The Route to Standardisation - TMF-Workshop

GROWTH Project n° GRD2-2000-30014 

TMF-Standard 

Final Meeting/Workshop, 20-23/09/05, Berlin 

Thermo-Mechanical Fatigue: 

The Route to Standardisation 

Peter Hähner 

JRC Institute for Energy, European Commission, Petten, The Netherlands 

Ernst Affeldt, MTU Aero Engines, München (D) 

Henrik Andersson, KIMAB, Stockholm (S) 

Tilmann Beck, University of Karlsruhe (D) 

Valerio Bicego, CESI, Milan (I) 

Hellmuth Klingelhöffer, BAM, Berlin (D) 

Alain Köster, Ecole Nationale Superieure des Mines de Paris (F) 

Malcolm Loveday, NPL, Teddington (UK) 

Massimo Marchionni, CNR-IENI, Milan (I) 

Catherine Rae, University of Cambridge (UK)

Scope of this workshop: 

• dissemination of results of European TMF-Standard project 

promotion of strain-controlled TMF as close-to-service test 

exchange of scientific results relating to TMF applications 

Outline of this presentation: 

Introduction 

Review of TMF-Standard project 



Final Meeting/Workshop, 20-23/09/05, Berlin




Thermo-Mechanical Fatigue (TMF): 

Design & residual life analysis of safety critical components 

exposed simultaneously to thermal & mechanical loads 

(gas turbines, aero engines, automotive & process industries): 

Internal thermal constraints of representative volume element 

simulated by uniform temperature and mechanical strain fields 

imposed on laboratory specimen with uniform gauge section




mech. strain 

TMF cycles with dwell: 

in-phase: � =0 o 

R � = � 1 

time 

R � = � m,min/� m,max 




temperature [arb. units] 

mech. strain 

T = T 0 + �T F(�t) 

� m = � m,0 + �� F(�t ��) 

F(x) = F(x + 2�), � x 

out-of-phase: � =180 o 

R � = � 1 

time 

temperature [arb. units]

Mechanical Strain [%] 

1.2 

1.0 

0.8 

0.6 

0.4 

0.2 




Triangular TWF waveforms: R � = � m,min/� m,max 

��0, R � = 0 

0.0 

350 

0 50 100 150 200 

Time [sec] 

950 

850 

750 

650 

550 

450 

Temperature [ o C] 

Mechanical Strain [%] 

0.0 

-0.1 

-0.2 

-0.3 

-0.4 

-0.5 

-0.6 

-0.7 

��180 o , R � = �� 

-0.8 

350 

0 50 100 150 200 

Time [sec] 

950 

850 

750 

650 

550 

450 

Temperature [ o C]

Hysteresis loops: 

Stress MPa 

800 

600 

400 

200 

-400 

-600 

-800 




0 

-0,4 -0,3 -0,2 -0,1 0 

-200 

0,1 0,2 0,3 0,4 

900°C 

400°C 

650°C 

650°C 

Mechanical strain % 

OP cycle 

IP cycle 

400°C 

900°C 

Out-of-phase 

In-phase 

� m = � el + � in

Load train alignment 

Precision extensometry 

LCF Thermal 

fatigue 




Load-contr. 

TMF 

Dynamic temperature measurement & control 

Strain-contr. 

TMF 

Therm. – mech. load phasing 

Pre-cycling, start-up procedures 

Thermal strain compensation 

� tot = � m + � th




TMF-Standard GRD2-2000-30014 

Thermo-mechanical fatigue – the route to standardisation 

(funded within the GROWTH Programme of the Europ. Comm.) 

Objectives: to establish a TMF testing platform in Europe 

to issue a validated code-of-practice 

to disseminate and exploit the results 

Starting date: 1. October 2001 

Duration: 48 months 

Budget: ~ 1.800.000 Euro (~ 1.080.000 EC contribution) 

Consortium: 10 principal contractors 

9 assistant contractors, 1 external participant 

No. of tests: ~ 400 incl. 120 validation tests




Partners: JRC Institute for Energy, Petten (NL) 

MTU Aero Engines, München (D) 

University of Karlsruhe (D) 

BAM, Berlin (D) 

NPL, Teddington (UK) 

University of Cambridge (UK) 

Ecole Nationale Superieure des Mines de Paris (F) 

CNR-IENI, Milan (I) 

CESI, Milan (I) 

KIMAB (ex-SIMR), Stockholm (S) 

Forschungszentrum Jülich (D) 

Tech. University of Darmstadt (D) 

University of Siegen (D) 

CEAT, Toulouse (F) 

