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An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

《工程管理前沿（英文）》 2016年第3卷第2期页码 107-114 doi: 10.15302/J-FEM-2016025

摘要： Surface integrity is the major factor impacting on the operation quality, service life and reliability of the aeroengine components. The surface integrity of aeroengine component is damaged by the failures such as crack, deformation, oxidation, corrosion, erosion, and microstructural degeneration. It adopts advanced remanufacturing technologies to restore or improve the surface integrity and regenerate these high value parts. This paper firstly puts forward the concept, namely surface integrity remanufacturing for aeroengine components, and its connotation. The key remanufacturing technologies have been developed to repair the components with surface damages. Ultimately, some application examples of surface integrity remanufacturing technologies as well as their effects in aeroengine maintenance are introduced. The discarded components have been reused and their service lives have been extended and their reliability has been increased by implementing surface integrity remanufacturing. It has realized “The Repaired Components Outpacing the New Ones”, material saving, energy saving, and emission reduction.

关键词： aeroengine component surface integrity remanufacturing surface integrity remanufacturing

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Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

《机械工程前沿（英文）》 2018年第13卷第2期页码 243-250 doi: 10.1007/s11465-018-0479-9

摘要：

The Inconel 718 alloy is widely used in the aerospace and power industries. The machining-induced surface integrity and fatigue life of this material are important factors for consideration due to high reliability and safety requirements. In this work, the milling of Inconel 718 was conducted at different cutting speeds and feed rates. Surface integrity and fatigue life were measured directly. The effects of cutting speed and feed rate on surface integrity and their further influences on fatigue life were analyzed. Within the chosen parameter range, the cutting speed barely affected the surface roughness, whereas the feed rate increased the surface roughness through the ideal residual height. The surface hardness increased as the cutting speed and feed rate increased. Tensile residual stress was observed on the machined surface, which showed improvement with the increasing feed rate. The cutting speed was not an influencing factor on fatigue life, but the feed rate affected fatigue life through the surface roughness. The high surface roughness resulting from the high feed rate could result in a high stress concentration factor and lead to a low fatigue life.

关键词： roughness hardness residual stress microstructure fatigue life

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Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

《机械工程前沿（英文）》 2022年第17卷第2期 doi: 10.1007/s11465-022-0680-8

摘要： Fiber-reinforced composites have become the preferred material in the fields of aviation and aerospace because of their high-strength performance in unit weight. The composite components are manufactured by near net-shape and only require finishing operations to achieve final dimensional and assembly tolerances. Milling and grinding arise as the preferred choices because of their precision processing. Nevertheless, given their laminated, anisotropic, and heterogeneous nature, these materials are considered difficult-to-machine. As undesirable results and challenging breakthroughs, the surface damage and integrity of these materials is a research hotspot with important engineering significance. This review summarizes an up-to-date progress of the damage formation mechanisms and suppression strategies in milling and grinding for the fiber-reinforced composites reported in the literature. First, the formation mechanisms of milling damage, including delamination, burr, and tear, are analyzed. Second, the grinding mechanisms, covering material removal mechanism, thermal mechanical behavior, surface integrity, and damage, are discussed. Third, suppression strategies are reviewed systematically from the aspects of advanced cutting tools and technologies, including ultrasonic vibration-assisted machining, cryogenic cooling, minimum quantity lubrication (MQL), and tool optimization design. Ultrasonic vibration shows the greatest advantage of restraining machining force, which can be reduced by approximately 60% compared with conventional machining. Cryogenic cooling is the most effective method to reduce temperature with a maximum reduction of approximately 60%. MQL shows its advantages in terms of reducing friction coefficient, force, temperature, and tool wear. Finally, research gaps and future exploration directions are prospected, giving researchers opportunity to deepen specific aspects and explore new area for achieving high precision surface machining of fiber-reinforced composites.

