Search Results (124)

During hypersonic flight, the air rudder shaft can undergo huge aerodynamic heating load, where it is necessary to design the thermal protection system of the air rudder shaft. Aiming to prevent the rudder shaft from thermal failure due to the heat endurance limit of materials, numerical investigations are conducted systemically to predict the active cooling performance of the rudder shaft with liquid water considering phase change. The validation of the numerical simulation method considering phase-change heat transfer is further investigated by experiments. The effect of coolant injection flow velocity on the active cooling performance is further analyzed for both the steady state and transient state. Finally, to achieve better cooling performance, an optimized design of the cooling channels is performed in this work. The results of the transient numerical simulation show that, employing the initial cooling structures, it may undergo the heat transfer deterioration phenomenon under the coolant injection velocity below 0.2 m/s. For the rudder shaft with an optimized structure, the heat transfer deterioration can be significantly reduced, which significantly reduces the risk of thermal failure. Moreover, the total pressure drop of the optimized rudder shaft under the same coolant injection condition can be reduced by about 19% compared with the initial structure. This study provides a valuable contribution to the thermal protection performance for the rudder shaft, as a key component of aircraft under the aero heating process. Full article

To analyze the wear performance induced by rotor–stator rubbing in an aero-engine sealing structure under authentic operating conditions, a transonic rotor system with double bearing is constructed. This system incorporates the disk, shaft, blades, joint bolts, and auxiliary support structure. The system was evaluated in terms of its critical speed, vibration characteristics, component strength under operational conditions, and response characteristics in abnormal extreme scenarios. A ball screw-type feeding system is employed to achieve precise rotor–stator rubbing during rotation by controlling the coating feed. Additionally, a quartz lamp heating system is used to apply thermal loads to coating specimens, and the appropriate heat insulation and cooling measures are implemented. Furthermore, a high-frequency rubbing force test platform is developed to capture the key characteristics caused by rubbing. The test rig can conduct response tests of the system with rotor–stator rubbing and abrasion tests with tip speeds reaching 425 m/s, feed rates ranging from 2 to 2000 μm/s, and heating temperatures up to 1200 °C. Test debugging has confirmed these specifications and successfully executed rubbing tests, which demonstrate stability throughout the process and provide reliable rubbing force test results. This designed test rig and analysis methodology offers valuable insights for developing high-speed rotating machinery. Full article

This study examines the labyrinth seal disc of an aero-engine, specifically analysing the radial deformation caused by centrifugal force and heat stress during operation. This distortion may lead to discrepancies in the performance attributes of the labyrinth seal and could potentially result in contact between the labyrinth seal tip and neighbouring components. A numerical analytical model incorporating the rotor and stator cavities, along with the labyrinth seal disc structure, has been established. The sealing integrity of a standard labyrinth seal disc’s flow channel is evaluated and studied at different clearances utilising the fluid–solid-thermal coupling method. The findings demonstrate that, after considering radial deformation, a cold gap of 0.5 mm in the conventional labyrinth structure leads to stabilisation of the final hot gap and flow rate, with no occurrence of tooth tip rubbing; however, both the gap value and flow rate show considerable variation relative to the cold state. When the cold gap is 0.3 mm, the labyrinth plate makes contact with the stator wall. To resolve the problem of tooth tip abrasion in the conventional design with a 0.3 mm cold gap, two improved configurations are proposed, and a stability study for each configuration is performed independently. The leakage and temperature rise attributes of the two upgraded configurations are markedly inferior to those of the classic configuration at a cold gap of 0.5 mm. At a cold gap of 0.3 mm, the two improved designs demonstrate no instances of tooth tip rubbing. Full article

In recent times, blades that have the ability to change shape passively or actively have garnered interest due to their ability to optimize blade performance for varying flow conditions. Various versions of morphing exist, from simple chord length changes to full blade morphing with multiple degrees of freedom. These blades can incorporate smart materials or mechanical actuators to modify the blade shape to suit the wind conditions. Morphing blades have shown an ability to improve performance in simulations. These simulations show increased performance in Region 2 (partial load) operating conditions. This study focuses on the effects of the wake for a flexible wind turbine with actively variable twist angle distribution (TAD) to improve the energy production capabilities of morphing structures. These wake effects influence wind farm performance for locally clustered turbines by extracting energy from the free stream. Hence, the development of better wake models is critical for better turbine design and controls. This paper provides an outline of some approaches available for wake modeling. FLORIS (FLow Redirection and Induction Steady-State) is a program used to predict steady-state wake characteristics. Alongside that, the Materials and Methods section shows different modeling environments and their possible integration into FLORIS. The Results and Discussion section analyzes the 20 kW wind turbine with previously acquired data from the National Renewable Energy Laboratory’s (NREL) AeroDyn v13 software. The study employs FLORIS to simulate steady-state non-linear wake interactions for the nine TAD shapes. These TAD shapes are evaluated across Region 2 operating conditions. The previous study used a genetic algorithm to obtain nine TAD shapes that maximized aerodynamic efficiency in Region 2. The Results and Discussion section compares these TAD shapes to the original blade design regarding the wake characteristics. The project aims to enhance the understanding of FLORIS for studying wake characteristics for morphing blades. Full article

Accurate fault diagnosis in aerospace transmission systems is essential for ensuring equipment reliability and operational safety, especially for aero-engine bearings. However, current approaches relying on Convolutional Neural Networks (CNNs) for Euclidean data and Graph Convolutional Networks (GCNs) for non-Euclidean structures struggle to simultaneously capture heterogeneous data properties and complex spatio-temporal dependencies. To address these limitations, we propose a novel Spatial–Temporal Hypergraph Fault Diagnosis framework (STHFD). Unlike conventional graphs that model pairwise relations, STHFD employs hypergraphs to represent high-order spatial–temporal correlations more effectively. Specifically, it constructs distinct spatial and temporal hyperedges to capture multi-scale relationships among fault signals. A type-aware hypergraph learning strategy is then applied to encode these correlations into discriminative embeddings. Extensive experiments on aerospace fault datasets demonstrate that STHFD achieves superior classification performance compared to state-of-the-art diagnostic models, highlighting its potential for enhancing intelligent fault detection in complex aerospace systems. Full article

This paper details the development of a full turbine model and ensuing aero-servo-elastic analysis of the International Energy Agency’s 15MW Reference Wind Turbine. This model provides the means to obtain realistic turbine performance data, of which normal and tangential blade loads are extracted and applied to a simplified drivetrain model developed expressly to quantify the shaft eccentricities caused by aerodynamic loading, thus determining the impact of aerodynamic loading on the generator structure. During this process, a method to determine main bearing stiffness values is presented, and values for the IEA-15MW-RWT obtained. It was found that wind speeds in the region of turbine cut-out induce shaft eccentricities as high as 56%, and that tangential loading has a significant contribution to shaft eccentricities, increasing deflection at the generator area by as much as 106% at high windspeeds, necessitating its inclusion. During a subsequent generator structure optimisation, the shaft eccentricities caused by the loading scenarios examined in this paper were found to increase the necessary mass of the rotor structure by 40%, to meet the reduced airgap clearance. Full article

In this study, an optimization framework for turbomachinery blades using a hybrid surrogate model assisted by proper orthogonal decomposition (POD) is introduced and then applied to the aero-structural multidisciplinary design optimization of a transonic fan rotor, NASA Rotor 67. The rotor blade is optimized through blade sweeping controlled by Gaussian radial basis functions. Calculations of aerodynamic and structural performance are achieved through computational fluid dynamics and computational structural mechanics. With a number of performance snapshots, singular value decomposition is employed to extract the basis modes, which are then used as the kernel functions in training the POD-based hybrid model. The inverse multi-quadratic radial basis function is adopted to construct the response surfaces for the coefficients of kernel functions. Aerodynamic design optimization is first investigated to preliminarily explore the impact of blade sweeping. In the aero-structural optimization, the aerodynamic performance, and von Mises stress are considered equally important and incorporated into one single objective function with different weight coefficients. The results are given and compared in detail, demonstrating that the average stress is dependent on the aerodynamic loading, and the configuration with forward sweeping on inner spans and backward sweeping on outer spans is the most effective for increasing the adiabatic efficiency while decreasing the average stress when the total pressure ratio is constrained. Through this study, the optimization framework is validated and a practical configuration for reducing the stress in a transonic fan rotor is provided. Full article

