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Proceedings Papers
Proc. ASME. GT2020, Volume 8: Industrial and Cogeneration; Manufacturing Materials and Metallurgy; Marine; Microturbines, Turbochargers, and Small Turbomachines, V008T18A005, September 21–25, 2020
Paper No: GT2020-14808
Abstract
In this paper, AM produced test samples of a IN939 derivative nickel-based alloy were tested for tensile, fatigue and creep properties at temperatures up to 871°C and compared to the traditional cast material. Initial results showed improved tensile and fatigue strength, but a reduction in both long-term creep rupture strength and creep ductility in the AM produced material compared to the cast baseline. Microstructural observations in the AM produced material showed a significant difference in the overall metallurgical characteristics beyond grain size compared to the castings. In addition to the laboratory studies and to provide a direct comparison between AM and traditional castings, both AM and cast components were tested in live engine trials exceeding 4,000 hours. Detailed scanning electron microscopy techniques were used to evaluate the evolution of grain size, gamma-prime, MC carbide and secondary M 23 C 6 carbide size and distribution throughout a 5-step heat treatment process. Post-test evaluations for creep rupture specimens of the AM material showed creep cavitation near grain boundaries. The results from the AM produced material are discussed in comparison to expected properties and characteristics from traditional casting methods. Results have shown that material production and short-term metallurgical properties are sufficient to produce quality high temperature stationary guide vanes, but additional research and development is needed to optimize the AM process to achieve high-temperature creep behavior comparable to castings.
Proceedings Papers
Proc. ASME. GT2019, Volume 6: Ceramics; Controls, Diagnostics, and Instrumentation; Education; Manufacturing Materials and Metallurgy, V006T24A011, June 17–21, 2019
Paper No: GT2019-90947
Abstract
The defect-free processing of TiAl alloy TNM™-B1 by means of Laser Powder Bed Fusion (LPBF) is demonstrated by manufacturing of an automobile turbocharger wheel. Similar precision cast material was used as reference. TNM™-B1 was manufactured crack free with a density > 99.5% using elevated process temperatures above the brittle-to-ductile transient temperature (BDTT). The preheating temperature was provided by an induction preheating system. To minimize oxygen pick up during the LPBF process, the process atmosphere was actively cleaned using a gas-purification system. Produced test samples were analyzed in as-built and heat-treated condition regarding density, micro structure and phases by means of a Light Optical Microscope (LOM) and Scanning Electron Microscopy (SEM). Micro hardness was measured according to Vickers. Oxidation measurements were performed by means of carrier-gas hot extraction. Mechanical properties were determined using room temperature tensile tests. The final automobile turbocharger wheel was analyzed for defects using a Micro-Computer Tomography scanner (MCT). Besides bulk test samples, thin-walled specimens can be manufactured with sufficient density. Depending on the process parameters, an oxygen content < 1000 ppm could be reached. The as-built microstructure consists of lamellar (α 2 +γ) colonies and nearly globular γ as well as β/β 0 at the grain boundaries. High cooling rates in the magnitude of 10 5 to 10 6 K/s provide small grain sizes of 1–7 μm. Hardness measurements reveal an increased hardness (515-560HV0.3) compared to cast material (390HV0.3). Samples for tensile tests show tensile strength around 840 MPa and a total elongation of 1.1% for LPBF-manufactured and hot isostatic pressed (HIP) samples. The CT analysis of the turbocharger wheel confirms that complex geometries made of TiAl can be additively manufactured free of cracks.
Proceedings Papers
Proc. ASME. GT2017, Volume 7A: Structures and Dynamics, V07AT31A018, June 26–30, 2017
Paper No: GT2017-65189
Abstract
Considerable efforts have been conducted on the modeling of fatigue crack growth (FCG), aiming at an accurate prediction of fatigue life. However, due to the influence of microstructure, it is still challenging to describe FCG behavior, especially for small cracks. The FCG exhibits obvious variation at small crack growth procedure. In this regard, a probabilistic model by integrating N-R model is proposed to simulate the FCG process at stage I. The concerned material is nickel based superalloy GH4169. The proposed model involves both macroscopic and microscopic material parameters for the extension of dislocation with the impediment from grain boundary. Random grain size is represented by the fluctuation of FCG rate. Model validation is performed by comparing the simulation results and experimental data. It is revealed that the dependence tends to be less prominent on longer crack length, smaller grain size and higher applied stress.
