PSI - Issue 7

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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) 67–74 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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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 Elsevi r B.V. Peer-review und r responsibility of the Scientific Committee of the 3rd Intern tional Symposiu on Fatigue D sign and Material Defects. 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy A novel test method for the fatigue characterization of met l powder bed fused allo s Gianni Nicoletto * University of Parma, Dept. of Engineering and Architecture, 43124 Parma, Italy Abstract This research addresses the conflicting factors of high costs of fatigue testing and large number of influencing factors that need to be investigated for PBF material and process qualification. Metal powders are remarkably expensive, the PBF production process requires expensive systems and fatigue testing requ res multiple specimens (depending the required degree of confidence) t characterize a single material/process combination. In this paper a novel fatigue test method aimed at the peculiar needs of PBF technology is initially presented and fatigue data obtained on Direct Metal Laser Sintering Ti6Al4V are validated against standard rotating bending test results. Then, the link between microstructure and directional fatigue behavior is demonstrated using the present methodology and SLM Inconel 718: namely, the stress direction parallel to build direction is the most severe. Finally, the new test method is applied to the investigation of the fatigue notch sensitivity of DMLS Ti6Al4V in relation to the notch fabrication process. Round notches in specimens with opposite fabrication orientations (i.e. up-skin vs down-skin) resulted in two notch fatigue factors and the up-skin notch has a better fatigue strength than the down-skin notch. © 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: Fatigue, test method, powder bed fusion, Ti-6Al-4V , IN718, notch 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy A n v l test method for the fatigu characterizati n of metal powder bed fused alloys Gianni Nicoletto * University of Parma, Dept. of Engineering and Architecture, 43124 Parma, Italy Abstract This research addresses the conflicting factors of high costs of fatigue testing and large umber of influencing factors that eed to be investigated for PBF material and pr cess qualification. Metal powders are remarkably expensive, the PBF production process requires expensive systems and fatigue testing requires multiple specimens (depending the required degree of confi ence) to characterize a single material/process combination. In this paper a novel fatigue test method aimed at the peculiar needs of PBF technology is initially presented and fatigue data obtained on Direct Metal Laser Sintering Ti6Al4V are validated against standard rotating bending test results. Then, the link between microstructure and directional fatigue behavior is dem strated using the present methodology and SLM Inconel 718: namely, the stress direction parallel to build direction is the most severe. Finally, the new test method is applied to the investigation of the fatigue notc sensitivity of DMLS Ti6Al4V in relation to the notch fabrication process. Round notches in specimens with opposite fabrication orientations (i.e. up-skin vs down-skin) resulted in two notch fatigue factors and the up-skin notch has a better fatigue strength than the down-skin notch. © 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: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation.

* Corresponding author. Tel. +39 0521 905884. Fax. +39 0521 905705. E-mail address: gianni.nicoletto@unipr.it * Corresponding author. Tel. +39 0521 905884. Fax. +39 0521 905705. E-mail address: gianni.nicoletto@unipr.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.2017.11.062

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