Search Results (247)

The development of future electrical aircraft, such as the Hybrid-Electric Regional Aircraft (HERA) platform, presents challenging cooling demands due to the heat generated by electric powerplants, fuel cells and power electronics. Traditional heat exchangers in ram air channels may not be sufficient, necessitating alternative solutions like Skin Heat Exchangers (SHXs) to enhance heat transfer and reduce parasitic drag. Aircraft drag reduction and efficiency increase are expected with the integration of SHXs in two-phase cooling systems. This study employs Computational Fluid Dynamics (CFD) models, specifically the Volume of Fluid (VOF) multiphase model together with the Lee model, to simulate the condensation process of two Hydrofluoroolefin (HFO) refrigerants in SHX channels (R1233zd(E) and R1234yf). An analytical model based on empirical equations is used to preliminarily correlate and validate the CFD results, showing deviations below 15%. The simulations reveal distinct flow behaviours for each refrigerant, influenced by the differences in liquid and gas densities. The study also establishes a basis for understanding and selecting the inverse of the relaxation time coefficient, which is crucial for multiphase CFD modelling. The CFD models used in this article could be of great importance for future SHX design optimization. Full article

To improve coating adhesion and tribological stability on aircraft-grade aluminum, this work utilizes periodic fiber-laser microtexts as a surface-engineering pre-treatment before applying an epoxy primer. AA2024-T3 panels were imprinted with rhombus, hexagon, and circular lattices (scale factors 100–250 µm; scan speeds 250–750 mm s⁻¹), then primed with an aerospace epoxy primer and evaluated within reciprocating sliding wear tests. Areal profilometry and sessile-drop goniometry measured topography and wettability, whereas friction–distance traces and scratch-track metrology resolved interfacial integrity. The textures expanded surface area and modified energy states in a geometry- and scale-dependent fashion, producing stable friction plateaus and smaller, less-lateral scratch scars compared to the untextured reference. Circular dimples reliably provided the best damage-tolerant behavior, a function of improved mechanical interlocking and debris/film management (reservoir and micro-trap effects), whereas polygonal lattices evidenced greater sensitivity to both scale and speed. Factorial analyses disclosed prevalent interaction effects amongst geometry, scale, and scan speed, reinforcing the notion that performance arises from co-optimized texture architecture rather than a single parameter. In systemic terms, laser-defined microtexts complemented with aerospace-standard primers represent a controllable pathway to vary friction, dampen wear, and improve coating–substrate adhesion. These results provide practical selection guides; and a broad selection prefers larger, well-spaced circular dimples for best-in-class performance and a transferable framework for designing texture-coating systems across aerospace and allied manufacturing contexts. Full article

In the aerospace industry, thin-web gears are preferred for achieving high power-density transmission. However, thin-webbed structures always lead to out-of-plane resonance during the transmission process, which commonly happens in helical gears, manifesting as severe vibration at a specific rotational speed. To address this, a shaft–web–ring dynamic model is proposed. The shaft, gear web, and gear ring are modelled based on the Timoshenko straight beam, Mindlin plate, and Timoshenko bent beam theory. Simultaneously, the potential energy caused by the time-varying meshing stiffness is coupled to the gear ring. The kinetic and potential energies of each discretized finite element of the components are derived based on elastic deformation theory, and the governing equations of each element are obtained using Hamilton’s principle. The model is verified through a modal experiment. The comparison with traditional rotor-gear models has demonstrated the significance of gear body flexibility in helical gears with thin webs. The effects of the web thickness and helix angle on dynamic response are studied, revealing that gear web elasticity and an appropriately high helix angle can effectively reduce vibrations at the support bearing, prevent excessive vibrations, and contribute to vibration and noise reduction in the transmission system. Full article

As a core load-bearing component, the aero-engine rear cooling plate requires its design to simultaneously meet strength requirements and lightweight indicators. The topology optimization method considering stress constraints is the core technical path to achieve this goal, but it suffers from insufficient control precision in key areas, easily leading to material redundancy. To address this issue, a partitioned topology optimization method based on the multi-feature K-means algorithm is proposed. First, by integrating multi-dimensional features including element stress, physical density, and spatial position, an innovative multi-feature K-means algorithm is employed to realize dynamic adaptive partitioning during the optimization process. Secondly, combined with the p-norm method for partitioned stress aggregation, a precise prediction and control method for partitioned stress is adopted to refine stress constraints. Thirdly, a topology optimization model of the rear cooling plate with multi-feature partitioned stress constraints is constructed, and the adjoint method is used to solve the stress sensitivities under centrifugal loads. Finally, the effectiveness of the proposed method is verified using the rear cooling plate model. The rear cooling plate is discretized with 0.5 mm 2D axisymmetric finite elements, the filter radius is 4 mm, and the Method of Moving Asymptotes (MMA) is employed for the solution. The mass fraction of the finally optimized rear cooling plate structure is 0.157, which is 13.7% lower than that obtained by the global stress constraint method and 11.3% lower than that obtained by the topology optimization method considering both the geometric partitioned stress constraints and global stress constraints. The proposed method provides a new approach for the lightweight design of the aero-engine rear cooling plate. Full article

