镍基单晶涡轮叶片上通常布置数百个、直径在0.2-0.8mm之间的气膜孔，气膜孔的存在破坏了涡轮叶片结构完整性，在高温疲劳载荷下成为叶片失效断裂的多发部位。为此，针对气膜孔制造初始损伤与疲劳断裂行为强相关的问题，以镍基单晶合金飞秒激光制造气膜孔试样开展疲劳断裂研究。首先，采用流体动力学方法建立了三维螺旋制孔仿真模型，获取制孔过程孔型演化规律；随后从几何、微观结构和力学性能三方面对气膜孔表面完整性进行分析，气膜孔锥度为0.19°，孔边热损伤区的深度约为18μm且发生严重氧化，孔边残余应力最大值为463MPa；紧接着，对980℃疲劳裂纹扩展试验的断口发现，裂纹起源于孔壁热影响区，以近似椭圆形状轮廓逆时针旋转约6°平面沿着垂直于载荷的方向传播。最后，提出了基于增量塑性和构形力理论的M积分裂纹扩展驱动力模型，并在此基础上构建了气膜孔疲劳裂纹扩展率与有效裂纹扩展驱动力之间关系的有效函数描述模型。

Nickel-based single crystal turbine blades are usually arranged with hundreds of film-cooling holes with a diameter of 0.2-0.8mm. The existence of film-cooling holes destroys the structural integrity of turbine blades, and becomes a fre-quent part of blade failure and fracture under high temperature fatigue load. Therefore, the fatigue fracture study of the nickel-based single crystal film-cooling hole specimen fabricated by femtosecond laser was carried out to solve the strong relation between the initial manufacturing damage of film-cooling holes and the fatigue fracture behavior. Firstly, a three-dimensional spiral hole-making simulation model was established by hydrodynamic method to obtain the hole shape evolution law in the hole-making process; Subsequently, the surface integrity of the filming-cooling hole was analyzed from three aspects: geometry, microstructure and mechanical properties, the taper of the air film pore was 0.19°, the depth of the thermal damage zone at the pore edge was about 18 μm and severe oxidation, and the maxi-mum residual stress at the pore edge was 463MPa; Afterwards, the fracture of the 980°C fatigue crack propagation test found that the crack originated in the heat-affected zone of the hole wall and propagated in a direction perpen-dicular to the load in a counterclockwise rotation of about 6° in an approximately elliptical profile. Finally, an M-integral crack propagation driving force model based on the theory of incremental plasticity and conformational force is pro-posed, and an effective function description model of the relationship between the fatigue crack propagation rate and the effective crack propagation driving force of air film pore is constructed on this basis.