Improved Life Prediction of Turbine Engine Components

The purpose of this Phase I SBIR proposal is to develop the foundation of a new computer software model entitled Turbine Field Life Analysis Multi-physics Engine Simulation, or TFLAMES, for conducting stress and life analysis of turbine aircraft enginesthat will reduce the conservatism currently found in such analyses. We will do that by managing the life of individual engines using actual flight data collected for the aircraft rather than using generic missions and bookkeeping Total Accumulated Cycles(TAC). This new and innovative approach will meet the Air Force's goal of extending time on wing for turbine rotating components while assuring the safety of air crew and enhancing mission readiness.The TFLAMES approach will integrate the thermodynamic cycle model, the heat transfer model, and the rotating component stress model for the full turbine engine using both proprietary and commercial analysis codes. The TFLAMES model will analyze stressconditions for a turbine in the field using data gathered during the actual mission flown (i.e. OAT, density altitude, high and low pressure turbine speeds, turbine inlet pressures, exhaust gas temperatures, etc.) then post-process stress results for nearreal time feedback of cycle damage accumulated for the flight. The TFLAMES life management model is equally applicable to the commercial fleet of turbine aircraft engines and will aid the airline industry in reducing engine overhaul costs and the associated loss of revenue service by increasing time betweenoverhauls.Given the current economic climate it is clear that more accurately calculating turbine component lives based on actual mission conditions could yield much needed operating cost reductions. The conservative nature of current life analysis methodologymakes it likely that the vast majority of individual turbine engines would benefit in calculated life and possibly enjoy more reasonable safety factors because of improved accuracy.