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航空发表于 2011-4-11 09:34:45

Lufthansa N2 Review – HPT Blades CFM56 HPT Blade 3D Aero

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航空发表于 2011-4-11 09:35:04

CFM56 HPT Blade 3D Aero Lufthansa N2 Review – HPT Blades B.Davey 9/17/03 Lufthansa request: -5B/P and –7 shank cracking sampling program/field recommendation -5B/P and –7 shank airfoil liberation CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades 3 failures due to to internal cavity 2 shank fatigue cracks Root cause identified – cracking caused by thick coating exacerbated by high local stress induced geometry Released current production blade (M10P01) Nov, ’01 with thin coating and reduced stress geometry Task force in place to evaluate field return blade sets – returned for TE root cracks and proactively removed from select high time engines – in excess 10,800 blades inspected Shank 3 X X Liberation 7 field events – between May ’00 & Oct ’02 - M52P05 (3), M52P11 (3), M10P01 (1) Root cause unidentified – yttrium oxide inclusion contributing factor Change material to N5- LS (M10P03) – eliminate yttrium oxide from process Airfoil 7 X X X X Factory assurance cyclic engine TTF 4th Q ’03 - production intro March ’04 Liberation M10P03 M10P01 Comments / Status M52P14 M52P09/P11 M52P04/P05 Field Events (IFSD, ATO) Distress Mode P/N Affected Airfoil Separation Shank Separation CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades 2002M52P05 N5 Full Wrap TBC Improved Film Cooling P04: -5B/P Baseline (1994) P05: SB 72-163 (1997) 2002M52P09/P11/P14 N5 P09 Full Wrap TBC P11 1/2 Wrap TBC Platform Cooling P14 same as P11 with Thinned Shank Coating P09/P11: SB 72-232/271 (1998/89) P14: SB 72-400 (2001) N5 P11 plus optimized T/E cooling Shank Improvements M10P01: SB 72-0422R1 (2002) 1957M10P01 Configurations CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades Event date Model ESN TSN CSN Part Number Engine Delivery May 2000 -7B22 875-256 5057 3265 2002M52P05 June 1998 Oct 2000 -7B24 874-163 6401 6164 2002M52P05 April 1998 Feb 2001 -7B26 876-561 769 1006 2002M52P11 Aug 2000 Jul 2001 -5B3/P 779-384 1567 758 2002M52P05 June 1998 Jun 2002 -5B6/P 779-795 4967 2800 2002M25P11 Nov 2000 Sept 2002 -7B24 889-236 531 381 2002M52P11 Jan 2001 Oct 2002 -7B22 889-983 691 489 1957M10P01 June 2002 Engine 779-795 Origin: •At Rib 7 •0.235” above Platform •No Yttrium Oxide Inclusion Founded due to secondary damage. •Slot No: 80 Engine 875-256, Origin: •At Rib 6, 0.225” above Platform •Yttrium Oxide Inclusion, 0.011” •Slot No: 30 Engine 779-384 Origin: •At Rib 4 •0.300” above Platform •Yttrium Oxide Inclusion •0.012” Y2O3 •Slot No: 53 Engine 889-983, Origin: •Rib 5, 0.23” above Platform •Yttrium Oxide Inclusion: 0.012” •Slot No: 54 YY22OO33inincclulussioionnssoobbsseerrvveedd inin33ooff44pprrimimeebblaladdeeccrraacckkoorrigigininloloccaatitoionnss.. Airfoil Separations – Mixed Models, Cycles, Part Configurations Lufthansa N2 Review – HPT blades CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades ORIGIN AREA CAVIT Y No. 5 CAVIT Y No. 6 Blade No. 54 CAVIT Y No. 7 P2 FRACTURE SURFACE PLATINUM ALUMINIDE COATING BACKSCATTER ELECTRON IMAGE FATIGUE ORIGIN Summary • 7 cases of airfoil liberation – 4 prime blades found, 3 w/Yttria inclusions • CFM approved intro of M10P03 blade of N5-(low sulfur) material • This new material will eliminate Yttrium based facecoat inclusions • Production introduction by 1st Qtr. 2004 CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades -5B/P & -7B HPT Blade Internal Shank Cracks Background First event: ESN 779-234, IFSD, Nov. 2000 TSN / CSN = 9027 / 8745 PN 2002M52P04 Second event: ESN 779-271, ATO, Oct. 2002 TSN / CSN = 13626 / 9937 PN 2002M52P05, SN 53J85 Third event: ESN 874-126, IFSD, Feb. 2003 TSN / CSN = 15174 / 10229 PN 2002M52P05 Investigation Status (as of Sept 11, 2003) Current Plan: – Sampling engines plus “other” shop visits – Sampling - High-time engines CSN 12395 – Continuing to postulate Weibuls – Visual, eddy current, and metallurgical • 11210 blades inspected by ECI – 549 blades found w/cracks – 3 coating sources – 99% of cracks from 1 coater ESN 874-126 Findings Failure analysis findings: – LCF 85 mils deep prior to transition to crystallographic – 2.4 mils coating thickness – Finite time from crystallographic fatigue initiation to final tensile overload •Previous two event blades to badly damaged to see this feature What we have learned : Field • continue to sample high-time engines • max. cracks have been found on high-cycle engines 8 to 12 K • Weibulls predict 3 times the amount of current failures • the 5B/P and –7B fleets are 404 engines with P04/5 blades • roughly 350 engines have heavy coater blades • CFM considering cyclic limits for exposure of these certain blades • Timing – before year-end CFM Proprietary Information - Unauthorized Disclosure, Use, or Export is Prohibited. Lufthansa N2 Review – HPT blades 24 27 30 32 1000 10000 99 95 90 80 70 60 50 40 30 20 10 5 32 1 0.1 Cycles to 5mm Crack Length Percent Probability Plot for PCSN Weibull Distribution Mar-2003 Data Changes (vs Jan-02): Shape ~4.0, except 7BLow Only 7BLow has removals>10KC Model Thrust Group Shape Scale Mean Uncen Rt Cen 5BP 32&31 3.63 7,168 6,461 36 26 5BP 30&below 4.11 11,035 10,094 37 144 7B 27&26 4.35 8,003 7,289 36 126 7B 24&below 9.18 11,173 10,590 47 174 Weibull: 2002M52P04&5 HPT Blades (Mar-03 for reference)

979199501 发表于 2011-4-12 00:17:06

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CFM56-7B TRAINING MANUAL ENGINE FAN TRIM BALANCE

kinran 发表于 2011-6-4 23:45:05

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bocome 发表于 2011-7-31 04:10:11

Lufthansa N2 Review – HPT Blades CFM56 HPT Blade 3D Aero

zcchhccz 发表于 2013-12-4 11:22:00

楼主大好人

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Lufthansa N2 Review – HPT Blades CFM56 HPT Blade 3D Aero

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