| 引用本文: | 裴会平,杨玉磊,姚利盼,程冰雪.航空发动机压气机转静子高速摩擦机制研究进展[J].中国表面工程,2024,37(5):37~56 |
| PEI Huiping,YANG Yulei,YAO Lipan,CHENG Bingxue.Research Progress on High-speed Rub Mechanisms of Aero-engine Compressor Rotor-stator Systems[J].China Surface Engineering,2024,37(5):37~56 |
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| 摘要: |
| 航空发动机压气机转静子高速摩擦问题已有大量研究，但缺乏相关研究进展的系统介绍。从高速摩擦磨损和能量耗散机制出发，综述相关研究成果，对先进航空发动机安全设计具有重要意义。压气机转静子工作间隙小、线速度高、气流压力温度高，转静子径向碰磨不可避免，这种高速摩擦轻则造成涂层、叶片损伤，重则导致航空发动机“钛火”等严重事故。转静子高速摩擦受侵入速率、摩擦速度、摩擦深度等工况条件和叶片厚度、涂层硬度、材料热物性参数等摩擦配副自身特点的综合影响，摩擦磨损机制主要表现为黏着磨损、切削磨损或氧化磨损等，诸多因素中，侵入速率和摩擦速度的影响最为显著。 对于高速摩擦热问题，温升预测是关键，而确定热流分配是难点，在早期基本假说基础上发展的不同热流分配计算方法，能够为摩擦温升预测提供理论依据，结合试验结果修正可提高计算可信度。高速摩擦热的产生会对摩擦磨损行为产生显著影响， 而摩擦条件与摩擦机制的改变也会导致明显的能量耗散差别，进而影响摩擦热的生成和摩擦温升。首次从摩擦磨损与摩擦能量耗散角度进行系统综述，讨论引发“钛火”的摩擦热导致的温升计算方法，并提出采用流-热-固多场耦合方法开展研究的新观点。摩擦热的计算、转静子摩擦磨损机制的全面揭示和新型涂层体系的开发具有指导意义。 |
| 关键词: 航空发动机 压气机 高速摩擦 转静子 涂层 |
| DOI：10.11933/j.issn.1007-9289.20230921001 |
| 分类号:TG156；TB114 |
| 基金项目:清华大学自主科研计划（20224186005） |
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| Research Progress on High-speed Rub Mechanisms of Aero-engine Compressor Rotor-stator Systems |
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PEI Huiping1，2，YANG Yulei3，YAO Lipan2，CHENG Bingxue1
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1.State Key Laboratory of Tribology in Advanced Equipment, Tsinghua University, Beijing 100084 , China ；2.KeyLaboratory of Light-duty Gas-turbine, Institute of Engineering Thermophysics,Chinese Academy of Sciences, Beijing 100190 , China ；3.School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094 , China
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| Abstract: |
| The high-speed rub between the rotating and stationary parts of compressors plays a crucial role in the safe operation of aero engines. Extensive research has been reported on high-speed friction issues concerning compressor rotors and stators. Nevertheless, systematic reviews of relevant research progress have been lacking. This issue must be examined from the perspective of high-speed friction wear and energy-dissipation mechanisms so as to ensure the safe design of advanced aero engines. The operating conditions of the compressor rotor–stator systems are characterized by small radial clearances, high relative tangential velocities, high airflow pressures, and elevated temperatures, which inevitably result in radial rubbing. This high-speed rubbing can damage both the stator coatings and rotor blades, and in extreme cases, lead to serious safety incidents such as "titanium fires " in aero engines. This paper presents a systematic review of research findings pertaining to high-speed friction and wear in rotor–stator interactions, focusing on the mechanisms of friction-induced wear and the associated heat generation. On one hand, the high-speed friction between compressor rotors and stators is influenced by various operational parameters such as intrusion rate, sliding velocity, and contact depth. On the other hand, factors inherent to the rubbing surfaces, such as blade thickness, coating hardness, and material thermophysical properties, also play a crucial role in determining the rubbing behaviors and mechanisms. The predominant wear mechanisms include adhesive wear, abrasive wear, oxidative wear, and several wear maps have been established. Among the operational parameters, intrusion rate and rubbing velocity have the greatest influence. In addition to the typical stator coatings, several new coatings for both the rotor and the stator have been proposed, and corresponding friction and wear mechanisms have been investigated under laboratory conditions. Accurate prediction of the increase in temperature is critical for addressing the heat generation during high-speed friction. A major challenge lies in determining the heat flow distribution; in this regard, various calculation methods have been developed based on fundamental assumptions. These methods provide a theoretical basis for estimating the increase in temperature. After determining the heat flow distribution, a thermal–structural coupled model can be established using finite element analysis to calculate the temperature increase. Experimental results can be used to refine the model and improve the calculation reliability. Moreover, molecular dynamic simulation provides a novel approach to calculate friction heat distribution and flash temperature, without requiring the use of the currently used heat partition coefficients. The heat generated during high-speed friction significantly affects the wear behaviors and mechanism, which is the focus of current studies. However, variations in wear mechanisms may also influence the friction heat generation and partition, especially when tribo-films or tribo-layers with distinct thermal properties from those of the original materials are formed on the surface. By controlling the operational conditions and designing friction interfaces, the generation, distribution, and dissipation of frictional heat can be altered and controlled, thereby reducing the friction and wear produced and, most importantly, the probability of titanium fires. Previous research has revealed friction wear mechanisms and the influence of friction heat under the action of multiple factors, providing theoretical guidance and a basis for engine structural design and coating development. Further studies should focus on novel coating–metal material combinations and explore the effects of additional operational conditions, as well as the influence of complex high-temperature, high-pressure, and high-velocity flows. Moreover, the effects of heat–solid–flow coupling and flash temperature on the friction, wear mechanism, and energy dissipation mechanism should also be considered to effectively address complex problems such as titanium fires. This review provides meaningful guidance for frictional heat calculation, comprehensive analysis of the friction and wear mechanisms of the rotor–stator systems, and development of novel coatings. |
| Key words: aero-engine compressor high-speed rub rotor-stator coating |