关键词： milling grinding fiber-reinforced composites damage formation mechanism delamination material removal mechanism surface integrity minimum quantity lubrication

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高强度合金抗疲劳应用技术研究与发展

越振业

《中国工程科学》 2005年第7卷第3期页码 90-94

摘要：

评述了超高强度钢、高强度A1合金和Ti合金表面完整性抗疲劳应用技术的研究和发展。高强度合金疲劳性能对应力集中敏感，不适当的加工工艺和切削热等造成的表面损伤和髙拉应力使其疲劳和应力腐蚀性能损失殆尽。先进的表面完整性加工尤其是表面改性可显著提高疲劳性能，如激光冲击使7475-T761拉-拉疲劳寿命提高约89%，7075-T6裂纹扩展速率降低到原来的1/1500;超声喷丸使超高强度钢低周疲劳强度提高约50%，Ti7A14Mo合金髙周疲劳强度提高约15%;表面超硬化可使Vasco X-2M齿轮钢接触疲劳寿命提高30～35倍等。

关键词：高强度合金表面完整性激光冲击表面超硬化

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表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

《工程（英文）》 2018年第4卷第6期页码 754-758 doi: 10.1016/j.eng.2018.11.005

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Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

《机械工程前沿（英文）》 2023年第18卷第1期 doi: 10.1007/s11465-022-0730-2

摘要： Ultrasonic vibration-assisted grinding (UVAG) is an advanced hybrid process for the precision machining of difficult-to-cut materials. The resonator is a critical part of the UVAG system. Its performance considerably influences the vibration amplitude and resonant frequency. In this work, a novel perforated ultrasonic vibration platform resonator was developed for UVAG. The holes were evenly arranged at the top and side surfaces of the vibration platform to improve the vibration characteristics. A modified apparent elasticity method (AEM) was proposed to reveal the influence of holes on the vibration mode. The performance of the vibration platform was evaluated by the vibration tests and UVAG experiments of particulate-reinforced titanium matrix composites. Results indicate that the reasonable distribution of holes helps improve the resonant frequency and vibration mode. The modified AEM, the finite element method, and the vibration tests show a high degree of consistency for developing the perforated ultrasonic vibration platform with a maximum frequency error of 3%. The employment of ultrasonic vibration reduces the grinding force by 36% at most, thereby decreasing the machined surface defects, such as voids, cracks, and burnout.

关键词： ultrasonic vibration-assisted grinding perforated ultrasonic vibration platform vibration characteristics apparent elasticity method grinding force surface integrity

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Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

《机械工程前沿（英文）》 2020年第15卷第3期页码 504-515 doi: 10.1007/s11465-020-0586-2

摘要： The damage-tolerant titanium alloy TC21 is used extensively in important parts of advanced aircraft because of its high strength and durability. However, cutting TC21 entails problems, such as high cutting temperature, high tool tip stress, rapid tool wear, and difficulty guaranteeing processing quality. Orthogonal turn-milling can be used to solve these problems. In this study, the machinability of TC21 in orthogonal turn-milling is investigated experimentally to optimize the cutting parameters of orthogonal turn-milling and improve the machining efficiency, tool life, and machining quality of TC21. The mechanism of the effect of turn-milling parameters on tool life is discussed, the relationship between each parameter and tool life is analyzed, and the failure process of a TiAlN-coated tool in turn-milling is explored. Experiments are conducted on the integrity of the machined surface (surface roughness, metallographic structure, and work hardening) by turn-milling, and how the parameters influence such integrity is analyzed. Then, reasonable cutting parameters for TC21 in orthogonal turn-milling are recommended. This study provides strong guidance for exploring the machinability of difficult-to-cut-materials in orthogonal turn-milling and improves the applicability of orthogonal turn-milling for such materials.

关键词： orthogonal turn-milling damage-tolerant titanium alloy tool life and failure machined surface integrity machinability

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Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

《机械工程前沿（英文）》 2013年第8卷第3期页码 283-290 doi: 10.1007/s11465-013-0250-1

摘要：

In this paper, the local fracture properties in a Alloy52M dissimilar metal welded joint (DMWJ) between A508 ferritic steel and 316 L stainless steel in nuclear power plants were investigated by using the single-edge notched bend (SENB) specimens, and their use in integrity assessment of DMWJ structures was analyzed. The results show that the local fracture resistance in the DMWJ is determined by local fracture mechanism, and which is mainly related to the microstructures and local strength mismatches of materials at the crack locations. The initial cracks always grow towards the materials with lower strength, and the crack path deviation is mainly controlled by the local strength mismatch. If the local fracture properties could not be used for cracks in the heat affected zones (HAZs), interface and near interface zones, the use of the fracture properties ( -resistance curves) of base metals or weld metals following present codes will unavoidably produce non-conservative (unsafe) or excessive conservative assessment results. In most cases, the assessment results will be potentially unsafe. Therefore, it is recommended to obtain and use local mechanical and fracture properties in the integrity assessment of DMWJs.

