Chapter 1

Introduction
1.1.

Background

Gas turbine is a type of internal combustion engine. The gas turbine power plants are
complex machines, they basically involve three main components.

Compressor (for compression of working fluid).

Combustion Chamber (for rising the temperature of the fluid before

expansion).
Turbine (for the expansion of the working fluid).

In practical cycle losses do occur in both the compressor and turbine which increase
the power absorbed by the compressor and decrease the power output of turbine. The
two main factors that will affect the performance of the gas turbine are the efficiencies
of various components and turbine working temperature.
The purpose of the gas turbine determines the design so that the most desirable form
of energy can be maximized. Gas turbines are used to power aircraft, ships and
electrical generators etc.
Gas turbine blade can be defined as the medium of transfer of energy from high
temperature and pressure gases to the turbine rotor. Turbine blades are subjected to
very strenuous environment inside a gas turbine. Efficiency of gas turbine greatly
depends upon design of blade and designing of gas turbine blade is one of the
challenging problem in the area of gas turbine power plant. Technological
advancement in materials, aerodynamics and cooling methodology also motivate us to
do this project.

1.2.

Simple Gas Turbine

A gas turbine is a rotating engine that extracts energy from a flow of combustion
gases that result from the ignition of compressed air and a fuel. The main contributor
to the popularity of the gas turbine is without question the Aviation industry. For many
1

years the piston engine was the only possible choice of air born propulsion. During
the Second World War a lot of effort was put in to developing faster aircraft which in
the end led to the first commercial gas turbine engines. They were lighter and a lot
more powerful compared to a piston engine of equivalent size. Nowadays using
anything else than a gas turbine for aircraft propulsion is almost unthinkable. During
the second half of the 20th-century gas turbines were beginning to be used more and
more in stationary applications such as mechanical drive and power generation. When
coupled to a steam turbine and used in a combined plant the efficiency can be on par
with the best of piston engines. The earliest patent on gas turbine was that of the
Englishman, Johan Barber, in 1879. Early designs were unsuccessful, largely due to
two factors.
(i) The low efficiency of the compressors, and
(ii) The combustion temperature limitations imposed by the materials.
Serious development of gas turbine began only after the Second World War with shaft
power in mind, but attention was shifted to the turbojet engine for aircraft propulsion.
The gas turbine, in many respects, seems to be the most satisfactory power plant
because of(i) The absence of reciprocating and rubbing parts which reduces the vibration
and balancing problems.
(ii) High reliability.
(iii)
Low lubricating-oil consumption, and
(iv) High power to weight ratio.

1.3. The Ideal Gas Turbine Cycle- Brayton Cycle

In essence a gas turbine consists of three major parts: a compressor, a combustor and
a turbine. First air is sucked in to the compressor part of the gas turbine where there is
an increase in pressure. The flow of air is then mixed with fuel and ignited in the
combustor. Finally the hot gas stream is expanded in the turbine and then expelled
through an exhaust pipe.
A gas turbine can be considered a cyclic device hence it is often analyzed using a
thermodynamic cycle. By making certain assumptions simple analytical expressions
of efficiency and specific work can be derived. It is common to make use of a closed
cycle approximation for making the calculations easy.
Assumptions in ideal cycle analysis
(i) The change in kinetic energy of the working fluid is negligible.
2

(ii) Compression and expansion are reversible and adiabatic (isentropic).

(iii)
There is no pressure losses in the system.
(iv) Heat exchanger effectiveness is assumed 100%.
(v) The mass flow rate of the gas is constant throughout the cycle.
(vi) The working medium is considered as ideal gas with constant specific heat.

Figure 1.1 Simple Gas Turbine

Figure Reference-http://sounak4u.weebly.com/gas-power-cycle.html
In Brayton cycle air is compressed isentropically, combustion occurs at constant
pressure, and expansion over the turbine occurs isentropically back to the starting
pressure. As with all heat engine cycles, higher combustion temperature means greater
efficiency. The limiting factor is the ability of the steel, ceramic, or other materials
that make up the engine to withstand heat and pressure.

Figure 1.2 The Brayton Cycle

Figure Reference-http://en.wikipedia.org/wiki/Brayton cycle
In order to conduct an energy analysis, a so called system that defines the actual space
in which the study is taking place must be constructed. Everything outside of the
system boundary is called the surroundings. A system (commonly called a control
volume) can be either closed or open depending on if mass is allowed to cross the
boundary or not. The system can possess kinetic, potential and internal energy which
constitute the total energy of a system neglecting energies associated with surface
tension, electric and tension effects. Across the boundary energy can be transferred in
the form of work, heat and mass flow. The first law of thermodynamics states that
energy cannot be created nor destroyed only transformed between one forms to
another. This can be expressed mathematically:
E in E out = E for a steady flow process the above relation becomes:

EinEout =

Rearranged:

dEsystem
=0
dt
Ein=Eout

Mass cannot be created nor destroyed, this simple fact will state that all the mass
entering a control volume must also come out during steady state operation:
4

MinMout=

dE
=0
dt

And

Min=Mout

The energy equation and the continuity equation for a steady flow process will be
used in the analysis of the Brayton cycle. By treating each part of the cycle separately
using a control volume approach on a per unit mass basis:
Compressor:
W in = h 2 h 1
Turbine:
W out = h 3 h 4
Combustor:
Q in = h 3 - h 2
The thermodynamic efficiency is defined asQ
W net
th=
The net amount of work done:
W net = W in W out
1

=1

Where

P2
p1

(pressure ratio)

It is obvious that the thermal efficiency of the Brayton cycle is only affected by the
pressure ratio for a given working fluid. An expression for the specific work will yield
a dependency of both pressure ratio and maximum temperature. The temperature also
influences the efficiency when component losses are taken into account. However the
efficiency is much more dependent on the pressure ratio than maximum temperature.
Whenever dealing with non-ideal processes the concept of isentropic efficiency is
very commonly used. It is defined for an adiabatic turbine as the actual work output

divided by the ideal work output which corresponds to the actual enthalpy drop
divided by the isentropic enthalpy drop.

