Mitigation of Fretting Fatigue Damage in Blade and Disk Pressure Faces With Low Plasticity Burnishing

2007 ◽  
Author(s):  
Paul S. Preve´y ◽  
N. Jayaraman ◽  
Ravi A. Ravindranath ◽  
Michael Shepard
Keyword(s):  
Gas Turbine ◽  
Design Method ◽  
Surface Damage ◽  
Gas Turbine Engine ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Residual Stress Field ◽  
Treatment Technology ◽  
Turbine Engine ◽  
Low Plasticity Burnishing

Low Plasticity Burnishing (LPB) is now established as a surface enhancement technology capable of introducing through-thickness compressive residual stresses in the edges of gas turbine engine blades and vanes to mitigate foreign object damage (FOD). The “Fatigue Design Diagram” (FDD) method has been described and demonstrated to determine the depth and magnitude of compression required to achieve the optimum high cycle fatigue (HCF) strength, and to mitigate a given depth of damage characterized by the fatigue stress concentration factor, kf. LPB surface treatment technology and the FDD method have been combined to successfully mitigate a wide variety of surface damage ranging from FOD to corrosion pits in titanium and steel gas turbine engine compressor and fan components. LPB mitigation of fretting induced damage in Ti-6AL-4V in laboratory samples has now been extended to fan and compressor components. LPB tooling technology recently developed to allow the processing of the pressure faces of fan and compressor blade dovetails and mating disk slots is described. Fretting induced micro-cracks that form at the pressure face edge of bedding on both the blade dovetail and the dovetail disk slots in Ti-6-4 compressor components can now be arrested by the introduction of deep stable compression in conventional CNC machine tools during manufacture or overhaul. The compressive residual stress field design method employing the FDD approach developed at Lambda Technologies is described in application to mitigate fretting damage. The depth and magnitude of compression and the fatigue and damage tolerance achieved are presented. It was found that microcracks as deep as 0.030 in., (0.75 mm) large enough to be readily detected by current NDI technology, can be fully arrested by LPB. The depth of compression achieved could allow NDI screening followed by LPB processing of critical components to reliably restore fatigue performance and extend component life.

Mitigation of Fretting Fatigue Damage in Blade and Disk Pressure Faces With Low Plasticity Burnishing

2010 ◽  
Vol 132 (8) ◽  
Author(s):  
Paul S. Prevéy ◽  
N. Jayaraman ◽  
Ravi A. Ravindranath ◽  
Michael Shepard
Keyword(s):  
Gas Turbine ◽  
Design Method ◽  
Gas Turbine Engine ◽  
Numerical Control ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Residual Stress Field ◽  
Treatment Technology ◽  
Turbine Engine ◽  
Low Plasticity Burnishing

Low plasticity burnishing (LPB) is now established as a surface enhancement technology capable of introducing through-thickness compressive residual stresses in the edges of gas turbine engine blades and vanes to mitigate foreign object damage (FOD). The “fatigue design diagram” (FDD) method has been described and demonstrated to determine the depth and magnitude of compression required to achieve the optimum high cycle fatigue strength, and to mitigate a given depth of damage characterized by the fatigue stress concentration factor, kf. LPB surface treatment technology and the FDD method have been combined to successfully mitigate a wide variety of surface damage ranging from FOD to corrosion pits in titanium and steel gas turbine engine compressor and fan components. LPB mitigation of fretting-induced damage in Ti–6Al–4V in laboratory samples has now been extended to fan and compressor components. LPB tooling technology recently developed to allow the processing of the pressure faces of fan and compressor blade dovetails and mating disk slots is described. Fretting-induced microcracks that form at the pressure face edge of bedding on both the blade dovetail and the dovetail disk slots in Ti-6-4 compressor components can now be arrested by the introduction of deep stable compression in conventional computer numerical control (CNC) machine tools during manufacture or overhaul. The compressive residual stress field design method employing the FDD approach developed at Lambda Technologies is described in application to mitigate fretting damage. The depth and magnitude of compression and the fatigue and damage tolerance achieved are presented. It was found that microcracks as deep as 0.030in.(0.75mm) large enough to be readily detected by current nondestructive inspection (NDI) technology can be fully arrested by LPB. The depth of compression achieved could allow NDI screening followed by LPB processing of critical components to reliably restore fatigue performance and extend component life.

