..

' I 1716

NASA TP
c. 1

NASA Technical Paper 1716

. ' !

-~

.Effect of Hole Geome.try and Discharge Machining (EDM) on ,Airflow. Rates; Through' Small-Diameter Holes. in Turbine Blade. Material
, I
i -

'

."

"

. '

Steven A. 'Hippensteele a n d -Reeves P., Cochran .

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.,~

NOVEMBER- 1980

NASA

II

"

TECH LIBRARY KAFB, NY

NASA Technical Paper 1716

Effect of Hole Geometry and ElectricDischarge Machining (EDM) on Airflow Rates Through Small-Diameter Holes in Turbine Blade Material

Steven A. Hippensteele and Reeves P. Cochran

Lewis Research Center Cleveland, Ohio

National Aeronautics and Space Administration

Scientific and Technical Information Branch

1980

Summary
An experimental investigation was conducted to determine the effect on air flow rate of two design parameters, electrode diameter and hole angle, and two machine parameters, electrode current and electrode current-on time. Test specimens were prepared from a typical turbine blade material (IN-100) of a typical thickness (1.6 mm). Holes were electric discharge machined individually in rows of 14 holes each using solid brass electrodes. Electrode diameters were varied from 0.257 to 0.462 m m , and hole angles (angle between surface normal and centerline of the hole) were varied from 40" to 7 5 " . The ranges of electrode current and electrode current-on time usedwere from 20 to 40 amperes and from 3 to 19 percent, respectively. Time to E D M individual holes (burn time), hole diameters, air flow-rates, and air-flow-rate deviations were determined functions as the of four control parameters. A cursory metallurgical examination was made of the recast layer and microcracks on the hole surfaces. The results of the investigation showed a n exponential increase in average burn time with increasing hole length (a function of hole angle) and a linear decrease in overburn (difference between finished hole diameter and electrode diameter) with increasing electrode diameter. Average air flow rates perhole increased linearlywith the square ofthe electrode diameter (cross-sectional area)and with electrode current-on time, but changed little with changes in hole angle and electrode current.The average flow-rate deviation (from the mean flow rate for a given row of 14 holes) decreased with electrode diameter, increased with hole angle, and changed very little with electrode current and current on-time. The recast layer was less than 4 percent of the hole diameter, and the microcracks did not extend beyond the limits of the recast layer on the examined specimens.

Introduction
Film-cooled gas turbine vanes and blades often contain a multiplicity of small-diameter (as small as 0.25 mm) holes for ejecting cooling air onto surfaces exposed to thehot gas path. The most commonly used method for putting cooling holes in the

superalloy materials used for turbine components is electric discharge machining (EDM). Fabrication experience has shown that the size (diameter) of the EDM electrode or the hole is not a sufficient criterion for establishing the required cooling-air flow rates through the holes because of difficulties in measuring hole diameters accurately. Hole characteristics such as surface roughness, inlet and exit shapes, length, etc., may significantly affect the resulting hole flow rates. Since heat-transfer analyses of film-cooled components are based on hole cooling-air flow rates, a logical specification and inspection criterionfor theseholeswould be air flow rates. However, no published information exists on the quantityand uniformity of coolant flow through EDM holes; nor is there any known published information on practical tolerances for specifying deviations in flow rates through such holes. lnherent to the EDM process is the formation of a relatively rough surface where metal isremovedby deplating and the creation of a recast layer on this surface as the remaining metal resolidifies. Surface roughness retards airflow and must be controlled or compensated for with a largerhole diameter.The recastlayer is thesource of microcracks that can propagate into the base metal and can result in structural Therefore, failure. controlling the thickness ofthe recastlayer and the formation of microcracks within this layer are important considerations in the use of EDM for small-diameter cooling air holes. This report describes an experimental study at the NASA LewisResearch Center to determine under controlledconditionsthe effect oftwo design and two machine parameters on the air flow rates through small-diameter EDM holes. The controlled design parameters were electrode diameter and hole angle, and the controlled machine parameters were electrode current and electrode current-on time. The design parameters (electrode size and holeangle) obviously determine the nominal cross-sectional area and length, respectively, of the hole. The machine parameters (electrode current and electrode currenton time) affect the nature of the EDM hole surface. The study was conducted over ranges of electrode diameters from 0.257 to 0.462 mm, holes angles from 40" to 75",electrode current from 20 to 40 A, and electrode current-on times from 3 to 19 percent. A typical turbine blade material (IN-100)of a typical thickness (1.6mm) was used. The air flow rates were

