P. S. Prevey, Lambda Technologies, Cincinnati, OH; D. N. Jayaraman, Lambda Research, Cincinnati, OH; R. Ravindranath, NAVAIR, Patuxent River, MD
The deep stable layer of compressive residual stress produced by low plasticity burnishing (LPB) has been demonstrated in laboratory coupons to improve the damage tolerance in engine alloys IN718, Ti-6Al-4V, and 17-4PH. This paper describes the benefits of application of LPB to produce deep compression in the dovetail section of a Ti-6Al-4V first stage fan blade to mitigate the adverse effects of fretting-induced microcracks. Blades removed from fielded engines were LPB processed to protect the dovetail region of the blade, and specially designed feature specimens were also used to simulate these dovetail regions. Both the feature specimens and actual dovetail sections were fatigue tested in cantilever bending mode at R>0 using specially designed test fixtures. Microcracks were simulated with electrical discharge machined (EDM) notches. Residual stress and cold work distributions were measured using x-ray diffraction mapping techniques.
LPB produced a zone of compression in the dovetail region up to a depth of 0.065 in. The HCF performance with EDM notches up to 0.040 in. deep was tested. LPB processed specimens with 0.020 in. deep EDM notch showed an endurance limit of 100 ksi. This fatigue performance is better than the untreated baseline specimens without the notch. The specimens with 0.030 in. and 0.040 in. deep notches showed endurance limits of 60 and 50 ksi, respectively.
Linear elastic fracture mechanics analysis including the residual stress fields confirms the HCF and FOD performance in the presence of high residual compression. A novel approach for determining the residual stress field design to provide a desired fatigue life and FOD tolerance is introduced.