Failure Analysis of Gas Turbine Blades

222 Microsc Microanal 11(Suppl 2), 2005
DOI: 10.1017/S1431927605509292 Copyright 2005 Microscopy Society of America
Failure Analysis of Gas Turbine Blades
Rybnikov A.I.*, Getsov L.B.*, Leontiev S.A.**
* Polzunov Central Boiler and Turbine Institute (NPO CBTI), Saint-Petersburg, Russia
** Turbine-Building Production Association "LMZ", Saint-Petersburg, Russia
Different failures of blades made from superalloys may be observed during gas turbine plant
testing and operation. The cause of these failures is usually identified both by metallographic
methods (microstructural studies, fractography, X-ray crystal analyses), bench and laboratory
strength tests, and by strength calculation methods, including non-conventional methods.
Long-term gas turbine operation leads to the structural degradation of superalloy blades - there is
a change in a number, shape and size of γ'-phase particles and in carbide amounts, distribution
and composition. The formation of close-packed topological phases (σ, µ, λ-phases) can also be
observed. In a number of cases, the structural degradation results in a significant change in the
mechanical properties, which can cause blade failures.
The present paper deals with several investigations into the causes of typical blade failures during
long-term service.
Static stress failure of gas turbine blades made of superalloys. The industrial production of
blades by different manufacturers may involve process violations causing a displacement of the
mass center and, as a consequence, the static failure of blades at a fairly high carrying capacity
strength margin. Such blade failures were observed in aircraft, marine and stationary gas turbine
plants. Thus, 13 cases of rotor blade failures were discovered in a generating gas turbine plant
after operation for 1000 to 6000 h. The fractographic study revealed a static cracking mechanism
initiated at blade edges. Blade strength calculations were carried out by the finite element method
with regard to creep under the conditions of centrifugal forces and mass center displacement. It
was determined that, due to the stress increase at edges and the difficulties associated with stress
redistribution during creep, the stresses can reach the material long-term strength values
corresponding to rupture life.
Another cause of static stress failure of blades is blade overheating related to the departures from
normal operating conditions. Such failures are detected by metallographic methods based on
metal structural variations throughout the entire blade section or in its separate regions as well as
on the formation of thick de-alloyed surface layers. Thus, cracks on ZhS6K-alloy guide blade
edges were discovered after GT adjustment testing for 103 h. with 57 start-ups. The
metallographic study revealed γ'-phase size growth, which suggests that the operating
temperature of metal had risen to about 10500C (instead of the normal 8500C operating
condition). The analysis showed that this temperature elevation could be caused by the disruption
of cooling conditions in the channel (because of the non-removed ceramic rod, casting residues,
etc.). The elevated metal temperature resulted in a drastic deterioration of mechanical properties
and, above all, in reduced metal fatigue resistance that caused cracking.
Thermal fatigue cracking of rotor and guide blades. Thermal fatigue cracks are the
characteristic type of edge failures in gas turbine cooled blades, including those manufactured
from single-crystal and directional-solidified alloys. In long-term operation, such cracks also
form on blades made from wrought high-temperature alloys. Based on the metallographic studies
Microsc Microanal 11(Suppl 2), 2005 223
of micro-crack propagation in wrought alloys at elevated temperatures, a diagram has been

developed in order to predict a type of alloy rupture depending on the temperature and frequency
of cyclic loading. The diagram allows diagnostics to be made of blade damage detected in
operation.
Thermal fatigue cracking of rotor and guide blade coatings. Coating cracking is induced by a
local corrosion failure of blade base metal under the coating. A method for testing small-size
coating specimens has been developed. The method makes it possible to observe strain relief
characteristics during testing and to study the mechanisms of crack initiation and propagation in a
coating up to specimen failure. A series of thermal fatigue tests was performed using different
superalloy specimens with different coatings. The mechanisms of micro-crack initiation and
suppression in multi-layer coatings have been determined.
Corrosion and corrosion fatigue cracking of rotor and guide blades. High-temperature sulfide-
oxide corrosion and high-temperature alloy surface de-alloying processes have been investigated
by blade surface metallography (X-ray, EDS spectrum analysis). It has been found that after
operation for 100000 h., the uncoated rotor blades made from wrought alloy EI893 experience a
decrease in chromium content in a layer up to 100 µm thick.
The analysis of surface layer composition in the region of cracks in blades made from high-
temperature alloys EI929, ZMI-3 and CNK-7 after operation for 25000 to 35000 h. revealed a
local increase in sulfur content related to sulfide-oxide corrosion attack.
The long-term corrosion and de-alloying effects on material and fatigue strength characteristics
have been analyzed. Thus, it has been found that corrosion cracking processes develop from
blade metal surface exposure to the action of fuel combustion products containing sulfur-rich
compounds.
High-temperature alloy and protective coating corrosion life was estimated and the results were
compared to the experimental data obtained during blade inspection after long-term operation.
The agreement between the results was found to be satisfactory.

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222 Microsc Microanal 11(Suppl 2), 2005

DOI: 10.1017/S1431927605509292 Copyright 2005 Microscopy Society of America

Failure Analysis of Gas Turbine Blades

Rybnikov A.I., Getsov L.B., Leontiev S.A.**

of micro-crack propagation in wrought alloys at elevated temperatures, a diagram has been

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