PSI - Issue 4

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ScienceDirect Available online at www.sciencedirect.com Av ilable o line at ww.sciencedire t.com ScienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 P o edi Structural Integr ty 4 (2017) 64–70 Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2017) 000–000

www.elsevier.com / locate / procedia

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www.elsevier.com/locate/procedia ESIS TC24 Workshop ”Integrity of Railway Structures”, 24-25 October 2016, Leoben, Austria RAAI Project: Life-prediction and prognostics for railway axles under corrosion-fatigue damage S. Beretta a, ∗ , F. Sangalli a , J. Syeda b , D. Panggabean b , J. Rudlin b a Politecnico di MIlano, Dept. Mech. Engineering, Via La Masa 1, Milano 20156, Italy b TWI, Granta Park, Great Abington, Cambridge CB21 6AL, UK Abstract Corrosion damage induced by atmospheric agents has been shown to be able to trigger fatigue failures of railway axles. In this paper we firstly discuss consolidated results in modelling the growth of damage under corrosion-fatigue and its detection. This is the background for describing the development of a new prognostic tool within the RAAI EU-funded project. In details, the new tool relies on a new autom ted scanner able to e ffi ciently analyse optical measurements of the corroded axle surface and crack growth simulation tool tuned through full-scale measurements of axle corrosion-fatigue damage. c 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. Keywords: railway axles; corrosion-fatigue ; detection; prognostics ESIS TC24 Workshop ”Integrity of Railway Structures”, 24-25 October 2016, Leoben, Austria RAAI Project: Life-prediction and prognostics for railway axles under corrosion-fatigue dam ge S. Beretta a, ∗ , F. Sangalli a , J. Syeda b , D. Panggabean b , J. Rudlin b a Politecnico di MIlano, Dept. Mech. Engineering, Via La Masa 1, Milano 20156, Italy b TWI, Granta Park, Great Abington, Cambridge CB21 6AL, UK Abstract Corro ion dam ge induced by atmospheric agents has been shown t be able t trigger fatigue failures of railway axles. In this paper e firstly discuss consolidated re ults in modelling th gr wth of damag under corrosi n-fatigue and its detection. This is the backgrou d f r describing the development of a new pr gnosti to l within the RAAI EU-funded project. In details, the new tool relies on a new automated scanner able to e ffi ciently analyse optical measurements of the corroded axle surface and a crack growth simulation tool tuned through full-scale measurements of axle corrosion-fatigue damage. c 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. Keywords: railway axles; corrosion-fatigue ; detection; prognostics www.elsevier.com / locate / procedia ESIS TC24 rkshop ”Integrity of Railway Structures”, 24-25 October 2016, Leoben, Austria I Project: Life-prediction and prognostics for rail ay axles under corrosion-fatigue da age S. Beretta a, ∗ , F. Sangalli a , J. Syeda b , D. Panggabean b , J. Rudlin b a Politecnico di MIlano, Dept. Mech. Engineering, Via La Masa 1, Milano 20156, Italy b TWI, Granta P rk, Great Abing on, Cambridge CB21 6AL, UK Abst act Corrosion damage induced by atmospheric agents has been shown to be able to trigger fatigue failures of railway axles. In this paper we firstly discuss consolidated results in modelling the growth of damage under corrosion-fatigue and its detection. This is the background for describing the development of a new progn stic tool within the RA I EU-funded project. In details, the new tool relies on a new automated scanner able to e ffi ciently analyse optical measurements of the corroded axle surface and a crack growth simulation tool tuned through full-scale measurements of axle corrosion-fatigue damage. c 2017 The Authors. Published by Els vier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. Keywords: railway axles; corrosion-fatigue ; detection; prognostics Copyright © 2017. The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. 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. Localised c rrosive attack due to the electroc mical action of atmosph ric agents, onto the surface of un oated axles or corresponding to damaged zones of the coating for coated axles, are often found at the maintenance inspec tions. Moreover, it has been reported that fatigue cracks initiated at corrosion pits, have been the cause of recent railway axle failures both as reported by Hoddinott (2004); Transportation Safety Board of Canada (2001). The degra dation due to corrosion shown by railway axles has increasingly become an area of concern. However, in spite of the many recent research activities on experiments (small-scale and full-scale tests) and degradation models, the problem that remains still open is the unavailability of a tool for quickly assessing the remaining service life of a corroded axle. This is one of the aims of the RAAI (2015) EU-funded Project, whose concept for a new NDT method for mea suring and assessing the corrosion-fatigue damage of an axle is here discussed after a brief overview of the previous results by the authors in this area. 1. Introduction Localised corrosive attack due to the electrochemical action of atmospheric agents, onto the surface of uncoated axles or corresponding to damaged zones of the coating for coated axles, are often found at the maintenance inspec tions. Moreover, it has been reported that fatigue cracks initiated at corrosion pits, have been the cause of recent railway axle failures both as rep rted by Hoddinott (2004); Transportation Safety Board of Canada (2001). The degra dation due to corrosion shown by railway axles has increasingly become an area of concern. However, in spit of the many recent research ctivities on experiments (small-scale and full-scale tests) and degradation models, the problem that remains still open is the unavailability of a tool for quickly ass ssing the remaining service life of a corroded axle. This is one of the aims of the RAAI (2015) EU-funded Project, whose concept for a new NDT method for mea suring and assessing the corrosion-fatigue damage of an axle is here discussed after a brief overview of the previous results by the authors in this area. 1. Introduction Localised corrosive attack due to the electrochemical action of atmospheric agents, onto the surface of uncoated axles or corresponding to damaged zon s of the coating for coated axles, are often found at the maintenance inspec tions. Moreover, it has been reported that atigue cracks initiated at corrosion pits, have been the cause of recent railway axle failures both as reported by Hoddinott (2004); Transportation Safety Board of Canada (2001). The degra dation due to corrosion shown by railway axles has increasingly become an area of concern. However, in spite of the many recent research activities on experiments (small-scale and full-scale tests) and degradation models, the problem that remains still open is the unavailability of a tool for quickly assessing the remaining service life of a corroded axle. This is one of the aims of the RAAI (2015) EU-funded Project, whose concept for a new NDT method for mea suring and assessing the corrosion-fatigue damage of an axle is here discussed after a brief overview of the previous results by the authors in this area. © 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. 1. Introduction

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216 Copyright  2017. The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24 10.1016/j.prostr.2017.07.010 ∗ Corresponding author. Tel.: + 39-0223998246 ; fax: + 39-0223998202. E-mail address: stefano.beretta@polimi.it 2452-3216 c 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. ∗ Corresponding author. Tel.: + 39-0223998246 ; fax: + 39-0223998202. E-mail address: stefano.beretta@polimi.it 2452-3216 c 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. ∗ Corresponding author. Tel.: + 39-0223998246 ; fax: + 39-0223998202. E-mail address: stefano.beretta@polimi.it 2452-3216 c 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ESIS TC24. * Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt