Abstract

This progress report presents study of failure analysis of gas turbine. Gas turbine has enormous applications from ground based power plants to
aircrafts where they are used as engines. Nowadays, a lot of work is done on how to stop failure of gas turbines during operations in order to
enhance their efficiency and gain maximum economic benefit from them.
In the beginning, a statistical analysis is given of the various research papers which I have read throughout the semester giving proportion of
which component which attributed towards most of the failures. Turbine blade failure caused most of the failure contributing about 67% of the
failures. Then, turbine and compressor blade failures are explained, giving its origins and how to prevent them. In the end, a table summarizes all
research papers stating which component failed, its mode of failure and page of research paper where that analysis was carried out.

Table of Contents
1.

Introduction..........................................................................................................................................................................................2

2.

Case Study of various research papers.................................................................................................................................................2

3.

Statistical Analysis...............................................................................................................................................................................2

4.

Turbine Blade Failure...........................................................................................................................................................................4

5.

Compressor Blade Failure....................................................................................................................................................................6

6.

Research Papers Summarized in Table.................................................................................................................................................7

7.

References..........................................................................................................................................................................................34

1. Introduction
The purpose of my thesis is to study the failure analysis of gas turbine. After completion of my thesis, I should be able to identify the causes of
failure, their identification, how to repair them and to prevent them from occurring in the future. For that objective, I have gone through various
books, research papers and articles to develop thorough understanding of this concept of failure analysis. In the previous report, I explained the
Page 1 of 45

common modes of failure discussed in detail their causes and how to avoid them. This report includes the work done by me so far in this
semester. I have made a table in which all research papers regarding failure analysis which I read are included. Table provides information which
component of gas turbine failed, its mode of failure and pages on the research paper which identifies that mode.

2. Case Study of various research papers

I have gone through various research papers regarding failure analysis of gas turbine and prepared the table in which failure mode, indication
and methods to prevent them are given. I read total of 55 papers and these papers were about failure analysis of different components of gas
turbine like compressor, turbine, nozzle etc. But most of the failures were due to turbine blade failure. A statistical analysis is given below
showing details of various components contributing towards failure.

3. Statistical Analysis
Number of Papers read
Compressor Blade Failure
Turbine Blade Failure
Nozzle
Others

55
12
37
4
2

Percentage
22%
67%
7%
4%

Page 2 of 45

Statistical Analysis

10

15

20

Compressor Blades

25

30

Turbine Blades

Nozzles

35

40

Others

Fig 1. Bar Chart

This analysis clearly shows that turbine failure attributed to most of failure causes. The main reason behind it that turbine are subjected to severe
conditions. Gas at high temperature and pressure enters the turbine blade and therefore good coating must be applied to them to avoid the
failure. Due to high temperature exposure, creep phenomenon can find its way to damage the blades. Moreover, chemical composition of gases
cause promote corrosion phenomenon. Also, cyclic loading can promote fatigue phenomenon. So, to avoid them, suitable precautionary
measures should be adopted and proper SOPs should be followed to avoid them. Some causes and methods to avoid them are given in table.

Page 3 of 45

4. Turbine Blade Failure

Gas turbine blades are made of nickel-base and cobalt-base superalloys principally. During the operation of power generation gas turbines, the
blades and other elements of hot gas path suffer service induced degradation which may be natural or accelerated due to different causes. The
degradation or damage may have a metallurgical or mechanical origin and results in reduction of equipment reliability and availability.
It also increases risk of failure occurring. Also, due to blade material metallurgical deterioration, the material creep, fatigue, impact and corrosion
properties decrease. There are different factors which influence blade lifetime as design and operation conditions but the latter are more critical.
Generally speaking, most blades have severe operation conditions characterized by the following factors:

Operation environment (high temperature, fuel and air contamination, solid particles, etc.).

High mechanical stresses (due to centrifugal force, vibratory and flexural stresses, etc.).

High thermal stresses (due to thermal gradients).

Typically there are acting two or more factors simultaneously causing reduction of blade lifetime under the following damage mechanisms [1]:

Creep

Thermal fatigue (low cycle fatigue)

Thermomechanical fatigue (high cycle fatigue)

Corrosion

Erosion

Oxidation

Foreign object damage

The type of damage which occurs in gas turbine blades and nozzles after a service period can be divided into:
Page 4 of 45

External and internal surfaces damage (corrosion, oxidation, crack formation, erosion, foreign object damage and fretting).

Internal damage of microstructure as gamma prime [Ni3(Al,Ti)] phase aging (rafting), grain growth, grain boundary creep voiding,
carbides precipitation and brittle phases formation.