关键词： local fracture properties dissimilar metal welded joint integrity assessment strength mismatch crack growth path

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Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

《机械工程前沿（英文）》 2007年第2卷第4期页码 375-387 doi: 10.1007/s11465-007-0066-y

摘要： Structural integrity technology has been widely used with great success for the design, manufacture and failure prevention of modern constructions such as chemical and petrochemical plants, power generation and energy conversion systems, as well as space and oceanic exploration. The modern needs of structural integrity technology are largely attributed to the increase of service temperature of the structures that results in the efficiency improvement in energy conversion and chemical processing technologies. Besides the needs arising from large-scale high-temperature plants, the high tech developments, such as micro chemo-mechanical systems and high-power electronics, provide new challenges to structural integrity technology. The present paper summarizes the recent technical progresses in large process plants and the aviation industry, micro chemo-mechanical systems, fuel cells, high-temperature electronics, and packaging and coating technologies. The state-of-the-art of structural integrity technology for high temperature applications is reviewed. Suggestions are provided for the improvement of current design and assessment methods.

关键词： manufacture aviation industry conversion petrochemical temperature

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Recent development in low-constraint fracture toughness testing for structural integrity assessment of

Jidong KANG, James A. GIANETTO, William R. TYSON

《机械工程前沿（英文）》 2018年第13卷第4期页码 546-553 doi: 10.1007/s11465-018-0501-2

摘要：

Fracture toughness measurement is an integral part of structural integrity assessment of pipelines. Traditionally, a single-edge-notched bend (SE(B)) specimen with a deep crack is recommended in many existing pipeline structural integrity assessment procedures. Such a test provides high constraint and therefore conservative fracture toughness results. However, for girth welds in service, defects are usually subjected to primarily tensile loading where the constraint is usually much lower than in the three-point bend case. Moreover, there is increasing use of strain-based design of pipelines that allows applied strains above yield. Low-constraint toughness tests represent more realistic loading conditions for girth weld defects, and the corresponding increased toughness can minimize unnecessary conservatism in assessments. In this review, we present recent developments in low-constraint fracture toughness testing, specifically using single-edge-notched tension specimens, SENT or SE(T). We focus our review on the test procedure development and automation, round-robin test results and some common concerns such as the effect of crack tip, crack size monitoring techniques, and testing at low temperatures. Examples are also given of the integration of fracture toughness data from SE(T) tests into structural integrity assessment.

关键词： fracture toughness constraint effect single-edge-notched tension test pipeline structural integrity assessment

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How does the improved DB mode degrade the complex integrity of infrastructure mega-projects?

Jinwen ZHANG, Yumin QIU

《工程管理前沿（英文）》 2018年第5卷第1期页码 40-51 doi: 10.15302/J-FEM-2018083

摘要： Complex integrity is one of the main characteristics of infrastructure mega-projects (IMPs). Cost, technology, risk, duration, environmental impact, and other uncertain complexities are interrelated and constitute a challenging and complex management problem. At present, there is no unified understanding of or solutions to these complex integrity problems. This study analyzes the complex integrity of the island-tunnel subproject of the Hong Kong-Zhuhai-Macao Bridge (HZMB) project and proposes an improved design-build (DB) mode in which the owner provides a preliminary design and has the right to form and manage consortium. This improved DB mode creatively degrades the special complexities that arise from multiple dimensions. On this basis, it is an efficacious way to grasp the main contradictions, integrate the effective resources, and degrade the complex integrity in multiple dimensions and at multiple levels so as to effectively deal with the complexity management of IMPs.

关键词： Hong Kong-Zhuhai-Macao Bridge project island-tunnel subproject complex integrity complexity degradation the general contracting mode of design-build the design-build consortium

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一种超高强度钢构件抗疲劳实验研究

赵振业,宋德玉,李向斌,杨树勋,马新闻

《中国工程科学》 2005年第7卷第10期页码 51-55

摘要：

提出了超高强度钢“无应力集中”抗疲劳概念。喷丸、孔挤压、螺纹滚压等表面层组织再造改性造成的残余压应力和高位错密度胞状结构将裂纹推移至亚表面萌生并阻滞其扩展，回复不同应力集中处的疲劳强度至接近钢的固有疲劳强度，形成“无应力集中”表面完整性状态。“无应力集中”抗疲劳概念表述为构件表面形成完整的接近于钢固有疲劳强度的等疲劳强度包络。

关键词：超高强度钢抗疲劳应力集中表面完整性

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Propagation characteristics of transient waves in low-strain integrity testing on cast-in-situ concrete

