Breakdown of lamina of job of turbine of some engine high pressure and model repair a technology

05mm. The lamina of high-pressured turbine job that discards as useless because of stretchy quantity out of tolerance since overhaul has more than 1000, its discard as useless the reason that has 3 sides: (1) the reason check level that stretchy quantity exceeds overhaul to set; (2) be worth without primitive lamina length; (3) stretchy quantity is negative worth. 4 lamina wall is large design a requirement to make sure blade face is accorded with, in the regulation in repairing, tall eddy lamina changes when coating, undertake to its acerbity scour off divides former surface ooze (besmear) layer, allow exterior remains coating 0.

015mm; Ministry of play a game of chess exceeds the position of rudimental coating standard, allow to use coating of purify of local burnish law, thick to grinding the surface to examine blade wall with ultrasonic method via repairing, allow a wall thick decrease thin do not exceed 0.

1mm. The know exactly about sth in repairing 100 lamina wall is large decrease Bao Chao to set a requirement too. 5 other breakdown are being repaired in, outside removing afore-mentioned trouble, still a few lamina are mauled, engine work overheating causes the trouble such as blade overheat. Breakdown analysis considers to search breakdown account for the analysis, put forward to solve measure, make contented engine repair, of use requirement repair standard and repair method, according to statistical result, work to turbine of the high pressure in overhaul respectively thick primary failure exceeding bid had blade apex crackle, discharge, stretchy quantity and blade wall research of analysis, experiment. Out of tolerance of blade apex crackle works as a result of high-pressured turbine in overhaul of analysis of crackle of 1 lamina apex and bring about blade to discard as useless the issue is more outstanding, this affected engine overhaul plan not only, also add those who added engine to repair charge greatly. Turbine lamina is the part of high temperature roll with important engine, very great centrifugal power, pneumatic force, oscillatory stress and temperature stress action bear in the job, working requirement is most abominable. 1650K is as high as in flame tube outlet temperature (1377 ℃ ) below the circumstance, to improve cooling result, complex heat exchange structure was used on the design, designed a sky technically on engine - empty heat exchanger, air of the contain outside introducing undertakes cooling to 2 air current of cooling lamina, this one unique design makes temperature of 2 air current reduces 125 ～ 210 ℃ , make blade achieves better cooling result; In the meantime, also make the difference in temperature of surface of blade inside and outside is increased, fatigue aggravate is heated up in the job; Apex and photograph of outer shroud of guider of one class turbine grind farther aggravate the generation of crackle and patulous. Look from statistical result, as the addition of working hours, the generation amount of apex crackle and crack length also increase. The blade that produces apex crackle through be opposite undertakes dissection, observation of scanning report lens and metallographic analysis can see: Blade apex crackle belongs to hot fatigue crackle, its are formed with development it is thermal stress and the result that light joint action of compression ring condition. 2 lamina discharge is analysed to search the account of blade discharge out of tolerance, from blade 2 respects had the metabolic case of primitive discharge and discharge of the lamina after be being made via permanent worker the experiment analyses the job. (1) taste blade discharge distributinging circumstance newly. Tasted blade newly to two batches to undertake discharge is measured, the first batch of discharge measure a result to make clear, blade measures median into the Kong Liu side gas for 6.

196L/min, exhaust edge seams discharge median for 10.

015L/min (see a picture 1, 2) , the 2nd batch of lamina measure median into the Kong Liu side gas for 6.

175L/min, blade exhaust edge seams discharge median for 11.

62L/min. Nextpage 　 measures a result to look from discharge of two batches of lamina, taste blade discharge out of tolerance newly to lead for 20.

4% (press original standard) , and the discharge of lamina of major out of tolerance is worth under the standard. (2) long try around lamina discharge to distributing reach metabolic situation. Long try discharge of lamina of turbine of around high pressure to measure a result to see a picture 3, 4. Among them, graph 3 try around lamina exhaust to grow edge aperture discharge distributings, graph the 4 discharge that try around lamina to take gas edge crack to grow distributing. See by the graph, grow Kong Zhong of discharge of the lamina before trying to be worth for 6.

