Integrated lifing analysis for gas turbine components

A method to predict gas turbine component life based on engine performance analysis has been developed [1]. 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. With a combination of a heat transfer and thermal finite element model the temperature distribution in the component is calculated. The stress distribution is obtained with a structural finite element analysis and finally a life consumption model is used to determine the damage accumulation in the component. The applicability of the tool is demonstrated with a number of analyses on real engine components. Examples are a creep life analysis of the F100-PW-220 engine 3 stage turbine rotor blade during a recorded RNLAF F-16 mission and a crack growth analysis for the 2 stage fandisc hub for a representative mission mix. Furthermore, using the engine system model with a detailed control system, the effect of engine deterioration on blade life consumption rate was determined. The tool has significant potential to enhance on-condition maintenance and optimize aircraft operational use.