PSI- Issue 9

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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” New Method of Resistance Spot Welding for Dissimilar 1008 Low Carb Steel-505 Aluminum Alloy Mohammad Jameel Zedan * , Qasim M. Doos Department of Mechanical Engineering, University of Baghdad, Baghdad, Iraq Abstract The resistance spo welding (RSW) joi i g the dissimilar alloys such as aluminum alloy 5052 and low carbon steel alloy 008. A new technique is developed due to the difficulties in such weldments. Therefore, a circular hole 3 mm diameter in the center of the aluminum alloy was drilled to overcome the high thermal expansion of aluminum. The electrode force 1500-2400 N, welding current 11.25-14.25 KA, and the welding time 25-40 cycle were used. The desired weld nugget has been obtained and the difficulties have been eliminated. The maximum tensile shear load of these dissimilar joints was 3210 N. Weld nugget diameter of 9.75 mm is formed. The intermetallic compound layer (IMC) is noticed with thickness 1-5 μm. The tongue-like shape and needle shaped of IMC layer adjacent to the 1008 low carbon steel and aluminum sides have been investigated, respectively. © 2018 The Aut ors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. Keywords: Fractu load; Micr structure; Resist ce spot welding; Thermal expansion; W lding parameters 1. Introduction The joining of dissimilar metals is desirable for some designing requirements. In the 1990s, the aluminum panels began to be used in car body due to the environmental issue and weight reduction (Carle and Blount 1999)(Barnes and Pashby 2000)(Sakurai 2008)(Oikawa et al. 1999). Among many aluminum alloys, the automotive industry is used the 5XXX and 6XXX Al-alloys. So the 5052 alloy was chosen for its strain hardenable, and weldability (Davis 2013). Car manufacture s p fer ed low carbon steels due to their fast press forming into panels from flat sheets. This steel IGF Workshop “Fracture and Structural Integrity” New Method of Resistance Spot Welding for Dissimilar 1008 Low Carbon Steel-5052 Aluminum Alloy Moha ma Jameel Zedan * , Qasim M. Doos Department of Mechanical Engineering, University of Baghdad, Baghdad, Iraq Abstract The r sistanc spot welding (RSW) joining the dissimilar alloys such as aluminum alloy 5052 and low carbon steel alloy 1008. A new technique is developed due to the difficulties in such weldments. Therefore, a circular hole 3 mm diameter in the center of the aluminum alloy was drilled to overcome the high thermal expansion of aluminum. The electrode force 1500-2400 N, welding current 11.25-14.25 KA, and the welding ti e 25-40 cycle were used. The desired weld nugget has been obtained and the difficulties have been eliminated. The maximum tensile shear load of these dissimilar joints was 3210 N. Weld nugget diameter of 9.75 mm is formed. The intermetallic compound layer (IMC) is noticed with thickn ss 1-5 μm. The tongue-like shape and needle shaped of IMC layer adjacent to the 1008 low carbon steel and aluminum sides have been investigated, respectively. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Gruppo Italiano Frattura (IGF) ExCo. Keywords: Fracture load; Microstructure; Resistance spot welding; Thermal expansion; Welding para eters 1. Introduction The joining of dissimilar metals is desirable for some designing requirements. In the 1990s, the aluminum panels began to be used in car body due to the environmental issue and weight reduction (Carle and Blount 1999)(Barnes and Pashby 2000)(Sakurai 2008)(Oikawa et al. 1999). Among many aluminum alloys, the automotive industry is used the 5XXX and 6XXX Al-alloys. So the 5052 alloy was chosen for its strain hardenable, and weldability (Davis 2013). Car manufacturers preferred low carbon steels due to their fast press forming into panels from flat sheets. This steel © 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’s, Tel: +964 7701218018 E-mail address: mohammadjameelzidan@gmail.com * Corresponding auth r’s, Tel: +964 7701218018 E-mail address: mohammadjameelzidan@gmail.com

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.2018.06.008 * Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452 3216 © 2018 Th 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.