CN111855467B - Abradable coating performance test system and method for precisely calibrating rub-impact zero point - Google Patents
Abradable coating performance test system and method for precisely calibrating rub-impact zero point Download PDFInfo
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- CN111855467B CN111855467B CN202010758605.2A CN202010758605A CN111855467B CN 111855467 B CN111855467 B CN 111855467B CN 202010758605 A CN202010758605 A CN 202010758605A CN 111855467 B CN111855467 B CN 111855467B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N3/00—Investigating strength properties of solid materials by application of mechanical stress
- G01N3/56—Investigating resistance to wear or abrasion
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/14—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object using acoustic emission techniques
Abstract
The application relates to a system and a method for testing the performance of an abradable coating, wherein the testing method comprises the following steps: rotating the test blade under the test working condition; calibrating a rub-impact zero point, wherein the operation comprises the steps of controlling an intrusion platform provided with an abradable coating to intrude into the test blade from an initial position at a preset speed, monitoring the abradable coating by utilizing an acoustic emission sensor and an acceleration sensor simultaneously in the intrusion process, respectively monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds, and judging that the rub-impact zero point is reached when the signal output by any one of the sensors is monitored to exceed the preset thresholds; controlling an intrusion platform with an abradable coating mounted thereon to perform an intrusion motion relative to the test blade based on the determined rub-impact zero; and acquiring rub-impact experimental data of the abradable coating and the test blade, and recording.
Description
Technical Field
The application belongs to the field of aerospace material detection, and particularly relates to a system and a method for testing the performance of an abradable coating, which can accurately calibrate a rub-impact zero point.
Background
The abradable coating is widely applied to aeroengines and gas turbines, is coated on stator components which are in contact with and abrade with a rotor, and realizes minimum gap control of the rotor/stator by active sacrificial abrasion of the coating, thereby effectively improving the engine efficiency and reducing the oil consumption. The ability of an abradable coating to rub against a rotor blade at high temperatures and high speeds, the characteristic of the coating to actively abrade without abrading or sticking to the rotor blade, is known as abradability, and accurate assessment of abradability of the abradable coating is an important problem to be solved in the art.
The high-temperature high-speed rub test for the abradable coating is that a test blade is clamped at the outer edge of a wheel disc capable of rotating at a high speed, a coating sample is clamped on an intrusion platform capable of moving forwards and backwards relative to the wheel disc, the coating and the blade can be heated, and the platform drives the coating sample to move towards the wheel disc at a certain speed under the condition that the wheel disc rotates at a certain speed, so that the high-temperature high-speed rub of the blade and the coating is realized.
In the impact grinding test, accurate judgment of the impact grinding zero point (the zero point of the impact grinding position and/or the zero point of the impact grinding time) is one of the keys for obtaining accurate test results. However, due to the abrasion difference of the coating, vibration of equipment, heating of the blade, and elongation of centrifugal force in the high-temperature high-speed test, great technical difficulty exists in accurately judging the starting point of the collision and abrasion of the blade and the coating. Inaccurate control of the bump grinding zero point can cause insufficient control precision of the intrusion depth, the actual intrusion depth and the set intrusion depth are generally deviated by more than 30%, and the repeatability of test results is poor.
Some related technologies adopt a static zero calibration method to calibrate the collision and grinding zero point. That is, before the test begins, the blade is rotated to a position opposite to the coating, and the intrusion platform is manually controlled to push the coating into the blade. And (3) setting the position where the coating is just contacted with the blade as a zero point of a collision and grinding position, and then manually controlling the platform to retreat a certain distance. After the start of the test, when the intrusion distance of the intrusion platform is equal to the distance from the rub-off zero point before the test, it is determined whether the rub-off zero point is reached.
Some related technologies adopt a grating ruler calibration method to calibrate the collision and grinding zero point. Before the test starts, calibrating the position of the coating intrusion platform when the blade is contacted with the coating sample and recording the position as a zero position, judging whether the intrusion platform reaches a collision and grinding zero point or not through the intrusion platform displacement given by the grating ruler during the test, and when the method is mainly characterized in that the equipment vibrates at a high rotating speed, the zero position is shifted; in addition, the test blade stretches under the influence of centrifugal force, thermal expansion and other factors, and the test blade can rub against the coating earlier than a zero point, so that the actual invasion depth is seriously deviated from a set value.
Some related technologies use a method of collision and grinding force monitoring to calibrate a collision and grinding zero point. In the intrusion process of the intrusion platform, detecting whether the impact abrasion force between the coating sample and the test blade is suddenly changed or not, and taking the sudden change of the impact abrasion force as a standard whether the impact abrasion zero point is reached or not. The method for monitoring the rub-impact force is to install a three-way force sensor between the coating sample and the intrusion platform and monitor the abrupt change of the friction force, the positive pressure and the axial force of the coating. However, the inventors found that the above method for monitoring the rubbing force cannot always obtain a test result with good repeatability in an actual test process, and particularly for an abradable coating with excellent abradability or for a blade with a cutting function, the rubbing force between the test blade and the coating is very weak, the force value is substantially at the same level as the bottom noise force signal of the force sensor, and the mutation of the rubbing force cannot be effectively monitored by the method for monitoring the rubbing force.
