CORDIS provides links to public deliverables and publications of HORIZON projects.
Links to deliverables and publications from FP7 projects, as well as links to some specific result types such as dataset and software, are dynamically retrieved from OpenAIRE .
Deliverables
The aim of the project, which focused principally on combustors, was to produce verified lifting methodology for the design and in-service support of all gas turbine components that are subjected to both creep and plasticity during every engine cycle. At its core was the development of three types of materials behaviour model and their implementation in the Finite Element (FE) programs used for component design:
- Deformation models to predict stabilised component stresses as efficiently as possible
- Crack initiation/damage models, based on parameters from the FE calculations, to predict component lives at the design stage
- Crack growth models to allow safe inspection intervals to be specified where in-service problems exist
Development of the models was based on thermo-mechanical fatigue (TMF) and isothermal test results on standard laboratory specimens and specimens containing representative component features. Their final verification used results from rig testing on sub-elements of combustor and turbine casing geometry under component loading conditions. Two materials were studied, C263 and Haynes 230.
The deformation modelling activity produced a number of complementary approaches that could predict stabilised component stresses and strains to the required accuracy. Very good lifing correlations were obtained for isothermal specimens tested under a wide range of loading conditions, although extension of the models to TMF cycles and laser drilled holes proved difficult. The crack propagation modelling work proved successful in predicting the behaviour of plain and featured isothermal specimens.
Methods for reducing the run times of non-linear finite element analyses were investigated, but in general the resulting loss in accuracy was unacceptably high. This remains an important area for future research in order to implement the improved lifing methods from this programme without increasing development timescales for new components.
Three rig test types were developed to allow the accuracy of the life prediction methods to be assessed on engine hardware run under controlled conditions, combustor tests on a single component and two in series plus a scaled turbine exhaust casing. A series of technical problems with both combustor tests, however, prevented the components being run to failure and providing datum points for verifying the lifing models.
The thermal and structural analysis work on the rig tests allowed new techniques to be developed for reading thermal paint data onto an FE mesh and analysing sub-models of local regions of the component. These will help to reduce analysis times for new components.
Overall, significant progress was made on developing and verifying lifing methods for combustors and turbine casings. The lifing curves derived for holes in combustors, however, are currently considered to be over-conservative. Further work is planned using the CPLIFE results to allow design lives based on these data to be increased.
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