PSI - Issue 7

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at ww.sciencedire t.com ienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 P o edi Structural Integr ty 7 (2017) 19–26 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2017) 000–000

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2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of the 3rd International Symposium on Fatigue Design and Material Defects. D efects were mostly gas porosity and those made by lack of fusion. Many pores which were formed near surface were eliminated by HIP and ventually HIP mproved fatigue strength drastically to the level of the ideal fatigue limit to be expected from the hardness. Surface roughness had strong detrimental influenc on fatigue strength. The method for estimating the effective size √ area effmax of irregularly shaped defects and interacting adjacent defects was proposed from the viewpoint of fracture mechanics. Although the stati tics of extremes analysis is useful for th quality control of AM, the particular surface effect and interaction effect of adjacent defects must be carefully considered. The effective defect size for adjacent defects is much larger than a single defect. Since the orientations of defects in AM materials are random, a defect in contact with specimen surface has a higher influence (termed as the effective defect size √ area eff ) than the real size of the defect from the viewpoint of fracture mechanics. Considering the volume and number of productions of components, the lower bound of the fatigue limit σ wl based on √ area effmax can be determined by the √area parameter model. _______________________________________________________________________________________________________ * Corresponding author. E-mail address: murakami.yukitaka.600@m.kyushu-u.ac.jp 2452-3216 © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of the 3rd International Symposium on Fatigue Design and Material Defects. Abstract The additive manufacturing (AM) is expected to be the promising manufacturing process for high strength or hard steels such as Ti-6Al-4V for the aerospace industry components having complex shapes. However, disadvantage or challenge of AM is presence of defects which are inevitably contained in the manufacturing process. This paper focuses on the effects of defects, surface roughness and Hot Isostatic Pressing (HIP) process on the fatigue strength of a Ti-6Al-4V manufactured by AM. The guide is presented for the fatigue design and development of high quality and high strength Ti-6Al-4V by AM processing based on the combination of the statistics of extremes on defects and the √ area arameter model. D efects were mostly gas porosi y and those made by lack of fusion. Many pores which were formed near surface were eliminated by HIP and ventually HIP mproved f tigue strength drastically to the level of the ideal fatigue limit to e exp ct d from the hardness. Surf ce ro g ne s had strong d trime tal influence on fatigue strength. The method for estimating the effective size √ ar a effmax of irregularly shaped defects and interacting adjacent defects was pr posed from th viewpoi t of fracture mechanics. Although the statistics of extremes analysis is useful for the quality control of AM, the particular surface effect and interaction effect of adjacent defects must be carefully considered. The effective defect size for adjacent defects is uch larger than a single defect. Since the orientations of defects in AM materials are random, a defect in contact with specimen surface has a higher influence (termed as the effective defect size √ area eff ) than the real size of the defect from the viewpoint of fracture mechanics. Considering the volume and number of productions of compon nts, the lower bound of the fatigue limit σ wl based on √ area effmax can be determin d by the √area parameter model. _______________________________________________________________________________________________________ * Corresponding author. E-mail address: murakami.yukitaka.600@m.kyushu-u.ac.jp 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. 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Eff cts f Defects, Surface Roughness and HIP on Fatigue Strength of Ti-6Al-4V m nufactured by Additive Manufacturing Hiroshige Mas uo a , Yuzo Tanaka b , Shotaro Morokoshi a , HajimeYagura a , Tetsuya Uch da a , Yasuhiro Yamamoto a Yuk t ka Murakam b,c* a Metal Technology Co.Ltd., Ebina, Kanagawa, 243-0424, Japan b KMTL (Kobe Material Testing Laboratory Co. Ltd., Kako-gun, Hyogo, 675-0155, Japan c Kyushu University, Fukuoka, Japan Abstract The additive manufacturing (AM) is expected to be the promising manufactu ing process for high strength or h rd steels such as Ti-6Al-4V for the aerospace industry components having complex shapes. However, disadvantage or challenge of AM is presence of def cts which are inevitably contained in th manufacturing process. This paper focus s on the effects of defects, su face ro ghness and Hot Isostatic Pressing (HIP) proc ss n the fatigue strength of a Ti-6Al-4V m nufactured by AM. The guid is presented for the fatigue design and dev lopment of high quality and high strength Ti-6Al-4V by AM processing based on the combination of the statistics of extremes on defects and the √ area parameter model 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Effects of Defects, Surface Roughness and HIP on Fatigue Strength f Ti-6Al-4V manufactured by Additive Manufacturing Hiroshige Mas uo a , Yuzo Tanaka b , Shotaro Morokoshi a , HajimeYagura a , Tetsuya Uchida a , Yasuhiro Yamamoto a , Yukitaka Murakami b,c* a Metal Technology Co.Ltd., Ebina, Kanagawa, 243-0424, Japan b KMTL (Kobe Material Testing Laboratory Co. Ltd., Kako-gun, Hyogo, 675-0155, Japan c Kyushu University, Fukuoka, Japan © 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 Copyright  2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of the 3rd International Symposium on Fatigue Design and Material Defects. 10.1016/j.prostr.2017.11.055 Copyright © 2017 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of the 3rd International Symposium on Fatigue Design and Material Defects.