International Journal of Advanced Science and Technology

Vol.85 (2015), pp.17-28

http://dx.doi.org/10.14257/ijast.2015.85.03

An Investigation of Transient Thermal Analysis of 1st Stage Gas

Turbine Blade Manufactured by Directional Solidification and
Mechanically Alloyed Nickel-Based Superalloys
B.P.V Saikrishna Mukherji, Raja.K1, G.Naresh2,
V. Naga Bhushana Rao3 and I.N. Niranjan Kumar4
1

Research assistant, Department of Marine Engineering, Andhra University, India

2
Research associate, Department of Marine Engineering, Andhra University,
India
3
Professor, Department of Mechanical Engineering, Raghu Institute of
Technology, India
4
Professor, Department of Marine Engineering, Andhra University, India
[email protected]
Abstract

The turbine rotor blades of a gas turbine engine are designed for operation at elevated
temperatures, particularly first stage gas turbine blades. During operation, the turbine
blades are subjected to high temperatures and large centrifugal forces. In addition to
these, the temperature variations occur at start-up and shutdown cycles of the engine.
Due to sudden changes in temperature, transient thermal effects are sighted and timedependent temperature gradients appear. The estimates of the thermal variations sighted
on the turbine blade at various operational speeds of the gas turbine rotor are important
in determining the fatigue life. The thermal condition during the startup sequence
initiated is considered as a major factor in determining the rotor maintenance interval
and individual rotor component life. This work has primarily focused on transient thermal
stresses arising in the rotor blade by using Finite Element Analysis. Nowadays, the
thermal stresses of the gas turbine parts are determined by user defined softwares that is
based on numerical methods which are being used significantly. A typical turbine rotor
blade has been modeled by using CATIA V5R21. Turbine blades are made of Nickelbased superalloys have been selected for transient thermal analysis by using ANSYS 15.0.
Comparative analysis has also been carried out to determine the suitability and strength
of turbine blade material under the same operating conditions. Two blade materials such
as IN 792 DS and IN 754 MA have been selected for comparative analysis and these
blades were manufactured by Directional solidification and mechanical alloying methods
respectively. The physical and mechanical properties are updated to the model and
appropriate boundary conditions are applied. Thermal stresses are evaluated for both
materials and the results have been compared with IN 738 LC. Static analysis has also
been carryout out to examine the structural performance of the alloys. It has been
observed that maximum stress and strain are sighted near the root of the turbine blade.
The temperature gradients sighted on the turbine blade during acceleration and
decelerations are below the melting temperature of the blade materials. It has been
noticed that the transient thermal stresses are higher than the steady state thermal
stresses. It has been observed that IN 792 DS has better physical and thermo mechanical
properties that can withstand higher turbine inlet temperatures and could be suitable
material for the manufacturing of turbine blade at Marine and Related Environments.
Keywords: Transient thermal analysis, Gas turbine blade, Superalloys, Finite element
method

ISSN: 2005-4238 IJAST

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International Journal of Advanced Science and Technology

Vol.85 (2015)