Accurate prediction and optimization of assembly accuracy are critical to ensuring assembly quality and efficiency for multistage connected aero-engine rotors. To mitigate the effects of residual alignment errors induced by repeated component measurements and to avoid the formation of bowed rotors caused by conventional stacking strategies that only minimize parallel misalignment, a harmonic decomposition-based registration method is proposed to unify inconsistent measurement datums among multiple setups. Meanwhile, key assembly process parameters are considered simultaneously, including front-and-rear support concentricity, front-and-rear bearing mounting face end-face runout, rotor blade-tip runout, and rotor unbalance. Taking the discrete assembly phase angles of each rotor stage as independent variables, a multi-objective genetic algorithm is adopted to realize the assembly accuracy prediction and optimization of multistage flange-bolted rotors. The proposed method is validated using a four-stage simulated rotor assembly. Experimental results show that the harmonic decomposition-based registration method improves the average geometric prediction accuracy of rotor assembly by 1.2 percentage points, with the prediction error of geometric assembly parameters for each stage not exceeding 8.4% and the unbalance prediction error not exceeding 29.0%. Compared with random assembly, four-objective comprehensive optimization achieves significant reductions in all objectives: front-and-rear support concentricity is reduced by 66.2%, front-and-rear support shoulder end-face runout by 63.9%, blade-tip runout by 16.7%, and unbalance by 33.8%. The residual alignment error compensation method and stacking optimization strategy proposed in this study provide valuable engineering guidance for improving rotor assembly prediction accuracy and enhancing assembly reliability. Full article

The article documents the cause of a sharp decrease in the fracture toughness of HR3C austenitic steel intended for heat exchange surfaces of supercritical energy blocks during its exposure to elevated temperature. The documentation of the cause of the decrease in fracture toughness is based on a combination of fractographic observation of the fracture surfaces of the tested samples, linked through ongoing precipitation changes in the steel to the fracture toughness of the steel. The result is a description of the decrease in fracture toughness in relation to the Larson–Miller parameter and subsequently the change in fracture toughness in relation to the precipitation changes in HR3C steel. This dependence provides a tool for numerical calculations and simulations of heat exchange surfaces of power plants made of HR3C steel and the simulation of their behavior when cracks are present. Full article

The service environment of the turbine blade–disk dovetail joint structure in aero-engines is complex. Uncertainties in material properties and geometry, as well as the failure correlations among multiple locations or components, make reliability assessment challenging. First, a probabilistic life modeling method based on linear heteroscedastic regression is proposed, and the Manson–Coffin probabilistic life models of DD6 and FGH96 alloys at 650 °C are established. Then, the Copula function is introduced to characterize the failure dependence structure, and the effectiveness of the method is verified through numerical examples. Fatigue-critical locations of the dovetail are identified, and a Kriging surrogate model is established to obtain the probabilistic stress distribution at the critical locations. Subsequently, the Copula method is employed to conduct reliability analysis of dovetail structures. The results show that the reliability of multiple dovetails considering correlation lies between that of a single dovetail and that under the assumption of complete independence. Moreover, the life of the entire disk dovetail structure is significantly influenced by the number of dovetails and the required reliability level. Finally, the study is extended to the blade–disk dovetail multi-component system. The results indicate that when correlation is considered, the reliability of both components decreases, and the overall structural life is dominated by the dovetail component with the lower life. The analytical method proposed in this paper provides theoretical support and engineering reference for the reliability design and life assessment of aero-engine rotor structures. Full article

Wire and arc additive manufacturing (WAAM) offers high deposition efficiency for large-scale aluminum components; however, layer-by-layer thermal cycling often induces microstructural anisotropy and spatial heterogeneity, which compromise structural reliability. In this study, an ultrasonic-based quantitative framework is proposed to evaluate and optimize anisotropy and heterogeneity in WAAM 2319 aluminum alloy. Nine blocks were fabricated using an orthogonal design with three key process parameters: torch travel speed, arc current, and shielding gas flow rate. Ultrasonic velocity and attenuation were employed to construct anisotropy and heterogeneity indicators. Results show that velocity-based anisotropy remains below 0.53%, indicating nearly isotropic elastic stiffness, whereas attenuation-based anisotropy reaches up to 76%, revealing pronounced direction-dependent microstructural and porosity features. Metallographic analysis confirms that grain morphology variation and interlayer porosity jointly govern attenuation responses. Response surface surrogate models were established to correlate ultrasonic indicators with process parameters, and both single- and multi-objective optimizations were performed within the feasible process window. The proposed framework provides a non-destructive, volumetric approach for microstructure-informed process parameter optimization in WAAM aluminum alloys. Full article

