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Frontiers of Mechanical Engineering

Front. Mech. Eng.
REVIEW ARTICLE
Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review
Haiyang LU1,2,3, Yanle LI1,2,3(), Fangyi LI1,2,3(), Xingyi ZHANG1,2,3, Chuanwei ZHANG1,2,3, Jiyu DU1,2,3, Zhen LI1,2,3, Xueju RAN1,2,3, Jianfeng LI2,3,4, Weiqiang WANG1
1. School of Mechanical Engineering, Shandong University, Jinan 250061, China
2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan 250061, China
3. Key Laboratory of High Efficiency and Clean Mechanical Manufacture, Ministry of Education, Shandong University, Jinan 250061, China
4. Engineering Training Center, Shandong University, Jinan 250002, China
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Abstract

The theoretical and technological achievements in the damage mechanism and evaluation model obtained through the national basic research program “Key Fundamental Scientific Problems on Mechanical Equipment Remanufacturing” are reviewed in this work. Large centrifugal compressor impeller blanks were used as the study object. The materials of the blanks were FV520B and KMN. The mechanism and evaluation model of ultra-high cycle fatigue, erosion wear, and corrosion damage were studied via theoretical calculation, finite element simulation, and experimentation. For ultra-high cycle fatigue damage, the characteristics of ultra-high cycle fatigue of the impeller material were clarified, and prediction models of ultra-high cycle fatigue strength were established. A residual life evaluation technique based on the “b-HV-N” (where b was the nonlinear parameter, HV was the Vickers hardness, and N was the fatigue life) double criterion method was proposed. For erosion wear, the flow field of gas-solid two-phase flow inside the impeller was simulated, and the erosion wear law was clarified. Two models for erosion rate and erosion depth calculation were established. For corrosion damage, the electrochemical and stress corrosion behaviors of the impeller material and welded joints in H2S/CO2 environment were investigated. KISCC (critical stress intensity factor) and da/dt (crack growth rate, where a is the total crack length and t is time) varied with H2S concentration and temperature, and their variation laws were revealed. Through this research, the key scientific problems of the damage behavior and mechanism of remanufacturing objects in the multi-strength field and cross-scale were solved. The findings provide theoretical and evaluation model support for the analysis and evaluation of large centrifugal compressor impellers before remanufacturing.

Keywords remanufacturing      centrifugal compressor impeller      remanufacturing blank      damage mechanism      evaluation model     
Corresponding Authors: Yanle LI,Fangyi LI   
Just Accepted Date: 16 July 2019   Online First Date: 30 August 2019   
 Cite this article:   
Haiyang LU,Yanle LI,Fangyi LI, et al. Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review[J]. Front. Mech. Eng., 30 August 2019. [Epub ahead of print] doi: 10.1007/s11465-019-0548-8.
 URL:  
http://journal.hep.com.cn/fme/EN/10.1007/s11465-019-0548-8
http://journal.hep.com.cn/fme/EN/Y/V/I/0
Fig.1  Ultra-high cycle fatigue S-N curves of impeller materials FV520B and KMN [32,33].
Fig.2  Ultra-high cycle fatigue S-N curves under different (a) sample sizes [34] and (b) surface roughness values [35,36].
Rz/mm Experimental sR,W/MPa Murakami model Equivalent surface crack model
Predicted sR,W/MPa Deviation/% Predicted sR,W/MPa Deviation/%
0.6 610 671 10.0 643 5.4
1.4 520 600 15.4 558 7.3
2.5 450 542 20.4 506 12.4
Tab.1  Comparison of prediction model deviation of surface fatigue strength
Fig.3  Relationship between fatigue life N and nonlinear parameter b via (a) vibration fatigue, (b) three-point bending fatigue, and (c) tensile-bending fatigue test [40].
Fig.4  Two-value problem and solution. (a) Two-value problem; (b) β-β method; (c) b-HV-N double criterion method.
Location Gas pressure/MPa Impact velocity/(m·s−1) Impact angle/(° )
Leading edge 0.17–0.24 200 30–60
Pressure surface 0.17–0.24 150 20–30
Root of the trailing edge 0.17–0.24 120 10–20
Tab.2  Simulation results of the gas-solid two-phase flow field
Fig.5  Law of erosion (a) hardening and (b) residual stress [43].
Fig.6  KISCC varies with (a) H2S concentration and (b) temperature [47].
Fig.7  da/dt varies with (a) H2S concentration and (b) temperature [47].
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