1.4.

Gas Turbine Blade

Turbine blades are one of the most important components in a gas turbine. These are
the components across which flow of high pressure gases takes place to produce
work. A blade can be defined as the medium of transfer of energy from the gases to
the turbine rotor. The blade is subjected to forces in these three directions as follow(i) The rotor driving force along the radial direction.
(ii) The axial force caused by the gas flow.
(iii)
The forces acting normal to the turbine shaft due to the centrifugal
forces.
Except these, the blade is subjected to differential thermal stresses, erosion-corrosion.

Figure 1.3 Gas Turbine Blade

1.4.1 Blade Materials

Different alloy composition have been developed which have good stability to
withstand the thermal stresses. These alloys have been modified to give good erosion6

corrosion characteristics to the blade. Steels, Titanium alloys and nickel base alloys
are mainly used, having varying proportions of chromium and aluminum to improve
the strength and corrosion at high temperatures. Titanium alloys are preferred to steels
because of its lower density (nearly 50%).
In the present work, turbine blade has been designed with three different materials
named as AISI 4130 Steel (super alloy steel), Inconel Alloy 718 and Haynes Hastelloy
C-276.
Blade materials should possess the following characteristics:
(i) Forgeability or Casteability,
(ii) Weldabilty,
(iii)
Machinability and
(iv) No embrittlement during operation.

1.4.2 Manufacturing Techniques

There are many restrictions and requirements which will affect the manufacturing
process. The various techniques of blade manufacturing are(i) Forging
(ii) Casting
(iii)
Fabrications and
(iv) Powder metallurgy.

1.4.3 Blade Fixing

The blades of gas turbine are to be fitted carefully to the discs. This is served by the
blade root which is either welded or fixed to the disc circumference.
(i) The root should be able to transmit the centrifugal force and vibrations to the
turbine disc.
(ii) It should be easy to mount the blade on the turbine disc.
(iii)
The manufacturing process should be affordable.
(iv) The temperature effects on the blade and the disc should not cause expansion
due to high temperature.
The following are some of the methods for fixing blade to the wheel:
(i) Blub Root Method
(ii) Tee and Double
(iii)
Anchor pin
(iv) Fir Tree Method
(v) Grub Screw Method
7

(vi) Welding
We have used the Fir-tree root method of blade fixing in designing of our turbine
blade model.

Figure 1.4 Fir-tree root method of blade fixing

Figure Reference-http://www.marineengineering.org.uk/page36.html

1.4.4 Blade Cooling

The turbine blades are subjected to high temperature which leads to higher
thermal efficiency, higher power to weight ratio and lower specific fuel consumption.
If a blade is heated rapidly to high temp it causes uneven temperature it causes
uneven temperature distribution and several thermal stresses are developed
within the material. Beyond certain level of temp (650-800C) the blade material
does not remain elastic and continues to stretch under the applied forces.
There are the following two options to overcome these problem.
(i) A new material may be sought which is capable of operating at high
temperatures.
8

(i) Blade cooling which maintains the temperature of the blades at a value
low enough to preserve the desired material properties.
Blade cooling is one the most effective way of maintaining high operating
temperatures making use of the available materials. Blade cooling can be classified
based on the cooling site as external and internal cooling and another classification is
based on the cooling medium is liquid and air cooling.

Figure 1.5 Turbine Blade with Internal and External Cooling

In general without cooling technology turbine entry temperature (TET) vary from
800K to 1200K because of metallurgical limit. But after implementing cooling
methods TET can be increased up to 2000K.
Following are the cooling methods:
(i) Internal convection cooling
(ii) Internal impingement cooling
(iii)
Discrete film cooling
(iv) Full blade film cooling
(v) Full blade transpiration cooling (porous blade)

Figure 1.6 Turbine Blade Cooling Configuration

Fig. Ref-http://web.mit.edu/16.unified/www/SPRING/propulsion/notes/node121.html

1.5.

Objectives of the Project

In the present study of exploring opportunities on Design and Analysis of Gas

Turbine Blade, following are the main objectives:
(i) To carry out literature survey on the topic.
(ii) To study existing gas turbine blade and collect data for the blade profile.
(iii)
To design the gas turbine blade using CATIA V5 and Autodesk Inventor
software.
(iv) To carry out structural analysis to look into the effect of stresses, shear stress and
deformation of gas turbine blade due to coupling effect of pressure and centrifugal
loads.
(v) To carry out thermal analysis to look into the effect of temperature variation due
to thermal loading.
(vi) To select the best material for gas turbine blade out of these three (AISI 4130
Steel (super alloy steel), Haynes Haste alloy C-276, INCONEL 718 alloy), based
on the comparative study of results.

10

Chapter 2
Literature Review
A detailed literature survey have been done on this topic. We have read 25 research
papers on gas design and analysis of gas turbine blade. These papers shows
experimental as well as computational analyses on design of gas turbine blade. Useful
analytical and numerical simulations can potentially aid the turbine designer toward
accurate predictions of gas turbine blade design.