Proceedings Papers
Proc. ASME. GT2017, Volume 6: Ceramics; Controls, Diagnostics and Instrumentation; Education; Manufacturing Materials and Metallurgy, V006T24A012, June 26–30, 2017
Paper No: GT2017-64043
Abstract
The microstructural evolution of Inconel 718Plus during hot forming operations is modeled through a physically based model which includes the effects of precipitating particles. Inconel 718Plus has been a successful alloy since its introduction in 2003 owing to its moderate cost, good formability and weldability, and its higher maximum service temperature compared to its ancestor, Inconel 718. It is well known that the service performance and hot-flow characteristics of this alloy are strongly dependent on the microstructure, particularly the grain size. Thus, comprehension of the microstructural evolution and its modeling is an important task. In precipitation hardening superalloys and microalloyed steels, it is particularly more challenging to model the microstructural evolution in the processing windows where material softening and precipitation processes take place concurrently. The model presented in this work is based on dislocation density evolution which is considered as a result of the competition between dislocation generation and dynamic recovery at the early stages of deformation. In the hardening region, recovery through climb is described by the diffusion of vacancies and glide is assumed to be proportional to the strain rate in accordance with the models proposed by Bergstrom. Since the deformation is assumed to be controlled by glide and climb, the peak stress is modeled based on a modified hyperbolic-sine model which takes into account the temperature dependence of self-diffusion of Nickel and elastic modulus. It is known that under high temperature deformation conditions Inconel 718Plus may undergo dynamic precipitation. Second-phase particles in the material may impede the grain boundary motion and contribute to an increase in flow-stress due to Orowan looping. To account for the dynamic precipitation, the present model combines previously obtained experimental results and precipitation models to predict volume fraction and particle radius. For the peak stress modeling, the effect of precipitation is expressed as an extra stress term. The flow stress is calculated for the deformed and the recrystallized material separately and the total flow stress for the material is calculated using a law of mixtures considering the fraction of recrystallized material, while recrystallization is described as a nucleation-growth process via Avrami formalism. Cylindrical compression tests were employed to observe the hot flow behavior and validate the model. The predictions are compared with the experimental findings and good agreement is observed.
Proceedings Papers
Proc. ASME. GT2016, Volume 6: Ceramics; Controls, Diagnostics and Instrumentation; Education; Manufacturing Materials and Metallurgy, V006T21A001, June 13–17, 2016
Paper No: GT2016-56120
Abstract
Nozzle guide vanes (NGV) of gas turbine engines are the first components to withstand the impingement of hot combustion gas, and therefore often suffer thermal fatigue failures in service. A lifing analysis is performed for the NGV of a gas turbine engine using the integrated creep-fatigue theory (ICFT). With the constitutive formulation of inelastic strain in terms of mechanism-strain components such as rate-independent plasticity, dislocation glide-plus-climb, and grain boundary sliding, the dominant deformation mechanisms at the critical locations are thus identified quantitatively with the corresponding mechanism-strain component. The material selection scenarios are discussed with regards to damage accumulated during take-off and cruise. The interplay of those deformation mechanisms in the failure process are elucidated such that an “optimum” material selection solution may be achieved.
Proceedings Papers
Proc. ASME. IGT1985, Volume 4: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Process Industries; Technology Resources; General, V004T07A004, September 1–7, 1985
Paper No: 85-IGT-140
Abstract
A high-strength, low-expansion alloy can greatly increase the efficiency of gas turbines by permitting decreased clearances between rotating and stationary parts. This paper describes development work on a series of nickel-iron-cobalt alloys having the desired combination of high strength and low thermal expansion. The first attempts to develop alloys of this type resulted in materials that required extensive thermomechanical processing and were susceptible to the phenomenon of stress-accelerated grain-boundary oxygen embrittlement (SAGBO). Further development resulted in INCOLOY alloy 909, the first low-expansion superalloy combining good resistance to SAGBO with high mechanical properties achieved without restrictive thermomechanical processing. Those substantial improvements were brought about by the addition of 0.3% to 0.6% silicon to a low-aluminum, 38% nickel, 13% cobalt, 1.5% titanium, 4.7% niobium (columbium), balance iron composition.
