Transcript GAS TURBINE ENGINE JTP FATIGUE TESTING

GAS TURBINE ENGINE JTP
FATIGUE TESTING
HCAT Review Meeting
1-2 April 2003
San Diego
BASIC DoE MATRIX
SUBSTRATES
• IN 718 (304)
• IN901 (184)
• A286 (136)
• AM355 (184)
• 4340(184)
• 9310 (96)
• 17-4PH (184)
COATINGS (0.003”, 0.015”)
• Bare (Peened/Unpeened)
• EHC
• HVOF
–
–
–
–
WC-17Co
T-800
T-400
Cr3C2-20(Ni,Cr)
• Plasma Spray
– T-400
– WC-17Co
• HVOF/Natural Gas
– IN718, 4340, AM355
FATIGUE DoE VARIABLES
•
•
•
•
Baseline (bare) vs. coating
Peened vs. unpeened (bare only)
Temperature - 300°F vs. 750°F
Dynamic ratio (test type)
– A = 0.95 ( control) vs. 0.5 (P control)
– R = 0.025 ( control) vs. 0.33 (P control)
0.5” coating
patch
ALLOY
PEEN
COATING
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
EHC
EHC
EHC
EHC
HVOF Cr3C2-20NiCr
HVOF Cr3C2-20NiCr
HVOF Cr3C2-20NiCr
HVOF Cr3C2-20NiCr
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17 Co
None
None
None
None
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS WC-17 Co
PS WC-17 Co
PS WC-17 Co
PS WC-17 Co
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
NA
0.95
300
10
NA
0.95
300
10
NA
0.95
750
10
NA
0.95
750
10
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
208
Complete
Testing
To be coated
ALLOY
PEEN
COATING
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286
A286 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
EHC
EHC
EHC
EHC
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF WC-17 Co
HVOF WC-17 Co
None
None
None
None
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS WC-17 Co
PS WC-17 Co
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.95
750
6
NA
0.95
300
10
NA
0.95
300
10
NA
0.95
750
10
NA
0.95
750
10
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.95
750
6
136
Complete
Testing
To be coated
ALLOY
PEEN
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355 TOTAL
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
COATING
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
EHC
0.015
0.95
300
6
EHC
0.015
0.5 HCF
300
6
EHC
0.015
0.95
750
6
EHC
0.003
0.95
750
6
HVOF Tribaloy 400
0.015
0.95
300
6
HVOF Tribaloy 400
0.015
0.95
750
6
HVOF WC-17 Co
0.015
0.95
300
6
HVOF WC-17 Co
0.015
0.5 HCF
300
6
HVOF WC-17 Co
0.015
0.95
750
6
HVOF WC-17 Co
0.003
0.95
750
6
None
NA
0.95
300
10
None
NA
0.95
300
10
None
NA
0.95
750
10
None
NA
0.95
750
10
PS Tribaloy 400
0.015
0.95
300
6
PS Tribaloy 400
0.015
0.5 HCF
300
6
PS Tribaloy 400
0.015
0.95
750
6
PS Tribaloy 400
0.003
0.95
750
6
PS WC-17 Co
0.015
0.95
300
6
PS WC-17 Co
0.015
0.95
750
6
136
Complete
Testing
To be coated
ALLOY
PEEN
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310
9310 Total
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
COATING
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
Carburized
NA
0.95
300
10
EHC
0.015
0.95
300
6
EHC
0.015
0.5 HCF
300
6
EHC
0.003
0.5 HCF
300
6
HVOF Tribaloy 400
0.015
0.95
300
6
HVOF WC-17 Co
0.015
0.95
300
6
HVOF WC-17 Co
0.015
0.5 HCF
300
6
HVOF WC-17 Co
0.003
0.5 HCF
300
6
None
NA
0.95
300
10
None
NA
0.95
300
10
PS Tribaloy 400
0.015
0.95
300
6
PS WC-17 Co
0.015
0.95
300
6
PS WC-17 Co
0.015
0.5 HCF
300
6
PS WC-17 Co
0.003
0.5 HCF
300
6
96
Complete
Testing
To be coated
ALLOY
PEEN
COATING
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901
IN901 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
EHC
EHC
EHC
EHC
HVOF Cr3C2-NiCr
HVOF Cr3C2-NiCr
HVOF Cr3C2-NiCr
HVOF Cr3C2-NiCr
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17 Co
None
None
None
None
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
NA
0.95
300
10
NA
0.95
300
10
NA
0.95
750
10
NA
0.95
750
10
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
184
Complete
Testing
To be coated
ALLOY
PEEN
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340
4340 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