The module division scheme of commercial aircraft and other complex system products has a significant impact on the functionality, performance, and cost of the aircraft. To obtain scientifically rational modular division solutions for commercial aircraft, this study establishes an Analytic Hierarchy Process–Gray Fuzzy Comprehensive Evaluation (AHP-GFCE) model by integrating hierarchical analysis method and gray fuzzy evaluation theory. This model develops a comprehensive evaluation methodology for aircraft modular division schemes. The proposed method was applied to evaluate the structural modular division scheme of the nose structure section of a certain type of aircraft. Results demonstrate that the AHP-GFCE model successfully identified the optimal nose structure modular division scheme. Compared with traditional installation processes, this optimal solution achieves a 40% improvement in overall assembly efficiency and a 25% reduction in total production cycle duration while better aligning with the engineering and manufacturing requirements of nose structure fabrication, thus revealing the superiority of the AHP-GFCE model in modular division evaluation. This research provides novel insights for modular division schemes of complex system products like commercial aircraft, and the methodology can be extended to modular maintenance domains of sophisticated products such as aero-engines. Although there remains room for model refinement, the findings carry significant theoretical and practical implications for modular division of complex system products. Full article

Heat pipes are highly efficient heat transfer devices relying on phase-change mechanisms, with performance heavily influenced by working fluids and operational dynamics. This review article comprehensively examines hydrodynamics and heat transfer in heat pipes, contrasting conventional working fluids with nanofluid-enhanced systems. In the present work we discuss mathematical models governing fluid flow and heat transfer, emphasizing continuum and porous media approaches for wick structures. Functional dependencies of thermophysical properties (e.g., viscosity, surface tension, thermal conductivity) are reviewed, highlighting temperature-driven correlations and nanofluid modifications. Transport mechanisms within wicks are analyzed, addressing capillary-driven flow, permeability, and challenges posed by nanoparticle integration. Fourth, interfacial phase-change conditions—evaporation and condensation—are modeled, focusing on kinetic theory and empirical correlations. Also, numerical and experimental results are synthesized to quantify performance enhancements from nanofluids, including thermal resistance reduction and capillary limit extension, while addressing inconsistencies in stability and pressure drop trade-offs. Finally, applications spanning electronics cooling, aero-space, and renewable energy systems are evaluated, underscoring nanofluids’ potential to expand heat pipe usability in extreme environments. The review identifies critical gaps, such as long-term nanoparticle stability and scalability of lab-scale models, while advocating for unified frameworks to optimize nanofluid selection and wick design. This work serves as a foundational reference for researchers and engineers aiming to advance heat pipe technology through nanofluid integration, balancing theoretical rigor with practical feasibility. Full article

Single-crystal superalloys have attracted considerable interest in aero engine blade manufacture due to their superior mechanical properties, which maintain structural integrity at high temperatures. However, their anisotropic microstructure results in direction-dependent properties that pose a challenge for defect detection. This study proposes a methodology to determine the crystal orientation, which is subsequently used to improve the Total Focusing Method (TFM) by incorporating the refracted beam directivity. Firstly, simulations were performed using semi-analytical models (CIVA software 2023 SP4.1) to reproduce different grain orientations. The results were then post-processed to determine the grain orientation. Finally, the TFM was adapted to take into account not only the velocity variations due to orientation but also the directivity of the ultrasonic beam based only on slowness curves. The implementation of this methodology has improved the defect detection capability, optimizing the defect positioning by up to 61% and increasing the signal-to-noise ratio by up to 5 dB. This study demonstrates the effectiveness of an adapted inspection procedure for single crystals. Full article