Proceedings Papers
Proc. ASME. GT1989, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; General, V005T13A010, June 4–8, 1989
Paper No: 89-GT-127
Abstract
The paper reports on recent extensions to ongoing research into probabilistic structural analysis modeling of advanced space propulsion system hardware. The advances concern probabilistic dynamic loading, and probabilistic nonlinear material behavior. In both cases, the reported work represents a significant advance in the state-of-the-art for these topics. Random, or probabilistic loading is normally concerned with the loading described in power spectral density (PSD) terms. The current work describes a method for incorporating random PSD’s along with random material properties, damping, and structural geometry. The probabilistic material response is concerned with the prediction of nonlinear stress-strain behavior for physical processes that can be linked to the original microstructure of the material. Such variables as grain size and orientation, grain boundary strength, etc. are treated as random, initial variables in generating stochastic stress-strain curves. The methodology is demonstrated for a creep simulation.
Proceedings Papers
Proc. ASME. GT1991, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award; General, V005T14A012, June 3–6, 1991
Paper No: 91-GT-119
Abstract
Microcracks caused by hot cracking or strain age cracking mechanisms are very likely to be discovered in the weld repair zone of precision cast IN738LC gas turbine blades. The possibility of crack propagation under the operating conditions of the gas turbine thereby becomes a crucial issue for gas turbine designers. The creep crack growth rate in air of the hipped and fully heat treated IN738LC was measured at the service temperature experienced by the first stage turbine blade tip. The corresponding growth behaviour was also studied. The creep crack growth rate, da/dt, versus crack tip stress intensity factor, K1, a relation which exhibits the typical primary, secondary and tertiary behaviour, supports the applicability of K1 as an appropriate correlating parameter for the creep crack growth of this Ni-based superalloy under the loading conditions used in this study. Microstructural examination illustrated that the creep crack growth of IN738LC principally takes place by the nucleation, growth, coalescence and link-up of grain boundary microvoids and microcracks. An excellent approximation of the stress intensity factor under service loading conditions in the vicinity of the crack tip was obtained by using the Westinghouse WECAN finite element analysis. It is shown that the crack tip stress intensity factor under normal loading conditions will not be able to drive the transverse through-the-wall-thickness blade tip crack in this study.
Proceedings Papers
Proc. ASME. GT1991, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award; General, V005T12A003, June 3–6, 1991
Paper No: 91-GT-016
Abstract
Results from an analysis of cracked first stage blades (or buckets) from two General Electric Frame 7001E industrial/electric utility gas turbines are presented. Numerous cracks were observed along the leading-edge and mid-chord regions of the pressure and suction surfaces. In one unit cracks were found after 874 start-stop cycles, which included 218 trips from load and 11,000 service hours. Buckets in the sister engine were examined after 1800 cycles, which included 218 trips from load and 24,000 service hours. In both cases, cracks initiated in the platinum aluminide coating and propagated into the IN-738LC base metal. For the 11,000-hour bucket, 20-mil (0.5-mm) deep cracks were observed, and for the 24,000-hour bucket, the leading edge cracks had grown to the leading edge cooling hole, a distance of 0.2 inches (5 mm). The number of cycles to crack initiation was in good agreement with thermal mechanical fatigue (TMF) predictions from the REMLIF computer program, which is part of the Electric Power Research Institute’s (EPRI) Life Management System. The cracking was greatly accelerated by the large number of trips experienced. The extensive crack propagation that occurred is thought to have been strongly assisted by oxygen and sulfur penetration along the grain boundaries. The coating on the leading edge degraded from the original platinum-aluminide plus beta phases to a gamma prime phase after 24,000 hours of service, but it was still protective except where it was cracked. Where the coating was cracked, environmental attack of the interdiffusion zone and base metal occurred, resulting in spallation of the coating and preferential grain boundary attack. Operating and maintenance considerations for optimizing bucket life in demanding cyclic duty environments are also discussed.
Proceedings Papers
Proc. ASME. GT1992, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education, V005T12A006, June 1–4, 1992
Paper No: 92-GT-274
Abstract
A metallurgical investigation was conducted on transitions from two land-based 105 MW gas turbines. One transition suffered catastrophic failure, and two transitions had cracking at the top panel. Two alloys, IN-617 and a modified IN-617, were used in these transitions. The investigation consisted of thickness measurements, optical and scanning electron microscope fractographic studies, metallography, EDS and Auger analysis of precipitates, chemical analysis, and hardness measurements. In both units, heavy oxidation of the top panel on the hot gas side (inside) occurred. Oxide intrusion along the grain boundaries and exfoliation of the oxide layer occurred. This caused thinning of the panel with a resultant loss of about 50% of the panel thickness. Bulk creep cavitation along the grain boundaries and multiple discontinuous creep cracks were present. Crack origins were located at the outer surface of the top panels. Creep cracks and cavities, carbide precipitates, agglomeration of grain boundary carbides, and aluminum nitride were present in the microstructure. The primary cause of cracking was the increase in net section stress, which exceeded the creep strength of the panel. The effect of microstructural changes on the formation of cracks was secondary in nature. Cracks were not associated with welds.
