• Transactions of the KSME C: Technology and Education
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• v.4 no.2
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• pp.93-99
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• 2016

High pressure nozzles and turbines of a gas turbine engine should be required to be operated under extreme operating conditions in order to maximize the performance. Engine manufactures have utilized nickel-base superalloys, enhanced cooling design, and thermal barrier coating techniques to overcome them and furthermore, material modeling, finite element analysis, optimization techniques, and etc. have been utilized widely for elaborate predictions. We aim to evaluate the effects on the low cycle fatigue life of the high pressure turbine blade caused by thermal barrier coatings and the cooling design of the endwall of the first stage turbine nozzle. To achieve it, the structural analysis, which utilized the results of conjugate heat transfer analysis as loading boundary conditions, was performed and then the results were the input for the assessment of low cycle fatigue life at several critical zones.

• Transactions of the Korean Society of Mechanical Engineers B
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• v.23 no.11
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• pp.1410-1417
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• 1999

A thorough understanding of the transient behavior during start-up is essential in the design and operation of the heat recovery steam generator(HRSG). During this period of time, material that is exposed to high temperature and experiences a large temperature variation is subject to high thermal stress. In this work, a transient formulation of the HRSG is constructed including the estimation of the thermal stress and fatigue of the drum wall. Start-up behavior of a single-pressure HRSG is analyzed and the effect of bypassing part of the gas turbine exhaust flow on the thermal stress evolution is examined. It is found that the modulation of the gas flow rate using a bypass damper is very useful in view of reducing the thermal stress of the drum and ensuring the fatigue lifetime.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.28 no.4
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• pp.427-434
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• 2004

Ferritic stainless steel is recently used in high temperature structures because of its good properties of thermal fatigue resistance, corrosion resistance, and low price. Tensile and low-cycle fatigue (LCF) tests on 429EM stainless steel used in exhaust manifold were performed at several temperatures from room temperature to 80$0^{\circ}C$. Elastic Modulus, yield strength, and ultimate tensile strength monotonically decreased when temperature increased. Cyclic hardening occurred considerably during the most part of the fatigue life. Dynamic strain aging was observed in 200~50$0^{\circ}C$, which affects the cyclic hardening behavior. Among the fatigue parameters such as plastic strain amplitude, stress amplitude, and plastic strain energy density (PSED), PSED was a proper fatigue parameter since it maintained at a constant value during LCF deformation even though cyclic hardening occurs considerably. A phenomenological life prediction model using PSED was proposed considering the influence of temperature on fatigue life.

• International Journal of Automotive Technology
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• v.8 no.2
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• pp.243-248
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• 2007

The durability of a cylinder head is influenced by the thermal and mechanical history during the manufacturing process, as well as engine operation. In order to improve the durability of cylinder head, both load from engine operation and the preload conditions from the manufacturing process must be considered. The aluminum cylinder head used for a HSDI diesel engine is investigated to reduce the possibility of high cycle fatigue crack in this study. FE analysis is performed to elucidate the mechanism of high cycle fatigue crack in the HSDI diesel cylinder head. Two separate approaches to increase the durability of the cylinder head are discussed: reducing load from engine operation and re-arranging preload conditions from the manufacturing process at the critical location of the cylinder head. Local design changes of the cylinder head and modification of pretension load in the cylinder head bolt were investigated using FE analysis to relieve load at the critical location during engine operation. Residual stress formed at the critical location during the manufacturing process is measured and heat treatment parameters are changed to re-arrange the distribution of residual stress. Results of FE analysis and experiments showed that thorough consideration of the manufacturing process is necessary to enhance the durability of the cylinder head.

• Journal of the Korean Society for Precision Engineering
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• v.14 no.11
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• pp.69-76
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• 1997

The rotating bending fatigue tests were performed using the specimens taken from Cr-Mo-V steel, widely sued in thermal power plant turbines, at various temperatures such as room temperature, 300 .deg. C, 425 .deg. C and 550 .deg. C. The characteristics of fatigue crack propagation were examined and analyzed by using fracture mechanics parameter. The plastic replica method was also applied in order to measure the crack length on the basis of serial observation of fatigue crack propagation behavior on the defected specimen surface. The fatigue crack propagation behavior of Cr-Mo-V steel was investigated within the frame work of elastic-plastic fracture mechanics. The propagation law of fatigue crack is obtained uniquely by using the term .sigma. $^{n}$ sub a/where .sigma. $_{a}$ is the service stress, a is the crack length and n is a constant. The values of constant n are nearly equal to 2.48, 2.60 and 8.61 at room temperature, 300 .deg. C and 425 .deg. C.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2009.05a
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• pp.385-390
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• 2009

The gas turbine engine structures usually are placed on high thermal mechanical stress condition. For general low cycle fatigue evaluation, simple fatigue criterion based on critical plane approach is developed. LCF life of turbine wheel is evaluated with this criterion and process contrived together.

