Integrated lifing analysis of a film-cooled turbine blade

A method to predict gas turbine component life based on engine performance analysis is demonstrated on a hot section gas turbine component. The mechanical and thermal loading of the first stage high pressure turbine rotor blade of the FlOO-PW-220 engine, one of the most severely loaded components in the engine, is analyzed and a life assessment is performed. For this analysis, engine performance history is obtained from in-flight monitored engine parameters and flight conditions and downloaded for processing by a tool integrating a number of software tools and models. Data acquisition is performed by the FACE system installed in a large number of RNLAF F-16 fighter aircraft. Data then is processed by a thermodynamical engine system model, calculating gas properties like pressure and temperature at the required station in the engine. A computational fluid dynamics model, including the blade film cooling, is used to calculate the heat transfer to the blade. A thermal finite element model calculates the temperature distribution in the component and the stress distribution is obtained with a structural finite element analysis. Finally a life consumption model is used to determine the creep and fatigue damage accumulation in the component. The tool has significant potential to enhance on-condition maintenance and optimize aircraft operational use.