This study presents a rational inverse inference framework for k-out-of-n systems that derives component-level reliability characteristics from system-level failure and monitoring data. The framework employs a hazard-rate matrix to represent the degradation hierarchy and applies the principle of maximum entropy to allocate system-level probabilities to latent component-state configurations without bias, yielding analytical solutions for component hazard rates. The key innovation lies in combining maximum entropy with the hazard-rate matrix, which overcomes the ill-posed nature of the inverse problem and enables systematic integration of heterogeneous auxiliary information within a unified formulation, including system-level multi-state observations, component-wise moment constraints, sub-component data, and inter-component dependencies. This flexibility addresses a major limitation of existing inverse methods, such as Bayesian approaches, which are typically restricted to a single data type and often require strong prior assumptions or extensive failure datasets. The practical applicability of the framework is demonstrated through a case study of a west-to-east gas pipeline pumping system, highlighting its effectiveness in processing multiple information types and delivering actionable component-level reliability assessments for maintenance decision support. To the best of our knowledge, this is the first study to formulate and solve the inverse inference problem for k-out-of-n systems in a theoretically grounded and information-theoretically optimal manner. Full article

This study investigates the stiffness characteristics of elastic ring supports and the dynamic response of aero-engine rotor systems. First, comparative analysis demonstrates that the finite element model provides higher accuracy in predicting the stiffness of the elastic ring compared to traditional analytical methods, with the experimental error controlled within 5%. Grid independence verification further reveals that the mesh density in the boss region is a critical factor determining the accuracy of stiffness calculations. On this basis, the influence mechanism of contact states on stiffness characteristics was deeply explored; it was found that the transition between frictional and bonded contact states can lead to a stiffness deviation of up to 46.8%. Furthermore, quantitative analysis of manufacturing tolerances indicates that the thickness deviation of the boss should be strictly controlled within 0.02 mm to ensure the stability of support performance. Finally, a dynamic model of the rotor system developed using two-dimensional beam elements was fully validated against experimental data, with a calculation error of only 2%. The results of this study provide an important reference for the precise design and stiffness evaluation of elastic ring supports, as well as the engineering testing of rotor system dynamic characteristics. Full article

This study investigates how torch standoff distance influences the microstructure, surface topography, and progressive-load scratch response of air plasma-sprayed 8YSZ and rare-earth co-doped GdYbYSZ thermal barrier coatings on an St-52 grade carbon steel substrate. Three nozzle-to-substrate spraying distances were examined: 80, 100, and 120 mm. X-ray diffraction revealed that the 8YSZ coatings possessed a predominantly tetragonal (t′) structure, with minor monoclinic fractions detected in the coatings obtained with the 80 mm and 100 mm distance parameters. The GdYbYSZ coatings, in contrast, exhibited a single-phase cubic defect-fluorite structure; their diffraction peaks appeared at lower 2θ angles relative to undoped cubic ZrO₂, consistent with lattice expansion caused by the substitution of Zr⁴⁺ by the larger Gd³⁺ and Yb³⁺ cations. Surface topography was quantified by non-contact laser profilometry, providing areal (Sa) and profile (Ra) roughness parameters for the as-sprayed condition as well as three-dimensional scratch-damage morphology after testing. Progressive-load scratch tests were performed using a Rockwell diamond indenter over a 2 mm track with the normal load ramped from 0.03 N to 30 N. Penetration depth, residual depth, tangential force, and acoustic emission were recorded continuously to identify critical damage transitions. Across all spraying distances, 8YSZ exhibited systematically shallower scratch grooves than GdYbYSZ; end-of-track maximum groove depths remained below 37 µm for 8YSZ, whereas GdYbYSZ reached up to 72 µm under identical loading conditions. The novelty of this study lies in combining torch standoff distance as a processing variable with multi-channel progressive-load scratch diagnostics, including in situ acoustic emission, depth profiling, and friction monitoring, to comparatively assess the scratch wear performance of 8YSZ and rare-earth co-doped zirconia TBCs for the first time. Full article

