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B2 compressor 11,718 OH, 40 S and 3,375 High Fogging OH
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Ba TGNTT Kellerer R. 1
Ba TGDC Conzelmann, R. 1
Ba TGDC Lipfert, C. 1
Ba TGNT Schroeder, N. 1
Ba CSGIX Matz, C. 1 Auftraggeber

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Replicas of compressor blade 1 were sent to Baden for analysis. The extent of the erosion has been
measured with respect to roughness.

- Results show that the AxEnergy nozzles are causing a slightly higher erosion rate than their Caldwell
counterparts after 3,375 High Fogging OH. However, the rate of erosion is within the predicted range
defined by TN03/0905.

- The stellite 6, laser cladded blade is performing to expectation with a considerably lower erosion rate
compared to uncoated St70AH.

- Results show that the Stellite 6 laser cladded blades have approximately half the roughness that the
non cladded St70AH blades has after 3,375 High Fogging OH.

Account : D541003807
Search Info
Plant : Hermosillio GT24 Descriptors :
Component : KLA1 GT24 test abbreviation list :
Material : St70AH and stellite 6 laser cladding
ALSTOM (Switzerland) Ltd We reserve all rights in this document and in the information Release Resp.
Materials TTCM contained therein. Reproduction, use or disclosure to third
+41 56 205 31 84 parties without express authority is strictly forbidden.
www.alstom.ch FM000001/GTWM/20020415/E © ALSTOM (Switzerland) Ltd 2006
 TTCM-D2577

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This is the first ‘B’ inspection since the B2 compressor upgrade in March 2004. There are signs of
erosion on the laser clad section of the blade 1. Replicas of 4 blades were taken (same 4 blades as
D1094) including the laser clad section, and sent to Baden for analysis. The extent of the erosion with
respect to roughness will be measure and compared to the initial ‘A’ inspection. Since the B2 upgrade
the engine has accumulated 3,375 High Fogging OH.

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The replicas delivered to the materials laboratory in Baden were cut to size to allow the measurement
needle to pass unhindered through the trough of the replica. Three measurements were taken for
each replica to give representative values. The measurement areas were selected due to being free
from features not representative of the surface topography, including embedded dirt and grit.

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The Rz value for roughness was chosen to evaluate the initial erosion depth as it represents the
average of the 5 Rmax values (peak to valley height) over a measuring period along the leading edge.

The maximum erosion depth Rt represents the largest Rmax figure (peak to valley height) over all 5
sector.

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ALSTOM (Switzerland) Ltd, TTCM, CH-5401 Baden FM000001/GTWM/20020415/E Page 2 of 6

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Measurement parameters used were according to DIN EN ISO 4288:1998 and DIN EN ISO 3274:1998

lt 15.0mm
lc 2.50 (cut off wave length)
Stylus range 300µm

Device Hommelwerke (Hommel tester T8000)

Roughness values taken from the replicas are listed below in Table 1.

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Measurement %ODGH3RVLWLRQ
6 12 25
Root Mean Tip Root Mean Tip Root Mean Tip
Ra [µm] 20.0 21.8 28.2 17.2 22.9 28.0 19.1 25.3 39.4
1 Rz [µm] 112.3 129.2 154.8 108.8 126.7 139.7 108.0 140.5 206.3
Rt [µm] 154.2 211.3 196.5 136.6 171.7 178.2 136.8 166.2 289.2
Ra [µm] 15.6 20.8 32.2 19.2 24.7 27.7 20.8 32.1 37.9
2 Rz [µm] 106.1 118.7 158.6 109.8 142.5 160.7 113.4 160.4 193.0
Rt [µm] 121.4 155.6 206.8 155.0 176.5 212.7 160.0 192.4 258.6
Ra [µm] 18.1 19.0 30.9 19.0 23.7 27.2 19.9 28.7 38.9
3 Rz [µm] 110.1 116.7 157.6 98.4 129.8 139.8 133.7 154.2 204.7
Rt [µm] 152.5 168.2 191.2 128.1 179.9 177.7 168.0 197.7 289.1
Ra [µm] 17.9 20.5 30.4 18.5 23.8 27.6 19.9 28.7 38.7
Average Rz [µm] 109.5 121.5 157.0 105.7 133.0 146.7 118.4 151.7 201.3
Rt [µm] 142.7 178.4 198.2 139.9 176.0 189.5 154.9 185.4 279.0

Results from Table 1 are summarised in Table 2. They show that erosion is higher towards the tip,
which is expected.