Improved High Cycle Fatigue Damage Tolerance of Turbine Engine Compressor Components by Low Plasticity Burnishing (LPB)

2006 ◽  
Author(s):  
Paul S. Preve´y ◽  
N. Jayaraman ◽  
Ravi A. Ravindranath ◽  
Michael Shepard
Keyword(s):  
Damage Tolerance ◽  
Cnc Machine Tools ◽  
Cnc Machine ◽  
Turbine Engine ◽  
Solution Approach ◽  
Industry Standards ◽  
Low Plasticity Burnishing ◽  
Recent Developments ◽  
Engine Components ◽  
And Control

Significant progress has been made in the application of low plasticity burnishing (LPB) technology to military engine components, leading to orders of magnitude improvement in damage tolerance. Improved damage tolerance can facilitate inspection, reduce inspection frequency, and improve engine operating margins, all leading to improved military readiness at significantly reduced total costs. Basic understanding of the effects of the different LPB process parameters has evolved, and finite element based compressive residual stress distribution design methodologies have been developed. By incorporating accurate measurement of residual stresses to verify and validate processing, this combined technology leads to a total solutions approach to solve damage problems in engine components. An example of the total solution approach to develop LPB processing of a 1st stage Ti-6Al-4V compressor vane to improve the foreign object damage (FOD) tolerance from 0.002 in. to 0.025 in. is presented. The LPB process, tooling, and control systems are described, including recent developments in real-time process monitoring for quality control. Performed on CNC machine tools, LPB processing is easily adapted to overhaul and manufacturing shop operations with quality assurance procedures meeting military and industry standards, facilitating transition to military depots and manufacturing facilities.

Surface Damage Tolerance Analysis of a Gas Turbine Engine Rotor

2005 ◽  
Author(s):  
Ahsan Jameel
Keyword(s):  
Gas Turbine ◽  
Tolerance Analysis ◽  
Surface Damage ◽  
Gas Turbine Engine ◽  
Jet Engines ◽  
Commercial Aircraft ◽  
Design Assessment ◽  
Turbine Engine ◽  
Southwest Research Institute ◽  
Probability Of Fracture

DARWIN™ (Design Assessment of Reliability With INspection) is a simulation-based computer program for probabilistic fatigue life prediction of rotors and disks in commercial aircraft jet engines. This program is being developed by Southwest Research Institute® (SwRI®) and a team of major aircraft gas turbine engine manufacturers (General Electric, Pratt & Whitney, Honeywell, and Rolls Royce Indianapolis) as a major research and development initiative. This paper is a presentation of the experience of Honeywell in the use of DARWIN to assess probability of fracture (POF) due to surface damage in a highly stressed bolthole in a nickel component.

Flexible manufacturing in repair of gas turbine engine components

1992 ◽  
Author(s):  
KIRK D ◽  
ANDREW VAVRECK ◽  
ERIC LITTLE ◽  
LESLIE JOHNSON ◽  
BRETT SAYLOR
Keyword(s):  
Gas Turbine ◽  
Flexible Manufacturing ◽  
Gas Turbine Engine ◽  
Turbine Engine ◽  
Engine Components

Fracture of a Compressor Stator Blade in a Gas Turbine Engine

2013 ◽  
Vol 50 (1) ◽  
pp. 43-49
Author(s):  
A. Neidel ◽  
B. Matijasevic-Lux
Keyword(s):  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Turbine Engine ◽  
Stator Blade

Uncharacteristic Circumferential TMF Cracking in a Heavy-duty Stationary Gas Turbine Engine Burner Outlet

2015 ◽  
Vol 52 (6) ◽  
pp. 334-341
Author(s):  
A. Neidel ◽  
Th. Ullrich ◽  
S. Wallich
Keyword(s):  
Gas Turbine ◽  
Gas Turbine Engine ◽  
Heavy Duty ◽  
Turbine Engine
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