0
Research Papers

Effect of Aluminized Coating on Combined Low and High Cycle Fatigue Life of Turbine Blade at Elevated Temperature

[+] Author and Article Information
Cao Chen

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
AVIC CAPDI Integration Equipment Co., Ltd.,
Beijing 102206, China

Xiaojun Yan

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
Collaborative Innovation Center
of Advanced Aero-Engine,
Beijing 100191, China;
National Key Laboratory of Science and
Technology on Aero-Engine
Aero-Thermodynamics,
Beijing 100191, China;
Beijing Key Laboratory of Aero-Engine
Structure and Strength,
Beijing 100191, China

Xiaoyong Zhang

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
Collaborative Innovation Center of
Advanced Aero-Engine,
Beijing 100191, China;
National Key Laboratory of Science and
Technology on Aero-Engine
Aero-Thermodynamics,
Beijing 100191, China;
Beijing Key Laboratory of Aero-Engine
Structure and Strength,
Beijing 100191, China
e-mail: zhangxy@buaa.edu.cn

Yingsong Zhang

School of Energy and Power Engineering,
Beihang University,
Beijing 100191, China;
Xiangyang Hangtai Power Machinery Factory,
Xiangyang 441002, Hubei, China

Min Gui, Min Tao

Xiangyang Hangtai Power Machinery Factory,
Xiangyang 441002, Hubei, China

1Corresponding author.

Manuscript received October 28, 2017; final manuscript received August 7, 2018; published online October 11, 2018. Assoc. Editor: Damian M. Vogt.

J. Eng. Gas Turbines Power 141(3), 031018 (Oct 11, 2018) (7 pages) Paper No: GTP-17-1585; doi: 10.1115/1.4041252 History: Received October 28, 2017; Revised August 07, 2018

Some cracks were detected on the fir-tree root of turbine blade in an in-service aero-engine, and the aluminized coating was considered to be the main cause of these cracks. To study the effect of aluminized coating on fatigue life of turbine blade, the combined low and high cycle fatigue (CCF) tests are carried out at elevated temperature on both aluminized and untreated turbine blades. Probability analysis of test data is conducted and the result indicates that the median life is decreased by 62.2% due to the effect of the aluminized coating. Further study on the mechanism of crack initiation and propagation has been conducted based on fractography and cross section morphology analysis by using scanning electron microscope (SEM), and the results indicate: (1) The aluminized coating consists of two layers, of which the inner layer is considered to contain the σ phase and it reduces the resistance to fatigue of blade. (2) Many cavities are found in the inner layer of aluminized coating, which lead to the initiation of cracks and result in the reduction of crack initiation life. (3) The marker band widths of aluminized and untreated blade are very close, which indicated the aluminized coating may have no effect on the crack propagation life of the blade.

FIGURES IN THIS ARTICLE
<>
Copyright © 2019 by ASME
Your Session has timed out. Please sign back in to continue.

