目的 针对特TC4钛合金在航空发动机关键部件中服役时存在的疲劳性能不足问题,开展偏转磨料水射流表面强化工艺研究,建立覆盖率理论计算与修正模型,阐明其对表面完整性及疲劳性能的影响规律。方法 基于KIRK覆盖率模型,构建磨料颗粒冲击覆盖率理论预测模型。通过图像处理方法测量实际覆盖率,引入有效冲击颗粒占比η和取样区域分布修正因子θ,建立修正模型,并表征不同覆盖率下的粗糙度、显微硬度、残余应力及高周疲劳性能。结果 η和θ分别为0.08和0.74,修正模型误差控制在20%以内,坑痕深度和直径实测均值为13.9 μm和35.7 μm,相对误差为22.70%和8.89%,覆盖率由190%提高至930%时,Ra由0.578 μm降至0.361 μm,显微硬度最高提高16.7%,残余压应力由-387.89 MPa提高至-520.08 MPa,残余应力层深度由79.6 μm增至126.4 μm,疲劳寿命最高提升至原始试样的3.28倍。结论 覆盖率是表征强化质量与疲劳性能提升效果的关键控制参数,合理工艺参数下获得的高覆盖率强化层能够改善表面完整性,使裂纹源向边角或次表面迁移,从而提升特TC4钛合金疲劳服役性能。
Abstract
To improve the controllability of the deflected abrasive water jet peening (DAWJP) process for special TC4 titanium alloy used in key aero-engine components, the theoretical calculation and correction of surface coverage were investigated, and the influence of coverage on surface integrity and fatigue performance was clarified. Based on the KIRK coverage model, a theoretical prediction model for abrasive particle impact coverage was established. The actual surface coverage was measured by image processing, in which the impact craters on the strengthened surface were identified and the covered area was calculated from the pixel ratio in the selected analysis region. Considering that only part of the abrasive particles transported by the jet could form identifiable impact craters on the target surface, and that the particle distribution in the sampling region was not completely uniform, an effective impact particle proportion and a sampling-area distribution correction factor were introduced to modify the original coverage model. A series of DAWJP experiments were then carried out on special TC4 titanium alloy specimens under different process parameters, and the surface roughness, microhardness, residual stress distribution and high-cycle fatigue performance under different coverage levels were systematically characterized. The results showed that the effective impact particle proportion η and the sampling-area distribution factor θ were 0.08 and 0.74, respectively. After correction, the prediction error of the coverage model was controlled within 20%, indicating that the modified model could better describe the actual particle impact behavior in the DAWJP process. The measured average depth and diameter of single-particle craters were 13.9 μm and 35.7 μm, respectively, and the relative errors between the measured and calculated values were 22.70% and 8.89%, respectively. As the coverage increased from 190% to 930%, the surface morphology gradually changed from discrete impact craters to a more overlapped and homogenized impact surface. The surface roughness Ra decreased from 0.578 μm to 0.361 μm, while the surface microhardness increased, with a maximum increase of 16.7%. Meanwhile, the surface compressive residual stress increased from -387.89 MPa to -520.08 MPa, and the depth of the residual stress layer increased from 79.6 μmto 126.4 μm. These results indicated that increasing coverage could promote surface smoothing, surface hardening and the deepening of the compressive residual stress layer. The fatigue test results further showed that, within the coverage range of 850%-930%, the fatigue life was significantly improved, with the maximum fatigue life reaching 3.28 times that of the untreated specimen. Fracture morphology analysis indicated that the fatigue crack source of the untreated specimen was mainly located on the long-side surface, whereas after high-coverage DAWJP treatment, the crack source shifted toward the edge or subsurface region. This phenomenon suggested that the strengthened surface layer could suppress surface crack initiation and delay early crack propagation. It is concluded that, in the DAWJP process, coverage is therefore a key control parameter for evaluating strengthening quality and fatigue performance improvement. However, the fatigue enhancement effect is not determined by coverage alone, but is closely related to the combined effects of particle impact energy, surface roughness, hardening behavior and residual stress layer depth. Under appropriate process parameters, a high-coverage strengthened layer can significantly improve the surface integrity and fatigue service performance of special TC4 titanium alloy, providing a theoretical basis and technical support for the engineering application of DAWJP in complex aerospace components.
关键词
磨料水射流 /
表面覆盖率 /
特TC4钛合金 /
表面完整性 /
疲劳寿命
Key words
abrasive water jet /
surface coverage /
special TC4 titanium alloy /
surface integrity /
fatigue life
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