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

In the proposed Phase I program we intend to develop a physics-based, microstructure-sensitive 3D constitutive model for the prediction of fatigue, creep and resulting damage behaviors of advanced hot-section gradient-microstructure turbine disk materials.  We will interface the proposed fatigue and creep model with an analytical yield-strength prediction model to effectively incorporate microstructural effects.  We also intend to develop a doable experimental protocol for the validation of our modeling approaches.  The proposed research program will address key issues regarding the microstructural and thermomechanical transition zone of a turbine disk, and provide a computational basis for the reliable life prediction of an advanced turbine disk having a gradient microstructure.  We will actively collaborate with our OEM partner, Rolls Royce, in order to intensively work on their third-generation gradient-microstructure turbine disk material RR1000 for the proposed Phase I program.  UES scientists have over 15 years of experience in modeling and simulations of structure-property predictions in advanced metals, and over 5 years of experience in modeling the yield strength and creep of Ni-based superalloys.  We will use this expertise and our collaborators expertise in disk materials, to develop computational tools to simulate the behavior of the transition zone in a turbine disk RR1000. 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.  The proposed Phase I effort will bring a microstructure-sensitive computational basis and a validation protocol for reliable 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 have chosen a Rolls Royce third-generation turbine disk material RR1000 as a target material.  We will work closely with Rolls Royce to transition the prediction tool and apply it to a component.  At the end of the Phases I and II programs, we anticipate licensing the modeling tool to our partner and continue to refine the product in the years following.