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Article history: In the current review, the failure analysis of gas turbine blades and to overcome those failures the devel-
Received 2 January 2020 opment of materials have been discussed. The properties of a gas turbine blades should have exhibit have
Received in revised form 21 February 2020 been reported in the current review. In addition to the above, the importance of coating in gas turbine
Accepted 24 February 2020
blade has been listed. After the brief investigation of the failure analysis and materials developed it is
Available online xxxx
observed that still there are some properties to be developed to obtain an optimum gas turbine blade.
Ó 2020 Elsevier Ltd. All rights reserved.
Keywords:
Selection and Peer-review under responsibility of the scientific committee of the 2nd International
Gas turbine
Blades
Conference on Processing and Characterization of Materials.
Failure
Materials
Coating
https://doi.org/10.1016/j.matpr.2020.02.859
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and Peer-review under responsibility of the scientific committee of the 2nd International Conference on Processing and Characterization of Materials.
Please cite this article as: B. Swain, P. Mallick, S. Patel et al., Failure analysis and materials development of gas turbine blades, Materials Today: Proceedings,
https://doi.org/10.1016/j.matpr.2020.02.859
2 B. Swain et al. / Materials Today: Proceedings xxx (xxxx) xxx
by Kumari et al. revealed that the core wear mechanisms on the compressor blade damages occurred due to solid particle erosion
leading and trailing edges are the cuts, dents and nicks. These wear wear is shown in the (Fig. 1).
effects were the consequences of the pitting action caused by local-
ized oxidation at the substrate/coating interface [10]. Khajavi et al. 3. Materials development for gas turbine blades
performed an investigation on the first stage of gas turbine blade
failure and finally, he got two major mechanisms of blade failure Several steps have been initiated to acquire an optimized mate-
(hot corrosion combined with solid particle erosion wear) [11]. rial and method for getting a successful piece of the blade which is
Qu et al. observed from the failure analysis of a gas turbine blade having all the required properties. From the early 50 s the techno-
manufactured of IN738 nickel-base super-alloy and concluded that logical developments of the gas turbine/compressor blades have
the porosity flaws in the blade trailing edge were the main cause been started. The history of the gas turbine/compressor blades
behind the fatigue fracture and instantaneous fracture in the blade spectacle the journey from wrought materials to coatings [16].
[12]. Hou et al. analysed the failure reasons of gas turbine blades All the efforts made by the researchers are given by the (Table 1)
and found that blade tip/casing rub strap impact was also a cause and a graphical representation of the evolution of gas turbine blade
of fatigue failure of the blade [13]. A graphical representation of the manufacturing is shown in (Fig. 2).
Table 1
Reported literature about possible methods of gas turbine blades manufacturing.
Without coating
Authors Materials and methods Issues
Backman et al. [1] Conventional investment casting of nickel based alloys. Could not survive at high temperature. Grain boundary cracking
of casts.
Versnyder et al. [2–6] Directional solidification of nickel based superalloy (Mar-M200). Having lower creep strength, axial thermal fatigue resistance and
oxidation resistance [7]. Strengthening phase c’ was compara-
tively small.
Duhl et al. [8–12] Directional solidification of nickel based superalloy (Mar-M200) Limitations concerning chemical content variability [13].
+ hafnium (Hf). Other alloys are also manufactured by this process
such as IN 792 and IN 939 etc.
Caron et al. [14] Single crystal Ni based superalloy Creep strength was low. [14]
With coating
Authors Materials and methods Issues
Warnes et al. [15–21] Diffusion coating (pack cementation aluminizing, Chemical It is a non-line-of-sight technique. Expensive due to improper
vapour deposition (CVD) process, out of contact). masking and tooling [22].
Nicholls et al. [23–27] Overlay coating (like physical vapour deposition (PVD), electron Limitation of PVD or EBPVD processes are it becomes more
beam physical vapour deposition (EBPVD), air plasma spraying complex with the increase in complexity of chemical composition
(APS),) of MCrAlY on nickel based super-alloys. [28].
Clarke et al. [29–38] Thermal barrier coating (like APS, EBPVD, Suspension plasma Bond coat has to be coated to increase the adhesion strength of
spraying) of Yttria-stabilized Zirconia (YSZ). the top coat and substrate. So it will be more expensive to coat
both the bond coat and top coat.
Please cite this article as: B. Swain, P. Mallick, S. Patel et al., Failure analysis and materials development of gas turbine blades, Materials Today: Proceedings,
https://doi.org/10.1016/j.matpr.2020.02.859
B. Swain et al. / Materials Today: Proceedings xxx (xxxx) xxx 3
5. Conclusion
The failure of the gas turbine blades is mainly due to the fatigue,
solid particle erosion wear, oxidation of the trailing edge and
corrosion of the surface.
The coating is very much essential for the protection of the
blade surface from erosion and corrosion and also to increase
the reliability of the blade. Among all the coatings, thermal
spray coating is widely used for aerospace application for better
properties.
The coating should have corrosion and oxidation resistance,
erosion resistance, coating and alloy interfacial stability, coating
adhesion and aerodynamic properties to sustain the harsh envi-
ronment of aerospace.
Please cite this article as: B. Swain, P. Mallick, S. Patel et al., Failure analysis and materials development of gas turbine blades, Materials Today: Proceedings,
https://doi.org/10.1016/j.matpr.2020.02.859
4 B. Swain et al. / Materials Today: Proceedings xxx (xxxx) xxx
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Please cite this article as: B. Swain, P. Mallick, S. Patel et al., Failure analysis and materials development of gas turbine blades, Materials Today: Proceedings,
https://doi.org/10.1016/j.matpr.2020.02.859