Br,
-t
i
NASA 0R-159464
VOLUME 1 OF 2
....
^ m_e=^l_rW
(NASA-CB-159q6q)
LON-COST
DZR2CTZONALI, Y-SCL'I'D-._F.I_D TURBINE BIADES_
VOLUNE 1 Conpletton
8epo£t
(AiReseacch
_f9.
Co.e Phoenizr
A_tz.)
272 F tic A12/MF A01
CSCI. 11P G3/26
_1-_q53-1
N79-24121
0nclas
22146
MATERIALS FOR ADVANCED TURBINE ENGINES
PROJECT COMPLETION REPQBT
PROJECT 1
-
LOW-COST DI RECTIONALLY-SOLIDIFIED
TURBINE BLADES
VOLUME I
by
-
L.W.
Sink
-
G, S, Hoppin, IlL,
--;;
M.-Fujii .
--
AIRESEARCH MANUFACTURING COMPANY OF ARIZONA
A DIVISION OF THE GARRETT CORPORATION
=-
.:_•
JANUARY "1979 .....
£
-"
-"=
Prepared for
"
....
!
National Aeronautics and Space Administration
NASA-Lewls Research Center
Contract NAS3-20073
"_
!
i.....
FOREWORD.
,1
This Preject Completion
Report was PreDated
for the National
Aeronautics
and Space Administration,
Lewis Research
Center.
It
presents
the
results
exotbermic
heated
of
casting
_._
cost,
[i
:_[
tuzbine
enqines.
The
Materlals_
for
Advanced
_,
F_
Contract
[ -
The
Materials
Major
M.
Drogram
technology
_irectionally-solidlfied,
authors
wish
and
to
establish
for. the manufacture
uncoole_
program
Turbine
turbine
blades
of
low-
for
aas
was conducted
as part
of
the
Enqines
(MATE)
Proqram
under
and
to acknowledge
the
C. P. Blankenship,
Structures
contributions
PhioDs
conducted
NAS3-20073.
of _. L. Saunders,
-
a
Ai
I
Division
to the
R. J. Ouigg
assistance
of the program
of Jetshapes,
b
£11
quidance
and R. L. Dreshfield
of NASA-Lewis
success
and
Research
were
of the
Center.
ma4e
bv C
.Inc..............................................
L.
v
TABLE
OF CONTENTS ..................................
INTRODUCTION
1
iI_;_r,_I_PAGB
_N_
lgO? FILMED.
SUMMARY
TASK
4
I - CASTING
TECHNOLOGY
Exothermically-Heated
Process
7
Casting
Development
Casting
and
results
10
behavior
Mechanical-property
Chemical
27
evaluations
analyses
Recommended
Casting
29
40
Practice
40
manufacture
42
Wax
assembly
Mold
manufacture
Casting
7
10
t_ials
Exothermic
TASK
Sy__tem
42
process
II - ALLOY/PROCESS
42
SELECTION
45
Scope
45
Test
Material
Production
45
Heat
Treatment.
Studies
48
Evaluation
53
Metallurgical
Nondestructive
(NDE)
53
Chemical
analyses
63
Mechanical
tests
68
Thermal
fatigue
tests
88
Dynamic
modulus
testing
92
examination
95
Metallographic
Alloy
evaluation
Selection
101
V
_
,i
¥,
TABLE
OF
CONTENTS
(Coned)
1
TASK
-
I_I - ALLOY..PRORERT_Z_CHARACTERIZATION
102
Scope
102
Test
i-
TASK
Material
Production
102
PropertyTesting
103
_=.,- BLADE
154
DESIGN
Scope
_--
"
154 ........
Preliminary
Final
Design
- High
Pressure
Turbine
Aerodynamic
design
- preliminary
Stress
and
thermal
analyses
Design
- High-Pressure
design
Blade
blade
_"
155
155
166
Turb%ne
- final
(HPT)
Blade
design
blade
169
.
