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X-ray diffraction is used to measure residual stresses in nickel-based superalloys used in gas turbine engines. Residual stresses develop due to manufacturing processes like machining and can affect fatigue life. The document discusses using x-ray diffraction to measure residual stresses in Inconel 718 compressor blades to improve stress analysis for gas turbine design and performance. High rotational speeds in gas turbines produce substantial stresses, so reducing component stresses through analysis is important.

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47 views6 pages

Abstract

X-ray diffraction is used to measure residual stresses in nickel-based superalloys used in gas turbine engines. Residual stresses develop due to manufacturing processes like machining and can affect fatigue life. The document discusses using x-ray diffraction to measure residual stresses in Inconel 718 compressor blades to improve stress analysis for gas turbine design and performance. High rotational speeds in gas turbines produce substantial stresses, so reducing component stresses through analysis is important.

Uploaded by

nemidass
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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X-RAY DIFFRACTION TECHNIQUE

ABSTRACT
Residual stresses are locked up stresses in material and play an important role in determining properties such as strength, wear resistance, stress corrosion, cracking, fatigue etc. These stresses arise because of the continuity, elasticity of the medium and presence of a sub-surface plasticized zone within the material they are generated during various machining operations, forming operations, welding and heat treatments. They may also arise due to sudden loading conditions in service. They can also intentionally add into the materials by processes such as Shot penning and Glass penning. The nature of stresses may be compressive and tensile. They are accompanied by an offsetting tensile or compressive stress in sub-surface zones. The stresses are confined to a depth of about 500-600 microns maximum and for all practical purpose considered to be bi-axial. Normal machining operations are generally found to produce compressive stresses. However abusive machining operations such as those accompanying insufficient cooling result in tensile residual stresses. Heat treatments involving quenching from high temperature result in relative contraction of the surface layers compared to the core and may result in high magnitude of tensile residual stresses. Residual stresses can add or debit from the applied stresses. Compressive residual stresses debit from the applied stresses, inhibit crack initiation and slow down crack propagation rate thereby extending the fatigue life. Tensile residual stresses add to the applied stresses, promote crack initiation, enhance crack propagation rate and reduce fatigue life. Besides, other properties such as stress corrosion cracking and wear resistance are also affected either favorably or adversely in accordance with the nature of stresses.

Dept. of Mechanical Engg BMSECE

X-RAY DIFFRACTION TECHNIQUE


Residual stress can be measured by strain gauge and x-ray diffraction technique. The present work covers the stress determination in nickel base super alloy INCONEL 718 used in high temperature application in gas turbine engines using x-ray diffraction technique. VERY high rotational speeds necessitated by humongous stress thrust requirements of gas turbine engines necessarily lead to substantial stressing of the rotating components like compressor rotor blades and discs. high thrust to weight ratio a design feature that is inherent to the mission performance of gas turbine engines demand that the component stressing should mitigated with least material addition. These conflicting set of requirements often render comprehensive full filled stress analysis as a very critical phase of engine development. This dissertation work process a rapid experimental methodology for providing quick insight in to the surface stress distribution of the compressor blades.

Dept. of Mechanical Engg BMSECE

X-RAY DIFFRACTION TECHNIQUE

ACKNOWLEDGEMENT
For the successful completion of this project, quite a lot of people have extended their help and spared their precious time and immense patience. With great pleasure we wish to acknowledge the help of these individuals and the institutions. We wish to thank Sri. T. Mohan Rao, Director , Gas Turbine Research Establishment (GTRE) for providing us an excellent opportunity to participate in activities and processes those were not only new to us but also at the same time extremely challenging. We express our deep sense of gratitude to Dr.

U.CHANDRASHEKAR doing project.

