Analysis on the turning point of dynamic in-plane compressive strength for a plain weave composite

Experimental investigations on dynamic in-plane compressive behavior of a plain weave composite were performed using the split Hopkinson pressure bar. A quantitative criterion for calculating the constant strain rate of composites was established. Then the upper limit of strain rate, restricted by stress equilibrium and constant loading rate, was rationally estimated and confirmed by tests. Within the achievable range of 0.001/s-895/s, it was found that the strength increased first and subsequently decreased as the strain rate increased. This feature was also reflected by the turning point(579/s) of the bilinear model for strength prediction. The transition in failure mechanism, from local opening damage to completely splitting destruction, was mainly responsible for such strain rate effects. And three major failure modes were summarized under microscopic observations: fiber fracture, inter-fiber fracture, and interface delamination. Finally, by introducing a nonlinear damage variable, a simplified ZWT model was developed to characterize the dynamic mechanical response. Excellent agreement was shown between the experimental and simulated results.

Simulation and experimental analysis of melt pool evolution in laser engineered net shaping

In this work,the evolution of melt pool under single-point and single-line printing in the laser engineered net shaping(LENS)process is analyzed.Firstly,the basic structure of the melt pool model of the LENS process is established and the necessary assumptions are made.Then,the establishment process of the multi-physical field model of the melt pool is introduced in detail.It is concluded that the simulation model results are highly consistent with the online measurement experiment results in terms of melt pool profile,space temperature gradient,and time temperature gradient.Meanwhile,some parameters,such as the 3D morphology and surface fluid field of the melt pool,which are not obtained in the online measurement experiment,are analyzed.Finally,the influence of changing the scanning speed on the profile,peak temperature,and temperature gradient of the single-line melt pool is also analyzed,and the following conclusions are obtained:With the increase in scanning speed,the profile of the melt pool gradually becomes slender;The relationship between peak temperature and scanning speed is approximately linear in a certain speed range;The space temperature gradient at the tail of the melt pool under different scanning speeds hardly changes with the scanning speed,and the time temperature gradient at the tail of the melt pool is in direct proportion to the scanning speed.

Quantifying Solid Solution Strengthening in Nickel-Based Superalloys via High-Throughput Experiment and Machine Learning

Solid solution strengthening(SSS)is one of the main contributions to the desired tensile properties of nickel-based superalloys for turbine blades and disks.The value of SSS can be calculated by using Fleischer’s and Labusch’s theories,while the model parameters are incorporated without fitting to experimental data of complex alloys.In thiswork,four diffusionmultiples consisting of multicomponent alloys and pure Niare prepared and characterized.The composition and microhardness of singleγphase regions in samples are used to quantify the SSS.Then,Fleischer’s and Labusch’s theories are examined based on high-throughput experiments,respectively.The fitted solid solution coefficients are obtained based on Labusch’s theory and experimental data,indicating higher accuracy.Furthermore,six machine learning algorithms are established,providing a more accurate prediction compared with traditional physical models and fitted physical models.The results show that the coupling of highthroughput experiments and machine learning has great potential in the field of performance prediction and alloy design.

Meta-silencer with designable timbre

Timbre,as one of the essential elements of sound,plays an important role in determining sound properties,whereas its manipulation has been remaining challenging for passive mechanical systems due to the intrinsic dispersion nature of resonances.Here,we present a meta-silencer supporting intensive mode density as well as highly tunable intrinsic loss and offering a fresh pathway for designable timbre in broadband.Strong global coupling is induced by intensive mode density and delicately modulated with the guidance of the theoretical model,which efficiently suppresses the resonance dispersion and provides desirable frequency-selective wave-manipulation capacity for timbre tuning.As proof-of-concept demonstrations for our design concepts,we propose three meta-silencers with the designing targets of high-efficiency broadband sound attenuation,efficiency-controlled sound attenuation and designable timbre,respectively.The proposed meta-silencers all operate in a broadband frequency range from 500 to 3200 Hz and feature deep-subwavelength sizes around 50 mm.Our work opens up a fundamental avenue to manipulate the timbre with passive resonances-controlled acoustic metamaterials and may inspire the development of novel multifunctional devices in noise-control engineering,impedance engineering,and architectural acoustics.

