HPT BLADE OBSERVATIONS
**** Hidden Message ***** 1 of 45<BR>VIEW<BR>FLA<BR>VIEW<BR>ALF<BR>CONCAVE SIDE<BR>CONVEX SIDE<BR>VIEWS OF HPT BLADE S/N 7AS93<BR>OBSERVATIONS<BR>2 of 45<BR>• P/N 1668M46P08 HPT blades<BR>• 7 HPT blades broken<BR>- 5/8 mm above platform<BR>• Evidence of heavy rub on the tip<BR>• Seal ring broken<BR>•<BR>EESSNN773311--776677HHPPTTBBllaaddeess<BR>BACKGROUND TO<BR>INVESTIGATION<BR>3 of 45<BR>BACKGROUND TO<BR>INVESTIGATION<BR>EESSNN773311--224411HHPPTTBBllaaddeess<BR>HPT BLADE MISSING<BR>ABOUT 1/2 OF AIRFOIL<BR>IMPACT DAMAGE<BR>• P/N 1668M46P08 HPT blades<BR>• 1 HPT blade missing about 1/2 of airfoil<BR>• Impact damage to trailing edge of several other<BR>HPT blades<BR>4 of 45<BR>~ 0.75 INCH<BR>OF FATIGUE<BR>PROPAGATION<BR>ALONG CONCAVE WALL<BR>~ 0.40 INCH<BR>OF FATIGUE<BR>PROPAGATION<BR>ALONG CONVEX WALL<BR>VIEWS OF AIRFOIL FRACTURE ON BLADE S/N 7AS93 SHOWING POSITION OF ORIGIN<BR>AT TRAILING EDGE RELATIVE TO BLADE PLATORM AND EXTENT OF<BR>FATIGUE PROPAGATION ALONG CONCAVE AND CONVEX AIRFOIL WALLS<BR>0.15 INCH<BR>ORIGIN AREA<BR>ALONG PRESSURE SIDE<BR>OF TRAILING EDGE<BR>OBSERVATIONS<BR>5 of 45<BR>ORIGIN AREA<BR>ALONG PRESSURE SIDE<BR>OF TRAILING EDGE<BR>FATIGUE<BR>OVERLOAD<BR>VIEW OF BLADE S/N 7AS93 ILLUSTRATING PORTION OF AIRFOIL FRACTURE<BR>WHICH EXHIBITED FATIGUE CRACK PROPAGATION<BR>OVERLOAD<BR>OBSERVATIONS<BR>6 of 45<BR>S/N 0AN48 S/N 8AS10 S/N 2BE85 S/N 0AN48 S/N 8AS10 S/N 2BE85<BR>IMPACT DAMAGE<BR>CONVEX SIDE CONCAVE SIDE<BR>HPT BLADES REMOVED FROM ESN 731-241 WHICH EXHIBITED<BR>IMPACT DAMAGE TO AIRFOIL TRAILING EDGE<BR>OBSERVATIONS<BR>7 of 45<BR>S/N 0AN48 S/N 8AS10 S/N 2BE85 S/N 0AN48 S/N 8AS10 S/N 2BE85<BR>VIEW<BR>FLA<BR>VIEW<BR>ALF<BR>HPT BLADES REMOVED FROM ESN 731-241 WHICH EXHIBITED<BR>IMPACT DAMAGE TO AIRFOIL TRAILING EDGE<BR>OBSERVATIONS<BR>8 of 45<BR>S/N 0AN48 - TRAILING EDGE<BR>S/N 8AS10 - TRAILING EDGE<BR>S/N 2BE85 - TRAILING EDGE<BR>VIEWS OF THE PRESSURE SIDE OF THE AIRFOIL TRAILING EDGE ON<BR>THE THREE HPT BLADES REMOVED FROM ESN 731-241 WHICH EXHBITED IMPACT DAMAGE<BR>OBSERVATIONS<BR>9 of 45<BR>S/N 0AN48 - SEM BEI VIEW OF FIRST T/E SLOT<BR>S/N 0AN48 - SEM BEI VIEW OF FIRST T/E SLOT<BR>SEM BEI VIEWS SHOWING MULTIPLE CRACKS VISIBLE ALONG PRESSURE SIDE OF<BR>TRAILING EDGE AT FIRST SLOT ON BLADE S/N 0AN48<BR>OUTBOARD<BR>OBSERVATIONS<BR>10 of 45<BR>S/N 8AS10 - SEM BEI VIEW OF FIRST T/E SLOT<BR>SEM BEI VIEWS SHOWING MULTIPLE CRACKS VISIBLE ALONG PRESSURE SIDE OF<BR>TRAILING EDGE AT FIRST SLOT ON BLADE S/N 8AS10<BR>S/N 8AS10 - SEM BEI VIEW OF FIRST T/E SLOT<BR>OUTBOARD<BR>OBSERVATIONS<BR>11 of 45<BR>S/N 2BE85 - SEM BEI VIEW OF FIRST T/E SLOT<BR>SEM BEI VIEWS SHOWING MULTIPLE CRACKS VISIBLE ALONG PRESSURE SIDE OF<BR>TRAILING EDGE AT FIRST SLOT ON BLADE S/N 2BE85<BR>S/N 2BE85 - SEM BEI VIEW OF FIRST T/E SLOT<BR>OUTBOARD<BR>OBSERVATIONS<BR>12 of 45<BR>OUTBOARD<BR>S/N 7AS93 - SEM BEI VIEW OF FIRST T/E SLOT<BR>SEM BEI VIEWS OF<BR>PRESSURE SIDE OF TRAILING EDGE ADJACENT TO FRACTURE ORIGIN ON BLADE S/N 7AS93.