Effect of Foreign Object Damage on Vibration Fatigue Crack Propagation of Blades

doi:10.12382/bgxb.2022.0109

Abstract

Abstract:

In order to study the effect of foreign object damage (FOD) on the fatigue crack propagation of aero-engine blades, using the drop weight impact testing equipment, the FOD simulation test and vibration fatigue test of TC4 titanium alloy specimens were carried out under different impact energies. The relationship between the crack length and fatigue life of the damaged specimens was obtained, and the parameters of fatigue fracture crack morphology were fitted to establish a fatigue crack growth prediction and calculation model. The results showed that: The depth and width of the notch decreased nonlinearly with the decrease of impact energy; when the impact energy is large, the fatigue crack propagates first along the bending microcrack and then along the straight line; when the impact energy is small, the fatigue crack of the specimen keeps linear propagation; the crack initiation life is related to both impact energy and stress level.

Key words: foreign object damage, blade, drop impact, TC4 titanium alloy, vibration fatigue, crack propagation

YANG Shuo, DU Tianwei, ZHANG Xiaopeng, MA Liang, ZHANG Guichang. Effect of Foreign Object Damage on Vibration Fatigue Crack Propagation of Blades[J]. Acta Armamentarii, 2023, 44(6): 1713-1721.

Figures/Tables 17

Table 1 Chemical composition of TC4 titanium alloy

Table 2 Mechanical properties of TC4 titanium alloy

屈服应力/ MPa	极限应力/ MPa	弹性模量/ GPa	密度/ (kg·m^-3)	泊松比
881	1025	112	4420	0.34

Fig.1 Geometry and dimensions of specimen (unit: mm)

Fig.2 Geometry and dimensions of drop hammer

Fig.3 Impact testing equipment

Table 3 Impact test scheme

试件编号	E/J	h/m
H45-1	4.52	0.45
H45-2
H35-3	3.52	0.35
H35-4
H25-5	2.51	0.25
H25-6

Table 4 Morphologies of notch-type damage under different impact energies

Table 5 Notch depths x and widths y for different energies

试件编号	h/m	E/J	x/mm	y/mm
H45-1	0.45	4.52	1.56	0.77
H45-2	0.45	4.52	1.58	0.74
H35-3	0.35	3.52	1.44	0.63
H35-4	0.35	3.52	1.39	0.62
H25-5	0.25	2.51	1.08	0.31
H25-6	0.25	2.51	1.15	0.35

Fig.4 Equipment andspecimen

Fig.5 Amplitude vs stress curves

Fig.6 Crack propagation of notched specimen

Table 6 Test results of crack growth life

试件编号	2A/mm	表面应力/MPa	f_i/Hz	f_f/Hz	N_i/次	N_f/次	N_p/次	c_i/mm	c_f/mm
H45-1	12	208	92.1	87.4	42057	124057	82000	0.4	8.1
H45-2	11	191	98.9	90.9	54054	144063	90009	0.4	5.9
H35-3	11	191	92.9	86.6	145047	236047	91000	0.5	8.0
H35-4	12	208	97.8	91.4	170045	226059	56014	0.4	7.6
H25-5	18	309	96.7	92.7	20066	48053	27987	1.0	7.5
H25-6	15	258	95.8	91.8	25488	70066	44578	1.0	7.3

