Strain Life Techniques

8/10/2019 Strain Life Techniques

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NASA/TM2004-212985 RL-TR-3178

GT2004-53939

RESEARCHLABORATORY

Strain-Life

Assessment

of

Grainex

Mar-M

247

forNASA's

Turbine

Seal

Test

Facility

Irebert

R .

Delgado

U.S.ArmyResearch

Laboratory,

Glerm

Research

Center,

Cleveland,Ohio

Gary

R .Halfordand

Bruce

M .Steinetz

Glenn

Research

Center,Cleveland,Ohio

ClareM .

Rimnac

Case

Western

Reserve

University,

Cleveland,Ohio

DlSTBlBUTlOHSWTEMEirrA

Approved

f o r

Public

Release

Distribution

Unlimited

April 2004


2/12

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1.GENCYUSEONLY(/.save

Wanfc )

2. REPORT

DATE

April2004

REPORTTYPEAND

DATES

COVERED

Technical

Memorandum

4.ITLE

AND

SUBTITLE

Strain-Life

Assessment

ofGrainex

Mar-M

24 7fo rNASA's

TurbineSeal

Test

Facility

6.

UTHOR(S)

IrebertR .Delgado,GaryR .Halford,BruceM.Steinetz,an dClareM.

Rimnac

5. FUNDINGNUMBERS

WBS-22-714-09-18

1L161102AF20

7. PERFORMINGORGANIZATION

NAME(S)ANDADDRESS(ES)

National Aeronauticsan dSpace Administration

JohnH.

GlennResearchCenterat

Lewis

Field

Cleveland,

Ohio

44135-3191

8. PERFORMINGORGANIZATION

REPORTNUMBER

E-14460

9.

PONSORING/MONITORING

AGENCY

NAME(S)ANDADDRESS(ES)

NationalAeronauticsan dSpaceAdministrat ion

Washington,

D C

0546-0001

an d

U.S.ArmyResearchLaboratory

Adelphi,

Maryland

0783-1145

10 .

PONSORING/MONITORING

AGENCYREPORT

NUMBER

NAS A

TM-2004-212985

ARL-TR-3178

GT2004-53939

11.UPPLEMENTARY

NOTES

Preparedfo r

th e

Turbo

Expo2004

sponsored

by

th e

American

Societyof

MechanicalEngineers,

Vienna,

Austria,

June14-17,2004.IrebertR .

Delgado,

U.S.

Army

ResearchLaboratory,NASA

Glenn

ResearchCenter,

Gary

R.

Halford

an d

Bruce

M.Steinetz,

NASA

GlennResearchCenter;an d

Clare

M.

Rimnac,

Case

Western

Reserve

University,

Cleveland,

Ohio44106.Responsibleperson,IrebertR .

Delgado,organizationcode0300,216-433-3935.

12a. DISTRIBUTION/AVAILABILITYSTATEMENT

Unclassified

-

Unlimited

Subject Category:07

Availableelectronicallyathttp://gltrs.grc.nasa.gov

ThispublicationisavailablefromtheNASACenter

for

AeroSpace

Information,301-621-0390.

Distribution:

Nonstandard

12b.ISTRIBUTIONCODE

13.

BSTRACT(Maximum

200

words)

NASA's

TurbineSeal

Test

Facilityis

used

to

test

air-to-air

sealsfo r

us e

primarilyinadvanced jet

engine

applications.

Combinationsof

high

temperature,

high

speed,

an d

highpressurelimitthedisklife,

du e

to

the

concern

of

crack

initiation

in

th e

bolt

holes

of

the

Grainex

Mar-M

24 7

disk.

