This paper contains the in-service fatigue fracture analysis for the first stage low-pressure compressor disk of the aircraft engines D30KU-154. Based on the results of the fractographic investigation on collapsed compressor disks the fatigue crack initiation and propagation mechanisms were established. It is shown that the crack initiation in the rim part of the compressor disk is due to a high frequency loading that leads to very high cycle fatigue fracture. The total fatigue life of the compressor disk is determined by simultaneous action of low amplitude loading due to blades vibration, and high amplitude loading due to flight cycle (centrifugal forces). To study the in-service fracture of the compressor disk the numerical simulation of the stress state in the damaged zone under corresponding loading conditions was evaluated. The estimation of fatigue life and crack path predictions were performed based on the multi-regime fatigue fracture model proposed by the authors.

The use of an additive technology production in an industrial application opens a new engineering opportunity for structural elements design. The new production technology allows a new design concept aimed to gain the weight save, decrease the number of joints in the mechanisms and other valuable benefits. However, it was reported that mechanical properties of a 3D printed materials are very sensitive to the external loading parameters. Nowadays the quasi-static mechanical properties of the materials obtained by selected laser melting (SLM) technology are close, or even superior the mechanical properties of traditional production technologies, while cyclic mechanical properties are still low. This paper introduces the VHCF properties of the SLM aluminum alloy AlSi10Mg and hot-rolled aluminum alloy D16T under axial VHCF loading. The fracture surfaces of both alloys were investigated by scanning electron microscopy (SEM) to study crack initiation mechanisms and early crack growth.