Surface damage produces blades/nozzles dimensional changes which result in operational stress increase and turbine efficiency deterioration.In
service, blade material deterioration is related to the high gas temperature, high steady state load levels (centrifugal load) and high thermal
transients loads (trips, start-ups and slowing downs). However, the degree of deterioration in individual blades differs due to several factors such
as:

Total service time and operation history (number of start-ups, shut-downs and trips).

Engine operational conditions (temperature, rotational speed, mode of operation (base load, cyclic duty)).

Manufacturing differences (grain size, porosity, alloy composition, heat treatment).

The Inconel 738LC alloy commonly used for gas turbine blades is strengthened by precipitation of gamma prime phase. The microstructural
changes due to blade operation at high temperature include irregular growing of gamma prime particles (rafting) and formation of carbides in
grain boundaries and matrix [2]. This leads to alloy creep properties reduction [3].

In order to have an instrument for the deterioration evaluation of gas turbine blade alloy, it is necessary to correlate the influence of service
induced microstructural degradation to the change in mechanical properties. This can be used for monitoring and evaluation of extent and degree
of material damage and lifetime consumed and to obtain recommendations for blade rejuvenation treatments, operation and reposition [4].
Application of effective methods of material deterioration evaluation can be used for practical lifetime prediction, just in-time blade
rehabilitation (rejuvenation), safe and cost-effective lifetime extension and to avoid blade catastrophic failure. [1]
Page 5 of 45

5. Compressor Blade Failure

Aeroengine gas turbine components operate in a particularly aggressive environment where both high temperature and mechanical loading
promote creepfatigue damage at compressor blades. At the same time there is a continuous demand for higher thrust and lower fuel
consumption and consequently each stage in the engine is required to work with higher loads without compromising safety. Therefore, the
maximization of reliability levels of aeroengines is of paramount importance and several lifing procedures have been developed with this
purpose. However there is still a significant number of failures affecting critical components during normal operation and the rejection rate
during overhaul for contention of incipient failure mechanisms is fairly high.
Compressor blades are within the most affected components for two main different reasons: either by the ingestion of debris, such as birds or
sand, causing Foreign Object Damages (FOD) or by typical degrading mechanisms resulting from cyclic loading and high temperature
environments (creepfatigue interaction). In the former case, the impact of small debris induces nicking of the blades which, in turn, will act as
stress raisers prone to crack initiation . Parallel to this, the damage caused by FOD tends to compromise the mechanical balance of the rotating
components and also alters the aerodynamic flow over the blade airfoil leading to significant vibration or flutter which can promote crack
propagation due to fatigue which, in turn, is a common cause of component breakage.
The interaction of both creep and fatigue mechanisms is the other main cause of failure in compressors and turbines of aeroengines. Creep
damage is a thermally activated and time dependent mechanism which results from structural changes leading to continuous reduction in the
strength of the material during service mainly due to the formation of intergranular voids and subsequent cracking. By

the other hand, fatigue crack propagation is a cyclic dependent mechanism occurring for temperatures below the creep range of the materials. In
this case, a continuous plastic deformation process will extend to a size covering a significant region of the fracture surface with clear evidences
of transgranular cracking and the formation of well defined striations. High temperature fatigue is an important issue when considering the
mechanical behaviour of critical aeroengine components and there is a large bulk of investigations relating crack growth rates with different
types of external effects, such as temperature, frequency of loading and cyclic stress ratio.[6]

Page 6 of 45

6. Research Papers Summarized in Table

Page 7 of 45

Researc
h Paper

[1]

Compres
sor
Blades

Turbine
Blades

Nozzles

Cooling
Water
pipes

[2]

[3]

[4]

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

The Compressor stator blade was found to have

failed in progressive mode, i.e. by fatigue.
The crack origin was at the blade hub-stem
junction on the leading edge side.
Presence of machining/filing marks appeared
to be the reason for the fatigue crack initiation
from this region.
The copperzinc alloy pipes used in the
condensed water system of a power plant failed
within a period of 5 to 6 years.
Examination revealed that the pipes damaged
over this relatively short period of time were
constructed of copperzinc alloys that are not
resistant to dezincification corrosion.
Dezincification corrosion occurred on the
copper-zinc alloys pipes in the form of holes.
The cause of failure is found to be
intergranular cracks which started during
exposure to high temperature. The cracks
initiated from the grain boundaries and
propagated to the critical length to result in
catastrophic fracture. Thus Creep Mechanism
failure occurred.
The gas turbine blade under examination was

Pages
935,936,937

Pages
169,170

Pages
746,747

Page 46
Page 8 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

Nozzles

[5]

[6]