T he

primary

purpose

ofthis

current

work

is

todetermine

aninspection

intervaltoensuresafeoperation.Thecurrentworkpresents

high

temperature

fatigue

strain-lifedatafo rtestspecimens

cu t

from

anactualGrainexMar-M247 disk.Several

different

strain-life

models

werecomparedtothe

experimental

data

includingth eManson-HirschbergMethod

of

Universal

Slopes,theHalford-NachtigallMeanStressMethod,an dth e

Modified

Morrow

Method.The

Halford-Nachtigall

Method

resulted

inonlyan

18

percent

difference

between

predicted

an dexperimentalresults.Usingth eexperimentaldataata

-99.95percentprediction

level

andth epresenceof

6bolt

holes

it

was

found

that

thedisk

should

be inspected

after

66 5cycles

based

ona

totalstrain

of

0.5

percent

at

64 9

C .

2 0 0 4 1 0 0 8

3

14 . SUBJECTTERMS

Superalloy;

Mar-M

247;

Fatigue

strain-life;

Nickel-based;Crackinitiation;

Life

estimation;

Turbinesealingtesting;Turbinedisk

13. numDcn rrMuco

13

16 .

PRICE

CODE

17 .

SECURITYCLASSIFICATION

OFREPORT

Unclassified

18 .

ECURITYCLASSIFICATION

OF

THIS

PAGE

Unclassified

19.

ECURITY

CLASSIFICATION

O F

ABS T RACT

Unclassified

20.

LIMITATION

OF

ABSTRACT

NS N7540-01-280-5500

StandardForm298(Rev.2-89)

PrescribedbyANSIStd.Z39-18

298-102


4/12

NASA/TM2004-212985 RL-TR-3178

u.s..Rv

T200^53939

RESEARCHLABORATORY

Strain-Life

Assessment

of

Grainex

Mar-M

247

for

NASA'sTurbine

Seal

Test

Facility

IrebertR.

Delgado

U.S.

Army

Research

Laboratory,

Glenn

Research

Center,

Cleveland, Ohio

GaryR.

Halford

and

Bruce

M.Steinetz

Glenn

Research

Center,

Cleveland,

Ohio

Clare

M.Rimnac

Case

Western

Reserve

University,Cleveland,Ohio

Prepared

fo rthe

Turbo

Expo

2004

sponsored

by

theAmerican

Society

ofMechanical

Engineers

Vienna,Austria,June14-17,2004

National

Aeronauticsand

Space

Administration

Glenn

Research

Center

April 2004


5/12

Acknowledgments

The

authors

wish

to

acknowledge

NASA

Glenn

R^earch

Center,

the

Army

Research

Laboratory,

and

Case

WesternReserveUniversity

for

their

support.

Thisreportis

a

formaldraft

or

working

paper,

intendedto

solicitcomments

and

ideasfrom

a

technicalpeergroup.

Tradenames

or

manufacturers'namesareusedinthfereportfor

identification

only.

Thisusage

doesnot

cor^titutean

official

endorsement,

either

expressed

or

implied,by

the

National

AeronauticsandSpaceAdministration.

Availablefrom

NASA

Center

for

Aerospace

Information

7121StandardEWve

Hanover,M D 21076

National

Technical

InformationService

5285

PortRoyalRoad

Springfield,

VA

22100

Availableelectronically

at

http:

/

/gltrs.grc.nasa.gov


6/12

STRAIN-LIFE

A S S E S S M E N TO FGRAINEXMAR-M

247

FO R

N A S A S

TURBINE S E A L

T E S T

FACILITY

IrebertR.

Delgado

U.S.

Army

Research

Laboratory

Glenn

ResearchCenter

Cleveland,

Ohio44135

Gary

R.

Halford

an d

BruceM.Steinetz

NationalAeronauticsand

SpaceAdministration

Glenn

Research

Center

Cleveland,

Ohio

44135

Clare

M.Rimnac

CaseWesternReserve

University

Cleveland,

Ohio

44106

A B ST R A C T

NASA'sTurbine

Seal

Test

Facility

is

used

totest

air-to-

ai realsor

se

rimarilyn

dvanced

et

ngine

applications.

Combinations

of

high

temperature,

high

speed,

an dhighpressureimit

th e

iskife,

ue

oheoncern

f

crackinitiationin

th e

boltholes

of

the

Grainex

Mar-M

24 7

disk.he

rimary

urpose

fhi surrent

or k

so

determinennspectionntervalonsure

afeperation.

