This paper describes some of the new surface damage capabilities in DARWIN™, a probabilistic fracture mechanics software code developed to evaluate the risk of fracture associated with aircraft jet engine titanium rotors/disks. An initial framework is presented in which a graphical user interface (GUI) is used to explicitly define the stresses and temperatures at the crack location for several crack geometries. A summary of the approach used to develop new stress intensity factor solutions for these geometries is also presented, including selected validation results.

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First–principle computational methods have been utilized to compute the diffusion mobility of Mo, Cr, Fe, and W. A local density-based full-potential linearized augmented plane wave (FLAPW) code, named WIEN2K, was utilized to compute the electronic structure and total energy of an n-atom supercell with atom positions designed to simulate the desired diffusion processes. The computational procedure involves the calculations of the energy for vacancy formation and the energy barrier for solute migration in the host metal. First-principles computational results of the energy of vacancy formation, solute migration energy, activation energy for self-diffusion, as well as diffusion of Mo, Cr, Fe, and W solutes in Ni and vice versa are presented and compared against experimental data from the literature.

Recently a new methodology was developed for automated fatigue crack growth (FCG) life analysis of components based on finite element stress models, weight function stress intensity factor solutions, and algorithms to define idealized fracture geometry models. This paper describes how the new methodology is being used to integrate FCG analysis into highly automated design assessments of component life and reliability. In one application, the FCG model automation is supporting automated calculation of fracture risk due to inherent material anomalies that can occur anywhere in the volume of the component. Automated schemes were developed to divide the component into a computationally optimum number of sub-volumes with similar life and risk values to determine total component reliability accurately and efficiently. In another application, the FCG model automation is supporting integration of FCG life calculations with manufacturing process simulation to perform integrated computational materials engineering. Calculation of full-field, location-specific residual stresses or microstructure is being linked directly with automated life analysis to determine the impact of manufacturing parameters on component reliability.