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

operated at elevated temperatures in corrosive

environmental attack such as oxidation, hot
corrosion and sulphidation.
Blade suffered multiple failure mechanisms
such as hot corrosion and fatigue. Hot
corrosion reduced the thickness of the blade
materials and weakened the blade. The
reduction of thickness reduced fatigue strength
and ultimately caused the failure.
The nozzle experience cracks in different vane Page 919
airfoil sections assisted by base alloy
degradation due to an operation at high
Temperature. It was found that the vane crack
initiation and propagation was derived by
thermal fatigue mechanism.
The vane crack initiation and propagation were
due to fatigue mechanism which was facilitated
by grain boundaries brittleness caused by
formation of continuous film of carbides on
grain boundaries, grains coarsening, and high
thermal stress level.
It was evaluated that the crack initiation and Page 515
propagation was derived by thermal-fatigue
mechanism. Microstructural changes and
Page 9 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

[9]

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

[7]

[8]

Nozzles

Failure Mode

repairing defects caused the crack propagation

and this phenomenon resulted in separating
some fragments that damaged other parts of the
nozzle due to high speed rotation of the rotor
and high flow rate of the hot gas.
Examination of the fracture surfaces by using
electron microscopy revealed the cracks
propagated in accordance with a high cycle
fatigue mechanism induced by in-service
typical loads, such as vibrations and air
turbulent flows.
A 150MW gas turbine experienced a forced
break down because of extremely high
vibrations and subsequent output power
reduction down to almost zero.
The cause of blade failure was low cycle
fatigue that originated a crack in the securing
pin hole (stress raiser) located at the root of the
blade and propagated.
The identified fracture mechanism was high
cycle fatigue originated by fretting on the fir
tree lateral surface (i.e. fretting fatigue).
Debris formation and wear products on the
contact surfaces of the fir tree root, presence of

Remarks

Pages 288290,293

Page 1802

Pages 387390

Page 10 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

[10]

[11]

[12]

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

wear tracks, crack initiation near wear

damages, and the slant orientation of fatigue
crack origin, present primary evidence of the
mechanism of fretting fatigue to the blade
failure process.
The blade experienced base alloy degradation
due to operation at high temperature. On the
basis of the observed microstructures and the
phases present in the alloy, the main cause of
failure was found to be creep damage.
The first-stage blades of a gas turbine had
suffered a severe deterioration after around 10
500 h service.
Blades, manufactured in the nickel superalloy
CMSX-4, lost the protective coatings from
their tips due to wear. Unprotected surfaces
suffered high-temperature hot corrosion (TypeI corrosion). It is concluded that failure was
mainly caused by an uneven clearance (out-ofline) between rotor and lining.

Remarks

Pages
213,214

Pages
266,267

In this paper blade fatigue failures are Pages

investigated by mechanical analyses and by 202,206,20
7,
examination of failed blades.
Page 11 of 45

Researc
h Paper

[13]

[14]

Compres
sor
Blades

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

The likely cause of blade failure is considered

to be a mixture of LCF and HCF as a
consequence of blade tip/casing rub strap
impact. The cause of such impact may be
variation of the as new blade length and/or
increases in blade length as a consequence of
creep after an extended period in service. In
both cases the risk of failure would clearly be
exacerbated by poor material quality.
The crack initiated at the trailing edge
of the blade and propagated by fatigue. The
remaining fracture surface shows an intergranular fracture morphology, which indicates
the typical feature by overload at the last
moment.
The investigation revealed that the triple point
creep cracks were initiated on the trailing edge
of blade-airfoil near root region. Grain
dropping was also observed within these
cracks. One of these cracks was propagated
under the high cycle fatigue mechanism,
circumscribing almost 50% of the fracture
area. When this fatigue crack might have
propagated to a critical length, the airfoil of the

210

Page 2321

Pages
1409-1412

Page 12 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

[15]

[16]

[17]

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

blade fractured catastrophically under overload

condition. The primary cracking was due to
creep.
The turbine blade had initially cracked
by a fatigue mechanism over a period of time
and then fractured by the overload at the last
moment. The crack initiated at the subsurface
or close to the surface and showed the
cleavage-like features. The segregated area
of Ti and Mo, caused usually by improper
manufacturing process, is found by the
microstructure and EDX analysis of the
blade. The crack initiated at this area and was
due to the stress concentration at the
segregation of Ti and Mo near the
blade surface.
Turbine blade had initially cracked by a fatigue
mechanism over a period of time and then
failed by overload at the last moment. The
fatigue crack initiated on a surface damaged by
rubbing.
It is found that one of four fractured blades (the
No. 62 blade) had initially cracked by a fatigue
mechanism over a period of time, and then

Remarks

Pages
879,880,88
1

Pages
594,595

Pages
294,295

Page 13 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

[18]

[19]