The

urrent

workpresentsighemperature

atigue

train-

life

data

fo rtest

specimens

cu t

froman

actualGrainex

Mar-

M

47

isk.

everal

ifferent

train-life

odels

er e

compared

o

he

xperimental

at a

ncluding

he

Manson-

Hirschbergethod

f

niversallopes,he

alford-

NachtigallMeantressMethod,

nd

theModifiedMorrow

Method.heHalford-NachtigallMethodresultedinonlyan

18 %

ifference

between

predicted

an d

experimental

results.

Using

he

xperimentalata

t

-99.95

redictionevel

an dthepresenceof6boltholes

t

wasoundthattheis k

shouldbeinspected

after

66 5cyclesbasedonatotalstrain

of

0.5%

at

64 9

a

INTRODUCTION

The

High

emperature

High

peed

urbine

ea l

es t

facility

(figure

),located

at

NASA'sGlennResearchCenter

in

Cleveland,

Ohio

rovides

ritical

esting

of

air

eals

or

aircraftenginest

conditions

f

highai rtemperatures,igh

sealpressures,andsurfacespeedsgreaterthan3 05

m/s.

Thees tacility

se s

is k

made

f

GrainexMar-M

247,acastnickelbasedsuperalloy.

Analysis

hasshownthat,

in

he

icinity

f

th e

isk

ol toles,

he

materiallightly

entersthe

plastic

region

of

the

stress-strain

curve

[1].

Dueto

these

emandinges t

onditions,he

ossibility

xistsha t

fatiguerackswill

evelop

with

ycling

the

ol t

ol e

locations,

whichfasten

the

test

disk

to

the

main

shaft

of

th e

test

tand.f

allowed

o

ro wo

ritical

ize,

he

racks

couldcausethedisk

to

catastrophically

burst

duringuse.

Preliminarynalysesyon gndteinetz1]av e

placed

train-life

atigue

imit,

L ^ y s

of

6000yclesased

upon

an

equivalent

-3a

reduction

actoran da

probabilistic

approach[2 ]accountingfor=6bohholes:

=A

sys

(1 )

Figure

1.NASA

Glenn Research

Center

turbine

seal

test

facility.

NASATTM2004-212985


7/12

eq .1)sbased

on

th eundberg-Palmgren3 ]nalysisor

rollingelementbearingsystemlives.Ls

th e

predictedlife

fo r

a

diskwith

asingle

bolt

hole.

T he

predicted

life,L,

an d

Weibulllope

parameter,e,ar eassumedto

be

identicalor

al l

sixdiskboltholes.O necycleisdefinedasarampupan d

down

in

speed.

Inhistudy,

train-life

ests

er e

onducted

ver

variousstrainrangesata temperatureof

649

C

todetermine

th e

cycles

to

cracknitiation.

his

data

was

compared

with

previousnalyses

s

well

s

iteratureata

nd

train-life

modelestimatesbased

upon

tensiledata.

NOMENCLATURE

30standarddeviations

A

constantcoefficient

B

constant

coefficient

C

constantcoefficient

bfatiguestrengthexponent

cfatigueductilityexponent

e

Weibullslopeparameter

=

3.57(Gaussian)

EYoung'sModulus

k

transfer

function

L

calculateddisk

life

Z , y , , j =

overall

systemlife

n

numberof boltholes=

6

strainratio=e//e

coefficient

of

determination

cycles

to

crackinitiation

cyclestofailure

transitionlifeunderzeromean

stress

cyclestofailure

under

zeromeanstress

cycles

tofailure

in

presence

of

mean

stress

effectiveratioofmean

stress

tostress

amplitude

ratio

of

mean

stress

to

stress

amplitude

coiKtant

exponent

change

in

mean

stress

[MPa]

totalstrainrange

elastic

strain

range

inelastic

strain

range

stressrange[MPa]

strainamplitude

true

fi-acture

ductility

fatigueductilitycoefficient

truefi-acture

strain

minimum strain

maximumstrain

stressamplitude

[MPa]

fatiguestrengthcoefficient

[MPa]

truefracturestrength[MPa]

meanstress[MPa]

ultimatetensilestrength

[MPa]

