Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.

1007/s12206-023-0717-x

Journal of Mechanical Science and Technology 37 (8) 2023

Original Article
DOI 10.1007/s12206-023-0717-x
Failure investigations of last stage low-
pressure steam turbine blade
Keywords:
· Steam turbine blade
Nitin Sehra and Sushila Rani
· Scanning electron microscopy (SEM)
· Corrosion pits
Department of Mechanical, Production, Industrial and Automobile Engineering, Delhi Technological Uni-
· Fatigue striations
versity, Delhi 110042, India

Correspondence to:
Nitin Sehra
nitinsehra441@gmail.com
Citation:
Sehra, N., Rani, S. (2023). Failure inves-
tigations of last stage low-pressure steam
turbine blade. Journal of Mechanical
Science and Technology 37 (8) (2023)
4017~4023.
http://doi.org/10.1007/s12206-023-0717-x
Abstract This research study examines the failure of the last stage low-pressure steam
turbine blade. The blade is made up of martensitic steel of X10CR alloy. The main focus of this
paper is to analyze the fracture that appears on the leading edge of the blade at a distance of
350 mm from the blade tip. The investigation includes a visual examination, SEM fractography,
microstructure characterization & mechanical testing. On Investigation, silicon oxide (Sio2) is
detected on the cracked part of the blade along with sodium, potassium, chlorides, oxide, sili-
cate & sulfides inside the corrosion pits on the fracture surface. Further, an Intergranular frac-
ture followed by fatigue striations is observed on the blade's leading edge. It is concluded that
the failure of the low-pressure steam turbine blade may have been caused by corrosion fatigue.

Received November 3rd, 2022

Revised April 23rd, 2023
Accepted May 8th, 2023
† Recommended by Editor
Chongdu Cho
© The Korean Society of Mechanical
Engineers and Springer-Verlag GmbH
Germany, part of Springer Nature 2023
1. Introduction
Low-pressure steam turbine blades are essential in power generation systems that convert
steam energy into electrical power. These blades are designed to withstand extreme heat and
pressure, which makes them critical to conduct the smooth operation of a power plant. In a
steam turbine, there are multiple stages through which steam passes before it enters the tur-
bine, including HP (high pressure), IP (intermediate pressure), and LP (low pressure) zones [1].
Steam turbine blades are more prone to failure at LP than the HP and IP blades, as LP blades
capture the major part of the energy from the flowing steam compared to IP and HP blades [2].
However, despite their robust construction, turbine blades are susceptible to various forms of
damage, which can lead to failure and, in some cases, catastrophic consequences from re-
peated stress cycles due to operational or loading conditions, leading to blade cracking or frac-
ture [3-5].
Low-pressure turbine blades may fail due to various factors, including mechanical stress [6],
corrosion [7-9], erosion [10-12], fatigue [13-15], and vibration [16-19]. Mechanical stress may
arise due to excessive vibration, misalignment, or improper balancing, leading to blade defor-
mation, creep, thermal distortion, which results in blade cracking. Corrosion may occur due to
the presence of contaminants in the steam or condensate, resulting in blade pitting or corrosion
fatigue. Erosion can occur due to the impact of solid particles or droplets in the steam, leading
to blade surface erosion or wear, which results in fatigue failure of the blade.
Recent research has focused on understanding the mechanisms of failure in steam turbine
blades mainly made up of martensitic steel, particularly emphasizing the role of corrosion pits,
fatigue cracks, intergranular failure, and corrosion fatigue failure. Corrosion fatigue is a signifi-
cant factor contributing to the failure of low-pressure steam turbine blades in industrial applica-
tions. Corrosion fatigue is a form of material degradation caused by the combined action of
mechanical stress and corrosion. Corrosion pits developing on the material's surface indicate
the initiation of the corrosion fatigue process, which acts as stress concentrators. As the mate-
rial is subjected to cyclic loading, cracks develop at the site of the corrosion pits, which can
eventually propagate through the material, leading to its failure.
Kim [20] investigated the root causes of crack formation in the fourth-stage blade of a low-
pressure steam turbine. The study utilized non-destructive testing techniques, such as ultra-

