The Route to Standardisation - TMF-Workshop
The Route to Standardisation - TMF-Workshop
The Route to Standardisation - TMF-Workshop
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GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
<strong>The</strong>rmo-Mechanical Fatigue:<br />
<strong>The</strong> <strong>Route</strong> <strong>to</strong> <strong>Standardisation</strong><br />
Peter Hähner<br />
JRC Institute for Energy, European Commission, Petten, <strong>The</strong> Netherlands<br />
Ernst Affeldt, MTU Aero Engines, München (D)<br />
Henrik Andersson, KIMAB, S<strong>to</strong>ckholm (S)<br />
Tilmann Beck, University of Karlsruhe (D)<br />
Valerio Bicego, CESI, Milan (I)<br />
Hellmuth Klingelhöffer, BAM, Berlin (D)<br />
Alain Köster, Ecole Nationale Superieure des Mines de Paris (F)<br />
Malcolm Loveday, NPL, Tedding<strong>to</strong>n (UK)<br />
Massimo Marchionni, CNR-IENI, Milan (I)<br />
Catherine Rae, University of Cambridge (UK)
Scope of this workshop:<br />
• dissemination of results of European <strong>TMF</strong>-Standard project<br />
promotion of strain-controlled <strong>TMF</strong> as close-<strong>to</strong>-service test<br />
exchange of scientific results relating <strong>to</strong> <strong>TMF</strong> applications<br />
Outline of this presentation:<br />
Introduction<br />
Review of <strong>TMF</strong>-Standard project<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
<strong>The</strong>rmo-Mechanical Fatigue (<strong>TMF</strong>):<br />
Design & residual life analysis of safety critical components<br />
exposed simultaneously <strong>to</strong> thermal & mechanical loads<br />
(gas turbines, aero engines, au<strong>to</strong>motive & process industries):<br />
Internal thermal constraints of representative volume element<br />
simulated by uniform temperature and mechanical strain fields<br />
imposed on labora<strong>to</strong>ry specimen with uniform gauge section
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin
mech. strain<br />
<strong>TMF</strong> cycles with dwell:<br />
in-phase: � =0 o<br />
R � = � 1<br />
time<br />
R � = � m,min/� m,max<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
temperature [arb. units]<br />
mech. strain<br />
T = T 0 + �T F(�t)<br />
� m = � m,0 + �� F(�t ��)<br />
F(x) = F(x + 2�), � x<br />
out-of-phase: � =180 o<br />
R � = � 1<br />
time<br />
temperature [arb. units]
Mechanical Strain [%]<br />
1.2<br />
1.0<br />
0.8<br />
0.6<br />
0.4<br />
0.2<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Triangular TWF waveforms: R � = � m,min/� m,max<br />
��0, R � = 0<br />
0.0<br />
350<br />
0 50 100 150 200<br />
Time [sec]<br />
950<br />
850<br />
750<br />
650<br />
550<br />
450<br />
Temperature [ o C]<br />
Mechanical Strain [%]<br />
0.0<br />
-0.1<br />
-0.2<br />
-0.3<br />
-0.4<br />
-0.5<br />
-0.6<br />
-0.7<br />
��180 o , R � = ��<br />
-0.8<br />
350<br />
0 50 100 150 200<br />
Time [sec]<br />
950<br />
850<br />
750<br />
650<br />
550<br />
450<br />
Temperature [ o C]
Hysteresis loops:<br />
Stress MPa<br />
800<br />
600<br />
400<br />
200<br />
-400<br />
-600<br />
-800<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
0<br />
-0,4 -0,3 -0,2 -0,1 0<br />
-200<br />
0,1 0,2 0,3 0,4<br />
900°C<br />
400°C<br />
650°C<br />
650°C<br />
Mechanical strain %<br />
OP cycle<br />
IP cycle<br />
400°C<br />
900°C<br />
Out-of-phase<br />
In-phase<br />
� m = � el + � in
Load train alignment<br />
Precision extensometry<br />
LCF <strong>The</strong>rmal<br />
fatigue<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Load-contr.<br />
<strong>TMF</strong><br />
Dynamic temperature measurement & control<br />
Strain-contr.<br />
<strong>TMF</strong><br />
<strong>The</strong>rm. – mech. load phasing<br />