Aerodynamic
:
Thermal
analysis
185
Stress
analysis
185
Vibration
design
k
analysis
169
191
L
Final
Design
- High-Pressure
Aerodynamic
Final
Turbine
Vane
design
191
191
Thermal
analysis
203
Design
parameters
203
Design
-. Other
Components
212
r
_
;
High-pressure
turbine
disk•
212
i
-
High-pressure
turbine
shroud
212
High-pressure
turbine
nozzle
v_
k
supports
216
J
Q_
,>
_;
TABLE
: :
TASK
V - COMPONENT
i
; :
S_ope
Blade
!:J_:
Special
ii _
,,: :
_,-
COST
OF
CONTENTS
(Contd)
MANUFACTURE
217
217
217
Manufacture
Engine
Components
Manufacture
226
AND WEIGHT OBJECTXVES
Engine Weight
228
229
Manufacturing
229
Direct
Costs
Costs
Optimized
_ '
Total
230
Engine
Costs
230
Costs
_.
Engine
_i:
CONCLUSIONS
237
APPENDIX
241
--"
APPENDIX_B
Maintenance
233
Costs
233
A
.................
245
vi_
k
d
,b
¥
I
LIST
1
OF
ILLUSTRATIONS.-
Simplified
Schematic
of
Directlonal-So_idification
I Straight
3
Task
I Spiral
4-
Task I,.Mold
2 Blade& Showing GoodGrain
Structure
in Bl_de "CY' with Undesirable
Grain
Structure
in the Other Three Blade Castings
•.
16
Task I, Mold 4 Blades Showing
Straight
Grains
in Castings
"C3" and '_C4"
18
6
7
8
9
Mold
Configuration
8
Task
Sp_ke
Mold
_
....
2
5
Spoke
Exothermically-Cast
Casting
Process
12
Con/iguration
14.................
Columnar
Task I, Mold 5 Blade Castings
Showing
Desirable
Grain Structure
Near the Outside
"A"
Casting
of the Mold Cluster
with Trailing-Edge
Nucleation
in the Interior
"D" Castings
20
Task I, Mold 10 Spoke "B" MacroetchedBlades
Showing Consistent
Directional
Grain Orientations
23
Suction
Sides of the Injected
Task I Turbine
Blades
(Mag.:
25
Casting
1.5X)
Waxes
for
Wax Assembly
for Task I Mold 13.
Waxes of the
Initial Design TFE731-3
Blade Used in BladeRoot-Up
Position
26
10.
Mini-Bar
30
iI
Longitudinal
Orientation
of Machined
Mini-Bar
Test Specimen
with Respect
to ExothermicallyCast DS TFE731-2
Turh/ne.Blade
31
12
Standard
32
13
Completed
Task I Final Configuration
Open-Bottom
Mold, After Dewaxing,
Prepared
for Exothermlc
Casting
the Preliminary
Design
Uncooled
TFE731-3
Turbine
Blades
43
Wax Pattern Assembly
for Exothermic
DS Casting
Twenty Task II Preliminary
Design TFE731°,3 Turbine
Blades
46
14
Test
Specimen
Tensile
Test
Specimen
viii
._
LIST
DE
ILLUSTRATIONS
(Contd)
Title
"
15
r:4
16
_
l'A.__
Wax Pattern
SiX Task II
Assembly
for Exothermic
Tes_ Slabs
20
21
:
k
49
54
Typical Microstructures
Of DS MAR-M .247
Turbine
Blades Solution
T/eated
for Two. Hours
at the Indicated
Temperatures.
Grain Growth
Direction
is Vertical.
Kallings
Etch.