Disclosure of Invention
In the bump grinding test, the invasion depth is generally controlled by controlling the invasion rate and the invasion duration, the invasion rate is generally controlled by adopting a stepping motor, and the precision of the invasion rate meets the test requirement; and the intrusion time length is required to be accurately controlled by accurately obtaining the collision and grinding zero point.
In order to find a method capable of accurately calibrating the collision and grinding zero point, the inventor conducts a great deal of theoretical research and experimental tests, and finally discovers a sensitive and reliable method for calibrating the collision and grinding zero point. The method can accurately judge the collision and grinding zero point, further can control the deviation between the invasion depth and the actual invasion depth to be within 10%, and compared with the deviation of 30% of the prior related technology, the method disclosed by the application improves the test precision by more than 200% times, and the effect is obvious to an unexpected degree.
Based on the above findings, the present disclosure provides an abradable coating performance test method based on a rub-impact test, comprising:
rotating the test blade under the test working condition;
calibrating a rub-impact zero point, wherein the operation comprises the steps of controlling an intrusion platform with an abradable coating to intrude into a test blade from an initial position at a preset speed (such as uniform linear intrusion), monitoring the abradable coating by utilizing an acoustic emission sensor and an acceleration sensor simultaneously in the intrusion process of the intrusion platform, respectively monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds, and judging that the rub-impact zero point is reached when the signal output by any one sensor is monitored to exceed the preset thresholds;
controlling an intrusion platform with an abradable coating mounted thereon to perform an intrusion motion relative to the test blade based on the determined rub-impact zero;
and acquiring rub-impact experimental data of the abradable coating and the test blade, and recording.
A large number of test data prove that the method can accurately judge the position and time of occurrence of the rub-impact zero point, and further can accurately control the invasion depth, so that the deviation between the actual invasion depth and the preset invasion depth is within 10%.
In the above-mentioned scheme, it is critical to simultaneously monitor the acceleration signal and the acoustic emission signal of the abradable coating by using the acceleration sensor and the acoustic emission sensor. It has been found experimentally that monitoring the acceleration of the abradable coating or the elastic wave of the abradable coating by means of an acceleration sensor or an acoustic emission sensor alone does not allow an accurate determination of the rub-impact zero point.
When the blade rotation line speed is low (for example, lower than 240 m/s), the acoustic emission sensor can detect the rub-impact zero more sharply and accurately. Without being limited by theory, this may be due to microscopic fracture and plastic deformation of the coating material at the coating surface as the test blade rubs against the coating, which is accompanied by rapid release of energy to produce transient elastic waves having a particular frequency, which are significantly different from the fluctuating signals caused by the vibration of the device itself in high-speed tests, i.e., acoustic emissions, which are released from the material.
When the blade rotation line speed is high (for example, higher than 400 m/s), the acceleration sensor can more acutely and accurately detect the rub-impact zero point. Without being limited by theory, this may be due to the fact that when the wind force generated by the high-speed rotation of the rotor blade is strong, the equipment vibrates greatly, high-frequency vibration impact grinding exists between the components of the clamping coating intrusion platform, and the elastic wave generated by the first impact grinding of the blade and the coating is covered by the elastic wave intensity generated by the high-frequency vibration impact grinding, so that the acoustic emission sensor cannot accurately obtain an effective detection signal.
Therefore, the acceleration sensor and the acoustic emission sensor form double insurance for accurately detecting the rub-impact zero point together, and accidental errors generated by the system are effectively reduced. By monitoring the acceleration signal and the acoustic emission signal of the abradable coating by utilizing the acceleration sensor and the acoustic emission sensor at the same time, the collision and abrasion zero point can be accurately judged, and the deviation between the actual penetration depth and the preset penetration depth can be controlled within 10%.
In some embodiments, rub-on experimental data for the abradable coating and test blade is obtained and recorded along with intrusion location data for the intrusion platform at the corresponding time.
In some embodiments, when it is determined that the rub-impact zero is reached, the current location of the intrusion platform (i.e., location zero) and/or the current time (i.e., time zero) is recorded.
In some embodiments, the intrusion platform with the abradable coating mounted thereon is controlled to perform an intrusion motion relative to the test blade as a function of a predetermined impact track variation.
In some embodiments, the abradable coating performance test method further includes the step of taking a rub trace variation function between the engine blade and the casing coating under test conditions.
In some embodiments, the rub trace variation function comprises a radial direction (x) function and/or an axial direction (z) direction function of at least one period. The radial direction function and/or axial direction function may be one or more functions of time (t).
In some embodiments, axial refers to a direction parallel to the axis of rotation of the blade. Radial refers to a direction perpendicular to the axial direction.
In some embodiments, the bump track change function is a radial intrusion (e.g., uniform linear intrusion), where the path x=vt, x is the intrusion distance and v is the intrusion speed.