Novel confinement combustion method of nanosized WC/C for efficient electrocatalytic oxygen reduction

Nanosized tungsten carbide(WC)/carbon(C)catalyst was synthesized via a novel ultra-rapid confinement combustion synthesis method.The amount of activated carbon(AC)plays an important role in the morphology and structure,controlling both the precursor and final powder.The WC particles synthesized inside the pores of the AC had been 10-20 nm because of the confinement of the pore structure and the large specific surface area of AC.When used for oxygen reduction performance,the half-wave potential was−0.24 V,and the electron transfer number was 3.45,indicating the main reaction process was the transfer of four electrons.The detailed electrocatalytic performance and underlying mechanism were investigated in this work.Our study provides a novel approach for the design of catalysts with new compositions and new structures,which are significant for promoting the commercialization of fuel cells.

Improvement of titanium alloy TA19 fatigue life by submerged abrasive waterjet peening:Correlation of its process parameters with surface integrity and fatigue performance

Submerged abrasive waterjet peening(SAWJP)is an effective anti-fatigue manufacturing technology that is widely used to strengthen aeroengine components.This study investigated the correlation of SAWJP process parameters on surface integrity and fatigue life of titanium alloy TA19.SAWJP with different water pressures and standoff distances(SoDs)was conducted on the TA19 specimens.The surface integrity of the specimens before and after SAWJP with different process parameters was experimentally studied,including microstructure,surface roughness,microhardness,and compressive residual stress(CRS).Finally,fatigue tests of the specimens before and after SAWJP treatment with different process parameters were carried out at room temperature.The results highlighted that the fatigue life of the TA19 specimen can be increased by 5.46,5.98,and 6.28 times under relatively optimal process parameters,which is mainly due to the improved surface integrity of the specimen after SAWJP treatment.However,the fatigue life of specimens treated with improper process parameters is decreased by 0.55 to 0.69 times owing to the terrible surface roughness caused by the material erosion.This work verifies that SAWJP can effectively improve the surface integrity and fatigue life of workpieces,and reveals the relationship between process parameters,surface integrity,and fatigue life,which provides support for the promotion of SAWJP in the manufacturing fields.

Wind Turbine Gearbox Fault Diagnosis Based on Multi-sensor Signals Fusion

This paper proposes a novel fault diagnosis method by fusing the information from multi-sensor signals to improve the reliability of the conventional vibration-based wind turbine drivetrain gearbox fault diagnosis methods.The method fully extracts fault features for variable speed,insufficient samples,and strong noise scenarios that may occur in the actual operation of a wind turbine planetary gearbox.First,multiple sensor signals are added to the diagnostic model,and multiple stacked denoising auto-encoders are designed and improved to extract the fault information.Then,a cycle reservoir with regular jumps is introduced to fuse multidimensional fault information and output diagnostic results in response to the insufficient ability to process fused information by the conventional Softmax classifier.In addition,the competitive swarm optimizer algorithm is introduced to address the challenge of obtaining the optimal combination of parameters in the network.Finally,the validation results show that the proposed method can increase fault diagnostic accuracy and improve robustness.

Tomographic particle image velocimetry measurement on three-dimensional swirling flow in dual-stage counter-rotating swirler

Three-Dimensional(3D)swirling flow structures,generated by a counter-rotating dualstage swirler in a confined chamber with a confinement ratio of 1.53,were experimentally investigated at Re=2.3×10^(5)using Tomographic Particle Image Velocimetry(Tomo-PIV)and planar Particle Image Velocimetry(PIV).Based on the analysis of the 3D time-averaged swirling flow structures and 3D Proper Orthogonal Decomposition(POD)of the Tomo-PIV data,typical coherent flow structures,including the Corner Recirculation Zone(CRZ),Central Recirculation Zone(CTRZ),and Lip Recirculation Zone(LRZ),were extracted.The counter-rotating dual-stage swirler with a Venturi flare generates the independence process of vortex breakdown from the main stage and pilot stage,leading to the formation of an LRZ and a smaller CTRZ near the nozzle outlet.The confinement squeezes the CRZ to the corner and causes a reverse rotation flow to limit the shape of the CTRZ.A large-scale flow structure caused by the main stage features an explosive breakup,flapping,and Precessing Vortex Core(PVC).The explosive breakup mode dominates the swirling flow structures owing to the expansion and construction of the main jet,whereas the flapping mode is related to the wake perturbation.Confinement limits the expansion of PVC and causes it to contract after the impacting area.

