Metallurgical Examination of 3rd Stage Gas Turbine

Blades

Report Number M13161

Date xxxxxxxxxxxxxxxx

Purchase Order Number xxxxxxxxxxxxxxxx

Customer Reference Number xxxxxxxxxxxxxxxx

Customer xxxxxxxxxxxxxxxx
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Customer Contact xxxxxxxxxxxxxxxx

Report by: Approved by:

S L Bagnall Dr A R Franks
Consultant Metallurgist Director

This report is Copyright © Metamet Consultants Limited and is technically and

commercially confidential.
 1. Introduction

XXXX operates a gas turbine, originally manufactured by XXXX. The gas turbine
burns natural gas in combination with gases from the plant. The unit generates
approximately 120 – 130MW of electrical power. The residual exhaust heat is used to
generate steam for refinery operations (cogeneration plant).

In June 2013, the gas turbine tripped due to high vibration levels. Inspection identified
a failed blade in the final (3rd) row of the turbine section. This blade had failed
130mm from the blade root. This was removed and sent to XXXX for metallurgical
examination. In parallel to this activity, the site management requested an
independent metallurgical examination of the non-failed 3rd row blades, and this is the
purpose of the present report.

The blade material was advised as being Udimet 500, a nickel – chromium – cobalt
alloy suitable for operation at high temperatures and stresses. In the unit, the exhaust
temperature is controlled at 560oC. These 3rd stage blades were installed in the
turbine in July 2012, so had run for approximately 1 year before failing. The unit
operates at 3000 rpm, nominally for 24h/day and 365 days/year, although there are
some planned interventions for inspections. The blades had therefore seen
approximately 109 cycles since installation in 2012. Prior to 2012, the blades had run
for 48,000 hours at another facility, for which the operating conditions are unknown,
and had been refurbished by XXXX, prior to installation at the plant. This
refurbishment (presumed to include heat treatment) nominally provides an additional
24,000 hours of operational service life (i.e. ~ 3 years operation until 2015).

Two blades were removed for examination and these were identified as 19 and 46.
The blades, as-received, are shown in figures 1.1 and 1.2. Damage evident at the blade
tips was as a result of the fractured blade.

Figure 1.1 Blade 19, as-received

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 Figure 1.2 Blade 46, as-received

Metamet were requested to non-destructively test both blades using radiography and
dye penetrant and use only one blade for destructive testing. For the metallurgical
assessment Metamet were requested to take samples from four locations at the leading
edge, centre span and trailing edge as follows:

(1) Blade fixture point

(2) Blade root (blended radius of blade to main body)
(3) 130mm from blade root (location of fracture on failed blade)
(4) Close to blade tip (not in the region of the mechanical damage
from failed blade)

The positions requested are shown in figure 1.3.

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 Figure 1.3 Locations requested for metallurgical assessment

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 2. Non-Destructive Examination

2.1 Radiography

The turbine blades were examined using gamma radiography. No indications were
evident for either of the blades.

2.2 Liquid Penetrant Inspection

2.2.1 Blade 19

Blade 19 was examined using liquid penetrant. Some surface breaking indications
were evident on the trailing edge of the blade, as shown in figure 2.1. These
indications were identified as A, B and C and are shown more closely in figures 2.2 to
2.6. Indications B and C were longitudinal and appeared to have very little depth.
Indication A appeared to be a small nick in the surface which again had very little
depth.

C
B

Figure 2.1 Blade 19, showing indications revealed by liquid penetrant inspection

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 A

Figure 2.2 Blade 19, showing indication A (evident on the trailing edge) revealed by
liquid penetrant inspection

B C

Figure 2.3 Blade 19, showing indications B and C (evident on the trailing edge)
revealed by liquid penetrant inspection

Figure 2.4 Blade 19, showing indication B (evident on the trailing edge) revealed by
liquid penetrant inspection

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 Figure 2.5 Blade 19, showing indication C (evident on the trailing edge) revealed by
liquid penetrant inspection

Figure 2.6 Blade 19, showing indication A (evident on the trailing edge) revealed by
liquid penetrant inspection

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 2.2.2 Blade 46

Blade 46 was examined using liquid penetrant. Some surface breaking indications
were evident on the trailing edge of the blade, as shown in figure 2.7. These
indications were identified as A and B and are shown more closely in figures 2.8 to
2.10. For indication A, the features highlighted in yellow are thought to be surface
damage. For the feature indicated with the red arrow and indication B, these are
thought to be similar to those longitudinal indications observed on blade 19.

