1
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Omidvarnia F, Sarhadi A. Nature-Inspired Designs in Wind Energy: A Review. Biomimetics (Basel) 2024; 9:90. [PMID: 38392136 PMCID: PMC10886931 DOI: 10.3390/biomimetics9020090] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/16/2024] [Revised: 01/24/2024] [Accepted: 01/26/2024] [Indexed: 02/24/2024] Open
Abstract
The field of wind energy stands at the forefront of sustainable and renewable energy solutions, playing a pivotal role in mitigating environmental concerns and addressing global energy demands. For many years, the convergence of nature-inspired solutions and wind energy has emerged as a promising avenue for advancing the efficiency and sustainability of wind energy systems. While several research endeavors have explored biomimetic principles in the context of wind turbine design and optimization, a comprehensive review encompassing this interdisciplinary field is notably absent. This review paper seeks to rectify this gap by cataloging and analyzing the multifaceted body of research that has harnessed biomimetic approaches within the realm of wind energy technology. By conducting an extensive survey of the existing literature, we consolidate and scrutinize the insights garnered from diverse biomimetic strategies into design and optimization in the wind energy domain.
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Affiliation(s)
- Farzaneh Omidvarnia
- Department of Wind and Energy Systems, Technical University of Denmark (DTU), Frederiksborgvej 399, 4000 Roskilde, Denmark
| | - Ali Sarhadi
- Department of Wind and Energy Systems, Technical University of Denmark (DTU), Frederiksborgvej 399, 4000 Roskilde, Denmark
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2
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Chen G, Zhao F, Zeng Y, Su Z, Xu L, Shao C, Wu C, He G, Chen Q, Zhao Y, Sun D, Hai Z. Conformal Fabrication of Thick Film Platinum Strain Gauge Via Error Regulation Strategies for In Situ High-Temperature Strain Detection. ACS Appl Mater Interfaces 2024; 16:966-974. [PMID: 38109359 DOI: 10.1021/acsami.3c10866] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/20/2023]
Abstract
Monitoring high-temperature strain on curved components in harsh environments is a challenge for a wide range of applications, including in aircraft engines, gas turbines, and hypersonic vehicles. Although there are significant improvements in the preparation of high-temperature piezoresistive film on planar surfaces using 3D printing methods, there are still difficulties with poor surface compatibility and high-temperature strain testing on curved surfaces. Herein, a conformal direct ink writing (CDIW) system coupled with an error feedback regulation strategy was used to fabricate high-precision, thick films on curved surfaces. This strategy enabled the maximum amount of error in the distance between the needle and the substrate on a curved surface to be regulated from 155 to 4 μm. A conformal Pt thick-film strain gauge (CPTFSG) with a room-temperature strain coefficient of 1.7 was created on a curved metallic substrate for the first time. The resistance drift rate at 800 °C for 1 h was 1.1%, which demonstrated the excellent stability and oxidation resistance of the CPTFSG. High-temperature dynamic strain tests up to 769 °C revealed that the sensor had excellent high-temperature strain test performance. Furthermore, the CPTFSG was conformally deposited on an aero-engine turbine blade to perform in situ tensile and compressive strain testing at room temperature. High-temperature strain tests were conducted at 100 and 200 °C for 600 and 580 με, respectively, demonstrating a high steady-state response consistent with the commercial high-temperature strain transducer. In addition, steady-state strain tests at high temperatures up to 496 °C were tested. The CDIW error modulation strategy provides a highly promising approach for the high-precision fabrication of Pt thick films on complex surfaces and driving in situ sensing of high-temperature parameters on curved components toward practical applications.