Imperial College, London (UK) 

Silesian University of Technology, Katowice (PL) 

ONERA, Chatillon (F) 

Forschungszentrum Karlsruhe (D) 

SNECMA Villaroche (F) 

ALSTOM Baden (CH)

Three distinct phases: 




1. Preparatory phase: 

Inventory of TMF testing procedures in Europe (WP1) 

Material procurement, characterization & distribution (WP2) 

2. R&D phase: 

Pre-normative testing (WP3, Task 1 – 5) 

Validation testing (WP4) 

Statistical sensitivity analysis (WP5) 

3. Exploitation and dissemination phase: 

Drafting of Code-of-Practice (WP6) 

Dissemination of CoP, workshop (WP7)




WP 3: Pre-normative research on TMF procedures & tolerances 

Task 1: Pre-cycling, start, interrupt, restart procedures 

Task 2: Dynamic T measurement and control 

Task 3: Thermal strain comp., deviations from nominal T 

Task 4: T gradient effects in 3 sample geometries 

(solid cylindrical, hollow cyl., solid rectangular) 

Task 5: Deviations from nominal phase angle 

Reference testing as preparation for WP4

WP 4: Validation testing 




Period: June 2004 – March 2005 

Partner(s): “inner circle” – centrally machined samples of 

three common geometries (solid cyl., hollow cyl., flat): 

MTU, JRC-IE, IWK, BAM, ENSMP, 

UCAM, CNR, CESI, SIMR 

“outer circle” – individually machined samples of various 

geometries: 

NPL, FZJ, TUD, Uni Siegen, CEAT, ICON, SUT, 

ONERA, FZK, SNECMA, ALSTOM

Validation TMF cycles: 

1.) symmetrical triangular OOP 

R� = - 1, � = 180° 

Tmin = 400°C, Tmax = 850°C 

tcycle = 180s � dT/dt = � 5K/s 

�� m = 0.8% � N f � 1000 

2.) symmetrical triangular IP 

R� = - 1, � = 0° 

Tmin = 400°C, Tmax = 850°C 

tcycle = 180s � dT/dt = � 5K/s 

�� m = 0.7% � N f � 1000 




mech. strain [%] 

0.4 

0.2 

0.0 

-0.2 

-0.4 

400 500 600 700 800 900 

temperature [°C] 

=> 120 validation tests




WP 5: Sensitivity analysis of validation test results 

Cycles to 10% Load Drop 

O-P TMF Test Results : Nimonic 90 - All Data 

0.8% Mechanical Strain range, 400°C - 850°C, 5°C/s 

2000 

1500 

1000 

500 

0 

Solid Bars 

Hollow 

Flat 

0 5 10 15 20 

Laboratory




Web-enabled Mat-DB - TMF-Standard data sets 

To get access to TMF Standard data and documentation please register on the JRC Petten ODIN 

website (https://odin.jrc.nl), register for Mat-DB and DoMa and mention under comments that you 

request access to the TMF-Standard project results. 

Selection of TMF-Standard data within the web-enabled Mat-DB data retrieval part




Selection of TMF Standard data within the web-enabled Mat-DB data retrieval part




Graphical output of TMF Standard data within the web-enabled Mat-DB data retrieval part




Thermo-Mechanical Fatigue: 

The Route to Standardisation 

Peter Hähner 

JRC Institute for Energy, European Commission, Petten, The Netherlands 

Ernst Affeldt, MTU Aero Engines, München (D) 

Henrik Andersson, KIMAB, Stockholm (S) 

Tilmann Beck, University of Karlsruhe (D) 

Valerio Bicego, CESI, Milan (I) 

Hellmuth Klingelhöffer, BAM, Berlin (D) 

Alain Köster, Ecole Nationale Superieure des Mines de Paris (F) 

Malcolm Loveday, NPL, Teddington (UK) 

Massimo Marchionni, CNR-IENI, Milan (I) 

Catherine Rae, University of Cambridge (UK)




Acknowledgements: 

Johan Bressers, JRC Institute for Energy, Petten (NL) 

Rainer Marquardt & Roland Schmier, MTU Aero Engines, München (D) 

Anja Archie & Birgit Skrotzki, BAM, Berlin (D) 

Frits de Haan, Stefan Ripplinger, Helmut Over, JRC-IE, Petten (NL) 

Thomas Brendel, MTU Aero Engines, München (D) 

Joachim Hammer, FH Regensburg (D) 

Hans-Joachim Kühn, BAM, Berlin (D) 

Luc Remy, Ecole Nationale Superieure des Mines de Paris (F) 

