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Tomography and FEM analysis on turbine blade for aeronautic

Description


 

Fatigue Reliability

In the modern industry, the reliability of mechanical components plays a crucial role: tomography associated with structural FEM analysis allows fatigue assessments to improve the acceptance criteria of components made in casting or additive manufacturing.

TEC Eurolab and Asotech have combined their competences in order to identify, through tomography, defects internal to castings and to perform FEM tests of fatigue of the detected geometry; the study can be thoroughly investigated by inserting validating testing and optimization of component.

To validate service processes, industrial tomography and structural FEM analysis were applied to defective problems of aeronautical blades made in additive manufacturing

 

Case study

Aeronautical turbine samples were created in aluminum AlSi10Mg inclosing the typical defects of such technology: gas porosity and casting failure. Asotech, with Ansys Workbench, has developed fatigue FEM simulations on aeronautical blade by reproducing an operating cycle inside the engine.

The purpose of the activity was to estimate fatigue life due to the presence of defects typical of additive manufacturing technology. 3D software has allowed importing into ANSYS environment the STL file generated by tomography containing defects on aeronautical blades.

The analyses highlighted the fatigue life expectancy of components with a 5% deviation on the later tests performed by TEC Eurolab.

The study also allowed excluding a potential breakage of the component at the defect, by indicating a connecting radius as the most critical point. STL allowed for a better correlation of data between virtual and experimental reality, as well as the correction of fatigue life expectancy with average values of less than 30% to those of a defect-free geometry

 

Advantages

The partnership between TEC Eurolab and Asotech provides a new and more detailed treatment on components reliability.

Tomography allows identifying components defects made with castings or additive manufacturing; combined with structural verification software, this technology provides a better understanding of real components operation and a more accurate assessment of the useful life of the components: the new method exceeds current quality controls and ensures better acceptability criteria.

This analysis allows intervening with structural and designing modifications to improve the reliability of the components.

Case study presented at MR FORUM in collaboration with TEC-EUROLAB.