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Affiliation(s)
- Guochun Chen
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Fuxin Zhao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Yingjun Zeng
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Zhixuan Su
- Department of Mechanical & Electrical Engineering, Xiamen University, Xiamen 361005, P. R. China
| | - Lida Xu
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Chenhe Shao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Chao Wu
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Gonghan He
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Qinnan Chen
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Yang Zhao
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Daoheng Sun
- Pen-Tung Sah Institute of Micro-Nano Science & Technology, Xiamen University, Xiamen 361005, P. R. China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
| | - Zhenyin Hai
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, P. R. China
- Department of Mechanical & Electrical Engineering, Xiamen University, Xiamen 361005, P. R. China
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3
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Eversberg L, Lambrecht J. Combining Synthetic Images and Deep Active Learning: Data-Efficient Training of an Industrial Object Detection Model. J Imaging 2024; 10:16. [PMID: 38249001 DOI: 10.3390/jimaging10010016] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/28/2023] [Revised: 12/29/2023] [Accepted: 01/04/2024] [Indexed: 01/23/2024] Open
Abstract
Generating synthetic data is a promising solution to the challenge of limited training data for industrial deep learning applications. However, training on synthetic data and testing on real-world data creates a sim-to-real domain gap. Research has shown that the combination of synthetic and real images leads to better results than those that are generated using only one source of data. In this work, the generation of synthetic training images via physics-based rendering is combined with deep active learning for an industrial object detection task to iteratively improve model performance over time. Our experimental results show that synthetic images improve model performance, especially at the beginning of the model's life cycle with limited training data. Furthermore, our implemented hybrid query strategy selects diverse and informative new training images in each active learning cycle, which outperforms random sampling. In conclusion, this work presents a workflow to train and iteratively improve object detection models with a small number of real-world images, leading to data-efficient and cost-effective computer vision models.
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Affiliation(s)
- Leon Eversberg
- Industry Grade Networks and Clouds, Faculty IV Electrical Engineering and Computer Science, Technische Universität Berlin, Straße des 17. Juni 135, 10623 Berlin, Germany
| | - Jens Lambrecht
- Industry Grade Networks and Clouds, Faculty IV Electrical Engineering and Computer Science, Technische Universität Berlin, Straße des 17. Juni 135, 10623 Berlin, Germany
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4
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Stawiarski A, Chwał M, Barski M, Augustyn M. The Wrinkles Characterization in GFRP Composites by Infrared Active Thermography. Materials (Basel) 2023; 16:4236. [PMID: 37374420 DOI: 10.3390/ma16124236] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 05/04/2023] [Revised: 05/26/2023] [Accepted: 06/05/2023] [Indexed: 06/29/2023]
Abstract
An experimental study has been carried out to assess the effectiveness of infrared thermography in wrinkle detection in composite GFRP (Glass Fiber Reinforced Plastic) structures by infrared active thermography. Wrinkles in composite GFRP plates with different weave patterns (twill and satin) have been manufactured with the use of the vacuum bagging method. The different localization of defects in laminates has been taken into account. Transmission and reflection measurement techniques of active thermography have been verified and compared. The section of a turbine blade with a vertical axis of rotation containing post-manufacturing wrinkles has been prepared to verify active thermography measurement techniques in the real structure. In the turbine blade section, the influence of a gelcoat surface on the effectiveness of thermography damage detection has also been taken into account. Straightforward thermal parameters applied in structural health monitoring systems allow an effective damage detection method to be built. The transmission IRT setup allows not only for damage detection and localization in composite structures but also for accurate damage identification. The reflection IRT setup is convenient for damage detection systems coupled with nondestructive testing software. In considered cases, the type of fabric weave has negligible influence on the quality of damage detection results.
