Fatigue behavior of multi-row film cooling holes manufactured by lasers with different pulses under complex-temperature fields

Abstract

This research investigates the fatigue behavior of multi-row film cooling holes produced by lasers with diverse pulse widths amid intricate thermal environments. Through laser drilling experiments, conjugate heat transfer simulations, and crystal plasticity finite element analyses, it explores the interplay of temperature and stress fields among multiple holes in these structures, and factors influencing fatigue damage and its severity. Additionally, it anticipates the fatigue fracture paths of multi-row film cooling hole structures. Findings reveal that while the drilling process and aerodynamic parameters significantly impact cooling effectiveness, their influence on cooling distribution is negligible. Fatigue damage distribution is shaped by structural imperfections from different processes, stress field interference among multiple holes, and material property alterations due to temperature changes. The extent of damage is primarily dictated by roundness errors resulting from the drilling process, with taper playing a minor role. Nonetheless, stress interference among multiple holes notably exacerbates stress concentration at the interference zone, leading to increased damage levels in film cooling holes crafted by picosecond lasers with minimal roundness errors. Moreover, in complex thermal environments, fatigue fracture paths of multi-row film cooling holes migrate and evolve contingent on temperature-induced shifts in material properties.