目的 以FGH99粉末高温合金为研究对象,揭示磨削加工表面粗糙度对其高温微动行为的影响规律及其作用机制,为航空发动机榫槽等接触承载结构的表面完整性调控与寿命提升提供理论依据。方法 采用立方氮化硼砂轮在固定磨削参数的条件下,通过改变砂轮粒度制备具有不同表面粗糙度试样,并以抛光试样作为对照。开展750 ℃条件下微动磨损试验,系统表征摩擦系数、磨损体积、磨痕形貌及亚表面损伤特征,分析表面粗糙度对磨损行为的影响机制。结果 随着砂轮粒度从60#增加至600#,试样表面粗糙度Sa由1.10 μm降低至0.10 μm,抛光试样为0.02 μm。磨损体积与表面粗糙度呈显著非线性关系,随粗糙度降低表现出“先减小后增大”的变化趋势。其中,中等粗糙度表面（Sa=0.10 μm）磨损体积最小,表现出最优抗微动磨损性能。结论 表面粗糙度通过调控接触界面形貌与磨屑演化行为,显著影响微动磨损机制：低粗糙度表面以粘着磨损和氧化磨损为主;中表面粗糙度表面的磨损机制转变为由磨屑细化和釉质层形成所主导的三体磨损;高表面粗糙度的磨损机制主要表现为磨粒磨损与疲劳磨损的协同作用。研究表明,合理控制表面粗糙度可在接触界面形成有利的第三体层结构,从而显著提升高温合金构件的抗微动损伤能力。
Abstract
Aero-engine turbine disk tenon/mortise joints operate under extreme high-temperature and high-vibration conditions, making them highly susceptible to severe fretting degradation. To address this critical issue, the work aims to systematically investigate the profound effect of grinding-induced surface roughness on the high-temperature fretting wear performance and underlying damage mechanisms of the FGH99 powder metallurgy nickel-based superalloy, ultimately seeking to provide a solid theoretical basis and practical engineering guidance for optimizing surface integrity manufacturing processes and significantly improving the fretting fatigue life of aero-engine tenon/mortise structures. Cubic boron nitride (CBN) grinding wheels were employed to perform surface grinding on FGH99 superalloy specimens. While processing parameters such as wheel linear speed, feed rate, and grinding depth were kept consistent, specimens with varying surface roughness were prepared by sequentially changing the grinding wheels of different grit sizes (60#, 240#, 400#, and 600#). Simultaneously, lapped and polished specimens were prepared as a control group. Fretting wear tests were conducted with a high-temperature fretting wear tester. Advanced characterization techniques, including a 3D white-light interferometer, scanning electron microscope (SEM), and energy-dispersive X-ray spectroscopy (EDS), were utilized to conduct multi-scale systematic characterization on the dynamic friction coefficient evolution, 3D wear scar morphology, wear volume, as well as the subsurface damage layer and cross-sectional wear scars in the contact zone of specimens with different surface roughness levels. This was done to deeply analyze the micro-regulation mechanism of surface roughness on the high-temperature fretting wear resistance of the FGH99 superalloy. The results indicated that the alteration of surface roughness fundamentally regulated the distribution state of interfacial contact stress and the evolution behavior of wear debris, leading to different dominant fretting wear mechanisms for surfaces with varying roughness. For the low-roughness polished surface (Sa=0.02 μm), due to the relatively smooth interface, the real contact area increased, making it highly susceptible to severe metal adhesion at a high temperature of 750 ℃. Moreover, the nascent wear debris was difficult to discharge, and the dominant wear mechanisms were characterized by adhesive wear and oxidative wear. For specimens with moderate surface roughness (Sa=0.10 μm), the moderate microscopic valley morphology could effectively capture the free oxide debris. Under continuous high-temperature cyclic extrusion, this promoted the refinement, compaction, and high-temperature sintering of the debris, ultimately forming a dense glaze layer with high load-bearing capacity in the contact zone. This wear mechanism was dominated by a protective third-body layer, effectively isolating the direct contact between the metal matrices. Conversely, for specimens with high surface roughness (Sa=1.10 μm), the coarse asperities led to extreme stress concentration at the contact points. These asperities were highly prone to fracture under cyclic shear forces, generating large-particle hard abrasives. The wear mechanism was mainly manifested as a synergistic effect of severe abrasive wear and subsurface fatigue wear. This work fully confirms that optimizing the grinding process to obtain a moderate surface roughness is a key approach to promoting the formation of a high-temperature protective glaze layer and effectively inhibiting the fretting damage of the FGH99 superalloy.
关键词
表面粗糙度 /
高温微动磨损 /
磨损机制 /
FGH99合金 /
磨削加工
Key words
surface roughness /
high-temperature fretting wear /
wear mechanism /
FGH99 superalloy /
grinding
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