PSI - Issue 2_A

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at ww.sciencedire t.com Sci ceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 2 (2016) 358–365 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2016) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2016) 000–000 il l li t . i i t. t t l Integrit cedia 00 (2016) 000–000

www.elsevier.com/locate/procedia www.elsevier.com / locate / procedia www.elsevier.com / locate / procedia . l i . / l t / i

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Copyright © 2016 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 ECF21. 10.1016/j.prostr.2016.06.046 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. ∗ Corresponding author. Tel.: + 49-3731-393452 ; fax: + 49-3731-393703. E-mail address: sebastian.henschel@iwt.tu-freiberg.de 2452-3216 © 2016 The Authors. Published by Elsevier B.V. e r-review under responsibil ty of the Scientific Committee of ECF21. © 0 t . li l i . . i i ilit t i ti itt e 1. Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. Non-metallic inclusions in a cast steel can originate from the refractory materials or the melt treatment (Zhang and Thomas (2003)). As a result of the deoxidation treatment, oxide inclusion are formed and transferred to the slag. However, a certain amount of oxygen and deoxidation agent (Al) will remain dissolved in the metal melt. During the cooling in the casting process, these elements will form endogenous inclusions (Dekkers et al. (2002)). It is known that non-metallic inclusions have a detrimental e ff ect on the mechanical properties of metals, such as elongation at fracture (Henschel et al. (2013)). The detrimental e ff ect is the result of the promotion of ductile fracture (Henschel and Kru¨ger (2016)). Ductile fracture initiates preferentially at non-metallic inclusions due to their large size compared to other initiation sites, e.g. carbides (Garrison and Moody (1987)). Non-metallic inclusions in a cast steel can originate from the refractory materials or the melt treatment (Zhang and Thomas (2003)). As a result of the deoxidation treatment, oxide inclusion are formed and transferred to the slag. However, a certain amount of oxygen and deoxidation agent (Al) will remain dissolved in the metal melt. During the cooling in the casting process, these elements will form endogenous inclusions (Dekkers et al. (2002)). It is known that non-metallic inclusions have a detrimental e ff ect on the mechanical properties of metals, such as elongation at fracture (Henschel et al. (2013)). The detrimental e ff ect is the result of the promotion of ductile fracture (Henschel and Kru¨ger (2016)). Ductile fracture initiates preferentially at non-metallic inclusions due to their large size compared to other initiation sites, e.g. carbides (Garrison and Moody (1987)). 2 o H c ff ff ( * Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt ∗ Corresponding author. Tel.: + 49-3731-393452 ; fax: + 49-3731-393703. E-mail address: sebastian.henschel@iwt.tu-freiberg.de i t . l.: ; : . il ti . l i t.t i . 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. 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy E ff ect of non-metallic inclusions and shrinkage cavities on the dynamic fractur toughness of a high-strength G4 CrMo4 cast teel S. Henschel a, ∗ , S. Dudczig b , L. Kru¨ger a , C. G. Aneziris b a Institute of Materials Engineering, TU Bergakademie Freiberg, Gustav-Zeuner-Str. 5, 09599 Freiberg, Germany b Institute of Ceramic, Glass and Construction Materials, TU Bergakademie Freiberg, Agricolastr. 17, 09599 Freiberg, Germany Abstract The formation and clustering of non-metallic inclusions was investigated by applying a steel casting simulator. In a fully controlled atmosphere, the oxygen content of the steel melt was intentionally increased. At a specified level, the steel was deoxidized by pure aluminum. After the treatment, the melt was cooled down in the crucible. The e ff ects of the inclusions and the cavities were determined by means of metallography, tensile tests, dynamic fracture toughness tests, and fractography. Metallographic results show that alumina particles have a strong tendency to aggregate at the walls of the crucible. Neglecting this aggregation, a relatively homogeneous distribution of alumina inclusions was observed. Furthermore, the solidified steel exhibited manganese sulphide inclusions and shrinkage cavities. The results of the