## 3 Results
### Stress Analysis Results  
The thermal results from the 2D axisymmetric analysis and the 3D analysis were similar. Figure 10 shows the steady-state temperature distribution from the 2D analysis. The highest temperatures occur behind the lead edge region of the blade at the aft end. This was anticipated and further validates the assumptions in the 1D results. The temperature distribution also confirms that the area of concern is concentrated at the aft end where the insert is constrained by the aluminum components. This region presents the highest temperatures and least room for thermal growth, which is where thermal stress will increase the most. The results from the 2D axisymmetric stress analysis did not indicate any issues with the design. The von Mises equivalent stress and maximum principal stress were well below the ultimate strength for the AM inserts. The minimum principal stress had the highest magnitude of compressive stresses; however, they were still below the ultimate strength. In fact, the compressive stresses at the aft end of the insert, where it is constrained by the aluminum, were of very similar magnitudes compared to those of the 1D analysis. The 2D axisymmetric results do not give any insight into the stresses inside the notches since there is no way to include them in an axisymmetric model. Mesh convergence studies were performed using the 2D analysis and an appropriate amount of elements were incorporated into the model. The 3D stress results were evaluated at two cross-section planes and focused on the AM inserts; stresses in the metal components were not a concern. The cross-section locations are indicated in Figure 11. Plane A is a slice of the bottom insert that includes the alignment notches. It was important to capture the behavior in this region due to the anticipated stress concentration. Plane B serves as a comparison of the insert without the notch involved. Both planes do not have any geometric features related to instrumentation  
Figure 10: Two-dimensional steady-state thermal analysis results. \begin{table}
\begin{tabular}{c c} \hline \hline
**ANSYS Parameter** & **Value** \\ \hline Friction Coefficient & 0.2 \\ Penetration Tolerance & 0.0005 \\ AM Insert Contacts & Frictional \\ Metal Contacts & Bonded \\ Mesh Size (3D) & \textasciand so they represent stresses associated with the majority of the inserts. Stresses around major features were checked separately to ensure they were within limits. The values of maximum principal stress were the lowest of the three criteria used in the analysis. This was unsurprising as the highest stresses were expected to be compressive and the magnitudes were similar in both planes. The von Mises equivalent stress was significantly higher in Plane A compared to Plane B. The highest stress occurs at the aft end of the insert at the apex of the notch. Stress contours for the von Mises stress are produced in Figure 12. The von Mises stress is reduced sharply in Plane B, away from the notch. Although the maximum stress is high in this region, it is still below the ultimate strength of the material. In Plane B, von Mises stress is significantly lower. The highest stresses are limited to the aft end of the insert, especially on the outer surface where it contacts the metal. The stress in this area is very similar to the predicted von Mises stress in the 2D axisymmetric model. The minimum principal stress calculation produced the highest stresses of all three criteria. Most of the values are less than zero, which represents compressive stresses. The highest magnitudes were localized to the apex of the notch in Plane A. These stresses were more of a concern because the magnitude was nearly equal to the PerFORM ultimate strength. Notably, the stress magnitude decreased sharply at even small distances away from the area. This is likely a result of a stress singularity due to a sharp corner in the geometry. Stresses in Plane B were not of concern.