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NASA/TM2004-212985 RL-TR-3178
GT2004-53939
RESEARCHLABORATORY
Strain-Life
Assessment
of
Grainex
Mar-M
247
forNASA's
Turbine
Seal
Test
Facility
Irebert
R .
Delgado
U.S.ArmyResearch
Laboratory,
Glerm
Research
Center,
Cleveland,Ohio
Gary
R .Halfordand
Bruce
M .Steinetz
Glenn
Research
Center,Cleveland,Ohio
ClareM .
Rimnac
Case
Western
Reserve
University,
Cleveland,Ohio
DlSTBlBUTlOHSWTEMEirrA
Approved
f o r
Public
Release
Distribution
Unlimited
April 2004
8/10/2019 Strain Life Techniques
2/12
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1.GENCYUSEONLY(/.save
Wanfc )
2. REPORT
DATE
April2004
REPORTTYPEAND
DATES
COVERED
Technical
Memorandum
4.ITLE
AND
SUBTITLE
Strain-Life
Assessment
ofGrainex
Mar-M
24 7fo rNASA's
TurbineSeal
Test
Facility
6.
UTHOR(S)
IrebertR .Delgado,GaryR .Halford,BruceM.Steinetz,an dClareM.
Rimnac
5. FUNDINGNUMBERS
WBS-22-714-09-18
1L161102AF20
7. PERFORMINGORGANIZATION
NAME(S)ANDADDRESS(ES)
National Aeronauticsan dSpace Administration
JohnH.
GlennResearchCenterat
Lewis
Field
Cleveland,
Ohio
44135-3191
8. PERFORMINGORGANIZATION
REPORTNUMBER
E-14460
9.
PONSORING/MONITORING
AGENCY
NAME(S)ANDADDRESS(ES)
NationalAeronauticsan dSpaceAdministrat ion
Washington,
D C
0546-0001
an d
U.S.ArmyResearchLaboratory
Adelphi,
Maryland
0783-1145
10 .
PONSORING/MONITORING
AGENCYREPORT
NUMBER
NAS A
TM-2004-212985
ARL-TR-3178
GT2004-53939
11.UPPLEMENTARY
NOTES
Preparedfo r
th e
Turbo
Expo2004
sponsored
by
th e
American
Societyof
MechanicalEngineers,
Vienna,
Austria,
June14-17,2004.IrebertR .
Delgado,
U.S.
Army
ResearchLaboratory,NASA
Glenn
ResearchCenter,
Gary
R.
Halford
an d
Bruce
M.Steinetz,
NASA
GlennResearchCenter;an d
Clare
M.
Rimnac,
Case
Western
Reserve
University,
Cleveland,
Ohio44106.Responsibleperson,IrebertR .
Delgado,organizationcode0300,216-433-3935.
12a. DISTRIBUTION/AVAILABILITYSTATEMENT
Unclassified
-
Unlimited
Subject Category:07
Availableelectronicallyathttp://gltrs.grc.nasa.gov
ThispublicationisavailablefromtheNASACenter
for
AeroSpace
Information,301-621-0390.
Distribution:
Nonstandard
12b.ISTRIBUTIONCODE
13.
BSTRACT(Maximum
200
words)
NASA's
TurbineSeal
Test
Facilityis
used
to
test
air-to-air
sealsfo r
us e
primarilyinadvanced jet
engine
applications.
Combinationsof
high
temperature,
high
speed,
an d
highpressurelimitthedisklife,
du e
to
the
concern
of
crack
initiation
in
th e
bolt
holes
of
the
Grainex
Mar-M
24 7
disk.