As a critical core component in the STOVL aircrafts, the dynamic and thermal performance of the aviation dry clutch directly determines the reliability of power transmission and the precision control, especially in high relative speed engagement and high power density conditions. Accordingly, this study proposes a 4-DOF dynamic model considering the time-varying of friction coefficient and nonlinear load characteristics, integrated with a transient thermal model incorporating the time-varying thermal parameters. The effects of pressure loading strategies and rotation speed on the dynamic and transient thermal responses are systematically analyzed. Furthermore, a novel temperature uniformity coefficient is developed to characterize the temperature field distribution. The results indicate that the pressure loading strategy fundamentally dictates the trade-off between engagement smoothness and thermal performance. Specifically, compared with other loading strategies, the linear loading strategy yields the most uniform thermal field ($U_{Tz}=0.4361$, $U_{Tr}=0.3971$) and the engagement smoothness ($J_{er}=2.353\times {10}^5{\mathrm{rad}·\mathrm{s}}^{-3}$) but increases sliding friction work (163.67 kJ). As rotation speed increases from 1500 r/min to 6000 r/min, the sliding friction work increases from 8.85 kJ to 163.67 kJ. Concurrently, the peak values of temperature, axial temperature gradient and axial temperature uniformity coefficient reach 116.557 °C, 80.622 °C and 0.4361, respectively. Consequently, an appropriate reduction in rotation speed combined with the adoption of linear loading strategy can not only facilitate the smoothness and friction loss reduction but also achieve a more uniform temperature distribution. These findings are not only essential for optimizing the thermal management and structural design of aviation dry clutches but also establish a quantitative basis for optimizing engagement strategies. Full article

This study presents a predictive method for the fatigue behavior of Ti-6Al-4V based on a crystal plasticity finite element (CPFE) model. A thermally activated constitutive model is calibrated using experimental cyclic stress–strain data. The calibrated model simulates the macroscopic cyclic response and grain-scale deformation heterogeneity. By analyzing the simulated micromechanical fields, a scalar fatigue indicator parameter (FIP) is defined based on the accumulated inelastic work. The predictive capability of this FIP is validated against experimental data at multiple stress levels, demonstrating its effectiveness for microstructure-sensitive fatigue assessment. Full article

High-power clutches operating under high-frequency engagement–disengagement cycles demand piston ring seals with exceptional leakage control and tribological reliability. Conventional architectures often experience lubrication failure and severe adhesive wear during transient pressure fluctuations. This research proposes an autonomous intelligent sealing strategy leveraging fluid pressure-induced morphological evolution. By strategically integrating periodic macroscopic structural relief features on the non-sealing surface, the sealing interface transforms into a micron-scale wavy topography in response to hydraulic loading. This structurally embedded intelligence significantly improves fluid pressure distribution, facilitating a transition toward a more favorable lubrication regime. Furthermore, a “self-healing and positional stagnation” logic is elucidated: upon pressure dissipation, the induced waviness elastically recovers to a planar state to ensure sealing integrity, while the ring maintains its axial position due to the predominant frictional resistance of the secondary seal. This synergistic mechanism effectively precludes deleterious dry friction during the clutch disengagement phase. High-fidelity numerical investigations, benchmarked against established experimental data, identify the rectangular groove configuration as the optimal geometry for maximizing waviness amplitude (≈1.5 µm). This research provides a robust framework for developing responsive, zero-wear intelligent seals in advanced power transmissions. Full article

As a critical aerospace structural material, the fatigue crack propagation behavior and fatigue life of the nickel-based GH4169 superalloy are directly related to the service safety of engineering components. The crack closure effect is one of the key factors influencing the fatigue life of metallic materials. At present, the finite element method (FEM) is widely used to investigate fatigue crack propagation in metals. However, the commercial software ABAQUS 2021b employs the conventional Paris law for crack growth simulation, which neglects the influence of crack closure. In addition, ABAQUS cannot simultaneously perform fatigue life prediction and crack path prediction within a single numerical model. To overcome these limitations, the bi-prism-based single-lens (BSL) three-dimensional digital image correlation (3D DIC) technique was employed to experimentally investigate the crack closure behavior during fatigue crack propagation in GH4169 compact tension (CT) specimens. A new parameter, termed the crack opening ratio (COR), was introduced to quantitatively characterize the crack closure effect. Furthermore, a self-developed plugin was implemented on the ABAQUS platform through secondary development, enabling the numerical model to incorporate the influence of crack closure during fatigue crack propagation. The plugin automatically records the crack tip coordinates at each propagation step, calculates the stress intensity factors near the crack tip, and predicts the corresponding fatigue life, thereby integrating crack path prediction and fatigue life prediction within a unified framework. The results demonstrate that the COR effectively characterizes the crack closure effect in the numerical model, and the predicted fatigue life agrees with experimental results within an 11% deviation once the crack reaches a certain length. Full article