Physics-Based Probabilistic Life-Prediction Model for Advanced Hot-Section Turbine Disk Materials With Gradient Microstructures

In the Phase I program UES and QuesTek in separate collaboration with Rolls-Royce developed various multi-physics based property prediction models for a dual microstructure heat treatment (DMHT) turbine disk alloy RR1000, and demonstrated feasibilities of those models and approaches for the property prediction in the microstructure transition region of the DMHT RR1000. Models and approaches developed and utilized in the Phase I program include a fast acting yield stress prediction code, a microstructure-sensitive creep model, a microstructure-sensitive fatigue life (S/N) prediction framework, and an analytical method for volume-based probabilistic description of microstructure anomalies. In the Phase II program UES shall actively collaborate with QuesTek and Rolls-Royce in order to refine, calibrate and validate our microstructure-sensitive modeling tools and approaches, and integrate those modeling tools and approaches for the prediction of location specific properties in the microstructure transition region of a DMHT RR1000 disk. We are confident that UES’s expertise combined with QuesTek’s expertise (together with the technical support from Rolls-Royce) will bring a synergistic effect for the successful completion of the proposed Phase II program, which will provide better lifing tools to predict and control complex thermomechanical responses in the microstructure transition region of DMHT disks. BENEFIT: Third-generation turbine disk materials were designed for the advanced turbine disk performance at the higher temperature. Due to the microstructural complexity and dynamic thermomechanical operating conditions of hot-section turbine disks lifing requires rigorous numerical approaches to account for the influence of microstructural heterogeneities under imposed thermomechanical conditions. Building reliable life prediction computational tools for advanced hot-section turbine disks is also a hot issue in turbine engine industries. UES and QuesTek in Phase I programs developed various multi-physics based property prediction tools and approaches for a DMHT turbine disk alloy RR1000, and demonstrated feasibilities of those tools and approaches for the property prediction in the microstructure transition region of the DMHT RR1000. The proposed Phase II program shall bring microstructure-sensitive computational tools and approaches for reliable property prediction and lifing of advanced hot-section turbine disk materials. We have already entered in to a partnership with an OEM, Rolls-Royce, under an NDA. We shall work closely with Rolls-Royce to transition the prediction tools and apply those tools to a component. At the end of the Phase II programs, we anticipate licensing modeling tools to our partner and continue to refine the products in the years following.