PSI - Issue 13

ScienceDirect Available online at www.sciencedirect.com Av ilable o line at www.sciencedire t.com ScienceDirect Structural Integrity Procedia 00 (2016) 000 – 000 Procedia Structu al Integrity 13 (2018) 676–679 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2018) 000 – 000

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ECF22 - Loading and Environmental effects on Structural Integrity Fatigue Testing at 1000Hz Testing Frequency ECF22 - Loading and Environmental effects on Structural Integrity Fatigue Testing at 1000Hz Testing Frequency

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. Markus Berchtold*, Ingbert Klopfer RUMUL Russenberger Prüfmaschinen AG Switzerland In 2014 RUMUL could present a new resonant fatigue testing machine, with a testing frequency of 1000Hz. The dynamic load of maximum 50kN peak-peak is produced with an electromagnetic system. Similar to established resonant systems which run on testing frequencies from about 40 up to 250H. The static portion of the load is provided by a mechanical spindle, the maximum load of the system is +/- 50kN. Any load ratio can be selected. Flat and round specimen types that are normally used in fatigue testing can be used. The new testing machine offers ew possibilities for investigat ons of material properties in the very high cycle fat gue (VHCF) regime. Compared to other systems used in the field of VHCF testing the RUMUL GIGAFORTE provides several advantages. The size of the machine is smaller and energy consumption less compared to a servo hydraulic system. The actually tested material volume is larger than the material volume that is tested on ultrasonic systems. The testing frequency of 1000Hz allows normally continuous testing, without stopping for cooling down the specimen. In the past three years the new testing machine was intensively used for example at the laboratory of the Fraunhofer institute IWS Dresden in Germany. Effects of the 1000Hz testing frequency on the fatigue behaviour of the material were observed. This talk shows some example of heating up of the specimen related to the 1000Hz testing frequency and highlights some of the found frequency related effects on fatigue strength. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: New Resonant Fatigue Testing Machine; Giga cycle (VHCF); Frequency effects © 2018 The Authors. P blished by Elsevier B.V. Peer-review und responsibility of the ECF22 organiz rs. Markus Berchtold*, Ingbert Klopfer RUMUL Russenberger Prüfmaschinen AG Switzerland Abstract In 2014 RUMUL could present a new resonant fatigue testing machi e, with a testing frequency of 1000Hz. The dynamic load of maximum 50kN peak-peak is produced with electromagnetic system. Similar to established resonant systems which run on testing frequencies from about 40 up to 250H. The static portion of the load is provided by a mechanical spindle, the maximum l ad of the system is +/- 50kN. Any load ratio can be selected. Flat and round specimen types that are ormally us d in fatigue testing can b used. The new testing machine ffers n w possibilities for inves igations of material properties in the very high cycle fatigu (VH F) regime. Compared to other systems u ed in he fi ld of VHCF testing the RUMUL GIGAFORTE provides several advantages. Th size of the machin i smaller an e ergy consumption less compared to a servo hydraulic system. The actually tested material volume is larger than the materi l volume that is tested on ultrasonic systems. The testing frequency of 1000Hz allows normally continuous testing, wit out stopping for cooling down the specimen. In the past thre y ars the new testing machine was intensivel used for example at the laboratory of the Fraunhofer institute IWS Dresden in G rmany. Effects of the 1000Hz testing frequ ncy on the fatigue behaviour f the material were bserved. This talk shows some ex mple of heating up of the specimen related to the 1000Hz testing frequency and highlights some of the found frequency related effects on fatigue strength. © 2018 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the ECF22 organizers. Keywords: New Resonant Fatigue Testing Machine; Giga cycle (VHCF); Frequency effects 1. Introduction ‘‘There is no infinite fatigue life in metallic materials” [1]. Studies on damage mechanism on higher number of load cycles, in the range of up to 1010 cycles and more could well proof the finding published by Claude Bathias and others. Thanks to the development of faster testing technics and the shortening of testing time a large number of © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. ‘‘There is no infinite fatigue life in metallic materials” [1]. Studies on damage mechanism on higher number of load cycles, in the range of up to 1010 cycles and more could well proof the finding published by Claude Bathias and others. Thanks to the development of faster testing technics and the shortening of testing time a large number of Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. Abstract 1. Introduction

* Corresponding author. Tel.: +4152 672 43 22; E-mail address: mberchtold@rumul.ch * Corresponding author. Tel.: +4152 672 43 22; E-mail ad ress: mbe chtold@rumul.ch

* 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 ECF22 organizers. 2452-3216 © 2018 The Authors. Published by Elsevier B.V. Peer review under r sponsibility of the ECF22 o ganizers.

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 ECF22 organizers. 10.1016/j.prostr.2018.12.112