In recent decades, the application of composite materials in aerostructures has significantly increased, with modern commercial aircraft progressively replacing aluminum alloys with composite components. This shift is exemplified by comparing the material compositions of the Boeing 777 and the Boeing 787 (Dreamliner). The Boeing 777 incorporates approximately 50% aluminum alloy and 12% composite materials, whereas the Dreamliner reverses this ratio, utilizing around 50% composites and 12% aluminum alloy. While metals remain advantageous due to their availability and ease of machining, composites offer greater potential for property tailoring to meet specific performance requirements. They also provide superior strength-to-weight ratios and enhanced resistance to corrosion and fatigue. To ensure the reliability of composites in aerospace applications, comprehensive testing under various loading conditions, particularly impact, is essential. Impacts were performed on quasi-isotropic (QIT) carbon-fiber reinforced epoxy panels with stainless steel, round-nosed and flat-ended impactors with rubber discs of 1-, 1.5- and 2 mm thickness, adhered to the flat-ended impactor to simulate the transition between hard and soft impact loading conditions. QIT composite panels were tested in this research employing similar lay-ups often being implemented in aircraft wings and other structures. The rubber discs were applied in the flat-ended impactor case but not for the round-nosed impactor due to the limited adhesion between the rubber and the rounded stainless-steel surface. Impact energies of 7.5, 15 and 30 J were investigated, and the performance of the panels was evaluated using force-time and force-displacement data alongside post-impact ultrasonic C-scan imaging to assess the damaged area. Damage was observed at all three energy values for the round-nosed impacts but only at the highest impact energy when using the flat-ended impactor, leading to the hardness study with adhered rubber discs being performed at 30 J. The most noticeable difference with the addition of rubber discs was the reduction in the damage in the plies nearest the top (impacted) surface. This suggests that the rubber reduces the severity of the impact, but increasing the thickness of the rubber from 1 to 2 mm does not notably increase this effect. Indentation clearly plays a significant role in promoting delamination at low-impact energies for the round-nosed impactors. Full article

With the advancement of aero-engine thrust-to-weight ratios, turbine blades now incorporate complex hollow structures fabricated using ceramic cores. The emergence of light-curing 3D printing technology for ceramic cores offers a viable solution to producing such complex structural components. To avoid the breakage of the core when removing the support after the printing of the general paste, we used a rheological additive, organic bentonite, to prepare a light-curing 3D-printed silicon-based ceramic core paste that can allow for unsupported printing. This study pursues two primary research objectives: Firstly, the effect of organic bentonite on the rheological behavior and stability properties of silicon-based ceramic was investigated. Secondly, we conducted a comprehensive analysis of how organic bentonite modification influences the performance of silicon-based ceramics. The results show that, firstly, the addition of organic bentonite dramatically improves the rheology and stability of silicon-based ceramic paste, and that the optimal content is between 1 and 2 wt.% for the best effect. Second, after the primary sintering process (1250 °C), partial bentonite can produce a small amount of cordierite phase and promote the generation of cristobalite. The room-temperature performance of the ceramic core can be improved. However, organic bentonite, after secondary sintering at 1550 °C, completely forms cordierite and reduces the amount of square quartz produced. Then, it negatively affects the high-temperature performance of the ceramic core. Therefore, when the content of organic bentonite is 1 wt.%, the ceramic paste has superior rheology and stability, making unsupported printing possible. Our study revealed an apparent porosity of 32.43%, a bulk density of 1.64 g/cm³, a sintering shrinkage value of 2.94%, a room-temperature flexural strength of 24.7 MPa, a high-temperature (1550 °C) flexural strength of 10.1 MPa and a high-temperature deflection of 1.24 mm, which meet the requirements of core printing. Full article