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Affiliation(s)
- Adam Stawiarski
- Department of Machine Design and Composite Structures, Faculty of Mechanical Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
| | - Małgorzata Chwał
- Department of Machine Design and Composite Structures, Faculty of Mechanical Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
| | - Marek Barski
- Department of Machine Design and Composite Structures, Faculty of Mechanical Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
| | - Marcin Augustyn
- Department of Machine Design and Composite Structures, Faculty of Mechanical Engineering, Cracow University of Technology, Al. Jana Pawła II 37, 31-864 Kraków, Poland
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5
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Khalid Mohammed Ridha W, Reza Kashyzadeh K, Ghorbani S. Common Failures in Hydraulic Kaplan Turbine Blades and Practical Solutions. Materials (Basel) 2023; 16:ma16093303. [PMID: 37176185 PMCID: PMC10179411 DOI: 10.3390/ma16093303] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 03/07/2023] [Revised: 04/15/2023] [Accepted: 04/19/2023] [Indexed: 05/15/2023]
Abstract
Kaplan turbines, as one of the well-known hydraulic turbines, are generally utilized worldwide for low-head and high-flow conditions. Any failure in each of the turbine components can result in long-term downtime and high repair costs. In a particular case, if other parts are damaged due to the impact of the broken blades (e.g., the main shaft of the turbine), the whole power plant may be shut down. On the other hand, further research on the primary causes of failures in turbines can help improve the present failure evaluation methodologies in power plants. Hence, the main objective of this paper is to present the major causes of Kaplan turbine failures to prevent excessive damage to the equipment and provide practical solutions for them. In general, turbines are mainly subjected to both Internal Object Damage (IOD) and Foreign Object Damage (FOD). Accordingly, this paper presents a state-of-the-art review of Kaplan turbine failures related to material and physical defects, deficiencies in design, deficits in manufacturing and assembly processes, corrosion failures, fatigue failure, cavitation wear, types of cavitation in hydro turbines, hydro-abrasive problems, and hydro-erosion problems. Eventually, the authors have attempted to discuss practical hints (e.g., nanostructured coatings) to prevent damages and improve the performance of Kaplan turbines.
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Affiliation(s)
- Waleed Khalid Mohammed Ridha
- Department of Mechanical Engineering Technologies, Academy of Engineering, Peoples' Friendship University of Russia (RUDN University), 6 Miklukho-Maklaya Street, 117198 Moscow, Russia
| | - Kazem Reza Kashyzadeh
- Department of Transport, Academy of Engineering, Peoples' Friendship University of Russia (RUDN University), 6 Miklukho-Maklaya Street, 117198 Moscow, Russia
| | - Siamak Ghorbani
- Department of Mechanical Engineering Technologies, Academy of Engineering, Peoples' Friendship University of Russia (RUDN University), 6 Miklukho-Maklaya Street, 117198 Moscow, Russia
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6
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Xu L, Li L, Tang L, Zeng Y, Chen G, Shao C, Wu C, He G, Chen Q, Fang G, Sun D, Hai Z. Rapid Printing of High-Temperature Polymer-Derived Ceramic Composite Thin-Film Thermistor with Laser Pyrolysis. ACS Appl Mater Interfaces 2023; 15:9996-10005. [PMID: 36780511 DOI: 10.1021/acsami.2c20927] [Citation(s) in RCA: 3] [Impact Index Per Article: 3.0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 06/18/2023]
Abstract
Polymer-derived ceramic (PDC)-based high-temperature thin-film sensors (HTTFSs) exhibit promising applications in the condition monitoring of critical components in aerospace. However, fabricating PDC-based HTTFS integrated with high-efficiency, high-temperature anti-oxidation, and customized patterns remains challenging. In this work, we introduce a rapid and flexible selecting laser pyrolysis combined with a direct ink writing process to print double-layer high-temperature antioxidant PDC composite thin-film thermistors under ambient conditions. The sensitive layer (SL) was directly written on an insulating substrate with excellent conductivity by laser-induced graphitization. Then, the antioxidant layer (AOL) was written on the surface of the SL to realize the integrated manufacturing of double-functional layers. Through characterization analysis, it was shown that B2O3 and SiO2 glass phases generated by the PDC composite AOL could effectively prevent oxygen intrusion. Therefore, the fabricated PDC composite thermistors exhibited a negative temperature coefficient in the temperature range from 100 to 1100 °C and high repeatability below 800 °C. Meanwhile, it has excellent high-temperature stability at 800 °C with a resistance change of only 2.4% in 2 h. Furthermore, the high-temperature electrical behavior of the thermistor was analyzed. The temperature dependence of the conductivity for this thermistor has shown an agreement with the Mott's variable range hopping mechanism. Additionally, the thermistor was fabricated on the surface of an aero-engine blade to verify its feasibility below 800 °C, showing the great potential of this work for state sensing on the surface of high-temperature components, especially for customized requirements.