In some embodiments, an acoustic emission signal of the coating is detected with an emission sensor. The emission sensor outputs charges according to the intensity of the acoustic emission signals, and the charges are amplified and converted into voltage signals through the charge amplifier and the measuring circuit.
In some embodiments, the voltage signal strength of the coating is detected using an acceleration sensor. The acceleration sensor outputs electric charge according to the intensity of acceleration, and the electric charge is amplified and converted into a voltage signal by the electric charge amplifier and the measuring circuit.
In some embodiments, it is monitored whether the intensity of the voltage signal output by the acoustic emission sensor exceeds a first preset threshold. And monitoring whether the intensity of the voltage signal output by the acceleration sensor exceeds a second preset threshold value. When the signals output by any sensor are monitored to exceed the respective preset threshold values, the judgment that the collision and grinding zero point is reached is made.
In some embodiments, the acoustic emission sensor outputs a preset threshold value a of signal strength 1 Is set to be greater than or equal to 1.3A 0 (e.g. A 1 ＝1.3A 0 ～2A 0 )，A 0 Refers to the intensity value of the output signal of the acoustic emission sensor when no rub-impact occurs.
In some embodiments, the acceleration sensor outputs a preset threshold value B of signal strength 1 Is set to be greater than or equal to 1.5B 0 (e.g. B 1 ＝1.5B 0 ～2B 0 )，B 0 The intensity value of the output signal of the acceleration sensor when no rub-impact occurs.
In some embodiments, the acoustic emission sensor refers to a charge-output acoustic emission sensor.
In some embodiments, the acoustic emission sensor is a piezoelectric acoustic emission sensor.
In some embodiments, the acceleration sensor refers to a charge output type acceleration sensor.
In some embodiments, the acceleration sensor is a piezoelectric acceleration sensor.
In some embodiments, the acceleration sensor is a vibratory acceleration sensor.
In some embodiments, the detection of the voltage signal may be direct or indirect. Indirect detection refers to one or more steps of linear transformation (e.g., amplification) of the voltage value, followed by detection.
In some embodiments, the acoustic emission sensor has a frequency response in the range of 50-220kHz.
In some embodiments, the frequency response of the acceleration sensor ranges from 0.5 to 10000Hz (e.g., 1 to 7000 Hz).
In some embodiments, the acoustic emission sensor has a frequency response in the range of 50-220kHz, a resonant frequency of 112-168 kHz, and a sensitivity of 71+ -3 dB.
In some embodiments, the acceleration sensor has a frequency response in the range of 0.5 to 10000Hz (e.g., 1 to 7000 Hz), a sensitivity of 30 to 40pC/g, and a maximum lateral sensitivity of 5% or less.
In some embodiments, the acoustic emission sensor is mounted on a side of the abradable coating facing away from the test blade;
in some embodiments, the acceleration sensor is mounted on a fixture for securing the abradable coating.
In some embodiments, after controlling intrusion of the intrusion platform to a preset depth or for a preset length of time, further comprising: the intrusion platform is controlled to stop moving for a preset length of time and then to retract to the initial position at a preset speed.
In some embodiments, the rub test refers to a test blade mounted on the outer edge of a rotatable wheel disc, an abradable coating sample mounted on an intrusion platform that can move forward and backward relative to the wheel disc, the coating and the blade can be heated, and under the condition that the wheel disc rotates, the platform drives the coating sample to move towards the wheel disc, so that rub of the blade and the coating is achieved.
In some aspects, an abradable coating performance test system is provided, comprising:
the rotor system comprises a test blade and a driving mechanism for driving the test blade to rotate;
the intrusion system comprises an intrusion platform and a data testing instrument, wherein the intrusion platform is used for driving the abradable coating to execute intrusion motion relative to the test blade, and the data testing instrument comprises an acceleration sensor and an acoustic emission sensor which are respectively used for monitoring acceleration signals and acoustic emission signals of the abradable coating sample;
the control unit is used for controlling the driving mechanism to drive the test blade to rotate according to the test working condition, determining a rub-impact zero point, then controlling the intrusion platform provided with the abradable coating to execute intrusion motion relative to the test blade based on the determined rub-impact zero point, acquiring rub-impact experimental data of the abradable coating and the test blade from the data test instrument, and recording the rub-impact experimental data and intrusion position data of the intrusion platform at corresponding moments;
the control unit comprises a zero point determining module, wherein the zero point determining module is used for controlling the intrusion platform to intrude into the test blade from an initial position at a preset speed (such as uniform linear intrusion), monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds or not respectively in the intrusion process of the intrusion platform, and judging that the impact grinding zero point is reached when the signals output by any one of the sensors are monitored to exceed the preset thresholds at first.
In some embodiments, the intrusion system includes a clamp for holding the abradable coating sample, the acceleration sensor is mounted on the clamp, and the acoustic emission sensor is mounted on the abradable coating sample.
In some embodiments, the acoustic emission sensor has a frequency response in the range of 50-220kHz, a resonant frequency in the range of 112-168 kHz, and a sensitivity of 71+ -3 dB.
