Further Development of Modified Theta Project Creep Models With Life Fraction Hardening

2017 ◽  
Author(s):  
W. David Day ◽  
Ali P. Gordon
Keyword(s):  
Structural Integrity ◽  
Turbine Blades ◽  
Material Behavior ◽  
Creep Model ◽  
Effect Of Temperature ◽  
Rotor Steel ◽  
State Variables ◽  
Creep Tests ◽  
Hardening Rule ◽  
Life Fraction

In order to optimally design a hot section component for creep, the designer and turbine durability specialist must have confidence in their predictive tools and be able to gain design insight from these analytical tools. The modified theta projection (MTP) creep model was previously presented as an accurate means of describing creep behavior as a function of stress, temperature and time. The MTP was then implemented in an analytical model using a life fraction hardening (LFH) rule to calculate creep in the presence of time-varying stresses, and the results presented in a second paper. This paper presents improvements to the technique through the use of state variables in addition to the previously shown strain life fraction (ELF) and temperature margin (TMar). The need for performing multiple creep analyses is avoided by adding state variables to that track estimates of the effect of temperature changes on stress relaxation and life fraction, as well as an allowance for material variability and an inexact fit of material behavior. The results of creep tests, on a nickel blade alloy, with incrementally increasing or decreasing loads are presented to provide validation of the accuracy of the life fraction hardening rule. The use of MTP and LFH has now been expanded to steels. Incremental testing results are examined for a NiCrMoV rotor steel to further validate the technique. The effect of true stress on model accuracy is also presented. Now that an accurate creep model and hardening rule have been implemented, expansion of the techniques to provides more useable design information and allows us to improve the structural integrity of turbine blades, vanes and rotors.

Life Fraction Hardening Applied to a Modified Theta Projection Creep Model for a Nickel-Based Super-Alloy

2014 ◽  
Author(s):  
W. David Day ◽  
Ali P. Gordon
Keyword(s):  
Strain Hardening ◽  
Analytical Calculation ◽  
Tertiary Creep ◽  
Creep Model ◽  
Integration Scheme ◽  
Hardening Rule ◽  
Creep Models ◽  
Computationally Intensive ◽  
Super Alloy ◽  
Life Fraction

This paper presents the application of a life fraction hardening rule to the analytical calculation of creep in hot section components. Accurate prediction of creep is critical to assuring the mechanical integrity of heavy-duty, industrial gas turbine (IGT) hardware. The accuracy of such predictions depend upon both the creep models assumed and how those models are implemented in a finite element solution. A modified theta projection creep model for a nickel-based super alloy was presented in a previous paper as an accurate simulation of creep behavior [1]. Application of such a user defined creep law depends upon definition of a hardening rule in the form of either an explicit or an implicit integration scheme in order to calculate incremental strains during any time increment. Time hardening is the simplest and least computationally intensive of the two most common hardening rules, but does not correctly show the effect of changing stresses or temperatures. Strain hardening may provide the most accurate solution, but the creep models are too complex to invert, which results in highly iterative and computationally intensive solutions. A life fraction hardening rule has been presented in other works [2] as a compromise between time hardening and strain hardening. Life fraction hardening is presented here as a highly efficient and accurate means of calculating incremental creep strain when applied to a modified theta projection creep model. A user creep subroutine was defined using a state variable to represent the strain life fraction at any time. By using the time to tertiary creep as the denominator for the life fraction, no new material constants are needed to relate to creep failure. The start of tertiary creep is effectively considered to be a failure. Additional design insight can be provided through the inclusion of other state variables to calculate temperature margins at current conditions. Material testing with changing stress levels will be used to help validate the technique. A simplified example of the technique is presented in the paper. More accurate creep predictions allow our company to improve the structural integrity of its turbine blades and vanes.

Modeling the Creep Damage of P91 Steel Using Peridynamics

2019 ◽  
Author(s):  
Shank S. Kulkarni ◽  
Alireza Tabarraei ◽  
Xiaonan Wang
Keyword(s):  
Experimental Data ◽  
High Temperature ◽  
Structural Integrity ◽  
Creep Damage ◽  
Creep Model ◽  
Creep Tests ◽  
P91 Steel ◽  
Damage Models ◽  
Modeling Creep ◽  
Non Local

Abstract Creep is an important failure mechanism of metal components working at a high temperature. To ensure the structural integrity and safety of systems working at high temperature it is essential to predict failure due to creep. Classical continuum based damage models are used widely for modeling creep damage. A more recently developed non-local mechanics formulation called peridynamics has displayed better performance in modeling damage with respect to classical local mechanics methods. In this paper, the peridynamic formulation is extended to model creep in metals. We have chosen Liu-Murakami creep model for developing a peridynamic formulation for modeling creep. The proposed formulation is validated by simulating creep tests for P91 steel and comparing the results with experimental data from the literature.

