PSI - Issue 1

ScienceDirect Procedia Structural Integrity 1 (2016) 289–296 Available online at www.sciencedirect.com Av ilable online at www.sciencedirect.com ienceDirect Structural Integ ity Procedia 00 (2016) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2016) 000 – 000

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

www.elsevier.com/locate/procedia

XV Portuguese Conference on Fracture, PCF 2016, 10-12 February 2016, Paço de Arcos, Portugal Thermo-mechanical modeling of a high pressure turbine blade of an airplane gas turbine engine P. Brandão a , V. Infante b , A.M. Deus c * a Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal b IDMEC, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal c CeFEMA, Department of Mechanical Engineering, Instituto Superior Técnico, Universidade de Lisboa, Av. Rovisco Pais, 1, 1049-001 Lisboa, Portugal Abstract During their operation, modern aircraft engine components are subjected to increasingly demanding operating conditions, especially the high pressure turbine (HPT) blades. Such conditions cause these parts to undergo different types of time-dependent degradation, one of which is creep. A model using the finite element method (FEM) was developed, in order to be able to predict the creep behaviour of HPT blades. Flight data records (FDR) for a specific aircraft, provided by a commercial aviation company, were used to obtain thermal and mechanical data for three different flight cycles. In order to create the 3D model needed for the FEM analysis, a HPT blade scrap was scanned, and its chemical composition and material properties were obtained. The data that was gathered was fed into the FEM model and different simulations were run, first with a simplified 3D rectangular block shape, in order to better establish the model, and then with the real 3D mesh obtained from the blade scrap. The overall expected behaviour in terms of displacement was observed, in particular at the trailing edge of the blade. Therefore such a model can be useful in the goal of predicting turbine blade life, given a set of FDR data. XV Portuguese Conference on Fracture, PCF 2016, 10-12 February 2016, Paço de Arcos, Portugal Selective laser melting (SLM) and topology optimization for lighter aerospace componentes Miguel Seabra a, * , José Azevedo b , Aurélio Araújo a , Luís Reis a , Elodie Pinto c , Nuno Alves c , Rui Santos d and João Pedro Mortágua b a IDMEC - Instituto Superior Técnico, Universidade de Lisboa, Portugal b Centro para a Excelência e Inovação na Indústria Automóvel (CEIIA) c Centre for Rapid and Sustainable Product Development, Polytechnic Institute of Leiria, Portugal d IN+ C nter for In ovation, Technology and Policy Research; In tituto Superior Técnico (IST) Abstract Additive Manufacturing (AM) is a manufacturing process through which a 3D component is produced by consecutively adding material. One of th most promisi g AM processes is SLM. I SLM a laser completely melts metallic powder articles t gether forming a 3D component. SLM is known for its freedom of manufacturing constraints allowing complex geometries and high material efficiency. Topology Optimisation (TO) is an optimisation type that calculates the optimal material distribution for a given problem. The combination of SLM with TO is being developed to create lightweight components. In this work, the whole development process, from optimisation to design, production and testing is addressed. Initially, an aircraft bracket topology was optimised to be produced by means of SLM. The TO solution was interpreted and designed for AM. During the interpretation and design process, a design methodology was defined in order to facilitate and make more accurate the TO solution design and make it ready for AM. After the optimised component was produced, metrological and mechanical tests were performed in order to validate the final design and the computer analysis. The optimised component showed considerable weight reduction with an increase of the factor of safety. The experimental tests revealed a good relation to the computer analysis evidencing, however, room for improvement, both in the computer model and the experimental tests. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. XV Portuguese Conference on Fracture, PCF 2016, 10-12 February 2016, Paço de Arcos, Portugal Selective laser melting (SLM) and topology optimization for lighter aerospace componentes Miguel Seabra a, * , José Azevedo b , Aurélio Araújo a , Luís Reis a , Elodie Pinto c , Nuno Alves c , Rui Santos d and João Pedro Mortágua b a IDMEC - Instituto Superior Técnico, Universidade de Lisboa, Portugal b Centro para a Excelência e Inovação na Indústria Automóvel (CEIIA) c Centre for Rapid and Sustainable Product Development, Polytechnic Institute of Leiria, Portugal d IN+ Center for Innovation, Technology and Policy Research; Instituto Superior Técnico (IST) Abstract Additive Manufacturing (AM) is a manufacturing process through which a 3D component is produced by consecutively adding material. One of the most promi ing AM processes is SLM. In SLM a laser completely melt metallic powder particl s together forming a 3D component. SLM is known f r it freedom of manufact ring constrai ts llowing com lex geometr es and high material efficiency. Topology Opt misation (TO) is an optimisation type that calculates the optimal material distribution for a given problem. The combination of SLM with TO is being develop d to create lightweight components. In this work, the whole de elo ment process, from optimisation to design, production and t sting is ddressed. Initially, an aircraft bracket topology was optimised to be produced by means f SLM. The TO solution was interprete and esigned for AM. During the interpretation and de ign process, a design methodology was defined in order to facilitate and make more accurate the TO solution design and make it ready for AM. After the optimised component was produced, metrological and mech nical tests were performed in order to validate the final design and the computer analysis. The optimised component showed considerable weight reduction with an increase of the factor of safety. The ex erime tal te ts revealed a good relation to the computer nalysis evid ncing, however, room for improvement, both in the com uter model and the xperimental t sts. © 2016 The Authors. Published by Elsevier B.V. Peer-review under esponsibility of the Scientific Committee of PCF 2016. Keywords: Additive Manufacturing (AM); Selective Laser Melting (SLM); Topology Optimisation; Design for AM; Experimental testing. Copyright © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativ commons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the Scientific Committee of PCF 2016. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. Keywords: Additive Manufacturing (AM); Selective Laser Melting (SLM); Topology Optimisation; Design for AM; Experimental testing.

_________ _________

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt * Corresponding author. Tel.: +351 914 622 150 E-mail address: *lmiguelseabra@gmail.com 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. * Corresponding author. Tel.: +351 914 622 150 E-mail address: *lmiguelseabra@gmail.com 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016.

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Copyright © 2015 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license ( http://creativecommons.org/licenses/by-nc-nd/4.0/ ). Peer review under responsibility of the Scientific Committee of PCF 2016. 10.1016/j.prostr.2016.02.039