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Affiliation(s)
- Lida Xu
- School of Aerospace Engineering, and Discipline of Intelligent Instrument and Equipment, Xiamen University, Xiamen 361102, China
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Lanlan Li
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Lantian Tang
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Yingjun Zeng
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Guochun Chen
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Chenhe Shao
- School of Aerospace Engineering, and Discipline of Intelligent Instrument and Equipment, Xiamen University, Xiamen 361102, China
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Chao Wu
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Gonghan He
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Qinnan Chen
- School of Aerospace Engineering, and Discipline of Intelligent Instrument and Equipment, Xiamen University, Xiamen 361102, China
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Guicai Fang
- Aerospace Technology Institute, China Aerodynamics Research and Development Center, Mianyang 621000, China
| | - Daoheng Sun
- School of Aerospace Engineering, and Discipline of Intelligent Instrument and Equipment, Xiamen University, Xiamen 361102, China
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
| | - Zhenyin Hai
- School of Aerospace Engineering, and Discipline of Intelligent Instrument and Equipment, Xiamen University, Xiamen 361102, China
- Department of Mechanical and Electrical Engineering, School of Aerospace Engineering, Xiamen University, Xiamen 361102, China
- Fujian Micro/Nano Manufacturing Engineering Technology Research Center, Xiamen University, Xiamen 361102, China
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7
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Han R, Zeng F, Li J, Yao Z, Guo W, Zhao J. A Dilated Residual Network for Turbine Blade ICT Image Artifact Removal. Sensors (Basel) 2023; 23:1028. [PMID: 36679825 PMCID: PMC9866201 DOI: 10.3390/s23021028] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 11/14/2022] [Revised: 01/02/2023] [Accepted: 01/05/2023] [Indexed: 06/17/2023]
Abstract
Artifacts are divergent strip artifacts or dark stripe artifacts in Industrial Computed Tomography (ICT) images due to large differences in density among the components of scanned objects, which can significantly distort the actual structure of scanned objects in ICT images. The presence of artifacts can seriously affect the practical application effectiveness of ICT in defect detection and dimensional measurement. In this paper, a series of convolution neural network models are designed and implemented based on preparing the ICT image artifact removal datasets. Our findings indicate that the RF (receptive field) and the spatial resolution of network can significantly impact the effectiveness of artifact removal. Therefore, we propose a dilated residual network for turbine blade ICT image artifact removal (DRAR), which enhances the RF of the network while maintaining spatial resolution with only a slight increase in computational load. Extensive experiments demonstrate that the DRAR achieves exceptional performance in artifact removal.
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Affiliation(s)
- Rui Han
- State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China
| | - Fengying Zeng
- China Gas Turbine Establishment, Aero Engine Corporation of China, Chengdu 610500, China
| | - Jing Li
- China Gas Turbine Establishment, Aero Engine Corporation of China, Chengdu 610500, China
| | - Zhenwen Yao
- State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China
| | - Wenhua Guo
- State Key Laboratory for Manufacturing Systems Engineering, Xi’an Jiaotong University, Xi’an 710049, China
| | - Jiyuan Zhao
- School of Automation, Beijing Information Science and Technology University, Beijing 100192, China
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Fameso F, Desai D, Kok S, Armfield D, Newby M. Residual Stress Enhancement by Laser Shock Treatment in Chromium-Alloyed Steam Turbine Blades. Materials (Basel) 2022; 15:5682. [PMID: 36013817 PMCID: PMC9415996 DOI: 10.3390/ma15165682] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 06/10/2022] [Revised: 07/24/2022] [Accepted: 07/27/2022] [Indexed: 06/15/2023]
Abstract
In-service turbine blade failures remain a source of concern and research interest for engineers and industry professionals with attendant safety and economic implications. Very high-pressure shock impacts from laser shots represent an evolving technique currently gaining traction for surface improvement and failure mitigation in engineering components. However, the physical characteristics and effects of parameter variations on a wide range of materials are still not fully understood and adequately researched, especially from a computational point of view. Using the commercial finite element code ABAQUS©, this paper explores the application of laser shock peening (LSP) in the enhancement of residual stresses in Chromium-based steel alloyed turbine blade material. Results of the numerically developed and experimentally validated LSP model show that peak compressive residual stresses (CRS) of up to 700 MPa can be induced on the surface and sub-surface layers, while the informed varying of input parameters can be used to achieve an increase in the magnitude of CRS imparted in the peened material. Analysis of the hierarchy of influence of the five input parameters under investigation on residual stress enhancement reveals the laser shock intensity as the most influential, followed in descending order of influence by the exposure time, shot size, degree of overlaps, and the angle of shot impact.
