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On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments

N. D’Souza, S. Ravichandran, S. Donovan, P. Daum, R. Morrell, Zachariah Nye, Robert Lancaster Orcid Logo

Additive Manufacturing, Volume: 56, Start page: 102905

Swansea University Authors: Zachariah Nye, Robert Lancaster Orcid Logo

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DOI (Published version): 10.1016/j.addma.2022.102905

Abstract

A novel approach for down-selection of a repaired support structure design produced using Laser Blown Powder – Direct Energy Deposition (LBP-DED) and filled with interstitial Ni-Al powder (∼0.75 area fraction) in a turbine segment was investigated. Simulation of flattening and un-flattening of the s...

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Published in: Additive Manufacturing
ISSN: 2214-8604
Published: Elsevier BV 2022
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URI: https://cronfa.swan.ac.uk/Record/cronfa60088
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Simulation of flattening and un-flattening of the segment with implications to degradation of the support structure was quantified using a four-point bend test to identify the role of axial Young&#x2019;s modulus in out-of-plane flexure. Two markedly different LBP additive structures; Diamond Lattice (DL) - nodal and Continuous Path (CP) &#x2013; non-nodal, were produced and compared with the un-repaired condition. At room temperature, the forward and rear walls and internal nodes of the original equipment (OE) and DL support structures were found to contribute significantly to the Young&#x2019;s modulus, with significantly reduced stiffness observed in the CP structures. Oxidation plays a key role in the development of internal compressive stresses within the abradable, with a two-fold increase in elastic modulus in the CP structure, but a smaller increase occurred in OE and DL support structures. A decrease in elastic modulus and concomitant increase in radius of curvature (flattening) occurred with an increasing number of flexural cycles. Cracking is most prominent in the nodal design within the front and rear walls and cracks propagate either to the surface or towards the base of the abradable lattice. No such degradation was observed for equivalent flexural cycles in the original and CP support structures, even up to a significant number of cycles. A criterion for catastrophic failure of the abradable was deduced from a steep decrease in flexural elastic modulus accompanied with a marked change in curvature. 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spelling 2022-10-31T17:09:54.3115316 v2 60088 2022-05-26 On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments ef996ae7fffe1dfc162d5b44e24123a3 Zachariah Nye Zachariah Nye true false e1a1b126acd3e4ff734691ec34967f29 0000-0002-1365-6944 Robert Lancaster Robert Lancaster true false 2022-05-26 EEN A novel approach for down-selection of a repaired support structure design produced using Laser Blown Powder – Direct Energy Deposition (LBP-DED) and filled with interstitial Ni-Al powder (∼0.75 area fraction) in a turbine segment was investigated. Simulation of flattening and un-flattening of the segment with implications to degradation of the support structure was quantified using a four-point bend test to identify the role of axial Young’s modulus in out-of-plane flexure. Two markedly different LBP additive structures; Diamond Lattice (DL) - nodal and Continuous Path (CP) – non-nodal, were produced and compared with the un-repaired condition. At room temperature, the forward and rear walls and internal nodes of the original equipment (OE) and DL support structures were found to contribute significantly to the Young’s modulus, with significantly reduced stiffness observed in the CP structures. Oxidation plays a key role in the development of internal compressive stresses within the abradable, with a two-fold increase in elastic modulus in the CP structure, but a smaller increase occurred in OE and DL support structures. A decrease in elastic modulus and concomitant increase in radius of curvature (flattening) occurred with an increasing number of flexural cycles. Cracking is most prominent in the nodal design within the front and rear walls and cracks propagate either to the surface or towards the base of the abradable lattice. No such degradation was observed for equivalent flexural cycles in the original and CP support structures, even up to a significant number of cycles. A criterion for catastrophic failure of the abradable was deduced from a steep decrease in flexural elastic modulus accompanied with a marked change in curvature. A non-nodal design support structure is optimum to counter in- service flattening/un-flattening. Journal Article Additive Manufacturing 56 102905 Elsevier BV 2214-8604 Blown powder; Abradables; Cyclic behaviour; Flexural 1 8 2022 2022-08-01 10.1016/j.addma.2022.102905 COLLEGE NANME Engineering COLLEGE CODE EEN Swansea University SU Library paid the OA fee (TA Institutional Deal) 2022-10-31T17:09:54.3115316 2022-05-26T11:45:54.8522550 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering N. D’Souza 1 S. Ravichandran 2 S. Donovan 3 P. Daum 4 R. Morrell 5 Zachariah Nye 6 Robert Lancaster 0000-0002-1365-6944 7 60088__24189__3d5782b52f034e58bd9081eb56b954a7.pdf 60088.pdf 2022-05-26T11:50:45.1867136 Output 19976700 application/pdf Version of Record true © 2022 The Author(s). This is an open access article under the CC BY license true eng http://creativecommons.org/licenses/by/4.0/
title On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
spellingShingle On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
Zachariah Nye
Robert Lancaster
title_short On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
title_full On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
title_fullStr On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
title_full_unstemmed On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
title_sort On the Design Optimisation of Direct Energy Deposited Support Structures to Repair Aero-Engine Turbine Segments
author_id_str_mv ef996ae7fffe1dfc162d5b44e24123a3
e1a1b126acd3e4ff734691ec34967f29
author_id_fullname_str_mv ef996ae7fffe1dfc162d5b44e24123a3_***_Zachariah Nye
e1a1b126acd3e4ff734691ec34967f29_***_Robert Lancaster
author Zachariah Nye
Robert Lancaster
author2 N. D’Souza
S. Ravichandran
S. Donovan
P. Daum
R. Morrell
Zachariah Nye
Robert Lancaster
format Journal article
container_title Additive Manufacturing
container_volume 56
container_start_page 102905
publishDate 2022
institution Swansea University
issn 2214-8604
doi_str_mv 10.1016/j.addma.2022.102905
publisher Elsevier BV
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 1
active_str 0
description A novel approach for down-selection of a repaired support structure design produced using Laser Blown Powder – Direct Energy Deposition (LBP-DED) and filled with interstitial Ni-Al powder (∼0.75 area fraction) in a turbine segment was investigated. Simulation of flattening and un-flattening of the segment with implications to degradation of the support structure was quantified using a four-point bend test to identify the role of axial Young’s modulus in out-of-plane flexure. Two markedly different LBP additive structures; Diamond Lattice (DL) - nodal and Continuous Path (CP) – non-nodal, were produced and compared with the un-repaired condition. At room temperature, the forward and rear walls and internal nodes of the original equipment (OE) and DL support structures were found to contribute significantly to the Young’s modulus, with significantly reduced stiffness observed in the CP structures. Oxidation plays a key role in the development of internal compressive stresses within the abradable, with a two-fold increase in elastic modulus in the CP structure, but a smaller increase occurred in OE and DL support structures. A decrease in elastic modulus and concomitant increase in radius of curvature (flattening) occurred with an increasing number of flexural cycles. Cracking is most prominent in the nodal design within the front and rear walls and cracks propagate either to the surface or towards the base of the abradable lattice. No such degradation was observed for equivalent flexural cycles in the original and CP support structures, even up to a significant number of cycles. A criterion for catastrophic failure of the abradable was deduced from a steep decrease in flexural elastic modulus accompanied with a marked change in curvature. A non-nodal design support structure is optimum to counter in- service flattening/un-flattening.
published_date 2022-08-01T04:17:54Z
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score 11.017731

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