压气机转子叶片掉块断裂分析

某型发动机外场服役中多次出现压气机转子叶片叶尖掉块断裂故障,通过掉块叶片表面形貌观察、断口分析、硬度检测、金相检验、多起失效件的类比分析以及叶片振动模态分析,对叶片掉块断裂原因进行了分析。结果表明:所有压气机转子叶片掉块断裂模式相同,均属振动疲劳断裂掉块;叶片在发动机工作转速范围内存在高阶复合振动点,引起叶片共振是导致其振动疲劳断裂掉块的主要原因;叶片与机匣摩擦导致叶尖局部过烧或形成摩擦热应力裂纹促进了疲劳裂纹的萌生。最后针对叶片掉块断裂原因提出了相应的解决措施。     

LY6铝合金的局部腐蚀行为研究

探讨LY6合金的局部腐蚀行为对扩大其应用范围意义重大,采用加速腐蚀试验和微观腐蚀形貌观察等方法,研究了经自然时效处理的LY6铝合金在含Cl-的典型环境中的点蚀、晶间腐蚀、应力腐蚀断裂和剥蚀等局部腐蚀行为,并讨论了它们的机理和相互关系.在试验环境下,LY6铝合金对点蚀、晶间腐蚀、剥蚀和应力腐蚀断裂都存在敏感性,合金中S相(Al2CuMg)、θ相(CuAl2)及MnAl6等第二相的存在是发生上述局部腐蚀的根本原因.研究表明,合金的剥蚀是一个从点蚀发展到晶间腐蚀,然后在应力协同作用下发生破坏的过程.恒载荷应力腐蚀拉伸法和断口形貌观察发现,LY6铝合金应力腐蚀断裂是由于阳极溶解作用的结果.     

超临界机组汽轮机低压缸叶片腐蚀案例及原因分析

超临界机组大修检查普遍发现汽轮机低压缸叶片存在点蚀现象.为了分析低压缸叶片点蚀的产生原因,采用扫描电镜、能谱仪对腐蚀产物进行了分析,采用离子色谱仪对机组水汽进行了检测.结果 表明:水汽中CO2含量很少,对叶片点蚀的影响不大;点蚀主要原因是精处理混床运行终点控制不当,造成水汽中氯离子含量偏高所致.控制好精处理混床运行终点,可以有效避免超临界机组汽轮机低压缸叶片的点蚀问题.     

节流阀阀套断裂失效分析

国外某气田单井的井口节流阀阀套在运行10d(天)左右后便发生了断裂失效。为了研究阀套的失效原因,对其宏观形貌、化学成分、显微组织、硬度和断口形貌等方面进行了分析。结果表明:阀套主要呈脆性断裂特征,表现形式为沿晶断裂,断裂与环向应力和轴向应力相关;裂纹从阀套外表面的点蚀坑底部萌生,沿壁厚方向扩展,阀套在受到较大的环向应力时发生应力腐蚀开裂。     

6061铝合金在模拟工业-海洋大气环境下的腐蚀研究

通过紫外辐射老化试验和周期浸润试验,利用腐蚀表面和截面形貌分析、力学性能测试及拉伸断口扫描分析等,研究了6061铝合金在模拟工业-海洋大气环境下的腐蚀行为及机理。腐蚀形貌观察发现,6061铝合金在该环境下的腐蚀由点蚀引起并扩展,同时,试样发生沿晶腐蚀,8个周期后沿晶腐蚀裂纹扩展深度达80μm。模拟工业-海洋大气环境中的硫化物不仅对试样表面的点蚀产生很大影响,而且硫酸根离子会随着腐蚀介质深入晶界,加速沿晶腐蚀。力学性能分析表明,在该环境下腐蚀8个周期后,试样的延伸率大幅下降,下降率达26%,断裂机理发生改变,点蚀和沿晶腐蚀导致6061铝合金从韧性断裂转变为解理脆性断裂。     