1. Introduction
Transient thermal analysis is a relatively a new technique and is being applied to some
aero and marine gas turbine engines. A transient condition said to be when condition
parameters such as speed, firing temperature and load varying with time. Start-up and
shutdown are transient events when there is a change in load or an acceleration event.
White (1988) has summarized the main differences between steady state and transient
conditions. During transient, shaft inertia will either be damaged or produce power
(depending on whether it is being accelerated or decelerated). Pressure and temperature
gradients occur during transient causing changes in the mass flow rates in and out of
components. Dimensions of various components can change due to temperature and
centrifugal effects. Tip clearances can be affected. In large critical turbo machines
however, problems often develop under transient conditions due to factors such as
increase in loading, thermal stresses, changes in tip clearances and changes in thrust
position. Several gas turbine operators use transient analysis to measure coast down times
or plot start-up curves using strip charts or by trending packages. Besides high turbine
inlet temperature (TIT), it is well known that start-up and shutdown cycles affect blade
life through thermal fatigue of the structural material this is because of variations in
thermal loads. Blade failures in rotating engines may have severe impact on the
availability of engines. Therefore, it is observed as an important challenge especially, in
gas turbine engines. Blade failures are caused by a number of mechanisms under the
turbine operating conditions of high rotational speed at elevated temperatures. These
failures may have different causes, such as creep or fatigue damage, external and internal
damage of blade tip and turbine casings [1-8]. Turbine blades are the most important
components in a gas turbine and are responsible for extracting energy from high
temperature gases. The transient behavior takes some time before it attains an equilibrium
temperature. During this interim period, the temperature is varied with time and the disk
is said to be in transient state. Transient thermal analysis indicates the thermal shocks that
are induced in the disk. Thermal shock is produced by transient temperature gradients that
are applied abruptly. The temperature gradients that can be established in the transient
state are generally higher that those occur in steady state. Due to these reasons there is a
great importance in predicting life of a gas turbine blade to with stand at higher elevated
temperatures [9].
At design point the gas turbines operate efficiently and safely because all their
components are well matched and the flow aligned with the blade passages to avoid
losses. Certainly, gas turbines are required to operate at off-design over a wide range of
operating conditions, which depends up on the engine applications whether at land, sea or
air, both civil and military [10].
During start-up, the rotors that are cold experiences transient thermal stresses as the
turbine is brought on line. Large rotors with their longer thermal time constants develop
higher thermal stresses than smaller rotors undergoing the same startup time sequence.
High thermal stresses reduce thermo-mechanical fatigue life and the inspection interval
[11].
1.1. Nickel-based Superalloys
Nickel-based superalloys of directional solidification (DS) for industrial gas turbine
blades were developed based on alloy IN 792 with approximately 12 mass % Cr. From
preliminary test results a temperature gain in stress-rupture strength of 30 K can be
expected, compared to Re-free aero engine alloys with columnar grains. This significant
strength improvement can be achieved by adding 2 to 3 mass % Re in the group of 12
mass % Cr alloys. With balanced Cr-, Al-, and Ti- contents they also exhibit superior hot
corrosion resistance compared to typical high Al / low Cr / low Ti aero engine alloys.

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The present development leads to the optimized and modified alloying concepts; a new
DS alloy was developed, IN 792 DS this new alloy exhibits enhanced properties regarding
creep strength and castability, combined with good corrosion resistance. Increasing the
Al-content above the limit to form an Al2O3 scale (i.e., above about 5%) gives rise to
catastrophic hot corrosion attack [12].
MA 754 alloy, showing excellent thermal fatigue and high temperature mechanical
resistance due to its high stability of Y2O3 hardening dispersion, has been adopted for
vanes atleast in one application. They are known as Oxide dispersion strengthened
superalloys (ODS). ODS alloys are produced by mechanical alloying and contain fine
incoherent oxide particles which are harder than the matrix phase [13].
Like other ODS materials, MA 754 alloy has a very fine, flat, log stress-log rupture life
slope compared to convectional alloys. The strength of MA 754 alloy is about 100Mpa for
100 hours life, this is somehow higher than the other ODS alloys and several times greater
than the conventional materials, like MAR-M alloy 509 and alloy 80 A. Thus, while MA
754 alloy is compared to TD (Thoria dispersed) Ni-Cr, it has a non-radioactive dispersoid
and high strength, so it is suitable for the applications such as gas turbine vanes [14].
IN 738 LC has remarkable corrosion resistance and also creep resistance in high
temperatures. Creep is known as one of important restrictive options of the gas turbine
blade life. The IN 738 LC alloy is commonly used for gas turbine blades are strengthened
by precipitation of () phase [15].
1.2. Problem Statement
Previously some work had been carried out on failure of turbine blade through
metallurgical and mechanical analysis. Mechanical analysis has been carried out assuming
that there might be a failure in the blade material due to blade operation at elevated
temperatures and subjected to large centrifugal forces which finally led to the ultimate
failure of gas turbine blade. Structural and steady state thermal analysis has been carryout
as a part of mechanical analysis [16-19]. An attempt has been made on transient thermal
analysis of gas turbine blade. Transient thermal analysis has been carried out for
estimation of transient effects on turbine blades for predicting the steps that could be
taken for improvement of blade life. Nickel-based superalloys are considered for
evaluation of thermal effects that are induced on blade by applying appropriate boundary
conditions. The principal forces acting on the blade are observed as gas pressure and force
due to change in momentum that enables the rotation, pressure force accompanied by
axial and tangential components of the gas flow. Since the turbine rotor is subjected to
large temperature variations, the material properties such as Specific heat, Enthalpy and
Young's modulus undergo variation with time. In such conditions, there is a probability of
failure of the rotor, if the turbine rotor is not designed to withstand at transient event. The
convective heat transfer coefficient has been calculated by using the heat transfer
empirical relations taken from the heat transfer data book. Therefore the investigation of
the transient thermal effects that are sighted at transient regime; Von-mises stress, Total
deformation and strain are also calculated to justify the structural stability of the
materials, which could be suitable for marine environments [20-23].