Pre-cycling, start-up procedures<br />
<strong>The</strong>rmal strain compensation<br />
� <strong>to</strong>t = � m + � th
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
<strong>TMF</strong>-Standard GRD2-2000-30014<br />
<strong>The</strong>rmo-mechanical fatigue – the route <strong>to</strong> standardisation<br />
(funded within the GROWTH Programme of the Europ. Comm.)<br />
Objectives: <strong>to</strong> establish a <strong>TMF</strong> testing platform in Europe<br />
<strong>to</strong> issue a validated code-of-practice<br />
<strong>to</strong> disseminate and exploit the results<br />
Starting date: 1. Oc<strong>to</strong>ber 2001<br />
Duration: 48 months<br />
Budget: ~ 1.800.000 Euro (~ 1.080.000 EC contribution)<br />
Consortium: 10 principal contrac<strong>to</strong>rs<br />
9 assistant contrac<strong>to</strong>rs, 1 external participant<br />
No. of tests: ~ 400 incl. 120 validation tests
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Partners: JRC Institute for Energy, Petten (NL)<br />
MTU Aero Engines, München (D)<br />
University of Karlsruhe (D)<br />
BAM, Berlin (D)<br />
NPL, Tedding<strong>to</strong>n (UK)<br />
University of Cambridge (UK)<br />
Ecole Nationale Superieure des Mines de Paris (F)<br />
CNR-IENI, Milan (I)<br />
CESI, Milan (I)<br />
KIMAB (ex-SIMR), S<strong>to</strong>ckholm (S)<br />
Forschungszentrum Jülich (D)<br />
Tech. University of Darmstadt (D)<br />
University of Siegen (D)<br />
CEAT, Toulouse (F)<br />
Imperial College, London (UK)<br />
Silesian University of Technology, Ka<strong>to</strong>wice (PL)<br />
ONERA, Chatillon (F)<br />
Forschungszentrum Karlsruhe (D)<br />
SNECMA Villaroche (F)<br />
ALSTOM Baden (CH)
Three distinct phases:<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
1. Prepara<strong>to</strong>ry phase:<br />
Inven<strong>to</strong>ry of <strong>TMF</strong> testing procedures in Europe (WP1)<br />
Material procurement, characterization & distribution (WP2)<br />
2. R&D phase:<br />
Pre-normative testing (WP3, Task 1 – 5)<br />
Validation testing (WP4)<br />
Statistical sensitivity analysis (WP5)<br />
3. Exploitation and dissemination phase:<br />
Drafting of Code-of-Practice (WP6)<br />
Dissemination of CoP, workshop (WP7)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
WP 3: Pre-normative research on <strong>TMF</strong> procedures & <strong>to</strong>lerances<br />
Task 1: Pre-cycling, start, interrupt, restart procedures<br />
Task 2: Dynamic T measurement and control<br />
Task 3: <strong>The</strong>rmal strain comp., deviations from nominal T<br />
Task 4: T gradient effects in 3 sample geometries<br />
(solid cylindrical, hollow cyl., solid rectangular)<br />
Task 5: Deviations from nominal phase angle<br />
Reference testing as preparation for WP4
WP 4: Validation testing<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Period: June 2004 – March 2005<br />
Partner(s): “inner circle” – centrally machined samples of<br />
three common geometries (solid cyl., hollow cyl., flat):<br />
MTU, JRC-IE, IWK, BAM, ENSMP,<br />
UCAM, CNR, CESI, SIMR<br />
“outer circle” – individually machined samples of various<br />
geometries:<br />
NPL, FZJ, TUD, Uni Siegen, CEAT, ICON, SUT,<br />
ONERA, FZK, SNECMA, ALSTOM
Validation <strong>TMF</strong> cycles:<br />
1.) symmetrical triangular OOP<br />
R� = - 1, � = 180°<br />
Tmin = 400°C, Tmax = 850°C<br />
tcycle = 180s � dT/dt = � 5K/s<br />
�� m = 0.8% � N f � 1000<br />
2.) symmetrical triangular IP<br />
R� = - 1, � = 0°<br />
Tmin = 400°C, Tmax = 850°C<br />
tcycle = 180s � dT/dt = � 5K/s<br />
�� m = 0.7% � N f � 1000<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
mech. strain [%]<br />
0.4<br />
0.2<br />
0.0<br />
-0.2<br />
-0.4<br />
400 500 600 700 800 900<br />