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

fractured by the overload at last moment and

the other three fractured blades (the No. 63,
No. 1 and No. 2 blades) are all instant fracture
with the dendrite morphology.
The investigation has revealed that the damage
of surface coating has caused severe localized
oxidation attack to I stage blade A, leading to
the formation of oxide at interface between
coating and substrate and pits as well as
dislodgement of surface coating at several
locations on the surface of the aerofoil. Fatigue
cracks have initiated at these pits and
propagated during service and led to the
fracture of the first stage blade. Subsequently,
the broken pieces of the first stage blade has
caused further damage (internal object damage)
to other first stage as well as the second and the
third stage turbine blades in the form of dents
and nicks on leading/trailing edges by impact.
The wear modes were severe pitting action,
large craters similar to those observed in solid
particle erosion when the samples are impacted
at normal incidence, corrosion and a few
irregular scratches similar to ploughing action

Remarks

Pages 240243

Pages
6,7,8,9

Page 14 of 45

Researc
h Paper

[20]

Compres
sor
Blades

Turbine
Blades

Transiti
on
pieces

[21]

[22]

Nozzles

Gas
Turbine
Buckets

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

in abrasive wear.
This paper presents the analysis of two in
service failures involving blades breakage
belonging to different compressor stages.
The analysis of the different fracture surfaces
shows that crack propagation is mainly related
with fatigue mechanisms whilst crack initiation
can be attributed to distinct causes, either the
presence of defects in the surface of the blade
due to impact of debris or intrinsic material
defects or some degrading mechanisms
affecting the internal microstructure of
the material.
It was revealed that the thermal fatigue was the
main reason for the failure and also oxidation
facilitated the crack propagation.
In order to prevent the failure of transition
pieces, it was proposed to create a row of
holes, at 1 cm above the impaired region for
local cooling and stopping probable cracks.
The failure of a gas turbine first stage bucket
was investigated by visual inspection and finite
element analysis. Changes of microstructural
morphologies of the damaged buckets under

Remarks

Pages
1120,1121,
1122

Pages
407,408,40
9

Pages
561,563,56
6,
567
Page 15 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

Nozzles

[23]

Gas
turbine
Generat
or
cooling
fan
blades

[24]

[25]

Turbine
Disk

[26]

Cooling
Water
pipes

Inlet

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

the thermal and mechanical stress were

observed.
The TMF cracking of surface coatings on the
suction and pressure sides of the bucket was
described.
Analysis results show that the final fracture of
blades is due to fatigue conditions in resonance
state and growth of existent tiny probable
cracks.

Pages
1688,
1689,1690,
1691,1692

It was found that the crack initiated by the hot

corrosion from the leading edge and
propagated by fatigue and finally, as a result of
the reduction in cross-section area, fracture was
completed.
From the visual examination of the fractured
surface, it was possible to observe beach
marks, typical of fatigue failure.
High stress zones were found at the region of
the lower fir-tree slot, where the failure
occurred.
It was established that failure occurred by

Pages
1113,
1115,1117,
1118,1122,
1125,1127
Pages
10,11,
14

Pages 420,
421,422,
Page 16 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

Nozzles

guide
vane

[27]

[28]

[29]

[30]

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

fatigue crack growth which was initiated from

a surface defect, in the form of a non-metallic
inclusion cluster, at the vane root location
where working stresses were highest.
The result shows that the fatigue fracture of the
blade was originated during transient events
internal to the combustion chamber which was
close to the resonance condition of the
assembled blades.

425

HPTR blades were sectioned to study under

SEM. Regions of platinum modified aluminide
coating degradation and DS CM 247 LC base
material cracking were observed which make
the particular lot unusable.
Fracture of both the blades and vanes was
found to occur by a mixed mode involving
intergranular cracking and fatigue. Most
evidence pointed out that initial damage by
creep resulting in intergranular cracking had
shortened the fatigue life of blades and vanes.
Micro-cavities were found on fracture surfaces
that served as an origin of a creeping failure
mechanism

Pages
2109,
2110

Pages
1970,
1971,1972

Page
279

Pages
5,6,7,8

Page 17 of 45

Researc
h Paper

Compres
sor
Blades

Lock Pin

[31]

[32]

[33]

[34]

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

Fractography investigation showed typical

fatigue fracture surfaces in the neck of failed
lock-pins and localized pitting signs near the
head of lock-pin, where crack had been
nucleated. In addition, there were extensive
fretting corrosion effects in the serration areas
of disc and blades. It seemed the failure has
been started by fatigue fracture in a lock-pin
and then the bucket could move out side of disc
serrations.
A matched blade tenon and disk mortise of the
first stage compressor in an aeroengine
fractured simultaneously.
Investigation revealed that the design
shortcoming resulted in over-compensation of
centrifugal bend moment and bad contact
condition.
The cause of accident was a blade failure due
to fatigue process promoted by corrosion pits
which acted as stress concentration site.
The research result shows that turbine blade tip
is initially damaged by rubbing and corrosion
over a period time, premature cracking of blade
tip is caused by a combination mechanism of