Hanlong LIU, Xuanming DING

《结构与土木工程前沿（英文）》 2009年第3卷第2期页码 240-240 doi: 10.1007/s11709-009-0100-8

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is essential for the integrity of stereociliary rootlet in cochlear hair cells in mice

Yuqin Men, Xiujuan Li, Hailong Tu, Aizhen Zhang, Xiaolong Fu, Zhishuo Wang, Yecheng Jin, Congzhe Hou, Tingting Zhang, Sen Zhang, Yichen Zhou, Boqin Li, Jianfeng Li, Xiaoyang Sun, Haibo Wang, Jiangang Gao

《医学前沿（英文）》 2019年第13卷第6期页码 690-704 doi: 10.1007/s11684-018-0638-8

摘要： encodes the taperin protein, which is concentrated in the tapered region of hair cell stereocilia in the inner ear. In humans, mutations cause autosomal recessive nonsyndromic deafness (DFNB79) by an unknown mechanism. To determine the role of in hearing, we generated -null mice by clustered regularly interspaced short palindromic repeat/Cas9 genome-editing technology from a CBA/CaJ background. We observed significant hearing loss and progressive degeneration of stereocilia in the outer hair cells of -null mice starting from postnatal day 30. Transmission electron microscopy images of stereociliary bundles in the mutant mice showed some stereociliary rootlets with curved shafts. The central cores of the stereociliary rootlets possessed hollow structures with surrounding loose peripheral dense rings. Radixin, a protein expressed at stereocilia tapering, was abnormally dispersed along the stereocilia shafts in null mice. The expression levels of radixin and -actin significantly decreased. We propose that is critical to the retention of the integrity of the stereociliary rootlet. Loss of in -null mice caused the disruption of the stereociliary rootlet, which resulted in damage to stereociliary bundles and hearing impairments. The generated -null mice are ideal models of human hereditary deafness DFNB79.

关键词： TPRN stereocilia stereociliary rootlet actin filament CRISPR/Cas9 hearing

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Cell surface protein engineering for high-performance whole-cell catalysts

Hajime Nakatani,Katsutoshi Hori

《化学科学与工程前沿（英文）》 2017年第11卷第1期页码 46-57 doi: 10.1007/s11705-017-1609-3

摘要： Cell surface protein engineering facilitated by accumulation of information on genome and protein structure involves heterologous production and modification of cell surface proteins using genetic engineering, and is important for the development of high-performance whole-cell catalysts. In this field, cell surface display is a major technology by exposing target proteins, such as enzymes, on the cell surface using a carrier protein. The target proteins are fused to the carrier proteins that transport and tether them to the cell surface, as well as to a secretion signal. This paper reviews cell surface display systems for prokaryotic and eukaryotic cells from the perspective of carrier proteins, which determine the number of displayed molecules, and the localization, size, and direction ( or terminal anchoring) of the passengers. We also discuss advanced methods for displaying multiple enzymes and a new method for the immobilization of whole-cell catalysts using adhesive surface proteins.

关键词： cell surface engineering surface display whole-cell catalysts bioprocess

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标题作者时间类型操作

An Exploration of Surface Integrity Remanufacturing for Aeroengine Components

Qiao Xiang,Yong He,Ting-hong Hou

期刊论文

Experimental study of surface integrity and fatigue life in the face milling of Inconel 718

Xiangyu WANG, Chuanzhen HUANG, Bin ZOU, Guoliang LIU, Hongtao ZHU, Jun WANG

期刊论文

Fiber-reinforced composites in milling and grinding: machining bottlenecks and advanced strategies

期刊论文

高强度合金抗疲劳应用技术研究与发展

越振业

期刊论文

表面完整性研究的进展与展望

房丰洲, 顾春阳, 郝然, 游开元, 黄思雨

期刊论文

Vibration characteristics and machining performance of a novel perforated ultrasonic vibration platform in the grinding of particulate-reinforced titanium matrix composites

期刊论文

Machinability of damage-tolerant titanium alloy in orthogonal turn-milling

Tao SUN, Lufang QIN, Junming HOU, Yucan FU

期刊论文

Local fracture properties and dissimilar weld integrity in nuclear power plants

Guozhen WANG, Haitao WANG, Fuzhen XUAN, Shantung TU, Changjun LIU

期刊论文

Emerging challenges to structural integrity technology for high-temperature applications

TU Shantung

期刊论文

Recent development in low-constraint fracture toughness testing for structural integrity assessment of

Jidong KANG, James A. GIANETTO, William R. TYSON