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Crystal plasticity modeling of polycrystalline Ni-base superalloy honeycombs under combined thermo-mechanical loading

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Abstract

To meet the ever-growing demands for the efficient operation of turbomachinery, a minimum clearance between the rotating and the stationary components is of great importance. A lack of controlling this clearance often leads to interface rubbing. As a result, thermo-mechanical loads arise that can critically damage both components. Maintaining operational reliability and high efficiency requires seal systems that can tolerate rubbing. Honeycomb labyrinth seals can fulfill this task. In this contribution, we present a three-dimensional microstructure-based simulation approach considering the periodic unit cell of a polycrystalline Ni-base superalloy (Hastelloy X) honeycomb structure. Different honeycomb geometries are investigated, and various loading conditions are applied to simulate the thermo-mechanical behavior of the honeycomb structure during rubbing. The problem is solved in a finite element framework, and the deformation behavior is described by a crystal plasticity model accounting for microstructure attributes of the material. To calibrate the material model, numerical simulations on a representative volume element discretized with a realistic three-dimensional periodic mesh are carried out. The overall thermo-mechanical response of the honeycomb structure as well as the development of local field quantities is investigated. The study reveals that large contact areas seem to be very critical for the initiation of premature damage of the honeycomb structure.

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Acknowledgements

This work is part of the research project WE 2351/14–1, funded by the DFG (Deutsche Forschungsgemeinschaft). We thank the Max Planck Institut für Eisenforschung in Düsseldorf for providing the simulation kit DAMASK.

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Authors and Affiliations

  1. Institute of Material Science and Mechanics of Materials, Technische Universität München, Boltzmannstraße 15, 85748, Garching, Germany

    Tim Fischer & Ewald Werner

  2. Metals and Alloys, Universität Bayreuth, Ludwig-Thoma-Straße 36b, 95447, Bayreuth, Germany

    Sonun Ulan kyzy

  3. Institute of Thermal Turbomachinery, Karlsruher Institut für Technologie, Kaiserstraße 12, 76131, Karlsruhe, Germany

    Oliver Munz

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  1. Tim Fischer
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Correspondence to Tim Fischer.

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Communicated by Andreas Öchsner.

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Fischer, T., Werner, E., Ulan kyzy, S. et al. Crystal plasticity modeling of polycrystalline Ni-base superalloy honeycombs under combined thermo-mechanical loading. Continuum Mech. Thermodyn. 31, 703–713 (2019). https://doi.org/10.1007/s00161-018-0721-z

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