Pages
849,
850,
851

Pages
386-388

Pages
1151,1152
Pages
1431,1432,
1433

Page 18 of 45

Researc
h Paper

Compres
sor
Blades

[35]

[36]

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

environment and thermal stress. During turbine

blade maintenance and refurbishment, coating
of both oxidation-resistance and abrasionresistance should be applied in blade squealer
tip to counteract the problem.
From the visual examination of the fractured
surface, the turbine blade had initially cracked
by a fatigue mechanism over a period of time
and then fractured by the overload at the last
moment. On further examination, the crack
initiated at the trailing edge of the blade, and
propagated by the fatigue under the cyclic
loading experienced by the blade during
service.
Failure of the blades is attributed to the impacts
of sand or stones against the leading edge of
the blades. That is the so-called foreign object
damage (FOD).
The foreign substance present on the fracture
surfaces of the blades is so deeply adhered and
encrusted that even after a second strong
cleaning is not completely removed. This fact
represents a support to the above formulated
hypothesis in the sense that this substance

Remarks

Pages
2321,2322

Pages 667,
668, 673

Page 19 of 45

Researc
h Paper

[37]

[38]

Compres
sor
Blades

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

(mainly silica) is responsible of the failure

and not simply deposited on the surfaces once
fractures occurred.
During the shut down period, a 32 MW gas
turbine experienced a severe failure
accompanied by a loud noise near its second
natural frequency at 4200 rpm. After opening
the turbine casing, it was revealed that the
disks of stages 16 and 17 of the compressor
had been fractured and all of the stationary and
rotary blades of stages 1418 of the
compressor had been detached from the
dovetail region of the disks.
Analysis showed that multiple cracks had been
initiated in the interface of the disks and shaft
by the fretting fatigue mechanism and had been
propagated by fatigue mechanism. Finally,
unexpected and/or excessive forces or impact
loads had led to the final brittle fracture of the
disks.
It was found that the coating/substrate crack
initiation and propagation was driven by a
mixed fatigue/creep mechanism. The coating
degradation facilitates the crack initiation due

Remarks

Pages
476,477,47
8,
483

Pages
476,477,48
0,
481,484
Page 20 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

[39]

[40]

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

to thermal fatigue.
The substrate intergranular crack initiation and
propagation were due to a creep mechanism
which was facilitated by grain boundary
brittleness caused by formation of a continuous
film of carbides on grain boundaries, the
degradation of gamma prime due to elongation
(rafting)
and
coalescence,
and
high
thermomechanical stress level.
The microstructural investigation of the blade Pages
airfoil revealed the presence of continuous film 746,747
of carbides in grain boundaries of the base
material as a result of transformation
of carbides of MC type to carbides of M6C
type due to high temperature operation of the
blades.
A large number of intergranular cracks were
found in the failed blade airfoil. On the fracture
surfaces were found micro-cavities that served
as the origin of a creep failure mechanism. On
the other hand it is evident from the rubbing
marks that the turbine blades were touched by
other objects during revolution.
During a test run of an aeroengine, a low- Pages
Page 21 of 45

Researc
h Paper

[41]

[42]

Compres
sor
Blades

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

pressure turbine rotor blade had failed.

Investigation revealed that the blade had failed
by fatigue. It was concluded that the coating on
the blade had developed cracks due to
excessive bending/vibration, which in turn
propagated by fatigue leading to the failure.
Fractography experiments showed clearly
multiple crack initiation sites and fatigue beach
marks. Debris particles were observed on the
fracture surface of samples and in the mouth of
initiated cracks. The blade surface in contact to
the disc in the dovetail region showed a higher
surface roughness than the other surfaces.
Based on the results obtained, the fretting
fatigue mechanism was proposed for the
premature failures. It was concluded that the
stress concentration has been caused by either
unsuitable curvature ratio of the disk dovetail,
incorrect design of the blade or insufficient
distance between the blade root and the disk in
dovetail region.
Metallographic investigation for three spot
selections (trailing edge, leading edge, and
high-temperature region) for the failed

1203,
1204,1205,
1206,1207,
1217

Pages
564,565,56
6,
567

Pages
3122,3123,
3124
Page 22 of 45

Researc
h Paper

[43]