Proceedings Papers
Proc. ASME. GT1992, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education, V005T13A003, June 1–4, 1992
Paper No: 92-GT-317
Abstract
This study deals with microstructural investigations of plasma sprayed yttria partially stabilized zirconia thermal barrier coatings, performed by classical and analytical transmission electron microscopy. The aim of the study was to determine eventual relationships between coating microstructure and toughness. The ceramic/metal interface which plays an important role during TBC thermomechanical sollicitation, has also been studied. In the 6 to 8 weight % Y 2 O 3 range, the metastable tetragonal t’ phase is observed, showing special faulted microstructural features, such as grain twinning and antiphase boundary planes. Moreover, after high temperature annealing in air, a very fine and stable precipitation of the equilibrium cubic phase appears. It is believed that these microstructural elements could act as crack deviation sites and enhance coatings intrinsic toughness. Microstructural investigations of the alumina scales grown during high temperature annealing reveal yttrium segregation at oxide grain boundaries as well as significant quantities of zirconium inside the alumina grains. The oxide growth seems to be dominated by a classical grain boundary oxygen diffusion mechanism. The presence of zirconium inside the alumina grains suggests that Al 2 O 3 also partially forms by chemical reduction of ZrO 2 by Al.
Proceedings Papers
Proc. ASME. GT1993, Volume 3B: General, V03BT16A037, May 24–27, 1993
Paper No: 93-GT-281
Abstract
During the normal operation of a land based gas turbine attack will occur of the gas washed surfaces of the rotating and stationary blades in the turbine hot section. This attack and its intensity can be variable depending on the blades position in the turbine hot section. This attack will progressively degrade these gas washed surfaces even if these surfaces have been previously coated with a protective layer. During the service period of the turbine, it will be necessary to refurbish the blades from the hotter section of the turbine. One of the refurbishment steps will be to provide the blades with a suitable replacement coating to afford protection until the next service period. Conventional refurbishment techniques used to clean the blade surface rely on abrasive cleaning and/or chemical pickling. These processes may be capable of removing superficial oxidation and any residual coating but are not able to consistently remove the substrate material that has suffered from corrosive attack. It is important that this attacked substrate layer is removed completely otherwise any residual corrosion products, particularly the presence of deeply penetrated sulphides in grain boundaries, could significantly reduce the life of any subsequent coating. The technique described in this Paper essentially activates the surface layer of the substrate that is corroded, thus rendering it more easily removed by chemical and physical means. It is possible by this method to remove up to 400 microns of the substrate material and provided that all the corrosion products are contained within this zone, it is demonstrated how this produces a clean unattacked surface that is necessary for any subsequent welding, brazing or recoating operation.
Proceedings Papers
Proc. ASME. GT1993, Volume 3C: General, V03CT17A078, May 24–27, 1993
Paper No: 93-GT-417
Abstract
The Ceramic Technology Project was initiated in 1983 for the purpose of developing highly reliable structural ceramics for applications in advanced heat engines, such as the automotive gas turbines and advanced heavy duty diesel engines. The reliability problem was determined to be a result of uncontrolled populations of processing flaws in the brittle, flaw-sensitive materials, along with microstructural features, such as grain boundary phases, that contribute to time dependent strength reduction in service at high temperatures. The approach taken to develop high reliability ceramics included the development of tougher materials with greater tolerance to microstructural flaws, the development of advanced processing technology to minimize the size and number of flaws, and the development of mechanical testing methodology and the characterization of time dependent mechanical behavior, leading to a life prediction methodology for structural ceramics.
