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HBM Prenscia invites you to attend the 2019 HBM Prenscia Technology Day: Overcoming Real World Fatigue Testing and Simulation Challenges.

This one-day free seminar introduces industry challenges and solutions for improving fatigue testing and fatigue simulation. Guest speakers representing a number of industries will present their solutions for improving a product’s durability and reliability through fatigue simulation, probabilistic analyses, and additive manufacturing and maintenance directed fatigue testing. Presenting companies include:

  • Leonardo Helicopters
  • Select Engineering Services (Layton, UT, USA)
  • TWI
  • Coventry University
  • Malvern Panalytical
  • HBM Prenscia
  • University of Bristol
  • Jaguar Land Rover

In addition, HBM Prenscia technical staff will share an in-depth look at solutions for delivering reliability and durability through product design and operation, using design and process FMEA/FMECA, life data analysis, and combining desktop and web browser solutions to improve analysis productivity.

Agenda - 19th November 2019

Registration and coffee
Welcome and introduction
The Durability Challenges of Tiltrotor Aircraft
David Matthew, Leonardo Helicopters
Surface Treatment Effects in Fatigue Analysis of Landing Gear Materials
Ben Griffiths, Select Engineering Services (Layton, UT, USA)
Refreshments
Track 1
Porosity Reduction to Improve Fatigue Performance in Laser – Powder Bed Fusion (L-PBF) Additive Manufacturing
Dr. Paul Goodwin, TWI | Principal Project Leader at TWI Technology Centre

With its greater design freedom for complex shaped components and its higher buy-to-fly ratio with minimal material waste compared with conventional manufacturing, selective laser melting (SLM) / Laser-Powder Bed Fusion (L-PBF) of metallic alloys is of significant interest in a number of industrial applications. Component quality is sensitive to a number of factors however, including both the SLM/L-PBF system set up and processing parameters related to specific alloy systems. These parameters significantly affect resultant defect populations in the microstructures of the as-built material, which determine the subsequent mechanical properties. In particular, fatigue performance is dictated by the size, morphology and volume fraction of the defects present. Achieving full density is thus one of the most desired outcomes for SLM-processed materials which will contribute to improved fatigue performance. It is recognised that this represents one of the largest barriers to the wider application of additive manufactured (AM) parts faced by customer companies.

This presentation will outline the approach TWI has been taking in order to control all aspects of the end to end process chain for SLM/L-PBF parts with a view to approval of part certification through Lloyds Register.  As part of this strategy, a new R&D project has commenced in 2019, in partnership with HBM Prenscia, in order to generate a database of statistically significant fatigue performance data which is crucial for TWI to being able to verify the success, or otherwise, of all recent developments made in the area of SLM/L-PBF process technology – both in terms of powder quality / characterisation / handling as well as process parameter development methodology.


About the presenter
Paul Goodwin obtained his BSc in Materials Technology and PhD in Metallurgy from the University of Surrey between 1981 and 1988. He then spent 14 years at the Royal Aerospace Establishment / DRA / DERA / QinetiQ in Farnborough, Hampshire as a research scientist on a wide range of topics in the field of powder metallurgy, including materials synthesis, processing, characterisation and property evaluation. During his final five years at QinetiQ he was responsible for initiating research programmes in additive manufacturing, specifically on the laser deposition of titanium alloys, nickel superalloys and refractory metal component production. He then relocated to Sheffield in 2003, where he worked at Castings Technology International (Cti) and Corus / Tata Steel in Rotherham before becoming R&D Manager / Metallurgist at Laser Cladding Technology Ltd, Worksop in 2007 where he was responsible for all aspects of running the company R&D programme.

Paul joined TWI in 2015 as a Principal Project Leader in the Laser Additive Manufacturing (LAM) section at TWI Yorkshire where his current role is Selective Laser Melting (SLM) Team Lead. His main responsibilities include the application and strategic development of all aspects of SLM technology. One particular focus is the certification of SLM parts, in partnership with Lloyds Register, through understanding and controlling the causes of defects in SLM builds and the consequent effects these have on mechanical performance, including fatigue.

Paul has authored over 50 publications (24 as first author) and has made presentations at numerous International conferences in UK, Europe, USA, Canada and Japan. He has previously served as a member of the Steering Committee of the Association of Industrial Laser Users (AILU) and is currently chairman of the AILU Special Interest Group on Additive Manufacturing.

High Cycle Fatigue of Wire + Arc Additive Manufactured Titanium (WAAM Ti-6Al-4V) – Effects of Porosity Defect, Microstructure and Texture
Dr. Abdul Khadar Syed, Coventry University | Assistant Professor, Institute for Future Transport and Cities
Characterization of Metals Using X-ray Diffraction; Phase, Texture and Residual Stress
Dr. Paul O Meara, Malvern Panalytical | XRD Application Specialist
Track 2
Delivering Reliability through Design and Process FMEA
Chris Wynn-Jones, HBM Prenscia | Application Engineer - Reliability
This presentation shows how reliability analysis concepts and methods are used to focus a failure mode and effect analysis (FMEA) before costly design or process changes are made in order to improve the reliability of a product, process or service. Reliability engineering tools are used to show how to identify and justify improvements in the product, process or service.