Compres
sor
Blades

Turbine
Blades

Turbine
Casing

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

superalloy
blade
proved
detrimental
microstructural features of gamma prime
-particle coarsening, cavities and carbide-phase
film at grain boundaries. It is concluded that
the trailing edge (transverse cross-section) of
the blade failed by creep damage. Hence, it is
not at all safe to continue to use the blade in the
gas-turbine engine in the power plant of the
company (TNB, Malaysia).
It is recommended that more efficient blade
cooling and/or thermal barrier coatings (TBC)
should be applied to the turbine
blades.
In this work, an attempt of explanation of the
turbine casing fracture was made. The visual
inspection was incomplete because of fact that
the damaged part was repaired by welding.
In presented case, the finite element numerical
stress analysis for the turbine casing was
performed. During analysis of the numerical
model, loads and complicated boundary
conditions were defined. By specification of
two load components (thermal and mechanical)
and analysis of the results obtained for

Remarks

Pages
915,916,91
7,
918,919

Page 23 of 45

Researc
h Paper

Compres
sor
Blades

Turbine
Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

separated loads, the failure process of turbine

casing can be better understood.
During the work preparation, the following
conclusions can be formulated:
1. The reduced stress in the critical zone where
the B crack (see Fig. 3) occurs is at about 211
MPa (Figs. 8, 9a). This value is close to the
yield stress of the material (219 MPa for
temperature 300 Degree C). Tensile stress in
the region of outer cylindrical casing (near
connection to the radial deflector) achieves 142
MPa. The maximum stress areas overlap the
zones on the casing where the cracks were
detected. Stress analysis of casing model for
separated loads shows that the thermal stresses
arising in casing were about two times larger
than the mechanical stresses (Figs. 12 and 13).
The cyclic variation of thermal stress (known
as low cycle thermal fatigue (LCTF)) in the
critical zone of casing was probably reason for
fatigue cracks arising.
2. It can also be concluded that the additional
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Blades

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

stresses as a result of vibrations of the engine

were the reason for decreasing
the fatigue life of the casing. However, the
dynamic analysis was not performed in this
work.
In this study the numerical and experimental
analysis were performed to investigate the
damage mechanisms of the compressor
blade of the small helicopter engine. The visual
examination shows that failure was a typical
fatigue fracture with beach marks. The
corrosion pits were located both in the crack
origin zone and also on the attack edge of blade
near the rupture area. It was evident that
corrosion pit was a main reason for the rapid
crack initiation. Moreover if the helicopter was
used in the maritime operations, the sea water
environment caused acceleration of the crack
growth and in consequence rapid damage of
the blade. Results of the numerical stress
analysis show which kind of load was more
dangerous under fatigue damage process:
rotation or vibration of the blade. By
comparison results of visual inspection (shape

Remarks

Pages
1617,
1618,1619,
1620

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intake
door

Failure Mode

of the beach marks) and FEA simulation (stress

distribution) it seems that the crack initiation
process can be accelerated by
torsional vibrations whereas meaningful
influence on the rack growth process has the
transverse vibrations of the blade.
The general remark can also be formulated
based on results of this analysis: the vibrations
(high-cycle fatigue) are more dangerous then
oscillated rotation (low-cycle fatigue) for
compressor blade from the point of view of the
fatigue strength.
This paper describes the methodology
employed for the failure analysis of aircraft
blades and its application to two premature
failed sets.
The first one corresponds to the high pressure
compressor manufactured in a 718 nickel base
superalloy. The failure analysis carried out on
this blade points towards foreign object
damage (FOD).
The second set belongs to the high pressure
turbine of another engine. Scanning electron
microscopy attributes the

Remarks

Pages
642,643,64
4,
645,646

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intake
door

Failure Mode

Remarks

first fail to the premature failure by a thermomechanical fatigue mechanism of one blade
with an inadequate microstructure. The
remaining blades of this set, which possess a
correct microstructure, failed due to the
impacts of the debris generated by the fracture
of the first one.
Based on the analysis, the failure of the 1st Pages
stage compressor blade from the subject GT 92,93,
94,95,100
occurred by a high-cycle fatigue
(HCF) mechanism. The root cause of the
failure was attributed to an internal
metallurgical anomaly near the airfoil leading
edge. Fatigue cracks initiated from the anomaly
region and propagated towards airfoil midchord until final tensile overload
separation occurred.
Therefore, manufacturing process of the GT
blades should be well monitored and controlled
to avoid residual stresses or surface defects.
Random checks on blades from each forging
heat lot will reduce such risks. Operator should
implement a rigorous on-condition monitoring
of the GT rotor and spot any side bands close
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pipes