Fig.7 Crack length vs cycles curves

Fig.8 Crack shape of specimen at fracture surface

Fig.9 Fitted curves of fracture shape and surface crack length

Fig.10 Results of crack growth rate

Fig.11 Comparison of test results and prediction results of crack growth life

References 29

[1]	FARAHANI H K, KETABCHI M, ZANGENEH S, et al. Characterization of damage induced by impacting objects in Udimet-500 alloy[J]. Journal of Failure Analysis and Prevention, 2016, 16(4): 629-634. doi: 10.1007/s11668-016-0129-7 URL
[2]	关玉璞, 陈伟, 高德平. 航空发动机叶片外物损伤研究现状[J]. 航空学报, 2007, 28(4): 851-857.
	GUAN Y P, CHEN W, GAO D P. Present status of investigation of foreign object to blade in aero-engine[J]. Acta Aeronautica et Astronautica Sinica, 2007, 28(4): 851-857. (in Chinese)
[3]	马超, 王玉娜, 武耀罡, 等. 航空发动机风扇叶片硬物冲击损伤特征[J]. 航空动力学报, 2017, 32(5): 1105-1111.
	MA C, WANG Y N, WU Y G, et al. Hard object impact damage characteristic of aero-engine fan blade[J]. Journal of Aerospace Power, 2017, 32(5): 1105-1111. (in Chinese)
[4]	舒畅, 程铭, 许煜, 等. 航空发动机压气机叶片外物损伤规律研究[J]. 机械工程学报, 2019, 55(13): 87-94. doi: 10.3901/JME.2019.13.087
	SHU C, CHENG M, XU Y, et al. Study on foreign object damage regular pattern of aero engine compressor blades[J]. Journal of Mechanical Engineering, 2019, 55(13): 87-94. (in Chinese) doi: 10.3901/JME.2019.13.087
[5]	胡绪腾, 宋迎东. 外物损伤对风扇/压气机叶片高循环疲劳性能影响的研究[J]. 航空发动机, 2017, 38(3): 18-23.
	HU X T, SONG Y D. Research on effect of foreign object damage on high cycle fatigue performance for fan/compressor blades[J]. Aeroengine, 2017, 38(3): 18-23. (in Chinese)
[6]	BHAUMIK S K, SUJATA M, VENKATASWAMY M A, et al. Failure of a low pressure turbine rotor blade of an aeroengine[J]. Engineering Failure Analysis, 2006, 13(8): 1202-1219. doi: 10.1016/j.engfailanal.2005.12.002 URL
[7]	李静, 孙强, 李春旺, 等. 某型航空发动机压气机叶片振动疲劳寿命研究[J]. 应用力学学报, 2011, 28(2): 189-193.
	LI J, SUN Q, LI C W, et al. Study on the vibration fatigue life for aero-engine compressor blade[J]. Chinese Journal of Applied Mechanics, 2011, 28(2): 189-193. (in Chinese)
[8]	MAJILA A N, RAMACHANDRA A S, MANNAN S L, et al. Influence of foreign object damage on high cycle fatigue of Ti-6Al-4V[J]. Transactions of The Indian Institute of Metals, 2015, 68(8): 1-7.
[9]	于霞, 张卫民, 邱忠超, 等. 航空发动机涡轮叶片裂纹检测信号特征提取[J]. 兵工学报, 2014, 35(8): 1267-1274. doi: 10.3969/j.issn.1000-1093.2014.08.020
	YU X, ZHANG W M, QIU Z C, et al. Signal feature extraction of aero-engine turbine blade crack detection[J]. Acta Armamentarii, 2014, 35(8): 1267-1274. (in Chinese) doi: 10.3969/j.issn.1000-1093.2014.08.020
[10]	马楠楠, 陶春虎, 何玉怀, 等. 航空发动机叶片多轴疲劳试验研究进展[J]. 航空材料学报, 2012, 32(6): 44-49.
	MA N N, TAO C H, HE Y H, et al. Research progress of multiaxial fatigue test methods on blades of aviation engine[J]. Journal of Aeronautical Materials, 2012, 32(6): 44-49. (in Chinese)
[11]	PETERS J O, RITCHIE R O. Foreign-object damage and high-cycle fatigue of Ti-6Al-4V[J]. Materials Science & Engineering A, 2013, 319(1): 597-601.
[12]	WITEK L. Crack propagation analysis of mechanically damaged compressor blades subjected to high cycle fatigue[J]. Engineering Failure Analysis, 2011, 18(4): 1223-1232. doi: 10.1016/j.engfailanal.2011.03.003 URL
[13]	LUO S, NIE X F, ZHOU L C, et al. High cycle fatigue performance in laser shock peened TC4 titanium alloys subjected to foreign object damage[J]. Journal of Materials Engineering & Performance, 2018, 27(3): 1-9.
[14]	舒畅, 程铭, 许煜, 等. 不同金属硬物冲击航空发动机叶片损伤研究[J]. 航空动力学报, 2020, 35(1): 18-29.