Surface Modification and its Influence on the Microstructure and Creep Resistance of Nickel Based Superalloy René 77 / Modyfikacja Powierzchniowa Oraz Jej Wpływ Na Mikrostrukture I Wytrzymałosc Na Pełzanie Odlewów Z Nadstopu Niklu Ren´E 77

2013 ◽  
Vol 58 (1) ◽  
pp. 95-98 ◽  
Author(s):  
M. Zielinska ◽  
J. Sieniawski
Keyword(s):  
Mechanical Properties ◽  
Grain Size ◽  
Surface Modification ◽  
Turbine Blades ◽  
Processing Parameters ◽  
Grain Structure ◽  
Creep Tests ◽  
Cobalt Aluminate ◽  
Nickel Based Superalloy ◽  
Average Grain Size

Superalloy René 77 is very wide used for turbine blades, turbine disks of aircraft engines which work up to 1050°C. These elements are generally produced by the investment casting method. Turbine blades produced by conventional precision casting methods have coarse and inhomogeneous grain structure. Such a material often does not fulfil basic requirements, which concern mechanical properties for the stuff used in aeronautical engineering. The incorporation of controlled grain size improved mechanical properties. This control of grain size in the casting operation was accomplished by the control of processing parameters such as casting temperature, mould preheating temperature, and the use of grain nucleates in the face of the mould. For nickel and cobalt based superalloys, it was found that cobalt aluminate (CoAl2O4) has the best nucleating effect. The objective of this work was to determine the influence of the inoculant’s content (cobalt aluminate) in the surface layer of the ceramic mould on the microstructure and mechanical properties at high temperature of nickel based superalloy René 77. For this purpose, the ceramic moulds were made with different concentration of cobalt aluminate in the primary slurry was from 0 to 10% mass. in zirconium flour. Stepped and cylindrical samples were casted for microstructure and mechanical examinations. The average grain size of the matrix ( phase), was determined on the stepped samples. The influence of surface modification on the grain size of up to section thickness was considered. The microstructure investigations with the use of light microscopy and scanning electron microscopy (SEM) enable to examine the influence of the surface modification on the morphology of ’ phase and carbides precipitations. Verification of the influence of CoAl2O4 on the mechanical properties of castings were investigated on the basis of results obtained form creep tests.

An Experimental Study on the Effect of Prior Plastic Straining on Creep Behavior of 304 Stainless Steel

1993 ◽  
Vol 115 (2) ◽  
pp. 200-203 ◽  
Author(s):  
Z. Xia ◽  
F. Ellyin
Keyword(s):  
Stainless Steel ◽  
Plastic Strain ◽  
Strain Rate ◽  
Creep Behavior ◽  
Test Procedure ◽  
Constant Strain Rate ◽  
304 Stainless Steel ◽  
Creep Model ◽  
Plastic Strain Rate ◽  
Creep Tests

Constant strain-rate plastic straining followed by creep tests were conducted to investigate the effect of prior plastic straining on the subsequent creep behavior of 304 stainless steel at room temperature. The effects of plastic strain and plastic strain-rate were delineated by a specially designed test procedure, and it is found that both factors have a strong influence on the subsequent creep deformation. A creep model combining the two factors is then developed. The predictions of the model are in good agreement with the test results.

scholarly journals Study on creep performance of launch canister under long-term storage

2019 ◽  
Vol 43 (2) ◽  
pp. 199-208 ◽  
Author(s):  
Cun-Gui Yu ◽  
Tong-Sheng Sun ◽  
Guang-Yuan Xiao
Keyword(s):  
Residual Deformation ◽  
Bottom Layer ◽  
Tensile Creep ◽  
Creep Model ◽  
Model Parameters ◽  
Creep Tests ◽  
Software Environment ◽  
Long Term Storage ◽  
Term Storage

In this paper, the creep performance of a multi-barrel rocket launch canister under long-term stacking storage is studied. Based on the Bailey–Norton model, a creep model for the frame material of a launch canister was established. Constant stress tensile creep tests under different stress levels at room temperature were carried out on the frame materials of the launch canister and the creep model parameters were obtained by test data fitting. The three-dimensional finite element model of the launch canister was established in the ABAQUS software environment and the creep deformation of the launch canister after long-term stacking storage was studied. The results indicated that the bottom layer of the launch canister frame presented an extended residual deformation when the stacking storage solution with the original support pad was used. Therefore, a position adjustment program of the support pad was put forward. The residual deformation of the launch canister frame after long-term storage could be significantly reduced, thus the performance requirements for the launch canister are guaranteed.

