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Manufacture of dual alloy turbine engine disks

Objective



Objectives and content: In order to compete with the US manufacturers, the European gas turbine industry is bound to continue improving its technical capabilities in terms of achieving higher efficiencies & safety standards & of complying with future environmental legislation. In direct response to this challenge this RTD programme aims at the introduction of the bi-metallic disk technology in land based power turbines & aero-engines. Although the focus of the programme is on gas turbine disks the technology will be generic in that it provides manufacturing routes & verified lifing model for the design of bonded bi-metallic components subjected to variable loading conditions. The concept of the bi-metallic gas turbine disk enables the differing mechanical property requirements of hub region (tensile strength & low cycle fatigue resistance) & rim region (creep & high cycle fatigue resistance) of the disk to be reconciled in a single disk structure as opposed to the mono-alloy disk. Therefore bi-metallic gas turbine disks offer considerable advantages over their mono-alloy counterparts in terms of higher temperature & larger size capabilities, allowing substantial power & efficiency gains, & reduced emissions. Today, the main limitation for the introduction of high integrity bi-metallic disks is the manufacturing technology.

Objectives of the proposed project are:
- to develop that manufacturing technology, demonstrating the ability of existing joining & post-manufacturing heat treatment routes for realising the desired bi-metallic disk structures & to engineer these further based on reliability & economy considerations;
- to set up validated qualification & NDT inspection procedures for bi-metallic disks;
- to validate, by means of disk spin testing, a lifing method for bi-metallic disks that is being developed by BE97-4296 BI-METAL project. Validated procedures are necessary because of the safety critical nature of disks

The manufacturing technology will be developed for two applications:
- bi-metallic disks for land based power gas turbines where the goal is to achieve a temperature capability of 50 to 200ÐC in excess of that of mono-alloy disks, & larger disk diameters;
- bi-metallic radial wheels for aero-engines where the objective is to realise larger dimensions & temperature capability of 150ÐC in excess of that of current mono-alloy wheels. The approach selected to achieve the project goals is as follows. The in-service requirements of disks and wheels will be extensively analysed so as to enable the selection of materials with adequate properties for the hub rim & joint. The conditions for the chosen joining routes, HlP-assisted diffusion bonding with or without forge enhancement, & for the post joining heat-treatments that are necessary to optimise the parent material & joint microstructures will be determined during a series of manufacturing trial experiments. This will be followed by mechanical screening & qualification testing aimed at identifying the optimum manufacturing parameters & combinations of materials/material grades. The most promising manufacturing route will be selected & optimised for the ultimate production of nine full scale disks (three disks/ wheels per each of three selected material/ material grade combinations).

These disks will be used:
- for the qualification testing of the production route & for mechanical testing to provide input data into the life prediction method being developed by the BE97-4296 BI-METAL &;
- for spin testing, aimed at validating the life prediction method.

NDT techniques that are valued the most promising for inspecting the likely critical defects in the bi-metallic joints will be tested both on manufacturing trial specimens without and with artificial defects for validation purposes, & subsequently applied to the full scale disks. The MANDATE consortium of 6 partners and 7 associated partners from 6 European countries consists of 2 major European gas turbine manufacturers as end users, 4 component manufacturers and 7 research institutes, all with a wide and complementary experience in the work areas concerned. The large number of industrial participants reflects the strategic importance and the potential cost savings of the bi-metallic gas turbine disk technology. BE97-4650

Coordinator

ALSTOM POWER UK LTD.
Address
Lichfield Road
ST17 4LN Stafford
United Kingdom

Participants (12)

ASSOCIATION POUR LA RECHERCHE ET LE DEVELOPPEMENT DES METHODES ET PROCESSUS INDUSTRIELS
France
Address
Enceinte Snecma Evry-corbeil 032
91003 Evry
AUBERT ET DUVAL
France
Address
Rue De Villiers
63770 Les Ancizes
BODYCOTE H.I.P. LIMITED
United Kingdom
Address
Hulley Road, Hurdsfield
SK10 2SG Macclesfield
Bundesanstalt für Materialforschung und Materialprüfung
Germany
Address
87,Unter Den Eichen
12205 Berlin
Commissariat á l'Energie Atomique
France
Address
17,Rue Des Martyrs
38054 Grenoble
Commission of the European Communities
Netherlands
Address
3,Westerduinweg
1755 ZG Petten
Defense Evaluation and Research Agency
United Kingdom
Address
Ively Road
GU14 0LX Farnborough - Hampshire
Laboratoire Fédéral d'Essai des Matériaux et de Recherches
Switzerland
Address
129,Überlandstraße
8600 Dübendorf
NATIONAL RESEARCH COUNCIL OF ITALY
Italy
Address
Via R. Cozzi 53
20125 Milano
Tecphy S.A.
France
Address
Avenue Jean Jaurès
58160 Imphy
Thyssen Umformtechnik Guss GmbH
Germany
Address
37,Papenbergerstraße
42859 Remscheid
Turbomeca SA
France
Address
Avenue Du Président Szydlowski
64511 Bordes