Figure 2.7 Blade 46, showing indications revealed by liquid penetrant inspection

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 A
B

Figure 2.8 Blade 46, showing indications A and B (evident on the trailing edge)
revealed by liquid penetrant inspection

Figure 2.9 Blade 46, showing indication A (evident on the trailing edge) revealed by
liquid penetrant inspection

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 Figure 2.10 Blade 46, showing indication B (evident on the trailing edge) revealed by
liquid penetrant inspection

3. SEM Examination of Blade 46, indication A

In order to examine indication A, a section was taken through the blade as shown in
figure 3.1

Figure 3.1 Section taken to examine indication A

Indication A was examined using a Zeiss EVO 60 scanning electron microscope with
Oxford INCA EDX microanalysis. Indication A is shown in figures 3.2 to 3.4.

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 Damage

Figure 3.2 Blade 46, showing indication A

Figure 3.3 Blade 46, showing indication A

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 Figure 3.4 Blade 46, showing indication A

The surface in the area of indication A appeared to be porous in comparison to the

surface away from the indication. This is thought to be pores in the oxide layer which
the penetrant subsequently seeped out of.

4. Replication Metallography

Blade 46 was selected for metallurgical examination. Replication metallography was

undertaken in the equivalent area of the fracture of the failed blade. The area was 110-
160mm away from the blade root, see figure 4.1, and incorporated the entire width of
the blade. Assessment was carried out on the concave surface of the blade. After
etching with Kalling’s reagent it was apparent that the grain boundaries were heavily
sensitised, see figures 4.2 to 4.6. There were no voids evident at the surface of the
blade.

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 110 mm

160 mm

Figure 4.1 Blade 46, showing position of replication metallography

Figure 4.2 Replica showing surface microstructure of concave surface in the

equivalent area of failure of the fractured blade

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 Figure 4.3 Replica showing surface microstructure of concave surface in the
equivalent area of failure of the fractured blade

Figure 4.4 Replica showing surface microstructure of concave surface in the

equivalent area of failure of the fractured blade

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 5. Metallographic Examination

Longitudinal sections were taken in the areas requested by XXXX and were mounted,
ground and polished to a one micron finish. The sections were examined in both the
as-polished and etched conditions using Kalling’s reagent as the etchant. The general
microstructure is shown in figures 5.1 to 5.3 and the microstructural features were the
same for all samples. The structure is dendritic in nature with gamma prime
precipitated within the interdendritic areas. The strengthening mechanism of this alloy
is precipitation hardening through these gamma prime precipitates. MC carbides were
also evident which were confined to the interdendritic areas and were evident at grain
boundaries. M23C6 carbides were also evident at the grain boundaries.

Figure 5.1 General microstructure of blade 46

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 M23C6 carbides on
grain boundaries

Ɣ’ precipitates

MC carbides

Figure 5.2 General microstructure of blade 46

M23C6 carbides on
grain boundaries

MC carbides on grain
boundaries

Figure 5.3 General microstructure of blade 46

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 5.1 Blade 46, indication A

To verify whether indication A was a surface artefact, a transverse section was taken
through the indication as shown in figures 5.4 to 5.6.

Figure 5.4 Section taken through indication A of blade 46

Figure 5.5 Section taken through indication A of blade 46

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 Figure 5.6 Section taken through indication A of blade 46, showing face examined

There was no evidence of any defects at the surface in the area of indication A.
Examination of the sample away from the surface revealed voids which were
associated with triple points, grain boundaries or MC carbides, see figures 5.7 to 5.9.
A precipitate free zone was apparent adjacent to the majority of the grain boundaries,
this is clearly demonstrated in figure 5.9.