2. Background Data
It was reported that the turbine blades under investigation were made up of
Nickel-based superalloys IN 792 DS and IN 754 MA and were manufactured by
Directional solidification and mechanical alloying methods respectively.

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Table 1. Chemical Composition of HPT Turbine Blade Made of Nickel-based

Superalloy
Superalloy

Ni

Cr

Ti

Al

Mo

Ta

Zr

Hf

Co

Y2 O3

IN 792 DS

bal

12.7

3.9

3.4

1.8

4.2

0.012

0.016

4.3

0.03

0.89

8.7

IN 754 MA

bal

15.5

2.5

4.5

2.0

1.9

0.06

0.01

0.6

1.1

IN 738 LC

bal

16

3.4

3.4

1.7

1.7

8.5

0.01

2.6

0.10

0.90

0.17

Table 2. Physical and Mechanical Properties

Property
Youngs modulus(Gpa)
Thermal conductivity (W/m C)
Possions ratio ()
Density (Kg/m3)
Specific heat (J/Kg. k)

IN 792 DS
220
10
0.29
8250
460

IN 754 MA
228
14.3
0.27
8550
500

IN 738 LC
175
16.2
0.33
8110
450

3. Modeling of Gas Turbine Blade

Reverse Engineering (RE) is being applied to generate 3D surface data of turbine
blade. The data to make real model of a turbine blade is obtained using Coordinate
Measuring Machine (CMM). The blade model profile is generated by using CATIA
V5R21 software. 3D model of a gas turbine blade with root was done in two stages. These
two were then combined to make a single volume using union Boolean operation.
Geometric model of gas turbine blade using CATIA V5 R21 is shown in Figure 1.

Figure 1. Geometric Model of Gas Turbine Blade Using CATIA V5 R21

4. Design Operating Conditions

Gas Turbine blade operating conditions are considered at transient operation during
start-up as shown in Figure 2. Steady state heat transfer coefficients are considered as the
initial boundary condition at the start up. Boundary conditions are updated on the model
to simulate the actual environment where rotor blades are exposed to high temperature.

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Initial temperature turbine is given as 950C. Ambient temperature is raised from

400C to 1300C. Heat flux and convective film coefficients vary with time and
temperature, which are calculated by using the following empirical relation for laminar
flow over a flat plate [24],
Nu = 0.332 Pr 1/3 Re1/2
Bulk temperature ranging at 787.5C Reynolds number is found in range from 2.0105
- 2.7 105. Since Re < 5 105 flow is laminar. Obtained heat transfer coefficients are kept
for analysis using ANSYS. The loads acting on blade materials are static loads axial,
tangential by gas pressure and centrifugal load due to rotation.

