PSI - Issue 13

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedire t.com ienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 13 (2018) 311–316 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural I tegrity 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. ECF22 - Loading and Environmental effects on Structural Integrity Optimization of the fracture mechanical properties of additively manufactured EN AW-7075 J.-P. Brüggemann*, L. Risse, G. Kullmer, H. A. Richard Paderborn University, Direct Manufacturing Research Center (DMRC), Mersinweg 3, 33098 Paderborn, Germany Paderborn University, Fachgruppe Angewandte Mechanik (Applied Mechanics), Pohlweg 47-49, 33098 Paderborn, Germany Additive Manufacturing (AM) is a new innovative technique that allows the direct manufacturing of complex products based on their 3D data in a layer technology without tools like molds. In the meantime there are lots of materials available for AM, e.g. plastics or metals. They are used in several areas of application like aerospace, aircraft, medical technology and the automotive industry. In order to fulfil the high requirements of these industrial branches, high-quality products are expected. Selective Laser Melting (SLM) enables the production of finished parts, which can be mechanically and thermally stressed to a very high level. In aerospace, aircraft and automotive industry the lightweight design is of paramount importance. Consequently, in these industries materials with low density and high mechanical properties such as aluminum alloys are used. Therefore, high strength aluminum alloy EN AW-7075 powder, which was not previously used for AM, was produced by gas atomization and pr cessed by SLM. Initially, several process parameters w re varied in order to find th set of process parameters for the best possible result. With this set of parameters samples were produced to examine the fracture mechanical properties. To investigate the influence of the building direction regarding possible anisotropic behavior, specimens were manufactured with starting notches parallel as well as perpendicular to the building direction. For the fracture mechanical examination compact tension specimens, according to ASTM 647-08, were analyzed in order to achieve fatigue crack growth curves. To compare AM products with the conventionally manufactured aluminum alloy EN AW-7075 two different conditions (as-built and heat-treated) were examined. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. ECF22 - Loading and Environmental effects on Structural Integrity Optimization of the fracture mechanical properties of additively manufactured EN AW-7075 J.-P. Brügge ann*, L. Risse, G. Kullmer, H. A. Richard Paderborn University, Direct Manufacturing Research Center (DMRC), Mersinweg 3, 33098 Paderborn, Germany Paderborn University, Fachgruppe Angewandte Mechanik (Appli d Mechanics), Pohlweg 47-49, 33098 Paderborn, Germany Abstract Additive Manufacturing (AM) is a new innovative technique that allows the direct manufacturing of complex products based on their 3D data in a layer technology without tools like molds. In the meantime there re lots of materials available for AM, e.g. plastics or metals. Th y are used in several area of applicatio like aerospace, aircr ft, medical technology and the automotive industry. In order to fulfil the high requirements of these industrial br nches, high-quality products are expected. Selective Laser Melting (SLM) enables the production of finished parts, which c n be mechanically nd thermally stressed to a very high level. In aerospace, aircraft and automotive industry the lightweight design is of paramount i portanc . Consequently, in these i dustries materials with low density and high mechanical properties such as aluminum alloys are used. Therefore, high strength aluminum alloy EN AW-7075 powder, w ic was not previously used for AM, was produced by gas atomizati n and proc ssed by SLM. Initially, several process parameters were vari d in order to find the set of pro ss par meters for the best possible result. With this set of parameters samples were produced to examine the fracture mechanical properties. To investigate th influence of t e building direction regarding possible anisotropic behavior, specimens were manufactured with starting notches parallel as well as perpen icular to the building direction. For the fracture mechanical examination ompact tension specimens, according to ASTM 647-08, were analyzed in order to achieve fatigue crack growth curves. To compare AM products with the conventionally manufactured aluminum alloy EN AW-7075 two differ nt conditions (as-built and heat-treated) were examined. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: Additive manufacturing; selective laser melting; aluminium alloy EN AW-7075; mechanical properties; fatigue crack growth b haviour © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: Additive manufacturing; selective laser melting; aluminium alloy EN AW-7075; mechanical properties; fatigue crack growth behaviour Abstract

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 r sponsibility of the ECF22 organizers. * Corresponding author. Tel.: +49-5251-60-4388; fax:+49-5251-60-5322. E-mail address: brueggemann@fam.upb.de * Corresponding author. Tel.: +49-5251-60-4388; fax:+49-5251-60-5322. E-mail ad ress: brueggemann@fam.upb.de

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.2018.12.052