Elastic rings are extensively utilized in aero-engine rotor systems owing to their compact size and ease of assembly, where they play a critical role in vibration suppression during engine operation. The dynamic behavior of elastic rings is governed by their structural parameters, with stiffness being a pivotal factor influencing the rotor system’s performance. This study employs finite element methods to investigate the effects of elastic ring structural parameters, particularly the geometric features of bosses and internal/external assembly clearances, on stiffness nonlinearity, with a focus on its mechanisms and contributing factors. The results reveal that stiffness nonlinearity emerges when the whirling radius exceeds a critical threshold. Specifically, increasing the boss width, reducing the boss height, or augmenting the number of bosses all attenuate stiffness nonlinearity under identical whirling radii. Furthermore, external clearances exhibit a stronger capability to suppress stiffness nonlinearity compared to internal clearances. Engineering insights suggest that maintaining a small clearance fit during assembly effectively mitigates stiffness nonlinearity, thereby enhancing the rotor’s dynamic performance. This study elucidates the stiffness nonlinearity behavior of elastic rings in practical applications and provides actionable guidance for their design and operational optimization in rotor systems. Full article

Aiming at the overfitting problem caused by the limited sample size in the spectral classification of aero-engine hot jets, this paper proposed a synthetic spectral enhancement classification network FTIR-SpectralGAN for the FT-IR of aeroengine hot jets. Firstly, passive telemetry FTIR spectrometers were used to measure the hot jet spectrum data of six types of aero-engines, and a spectral classification dataset was created. Then, a spectral classification network FTIR-SpectralGAN was designed, which consists of a generator and a discriminator. The generator architecture comprises six Conv1DTranspose layers, with five of these layers integrated with BN and LeakyReLU layers to introduce noise injection. This design enhances the generation capability for complex patterns and facilitates the transformation from noise to high-dimensional data. The discriminator employs a multi-task dual-output structure, consisting of three Conv1D layers combined with LeakyReLU and Dropout techniques. This configuration progressively reduces feature dimensions and mitigates overfitting. During training, the generator learns the underlying distribution of spectral data, while the discriminator distinguishes between real and synthetic data and performs spectral classification. The dataset was randomly partitioned into training, validation, and test sets in an 8:1:1 ratio. For training strategy, an unbalanced alternating training approach was adopted, where the generator is trained first, followed by the discriminator and then the generator again. Additionally, weighted mixed loss and label smoothing strategies were introduced to enhance network training performance. Experimental results demonstrate that the spectral classification accuracy reaches up to 99%, effectively addressing the overfitting issue commonly encountered in CNN-based classification tasks with limited samples. Comparative experiments show that FTIR-SpectralGAN outperforms classical data augmentation methods and CVAE-based synthetic data enhancement approaches. It also achieves higher robustness and classification accuracy compared to other spectral classification methods. Full article

Addressing the challenge of acquiring depth information in aero-engine assembly scenes using monocular vision, which complicates mixed reality (MR) virtual and real occlusion processing, we propose an ORB-SLAM3-based monocular vision assembly scene virtual and real occlusion processing method. The method proposes optimizing ORB-SLAM3 for matching and depth point reconstruction using the MNSTF algorithm. MNSTF can solve the problems of feature point extraction and matching in weakly textured and texture-less scenes by expressing the structure and texture information of the local images. It is then proposed to densify the sparse depth map using the double-three interpolation method, and the complete depth map of the real scene is created by combining the 3D model depth information in the process model. Finally, by comparing the depth values of each pixel point in the real and virtual scene depth maps, the virtual occlusion relationship of the assembly scene is correctly displayed. Experimental validation was performed with an aero-engine piping connector assembly scenario and by comparing it with Holynski’s and Kinect’s methods. The results showed that in terms of virtual and real occlusion accuracy, the average improvement was 2.2 and 3.4 pixel points, respectively. In terms of real-time performance, the real-time frame rate of this paper’s method can reach 42.4 FPS, an improvement of 77.4% and 87.6%, respectively. This shows that the method in this paper has good performance in terms of the accuracy and timeliness of virtual and real occlusion. This study further demonstrates that the proposed method can effectively address the challenges of virtual and real occlusion processing in monocular vision within the context of mixed reality-assisted assembly processes. Full article