T he
primary
purpose
ofthis
current
work
is
todetermine
aninspection
intervaltoensuresafeoperation.Thecurrentworkpresents
high
temperature
fatigue
strain-lifedatafo rtestspecimens
cu t
from
anactualGrainexMar-M247 disk.Several
different
strain-life
models
werecomparedtothe
experimental
data
includingth eManson-HirschbergMethod
of
Universal
Slopes,theHalford-NachtigallMeanStressMethod,an dth e
Modified
Morrow
Method.The
Halford-Nachtigall
Method
resulted
inonlyan
18
percent
difference
between
predicted
an dexperimentalresults.Usingth eexperimentaldataata
-99.95percentprediction
level
andth epresenceof
6bolt
holes
it
was
found
that
thedisk
should
be inspected
after
66 5cycles
based
ona
totalstrain
of
0.5
percent
at
64 9
C .
2 0 0 4 1 0 0 8
3
14 . SUBJECTTERMS
Superalloy;
Mar-M
247;
Fatigue
strain-life;
Nickel-based;Crackinitiation;
Life
estimation;
Turbinesealingtesting;Turbinedisk
13. numDcn rrMuco
13
16 .
PRICE
CODE
17 .
SECURITYCLASSIFICATION
OFREPORT
Unclassified
18 .
ECURITYCLASSIFICATION
OF
THIS
PAGE
Unclassified
19.
ECURITY
CLASSIFICATION
O F
ABS T RACT
Unclassified
20.
LIMITATION
OF
ABSTRACT
NS N7540-01-280-5500
StandardForm298(Rev.2-89)
PrescribedbyANSIStd.Z39-18
298-102
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NASA/TM2004-212985 RL-TR-3178
u.s..Rv
T200^53939
RESEARCHLABORATORY
Strain-Life
Assessment
of
Grainex
Mar-M
247
for
NASA'sTurbine
Seal
Test
Facility
IrebertR.
Delgado
U.S.
Army
Research
Laboratory,
Glenn
Research
Center,
Cleveland, Ohio
GaryR.
Halford
and
Bruce
M.Steinetz
Glenn
Research
Center,
Cleveland,
Ohio
Clare
M.Rimnac
Case
Western
Reserve
University,Cleveland,Ohio
Prepared
fo rthe
Turbo
Expo
2004
sponsored
by
theAmerican
Society
ofMechanical
Engineers
Vienna,Austria,June14-17,2004
National
Aeronauticsand
Space
Administration
Glenn
Research
Center
April 2004
8/10/2019 Strain Life Techniques
5/12
Acknowledgments
The
authors
wish
to
acknowledge
NASA
Glenn
R^earch
Center,
the
Army
Research
Laboratory,
and
Case
WesternReserveUniversity
for
their
support.
Thisreportis
a
formaldraft
or
working
paper,
intendedto
solicitcomments
and
ideasfrom
a
technicalpeergroup.
Tradenames
or
manufacturers'namesareusedinthfereportfor
identification
only.
Thisusage
doesnot
cor^titutean
official
endorsement,
either
expressed
or
implied,by
the
National
AeronauticsandSpaceAdministration.
Availablefrom
NASA
Center
for
Aerospace
Information
7121StandardEWve
Hanover,M D 21076
National
Technical
InformationService
5285
PortRoyalRoad
Springfield,
VA
22100
Availableelectronically
at
http:
/
/gltrs.grc.nasa.gov
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STRAIN-LIFE
A S S E S S M E N TO FGRAINEXMAR-M
247
FO R
N A S A S
TURBINE S E A L
T E S T
FACILITY
IrebertR.
Delgado
U.S.
Army
Research
Laboratory
Glenn
ResearchCenter
Cleveland,
Ohio44135
Gary
R.
Halford
an d
BruceM.Steinetz
NationalAeronauticsand
SpaceAdministration
Glenn
Research
Center
Cleveland,
Ohio
44135
Clare
M.Rimnac
CaseWesternReserve
University
Cleveland,
Ohio
44106
A B ST R A C T
NASA'sTurbine
Seal
Test
Facility
is
used
totest
air-to-
ai realsor
se
rimarilyn
dvanced
et
ngine
applications.
Combinations
of
high
temperature,
high
speed,
an dhighpressureimit
th e
iskife,
ue
oheoncern
f
crackinitiationin
th e
boltholes
of
the
Grainex
Mar-M
24 7
disk.he
rimary
urpose
fhi surrent
or k
so
determinennspectionntervalonsure
afeperation.
