A high-temperature rotor perforated lead structure and its preparation method

Abstract

This application belongs to the field of aero-engine parameter testing, and discloses a high-temperature rotor perforated lead wire structure and its preparation method. The structure includes a lead wire channel, a first functional layer, a second functional layer, test leads, and a third functional layer. The lead wire channel has a drum-shaped structure, with the top diameter smaller than the bottom diameter. The third functional layer also has a drum-shaped structure and is coaxially located in the middle of the lead wire channel. Multiple sets of test leads are spaced apart along the circumferential direction of the third functional layer. The second functional layer is a hollow drum-shaped structure and is fitted over the outside of the test leads. The first, second, and third functional layers, as well as the lead wire channel, all adopt a drum-shaped cross-section, which reliably supports the lead wire structure in the centrifugal force direction and applies bidirectional limiting constraints, thereby reducing the safety risk of the lead wire structure detaching from the rotor base under harsh operating conditions.

Description

Technical Field

[0001] This application belongs to the field of aero-engine parameter testing, and specifically relates to a high-temperature rotor perforated lead wire structure and its preparation method. Background Technology

[0002] When testing the temperature / stress and other parameters of high-temperature rotors (e.g., compressors, turbines, etc.) of aero-engines, it is usually necessary to install test sensors on the high-temperature rotors and connect the test leads of the sensors to the rotor disk center and signal transmission devices such as lead generators or telemetry devices by drilling holes in the rotor flow channels.

[0003] Typically, through-hole wire structures are either stepped holes or ordinary holes with a constant diameter (see...). Figure 1 By placing a high-temperature insulating sleeve with multiple through holes inside the stepped hole or ordinary hole, short circuits between test leads are avoided, and insulation between the test leads and the metal rotor substrate material is ensured. Finally, the two ends of the stepped hole or ordinary hole are sealed with high-temperature insulating material to fix the test leads.

[0004] Existing technical solutions require the use of high-temperature insulating sleeves with multiple through holes (e.g., ceramic tubes, corundum tubes, typically manufactured using processes such as slip casting or extrusion molding), which has the following disadvantages:

[0005] 1) Strict dimensional accuracy requirements for bushings result in high customization costs. To reduce the risk of lead wire breakage caused by bushing movement under harsh operating conditions such as high temperature, vibration, and high airflow scouring, it is necessary to strictly control the small clearance fit between the outer wall of the bushing and the stepped hole. This results in high dimensional accuracy requirements for the bushing, leading to increased costs for customized bushings.

[0006] 2) Poor reliability of the test lead fixation within the bushing via increases the risk of breakage. The diameter of the via within the bushing must be larger than the diameter of the test lead (typically 0.1 mm) to allow the lead to pass through. Existing technology cannot guarantee that the test lead is completely fixed to the inner wall of the via, giving the test lead a certain degree of freedom within the via, which increases the risk of breakage at high speeds.

[0007] 3) The sealing layer is prone to detachment at high temperatures, affecting engine test safety. Due to the different coefficients of thermal expansion of the sealing layer and the sleeve at high temperatures, and the lack of limiting constraints in the direction of centrifugal force, the two may separate from each other under harsh operating conditions due to the mismatch in their coefficients of thermal expansion. Once the sealing layer detaches and is thrown out into the flow channel, it will seriously affect the test safety of the engine.

[0008] 4) The implementation process is complex and inefficient. Existing technical solutions involve multiple steps such as custom sleeves, sleeve installation, and end sealing, and involve various materials and components. The process is relatively complex and the efficiency of lead wire fixing is low.

[0009] Therefore, how to reduce the cost and precision requirements of high-temperature insulating bushings while improving reliability is a problem that needs to be solved. Summary of the Invention

[0010] The purpose of this application is to provide a high-temperature rotor perforated lead wire structure and its preparation method to solve the problems of high precision requirements and poor reliability of existing high-temperature insulating bushings.

[0011] The technical solution of this application is: a high-temperature rotor perforated lead wire structure, including a lead wire channel, a first functional layer, a second functional layer, test leads, and a third functional layer; the lead wire channel has a drum-shaped structure, and the top diameter of the lead wire channel is smaller than the bottom diameter of the lead wire channel; the third functional layer has a drum-shaped structure and is coaxially disposed in the middle of the lead wire channel; multiple sets of test leads are spaced apart along the circumferential direction of the third functional layer; the second functional layer has a hollow drum-shaped structure and is sleeved on the outside of the test leads; the first functional layer has a hollow drum-shaped structure and is disposed between the inner wall of the lead wire channel and the outer wall of the second functional layer; both the second and third functional layers are high-temperature insulating layers; the test leads are continuously and seamlessly bonded between the second and third functional layers; the first functional layer is an alloy layer; and the first, second, and third functional layers are all processed by thermal spraying.