(Mag.: 100X)
55
247 _asK II Exothermically
Cast
Design TFE711-3
Turbine_Blades
58
Typical
NASA-TRW-R
Task II Exothermically
Cast
DS Preliminary
Design TFE731-3
Turbine
Blades
59
Typical MAR-M
200+Hf Task II Exothermically
Preliminary
Design TFE731-3
Turbine Blades
Cast
Typical
IN 792+Hf Task II Exothermically
Cast
Preliminary
Design TFE731-3
Turbine
Blades
DS
60
DS
Cyclic
23
Sumn%arZ of Task II I033°K
(1400°F) Cycllc-Rupture
Test Results
on Test Specimens
Machined
from
Exothermically
DS Cast Slabs of Three Alloys
87
Surface Appearance
of DS MAR-M
247 Preliminary
Design TFE731-3
Turbine
Blades As-Received
and
After 1000 Thermal
Cycles Between
308°K and-1228°K
(95°F and 1751°P)
and 1000 Thermal Cycles
Between
308°K and 1283°K
(95°F and 1850°F).
(Mag.:
IX)
91
Appearance
Of Equiaxed
and DS MAR-M
247 TFE73i
Turbine
Blades after 1000 Thermal Cycles
between
311°K and 1228°K
(100°F and 1750°F)
and i000
Thermal
Cycles Between
311°K and 1283°K
(100°F
and 1850°F)
93
""
25
Specimen
61
22
24
Rupture
ix
k
DS Casting
Tyical MicroStructures
of DS MAR-M 247 Turbine
Blades Solution
Treated
for Two Hours at the
Indicated
Temperatures.
Gr.ain.GrQwth Direction
is Vertical.
KallingS
Etch.
(Mag.t 10QX)
.18..........
Typical MAR-M
DS Preliminary
19
Page
83
....
i
d
LZST
26
ILLUSTRATIONS
(Contd)
Appearance
of Thermal-_atlgue_racks
at Trailing
Edge Near Root of Equiaxed
MAR-M 2_7 Blade
Nos. 14 and 16 after 1000 Cycles at 1283°K
(1850°F)
•
-_
i_
OF
27
Typical M/crostructu_es
of Exothermlcally
Cast
DS Preliminary
Design TFE_31-3
Turbine
Blades
of MAR-M 247.
Kalllngs
Etch.
(Mag.: 100X)
__
2_
Typical Microstructures
of Exothermically
Cast DS Preliminary
Design TFE731-3
Turbine
Blades of MAR-M 200+Hf.
Kalllngs
Etch.
ii"
(Mag.:
29
[
30
I
_ "
94
-
,
97
100X)
98
Typical Microstructures
of Exothe.rmically
Cast
Preliminary
Design TFE731-3
Turbine
Blades of
NASA-TRW-R.
Kalllngs
Etch.
(Mag.: 100X_
DS
Typical Microstructurez
of Exothermically
Cast
Preliminary
Design TFE731-3
Turbine
Blades of
IN 792+Hf.
Kallings
Etch.
(Mag.: 100X)
DS
99
I00
l
31
_ "
Tensile Properties
Versus Temperature
for
Longitudinal
Specimens
Machine
From Task III
MAR-M 247 Exothermically
Cast DS Preliminary
Design TFE731_3
Turbine
Blades
109
b
32
_
Tensile
Temperature
TransverseProperties
Specimens Versus
Machined
From TaskforIII
MAR-M 247 Exothermically
Cast DS Preliminary
i :
Design
33
i-
35
I[
RL
36
34
TFE731-3
Turbine
Blades
!
iii
Average
Stress-Rupture
Strength
Versus Equlaxed
IN100, 0.178-cm
MFB Test Specimens ...........
ef Dg MAR-M 247
(0.071_.-inch)
DS MAR-M 247, Longitudinal
Data,
(0.070-1nch)
MFB Test Specimens
0.178-cm
_
119
121
Larson-Mlller
0.5-Percent
Creep Curve for
DS MAR-M 247, Longitudinal
Data,_0.178-cm
(0.070-Inch)
MFB Test Specimens
121
Larson-Miller
1.0-Percent
Creep Curve for
Larson-Miller
Curve0.178-cm
for
DS
MAR-M 247, Stress-Rupture
Longitudinal
Data,
(0.070-Tnch)
MFB Test Specimens
122
LIST
OF
_LLUSTRATIONS-(Contd)
.....................