<BR>NO OTHER CRACKS WERE VISIBLE ALONG THE PRESSURE SIDE SURFACE.<BR>S/N 7AS93 - SEM BEI VIEW OF FIRST T/E SLOT<BR>ORIGIN AREA<BR>ALONG PRESSURE SIDE<BR>OF TRAILING EDGE<BR>OBSERVATIONS<BR>13 of 45<BR>OBSERVATIONS<BR>VIEW OF FRACTURE AREA EXHIBITING FATIGUE CRACK PROPAGATION ON BLADE S/N 7AS93<BR>ORIGIN<BR>AREA<BR>14 of 45<BR>OBSERVATIONS<BR>ORIGIN<BR>AREA<BR>VIEW OF FRACTURE ORIGIN AREA ON BLADE S/N 7AS93<BR>15 of 45<BR>1<BR>2<BR>3<BR>4<BR>5<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>VIEW OF FATIGUE PORTION OF BLADE 7AS93 FRACTURE SURFACE WITH THE NUMBERED<BR>SITES INDICATING AREAS DOCUMENTED WITH SEM IMAGES SHOWN ON SUBSEQUENT PAGES<BR>16 of 45<BR>1-A<BR>BLADE 7AS93 - FRACTURE SURFACE - SEM LOCATION 1 SEI<BR>SEM SEI VIEW OF THE FRACTURE AREA IMMEDIATELY ADJACENT<BR>TO THE TRAILING EDGE OF BLADE 7AS93. THE WHITE ARROWS DEPICT THE<BR>DIRECTION OF FATIGUE CRACK GROWTH.<BR>17 of 45<BR>BLADE 7AS93 - FRACTURE SURFACE - SEM LOCATION 1 BEI<BR>SEM BEI VIEW OF THE FRACTURE AREA IMMEDIATELY ADJACENT<BR>TO THE TRAILING EDGE OF BLADE 7AS93.<BR>18 of 45<BR>1-B<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 1-A SEI<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 1-A BEI<BR>SEM VIEWS OF THE FRACTURE ORIGIN AREA OF BLADE 7AS93<BR>19 of 45<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 1-B SEI<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 1-B BEI<BR>ADDITIONAL SEM VIEWS OF THE FRACTURE ORIGIN AREA OF BLADE 7AS93<BR>20 of 45<BR>OBSERVATIONS<BR>ORIGIN<BR>AREA<BR>S/N 7AS93 - SEM BEI VIEW T/E FRACTURE NEAR ORIGIN<BR>S/N 7AS93 - SEM BEI VIEW T/E FRACTURE NEAR ORIGIN<BR>SEM BEI VIEWS OF FRACTURE ORIGIN AREA ON BLADE S/N 7AS93 OBTAINED WITH<BR>SAMPLE TILTED TO SHOWTHE TRAILING EDGE AND CONCAVE AIRFOIL SURFACES<BR>21 of 45<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 2 SEI<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 3 SEI<BR>SEM VIEWS OF FRACTURE LOCATIONS 2 AND 3 ON THE FRACTURE SURFACE OF<BR>BLADE 7AS93. REFER TO PAGE 20 FOR LOCATION ON FRACTURE.<BR>OBSERVATIONS<BR>22 of 45<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 4 SEI<BR>BLADE 7AS93 - FRACTURE SURFACE<BR>SEM LOCATION 5 SEI<BR>SEM VIEWS OF FRACTURE LOCATIONS 4 AND 5 ON THE FRACTURE SURFACE OF<BR>BLADE 7AS93. REFER TO PAGE 20 FOR LOCATION ON FRACTURE.<BR>OBSERVATIONS<BR>23 of 45<BR>BLADE 7AS93 - MT. NO. 02-11113 BLADE 7AS93 - MT. NO. 02-11113<BR>VIEWS OF TRAILING EDGE SECTION THROUGH BLADE 7AS93. AT THIS PLANE OF POLISH,<BR>THE TRAILING EDGE THICKNESS MEASURED 0.022, INCLUDING 0.028 INCH COATING ON<BR>THE CONCAVE SIDE AND 0.0039 INCH COATING ON THE CONVEX SIDE.