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 Structural Integrity 7 (2017) 158–165 Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com 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. ∗ Corresponding author. Tel.: + 33686128527 E-mail address: theo.persenot@insa-lyon.fr 2210-7843 c 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. Additive manufacturing which can be used to produce solid parts layer by layer gives an outstanding geometrical freedom w ich opens qua i unlimited design possibilities. This technique has therefore become very attractive for producing geometrically co plex parts (Conner et al. (2014)) and in particular lattice structures which can give access to new properties that bulk material could not reach. However, before taking any step further in the industrialisation of new manufacturing techniques like Laser Beam Melting (LBM) or Electron Beam Melting (EBM), there is a strong need to characterize the mechanical properties of the constitutive material fabricated by such techniques first at a sample level and in a second step in more complex structures such as lattices. Results obtained on Ti alloys show that EBM and some traditionally manufactured samples (cast or wrought) share the same microstructure (primarily acicular -plate (Widmansttten) icrostructures) (Murr et al. (2009)). Tensile samples machined from EBM parts exhibit approximately the same mechanical (static and fatigue) properties as traditional materials (Murr et al. (2009), Facchini et al. (2009), Rafi et al. (2013), Li et al. (2016)). ∗ Corresponding author. Tel.: + 33686128527 E-mail address: theo.persenot@insa-lyon.fr 2210-7843 c 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. 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 Elsevier B.V. Peer-review under responsibility f the Sc entific Committee of the 3rd International Symp sium on Fatigue D sig and Materi l Defe ts. Fatigue properties of EBM as-built and chemically etched thin parts Theo Persenot a, ∗ , Jean-Yves Bu ffi ere a , Eric Maire a , Remy Dendievel b , Guilhem Martin b a INSA Lyon, CNRS, MATEIS, F-69621 Villeurbanne, France b Univ. Grenoble Alpes, CNRS, Grenoble INP, SIMAP, F-38000 Grenoble, France Abstract EBM as-built fatigue samples were manufactured from both fresh and recycled powder. They were characterised by laboratory X-ray tomography in order to observe the poro ity and surface state. Chemical etching w s used and a clear improvement of the surface geometry was observed and quantified through a roughness reduction. Fatigue tests were performed on as-built and etched samples. The fatigue resistance obtained for as-built samples is lower than that of machined samples ; powder recycling tends to also diminish the fatigue resistance whereas chemical etching improves it significantly. The study of the fracture surfaces coupled with the comparison of tomographic scans before and after failure shows that the crack leading to failure always initiate from a surface notch-like defect resulting from a lack of fusion. c 2017 The Authors. Published by Elsevier B.V. Peer-review under r sponsibility of the Scientific Committee of the 3rd International Symposium on Fatigue Design and Material Defects. Keywords: Electron Beam Melting, X-ray tomography, TA6V, powder recycling, Chemical etching, Fatigue tests; 1. Introduction Additive manufacturing which can be used to produce solid parts layer by layer gives an outstanding geometrical freedom which opens quasi unlimited design possibilities. This technique has therefore become very attractive for producing geometrically complex parts (Conner et al. (2014)) and in particular lattice structures which can give access to new properties that bulk material could ot reach. However, before taking any step further in the industrialisation of new manufacturing techniques like Laser Beam Melting (LBM) or Electron Beam Melting (EBM), there is a strong need t characterize the mechanical properties of the constitutive material fabricated by such techniques first at a sample level and in a second step in more complex structures such as lattices. Results obtained on Ti alloys show that EBM and some traditionally manufactured samples (cast or wrought) share the same microstructure (primarily acicular -plate (Widmansttten) microstructures) (Murr et al. (2009)). Tensile samples machined from EBM parts exhibit approximately the same mechanical (static and fatigue) properties as traditional materials (Murr et al. (2009), Facchini et al. (2009), Rafi et al. (2013), Li et al. (2016)). 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Fatigue properties of EBM as-built and chemically etched thin parts Theo Persenot a, ∗ , Jean-Yves Bu ffi ere a , Eric Maire a , Remy Dendievel b , Guilhem Martin b a INSA Lyon, CNRS, MATEIS, F-69621 Villeurbann , France b Univ. Grenoble Alpes, CNRS, Grenoble INP, SIMAP, F-38000 Grenoble, France Abstract EBM as-built fatigue samples were manufactured from both fresh and recycled powder. They were characterised by laboratory X-ray tomography in order to observe the porosity and surface state. Chemical etching was used and a clear improvement of the surface geometry was observed and quantified through a roughness reduction. Fatigue tests were performed on as-built and etched samples. The fatigue resistance obtained for as-built samples is lower than that of machined s mples ; powder recycling tends to also diminish the fatigue resistance whereas chemical etching improves it significantly. The study of the fracture surfaces coupled with the comparison of tomographic scans before and after failure shows that the crack leading to failure always initiate from a surface notch-like defect resulting from a lack of fusion. c 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: Electron Beam Melting, X-ray tomography, TA6V, powder recycling, Chemi al etching, Fatigue tests; 1. Introduction © 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.2017.11.073 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy