Three-Dimensional Nonlinear Structural Analysis Methods for Gas Turbine Engine Metallic Components and Component Assemblies

The objective of this Phase II program is to implement, demonstrate and validate the computational techniques that were developed in Phase I that can be used for materials-damage based prognosis of gas turbine engine components and component assemblies. This approach will consist of a probabilistic multi-axial three-dimensional non-linear structural analysis method to enable the implementation of advanced life prediction and prognosis systems for aerospace gas turbine engine components and assemblies. The proposed methodology is based on key damage mechanisms including three dimensional crack growth in components and assemblies of components, material behavior, surface-treatment induced residual stress effects, and complex mission loading, coupled with detectable sensor parameters. Since the implementation of such advanced systems requires integration with the operation of the engines, close technical collaboration with OEMs will be maintained. This program will develop an efficient three-dimensional method that can be utilized for prediction of damage progression in a complex tri-axial stress state. Capability will be demonstrated through component life predictions and comparison with crack growth to failure results to be obtained from a scaled gas turbine engine testing.