PSI - Issue 2_A

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 Struc ural Integrity 2 (2016) 3168–3176 Available online at www.sciencedirect.com Sci ceDirect Structural Integrity Procedia 00 (2016) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2016) 000–000

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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. 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Fatigue characterization of Titanium Ti-6Al-4V samples produced by Additive Manufacturing Victor Chastand a,b *, Astrid Tezenas a , Yannick Cadoret a , Philippe Quaegebeur b , Wilson Maia a , Eric Charkaluk b a Thales Global Services, 19/21 avenue Mora e Saulnier, 78140 Vélizy-Villacoublay, France b Laboratoire de Mécanique de Lille (LML), CNRS, UMR 8107, Cité Scientifique, 59650 Villeneuve d’Ascq, France Abstract Additive Manufacturing offers real opportunities in Thales, since it enables a flexible and cost-effective production of metallic components directly from a 3D digital data model. The manufacture of the parts, layer by layer, allows building more complex geometries by adding new functionalities or reducing the weight. The products of Thales can be more competitive and attractive. Studying and analysing the mechanical properties of such samples is essential. In order to be able to choose the eligible parts, design these parts and ensure their robustness, it is necessary to understand the static and fatigue behaviour of materials built by Additive Manufacturing and, more particularly, the damaging process regarding the microstructure. Following a first study on the static properties of a Titanium alloy used within Thales, a large set of fatigue tests, including both HCF and LCF, have been performed to evaluate the fatigue performances of Ti-6Al-4V samples built by a powder bed fusion process. The fatigue mechanisms and the obtained lifetimes were compared with more conventional processes (casting, wrought). In this paper, the results of these fatigue tests on Titanium (Ti-6Al-4V) samples will be presented. Different parameters have been compared: building orientation, heat treatment (HIP) and post-machining. The fracture mechanisms have also been analysed by performing a correlation between the microstructure analysis (porosity, metallography) and fractographies. It is shown that fatigue performances depend on the selected parameters but these effects are different, depending on the loading domain (HCF, LCF). © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. 21st European Conference on Fracture, ECF21, 20-24 June 2016, Catania, Italy Fatigue characterization of Titanium Ti-6Al-4V samples produced by Additive Manufacturing Victor Chastand a,b *, Astrid Tezenas a , Yannick Cadoret a , Philippe Quaegebeur b , Wilson Maia a , Eric Charkaluk b a Thales Global Services, 19/21 avenue Morane Saulnier, 78140 Vélizy-Villacoublay, France b Laboratoire de Mécanique de Lille (LML), CNRS, UMR 8107, Cité Scientifique, 59650 Villeneuve d’Ascq, France Abstract Additive Manufacturing offers real opportunities in Thales, since it enables a flexible and cost-effective production of metallic compon nts directly from a 3D digital da a model. The manufa ture of th p rts, lay r by layer, allows buil ing more comp ex geometries by adding new functionalities or reducing t e weight. Th products of Thal s can be more competitive and attractiv . Studying and nalysing the mechanical prop rties of such samples is essen ial. In order to able to choose the eligible parts, design these p rts and ensure their robustness, it i necessary to understand he static and fatigue b haviour of mat r als built by Additive Manufacturing and, more particularly, he damaging process regarding the microstruct re. Following a first s dy on the static p operties of a Titanium all y u ed within T ales, a la ge set of fatigue tests, including both HCF and LCF, have bee p rformed to valuate the f t gue performances of i-6Al-4V samples buil by a powder bed fusion process. The fatigue m chanisms and the obtained lifetimes wer c par d with more conventional processes (casting, wro ght). In thi paper, the r sults of the e fatigue tests on Ti anium (Ti-6Al-4V) samples will be presented. Different parameters have been com a ed: building orientation, heat tr atme t (HIP) and post-machining. The fracture mechanisms hav also been analysed y performing a correlati n between the microstructure analysis (poros ty, metallography) and fractographies. It is shown that fatigue perform nces depe d on th sel cted parame e s but the e effects are different, depending on the loading domain (HCF, LCF). © 2016 The Authors. Published by Elsevier B.V. Peer-review under espons bility of the Scientific Committee of ECF21. Copyright © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the Scientific Committee of ECF21. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016.

Keywords: Additive Manufacturing ; Fatigue ; Titanium

Keywords: High Pressure Turbine Blade; Creep; Finite Element Method; 3D Model; Simulation. Keywords: Additive Man fact ing ; Fatigue ; Titanium

* Corresponding author. Tel.: +33(0)1 70 28 24 54. E-mail address: victor.chastand@thalesgroup.com * Corresponding author. Tel.: +33(0)1 70 28 24 54. E-mail ad ress: victor.chastand@thalesgroup.com

* Corresponding author. Tel.: +351 218419991. E-mail address: amd@tecnico.ulisboa.pt 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review und r responsibil ty of the Scientific Committee of ECF21. 2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer review under r sponsibility of the Scientific Committee of ECF21.

2452-3216 © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of PCF 2016. Copyright © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license ( http://creativecommons.org/licenses/by-nc-nd/4.0/ ). Peer review under responsibility of the Scientific Committee of ECF21. 10.1016/j.prostr.2016.06.395