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

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-07-C-5216
Agency Tracking Number: F061-095-1755
Amount: $712,246.00
Phase: Phase II
Program: SBIR
Awards Year: 2007
Solicitation Year: 2006
Solicitation Topic Code: AF06-095
Solicitation Number: 2006.1
Small Business Information
FRACTURE ANALYSIS CONSULTANTS, INC.
121 Eastern Heights Drive, Ithaca, NY, 14850
DUNS: 608112389
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Paul Wawrzynek
 Managing Engineer
 (607) 257-4970
 wash@fracanalysis.com
Business Contact
 Paul Wawrzynek
Title: Managing Engineer
Phone: (607) 257-4970
Email: wash@fracanalysis.com
Research Institution
N/A
Abstract
This Phase II proposal describes the continued development of three-dimensional, nonlinear structural analysis methods for use in prognosis systems for aerospace, gas turbine, metallic components and component assemblies. In Phase I, Fracture Analysis Consultants Inc. (FAC) demonstrated the feasibility of using a three-dimensional fracture propagation program, Franc3D/NG, to automatically generate finite element models that relate sensor-measurable structural response to damage scenarios involving fatigue cracks. These numerical results were used to generate probabilistic predictions of remaining useful component life. In Phase II, FAC proposes to work closely with Pratt & Whitney to expand on the Phase I work with four key areas of emphasis. First, we propose to incorporate realistic engine loads, such as combined high and low frequency cycling, and realistic materials, such as single crystal alloys. Second, we propose to incorporate advanced 3D fracture mechanics, including mixed mode I, II, and III loading, orthotropic material behavior, and crack growth in residual stresses due to surface treatments. Third, we propose to verify the software using historical and newly generated test results. Fourth, we propose to verify the software and demonstrate its usefulness and usability in an actual engine development and production environment.

* information listed above is at the time of submission.

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