Damage mechanism and evaluation model of compressor impeller remanufacturing blanks: A review

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-H_V-N” (where b was the nonlinear parameter, H_V 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. K_ISCC (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.

Key words： remanufacturing; centrifugal compressor impeller; remanufacturing blank; damage mechanism; evaluation model

Acknowledgements

We gratefully acknowledge the assistance provided by the National Program on Key Basic Research Project (Grant No. 2011CB013401) and the Shandong Key Research and Development Program.

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