2.1. Design of Gas Turbine Blade

[1] Vijaya Kumar, R. Lalitha and Ch. Srinivas have published a research paper on
design and analysis of gas turbine blade by potential flow approach. In this paper they
have designed gas turbine blade using the CMM points available. These key points
have been taken from coordinate measuring machine. The designed blade was
analyzed only for mechanical stresses. As the temperature has a significant effect on
the overall stress in the blade, a detailed study have been carried out on the
temperature effects to have a clear understanding of the combined mechanical and
thermal stresses.

11

[2] Theju V, Uday P S, PLV Gopinath Reddy and C.J. Manjunath have published
an international journal on design and analysis of gas turbine blade. They have
designed and analyzed a turbine blade of a jet engine. In their work they have
designed the blade with two different materials named as Inconel 718 and Titanium T6. A thermal analysis has been carried out to look into the direction of temperature
variation due to thermal loading. A structural analysis has been carried out to look into
the stresses, shear stress and displacement of turbine blade due to coupling effect of
thermal and centrifugal loads. Based on plots and results Inconel 718 considered as
the best material which is economical.
[8] T. Korakianitis, I.A. Hamakhan, M.A. Rezaienia, A.P.S. Wheeler, E.J. Avital
& J.J.R. Williams have done research on design of high efficiency turbomachinery
blades for energy conversion devices with the three-dimensional prescribed surface
curvature distribution blade design (CIRCLE) method. The purpose of this paper is to
present the advantages of the direct CIRCLE method for the design of highefficiency
turbomachinery blades.
These advantages are illustrated by redesigning several examples of axial
turbomachinery blades of interest to energy conversion devices and discussing in
detail the aerodynamic performance and efficiency improvements of the redesigned
blades over the original geometries.
[9] I.A. Hamakhan and T. Korakianitis have done research on aerodynamic
performance effects of leading- edge geometry in gas turbine blades. The purpose of
this paper is to illustrate the advantages of the direct CIRCLE method (originally
proposed by Korakianitis) for the leading edge design of turbine blades and by
extension for other types of airfoil shapes. The leading edge shape design of blade is a
critical process. It is quite difficult to completely control with inverse, semi-inverse or
other direct design methods. The results using two difficult example cases of leading
edge geometry illustrate the superiority and utility of this blade design method when
compared with other direct or inverse blade design methods.
[10] Ch .V Prudhvi Raj, K. Arun Kumar have presented an international journal on
stress analysis of gas turbine multistage rotor assembly. In this, they have analyzed
the gas turbine rotor assembly for thermal loads, centrifugal forces and natural
12

frequencies due to the mass of rotor assembly. The structural and thermal
characteristics in the assembly due to various operating conditions have been
analyzed using FEA software ANSYS Workbench 14.0 and results are plotted.

2.2. Structural and Thermal Analysis of Gas Turbine Blade

As the gas turbine blades are subjected very strenuous environment (high temperature
and high pressure) inside a gas turbine power plant. So structural and thermal analysis
of gas turbine blade have to carry out to analyze the effect of these severe operating
conditions. We have done a detailed literature survey on structural and thermal
analysis of gas turbine blade.
[3] P.V. Krishnakanth, G. Narasa Raju, R.D.V. Prasad and R. Saisrinu have
published an international journal on Structural and Thermal Analysis of Gas Turbine
Blade by Using F.E.M. Since the gas turbine blades are subjected to high tangential,
axial and centrifugal forces during their working conditions. In this project they have
designed the gas turbine blade using CATIA V5 for solid modeling of blade with the
help of spline and extrude options. ANSYS Workbench 11.0 is used for analysis of
finite element model.
[4] Narendranath and S. Suresh have published an international journal of
engineering research and applications on Thermal Analysis of a Gas Turbine Rotor
Blade by Using Ansys. In their work, they have analyzed the first stage rotor blade of
gas turbine using ANSYS Workbench 9.0. The tangential and axial forces were
determined by constructing velocity triangles at inlet and exit of rotor blade. The
geometric model of blade was generated with splines and extrusion in CATIA V5. The
first rotor blade of gas turbine was analyzed for structural, thermal and modal analysis
using ANSYS Workbench 9.0.
[5] Ganta Nagarajun, Venkata Ramesh Mamilla and M.V. Mallikarjun have
published an international journal of engineering, business and enterprise applications
on Design Optimization and Static & Thermal Analysis of Gas Turbine Blade. CATIA
V5 is used for design of solid model and ANSYS Workbench for analysis of finite
element model generated by applying boundary conditions. This paper also includes
specific post-processing and life assessment of blade. The objective of this paper is to
get natural frequency and mode shape of the turbine blade.
13

[6] Ahmad Abdul Hussein Jabbar, A.K. Rai, P. Ravinder Reddy & Mahmood
Hasan Dakhil have published an international journal of mechanical and production
engineering research and development on Design and Analysis of gas Turbine blade.
In this paper, the first stage rotor blade of gas turbine has been analyzed for structural
and thermal analysis using ANSYS Workbench 12.0. In the process of getting the
thermal stresses, the temperature in the rotor blade has been evaluated using this
software. Different materials Titanium alloy, Stainless steel alloy, and Aluminum 2024
alloy have been considered for the purpose of analysis.
Except these papers, we have read around 15 more research papers related to design
and analysis of gas turbine blade from different authors. On the basis of this literature
survey, we have decided to do our project on design and analysis of gas turbine blade
and identified the objectives of the projects. We decided to analyze the gas turbine
blade for three different materials named as AISI 4130 Steel (super alloy steel),
Haynes Hastelloy C-276 and Inconel 718 alloy. We have also considered cooling
methodology in designing of gas turbine blade.