measured for individual using holes roomtemperature air discharging to atmospheric pressure at aconstantpressure drop acrossthe holes. The results are presented as plots of average-hole flow rate and average-hole flow-rate deviation as functions of eachof the controlled parameters. Only acursorymetallurgicalexamination ofthe recast layer and its indigenous microcracks was performed.

Symbols
barometric pressure downstream of holes, kPa diameter, mm hole length, mm hole humber in row, 1 to 14 total pressure upstream of holes, 55.2 kPa above barometric pressure T absolute temperature, K t burn time, sec W flow rate per hole, mg/sec e hole angle measured between the surface normal and the hole centerline, deg Y isentropic exponent, 1.40 7 percent time that the electrode current is turned on A flow-rate deviation of the holes in a row, percent Subscripts av mean average in a row of 14 alike holes e electrode h finished hole rn measured condition n hole number in row, 1 to 14 s standarizedcondition(temperatureof 289.8 K and barometric pressure of 101.7 kPa)

B D L n P

per strip and a total of 62 rows, were prepared. All machining was done with solid brass electrodes. The diameters of the electrodes used in this study were measured within 0.00127 mm. Industry standards for these size electrodes allow *0.0127-mm tolerance on the diameter. The two design parameters investigated were electrode diameter and hole angle (the anglebetween the normal surface and the hole centerline). Electrode diameter of 0.257, 0.272, 0.361, and 0.462 mm and hole angles of 40, 60",and 75" were used. These values covered ranges of interest for typical the holes in film-cooled turbine blades and vanes. The machine two parameters investigated were electrode current and electrode current-on time. Currents of 20, 30, and 40 A and current-ontimes of 3, 6, 1 1 , and 19 percent were used. Therangeof current levels covered slow to fast burn rates; burn rates affect surface roughness and the development of the recast layer with its attendant rnicrocracks. The range of current-on permitted times an evaluation of the oil flushing effectiveness on burn rate surface and condition. Only the 3 percent current on time was used with all variations of each of other the control parameters. For the other current-on times, selected values ofother the parameters were used. EDM Equipment The EDM machine used in the preparation of test specimens for this experimental investigation had a powersupplythat was adapted for the drillingof small-diameter holes. Airflow Measuring System The systemused to measure the cooling-air flow rates through the small-diameter EDM film-cooling holes is shown in figure 1 ; this system is similar to and is based on experience from the one described in reference 1 . Pressurized air at about 860 kPa entered the measuring system throughacontrol valve and passed through and a filter a pair of pressure regulators which reduced the pressure to 206.8 kPa. The then air passed throughrotameter a a and throttling valve to the test strip holder. Air exited the test strip through one the EDM holes in one of the of test specimen rows; all other holesin the test strip were sealed with vinyl tape a during given measurement. The accuracy of the rotameter f1 was percent of the full-scale reading, the accuracy of the pressure gages was f0.3 kPa, and the accuracy of the temperature gages was *0.3 K. Accuracy of the airflow measuring system was f1.5 percent.

Apparatus
Test Specimens Test specimens were made vacuun-cast from IN-100 (nickel alloy)strips 1.6 mm thick, 4.7 cm long, and 3.5 cmwide. Identicalround holeswere electric dischargemachinedindividually into these strips to form specimensrows of 14 holes each. In each specimen row the 14 holes making up the row were machined with all four control parameters held constant. Eighteen strips., with a maximum of 5 rows
L

Hole angle--

-- - "-\

Barometric
nrxcttrn R

Test strip thickness, 1.6 mm--

""_

Temperature

. '\
\low

Test pressure (55.2 kPa abo

"Pressure regulators Figure 1. - Flow measuring apparatus with test strip holder.