Influence of the Acoustic Liner in Large Eddy Simulation of Longitudinal Thermoacoustic Instability in a Model Annular Combustor

Although extensive efforts have been made to dampen the thermoacoustic instability,successfully controlling the pressure oscillations in modern gas turbines or aeroengines remains challenging.The influence of the acoustic liner on the longitudinal thermoacoustic mode in a model annular combustor is investigated by Large Eddy Simulation(LES) in this work.The result of the self-excited longitudinal thermoacoustic instability without the liner agrees well with the frequency and acoustic analysis of the pressure mode based on experimental data.Three different bias flow velocities of the liner located downstream of the combustor are then simulated.The results reveal that the existence of the liner influences not only the acoustic field but also the flow field.When the bias velocity is large,it leads to intense turbulence-induced fluctuations,and the pressure oscillation is modulated intermittently.It shows that the weak coupling between flow and pressure oscillations plays a significant role in the onset of the intermittency of a thermoacoustic system.Based on the dynamic analysis of the thermoacoustic system with the acoustic liner,this intermittency is caused by the influence of the flow field on the flame-acoustic coupling.Finally,a low-order modeling method based on Van der Pol(VdP) oscillator with additive stochastic forcing is conducted to reproduce the evolving dynamics of the thermoacoustic system.Although the numerical cases demonstrated in this work are relatively simpler than those in a practical combustion system,the results are helpful for us to understand the effect of the acoustic liner and show the attractive potential to apply this device to suppress thermoacoustic instability.

Optimal location and shape definition of elliptical ventilation openings on aero engine turbine rotors with stress concentration effect

The aero engine turbine rotors are under strong centrifugal load and the highest thermal load.The ventilation openings on the rotors are inevitable,because air flow need to pass through them to cool the temperatures down and keep the air pressure balanced in internal aero engine.The ventilation openings will lead to stress concentration effect.In this paper,the stress concentration factor of elliptical opening on rotating disc is deduced by superposition method.How to define the optimal location and shape of the elliptical opening on rotating disc to decrease the stress concentration effect has been investigated specifically.The reliability and accuracy of the theoretical deviation process is verified by Finite Element Method(FEM).The process of how to obtain the optimal location of the elliptical ventilation opening with particular shape on turbine sealing disc is described as an engineering application case.The investigation provides sufficient theoretical support for optimal location and shape definition of elliptical ventilation opening on aero engine rotors with stress concentration effect by pure mechanics consideration.

Two-sided ultrasonic surface rolling process of aeroengine blades based on on-machine noncontact measurement

As crucial parts of an aeroengine,blades are vulnerable to damage from long-term operation in harsh environments.The ultrasonic surface rolling process(USRP)is a novel surface treatment technique that can highly improve the mechanical behavior of blades.During secondary machining,the nominal blade model cannot be used for secondary machining path generation due to the deviation between the actual and nominal blades.The clamping error of the blade also affects the precision of secondary machining.This study presents a two-sided USRP(TS-USRP)machining for aeroengine blades on the basis of on-machine noncontact measurement.First,a TS-USRP machining system for blade is developed.Second,a 3D scanning system is used to obtain the point cloud of the blade,and a series of point cloud processing steps is performed.A local point cloud automatic extraction algorithm is introduced to extract the point cloud of the strengthened region of the blade.Then,the tool path is designed on the basis of the extracted point cloud.Finally,an experiment is conducted on an actual blade,with results showing that the proposed method is effective and efficient.

Airside pressure drop characteristics of three analogous serpentine tube heat exchangers considering heat transfer for aero-engine cooling

This study explores the design,analysis,and air pressure drop assessment of three analogous air–fuel heat exchangers consisting of thin serpentine tube bundles intended for use in high Mach number aero-engines.In high speed flight,the compressor bleed air used to cool high temperature turbine blades and other hot components is too hot.Hence,aviation kerosene is applied to precool the compressor bleed air by means of novel air–fuel heat exchangers.Three light and compact heat exchangers including dozens of in-line thin serpentine tube bundles were designed and manufactured,with little difference existing in aspects of tube pitches and outer diameters among three heat exchangers.The fuel flows inside a series of parallel stainless serpentine tubes(outer diameter:2.2,1.8,1.4 mm with 0.2 mm thickness),while the air externally flows normal to tube bundles and countercurrent with fuel.Experimental studies were carried out to investigate the airside pressure drop characteristics on isothermal states with the variation of air mass flow rates and inlet temperatures.Non-isothermal measurements have also been performed to research the effect of heat transfer on pressure drops.The experimental results show that inlet temperatures have significant influence on pressure drops,and higher temperatures lead to higher pressure drops at the same mass flow rate.The hydraulic resistance coefficient decreases quickly with Reynolds number,and the descent rate slows down when Re>6000 for all three heat exchangers.Additionally,the pressure drop on heat transfer states is less than that on isothermal states for the same average temperatures.Moreover,the pressure drop through heat exchangers is greatly affected by attack angles and transverse pitches,and an asymmetric M-shaped velocity profile is generated in the crosssection of sector channels.

