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Guided by
Prof KN Pandey
MED MNNIT
Allahabad
Submitted by
Sudhanshu
Balodi
2015DN02
Turbine blade
Microstructures of Ni
superalloy
Strengthening Mechanism
strengthening mechanism used in
Ni superalloy are :
Solid solution strengthening
Cr,Mo,Al,Nb,Ti and others
Coherent precipitate hardening
Mostly due to Al and Ti
Ni3(Ti,Al),gamma prime
Investment Casting
Powder Metallurgy
Directional Solidification
Single crystal
Current Examples
SpaceX is using INCONEL alloy 718 for its new
Super Draco engine for the Dragon V2 crewcarrying space capsule.
INCONEL alloy X-750 was used for the F-1 rocket
engine used in the first stage of the Saturn V
booster.
GE uses Ceramic Matrix Composite for its Gas
turbine engines. Enters into service in 2016 for
Airbus A320neo and 2017 for the Boeing 737max.
Failure Mechanisms
Brief Overview
Failure Mechanism of blade
Thermomechanical Fatigue
Creep
Oxidation
Fatigue
Fatigue life estimation model
Stress based life estimation
Fatigue based life estimation
Strain based life estimation
Cumulative damage approach for life prediction of
turbine blade
Brief Overview
TMF has become more critical to the life of gas
turbine blades due to the use of improved blade
cooling technologies that enables higher gas
temperature there by improving turbine efficiency.
In recent cooling technologies steam cooling and
advanced air cooling is used which introduced
humidity into the turbine blade and play its role in
decreasing the life of blade.
Thermomechanical Fatigue
The two basic TMF cycle that are most often used
to assess lives under TMF conditions are
In-phase (IP) TMF (tensile strain and peak
temperature coinciding)
out-of-phase (OP) TMF (tensile strain and the
minimum temperature coinciding).
Fatigue
The time-independent crack growth mode (also known as
cycle-dependent crack growth, or fatigue crack growth)
depends on three main parameters [23], namely,
frequency, load ratio, and maximum load/temperature.
At higher frequencies transgranular failure occurs, as
fatigue
dominates,
while
at
lower
frequencies
creep/oxidation exert greater influence and intergranular
failure occurs.
Intergranular/Transgranular crack
propagation
Creep
Creepis the tendency of a solid material to
slowly move or deform permanently under the
influence of stresses. It occurs as a result of long
term exposure to high levels of stress that are
below the yield strength of the material. Creep is
more severe in materials that are subjected to
heat for long periods, and near the melting
point. Creep always increases with temperature.
Creep Crack
Growth
Creep crack growth is described as a phenomenon of
quasi-static growth of cracks in structural components at
elevated temperature under sustained load that is much
less than its critical value for fast crack propagation .
The creep strain rate tends to decrease with time in the
primary stage of creep, and to increase with time in the
tertiary stage.
The data are plotted in two ways: creep strain vs. time
and creep strain rate vs. creep strain the latter is
helpful since it allows periods of creep hardening to be
identified, during which the creep strain rate decreases
with increasing creep strain.
Rafting Regime
At high temperature the creep strain show a distinct
plateau before creep strain increase catastrophically.
There is a creep hardening effect at first before the
plateau during which creep strain do not varies strongly
with time.
At this high temperature the creep behavior is affected
by the degradation of the / microstructure.
In the rafting regime, the / microstructure degrades
rather quickly because thermally activated processes
are favoured strongly since the temperature is high.
Oxidation
Oxidation-induced crack growth is described as
the repeated formation of an oxide layer at the
crack tip and its rupture, exposing fresh metallic
material to the environment. Crack nucleation is
defined as the rupture of the first oxide layer
formed.
Type 1 growth
Initially oxide layer forms on the surface when
the oxide layer reaches the critical thickness the
oxide ruptures and crack nucleation has
occurred. Then a fresh metallic surface is
exposed to the environment which rapidly
oxidizes. When thickness of this oxide layer
Type 2 growth
The progression of growth is similar as that of type
1 growth in that the oxide ruptures when it reaches
to the critical thickness. However in type 2 growth
when oxide ruptures It scrap off some of the
material. This result in large surface area exposed
to the environment which cause wide spread of the
oxidation effect.
Type I growth is characterized by a "continuous
oxide layer. A "continuous" oxide layer results in
oxide intrusions with no visible stratification in the
oxide. This will be distinguished from Type II growth
which is characterized by "multilayer" or "stratified"
oxide growth.
Oxidation Failure
Oxidation failure
In particular, the degradation of either coated or
uncoated Ni-base superalloys caused by the oxidation
of a surface and its effect on surface crack initiation
and propagation behaviour will be discussed.
At the high temperature regime, the microstructure is
not stable: the precipitates coarsen rapidly,
especially under stress and, in the vicinity of free
surfaces (e.g notches), there is a depletion of the
precipitates due to surface oxidation . Both
mechanisms lead to a local softening of the material
which in turn reduces the local stresses
Fatigue
A metal subjected to repetitive or fluctuating load
will fail at a stress magnitude much lower than that
required for failure on a single application of load .
Fatigue due to cyclic load fluctuation, known as
mechanical fatigue and, will lead to crack initiation
and propagation which leads to fracture.
The mechanical fatigue can be
classified
into two types of fatigue
High Cycle Fatigue
Low Cycle Fatigue
Cumulative Damage
Approach
References
Andre Pineau , Stephen D. Antolovich,High temperature fatigue of nickel based
super alloys- a review with special emphasis on deformation mode and
oxidation,Elsevier Engineering failure analysis 26682697, (2009).
Kadioglu, Y. and Sehitoglu, H., "Modeling of thermo-mechanical fatigue damage
in coated alloys", Proceedings of the Symposium on thermo-mechanical Fatigue
Behavior of Materials, San Diego, CA, USA, ASTM,17-34, (1993).
Y. Kadioglu, and H. Sehitoglu, "Modeling of thermo-mechanical fatigue damage
in coated alloys" ASTM Special Technical Publication, no. 1186, 17-34, (1993).
A. Izquierdo, A review of suitable oxidation models for aero gas turbine engines,
Cranfield University, (2010).
Thank you