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随着航空发动机涡轮前温度的提高，涡轮叶片逐步采用DD9合金等能承受更高温度的第三代单晶高温合金铸造而成，同时在铸造成形后的叶片表面加工出气膜孔进行气膜冷却来降低其表面温度，气膜孔的加工质量对叶片的冷却效果和疲劳寿命具有重要影响。为探索针对DD9合金涡轮叶片的低重铸层电火花制孔工艺，分别基于晶体管脉冲电源和Tr-RC电源进行了工艺实验和检测分析。结果表明，基于晶体管脉冲电源加工DD9合金的最大重铸层厚度可优化至18μm，基于Tr-RC电源加工DD9合金的最大重铸层厚度可降低至7μm，同时加工效率明显提高，单孔加工时间从26 s缩短至15 s。此外，若一定程度牺牲加工效率指标，基于Tr-RC电源加工DD9合金的最大重铸层厚度可降低至5μm，此时单孔加工时间增大至90 s。
Abstract：With the increase of aero-engine turbine working temperature,turbine blades are gradually cast using third-generation single-crystal superalloys such as DD9 that could withstand higher temperature. After the blades are cast,film cooling holes are machined on the surface to achieve film cooling and reduce blade surface temperature. The machining quality of film cooling holes has a significant impact on the cooling effect and fatigue life of the blades. To explore a low-recast-layer EDM process for DD9 alloy turbine blades,experiments and analyses were conducted based on transistor pulse power supply and Tr-RC power supply respectively. The results show that with transistor pulse power supply,the maximum recast layer thickness of DD9 alloy is optimized to 18 μm.While with Tr-RC power supply,the maximum recast layer thickness of DD9 alloy is reduced to 7 μm,and machining efficiency is significantly improved that single hole machining time decreases from 26 s to 15 s. Furthermore,if machining efficiency is sacrificed to some extent,the maximum recast layer thickness of DD9 alloy machined by Tr-RC power supply could be reduced to 5 μm,while the single hole machining time increases to 90 s.
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基本信息:
DOI：
中图分类号:V263;TG661
引用信息:
[1]梁威,祝玉兰,佟浩,等.DD9合金涡轮叶片电火花制孔工艺研究[J].电加工与模具,2025,No.390(04):13-16+21.
基金信息:
清华大学自主科研计划项目(20244186005)