Aerospace structures must be designed in such a way so as to be able to withstand even more flight cycles and/or increased loads. Damage tolerance analysis could be exploited more and more to study, understand, and calculate the residual life of a component when a crack occurs in service. In this paper, the authors are presenting the results of a systematic crack propagation analysis campaign performed on a compressor-blade-like structure. The point of novelty is that different blade design parameters are varied and explored in order to investigate how the crack propagation rate in low cycle fatigue (LCF, at R ratio R = 0) could be reduced. The design parameters/variables studied in this work are: (1) The length of the contact surfaces between the dovetail root and the disc and (2) their inclination angle (denoted as “flank angle” in the aero-engine industry). Effects of the friction coefficient between the disc and the blade root have also been investigated. The LCF crack propagation analyses have been performed by recalculating the stress field as a function of the crack propagation by using the FRacture ANalysis Code (Franc3D^®).

The present work deals with natural and whirl frequency analysis of a porous functionally graded (FG) rotor–bearing system using the finite element method (FEM). Stiffness, mass and gyroscopic matrices are derived for porous and non-porous FG shafts by developing a novel two-noded porous FG shaft element using Timoshenko beam theory (TBT), considering the effects of translational inertia, rotatory inertia, gyroscopic moments and shear deformation. A functionally graded shaft whose inner core is comprised of stainless steel (SS) and an outer layer made of ceramic (ZrO₂) is considered. The effects of porosity on the volume fractions and the material properties are modelled using a porosity index. The non-linear temperature distribution (NLTD) method based on the Fourier law of heat conduction is used for the temperature distribution in the radial direction. The natural and whirl frequencies of the porous and non-porous FG rotor systems have been computed for different power law indices, volume fractions of porosity and thermal gradients to investigate the influence of porosity on fundamental frequencies. It has been found that the power law index, volume fraction of porosity and thermal gradient have a significant influence on the natural and whirl frequencies of the FG rotor–bearing system.

Corrosion causes a loss of material resulting in the reduction of mass and stiffness of a component, which consequently affects the dynamic characteristics of any system. Fundamental frequency analysis of a corroded functionally graded (FG) rotor system, using the finite element method based on the Timoshenko beam theory, was investigated in the present paper. The functionally graded shaft consisting of an inner metallic core and an outer ceramic layer was considered with the radial gradation of material properties based on the power law. Nonlinear temperature distribution (NLTD) based on the Fourier law of heat conduction was used to simulate the thermal gradient through the cross-section of the FG rotor. The finite element formulation for a functionally graded shaft with a corrosion defect was developed and the dynamic characteristics were investigated, which is the novelty of the present work. The corrosion parameters such as length, depth and position of the corrosion defect in the shaft were varied and a parametric study was performed to investigate changes in the natural and whirl frequencies. An analysis was carried out for different power indexes and temperature gradients of the functionally graded shaft. The effects of corrosion were analysed and important conclusions are drawn from the investigations.