航空发动机关键构件抗疲劳制造表面的创成、演化及工艺调控

Aero-engine is an important strategic weapon for national security. However, due to a long-term mapping and imitation in domestic, it fails to master the influence law and process control methods of macro-micro geometry and property for surface and subsurface on the service performance of key components, which leads to the thrust-weight ratio and life reliability of domestic engines are difficult to meet the standard for a long time. This project takes the key components of aero-engine as the research object. Through basic research and simulation verification related to anti-fatigue manufacturing surface, the formation and reconstruction mechanism of component surface state during single process and integration manufacturing processes will be revealed, respectively. Besides, the evolution and failure mechanism of surface metamorphic layer during thermal-mechanical stress coupling will be revealed. Based on this, component-oriented manufacture surface state characterization models and evaluation methods are proposed and established, as well as an inverse design method of anti-fatigue manufacturing surface. Based on fatigue resistance manufacture, the process parameter optimization and control method are proposed. The research results can innovate the theory of ultimate fatigue resistance manufacturing. Moreover, it also can support advanced durability damage tolerance design and provide the basic model and process method of anti-fatigue manufacturing for solving the difficult problem of long life and high reliability manufacturing of key components.

航空发动机是关系国家安全的战略重器。然而，由于国内长期测绘仿制，未能掌握制造表面/表层宏微形性对关键构件服役性能的影响规律和工艺控制方法，导致国产发动机推重比等性能和寿命可靠性长期难以达标。本项目以发动机关键构件为应用对象，通过对抗疲劳制造表面相关问题的基础研究和模拟验证，揭示构件表面状态形成与多工艺复合重构机理，阐明热/机循环载荷作用下表面变质层演化规律与失效机制，建立面向构件的制造表面状态表征模型与评价方法、抗疲劳制造表面状态反演设计方法，以及抗疲劳制造工艺优化与调控方法，创新极限抗疲劳制造理论，支撑先进的耐久性损伤容限设计，为破解关键构件长寿命高可靠制造难题提供抗疲劳制造基础模型和工艺方法。

航空发动机是关系国家安全的战略重器。然而，由于国内长期测绘仿制，未能掌握制造表面/表层宏微形性对关键构件服役性能的影响规律和工艺控制方法，导致国产发动机推重比等性能和寿命可靠性长期难以达标。本项目以发动机关键构件为应用对象，通过理论建模、工艺实验、测试分析、疲劳试验等，开展航空发动机关键构件抗疲劳制造表面的创成、演化及工艺调控研究，主要研究内容包括：构件制造表面状态表征与评价、构件表面状态形成与多工艺复合重构机理、热/机循环载荷作用下表面变质层演化规律与失效机制、构件制造表面状态反演设计方法和基于抗疲劳表面状态的工艺参数优化与调控方法等。通过对抗疲劳制造表面相关问题的基础研究和模拟验证，建立了构件制造表面状态表征与评价方法，揭示了构件表面状态形成与多工艺复合重构机理，建立了制造工艺与表面状态间的映射关系，研究并阐明了热/机循环载荷作用下表面变质层演化规律与失效机制，建立了表面变质层微力学微结构特征与疲劳性能的映射关系，提出并建立了构件制造表面状态反演设计新方法和基于抗疲劳表面状态的工艺参数优化与调控方法，实现了疲劳性能到表面状态到制造工艺的反演与工艺调控，并在发动机薄壁叶片模拟件上实现了综合应用验证。研究成果为建立极限抗疲劳制造理论，支撑先进的耐久性损伤容限设计，实现我国航空发动机关键构件的长寿命高可靠制造提供了基础模型和工艺方法。