(Additional

Director, SIMA GTRE), for

providing us an excellent opportunity to participate in their group for

We also thank sri. Anbazhagan, scC and Sri Damodar K Cheluvadi and Sri. Nagesh,ScB of MBSI for sharing their technical knowledge to carry out the project. We are forever indebted to all the members of NCT 7and MBSI, GTRE whose vast knowledge and knee interest has helped us in successfully completing this project, whose guidance was of immense help to us. We express our heartfelt thanks with a great pleasure to Dr.RAVISHANKAR DEEKSHEET, Principal, Dr.GURUPRASAD, HOD MECHANICAL, and our project guide K.VENKATA RAO, Asst. Professor BMSECE Bangalore for creating an ideal atmosphere for the positive development of an individual under his continuous guidance and able administration and encouraging us to carry out this project We would like to express our sincere thanks and gratitude to teaching and non-teaching staff, Dept of Mechanical Engineering, BMS Dept. of Mechanical Engg BMSECE

X-RAY DIFFRACTION TECHNIQUE


Evening College of Engineering. We also express our gratitude to our

beloved parents and everyone, who have directly or indirectly contributed towards the success of this report.

HISTORICAL BACKGROUND
With, the aero gas turbine engine development as the main charter of duties, GAS TURBINE RESEARCH CENTRE was started in 1959 at BRDAF station, Kanpur. In November 1961 it was shifted to Bangalore and renamed as GAS TURBINE RESEARCH ESTABLISHMENT (GTRE) Now, GTRE is a fully fledged R & D center with latest technical facilities for the design, development and testing of advanced gas turbine engines for combat aircraft. The establishment is presently engaged in the Kaveri Engine development programme for the Tejas.

Organization Details
GTRE is one of the pioneering research and development organizations under the Ministry of Defense, Government of India. The main charter of the establishment is to design and develop aero gas turbine engines for military applications, besides carrying out advanced research work in the area of aero gas turbine subsystems. In addition, the establishment is also responsible for establishing the requisite testing and prototype manufacturing facilities for components and full-scale engine development. The establishment has a string team of about 1250 technical personnel drawn from various facilities of science and engineering which include Aeronautics, Mechanical, and Electronics, Computer science, Material science and Applied Mathematics. A team of about 340 personnel who are involved in Administration, Management, Finance and Accounts supports these engineers and Scientists. Dept. of Mechanical Engg BMSECE

X-RAY DIFFRACTION TECHNIQUE


The Organization structure has been evolved based on the modules that constitute the engine. The major module groups that are involved in aero thermodynamic and Mechanical design are Compressor Combustion, Turbine, after burner and Exhaust system, Rotor support and internal flows, Heat transfer, Vibration stress and Wright Engineering groups. The Mechanical Engineering and analysis of the engine components are carried out by group of engineers specializing in CAD, FEM and experimental stress analysis. Engine control system group deals with design and development of digital control system. Measurement engineering system group deals with data acquisition and instrumentation of the engine on the test bed and also on various component test rigs. Quality assurance group deals with the measurement and dimensional analysis of the engine components manufactured both inside and outside the establishment. The engine performance and simulation studies are done by a separate group of specialists who develop and maintain software for the analysis of Engine test bed data. Prototype fabrication division takes care of manufacturing of various components of the engine using latest computational tools. The programme management office is responsible for monitoring the programs of the Kaveri engine projects. There are various support groups as Administration, Finance and Accounts, Computer, Material management, Technical coordination etc., which carry out the inherent administrative, material management and finance activities.

Departments in GTRE
Compressor group. After Burner group. Gearbox group Rotor dynamics group Materials Group Dept. of Mechanical Engg BMSECE

X-RAY DIFFRACTION TECHNIQUE


Mechanical Analysis and Structural integrity group X-ray diffraction method Photo elastic analysis Strain Gage laboratory Engine control system group Engine Testing Group Measurement engineering group Prototype Fabrication group Quality Assurance group Machine Shop Programme Management group Turbine group Combustor group Exhaust Nozzle group Computation Fluid Dynamics Group Assembly Hanger Technical information Center Engine Test facility Engine Testing Group

Dept. of Mechanical Engg BMSECE

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