60L/min, long after trying, be 6.

69L/min, aperture discharge grows the median before trying for 11.

49L/min, long after trying, be 11.

58L/min. Long after trying, blade discharge has addition tendency. Result of above experiment, statistic makes clear: The problem of blade discharge out of tolerance that appears in overhaul reason check basically is by be caused by of blade savagery out of tolerance; Through the lamina of long-term job, its discharge has increase a current, but metabolic volume is minor, not be the main factor that brings about blade discharge out of tolerance. Stretchy quantity analysis is 3 lamina search blade the reason of stretchy quantity out of tolerance, the constituent change of the lamina after from blade stretchy quantity measures system and classics permanent worker to make and respect of blade creep analysis undertook statistic, experiment and computation work. (1) blade is stretchy the quantity measures count. Be aimed at high-pressured turbine lamina the problem of stretchy quantity, measuring aspirant travel many statistic, analysis works, buy external above all taste spare parts of tall eddy lamina newly to undertake factory answer measure, cost of as primitive as offerred lamina length undertakes comparative, analyse through normal school statistic (see a picture 5) reach, both sides measures average to differ to blade length 0.

01mm (deviation differs 0.

0001) , the result of blade actual measurement of 54% and primitive length cost differ in 0.

01 ～ 0.

Between 05mm, differ a value to be less than among them of 0 occupy 7% , be more than of 0 occupy 46.

8% . This shows, the measured value of stretchy quantity is more than the of nearly 50% lamina in overhaul reason check actual lamina is stretchy quantity 0.

01mm above. Arrive via consulting knowledge, some repairs a factory to be in check of reason of tall eddy lamina, the phenomenon that appears to discard as useless because of stretchy quantity out of tolerance rarely. Undertake for this stretchy quantity contrast measures blade, discovery measures a result to differ bigger, the data phase that repairs a factory to measure with some is compared, blade is stretchy quantity average slants big 0.

024mm. (2) blade metallographic organizes an analysis. The stretchy quantity that chooses working hours to be controlled for 300h, 600h respectively is eligible, train in excess specified length respectively, shorten lamina of tall eddy of 3 kinds of condition each 3 (in all 6) undertake metallographic analyses his to organize metabolic circumstance dissection, its eventuate: The stretchy quantity of working 300h and 600h is the eligible, train in excess specified length, blade material that shorten to organize (the configuration of carbide, amount, dimension and distributing, the configuration of γ photograph and dimension) without clear distinction, its organization is in initiative creep phase. (3) creep computation is analysed. According to home some engine uses load chart and design load music actually, use three-dimensional and finite yuan nonlinear stress calculation method, undertook to lamina of high-pressured turbine rotor creep is out of shape computation is analysed, creep is out of shape analytic computation sees next tables as a result. Computation makes clear as a result, with the design load chart photograph is compared, home uses lamina of job of turbine of the high pressure below operating mode actually to be out of shape in the creep inside 1500h operating period lesser, high-pressured turbine lamina is during whole job, creep is out of shape is not very apparent, the creep that stretchy quantity measurement point issues in design load chart still is in the 2nd phase, because this is OK affirmatory, odd from creep stretchy quantity is assessed, the life of the 1500h below real load operating mode period inside, stretchy quantity won't exceed blade creep level of concessional and stretchy volume. Analysis of above of Nextpage 　 classics can reach, engine repairs lamina of job of turbine of the high pressure in reason check because measure,what stretchy quantity exceeds mark to discard as useless basically is system and foreign measure a system to exist bigger difference causes. Thick analysis of 4 lamina wall is aimed at wall of the lamina in repairing thick reduce problem of small out of tolerance from repair craft and measured 2 respects to undertake an analysis. (1) repair profound to blade wall influence. Because need to change to lamina of high-pressured turbine job,repairing coating, undertake to its acerbity scour off divides former surface ooze above all (besmear) layer (the experience value of pickling purify ply is 0.