Proceedings Papers
Proc. ASME. GT1993, Volume 3C: General, V03CT17A026, May 24–27, 1993
Paper No: 93-GT-365
Abstract
The effects of predeformation on the high temperature, low frequency crack growth rate of wrought Alloy 718 is investigated. A series of crack growth experiments were carried out on specimens with different levels of deformation, in addition to specimens in the as received conditions. The experiments included continuous measurements of the crack length and its near field crack tip displacements, fractographic analysis of fracture surface facets and qualitative estimation of the slip density in the crack tip region. Furthermore the thickness of surface oxide layers formed during the fracture process was determined using Auger Spectroscopy. Results of this study show that predeformation enhances the crack tip resistance to environmental effects. This result has been analyzed on the basis of the concept that the deformation-associated slip line density controls the chromium oxide build up taking place along the effected grain boundaries in the crack tip region.
Proceedings Papers
Proc. ASME. GT1995, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award, V005T12A013, June 5–8, 1995
Paper No: 95-GT-425
Abstract
The Nimonic 105 first stage turbine blade of the Rolls Royce Viper 22/1 engine has a design life of 2400 hrs. Over the years, these blades have prematurely failed (1 200–1 800 hrs), necessitating a service limit of 1 000 hrs. Initial investigations thought the cause of failure to be linked with higher than desired lead content but the final cause of failure was attributed to an incorrect heat treatment, forming continuous grain boundary carbides, resulting in embrittlement of the blade. A rejuvenation heat treatment was then developed. The IN-713 and IN-X-40 first stage vanes of the Allison T56 engine suffer thermal fatigue cracking. The IN-713 vanes suffer narrow, fine but long cracks, whereas the X-40 vanes suffer severe cracking (cracks as wide as 3 mm) and excessive oxidation due to overheating. The X-40 alloy is protected by a Cr 2 O 3 scale compared with Al 3 O 3 on the IN-713 alloy. Above 1 000 °C the Cr 2 O 3 breaks down and excessive oxidation results. A braze repair was developed for the X-40 vanes.
Proceedings Papers
M. Sato, Y. Kobayashi, H. Matsuzaki, H. Tamaki, A. Yoshinari, K. Iijima, Y. Fukui, H. Kodama, K. Wada
Proc. ASME. GT1995, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award, V005T12A006, June 5–8, 1995
Paper No: 95-GT-365
Abstract
This paper describes successful results of trial manufacturing of single crystal (SC) buckets, 235mm long, for industrial gas turbines. The bypass method was adopted for casting of the SC buckets. Directionally solidified (DS) buckets, whose size is the same as SC buckets, were cast without grain boundary cracking. The materials for the buckets are CMSX-4 for the SC buckets and CM186LC for the DS buckets. Applicability of these buckets was mainly evaluated by creep rupture tests. The degradation due to casting defects is negligible for both SC and DS buckets which achieve the aimed creep rupture strength for the 1500°C class industrial gas turbines, because these creep rupture strengths are similar to the cast to size (CTS) specimens. The other properties such as tensile strength, hot corrosion resistance, oxidation resistance and low cycle fatigue (LCF) were also obtained from the CTS specimens.
Proceedings Papers
Proc. ASME. GT1996, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; General, V005T12A003, June 10–13, 1996
Paper No: 96-GT-380
Abstract
INCONEL ® alloy 783 is an oxidation resistant low coefficient of thermal expansion (low CTE) superalloy developed for gas turbine applications. Turbine efficiency can be increased through the use of low CTE shrouds and case components that maintain tight blade tip clearances at different turbine operating temperatures. To achieve low CTE, alloys based on Ni-Fe-Co compositions require Cr content be maintained at low levels. Added Cr lowers the Curie temperature and thereby increases thermal expansion rate over a wider temperature range. The necessary lack of Cr minimizes resistance to both general oxidation and stress accelerated grain boundary oxygen enhanced cracking (SAGBO). Increased amounts of Al in alloys strengthened by γ’ alone also promotes SAGBO. Alloy 783 is the culmination in the development of an alloy system with very high aluminum content that, in addition to forming γ′, causes β aluminide phase precipitation in the austenitic matrix. It was discovered that this type of structure can be processed to resist both SAGBO and general oxidation, while providing low thermal expansion and useful mechanical properties up to 700°C. The high Al content also reduces density to 5% below that of superalloys such as INCONEL alloy 718. Key aspects of the alloy development are presented, including the assessment of SAGBO resistance by evaluating elevated temperature crack growth in air. The alloy, now commercially available, has been successfully fabricated and welded into gas turbine engine components.
