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HP Turbine Blade Failure Modes
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Gas Turbine Systems Supervisor - Supervisor manual for Gas Turbine Engines
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Evaluating  Physical  Size

Cracks  in  all  areas  of  the  blade,  including  radial cracks   in   the   tips.   Cracks   generally   start   at   the cooling  holes. FOD/DOD,   including   nicks   and   dents. Aluminum  spattering  that  appears  as  metallic deposits   on   the   blade.   This   results   from compressor   tip   rubs. HP  turbine  blade  tip  rubs.  This  results  in  coating removal   and   tip   damage. TURBINE   MIDFRAME   DAMAGE.—  T h e following   paragraphs   describe   damage   that   you   may find   when   inspecting   the   turbine   midframe. Discoloration.  — On  low-time  liners,  the  coloration is  random  and  sometimes  appears  as  a  wavy  surface. T h e    c o l o r a t i o n    i s    r a n d o m    b o t h    a x i a l l y    a n d circumferentially.   On   high-time   liners   you   may   observe some  axial  carbon  streaking.  There  are  no  service  limits on    discoloration Liner   Cracking.—  Initial   deterioration   of   the turbine  midframe  liners  occurs  at  the  forward  inner  liner flange   in   the   form   of   axial   cracking.   It   is   difficult   to determine  the  magnitude  or  length  of  a  crack  in  this  area. The   area   is   immediately   aft   of   the   HP   turbine   stage   2 blade  platforms.  Small  tight  cracks  will  probably  not  be noticed.  Of  primary  interest  is  that  there  are  no  cracks with  visible  turned  up  edges.  If  cracking  is  observed  in the  forward  inner  liner  flange,  you  can  use  a  fiberscope for  a  closer  look  to  establish  the  extent  of  the  crack  and the   adjacent   area   condition.   Cracking   can   also   occur around  the  leading  edge  weld  beads  on  the  strut  fairings at  both  the  inner  and  outer  liner  areas. Liner  Distortion.—  Turbine   midframe   distortion most  commonly  occurs  in  the  10  to  12  o’clock  area  of the   outer   liner   forward   flange.   The   only   relative   gauge a v a i l a b l e f o r c o m p a r a t i v e a s s e s s m e n t (roundness/contour)  is  the  HP  turbine  stage  2  blade  tip arc   and   the   stage   2   shroud   contour.   A   fiberscope   is recommended  for  the  final  assessment  of  any  suggested distortion   of   the   liner.   You   will   need   a   guide   tube   to position   the   fiberscope. Power  Turbine The  most  common  problem  in  the  power  turbine section is usually a loss of the hard coat on the tip shroud. Notch   wear   and   subsequent   blade   bending   are   direct results  of  tip  shroud  hard  coat  loss.  Notch  wear  and blade   bending   will   ultimately   lead   to   fatigue   failure   of the   airfoil.   The   actual   loss   of   the   hard   coat   cannot   be confirmed   through   the   borescope.   It   can   be   confirmed by   removal   of   the   upper   case   and   actual   physical inspection  of  the  tip  shrouds.  You  can  seethe  symptoms through   the   borescope   by   looking   at   the   notch   with probe   No.   1.   Uneven   notch   wear   may   indicate   loss   of the   hard   coat.   You   should   carefully   inspect   for   any transverse   cracks   in   the   blade   airfoil   around   the   10 percent  span.  Any  cracking  is  cause  for  replacement  of the   power   turbine. The   power   turbine   first-stage   blades   also   have   a history  of  deposit  buildup  that  leads  to  rotor  unbalance and   excessive   vibration. For   reference   to   parts nomenclature  used  in  this  section,  refer  to  figure  2-11, sections  F  and  G.  Power  turbine  damage  that  you  may find  is  described  in  the  following  paragraphs. CRACKS  IN  BLADES.—   Inspect  the  total  airfoil, platform,  and  tip  shrouds  for  evidence  of  cracks.  If  you suspect   a   specific   area,   use   the   high-magnification probe.  You  will  see  a  limited  amount  of  the  stage  1 blading  when  viewing  aft  from  the  turbine  midframe liner   inspection   ports.   You   can   see   more   detail   with   a fiberscope   or   by   viewing   forward   from   the   turbine exhaust   duct.   Cracks   will   show   depth   and   under magnification   will   show   edge   material   definition.   Be sure  to  distinguish  cracks  from  false  indications  such  as smears   and   carbon   streaks. NICKS   AND   DENTS.—  Record   these   defects   in relation   to   the   percent   span   and   percent   chord   for magnitude   and   location   on   the   blade.   Record   also   the condition   of   the   blade   material   adjacent   (at   the extremities  of  the  defect)  to  the  observed  defect.  Record any  cracking  or  sharpness  of  nicks  or  dents.  Investigate smooth  impact  deformities  to  determine  the  origin  of damage. WEAR.—   Inspect  LP  turbine  rotor  blade  tip  shroud interlocks  or  circumferential  mating  surface  for  wear  at stage  1.  Wear  is  observable  and  will  appear  as  shown in  figure  2-31. D I R T ,    C O L O R A T I O N ,    P I T T I N G ,    A N D CORROSION.— High-time LP turbine rotor assemblies  may  show  airfoil  surface  irregularities  that could   be   dirt   accumulation,   carbon   buildup,   surface pitting  from  particles  in  the  gas  stream,  or  corrosion  of the  blade  material.  Dirt  and  coloration  are  of  little concern;   however   pitting   and   corrosion   may   be significant. 2-24

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