Figure 2. Transient Loading Condition

Figure 3. Meshing of Turbine Blade

4. Finite Element Method

Finite element analysis is run by taking the geometry of a component and splitting it
into a number of elements. Each element is then given a material property (such as
Youngs modulus and thermal conductivity) and is connected to other elements by nodes
as shown in Figure 3. Test conditions such as load and temperature are applied and the
model is run in a number of small time steps. Since the conditions at points within each
element are varied for each time step, the equations derived from mechanical testing can
be applied and the material response can be predicted. Using this method a prediction of
the material response of the whole component can be estimated. The turbine blade is
analyzed for its thermal and structural performance. The structural and thermal analysis of
a gas turbine is carried out using ANSYS 15.0.

5. Transient Thermal Analysis

Engineer/analysts often perform a steady state analysis before performing a transient
thermal analysis, to help establish initial conditions. A steady state analysis can be the last
step of a transient thermal analysis [25].

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Figure 4. Transient Temperature Distribution Using Steady State Heat

Transfer Coefficients at 1s on IN 792 DS and IN 754 MA

Figure 5. Transient Temperature Distribution Using Steady State Heat

Transfer Coefficients at 26s on IN 792 DS and IN 754 MA

Figure 6. Transient Temperature Distribution Using Steady State Heat

Transfer Coefficients at 50s on IN 792 DS and IN 754 MA
5.1. Steady State Thermal Analysis
Steady state thermal analysis is carried out before conducting transient analysis to
obtain intial boundary conditions such as firing tempertaure, heat flux and film coefficient
values. Thermal effects which are sighted during transient operation are shown in Figure
4, Figure 5 and Figure 6 are distributed along the blade surface at speeds 5000, 7000 and
9000 rpm respectively. Figure 7 shows the steady state thermal distribution at speed 9000
rpm of IN 792 DS and IN 754 MA.

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Figure 7. Steady State Thermal Distribution at Speed 9000 rpm on IN 792 DS

and IN 754 MA

6. Results
6.1. Transient Thermal analysis
In this section, the results of the transient thermal analysis have been presented. For
this simulation, the turbine inlet temperature is 950C i.e., from the design point of view a
time of 50s is required until the stabilization of new steady state condition is reached.
Time-step taken at each iteration is 0.02s. Maximum temperature distribution on
superalloys IN 792 DS, IN 754 MA and IN 738 LC at various speeds with respect to time
are shown in Table 3.
The temperature variation results with respect to engine parameters such as speed,
turbine inlet temperature and ambient temperature. It has been observed that the
temperature distribution is uniform and the maximum temperature obtained is within the
melting point.
Table 3. Transient Thermal Distribution on Blade Materials with Time
Speed

5000
7000
9000

Time
(s)
35.25
41.74
47.54

IN 792 DS
Max. Temp.
obtained (C)
1089
1108
1123

Time
(s)
28.00
35.05
41.14

IN 754 MA
Max. Temp.
obtained (C)
1041
1061
1076

Time
(s)
23.74
30.34
36.64

IN 738 LC
Max. Temp.
obtained (C)
1024
1044
1060

Table 4. Maximum Temperature Distribution Obtained On Turbine Blade

Materials
Superalloy

Melting Temperature (C)

Max. Temperature obtained (C)

IN 792 DS
IN 754 MA
IN 738 LC

1450
1370
1300

1123
1076
1060

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Figure 8. Temperature Distribution on Turbine Blade during Start-Up

