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U22011 Structural Integrity Assignment Help

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U22011 Structural Integrity Assignment - University of Portsmouth, UK

Structural Integrity Assessment -

1. Summary - The coursework draws on experience from industrial consulting work on the application of fracture mechanics and creep-fatigue analysis, and is aimed at providing a realistic opportunity for work experience at engineering consulting in some of the key areas of structural integrity assessment.

2. Instructions - You are expected to start with a literature review on the background and recent developments of the subject, followed by a search for material data and test standards, which should help you with the quantitative assessments. The report should follow the following format: introduction, literature review, methods, analysis, discussion, conclusions and references; and should be written clearly in technical terms, using figures/tables as necessary. References must be given and cited in the text.

Part A - Damage Tolerance Analysis of Aero-Engine Fan Blade

You have just joined an engineering consulting firm specialising in damage tolerance analysis. Your client, an aero-engine manufacturer, requested a fracture mechanics analysis of fan blade.

Specifically, they requested that the component is to be simplified as a centre-cracked panel and the centrifugal force experienced as uniformly distributed tensile stresses across the ends of the panel. Ti-6Al-4V is used currently, and a conservative estimate of an initial defect size from two independent NDT inspections found 2a=0.5 mm. W=0.5m. The client is interested in the following information:

I. Would fatigue crack growth occur under an operational cyclic stress range -30 to 220 MPa? What if the maximum stress is increased by 50% whilst the stress range stays the same?

II. If the component is sufficiently strong to sustain an overload of 5 times of the maximum nominal stress 220 MPa?

III. When an inspection should be scheduled, if this must be done at 70% of component life predicted for a baseline loading cycle 0 - 220 MPa?

IV. What if this major cycle is superimposed with a vibrational minor cycle 200-240 MPa? Should the inspection period be revised?

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Although not part of the client's briefing, your project manager suggested that you should also:

V. Find the background information on fan blades of aero-engines, and the essential material information about Ti-6Al-4V and its properties from literature. In particular: Fatigue threshold, ΔKth; Paris Law parameters C and m: da/dN = CΔKm and Fracture toughness Kc.

VI. Check if Small Scale Yielding (SSY) condition is satisfied in all the cases you calculated and comment on the results.

VIII. Research alternative materials to Ti-6Al-4V for fan blades in aero-engines. Discuss the pros and cons of the alternative materials compared with Ti-6Al-4V. Comment on how damage tolerant assessments should be conducted if alternative materials are used.

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Part B - Life assessment of high temperature header piping and tube system

The project aims for a life assessment of a high temperature steam header piping and tube system at a power generation plant. The client has requested a life assessment to be performed on one of their superheater header, as shown in Figure 2.1, which is a central manifold for other piping runs that is used to convert saturated or wet steam into superheated or dry steam.

The plant is considering to change its operation mode to a two-shifting mode, where the plant will be shut down over the weekend (Friday night at 8pm) and restarts the operation back on Monday at 8am. The header has experienced some 82000 hours operation already.

Using pressure vessel design codes such as the EN12952 or ASME B31.1, estimate the remaining fatigue and creep life of a header with a stub configuration, as shown in Figure 2.2 if the two-shifting mode is to be run. They would also like to understand the geometrical effects of a row of tubes/stubs on the stress in the header and to estimate the fatigue and creep life of the header. These effects are taken into account through the parameter VL called ligament efficiency. The main dimensions of the component and operating conditions are reported in Table 1.

The owner of the plant welcomes recommendations with respect to header maintenance following the proposed change in operation as well as improvements in the design, optimisation of materials and manufacturing of the steam header piping and tubing.

Table 1: Nominal dimensions & Operating conditions

Material

Header

2¼CrMo (P22)

Tube

Geometry

Header outer diameter Do, mm

390

Header thickness, t, mm

56

Tube stub outer diameter do, mm

57

Tube thickness tb, mm

9

Pitch between tube holes L1, mm

336

Pitch between tube holes L2, mm

400

Operating condition

Pressure P, MPa

14

Temperature T, oC

565

Total in-service time, hrs

82000

Note - The word limit for the report is 3000 words (each up to 1500 words, or approximately 5 pages).

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