0.2% yieldstrength[MPa]

percentelongation

percentreductioninarea

percenttotalstrainrange

R

R'

Ni

Nf

Nm

Np

Vef f

a

80

Mel

Ae,

A0

^max

< Sa


8/12

DataAnalys is

The

fatigue

strain-life

results

wereevaluatedfollowinga

simple

linear

model

in

log-log

coordinates:

Nj=A{ AEf

where

heonstant

nd

xponent

aer eetermined.

Linearregression

analysisof

thelog-logtransformed

fatigue

strain-lifeehavioras

onducted

o

etermine

he

coefficient

A

an d

theexponentafo rthe

i?

=0

data.

Thus,

log(NA=

logA

+

alog

( % A 8 )

(3 )

Standard

tatisticalnalyses

werelso

erformedo

heck

fo rignificance

f

heegression, es torormal

distribution,

utliers,

ack-of-fit,

nd

lsoo

alculate

he

-99.95 prediction

interval.

[4 ]

Method

ofUniversal

Slopes

TheManson-HirschbergMethodfUniversallopes

(MUS)

was

usedto

estimate

strainlife

with

zero

mean

stress

based

only

upon

tensile

data

[5]:

Ae

=

ACg/

-I -

Ae

p/

(4 )

an d

:exp

-70

A^i

Ae,

el J

(10)

(2 )

A t

th ebeginningofeachtest,

note

that

forzero

to

maximum

loading

it

is

assumedthat

^= 1.

hiscouldbetrue

if

th e

cycle

s

lastic,

ut

s

lasticity

s

ncountered

he

mean

stress

ratio

beginstorelaxaccordingtoeq.

(9 )

an d

eq.(10).

ModifiedMorrowwithMean

Stress

Effects

T he

Modified

Morrow

equationwasused

to

account

fo r

mean

stress,a ,

effectsresultingfi^omthe i?=

0

tests

[7]:

E

V

(2^/)

+ e.

(iNff (11)

Theoefficientsndxponentswerealculatedsinghe

R

train-life

es t

atandEromheensile

ests.

Constraints

were

laced

n

xponents

nd

ased

pon

previous

observationsonengineeringmetalbehavior

[7]:

-0.12


9/12

RESULTS:

FATIGUE

STRAIN-LIFE

R=0

T hecyclestocrackinitiation,N j,

an d

cyclesto

failure,

N fi

were

determinedforeachofth e=0fatigue

strain-life

testsat649

C

(table

2).

D ueto

cycle

recordermalfunctions

in

th e

dataacquisition

system,

some

results

wereunavailable.

Linearregressionanalysisofth e=0

total

strainrange

versus

ycles

o

rack

nitiation

(Nj)

yclic

train

life

ests

(table

)

esulted

n

n

xponent,

t,

f6.48

nd

coefficient,of162.18withR^=

0.86using

eq .

(2).

(figure

3,99.95 predictionintervalshown).

Linearregression

analysisofth eR=

0

total

strain

range

versuscyclestoailureN j)

ycHc

trainifetests(table2)

resultedinan

exponent,

a,

of-5.62

and

a

coefficient,

A,of

316.23 ith

.8 7

singq.

2) .

figure

,

9.95%

prediction

interval

shown).

Table

ummarizes

hemeannd-99.95 prediction

cyclic

life

fo rth e

^

=0dataatbothcyclestocrackinitiation

an dcycles

toailure

atth e

0.5%

designtrainrangeofthe

Grainex

Mar-M

47

is kse elso

igures

nd).

T he

-99.95 predictionintervalsgive

a

failurerateof

n

2000

parts.

1.11

0.9

N

A

\

4

0^

w 0.7

S

V

/v^

Its

H.

A

X.

A

S

\

N

1 0.6

X N

N

A

X A S

w

>


12/12

Strain Life Techniques

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