Figure 5.7 Section taken through indication A of blade 46, showing voids at triple
points and grain boundaries

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 Figure 5.8 Section taken through indication A of blade 46, showing void at grain
boundary

MC Carbide

Precipitate free zone

Figure 5.9 Section taken through indication A of blade 46, showing voids at MC
carbides

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 5.2 Blade 46, Area 1

Sections were taken in the firtree root as shown in figure 5.10. The arrows indicate the
face of the sample prepared. Macro etched metallographic sections of the firtree root
showing the coarse dendritic structure of the cast alloy are shown in figures 5.11 to
5.13. Voids were evident throughout the microstructure in all areas as shown in
figures 5.14 to 5.22. The concentration of these voids was more significant at the
centre span (position B). These voids were evident at grain boundaries, triple points
and MC carbides and were confined to the interdendritic areas. A precipitate free zone
was apparent adjacent to the majority of the grain boundaries.

LE (position C)

Centre (position B)

TE (position A)

Figure 5.10 Area 1 of blade 46, showing sections taken

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 Figure 5.11 Area 1, position A, after etching

Figure 5.12 Area 1, position B, after etching

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 Figure 5.13 Area 1, position C, after etching

Figure 5.14 Area 1, position A, showing voids, etched

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 Figure 5.15 Area 1, position A, showing voids

Figure 5.16 Area 1, position A, showing voids, etched

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 Figure 5.17 Area 1, position B, showing voids, etched

Figure 5.18 Area 1, position B, showing voids

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 Figure 5.19 Area 1, position B, showing voids, etched

Figure 5.20 Area 1, position C, showing voids, etched

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 Figure 5.21 Area 1, position C, showing voids

Figure 5.22 Area 1, position C, showing voids, etched

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 5.3 Blade 46, Area 2

Sections were taken in the radius between the root and the blade as shown in figures
5.23 and 5.24. The arrows indicate the face of the sample prepared. Voids were
evident throughout the microstructure in all areas as shown in figures 5.24 to 5.29.
The concentration of these voids was more significant at the centre span (position B).
The voids were evident at grain boundaries, triple points and MC carbides and were
confined to the interdendritic areas. Precipitate free zones were apparent adjacent to
the majority of the grain boundaries.

TE (A)

Centre (B)

LE (C)

Figure 5.23 Area 2 of blade 46, showing sections taken

TE (position A)

Centre (position B)

LE (position C)

Figure 5.24 Area 2 of blade 46, showing sections taken

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 Figure 5.25 Area 2, position A, showing voids

Figure 5.26 Area 2, position A, showing voids, etched

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 Figure 5.27 Area 2, position B, showing voids

Figure 5.28 Area 2, position B, showing voids, etched

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 Figure 5.29 Area 2, position C, showing voids

Figure 5.30 Area 2, position C, showing voids, etched

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 5.4 Blade 46, Area 3

Sections were taken in the equivalent area of failure as shown in figures 5.31 and
5.32. The arrows indicate the face of the sample prepared. Voids were evident
throughout the microstructure in all areas as shown in figures 5.33 to 5.40. The voids
were more extensive at the centre span of the blade (position B). These voids were
evident at grain boundaries, triple points and MC carbides and were confined to the
interdendritic areas. Precipitate free zones were apparent adjacent to the majority of
the grain boundaries.

TE (A)

Centre (B)

LE (C)

Figure 5.31 Area 3 of blade 46, showing sections taken

LE (position C)
TE (position A) Centre (position B)

Figure 5.32 Area 3 of blade 46, showing sections taken

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 Figure 5.33 Area 3, position A, showing voids

Figure 5.34 Area 3, position A, showing voids, etched

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 Figure 5.35 Area 3, position B, showing voids, etched

Figure 5.36 Area 3, position B, showing voids

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 Figure 5.37 Area 3, position B, showing voids, etched

Figure 5.38 Area 3, position B, showing voids, etched

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 Figure 5.39 Area 3, position C, showing voids, etched

Figure 5.40 Area 3, position C, showing voids, etched

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 5.6 Blade 46, Area 4

Sections were taken towards the tip of the blade, as shown in figures 5.41 and 5.42.
The arrows indicate the face of the sample prepared. Voids were evident throughout
the microstructure in all areas as shown in figures 5.43 to 4.48. The concentration of
these voids was more significant at the centre span (position B). The voids were
evident at grain boundaries, triple points and MC carbides and were confined to the
interdendritic areas. Precipitate free zones were apparent adjacent to the majority of
the grain boundaries.