Experimental Procedure
Measurement of Burn Time and Finished Hole Diameter During the machining of the holes, burn time (in seconds) was measured for individual holeswith a stop Subsequently, watch. hole diameter was measured using a set of round gage pins graduated in 0.0254-mm increments. The hole diameter was defined as the average of the diameter of the largest pin that would pass through a given hole and the smallestpin that would not pass through the hole. Accurate hole diameters arevery difficult to measure because thesurfacesoftheEDM holes are very irregular and gage pins are calibrated in large increments compared with the diameters. hole Because oftheinherent"overburn"inEDM,the hole diameter will always be larger than the diameter of the electrode used to make the hole. Measurement of Air Flow Rates Individual measurements of air flow rates through each of the EDM holes were made. All holes in the test strip except one were sealed with vinyl tape beforetesting.Then the strip was mounted in the specimen holder in the flow measuring system and

subjected to a constant pressure difference of 55.2 kPa between the pressure inside the holder and atmospheric (barometric) pressure. This value of constant pressure drop was chosen because experience has shown that the flow coefficients of the holes are less sensitive to pressure drop variations at this value (approximately half an atmosphere) than at other values. Temperature,pressure,and flow readings at the rotameter and temperature, internal pressure, and barometricpressure readings at the test specimen holder were recorded for flow through each individual hole.

Analytical Procedure
Standardization of Measured Flow Rates The measured airflowratesthroughtheEDM holes were standardized to correct for the effect of air density variations. The following equation comes from the standard, one dimensional, isentropic flow equations to adjust for differences in pressure ratio in reference 2:

(All symbols are defined in Symbols.) Using a standard temperature of 289.8 K, standard a barometricpressureof 101.7 kPa, and a standard upstream pressure of 156.9 kPa, this correction factor becomes:

Results and Discussion

The burn times, finished holes diameters, air flow rates,andflow-ratedeviations for small-diameter, EDM holes in 1.6-mm-thick IN-100 strips using solid brass electrodes are presented herein as functions of the two design parameters, electrode diameter and hole angle, and themachine two parameters, electrodecurrent and electrodecurrent-ontime. A brief discussion the of recast layer and the microcracks that resulted from the EDM process is also given.

All measured flow rates were multiplied by this correctionfactortoarriveatacommon basis for comparison.

Averaging of Standardized Flow Rates The standardized flow rates for the individual holes in each row of 14 holes were averaged to obtain a single value of flow rate to be used in correlations with the controlled parameters. This averaging was done using the following relationship.
n= 1 4

Average Burn Time and Average Finished Hole Diameter The average burn time (timein seconds to EDM an individual hole) for the experimental specimen rows are tabulated on table I. The analysis of variance for these data showed thatthesignificantinfluencing parameter was holelength. Because the test strip thickness in this investigation was constant, hole length was directly related to hole angle. Figure is a 2 plot of average the burn times for all 3-percent electrode current-on time data against hole length. A least square curve fit of these data is

C wuu - n=l -

Wn

14

Deviations of Standardized Flow Rates The variation offlow rate in the individual holes in each row of 14 holes was evaluated by determining an average deviation of the standardized flow rate for each row using the following relationship: The average burn time increased exponentially from 37 to 154 secas the holelength increased from 2.07 to 6.13 mm. The maximum variation from the curve fit was ~ t 2 4percent the over full range of control parameters. The relationship between electrodediameterand finishedholediameter is shown in figure 3. Each plotted represents point several measurements of measuredholediameter. Because the go,no-go pin measurementshole for diameter were very approximate, the hole diameters recorded for the two smallest electrodes are identical. A least squares curve fit of the average finished hole diameter for each of the four electrode diameters is

Statistical Analyses Statistical analyses (analysis of variance of factorial experiments, ref. 3) were made of the hole flow rate, average flow rate deviation, and burn time data. analytical This technique shows whether variations in testresultsthat aredueto planned changes in the control parameters can be distinguished from variations that are due to system errors (ref. 4). Where variations due to the control parameters distinguishable, are the data will be presented as functions of these parameters.
4

The maximum variation of the measured finished hole diameter from the curve was only 4.4 percent. fit This comparison is based on electrode diameters that were measured within 0.00127 mm. If industry standards of &0.0127 mm had been allowed,the variation would have been much greater.

