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STOCHASTIC MUTISCALE/MULTISTAGE MODELING OF ENGINE DISKS
Navy STTR FY2010.A
| Sol No.: |
Navy STTR FY2010.A |
| Topic No.: |
N10A-T028 |
| Topic Title: |
STOCHASTIC MUTISCALE/MULTISTAGE MODELING OF ENGINE DISKS |
| Proposal No.: |
N10A-028-0433 |
| Firm: |
Advanced Dynamics, Inc.
1500 Bull Lea Road, Suite 203
Lexington, Kentucky 40511-1268 |
| Contact: |
Nicholas Zabaras |
| Phone: |
(607) 225-9104 |
| Web Site: |
www.advanceddynamics-usa.com |
| Abstract: |
Turbine disks are amongst the most critical components in aero- and naval-vessel engines. They operate in a high pressure and temperature environment requiring demanding properties. Nickel-based supperalloys which have high creep and oxidation resistance at high temperatures are widely used as the material of turbine disks. The elevated-temperature strength of this supperalloy and its resistance to creep deformation significantly depend on the volume fraction, size and antiphase boundary energy of the γ' phase as well as on the grain size and texture. Future propulsion systems will require turbine disks with an increased material temperature capability and with optimized dual microstructures presenting high creep resistance and dwell crack growth resistance in the rim region and high strength and fatigue resistance in the bore and web regions. In the proposed STTR project, a state of the art, multi-fidelity, and efficient multiscale and multistage process modeling and simulation methodology will be developed together with a computer software package for advanced dual microstructure nickel-base supperalloy turbine disks. The proposed methodology is based on an integration of realistic microstructure evolution modeling, dislocation dynamics, crystal plasticity theory, finite element deformation and thermal processing simulation, and probabilistic, statistical and statistic learning methodologies. The proposed developments significantly advance the science of multiscale modeling by connecting the microstructure uncertainties to macroscale processing control, and further, to the resulting variability of material properties. Innovative techniques in data-driven representation of microstructure uncertainties will be employed together with adaptive sparse grid collocation based techniques for modeling uncertainty propagation in multiscale materials simulations. Moreover, a validated model that optimizes the processing technology to produce complex gas turbine engine components with controlled microstructures, defect populations and desirable mechanical properties will be developed, thus providing reliable guidance for industrial manufacture. |
| Benefits: |
Turbine disks are among the most critical components in aero- and naval-vessel engines. Nickel-based superalloys are commonly used for turbine disks because of their advanced properties. Future propulsion systems require turbine disks with an increased material temperature capability and with optimized dual microstructures presenting high creep resistance and dwell crack growth resistance in the rim region and high strength and fatigue resistance in the bore and web regions. Therefore, advanced turbine disks that can run hotter and faster than what is possible using today's materials and processes are of great interest and importance to the mission of the U.S. Navy. Although superalloys have been used for turbine disks in jet engines for decades, their processing is not without challenges. The manufacturing stream is quite lengthy, involving a number of material suppliers, melters and forge masters. At each stage, there is a risk that uncontrollable defects will be introduced. In addition, the design and process of superalloy turbine disks is complicated and costly. A reliable computational framework that can provide guidance to the manufacturing industry is valuable. In the proposed project, we are aiming at developing a multiscale, multistage stochastic framework for the analysis and process design of nickel-based superalloy turbine disks, from which the microstructures and properties will be predicted and optimized. Uncertainty modeling and quantification will be considered at all stages of the analysis/design of engine disks allowing predictive modeling and design in the presence of uncertainties.
The outcomes of the proposed project will benefit the U.S. Navy and disk manufacturing industry in multiple ways including the following:
1. The computational model will lead to a reduction in the number of expensive and time-consuming design/make iterations required during component prototyping of engine disks.
2. It can predict the microstructures and evaluate the mechanical properties with error-bars of turbine disk products, if critical processing parameters are provided beforehand. The multistage processes that would provide preferable disk properties can be optimized accounting for process and microstructural uncertainties as well as allowable variability in the desired objectives.
3. Guidance will be provided to the manufacturing industry in the forms of spreadsheets to explore the structure/property relations in the multistage processes in order to allow practitioners to adapt the methodologies developed and results provided to alternate design objectives.
4. The proposed work will provide a comprehensive insight into the superalloy processing, so that the grain structure evolution, defect generation, and hardening mechanism of superalloys during manufacture will be further understood.
All of the above aspects will greatly reduce the cost of analysis of superalloy turbine disks and facilitate the process design for advanced turbine disks of higher quality and performance.
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