TE (A)

Centre (B)

LE (C)

Figure 5.41 Area 4 of blade 46, showing sections taken

LE (position C)

Centre (position B)

TE (position A)

Figure 5.42 Area 4 of blade 46, showing sections taken

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 Figure 5.43 Area 4, position A, showing voids, etched

Figure 5.44 Area 4, position A, showing voids, etched

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 Figure 5.45 Area 4, position B, showing voids, etched

Figure 5.46 Area 4, position B, showing voids, etched

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 Figure 5.47 Area 4, position C, showing voids, etched

Figure 5.48 Area 4, position C, showing voids, etched

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 6. SEM Examination of Microstructure

The microstructure in areas 1 and 3 was examined using a Zeiss EVO 60 scanning
electron microscope with Oxford INCA EDX microanalysis. The γ’ precipitates are
shown in figures 6.1 to 6.5. Primary (large precipitates) and secondary (small
precipitates) were evident. The primary precipitates were cuboid in shape and
typically 0.4µm square in section.

Figure 6.1 Area 1, showing γ’ precipitates

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 Figure 6.2 Area 1, showing γ’ precipitates

Figure 6.3 Area 2, showing γ’ precipitates

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 Figure 6.4 Area 2, showing γ’ precipitates

Figure 6.5 Area 2, showing γ’ precipitates

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 The dendritic and interdendritic areas were analysed by EDX analysis to determine
whether there were any compositional differences. Images showing the areas analysed
are shown in figures 6.6 and 6.7 and the results are shown in table 6.1. The results
show that there is very little difference between the two areas.

Figure 6.6 Area 2, analysis of dendritic and interdendritic areas

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 Figure 6.7 Area 2, analysis of dendritic and interdendritic areas

Table 6.1 Semi-quantitative EDX microanalysis of dendritic and interdendritic areas

Approximate Weight % Element (Note)
Sample ID
Al Ti Cr Mn Co Ni Mo
Fig 6.5-spec 1 (interdendritic area) 2.4 3.1 20 0.5 18 51 4.6
Fig 6.5-spec 2 (dendritic area) 2.8 2.5 20 0.4 19 51 4.1
Fig 6.6-spec 1 (interdendritic area) 2.4 3 20 19 51 4.6
Fig 6.6-spec 2 (dendritic area) 2.7 2.5 20 0.5 19 50 4.2

Note
The quantification procedure strictly applies to polished surfaces and therefore the results on rough
surfaces such as particulates, may only be considered semi-quantitative. Carbon can be detected but not
quantified i.e. d = detected and D = detected in significant amounts. For other elements:- blank cell =
element not detected. The above results indicate only the relative proportions of each element.

The MC carbide was also analysed, see figures 6.8 and 6.9. The results are shown in
table 6.2. The phase is a titanium-molybdenum rich carbide.

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 Figure 6.8 Area 3, showing MC carbide analysed

Figure 6.9 Area 3, showing MC carbide analysed

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 Table 6.2 Semi-quantitative EDX microanalysis of MC carbide
Approximate Weight % Element
(Note)
Sample ID
Al Ti Cr Co Ni Mo
Fig 6.6-spec 1 64 2 0.8 2 31
Fig 6.7-spec 1 0.4 51 7 4.3 12 25

Note
The quantification procedure strictly applies to polished surfaces and therefore the results on rough
surfaces such as particulates, may only be considered semi-quantitative. Carbon can be detected but not
quantified i.e. d = detected and D = detected in significant amounts. For other elements:- blank cell =
element not detected. The above results indicate only the relative proportions of each element.

