PSI - Issue 13

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at ww.sciencedirect.com ienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structural Integrity 13 (2018) 1353–1358 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Int gri y Procedia 00 (2018) 000–000

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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. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. ECF22 - Loading and Environmental effects on Structural Integrity Finite element prediction and validation of residual stress profiles in 316L samples manufactured by laser powder bed fusion Richard J. Williams*, Paul A. Hooper, Catrin M. Davies Department of Mechanical Engineering, Imperial College London, SW7 2AZ, UK. Abstract Laser powder bed fusion (LPBF) processes continue to grow in popularity and much progress has been made in recent years. However, due to the extreme thermal gradients present, significant residual stresses are inevitable and can be detrimental during component service. Critical to mitigating these stresses effectively is the ability to model the thermo-mechanical process accurately and efficiently. A simplified FE modelling methodology has been developed and applied to a cylindrical component built in both the horizontal and vertical orientations. The resulting distortion of the parts following a slitting process was compared with those predicted by the model and good agreement to within 5% was found. The final stress fields in the components were predicted by the model and then examined to assess the principal stresses driving the distortion and the causes of difference in results between the two build orientations. © 2018 The Authors. Published by Elsevier B.V. Peer-revi w under responsibility of th ECF22 organiz rs. Keywor s: Las r powder bed fusion; LPBF; residual stress; istortion; finite e ement modelli g * Corresponding author. E-mail addr ss: r.williams16@imperial.ac.uk 1. Introduction Residual stresses and subsequent distortions are inevitable in components manufactured through laser powder bed fusion (LPBF). Large regions of high tensile stress, in particular, are problematic and often present in components manufactured via LPBF (Yang Liu et al. (2016)). This coupled with the rough surface finish and internal porosity also characteristic of LPBF parts can be detrimental to fracture and fatigue behavior. Efficient and accessible modelling tools are required to predict these residual stress profiles and component net shape to accommodate them at the component design and build configuration stage and mitigate their effects. ECF22 - Loading and Environmental effects on Structural Integrity Finite element prediction and validation of residual stress profiles in 316L samples manufactured by laser powder bed fusion Richard J. Williams*, Paul A. Hooper, Catrin M. Davies Department of Mechanical Engineering, Imperial College London, SW7 2AZ, UK. Abstract Laser powder bed fusion (LPBF) processes continue to grow in popularity and much progress has been made in recent years. However, due to the extreme thermal gradients present, significant residual stresses are inevitable and can be detrimental during component service. Critical to mitigating these stresses effectively is the ability to model the thermo-mechanical process accurately and efficiently. A si plified FE modelling methodology has been devel ped and applied to a cylindrical mponent built in both the horizontal and vertical orientations. The resulting distortion of the parts following a slitting process was compared with those predicted by the model and good agreement to within 5% was found. The final stress fields in the components were predicted by the model and then examined to assess the principal stresses driving the distortion and the causes of difference in results between the two build orientations. © 2018 The Aut ors. Publish d by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: Laser powder bed fusion; LPBF; residual stress; distortion; finite element modelling * Corresponding author. E-mail address: r.williams16@imperial.ac.uk 1. Introduction Residual stresses and subsequent distortions are inevitable in components manufactured through laser powder bed fusion (LPBF). Large regions of high tensile stress, in particular, are proble atic and often present in components manufactured via LPBF (Yang Liu et al. (2016)). This coupled with the ro gh surface finish and internal porosity also characteristic of LPBF parts can be detrimental to fracture and fatigue behavior. Efficient and accessible modelling tools are required to predict these residual stress profiles and component net shape to accommodate them at the component design and build configuration stage and mitigate their effects. © 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.

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers.

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016.

2452-3216  2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. 10.1016/j.prostr.2018.12.283