Life Management and Extension Studies

Several life management and extension (LM&E) studies for hot section components of various turbines are performed at Southwest Research Institute (SwRI). The methodology for LM&E includes: Condition Assessment Material and coating degradation Material properties evaluation Nondestructive evaluation Stress Analysis Mechanical analysis Aero and thermal stress analysis Vibration analysis and frequency testing Life Evaluation Failure modes Life evaluation methodology Turbine Condition Assessments SwRI performs condition assessments of hot section components to evaluate the extent of base material and coating degradation and to help clients make run, repair, and replacement decisions. We have developed algorithms and computerized programs for life prediction, life management, and life extension of gas turbine engines to increase component usage, maximize engine availability, and reduce maintenance costs. We have has also developed methodologies and software to predict the life of gas turbine hot section blades for GE frame gas turbines. Extensive materials testing of new and service-exposed components was conducted to develop pertinent material properties, which were used in the life assessment algorithm and software, GTD LIFE. Using these data in their turbine fleet life management program, clients can realize economic gains by prudently scheduling the inspection and maintenance intervals while maintaining good availability and reliability of their engines. SwRI can offer you a full range of capabilities and experience in gas turbine technology including becoming an extension of your engineering department. For more information about our gas turbine life management and extension studies and capabilities, or how you can contract with SwRI, please contact Klaus Brun, Ph.D., atkbrun@swri.org or (210) 522-5449. gasturbine.swri.org

he most current technology, including finite element and boundary element methods, is applied to the stress analysis of gas turbine components at Southwest Research Institute (SwRI). SwRI is a pioneer in probabilistic structural mechanics, which integrates computational mechanics and probabilistic methods to manage distribution of material properties, dimensions, and loads. Computational facilities include a central VAX computer, distributed workstations, and access to CRAY supercomputers. Available numerical codes include ABAQUS, ANSYS, and NASTRAN.

Two of the vibrational modes of a space shuttle APU turbine blade are shown. SwRI combined its vibrational analysis with Institute-developed probabilistic structural analysis methods to determine allowable inspection intervals. NASA is using the results for engine maintenance.

Air-cooled gas turbine blades have complex temperature and stress profiles. Temperatures are shown in the upper figure and longitudinal stresses are below. This analysis uses a generalized plane strain finite element methodology.

SwRI can offer you a full range of capabilities and experience in gas turbine technology including becoming an extension of your engineering department. For more information about our gas turbine stress and thermal analysis capabilities, or how you can contract with SwRI, please contact Klaus Brun, Ph.D., at kbrun@swri.org or (210) 522-5449. gasturbine.swri.org

Failure Modes To evaluate the life of components, it is essential to identify the probable failure modes for a given component. The possible failure modes for hot section components include thermal mechanical fatigue (TMF), hot corrosion, creep, and coating oxidation and degradation. Engineers at Southwest Research Institute (SwRI) examine the parts using state-of-the-art laboratory facilities. They examine hot section parts failed in service and identify the most probable cause of failure. Life Evaluation Methodology In gas turbines, the life and integrity of the coatings, applied to protect the components from environmental attack and degradation, govern the life and maintenance intervals of hot section components. SwRI has developed state-of-the-art coating and TMF life prediction methods for several substrate/coating systems. The TMF model has been calibrated with service experience and can be used to predict the life of a specific coating on turbine blades in service. Through an industry consortium program, GTD LIFE software was developed to calculate the remaining life of GE MS5002 engine first-stage buckets. This software is available to turbine users. Coating Oxidation Coating Degradation

Photomicrographs showing bond coating oxidation and degradation

Photograph of a corrosion-attacked area on a Frame 5 blade after 40,000 hours of service

Flow diagram shows the tasks required to develop a life management system for determining the life of gas turbine components. SwRI is one of the few organizations capable of performing each step in the development of these systems.

Metallography Results

COATLIFE Calculation

Click photo for larger image

Click photo for larger image

In-service degraded coating of a 7FA blade (left) and a 9FA blade (right) after 21,000 hours of service

COATLIFE validation for Frame 7/9FA blades (GT29+ coating). Model prediction is in good agreement with metallographic results.

Metallography Results

COATLIFE Calculation

Click photo for larger image

Click photo for larger image 9FA blade after 17,000 hours of service Click graph for larger image TMF model validation for Frame 7FA and 9FA blades. Model prediction is in good agreement with metallographic results.

7FA blade after 21,000 hours of service

Typical interface cracking and crack growth as a function of time

Cracking at the bond coat/ thermal barrier coating (TBC) interface leads to TBC spallation. The results generated at SwRI show that these cracks form at the early stages of component life.

SwRI can offer you a full range of capabilities and experience in gas turbine technology including becoming an extension of your engineering department. For more information about our gas turbine life

evaluation capabilities, or how you can contract with SwRI, please contact Klaus Brun, Ph.D., at kbrun@swri.org or (210) 522-5449. gasturbine.swri.org