Research Papers: Gas Turbines: Manufacturing, Materials, and Metallurgy

A Modeling Approach to Predict Fretting Fatigue on Highly Loaded Blade Roots

[+] Author and Article Information
Patrick Wackers, Victor Arrieta

 MTU Aero Engines GmbH, Munich, Bavaria 80995, Germany

Marcel Alquezar-Getan

 ATENA Engineering, Munich, Bavaria 80995, Germany

Andrei Constantinescu, Habibou Maitournam

LMS-CNRS, École Polytechnique Palaiseau, Palaiseau Cedex 91128, France

J. Eng. Gas Turbines Power 132(8), 082101 (May 10, 2010) (9 pages) doi:10.1115/1.3205026 History: Received April 08, 2009; Revised April 15, 2009; Published May 10, 2010; Online May 10, 2010

A lifing technique for predicting fretting fatigue on highly loaded blade-disk attachments has been developed and calibrated. The approach combines extensive testing on nickel and titanium based alloys using a specially devised multiaxial fretting test machine and an analytical lifing procedure, based on finite element contact calculations and multiaxial shakedown fatigue models. In order to reproduce realistic operational conditions and standardize testing conditions, a special fretting fatigue testing machine with high temperature testing capabilities was developed. The machine was employed to perform systematic testing under prescribed load and displacement conditions at representative temperatures. Making use of FEA , the rig test results were calculated to identify relevant parameters such as friction coefficient, slip conditions, and machine compliance. The computation procedure involves the calculation of several major loading cycles until a stabilized response of the structure is achieved. The material response is assumed to be elastoplastic, and a nonlinear friction law (space and time) was applied. From the computed mechanical variables, several life prediction models are benchmarked to establish their capabilities to predict fretting fatigue life. Finally, a most promising life estimation procedure was applied to predict life in a real compressor blade-disk attachment. Predicted failure location and number of cycles to failure are compared against engine test results. The experimental-analytical approach has the potential to predict fretting fatigue risk during the design phase on highly loaded joints, as well as estimating the preventive overhaul intervals for parts already in service.

Copyright © 2010 by American Society of Mechanical Engineers
Topics: Fatigue , Friction , Stress , Blades , Cycles
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Figure 1

Fretting-fatigue damage on blade-disk attachment

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Figure 2

View of the multiaxial fretting rig

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Figure 3

Cross section of pads and specimen

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Figure 4

Finite element mesh at rig contact zone

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Figure 5

Friction coefficient evolution for Ti64 at different temperatures with k=3

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Figure 6

Friction coefficient distribution along the contact interface for IN718 at 650°C, derived from a 2D FEA

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Figure 7

Interpolation technique for Dang Van

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Figure 8

Failure location in test compared with FEA damage distribution

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Figure 9

Representative volume technique in a Dang Van diagram—critical and averaged loading paths

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Figure 10

Dang Van real versus estimated life plots of Inconel—20°C without REV

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Figure 11

Dang Van real versus estimated life plots of Inconel—20°C with REV

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Figure 12

Histogram of the Dang Van prediction for IN718 at room temperature without REV

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Figure 13

Histogram of the Dang Van prediction for IN718 at room temperature with REV

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Figure 14

3D FE mesh on blade root

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Figure 15

Friction coefficient distribution on blade contact surfaces

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Figure 16

Damage location as observed in engine tests compared with Dang Van damage distribution from FEA

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Figure 17

Averaged Dang Van loading path (REV) for critical location on blade contact surface




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