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Robust Model for Behavior of Complex Materials during Spin Testing

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA9550-10-C-0057
Agency Tracking Number: F08A-013-0135
Amount: $749,999.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: AF08-T013
Solicitation Number: 2008.A
Solicitation Year: 2008
Award Year: 2010
Award Start Date (Proposal Award Date): 2010-03-31
Award End Date (Contract End Date): 2012-03-31
Small Business Information
2901 Benvenue Ave.
Berkeley, CA 94705
United States
DUNS: 102090847
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Shmuel Weissman
 President & CEO
 (510) 528-1251
Business Contact
 Shmuel Weissman
Title: President & CEO
Phone: (510) 528-1251
Research Institution
 University of California, Berkeley
 Panayiotis Papadopoulos
6131 Etcheverry Hall, Mailstop U.C. Berkeley
Berkeley, CA 94720
United States

 (510) 642-3358
 Nonprofit College or University

The objective of this project is to develop a practical finite element-based simulation of spin-pit tests of disks. The performance of disks in spin-pit tests critically depends on localized effects, such as residual stresses, dislocations, and microstructure gradients. Therefore, a two-scale modeling approach is adopted. At the global-scale, the disk is represented by means of finite elements with embedded internal discontinuities. Local-scale models are employed to account for localized effects, such as the influence of microstructure on inelastic properties (e.g., creep and plastic hardening). An important feature of the proposed approach is that it enables the simulation of arbitrarily oriented localized “softening” effects (relative to the geometry of the finite element mesh). This feature is critical because it enables the simulation of the propagation of oriented localized effects, such as fatigue cracks, independent of the mesh geometry. This project will also result in novel two-scale material models, and procedures to obtain the associated material properties. Numerical simulations of spin-pit tests of dual-heat treated disks will be used to validate the proposed development. Both two- and three-dimensional simulations will be performed. These simulations will include both steady-state disk spinning, as well as transient states (i.e., acceleration and deceleration). BENEFIT: The outcome of this project is simulation software to predict the performance of advanced turbine disks in spin pit tests. In particular, it will permit the analysis of the influence of imperfections and residual stresses, introduced during the manufacturing process, on the performance of turbine dicks. This software will enable improved optimization of disk design, leading to increased fatigue life, and reduced maintenance. In particular, it will enable reliable analyses of advanced disks such as dual-heat treated disks, which are used in the high-pressure section of jet engines for both civil and military applications. The demand for higher fuel efficiency mandates that engines operate at higher temperatures. As a result, the need for advanced disks (i.e., dual-heat treated and hybrid disks) is increasing. In fact, future advancements in jet engine technology hinges on the availability of such disks. The tool that Symplectic Engineering is proposing, therefore, is aimed at meeting a clear demand identified by jet engine manufacturers (e.g., GE, Pratt & Whitney, and Rolls-Royce), as well as by the Air Force and Navy. For this reason, Symplectic Engineering expects to successfully commercialize its technology.

* Information listed above is at the time of submission. *

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