Fatigue crack growth

Based on very early occurring ruptures found in the first stage high pressure turbine blades of a turbo reactor in a local aviation company, this study has the aim to determine their safe life. The first stage blades are subjected to simultaneous action of gas pressure coming from the combustion chamber, centrifugal forces in the case of the rotor blades and to important temperatures transients, which progress in a very aggressive environment due to hot gases. These combined parameters cause a high state of stress involving several complex mechanisms of damage, such as: fatigue caused by mechanical stress fluctuations, thermo-mechanical fatigue caused by temperature variations and corrosion caused on the stressed elements. Life cycle determination asks for stress evaluation of blades regarding several variables which are approached deterministically in the study. Heat exchange between combustion gases and metal blades is considered. The total stress on two kinds of blades is calculated by the addition of the thermal effect and the mechanical loading. The stress cycle is then calculated for different steps of the engine function during the operation by considering the variation of the thermal and the mechanical properties of the system. Safe life determination is done by two different approaches: the safe life approach by the initiation model and the damage tolerance approach considering the defect growth mechanics and considering the pitting corrosion effect. The calculation is applied for stator and rotor blades of an aero engine high pressure turbine made of NI 738. Since these parts are high risk components from the point of view of potential failure consequences, the risk is assessed as well. The results obtained are studied to determine the solution to the problem, and to propose a safe decision to be taken about the design or maintenance procedures.