For a representative time period, in-service operational and incident data are analysed to identify components or processes with frequent or critical incidents, in order to prioritise these for further analysis. This requires a full understanding of the components function, failure modes, effects and causes in order to determine the appropriate corrective action. Risk discovery and criticality ratings are considered for each failure mode to determine which components carry the highest risk.

Using the in-service data from these high-priority components or processes, life data analysis (LDA), in the form of Weibull distributions, are performed to understand the trend of in-service incidents over time. These LDA models are combined with their FMEA to calculate a universal reliability definition (URD) model to compare the effect and probability of their failure modes.

About the presenter

Chris Wynn-Jones is an Applications Engineer who joined Prenscia from reliability consultancy 18 months ago. Since being with the company Chris has been supporting and training users of ReliaSoft applications for customers from a range of industries including aerospace and automotive in the UK and Europe.
An Introduction to Life Data Analysis and Probabilistic Analysis
Chris Wynn-Jones, HBM Prenscia | Application Engineer – Reliability
Virrinder Kumar, HBM Prenscia | Application Engineer – Durability
AMCT laboratory tour
Dr. Michelle Hill, HBM Prenscia | Head of Materials Testing
Buffet lunch
Track 1
Fatigue Durability Estimation Approach for Unidirectional CFRP Laminates
Dr. Peter Heyes, HBM Prenscia | Principal Technologist

FE-based Strength calculations for composite structures are often carried out using a ply-by-ply application of classic failure criteria such as the Tsai-Wu criterion.  When applied to laminates made from UD carbon fibre, such a “first ply failure” (FPF) approach tends to give very pessimistic predictions – effectively predicting the onset of matrix cracking in transversely loaded plies.  In practice there is a lot of residual strength in the structure after the onset of such cracking.  On the other hand, progressive damage modelling methods are far more complex and computationally intensive, with non-linear FE and material models that may be difficult and expensive to calibrate.

Tsai and Melo recently described simple methods that promise to deliver more realistic strength estimates for UD laminates using a “last ply failure” (LPF) approach.  These methods have advantages that include relatively simple material characterisation and use of linear elastic FE.  This presentation describes how these simple methods for static strength have been extended to fatigue and incorporated in nCode DesignLife as a beta test feature.

About the presenter

Peter read Natural Sciences at Cambridge, mainly physics with a side-order of materials.  He then spent 5 years teaching Physics in a secondary school before going back to University to do a PhD in Metal Fatigue at Sheffield University. Since then, apart from a brief period doing vehicle body CAE work, he has been part of the nCode business, in various roles including consultancy, application engineering and product management.  He is currently part of the technology group, mainly focused on methods for modelling fatigue in composite materials and structural joints.

Probabilistic Fatigue and Reliability Simulation
Dr. Andrew Halfpenny, HBM Prenscia | Chief Technologist
A Framework to Implement Probabilistic Fatigue Design for Landing Gear Structures
Joshua Hoole, University of Bristol | Research Associate in Probabilistic Design
Track 2
Sensor Data Analytics to Support Predictive Maintenance
Manish Gautam, HBM Prenscia | Application Engineer

With the advent of ultrafast internet and 5G the means of data collection will change. Soon engineers will have the ability to access huge quantities of customer usage data through their connected products, this data will need to be turned into useful information so that engineering decisions can be made.

This presentation discusses the challenges concerning the management of this data as well as the those related to data analytics. A case study will also be presented covering the area of large-scale customer usage monitoring and the application of the HBM Prenscia toolset to achieve the goal.

About the presenter
Manish Gautam is an Applications Engineer who joined nCode (now HBM Prenscia, within HBK) as a graduate 7 years ago. Since being with the company Manish has mainly dealt with data management and analytics projects for customers from a range of industries including automotive, defence and power generation.

Developing “Client Appropriate” Material Fatigue Testing Programmes at the AMCT
Robert Cawte, HBM Prenscia | Senior Engineering Consultant
AMCT laboratory tour
Dr. Michelle Hill, HBM Prenscia | Head of Materials Testing
Refreshment break
Creating a Fatigue Damage Model to Enable CAE Fatigue Life Prediction to Reduce Costs
Andrew Blows, Jaguar Land Rover | Principal Technical Specialist, Body Strength and Durability CAE
A Unified Approach for Calculating Life of Components Combining Crack Initiation and Growth
Dr. Andrew Halfpenny, HBM Prenscia | Chief Technologist
Summary, questions and close

Event Details

Agenda

19th November 2019
8:00 AM - 5:00 PM

Location

AMP Technology Centre
Brunel Way, Catcliffe,
Rotherham S60 5WG, UK

Registration

While the event is free to attend, we do request that you register in advance so that we can confirm accurate numbers with the venue. Please complete this form in order to confirm your attendance.