TABLE I.

- EXPERIMENTAL DATA
Average
burn t h e , sec

ipecimer
row

Design parameters Electrode dlnmetera. mm

0.251

Kachine parametel Ilectrode current,

A
~ ~~~

Hole mgle. deg

40 40 40

:urren
~nUmf

mg/sec

mrcen
3

deviatlon, percent
3.81 5.41 2.48 4.50 4.74 5.83 4.31 6.16 6.41 2.29 3.57 4.44 3.48 6.43 7.58 4.54 3.09 0.R3 1.90 1.72 1.76 2.72 2.06 1.92 2.52 1.50 2.19 5.02 2.12 2.53 1.56 2.53 3.93 2.29 3.13 1.86 1.81 2.88 2.21 2.53 1.61 1.92 2.93 3.41 3.17 4.51 3.92 0.54 .16 .85 .84 .99 .90 .83 .41 1.26 1.31 1.20 1.w .Dl 3.35 2.05 26.283 26.712 24.910 25.313 26.283 25.464 26.850

54 55 56 51 58 59 60 61 62
_____

15

1
0.212

i
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20 30 40 20 30 30 30 40 20
~

1
3

48.14 41.23 28.21 54.43 41.21 52.00 53.67 56.01 180.38

" " "

0.356 27.531 24.601

1
0.356 28.198 26.901 29.786 28.047 29.055 29.131 27.316 28.035 40.546 42.008 41.R60 41.819 41.136 40.123 38.581 40.105 40.823 44.830 41.819 41.529 42.701 42.234 41.516 45.233 14.024 45.095 45.069 41.602 41.438 46.329 42.915 41.542 42.159 44.200 45.032 41.680 42.839 42.663 0.533 60.025 60.366 60.114 61.928 64.020 62.141 62.936 57.871 59.411 60.340 61.109 61.122 51.31'1 60.131 62.848

46 41 48 49 50 51 52 53
1

30 20 30

" " "

" " "

" " "

" " "

" " "

" " "

1
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I
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v
3

" " "

20
30

2 3 4
5

30
30

6 I 8 20 25 9 10 11 12 13 21 22 23 26 21 28 29 14 15 16 24 30 17 18 19
_____

40 20

30

6 11

I
6

29.93 35.01 33.50 36.19 36.01 53.86 51.36 64.36 63.51 31.21 0.86 67.29 61.64
" " " " " "

6
11 I9

1
40

20
30 40

10 19 3 3 3 6 11 3 3 3

53.71 48.29 54.57 66.29 47.83 44.17 43.15 60.36 58.11 63.29 96.57 15.43 155.80 158.93 125.36 42.86 42.57 44.01 39.51 28.29 31.86 29.14 51.64 47.36 46.93 49.64 56.21 146.92 135.62 123.80

31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 _____

0.462

40

15 15 15
~

30 40 20 30 30 40 20
30

40

"+o.00121 mm b * ~ . m ml ~ ~ ~ .

Current, A

Angle,

e.
deg 40

b
180

20

60

Figure 2.

- Average burn time as function of hole length.

55r
E
E

a l

C '

? Md I
.25

.30

.35

.0 4

.45

.50

Electrode diameter, De. mm Figure 3

- Finished hole diameter

as function of hole diameter.

It also can be seen from the figure that the overburn(defined as Dh -De), decreasedlinearly from 0.09 to 0.06mm (or from 35 percent to 13 percent) as the elettrode diameterincreasedfrom 0.257 to 0.462 mm.

