Calibrated the direct current potential drop method for fatigue crack propagation testing of nickel-based superalloy with film cooling hole

IF 5 2区工程技术 Q1 ENGINEERING, MECHANICAL

Theoretical and Applied Fracture Mechanics Pub Date : 2024-10-02 DOI:10.1016/j.tafmec.2024.104706

Xi Ren , Fei Li , Zhixun Wen , Hao Cheng , Zhufeng Yue

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Abstract

Turbine blades in aviation engines commonly feature a nickel-based superalloy structure integrated with film cooling holes to enhance inlet gas temperature. However, the presence of these film cooling holes often results in frequent occurrences of fracture failures nearby. The direct current potential drop (DCPD) method, renowned for its exceptional crack sensitivity, is frequently utilized for crack length monitoring. This study establishes a FEM model of the film cooling hole plate specimen to determine the optimal probe point location. Subsequently, a mapping relationship is derived to calibrate Johnson’s formula, accounting for the unequal crack lengths at the edges of film cooling holes. It is confirmed that the crack length measured by the DCPD method represents the cumulative crack lengths on both sides of the hole. Fatigue crack propagation experiments are then conducted, with crack length monitored using a microscope. The results affirm the successful application of the calibrated formula to the film cooling hole plate specimen, exhibiting an average error within 0.1 mm.

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校准带薄膜冷却孔的镍基超合金疲劳裂纹扩展测试中的直流电位下降法

航空发动机涡轮叶片通常采用镍基超合金结构，并集成有薄膜冷却孔，以提高进气温度。然而，这些薄膜冷却孔的存在往往导致附近经常出现断裂故障。直流电位滴 (DCPD) 方法因其卓越的裂纹灵敏度而闻名，常用于裂纹长度监测。本研究建立了薄膜冷却孔板试样的有限元模型，以确定最佳探测点位置。随后，考虑到薄膜冷却孔边缘裂纹长度不等的情况，得出了一种映射关系来校准 Johnson 公式。经证实，DCPD 方法测得的裂纹长度代表了孔两侧的累积裂纹长度。然后进行了疲劳裂纹扩展实验，使用显微镜监测裂纹长度。结果表明，在薄膜冷却孔板试样上成功应用了校准公式，平均误差在 0.1 毫米以内。

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来源期刊

Theoretical and Applied Fracture Mechanics 工程技术-工程：机械

CiteScore

8.40

自引率

18.90%

发文量

435

审稿时长

37 days

期刊介绍： Theoretical and Applied Fracture Mechanics'' aims & scopes have been re-designed to cover both the theoretical, applied, and numerical aspects associated with those cracking related phenomena taking place, at a micro-, meso-, and macroscopic level, in materials/components/structures of any kind. The journal aims to cover the cracking/mechanical behaviour of materials/components/structures in those situations involving both time-independent and time-dependent system of external forces/moments (such as, for instance, quasi-static, impulsive, impact, blasting, creep, contact, and fatigue loading). Since, under the above circumstances, the mechanical behaviour of cracked materials/components/structures is also affected by the environmental conditions, the journal would consider also those theoretical/experimental research works investigating the effect of external variables such as, for instance, the effect of corrosive environments as well as of high/low-temperature.