The results of a prognostics case study on GE Frame 5001P first stage turbine disc are presented in this paper. Currently used and promoted practices for metallurgical analysis such as hardness testing and replica based microstructural assessment and inspection of rotors for dimensional checks and cracks are not sufficient to ensure safety and reliability of the engine. The uncertainly of all engine variables including operational environment must be considered prior to returning the engine to service. It is required to accurately predict the temperature profile of the discs that can have serious consequences on the residual life assessment of the fracture prone rotors. The safe inspection interval (SII) determination of the design life expired engines and defining non-destructive inspection (NDI) sensitivity requirements for continued safe operation of the engine are equally important.

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