Enhanced material lifing model for rotating welded structures (LIFEMOD)

Research Project, 2013 – 2015

Green and sustainable engines require accurate and well documented material data for safe operation of the engines at optimum efficiency. The SAGE project aims at demonstrating open rotor engines and technologies to reduce fuel consumption, weight and increased efficiency of engine components. Structural integrity and safety of engine critical parts have to be considered with regard to design, manufacturing aspects and in-service maintenance and overhaul.The engine operating conditions, thermal and mechanical loads, material properties and other influencing parameters are affecting the Approved Life of the component. Extensive analysis, component & engine tests, and inspections during both component manufacturing and in-service have to be performed for verification. In particular, the regulations required for critical parts to fulfil appropriate damage tolerance criteria has to be considered, and the potential for failure from material, manufacturing and service induced anomalies within the Approved Life of the part. This means that the potential existence of various imperfections, defects and flaws in the component are recognized and are due to material issues, component design and manufacturing. This situation can be handled through the incorporation of fracture resistant design, process control and Non-destructive Testing (NDT).In fabricated components and structures different visual inspection and NDT methods are being used for weld inspection. The quality of the welds will determine the fatigue life of a component. This project will focus on welds made in IN718, both laser welds and TIG welds. Before testing the specimens will be NDT tested (WP2), then high cycle fatigue tested (WP4), creep fatigue tested (WP5), fracture surfaces examined (WP3), statistical analysis performed (WP6) and finally the lifing model developed (WP7). The model will then be put to use by the topic manager for design of green and sustainable engines.

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Related Areas of Advance and Infrastructure

Sustainable development

Driving Forces

Life Science Engineering (2010-2018)

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