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 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0717-x

sonic testing and visual inspection, to evaluate the cracks' ex- (energy dispersive spectroscopy).
tent and severity. The findings suggest that a combination of
high-temperature exposure and mechanical stress were the
main reasons for crack formation. Also, they have recom-
2. Experimental details
mended implementing preventive measures, such as improv- The last stage steam turbine blade of the L-0 row is collected
ing the blade design and manufacturing process in order to and investigated fractographically to determine the main rea-
reduce the risk of crack formation. Bhagi et al. [21] analysed sons for its failure. A transverse crack was noticed on the
the failed L-1 low-pressure steam turbine blade to understand blade’s airfoil-leading edge at a distance of 350 mm from the
its failure mechanism. They observed that cyclic stresses and blade's tip, as shown in Fig. 1. The samples were prepared
environmental effects accelerate corrosion fatigue. They have from the cracked region of the blade as shown in Fig. 2. The
concluded that corrosion fatigue is the prime reason for blade specimen was prepared using standard metallographic tech-
failure, as evidenced by the transgranular cleavage fracture. niques for fractographic analysis, and the prepared sample's
Katinic and Kozak [22] presented the fracture investigations of microstructure was revealed using Glycergia etchant through
the two adjacent rotor blades, which failed at their roots & ob- an optical microscope. For crack morphology, scanning electron
served that the blades failed due to corrosion fatigue. They microscopy of the prepared sample is carried out on VEGA3,
redesigned the blade to increase their fatigue life. Wei et al.
[23] presented the corrosion fatigue cracking mechanism of the
17-4 PH blade of a low-pressure rotor of a steam turbine. They
discovered that in a steam environment, potassium ions (K+)
and chlorine ions (Cl-) interact physically, chemically, and elec-
trochemically with the turbine blades to produce localized spot
corrosion and corrosion pits, which act as stress concentrators
& found that the blade cracks formed due to corrosion fatigue.
Khan and Sasikumar [24] investigated the failed low-pressure
steam turbine blade made of AISI 420 steel. They observed
shallow corrosion pits near the crack initiation point and varying
loads increased the vibration in the turbine, which caused the
fatigue cracks in the weaker zones, leading to the catastrophic
failure of the turbine blade. Rivaz et al. [25] examined the 410
stainless steel failed blade after 165000 hours of working. Find-
ings revealed that the inclusion of foreign particles like silicon
oxide and ferric oxide in steam could cause corrosion in blades,
and corrosion fatigue is the main reason for failure. Rani and
Agrawal [26] presented the failure investigations of 210 MW
last-stage low-pressure steam turbine blades after 152241
.
hours of working. They have analysed the blade through me-
chanical analysis, metallurgical analysis, and Non-destructive Fig. 1. Transverse crack on the airfoil-leading edge of the steam turbine
testing (NDT) and found that near the edges of the blade, wa- blade.
ter-droplet erosion creates erosion pits, which leads to the fail-
ure of the blade.
After a comprehensive literature review, it is observed that
preventive measures have to be taken to reduce the crack
formation and risk of blade failure resulting in enhancing the
fatigue life of the blade. There are different methods to en-
hance the blade’s fatigue life, like shot peening [27-29], coating
the blade [30, 31], and providing dampers between the blades
[32] in order to reduce the failure rate of the blade.
In this research work, failure analysis of a low-pressure steam
turbine blade of a 210 MW thermal power plant is presented.
High levels of noise and vibration at the LP zone during opera-
tion caused the unit to shut down and one of the blades from
the 29th stage was found to be fractured on opening the turbine
casing. The fractured blade is made of X10CrNiMoV12-2-2 alloy.
The investigations include visual observations, mechanical tests,
and scanning electron microscopy (SEM) accompanied by EDS Fig. 2. Sample cut at the cracked region for fractographic investigation.