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Ra [µm] 18.8 24.3 32.3
$YHUDJH Rz [µm] 111.2 135.4 168.4
Rt [µm] 145.8 179.9 222.2
Ra [µm] 1.0 4.1 5.8
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'HYLDWLRQ Rz [µm] 6.5 15.2 29.0
Rt [µm] 8.0 4.9 49.3

ALSTOM (Switzerland) Ltd, TTCM, CH-5401 Baden FM000001/GTWM/20020415/E Page 3 of 6

 TTCM-D2577

Table 3 shows the roughness values for the laser cladded blade. The show that the Stellite 6 laser
cladding is performing as expected with much reduced erosion rates.

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Blade 19
Measurement
Laser Cladded Non-Cladded
Ra [µm] 4.7 18.0
1 Rz [µm] 33.8 95.0
Rt [µm] 49.1 117.9
Ra [µm] 6.5 14.5
2 Rz [µm] 47.4 86.4
Rt [µm] 69.9 120.2
Ra [µm] 4.7 12.8
3 Rz [µm] 34.0 69.2
Rt [µm] 50.4 94.4

Table 3 is summarised in Table 4, it shows a significant difference between the cladded and non
cladded areas.

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Laser Cladded Non-Cladded
Ra [µm] 5.3 15.1
$YHUDJH Rz [µm] 38.4 83.5
Rt [µm] 56.5 110.8
Ra [µm] 1.0 2.7
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Rt [µm] 11.7 14.3

The results from Table 4 show that the laser cladding has reduced roughening of the leading edge by
a factor of approximately two after 3,375 High Fogging OH. The effect of cladding can be seen below
in the roughness profile of the transition zone between the cladded and non-cladded areas. Slight
erosion on the transition between the cladded and non-cladded areas are visible in the image below,
this is picked up by the roughness profile in Figure 3.

ALSTOM (Switzerland) Ltd, TTCM, CH-5401 Baden FM000001/GTWM/20020415/E Page 4 of 6

 TTCM-D2577

Non-Cladded Cladded

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ALSTOM (Switzerland) Ltd, TTCM, CH-5401 Baden FM000001/GTWM/20020415/E Page 5 of 6

 TTCM-D2577

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The measured rate of average erosion depth Rz of compressor blade 1, B2 compreesor after 3,375
High Fogging OH with the AxEnergy nozzles compared to past experience of the B compressor with
Caldwell nozzles is displayed in Figure 4.

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Hermosillio (High Fogging AxEnergy nozzles)

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It can be seen that the AxEnergy nozzles are causing a slightly higher erosion rate than their Caldwell
counterparts after 3,375 High Fogging OH. However, the rate of erosion is within the predicted range
defined by TN03/0905.

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Replicas of compressor blade 1 were sent to Baden for analysis. The extent of the erosion has been
measured with respect to roughness.

- Results show that the AxEnergy nozzles are causing a slightly higher erosion rate than their Caldwell
counterparts after 3,375 High Fogging OH. However, the rate of erosion is within the predicted range
defined by TN03/0905.

- The stellite 6, laser cladded blade is performing to expectation with a considerably lower erosion rate
compared to uncoated St70AH.

- Results show that the Stellite 6 laser cladded blades have approximately half the roughness that the
non cladded St70AH blades has after 3,375 High Fogging OH.

ALSTOM (Switzerland) Ltd, TTCM, CH-5401 Baden FM000001/GTWM/20020415/E Page 6 of 6