In some embodiments, the acceleration sensor has a frequency response in the range of 0.5 to 10000Hz (e.g., 1 to 7000 Hz) and a sensitivity in the range of 30 to 40pC/g with a maximum lateral sensitivity of 5% or less.
In some embodiments, the control unit controls the intrusion platform with the abradable coating mounted thereon to perform an intrusion motion relative to the test blade according to the rub trace variation function
In some embodiments, the control unit further comprises any one of the following modules:
the function calling module is used for calling a collision abrasion track change function between the test blade and the abradable coating under the test working condition, and the control unit controls the intrusion platform provided with the abradable coating to execute intrusion motion relative to the test blade according to the preset collision abrasion track change function;
the blade control module is used for controlling the driving mechanism to drive the test blade to rotate according to the test working condition;
an intrusion control module for controlling an intrusion platform with an abradable coating installed therein to perform an intrusion motion with respect to the test blade based on the determined rub-against zero;
the data recording module is used for acquiring the rub-impact experimental data of the abradable coating and the test blade from the data testing instrument, and then recording the rub-impact experimental data and the intrusion position data of the intrusion platform at the corresponding time;
and the retraction control module is used for controlling the intrusion platform to stop moving within a preset time length after the intrusion control module controls the intrusion platform to intrude to a preset depth or intrude for a preset time length, and then retracting the initial position at a preset speed.
In some embodiments, the operating temperature range of the abradable coating performance test system is from room temperature to 1200 ℃.
In some embodiments, the test blade line speed ranges from 100 to 520m/s.
The novel abradable coating performance test methods and systems of the present disclosure are compatible with or combinable with any abradable coating performance test methods and systems previously developed by the applicant, the entire contents of the following chinese patent applications are incorporated herein by reference: CN201811195700.5, CN201811195717.0, CN201811195685.4, CN201320109549.5, CN201310076983.2, CN201220641509.0, CN201210496279.8.
Interpretation of the terms
The present disclosure may have the following explanations if the following terms are used:
the term "high temperature and high speed" means that the temperature ranges from room temperature to 1200 ℃ and the rotation linear speed of the blade ranges from 100 to 520m/s.
The terms "intrusion" and "feed" have the same meaning, both referring to the operation of mounting a blade that is moved toward rotation by an intrusion platform of the coating.
The term "acceleration sensor" refers to a device capable of converting acceleration of an object into electrical energy (charge or voltage).
The term "acoustic emission sensor" refers to a device capable of converting an acoustic emission signal of an object into an electrical quantity (charge or voltage).
The term "exceeding" means higher than or equal to.
The seal coating and abradable coating have the same meaning, both referring to coatings that are capable of actively abrading themselves during counter-abrasion with other components.
Advantageous effects
One or more embodiments of the present disclosure have one or more of the following benefits:
(1) The collision and grinding zero point can be accurately calibrated in a wider temperature range;
(2) The collision and grinding zero point can be accurately calibrated in a wider linear speed range.
Drawings
FIG. 1 is a block schematic diagram of an abradable coating performance test system according to an embodiment.
FIG. 2 is a schematic diagram of an intrusion system in an abradable coating performance test system according to one embodiment.
FIG. 3 is a schematic diagram of an assembled configuration of a rotor system and an intrusion system in an abradable coating performance test system according to one embodiment.
FIG. 4 is a flow chart of a method for testing the performance of an abrasive coating according to an embodiment.
Detailed Description
The technical scheme of the application is further described in detail through the drawings and the embodiments.
FIG. 1 is a block diagram of an exemplary abradable coating performance test system according to the present application. In fig. 1, an abradable coating performance test system includes: rotor system 10, intrusion system 20 and control unit 30. The rotor system 10 may include a test blade 11 and a drive mechanism 12 that drives the test blade 11 in rotation. The driving mechanism 12 can drive the test blade 11 to rotate according to the working condition of the engine to be tested, so that the test blade 11 can operate according to the rotating speed under the working condition. Intrusion system 20 includes an intrusion platform 21 and a data testing instrument 22. The intrusion platform 21 has a coating sample mounted thereon and enables a precise intrusion operation. The data testing instrument 22 includes an acceleration sensor and an acoustic emission sensor for monitoring an acceleration signal and an acoustic emission signal, respectively, of the abradable coating sample.
Referring to FIGS. 2 and 3, intrusion system 20 may be supported with a rigid base 40 to ensure that the system stiffness meets the test requirements (e.g.,. Gtoreq.500N/. Mu.m). The rigid base 40 can be made of square steel with good stability, and the square steel can be connected with the main machine of the abradable tester through a guide rail and slide on the guide rail to adjust the axial position. A support base 23 for adjusting the height of the intrusion platform 21 can be mounted on the rigid base 40, and the support base 23 can be adjusted in position on the rigid base 40 to ensure that the intrusion platform 21 can operate in an optimal range of travel.
