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    Practical Experience With Single Crystal Turbine Blade Repairs

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    katibra
    The document summarizes a presentation given at the 7F Users Group Annual Conference in 2018 on practical experiences with single crystal turbine blade repairs. The presentation discusses how single crystal turbine blades allow for greater performance but are more expensive to repair than equiaxed blades. It then reviews Liburdi Turbine Services' experiences conducting full rejuvenation heat treatments and welding repairs on cracked single crystal blades, finding that over 90% of repaired blades met specifications with one achieving a full nominal service interval, demonstrating the feasibility of single crystal blade repairs.

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    Practical Experience With Single Crystal Turbine Blade Repairs

    Uploaded by

    katibra
    166 views17 pages
    The document summarizes a presentation given at the 7F Users Group Annual Conference in 2018 on practical experiences with single crystal turbine blade repairs. The presentation discusses how single crystal turbine blades allow for greater performance but are more expensive to repair than equiaxed blades. It then reviews Liburdi Turbine Services' experiences conducting full rejuvenation heat treatments and welding repairs on cracked single crystal blades, finding that over 90% of repaired blades met specifications with one achieving a full nominal service interval, demonstrating the feasibility of single crystal blade repairs.

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    Practical-Experience-with-Single-Crystal-Turbine-Blade-Repairs

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    20-Liburdi-2018-Practical-Experience-with-Single-Crystal-Turbine-Blade-Repairs

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    The document summarizes a presentation given at the 7F Users Group Annual Conference in 2018 on practical experiences with single crystal turbine blade repairs. The presentation discusses how single crystal turbine blades allow for greater performance but are more expensive to repair than equiaxed blades. It then reviews Liburdi Turbine Services' experiences conducting full rejuvenation heat treatments and welding repairs on cracked single crystal blades, finding that over 90% of repaired blades met specifications with one achieving a full nominal service interval, demonstrating the feasibility of single crystal blade repairs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    166 views17 pages

    Practical Experience With Single Crystal Turbine Blade Repairs

    Uploaded by

    katibra
    The document summarizes a presentation given at the 7F Users Group Annual Conference in 2018 on practical experiences with single crystal turbine blade repairs. The presentation discusses how single crystal turbine blades allow for greater performance but are more expensive to repair than equiaxed blades. It then reviews Liburdi Turbine Services' experiences conducting full rejuvenation heat treatments and welding repairs on cracked single crystal blades, finding that over 90% of repaired blades met specifications with one achieving a full nominal service interval, demonstrating the feasibility of single crystal blade repairs.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    7F Users Group Annual Conference 2018

    Atlanta Marriott Marquis, May 8 2018

    Practical Experience with Single


    Crystal Turbine Blade Repairs

    Doug Nagy, P.Eng. [[email protected]]


    Justin Kuipers, P.Eng. [[email protected]]
    Liburdi Turbine Services, Inc.
    Dundas, Ontario, Canada
    Use of single crystals for turbine blades

    Use of single crystals for turbine blades allows greater


    performance and/or service interval
    • Higher firing temperatures for higher efficiency
    • Higher power for given footprint

    These advantages come at a financial cost


    • New part price is substantially higher.
    • Reduced availability of aftermarket parts equiaxed columnar single
    • Repair processes need to be re-qualified crystal
    directional solidification

    Timeline of Single Crystal Adoption

    1970 1980 1990 2000 2010 2020

    IGT Heavy
    Single Crystal Turbine Blade Repair Options

    Scrap

    Piece parts from


    Repair processes must be service Out of tolerance damage
    modified for single crystal i.e. corrosion, cracking, impact etc
    turbine blades
    • Strip & recoat Life Analysis Triage

    – Internal?
    • Limited to reparable areas Local stripping Full stripping

    • Tip repair
    Local weld Weld repair
    – Mini-tip process
    • Full weld repair Stress relieve Full or partial rejuvenation HT
    – Partial or full
    rejuvenation
    Re-establish
    cooling holes
    The critical consideration is the
    affect of processing on the coating
    alloy (microstructure).
    QA verification and
    return to service
    Single Crystal Heat Treatment - Background

