The 22nd Advanced Aerospace Materials and Processes (AeroMat) Conference and Exposition (May 23-25, 2011) of ASM

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Wednesday, May 25, 2011 - 9:30 AM
MDE4.3

Computational Microstructural Models for Lifing Superalloy Disk Designs

R. Tryon, R. Matthews, VEXTEC, Brentwood, TN

Probabilistic computational tools to simulate the mechanical metallurgy of materials will be presented. The tools simulate from the material microstructure to large complex components to fleet wide usage variability. The simulations use, as their input, the quantitative three dimensional description of microstructure, processing anomalies, bulk residual stresses, component geometry and applied cyclic loading. The tools integrate directly into the product design cycle through popular computational structural FEA software such as ANSYS and NASTRAN. The traditional design variables of stress, strain and temperature are read from the FEA. The probabilistic microstructural lifing analysis is performed for every elemental location of the FEA. The probability of failure is determined at each location. System reliability methods are used to determine the probability of failure for the entire component and then expanded to all components in the fleet. The integration of computational process models with the probabilistic microstructural lifing simulation to design turbine disks will be discussed. By integrating computational disk process models, computational disk structural models and computational disk lifing models, materials engineering becomes an enabler in the product design process.