The infiltration stage 21 may employ a high-precision crossed roller screw mechanism capable of achieving precise infiltration. Specifically, the stepper motor can rotate according to the pulse frequency given by the control unit 30, and transmits torque to the high-precision crossed roller screw through the coupler to drive the roller screw to rotate, so as to drag the intrusion platform 21 to slide back and forth in the radial direction and the axial direction of the test blade 11. The coating sample 24 can be mounted on the side of the intrusion platform 21 near the test blade 11 by a fixture, and when the intrusion platform 21 moves, the coating sample 24 is also driven to realize precise intrusion together.
A linear grating scale capable of high resolution may also be included in invasive system 20 for real-time detection of the position of the platform motion and feedback of the position data to the control unit for closed loop feedback control of invasive system 20.
In fig. 3, the intrusion platform 21 may enable bi-directional intrusion with respect to the radial x and axial z directions of the test blade 11. And, the data testing instrument 22 includes an acceleration sensor and an acoustic emission sensor for monitoring an acceleration signal and an acoustic emission signal of the abradable coating sample, respectively, and a voltage signal output by the acceleration sensor and the acoustic emission sensor is transmitted to the control unit (optionally amplified and transmitted to the control unit) for display and processing.
In some embodiments the control unit 30 further comprises a display instrument, which may be a spectrometer and/or an oscilloscope.
The data testing instrument 22 may also include a three-way load cell. In the high-speed collision and grinding process of the blade and the coating sample, the radial positive pressure Fx, the circumferential friction force Fy and the axial pressure Fz are mainly generated, and the three-way force sensor can accurately measure forces in the directions of x, y and z. Preferably, a piezoelectric three-way load cell is used for friction force measurement, and the rigidity, the natural frequency and the resolution of the type of load cell are high, so that small dynamic force change on large force can be measured. For example, a piezoelectric three-way dynamometer is selected with a range of 5000N and a natural frequency of 3.5kHz. In addition, the charge signal collected by the three-way force transducer can be amplified by a charge amplifier and further converted into a collectable voltage signal, and the collectable voltage signal is transmitted to the control unit for display and processing. It is also possible to measure rub test data, such as radial positive pressure, circumferential friction, etc., at high rub speeds between the coating sample and the test blade 11.
In some embodiments, the control unit 30 may be configured to invoke a rub-on trajectory variation function between the test blade and the casing coating under the test condition, and the control unit may control the intrusion platform on which the abradable coating is mounted to perform an intrusion motion with respect to the test blade according to the pre-set rub-on trajectory variation function. The collision and wear track change function can be provided by an engine manufacturer to be tested, or obtained by fitting after data acquisition through actual operation of the engine, or designed according to test requirements.
For a certain type of engine, when the engine is slow to 100% N2R (high temperature take off), 50% oil is supplied, the rub-over track change function is:
radial direction:
0s≤t≤4.7s，x 1 ＝0.0645t+0.48585；
axial direction:
0s≤t≤2.605s，z 2 ＝0.1153t；
2.605s＜t≤8s，z 1 ＝-0.00073t 3 +0.18072t 2 -0.16764t+0.627396。
it can be seen that the rubbing trajectory variation function has not changed at a constant speed in a specific period, but is a higher order polynomial function. According to the embodiment, the intrusion platform is controlled according to the collision track change function, so that more accurate and reliable test data can be obtained.
The control unit 30 is also capable of controlling the drive mechanism 12 to drive the test blade 11 to rotate according to the test conditions, and then controlling the intrusion platform 21 on which the coating sample 24 is mounted to perform an intrusion motion with respect to the test blade 11 based on the determined rub-impact zero point. In order to test the rub-impact experimental data under certain engine working conditions, the control unit 30 may first control the driving mechanism 12 to rotate the test blade 11 at a speed under the test working conditions, so as to match the test working conditions with the actual working conditions. In addition, the control unit 30 is also capable of acquiring rub test data of the coating sample 24 and the test blade 11 from the data testing apparatus 22, and then recording the rub test data together with the intrusion position data of the intrusion platform 21 at the corresponding time. The control unit 30 may be implemented by hardware or software of a device control main board or an upper computer.
In some embodiments, the control unit 30 further comprises: the function calling module is used for calling a collision abrasion track change function between the engine blade and the casing coating under the test working condition, and the control unit controls the intrusion platform provided with the abradable coating to execute intrusion motion relative to the test blade according to the preset collision abrasion track change function.
In some embodiments, the control unit 30 further comprises: and the blade control module is used for controlling the driving mechanism to drive the test blade to rotate according to the test working condition.
In some embodiments, the control unit 30 further comprises: and the intrusion control module is used for controlling an intrusion platform for installing the coating sample to execute intrusion motion relative to the test blade based on the determined rub-against point.
In some embodiments, the control unit further comprises: and the data recording module is used for acquiring the rub-impact experimental data of the coating sample and the test blade from the data testing instrument, and then recording the rub-impact experimental data and the intrusion position data of the intrusion platform at the corresponding moment.