7. Vickers Hardness Measurement

Vickers hardness measurements were undertaken in all four areas to BS EN 6507-

1:2005 using a 10kg load. The results are shown in table 7.1 below.

Table 7.1 Vickers hardness Measurements

Position Hardness HV10 Average HV10
1 353, 340, 338 344
2 326, 340, 333 333
3 368, 372, 403 381
4 403, 415, 398 405

Positions 3 and 4 (in the airfoil) exhibit slightly higher hardness levels than positions
1 and 2 (at the blade root). In the literature, a minimum tensile strength of 1310MPa is
specified for Udimet 500, this approximately converts to 400HV, thus positions 1, 2
and 3 are below this hardness level.

8. Micro Vickers Hardness Measurement

Micro Vickers hardness measurements were undertaken in the dendritic and

interdendritic areas of sample 4 using a 200g load. The results were as follows:

Interdendritic area HV0.2: 379, 370, 386, 407, Av: 386

Dendritic area HV0.2: 406, 401, 404, 408, Av: 405

The dendritic areas exhibit slightly higher hardness levels.

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 9. Chemical Analysis

The material was analysed by ICP and the results are shown in table 9.1. A typical
analysis specified in the literature is also presented in the table, though the specific
limits are unknown.

Table 9.1 ICP analysis results

Element Material Typical Udimet 500
Carbon 0.07 0.15 max
Silicon 0.05 0.75 max
Manganese <0.01 0.75 max
Phosphorus 0.008 0.015 max
Sulphur 0.003 0.015 max
Chromium 18.8 15.0-20.0
Nickel REM REM
Molybdenum 4.2 3.0-5.0
Cobalt 17.5 13.0-20.0
Aluminium 3.0 2.50-3.25
Titanium 3.1 2.50-3.25
Niobium 0.01 -
Copper <0.01 0.15 max
Boron 0.008 0.003-0.01
Iron 0.13 4.0 max
Vanadium 0.01 -

10. Discussion

Radiographic inspection of blades 19 and 46 revealed no indications. Liquid penetrant

inspection revealed some surface indications, though these are thought to be a result
of the penetrant leaking from breaks in the metal oxide layer.

The chemical analysis results of blade 46 are considered typical for the Udimet 500
grade. Positions 3 and 4 (in the airfoil) exhibited slightly higher hardness levels than
positions 1 and 2 (at the blade root). In the literature, a minimum tensile strength of
1310MPa is specified for Udimet 500, which approximately converts to 400HV.
Positions 1, 2 and 3 had hardness below this hardness level, whilst position 4 was
above it. However this tensile strength would be specified for components in the as-
manufactured condition. The material in this case had been heat treated, and then
thermally aged in service, therefore the hardness levels would be expected to be
slightly lower than the as-manufactured condition.

The general structure of the turbine blade 46 was dendritic in nature with gamma
prime, γ’, precipitated within the interdendritic areas. The γ’ precipitation was a

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 mixture of primary (large precipitates) and secondary (small precipitates). The
primary precipitates were cuboidal in shape and typically 0.4µm square in section.
Precipitate free zones were apparent adjacent to the majority of the grain boundaries.

Primary MC carbides were also present which were confined to the interdendritic area
and were evident at grain boundaries. In the MC carbide, the ‘M’ was found to be
titanium and molybdenum, as expected for this alloy (1). Secondary M23C6-type
carbides were also evident at the grain boundaries. This microstructure is considered
normal for this material grade. There were no significant elemental differences
between the dendritic and interdendritic areas.

Voids were evident in all of the sections examined. These voids were confined to the
interdendritic areas located at triple points, grain boundaries or MC carbides and are
thus thought to be associated with creep. The voids were more prominent in the
equivalent area of the failure of the fractured blade. In addition, for all four areas, the
concentration of voids was significantly higher at the centre span of the blade, than in
the rest of the section.

