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The development of gas turbines to increase fuel efficiency is resulting in progressively higher operating temperatures in the under platform regions of the blades. These regions have traditionally been considered low risk areas. However, higher metal temperatures combined with stresses and the deposition of contaminants from the cooling air system may result in complex degradation mechanisms. Static stress corrosion testing has been conducted on C-ring specimens at a range of stresses in a hot corrosion environment. Cracks were observed in C-rings after exposure times greater than 100 h. Scanning electron microscopy (SEM) systems were used to image cracks and characterise deposits to improve understanding of the mechanism. Finite element analysis (FEA) has been used to model the stress intensity under test conditions. CMSX-4 specimens subject to static stresses combined with hot corrosion demonstrated significant material degradation (crack initiation and propagation) suggesting a combined stress corrosion mechanism resulting in cracking.

A corrosive environment can have a detrimental effect on the fatigue life of a material due to a change in failure mechanism. Attempts have been made to replicate this change on nickel-base superalloy CMSX-4 cast in the <001> orientation. Fatigue testing in air, of this material typically produces a fracture on an angle of approximately 55° which is consistent with the fracture having propagated on a {111} slip plane. The aim of the research was to fatigue test in a corrosive environment with the purpose of producing a crack/fracture which deviated from the typical angle and thus confirm that the corrosive environment had affected the fatigue mechanism. It was concluded that the change in mechanism to high temperature corrosion fatigue was associated with a reduced load application rate together with precorroding the test specimens to trigger the initiation of the corrosion fatigue mechanism.

Gas turbines blades are required to operate at high temperatures whilst being subjected to stress and corrosive environments. These demanding conditions have led to the need to better understand the interactions between corrosion and loading in order to improve lifing algorithms used for service interval predictions. A new crack growth measurement technique involving direct current potential difference (PD) has been developed for use in these harsh conditions. A good correlation between PD signal and crack area has been achieved. Estimations of the crack depth have been made based on fracture surface imaging, these experimentally measured crack depth propagation rates have been compared with Paris law predictions. A stress intensity factor (SIF) interaction between multiple cracks was found, where the SIF is enhanced when cracks become close. It was found that both the fatigue cycle rate and the crack shape appear to influence the SIF magnitude and the crack depth at which specimens fail, or initiate into crack propagation which is consistent with fatigue.