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Accelerated Structural Assessment for Risk Reduction of a L-PBF Cruciform Rotor

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Conventional structural assessment and risk reduction measures required to conduct a spin test on a novel rotor calls for a significant amount of dynamic and mechanical material data. In addition, when considering parts made by additive manufacturing (AM), full volumetric (surface and subsurface) inspection is required to characterize potential anomalous features that might increase material property variability. Securing the information needed to prove structural viability of an AM component can be cost and time prohibitive, which in turn delays transition of the technology. However, if information from material testing, volumetric inspections, and design analysis can be tied together in a digital engineering chain, the material data needed for structural assessment can be optimized to reduce cost and time for development. The work detailed in this abstract investigates the use of minimal data for assessing the structural viabilities of a stainless steel 316L AM cruciform rotor in operation. The rotor is expected to experience induced vibration fatigue as well as centrifugal load stresses while demonstrating the inherent vibration suppression and damage tolerance capability of i-DAMP technology. The information acquired for structural assessment are directional tensile strength and fatigue, computed tomographic scan data from coupons and the rotor, and as-built finite element assessment. This information was appropriately referenced in order to gather full understanding of the structural performance of the rotor during operation and reduce the risk of conducting aggressive spin rig tests.

Learning Objectives:

  • Risk reduction and full understanding of the structural performance of the rotor during operation can be achieved with minimal data points.
  • Vibration of a dynamic component can be suppressed by more than 80% by leaving a 3.5% unfused powder volume in the part.