Bryan Roebuck, NPL, Teddington (UK) 

Giovanni Onofrio, CNR-IENI, Milan (I) 

Gemma Drew, Andrew Rayment & Siavash Pahlavanyali, University of Cambridge (UK) 

Claudia Rinaldi, CESI, Milan (I)




Acknowledgements cont’d: 

Roland Herzog, Forschungszentrum Jülich (D) 

Andreas Schmidt & Alfred Scholz, TU Darmstadt (D) 

Valerij Bauer & Hans-Jürgen Christ, University of Siegen (D) 

Christian Marfaing, CEAT, Toulouse (F) 

Peter Skelton, Imperial College, London (UK) 

Jerzy Okrajni, Silesian University of Technology, Katowice (PL) 

Franck Gallerneau & Didier Pacou, ONERA, Chatillon (F) 

Claus Petersen, Forschungszentrum Karlsruhe (D) 

Jean-Marc Rongvaux, SNECMA Villaroche (F) 

Arnd Jung, ALSTOM Baden (CH) 

Mauro Facchini, Thomas Fairley, DG-RTD, Brussels (B)




WP 1: Inventory of labs and test procedures in TMF testing 

Detailed questionnaire: >80 questions organized in various sections: 

Generalities 

Setup used for TMF 

Calibration 

Test preparation & pre-cycling 

TMF test execution 

Data recording, evaluation & reporting 

Comments 

Evaluation completed in Dec 02: 




responses from 17 partners received 

WP1 report: “Survey of strain-controlled TMF testing practices” 

excerpts used for “Recommendations for strain-controlled TMF testing” 

(~25 issues on Setup, Dyn. T measurem. & control, Definitions, 

Precycling, Reporting)




WP 2: Procurement and distribution of test material 

Material: 

Nimonic90 

Acceptance tests: 

grain size, HV, chem. comp. 

Aging heat treatment: 

5hrs @ 850 o 

Hardness, HV30 

350 

300 

250 

200 

0 2 4 6 8 10 12 14 16 

Hours at 850°C

E, MPa 

220000 

210000 

200000 

190000 

180000 

170000 

160000 

150000 




Task 1: Pre-cycling, start, interrupt, restart procedures 

Et up 

Et down 

Ec up 

Ec down 

Et T cost 

Ec T cost 

E pseudodynamic 

300 400 500 600 700 800 900 

T, °C




Task 2: Dynamic T measurement and control 

Ribbon-type TC (T control in the centre of GL) 

T [°C] 

900 

800 

700 

600 

500 

Desired T-path in 

the gage section 

dT/dt = 10°C/s 

400 

300 

ribbon type TC in the gage section 

Controller: spot welded TC on the 

200 

specimen shoulder 

0 20 40 60 80 100 120 140 160 180 200 

t [s] 

Spot-welded TC (T control outside GL)




Task 3: Thermal strain compensation, deviations from nominal T 

stress - MPa 

750 

700 

650 

-200 

-250 

T=400-850o T=400-850 C o T=420-830 C 

o T=420-830 C 

o C T=380-870o T=380-870 C oC Tmax nominal= 850 o Tmax nominal= 850 C 

o C 

temperature 

stress 

Tmin nominal= 400 o Tmin nominal= 400 C 

o C 

-300 

500 510 520 530 540 

350 

550 

C:\TMF-PNR\VERSUCHE\X1-5\X1-5 SIGMA MAX MIN VS ZYKLUS-02.WTP | 1.3.2004 

cycles 

Maximum- / minimum- stress changes as a result of temperature errors 

900 

850 

800 

450 

400 

temperature - o C




Task 4: T gradient effects in 3 different testpiece geometries 

(solid cylindrical, hollow cylindrical, solid rectangular) 

Temperature difference [K] 

60 

40 

20 

0 

-20 

-40 

-60 

T3 

T5 shank centre 

Set temperature [°C] 

RTC 

400 850 400 

T1

Temperature 




Task 5: Deviations from nominal phase angle 

- � + � 

Time 

Mechanical strain 

T- no phase 

shift 

T- positive 

phase shift 

T- negative 

phase shift 

Mechanical 

strain




“Inner circle” specimen geometries:

survey 

WP1 1 st draft 




WP 6: Drafting of TMF Code-of-Practice 

prel. CoP val.CoP 

WP2 WP3 WP4 WP5 

Material Pre-normative R&D Validation tests Statist. analysis 

2002 2003 2004 2005 

WP7 

Dissemination, 

TMF Workshop

The Route to Standardisation - TMF-Workshop

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