14

Chapter 3
3D-Modeling of Gas Turbine Blade
3.1 OVERVIEW
Solid modelling or modelling is a consistent set of principles for mathematical and
computer modelling of three dimensional solids. Solid modelling is distinguished
from related areas of geometric modelling and computer graphics by its emphasis on
physical fidelity. Together the principles of geometric and solid modelling form the
foundation of computer aided design and in general support the creation, exchange,
visualization, animation of physical objects.
A solid part model generally consists of a group of features, added one at a time, until
features; 2-D sketches that are swept along a path to become 3-D. These may be cuts
or extrusions for example. Design work on component is generally done within
context of whole product using assembly modelling methods. An assembly model
incorporates references to individual part models that comprise the product.
Another type of modelling technique is surfacing or freeform surface modelling.
Here, surfaces are defined, trimmed and merged, and filled to make solid. The
surfaces are usually defined with datum curves in space and a variety of complex
commands. Surfacing is more difficult, but is better applicable to some manufacturing
techniques, like injection modelling. Solid models for injection molded parts usually
have both surfacing and sketcher based features.
15

3.2 Modelling Gas Turbine Blade

Here we have created a 3-D model of simple gas turbine blade using ANSYS
Workbench 14.0, CATIA and Autodesk Inventor Professional software. Various steps
involved in creating 3-d model of gas turbine blade are following.

3.2.1 2-D Sketch

For creating 2-D sketch we have used two software namely ANSYS Workbench 14.0
and CATIA. We have fragmented this work in two parts after reading so many
research paper and collecting the design parameters. These two parts are

Key points
2-D sketch

3.2.1.1 Key Points

Key points have been generated in ANSYS Workbench14.0 software. In this work we
first read several research papers and collected the input parameters like inlet blade
angle, stagger angle etc. Our input design parameters are shown in Table no. 3.1
Table-3.1 Input design parameters
S. No.
1
2
3
4
5
6
7

Parameter
Blade height
Chord length
Blade inlet angle
Blade outlet angle
Twist angle
Stagger angle
At /Ar

Value
900.78
502.44
18.3
54.56
15
35
0.85

Rh /Rt

0.755

Unit
mm
mm
Deg.
Deg.
Deg.
Deg.

Now we have used these parameters as input in BladeGen tool in ANSYS Workbench
14.0 to generate blade airfoil.

16

Figure 3.1 Blade airfoil in BladeGen

We took 64 points from the BladeGen to generate airfoil. These key points are given
in Table 3.2.
Table 3.2 Key Points
S.

S.

S.

S.

No.
1.

-15.8

5.5

No.
17.

217.

70.6

No.
33.

400

249.

No.
49.

251.

31.6

18.

5
230.

34.

405.

8
246

50.

1
238.

18.5

19.

9
243.

35.

4
395.

231.

51.

5
224.

5.5

100.

36.

8
386.

6
217.

52.

8
210.

-6.9

8
112.3 37.

3
376.

3
202.

53.

8
195.

-18.8

38.

9
367.

5
188.

54.

8
180

-30

39.

1
357.

3
173.

55.

162.

-39.9

40.

4
348

6
159

56.

6
144

-48.7

2.
3.

5.5
22.5

15.8
17.5

80.2
90.4

4.

39

18.9

20.

9
256.

5.

54.5

20.1

21.

8
269.

22.

4
281.

123.

23.

9
294.

9
135.

24.

1
305.

9
147.

6.
7.
8.

68.5
81.4
93.4

21.1
22.3
23.5

17

9.

106.3

10.

119.4

25.4
27.8

25.

6
318.

9
161.

26.

3
328.

6
173.

41.

339.

145.

57.

123.

-53.3

42.

3
328.

9
130

58.

6
102

-58.9

5
186.

43.

5
318.

115.6 59.

79.5

-59

6
200

44.

5
308.

101.

60.

58.3

-54.8

45.

1
297.

1
86.9

61.

39.2

-47.3

46.

5
286.

72.9

62.

22.6

-37.9

58.9

63.

7.9

-27.3

45.2

64.

-5.5

-15.8

11.

133

31.1

27.

8
340.

12.

147.2

32.2

28.

1
351.

29.

5
362.

30.

1
373.

226.
6
239.

47.

6
275.

48.

3
263.

13.
14.

161.5
175.6

40.5
46.4

213

15.

189.6

53.8

31.

3
383.

16.

203.6

61.8

32.

9
394.

8
253.

3.2.1.2 2-D Sketch

Using key points given above in Table 3.2 we created smooth airfoil curve in CATIA
software. Snapshot of created final 2-D sketch is

18

Figure 3.2 2-D Sketch of Blade airfoil in CATIA

3.2.2 Solid Modelling

Solid modelling has been done using two software CATIA and Autodesk Inventor
Professional.
3.2.2.1 Simple Blade
We have made 3-D model of generated blade profile in CATIA software. In this model
we have given blade height 121mm, blade twist angle 15 degree and ratio of tip crosssectional area to root blade cross-sectional area 0.85 as mentioned in Table 3.1.

19

Figure 3.3 Solid Model of Blade without Root

3.2.2.2 Blade Root
Blade model generated in CATIA is now exported to Autodesk Inventor software for
other modelling works. In Autodesk Inventor first we made root to the blade model.
We selected Fir-tree root method to fix our blade in disk. Snapshot of blade model
with root is given in fig.

Figure 3.4 Solid Model of Blade with Root

20

3.3 Blade with Cooling System

Blade cooling is most effective way of maintaining high operating temperatures
making use of the available material. Cooling technology is based on science of heat
transfer. Heat transfer takes place by surface convection, conduction and then
internally mainly by forced convection. Radiation heat transfer is negligible.
If we increase the turbine entry temperature (TET) more work will be obtained. So
there will be great fuel saving. In general without cooling technology TET vary from
1000K to 1200K because of metallurgical limit. But after implementing cooling
technology TET can be increased up to 2000K.