Average Hole Flow Rate The average flow rate per hole as a function of electrode diameter squared is shown in figure 4 for the full ranges of hole angle and electrode current and for an electrode current-on time of 3 percent. A least-squares-curve fit of the averageof the flow rates for each value of electrode diameter squared is
W,, = 232.74 D2 e

+ 11.06

(7)

flow rate per hole Based on this curve fit, the average increased from 26.4 to 60.7 mg/sec, a 2.3-fold increase, as D2 increased from 0.066 to 0.213 mm2, a e 3.23-fold increase.However, if thecorresponding finished hole diameters from figure 3 are substituted for the electrode diameters, then the area ratio (or ratio of finished hole diameters squared) is 2.25. This ratio agrees closely with the ratio of the flow rates, as would be expected. The maximum variation from the curve fit of figure4 was ~ 5 . 8 mg/sec or +12.3 percent of the flow rate. As expected, the analysis of

variance confirmed that the flow rate per hole was a very strong function of electrode diameter. The average flow rate perhole as a function of hole angle is shown in figure 5 for the full ranges of electrode diametersand electrode currents and for an electrode current-on time of 3 percent. The lines in the figure connect the mean values of points having the same electrode diameter and electrode current at each hole angle. It can be seen from the figure that hole angle (or hole length) has very little effect on average flow rate per hole, which remained within +6.3 percent for the full range of hole angles when thesameelectrodediameter and electrodecurrent were used. The average flow rate per hole as a function of electrodecurrent is shown in figure6forthe full ranges of hole angles and electrode diametersand for an electrode current-on of time 3 percent. The electrode current had little effecton the average flow rate per hole;theflow rate remained within &7.5 percent for the full range of electrode currents when thesame hole angle and electrodediameter were used.The analysis ofvarianceconfirmedthatthe electrode current had little effect; it also showed that there was a verysmall effect of the interaction of electrode diameter and electrode current. This trend can be seen in figure 6 where the curves are not all parallel. The average flow rate perhole as a function of electrode current-on timeis shown in figure 7 for the full rangeofelectrodecurrents andfor electrode

Angle,

e.

deg

b
0

20
20
20

40
60

75
40
60

'0 30 O H ) 0 3 0

n4o
A
40

75
40

60
15
=

I
.05
.10

"

.I5 Electrode diameter squared. D ,:

'
.20

-Least-squares-cu ve fit: 1 Wav 232 74 De + 11.06

.25

A 4 0

mm2

Figure 4.

- Flow rate per hole as function

of electrode diameter squared.

70

rElectrode I

50

\3 30 30 0 0 30 2 1 4 0 A 40

rn

20 20

60 75
40 60

A
P L .272-.

40

75 40 60 75

'. .'

.257 20

{
40 50 Holeangle, e, deg 70
80

30

60

Figure 5. - Flow rate per hole as function of hole angle (measured between the surface normal and the hole centerline). Lines are mean of average f l o w rate per hole (same electrode diameter and current).

Electrode diameter, mrn - 0.462

{/

b
0

20 20 20

\3 30 0 3 0

0 3 0

A 4 0
A

.361

40 40

deg 40 60 75 40 60 75 40 60 75

e.

20 10 20

30
Electrode current, A

40
of average flow rate

Figure 6. - Flow rate per hole as function of electrode current. Lines are mean per hole (same electrode diameter and angle).

diameter./ Electrode mm

Current, A

Angle,

e,

deg

b [3
-WaV
=

20

60 40

- 0.462

0 . 4 7 5 ~+ 58.81

- --

0 3 0 60 A 4 0 60 Mean of average flow rate per hole (same electrode diameter,current,and angle). Least-squares-curve fit for the mean of average flow rate per hole (same electrode diameter).

-~~
~

J
4

8 12 Electrode current-on time, T percent .

- " 1 16 20

Figure 7. - Average flow rate per hole as function

of percent electrode current-on time.

Current, A

Angle,

e,

deg

40
60

75 40 60
75 40 60 15

.25

.30

.35 Electrodediameter,

.50 .40 De, mm

.45

Figure 8. - Average flow rate deviation (from mean among all holes in a row) as function of electrode diameter. Lines are least-squares-curves fits of mean of average flow rate deviation at same hole angles.