04mm) , ministry of play a game of chess exceeds the place of rudimental coating standard to use coating of purify of local burnish law, pickling and burnish will make blade wall large decrease thin. (2) blade wall is large measure an analysis. Analysis of statistic of thick to partial lamina wall measured value concludes: Blade wall is large the repeatability that measures an outcome is poor, to same measurement point, the measurement of 60% is put in deviation as a result; Before blade pickling, hind, the wall measuring a place of nearly 70% is large invariant, the 9% walls that measure a place are large add thick, before blade burnish, hind, the wall measuring a place of nearly 60% is large invariant, 4.

The 5% walls that measure a place are large add thick, this specification measures a system to be not stabilized. Data of blade wall large demand arrives accurately decimally hind 2, like 1.

17mm, 0.

79mm, and measure data to all be pressed 0.

05mm carry, this shows, this precision cannot satisfy a requirement. Analyse by above knowable, the main reason that causes blade wall thick out of tolerance is to measure the system is not stabilized and precision is low; The pickling that uses in repair and burnish technique make blade wall large decrease thin, also cause partial lamina to be used up normally discard as useless. Count of case of the breakdown in the experiment of thick breakdown exceeding bid, statistic analyses wall of stretchy to blade apex crackle, discharge, lamina quantity, lamina and repairing technical requirement and repair method course can know, affecting engine work dependability and the primary failure that repair cost is high-pressured turbine working lamina apex cracks a problem, the research that had the repair technology that gives priority to with crackle of repair lamina apex for this. The method that the lamina of high-pressured turbine job of breakdown of pointed to producing a page crackle has laser fusion welding undertakes repair research and thermal shock experiment and long-term test-drive are assessed, in order to make plan of rehabilitate of crackle of apex of lamina of high-pressured turbine job. The main and chemical class status that material of 1 filling solder chooses to expect according to blade material reachs function, mature in the select material of filling solder material filling solder material and base material should have close of good consistence, hot coefficient of expansion and good high temperature the element such as mechanical function, hot fatigue property, choose filling to be alloy of nickel radical high temperature (IMR-03) . The lamina of high-pressured turbine job that because apex crackle discards as useless,rehabilitate of filling solder of crackle of 2 lamina apex singles out (this lamina already working hours 500 ～ 600h) , by high-pressured turbine the overhaul of working lamina asked to have purify coat to its clean, after the job such as reason check, fluorescent examination, be based on craft of contented laser beam welding and make base material injures the principle of thoroughly the smallest, cleared crackle, according to crackle it is only straight flaw, concentrated the particular case such as degree of crackle, with machinery burnish and chromatic dog the law is cleared crackle. Have crackle repair with law of laser fusion welding, after repairing, with ultrasonic processing eliminates its welding stress, combinative overhaul craft had visual examination, fluorescent examination to blade, restore function heat treatment and answer besmear coating to wait for the job. Metallographic of 3 laser filling solder organizes metallographic to check a result to make clear, filling solder area and base material are united in wedlock for metallurgy, the interface is flawless, flawless, organization of filling solder area is petty afterbirth branch brilliant to organize. Experiment of 4 thermal shock uses blade of crackle of apex of rehabilitate of laser fusion welding for assessment fight ability of cold thermal shock, the lamina after be being repaired to solder undertook 300h (amount to 1000 times cold, hot exhaustion circulates) thermal shock experiments. The basis experiments the result is knowable, tall eddy lamina has appeared below very small loop number initiative crackle, but crackle expands speed is compared relatively slow, arrived 1000 times to circulate, apex crack length did not exceed 1.

8mm, look from crackle form appearance, should attribute hot fatigue flaw. The amount of crackle and length, accord with overhaul technology requirement, blade leaf body appears irregular tiny show belong to chap. After thermal shock experiments, fluorescent examination apex fills solder area did not discover flaw, handle to passing 300h thermal shock advocate blade refers analyse, area of Xie Penbu solder is checked after making metallographic sample, did not discover flaw. Filling solder discovers the laser that carries on the back to the leaf with scanning report lens when divisional analyse, place of two side predestined relationship has filling solder area each long about 0.

