单晶涡轮叶片高能束修复研究进展

doi:10.7527/S1000-6893.2021.25610

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单晶涡轮叶片高能束修复研究进展

张佩宇, 周鑫, 李应红

空军工程大学航空工程学院航空等离子体动力学国家重点实验室, 西安 710038

收稿日期:2021-03-30 修回日期:2021-04-28 发布日期:2021-06-29
通讯作者: 周鑫 E-mail:dr_zhouxin@126.com
基金资助:
国家自然科学基金（91860136，51801231）；陕西省重大专项（2018zdzx01-04-01）

Progress on high energy beam repair of single crystal turbine blades

ZHANG Peiyu, ZHOU Xin, LI Yinghong

Science and Technology on Plasma Dynamics Laboratory, College of Aeronautical Engineering, Air Force Engineering University, Xi'an 710038, China

Received:2021-03-30 Revised:2021-04-28 Published:2021-06-29
Supported by:
National Natural Science Foundation of China (91860136, 51801231); Key Science and Technology Project of Shaanxi Province (2018zdzx01-04-01)

摘要/Abstract

摘要： 单晶涡轮叶片高能束增材再制造是修复磨损、烧蚀和裂纹等损伤缺陷的主要方式，是航空发动机热端部件特种加工领域最具挑战性的工作之一，其中蕴含的外延生长组织接续与调控机制、内部冶金缺陷控制等科学问题和关键工艺尚未完全突破。梳理了熔焊熔池内凝固组织定向生长的理论发展，基于已有的枝晶异质形核和异向生长理论，构建了单晶高能束修复的基础原理框架；详细分析了"修复工艺-熔池特性-凝固组织"之间的内在关联，提出了保持单晶连续稳定生长的工艺调控准则和熔池监控方法；总结了修复区γ'相等微观组织以及热裂纹、气孔等冶金缺陷的演化规律和调控手段，凝练了单晶修复面临的主要挑战。此外，介绍了航空发动机热端部件再制造领域相关的国外重大研究计划，并对今后研究方向和发展趋势进行总结和展望。

关键词: 单晶涡轮叶片, 高能束修复, 增材制造, 凝固组织, 冶金缺陷, 工艺调控, 熔池监控

Abstract: As one of the most challenging tasks in the field of special processing for hot-section aero-engines parts, high-energy beam additive remanufacturing is the main way to repair damages such as wear, ablation and cracks of single crystal turbine blades. However, several scientific issues and key processes including epitaxial growth, defect formation mechanism, and their control methods, have not yet been completely broken through. In this paper, we sort out the development history of the rapid solidification theories. Based on the principles of columnar-to-equiaxed transition and oriented to misoriented transition, we establish a fundamental framework for high-energy beam repair of single crystal. After analyzing the intrinsic relationship among repair processes, melt pool characteristics and solidification structures in detail, we propose the process control criteria and monitoring method to maintain the continuous and stable growth of single crystal and summarize the of microstructure (e.g., γ'-phases) and defects (e.g., hot cracks and pores) development in the repaired zone, and the main challenges in single crystal repair. In addition, several major foreign research plans related to remanufacturing of aero-engines components are introduced, and future development trends are prospected.

Key words: single-crystal turbine blade, high-energy beam repair, additive manufacturing, solidification structures, metallurgical defects, process control, melt-pool monitoring

中图分类号:

V261

张佩宇, 周鑫, 李应红. 单晶涡轮叶片高能束修复研究进展[J]. 航空学报, 2022, 43(4): 525610-525610.

ZHANG Peiyu, ZHOU Xin, LI Yinghong. Progress on high energy beam repair of single crystal turbine blades[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2022, 43(4): 525610-525610.

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主管单位：中国科学技术协会主办单位：中国航空学会北京航空航天大学

单晶涡轮叶片高能束修复研究进展

Progress on high energy beam repair of single crystal turbine blades

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