The
urrent
workpresentsighemperature
atigue
train-
life
data
fo rtest
specimens
cu t
froman
actualGrainex
Mar-
M
47
isk.
everal
ifferent
train-life
odels
er e
compared
o
he
xperimental
at a
ncluding
he
Manson-
Hirschbergethod
f
niversallopes,he
alford-
NachtigallMeantressMethod,
nd
theModifiedMorrow
Method.heHalford-NachtigallMethodresultedinonlyan
18 %
ifference
between
predicted
an d
experimental
results.
Using
he
xperimentalata
t
-99.95
redictionevel
an dthepresenceof6boltholes
t
wasoundthattheis k
shouldbeinspected
after
66 5cyclesbasedonatotalstrain
of
0.5%
at
64 9
a
INTRODUCTION
The
High
emperature
High
peed
urbine
ea l
es t
facility
(figure
),located
at
NASA'sGlennResearchCenter
in
Cleveland,
Ohio
rovides
ritical
esting
of
air
eals
or
aircraftenginest
conditions
f
highai rtemperatures,igh
sealpressures,andsurfacespeedsgreaterthan3 05
m/s.
Thees tacility
se s
is k
made
f
GrainexMar-M
247,acastnickelbasedsuperalloy.
Analysis
hasshownthat,
in
he
icinity
f
th e
isk
ol toles,
he
materiallightly
entersthe
plastic
region
of
the
stress-strain
curve
[1].
Dueto
these
emandinges t
onditions,he
ossibility
xistsha t
fatiguerackswill
evelop
with
ycling
the
ol t
ol e
locations,
whichfasten
the
test
disk
to
the
main
shaft
of
th e
test
tand.f
allowed
o
ro wo
ritical
ize,
he
racks
couldcausethedisk
to
catastrophically
burst
duringuse.
Preliminarynalysesyon gndteinetz1]av e
placed
train-life
atigue
imit,
L ^ y s
of
6000yclesased
upon
an
equivalent
-3a
reduction
actoran da
probabilistic
approach[2 ]accountingfor=6bohholes:
=A
sys
(1 )
Figure
1.NASA
Glenn Research
Center
turbine
seal
test
facility.
NASATTM2004-212985
8/10/2019 Strain Life Techniques
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eq .1)sbased
on
th eundberg-Palmgren3 ]nalysisor
rollingelementbearingsystemlives.Ls
th e
predictedlife
fo r
a
diskwith
asingle
bolt
hole.
T he
predicted
life,L,
an d
Weibulllope
parameter,e,ar eassumedto
be
identicalor
al l
sixdiskboltholes.O necycleisdefinedasarampupan d
down
in
speed.
Inhistudy,
train-life
ests
er e
onducted
ver
variousstrainrangesata temperatureof
649
C
todetermine
th e
cycles
to
cracknitiation.
his
data
was
compared
with
previousnalyses
s
well
s
iteratureata
nd
train-life
modelestimatesbased
upon
tensiledata.
NOMENCLATURE
30standarddeviations
A
constantcoefficient
B
constant
coefficient
C
constantcoefficient
bfatiguestrengthexponent
cfatigueductilityexponent
e
Weibullslopeparameter
=
3.57(Gaussian)
EYoung'sModulus
k
transfer
function
L
calculateddisk
life
Z , y , , j =
overall
systemlife
n
numberof boltholes=
6
strainratio=e//e
coefficient
of
determination
cycles
to
crackinitiation
cyclestofailure
transitionlifeunderzeromean
stress
cyclestofailure
under
zeromeanstress
cycles
tofailure
in
presence
of
mean
stress
effectiveratioofmean
stress
tostress
amplitude
ratio
of
mean
stress
to
stress
amplitude
coiKtant
exponent
change
in
mean
stress
[MPa]
totalstrainrange
elastic
strain
range
inelastic
strain
range
stressrange[MPa]
strainamplitude
true
fi-acture
ductility
fatigueductilitycoefficient
truefi-acture
strain
minimum strain
maximumstrain
stressamplitude
[MPa]
fatiguestrengthcoefficient
[MPa]
truefracturestrength[MPa]
meanstress[MPa]
ultimatetensilestrength
[MPa]
0.2% yieldstrength[MPa]
percentelongation
percentreductioninarea
percenttotalstrainrange
R
R'
Ni
Nf
Nm
Np
Vef f
a
80
Mel
Ae,
A0
^max
< Sa
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DataAnalys is
The
fatigue
strain-life
results
wereevaluatedfollowinga
simple
linear
model
in
log-log
coordinates:
Nj=A{ AEf
where
heonstant
nd
xponent
aer eetermined.
