PSI - Issue 7

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) 513–52 Structural Integrity Procedia 00 (2017) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity 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 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 Influence of natural defects on the fatigue limit of a cast Al-Si alloy A. Rotella a,b* , Y. Nadot a , M. Piellard b , R. Augustin b a Institut Pprime, CNRS, ISAE-ENSMA, Universit é de Poitiers, T é l é port 2, 1 Avenue Cl é ment Ader, 86961 Futuroscope Chasseneuil Cedex, France b Safran Tech, Etablissement SAFRAN PARIS-SACLAY, 1 rue Genevi è ve Aub é , 78772 Magny Les Hameaux Cedex, France Abstract Experimental high cycle fatigue tests have been performed in order to define the impact of casting shrinkages on the fatigue limit of the A357-T6 cast Aluminum alloy. Both cavity and sponge shrinkages have been analyzed. The effect of the defect morphology on the fatigue limit has been investigated for natural and artificial surfa e defects. Th stress / strain distribution around a natural cavity shrinkage has been investigated by means of µ-CT analysis and finite elements simulations on the real defect shape. The results obtained on the real defect morphology have been compared with two equivalent geometries: a sphere and an ellipsoid. © 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: Cast Aluminum alloys, defect morphology, natural shrinkages, high cycle fatigue, µ-CT 1. Introduction Al-Si-Mg ast alloys are largely employed in both automotive and aeron u ical industry to produce r latively cheap and light complex components. These alloys are characterized by an excellent castability as well as a good strength to weight ratio. Cast component are regularly affected by the presence of natural defects of different nature, shrinkages, gas pores, inclusions. The presence of defects has normally a negative effect on the mechanical properties of the material and different studies proved the detrimental effect of surface natural defects toward the high cycle fatigue 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy Influence of natural defects on the fatigue limit of a cast Al-Si alloy A. Rotella a,b* , Y. Nadot a , M. Piellard b , R. Augustin b a Institut Pprime, CNRS, ISAE-ENSMA, Universit é de Poitiers, T é l é po t 2, 1 Avenue Cl é m nt Ader, 86961 Futuroscope hasseneuil C dex, France b Safran Tech, Etablissement SAFRAN PARIS-SACLAY, 1 rue Genevi è ve Aub é , 78772 Magny Les Hameaux Cedex, France Abstract Experimental high cycle fatigue tests have been performed in order to define the impact of casting shrinkages on the fatigue limit of the A357-T6 cast Aluminum alloy. Both cavity and sponge shrinkages have been analyzed. The effect of the defect morphology on the fatigue limit has been investigated for natural and artificial surface defects. The stress / strain distribution around a natural cavity shrinkage has been investigated by means of µ-CT analysis and finite elements simulations on the real defect shape. The result obtained on the real defect morphology have been compared with two equivalent geometries: a sphere and an ellipsoid. © 2017 The Authors. Publishe 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: Cast Aluminum alloys, defect morphology, natural shrinkages, high cycle fatigue, µ-CT 1. Introduction Al-Si-Mg cast alloys are largely employed in both automotive and aeronautical industry to produce relatively cheap and light complex components. The alloys are characterized by an excellent castability as well as a good strength to weight ratio. Cast component are regularly affected by the presence of natural defects of different nature, shrinkages, gas pores, inclusions. The presence of defects has normally a negative effect on the mechanical properties of the material and different studies proved the detrimental effect of surface natural defects toward the high cycle fatigue © 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.: +33(0)549498215; fax: +33(0)549498238. E-mail address: antonio.rotella@ensma.fr

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.: +33(0)549498215; fax: +33(0)549498238. E-mail address: antonio.rotella@ensma.fr

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016.

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.2017.11.120