Blade cooling may be classified based on the cooling sites as

External cooling
Internal cooling

Another method to classify blade cooling system is

Internal convection cooling

Internal impingement cooling
Discrete film cooling
Full blade film cooling
Full blade transpiration cooling (porous blade)

Full blade transpiration cooling is ideal cooling method of gas turbine blade. But for
this purpose blade should have infinite number of pours on its surface evenly
distributed so that cooling fluid comes out through these pours and cover blade in the
form of thin film. So far no materials has this porous properties with desired strength
and melting point. Research is going on this field to find new materials suitable for
this purpose.
We have implemented combination of internal convection cooling and full blade film
cooling. This type of cooling technology has both internal and external surface
cooling. Cooling medium may be either liquid or air. We have taken air as cooling
medium. Quantity of air for cooling technology is generally taken as 1-3% of main
flow entering the turbine stage. The temperature of cooling air may vary from 350K
to 650K.
21

3.3.1 Heat transfer mechanism of Gas turbine blade cooling technology

The heat transfer is mainly by surface convection, conduction and
then internally mainly by forced convection. Radiation heat transfer
is negligible.

Figure 3.4 Boundary Layer Formation

When burnt gas coming from combustion chamber, enters first row
blade it has very high heat content and its flow is laminar. At leading
edge and trailing edge there are stagnation points where velocity of
gas isentropically comes to zero. So there is high temperature
regions at leading edge and trailing edge. There is transition in flow
type from laminar to turbulent on the both suction side and pressure
side of blade as gases passes on it. Due to this transition from
laminar to turbulent now blade surface feels more temperature than
earlier in leading edge region. On suction side effective temperature
felt by blade surface gradually decrease after transition due to
generation

of

shock

waves.

But

on

pressure

side

effective

temperature felt by blade surface remain almost same after flow

transition occurs.

22

3.3.2 Cooling System Design

Cooling system design has been divided into four parts namely

Internal holes in blade

Air inlet passage in root
Blade cap
Surface holes on blade surface

Final solid model of blade with internal and external cooling passage is shown in fig

Figure 3.5 Turbine Blade with Cooling

Now we have made final model of gas turbine blade which has internal and external
film cooling system implemented. In next chapters we have done various structural
and static thermal analysis with different materials to select best material among them.

23

Chapter 4111Equation Chapter 1 Section 1

Static Structural Analysis
4.1 Introduction
The Static Structural analysis is one of the most basic type of analysis. It is available
as Static Structural analysis system under the Analysis System toolbox in the Toolbox
window. This system analyses the structural component for displacement
(deformation), stresses, strains and forces under different loading conditions. The load
under this analysis system are assumed not to have damping characteristics (Time
dependant).
To start analysis ,We specified the geometry on which the analysis has to been
done.To do so , We imported the geometry from Autodesk Inventor .After the model
is specified for an analysis,double click on the model cell of the Static Structural
analysis system to open the mechanical window.In this window, we specified the
parameter and run the analysis.
Analysis has been carried out in three major steps: Pre-processing,Solution ,Postprocessing.

4.2 Pre-Processing
The pre- processing of an analysis system involves specifying the material, generating
the mesh and defining boundary condition.

4.2.1 Specifying the Materials

In the present work, we have designed the gas turbine blade with three different
materials named as AISI 4130 Steel, INCONEL 718 and Haynes Hastelloy C-276
alloy. Properties of these materials are following:
Table 4.1 Properties of AISI 4130 steel (super alloy steel)
S N.
1
2
3
4
5

Properties
Mass Density
Elasticity Modulus
Poisson ratio
Ultimate tensile strength
Tensile yield strength

Value
7850
2.05e+011
0.285
5.6e+008
4.6e+008
24

Unit
Kg/m3
N/m2
N/m2
N/m2

Table 4.2 Properties of INCONEL 718 Alloy

S N.
1
2
3
4
5

Properties
Mass Density
Elasticity Modulus
Poisson ratio
Ultimate tensile strength
Tensile yield strength

Value
819047
2.15e+011
0.20
1375
1100

Unit
Kg/m3
N/m2
N/mm2
N/mm2

Table 4.3 Properties of Haynes Hastelloy C-276 alloy

S N.
1
2
3
4
5

Properties
Mass Density
Elasticity Modulus
Poisson ratio
Ultimate tensile strength
Tensile yield strength

Value
8890
2.05e+011
0.220
601.2
364.7

Unit
Kg/m3
N/m2
N/mm2
N/mm2

4.2.2 Meshing
A mesh is a discretization of a component into a number of a small element of defined
size. Finite element analysis is dividing the geometry into various small number of
element. These element are connected to each other at points called nodes. Each node
may have two or more than two elements connected to it. A collection of these
element is called mesh.
Meshing is a very important part of Pre-processing in any FEA software. In ANSYS
Workbench there are many tool and options available to help to create an effective
mesh. And a effective mess is the one that require less computational time and gives
maximum accuracy. In ANSYS Workbench, we generated mesh as set parameter as
our requirement.
We have imported .stp file of final 3-D model into ANSYS Workbench for generation
of mesh. After proper setting in mesh window we have generated mesh for all three
models. Fig. shows mesh generated for all models

25

Figure 4.1 Meshing of Simple Blade

Figure 4.2 Meshing of Blade with Internal Cooling Holes

26

Figure 4.3 Meshing of Blade with Internal and External Cooling Holes
Details of meshing for all three models are given in Table 4.4
Table 4.4 Meshing Details
S. No.
1
2
3