tensile tests revealed a relatively low ductility. Fractographic examinations showed that both non-metallic inclusions and shrinkage cavities promoted ductile fracture. Results of dynamic fracture toughness tests revealed a relatively large scatter in the dynamic crack r sistance. This was analogously attributed to the damaging e ff ect of the non-metallic inclusions and the shrinkage c vities. Fra t graphic investigations showed that not only alumina inclusions but pref renti lly ma ganese sulphide inclusions a ff ected ailure behavior of the investigated stee . © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibili y of the Scientific Committee of ECF21. Keywords: Non-metallic inclusions; shrinkage cavities; steel casting simulator; dynamic fracture toughness; high-strength steel 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy E ff ect of non-metallic inclusions and shrinkage cavities on the dynamic fracture toughness of a high-strength G42CrMo4 cast steel S. Henschel a, ∗ , S. Dudczig b , L. Kru¨ger a , C. G. Aneziris b a Institute of Materials Engineering, TU Bergakademie Freiberg, Gustav-Zeuner-Str. 5, 09599 Freiberg, Germany b Institute of Ceramic, Glass and Construction Materials, TU Bergakademie Freiberg, Agricolastr. 17, 09599 Freiberg, Germany Abstract The formation and clustering of non-metallic inclusions was investigated by applying a steel casting simulator. In a fully controlled atmosphere, the oxyg cont nt of the steel melt was intentionally increased. At a specified level, the steel was deoxidized by pure aluminum. After the treatment, the melt was cooled down in the crucible. The e ff ects of the inclusions and the cavities were determined by means of metallography, tensile tests, dynamic fracture toughness tests, and fractography. Metallographic results show that alumina particles have a strong tendency to aggregate at the walls of the crucible. Neglecting this aggregation, a relatively homogeneous distribution of alumina inclusions was observed. Furthermore, the solidified steel exhibited manganese sulphide inclusions and shrinkage cavities. The results of the tensile tests revealed a relatively low ductility. Fractographic examinations showed that both non-metallic inclusions and shrinkage cavities promoted ductile fracture. Results of dynamic fracture toughness tests revealed a relatively large scatter in the dynamic crack resistance. This was analogously attributed to the damaging e ff ect of the non-metallic inclusions and the shrinkage cavities. Fractographic investigations showed that not only alumina inclusions but preferentially manganese sulphide inclusions a ff ected the failure behavior of the investigated steel. © 2016 The Authors. Published by Elsevier B.V. P er-review under responsibility of the Scientific Committee of ECF21. Keywords: Non-metallic inclusions; shrinkage cavities; steel casting simulator; dynamic fracture toughness; high-strength steel 2 , tit t f t i l i i , i i , t t . , b , tit t of Cer i , lass and Const tion M terials, TU Bergakademie Freiberg, A i l t . , 09599 Freiberg, Germany T . , the oxygen content of the steel melt was intentionally increased. At a specified level, the steel was deoxidized by pure aluminum. Aft r the treatment, the melt was cooled o the crucible. T ff f the inclusion eans of metallography, tensile tests, dynamic fract re toughness tests, and fractography. Metallographic results show that alumina particles have a strong tendency to aggregate at the walls of the crucible. Neglecting this aggregation, a relatively homogeneous distribution of alumina inclusions was observed. Furthermore, the solidified steel exhibited manganese sulphide inclusions and shrinkage cavities. The results of the tensile tiv . raphic examinations showed that both non-metallic inclusions and shrinkage ca . ghness tests revealed a relatively large scatter in the dynamic crack r si tan . nalogously attributed to the damag n e ect of the non-metallic inclusion and the s . s but preferentially manganese sulphide inclusions a ected the failure behavior of the investigated steel. © 2016 The Auth . . . e n r e ponsibi ty of t C itte of E F21. K et lli i l i ; i c iti ; t l ti i l t ; i t t ; i t t t l Copyright © 2016 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/). P r-review under r spons bility f the Scientifi Committ of ECF21. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 1. Introduction 1. Introduction