Available online at www.sciencedirect.

com
Available online at www.sciencedirect.com
ScienceDirect
ScienceDirect
Available online at www.sciencedirect.com
Procedia Engineering00 (2017)000–000
Procedia Engineering00 (2017)000–000 www.elsevier.com/locate/procedia
ScienceDirect www.elsevier.com/locate/procedia
Procedia Engineering 206 (2017) 1813–1818

International Conference on Industrial Engineering, ICIE 2017

International Conference on Industrial Engineering, ICIE 2017
Methods of Accelerated Tests of Turbine Blades in Power Plants
Methods of Accelerated
Operated Tests of Turbine
under Multicomponent BladesConditions
Loading in Power Plants
Operated under Multicomponent Loading Conditions
A.S. Gishvarov, M.N. Davydov*
A.S. Gishvarov, M.N. Davydov*
Ufa State Aviation Technical University, 12б, Karl Marx Street, Ufa 450000, Russia
Ufa State Aviation Technical University, 12б, Karl Marx Street, Ufa 450000, Russia

Abstract
Abstract
The article presents a method of accelerated tests (ATs) of turbine blades in gas turbine power plants (GTPPs) (aircraft gas
turbine engines,
The article gas turbine
presents a methoddrives of compressors
of accelerated testsand electric
(ATs) generators,
of turbine etc.).
blades in It
gasis turbine
known that
powerthe plants
reliability and service
(GTPPs) lifegas
(aircraft of
GTPPs are mainly determined by the elements of the hot section (the moving blades and nozzle vanes, turbine
turbine engines, gas turbine drives of compressors and electric generators, etc.). It is known that the reliability and service life of disks), they are
exposed
GTPPs are to mainly
multicycle loads, repeated
determined static (low-cycle)
by the elements of the hotloads and(the
section long-term
movingstatic
bladesloads, as wellvanes,
and nozzle as to turbine
a high temperature
disks), they gasare
environment. Gas corrosion
exposed to multicycle loads,isrepeated
one of the serious
static types ofloads
(low-cycle) bladeanddamage whichstatic
long-term causes a decrease
loads, as wellinasreliability
to a highand efficiencygas
temperature of
turbines
environment.in GTPPs. The existing
Gas corrosion is onemethods of ATs
of the serious of turbine
types of bladeblades
damage which
whicharecauses
performed on individual
a decrease testand
in reliability benches do not
efficiency of
reproduce
turbines ina GTPPs.
completeThe picture of their
existing damage
methods of rate,
ATswhile the ATs
of turbine of GTPPs
blades whichreproduce the damage
are performed rate of blades
on individual caused only
test benches do notby
multicycle
reproduce aloads, low-cycle
complete picture loads and
of their long-term
damage rate, static
while loads,
the ATs butof they
GTPPsdo reproduce
not reproduce the damage
the damage rate ofrate caused
blades causedby only
the gasby
environment
multicycle loads, due to an insignificant
low-cycle loads andduration (as compared
long-term to the
static loads, butservice
they dolife)
notofreproduce
the exposurethe of a bladerate
damage to acaused
gas environment.
by the gas
Two options due
environment of performing blade ATs
to an insignificant are examined.
duration The first
(as compared option
to the consists
service life) in
of testing a bladeofseparately
the exposure a blade tofroma gastheenvironment.
GTPP. The
blade is subjected to block loading which consists of individual blocks. Each block reproduces
Two options of performing blade ATs are examined. The first option consists in testing a blade separately from the GTPP. in a successive order the damage
The
rate caused
blade by multicycle
is subjected to blockloads,
loadinglow-cycle loads and
which consists long-term static
of individual blocks.loads
Eachand the reproduces
block damage rateincaused by the order
a successive gas environment.
the damage
The second by
rate caused option consists
multicycle in ATs
loads, of a GTPP
low-cycle loads fitted with blades
and long-term which
static loadshave already
and the damagebecome outdated
rate caused byintheterms of corrosion
gas environment.
damage
The secondrate.option
The examined
consists methods
in ATs of of blade
a GTPP ATsfitted
enable
withto increase the reliability
blades which of thebecome
have already integrated assessment
outdated of the
in terms ofrobustness
corrosion
of GTPP blades operated under multicomponent loading conditions.
damage rate. The examined methods of blade ATs enable to increase the reliability of the integrated assessment of the robustness
©
of 2017
GTPPThe Authors.
blades operatedPublished by Elsevier B.V.loading conditions.
under multicomponent
© 2017 The
Peer-review Authors. Published
under responsibility by
of Elsevier Ltd. committee of the International Conference on Industrial Engineering.
the scientific
© 2017 The
Peer-review Authors.
under Published
responsibility byof Elsevier
the B.V. committee of the International Conference on Industrial Engineering
scientific
Keywords:
Peer-review gasunder
turbineresponsibility
power plant (GTPP); blade; long-term
of the scientific static loading,
committee low-cycle loading,
of the International multicycle
Conference on loading; highEngineering.
Industrial temperature gas
corrosion;
Keywords:accelerated
gas turbine tests;
powerdamage rate. blade; long-term static loading, low-cycle loading, multicycle loading; high temperature gas
plant (GTPP);
corrosion; accelerated tests; damage rate.