    • In many cases OEM life of industrial single crystal (SX) blades


    is two service intervals of 16,000 – 25,000 hours with one mid-
    life strip and recoat repair
    • Limits appear to be conservative based on destructive
    examination of 'life expired' SX blades
    • Liburdi has >30 years experience extending the life of equiaxed
    and DS alloys through full solution rejuvenation heat treatment
    • The primary concern with full solution rejuvenation of SX alloys
    is the formation of recrystallized (RX) grains on surfaces with
    residual stress (low levels of grain boundary strengthening
    elements)
    Single Crystal Heat Treatment - Background

    • Recrystallization: the formation of a new grain structure in a


    deformed material by the formation and migration of high angle
    grain boundaries driven by the stored energy of deformation.
    • Recrystallization (RX) results in reduced high temp fatigue life
    and stress rupture strength at temperatures ≥850°C (1560°F) of
    SX alloys
    • Previous results: recrystallization
    un-avoidable on previously peened
    surfaces when subject to full solution
    heat treatments
    Single Crystal Recrystallization Study

    • Previous study found that recrystallization did not result in a


    reduction in high cycle fatigue life of René N5 SX alloy tested
    at 650°C (1200°F)
    • Indicates rejuvenation HT of
    previously peened SX blades
    is feasible provided that RX be
    limited to root surfaces which
    operate at or below 650°C

    Rene N5 airfoil trailing edge Rene N5 post rejuvenation


    post service - rafted HT - like new
    Single Crystal FSR Demonstration Repair

    • Life expired SGT-100 HPT blades, CMSX-4 alloy


    • 28,000hrs → repair → 12,000hrs → life expired per OEM limit
    • Trial repair on 5 blades including: removal of the coating,
    dimensional and penetrant inspection, rejuvenation heat
    treatment, Rx grain inspection, platinum aluminide coating.

    Stress
    rupture bar

    SGT-100 HPT Blades Sectioning plan


    Inspection for Recrystallization

    • Full solution rejuvenation repaired blades need to be inspected for


    recrystallization – same as new single crystal casting → neither
    process expected to yield 100%.
    • Demonstrated that a significant proportion (>90%) of the tested
    blades were recovered within repair limits
    Single Crystal Turbine Blade Welding Considerations

    Single crystals have additional welding concerns:


    • Lack of matching filler alloys
    • Re-crystallization reactions
    • Thin-wall hollow structures
    • Embrittling phases
    • Epitaxial solidification
    Single Crystal Repair Experience: Part 1

    • Large industrial combustion turbine, base-loaded application


    • 12,000 hours, 850 starts, 27,000 equivalent hours on fuel gas.
    • Single crystal blades, PWA1483, un-shrouded tips.
    • Coating: MCrAlY overlay, internal aluminide
    • Tip cracking 4mm below squealer floor
    • Automated welding on LAWS1000 system
    Single Crystal Welding with LAWS1000

    Automated welding allows closer


    control of weld parameters
    • Improved yields
    • Accurate bead stacking
    • Optimized filler use
    Repaired Single Crystal Service Experience

    • “Rainbow” rotor installed


    • Borescope inspections on 6 month intervals
    • No abnormal cracking observed
    • Full nominal service interval achieved
    Single Crystal Repair Experience: Part 2

    Tip damage after second service cycle; coating removed, FPI results
    Repaired Blade Metallurgical Findings

    • Coatings chemically stripped, parts inspected


    • New blades exhibited “normal” crack densities
    • Repaired blades exhibited 130% of normal crack
    density
    • ~70% of repaired cracks re-cracked, 30% new cracks
    • Re-cracks were slightly longer and/or wider than first-
    service blade cracks.
    Single Crystal Repair Experience: Part 2

    After tip weld and blend prior to coating


    Summary

    • Repair of single crystal blades present unique


    metallurgical challenges, however, repairs are
    feasible with the appropriate understanding and
    technology
    • Opportunity to maximize the life of expensive
    components
    Thank you for your time

    Please contact Liburdi


    for further details.
    Copies of the formal
    papers are available
    at the Liburdi booth.

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