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research-article

The Influence of Thermal Transient Rates on Coated Turbine Parts Life Expectancy

[+] Author and Article Information
Alexander Staroselsky

United Technologies Research Center, East Hartford, CT, USA
starosav@utrc.utc.com

Thomas J. Martin

United Technologies Research Center, East Hartford, CT, USA
martintj@utrc.utc.com

Luke/B Borkowski

United Technologies Research Center, East Hartford, CT, USA
borkowlb@utrc.utc.com

1Corresponding author.

ASME doi:10.1115/1.4041110 History: Received June 26, 2018; Revised July 16, 2018

Abstract

During rapid engine throttling operations, turbine airfoils can experience very rapid heating and cooling, particularly at take-off conditions. These rapid transient events lead to the generation of high thermal gradients and non-uniform stress distributions through the thermal barrier coating, environmental barrier/bond coating and substrate. This in turn can lead to coating delamination, overheat of the substrate materials, creep and thermo-mechanical fatigue of the part. We present the process and computer modeling methodology for a physics-based prediction of deformation, damage, crack propagation and local failure modes in coated turbine airfoils and other parts operating at hot section turbine environment conditions as a function of engine operational regimes, with a particular emphasis on rapid transient events. The overall goal is to predict the effects and severity of the cooling and heating thermal rates on transient thermal mechanical fatigue life of coated hot parts (turbine airfoils, blade outer air seals and combustor liners). The computational analysis incorporates time-accurate, coupled aerothermodynamics with non-linear deformation thermal-structural finite element modeling and fracture mechanics modeling for high rate thermal transient events. Thermal barrier coating thermal failure and spallation are introduced by the use of interface fracture toughness and interface property evolution as well as dissipated energy rate. Applicability of the developed model is verified using experimental coupons and calibrated against burner rig test data for high flux thermal cycles. Our results show a decrease in TBC spall life due to high rate transient events.

United Technologies Corporation
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