Model Name

Grain Size

Relevanc

Number of Number of

Without holes
Medium
With
internal Medium

e
49
51

Elements
776349
2641657

Nodes
1129959
3775542

cooling holes
With internal and Fine

80

574017

899383

film cooling

4.2.3 Boundary Condition

In ANSYS Workbench, the various tools related to boundary conditions are available
in the Environment contextual tool bar which is displayed when we select the Static
Structural node in the tree Outline.
The accuracy of results of an analysis depends a lot on the mess quality of the model.
Ideally, the results obtain from a finite element analysis get more accurate with
increase more number of element. However, increase number of element also increase
the process time required to run an analysis. Therefore, it is always advised to find a
balance between the accuracy of the results and the process time required to run the
analysis.
27

In order to provide support to the model, we chose the required tool from the support
drop- down. We gave the support to the base .Similarly, to add the load, we chose the
desired tool from the Loads drop-down in the Environment contextual toolbar. We
have given 12 bar pressure to pressure side of gas turbine blade.

Figure 4.4 Blade with Pressure Load

The main purpose of an analysis is to evaluate the result. After the boundary condition
is set and loads are applied, we specified the desired outcomes of the analysis. In
ANSYS Workbench, we analysis various parameter such as deformation stresses, and
strains and so on. To do so, we specified the result required then evaluated them. We
used the tools available in the Solution contextual toolbar to specify results.

4.3 Solution
In the analysis, after pre-processing is done, the next step is to solve the analysis. In
ANSYS Workbench, we used the solve tool from the Standard toolbar to run the
solver. The solver run in the background of the software and acquires results of an
analysis, based on the specified boundary condition.
We have done total four types of structural analysis

Total Deformation
Equivalent Stress
Equivalent Strain
Strain Energy
28

There are three types of materials in our analysis as mentioned above. Now one by
one detail solution report is given below.

4.3.1 Total Deformation

Total deformation for final model with different materials are given below

Figure 4.5 Total Deformation for AISI 4130 Steel

Figure 4.6 Total Deformation for Haynes Hastelloy C-276

29

Figure 4.7 Total Deformation for INCONEL 718 Alloy

Table No.4.5 shows the maximum total deformation of blade with different materials
Table 4.5 Max. Total Deformation
S. No.
1.
2.
3.

Material
AISI 4130 Steel
Hastelloy C-276
INCONEL 718

Max. Total Deformation

13.356mm
5.2124mm
4.9683mm

4.3.2 Equivalent Stress

Equivalent stress for final model with different materials are given below

Figure 4.8 Equivalent Stress for AISI 4130 Steel

30

Figure 4.9 Equivalent Stress for Haynes Hastelloy C-276

Figure 4.10 Equivalent Stress for Inconel 718 Alloy

Table No.4.6 shows maximum equivalent stress of blades with different materials
Table 4.6 Equivalent Stresses
S. No.
1.
2.
3.

Material
AISI 4130 Steel
Hastelloy C-276
INCONEL 718

31

Equivalent Stress
291.88 MPa
300.81 MPa
303.58 MPa

4.3.3 Equivalent Strain

Equivalent strain for final model with different materials are given below

Figure 4.11 Equivalent Strain for AISI 4130 Steel

Figure 4.12 Equivalent Strain for Haynes Hastelloy C-276

32

Figure 4.13 Equivalent Strain for Inconel 718 Alloy

Table No.4.7 shows equivalent strain in blades with different materials
Table 4.7 Equivalent Strain
S. No.
1.
2.
3.

Material
AISI 4130 Steel
Hastelloy C-276
INCONEL 718

Equivalent Strain(m/m)
37.099
14.915
14.352

4.3.4 Strain Energy

Strain energy for final model with different materials are given below

Figure 4.14 Strain Energy for AISI 4130 Steel

33

Figure 4.15 Stain Energy for Haynes Hastelloy C-276

Figure 4.16 Strain Energy for Inconel 718 Alloy

Table No.4.8 shows maximum strain energy stored in blades with different materials.
Table 4.8 Max. Strain Energy
S. No.
1.
2.
3.

Material
AISI 4130 Steel
Hastelloy C-276
INCONEL 718

34

Strain Energy
10.297 J
4.0925 J
3.9215 J

4.4 Post-Processing
After the analysis is complete, we generated the report in the Mechanical window. To
do so, we chose the Report Preview tab from the bottom of graphics.
Now we have selected best material from each analysis and presented in Table no. 4.9
Table 4.9 Static Structural Analysis Summary
S. No.
1.
2.
3.
4.

Analysis Type
Total Deformation
Equivalent Stress
Equivalent Strain
Strain Energy

Best Material
INCONEL 718
AISI 4130 Steel
INCONEL 718
INCONEL 718

From above Table it is clear that INCONEL 718 is best material among three test
materials in total deformation, equivalent strain and strain energy analysis. Although,
equivalent stress is minimum in case of AISI 4130 Steel gas turbine but safety factor
in case of INCONEL 718 is almost 2.25 times greater than AISI 4130 Steel.

35

Chapter 5
Study State Thermal Analysis

5.1 Introduction
Before a model is finalized for production, it passes through several stages. Thermal
analysis is one of them and plays an important role in product development. Various
products such as I.C. engines, refrigerators, heat exchanges, turbine blades and so on
are designed on the basis of results of this analysis.
Thermal analysis is used to find out the temperature distribution and related thermal
quantities in the model. In this analysis, all heat transfer modes namely conduction,
convection and radiation are analyzed. The different outputs from a thermal analysis
can be the following:
a.
b.
c.
d.