COATING
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
EHC
0.015
0.95
300
6
EHC
0.003
0.95
300
6
EHC
0.015
0.5 HCF
300
6
EHC
0.003
0.5 HCF
300
6
HVOF Cr3C2-20NiCr
0.015
0.95
300
6
HVOF Cr3C2-20NiCr
0.015
0.5 HCF
300
6
HVOF Tribaloy 400
0.015
0.95
300
6
HVOF WC-17 Co
0.015
0.95
300
6
HVOF WC-17 Co
0.003
0.95
300
6
HVOF WC-17 Co
0.015
0.5 HCF
300
6
HVOF WC-17 Co
0.003
0.5 HCF
300
6
None
NA
0.95
300
10
None
NA
0.95
300
10
None
NA
0.5 HCF
300
10
None
NA
0.5 HCF
300
10
PS Tribaloy 400
0.015
0.95
300
6
PS Tribaloy 400
0.003
0.95
300
6
PS Tribaloy 400
0.015
0.5 HCF
300
6
PS Tribaloy 400
0.003
0.5 HCF
300
6
PS WC-17 Co
0.015
0.95
300
6
136
Complete
Testing
To be coated
ALLOY
PEEN
COATING
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH
17-4PH Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
EHC
EHC
EHC
EHC
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 400
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF Tribaloy 800
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17 Co
HVOF WC-17C
None
None
None
None
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS Tribaloy 400
PS WC-17 Co
PS WC-17 Co
PS WC-17 Co
PS WC-17 Co
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.5 HCF
300
6
NA
0.95
300
10
NA
0.95
300
10
NA
0.95
750
10
NA
0.95
750
10
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
0.015
0.95
300
6
0.015
0.5 HCF
300
6
0.015
0.95
750
6
0.003
0.95
750
6
184
GRAND TOTAL
1084
Complete
Testing
To be coated
ALLOY
PEEN
COATING
THICKNESS
A-RATIO
TEST TEMP. NO. SPECIMENS
(inches) (LCF or HCF)
(Deg. F)
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718
IN718 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Cr3C2-20NiCr
Cr3C2-20NiCr
Cr3C2-20NiCr
Cr3C2-20NiCr
Tribaloy 400
Tribaloy 400
Tribaloy 400
Tribaloy 400
Tribaloy 800
Tribaloy 800
Tribaloy 800
Tribaloy 800
WC-17 Co
WC-17 Co
WC-17 Co
WC-17 Co
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
300
300
750
750
300
300
750
750
300
300
750
750
300
300
750
750
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
96
4340
4340
4340
4340
4340
4340
4340
4340
4340 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Cr3C2-20NiCr
Cr3C2-20NiCr
Tribaloy 400
Tribaloy 400
Tribaloy 800
Tribaloy 800
WC-17 Co
WC-17 Co
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
300
300
300
300
300
300
300
300
6
6
6
6
6
6
6
6
48
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355
AM355 Total
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Cr3C2-20NiCr
Cr3C2-20NiCr
Tribaloy 400
Tribaloy 400
Tribaloy 800
Tribaloy 800
WC-17 Co
WC-17 Co
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.015
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
0.95
0.5 HCF
300
300
300
300
300
300
300
300
6
6
6
6
6
6
6
6
48
HVOF Natural Gas
GRAND TOTAL
192
PRELIMINARY COATING BEHAVIOR
OBSERVATIONS
• EVERYTHING YOU CAN IMAGINE!
–
–
–
–
–
+/- FRACTURE PLANE
LOOSE “CIGAR BAND”
MULTIPLE CIRCUMFERENTIAL CRACKS
TOTAL SPALLATION
SOME LONGITUDINAL CRACKS
• NO OBVIOUS PATTERN
–
–
–
–
UNDER PATCH/AT EDGE/OUTSIDE PATCH
TEMPERATURE
COATING TYPE/THICKNESS
SUBSTRATE TYPE
FRACTURE “STATISTICS”
FAILURE UNDER
PATCH
FAILURE AT EDGE OF
PATCH OR OUTSIDE
EHC
67%
33%
EHC w/o 4340
58%
42%
HVOF
46%
54%
LANDING GEAR JTP
EHC
54%
46%
LANDING GEAR JTP
HVOF
41%
59%
LG JTP WAS 4340/300M/A100 AT HRc 52-54
TESTING PROGRESS
• 194 individual test groups
– 145 coated (75%)
– 82 tested (42% of total, 56% of available)
• 1276 total test specimens
– 988 coated (77%)
– 785 tested (60% of total, 80% of coated)
STATUS – GTE FATIGUE PROGRAM
• ALL SPECIMENS MANUFACTURED/PEENED FOR
ALL PHASES
• BARE, EHC, HVOF (WC-Co, T-400, T-800, Cr3C220NiCr ), & PS T-400 COATED AND IN TEST
• PS WC-Co and HVOF/NATURAL GAS SPECIMENS
AVAILABLE
• WILL FINISH BY 12/31/03 IF REST OF SPECIMENS
ARE COATED SOON