Impact Wear Behavior of 2.25Cr-1Mo Heat Exchange Tubes Under Asymmetric Support Clearance

To investigate the influence of asymmetric support clearances (caused by manufacturing and assembly tolerances in practical engineering) on the fretting wear behavior of steam generator heat exchange tubes, this study focuses on 2.25Cr-1Mo alloy heat exchange tubes and 405 stainless steel anti-vibration bars. A high-precision impact wear test platform with adjustable bilateral clearances was designed, and its dynamic reliability was verified by theoretical calculations, finite element simulations and modal tests. An experimental model with asymmetric clearances (0.15 mm and 0.20 mm) was established to study the nonlinear contact force response and wear evolution under excitation frequencies of 60 Hz, 65 Hz and 70 Hz. The results show that asymmetric clearances induce two contact modes: high-frequency “quasi-static friction” on the small-clearance side and intermittent “collision-rebound-flight” impacts on the large-clearance side. The system exhibits a clear excitation instability threshold that shifts backward with increasing excitation frequency. The 0.20 mm side triggers dynamic instability, with wear volume and rate increasing explosively (106.2% and 41.36% at 65 Hz) beyond the threshold. Microscopic analysis reveals that the wear mechanism on the large-clearance side transitions from mild abrasive wear to severe fatigue delamination when crossing the threshold, with surface morphology deteriorating sharply from faint contact spots to extensive spalling craters. This study clarifies the energy distribution mechanism and identifies the large-clearance side as the core “trigger” for system instability and catastrophic failure, providing a theoretical basis for nuclear heat exchange tube monitoring and anti-vibration design.