Referring to the abradable coating performance test system embodiments of fig. 1-3, several embodiments of abradable coating performance test methods are also provided. FIG. 4 is a schematic flow chart of an embodiment of the method for testing the performance of an abradable coating according to the present application. In this embodiment, the abradable coating performance test method includes:
step 200, rotating the test blade under the test working condition;
step 400, calibrating a collision and grinding zero point; the operation comprises controlling an intrusion platform with an abradable coating to intrude into the test blade from an initial position (such as uniform linear intrusion) at a preset speed, monitoring the abradable coating by using an acoustic emission sensor and an acceleration sensor simultaneously in the intrusion process, respectively monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds, and judging that a rub-impact zero point is reached when the signal output by any one sensor is monitored to exceed the preset threshold firstly;
step 600, controlling an intrusion platform with an abradable coating mounted thereon to perform an intrusion motion relative to the test blade based on the determined rub-impact zero;
step 800, obtaining rub-impact experimental data of the abradable coating and the test blade, and recording.
In some embodiments, abradable coatings are recorded along with intrusion position data for the intrusion platform at the corresponding time of rub against the test blade.
The steps 200-800 may be executed by the control unit in a unified manner, or may be executed by a plurality of controllers to perform different control operations, respectively, and communicate with each other.
The method of testing the performance of an abradable coating is further illustrated by the specific examples below
Example 1
(1) Taking an aluminum-silicon polyphenyl ester sealing coating sample (the Al content in the coating is 52.8wt%, the Si content is 7.2wt%, and the polyphenyl ester content is 40 wt%) prepared by an atmospheric plasma spraying process, wherein the coating thickness is 2mm, the sample is in a flat plate shape, the size of the coating sample is 40mm multiplied by 60mm multiplied by 6mm, and the substrate material is stainless steel.
(2) The TC4 titanium alloy simulated blade is taken, the blade tip size is 0.7mm multiplied by 20mm, and the average height before the test is measured by using a TA025A type screw micrometer to be 20.101mm.
(3) And (3) clamping the sealing coating samples and the simulated blades in the step (1) and the step (2) on a BGRIMM-AST1000 type high-temperature high-speed abradable testing machine developed by mining and metallurgy technology group, wherein the radius of the testing machine after the blades are installed is 417.5mm.
(4) Attaching a Fuji AE144A type magnetic attraction acoustic emission sensor on the back of the coating sample, wherein the diameter of the sensor is 8mm, the frequency response range is 50-220kHz, the resonance frequency is 140+/-20% kHz, and the sensitivity is 71+/-3 dB; and connecting the sensor with an oscilloscope with the sampling rate of 6.25GS/S and the recording length of not less than 30M by adopting a wiring mode of a preamplifier, and adjusting the oscilloscope to a mode of displaying a voltage and time curve.
(5) Installing an acceleration sensor ZD-510 of Shanghai vibration Di detection technology Co on a clamp for clamping a coating sample in a bolt connection mode, wherein the frequency response range of the sensor is 1-7000 Hz, the sensitivity is 35pC/g, and the maximum transverse sensitivity is less than or equal to 5%; the acceleration sensor is connected with the measuring instrument in a voltage output mode, and the measuring instrument is adjusted to a mode of displaying a voltage-time curve.
(6) The high-temperature high-speed bump grinding test parameters are set as follows: the temperature is 150 ℃, the blade rotation linear speed is 200m/s, the intrusion speed is 50 mu m/s, the preset intrusion program is stopped after the intrusion is continued for 10s after reaching the impact grinding zero point, and the preset intrusion depth=50 mu m/s×10s=500 mu m.
(7) Adjusting an intrusion platform to keep a safe distance of 1.5mm between the blade tip and the surface of the coating, starting a BGRIMM-AST1000 type high-temperature high-speed abradable testing machine, enabling a coating sample to move towards the rotating blade tip at an intrusion rate of 50 mu m/s after the temperature and the linear speed reach set values, simultaneously observing a voltage-time signal curve of the oscillograph and a voltage-time curve of an acceleration measuring instrument in the step (4) and the step (5), firstly observing that the intensity of a voltage signal output by an acoustic emission sensor is controlled by a base line value A 0 Increase in jitter to A 1 (mutation Signal), A 1 ＝1.3A 0 And (the increase of the platform is about 30 percent), judging that the platform reaches the collision and grinding zero point, stopping after continuing to invade for 10 seconds, retracting the platform, and ending the test.
Taking down the sealed coating sample and the test blade after the impact grinding test by a testing machine, and measuring the depth of the coating grinding mark to 523.7 mu m by using a DL91150 vernier caliper; the blade height wear was measured to be 4 μm using a TA025A screw micrometer; the actual intrusion depth of the test = coating wear scar depth + blade height wear amount = 523.7 μm +4 μm = 527.7 μm. The deviation was only 5.54% compared to the set penetration depth of 500 μm.
In this embodiment, the acceleration sensor starts to feed back the more obvious fluctuation signal after 2.3s of the sudden change signal fed back by the acoustic emission sensor, and it can be seen that the sensitivity of the acceleration sensor is lower than that of the acoustic emission sensor under the condition of lower linear velocity.