Tit
37
38
39 ....
40
41
Pa_Lg...........
---A
Larso_-Miller
2.0-Percent
C_eep Curv_ for
DS MAR-M
247, Longitudinal
Data, 0.178-cm
(0.070-1nch)
MFB Test Specimens
K
112
Low-Cycle
Fatigue of Exothermically
C_8_
DS MAR-M 247.
[Longitudinal
Data,
I035°K
(1400°F), Load Controlled,
A = 1.0_ K_ = 1.0, Smooth Uncoated
Test Specimens
Machlned
from S_parately
Cast Test Bars]
129
Low-Cycle
Fatigue of Exothermically
Cast
DS MAR-M
147.
[Longitudinal. Data,
1033_K
(1400°E), Load Controlled,
A = 1.0, K_ = 1.8, Notched
Uncoated
Test Specimens
Machined
from Separately
Cast Test Bars]
129
Low-Cycle
Fatigue
of Exothermically
Cast
DS MAR-M 247.
[Longitudinal
Data
1033°K
(1400°F), Load Controlled,
A = 1.0, KL = 1.0, Smooth RT-21 Coated
Test Specimens
Machined
from-Separately
Cast Test Bars]
130
Lo_,:-Cycle Fatigue
[1033°K
(1400°F),
!
i
of Equiaxed
IN100.
Load Controlled
A = 1.0, K_ = 1.0, Smooth Uncoated
Test Specimens
Machlned
from Separately
Cast Test Bars]
42 ........
Thermal
Expansion
of Exothermically
MAR-M 247 and NASA_TRW_R
43
44
45
_hermal Conductivity
of
MAR_M 24_ and NASA-TRW-R
130
Cast
Exothermlcally
DS
138
Cast
DS
139
Schematic
of AiResearch
Oxidation
Hot-Corrosion
Burner Rig
141
Oxidation/Hot-Corrosion
142
Burner
xi
Rig
_m
.
L/ST
46
i
47
48
ILLUSTRATIONS_
49
; " '"
, _
' _
!
i_- .
50
(Coned)
Task Ill, Hot-Corroslon
Specimens
after
310-Hours
Exposure
at ll00°K
(1700°F)
to 5-ppm Synthetic
Sea Salt Added to the
Combustion
Products
of Jet-A Fuel
146
Microstructures
of DS MAR-M
247 Stress-Rupture
Specimen
No. 159-11 Tested at 1255°K/131
MPa
(1800°F/19
ksi) for 1678.3 Hours.
No_e Needles
of Acicular
P_ase
148
Microstructure
Test Specimen
of DS MAR-M 247
No. 148-1 Tested
The
AcicularMPaPhase
Formed
I144°K/317
(1600_F/46
is Absent
_i
[
OF
Stress-Rupture
at
at
(1800°F)
ksi)1255°K
for 1270
Hours.
149 .......
Microstructures
of DS MAR-M
247 Stress-Rupture
Test Specimen
Nos. 159-11
[Tested at 1255°K/131
MPa (1800"F/19
ksi) for 1678.3 Hours] and 148-7
[Tested at 1255°K/151.7
MPa (1800=F/22
ksi)
for 646.2 Hours].
Specimens
were Subsequently
Exposed
at 1283°K
(1850°F) for a Total
Combined
Time of Approximtely
1600 Hours.
The Acicular
Phase is Evident
in Both Specimens.
Metallography
by Micro-Met
Laboratories,
Inc.
150
Microstructures
DS MAR-MSpecimen
247 Stress-Rupture
Test Specimen
No.of 148-1.
was Tested
Hours.
No Acicular
Phase was Present.
Metallography
by Micro-Met
at I144°K 317 MPa
(1600°F/46 Laboratories,
ksi) for 1270Inc.
151
Acicular
Phase Formed
in DS MAR-M 247 Specimen
159-14 After Ekposure
to 1283°K
(1850OF) for
10B0 Hours.
Upper Photo Shows Acicular
Phase
in Microstructure.
