PSI- Issue 9

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 9 (2018) 165–171 Structural Integrity Procedia 00 (2018) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 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. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. IGF Workshop “Fracture and Structural Integrity” Mechanical Qualification of the Hybrid Metal Extrusion & Bonding (HYB) Process for Butt Welding of 4 mm Plates of AA6082-T6 Filippo Berto a, *, Lise Sandnes a , Øystein Grong a,b , Paolo Ferro c a Norwegian University of S ience and Technology, Departme t of Mechanical and Industrial Enginering, Richard Birkelands vei 2b, Tr ndheim 7491, Norway b HyBond AS, Alfred Getz vei 2, 7491 Trondheim, Norway c University of Padua, Department of Management and Engineering, Stradella San Nicola 3, Vicenza, Italy Abstract Hybrid Metal Extrusion & Bonding (HYB) is a novel solid state joining technique mainly developed for aluminum alloys. By the use of filler material addition and plastic deformation sound joints can be produced at operational temperatures below 400℃. Here, we present the results from an exploratory investigation of the mechanical integrity of a 4 mm AA6082-T6 HYB joint, covering both hardness, tensile and Charpy V-notch testing of different weld zones. The joint is found to be free from defects like pores, internal cavities and kissing-bonds. Still, a soft heat affected zone (HAZ) is present. The joint yield strength is 54 % of the base material, while the corresponding joint efficiency is 66 %. Therefore, there is room for further optimization of the HYB process. This work is now in progress. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. Keywords: Welding; Solid State; Hybrid Metal Extrusion & Bonding (HYB); Aluminum Alloys; Mechanical Properties. 1. Introduction The unique physical and mechanical properties of aluminum alloys, as the precipitation hardened Al-Mg-Si alloys, makes them attractive for a wide range of applications as structural components and welded assemblies. In particular, there is an increased use of aluminum alloys within the automotive industry as a result of the growing demand for IGF Workshop “Fracture and Structural Integrity” Mechanical Quali ication of the Hybrid Metal Extrusion & Bonding (HYB) Process for Butt Welding of 4 mm Plates of AA6082-T6 Filippo Berto a, *, Lise Sandnes a , Øystein Grong a,b , Paolo Ferro c a Norwegian University of Science and Technology, Dep rtment of Mechanical and I dustrial Engi ering, Richard Birkelands vei 2b, Trondheim 7491, Norway b HyBond AS, Alfred Getz vei 2, 7491 Trondheim, Norway c University of Padua, Department of Management and Engineering, Stradella San Nicola 3, Vicenza, Italy Abstract Hybrid Metal Extr sion & Bonding (HYB) is a novel solid state joining tech ique mainly developed for aluminum alloys. By the use of filler mat rial addition nd plastic deformation sound joints can be produced at operational temperatu es below 400℃. Here we present th results from an exploratory investigation of the m chanical integrity of a 4 mm AA6082-T6 HYB joint, covering both h rdness, tensile and Charpy V- otch t sting of different weld zon s. The joint is ound t be free from defects like pore , internal cavities and kissing-bonds. Still, a soft heat affected zone (HAZ) is present. The joint yield strength is 54 % of the base material, while the corresponding joint efficiency is 66 %. Therefore, there is room for further optimization of the HYB process. This work is now in progress. © 2018 The Authors. Published by Elsevier B.V. P er-review under responsibilit of the Gruppo Italiano Frattura (IGF) ExCo. Keywords: Welding; Solid State; Hybrid Metal Extrusion & Bonding (HYB); Aluminum Alloys; Mechanical Properties. 1. Introduction The unique physical and mechanical properties of aluminu alloys, as the precipitation hardened Al-Mg-Si alloys, makes them attractive for a wide range of applications as structural components and welded assemblies. In particular, there is an increased use of aluminum alloys within the automotive industry as a result of the growing demand for © 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.: +47 485 00 575; fax: +47 485 00 576. E-mail address: Filippo.Berto@ntnu.no

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. 2452-3216  2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 10.1016/j.prostr.2018.06.025 * Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. * Corresponding author. Tel.: +47 485 00 575; fax: +47 485 00 576. E-mail address: Filippo.Berto@ntnu.no