* Corresponding author. Tel.: +7-347-273-7954; fax: +7-347-273-7954.

E-mail address:author.
* Corresponding mar55@mail.ru
Tel.: +7-347-273-7954; fax: +7-347-273-7954.
E-mail address: mar55@mail.ru
1877-7058 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the International Conference on Industrial Engineering.
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.718
1814 A.S. Gishvarov et al. / Procedia Engineering 206 (2017) 1813–1818
2 A.S. Gishvarov, M.N. Davydov / Procedia Engineering00 (2017) 000–000

1. Introduction

The modern period of development of the GTPP is characterized by high reliability requirements and tight
deadlines for development and introduction into operation. In order to reduce the amount and duration of the
endurance tests of the GTPP, the methods of accelerated tests (ATs) are applied. They ensure the necessary
information on the reliability and service life in a shorter time [1-3]. The problem of the development of the AT
methods is very difficult and requires the solution of a number of complex tasks which are being studied in the
mathematical, physical, engineering and technical areas [1,2]. Solving these problems is significantly complicated
by the fact that the operation of modern GTPPs is characterized by a wide variety of application conditions, a wide
range of operating modes, the dynamic loads on the elements, a variety of environmental conditions and other
factors that determine their reliability and service life [1-4].

2. Topicality

It is known that the reliability and service life of GTPPs are determined mainly by the elements of the hot section
(the moving blades and nozzle vanes, turbine disks), they are exposed to multicycle loads, low-cycle (repeated
static) loads and long-term static loads, as well as to a high temperature gas environment [1-6].
The gas corrosion related to the impact of the GTPP combustion gases entering the air-gas channel is one of the
serious types of blade damage which cause decrease in reliability and efficiency of turbines [1,5,7-11].
The existing methods of independent tests of turbine blades on individual test benches with reproduction
(simulation) of multicycle loads, low-cycle (repeated static) loads and long-term static loads do not reproduce the
corrosion damage rate, because in this case the gas environment is not simulated and this decreases the reliability of
assessment of the robustness and service life of the blades. On the other hand, the ATs of blades in the GTPP system
which are performed with augmentation of the loading mode in terms of rotational speed, temperature, vibration,
etc. do not reproduce the corrosion damage rate either due to an insignificant duration (as compared to the service
life of the GTPP) of the exposure of a blade to a gas environment.
The existing methods of tests of turbine blades for high temperature gas corrosion (tests in the GTPP system,
tests on individual test benches, crucible tests in molten salts, tests in molten salts with electrochemical action, tests
with pre-application of a corrosive coating, etc.) do not ensure complete reproduction of the damage rate caused by
the multicomponent loading conditions or have a long duration [3,5,7-18].

3. Problem statement

Development of methods of ATs for turbine blades of GTPPs operated under the multicomponent loading
conditions which include multicycle loads, low-cycle (repeated static) loads and long-term static loads, as well as
the impact of a high temperature gas environment.

4. Theoretical part

In the event that a blade is simultaneously exposed to multicycle, low-cycle (repeated static) and long-term static
loads in a high temperature gas environment the condition of damage summation may be written as [3,4,6]:

D  DMC  DLC  D LTS  Dcor  a

 
 N* dN   N *p dN p 
  *
D       (1)
 0 N  σ a ( N ), T ( N )    0 N *p ε a ( N p ), T ( N p )  
    
 
 t dt   t dtcor 
  *   * a

 0 t  σ (t ), T (t )    0 t T , K  

 m   cor cor 
 A.S. Gishvarov et al. / Procedia Engineering 206 (2017) 1813–1818 1815
A.S. Gishvarov, M.N. Davydov / Procedia Engineering 00 (2017) 000–000 3

where DMC, DLC, DLTS, Dcor are the damage rates caused by multicycle, low-cycle and long-term static loads, as well
as by a high temperature corrosive environment; α, β, γ, ξ – the positive indices which depend on the material, the
load structure and the environment); a – the parameter which depends on the material, the load structure,
deformation, temperature, composition and concentration of the corrosive agents; N *  σ a ( N ), T ( N )  − the number
of cycles to failure at the amplitude of alternating stresses σа and at the temperature Т ; N *p  ε a ( N p ), T ( N p )  − the
number of cycles to failure at the amplitude of deformation εа and at the temperature Т ; t *  σ m (t ), T (t )  − durability
*
(time to failure) at the stress σm and at the temperature Т; tcor T , K cor  − durability in case of corrosion damage at the
temperature Т and the concentration of the corrosive agents Kcor.
The first element of the formula (1) denotes the damage caused by multicycle loads, the second – the damage
caused by low-cycle loads, the third – the damage caused by long-term static loads, the fourth − the damage caused
by a corrosive environment. The formula (1) includes average values of the number of cycles and the time to failure.
At α <1, β <1, γ <1 and ξ <1 the mutual influence of the heterogeneous mechanisms of damage becomes quite
significant. At α = β = γ = ξ = 1 the assessment normally contributes to the “longevity margin”. At α >2, β >2, γ >2
and ξ > 2 the mutual influence of the heterogeneous damage can be almost neglected [4,6].
The key parameters of loading are the amplitude of alternating stresses of the multicycle strength (fatigue) σa, the
amplitude of the alternating deformations of the low-cycle (repeated static) strength εа, the continuous stress of the
long-term static strength σm and the corrosiveness of the gas environment Kcor.
In the general case the damage summation from different types of loading may be represented as follows [3, 4,
6]:

 β γ ξ
 N   Np   t   tcor 
 *    *   *   * 1
  (2)

 N ( a , T )   N p (ε a , T )   t (σ m , T )   tcor (T , K cor ) 

The condition (2) enables to determine the longevity margins. The values N*, Np*, t* and t*cor in the formula (2)
correspond to the equations:

m *
 , ε ma 1 N *p C
σ ma N * C 1 , σm t Cd , 
K cor .t tcor Сcor (3)

where С, С1, Cd and Сcor are the parameters which depend on the material, manufacturing technology and other
factors.
At α = β = γ = ξ = 1 the condition (2) expresses the rule of linear summation of heterogeneous damage with а =1.
For accelerated reproduction of the corrosion damage rate the researchers [5,6,19,20] examine the method of ATs
of turbine blades in the GTPP which is implemented in the form of successive loads Ri: etching of the blade in an
electrolyte – Retch; electrochemical treatment (ECT) – RECT; high temperature treatment (HTT) in a corrosive gas
environment − RHTT.
The equivalence of the accelerated tests (ATs) and the long-duration (operational) tests (LDTs) under the
conditions of high temperature gas corrosion is ensured through obtaining a surface layer of a turbine blade which is
equivalent to the one in terms of the thickness of the corrosion layer, the composition and microstructure of the
surface layer [5,6,19,20]:

Dcor . AT f [ ( Retch ), ( RECT ), (
 RHTT )] D
cor . LDT f [ LDT ( R LDT )] (4)

where Dcor . AT , Dcor .LDT − the corrosion damage rate of the blades during the accelerated tests (ATs) and the long
 
duration tests (LDTs); τLDT ( R LDT ) – the duration of loading of a blade in the R LDT mode.
1816 A.S. Gishvarov et al. / Procedia Engineering 206 (2017) 1813–1818
4 A.S. Gishvarov, M.N. Davydov / Procedia Engineering00 (2017) 000–000

For the GTPP turbine blades TA-6A that are made of the heat-resistant alloy ZhS-6K, at etch= 0.08 h, ECT = 1.0
h and HTT = 7.5 h, the duration of the corrosion resistance (strength) tests decreases [5,6]:

τ LDT τ LDT 1400

KY
 =   146 times (5)
τ AT τetch + τ ECT + τ HTT 9,58

where LDT, AT – the duration of the operational and accelerated tests; etch – the duration of etching of the blade;
ECT – the duration of electrochemical treatment; HTT – the duration of high temperature treatment in a furnace (in a
corrosive gas environment) at the temperature ТAT = 920 оС, including the duration of heating heat, the holding time
hold and the cooling time cool (heat = 1.0 h, hold = 5.0 h and cool = 2.5 h).

