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Research Papers

Crack Growth Behavior of Full-Scale Turbine Attachment Under Combined High and Low Cycle Fatigue

[+] Author and Article Information
Dianyin Hu

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
Collaborative Innovation Center of
Advanced Aero-Engine,
Beijing 100191, China;
Beijing Key Laboratory of Aero-Engine
Structure and Strength,
Beijing 100191, China

Lin Yan, Ye Gao, Jianxing Mao

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China

Rongqiao Wang

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
Collaborative Innovation Center of
Advanced Aero-Engine,
Beijing 100191, China;
Beijing Key Laboratory of Aero-Engine
Structure and Strength,
Beijing 100191, China
e-mail: wangrq@buaa.edu.cn

1Corresponding author.

Manuscript received February 28, 2018; final manuscript received March 27, 2019; published online May 6, 2019. Assoc. Editor: Damian M. Vogt.

J. Eng. Gas Turbines Power 141(9), 091002 (May 06, 2019) (10 pages) Paper No: GTP-18-1102; doi: 10.1115/1.4043555 History: Received February 28, 2018; Revised March 27, 2019

Turbine attachments in the aero-engine are generally subjected to combined high and low cycle fatigue (CCF) loadings, i.e., low cycle fatigue (LCF) loading due to centrifugal and thermal loading stresses superimposed to the aerodynamically induced high cycle fatigue (HCF) loading. The primary focus of this study is to predict the crack growth life for the actual full-scale turbine attachment through experimentally examining the crack growth behavior under CCF loading at elevated temperature. The crack closure effect was first investigated by using the corner-notched (CN) specimen cut from the turbine attachment since the stress state of CN specimen is more similar to turbine attachment than compact tension (CT) specimen. Employing digital image correlation (DIC) technique, the level of crack closure of CN specimen was clarified under different stress ratios (R) for LCF loading. Afterward, a CCF crack growth model for the full-scale turbine attachment was proposed, which takes the crack closure effect, time-independent crack increment, and transient vibrational analysis into account. In order to verify the proposed method, a Ferris wheel system was established to conduct CCF test on the full-scale turbine attachment at elevated temperature. This study provides an effective methodology to predict the fatigue crack growth (FCG) life of full-scale turbine attachment under CCF loading.

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Figures

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Fig. 1

The geometries of (a) CN specimen, (b) turbine disk, (c) turbine blade, and (d) assembly sketch of the turbine attachment (unit: mm)

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Fig. 2

Precrack at the third tooth of turbine attachment

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Fig. 3

Geometric parameters of corner crack on the cross section of the specimen

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Fig. 4

Sketches of the CCF test system for full-scale turbine attachment: (a) constituent parts of the Ferris wheel system test system and (b) loading method: 1—upper jointer for LCF loading, 2—upper load-transmission pin, 3—drawplate, 4—hold-down bolt 1, 5—blade clamp, 6—rolling bearing 1, 7—left load-transmission plate, 8—heating coil 1, 9—part of actual turbine disk, 10—lower jointer for LCF loading, 11—lower load-transmission pin, 12—rolling bearing 2, 13—load-bearing bar, 14—right load-transmission plate, 15—actual turbine blade, and 16—vibration point

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Fig. 5

FCG results of GH2036 superalloy under different stress ratios for CN specimens

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Fig. 6

Variation of load and COD with frame number at crack length a =4.0 mm under stress ratios at (a) R =0.1, (b) R =0.4, and (c) R =0.7 for CN and plate specimen

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Fig. 7

Comparison of normalized crack opening SIF Kop using DIC measurement at different stress ratio

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Fig. 8

CCF crack propagation life prediction framework for turbine attachment subjected to CCF loading

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Fig. 9

Typical failure of turbine attachment after CCF test

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Fig. 10

Fracture surface of (a) CN specimen under LCF loading, which is for crack closure level study, and (b) turbine attachment under CCF loading

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Fig. 11

Crack propagation mode in (a) plated specimen and (b) turbine attachment under CCF loading

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Fig. 12

(a) Meshes of the turbine component, and FEM results of vibrational stress distribution at different crack length, (b) 1.0 mm × 1.0 mm, and (c) 2.0 mm × 2.0 mm

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Fig. 13

Comparisons between the experimental and predicted crack growth life of full-scale turbine attachment under CCF loading including (a) crack length versus crack growth life and (b) predicted life versus experimental life

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