[0012] Preferably, the thickness of the first functional layer is 0.1 mm, and the high-temperature linear expansion coefficient of the first functional layer is between that of the rotor substrate material and the second functional layer.

[0013] Preferably, the thickness of the second functional layer is 0.1 mm.

[0014] Preferably, the test leads are distributed at least 90° intervals along the circumferential direction on the inner wall edge S3 of the second functional layer, and at 180° intervals along the circumferential direction of the minimum diameter A of the perforation.

[0015] As one specific embodiment, a method for preparing a high-temperature rotor perforated lead structure, using the perforated lead structure described above, includes:

[0016] Determine the outline dimensions of the lead channel, including the line connecting the centers of the transition fillets O1O2, the minimum diameter of the perforation A, the top diameter of the lead channel S1, the bottom diameter of the lead channel S2, the radius of the transition fillet R, the ordinate of the center of the transition fillet B, the upper cone angle β of the perforation β, the lower cone angle α of the perforation α, the length of the working section of the drill bit L, and the wall thickness of the perforation C. On the upper side of the plane where the line connecting O1O2 is located, there is a cylinder with a diameter φA. The outline of the lead channel is machined on the rotor base using a forming drill bit.

[0017] Using thermal spraying technology, firstly, the angle θ between the spray gun and the lower conical surface of O1O2 is adjusted so that θ is approximately equal to 2α, and the spray gun is fixed. Then, the rotor is rotated at a constant speed around the central axis O3 of the lead wire channel. By controlling the spraying process parameters and spraying time, a first functional layer of a specified thickness is obtained. Then, the rotor is flipped up and down in place, and the rotor continues to rotate at a constant speed around the central axis O3 of the lead wire channel until the preparation of the first functional layer is completed.

[0018] The second functional layer was prepared again using thermal spraying technology and in the same manner on the inner wall surface of the first functional layer;

[0019] The test leads are assembled into the second functional layer, and the two ends of the test leads are temporarily fixed with high-temperature tape.

[0020] The third functional layer is prepared again using thermal spraying technology on the inner wall of the second functional layer in the same way, and the third functional layer is continuously sprayed until the remaining space of the lead channel is filled.

[0021] Preferably, the processing method of the lead channel contour is as follows: first, the lead channel contour on the lower side of O1O2 is processed using a forming drill bit, and then the rotor is flipped up and down in situ. Using the φA hole as a centering reference, the lead contour on the upper side of O1O2 can be processed using the same drill bit.

[0022] Preferably, given the known wall thickness C of the perforation, the contour dimensional parameters should satisfy the following constraints: A < S1 < S2, B = λC, 0.1 ≤ λ ≤ 0.4, R = B, α = β, 30° ≤ α ≤ 45°

[0023] This application discloses a high-temperature rotor perforated lead wire structure and its preparation method, comprising a lead wire channel, a first functional layer, a second functional layer, a test lead wire, and a third functional layer. The lead wire channel has a drum-shaped structure, and the top diameter of the lead wire channel is smaller than the bottom diameter of the lead wire channel. The third functional layer has a drum-shaped structure and is coaxially disposed in the middle of the lead wire channel. There are multiple sets of test leads, which are spaced apart along the circumferential direction of the third functional layer. The second functional layer has a hollow drum-shaped structure and is sleeved on the outside of the test lead wire. The test lead wire is stably fixed by using the first, second, and third functional layers processed by thermal spraying. The first, second, and third functional layers and the lead wire channel all adopt the 'drum' shaped cross-section feature, which can reliably support the lead wire structure in the centrifugal force direction and apply bidirectional limiting constraints, thereby reducing the safety risk of the lead wire structure detaching from the rotor base under harsh working conditions. Attached Figure Description

[0024] To more clearly illustrate the technical solutions provided in this application, the accompanying drawings will be briefly described below. Obviously, the drawings described below are merely some embodiments of this application.