References

Jedlinski, J. , and Borchardt, G. , 1991, “ On the Oxidation Mechanism of Alumina Formers,” Oxid. Met., 36(3–4), pp. 317–337. [CrossRef]
Rahmel, 1978, “Materials and Coatings to Resist High Temperature Corrosion,” Applied Science Pub, 126(126), pp. 1789–1813.
Kuenzly, J. D. , and Douglass, D. L. , 1974, “ The Oxidation Mechanism of Ni3Al Containing Yttrium,” Oxid. Met., 8(3), pp. 139–178. [CrossRef]
Daleo, J. A. , and Boone, D. H. , “ Failure Mechanisms of Coating Systems Applied to Advanced Turbine Components,” ASME Paper No. 97-GT-486.
Gleeson, B. , 2006, “ Thermal Barrier Coatings for Aeroengine Applications,” J. Propul. Power, 22(2), pp. 375–383. [CrossRef]
Patnaik, P. , and Immarigeon, J. , 1989, “ Protective Coatings for Aero Engine Hot Section Components,” Mater. Manuf. Process., 4(3), pp. 347–384. [CrossRef]
Taylor, H. S. , 1925, “ A Theory of the Catalytic Surface,” Proc. R. Soc. London. Ser. A, 108(745), pp. 105–111. [CrossRef]
Fromhold, A. T. , 1975, Theory of Metal Oxidation, American Elsevier Pub. Co., Amsterdam, The Netherlands.
Birks, N. , Meier, G. H. , and Pettit, F. S. , 2006, Introduction to the High Temperature Oxidation of Metals, Cambridge University Press, Cambridge, UK.
Godlewska, E. , Mitoraj, M. , and Morgiel, J. , 2009, “ Reaction and Diffusion Phenomena Upon Oxidation of a (γ+α2) TiAlNb Alloy in Air,” Mater. High Temp., 26(1), pp. 99–103. [CrossRef]
Niranatlumpong, P. , Ponton, C. B. , and Evans, H. E. , 2000, “ The Failure of Protective Oxides on Plasma-Sprayed NiCrAlY Overlay Coatings,” Oxid. Met., 53(3/4), pp. 241–258. [CrossRef]
Smialek, J. L. , and Lowell, C. E. , 1974, “ Effects of Diffusion on Aluminum Depletion and Degradation of NiAl Coatings,” J. Electrochem. Soc., 121(6), pp. 800–805. [CrossRef]
Vine, S. R. L. , 1978, “ Reaction Diffusion in the NiCrAl and CoCrAl Systems,” Metall. Mater. Trans. A, 9(9), pp. 1237–1250. [CrossRef]
Kuppusami, P. , and Murakami, H. , 2004, “ A Comparative Study of Cyclic Oxidized Ir Aluminide and Aluminized Nickel Base Single Crystal Superalloy,” Surf. Coat. Technol., 186(3), pp. 377–388. [CrossRef]
Hindam, H. M. , 1980, “ Growth and Microstructure of α-Al2O3 on Ni–Al Alloys: Internal Precipitation and Transition to External Scale,” J. Electrochem. Soc., 127(7), pp. 1622–1630. [CrossRef]
Hindam, H. , and Whittle, D. , 1983, “ High Temperature Internal Oxidation Behaviour of Dilute Ni-Al Alloys,” J. Mater. Sci., 18(5), pp. 1389–1404. [CrossRef]
Strutt, A. J. , and Vecchio, K. S. , 1999, “ Simultaneous Oxidation and Sigma-Phase Formation in a Stainless Steel,” Metall. Mater. Trans. A, 30(2), pp. 355–362. [CrossRef]
Firouzi, A. , and Shirvani, K. , 2010, “ The Structure and High Temperature Corrosion Performance of Medium-Thickness Aluminide Coatings on Nickel-Based Superalloy GTD-111,” Corros. Sci., 52(11), pp. 3579–3585. [CrossRef]
Rahmani, K. , and Nategh, S. , 2008, “ Influence of Aluminide Diffusion Coating on Low Cycle Fatigue Properties of René 80,” Mater. Sci. Eng. A, 486(1–2), pp. 686–695. [CrossRef]
Andersen, P. J. , Boone, D. H. , and Paskiet, G. F. , 1972, “ A Comparison of the Effect of Inward and Outward Diffusion Aluminide Coatings on the Fatigue Behavior of Nickel-Base Superalloys,” Oxid. Met., 4(2), pp. 113–119. [CrossRef]
Yan, X. J. , Sun, R. J. , Ying, D. , Liu, Z. N. , and Nie, J. X. , 2011, “ Experimental Study on Fatigue Curve Law of Turbine Blade Under Combined High and Low Cycle Loading,” Hangkong Dongli Xuebao/J. Aerosp. Power, 26(8), pp. 1824–1829.
Chen, X. , and Yan, X. , 2014, “ Combined Low and High Cycle Fatigue Tests on Full Scale Turbine Blades,” ASME Paper No. GT2014-26569.
Hu, D. , and Wang, R. , 2013, “ Combined Fatigue Experiments on Full Scale Turbine Components,” Aircr. Eng. Aerosp. Technol., 85(1), pp. 4–9. [CrossRef]
Hu, D. , Meng, F. , Liu, H. , Song, J. , and Wang, R. , 2016, “ Experimental Investigation of Fatigue Crack Growth Behavior of GH2036 under Combined High and Low Cycle Fatigue,” Int. J. Fatigue, 85, pp. 1–10. [CrossRef]
Wang, R. , Wei, J. , Hu, D. , Shen, X. , and Fan, J. , 2013, “ Investigation on Experimental Load Spectrum for High and Low Cycle Combined Fatigue Test,” Propul. Power Res., 2(4), pp. 235–242. [CrossRef]
Sun, R. J. , Yan, X. J. , and Nie, J. X. , 2012, “ Inverse Method for Estimating the Vibration Stress of Turbine Blades Based on Combined High-and-Low Cycle Fatigue Tests,” J. Aerosp. Power, 27(2), pp. 289–294.
Hou, N. X. , Wen, Z. X. , Yu, Q. M. , and Yue, Z. F. , 2009, “ Application of a Combined High and Low Cycle Fatigue Life Model on Life Prediction of SC Blade,” Int. J. Fatigue, 31(4), pp. 616–619. [CrossRef]
Zielińska, M. , Zagulayavorska, M. , Sieniawski, J. , and Filip, R. , 2013, “ Microstructure and Oxidation Resistance of an Aluminide Coating on the Nickel Based Superalloy Mar M247 Deposited by the CVD Aluminizing Process,” Arch. Metall. Mater., 58(3), pp. 697–701. [CrossRef]
Niu, J. , Zhang, L. W. , Pei, J. B. , and Zhang, F. Y. , 2006, “ Research on the Microstructure of Al and Al-Si Coatings on K4104 Nickel-Based Superalloy,” Cailiao Rechuli Xuebao/Trans. Mater. Heat Treat., 27(4), pp. 105–108.
Pei, J. B. , Zhang, L. W. , Niu, J. , and Zhang, Q. Z. , 2008, “ Microstructure and Formation Mechanism of Aluminized Coatings on Nickel-Based Superalloys,” Key Eng. Mater., 373–374, pp. 204–207. [CrossRef]
Kireev, V. B. , Kolyasnikova, N. V. , and Matyushenko, V. V. , 1989, “ Effect of Composition on the Formation of the Sigma-Phase in Nickel Alloys,” Met. Sci. Heat Treat., 31(12), pp. 892–895. [CrossRef]
Wangyao, P. , Pichaiwong, N. , Patama, V. , Chuankrerkkul, N. , and Hirunyagird, J. , 2014, “ Effects of Ni and Ni + Co Additions in P/M Stainless Steel 316 L on Sigma Phase and Oxide Formations After Long Term Heating,” Adv. Mater. Res., 894, pp. 227–233. [CrossRef]

