Integration and Automation of Residual Stress and Service Stress Modeling for Superalloy Component Design

The residual stress distribution generated during manufacturing processes of a jet engine component plays an important role in determining component life. The heat treatment, machining and pre-service spin variables (if used) contribute to the magnitude and location of residual stresses generated prior to service. Such variables have traditionally not been included in design optimization due to the lack of accurate and efficient process modeling design tools. Increased demand for higher speed and higher temperature disks has necessitated advanced multidisciplinary modeling tools in order to deliver high performance, robust and cost favorable solutions. Component process modeling that considers disk stresses through heat treatment, machining, pre-service spin and design operation has been linked and automated to minimize service stress for locations of interest. This paper uses a superalloy 718 disk as an example to illustrate integration and automation of residual stress and service stress modeling that will ultimately impact component life.