The small crackle of 6mm exists, filling solder area is normal heat treatment organization, without chap, filling solder area and matrix interface union are good. 5 factories and apex of long-term test-drive assessment fill after the tall eddy lamina of solder attended the factory test-drive of some engine, single out 2 lamina lacing film to install the long-term test-drive assessment that tried engine to play last a period of time more than hours 300 randomly at growing. Reason check and chromatic examination had to blade after assessment ends, the foliaceous basin of lamina of 2 tall eddy, leaf is carried on the back (area of filling solder of filling solder area and blame) all appeared the crackle of different level, the amount of crackle and length, accord with overhaul technology requirement. Organize metabolic circumstance to interpret data of the lamina after long-term test-drive, the crackle that carries on the back to leaf of a lamina refers near position of filling solder area examination of analyse section metallographic, from metallographic the examination looks as a result, filling solder area has a few the graininess photograph separate out of rich Cr, Mo, W, apparent diffusion layer exists between filling solder area and matrix, this is filling solder material and base material the result that long-term interaction each other diffuses, but the interface still is united in wedlock for firm metallurgy. Conclusion 　 (1) the lamina of high-pressured turbine job to breakdown of crackle of apex of the generation in the job, the Ni with content of tall W, Mo base exceed alloy to serve as filling, use electric spark beforehand buy filling and solid laser pulse optimize method integral solder technique has repair. The ultrasonic of classics of high-pressured turbine lamina after repair fills to laser processing of stress of solder area purify, after resuming the work such as coating of function heat treatment, heavy besmear, passed 300h (amount to 1000 times cold, heat circulates) thermal shock experiment and long-term test-drive assessment, blade laser beam welding repairs place to did not appear the crackle that exceeds requirement of overhaul reason check, accord with the reason check standard that blade repairs, satisfy engine work to ask. This deepness repairs craft to already was brought into repair a technology to ask and throw generation, make the lamina that because apex crackle exceeds bid,discards as useless in great quantities restored to use a function. (2) after blade classics permanent worker is made, air conditioning passageway suffers air current to erode affect and greaten, the trend that makes blade discharge increases somewhat. Discharge of lamina of turbine of the high pressure in overhaul slants little reason is blade savagery out of tolerance, the outcome that new spare parts measures also showed this. The lamina of the discharge out of tolerance that discovers in overhaul is assessed through working life, demonstrative discharge out of tolerance is in contented engine is repaired and the blade inside certain limits can use a requirement. Repair in engine at present in adjust blade discharge to check a level appropriately, make test and verify via be used for a long time and starting mechanic, this method result is favorable. (3) blade is stretchy because measure systematic error be caused by,the quantity basically is, repair in engine at present in used level of stretchy to tall eddy lamina volume to undertake what measure certainly measure error amendatory method, at the same time we from foreign introduced measure, united survey a system, eliminate measure an error, in order to make sure engine repairs a requirement. This measure solved blade effectively stretchy quantity out of tolerance, discard as useless generous problem. (4) because the wall is large,breakdown of thick out of tolerance of wall of the lamina in repairing basically is survey a system low be caused by of not stable, precision, to raise blade wall thick measure accuracy, already began use X light to measure the research work with blade large wall, raise blade to measure systematic stability, eliminate measure an error. Pass breakdown of lamina of job of turbine of the high pressure in be being repaired to some engine and model to repair technical research, the technology that put forward to make contented use demand asks and repair a method, make lamina of high-pressured turbine job discards as useless rate by about 15% of overhaul work early days, fall to 4% current. Make test and verify via manufacturing application and engine outfield permanent worker, its result is favorable, this research reduced engine to repair cost, raised the dependability that blade works. CNC Milling CNC Machining