PSI - Issue 19

A. Halfpenny et al. / Procedia Structural Integrity 19 (2019) 150–167 Author name / Structural Integrity Procedia 00 (2019) 000–000

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4.2. Deterministic simulation A finite element model of the intercooler was constructed using Abaqus. Fatigue analyses were performed using nCode DesignLife. The FEA model is shown in Fig. 10.

Fig. 10. Finite element model showing first 4 fatigue failure location sites

The header rail is made of aluminium alloy AL 3915. Strain-Life (EN) fatigue characterisation tests were performed on the sheet material by HBM Prenscia – Advanced Materials Characterisation and Testing (AMCT) services. The regression curve, with 90% confidence error bounds, is shown in Fig. 11.