Effects of pressure oscillation on aerodynamic characteristics in an aero-engine combustor

The effects of pressure oscillation on aerodynamic characteristics in an aero-engine combustor are investigated. A combustor test rig is designed to simulate the pressure drop characteristics of a practical annular combustor. The pressure drop characteristics are firstly measured under atmosphere condition with non-reacting flow(or cold flow), and the air mass flow proportion of each component(dome/liner) are obtained;these properties are base lines for comparison with combustion state. The combustion tests are then carried out under conditions of inlet temperature 340–450 K, fuel air ratio 0.010–0.028. The stability map and the oscillation frequencies are obtained in the tests, the results show that pressure oscillation amplitude increases with the increase of fuel air ratio. Phase trajectory reconstruction is applied to classify the pressure oscillation motion;there are three motions captured in the tests including: ‘‘disk", ‘‘ring" and ‘‘cluster". The pressure drops across the dome under strong pressure oscillation are distinctly divergent from the cold flow, and the changes of pressure drops are mainly affected by pressure oscillation amplitude, but is less influenced by pressure oscillation motion nor oscillation frequencies. Based on the mass flow conservation, the reduction of effective flow area of combustor under strong pressure oscillation is demonstrated. Liner wall temperatures are analyzed through Multiple Linear Regression(MLR)method to estimate the reduction of the air mass flow proportion of the liner cooling under strong pressure oscillation. Finally, the air mass flow proportions of each component under strong pressure oscillation are estimated, the results show that the pressure oscillation motion also has influence on air mass flow proportion.

Laser additive manufacturing of strong and ductile Al-12Si alloy under static magnetic field

Rapid cooling and solidification during laser additive manufacturing(LAM)can produce ultra-fine microstructure with higher strength.However,the non-uniform cell/grain structure can easily result in early stress concentration and fracture during deformation,which remains a major challenge for the LAM field.Using Al-12Si as the model alloy,we employed the external static magnetic field(SMF)to modulate the laser powder bed fusion process(L-PBF),demonstrating a uniform microstructure with a refined cell structure.The mechanical properties show that the SMF can produce a combination of high tensile strength of 451.4±0.5 MPa and large uniform elongation of 10.4%±0.79%,which are superior to those of previously-reported Al-Si alloys with post-treatment or element alloying.The mechanism analysis based on multi-scale simulation reveals the determining role of SMF in rapid solidification,and this method is applicable to the microstructure control of other metallic materials during LAM.

Toward developing Ti alloys with high fatigue crack growth resistance by additive manufacturing

Fatigue crack growth behaviors were investigated by three-point bending tests for TA19 alloy fabricated by laser metal deposition and four kinds of heat-treated samples.The crack growth resistance of the TA19 samples in the near-threshold regime and Paris regime was evaluated through the experimental characterization and theoretical analysis of the interaction between fatigue crack andα/βphase inter-face,columnar prior-βgrain boundary and colony boundary.The results show that in the near-threshold regime,the fatigue crack propagation threshold and resistance increase with the increase of widths of lamellarαp phases and colonies,and the decrease of the number ofαlaths with an angle(ϕ)relative to the applied stress direction ranging from 75°to 90°.In the Paris regime,the fatigue cracking path can be deflected at colony boundaries or columnar prior-βgrain boundaries.The larger the deflection angle,the more tortuous the cracking path and the lower the fatigue crack growth rate.The angle(γ)of the columnar prior-βgrain growth direction relative to the build direction affects not onlyϕof differentαvariants,but also the fatigue cracking path deflection angle(θij)at columnar prior-βgrain boundaries.An optimal combination ofγ=0°-15°-0°-15°for several adjacent columnar prior-βgrains is derived from the theoretical analysis,and that can effectively avoidϕbeing in the range from 75°to 90°and makeθij as large as possible.Such findings provide a guide for the selection of scanning strategies and process parameters to additively manufacture Ti alloys with high fatigue damage tolerance.