Example 2
(1) The porous zirconia sealing coating sample (the porosity of the coating is 28%, the yttrium oxide content is 7.62% by weight, and the zirconia content is 92.18% by weight) prepared by the atmospheric plasma spraying process is taken, the coating thickness is 2mm, the sample is in a flat plate shape, the size of the coating sample is 40mm multiplied by 60mm multiplied by 6mm, and the substrate material is nickel-based superalloy.
(2) The nickel-based superalloy simulated blade is adopted, the blade tip size is 2mm multiplied by 20mm, the heights of the left, middle and right before the test are respectively 20.141mm, 20.124mm and 20.163mm, and the average value is 20.143mm, which are measured by using a TA025A type screw micrometer.
(3) And (3) clamping the sealing coating samples and the simulated blades in the step (1) and the step (2) on a BGRIMM-AST1000 type high-temperature high-speed abradable testing machine developed by mining and metallurgy technology group, wherein the radius of the testing machine after the blades are installed is 417.5mm.
(4) Attaching a magnetic attraction type acoustic emission sensor (same as in example 1) to the back surface of the coating sample; and connecting the sensor with an oscilloscope with the sampling rate of 6.25GS/S and the recording length of not less than 30M by adopting a wiring mode of a preamplifier, and adjusting the oscilloscope to a mode of displaying a voltage and time curve.
(5) Installing an acceleration sensor on a clamp for clamping the coating sample in a bolt connection mode (the same as the embodiment 1); the acceleration sensor is connected with the measuring instrument in a voltage output mode, and the measuring instrument is adjusted to a mode of displaying a voltage-time curve.
(6) The high-temperature high-speed bump grinding test parameters are set as follows: the temperature is 1080 ℃, the blade rotation linear speed is 450m/s, the intrusion speed is 50 mu m/s, the preset intrusion program is stopped after the intrusion is continued for 10s after reaching the impact grinding zero point, and the preset intrusion depth=50 mu m/s×10s=500 mu m.
(7) Adjusting an intrusion platform to keep a safe distance of 1.5mm between the blade tip and the surface of the coating, starting a BGRIMM-AST1000 type high-temperature high-speed abradable testing machine, enabling a coating sample to move towards the blade tip rotating at a high speed at an intrusion rate of 50 mu m/s after the temperature and the linear speed reach set values, simultaneously observing the voltage-time curve of the oscilloscopes and the voltage-time curve of a measuring instrument connected with an acceleration sensor in the step (4) and the step (5), and firstly observing the intensity of a voltage signal of the measuring instrument from a base line value B 0 Increase in jitter to B 1 ，B 1 ＝1.7B 0 (increase of about 70%) to determine arrivalAnd (5) hitting the grinding zero point, continuing to invade for 10 seconds, stopping, retracting the platform, and ending the test.
Taking down the sealed coating sample and the test blade after the impact grinding test by a tester, and measuring the depth of the coating grinding mark to 442.4 mu m by using a DL91150 vernier caliper; the average value of the heights of the blades after the blade test is 20.039mm by using a TA025A type screw micrometer, and the abrasion loss of the heights of the blades is 104 mu m; the actual penetration depth for this test was =coating wear scar depth+blade height wear amount =442.4 μm+104 μm= 546.4 μm. The actual penetration depth is only 9.28% deviated from the preset penetration depth of 500 μm.
In the embodiment, when the linear speed of the blade tip reaches 450m/s and the invasive platform does not move yet, vibration friction and stress appear among invasive platform components due to wind power generated by the blade, vibration of a rotor main shaft and the like, the acoustic emission sensor has a feedback signal with higher strength, and whether the strength of the signal of the acoustic emission sensor is obviously suddenly changed is difficult to judge in the whole process from the start of the movement of the invasive platform to the end of an experiment.
From the above examples 1 and 2, it is known that the occurrence of the rub-impact zero point can be precisely calibrated by the method of the above examples, and further, the deviation of the reagent invasion depth from the preset invasion depth can be controlled to be not more than 10%.
In this specification, various embodiments are described in an incremental manner, where the emphasis of each embodiment is different, and where the same or similar parts of each embodiment are referred to each other. For the system embodiment, the whole and related module functions have corresponding relation with the content in the method embodiment, so that the description is simpler, and relevant parts only need to be referred to in the part of the description of the method embodiment.
Although embodiments of the present application have been described in detail, those skilled in the art will appreciate that various modifications and variations of detail are possible in light of all the teachings disclosed and such variations are within the scope of the present application. The full scope of the application is given by the appended claims and any equivalents thereof.
