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Research Papers: Gas Turbines: Structures and Dynamics

Transient Thermal Analysis and Viscoplastic Damage Model for Life Prediction of Turbine Components

[+] Author and Article Information
A. Staroselsky

United Technologies Research Center,
East Hartford, CT 01608
e-mail: starosav@utrc.utc.com

T. J. Martin

United Technologies Corporation,
Pratt & Whitney,
East Hartford, CT 01608
e-mail: thomas.martin@pw.utc.com

B. Cassenti

Department of Mechanical Engineering,
University of Connecticut,
Storrs, CT 06268
e-mail: cassenti@engr.uconn.edu

1Current affiliation: United Technologies Research Center, e-mail: martintj@utrc.utc.com.

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received July 16, 2014; final manuscript received August 26, 2014; published online October 28, 2014. Editor: David Wisler.

J. Eng. Gas Turbines Power 137(4), 042501 (Oct 28, 2014) (10 pages) Paper No: GTP-14-1403; doi: 10.1115/1.4028568 History: Received July 16, 2014; Revised August 26, 2014

This paper reports the process and computer methodology for a physics-based prediction of overall deformation and local failure modes in cooled turbine airfoils, blade outer air seals, and other turbomachinery parts operating in severe high temperature and high stress environments. The computational analysis work incorporated time-accurate, coupled aerothermal computational fluid dynamics (CFD) with nonlinear deformation thermal-structural finite element model (FEM) with a slip-based constitutive model, evaluated at real engine characteristic mission times, and flight points for part life prediction. The methodology utilizes a fully coupled elastic-viscoplastic model that was based on crystal morphology, and a semi-empirical life prediction model introduced the use of dissipated energy to estimate the remaining part life in terms of cycles to failure. The method was effective for use with three-dimensional FEMs of realistic turbine airfoils using commercial finite element applications. The computationally predicted part life was calibrated and verified against test data for deformation and crack growth.

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References

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Figures

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Fig. 1

Cutaway of a turbofan engine, showing the combustion chamber, a two-stage HPT with one vane and one blade per stage, and LPT

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Fig. 2

Illustration of CHT problem of a turbine airfoil, showing the velocity boundary layer, thermal boundary layer, and heat transfer

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Fig. 3

Flow chart of the loosely coupled conjugate transient thermal analysis process

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Fig. 4

Comparison of predicted versus measured wall temperature on the pressure (right) and suction (left) side of a second HPT blade [5]; shown are 3D conjugate aerothermal analysis (line), 2D thermal analysis (dashed), pyrometer data (open symbols), and thermocouple data (solid symbols)

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Fig. 5

Comparison of life prediction versus measured data for OP TMF and isothermal LCF coupon tests

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Fig. 6

Normalized plot of the representative mission, showing gas temperature profile versus mission time

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Fig. 7

(a) Instantaneous contour of wall temperature on the coating/metal interface surface of the blade at the end of climb and (b) distribution of instantaneous equivalent stress on the external surface of the blade at MCT

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Fig. 8

Slice of the stress distribution in the blade showing stress concentration (a) and residual stress distribution (b)

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Fig. 9

Calculated damage distribution in the blade after the block test; which lead to cracking in the actual test

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