5. Independent accelerated tests of turbine blades (outside the GTPP system)

In this case the ATs of blades are performed on individual benches by means of successive implementation of
block loading А1B1, А2B2,...,АzBz (fig. 1). In each block Ai the damage rate is reproduced: DMC. i, DLC. i, DLTS. i. In each
block Bi the corrosion damage rate is reproduced: Dcor. i.
z z z z
The tests are completed when  DMC.i  DMC ;  DLS.i  DLS ;  DLTS.i  DLTS ;  Dcor .i  Dcor .
i 1 i 1 i 1 i 1

Fig. 1. Diagram for performance of independent ATs of turbine blades (outside the GTPP system).

6. Accelerated tests of turbine blades in the GTPP system

Reproduction of the damage rates DMC, DLC and DLTS during the ATs of the GTPP is performed by means of
[2, 3]:
 exclusion of the modes that have little effect on the damage rate of the blade;
 steplike run in the operating speed range (the damage rate ( DMC ) AT  ( DMC ) LDT is reproduced). The steplike run
in the operating speed range is performed for the purpose of reproduction of the multicycle damage rate (fatigue).
Account is taken of the areas of application of loading in which  а   1 (fig. 2). Maximum stresses occur in
resonant modes. As long as hazardous resonant modes are normally not known, the steplike run is performed for the
rotation frequencies that differ by no more than 10 % (the natural frequency diversity of the blades and other parts
amounts to around 5…10 %). The run time at each level of rotation frequencies should ensure achievement of the
fatigue endurance limit, which corresponds to the run of (1…2)108 cycles [2,3];
 full reproduction of the transient modes (low-cycle loads) which are encountered during operation (GTPP starts
with achievement of the maximum mode, acceleration characteristics, chop decelerations, etc.). The damage rate
( DLC ) AT  ( DLC ) LDT is reproduced;
 increase in the run 1 in the heaviest duty conditions (the damage rate ( DLTS ) AT  ( DLTS ) LDT is reproduced).
 A.S. Gishvarov et al. / Procedia Engineering 206 (2017) 1813–1818 1817
A.S. Gishvarov, M.N. Davydov / Procedia Engineering 00 (2017) 000–000 5

The run duration  AT is determined according to the condition of equality of the long-term strength margins of
the blades in the accelerated and long-term tests [4]:

  k m1  k1  
mi m1
1SA SN
1 mi  σ д (Ti ,τi )  τi
 mi  mi i 
 ; k    ; τ AT τ1 1  1
   ...     τ1 ; (mi  m1 ) (6)
(ki )
i 1  i 1 (ki )  σi  τi   k2   k S  

where Ki is the strength margin of a blade in the ith operating mode; mi – the indicator of the degree of dependence
“stress-time” ( m = idem) for the long-term strength of the material at the temperature Ti;  i – the time to failure
at the temperature Ti and the stress i; SN, SA – the number of the modes taken into account in the program of the
long-term and accelerated tests.

Fig.2. Fatigue life model.

As long as reproduction of the damage rate Dcor . in the course of performance of the ATs is impossible due to the
short (as compared to the service life) duration of the exposure of blades to a gas environment, the tests are
performed on installed blades which have already become overaged in terms of the corrosion damage rate Dcor  ,
  Dcor
based on the condition: Dcor  Dcor , where Dcor is the corrosion damage rate accumulated during the period of
performance of the ATs – AT (fig. 3). The informativeness of the ATs can be enhanced by means of tests of blades
which different accumulated corrosion damage rate Dcor .i : Dcor
.1 0.9  Dcor .  ; Dcor
.2 0.8  Dcor .  ; Dcor
.3 0.7  Dcor . 
; ... . This will enable to use the results of the tests for assessment of the influence of Dcor .i on D ( D  f ( Dcor .i ) .
The blades that have the same values of Dcor .i are installed pairwise (symmetrically to each other) for the purpose of
prevention of imbalance of the turbine wheel (fig. 4).

Fig. 3. Dynamics of accumulation of the damage rates  , DА , D

Dcor of the ATs of turbine blades together with the GTPP.
1818 A.S. Gishvarov et al. / Procedia Engineering 206 (2017) 1813–1818
6 A.S. Gishvarov, M.N. Davydov / Procedia Engineering00 (2017) 000–000

DА  DMC  DLC  DLTS ; D

Fig. 4. Diagram for arrangement of the blades on the turbine wheel; cor
  Dcor
Dcor  ;
D DА  Dcor   Dcor
DА  Dcor  .