temperature [°C]<br />
=> 120 validation tests
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
WP 5: Sensitivity analysis of validation test results<br />
Cycles <strong>to</strong> 10% Load Drop<br />
O-P <strong>TMF</strong> Test Results : Nimonic 90 - All Data<br />
0.8% Mechanical Strain range, 400°C - 850°C, 5°C/s<br />
2000<br />
1500<br />
1000<br />
500<br />
0<br />
Solid Bars<br />
Hollow<br />
Flat<br />
0 5 10 15 20<br />
Labora<strong>to</strong>ry
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Web-enabled Mat-DB - <strong>TMF</strong>-Standard data sets<br />
To get access <strong>to</strong> <strong>TMF</strong> Standard data and documentation please register on the JRC Petten ODIN<br />
website (https://odin.jrc.nl), register for Mat-DB and DoMa and mention under comments that you<br />
request access <strong>to</strong> the <strong>TMF</strong>-Standard project results.<br />
Selection of <strong>TMF</strong>-Standard data within the web-enabled Mat-DB data retrieval part
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Selection of <strong>TMF</strong> Standard data within the web-enabled Mat-DB data retrieval part
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Graphical output of <strong>TMF</strong> Standard data within the web-enabled Mat-DB data retrieval part
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
<strong>The</strong>rmo-Mechanical Fatigue:<br />
<strong>The</strong> <strong>Route</strong> <strong>to</strong> <strong>Standardisation</strong><br />
Peter Hähner<br />
JRC Institute for Energy, European Commission, Petten, <strong>The</strong> Netherlands<br />
Ernst Affeldt, MTU Aero Engines, München (D)<br />
Henrik Andersson, KIMAB, S<strong>to</strong>ckholm (S)<br />
Tilmann Beck, University of Karlsruhe (D)<br />
Valerio Bicego, CESI, Milan (I)<br />
Hellmuth Klingelhöffer, BAM, Berlin (D)<br />
Alain Köster, Ecole Nationale Superieure des Mines de Paris (F)<br />
Malcolm Loveday, NPL, Tedding<strong>to</strong>n (UK)<br />
Massimo Marchionni, CNR-IENI, Milan (I)<br />
Catherine Rae, University of Cambridge (UK)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Acknowledgements:<br />
Johan Bressers, JRC Institute for Energy, Petten (NL)<br />
Rainer Marquardt & Roland Schmier, MTU Aero Engines, München (D)<br />
Anja Archie & Birgit Skrotzki, BAM, Berlin (D)<br />
Frits de Haan, Stefan Ripplinger, Helmut Over, JRC-IE, Petten (NL)<br />
Thomas Brendel, MTU Aero Engines, München (D)<br />
Joachim Hammer, FH Regensburg (D)<br />
Hans-Joachim Kühn, BAM, Berlin (D)<br />
Luc Remy, Ecole Nationale Superieure des Mines de Paris (F)<br />
Bryan Roebuck, NPL, Tedding<strong>to</strong>n (UK)<br />
Giovanni Onofrio, CNR-IENI, Milan (I)<br />
Gemma Drew, Andrew Rayment & Siavash Pahlavanyali, University of Cambridge (UK)<br />
Claudia Rinaldi, CESI, Milan (I)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Acknowledgements cont’d:<br />
Roland Herzog, Forschungszentrum Jülich (D)<br />
Andreas Schmidt & Alfred Scholz, TU Darmstadt (D)<br />
Valerij Bauer & Hans-Jürgen Christ, University of Siegen (D)<br />
Christian Marfaing, CEAT, Toulouse (F)<br />
Peter Skel<strong>to</strong>n, Imperial College, London (UK)<br />
Jerzy Okrajni, Silesian University of Technology, Ka<strong>to</strong>wice (PL)<br />
Franck Gallerneau & Didier Pacou, ONERA, Chatillon (F)<br />
Claus Petersen, Forschungszentrum Karlsruhe (D)<br />
Jean-Marc Rongvaux, SNECMA Villaroche (F)<br />
Arnd Jung, ALSTOM Baden (CH)<br />
Mauro Facchini, Thomas Fairley, DG-RTD, Brussels (B)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin
WP 1: Inven<strong>to</strong>ry of labs and test procedures in <strong>TMF</strong> testing<br />
Detailed questionnaire: >80 questions organized in various sections:<br />
Generalities<br />