(a) Magnification, X50.

(b) Magnification, X250.

Figure 9. - Microphotographs of cross section of typical EDM hole in IN-100 t-naterial.

10

diameters of 0.361 and 0.462 mm and holeangles of 40" and 60".The solid lines in the figure connect the mean values ofpointshaving thesame electrode diameter, hole angle, and electrode current at each electrode current-on time. Least square curve fits of these mean values are

Recast Layer and Microcracks The scope of this experimental investigation did not include an in-depth study of the formation of a recast layer and microcracks that areinherent in the EDM process. However, some samples..of.-EDM holes in IN-100 specimens were subjected to metallographic inspection to determine the general nature factors. shows of these Figure 9 microphotographsof a sample.Fortheelectrode currents, electrode current-on times, electrode diameters, and hole angles used for these samples, the recast layer did not exceed 0.016 mm (4percent of theholediameter), andthemicrocracksdidnot extend beyond the limits of the recast layer. (Note: Some slight taper in an EDM hole is normal, but the apparent exaggerated taper of the hole in figure 9(a) is duetothe fact thatthe specimen was notcut exactly on the centerline of the hole.)

for an electrode diameter of 0.361 mm and

for an electrodediameterof 0.462 mm.For the smaller electrodeand a hole angle of 60, the average flow rate per hole, based on these fits, curve increased 14.2 percent for an increase in electrode current-on time from 3 to 19 percent. For the larger electrodediameter, aholeangleof 40", andan electrode current of 20 A, the average flow rate per hole increased 6.3 percent for an increase in currenton time from 3 to 1 1 percent. Average Hole Flow Rate Deviations The variation in flow rates through the 14 holes in each row (average flow-rate deviations the from mean flow rate for the row) were determined by using equation ( ) The analysis of variance showed 4. that the average flow-rate deviation affected was significantly by electrode diameter, slightly by hole angle (or hole length), and little by electrode current and current-on time. Therefore, data the were plotted as a function of the electrode diameter. This relationship is shown in figure 8 where all points are at an electrode current-on time of 3 percent. Least square curve fits of the data are for 40"hole angle, for 60" holeangle, for 75" hole angle,
Aav =6.35 - 12.33De

Concluding Remarks
On the basis of the results from this experimental investigation of air flow rates through small diameter EDM holes, it can be concluded that for the range of parameters tested flow rates are reproducible within acceptabletolerances andthat theeffectsof the controlparameters used (electrode diameter, hole angle,electrode current,and electrodecurrent-on time) can be evaluated accurately orare negligible. In this investigation the electrode diameters were measured within 0.00127 mm. If industry standards of &0.0127 mm had been allowed, the variation in flow rate would have been much greater. A l l of the holes in this experimental investigation were electricdischargemachinedindividually, and the average burn times presented are on an individuai hole basis. In a production effort,rows of holes with like diameters and angles would possibly be machinedsimultaneously. Therefore,therecorded average burn times per hole may not be meaningful for production estimates. However, these times are applicable to model making and do show that, from amanpower/machinetimestandpoint,individualhole electric discharge machining a feasible way to is produce test models.

(10)
(11)

Aav = 10.13-20.14De

Summary of Results

Theresults ofanexperimental investigation to It can be seen fromthe figure thattheaverageflow-determinethe effects oftwo design parameters rate deviationdecreasedlinearly with electrode(electrodediameter and holeangle) andtwomachine diameter and increased with hole angle. For the full parameters (electrode current and electrode currentrangeofparameterstested,themaximumaverageontime)ontheairflowand physical characteristics flow rate deviation was less than 7 6 percent. . of small-diameter that machined holeswere
11

