PSI - Issue 7

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at ww.sciencedire t.com Sci ceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 7 (2017) 166–173 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 f 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 Strain concentrations in BCC micro lattices obtained by AM L. Boniotti * , S. Beretta, S. Foletti, L. Patriarca Politecnico di Milano, Dept. Mechanical Engineering, Via La Masa 1, 20156 Milano, Italy Abstract The micro-lattices produced by additive manufacturing process (AM) represent a recent important advancement for engineering structural applications, in particular for weight-saving purposes. The design of the components manufactured with these meta materials generally refers to the idealized structures. In reality, the geometry obtained by the AM process profoundly differs from the original one, in particular local geometrical irregularities were fou d to produce local stress and stra n localizations which are difficult to be a-priori predicted by the analyses on the idealized str ctures. These geometrical defects may have a significant role for the structural integrity of the component and it is important to quantify their effect on the local stress and strain fields. In this study, we present an experimental investigation of a typical AlSi10Mg micro-lattice, namely the BCC cell. 3D tomography was used to reconstruct the original geometry and, successively, full-field digital image correlation strain measurements were performed to capture the localization of strains which are considered the precursor of the micro-lattice damage. The local strain measurements were used to calculate and classify the strain concentration factors arising from the geometrical irregularities. These results were compared with the finite element results obtained for the idealized and the real micro-lattice geometries providing important considerations for the structural integrity assessment of the components produced with the AM micro-lattices. © 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: Additive Manufacturing, 3D tomography, Digital Image Correlation, Strain localization 3rd International Symposium on Fatigue Design and Material Defects, FDMD 2017, 19-22 September 2017, Lecco, Italy St ain concentrations in BCC micro lattices obtained by AM L. Boniotti * , S. Beretta, S. Foletti, L. Patriarca Politecnico di Milano, Dept. Mechanical Engineering, Via La Masa 1, 20156 Milano, Italy Abstra t The micro-lattices produced by additiv manufacturing process (AM) rep esent a recent important advancement for enginee ing structural applications, in particular f r weight-saving purpos s. he esig of the components manufactured with these meta materials generally refers to the idealized structures. In reality, the geom try obtain d by the AM process profoundly differs fr m the original one, i particular local geom trical irregularities were fou d to produce local str ss and strain localizations which are difficult to b a-priori predict d by the analyses on the idealized structures. These geometrical defects may have a significant role for the structural integrity of the compone t and it i important to quantify their effect on the local stre s and strain fi lds. In this study, w pr sent an experimental investigation of a typical AlSi10Mg micro-lattice, namely the BCC cell. 3D to ography wa used to reconstruct th original geometry and, successively, full-field digital image corr lation strain measurements were performed t capture the localization of strains which are considered the precursor of the micro-lattice damage. The local strain measurements were used to calculate and classify the strain concentration factors arising from the geometrical irregularities. These results were compared with the finite element results obtained for the idealized and the real micro-lattice geometries providing important considerations for the structural integrity assessment of the components produced with the AM micro-lattices. © 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.

© 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Keywords: Additive Manufacturing, 3D tomography, Digital Image Correlation, Strain localization

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

* Corresponding author. Tel.: +039 02 2399 8248. E-mail address: laura.boniotti@polimi.it * Corresponding author. Tel.: +039 02 2399 8248. E-mail address: laura.boniotti@polimi.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 © 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.2017.11.074