Setup used for <strong>TMF</strong><br />
Calibration<br />
Test preparation & pre-cycling<br />
<strong>TMF</strong> test execution<br />
Data recording, evaluation & reporting<br />
Comments<br />
Evaluation completed in Dec 02:<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
responses from 17 partners received<br />
WP1 report: “Survey of strain-controlled <strong>TMF</strong> testing practices”<br />
excerpts used for “Recommendations for strain-controlled <strong>TMF</strong> testing”<br />
(~25 issues on Setup, Dyn. T measurem. & control, Definitions,<br />
Precycling, Reporting)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
WP 2: Procurement and distribution of test material<br />
Material:<br />
Nimonic90<br />
Acceptance tests:<br />
grain size, HV, chem. comp.<br />
Aging heat treatment:<br />
5hrs @ 850 o<br />
Hardness, HV30<br />
350<br />
300<br />
250<br />
200<br />
0 2 4 6 8 10 12 14 16<br />
Hours at 850°C
E, MPa<br />
220000<br />
210000<br />
200000<br />
190000<br />
180000<br />
170000<br />
160000<br />
150000<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Task 1: Pre-cycling, start, interrupt, restart procedures<br />
Et up<br />
Et down<br />
Ec up<br />
Ec down<br />
Et T cost<br />
Ec T cost<br />
E pseudodynamic<br />
300 400 500 600 700 800 900<br />
T, °C
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Task 2: Dynamic T measurement and control<br />
Ribbon-type TC (T control in the centre of GL)<br />
T [°C]<br />
900<br />
800<br />
700<br />
600<br />
500<br />
Desired T-path in<br />
the gage section<br />
dT/dt = 10°C/s<br />
400<br />
300<br />
ribbon type TC in the gage section<br />
Controller: spot welded TC on the<br />
200<br />
specimen shoulder<br />
0 20 40 60 80 100 120 140 160 180 200<br />
t [s]<br />
Spot-welded TC (T control outside GL)
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Task 3: <strong>The</strong>rmal strain compensation, deviations from nominal T<br />
stress - MPa<br />
750<br />
700<br />
650<br />
-200<br />
-250<br />
T=400-850o T=400-850 C o T=420-830 C<br />
o T=420-830 C<br />
o C T=380-870o T=380-870 C oC Tmax nominal= 850 o Tmax nominal= 850 C<br />
o C<br />
temperature<br />
stress<br />
Tmin nominal= 400 o Tmin nominal= 400 C<br />
o C<br />
-300<br />
500 510 520 530 540<br />
350<br />
550<br />
C:\<strong>TMF</strong>-PNR\VERSUCHE\X1-5\X1-5 SIGMA MAX MIN VS ZYKLUS-02.WTP | 1.3.2004<br />
cycles<br />
Maximum- / minimum- stress changes as a result of temperature errors<br />
900<br />
850<br />
800<br />
450<br />
400<br />
temperature - o C
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Task 4: T gradient effects in 3 different testpiece geometries<br />
(solid cylindrical, hollow cylindrical, solid rectangular)<br />
Temperature difference [K]<br />
60<br />
40<br />
20<br />
0<br />
-20<br />
-40<br />
-60<br />
T3<br />
T5 shank centre<br />
Set temperature [°C]<br />
RTC<br />
400 850 400<br />
T1
Temperature<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
Task 5: Deviations from nominal phase angle<br />
- � + �<br />
Time<br />
Mechanical strain<br />
T- no phase<br />
shift<br />
T- positive<br />
phase shift<br />
T- negative<br />
phase shift<br />
Mechanical<br />
strain
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
“Inner circle” specimen geometries:
survey<br />
WP1 1 st draft<br />
GROWTH Project n° GRD2-2000-30014<br />
<strong>TMF</strong>-Standard<br />
Final Meeting/<strong>Workshop</strong>, 20-23/09/05, Berlin<br />
WP 6: Drafting of <strong>TMF</strong> Code-of-Practice<br />
prel. CoP val.CoP<br />
WP2 WP3 WP4 WP5<br />
Material Pre-normative R&D Validation tests Statist. analysis<br />
2002 2003 2004 2005<br />
WP7<br />
Dissemination,<br />
<strong>TMF</strong> <strong>Workshop</strong>