PSI - Issue 7

ScienceDirect Available online at www.sciencedirect.com Av ilable online at ww.sciencedire t.com Scie ceDirect Structural Integrity Procedia 00 (2016) 000 – 000 P o edi Structural Integr ty 7 (2017) 58–66 Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com 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 by El evier B.V. Peer-review und r responsibility of the Scient fic Committe of th 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 Fatigue Properties Of Additively Manufactured AlSi10Mg – Surface Treatment Effect Ana D. Brandão a , Johannes Gumpinger a* , Michael Gschweitl b , Christoph Seyfert c , Peter Hofbauer c , Tommaso Ghidini a a ESA/ESTEC, European Space Research and Technology Center b RUAG Schweiz AG, RUAG Space, Zurich, Switzerland c EOS GmbH Electro Optical Systems, Krailling / Munich, Germany Abstract Space industry strives to constantly increase performance and reduce costs of space missions. When dealing with producing space components Additiv Manufacturing (AM) is seen as a gam changing technology also towards these goals. The applicability f this technology has already been demonstrated for space products and parts are currently flying. However, further studies are still needed to better understand the process parameters-final properties relationship. With this aim, a cooperative R&D activity was designed by EOS, RUAG and ESA, in order to characterise the fatigue behaviour of AlSi10Mg processed via AM. This activity comprised the study of the influence of building direction, platform temperature, powder layer thickness, surface finish and heat treatment on the fatigue properties of the AM specimens. As a complementary assessmen , the defect population of the s mples was studied through X-ray Computed Tomo raphy (XCT). Results showed that th re is a direct correlation between the pr cess param ters nd he fatigue prop rties of AlSi10Mg arts, having received the same post processing. Observations indicat that changing the parameters influences the charact ristics of the defect population, determining the fatigue life of the specimens. In addition, the differen su face finishing methods have, as expected, a strong impact on he fatigue behaviour of AM AlSi10Mg mater als. This study shows that an optimised combination of proc ss parameters and surface finish can improve fatigue performance, without the need for machining of the AM parts. © 2017 Th Authors. Published by Elsevier B.V. eer-re ie un er res sibilit f t e cientific om ittee of the 3rd International ymposiu on atigue esign and aterial efects. 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Fatigue Properties Of Additively Manufactured AlSi10Mg – Surface Treatment Effect Ana D. Brandão a , Johannes Gumpinger a* , Michael schweitl b , Christoph Seyfert c , Peter Hofbauer c , Tomma o Ghidini a a ESA/ESTEC, European Space Research and Technology Center b RUAG Schweiz AG, RUAG Space, Zurich, Switzerland c EOS GmbH Electro Optical Systems, Krailling / Munich, Germany Abstract Space industry strives to constantly increase performance and reduce costs of space missions. When dealing with producing space components, Additive Manufacturing (AM) is seen as a game changing technology also towards these goals. The applicability of this technology has already been demonstrated for space products and parts are currently flying. However, further studies are still needed to better understand the process parameters-final properties relationship. With this aim, a cooperative R&D activity was designed by EOS, RUAG and ESA, in order to characterise the fatigue behaviour of AlSi10Mg processed via AM. This activity comprised the study of the influence of building direction, platform temperature, powder layer thickness, surface finish and heat treatment on the fatigue properties of the AM specimens. As a complementary assessment, the defect population of the samples was studied through X-ray Computed Tomography (XCT). Results showed that there is a direct correlation between the process parameters and the fatigue properties of AlSi10Mg parts, having received the same post processing. Observations indicate that changing the parameters influences the characteristics of the defect population, determining the fatigue life of the specimens. In addition, the different surface finishing methods have, as expected, a strong impact on the fatigue behaviour of AM AlSi10Mg materials. This study shows that an optimised combination of process parameters and surface finish can improve fatigue performance, without the need for machining of the AM parts. © 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. Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. 1. Introduction In the recent years, Additive Manufacturing (AM) has emerged as an enabling technology for high end applications, namely in biomedical, automotive, aeronautics and space industries. In AM physical objects are manufactured by adding material incrementally, layer by layer, allowing to build parts with high geometrical complexity, impossible to obtain using traditional 1. Introduction In the recent years, Additive Manufacturing (AM) has emerged as an enabling technology for high end applications, na ely in biomedical, automotive, aeronautics and space industries. In AM physical objects are manufactured by adding material incrementally, layer by layer, allowing to build parts with high geometrical complexity, impossible to obtain using traditional © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: Additive Manufacturing; AlSi10Mg; Fatigue Properties; Surface Finish; Defect Population Keywords: Additive Manufacturing; AlSi10Mg; Fatigue Properties; Surface Finish; Defect Population

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt * Corresponding author. Tel.: +31-71-565-4244; fax: +71-565-3864. E-mail address : Johannes.gumpinger@esa.int * Corresponding author. Tel.: +31-71-565-4244; fax: +71-565-3864. E-mail address : Johannes.gumpinger@esa.int

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-revi w under responsibility of the Scientifi Committee of the 3rd International Symposium on Fatigue Design and Material Defects. 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.2017.11.061 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.