individually into superalloy material by electrical discharge machining @DM) are summarized below. The ranges of the parameters tested were electrode diameter from 0.257 to 0.462 mm, hole angle from 40" to 75", electrode current from 20 to 40 A, and electrode current-on time from 3 to 19 percent. Over these ranges of the control parameters 1 . The average flow rate per hole was found a. to increase linearly with the square of the electrode diameter (by a factor of 2.3 for an 80 percent increase in diameter) b. to be affected little ( k 6 . 3 percent) by hole angle (related to hole length) c. to be affected little (&7.5 percent) by doubling the electrode current d. to increase linearly by 14.2 percent for a 6.3 times increase in electrode current-on time. 2. The average flow rate deviation (from the mean flow rate for a given row of 14 holes) was found a. to decrease linearly by a factor of about 3 as the electrode diameter increased by a factor of 1.8 b. to increase as the hole angle increased c. not to be affected significantly by electrode current and electrode current-on time d . to have maximum deviations of less than 7.6 percent for all tested values of the control parameters. 3 . The average burn time per increased hole exponentially (from 37 to 154 sec) with an increase in hole length from 2.07 to 6.13 mm.

4. The electrode overburn (difference between finished diameter hole and electrode diameter) decreasedlinearlyfrom 0.09 to 0.06 mm with an increase in electrode diameter from 0.257 to 0.462 mm . 5 . A cursory metallographic examination showed that the thickness of the recast layer was less than 4 percent of hole diameter and that the microcracks present did not extend beyond the limits the recast of layer.

Lewis Research Center, National Aeronautics and Space Administration, Cleveland, Ohio, April 14, 1980, 505-04.

References
1 . Hippensteele, Steven A.: Pressure-Loss and Flow Coefficients

Inside a Chordwise-Finned, Impingement, Convection, and

F l Air-Cooled Turbine Vane. NASA TM X-3028, 1974. im

2. Shapiro, Archer H.: The Dynamics and Thermodynamics of Compressible Fluid Flow. Vol. 1 . RonaldPress Company, 1953. 3. Hicks, Charles R.: Fundamental Concepts in Design the of Experiments Holt, Rinehartand Winston, 1964. 4. Davies, Owen L., ed.: The Design and Analysis of Industrial Experiments. Hafner Publishing Company, 1956.

'
~

1. Report No.

2 Government Accession No. .

3. Recipient's Catalog No.

4. Title and Subtitle

i
~

NASA TP-1716 EFFECT OF HOLE GEOMETRY AND ELECTRIC-DISCHARGE MACHWING (EDM) ON AIRFLOW RATES THROUGH SMALL-DIAMETERHOLES IN TURBINE BLADE MATERIAL
'

5. Report Date November 1980 6. Performing Organization Code

8. Performing Organization Report No.

7. Author(s)

Steven A. Hippensteele and Reeves P. Cochran

9. Performing Organization Name and Address

E-417
10. Work Unit No.

National Aeronautics and Space Administration Lewis Research Center Cleveland,Ohio 44135
12. Sponsoring AgencyNameandAddress

505-04
11. Contract or Grant No.

13. Type of Report and Period Covered

National Aeronautics and Space Administration Washington, D. 20546 C.

15. Supplementary Notes

Technical Paper
14. Sponsoring AgencyCode

16. Abstract

The effects of two design parameters, electrode diameter and hole angle, and two machine parameters, electrode current and current-on time, on air flow rates through small-diameter (0.257 to 0.462 mm) electric-discharge-machined (EDM) holes were measured. The holes were machined individually in rows of 14 each through 1.6-mm-thick IN- 100 strips. The data showed linear increase in air flow rate with increases in electrode cross-sectional area and current-on time and little change with changes in hole angle and electrode current. The average flow-rate deviation (from the mean flow rate for a given row) decreased linearly with electrode diameter and increased with hole angle. Burn time and finished hole diameter were also measured.

17. Key Words (Suggested

by Author(s))

18. Distribution Statement

Gas turbine engines; Turbine cooling; Fabrication; Film cooling; Electric discharge machining (EDM) 19. Security Classif. (of this report)

Unclassified unlimited STAR Category 07

20. Security Classif. (of this page)

21. No. of Pages

22. Price'

Unclassified

Unclassified

14
22161

A02
NASA-Langley, 1980

* F o r s a l e by the National Technical Information Service, Springfield, Virginia

fl