Proceedings Papers
Proc. ASME. GT1996, Volume 5: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; General, V005T14A062, June 10–13, 1996
Paper No: 96-GT-528
Abstract
The depth of internal oxidation and nitridation from the surface of the 16 cooling holes in a first-stage turbine blade was measured by optical microscopy after 32,000 hours of service. Maximum depth of penetration was 15.5 mils (0.4 mm) at the trailing edge hole. An effort was made to predict hole surface metal temperatures based on these measurements using the Arrhenius relationship between time and temperature with depth of oxidation assumed to be parabolic with time. Reasonable correlations were obtained between finite element analysis results and temperature estimates based on the oxidation measurements. In the thickest part of the airfoil, where metal temperature is minimum, intergranular cracks up to 12.6 mils (0.32 mm) in depth were found at the surface of the cooling holes. Measurable oxidation attack was only one to two mils (0.025–0.050mm). Based on an approximate elastic-relaxation-local inelastic stress analysis, it was calculated that inelastic local strains of over one percent occur at the points of cracking. No cracking was observed in the more heavily oxidized, lower stressed, hotter holes. However, cracking occurred in a trailing edge tip cooling hole when weld repair of the tip squealer was attempted, due to embrittlement and grain boundary oxidation from service exposure. Temperature estimates suitable for life assessment purposes using oxidation measurements appears to be a possible technique that should be further developed and validated.
Proceedings Papers
Proc. ASME. GT1997, Volume 4: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award, V004T12A005, June 2–5, 1997
Paper No: 97-GT-168
Abstract
In this study, the microstructure of IN738LC turbine blades ground by two different vendors was examined. Turbine blades from a grinding vendor reporting the occasional appearance of “linear indications” were evaluated. The indications were found to be grain boundary cracks, some over 1 mm in depth, running perpendicular to the grinding direction. The cracked blades showed signs of surface melting which can be regarded as a prerequisite for grain boundary cracking in the grinding of IN738LC. Blades ground by a different vendor, not reporting grinding problems, were also examined and no surface melting was seen. No fundamental difference was seen in the as-cast microstructure between the blades from the two vendors. All the observations in this study thus indicate that the grinding cracks in the blades from the first vendor resulted from improper or uncontrolled grinding conditions.
Proceedings Papers
Phil S. Burkholder, Malcolm C. Thomas, Randy Helmink, Donald J. Frasier, Ken Harris, Jacqueline B. Wahl
Proc. ASME. GT1999, Volume 4: Manufacturing Materials and Metallurgy; Ceramics; Structures and Dynamics; Controls, Diagnostics and Instrumentation; Education; IGTI Scholar Award; General, V004T01A005, June 7–10, 1999
Paper No: 99-GT-379
Abstract
There is a need to introduce advanced turbine technology at reduced cost. SX superalloy vanes demonstrate excellent engine performance and durability benefits compared to their polycrystalline counterparts. However, their manufacturing cost can be prohibitive due to low casting and solution heat treatment yields due to rejectable grain defects. High purity (carbon and boron free), ultra high creep and fatigue strength SX alloys are limited to low angle boundaries (LABs) normally not exceeding 6° in critical airfoil locations. Carbon (C) and boron (B) containing SX superalloys (Ross, et al., 1996) can accommodate low angle boundaries in the 9°–12° range with an overall sacrifice in creep and fatigue properties. Aero engine vane segments with complex configurations, can result in not only LAB defects exceeding 9°–12° but also high angle grain boundary (HAB) defects ≥ 15° occurring during the SX solidification process. This is further excaberated by recrystallised grains occurring during solution heat treatment from residual casting stresses and associated strain. CM 186 LC ® is a hafnium (Hf) containing nickel-base superalloy developed for directionally solidified (DS) columnar grain turbine airfoils. SX casting experience — development and production — has shown the alloy can be readily cast into aero turbine multi-airfoil segments. Mechanical property and turbine engine testing show the alloy can accommodate grain boundaries at least up to 30° resulting in high SX casting yields. The SX vane components are either used as-cast or approximately 50% partial solutioned which avoid any recrystallisation (Rx) problems. Component costs can be < 50% of that of a conventional high purity SX alloy. Mechanical property, oxidation and coating performance characterisation studies on SX CM 186 LC (including DS test pieces) and turbine engine test and application experience show a 72°F (40°C) metal temperature capability improvement (thin wall) over DS MAR M 002 alloy.