Deformation characterization method of typical double-walled turbine blade structure during casting process

To address the complex structures,large out-of-tolerance issues,and inconsistent quality of double-walled turbine blades,a mapping relationship between the structure and deformation was established based on a structural correlation study.Numerical simulations and pouring experiments were carried out based on the designed double-walled model,and a reliable displacement field model of the double-walled blade was established.A decoupling method for the displacement field of the double-walled blade castings was proposed,which decoupled the displacement field into bending,torsion,and expansion/shrinkage deformation vectors.Based on the displacement field analysis of the theoretical and physical models,an expansion/shrinkage model of double-walled blade structure castings was established.Furthermore,an experiment to determine the mapping relationship between double-walled construction and deformation was designed,which included the characteristic distribution distance and designed angle as structural parameters.The functional relationship between the deformation and the structural parameters was established based on a nonlinear regression method.

Influence of grain size on the small fatigue crack initiation and propagation behaviors of a nickel-based superalloy at 650℃

GH4169 at 650℃ in atmosphere was investigated by using single edge notch tensile specimens. The number of main cracks and crack initiation mechanisms at the notch surface strongly depended on the grain size. The crack initiation life accounted for more percentages of the total fatigue life for the alloy with smaller grain size. The fatigue life generally increased with increasing crack initiation life. The small crack transited to long crack when its length reached 10 times the grain size.

Low-cycle fatigue life prediction of a polycrystalline nickel-base superalloy using crystal plasticity modelling approach

A crystal plasticity model is developed to predict the cyclic plasticity during the low-cycle fatigue of GH4169 superalloy.Accumulated plastic slip and energy dissipation as fatigue indicator parameters(FIPs)are used to predict fatigue crack initiation and the fatigue life until failure.Results show that fatigue damage is most likely to initiate at triple points and grain boundaries where severe plastic slip and energy dissipation are present.The predicted fatigue life until failure is within the scatter band of factor 2 when compared with experimental data for the total strain amplitudes ranging from 0.8%to 2.4%.Microscopically,the adjacent grain arrangements and their interactions account for the stress concentration.In addition,different sets of grain orientations with the same total grain numbers of 150 were generated using the present model.Results show that different sets have significant influence on the distribution of stresses between each individual grain at the meso-scale,although little effect is found on the macroscopic length-scale.

Effect of thermal annealing on the microstructure, mechanical properties and residual stress relaxation of pure titanium after deep rolling treatment

The aim of this paper was to investigate the effect of thermal annealing on the microstructure, mechanical properties, and residual stress relaxation of deep rolled pure titanium. The microstructure and mechanical properties of the surface modified layer were analyzed by metallographic microscopy, transmission electron microscope and in-situ tensile testing. The results showed that the annealed near-surface layer with fine recrystallized grains had increased ductility but decreased strength after annealing below the recrystallization temperature, where the tensile strength was still higher than that of the substrate. After annealing at the recrystallization temperature, the recrystallized near-surface layer had smaller grain size,similar tensile strength, and higher proportional limit, comparable to those of the substrate. Moreover, the residual stress relaxation showed evidently different mechanisms at three different temperature regions:low temperature(T≤ 0.2 Tm), medium temperature(T≈(0.2–0.3) Tm), and high temperature(T≥ 0.3 Tm).Furthermore, a prediction model was proposed in terms of modification of Zener-Wert-Avrami model,which showed promise in characterizing the residual stress relaxation in commercial pure Ti during deep rolling at elevated temperature.

An innovative study on low surface energy micronano coatings with multilevel structures for laminar flow design

Laminar flow design is one of the most effective ways to reduce the drag of a commercial aircraft by expanding the laminar flow region on the surface of the aircraft. As material science develops, the emergence of new materials such as low surface energy materials has offered new choices for laminar flow design of commercial aircraft. Different types of low surface energy micro-nano coatings are prepared to verify the effects on the boundary layer transition position and the drag of the airfoil through wind tunnel tests. The infrared thermal imaging technology is adopted for measuring the boundary layer transition, while the momentum integral approach is employed to measure the drag coefficient through a wake rake. Infrared thermal imaging results indicate that the coatings are capable of moving backward the boundary layer transition position at both a low velocity of Mach number 0.15 and a high velocity of Mach number 0.785. Results of the momentum integral approach demonstrate that the drag coefficients are reduced obviously within the cruising angle of attack range from 1° and 5° by introducing the low surface energy micro-nano coating technology.