6.2. Static Structural Analysis
Static structural analysis for turbine blades made up of IN 792 DS and IN 754 MA has
been conducted. It has been observed that there is a significant effect on turbine blades at
higher rotational speeds and maximum von-mises stresses are sighted on IN 754 MA.
It has been observed that IN 738 LC has minimum von-mises stresses and IN 792 DS
has minimum total deformation compared to other materials which are considered for
structural analysis. Table 5 shows the maximum von-mises stresses, maximum equivalent
strain and total deformation at various rotational speeds for alloys IN 792 DS and IN 754
MA. Further as said, these materials are compared with IN 738 LC which shown in Table
6.
Table 5. Static Structural Analysis
SUPERALLOY
SPEED
5000
7000
9000

max
(Mpa)
291
510
833

INCONEL ALLOY 792 DS

max
max
(m)
(mm)
0.014
1.11
0.024
2.17
0.040
3.13

INCONEL ALLOY 754 MA

max
max
max
(Mpa)
(m)
(mm)
276
0.0012
1.14
526
0.0024
1.92
860
0.0039
3.13

Table 6. Comparative Static Structural Analysis

SUPERALLOY
SPEED
9000

max (Mpa)
820

INCONEL ALLOY 738 LC

max (m)
0.0041

max (mm)
3.29

From Figure 9 shows the total deformation on blade materials with respect to turbine
rotor speed (rpm). It has been observed that IN 738 LC has maximum deformation and IN
792 DS has minimum deformation at nominal rotor speeds and followed by IN 754 MA.

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Figure 9. Total Deformation Vs Rotation

From Figure 10 shows the von-mises stresses on blade materials with respect to turbine
rotor speed (rpm), considered for static structural analysis. It has been observed that IN
738 LC has minimum stresses and maximum for IN 754 MA and followed by IN 792 DS.

Figure 10. Von-Mises Stress Vs Rotation

From Figure 11 shows the equivalent elastic strain on blade materials with respect to
turbine rotor speed (rpm), considered for static structural analysis. It has been observed
that Maximum strain is located on IN 738 LC and minimum for IN 754 MA and followed
by IN 792 DS.

Figure 11. Equivalent Elastic Strain Vs Rotation

7. Conclusions
An attempt has been made to analyze the transient performance of the gas turbine
blade. The data to make a real model of a gas turbine blade has been obtained using Coordinate Measuring Machine (CMM). Blade model has been generated by using CATIA
V5 R21 software and been analyzed for their structural as well as thermal performance.

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Structural and transient thermal analysis of the turbine blade models have been carried out
using ANSYS 14.5.
The result of transient simulation for selected turbine blade model has been presented.
The method was effective with three-dimensional FEMs of realistic turbine airfoils using
commercial finite element applications. The main objective in solving transient thermal
effects is to produce the temperature variation at start-up and shutdown of the gas turbine
engine which estimates the turbine blade life.
The effects of various parameters on engine component life have been studied. ANSYS
an be processed in steady state or transient mode. Steady state mode is faster to analyze,
but it does not capture the engine dynamics during start-ups.
Both materials have significant effects on blade due to centrifugal loads and thermal
shock. During all computations it was assumed as a rotation of nominal speed and all the
boundary conditions varies as a function of time and temperature except the bulk
temperature. The maximum temperature gradients on the turbine blade during all the startup cycles were invariably registered at the center of the blade cross section. This zone
corresponds to temperature gradients occurring on the pressure side. Therefore it has been
observed that greater thermal stresses are sighted at transient regime.
From the results of static structural analysis, it has been observed that the stresses
induced in both the materials are found to be within the limit (Yield strength). Maximum
stresses are observed at the root section of the blade minimum stresses are observed in the
portion of blade root.

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Author
B. P. V. Saikrishna Mukherji was born on 3rd August 1992 and he is
currently doing research on Gas turbine blades as Research Assistant in the
department of Marine Engineering at Andhra University, Visakhapatnam,
India. His research interests are Gas Turbine Engines, life assessment of a
gas turbine blades and failure investigation of various components of gas
turbine engines. He got M.Tech in the specialization of Marine Engineering
and Mechanical Handling from the same department of Andhra University,
Visakhapatnam, India. He has completed B.Tech from Chaitanya
Engineering College affiliated to JNTUK Visakhapatnam, India.

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