PSI - Issue 13

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedirect.com ienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 13 (2018) 249–254 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity 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 Using the Hybrid Metal Extrusion & Bonding (HYB) Process for Dissimilar Joining of AA6082-T6 and S355 Filippo Berto* a , Lise Sandnes a , Filippo Abbatinali b , Øystein Grong a,c , Paolo Ferro b a Norvegian Unieversity of Science and Technology, Dept. of Mech. and Industrial Engng, Richard Birkelands vei 2b, 7491 Trodnheim, Norway b University of Padua, Department of Management and Engineering, Stradella San Nicola 3, 36100 Vicenza, Italy. c HyBond AS, NTNU Aluminum Product innovation center, Richard Birkelands vei 2b, 7491 Trodnheim Abstract Hybrid Metal Extrusion & Bonding (HYB) is a new solid state joining technique that uses filler material addition and plastic deformation to create sound joints. The filler material addition makes the HYB process more flexible and less vulnerable to weld defects compared to conventional solid state joining techniques. Moreover, the operational temperature during processing is even lower than that reported for conventional joining techniques, which reduces the width of the heat affected zone (HAZ) significantly as well as residual stresses and contaminants in the weld zone. Here we report the joining of the dissimilar materials aluminum alloy 6082-T6 and structural steel 355. The joint is found to be free from defects like pores and internal cavities and is fully characterized herein from a metallurgical point of view. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: Welding; Hybrid Metal Extrusion & Bonding (HYB); Solid State Process; Dissi ilar Metals; Intermetallic Compounds. 1. Introduction There is a growing demand for more fuel-efficient vehicles in order to reduce the emission of greenhouse gasses. As a result, there is an increased interest in lightweight structures and the application of mixed materials, as the combined use of aluminum and steel. However, welding and fabrication of aluminum-steel products is challenging because of their large difference in physical and thermal properties (e.g. melting temperature, coefficient of thermal expansion, heat capacity and solidification shrinkage), which may give rise to a variety of weld defects (see Atabaki ECF22 - Loading and Environmental effects on Structural Integrity Using the Hybrid Metal Extrusion & Bonding (HYB) Process for Dissimilar Joining of AA6082-T6 and S355 Filippo Berto* a , Lise Sandnes a , Filippo Abbatinali b , Øystein Grong a,c , Paolo Ferro b a Norvegian Unieversity of Science and Technology, Dept. of Mech. and Industrial Engng, Richard Birkelands vei 2b, 7491 Trodnheim, Norway b University of Padu , Department of Management and Enginee ng, Stradella S n Nicola 3, 36100 Vicenza, Italy. c HyBond AS, NTNU Alu i um Product innov tion cent r, Richa d Birkel ds vei 2b, 749 Trodnheim Abstract Hybrid Metal Extrusion & Bonding (HYB) is a new solid state joining technique that uses filler material addition and plastic defo mation to create sound joi ts. The filler material add tion makes the HYB process more flexible nd less vulnerable to weld ects compared to conventi nal solid stat joining techn ques. Moreov r, the operational t mperature uring proc ssing is even lower than that reported for conventional j i i techniques, which educes the width of the heat affected zo e (HAZ) significantly as well as residual stresses a d contaminants in th weld zone. Here we report the joining of the dissimilar materials aluminum alloy 6082-T6 and structural steel 355. The joint is found to be free from d fects like pores and internal cavities and i fully characterized herein from a metal urgical point of v ew. © 2018 The Aut ors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: Welding; Hybrid Metal Extrusion & Bonding (HYB); Solid State Proc ss; Dissimilar Metals; Intermetallic Compounds. 1. Introduction There is a growing demand for more fuel-efficient vehicles in order to reduce the emission of greenhouse gasses. As a result, there is an increased interest in lightweight structures and the application of mixed materials, as the combined use of aluminum and steel. However, welding and fabrication of aluminum-steel products is challenging because of their large difference in physical and th rmal properties (e.g. melting temperature, coefficient of thermal exp nsion, heat capacity and solidification shrinkage), which may give rise to a variety of w ld defe ts (see Atabaki © 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 r sponsibility of the ECF22 o ganizers. * Corresponding author. Tel.: +47 485 00 575; fax: +47 485 00 576. E-mail address: Filippo.Berto@ntnu.no * Corresponding author. Tel.: +47 485 00 575; fax: +47 485 00 576. E-mail ad ress: Filippo.Berto@ntnu.no

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.2018.12.042