The microstructure at the surface consisted of gamma grains with significant M23C6
carbide precipitation along the grain boundaries, this surface effect was approximately
50-100 microns deep. There was no evidence of any creep cavitation at the surface
most likely due to the fact that these carbides help to prevent the grain boundary from
sliding under applied stress (2).

At high service temperatures, diffusion of alloying elements increases which

subsequently leads to metallurgical degradation (2). Aging is largely a temperature
related phenomenon and creep is a response to the loads acting upon the component
(2)
. Creep eventually results in the formation of voids along grain boundaries which
can then coalesce to allow cracks to propagate, leading to creep fracture.

Gamma prime ageing is a significant form of material degradation in turbine

components (2); therefore, the degree of thermal degradation can be measured by the
morphology of the gamma prime particles (3). Diffusion of alloying elements at high
temperature results in precipitate coarsening, coalescing and rafting (1) (2). As ageing
continues, secondary gamma prime particles disappear and the primary particles
coarsen and coalesce (1) (2). Rafting is the result of precipitates coalescing in the
direction of an applied stress (2). These gamma prime particles which act as barriers to
dislocation motion retard creep, thus alteration of these particles diminishes the
material’s creep strength, allowing grain boundaries to slide and triple points to open
up (2). In a study conducted by Wangyao et al, the gamma prime particle size of the
virgin as-cast structure was approximately 0.4µm in section, the same as that observed
in blade 46 (3).

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 Aged microstructures can normally be identified by larger rounder primary gamma
prime precipitates with limited or no secondary particles (2). In the study conducted by
Liburdi et al (2) the microstructure of a service exposed airfoil showed signs of ageing
as shown in figure 10.1. In this figure, the primary γ’ precipitates have coalesced and
coarsened at the expense of the secondary γ’ which have completely disappeared.
Following a rejuvenation heat treatment, the microstructure was returned to an
optimal morphology, consisting of cuboidal primary γ’ particles and fine secondary
particles, see figure 10.2.

Figure 10.1 γ’ particles of service exposed mid airfoil (10,000x) (2)

Figure 10.2 γ’ particles following rejuvination heat treatment (10,000x) (2)

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 Refurbishment heat treatment can return the microstructure to its optimal morphology
to reduce the onset of creep cavitation. To regain the original microstructure, both
single and double ageing treatments are generally utilised. The standard heat
treatment for this alloy is as follows: solution treatment at 1150°C for 4 hours
followed by air cooling, primary aging at 1080°C for 4 hours followed by air cooling
and finally secondary aging at 760°C for 16 hours followed by air cooling (3).
Adequate solution heat treatments dissolve the γ’ precipitates and some carbides into
the gamma matrix. This is then followed by ageing cycles which reform the primary
and secondary gamma prime precipitates and carbides. Following this treatment, the
precipitates gain their optimal morphology and the creep strength of the material is
improved (2).

In order to eradicate any evidence of creep damage, hot isostatic pressing (HIP) can
be incorporated into the refurbishment. This process utilises a high temperature and
pressure environment to close and eliminate creep voids (2).

The morphology of the γ’ precipitates observed in blade 46 was near optimum and
these precipitates had not degraded significantly since the refurbishment. The
presence of precipitate free zones adjacent to grain boundaries may indicate early
signs of degradation, though this was also evident in the root of the blade. The near
optimum condition of the microstructure suggests that the creep voids observed were
present prior to the refurbishment since it is very unlikely that creep voids would have
formed without significant microstructural degradation.

The root of the turbine blade is located farthest from the hot gas path and ageing
should be slowest in this region (2). Thus the creep cavitation observed at the root of
blade 46 is considered unusual. However, the presence of creep voids at triple points
suggests that stress is the dominating factor in the formation of this creep damage
rather than temperature. Furthermore the thermal history prior to the refurbishment is
unknown. It should be noted that sufficient microstructural degradation would still be
required in order to initiate creep. With respect to blade 46, there were no significant
differences in the morphology of the gamma prime particles in the root compared with
the airfoil.

It is difficult to ascertain the service conditions necessary to attain the significant

creep damage observed due to the heat treatment conducted during the refurbishment
which removed any evidence of microstructural degradation. However, the presence
of creep damage at the root suggests that conditions were abnormal at some point
during the initial 48,000 hours of service i.e. due to over speeds/over temperature.

