Development and Validation of A Dual Titanium Alloy Dual Microstructure BLISK

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1 Development and Validation of A Dual Titanium Alloy Dual Microstructure BLISK Olaf Roder, MTU Aero Engines, Jean-Pierre Ferte, SNECMA, Ernst Gach, BSTG, Jose Mendez, CNRS-ENSMA, Marc Anglada, UPC and Antonio Mateo, UPC Fifth Aeronautic Days 2006, Vienna, Austria, June 19th 21st, 2006 CONTRACT N : PROJECT N : ACRONYM : G4RD-CT GRD DUTIFRISK 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 1

2 TWI as sub-contractor FSU-Jena as sub-contractor Dual Material Titanium Alloy Friction Welded BLISK 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 2

3 Agenda Introduction Base Material Characterization Welded Material Characterization Up-Scaling Presentation will give an overview of the DUTIFRISK program by means of some selected results. 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 3

4 Introduction Advanced compressor designs are critical to achieve higher efficiencies and safety standards and of complying with future environmental legislation goals. New and innovative rotor designs as envisaged for Very High Bypass Ratio engine concepts, are leading to: higher rotating speeds in the low pressure compressor higher end temperatures for each stage. Consequence: reliability, lifetime and temperature capability of today s state-of-theart materials and designs has to be improved. Important topic: Further improvement of BLISK (bladed disk or IBR = Integrated Bladed Rotor )-technology made out of conventionally titanium alloys to overcome the single material-condition BLISK. 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 4

Introduction Disk-blade attachment often life limiting due to fretting fatigue Improvement by using BLISKS Today BLISK are made out of one material condition Further

5 Introduction Disk-blade attachment often life limiting due to fretting fatigue Improvement by using BLISKS Today BLISK are made out of one material condition Further improvement LCF-optimised disk material plus HCF-optimised blade material Joining method: Linear Friction Welding 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 5

6 Linear Friction Welding Specimen Scale Process as it s done in Task 1.2 to 1.5 Production Scale / Prototype Process as it s done in Task May 2006 MTU Aero Engines GmbH, Munich, Germany 6

7 Expected Results: DUTIFRISK (Contract No.: G4RD-CT ) Identification of optimised linear friction weld parameters for each material combination. Determination of microstructure and mechanical properties of welds. Evaluation and adaptation of existing NDT-methods for aero engines with regard to dual titanium alloy / dual microstructure joints. Production and validation of two demonstrator BLISK (Ti-17 and Ti-6246 bore). Definition of a possible repair strategy and quality assurance guideline. Starting date: 1. April 2002 Duration: 48 months + 6 month prolongation Budget: ~ (Funding: ~ ) Consortium: 6 principal contractors 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 7

8 Project Phases (three distinct phases) Preparatory phase Material procurement, production (forging), characterization & distribution of base materials following pages R&D phase on specimen scale size Manufacture and testing of linear friction welded trial joints (not shown) Manufacture, testing and assessment of linear friction welded joints Aspects of repairing BLISK (not shown) Assessment and adaptation of existing NDT-methods Modelling of processes (not shown) Exploitation and dissemination phase Quality assurance guideline for LFW-joints (not shown) Production and validation of demonstrator BLISK 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 8

(Ti-6246, Ti-6242, Ti-64) pre forming (α+ß) pre pressing

9 Material Procurement and Forging Disk-Pancakes / Demonstrator (Ti-6246) pre pressing (α+ß) final pressing (ß) Blade-slabs (Ti-6246, Ti-6242, Ti-64) pre forming (α+ß) pre pressing final pressing 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 9

10 Base Material Characterization: Microstructures Disk-Pancake: β-ti6246 Blade-slabs: β-ti6246 / α/β-ti6246 Heat treatment: solution annealing at 915 C plus aging: 595 C / 8h / air 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 10

11 Base Material Characterization: Ultimate Tensile Strength 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 11

12 Base Material Characterization: High Cycles Fatigue of Blade Materials 1100 Maximum Stress σmax [MPa] Blade beta Ti6246: RT Blade (alpha+beta) Ti6246: RT Blade beta Ti6246: 450 C Blade (alpha+beta) Ti6246: 450 C Potenziell (Blade (alpha+beta) Ti6246: RT) Potenziell (Blade beta Ti6246: RT) HCF, smooth, R = 0.1 β vs α/β Ti6246 Blade Base Material 0 1.E+04 1.E+05 1.E+06 1.E+07 1.E+08 Cycles to Failure 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 12

13 From Forging(s) to Welded Specimens 60mm x 15mm Height = 36mm Linear friction welding plane Inner Part material characterisation spare 60mm x 15mm Height = 36mm Ø 250 mm 65mm 35mm 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 13

14 Hardness Profile of β-ti6246 Blade / β-ti6246 Disk 500 Hardness-Profil AC Mitte Zwickel 440 Härte HV Blade Strecke [mm] Blade Disk 1 May 2006 MTU Aero Engines GmbH, Munich, Germany Disk

15 Weld Area of β-ti6246 Blade / β-ti6246 Disk Blade 1500 µm 0 µm 1500 µm Disk 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 15

16 Hardness Profile of α/β-ti6246 Blade / β-ti6246 Disk Blade Disk 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 16

17 Weld Area of α/β-ti6246 Blade / β-ti6246 Disk Blade 1500 µm 0 µm 1500 µm Disk 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 17

18 Welded Material Characterization: Ultimate Tensile Strength 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 18

19 Welded Material Characterization: HCF 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 19

20 Welded Material Characterization: Summary Tensile properties similar to base materials properties. Failure occurs in one of the base materials well of the weld and heat affected zone High Cycle Fatigue properties similar to base materials properties. Failure occurs in one of the base materials well of the weld and heat affected zone. Further Tests performed Mechanical Tests: Hardness Profiles, Creep/Stress Rupture, Fracture Toughness, Fatigue Crack Propagation, Low Cycle Fatigue and Micro-Tensile Testing. Evaluation of Non-Destructive-Test-Methods Residual Stress Measurements Modeling 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 20

21 Up-Scaling Specimen Scale Process as it s done in Task 1.2 to 1.5 Production Scale / Prototype Process as it s done in Task May 2006 MTU Aero Engines GmbH, Munich, Germany 21

22 DUTIFRISK Demonstrator BLISK Configuration Simplified Blade Configuration Weld profile and configuration as for original blade Rectangular material blocks instead of original blades Original BLISK Bore BLISK-1 = β-forged Ti6246 BLISK-2 = β-forged Ti17 Blade materials for Ti6246 bore: β- and (α+β) Ti6246 β- and (α+β) Ti6242 (α+β) Ti64 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 22

23 DUTIFRISK Demonstrator 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 23

24 1 May 2006 MTU Aero Engines GmbH, Munich, Germany 24

Flow Controlled Core Overview

Flow Controlled Core Overview Hanna Reiss, Snecma Safran Group Introduction High BPR and/or new architectures will require highly loaded, efficient and operable HPC (+20/25% vs. in-service compressor)