Claims (8)
1. An abradable coating performance test method based on a rub-on test, comprising:
rotating the test blade under the test working condition;
calibrating a rub-impact zero point, wherein the operation comprises the steps of controlling an intrusion platform provided with an abradable coating to intrude into the test blade from an initial position at a preset speed, monitoring the abradable coating by utilizing an acoustic emission sensor and an acceleration sensor simultaneously in the intrusion process, respectively monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds, and judging that the rub-impact zero point is reached when the signal output by any one of the sensors is monitored to exceed the preset thresholds;
controlling an intrusion platform with an abradable coating mounted thereon to perform an intrusion motion relative to the test blade based on the determined rub-impact zero;
acquiring rub-impact experimental data of the abradable coating and the test blade, and recording;
wherein, the acoustic emission sensor outputs a preset threshold A of signal intensity 1 Is set to be greater than or equal to 1.3A 0 ，A 0 The intensity value of the output signal of the acoustic emission sensor when no rub-impact occurs;
wherein, the preset threshold B of the output signal intensity of the acceleration sensor 1 Is set to be greater than or equal to 1.5B 0 ，B 0 Refers to the intensity value of the output signal of the acceleration sensor when no rub-impact occurs,
the frequency response range of the acoustic emission sensor is 50-220kHz;
the frequency response range of the acceleration sensor is 0.5-10000 Hz.
2. A method according to claim 1, wherein the intensity of the voltage signals output by the acoustic emission sensor and the acceleration sensor are monitored separately for exceeding respective preset thresholds.
3. The method of claim 1, wherein,
preset threshold value A of acoustic emission sensor output signal intensity 1 Set to 1.3A 0 -2A 0 ，A 0 Refers to the intensity value of the output signal of the acoustic emission sensor when no rub-impact occurs,
preset threshold B of output signal intensity of acceleration sensor 1 Is set to be greater than or equal to 1.5B 0 -2B 0 ，B 0 The intensity value of the output signal of the acceleration sensor when no rub-impact occurs.
4. The method of claim 1, wherein,
the acoustic emission sensor is arranged on one side of the abradable coating, which is away from the test blade;
the acceleration sensor is mounted on a fixture for securing the abradable coating.
5. The method of claim 1, wherein after controlling the intrusion platform to intrude to a preset depth or for a preset duration, further comprising:
and controlling the intrusion platform to stop moving within a preset time length, and then returning to the initial position at a preset speed.
6. An abradable coating performance test system, comprising:
the rotor system comprises a test blade and a driving mechanism for driving the test blade to rotate;
the intrusion system comprises an intrusion platform and a data testing instrument, wherein the intrusion platform is used for driving the abradable coating to execute intrusion motion relative to the test blade, and the data testing instrument comprises an acceleration sensor and an acoustic emission sensor which are respectively used for monitoring acceleration signals and acoustic emission signals of the abradable coating sample;
the control unit is used for controlling the driving mechanism to drive the test blade to rotate according to a test working condition, determining a rub-impact zero point, then controlling an intrusion platform provided with an abradable coating to execute intrusion motion relative to the test blade based on the determined rub-impact zero point, acquiring rub-impact experimental data of the abradable coating and the test blade from the data test instrument, and recording;
the control unit comprises a zero point determining module, a first control module and a second control module, wherein the zero point determining module is used for controlling the intrusion platform to intrude into the test blade from an initial position at a preset speed, respectively monitoring whether the intensities of signals output by the acoustic emission sensor and the acceleration sensor exceed respective preset thresholds in the intrusion process, and determining that the current moment is a rub-impact zero point when the signal output by any one of the sensors is monitored to exceed the preset threshold at first;
wherein, the acoustic emission sensor outputs a preset threshold A of signal intensity 1 Is set to be greater than or equal to 1.3A 0 ，A 0 The intensity value of the output signal of the acoustic emission sensor when no rub-impact occurs;
wherein, the preset threshold B of the output signal intensity of the acceleration sensor 1 Is set to be greater than or equal to 1.5B 0 ，B 0 Refers to the intensity value of the output signal of the acceleration sensor when no rub-impact occurs,
the frequency response range of the acoustic emission sensor is 50-220kHz;
the frequency response range of the acceleration sensor is 0.5-10000 Hz.
7. The system of claim 6, having the following features:
the intrusion system comprises a fixture for holding a sample of the abradable coating, the acceleration sensor being mounted on the fixture, the acoustic emission sensor being mounted on the side of the abradable coating facing away from the test blade.
8. The system of claim 6, wherein the control unit further comprises any one of the following modules:
the function calling module is used for calling a collision abrasion track change function between the test blade and the abradable coating under the test working condition, and the control unit controls the intrusion platform provided with the abradable coating to execute intrusion motion relative to the test blade according to the preset collision abrasion track change function;
the blade control module is used for controlling the driving mechanism to drive the test blade to rotate according to the test working condition;
an intrusion control module for controlling an intrusion platform with an abradable coating installed therein to perform an intrusion motion with respect to the test blade based on the determined rub-against zero;
the data recording module is used for acquiring collision and abrasion experimental data of the abradable coating and the test blade from the data testing instrument, and then recording the collision and abrasion experimental data and the invasion position data of the invasion platform at the corresponding moment;
and the retraction control module is used for controlling the intrusion platform to stop moving within a preset time length after the intrusion control module controls the intrusion platform to intrude to a preset depth or intrude for a preset time length, and then retracting the initial position at a preset speed.
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