夏天成,杨晓峰,邵照宇,孙凯,李晓,王继,刘怡心,陈浩.超声滚压工艺对镍基单晶高温合金DD6表面完整性和疲劳寿命的影响[J].表面技术,2024,53(1):182-191.
XIA Tiancheng,YANG Xiaofeng,SHAO Zhaoyu,SUN Kai,LI Xiao,WANG Ji,LIU Yixin,CHEN Hao.Effect of Ultrasonic Rolling Process on Surface Integrity and Fatigue Life of Nickel-based Single Crystal Superalloy DD6[J].Surface Technology,2024,53(1):182-191
超声滚压工艺对镍基单晶高温合金DD6表面完整性和疲劳寿命的影响
Effect of Ultrasonic Rolling Process on Surface Integrity and Fatigue Life of Nickel-based Single Crystal Superalloy DD6
投稿时间:2023-01-02  修订日期:2023-04-15
DOI:10.16490/j.cnki.issn.1001-3660.2024.01.017
中文关键词:  超声滚压  镍基单晶合金  工艺参数  表面完整性  断裂特征  疲劳寿命
英文关键词:ultrasonic rolling  nickel-based single crystal superalloy  process parameters  surface integrity  fracture characteristics  fatigue life
基金项目:国家自然科学基金(5180052032)
作者单位
夏天成 华东理工大学,上海 200237 
杨晓峰 华东理工大学,上海 200237 
邵照宇 中国航发商用航空发动机有限责任公司,上海 201108 
孙凯 中国航发商用航空发动机有限责任公司,上海 201108 
李晓 湖州师范学院,浙江 湖州 313000 
王继 华东理工大学,上海 200237 
刘怡心 华东理工大学,上海 200237 
陈浩 华东理工大学,上海 200237 
AuthorInstitution
XIA Tiancheng East China University of Science and Technology, Shanghai 200237, China 
YANG Xiaofeng East China University of Science and Technology, Shanghai 200237, China 
SHAO Zhaoyu AECC Commercial Aircraft Engine Co., Ltd., Shanghai 201108, China 
SUN Kai AECC Commercial Aircraft Engine Co., Ltd., Shanghai 201108, China 
LI Xiao Huzhou University, Zhejiang Huzhou 313000, China 
WANG Ji East China University of Science and Technology, Shanghai 200237, China 
LIU Yixin East China University of Science and Technology, Shanghai 200237, China 
CHEN Hao East China University of Science and Technology, Shanghai 200237, China 
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中文摘要:
      目的 改善长期服役于高温高压环境的镍基单晶高温合金DD6材料的表面完整性,提高其使用寿命。方法 采用超声滚压表面强化工艺(Ultrasonic Rolling Process,USRP)对镍基单晶高温合金DD6试样进行表面强化,用正交试验法对三因素三水平的试样组进行试验,使用三维形貌仪、显微硬度仪、XRD射线衍射仪和MTS万能疲劳试验机探究静压力、进给速度和加工遍数等超声滚压参数对镍基单晶合金表面完整性和疲劳寿命的影响规律。结果 对于镍基单晶材料,超声滚压强化工艺能有效降低其表面粗糙度,提高表面显微硬度,并在材料内部引入一定的残余应力,并提升疲劳寿命。经USRP处理后,不同晶体取向的材料能够取得的最佳表面增益效果为,表面硬度从465HV提高到679.2HV,表面粗糙度从0.703 μm降低至0.253 μm,表面引入了约为782 MPa的残余压应力。不同晶向材料的疲劳寿命提升表现为,应力水平为742.4 MPa时,疲劳寿命提升1.3倍;应力水平为649.6 MPa时,疲劳寿命提升1.5倍。结论 超声滚压工艺能够有效降低DD6材料的表面粗糙度、提高表面显微硬度,并在表面引入一定的残余应力,疲劳断裂模式主要为沿{110}面的滑移断裂。在低于742.4 MPa的应力加载时,超声滚压强化可以明显提高DD6材料在高温下的疲劳寿命。
英文摘要:
      Nickel-based single crystal superalloy is one of the important materials for manufacturing aero-engine turbine blades. Due to long-term service in high-temperature and high-pressure environment, turbine blades are prone to wear, fracture and other accidents, and their surface integrity needs to be improved to extendtheir service life. In this work, ultrasonic rolling process(USRP) was used to strengthen the surface of nickel-based single crystal superalloy DD6. The vibration frequency of the ultrasonic generator was 10 kHz, and the static force and dynamic force were combined tobe applied to the workpiece surface. The orthogonal test method was used to test the three factors and three levels of sample group. The effect of ultrasonic rolling parameters such as static pressure, feeding rate and processing times on the surface integrity of nickel-base single crystal superalloy was investigated by three-position topography, microhardness tester, XRD diffraction and MTS universal fatigue tester, the corrosion solution mixed with 10% perchloric acid and 90% absolute ethanol was used to thin several strengthened samples layer by layer, and the distribution of residual stress on the surface of the strengthened samples with depth was studied after the average value was taken. The fatigue test was carried out at 650 ℃ high temperature to explore the law of improving the fatigue life of samples with different crystal orientations by ultrasonic rolling strengthening technology under different stress levels. The experimental results and theoretical analysis showed that the ultrasonic rolling strengthening process could reduce the surface roughness of the material, improve the surface microhardness, introduce a certain depth of residual stress in the material, and have different effects on improving the fatigue life under different stress levels. After USRP treatment, the best surface gain effect could be obtained for materials with different crystal orientations:the surface hardness increased from 465HV to 679.2HV, and the surface roughness decreased from 0.703 μm to 0.253 μm. The surface introduced residual compressive stress of about 782 MPa, and the average thickness of residual stress layer was 400 μm. It was found that residual stress layer and hardness layer were related to plastic deformation layer formed after surface impact. The fatigue life changes of materials were as follows:the fatigue life decreased when load was applied at a higher stress level. When load was applied at a stress level of 742.4 MPa, the fatigue life was 1.3 times higher than that of unreinforced samples, and the fatigue life was 1.5 times higher when the stress level was 649.6 MPa. The ultrasonic rolling process strengthening can effectively reduce the surface roughness of DD6 material, improve the surface microhardness and introduce a certain effective thickness of residual stress layer on the surface. The fatigue fracture is mainly slip fracture along {110} plane, and the fatigue life of DD6 under high temperature can be obviously improved by ultrasonic rolling strengthening. When the stress is lower than 742.4 MPa, ultrasonic rolling strengthening can significantly improve the fatigue life of DD6 material at high temperature.
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