PSI - Issue 2_B

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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. 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Time Saving Method for Measuring VHC Fatigue and Fatigue Crack Growth Data with the Ultrasonic Fatigue Technique Stefanie E. Stanzl-Tschegg a a University of Natur l Resources and Life Sciences, BOKU Vienna, Peter Jordan St. 82, 1190 Wien, Austria Abstract The principles of the ultrasonic 20 kHz technique are shortly described and its peculiaritie explained. Considering the technical requirements, such as an on-line amplitude and frequency feedback control and use of appropriate cooling allow obtaining data of high accuracy and reliability. Life-time data at constant and variable amplitudes, as well as fracture-mechanical values, such as (  a /  N ) vs.  K curves can be obtained, and especially endurance limit and  K thresholds can be obtained in a highly time saving way. Some examples of performing measurements under superimposed loading conditions are shown. One is on-line observation of specimens during loading and simultaneous mechanical measurements plus fractography after final fracture so that, the correlation of these results allows quantitative information on (  a /  N ) and  K values in the VHCF regime. Another new technique led to a two-step model of small-crack initiation and propagation from corrosion pits. Investigations on polycrystalline copper likewise rendered interior fatigue-crack formation from persistent slip bands and corroborated that, arrest of small cracks is mainly responsible for several unexpected results in the VHCF regime. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. Keywords: VHCF; small cracks; fatigue limits; (  a /  N vs.  K )-curves; thresholds. 1. Introduction Ultrasonic fatigue loading is a time-saving technique for determining fatigue, fatigue crack initiation and propagation properties and data especially in the very-high cycle fatigue (VHCF) regime. It has been used first by Neppiras (1959) for measuring S - N curves up to about 10 8 cycles in 1959, after Mason (1956) had applied ultrasonic loading to fracture materials by fatigue. Mitsche et al. (1973) demonstrated that, the ultrasonic technique is also appropriate to perform fracture mechanical measurements. Increased attention was paid to this technique after Naita et al. (1984) found out that high-strength steels failed at more than 10 9 cycles under special testing conditions. The main advantage of the ultrasonic technique is to obtain very high numbers of cycles, e.g. 10 10 cycles within reasonable testing times so that, it is appropriate to perform tests in a time-saving manner. Thus thresholds of life-times (endurance limits) and fracture mechanical thresholds (d a /d N and  K th ) can be determined in the VHCF regime that cannot be measured with conventional testing machines. The ultrasound machines have been developed to a universal testing technique by applying appropriate control units (Stanzl-Tschegg (1999)) which allow high accuracy and reliability of amplitude and frequency measurement (Mayer (1999)) and the introduction of periodic pauses so that, constant amplitude (CA), variable-amplitude (VA) loading with or without superimposed constant or varying-low amplitudes can be performed (Stanzl-Tschegg (2014)). 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Ti e Saving Method for Measuring VHC Fatigue and Fatigue Crack ro th ata ith the ltrasonic Fatigue Technique Stefanie E. Stanzl-Tschegg a a University of Natural Resources and Life Sciences, BOKU Vienna, Peter Jordan St. 82, 1190 Wien, Austria Abstract The principles of the ultrasonic 20 kHz technique are shortly described and its peculiarities explained. Considering the technical requirements, such as an on-line amplitude and frequency feedback control and use of appropriate cooling allow obtaining data of high accuracy and reliability. Life-time data at c nstant and variable amplitudes, as well as fracture-mechanical values, such as (  a /  N ) vs.  K curves can be obtained, and especially endurance imit and  K thresholds can be obtained in a highly time saving way. Some examples of performing measurements under superimposed loading conditions are shown. One is on-line observation of specimens during loading and simultaneous mechanical measurements plus fractography after final fracture so that, the correlation of these r sults llows quantitative information on (  a /  N ) an  K values in the VHCF regime. Another new technique led to a two-step model of small-crack initiation and propagation from corrosion pits. Investigations on polycrystalline copper likewise rendered interior fatigue-crack formation from persistent slip bands and corroborated that, arrest of small cracks is mainly responsible for several unexpected results in the VHCF regime. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility f the Sc entific Committee of ECF21. Keywords: VHCF; small cracks; fatigue limits; (  a /  N vs.  K )-curves; thresholds. 1. Introduction Ultrasonic fatigue loadi g is a time-saving technique for determining fatigue, fatigu crack initiation and propag tion properties and data especially in the very-high cycle f tigue (VHCF) regime. It has been us first by Neppiras (1959) for measuring S - N curves up to about 10 8 cycles in 1959, after Mason (1956) had applied ultrasonic loading to fracture materials by fatigue. Mitsche et al. (1973) demonstrated that, the ultrasonic technique is also appropriate to perform fracture mechanical measurements. Increased attention was paid to this technique after Naita et al. (1984) found out that high-strength steels failed at more than 10 9 cycles under special testing conditions. The main advantage of the ultrasonic technique is to obtain very high numbers of cycles, e.g. 10 10 cycles within reasonable testing times so that, it is appropriate to perform tests in a time-saving manner. Thus thresholds of life-times (endurance limits) and fracture mechanical thresholds (d a /d N and  K th ) can be determined in the VHCF regime that cannot be measured with conventional testing machines. The ultrasound machines have been developed to a universal testing technique by applying appropriate control units (Stanzl-Tschegg (1999)) which allow high accuracy and reliability of amplitude and frequency measurement (Mayer (1999)) and the introduction of periodic pauses so that, constant amplitude (CA), variable-amplitude (VA) loading with or without superimposed constant or varying-low amplitudes can be performed (Stanzl-Tschegg (2014)). 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/). eer-review under responsibility of the Scientific Committee of ECF21. © 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 © 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.2016.06.002 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21.