PSI - Issue 7

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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 Procedia Structu al Integrity 7 (2017) 505–512 StructuralIntegrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com ScienceDirect StructuralIntegrity Procedia 00 (2017) 000–000 ScienceDirect

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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. Copyright © 2017 The Authors. Published y Elsevier B.V. Peer-review under responsibility of he Scientific Committee of the 3rd Internation l Symposium on Fatigu Design and M terial D f cts. 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Effects of microstructure and casting defects on the fatigue behavior of the high-pressu e die-cast AlSi9Cu3(Fe) all y L. Lattanzi a *, A. Fabrizi b , A. Fortini a , M. Merlin a , G. Timelli b a University of Ferrara, Department of Engineering, Via Saragat 1, Ferrara 44122, Italy b University of Padua, Department of Management and Engineering, Stradella San Nicola 3, Vicenza 36100, Italy Abstract High-pressure die-cast (HPDC) components are being increasingly used due to good flexibility and high productivity. These aspects make HPDC suitable to produce several mass components, especially for the automotive sector. Due to the rapid filling of the die and high cooling rate, the process generally leads to the formati n of a wide variety of defects, such as porosity and oxide films. Such defects might act as starting points for fatigue cracks and thus deteriorating the fatigue behavior of the casting. To this respect, the fatigue behavior of die cast aluminum alloys is an important aspect to consider when assessing the performance of complex castings for automotive applications. In the light of these aspects, the goal of this work is to describe how the microstructure affects the fatigue crack initiation and propagation. Die cast AlSi9Cu3(Fe) specimens were produced by means of a specifically designed die and the microstructure was preliminary characterized. Uniaxial fatigue tests were performed at load co trol with a stress ratio of R = 0.1 and at a single level of stress amplitude. After the fatigue tests, the samples were investigated to assess the propagation of the fatigue cracks; the starting points of cracks were specifically identified and the obtained data suggested how defects strongly influence the damage mechanism of the material. © 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. 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Effects of microstructu and casting defects on the fatigue behavior of the high-pressure die-cast AlSi9Cu3(Fe) alloy L. Lattanzi a *, A. Fabrizi b , A. Fortini a , M. Merlin a , G. Timelli b a University of Ferrara, Department of Engineering, Via Saragat 1, Ferrara 44122, Italy b University of Padua, Department of Management and Engineering, Stradella San Nicola 3, Vicenza 36100, Italy Abstract High-pressure die-cast (HPDC) components are being increasingly used due to good flexibility and high productivity. These aspects make HPDC suitable to produce several mass components, especially for the automotive sector. Due to the rapid filling of the die and high cooling rate, the process generally leads to the form tion of a wide variety of defects, uch as orosity a d oxide films. Such defe s might act as starting points for fatigue cracks and thus deteriorating the fatigue b havior of the casting. To this resp t, t f ti behavior of die cast aluminum alloys i an important aspect to consid r when assessing the performan e of compl x casti gs for automotive applicatio s. In the light of thes aspects, the goal of this k is to describe how the microstructu affects the fatigue crack initiation and propagation. Die ca t AlSi9Cu3(Fe) specimens were produce by me ns of a cifically desig ed die and the microstructure was preliminary charact rized. Uniaxial fatigue tests were performed t load control with a stress ratio of R = 0.1 an t a singl level of stress amplitude. After the fatigue tests, the samples were investigated to assess the propagation of the fatigue cracks; the starting points of cracks were specifically identified and the obtained data suggested how defects strongly influence the damage mechanism of th material. © 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 D fects. Keywords: die cast aluminum alloy; casting defects; microstructure.

Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

* Corresponding author. Tel.: +39-0532-974843. E-mail address: lucia.lattanzi@unife.it * Corresponding author. Tel.: +39-0532-974843. E-mail address: lucia.lattanzi@unife.it

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. 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.

* 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.2017.11.119

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