[0025] Figure 1 This is a schematic diagram of the background technology structure;

[0026] Figure 2 This is a cross-sectional view of the high-temperature rotor perforated lead structure of this application;

[0027] Figure 3 This is a schematic diagram of the circumferential distribution of the test leads in this application;

[0028] Figure 4 This is the cross-sectional outline of the lead channel in this application;

[0029] Figure 5 A schematic diagram of the forming drill bit for machining the lead wire channel in this application;

[0030] Figure 6 This is a schematic diagram of the functional layer prepared by thermal spraying in this application.

[0031] 1. Lead channel; 2. First functional layer; 3. Second functional layer; 4. Test lead; 5. Third functional layer. Detailed Implementation

[0032] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0033] A high-temperature rotor perforated lead structure, such as Figure 2 The system includes a lead channel 1, a first functional layer 2, a second functional layer 3, test leads 4, and a third functional layer 5. The lead channel 1 has a drum-shaped structure, and the top diameter of the lead channel 1 is smaller than the bottom diameter. The third functional layer 5 has a drum-shaped structure and is coaxially located in the middle of the lead channel 1. There are multiple sets of test leads 4, which are spaced apart along the circumferential direction of the third functional layer 5. The second functional layer 3 has a hollow drum-shaped structure and is sleeved on the outside of the test leads 4. The first functional layer 2 has a hollow drum-shaped structure and is located between the inner wall of the lead channel 1 and the outer wall of the second functional layer 3. The second functional layer 3 and the third functional layer 5 are both high-temperature insulating layers. The test leads 4 are continuously and seamlessly bonded between the second functional layer 3 and the third functional layer 5. The first functional layer 2 is an alloy layer. The first functional layer 2, the second functional layer 3, and the third functional layer 5 are all processed by thermal spraying.

[0034] The test lead 4 is stably fixed by using a first functional layer 2, a second functional layer 3, and a third functional layer 5 processed by thermal spraying. The first functional layer 2, the second functional layer 3, the third functional layer 5, and the lead channel 1 all adopt a "waist drum" shaped cross-section, which can reliably support the lead structure in the direction of centrifugal force and apply bidirectional limiting constraints, thereby reducing the safety risk of the lead structure detaching from the rotor base under harsh working conditions. This solves the problems of high precision requirements, high customization costs, poor fixation reliability of the test lead 4 within the sleeve through-hole, and easy detachment of the sealing layer at high temperatures associated with existing technologies using high-temperature insulating sleeves. At the same time, it simplifies the manufacturing process and improves manufacturing efficiency.

[0035] The first functional layer 2 is an alloy layer parallel to the cross-sectional profile of the lead channel 1, attached to the inner wall of the lead channel 1, with a thickness of about 0.1 mm. Its high-temperature linear expansion coefficient is between that of the rotor substrate material and the second functional layer 3 material. Its function is to reduce the deformation incoordination gradient between the second functional layer 3 and the rotor substrate material at high temperatures and improve the bonding strength between the second functional layer 3 and the rotor substrate.

[0036] The second functional layer 3 is a high-temperature insulating layer parallel to the first functional layer 2, attached to the inner wall surface of the first functional layer 2, with a thickness of about 0.1 mm, used to ensure the high-temperature insulation between the test lead 4 and the first functional layer 2.

[0037] The third functional layer 5 is made of the same material and is manufactured in the same way as the second functional layer 3. It is used to reliably fix the test lead 4 on the inner wall of the second functional layer 3 and to fill the remaining space of the lead channel 1.

[0038] Test leads 4 are continuously and seamlessly attached to the inner wall surface of the second functional layer 3, and the test leads 4 are distributed at least 90° intervals along the circumferential direction on the inner wall edge S3 of the second functional layer 3, and at 180° intervals along the circumferential direction of the minimum diameter A of the perforation (see...). Figure 3 ), used to avoid short circuits between test leads 4.

[0039] As one specific embodiment, a method for preparing a high-temperature rotor perforated lead structure includes the following steps:

[0040] 1) Determine the outline dimensions of lead channel 1, and combine them with... Figure 4 The parameters include the line connecting the centers of the transition fillet O1O2, the minimum diameter of the perforation A, the top diameter S1 of the lead wire channel 1, the bottom diameter S2 of the lead wire channel 1, the radius of the transition fillet R, the ordinate of the center of the transition fillet B, the upper cone angle β of the perforation, the lower cone angle α of the perforation, the length of the working section of the drill bit L, and the wall thickness of the perforation C. Under the condition that the wall thickness of the perforation C is known, the contour dimension parameters should satisfy the following constraints: A<S1<S2, B=λC, 0.1≤λ≤0.4, R=B, α=β, 30°≤α≤45°.

[0041] 'A<S1<S2' reflects the 'waist-drum' shaped cross-section characteristic of the perforated lead structure. λ is a proportionality coefficient used to adjust the position of the transition fillet center line (O1O2) relative to the perforation wall thickness C. 'R=B' is used to adjust the stress concentration of the transition fillet radius to improve the overall strength of the lead structure. The perforation cone angles α and β are used to adjust the cone profile dimensions of the lead structure. '30°≤α≤45°' provides an operable angle for the spray gun in subsequent thermal spraying operations, improving the preparation quality of each functional layer. 'α=β' makes the cross-sectional profile of lead channel 1 locally symmetrical about the plane containing O1O2, simplifying subsequent preparation processes and improving preparation efficiency.

[0042] If we let Δ = R(1-cosα) / cosα, then the upper diameter of the perforation S1 = A - 2Δ + 2Rtanα, and the lower diameter of the perforation S2 = A - 2Δ + 4Rtanα. In practical applications, the optimal values ​​for the three parameters A, λ, and α should be selected based on the spatial size constraints of S1 and S2, combined with finite element strength verification.

[0043] like Figure 5 As shown, the shaped drill bit is characterized in that, on the lower side of the plane containing the O1O2 line, its cross-sectional profile is exactly the same as that of the lead wire channel 1; on the upper side of the plane containing the O1O2 line, it is a cylinder with a diameter of φA. The outline of the lead wire channel 1 is machined on the rotor base using the shaped drill bit. On the lower side of the plane containing the O1O2 line, its cross-sectional profile is exactly the same as that of the lead wire channel 1, while on the upper side of the plane containing the O1O2 line, it is a cylinder with a diameter of φA. The end face of the cylinder has a chamfer, and the working section length L of the drill bit is greater than the hole wall thickness C, i.e., L > C. Since α = β, the cross-sectional profile of the lead wire channel 1 is locally symmetrical about the plane containing the O1O2 line.

[0044] Preferably, the processing method for the lead channel 1 contour is as follows: First, the lead channel 1 contour on the lower side of O1O2 is processed using a forming drill bit. Then, the rotor is flipped up and down in situ, and the φA hole is used as a centering reference. The lead contour processing on the upper side of O1O2 can be completed using the same drill bit, which simplifies the preparation process and improves the preparation efficiency.

[0045] 2) Employ thermal spraying technology, such as Figure 6 As shown, first, adjust the angle θ between the spray gun and the lower conical surface of O1O2 so that θ is approximately equal to 2α, and fix the spray gun. Then, make the rotor rotate at a constant speed around the central axis O3 of the lead wire channel 1. By controlling the spraying process parameters and spraying time, the first functional layer 2 of a specified thickness is obtained. Then, flip the rotor up and down in place and continue to make the rotor rotate at a constant speed around the central axis O3 of the lead wire channel 1 until the preparation of the first functional layer 2 is completed.

[0046] 3) The second functional layer 3 is prepared again using thermal spraying technology and in the same manner on the inner wall surface of the first functional layer 2;

[0047] 4) Assemble the test lead 4 into the second functional layer 3, and temporarily fix both ends of the test lead 4 with high-temperature tape; ensure that the test lead 4 is continuously and seamlessly attached to the inner wall surface of the functional layer, and that the test leads 4 are distributed at least 90° intervals along the circumferential direction on the inner wall edge S3, and at 180° intervals along the circumferential direction of the minimum diameter of the perforation A (e.g., Figure 3 (As shown).

[0048] 5) The third functional layer 5 is prepared again on the inner wall of the second functional layer 3 using the same thermal spraying technique, and the third functional layer 5 is continuously sprayed until the remaining space of the lead channel 1 is filled. When the thickness of the third functional layer 5 is greater than the diameter of the test lead 4, the test lead 4 can be fixed on the inner wall of the second functional layer 3. Since the materials and preparation processes of the second functional layer 3 and the third functional layer 5 are completely identical, there is no problem of mismatch in the coefficients of thermal expansion at high temperatures (see...). Figure 2 ).