As-Built Geometry and Surface Finish Effects on Fatigue and Tensile Properties of Laser Fused Titanium 6Al-4V

2017 ◽  
Author(s):  
Onome Scott-Emuakpor ◽  
Tommy George ◽  
Emily Henry ◽  
Casey Holycross ◽  
Jeff Brown
Keyword(s):  
Tensile Properties ◽  
Surface Finish ◽  
Fatigue Behavior ◽  
Turbine Blades ◽  
Material Behavior ◽  
Small Scale ◽  
Internal Cooling ◽  
Roughness Effects ◽  
Form And Function ◽  
And Function

The as-built material behavior of additive manufactured (AM) Titanium (Ti) 6Al-4V is investigated in this study. A solution heat treated, aged, stress relieved, and hot isostatic pressed Laser Powder Bed Fusion (LPBF) AM process was used to manufacture the specimens of interest. The motivation behind this work is based on the ever-growing desire of aerospace system designers to use AM to fabricate components with novel geometries. Specifically, there is keen interest in AM components with complex internal cooling configurations such as turbine blades, nozzle vanes, and heat exchangers that can improve small scale propulsion performance. Though it is feasible to three-dimensionally print parts that meet the Fit portion of a part characteristic description and identification, the Form and Function portions have proven to be more difficult to conquer. This study addresses both the Form and Function characteristics of the LPBF AM process via the investigation of geometry variation and surface roughness effects pertaining to mechanical properties and fatigue behavior of Ti 6Al-4V. Results show that geometry variation may be the cause of increased vibration fatigue life uncertainty. Also, both fatigue and tensile properties show profound discrepancies associated with surface finish. As-built surface finish specimens have lower fatigue and ductility performance, but the results are more consistent than polished data.

scholarly journals Review of Icing Effects on Wind Turbine in Cold Regions

2018 ◽  
Vol 72 ◽  
pp. 01007 ◽  
Author(s):  
Faizan Afzal ◽  
Muhammad S. Virk
Keyword(s):  
Wind Turbine ◽  
Structural Integrity ◽  
Turbine Blades ◽  
Leading Edge ◽  
Added Mass ◽  
Cold Climate ◽  
Ice Accretion ◽  
Wind Turbine Blades ◽  
Turbine Performance ◽  
Ice Shedding

This paper describes a brief overview of main issues related to atmospheric ice accretion on wind turbines installed in cold climate region. Icing has significant effects on wind turbine performance particularly from aerodynamic and structural integrity perspective, as ice accumulates mainly on the leading edge of the blades that change its aerodynamic profile shape and effects its structural dynamics due to added mass effects of ice. This research aims to provide an overview and develop further understanding of the effects of atmospheric ice accretion on wind turbine blades. One of the operational challenges of the wind turbine blade operation in icing condition is also to overcome the process of ice shedding, which may happen due to vibrations or bending of the blades. Ice shedding is dangerous phenomenon, hazardous for equipment and personnel in the immediate area.

scholarly journals A Review of Recent Advancements in Offshore Wind Turbine Technology

Energies ◽  
2022 ◽  
Vol 15 (2) ◽  
pp. 579
Author(s):  
Taimoor Asim ◽  
Sheikh Zahidul Islam ◽  
Arman Hemmati ◽  
Muhammad Saif Ullah Khalid
Keyword(s):  
Wind Turbine ◽  
Wind Turbines ◽  
Structural Integrity ◽  
Turbine Blades ◽  
Offshore Wind ◽  
System Level ◽  
Offshore Wind Turbine ◽  
Component Level ◽  
Foundation Design ◽  
Offshore Wind Turbines

