过程中出现的气蚀、冲蚀磨损损伤,解决水轮机叶片表面金属流失造成的效率低和寿命短等问题,提高水轮机叶片的耐磨性能,研究者们采用了不同的方法,其中包括表面涂层技术。文章综述了水轮机叶片的磨损机理与金刚石涂层的相关研究,并对金刚石涂层在水轮机叶片上的应用进行了展望。

低压等离子喷涂NiCoCrAIYTa涂层的抗燃气热冲击性能研究

为了保障涡轮叶片材料的抗高温氧化与耐热腐蚀性能,采用低压等离子喷涂技术在航空发动机涡轮叶片试验件上成功制备了NiCoCrAlYTa涂层。通过对不同粉末制备的NiCoCrAlYTa涂层进行1000℃/75 h燃气热冲击试验,研究了带涂层叶片尺寸、涂层表面形貌、相组成和显微组织、涂层厚度和均匀性等性能参数的变化。结果表明:热冲击试验后,不同涂层叶片的整体尺寸未发生显著变化,表明涂层在高温环境下具有稳定的尺寸;涂层表面形成了Al_(2)O_(3)膜和NiAl_(2)O_(4)尖晶石,保留了较好的结构完整度,这有助于提高涂层的耐腐蚀性能;涂层的物相组成主要包括γ-Ni、γ’-Ni_(3)Al和少量的β-NiAl,形成了贫Al区、互扩散区、二次反应区等典型微区结构,析出的TCP相为R相,表明在热冲击过程中涂层发生了相变;不同粉末制备的NiCoCrAlYTa涂层均表现出了良好的抗热冲击性能,为航空发动机涡轮叶片的高温应用提供了可行的涂层方案。

航空发动机涡轮叶片热障涂层的现状与发展

热障涂层的研究对提高航空发动机涡轮叶片的工作效率和服役时间具有重要意义。本文重点介绍了热障涂层的结构、材料分类、制备及后处理技术、失效机制方面的研究现状,并对其未来发展进行了展望。高熵陶瓷材料等新型陶瓷材料因其优异的热稳定性及综合力学性能,具有良好的应用前景。激光表面改性技术具有效率高、形变小、局部选区处理等优势,可进一步提高热障涂层的安全可靠性。后续热障涂层的研究将聚焦高熵陶瓷材料、功能梯度材料等的研究及应用,充分采用数值分析及建模等深入研究涂层的失效与防护机制,为航空发动机涡轮叶片的发展奠定基础。

风力发电机叶片用防冰超疏水涂层的研究进展

风力发电机在冬季寒冷天气下运行时极易发生叶片覆冰现象,严重影响发电效率,甚至造成停机事故。为保障风力发电机安全高效地运行,分析超疏水涂层的防冰机理,总结其在防冰领域中应用的优势和存在的问题。结果表明:超疏水涂层是一种具有良好应用前景的风力发电机叶片防冰技术,但需要在涂层耐久性和工程化制备方面进行深入的研究。

风电叶片雨蚀测试技术浅析

风电叶片是风电机组的核心部件之一,受雨雪、风沙、冰雹等各种恶劣的天气因素影响,长期运行的风电叶片前缘会产生严重的侵蚀破坏,导致前缘连接处发生分层裂缝,严重影响叶片的结构稳定性。为了开发出更有利于保护叶片的涂层以及更好地维护叶片,对叶片的雨水侵蚀进行测试研究是十分必要的。本文系统介绍了风电叶片及其涂层受雨水侵蚀的影响过程、雨水侵蚀机理、雨水侵蚀测试方法、测试设备类型以及雨水侵蚀的评估方法,可为行业内开展风电叶片雨蚀防护研究提供参考。

舰载航空发动机用GH2150A压气机叶片的耐蚀性

高温、高湿、高盐雾的海洋环境,给舰载航空发动机带来了严重的腐蚀风险。压气机是大气流经发动机的主要通道,其叶片直接受到高压、高速和潮湿海洋大气的冲刷和腐蚀,造成的损伤与失效尤为突出。根据某型舰载航空发动机高压压气机叶片的服役条件,对GH2150A和GH2150A+化学钝化两种状态的高压压气机叶片进行了192h酸性盐雾试验、680h酸性大气腐蚀试验及100h,600℃涂盐热腐蚀试验。结果表明;两种状态的叶片都表现出良好的耐酸性盐雾和酸性大气腐蚀性能;然而,经过20h涂盐热腐蚀试验后,两种叶片均出现红色腐蚀斑点,60h后整个叶片均被腐蚀,其中经过化学钝化的叶片经100h涂盐热腐蚀试验后,碱洗质量损失较原始叶片更小,表明化学钝化在一定程度可以阻碍腐蚀,但防护能力有限。

基于氧化和烧结的涡轮导向叶片热障涂层区域失效分析

研究氧化与烧结共同作用下对涡轮导向叶片热障涂层区域失效情况的影响有着重要意义。使用UG构建三维叶片流场模型并采用Fluent对其进行温度场分析,观察各区域下的热生长氧化物生长行为和烧结情况对涂层物性参数和氧化层厚度重新标定,利用ANSYS获得各区域涂层应力分布与大小,分析了区域热障涂层失效原因。结果表明不均匀温度场导致的氧化与烧结行为差异性,是造成涡轮导向叶片热障涂层损伤程度不同的根本原因。在叶盆区域涂层出现高应力集中现象,最大拉应力可达+299 MPa,这一分析为部件寿命评估提供借鉴。

风力发电机叶片防覆冰涂层研究进展

【目的】风力发电机叶片在低温下容易发生结冰、覆冰,对防覆冰涂层技术进行研究具有重要意义。【方法】通过对涉及风力发电机叶片防覆冰涂层技术的文献进行检索、标引,综述了国内外现有防覆冰涂层文献技术,列举了现有防覆冰涂层的类型、原理。【结果】在疏水型涂层、发热型涂层及其他功能涂层中,疏水型涂层是现有研究的重点。【结论】采用疏水型涂层结合电热涂层进行除冰是未来风力发电机叶片防覆冰的主要解决方案。