• Transactions of the Korean Society of Automotive Engineers
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• v.11 no.3
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• pp.28-38
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• 2003

Finite element analysis of cylinder heat/block compound under assembly, thermal and firing condition were performed. FE model including two cylinders with gasket, head bolts, liners and valve seats was used. FE modeling method and boundary conditions were introduced. Stress distribution and deformation of cylinder head and block under each loading condition were presented. Gasket pressure distribution and bore distortion level were predicted. Measured data of bore distortion was compared with the analysis results. The analysis result showed similar trends with the experimental data. High cycle fatigue analysis on the basis of this result has been performed in order to find the critical areas of the engine assembly.

• Journal of Welding and Joining
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• v.33 no.5
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• pp.26-30
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• 2015

Hastelloy X in this study was applied in jet engine F-15 air fighter as shroud to isolate the engine from outer skin. After 15 years operation at elevated temperature the mechanical properties decreased gradually due to the precipitation of continues second phases in the grain boundaries and precipitated inside the grain. The crack happened at the edge of the shroud due to the thermal and mechanical stress from jet engine. Selective TEM analysis found that the grain boundaries consist of $M_{23}C_6$ carbide, $M_6$ Ccarbide and small percentage of sigma(${\sigma}$) phase. Furthermore, it was confirmed the nano size of ${\sigma}$ and miu (${\mu}$) phase inside the grain. In this study, it was investigated the microstructure of the degraded shroud component and HAZ of repair welded shroud. In the HAZ, it was observed the dissolution of the $M_{23}C_6$ carbides and smaller precipitates, the migration of the undissolved larger $M_{23}C_6$ carbide and $M_6$ Ccarbide. It is also observed the liquation due to the simply melt of the segregated precipitates in the grain boundaries. Interestingly, the segregated second phases which simply melt in the grain boundaries more easily happened at higher heat input welding condition. High temperature tensile test was done at $300^{\circ}C$, $700^{\circ}C$ and $900^{\circ}C$. It was obtained that the toughness of welded sample is lower compare to the non-welded sample. The solution heat treatment at $1170^{\circ}C$ for 5 minutes was suggested to obtain a better mechanical properties of the shroud. The high cycle fatigue number of the repair welded shroud shows a much lower compare to the shroud. In addition, the high cycle fatigue number at room temperature after solution heat treatment was almost double compare to the before solution heat treatment under 420-500MPa stress amplitude. However, the high cycle fatigue number of repaired welded sample was shown a much lower compare to the non- welded shroud and solution treated shroud. One of the main reasons to decrease the tensile strength and the high cycle fatigue properties of the repair welded shroud is the formation of the liquid phase in HAZ.

• Proceedings of the KSME Conference
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• 2007.05a
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• pp.1740-1743
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• 2007

In this study, two types of fatigue tests were conducted. First, cyclic bending tests were performed using the micro-bending tester. A four-point bending test method was adopted, because it induces uniform stress fields within a loading span. Second, thermal fatigue tests were conducted using a pseudo power cycling machine which was newly developed for a realistic testing condition. The pseudo-power cycling method makes up for the weak points in a power cycling and a chamber cycling method. Two compositions of solder are tested in all test condition, one is lead-free solder (95.5Sn4.0Ag0.5Cu) and the other is eutectic lead-contained solder (63Sn37Pb). In the cyclic bending test, the solder that exhibits a good reliability can be reversed depending on the load conditions. The lead-contained solders have a longer fatigue life in the region where the applied load is high. On the contrary, the lead-free solder sustained more cyclic loads in the small load region. A similar trend was detected at the thermal cycling test. A three-dimensional finite element analysis model was constructed. A finite element analysis using ABAQUS was performed to extract the applied stress and strain in the solder joints. A constitutive model which includes both creep and plasticity was employed. Thermal fatigue was occurred due to the creep. And plastic deformation is main damage for bending failure. From the inelastic energy dissipation per cycle versus fatigue life curve, it can be found that the bending fatigue life is longer than the thermal fatigue life.

• Proceedings of the Korean Society of Propulsion Engineers Conference
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• 2008.11a
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• pp.181-184
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• 2008

Austenitic stainless steel is used as high temperature components such as gas turbine blade and disk because of its good thermal resistance. In the present investigation, tensile and low cycle fatigue behavior of 316 stainless steel was studied at wide temperature range $20^{\circ}C{\sim}750^{\circ}C$. In the tensile tests, it was shown that elastic modulus, yield strength, ultimate tensile strength decreases when temperature increased. The effect on fatigue failure of the parameters such as plastic strain amplitude and plastic strain energy density was also investigated. With the experimental results, a structural analysis of turbine blades of 316 stainless steel were carried out.