<BR>CONCAVE CONVEX<BR>FRACTURE 0.0028 INCH 0.0039 INCH<BR>OBSERVATIONS<BR>24 of 45<BR>BLADE 7AS93 - MT. NO. 02-11113<BR>VIEW OF FRACTURE ORIGIN AREA LOCATED ALONG CONCAVE SIDE OF AIRFOIL TRAILING EDGE.<BR>ORIGIN AREA<BR>OBSERVATIONS<BR>25 of 45<BR>BLADE 7AS93 - MT. NO. 02-11114 BLADE 7AS93 - MT. NO. 02-11114<BR>VIEWS OF METALLOGRAPHIC SECTION THROUGH THE AXIAL CENTER OF THE FIRST<BR>TRAILING EDGE SLOT ON BLADE 7AS93. THE COATING ALONG THE CONCAVE SIDE OF THE<BR>AIRFOIL MEASURED 0.0020 INCH IN THICKNESS.<BR>CONCAVE CONVEX<BR>0.0020 INCH<BR>FRACTURE<BR>OBSERVATIONS<BR>26 of 45<BR>CONCAVE CONVEX<BR>FRACTURE<BR>ORIGIN AREA EDS-1<BR>SEM BEI VIEWS OF TRAILING EDGE SECTION THROUGH BLADE 7AS93. EDS ANALYSIS OF THE<BR>BLADE MATERIAL WAS OBTAINED AT SITE LABELED “EDS-1”.<BR>BLADE 7AS93 - MT. NO. 02-11113<BR>SEM BEI VIEW<BR>BLADE 7AS93 - MT. NO. 02-11113<BR>SEM BEI VIEW<BR>OBSERVATIONS<BR>27 of 45<BR>CONCAVE CONVEX<BR>EDS-2<BR>EDS-3<BR>SEM BEI VIEWS OF TRAILING EDGE SECTION THROUGH BLADE 7AS93 SHOWING COATING<BR>ON BOTH THE CONCAVE AND CONVEX SIDE OF TRAILING EDGE. EDS ANALYSES OF THE<BR>COATING WERE OBTAINED AT SITES LABELED “EDS-2” AND “EDS-3”.<BR>BLADE 7AS93 - MT. NO. 02-11113<BR>SEM BEI VIEW OF COATING ON CONCAVE SIDE<BR>BLADE 7AS93 - MT. NO. 02-11113<BR>SEM BEI VIEW OF COATING ON CONVEX SIDE<BR>OBSERVATIONS<BR>28 of 45<BR>BLADE 8AS10 - MT. NO. 02-11115<BR>BLADE 8AS10 - MT. NO. 02-11115<BR>FIRST SLOT<BR>SECOND SLOT<BR>CONCAVE CONVEX<BR>OBSERVATIONS<BR>29 of 45<BR>OBSERVATIONS<BR>BLADE 7AS93 - MT. NO. 02-11113 - POLISH P2 BLADE 7AS93 - MT. NO. 02-11113 - POLISH P2<BR>CONCAVE CONVEX<BR>PHOTOMICROGRAPHS OBTAINED FROM METALLOGRAPHIC SECTION THROUGH<BR>TRAILING EDGE OF BLADE 7AS93 AFTER AN ADDITIONAL STEP POLISH OF 0.015 INCH.<BR>THE TRAILING EDGE THICKNESS AT THIS LOCATION MEASURED 0.025 INCH.<BR>30 of 45<BR>FATIGUE ORIGIN AREA<BR>LOCATED AT FIRST TRAILING<BR>EDGE COOLING SLOT<BR>PRIMARY FRACTURE - HPT BLADE S/N 5BM74<BR>31 of 45<BR>1.0 INCH<BR>0.90 INCH<BR>FROM AIRFOIL TRAILING EDGE, FATIGUE PROPAGATION EXTENDED<BR>FOR DISTANCE OF 1.0 INCH ALONG CONCAVE SIDE OF AIRFOIL<BR>AND 0.90 INCH ALONG<BR>CONVEX SIDE OF AIRFOIL<BR>PRIMARY FRACTURE - HPT BLADE S/N 5BM74<BR>32 of 45<BR>PRIMARY FRACTURE - HPT BLADE S/N 5BM74<BR>MULTIPLE FATIGUE ORIGINS<BR>ALONG CONCAVE SIDE OF<BR>TRAILING EDGE AT A DISTANCE OF<BR>0.15 TO 0.20 FROM TRAILING EDGE<BR>WHITE ARROWS DEPICT<BR>DIRECTION OF FATIGUE<BR>PROPAGATION.<BR>BOUNDARY OF<BR>FATIGUE PROPAGATION<BR>33 of 45<BR>PRIMARY FRACTURE - HPT BLADE S/N 5BM74<BR>0.15 INCH<BR>ORIGIN AREA<BR>34 of 45<BR>FORWARD FACE AFT FACE<BR>PRIMARY FRACTURE - HPT BLADE S/N 5BM74<BR>HPT BLADE S/N 5BM74 MARKED AS POSITION NO. 23.<BR>NO REPAIR MARKINGS WERE OBSERVED. :victory: :victory: HPT BLADE OBSERVATIONS
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