| 引用本文: | 林永强,姚萍屏,王兴,周海滨,康丽,袁仔豪,邓敏文.电磁轨道发射用电枢表面损伤及其防护研究进展[J].中国表面工程,2024,37(5):19~36 |
| LIN Yongqiang,YAO Pingping,WANG Xing,ZHOU Haibin,KANG Li,YUAN Zaihao,DENG Minwen.Research Progress on the Surface Damage Mechanism and Protection of Armature for Electromagnetic Rail Launch[J].China Surface Engineering,2024,37(5):19~36 |
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| 电磁轨道发射用电枢表面损伤及其防护研究进展 |
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林永强1，姚萍屏1，王兴1，周海滨2，康丽1，袁仔豪1，邓敏文1
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1.中南大学粉末冶金研究院 长沙 410083 ；2.中南林业科技大学材料科学与工程学院 长沙 410004
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| 摘要: |
| 电磁轨道发射装置处于大电流（~MA 级）、强磁场（~T 级）、高热量（~103 K 级）、强作用力（~106 N 级）等极端服役工况，电枢作为将电能转化为动能的关键部件，在服役过程中会不可避免地发生一系列损伤，导致电枢与轨道（枢轨）载流摩擦副间的接触特性发生显著变化，从而显著影响电磁轨道发射系统效率和精度。综述了近年来国内外研究者对电磁轨道发射用电枢表面损伤与防护的相关研究进展，阐述电枢损伤的典型特征，归纳电枢损伤的机制，梳理电枢损伤的防护优化策略，探讨电枢损伤及防护的研究趋势。研究表明：电磁轨道发射用电枢损伤主要有三种形式：载流摩擦磨损、热熔化和转捩烧蚀，其损伤的严重程度与形貌受到服役变量及电枢自身参数的影响；电枢损伤机制的模拟与仿真基于接触应力集中、电流密度集中、热量集中等三方面展开，着力于枢轨载流摩擦副间接触方式和特性；电枢损伤的防护优化主要考虑枢轨载流摩擦副结构设计、材料选择、表面涂层等多种因素的影响。电磁轨道发射电枢表面损伤形成的极端苛刻性和多场耦合特性，导致电枢表面损伤的形貌研究尚未能形成系统性和完整性的时空演变规律。仿真复现手段以及与轨道损伤特征的对应关系等的理论分析和试验探索仍有待进一步深入研究。研究结论对提高电枢效能、电枢表面损伤与防护研究及新型电枢材料开发与结构设计具有指导意义。 |
| 关键词: 电磁轨道发射 电枢 表面损伤 载流摩擦副 防护 |
| DOI：10.11933/j.issn.1007-9289.20231114001 |
| 分类号:TB31；TJ399 |
| 基金项目:国家自然科学基金（92166202）；中南大学粉末冶金国家重点实验室（621022305） |
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| Research Progress on the Surface Damage Mechanism and Protection of Armature for Electromagnetic Rail Launch |
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LIN Yongqiang1，YAO Pingping1，WANG Xing1，ZHOU Haibin2，KANG Li1，YUAN Zaihao1，DENG Minwen1
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1.Powder Metallurgy Research Institute, Central South University, Changsha 410083 , China ；2.College of Materials Science and Engineering, Central South University of Forestry and Technology,Changsha 410004 , China
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| Abstract: |
| Electromagnetic launch technologies can directly convert electromagnetic energy into the instantaneous kinetic energy required for launching a payload within a short period. This technology has the advantages of high speed, high safety performance, and strong controllability, offering broad prospects for applications. Unlike mechanical and chemical energy, electromagnetic rail launch technology harnesses electromagnetic energy, enabling the achievement of ultrahigh launch velocities exceeding 2 km/s. During an electromagnetic launching process, a system is subjected to extreme launching conditions, such as high currents (~MA level), strong magnetic fields (~T level), high heat (~103 K), and strong forces (~106 N). Electrical energy is transformed into kinetic energy through an armature, making it a critical component of the launch system. However, the armature inevitably undergoes a series of damage during its operational lifespan, leading to significant changes in the contact characteristics between the armature and rail current-carrying friction pairs. This significantly affects the efficiency and precision of the electromagnetic rail launch system. This paper summarizes recent research progress on the surface damage mechanism and protection of armatures for electromagnetic rail launches, including typical damage characteristics and their influencing factors, a simulation and trend analysis of typical damage mechanisms, and the optimization of armature damage protection. Three primary forms of armature damage have been identified in various studies: current-carrying friction and wear, thermal melting, and transition erosion. The categories of current-carrying friction and wear encompass mechanical, current, and arc wear, presenting a distinct "three-stage" damage progression, correlating with the changes in current during the launch process. Thermal melting occurs owing to the contact resistance and friction between the armature and rails, which generate Joule and frictional heat, ultimately causing the armature surface to melt. Transition erosion manifests as a change in the contact mode between the armature and rails, leading to phenomena such as contact loss, which exacerbate the erosion on the armature surface and intensify the thermal melting damage. The severity and morphology of armature damage are influenced by service variables, inherent armature parameters, and their interplay. Simulations of armature damage mechanisms, conducted using finite element analysis software such as ANSYS, ABAQUS, and COMSOL, primarily focused on three aspects: the concentration of contact stress, current density, and heat. The optimization of armature damage protection requires considering various factors such as the structural designs of the armature and rail current-carrying friction substructure, material selection, and surface coating. These considerations aim to mitigate or prevent armature damage during launch. Existing studies have highlighted Al-Zn-Mg-Cu alloy as one of the most preferred materials for armatures, particularly when applies as a coating for surface protection. Currently, the preparation process, application conditions, and micro-mechanism of aluminum alloy armature coatings are not mature enough, especially in the extreme service environment of the launch process, which has a variety of coupled fields of physical quantities. Surface coatings with various impact resistances and other physical properties can meet the relevant standards, but systematic guidance is still lacking. Finally, a summary and outlook regarding the armature surface damage and protection are presented. The lack of a systematic and complete spatiotemporal evolution law in the morphological study of armature surface damage is attributed to the extreme harshness and multi-field coupling characteristics of the electromagnetic rail-launching armature surface damage formation. Further research is required for theoretical analysis, experimental validation of simulation reproduction methods, and correlation with rail damage characteristics. Future research should focus on the profound coupling of multiphysical fields, dynamic evolution of contact states between the armature and rail, development of three-dimensional analysis models under harsh operating conditions and material property evolution, and development of novel materials and structures for both the armature and rail. This study aims to enhance armature efficiency by incorporating insights from research on armature surface damage and protection, the development of new armature materials, and structural design improvements. |
| Key words: electromagnetic rail launch armature surface damage current-carrying friction pair protection |
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