Effects of Specimen Size and Welded Joints on the Very High Cycle Fatigue Properties of Compressor Blade Steel KMN-I

The effects of specimen size and welded joints on the very high cycle fatigue properties of compressor blade steel KMN-I were studied by ultrasonic fatigue testing. It was found that the S-N curve of large specimens had a slow decline above 107 cycles, and fatigue failure still occurred in the very high cycle regime (>107 cycles), while the very high cycle fatigue characteristics of welded specimens was less obvious, and the fatigue limit was observed. Metallographic observation and SEM analysis were carried out on the fracture of the specimens. The results showed that surface fractures were mostly observed in the large specimens, and only a small number of cracks initiated from non-metallic inclusions above 107 cycles. The cracks of welded specimens initiated from the surface below 107 cycles and initiated from the internal matrix above 107 cycles. In addition, the formation mechanism of GBF (granular bright facet) was analyzed by the “dispersive decohesion of spherical carbide” theory, and the fatigue strength and fatigue life were predicted, which was consistent with the experimental results.

Metallographic studies results of 20kH13 steel samples with textured relief, modified surface and protective coating

One of the possible ways to improve passive methods of the steam turbine blade material protection from water droplet erosion is to create “smart”-surface that combines the properties and characteristics that could not be implemented simultaneously when using one or another proven method of protection. To solve the problem of developing such surface, this article presents the metallographic researches results of the blade steel 20kH13 samples with various already used and promising passive methods of protection, consisting in the use of ion-plasma and polyurethane coatings, surface modification by means of diffusion saturation with nitrogen ions, creation of the structured surface relief by laser ablation. The results of the carried out researches have allowed to reveal both morphology of a possible “smart”-surface, and influence on a microstructure and characteristics of a near-surface layer of samples after treatments considered.

Research on Fatigue Damage of Compressor Blade Steel KMN-I Using Nonlinear Ultrasonic Testing

The fatigue damage of compressor blade steel KMN-I was investigated using nonlinear ultrasonic testing and the relation curve between the material nonlinearity parameter β and the fatigue life was obtained. The results showed that the nonlinearity parameter increased first and then decreased with the increase of the fatigue cycles. The microstructures were observed by scanning electron microscopy (SEM). It was found that some small defects like holes and pits appeared in the material matrix with the increase of the fatigue cycles, and the nonlinearity parameter increased correspondingly. The nonlinearity parameter reached the peak value when the microcracks initiated, and the nonlinearity parameter began to decrease when the microcracks further propagated to macrocracks. Therefore, it is proved that the nonlinearity parameter can be used to characterize the initiation of microcracks at the early stage of fatigue, and a method of evaluating the fatigue life of materials by nonlinear ultrasonic testing is proposed.