[0049] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0050] Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

[0051] In conclusion, the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high temperature rotor feedthrough lead structure, characterized by: It includes a lead channel (1), a first functional layer (2), a second functional layer (3), test leads (4), and a third functional layer (5); the lead channel (1) has a drum-shaped structure, and the top diameter of the lead channel (1) is smaller than the bottom diameter of the lead channel (1); the third functional layer (5) has a drum-shaped structure and is coaxially located in the middle of the lead channel (1); there are multiple sets of test leads (4) and they are spaced apart along the circumferential direction of the third functional layer (5); the second functional layer (3) has a hollow drum-shaped structure and the second functional layer (5) has a third functional layer (5). Layer (3) is sleeved on the outside of the test lead (4). The first functional layer (2) has a hollow drum-shaped structure and is located between the inner wall of the lead channel (1) and the outer wall of the second functional layer (3). The second functional layer (3) and the third functional layer (5) are both high-temperature insulating layers. The test lead (4) is continuously and seamlessly attached between the second functional layer (3) and the third functional layer (5). The first functional layer (2) is an alloy layer. The first functional layer (2), the second functional layer (3) and the third functional layer (5) are all processed by thermal spraying. The contour dimension parameters of the lead channel (1) include the line connecting the center of the transition fillet O1O2, the minimum diameter of the through hole A, the top diameter of the lead channel (1) S1, the bottom diameter of the lead channel (1) S2, the radius of the transition fillet R, and the vertical coordinate of the center of the transition fillet B; Given the wall thickness C of the perforation, the contour dimensions should satisfy the following constraints: A < S1 < S2, B = λC, 0.1 ≤ λ ≤ 0.4, R = B.

2. The high temperature rotor punched-lead structure of claim 1, wherein: The thickness of the first functional layer (2) is 0.1 mm, and the high-temperature linear expansion coefficient of the first functional layer (2) is between that of the rotor substrate material and the second functional layer (3).

3. The high temperature rotor punched-lead structure of claim 1, wherein: The thickness of the second functional layer (3) is 0.1 mm.

4. The high temperature rotor punched-lead structure of claim 1, wherein: The test leads (4) are distributed at least 90° apart circumferentially on the inner wall edge S3 of the second functional layer (3) and at 180° apart circumferentially on the minimum diameter A of the perforation.

5. A method of manufacturing a high-temperature rotor perforated lead structure using the perforated lead structure according to any one of claims 1 to 4, characterized by, include: The contour dimensions of the lead channel (1) are determined, including the line connecting the centers of the transition fillets O1O2, the minimum diameter of the perforation A, the top diameter of the lead channel (1) S1, the bottom diameter of the lead channel (1) S2, the radius of the transition fillet R, the ordinate of the center of the transition fillet B, the upper cone angle β of the perforation, the lower cone angle α of the perforation, the length of the working section of the drill bit L, and the wall thickness of the perforation C. On the upper side of the plane where the line connecting O1O2 is located, there is a cylinder with a diameter φA. The contour of the lead channel (1) is machined on the rotor base using a forming drill bit. Using thermal spraying technology, firstly, the angle θ between the spray gun and the lower conical surface of O1O2 is adjusted so that θ is approximately equal to 2α, and the spray gun is fixed. Then, the rotor is rotated at a constant speed around the central axis O3 of the lead wire channel (1). By controlling the spraying process parameters and spraying time, the first functional layer (2) of a specified thickness is obtained. Then, the rotor is flipped up and down in place, and the rotor is rotated at a constant speed around the central axis O3 of the lead wire channel (1) until the preparation of the first functional layer (2) is completed. The second functional layer (3) was prepared again using thermal spraying technology and in the same manner on the inner wall surface of the first functional layer (2); The test lead (4) is assembled into the second functional layer (3), and the two ends of the test lead (4) are temporarily fixed with high temperature tape. The third functional layer (5) is prepared again on the inner wall of the second functional layer (3) using the same method, and the third functional layer (5) is continuously sprayed until the remaining space of the lead channel (1) is filled.

6. The method of claim 5, wherein the high temperature rotor hole lead structure is prepared by the steps of: The processing method of the lead channel (1) contour is as follows: First, the lead channel (1) contour on the lower side of O1O2 is processed by forming drill bit. Then, the rotor is flipped up and down in place, and the φA hole is used as the centering reference. The lead contour on the upper side of O1O2 can be processed by the same drill bit. ​ 7. The method for preparing the high-temperature rotor perforated lead structure as described in claim 5, characterized in that, α=β，30°≤α≤45°。

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