饱和CO2溶液中Cl-浓度对马氏体不锈钢应力腐蚀敏感性的影响

为了明确Cl-浓度的变化对超级13Cr马氏体不锈钢耐蚀性能的影响规律,利用电化学动电位测试技术对比分析了Cl-浓度对超级13Cr腐蚀电位的影响关系;采用慢应变速率拉伸(SSRT)应力腐蚀开裂(SCC)试验方法和应力-应变曲线(σ-ε)、扫描电镜(SEM)等分析手段,研究了饱和CO2环境下在一定慢应变速率条件下Cl-浓度的变化对超级13Cr马氏体不锈钢的抗拉强度、延伸率、应力腐蚀敏感指数(ISSRT)的影响,并结合断口形貌分析了材料的断裂特征.结果 表明:在Cl-浓度≤60 g/L的饱和CO2溶液中,超级13Cr相对于空气中强韧性变化不大,属于韧性断裂模式;随着Cl-浓度的增大,材料的断裂寿命和伸长率均逐渐降低;材料断裂模式由韧性断裂逐渐转变为韧性-脆性混合断裂模式;当Cl-浓度增大到90 g/L时,断口侧面开始出现二次裂纹;当Cl-浓度≥120 g/L时,材料点蚀电位明显降低,点蚀敏感性增大,同时断口侧面出现点蚀现象,进一步促进了应力腐蚀开裂.     

几种超级不锈钢在模拟烟气脱硫环境中的点蚀行为

目前,针对904L,254s Mo和2507等几种主要备选超级不锈钢在烟气脱硫环境中的耐点蚀性能缺乏系统研究。在温度分别为20、40、70℃的死亡绿液溶液中,利用循环伏安曲线和扫描电镜(SEM)法,对316不锈钢和超级不锈钢904L、254s Mo及2507的极化行为和点蚀形貌进行了研究。结果表明:在该环境中,升高温度可降低4种不锈钢表面钝化膜稳定性并提高其点蚀敏感性;在不同温度环境下,316不锈钢均有严重的点蚀现象发生,而254s Mo和2507不锈钢表面均无明显点蚀迹象;在20℃时,904L不锈钢表面无明显点蚀迹象,40℃时,其表面出现典型的点蚀形貌,但点蚀坑尺寸较小,在70℃的高温下,其点蚀坑尺寸明显增大,点蚀损伤严重;254s Mo和2507均适合作烟气脱硫设备材料,而316、904L在该环境中需谨慎使用。     

某发动机一级涡轮叶片断裂分析

以某发动机涡轮一级事故叶片为研究对象，对断裂叶片进行了宏、微观形貌观察，硬度测试以及断口成分检查，分析了叶片裂纹的产生与发展过程，探讨了叶片断裂失效的原因。结果表明，叶片断裂模式为机械疲劳断裂。提出了预防措施。     

溶解氧对碳锰钢点蚀电位测定的影响

选择常用的碳素船体钢和锰系船体钢各一种,在除氧及不除氧的3%NaC l溶液中进行了极化试验,测定了钢的点蚀电位,并利用电子探针分析了腐蚀形貌。结果表明,钢样在除氧溶液中的阳极极化是典型的钝化-点蚀过程;在相同的电位区间,钢样在不除氧的溶液中的表观极化行为与前者截然不同,但是钢样自身的极化过程仍是钝化-点蚀过程,点蚀仍是由钢中的夹杂物诱发,所测点蚀电位值比溶液除氧条件下的结果更正;在有溶解氧条件下测得的点蚀电位同样可以比较不同钢之间的点蚀诱发敏感性,其结果更方便、准确。     

涡扇发动机二级转子叶片超温断裂分析

运用光学显微镜、扫描电子显微镜、电子探针微束分析仪对断裂叶片表面进行了宏观形貌、叶片断口宏观、微观形貌及显微组织分析,推断出叶片使用时不同部位所承受的温度范围,并对断裂原因进行了探讨.结果表明:启动超温致使叶片γ′相回溶甚至过烧至初熔状态,局部枝晶间和晶界出现明显液化现象,叶片前缘和后缘过烧程度严重,该区承受的温度达到...     

