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TECHNICAL PAPERS: Gas Turbines: Structures and Dynamics

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

[+] Author and Article Information
Paul S. Prevéy

Lambda Research, 5521 Fair Lane, Cincinnati, OH 45227pprevey@lambda-research.com

Ravi A. Ravindranath

NAVAIR, 22195 Elmer Road, Building 106, Room 202-G, Patuxent River, MD 10670-1534ravindranara@navair.navy.mil

Michael Shepard

Wright Patterson AFB, 2230 Tenth Street, Ste. 1, Wright Patterson AFB, OH 45433-7817michael.Shepard@wpafb.af.mil

Timothy Gabb

NASA Glenn Research Center, 21000 Brookpark Road, Building 49, Room 231, Cleveland, OH 44135-3191 timothy.gabb@lerc.nasa.gov

J. Eng. Gas Turbines Power 128(4), 865-872 (Sep 18, 2006) (8 pages) doi:10.1115/1.1807414 History: Received October 01, 2002; Revised March 01, 2003; Online September 18, 2006
Copyright © 2006 by ASME
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References

U.S. Patents 5,826,453 (October 1998), 6,415,486 B1 (Jul. 2002) other US and foreign patents pending.
2002, “Low Plasticity Burnishing,” NASA Tech Briefs, Aug., 50 p.
Hogan, B., ed., 2001, “Longer Life With Low-Plasticity Burnishing,” Manufacturing Engineering, SME, pp. 34–38.
Gabb, T., Telesman, J., Kantzos, P., and Prevéy, P., 2002, “Surface Enhancement of Metallic Materials,” Advanced Materials & Processes, ASM, ed., Peg Hunt, Jan., pp. 69–72.
Prevéy, P., 2000, “The Effect of Cold Work on the Thermal Stability of Residual Compression in Surface Enhanced IN718,” Proc. 20th ASM Materials Solutions Conf., St. Louis, MO, Oct. 10–12.
Prevéy, P. et al., 2000, “FOD Resistance and Fatigue Crack Arrest in Low Plasticity Burnished IN718,” Proc. 5th National HCF Conf.
Prevéy, P. et al., 2001, “The Effect of Low Plasticity Burnishing on the HCF Performance and FOD Resistance of Ti-6Al-4V,” Proc. 6th Natl. Turbine Engine HCF Conf., Jacksonville, FL, March 5–8.
Belozerov,  V. V., Makhatilova,  A. I., Turovskii,  M. L., and Shifrin,  I. M., 1986, “Increasing the Fatigue Resistance of High-Strength Steel Using Bulk and Surface Treatments,” Met. Sci. Heat Treat.,28(7-8), pp. 565–569.
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Figures

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(a) 17-4 PH compressor blade being processed on the leading edge (LE) with an LPB caliper tool to improve FOD tolerance; (b) Ti-6-4 fan blade LPB processed along the lower LE. The hole near tip was made for HCF testing in cantilever bending (see Fig. 8).
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Residual stress and cold work depth profiles for IN718 before and after exposure to service temperature of 525 and 600°C for 100 h
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Thermal relaxation of shot peened (8 A, 400%) and LPB processed Ti-6Al-4V after 795°F (425°C) for 10 h
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High cycle fatigue performance of shot peened (8 A, 400%) and LPB processed thick section IN718 after 100 h, exposures at 525 and 600°C
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HCF tolerance of dull and sharp FOD after elevated temperature exposure simulating engine environments for shot peened (8 A, 400%) and low plasticity burnished (LPB) thick section IN 718
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HCF performance of thick section Ti-6-4 after SP and LPB surface treatments with and without the presence of a 250 μm (0.01 in.) FOD after exposure to service temperatures
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Photograph showing the cantilever-loading fixture for fatigue testing of the first stage fan blade. Note the LPB patch along the (upper) leading edge of the blade.
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Effect of LPB in mitigating HCF and FOD damage in Ti-6-4 fan blades
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Effect of LPB in mitigating HCF and FOD damage in a Ti-6-4 low pressure vane (LPV)
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HCF performance of thick-section 17-4 PH stainless steel with 0.25 mm (0.010 in.) FOD for base line, shot peened and LPB surfaces
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Corrosion fatigue performance of Custom 450 stainless steel with FOD in acidic salt solution and FOD from 0.25 mm (0.010 in.) to 0.76 mm (0.030 in.)
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Photograph of the fretting fixture showing the top two fretting rods clamped onto the top surface of the thick section HCF specimen
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Ti-6Al-4V fretting fatigue data for shot peened and LPB surface treatments

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