The Bottom Photo Shows
the Second Phases After Extraction
from the
Matrix.
Metallography
by Micro-Met
Laboratories,
Inc.
153
52
Vector
158
53
Radial Distributions
of Stator
and Rotor Exit Angles
(_2)
_
51
Diagram
Nomenclature
..
i
-j
xii
=
(_i)
159
LIST
OF
ILLUSTRATIONS
(Contd)
k
54--
-Vector
55
Rotor Hub Section
[R = 10.77
Cylindrical
Cut---
cm
Rotor Tip Section
Cylindrical
Cut
cm
56
Diagram
Data
for
the
Rotor
160 ......................
--_
(4.24
in)]
161
[R = 14.16
(5.57
in)]
161
j
I
5Y
Rotor
58
Area
59
60
Loading
Loading
61
Average
Centrifugal
HPT Blade Design
62
63
64
65
Metal
Blade
Stack
at CG,
Plane
Distribution--of
the
of
of
162
RotOr
163
Blade
the
the Rotor-Hub
Rotor Tip
Temperature
Design
Preliminary
Solidified
Sections
Stress
163
165
--
Preliminary
167
-- Preliminary
MATE
HPT
167
Stress-Ruptur_
MAR-M
247
Data,
Directionally168
Critical
Mach
Versus Radius
Numbers
for the
and Flow
Stator
Angles
Crit'ical Math
Versus Radius
Numbers
for the
and Flow
Rotor
Angles
171
172
66
Reaction
67
Rotor Relative
Total Temperature
Nondimensionalized
by the Inlet
Total Temperature
Versus
Radius
Absolute
68
Velocity
Design
69
Work
70
Rotor Hub Section
[R = 10.77
the MATE Final Design
71
72
Versus
MATE
Radius
Triangles
of
173
the
173
Final
174
Distribution
175
cm
cm
Rotor Tip Section
of the MATE Final
cm
xiii
in.)]
of
176
Rotor Mean Section
[R m 12.37
of the MATE Final Design
[R = 14.16
Design
(4.242
14.872
in.I]
177
(5.57
inches)]
178
LIS'K-OE--I/_LUSTRATION S
73
Final
74
TrailingrEdge
75
Rotor
(4.24
76
77
HPT
Blade
Area
DistriDution
Blockages
Hub Section
inches)],.of
.........
cm
Rotor Tip Section
Loading
[R = 14.16
(5.57 inehes_
of the Final Design
c_
Blade
Temperatures
-- Final
Grid
for Thermal
80
Shank
Model
81
Minimum
82
Averge Stress Distributions
Final MATE Blade Design
MATEBlade
83
Final
84
Final Blade
and Shank
Design
85
Final
Blade
86
_ressuze
Side
at 2_,692 RPM
MATE
Blade
MATE
186
Design
188
Life
Airfoil
189
for
192
Design
193
-- Airfoil,
Platform,
194
Deslgn
Stresses
195
(KSI)
and
Deflections
196
Suction Side Stresses
at 29,692 RPM
(KSI)
and Deflections
197
_inal MATE
Stresses
Blade
89
Final
Design
90
Equivalent
Shank
Platform
Removed
Stresses
Equivalent
Stresses
MATE
Design
181
187
Stress-Rupture
MATE
181
Model
Final
180
180
Rotor Mean. Section
Loading
(R = 12.37
(4.87 inches)_
o£ the Final Design.
79
91
Radius
Loading
[R = 10.77-cm
the Final Design
HPT
88
179
Versus
78
87
(Contd)
Design
Trailing-Edge
198
Shank
at
29,692
RPM
(KSI)
199
-- Airfoil
and
200
xiv
(KSI)
201
9
n T. OF ILLUSTRATIONS
(Coned)
92
TFE731 Vibration
Interference
Diagram
--MATE
Final Design,
DS MAR-M
247 Blades; Mauhlned,
Heat Treated,
and Coated
202
93
Hub
Sectiomof
94
Tip
Section
95
Stack of
Sections)
26-Vane
Stator
206
26-Vane
Stator
206
of
the
26-Vane
Stator
(Plane
207
96
Stator
Hub
Section
Loading
208
97
Stator
Tip
Section
Loading
208
98
Pressure
Distribution
Base
Section
(PSl).