Due to the gross nature of the voids observed at the centre span of the section taken in
the area of the failure of the fractured blade it is thought that the turbine blade
examined showed extensive creep damage, and would probably not have been
suitable for further service.
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 11. Conclusions

11.1 The chemical analysis results of blade 46 are considered typical for the
Udimet 500 grade.

11.2 A minimum tensile strength of 1310MPa in the as-manufactured condition is

specified for Udimet 500, this approximately converts to 400HV. Hardness
results taken at positions 1, 2 and 3 (for location, see report above) were below
this specification. However the hardness levels would be expected to be
slightly lower than the as-manufactured condition since the material had been
subjected to ageing and a refurbishment heat treatment.

11.3 Inspection by radiography revealed no indications in blades 19 and 46. Surface

indications were shown by liquid penetrant, though these were thought to be a
result of breaks in the metal oxide layer.

11.4 The general microstructure of the blade was dendritic in nature and consisted
of γ’ precipitated within the interdendritic areas. Primary MC carbides were
also evident in the interdendritic areas and at grain boundaries. Secondary
M23C6-type carbides were also evident at the grain boundaries. This
microstructure is considered normal for this material grade.

11.5 Creep voids were evident in all of the sections examined. These voids were
confined to the interdendritic areas located at triple points, grain boundaries or
MC carbides. The voids were more prominent in the equivalent area of the
failure of the fractured blade. For all four areas sectioned, the concentration of
voids was significantly higher at the centre span of the blade than in the rest of
the cross section.

11.6 The γ’ precipitation was a mixture of primary and secondary precipitates. The
primary precipitates were cuboidal and typically 0.4µm square. The
morphology of the γ’ precipitates indicate that the microstructure is optimum
and these precipitates had not degraded since the refurbishment.

11.7 Precipitate free zones were apparent adjacent to the majority of the grain
boundaries, this may indicate early signs of degradation.

11.8 The near optimum condition of the microstructure suggests that the creep
voids were present prior to the refurbishment since it is very unlikely that
creep voids would have formed without significant microstructural
degradation.

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 11.9 The presence of creep voids at the firtree root is unusual. Much of the creep
damage was evident at triple points, which implies that stress was the
dominating factor in the formation of voids. Sufficient microstructural
degradation would still have been necessary to initiate the level of creep
damage observed.

11.10 The service conditions necessary to achieve the creep damage observed is
difficult to determine since the refurbishment has removed any evidence of
prior microstructural degradation. However, the presence of creep damage at
the root suggests that conditions may have been abnormal at some point
during the initial 48,000 hours of service prior to the refurbishment.

11.11 The extensive nature of creep cavitation in the equivalent area of the failure of
the fractured blade suggests that the blade examined had reached the end of its
creep life.

12. Recommendations for Further work

12.1 It would be useful to examine the failed blade in order to establish whether the
features observed here were consistent with the failed blade, and whether the
failure mechanism is consistent with these observations.

12.2 It may be beneficial to conduct some ambient tensile tests and stress rupture
tests to determine the remnant life in the blade examined here more precisely.

13. References

1) Noveed Ejaz, Muhammad Monsoor, Iftikhar Salam, “ Effect of High

Temperature Exposure on the Microstructure of Udimet 500 super alloy,” J
Mater Sci (2010). 45: 4507-4517.

2) Joseph Liburdi, Paul Lowden, Douglas Nagy, Tiberius Rusan De Priamus,

Stephanie Shaw, “Practical Experience with the Development of Superalloy
Rejuvenation,” ASME Turbo Expo 2009.

3) P. Wangyao, J. Zrnik, I. Mamuzic, S. Polsilapa, S. Klaijumrang, “Restoration

and Thermal Stability Investigation of Intermetallic Phase in Exposed Nickel
Base Superalloy Udimet 500 Turbine Blades,” Metabk 46 (3) 195-199 (2007)

Report No.M13161
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