Combined notch and size effect modeling in a local probabilistic approach for LCF

Current failure mechanisms and treatment methods of hot forging tools (dies) - a review

A Crystal Plasticity Finite Element (CPFE) framework is proposed for modeling the non-Schmid yield behavior of L12 type Ni3Al crystals and Ni-based superalloys. This framework relies on the estimation of the non-Schmid model parameters directly from the orientation- and temperature-dependent experimental yield stress data. The inelastic deformation model for Ni3Al crystals is extended to the precipitate phase of Ni-based superalloys in a homogenized dislocation density based crystal plasticity framework. The framework is used to simulate the orientation- and temperature-dependent yield of Ni3Al crystals and single crystal Ni-based superalloy, CMSX-4, in the temperature range 260-1304 K. Model predictions of the yield stress are in general agreement with experiments. Model predictions are also made regarding the tension-compression asymmetry and the dominant slip mechanism at yield over the standard stereographic triangle at various temperatures for both these materials. These predictions provide valuable insights regarding the underlying (orientation- and temperature-dependent) slip mechanisms at yield. In this regard, the non-Schmid model may also serve as a standalone analytical model for predicting the yield stress, the tension-compression asymmetry and the underlying slip mechanism at yield as a function of orientation and temperature.

Crystal plasticity modeling of non-Schmid yield behavior: from Ni3Al single crystals to Ni-based superalloys

Crack nucleation from non-metallic inclusions in aluminum alloys described by peridynamics simulations

PROBLEM TO BE SOLVED: To provide an apparatus and method for analyzing a structure modeled with inconsistencies mapped thereon.SOLUTION: A method for analyzing a structure includes processing nondestructive inspection (NDI) data 112 for a multi-layer structure to define areas of inconsistency at an internal layer or an interface between adjacent layers. The method includes mapping the areas of inconsistency to finite elements of a finite element model 114 of a nominal of the structure. The finite elements specified by mapping include finite elements for the affected internal layer or interface. The method includes producing a reconstructed finite element model 116 of the affected structure from the nominal finite element model 114, and a modified property or state value assigned to respective element datasets of the affected finite elements. The method includes performing a finite element method (FEM) failure analysis 110 of the reconstructed finite element model 116 under a load, which indicates an extent of residual integrity of the affected structure.SELECTED DRAWING: Figure 1

Analysis of a structure modeled with inconsistencies mapped thereon

A probabilistic estimation of fatigue crack life of a component is provided. A plurality of representations of the component is defined from material property scatter data and flaw-size scatter data, wherein each representation is defined by one possible material condition and flaw-size condition associated with the component. For each representation, a component location is selected and a determination is made whether said individual representation fails after a given number of cycles N, based on the calculation of a crack growth in the selected location. The crack growth is calculated on the basis of the material condition and the flaw-size condition in the selected location. Failure of the individual representation is determined if the crack growth is determined to be unstable. The sum total of the number of the representations that failed after N cycles is determined. A probability of failure of the component after N cycles is then determined.

Method and system for probabilistic fatigue crack life estimation


 Large gas turbine nickel based superalloys blades are typically manufactured using an investment casting process. In spite of superior processing and quality control, large turbine blades may contain manufacturing induced discontinuities such as porosities, segregation, chemical inhomogeneities, particles, etc in few of the manufactured parts. These manufacturing discontinuities can significantly influence the reliable component life if they are under a load condition where they will form a crack. A typical engineering approach is to treat these discontinuities as a crack from the beginning of the part life. This leads to a conservative life prediction, as crack nucleation and influencing geometrical details of the discontinuities are neglected. This paper presents a framework and path forward for a comprehensive life assessment. It includes computer tomography (CT) analysis, metallographic analysis, local stress analysis, crack formation, as well as state of the art fracture mechanics analysis. For instance, CT and destructive tests reveal details of the geometry of a porous region and thereby enabling the calculation of crack formation life. A subsequent fracture mechanics analysis by engineering tool, FRANC3D can then yield a comprehensive life assessment for comparisons to experimental findings and fleet experience. This approach enables Siemens to diligently ensure that comprehensive life predication assessment has been performed for the components for robust and reliable operation.

Life Assessment of Large Gas Turbine Blades

http://asmedigitalcollection.asme.org/data/journals/jetpez/0/gtp-17-1488.pdf

Probabilistic fracture mechanics for heavy duty gas turbine

Probabilistic Fracture Mechanics for Heavy-Duty Gas Turbine Rotor Forgings

A layer system including a substrate and a layer is provided. The layer system has a hole at least in the layer, and wherein at least one recess is present in a surface of the layer in a vicinity around the hole or directly adjoining a boundary line of the hole.

Modified interface around a hole

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