Crack growth rate and lifetime prediction for aviation gas turbine engine compressor disk based on nonlinear fracture mechanics parameters

•Expressions for the creep-fatigue interaction crack growth rate are derived.•A new equation for dimensionless nonlinear equivalent stress intensity factor is introduced.•An analysis is made between fatigue and creep the crack tip parameters behavior.•The comparison between the experimental and predicting data is found to be satisfactory. In this study, the fatigue crack growth and life-time prediction of aviation gas turbine engine compressor disks under operating conditions are analyzed. Different combinations of rotational speed, temperature, surface flaw forms and sizes, as well as elastic–plastic titanium alloy BT3-1 properties are considered. A crack growth rate equation, which included the fracture process zone size and nonlinear stress intensity factor, is derived. The assessments of the structural integrity of the rotating disk are compared for elastic and elastic-plastic solutions. It is indicated that the traditional elastic crack growth models overestimate the residual fatigue lifetime with respect to the nonlinear fracture mechanics approach.