Bending fatigue of electron-beam-welded foils. Application to a hydrodynamic air bearing in the Chrysler/DOE upgraded automotive gas tubine engine

A hydrodynamic air bearing with a compliment surface is used in the gas generator of an upgraded automotive gas turbine engine. In the prototype design, the compliant surface is a thin foil spot welded at one end to the bearing cartridge. During operation, the foil failed along the line of spot welds which acted as a series of stress concentrators. Because of its higher degree of geometric uniformity, electron beam welding of the foil was selected as an alternative to spot welding. Room temperature bending fatigue tests were conducted to determine the fatigue resistance of the electron beam welded foils. Equations were determined relating cycles to crack initiation and cycles to failure to nominal total strain range. A scaling procedure is presented for estimating the reduction in cyclic life when the foil is at its normal operating temperature of 260 C (500 F)

Strainrange partitioning: A total strain range version

Procedures are presented for expressing the Strainrange Partitioning (SRP) method for creep fatigue life prediction in terms of total strain range. Inelastic and elastic strain-range - life relations are summed to give total strain-range - life relations. The life components due to inelastic strains are dealt with using conventional SRP procedures while the life components due to elastic strains are expressed as families of time-dependent terms for each type of SRP cycle. Cyclic constitutive material behavior plays an important role in establishing the elastic strain-range - life relations as well as the partitioning of the inelastic strains. To apply the approach, however, it is not necessary to have to determine the magnitude of the inelastic strain range. The total strain SRP approach is evaluated and verified using two nickel base superalloys, AF2-1DA and Rene 95. Excellent agreement is demonstrated between observed and predicted cyclic lifetimes with 70 to 80 percent of the predicted lives falling within factors of two of the observed lives. The total strain-range SRP approach should be of considerable practical value to designers who are faced with creep-fatigue problems for which the inelastic strains cannot be calculated with sufficient accuracy to make reliable life predictions by the conventional inelastic strain range SRP approach

An update of the total-strain version of SRP

An updated procedure for characterizing an alloy and predicting cyclic life by using the total strain range version of strainrange partitioning (TS-SRP) has been developed. The principal feature of this update is a new procedure for determining the intercept of time dependent elastic strain range versus cyclic life lines. The procedure is based on an established relation between failure and the cyclic stress-strain response of an alloy. The stress-strain response is characterized by empirical equations presented in this report. These equations were determined with the aid of a cyclic constitutive model. The procedures presented herein reduce the testing required to characterize an alloy. Failure testing is done only in the high strain, low life regime; cyclic stress-strain response is determined from tests conducted in both the high and low strain regimes. These tests are carried out to stability of the stress-strain hysteresis loop but not to failure. Thus both the time and costs required to characterize an alloy are greatly reduced. This approach was evaluated and verified for two nickel base superalloys, AF2-1DA and Inconel 718

Application of strainrange partitioning to the prediction of creep-fatigue lives of AISI types 304 and 316 stainless steel

As a demonstration of the predictive capabilities of the method of Strainrange Partitioning, published high-temperature, low cycle, creep-fatigue test results on AISI Types 304 and 316 stainless steel were analyzed and calculated, cyclic lives compared with observed lives. Predicted lives agreed with observed lives within factors of two for 76 percent, factors of three for 93 percent, and factors of four for 98 percent of the laboratory tests analyzed. Agreement between observed and predicted lives is judged satisfactory considering that the data are associated with a number of variables (two alloys, several heats and heat treatments, a range of temperatures, different testing techniques, etc.) that are not directly accounted for in the calculations

Total strain version of strainrange partitioning for thermomechanical fatigue at low strains

A new method is proposed for characterizing and predicting the thermal fatigue behavior of materials. The method is based on three innovations in characterizing high temperature material behavior: (1) the bithermal concept of fatigue testing; (2) advanced, nonlinear, cyclic constitutive models; and (3) the total strain version of traditional strainrange partitioning

Application of strainrange partitioning to the prediction of MPC creep-fatigue data for 2 1/4 Cr-1Mo steel

Strainrange partitioning is used to predict the long time cyclic lives of the metal properties council (MPC) creep-fatigue interspersion and cyclic creep-rupture tests conducted with annealed 2 1/4 Cr-1Mo steel. Observed lives agree with predicted lives within factors of two. The strainrange partitioning life relations used for the long time predictions were established from short time creep-fatigue data generated at NASA-Lewis on the same heat of material

Design studies on the effects of orientation, lunation, and location on the performance of lunar radiators

Effects of orientation, lunation, and location on performance of lunar radiator - design studie

Ductility normalized-strainrange partitioning life relations for creep-fatigue life predictions

Procedures based on Strainrange Partitioning (SRP) are presented for estimating the effects of environment and other influences on the high temperature, low cycle, creep fatigue resistance of alloys. It is proposed that the plastic and creep, ductilities determined from conventional tensile and creep rupture tests conducted in the environment of interest be used in a set of ductility normalized equations for making a first order approximation of the four SRP inelastic strainrange life relations. Different levels of sophistication in the application of the procedures are presented by means of illustrative examples with several high temperature alloys. Predictions of cyclic lives generally agree with observed lives within factors of three

Evaluation of structural analysis methods for life prediction

The utility of advanced constitutive models and structural analysis methods are evaluated for predicting the cyclic life of an air-cooled turbine blade for a gas turbine aircraft engine. Structural analysis methods of various levels of sophistication were exercised to obtain the cyclic stress-strain response at the critical airfoil location. Calculated strain ranges and mean stresses from the stress-strain cycles were used to predict crack initiation lives by using the total strain version of the strain range partitioning life prediction method. The major results are given and discussed