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Research Papers: Gas Turbines: Structures and Dynamics

Three-Dimensional LEFM Prediction of Fatigue Crack Propagation in a Gas Turbine Disk Material at Component Near Conditions

[+] Author and Article Information
Christian Busse

Division of Solid Mechanics,
Linköping University,
Linköping 58183, Sweden
e-mail: christian.busse@liu.se

David Gustafsson

Siemens Industrial Turbomachinery AB,
Finspång 61283, Sweden
e-mail: david.gustafsson@siemens.com

Patrik Rasmusson

Siemens Industrial Turbomachinery AB,
Finspång 61283, Sweden
e-mail: patrik.rasmusson@siemens.com

Björn Sjödin

Siemens Industrial Turbomachinery AB,
Finspång 61283, Sweden
e-mail: bjorn.sjodin@siemens.com

Johan J. Moverare

Division of Engineering Materials,
Linköping University,
Linköping 58183, Sweden
e-mail: johan.moverare@liu.se

Kjell Simonsson

Division of Solid Mechanics,
Linköping University,
Linköping 58183, Sweden
e-mail: Kjell.simonsson@liu.se

Daniel Leidermark

Division of Solid Mechanics,
Linköping University,
Linköping 58183, Sweden
e-mail: daniel.leidermark@liu.se

1Corresponding author.

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received April 23, 2015; final manuscript received August 17, 2015; published online October 26, 2015. Assoc. Editor: Herman Shen.

J. Eng. Gas Turbines Power 138(4), 042506 (Oct 26, 2015) (8 pages) Paper No: GTP-15-1141; doi: 10.1115/1.4031526 History: Received April 23, 2015; Revised August 17, 2015

In this paper, the possibility to use linear elastic fracture mechanics (LEFM), with and without a superimposed residual stress field, to predict fatigue crack propagation in the gas turbine disk material Inconel 718 has been studied. A temperature of 400 °C and applied strain ranges corresponding to component near conditions have been considered. A three-dimensional crack propagation software was used for determining the stress intensity factors (SIFs) along the crack path. In the first approach, a linear elastic material behavior was used when analyzing the material response. The second approach extracts the residual stresses from an uncracked model with perfectly plastic material behavior after one loading cycle. As a benchmark, the investigated methods are compared to experimental tests, where the cyclic lifetimes were calculated by an integration of Paris' law. When comparing the results, it can be concluded that the investigated approaches give good results, at least for longer cracks, even though plastic flow was taking place in the specimen. The pure linear elastic simulation overestimates the crack growth for all crack lengths and gives conservative results over all considered crack lengths. Noteworthy with this work is that the 3D-crack propagation could be predicted with the two considered methods in an LEFM context, although plastic flow was present in the specimens during the experiments.

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Figures

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Fig. 1

Notched specimen geometry, units in mm

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Fig. 2

Schematic view of utilized load cycles

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Fig. 3

Composition of the local (left) and global (right) subregion

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Fig. 4

Schematic view of element setup at crack tip

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Fig. 5

Illustration of the mesh of the submodel with the (a) initial and (b) final cracks, respectively

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Fig. 6

Workflow of crack propagation procedure

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Fig. 7

Superposition for crack face traction

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Fig. 8

Schematic example of a stress–strain response showing the local stress as a function of applied strain at notch root for the uncracked model

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Fig. 9

Equivalent plastic strain (PEEQ) for (a) Δε = 0.6%, (b) Δε = 0.7%, (c) Δε = 0.8%, and the legend in (d)

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Fig. 10

SIFs over crack length for (a) Δε = 0.6%, (b) Δε = 0.7%, and (c) Δε = 0.8%

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Fig. 11

Absolute difference in SIFs between the two approaches for all test

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Fig. 12

Comparison of test results to simulation results for (a) Δε = 0.6%, (b) Δε = 0.7%, and (c) Δε = 0.8% in terms of crack length over loading cycles

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