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Affiliation(s)
- Festus Fameso
- Department of Mechanical and Mechatronics, Tshwane University of Technology, Pretoria 0183, South Africa
| | - Dawood Desai
- Department of Mechanical and Mechatronics, Tshwane University of Technology, Pretoria 0183, South Africa
| | - Schalk Kok
- Department of Mechanical and Aeronautical Engineering, University of Pretoria, Pretoria 0002, South Africa
| | - Dylan Armfield
- Department of Mechanical and Aeronautical Engineering, University of Pretoria, Pretoria 0002, South Africa
| | - Mark Newby
- Eskom Holdings SOC Ltd., Johannesburg 2001, South Africa
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9
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Bogdan M, Zieliński W, Płociński T, Kurzydłowski KJ. Electron Microscopy Characterization of the High Temperature Degradation of the Aluminide Layer on Turbine Blades Made of a Nickel Superalloy. Materials (Basel) 2020; 13:ma13143240. [PMID: 32708221 PMCID: PMC7412071 DOI: 10.3390/ma13143240] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/05/2020] [Revised: 07/16/2020] [Accepted: 07/17/2020] [Indexed: 11/16/2022]
Abstract
The effects of exposure to overheating (temperature above 1000 °C) on the degradation (modification) of layers of coatings (coatings based on aluminum) of uncooled polycrystalline rotor blades of aircraft turbine jet engines were investigated under laboratory conditions. In order to determine the nature of the changes as well as the structural changes in the various zones, a multi-factor analysis of the layers of the coating, including the observation of the surface of the blades, using, among others, electron microscopy, structural tests, surface morphology, and chemical composition testing, was carried out. As a result of the possibility of strengthening the physical foundations of the non-destructive testing of blades, the undertaken research mainly focused on the characteristics of the changes occurring in the outermost layers of the coatings. The obtained results indicate the structural degradation of the coatings, particularly the unfavorable changes, become visible after heating to 1050 °C. The main, strongly interacting, negative phenomena include pore formation, external diffusion of Fe and Cr to the surface, and the formation and subsequent thickening of Fe-Cr particles on the surface of the alumina layer.
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Affiliation(s)
- Mariusz Bogdan
- Department of Mechanical Engineering, Bialystok Technical University, 45 Wiejska, 15333 Białystok, Poland;
- Correspondence:
| | - Witold Zieliński
- Faculty of Materials Science and Engineering, Warsaw University of Technology, Woloska 141, 02507 Warszawa, Poland; (W.Z.); (T.P.)
| | - Tomasz Płociński
- Faculty of Materials Science and Engineering, Warsaw University of Technology, Woloska 141, 02507 Warszawa, Poland; (W.Z.); (T.P.)