209
99
Pressure
Distribution
Tip
Section
(PSl)
209
100
Heat
Transfer
Coefficients
-- Base
Section
210
i01
Heat
Transfer
Coefficients
-- Tip
Section
210 ....
102
Adiabatic
Wall
Temperatures
-- Base
Section
(°F)
211
I03.
Adiabatic
Wall
Temperatures
-- Tip
Section
(°F)
211
104
TFE731-3
Turbine
IN100
Blade
105
TFE731
Blades
106
107.
Turbine
with
with
Cooled
Uncooled
DS MAR-M
214
247
215
Exothermically
Cast DS TFE731-3
Turbine
Blade Castings
for Project
i Showing
Preliminary
(Left) and Final
(Right
Designs
218
Photographs
Illustrating
"Hot Tear" Cracks
Found in the Platform
Areas of Task V
Exothermically
Cast DS NAS-TRW-R
Alloy Turbine
Blade Castings.
Arrows
on (A) and (C) Identify
Typical Crack Locations.
Phetomlcrograph
(B)
Shows the Intergranular
Path of the Crack.
221
J
xv
_.
•
LIST
OF
ILLUSTRATIONS
(Contd)
k
--_
i08-
109
,_
"
-_
-
[
110
As-Cast
and Finish-Machined
Exothermically
Cast DS TFE7-31-3 Final Design Blades of
MAR--M 247
223
Pressuze
and Suction
Sides, of Two
Finlsh-Machined
Exothe_mically
Cast
DS TFE731-3
Final Design Blades-
224
Relative
Blade Costs of the TFE731
Blade Froduction
Versus MATE DS
xvi
L%
i
HP Turbine
231
_
r
i
im
•
LIsT
Table
'-
I
i._
i
II
Ill
IV
_-V
_,
i
OF
TABLES
•
::
i
i
[
_
_
VI
Title
Page
Task
Cast
I Stress-Rupture
Test Results
on DS
Machined-From-Blade
Test Specimens
34
Task
Cast
I Stress-Ruptu.re
Test Results
Separately
Cast Test Specimens
36
36
Task I Tensile
Test
Machined-From-Blade
37
Result_
on DS Cast
TestSpecimens
Task- I
Tensile
on
Separately
Cast Test
Test Results
Specimens
DS Cast
39
Results of Bulk Chemical
Analyses
of Task
Exothermlcally
Cast DS MAR-M 247 Blades
Summary
VIII
Task
IX
Summary
Rupture
_'
on DS
T_sk L Stress-Rupture
Test Results on Conventionally
Cast Equiaxed
MAR-M 247 Test
Specimens--
VII
X
k
of Task
II Mold
II Heat-Treatment
Bleaes
41
Identifications
50
Process
51
of Task II 1255°K
Test Results
Inspection
Results
Cast DS Preliminary
I
Summary
(1800°F)
Stress56
of Task
Design
II Exothermlcally
TFE731-3
Turbine
_
XI
Task
II Chemical
Analysis
i
XII
Task
II Chemical
Analysis
XIII ....
Task
II Chemical
XIV
Task
II Chemical
XV
Task
II Room-Temperature
Tensile
Test
Results
69
XVI
Task
II I033°K
Tensile
Test
Results
70
XVII
Task II 1033°K
(1400°F) Stress-Rupture
Test
Results
- Longitudinal
Grain Orlentation
71
Task II I033°K
(1400°F) Stress-Rupture
Results - Transverse
Grain Orlentatien
72
=
!
of MAR-M 247
of
NASA-TRW-R
64
65
Analysis
of MAR-M
66
Analysis
of
(1400°F)
200+Hi
IN 792+Hf
67
2
XVIII
_.
xvli
Test
¥
LzsoFTABLES
(Contdl
'i
_
Table
Title
Page
•
XIX
Task II 1255°K
CIS00°F) Stress-Rupture
Test
Resul_s
- Longitudinal
Grain Orientation
73
_,_:
_,
I
XX
_ .
