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Fatigue Fracture of Aircraft Engine Compressor Disks

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Abstract

Several compressor disks in military fighter and trainer aircraft gas turbine engines cracked prematurely in the bolt hole regions. The disks were made of precipitation-hardened AM355 martensitic stainless steel. Experimental and analytical work was performed on specimens from the fifth-stage compressor disk (judged to be the most crack-prone disk in the compressor) to determine the cause of the failures. Failure was attributed to high-strain low-cycle fatigue during service. It was also determined that the cyclic engine usage assumed in the original life calculations had been underestimated, which led to low-cycle fatigue cracking earlier than expected. Fracture mechanics analysis of the disks was carried out to assess their damage tolerance and to predict safe inspection intervals.

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References

  1. A.K. Koul, R. Thamburaj, M.D. Raizenne, W. Wallace, and M.C. Malherbe, Practical experience with damage tolerance based life extension of turbine engine components, in Proceedings of international conference of advisory group for aerospace research and development (AGARD) of NATO, AGARD-CP-393, paper 23, (April 1985).

  2. N.C. Bellinger, P. Stoute, G. Gould, A. Fahr, A.K. Koul, “The Nondestructive and Destructive Data for Compressor Discs for Detecting Bolt Hole LCF Cracks,” Report ST-490, National Research Council of Canada, (Dec 1987).

  3. N.C. Bellinger, A. Fahr, A.K. Koul, G. Gould, P. Stoute, “The Reliability and Sensitivity of NDI Techniques in Detecing LCF Cracks in Fastener Bolt Holes of Compressor Discs,” Report LTR-ST-1651, National Research Council of Canada, (Feb 1988).

  4. A.K. Koul, N.C. Bellinger, A. Fahr, Damage tolerance based life prediction of aeroengine compressor discs: a deterministic fracture mechanics approach, Int. J. Fatigue, 12(5), 379 (1990) https://doi.org/10.1016/0142-1123(90)90002-V.

  5. A.K. Koul, N.C. Bellinger, G. Gould, Damage tolerance based life prediction of aeroengine compressor discs: a probabilistic fracture mechanics approach. Int. J. Fatigue, 12 (5), 388 (1990). https://doi.org/10.1016/0142-1123(90)90003-W.

  6. A. Hull, R.V. Dainty, M.D. Raizenne, D.W. Hoeppner, Fatigue crack growth testing of compressor discs, J. Can. Aerospace Inst. 3(4), 321 (1986).

Selected References

  1. Fatigue Failures, Failure Analysis and Prevention, Vol 11, ASM Handbook, ASM International, 2002, p 700–727 https://doi.org/10.31399/asm.hb.v11.a0003544.

  2. M.P. Kaplan, T.A. Wolff, Fatigue-Life Assessment, Failure Analysis and Prevention, Vol 11, ASM Handbook, ASM International, 2002, p 276–288 https://doi.org/10.31399/asm.hb.v11.a0003516.

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Acknowledgments

The contributions of Dr. R. Thamburaj of the Orenda Division of Hawker Siddeley Canada (previously with Carleton University) and Dr. A. Hull of the University of Toronto in performing some parts of the experimental program are gratefully acknowledged. The analytical and technical help provided by our colleagues, Dr. J.J. Kacprzynski, Mr. M.D. Raizenne, and Mr. N.C. Bellinger (Structures and Materials Laboratory of IAR), is also appreciated. The financial assistance for this program was provided by the office of the Chief of Research and Development, Department of National Defence, Ottawa, Canada, through financial arrangement FA220787NRC06.

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Authors and Affiliations

  1. Structures and Materials Laboratory, Institute for Aerospace Research, National Research Council of Canada, Ottawa, Canada

    Ashok K. Koul & Raymond V. Dainty

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  1. Ashok K. Koul
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  2. Raymond V. Dainty
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This article is adapted from Handbook of Case Histories in Failure Analysis, Vol 1, Khlefa A. Esaklul, Ed., ASM International, 1992, p 241–250, https://doi.org/10.31399/asm.fach.v01.c9001081.

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Koul, A.K., Dainty, R.V. Fatigue Fracture of Aircraft Engine Compressor Disks. J Fail. Anal. and Preven. 22, 1995–2004 (2022). https://doi.org/10.1007/s11668-022-01516-4

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  • DOI: https://doi.org/10.1007/s11668-022-01516-4

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