PSI - Issue 2_A

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 Struc ural Integrity 2 (2016) 3264–3271 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 Cyclic Deformation Behavior of Friction Drilled Internal Threads in AlSi10Mg and AZ31 Profiles P. Wittke*, F. Walther TU Dortmund University, Department of Materials Test Engineering (WPT), Baroper Str. 303, D-44227 Dortmund, Germany Abstract Metallic lightweight materials are used for enhancing dynamic range, resource optimization and emission reduction in many fields of traffic engineering, whereby aluminium and magnesium components are manufactured by means of welded, adhesive and screw joints. Friction drilling, as forming process with subsequent manufacturing of threads, offers the opportunity to produce an internal thread in lightweight profiles with a usable thread depth larger than the profile thickness, making use of local material expansion. Moreover, the direct manufacturing offers a huge potential for time and cost saving in comparison to conventional thread machining. Microscopic-based characterization of mechanical properties of aluminium AlSi10Mg and magnesium AZ31 internal threads in thin-walled profile specimens was carried out using tensile tests and fatigue tests in tensile loading range. The internal threads were chipless manufactured by means of threa forming. Variations in the g ometric process parameter wall thickness were compared. Differences between the AlSi10Mg chill casting alloy and the AZ31 continuous casting alloy in maximum tolerable loads and fatigue limits were correlated with the production-related profile qualities of the profile specimens. The maximum tolerable loads increase linearly with increasing wall thickness of the specimens, whereby AlSi10Mg specimens were about 20 24% lower in the quasi-static range and about 37-47% lower in the cyclic range in comparison to AZ31 specimens due to oval forms of the core holes caused by the friction drilling process. Plastic strain behavior and deformation-induced changes in temperature in load increase tests were evaluated to reliably estimate the fatigue limit of magnesium AZ31 internal threads. 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. © 2016 The Authors. Published by Elsevier B.V. Peer-review under responsibility of the Scientific Committee of ECF21. Keywords: Aluminium alloy; magnesium alloy; AlSi10Mg; AZ31; friction drilling; thread forming; internal thread; fatigue properties

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

* Corresponding author. Tel.: +49 231 755 8031; fax: +49 231 755 8029. E-mail address: philipp.wittke@tu-dortmund.de

* 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 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.2016.06.407