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 Journal of Mechanical Science and Technology 37 (8) 2023
TESCAN model accompanied with energy dispersive spectros-
copy (EDS). Further, the hardness of the blade material was
evaluated using the Vickers hardness test at a force of 0.5 kg
for 10 seconds. And a tensile test was conducted to assess the
mechanical properties of the blade material.
3. Results & discussion
3.1 Visual observations
On visual examination, a transverse crack of around 20-
25 mm is observed at a distance 350 mm away from the
blade’s tip, which propagates from the leading edge towards
the trailing edge as shown in Fig. 1. Regions of black patches
i.e. iron oxide (Fe3O4) are also found on the blade’s surface
from tip to root of the blade as shown in Fig. 3 and presence of
iron oxide (Fe3O4) can make the blade material weak and duc-
tile. Further, water droplet erosion creates erosion pits on the
airfoil-leading edge but these are away from the transverse
crack as shown in Fig. 4, which concludes that the erosion pits
are not the reason for the failure of the blade.
3.2 Chemical analysis
An optical emission analyzer was used to identify the chemi-
cal makeup of the blade material. The result of the chemical
composition of X10CRNIMOV 12-2-2 is tabulated in Table 1.
Chemical testing results reveal that the turbine blade material
corresponds with AISI 410-grade martensitic steel.
Fig. 3. Black patches iron oxide (Fe3O4) observed on the blade’s surface.
Fig. 4. Erosion pits at the blade airfoil-leading edge.
DOI 10.1007/s12206-023-0717-x
3.3 Microstructure analysis
Optical microscope is used to identify the microstructure of the
blade material. Figs. 5(a) and (b) presented the microstructures
of blade material at 100x and 200x respectively. In the observed
microstructures hardened and tempered martensite is uniformly
distributed and showed no signs of microstructural deterioration.
The blade specification corresponds with the X10CRNIMOV12-2
alloy.
3.4 SEM analysis
For scanning electron microscopy (SEM) the specimen was
prepared from the cracked region of the steam turbine blade as
shown in Fig. 6. SEM of the specimen was carried out by using
a VEGA3 TESCAN MODEL equipped with an EDS facility. For
fractographic analysis, the specimen is divided into three
regions viz. R1, R2 & R3 as shown in Fig. 6(b). The
fractographic results of region R1 are shown in Fig. 7, which
depicts corrosion pits. The environment-assisted cracking of
LP steam turbine blades usually begins from corrosion pits.
The corrosion pits act as stress concentrators or stress raisers;
When a blade is in operation, it experiences cyclic loading due
to the rotational forces and the steam flow. These cyclic loads
can cause small cracks to initiate at the corrosion pits due to
the local stress concentrations. Over time, these cracks can
grow and eventually lead to a catastrophic failure of the blade.
The presence of corrosion pits can also reduce the fatigue life
Table 1. Composition of turbine blade material.
Composition C Cr Mo Ni V Mn Si
Measured weight-% 0.21 12.69 1.95 2.73 0.32 0.97 0.46
Fig. 5. Optical micrographs showing the tempered martensitic microstructure:
(a) microstructure at 100x; (b) microstructure at 200x.
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 Journal of Mechanical Science and Technology 37 (8) 2023
Fig. 6. (a) Macro-morphology of the cracked part of the blade; (b) micro-
morphology or SEM view of the rectangular portion divided into three differ-
ent regions R1, R2, and R3 for fractographic analysis.
Fig. 7. SEM fractography of R1 region depicts corrosion pits: (a) normal
view; (b) the magnified view of the corrosion part.
of the blade by reducing the thickness of the material at the pit.
This reduction in thickness can increase the stress level in the
material at the pit, making it more susceptible to crack initiation
and propagation.
The SEM analysis result of the R2 region shown in Fig. 8,
depicts the intergranular failure mode. The results of the SEM
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DOI 10.1007/s12206-023-0717-x
Fig. 8. SEM fractography of region 2 showing the intergranular fracture.
Fig. 9. (a) SEM analysis of the R3 region represents the beach marks and
fatigue striations followed by the intergranular fracture; (b) the magnified
view of intergranular fracture.
analysis of the R3 region are shown in Figs. 9(a) and (b),
representing the beach marks and fatigue striations followed by
the intergranular fracture. Fatigue striations are microscopic
lines or ridges that form on the surface of a material as a result
of repeated cycles of stress. Fatigue striations and intergranular
fractures on a low-pressure steam turbine blade can be caused
by a number of factors, including material defects, stress
concentrations, and cyclic loading. The fatigue striations also
show that the crack propagates toward the blade's trailing edge.
3.5 EDS analysis
EDS analysis was performed on the R1 region as shown in
Fig. 12. The results of the EDS analysis confirm the presence
of chlorine, silicon, oxygen, and other corrosion-promoting
products. Silicon and oxygen combine together to form SiO2
 Journal of Mechanical Science and Technology 37 (8) 2023 DOI 10.1007/s12206-023-0717-x

Table 2. Hardness values (HV) at a different location on the blade surface.

Distance from the fracture surface (mm) Hardness (HV)

0.5 492.43 HV0.5
1 466.63 HV0.5
1.5 416.89 HV0.5
2 395.08 HV0.5

Fig. 11. Vickers hardness test of the blade material at a force of 0.5 kg for
10 seconds.

