PSI - Issue 2_A

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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 C ack Propagatio in Additive Manufactured Materials and Structures Andre Riemer a,b, *, Hans Albert Richard a,b a Institute of Applied Mechanics, University of Paderborn, Pohlweg 47-49, 33098 Paderborn, Germany b Direct Manufacturing Research Center DMRC, University of Paderborn, Mersinweg 3, 33100 Paderborn, Germany Abstract Additive manufacturing processes gain more and more interest, among others, due to the feasibility for production of lightweight metallic components directly from design data. Selective laser melting (SLM) is a very promising direct manufacturing (DM) technique for fabrication of near net shape components. The reasons for this are the relative high surface quality and bulk density of SLM processed parts. Still, process induced imperfections, i.e. residual stresses upon processing, need to be considered for future applications, in particular in the aerospace and biomedical sectors. Moreover, fatigue loading is a critical scenario for such compo ents and needs to be investig ted thoroughly. In this p per, r sults from fatig e crack propagation tests on biocompatible SLM-materials (titanium alloy Ti-6-4 and stainless steel AISI 316L) will be presented. For that purpose, fracture mechanical analyses were carried out on these materials. For Ti-6-4 various treatments were taken into account. It could be shown, which optimization steps are required in order to achieve fracture mechanical properties that are comparable to the reference material. In case of 316L, crack growth data for different process parameter sets (different build-up rates) were examined and compared to make conclusions about the influence of increased build up rate on resultant crack growth behavior. Finally, based on the insights deduced from foregoing tests on Ti-6-4 crack growth propagation and the lifetime were simulated numerically by the use of the software ADAPCRACK3D. © 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 Crack Propagation in Additive Manufactured Materials and Structures Andre Riemer a,b, *, Hans Albert Richard a,b a Institute of Applied Mechanics, University of Paderborn, Pohlweg 47-49, 33098 Paderborn, Germany b Direct Manufacturing Research Center DMRC, University of Paderborn, Mersinweg 3, 33100 Paderborn, Germany Abstract Additive manufacturing processes gain more and more interest, among others, due to the feasibility for production of lightweight metallic components directly from design data. Selective la er elting (SLM) is a very promising direct manufacturing (DM) technique for fabrication of near net shape components. The r asons for this are the relative high surface quality and bulk density of SLM processed p rts. Still, proc ss induced imperfections, i.e. residual stress s upon proc ssing, need to be considered for future applications, in particular in the aerospa and biomedical sectors. Mor ov r, fatigue loadi is a critical scenario for s ch component and needs to be inv stigated thoroughly. In this paper, esults fr m fatigue cr ck pr pa ation tests on biocompatible SLM-materials (titaniu alloy Ti-6-4 a d stainless ste l AISI 316L) will be pres nted. For that urpose, fracture mechanic l analys s were carried out on these materials. For Ti-6-4 various treatments wer taken into account. It could be shown, w ich optimization steps e required in order to achieve fracture mechanical properties th t are c mparable to the ref rence material. In case of 316L, crack growth data for differ nt process para eter sets (different build-up rates) were examined a d co pared to mak conclusions bout the influence of ncreased build up rate on r ultant crack growth behavior. Fin lly, based on the insights deduced from foregoing tests o Ti-6-4 cr ck growth prop gation and the lifetime were simulated numerically by the use of the software ADAPCRACK3D. © 2016 The Authors. Published by Elsevi r B.V. Peer-review under espons bility of the Scientific Committee of ECF21. Keywords: Selective Laser Melting; titanium alloy Ti-6-4; stainless steel AISI 316L; threshold values of fatigue crack growth; da/dN-  K- curves; crack simulation in a hip joint implant Copyright © 2016 The Authors. Published by El evier B.V. This is an open access le under th CC BY-NC-ND lic nse (http://creativecommons.org/licenses/by-n -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: Selective Laser Melting; titanium alloy Ti-6-4; stainless steel AISI 316L; threshold values of fatigue crack growth; da/dN-  K- curves; crack simulation in a hip joint implant

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

* Corresponding author. Tel.: +49 5254 6498453 E-mail address: andre.riemer@gmx.de * Corresponding author. Tel.: +49 5254 6498453 E-mail address: andre.riemer@gmx.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 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.2016.06.157