Development and turbine engine performance of three advanced rhenium containing superalloys for single crystal and directionally solidified blades and vanes
- Rolls-Royce PLC, Derby (United Kingdom)
- Allison Engine Co., Indianapolis, IN (United States)
- Cannon-Muskegon Corp., MI (United States). SPS Technologies, Inc.
Turbine inlet temperatures over the next few years will approach 1,650 C (3,000 F) at maximum power for the latest large commercial turbofan engines, resulting in high fuel efficiency and thrust levels approaching 445 kN (100,000 lbs). High reliability and durability must be intrinsically designed into these turbine engines to meet operating economic targets and ETOPS certification requirements. This level of performance has been brought about by a combination of advances in air cooling for turbine blades and vanes, design technology for stresses and airflow, single crystal and directionally solidified casting process improvements, and the development and use of rhenium (Re) containing high {gamma}{prime} volume fraction nickel-base superalloys with advanced coatings, including full-airfoil ceramic thermal barrier coatings. Re additions to cast airfoil superalloys not only improves creep and thermo-mechanical fatigue strength, but also environmental properties including coating performance. Re dramatically slows down diffusion in these alloys at high operating temperatures. A team approach has been used to develop a family of two nickel-base single crystal alloys (CMSX-4 containing 3% Re and CMSX-10 containing 6% Re) and a directionally solidified, columnar grain nickel-base alloy (CM 186 LC containing 3% Re) for a variety of turbine engine applications. A range of critical properties of these alloys is reviewed in relation to turbine component engineering performance through engine certification testing and service experience. Industrial turbines are now commencing to use this aero developed turbine technology in both small and large frame units in addition to aero-derivative industrial engines. These applications are demanding, with high reliability required for turbine airfoils out to 25,000 hours, with perhaps greater than 50% of the time spent at maximum power. Combined cycle efficiencies of large frame industrial engines are scheduled to reach 60% in the US ATS program. Application experience to a total 1.3 million engine hours and 28,000 hours individual blade set service for CMSX-4 first stage turbine blades is reviewed for a small frame industrial engine.
- Sponsoring Organization:
- USDOE
- OSTI ID:
- 665380
- Report Number(s):
- CONF-970604-; ISSN 0742-4795; TRN: IM9830%%228
- Journal Information:
- Journal of Engineering for Gas Turbines and Power, Vol. 120, Issue 3; Conference: 42. international gas turbine and aeroengine congress and exhibition, Orlando, FL (United States), 2-5 Jun 1997; Other Information: PBD: Jul 1998
- Country of Publication:
- United States
- Language:
- English
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