This paper presents an efficient integrated multidisciplinary design optimization method for shaping a high-pressure cooling turbine blade in aero engines. This approach utilizes a novel regression/interpolation combination surrogate model (R/ICSM), facilitating comprehensive design optimization through collaborative coupling feature parameterization modeling and numerical simulation analysis across various disciplines. The optimized blade adjusts the load distribution on its surface, effectively eliminating flow separation at the tip and trailing edge. Notably, the optimized blade achieves a 0.69% increase in isentropic efficiency while satisfying aerodynamic, strength, and structural constraints. This highlights the effectiveness and progressiveness of the multidisciplinary design optimization method for a cooling turbine blade based on the R/ICSM in enhancing overall performance. It offers a novel and feasible approach for turbine blade design optimization and provides valuable insights for future research and applications.

In composites, fiber–matrix thermal mismatch induces stress heterogeneity that is beyond the resolution of macroscopic approaches. The asymptotic expansion homogenization method is used to create a multi-scale thermo-mechanical coupling model that predicts the elastic modulus, thermal expansion coefficients, and thermal conductivity of ceramic matrix composites at both the macro- and micro-scales. These predictions are verified to be accurate with a maximum relative error of 9.7% between the measured and predicted values. The multi-scale analysis method is then used to guide the vane’s thermal stress analysis, and a macro–meso–micro multi-scale model is created. The thermal stress distribution and stress magnitudes of the guide vane under a transient high-temperature load are investigated. The results indicate that the temperature and thermal stress distributions of the guide vane under the homogenization and lamination theory models are rather comparable, and the locations of the maximum thermal stress are predicted to be reasonably close to one another. The homogenization model allows for the rapid and accurate prediction of the guide vane’s thermal stress distribution. When compared to the macro-scale stress values, the meso-scale predicted stress levels exhibit excellent accuracy, with an inaccuracy of 11.7%. Micro-scale studies reveal significant stress concentrations at the fiber–matrix interface, which is essential for the macro-scale fatigue and fracture behavior of the guide vane.

Aiming at the phenomenon that the residual stress induced by Laser Shock Peening (LSP) will relax and redistribute under various loads, temperature, cyclic load, and the dual treatment of temperature and cyclic load on the residual stress relaxation of FGH95 powder superalloy after LSP treatment were studied, and the analysis model of relevant residual stress relaxation was constructed. The purpose is to understand the strengthening effect and stability of the alloy under temperature and cyclic load after LSP treatment. With the increase of treatment temperature, the relaxation of residual stress became more and more obvious. Most of the residual stress relaxation occurred in the first 30 min of temperature treatment, then slowed down and stabilized after 1 h. The residual stress was initially relaxed in the first 50 cycles, remained roughly unchanged between 50 and 5000 cycles. The intensify of the cyclic load increasing, adding material yield level, further plastic deformation and residual stress relaxation rate increases. With the increase of load intensify and load ratio, residual stress relaxation was also increased. The residual stress relaxation rate after 600 °C and cyclic load treatment was 56.2%, both greater than that after 600 °C or cyclic treatment of 25 °C, but less than the sum of the two conditions. The results of this paper provide a reference for the LSP of the FGH95 powder superalloy turbine disk and other aero engine parts.

Obtaining the mechanical parameters of SiC_f/SiC composites quickly and accurately is crucial for the performance evaluation and optimal design of novel turbine disc structures. A representative volume element (RVE) model of 2D woven SiC_f/SiC composites was developed using CT scanning and machine learning-driven image reconstruction techniques. The stress-strain curve was obtained by uniaxial tensile test, and the anisotropic mechanical parameters were obtained by inverse analysis using a non-dominated sorting genetic algorithm (NSGA-II). Subsequently, the uniaxial tension simulation was carried out based on the RVE model and mechanical parameters. The results show that the simulation curve is in good agreement with the test, and the errors of initial modulus and peak stress were 3.98% and 2.75%, respectively. Finally, the finite element models of the turbine disc with two braiding schemes were established to simulate the damage of the turbine disc. And the simulation results were verified by a centrifugal test. The failure modes of the two kinds of turbine discs are similar to the centrifugal test results, and the maximum rotating speed was close to the test results. The findings of this study provide a novel solution for obtaining the anisotropic mechanical parameters of SiC_f/SiC composites with different woven schemes.

Laser Shock Processing (LSP) is an excellent surface strengthening technology and an effective method to effectively solve this technical problem. The published literature only reports the LSP research on the blade tenon of large engine, and there is no LSP research on the turbine disk mortise of small engine (helicopter engine) with complex and narrow spatial structure. This paper was carried out Oblique LSP research on the complex structure of key parts of new helicopter engine, and the following research results were obtained: The residual stress of simulation and experiment were analyzed by the least-squares method, the flat-topped order of laser beam was corrected, and the pressure distribution model that better matches the shock wave induced by the flat-top laser beam was constructed; Due to the thin thickness and poor stiffness of the turbine disk mortise, the residual stress of the turbine disk mortise was compared between the LSP finite element simulation and the experiment by using the treatment method of equal laser power density and variable pulse width. The results show that the results of turbine disk mortise experiment were close to those of finite element simulation. The treatment method of equal power density and small pulse width can ensure the effect of strengthening the surface and reduce strain of turbine disk mortise.