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power
unit air
intake
door

Failure Mode

to the BPF excitation peaks. Load drop or

transient regime of the turbines increases
vibration amplitude when harmonic rotor
frequencies are interacted with blades
natural frequencies. Thus, the number of
engines start-up and shutdown of the GT shall
be reduced to the minimum.
This paper deals with a fracture investigation
of second stage turbine blades in a 32 MW unit
in a thermal power plant. Detailed
examinations of the blades indicated that the
primary failure event was related to the fracture
of a turbine blade at the top firtree root. The
fracture surface morphology exhibited features
characteristic of slow stable crack growth by
crystallographic faceted cracking and striation
formation
that
was
terminated
by
interdendiritic fracture at the final stage of
failure. These together with the results of
macrofractographic observations identified
high cycle fatigue as the primary contributing
fracture mechanism. The main fatigue crack
initiated on a surface that was damaged by
fretting wear as evident from the debris on the

Remarks

Pages
579,580,58
1,
582

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pipes

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unit air
intake
door

Failure Mode

contact surfaces of the firtree joint. The

physical characteristics of fretting damage in
relation to crack initiation are discussed based
on the microstructural and fractographic
findings presented.
In this paper, the root causes of the failed gas
turbine of a cogeneration plant whose
operation was stopped after a sudden
vibration of the bearing casing was reported
during normal operation were investigated. The
sudden vibration of the bearing casing was
caused by the fracture of one of the row 5
blades, and the fracture was initiated at the root
of the airfoil leading edge of the blade. The
fracture of the blade was supposed to be started
by a crack due to concentrated stresses around
a preexisting defect.
The initiated crack was propagated by a
combination of static and dynamic stresses
during operation under high cycle fatigue
loading conditions. Using SEM and SEM-EDS
analyses of the defect found in the fractured
blade, it could be inferred that the defect was
possibly formed before the turbine was

Remarks

Pages
718,719,72
0,
721

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power
unit air
intake
door

Failure Mode

operated, e.g., a forging defect during the

three-step forging process for making blades.
In addition, two non-cracked defects (i.e., a
cave-in defect and an open defect) found in
other row 5 blades were investigated by SEM
and SEM-EDS, and it was known that the
defect found at the fractured blade was
different from an open defect, i.e., a corrosion
pit.
In this study the linearly varying blade is
modeled and investigated the fatigue life by
considering damage at the leading edge of the
blade. When the damage depth is small it can
be considered as the semicircular one at the
same time if the damage depth is high it is
consider as U- notch. The maximum life for the
blade occurs when there will be no notches on
the blade. The life of the blade mainly depends
on the damage and position of the damage on
the blade from the root. As the damage is away
from the root of the blade the life of the blade
is more it can be shown from the graphs.
So that we can neglect the damage which is
near to the tip of the blade. In the graph results

Remarks

Pages
11169,111
70,11171,1
1172,1117
3,11174

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[50]

[51]

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pipes

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power
unit air
intake
door

Failure Mode

showed that the percentage variation of life

increases with the notch size and its position.
Percentage is very small when the notches are
away from the root. Similarly the percentage is
high when it is U-notch. Alternating stress and
stress intensity also increases as the notch
radius increases at the root at the same time
Alternating stress and stress intensity are
almost constant when the notch is near the tip
of the blade.
The failure of a second stage blade in a gas
turbine was investigated by metallurgical and
mechanical examinations of the failed blade.
The observation showed that a serious pitting
was occurred on the blade surfaces and there
were evidences of fatigue marks in the fracture
surface. The micro structural changes were not
critical changes due to blade operation at high
temperature. It was found that the crack
initiated by the hot corrosion from the leading
edge and propagated by fatigue and finally, as a
result of the reduction in cross-section area,
fracture was completed.
Metallurgical and finite element investigations

Remarks

Pages
39,40,41,4
2

Pages
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[52]

Turbine
Rotor
Blisk

[53]

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Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

of damaged blades of second stage of

compressor in the frame type gas turbine in one
of occurred in an on-shore gas complex,
showed high cycle fatigue (HCF) and foreign
object damages (FOD) which was the result of
separation of a piece of a blade and clashing
with other blades, were main reasons of failure.
The failure of the turbine blisk is attributed to
an improper microstructure at the blade airfoil
section and high operating temperature, which
led to crack initiation at the trailing edge by
stress rupture. The subsequent crack growth is
by fatigue under the cyclic loading conditions.
The present study clearly brings
out the importance of microstructural control in
promoting good stress rupture of the blisk.
The blade containment test is regarded as an
essential assessment of aeroengine safety. This
paper presents the results of a series of blade
containment tests where a double edge notched
blade was released at certain rotating speed
which subsequently impacted the inner wall of
the containment ring.