Linearregression
analysisof
thelog-logtransformed
fatigue
strain-lifeehavioras
onducted
o
etermine
he
coefficient
A
an d
theexponentafo rthe
i?
=0
data.
Thus,
log(NA=
logA
+
alog
( % A 8 )
(3 )
Standard
tatisticalnalyses
werelso
erformedo
heck
fo rignificance
f
heegression, es torormal
distribution,
utliers,
ack-of-fit,
nd
lsoo
alculate
he
-99.95 prediction
interval.
[4 ]
Method
ofUniversal
Slopes
TheManson-HirschbergMethodfUniversallopes
(MUS)
was
usedto
estimate
strainlife
with
zero
mean
stress
based
only
upon
tensile
data
[5]:
Ae
=
ACg/
-I -
Ae
p/
(4 )
an d
:exp
-70
A^i
Ae,
el J
(10)
(2 )
A t
th ebeginningofeachtest,
note
that
forzero
to
maximum
loading
it
is
assumedthat
^= 1.
hiscouldbetrue
if
th e
cycle
s
lastic,
ut
s
lasticity
s
ncountered
he
mean
stress
ratio
beginstorelaxaccordingtoeq.
(9 )
an d
eq.(10).
ModifiedMorrowwithMean
Stress
Effects
T he
Modified
Morrow
equationwasused
to
account
fo r
mean
stress,a ,
effectsresultingfi^omthe i?=
0
tests
[7]:
E
V
(2^/)
+ e.
(iNff (11)
Theoefficientsndxponentswerealculatedsinghe
R
train-life
es t
atandEromheensile
ests.
Constraints
were
laced
n
xponents
nd
ased
pon
previous
observationsonengineeringmetalbehavior
[7]:
-0.12
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RESULTS:
FATIGUE
STRAIN-LIFE
R=0
T hecyclestocrackinitiation,N j,
an d
cyclesto
failure,
N fi
were
determinedforeachofth e=0fatigue
strain-life
testsat649
C
(table
2).
D ueto
cycle
recordermalfunctions
in
th e
dataacquisition
system,
some
results
wereunavailable.
Linearregressionanalysisofth e=0
total
strainrange
versus
ycles
o
rack
nitiation
(Nj)
yclic
train
life
ests
(table
)
esulted
n
n
xponent,
t,
f6.48
nd
coefficient,of162.18withR^=
0.86using
eq .
(2).
(figure
3,99.95 predictionintervalshown).
Linearregression
analysisofth eR=
0
total
strain
range
versuscyclestoailureN j)
ycHc
trainifetests(table2)
resultedinan
exponent,
a,
of-5.62
and
a
coefficient,
A,of
316.23 ith
.8 7
singq.
2) .
figure
,
9.95%
prediction
interval
shown).
Table
ummarizes
hemeannd-99.95 prediction
cyclic
life
fo rth e
^
=0dataatbothcyclestocrackinitiation
an dcycles
toailure
atth e
0.5%
designtrainrangeofthe
Grainex
Mar-M
47
is kse elso
igures
nd).
T he
-99.95 predictionintervalsgive
a
failurerateof
n
2000
parts.
1.11
0.9
N
A
\
4
0^
w 0.7
S
V
/v^
Its
H.
A
X.
A
S
\
N
1 0.6
X N
N
A
X A S
w
>
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