	SHU C, CHENG M, XU Y, et al. Study on damage of aero-engine blades caused by different metal hard materials[J]. Journal of Aerospace Power, 2020, 35(1): 18-29. (in Chinese)
[15]	胡绪腾, 贾旭, 朱自佳, 等. 凹坑型硬物损伤对TC4材料疲劳强度的影响[J]. 航空动力学报, 2018, 33(4): 969-979.
	HU X T, JIA X, ZHU Z J, et al. Effect of dent-type foreign object damage on fatigue strength of TC4 material[J]. Journal of Aerospace Power, 2018, 33(4): 969-979. (in Chinese)
[16]	贾旭, 胡绪腾, 朱自佳, 等. FOD缺口型损伤对TC4疲劳极限强度的影响[J]. 航空动力学报, 2018, 33(7): 1584-1594.
	JIA X, HU X T, ZHU Z J, et al. Effect of FOD notch-type damage on fatigue limit strength of TC4[J]. Journal of Aerospace Power, 2018, 33(7): 1584-1594. (in Chinese)
[17]	杨百愚, 柴桥, 李春旺, 等. 外物撞击航空发动机转子叶片速度估算[J]. 航空动力学报, 2017, 32(12): 2843-2846.
	YANG B Y, CHAI Q, LI C W, et al. Estimation of velocity for foreign object that impacting rotor blade of aero-engine[J]. Journal of Aerospace Power, 2017, 32(12): 2843-2846. (in Chinese)
[18]	PERNAS-SANCHEZ J, ARTERO-GUERRERO J A, VARAS D, et al. Analysis of ice impact process at high velocity[J]. Experimental Mechanics, 2015, 55(9): 1669-1679. doi: 10.1007/s11340-015-0067-4 URL
[19]	尹冬梅, 钱林方. 叶片受软体和硬体外物撞击的损伤分析[J]. 振动与冲击, 2009, 28(3): 6-9.
	YIN D M, QIAN L F. Impact damage analysis of blades due to impacts from soft body and hard one[J]. Journal of Vibration and Shock, 2009, 28(3): 6-9. (in Chinese)
[20]	包珍强, 胡绪腾, 宋迎东. 不同冲击角度外物损伤对TC4钛合金高循环疲劳强度的影响[J]. 航空动力学报, 2015, 30(9): 2226-2233.
	BAO Z Q, HU X T, SONG Y D. Effect of foreign object damage at different impact angles on high cycle fatigue strength of TC4 titanium alloys[J]. Journal of Aerospace Power, 2015, 30(9): 2226-2233. (in Chinese)
[21]	SPANRAD S, TONG J. Characterization of foreign object damage (FOD) and early fatigue crack growth in laser shock peened Ti-6AL-4V aerofoil specimens[J]. Materials Science and Engineering A, 2011, 528(4): 2128-2136. doi: 10.1016/j.msea.2010.11.045 URL
[22]	柴桥, 李均盛, 杨百愚, 等. 外物形状对航空发动机压气机转子叶片撞击损伤的影响[J]. 应用力学学报, 2014, 31(6):825-829.
	CHAI Q, LI J S, YANG B Y, et al. Effects of foreign object shape on the aero-engine compressor blade impacted damage[J]. Chinese Journal of Applied Mechanics, 2014, 31(6): 825-829. (in Chinese)
[23]	尹冬梅, 钱林方, 栗保明, 等. 外物形状对发动机叶片中残余应力场的影响分析[J]. 机械强度, 2012, 34(3): 355-360.
	YIN D M, QIAN L F, LI B M, et al. Analysis for effects of foreign object shape on the residual stress field of engine blade[J]. Journal of Mechanical Strength, 2012, 34(3): 355-360. (in Chinese)
[24]	ZABEEN S, PREUSS M, WITHERS P J. Residual stresses caused by head-on and 45° foreign object damage for a laser shock peened Ti-6Al-4V alloy aerofoil[J]. Materials Science and Engineering A, 2013, 560: 518-527. doi: 10.1016/j.msea.2012.09.097 URL
[25]	潘辉, 赵振华, 陈伟. 航空发动机叶片外物损伤试验模拟方法[J]. 航空发动机, 2012, 38(1): 51-54.
	PAN H, ZHAO Z H, CHEN W, et al. Aeroengine blade foreign object damage test simulation method[J]. Aeroengine, 2012, 38(1): 51-54. (in Chinese)
[26]	发动机叶片及材料振动疲劳试验方法: HB 5277—1984[S]. 北京: 航空工业部, 1984.
	Aero-engine blade and material vibrated fatigue test method: HB 5277—1984[S]. Beijing: Ministry of Aeronautics Industry, 1984. (in Chinese)
[27]	NEWMAN J J, RAJU I S. Stress intensity factor equations for cracks in three-dimensional finite bodies subjected to tension and bending loads[R]. VA, US: U.S. National Aeronautics and Space Administration, 1984.
[28]	傅祥炯. 结构疲劳与断裂[M]. 西安: 西北工业大学出版社, 1995: 138.
	FU X J. Structural fatigue and fracture[M]. Xi’an: Northwestern Polytechnic University Press, 1995: 138. (in Chinese)
[29]	PARIS P C, GOMEZ M P, ANDERSON W E. A rational analytic theory of fatigue[J]. The Trend in Engineering, 1961, 13(1): 9-14.