146,147,14
8,
149

Pages
294,295,29
6-300

Pages
502,504,50
5,
506

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door

Failure Mode

Remarks

Following conclusions were drawn:

Deformation and failure characteristics of the
released blades and the containment rings vary
significantly for different initial rotating speed
of the blade and the wall thickness of the
containment ring. Large plastic deformation
area and/or penetration and perforation failure
may appear in the second impacted region on
the containment ring when the releasing speed
of the blade is high. With the increase of the
wall thickness, the containment ring can
absorb much more impact energy to prevent
failure.
Maximum radial penetration depth in second
impacted region is larger than that in other
impacted regions. Maximum radial penetration
depths and the circumferential distance
between two impact regions have linear
relationship with the initial kinetic energy of
the released blade.
The released blade is bent as it impacts the
containment ring. For a high initial rotating
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power
unit air
intake
door

Failure Mode

speed of the blade, it is curled into a U

shape. For a low rotating speed, the impact
bending occurs only near the tip of the blade.
The results reveal that the energy transfer and
dissipation in a blade containment process
involve a variety of events including
multiple impacts, plastic deformation, surface
sliding friction, penetration and perforation.
The micromechanisms of fatigue crack growth
have been studied in selected structural gas
turbine engine alloys (Inconel 718, single
crystal PWA 1472 and Ti-6Al-4V). The
following conclusions have been reached from
a detailed study of the dependence of fatigue
failure modes on delta K and Kmax:

Remarks

Pages
300,301,30
2,
303,304

1. The fatigue fracture modes in polycrystalline

Inconel 718 and single crystal PWA1472 are
crystallographic in nature up to mid-delta K
levels. In the Paris (steady state) regime, this
transitions to a classical striation mechanism in
the polycrystalline alloy and a cleavage-like
mechanism with associated striations in
the single crystal alloy. The faster fatigue crack
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Failure Mode

Remarks

growth rates in the high delta K regime,

particularly very close to final failure, is
associated with a combination of fatigue
and ductile-dimple (static) fracture modes. The
incidence of ductile-dimple fracture also
increases with increasing delta K and Kmax in
this regime.
2. The fatigue fracture modes in Ti-6Al-4V
depend strongly on the microstructural
morphology. In the case of equi-axed /
structures, a flat cleavage-like fracture
mode is observed in the near-threshold regime.
This transitions to a fatigue striation mode in
the Paris regime. Finally, a combination of
striations and ductile dimples is observed in the
high K regime. However, in the case of
lamellar / colony structures, faceted
crystallographic fracture modes are observed in
the near-threshold, Paris and high-delta K
regimes. The fracture surface roughness
increases with increasing delta K and Kmax,
and a combination of ductile-dimples and
crystallographic fracture is observed in the
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Blades

lube
feed

oil

Nozzles

Cooling
Water
pipes

Auxiliary
power
unit air
intake
door

Failure Mode

Remarks

high-delta K regime. The incidence of ductiledimple fracture also increases with increasing
delta K and Kmax.
3. The fatigue fracture modes at positive stress
ratios (0< R <1) can be summarized in fatigue
mechanism maps that correspond to a
triangular domain within a plot of Kmax
(ordinate) versus delta K (absissa). Within
such plots, the upper bound value of Kmax
corresponds to the fracture toughness, KIc.
Also, the values of delta K and Kmax
corresponding to constant R-ratio tests are
characterized by straight lines that radiate
outwards from the origin. The transitions from
the near-threshold to the paris and high-delta K
regimes are characterized by curves that radiate
outwards from the same point on the
ordinate where Kmax = KIc. Fatigue maps
have been presented in this paper for Inconel
718, PWA 1472 and
Ti-6Al-4V.
Tube collapse due to heating of a trapped fluid Pages
in confined annuli has become a major concern 1343,1344,
in production wells and lubrication systems in 1345,1346,
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collapse
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turbine

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intake
door

Failure Mode

Remarks

1348,1349
gas turbines. This is due to the fact that
tubes subjected to external pressure developed
by fluid heating can generate catastrophic
consequences that may lead to the damage of
major equipment in the field, which in turn
can have a great impact on the production. This
paper, therefore, presents a case study of
lube oil feed tube collapse of a gas turbine due
to pressure build-up caused by fluid heat-up
in trapped annulus of the failed tube. A
conduction/convection thermal analysis of the
tube and its surrounding environment was
performed using MATLAB where the obtained
results were used in finite element modeling to
determine the required buckling pressure of the
tube. ANSYS finite element package was used
to conduct the stress analysis of the tube
subjected to external pressure mimicking the
real situation from which the required collapse
pressure of the tube was obtained. In addition,
an analytical thermal analysis was performed
to acquire the build-up pressure at various
typical temperatures of the trapped
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Failure Mode

Remarks

oil in the annulus. The collapse pressure

obtained from the finite element analysis was
used to estimate the temperature causing
failure from the pressuretemperature chart
obtained analytically. It was found that the
collapse pressure is 125 MPa (18 ksi) which
corresponds to 160 C temperature rise in the
annulus. This temperature represents a typical
operating condition in the field.

7.

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