Fatigue crack growth simulation in a first stage of compressor blade

A first-stage rotary compressor blade of a Model GE-F6 gas turbine failed due to vibration in early March 2008. Initial investigations showed that pitting on the pressure side of the blade caused micro cracks, leading to larger cracks due to high cycle fatigue. To assess this failure, a series of experimental, numerical, and analytical analyses were conducted. Fractography of the fractured surface of the blade indicated that two semi-elliptical cracks incorporated and formed a single crack. In this study, static and dynamic stress analyses were performed in Abaqus software. Moreover, fracture mechanics criterion was accomplished to simulate fatigue crack growth. This was carried out using a fracture analysis code for 3-dimensional problems (Franc3D) in two states. Firstly, stress intensity factors (SIFs) for one semi-elliptical surface crack and then SIFs for two semi-elliptical surface cracks were taken into account. Finally, the Paris and Forman–Newman–De Koning models were used to predict fatigue life. Since stress level and crack shape in both conditions are the same and the SIF at the crack tip reaches the fracture toughness of the blade, SIFs results indicate that insertion of a second crack has no effect on the final SIF, however, the second crack facilitates the process of reaching the critical length. So, fatigue life in two-crack condition is less than in the one-crack state.     

汽轮机低压叶片断裂原因分析

针对国产300MW汽轮机低压缸扭叶片发生断裂失效事故进行研究分析;通过对扭叶片有限元计算、叶片振型模态实测,分析该叶片各阶自振频率,其计算结果和模态实测值基本吻合,为事故分析提供理论依据;对叶片材质元素成分测试,并着重对叶片实际运行工况及承受的各种可能的激振力分析,探求导致该级扭叶片疲劳断裂的真实原因,为同类型机组的安全、可靠运行提供一种借鉴作用和分析方法.     

Analysis of surface quality of multi-film cooling holes in nickel-based single crystal superalloy

The effect of the surface quality of multi-film cooling holes processed by laser drilling (LD) and electrical discharge machining (EDM) on the mechanical properties of blades have been studied. The physical features of the cooling holes, including the diameter, conicity and shape of the holes, are measured by optical microscopy, demonstrating that the EDM process is not as accurate as the LD process. Meanwhile, metallurgical characteristics, including the recast layer, heat affected zone and micro-cracking within the surface layer, are analysed by scanning electron microscopy, demonstrating that the radial crack generated in the LD process is more dangerous than the circumferential cracks generated in the EDM process. Using finite element analysis (FEA), the single crystal superalloy specimens with multi-film holes are simulated based on the crystal plasticity theory, showing that a significant increase of the stress gradient is observed in a real hole model than in an ideal circular hole model, which means that a shape simplification in the blade design will reduce the reliability of the blade. Based on the findings above, the influence of the surface quality of holes is investigated to obtain the possible damages to nickel single crystal turbine blades.     

Failure analysis of a second stage blade in a gas turbine engine

The failure of a second stage blade in a gas turbine was investigated by metallurgical and mechanical examinations of the failed blade. The blade was made of a nickel-base alloy Inconel 738LC. The turbine engine has been in service for about 73,500 h before the blade failure at 5:50 PM on 14 August 2004. Due to the blade failure, the turbine engine was damaged severely. The investigation was started with a thorough visual inspection of the turbine and the blades surfaces, followed by the fractography of the fracture surfaces, microstructural investigations, chemical analysis and hardness measurement.

The observation showed that a serious pitting was occurred on the blade surfaces and there were evidences of fatigue marks in the fracture surface. The microstructural changes were not critical. It was found that the crack initiated by the hot corrosion from the leading edge and propagated by fatigue and finally, as a result of the reduction in cross-section area, fracture was completed.

An analytical calculation parallel to the finite element method was utilized to determine the static stresses due to huge centrifugal force. The dynamic characteristics of the turbine blade were evaluated by the finite element modal and harmonic analyses. Finally according to the log sheet records and by using a Campbell diagram there was a good agreement between the failure signs and FEM results which showed the broken blade has been resonated by the third vibrational mode occasionally before the failure occurred.     

