Abstract
This paper addresses the influence on the fatigue life induced by the implementation of a capillary-based structural health monitoring methodology, patented under the name eSHM. It consists in integrating structurally small and pressurized capillaries into the component, so that when a fatigue crack breaches the capillary network, it results in a leak flow to the open atmosphere and loss of pressure in the galleries which is detected by a pressure sensor. The novelty of the proposed system resides in the opportunity to locate the capillary according to the designer’s need, as one resorts to additive manufacturing for the part production. However, the presence of these galleries in highly stressed regions raises concerns about crack initiation at the capillary itself and accelerated fatigue crack growth. This paper aims at the quantification of the influence the eSHM has on the fatigue behavior of the component and the determination whether this influence is significant or not. To that purpose, numerical simulations on a straight lug component, using the finite elements and eXtended Finite Elements Methods (XFEM), are performed. Various capillary sizes and shapes are assessed, so as to enable a general conclusion on the impact of the eSHM methodology in straight lugs.
Highlights
The history of aviation is sadly enough quite abundant with examples of propagating fatigue cracks that lead to a structural failure
Since the eSHM is originally targeted at aerospace applications, it has been decided to work on straight lug components
Health Monitoring methodology has been dealt within the context of straight lugs
Summary
The history of aviation is sadly enough quite abundant with examples of propagating fatigue cracks that lead to a structural failure. While additive manufacturing has shown significant potential for widespread usage in production of complex and/or customized parts, this potential has been dampened by, notably, the variation of mechanical properties, which includes the fatigue behavior of these parts [17] It is well-known in the literature that printing parameters such as technology used (powder bed fusion, laser metal deposition, etc.), scanning speed, powder flow rate (non-exhaustive list) have notably a strong influence on the microstructure and residual stresses present in the component, and on the mechanical properties. As a matter of fact, this study can be seen as the completion of our initial work [14], as both initiation and propagation are addressed, and as additional capillary topologies and initial flaws are studied This should enable to draw a more general conclusion on the eSHM influence on fatigue behavior of equipped lugs
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