Temperature distribution.
Amount of heat loss or gain depending on situation.
Thermal gradients.
Thermal fluxes.

This analysis is used in many engineering industries such as automobile, piping,

electronic, power generations, and so on. In ANSYS Workbench, two types of thermal
analysis can be carried out, namely Steady-State and Transient Thermal analysis. We
have carried out Steady-State Thermal analysis.
The following are the basic steps required to perform the thermal analysis:
1. Set the analysis preference.
2. Create or import solid model.
3. Define element attributes (element types, real constants, and material
4.
5.
6.
7.

properties).
Mesh the solid model.
Specify the analysis type, analysis options, and the loads to be applied.
Solve the analysis problem.
Post-process results.

36

5.2 Important Terms Used In Thermal Analysis

1. Heat Transfer Modes: Whenever two bodies having different temperature
come in contact, then the heat transfer takes place from body at high
temperature to the body at the lower temperature. There are three modes of
heat transfer: Conduction, Convection, and Radiation.
2. Thermal Gradient: It is the rate of change of temperature per unit depth in a
material.
3. Thermal Flux: It is defined as the rate of heat transfer per unit cross-sectional
area denoted by q.
4. Bulk Temperature: It is the temperature of a fluid flowing outside the material.
It is denoted by Tb. The bulk temperature is used in convective heat transfer.
5. Film Coefficient: It is a measure of the heat transfer through a thin film.
6. Emissivity: The emissivity of a material is the ratio of energy radiated by the
material to the energy radiated by a black body at the same temperature. It is
the measure of a material ability to absorb and radiate heat.

5.3 Types of Thermal Analysis

In ANSYS Workbench, two types of thermal analysis can be carried out, namely
Steady-State Thermal analysis and Transient Thermal analysis. We have carried out
Steady-State Thermal analysis.

5.3.1 Steady-State Thermal Analysis

In the Steady-State Thermal analysis, the thermal load does not vary with time and
remains constant throughout the period of application. These thermal loads include
convection, radiation, heat fluxes (heat flow per unit volume), and constant
temperature boundaries.
The Steady-State Thermal analysis may be either linear or nonlinear, with respect to
material properties that depends on temperature. The thermal properties of most of
the materials do vary with temperature; therefore the analysis is usually nonlinear.
Including radiation effects or temperature-dependent convection in a model also
makes the analysis nonlinear. But we have assumed it to be linear.

5.4 Steady-State Thermal Analysis of Gas Turbine Blade

We have carried out thermal analysis on three types of gas turbine blades namely
37

1. Simple blade without any hole (no cooling)

2. Blade with holes along the length (internal cooling)
3. Blade with holes along the length as well as on the surface of the
blade(internal cooling plus film cooling)
We have selected following three materials for the thermal analysis:
Table 5.1 Thermal Properties of Materials
S.

Material

N
1.
2.
3.

AISI 4130 Steel (super alloy steel)

Haynes Haste alloy C-276
INCONEL 718 alloy

Thermal Conductivity Melting point

34.8 W/m-k
23.1 W/m-k
23.75 W/m-k

1432 C
1370 C
1336 C

Note- We have taken thermal conductivity of the above materials at 800C.

5.4.1 Thermal Analysis of Blade with holes along the length as well as on
the Surface
The following steps have been followed for the analysis:
1.
2.
3.
4.

Importing the 3D model of the blade.

Mesh generation.
Applying thermal boundary conditions.
Analyzing the results.

5.4.1.1 Import and Mesh Generation

After starting ANSYS Workbench 14, we first started Steady-State Thermal analysis
and then imported the geometry of the blade. Now meshing has been selected. Details
of Mesh for the three different material (same for all) has been listed below:

38

Figure 5.1 Meshing of 3D model of blade with internal cooling and film cooling
Table 5.2 Meshing Details
S.N

Model Name

Grain

1.

Size
With internal and film Coarse

Relevance

Number of Number of

elements
264644

nodes
439218

cooling

5.4.1.2 Thermal Boundary Conditions

After generating mesh, we have applied the boundary conditions for the analysis. In
the Details of Temperature window, first the pressure side of the blade has been
selected and given 800C temperature. Now in Initial Temperature window, the
environment temperature is given as 22C. In the Details of Convection window,
the root surfaces have been selected as a medium for convection heat transfer.
5.4.1.3 Solutions
Next step is to solve the problem using Solver tool. The solver run in the background
of the software and acquires results of an analysis, based on the specified boundary
condition. The following three analysis have been carried out:
1. Total heat flux
2. Directional heat flux
3. Temperature
39

1. Total Heat Flux

Total heat flux for final blade for all the three material are given below:

Figure 5.2 Total Heat Flux for AISI 4130 Steel

Figure 5.3 Total Heat Flux for Haynes Haste alloy C-276

40

Figure 5.4 Total Heat Flux for INCONEL 718 alloy

Table 5.3 Comparison of Total heat flux for the three materials

S.N
1.

Material
AISI 4130 Steel (super alloy

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

Total heat flux (W/m2)

Min.
Max.
1.4771e-8
4.3324e5
3.7798e-9
5.5019e-9

4.2597e5
4.2655e5

2. Directional Heat Flux

Directional heat flux for all the three materials have been shown below:

41

Figure 5.5 Directional heat flux for AISI 4130 Steel

Figure 5.6 Directional heat flux for Haynes Haste alloy C-276

Figure 5.7 Directional heat flux for INCONEL 718 alloy

Table 5.4 Comparison of Directional heat flux for the three materials

S.N
1.