| | - Krzysztof Jan Kurzydłowski
- Department of Mechanical Engineering, Bialystok Technical University, 45 Wiejska, 15333 Białystok, Poland;
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10
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Bogdanowicz W, Krawczyk J, Paszkowski R, Sieniawski J. Primary Crystal Orientation of the Thin-Walled Area of Single-Crystalline Turbine Blade Airfoils. Materials (Basel) 2019; 12:ma12172699. [PMID: 31450755 PMCID: PMC6747559 DOI: 10.3390/ma12172699] [Citation(s) in RCA: 7] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 04/29/2019] [Revised: 08/19/2019] [Accepted: 08/20/2019] [Indexed: 11/16/2022]
Abstract
The thin-walled airfoil areas of as-cast single-crystalline turbine blades made of CMSX-4 superalloy were studied. The blades were produced by the industrial Bridgman technique at withdrawal rates of 2, 3 and 4 mm/min. The angle between the [001] crystallographic direction and blade axis, related to the primary orientation, was defined by the Ω-scan X-ray diffraction method at points on the camber line located near the tip of an airfoil and at points of a line located in parallel and near the trailing edge. Additionally, primary crystal orientation was determined by Laue diffraction at the selected points of an airfoil. The influence of mould wall inclination on the primary crystal orientation of the thin-walled areas is discussed. The effect of change in the [001] crystallographic direction, named as "force directing", was considered with regard to the arrangement of primary dendrite arms in relation to the trailing edge and the camber line. It was stated that when the distance between the mould walls is less than the critical value of about 1.5 mm the "force directing" increases as the distance between the walls of the mould decreases. The effect may be controlled by selecting an appropriate secondary orientation using a seed crystal in the blade production process. The model of dendrite interaction with the mould walls, including bending and "deflection", was proposed.
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Affiliation(s)
- Włodzimierz Bogdanowicz
- Institute of Materials Science, University of Silesia in Katowice, 1a 75 Pułku Piechoty St., 41-500 Chorzów, Poland
| | - Jacek Krawczyk
- Institute of Materials Science, University of Silesia in Katowice, 1a 75 Pułku Piechoty St., 41-500 Chorzów, Poland.
| | - Robert Paszkowski
- Institute of Materials Science, University of Silesia in Katowice, 1a 75 Pułku Piechoty St., 41-500 Chorzów, Poland
| | - Jan Sieniawski
- Department of Materials Science, Rzeszów University of Technology, 2 Wincentego Pola St., 35-959 Rzeszów, Poland
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11
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Zhao Z, Liu Z, Lyu Y, Gao Y. Experimental Investigation of High Temperature-Resistant Inductive Sensor for Blade Tip Clearance Measurement. Sensors (Basel) 2018; 19:s19010061. [PMID: 30586916 PMCID: PMC6338999 DOI: 10.3390/s19010061] [Citation(s) in RCA: 10] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/19/2018] [Revised: 12/19/2018] [Accepted: 12/20/2018] [Indexed: 11/24/2022]
Abstract
Turbine tip clearance of aero-engine is important to engine performance. Proper control of rotor tip clearance contributes to engine efficiency improvement and fuel consumption reduction. Therefore, accurate tip clearance measurement is essential. The inductive measurement method is one of the non-contact distance measurement methods, which has the characteristics of high sensitivity, fast response speed and strong anti-interference ability. Based on the principle of inductive sensor measuring tip clearance, the ambient temperature change will cause the material electromagnetic performance change for the conductivity and permeability varies with temperature. The calibration experiment was conducted to obtain the sensor resolution and sensing range. The effect of temperature on sensor parameters was extracted from high temperature experiment data. Results show the resolution of planar coil made of platinum wire can be 10 μm and the maximum sensing range can reach 5 mm. At temperature from 500 ℃ to 1100 ℃, coil inductance almost does not change with temperature while coil resistance varies exponentially with temperature, that means the coil inductance variation can reflect the tip clearance change and resistance can indicate the measuring temperature.
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Affiliation(s)
- Ziyu Zhao
- School of Power and Energy, Northwestern Polytechnical University, Youyi West Road 127#, Xi'an 710054, China.
| | - Zhenxia Liu
- School of Power and Energy, Northwestern Polytechnical University, Youyi West Road 127#, Xi'an 710054, China.
| | - Yaguo Lyu
- School of Power and Energy, Northwestern Polytechnical University, Youyi West Road 127#, Xi'an 710054, China.
| | - Yajun Gao
- School of Power and Energy, Northwestern Polytechnical University, Youyi West Road 127#, Xi'an 710054, China.