Surface Degradation and Cracking in Combustion Turbine Blade Cooling Passages

The depth of internal oxidation and nitridation from the surface of the 16 cooling holes in a first-stage turbine blade was measured by optical microscopy after 32,000 hours of service. Maximum depth of penetration was 15.5 mils (0.4 mm) at the trailing edge hole. An effort was made to predict hole surface metal temperatures based on these measurements using the Arrhenius relationship between time and temperature with depth of oxidation assumed to be parabolic with time. Good correlations were obtained between the finite element analysis results and the predictions. In the thickest part of the airfoil, where metal temperature is minimum, intergranular cracks up to 1.2.6 mils (0.32 mm∥ in depth were found at the surface of the cooling holes. Measurable attack was only one to two mils (0.025-0.050 mm). Based on an approximate elastic-relaxation-local inelastic stress analysis, it was calculated that inelastic local strains of over one percent occur at the points of cracking. No cracking was observed in the hotter holes, but cracking did occur in a trailing edge tip cooling hole when weld repair of the tip squealer was attempted indicating that embrittlement had occurred from the environmental attack.     

Failure of a low pressure turbine rotor blade of an aeroengine

During a test run of an aeroengine, a low-pressure turbine rotor blade had failed. The turbine blades were made of Ni-base superalloy of CM 247 LC grade and fabricated by DS investment casting. The blades were coated with platinum aluminide. Investigation revealed that the blade had failed by fatigue. It was concluded that the coating on the blade had developed cracks due to excessive bending/vibration, which in turn propagated by fatigue leading to the failure.     

镍基单晶合金涡轮叶片开裂原因

某发动机高压涡轮叶片为镍基单晶合金叶片,在室温下进行振动疲劳试验后发现叶片开裂,通过宏观观察、金相检验和扫描电镜分析等方法对叶片开裂的原因进行了分析。结果表明:进气边叶根和榫头伸根的开裂形式均为疲劳开裂;进气边叶根气膜孔内壁存在多处小缺口及榫头伸根亚表面存在疏松缺陷,这些缺陷部位容易形成裂纹源,促进了裂纹的萌生,裂纹扩展后最终导致开裂失效。     

Failure analysis of an un-cooled turbine blade in an aero gas turbine engine

Failure of an un-cooled turbine blade in an aero gas turbine engine is analyzed to determine its root cause. The operational condition of the engine was studied and metallurgical investigations are carried out on the fractured blade. The failure has originated from the leading edge and has propagated towards the trailing edge. Thermal cracks due to surface oxidation leading to fatigue were found to be the cause of the blade failure. Operation at elevated temperatures due to malfunction of sensors in the engine control system was found responsible for initiating the thermal cracks.     

气膜孔分布对DD6单晶高温合金高周疲劳断裂行为的影响

利用带不同电液束加工气膜孔分布的DD6单晶气冷叶片模拟试样,研究其在常温下的高周疲劳性能,并对试样断口及断口侧面形貌进行宏观与微观观察。结果表明:在相同的实验条件下,气膜孔的存在对试样高周疲劳寿命的影响较大,无孔试样的平均寿命约为带3排孔试样的4倍,但是气膜孔布局对疲劳寿命的影响相对较小。通过断口宏观与微观观察发现,无孔试样呈线源特征,而1~3排孔试样裂纹均从气膜孔附近起源,呈多源特征。根据断口和晶体学理论推测,对于无孔、1排孔和多排孔试样的中间部位,裂纹沿{001}滑移面扩展;而对于多排孔试样的上下2排孔孔周的裂纹沿{111}滑移面扩展。采用有限元方法分析4种不同试样孔边应力场的分布规律,数值模拟分析结果与试样的断裂位置及形貌吻合。     

Failure analysis of gas turbine transition pieces,leading to a solution for prevention

In this study the failure analysis of transition pieces of a gas turbine is investigated. Transition piece connects combustion chamber to the turbine and acts as a nozzle which leads hot gases to stationary blades of turbine. The problem of this transition piece in this gas turbine, which was common in other similar units, was cracks developing on the lower wall near the connection to the turbine. Study of gas turbine operation history, cracks apparent form microstructure analysis and fracture surface, revealed that the thermal fatigue was the main reason for the failure and also oxidation facilitated the crack propagation. In order to prevent the failure of transition pieces, it was proposed to create a row of holes, at 1 cm above the impaired region for local cooling and stopping probable cracks. Due to the implemented solutions, the failure of transition pieces and their annual repair are prevented.