Offshore wind turbines are becoming increasingly popular due to their higher wind energy harnessing capabilities and lower visual pollution. Researchers around the globe have been reporting significant scientific advancements in offshore wind turbines technology, addressing key issues, such as aerodynamic characteristics of turbine blades, dynamic response of the turbine, structural integrity of the turbine foundation, design of the mooring cables, ground scouring and cost modelling for commercial viability. These investigations range from component-level design and analysis to system-level response and optimization using a multitude of analytical, empirical and numerical techniques. With such wide-ranging studies available in the public domain, there is a need to carry out an extensive yet critical literature review on the recent advancements in offshore wind turbine technology. Offshore wind turbine blades’ aerodynamics and the structural integrity of offshore wind turbines are of particular importance, which can lead towards system’s optimal design and operation, leading to reduced maintenance costs. Thus, in this study, our focus is to highlight key knowledge gaps in the scientific investigations on offshore wind turbines’ aerodynamic and structural response. It is envisaged that this study will pave the way for future concentrated efforts in better understanding the complex behavior of these machines.

Acoustic Emission for Structural Integrity Assessment of Wind Turbine Blades

2014 ◽  
pp. 369-382 ◽  
Author(s):  
Nikolaos K. Tsopelas ◽  
Dimitrios G. Papasalouros ◽  
Athanasios A. Anastasopoulos ◽  
Dimitrios A. Kourousis ◽  
Jason W. Dong
Keyword(s):  
Acoustic Emission ◽  
Wind Turbine ◽  
Structural Integrity ◽  
Turbine Blades ◽  
Wind Turbine Blades ◽  
Integrity Assessment

Crystal Visco-Plastic Model for Directionally Solidified Ni-Base Superalloys Under Monotonic and Low Cycle Fatigue

2021 ◽  
Author(s):  
Navindra Wijeyeratne ◽  
Firat Irmak ◽  
Ali P. Gordon
Keyword(s):  
Grain Boundaries ◽  
Gas Turbines ◽  
Thermal Stresses ◽  
Low Cycle Fatigue ◽  
Turbine Blades ◽  
Material Behavior ◽  
Flow Rule ◽  
Cycle Fatigue ◽  
Directionally Solidified ◽  
Crystallographic Slip

Abstract Nickel-base superalloys (NBSAs) are extensively utilized as the design materials to develop turbine blades in gas turbines due to their excellent high-temperature properties. Gas turbine blades are exposed to extreme loading histories that combine high mechanical and thermal stresses. Both directionally solidified (DS) and single crystal NBSAs are used throughout the industry because of their superior tensile and creep strength, excellent low cycle fatigue (LCF), high cycle fatigue (HCF), and thermomechanical fatigue (TMF) capabilities. Directional solidification techniques facilitated the solidification structure of the materials to be composed of columnar grains in parallel to the <001> direction. Due to grains being the sites of failure initiation the elimination of grain boundaries compared to polycrystals and the alignment of grain boundaries in the normal to stress axis increases the strength of the material at high temperatures. To develop components with superior service capabilities while reducing the development cost, simulating the material’s performance at various loading conditions is extremely advantageous. To support the mechanical design process, a framework consisting of theoretical mechanics, numerical simulations, and experimental analysis is required. The absence of grain boundaries transverse to the loading direction and crystallographic special orientation cause the material to exhibit anisotropic behavior. A framework that can simulate the physical attributes of the material microstructure is crucial in developing an accurate constitutive model. The plastic flow acting on the crystallographic slip planes essentially controls the plastic deformation of the material. Crystal Visco-Plasticity (CVP) theory integrates this phenomenon to describe the effects of plasticity more accurately. CVP constitutive models can capture the orientation, temperature, and rate dependence of these materials under a variety of conditions. The CVP model is initially developed for SX material and then extended to DS material to account for the columnar grain structure. The formulation consists of a flow rule combined with an internal state variable to describe the shearing rate for each slip system. The model presented includes the inelastic mechanisms of kinematic and isotropic hardening, orientation, and temperature dependence. The crystallographic slip is accounted for by including the required octahedral, cubic, and cross slip systems. The CVP model is implemented through a general-purpose finite element analysis software (i.e., ANSYS) as a User-Defined Material (USERMAT). Uniaxial experiments were conducted in key orientations to evaluate the degree of elastic and inelastic anisotropy. The temperature-dependent modeling parameter is developed to perform non-isothermal simulations. A numerical optimization scheme is utilized to develop the modeling constant to improve the calibration of the model. The CVP model can simulate material behavior for DS and SX NBSAs for monotonic and cyclic loading for a range of material orientations and temperatures.

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