Fig. 10. EDX analysis of the fractured surface of the blade for the R1 region.

particles, which repeatedly strike the blade material and form

deposits that create grooves/pits in the blade material and
distort the steam passage. The pits penetrated the material,
causing localized stress concentrations leading to fatigue
cracks. The presence of foreign particles in the steam further
exacerbated the problem by providing additional stress
concentrations. The corrosion fatigue cracks frequently initiate Fig. 12. Graphical plot of hardness value vs distance from the fracture
from corrosion pits, especially when chlorine and oxygen are surface.
present & propagate under cycling loading. It is clear from the
above findings that corrosion fatigue might be the reason for
blade failure.

3.6 Hardness
A hardness test was conducted on a Vickers hardness test-
ing machine near the failed region of the blade. A force of
0.5 kg was applied on the surface of the blade material for 10
seconds as shown in Fig. 11. The results of the hardness test
are tabulated in Table 2. And plotted graphically as shown in
Fig. 12. It is observed that the hardness is significantly higher
on the blade's fracture surface. The increase in hardness of the
blade material may be due to strain hardening, Improper heat Fig. 13. Stress-strain curve for the failed and the unfailed region of the
treatment, contamination & aging factor that can make the blade.
material more brittle and could potentially reduce the fatigue
strength of the blade material that leads the blade more prone the failed region has a yield strength of 343 MPa and an ulti-
to cracking or fracture under stress or cyclic loading. mate tensile strength of 680 MPa. The reason for the lower
value of the failed region is as it has undergone significant
deformation and damage & which reduces the strength and
3.7 Tensile test ductility of the material.
Tensile tests were conducted on the blade’s failed and un-
failed regions of the blade. The stress-strain curve is shown in
Fig. 13. The unfailed region of the blade has a yield strength of 4. Conclusions and suggestions
530 MPa and an ultimate tensile strength of 865 MPa, while 1) The microstructure observed by an optical microscope re-

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 Journal of Mechanical Science and Technology 37 (8) 2023
vealed that hardened and tempered martensite blade micro-
structure is uniformly distributed and shows no signs of micro-
structural deterioration. From the findings it is determined that
there is no material flaw that causes the turbine blade to fail.
2) Water droplet erosion produces erosion pits on the leading
edge of the blade, but they are not near the transverse crack
and cannot be considered the cause of the blade's failure.
3) The results of mechanical tests showed that the material's
mechanical properties had deteriorated, with the material being
more brittle due to an increase in hardness and a fall in ulti-
mate tensile and yield stresses, respectively.
4) The presence of foreign particles and impurities in the
steam such as chlorine, silicon, oxygen, and other corrosion-
promoting products triggers the failure mechanism.
5) SiO2 particles repeatedly strike the blade material and
form deposits that create grooves/pits in the blade material and
distort the steam passage. These pits can act as stress con-
centrators and increase the risk of fatigue failure.
6) The corrosion pits develop the region of stress-raiser as
they form the stress concentration region & when the material
is subjected to cyclic loading, cracks develop at the site of the
corrosion pits. The crack is initiated & propagated towards the
trailing edge. The intergranular fracture occurred, followed by
fatigue striations. It has been determined that the failure of the
steam turbine blade was attributed to corrosion fatigue failure.
5. Suggestions
1) The chance of pitting is increased by steam contamination
which contains dissolved salts, chlorides, or other impurities
and could raise the corrosion potential. Regular monitoring of
steam quality can help detect contamination early. This can
include the measurement of parameters such as conductivity,
pH, and dissolved oxygen levels.
2) To enhance the fatigue life of low-pressure steam turbine
blades. It is advised to use an appropriate coating or surface
modification treatment, such as shot peening or metal-matrix
composite coatings. MMCs can be typically applied using a
thermal spray process, such as plasma spray or high-velocity
oxy-fuel (HVOF) spray.
Nomenclature------------------------------------------------------------------
LP : Low-pressure
CF : Corrosion fatigue
MPa : Mega pascal
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Nitin Sehra is a Ph.D. research scholar
in Machine Design in the Mechanical,
Production, Industrial and Automobile
Engineering Department at Delhi Tech-
nological University, Delhi, India. His
research area is fatigue failure analysis
of low-pressure steam turbine blades.
Sushila Rani has her Ph.D. in Machine
Design (Vibrations) from Delhi Techno-
logical University, Delhi, India. Presently,
she is working as an Assistant Professor
in the Mechanical, Production, Industrial
and Automobile Engineering Department
at Delhi Technological University, Delhi,
India. Her research interest is on fault
diagnosis in Machinery.
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