Total heat flux (W/m2)

Min.
Max.
46473
-2.5425e5

Material
AISI 4130 Steel (super alloy
42

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

45714
45775

-2.4995e5
-2.5029e5

3. Temperature
Temperature for all the three materials have been shown below:

Figure 5.8 Temperature for AISI 4130 Steel

Figure 5.9 Temperature for Haynes Haste alloy C-276

43

Figure 5.10 Temperature for INCONEL 718 alloy

Table 5.5 Comparison of Temperature for the three materials

S.N
1.

Material
AISI 4130 Steel (super alloy

Temperature (C)
Min.
Max.
771.85
800.26

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

758.39
759.46

44

800.39
800.38

Chapter 6
Results and Discussion
6.1 Static Structural Analysis of Blade

Table 6.1 Structural Analysis Details

S.

Solution

AISI 4130 Steel

Haynes

Inconel 718

No.
1
2
3
4

Deformation (mm)
Stress (MPa)
Strain (m/m)
Strain Energy (J)

13.3560
2918.8
37.099
10.297

Hastelloy C-276
5.2124
3008.1
14.915
4.0925

Alloy
4.9683
3035.8
14.352
3.9215

Maximum Total Deformation (mm)

AISI 4130 Steel

Hastelloy C-276

INCONEL 718

Figure 6.1 Total Deformation

45

Maximum Equivalent Stress (MPa)

AISI 4130 Steel

Hastelloy C-276

INCONEL 718

Figure 6.2 Equivalent Stress

Maximum Equivalent Strain (m/m)

AISI 4130 Steel

Hastelloy C-276

INCONEL 718

Figure 6.2 Equivalent Strain

46

Maximum Strain Energy (J)

AISI 4130 Steel

Hastelloy C-276

INCONEL 718

Figure 6.4 Strain Energy

6.2 Thermal Analysis of Blade

Table 6.2 Details of Total heat flux

S.N
1.

Material
AISI 4130 Steel (super alloy

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

Total heat flux (W/m2)

Min.
Max.
1.4771e-8
4.3324e5
3.7798e-9
5.5019e-9

4.2597e5
4.2655e5

Table 6.3 Details of Directional heat flux

S.N
1.

Material
AISI 4130 Steel (super alloy

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

Total heat flux (W/m2)

Min.
Max.
46473
2.5425e5
45714
45775

47

2.4995e5
2.5029e5

Table 6.4 Details of Temperature

S.N
1.

Material
AISI 4130 Steel (super alloy

Temperature (C)
Min.
Max.
771.85
800.26

2.
3.

steel)
Haynes Haste alloy C-276
INCONEL 718 alloy

758.39
759.46

800.39
800.38

6.3 Factor of Safety

Table 6.5 Factor of Safety
S.

Material

Working

Ultimate Tensile

FOS

No.
1
2
3

AISI 4130 Steel

Haynes Hastelloy C-276
Inconel 718 Alloy

Stress (MPa)
291.88
300.81
303.58

Strength (MPa)
560
601.2
1375

1.9185
1.9986
4.5292

6.4 Discussion
From above result data it is clear that INCONEL 718 is best material among three test
materials in total deformation, equivalent strain and strain energy analysis. Although,
equivalent stress is minimum in case of AISI 4130 Steel but factor of safety is much
greater (almost 2.25 times) in case of INCONEL 718 blade.
So from structural analysis result we have found INCONEL 718 as best among three
test materials.
In case of static thermal analysis result shows that data of maximum heat flux and
maximum directional heat flux for Hastelloy C-276 is 0.1359% less than from
INCONEL 718 blade.
Now if we see cumulative effect of both structural and static thermal analysis we find
that thermal effect is nearly same ( 0.1359 % more in case of INCONEL 718) for both
Hastelloy C-276 and INCONEL 718 but structural analysis shows INCONEL 718 is
best material among AISI 4130 Steel, Hastelloy C-276 and INCONEL 718.

48

Chapter 7
Conclusion

This project work deals with Design and Analysis of Gas Turbine Blade for
suggesting optimum material for the gas turbine blade. Initially literature survey and
data collection has been done to understand the methodology. Three materials are
selected named as AISI-4130 super alloy steel, Haynes Haste alloy C-276 and new
material INCONEL alloy-718 for performing analysis. Parametric modeling is done in
BladeGen in ANSYS Workbench 14.0 using parameters collected from the literature
survey. Using these design parameters, we have generated the key points for 2-D
airfoil of gas turbine blade. With the help of these key points, we have designed the
blade using CATIA V5 and Autodesk Inventor software. Using the above three
materials, static and thermal analysis has been conducted on gas turbine blade. Result
tables and graphs are prepared for the easy comparison and understanding. Static
structural analysis provides fully developed analysis using pressure load as per the
structural analysis Inconel alloy-718 is showing good characteristics (minimum value
of deformation, strain and strain energy).
The temperature has a significant effect on the overall stresses in the turbine blade. So
Thermal Analysis has been carried out to look into the effect of temperature on gas
turbine blade. Maximum temperatures are observed at the blade tip section and
minimum temperature variations at the root of the blade. Temperature distribution is
49

almost uniform at the curvature region along blade profile. The temperature is linearly
increasing from the root of the blade to the tip of the blade.
As per results obtained from analysis INCONEL alloy-718 gives the maximum life to
the gas turbine blade due to its good structural properties, low deformation, strain and
thermal behaviors. So we have selected INCONEL 718 for our gas turbine blade.
Future Scope, change the blade angles of gas turbine blade to apply different pressure
and temperature. Evaluate the decrease in deformation and strain value and increase
the stress value. Use different material alloy to increases life time of gas turbine blade
and to decrease the damages. Use ceramics to avoid the corrosion and erosion of the
gas turbine blade.

50

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53