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Zhu SP, Yue P, Yu ZY, Wang Q. A Combined High and Low Cycle Fatigue Model for Life Prediction of Turbine Blades. Materials (Basel) 2017; 10:ma10070698. [PMID: 28773064 PMCID: PMC5551741 DOI: 10.3390/ma10070698] [Citation(s) in RCA: 64] [Impact Index Per Article: 9.1] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/02/2017] [Revised: 06/16/2017] [Accepted: 06/22/2017] [Indexed: 11/16/2022]
Abstract
Combined high and low cycle fatigue (CCF) generally induces the failure of aircraft gas turbine attachments. Based on the aero-engine load spectrum, accurate assessment of fatigue damage due to the interaction of high cycle fatigue (HCF) resulting from high frequency vibrations and low cycle fatigue (LCF) from ground-air-ground engine cycles is of critical importance for ensuring structural integrity of engine components, like turbine blades. In this paper, the influence of combined damage accumulation on the expected CCF life are investigated for turbine blades. The CCF behavior of a turbine blade is usually studied by testing with four load-controlled parameters, including high cycle stress amplitude and frequency, and low cycle stress amplitude and frequency. According to this, a new damage accumulation model is proposed based on Miner's rule to consider the coupled damage due to HCF-LCF interaction by introducing the four load parameters. Five experimental datasets of turbine blade alloys and turbine blades were introduced for model validation and comparison between the proposed Miner, Manson-Halford, and Trufyakov-Kovalchuk models. Results show that the proposed model provides more accurate predictions than others with lower mean and standard deviation values of model prediction errors.
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Affiliation(s)
- Shun-Peng Zhu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
- Key Laboratory of Deep Earth Science and Engineering, Ministry of Education, Sichuan University, Chengdu 610065, China.
| | - Peng Yue
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
| | - Zheng-Yong Yu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
| | - Qingyuan Wang
- Key Laboratory of Deep Earth Science and Engineering, Ministry of Education, Sichuan University, Chengdu 610065, China.
- School of Architecture and Civil Engineering, Chengdu University, Chengdu 610106, China.
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13
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Yu ZY, Zhu SP, Liu Q, Liu Y. A New Energy-Critical Plane Damage Parameter for Multiaxial Fatigue Life Prediction of Turbine Blades. Materials (Basel) 2017; 10:E513. [PMID: 28772873 PMCID: PMC5459052 DOI: 10.3390/ma10050513] [Citation(s) in RCA: 48] [Impact Index Per Article: 6.9] [Reference Citation Analysis] [What about the content of this article? (0)] [Affiliation(s)] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 03/22/2017] [Revised: 05/02/2017] [Accepted: 05/04/2017] [Indexed: 11/16/2022]
Abstract
As one of fracture critical components of an aircraft engine, accurate life prediction of a turbine blade to disk attachment is significant for ensuring the engine structural integrity and reliability. Fatigue failure of a turbine blade is often caused under multiaxial cyclic loadings at high temperatures. In this paper, considering different failure types, a new energy-critical plane damage parameter is proposed for multiaxial fatigue life prediction, and no extra fitted material constants will be needed for practical applications. Moreover, three multiaxial models with maximum damage parameters on the critical plane are evaluated under tension-compression and tension-torsion loadings. Experimental data of GH4169 under proportional and non-proportional fatigue loadings and a case study of a turbine disk-blade contact system are introduced for model validation. Results show that model predictions by Wang-Brown (WB) and Fatemi-Socie (FS) models with maximum damage parameters are conservative and acceptable. For the turbine disk-blade contact system, both of the proposed damage parameters and Smith-Watson-Topper (SWT) model show reasonably acceptable correlations with its field number of flight cycles. However, life estimations of the turbine blade reveal that the definition of the maximum damage parameter is not reasonable for the WB model but effective for both the FS and SWT models.
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Affiliation(s)
- Zheng-Yong Yu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
| | - Shun-Peng Zhu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
| | - Qiang Liu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
| | - Yunhan Liu
- Center for System Reliability & Safety, University of Electronic Science and Technology of China, Chengdu 611731, China.
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