Root Cause Analysis of Steam Turbine Blade Failure

Harison, M C Antony; Swamy, M.; Pavan, A.; Jayaraman, G.

doi:10.1007/s12666-015-0750-2

Cited by 9 publications

(2 citation statements)

References 2 publications

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“…Fatigue failures in martensitic stainless steel turbine blades can occur due to the propagation of cracks caused by erosion caused by particle impingement [4]. Fatigue under corrosion has also been observed in the failure of x20CrMo13 steel turbine blades [5]. Installation problems that result in clearances at the root of the turbine blade cause failure due to fretting fatigue [6].…”

Section: Introductionmentioning

confidence: 99%

Failure analysis of a martensitic stainless steel steam turbine blade

Ruchert,

Carvalho

2024

J Braz. Soc. Mech. Sci. Eng.

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This work investigated the possible causes of premature failure of a steam turbine blade made from X20CrMo13 stainless steel. During their operation in power generation plants, the blades may suffer service failures that occur naturally or accelerated due to metallurgical or mechanical causes. In this work, one investigated the possible causes of the failure of a martensitic stainless steel turbine blade operating in a 25 MW turbine in a quenched and tempered cogeneration plant that fractured during operation. The results showed a martensitic structure with a delta ferrite content above 5%. Beach marks and fatigue striations were observed, arising from fatigue crack propagation. The tensile test showed an area reduction of 15%, probably due to carbide precipitation.

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Section: Introductionmentioning

confidence: 99%

Failure analysis of a martensitic stainless steel steam turbine blade

Ruchert,

Carvalho

2024

J Braz. Soc. Mech. Sci. Eng.

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“…For instance, Nickel-based alloy blades in jet engines can reach temperatures approaching 1,150°C, which is about 200°C below their T m . Hot corrosion fatigue and thermo-mechanical fatigue (TMF) can lead to problems such as cracks, excessive oxidation, mechanical degradation and ultimately, premature failure of the blade (Abu et al , 2014; Antony Harison et al , 2015; Mishra et al , 2017). To enable modern aero-turbine engines to operate with higher efficiency and durability at gas temperatures well above the T m of superalloy (>1,300°C), thermal barrier coatings (TBCs) made of low thermal conductivity ceramics are now being used on turbine blades to provide lubrication and thermal insulation to metallic portion from the hot gas stream in aero-turbine engines.…”

Section: Introductionmentioning

confidence: 99%

A robotic polishing trajectory planning method for TBCs of aero-engine turbine blade using measured point cloud

Liang

Cai

Zeng

et al. 2022

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Purpose The application of thermal barrier coatings (TBCs) allows aero-engine blades to operate at higher temperatures with higher efficiency. The preparation of the TBCs increases the surface roughness of the blade, which impacts the thermal cycle life and thermal insulation performance of the coating. To reduce the surface roughness of blades, particularly the blades with small size and complex curvature, this paper aims to propose a method for industrial robot polishing trajectory planning based on on-site measuring point cloud. Design/methodology/approach The authors propose an integrated robotic polishing trajectory planning method using point cloud processing technical. At first, the acquired point cloud is preprocessed, which includes filtering and plane segmentation algorithm, to extract the blade body point cloud. Then, the point cloud slicing algorithm and the intersection method are used to create a preliminary contact point set. Finally, the Douglas–Peucker algorithm and pose frame estimation are applied to extract the tool-tip positions and optimize the tool contact posture, respectively. The resultant trajectory is evaluated by simulation and experiment implementation. Findings The target points of trajectory are not evenly distributed on the blade surface but rather fluctuate with surface curvature. The simulated linear and orientation speeds of the robot end could be relatively steady over 98% of the total time within 20% reduction of the rest time. After polishing experiments, the coating roughness on the blade surface is reduced dramatically from Ra 7–8 µm to below Ra 1.0 µm. The removal of the TBCs is less than 100 mg, which is significantly less than the weight of the prepared coatings. The blade surface becomes smoothed to a mirror-like state. Originality/value The research on robotic polishing of aero-engine turbine blade TBCs is worthwhile. The real-time trajectory planning based on measuring point cloud can address the problem that there is no standard computer-aided drawing model and the geometry and size of the workpiece to be processed differ. The extraction and optimization of tool contact points based on point cloud features can enhance the smoothness of the robot movement, stability of the polishing speed and performance of the blade surface after polishing.

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Analysis of Steam Turbine Blade Failure Causes

Kale¹,

Arakerimath²

2019

ICRRM 2019 – System Reliability, Quality Control, Safety, Maintenance and Management

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Root Cause Analysis of Steam Turbine Blade Failure

Cited by 9 publications

References 2 publications

Failure analysis of a martensitic stainless steel steam turbine blade

Failure analysis of a martensitic stainless steel steam turbine blade

A robotic polishing trajectory planning method for TBCs of aero-engine turbine blade using measured point cloud

Analysis of Steam Turbine Blade Failure Causes

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