In accordance with the specified technology for the ATs, the reliability assessment was performed for the GTPP
that had the service life τLDT= 3000 h. During the AT the damage rates DMC, DLC, DLTS were reproduced (τAT
= 750 h, KA = 4) [4]. Application of the ATs to the corrosion damage rate in accordance with the diagram [4]
enabled to ensure a complex test of the blade reliability for the period τA = τAT + τcor = 770.5 h (KA = 3000/770.5
= 3.9).

References

[1] A.S. Gishvarov, M.N. Davydov, G.K. Ageyev, Primary objectives of improvement of the effectiveness of accelerated endurance tests of
engines and power plants, Vestnik UGATU. 2(47) (2012) 69–76.
[2] A.S. Gishvarov, Accelerated tests for reliability of aircraft units, Machine Building, Moscow, 2016.
[3] I.A. Birger, Deterministic and statistical models of durability: Book, The problems of reliability of aircraft, Machine Building, Moscow, 1985,
pp. 105–150.
[4] A.S. Gishvarov, The theory of accelerated endurance tests of engineering systems, Gilem Publishing House of the Academy of Sciences of
Bashkortostan, Ufa, 2000.
[5] A.S. Gishvarov, M.N. Davydov, Methods of tests of turbine blades for high temperature gas corrosion, Vestnik UGATU. 1(67) (2015) 45–54.
[6] A.S. Gishvarov, The damage rate of the materials of power plants under the conditions of a corrosive environment, Machine Building,
Moscow, 2014.
[7] B.I. Beketov, A.V. Ryabchenkov, A.I. Maksimov, V.A. Batyrev, P.Z. Reznikova, On the sulfide corrosion mechanism of austenitic Ni-Cr
steels in combustion products of high-sulfur fuel oils, Metal Protection. 1 (1977) 13–20.
[8] P.T. Kolomytsev, Gas corrosion and strength of nickel alloys, Metallurgy, Moscow, 1984.
[9] S.I. Lee, Impact of temperature on high temperature corrosion, Energy machines and power plants. 1 (1973) 71–80.
[10] V.I. Nikitin, Corrosion and protection of gas turbine blades, Machine Building, Leningrad, 1987.
[11] A.V. Ryabchenkov, Y.V. Kuznetsov, F.V. Myasnikova, High temperature corrosion of nickel-based alloys, Metal Protection. 5 (1986) 37–
44.
[12] S.Z. Bokshtein, S.T. Kishkin, E.Y. Olshanskaya, The influence of the surface condition of nickel-plated alloys on their oxidation rate, Metal
Protection. 2 (1974) 173–175.
[13] L.B. Getsov, V.I. Nikitin, I.P. Komissarova, A.A. Chikurova, The heat resistance of materials of gas turbine blades, Power Plant Industry. 2
(1978) 29–33.
[14] L.B. Getsov, A.I. Rybnikov, A.F. Potrebnyak, The impact of loss of surface alloying of heat-resistant alloys on their endurance, The issues
of strength. 2 (1989) 28–32.
[15] L.B. Getsov, A.L. Madorsky, A.G. Tereshchenko et al., The impact of ash deposits on the heat resistance of materials of gas turbine plant
blades, The issues of strength. 1 (1989) 71–76.
[16] G.P. Dmitrieva, O.S. Kostyrko, I.I. Maksyuta, N.A. Razumova, A.K. Shurin, High-temperature salt corrosion of nickel-carbide eutectic
alloys, Metal Protection. 2 (1987) 20–25.
[17] I.V. Oryshich, Development of the methods for testing heat-resistant alloys in molten salts, Metal Protection. 1 (1981) 16–23.
[18] I.N. Ozeryanaya, Corrosion of metals in molten salts during heat treatment, Metal technology and heat treatment of metals. 3 (1985) 14–17.
[19] M.N. Davydov, Accelerated simulation of high temperature gas corrosion of turbine blades, News of Higher Educational Institutions,
Aviation Technology. 4 (2005) 76–77.
[20] A.S. Gishvarov, M.N. Davydov, A.K. Rakhimov, Simulation of endurance of turbine blades under the conditions of a corrosive
environment, Vestnik UGATU. 20(1) (2016) 71–80.