Figures

Grahic Jump Location
Fig. 1

Cracks were found by fluorescence detection. The red arrows indicate the cracks in the fir-tree root of blade.

Grahic Jump Location
Fig. 2

Finite element model of blade. The aerodynamic force is applied as pressure on the blade airfoil. The normal displacement constraint and the pressure are applied on the fir-tree root.

Grahic Jump Location
Fig. 3

Stress distribution of blade under working condition using finite element method (Unit: MPa)

Grahic Jump Location
Fig. 4

The load spectrum of CCF test

Grahic Jump Location
Fig. 5

CCF test system incorporates a tensile testing machine (1), an electromagnetic exciter (2), a fixture (3), and a digital microscope (4)

Grahic Jump Location
Fig. 6

Transmission path of LCF load and HCF load. The red arrows show the transmission path of LCF load and the blue arrows show the transmission path of HCF load: 1—outer clamp, 2—electromagnetic exciter, 3—inner clamp, 4—blade, 5—induction coil, 6—rolling bearing, and 7—disk.

Grahic Jump Location
Fig. 7

Fractured blades in CCF tests, the numbers of the blade are shown in figure: (a) aluminized blades and (b) untreated baldes

Grahic Jump Location
Fig. 8

Distribution of fatigue life (HCF) of aluminized blades and untreated blades, the table on the top left shows the estimation distribution parameters and coefficients of fitting curves

Grahic Jump Location
Fig. 9

Macro fractures of the tested blades: (a) aluminized blade #6 and (b) untreated blade #12. Red arrows indicate the crack initiation sources.

Grahic Jump Location
Fig. 10

Microstructure of crack initiation sources: (a) No. 6 crack initiation source of aluminized blade #6, red arrows indicate directions of ridges, yellow arrows indicate cavities in the inner layer of aluminized coating and (b) No. 1 crack initiation source of aluminized blade #12, red arrow indicates the defect, blue arrows indicate the directions of ridges

Grahic Jump Location
Fig. 11

Microstructure and EDS of the aluminized coating: (a) microstructure of the aluminized coating in aluminized blade #6. The zone marked by red line is selected for EDS. (b) the result of EDS at zone A in (a). (c) the result of EDS at zone B in (a). The quantitative results of EDS are listed on the top right of the figure.

Grahic Jump Location
Fig. 12

Microstructures of the crack propagation area of (a) aluminized blade #6 and (b) untreated blade #12. The measurement results of marker bands are reported in the figure.

Tables

Errata

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In