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The nature and character of the destruction of the high-loaded airscrew shaft of the gas turbine engine made of steel 40KhN2MA are studied using the methods of scanning electron and optical microscopy and X-ray spectral microanalysis. We determined the chemical composition, microstructure and character of destruction of the flange part of the shaft. It is shown that chemical composition of the shaft material meets the requirements of the regulatory documents and defects of metallurgical origin are absent both in the metal of the shaft and in the fatigue fractures. All the identified cracks have been formed during operation, and developed according to the fatigue mechanism. Zones of fretting-wear and fretting-corrosion damage to the surface in the stud holes are the foci of the fatigue crack birth in the airscrew shaft. The cause of formation and development of the fatigue cracks in the shaft flange is a high level of contact stresses in the flange body, attribute to a poor quality of the interface of the splined joint due to significant fretting corrosion damage to the splines and vibration damages. A set of recommendations and measures aimed at elimination of the adverse factors is elaborated. To exclude the formation and development of fatigue cracks in the splined flange upon operation, we recommend to: optimize the tightening torque of the splined joint; introduce quality control of the interface between contact surfaces of the splined joint when replacing the airscrews; address the issue of dynamic balancing of the airscrews upon their production and repair.
The nature and character of the destruction of the high-loaded airscrew shaft of the gas turbine engine made of steel 40KhN2MA are studied using the methods of scanning electron and optical microscopy and X-ray spectral microanalysis. We determined the chemical composition, microstructure and character of destruction of the flange part of the shaft. It is shown that chemical composition of the shaft material meets the requirements of the regulatory documents and defects of metallurgical origin are absent both in the metal of the shaft and in the fatigue fractures. All the identified cracks have been formed during operation, and developed according to the fatigue mechanism. Zones of fretting-wear and fretting-corrosion damage to the surface in the stud holes are the foci of the fatigue crack birth in the airscrew shaft. The cause of formation and development of the fatigue cracks in the shaft flange is a high level of contact stresses in the flange body, attribute to a poor quality of the interface of the splined joint due to significant fretting corrosion damage to the splines and vibration damages. A set of recommendations and measures aimed at elimination of the adverse factors is elaborated. To exclude the formation and development of fatigue cracks in the splined flange upon operation, we recommend to: optimize the tightening torque of the splined joint; introduce quality control of the interface between contact surfaces of the splined joint when replacing the airscrews; address the issue of dynamic balancing of the airscrews upon their production and repair.
Stress corrosion cracking is one of the most dangerous types of corrosion damage in metallic materials. We present the results of studying the impact of environmental factors on the susceptibility of AMg6 aluminum alloy and 12Kh18N10T stainless steel to stress corrosion cracking under four-point bending. Tests of loaded samples were carried out in laboratory and field conditions of the moderately warm climate of the coastal zone over a period of six months. The samples were examined daily with fixation of the time to their destruction and upon completion of the tests the appearance of the samples and the depth of intergranular corrosion on microsections were assessed. A 3D relief was constructed using macro photography of the surface with the determination of the depth of corrosion foci. We also carried out a comparative analysis of the frequency of stress-induced destruction of steel samples of various grades both in atmospheric and laboratory conditions. It is shown that in atmospheric conditions characterized by the presence of dust particles acting as concentrators for the formation of corrosion foci, the aggressiveness of the corrosive effect of the environment increases, whereas the general corrosion resistance of materials decreases. The most pronounced effect of the environment was recorded in AMg6 alloy samples when exposed under a ventilated canopy in conditions of periodic spraying of seawater aerosols. The depth of surface corrosion damage was up to 0.1 mm. When the test samples were exposed under other conditions (salt fog chamber and louvered storage) the corrosion damage was absent. The results obtained can be used to predict the corrosion resistance of the products made of AMG6 alloy and 12Kh18N10T steel when operated in conditions of loading under the impact of environmental factors.
The problem of using specialized passivating metals and alloys lies in a rather narrow range of the protecting film performance. With a slight change in operating conditions, the film is destroyed and an avalanche-like process of local corrosion begins at the place of film breakdown. A sequence has been developed for determining parts destruction causes, including a sequential analysis of operating conditions; nature of the part destruction; corrosion products composition; phase inversion in the alloy during overheating or mechanical stress in the part.
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