The isothermal planar‐biaxial fatigue behavior was studied for two different disk batches of nickel‐base superalloy Inconel 718 using cruciform specimens at 400°C and 630°C under equi‐biaxial and shear loading. Additionally, non‐proportional tests were performed. The planar‐biaxial test results were compared with uniaxial reference tests using the von Mises equivalent strain hypothesis, a shear strain parameter of the critical plane, and a modified crack‐opening‐displacement strain range approach. Additionally, the crack initiation mechanism was analyzed. Using a modified crack‐opening‐displacement strain range approach, the low‐cycle fatigue lifetimes of the proportional planar‐biaxial tests (i.e., lifetimes up to 40,000 cycles) were described within a scatter band of two. Thus, it was better than using the equivalent strain of von Mises or a shear strain parameter. The fatigue crack initiation took place at oxidized primary carbides at the surface. The crack paths were presented.
Heat exchange applications at high temperatures of greater than 800°C under corrosive or abrasive conditions require heat exchangers based on ceramic materials instead of conventionally used metals. Heat exchangers based on heat pipes are exceptionally suitable since temperature gradients and correspondent thermal stresses are inherently low for this design. At high temperatures greater than 800°C, the structural material SSiC and working fluids sodium or zinc appear to be the most promising options. Encapsulating the working fluid in ceramic heat pipes with a sealing joint ensuring long term stability and high temperature resistance is particularly challenging. A nickelbased alloy has been identified as solder material for SSiC heat pipes using sodium as working fluid and a glass solder was used in case of zinc filled heat pipes. Manufactured heat pipes were tested in a hot-gas test rig at temperatures up to 1000°C.
Rotor blades are the highest thermal-mechanical loaded components of gas turbines. Their service life is limited by interaction of creep, low cycle fatigue (LCF), high cycle fatigue (HCF) and surface attack. Because assurance of adequate HCF strength of the rotor blade is an important issue of the blade design the European project PREMECCY has been started by the European aircraft engine manufacturers and research institutes to enhance the predictive methods for combined cycle fatigue (CCF), as a superposition of HCF and LCF. Although today’s predictive methods ensure safe blade design, there are certain shortcomings of assessing fatigue life with Haigh or “modified Goodman diagrams”, such as isolated HCF assessment as well as uni-axial and off-resonant testing. HCF and LCF are considered without taking into account their interaction. PREMECCY is aimed to deliver new and improved CCF prediction methods for exploitation in the industrial design process. Beside development of predictive methods the authors are involved in the design and testing of advanced specimens representing rotor blade features. In this connection the paper presents a novel test specimen type and a unique hot gas rig for CCF feature test at mechanical and ambient representative conditions.
Gas turbines and aircraft engines are dominated by cyclic operating modes with fatigue-related loads. This may result in the acceleration of damage development on the components. Critical components of turbine blades and discs are exposed to cyclic thermal and mechanical multi-axial fatigue. In the current work, planar-biaxial Low-Cycle-Fatigue (LCF) tests are conducted using cruciform specimens at different test temperatures. The influence on the deformation and lifetime behaviour of the nickel-base disk alloy Inconel 718 is investigated at selected cyclic proportional loading cases, namely shear and equi-biaxial. The calculation of the stress and strain distribution of the cruciform specimens from the experimental data is difficult to obtain due to complex geometry and temperature gradients. Therefore, there is a need for Finite Element (FE) Simulations. A viscoplastic material model is considered to simulate the material behaviour subjected to uniaxial and the selected planar-biaxial loading conditions. At first, uniaxial simulation results are compared with the uniaxial experiment results for both batches of IN718. Then, the same material parameters are used for simulating the biaxial loading cases. The prediction of FE simulation results is in good agreement with the experimental LCF test for both shear and equi-biaxial loadings. The equivalent stress amplitude results of the biaxial simulation are compared with the uniaxial results. Furthermore, the lifetime is calculated based on the stabilized cycle from the simulation and by using Crossland and Sines multi-axial stress-based approaches. The Crossland model predicts fatigue life significantly better than the Sines model. Finally, the simulated lifetime results are compared with the experimental lifetime.
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