Integrated Processing and Probabilistic Lifing Models for Superalloy Turbine Disks

There is a critical need for integrated material prediction tools to assure the United States future competitiveness and national security. Extensive libraries of integrated computational tools are available for structures, heat transfer, fluid dynamics, electronics and manufacturing. These tools have radically reduced the time required to optimize new products for decreased cost and increased performance. However, analogous computational tools are not widely used in materials engineering. As a result, the product design and development cycle now outpaces the materials development cycle, leading to a considerable mismatch. The object of this SBIR is to develop techniques to link validated processing models that predict the following: (a) location-specific microstructure, (b) location-specific size distribution of life-limiting microstructural features resulting from variations in process parameters, and (c) complete distribution of the bulk residual stresses, with probabilistic microstructure-sensitive component life prediction codes. The work plan is based on VEXTEC’s core competency in developing multidisciplinary probabilistic frameworks that integrate computational deterministic models for each of several disciplines to create stochastic system simulations. The techniques allows for uncertainty at each discipline to be tracked within the system model. Thus the sensitivities of the modeling parameters that drive the low life component are quantified. BENEFIT: New materials insertion into a new designs takes 10 to 20 years. New computational materials engineering tools integrated with existing product development processes will not only assure our nation security needs but reinforce the competitiveness of U.S. manufacturers. These tools promise to shorten the materials development by up to 80%.