...........
Task II 1255°K
(1800°F) Stress-Rupture
Results
- Transverse
Grain Orientation
Test
74
XXI
Task
II Room-TemperatureTensile
Test
Results
77
XXII
Task
II i033°K
(1400°F)
Tensile
Test
ReSults
78
XXIII
Task II I033°K.
Results
(1400°F
Stress-Rupture.
kt
Ii...
_.
,i!
i
XXIV
XXV
%
_
Test
79
Results
Ta_k II 1255°KTask II 1255°K
Results
80
(1800°F)
(1800°F)
Stress-Rupture
Stress-Rupture
Test
Test
81
•
XXVI
Task II i033°K
(1400°F)
Results
at Progressively
_ ..
_ "
!i
XXVII
Task II 1033°K
Cyclic-Rupture
Cyclic-Rupture
Test
Higher Stresses
84
r,
}....
XXVIII
XXIX
XXX
XXXI
XXXII
XXXIII
XXXIV
l:i
!.
:
I
(1400°F),
723.9
Test Results
MPa
(105 ksi)
84
Task II, i033°K
(1400°F) Cyclic-Rupture
Results
for Three Grain Orientations
Crack Propagation
Blades
Average
o£ Task
in the
Equiaxed
of TaSk
Design
Grain
Elasticity
96
IIl Exothermically
TFE731-3
III Exothermically
105
Chemical
Analyses
of Task III
Cast DS MAR-M 200+Hf Castings
Exothermically
Chemical
Exothermically
Cast
DS NASA-TRW-R
._
104
Chemical
Analyses
of Task
Cast DS MAR_M 247 Castings
Analyses
85
92
Dynamic Modulus
of
IIDS
Cast Alloys
Inspection
Results
CaSt DS Preliminary
Turbine Blades
Test
of Task
Castings
xviii
III
106
107
LIST
OF TABLES
Table
XXXV
XXXVI.
XXXVII
XXXVIII
_itl______e
Task III Tensile
Turbine
Blades
Results
on
DS MAR-M
III Tensile
Test Results
on Separately
Test Bars of DS MAR-M 247
114
Task
Cast
III TenSile
Test Results on
Tesk Bars of DS NASA_TRW-R
115
Task
Cast
If/ Tensile
Test Results
on Separately
Test Bars of DS MAR-M.200+Hf
116
III Stress-Rupture
Test
247 TeSt Specimens
Results
MAR-M
117
Task III Stress-Rupture
Test
MAR-200+Hf
and NASA-.TRW=R..
Results
Test
Results
XLII
Low Cycle-Fatigue
DS MAR-M 247
Test
Results. on
XLV
XLVI
XLVII
XLV_II--
XLIX
L
Separately
on
on
118
Low-Cycle-Fatigue
XLIV
247
108
xLI
XLIII
-
Test
Page
Task
Cast
XXX_Task
XL
(Contd)
on DS.MAR.M..247
123
124
Low-Cycle-Fatigue
Test Results
NASA-TRW-R
and Equiaxed
IN100
on
Low-Cycle-Fatlgue
DS MAR-M 200+Hf
on
Test
Results
125.
126
Estimated
Maximum
Low-Cycle-Fatigue
StreSs
Requiredto
Produce Failure
in Exothermically
Cast DS Alloys
and Eq_iaxe_
IN100
127 ..................
High-Cycle-Fa.tigue
on DS MAR-M 247
131
Test
Results
High-Cycle-Fatlgue
Test Results
on RT-21 Coated DS MAR-M 247
132
High-Cycle-Fatlgue
on DS MAR-M 247
Tests
133
High-Cycle-Fatlgue
on DS MAR-M 200
Test
High-Cycle-Fatlgue
on DS NASA-TRW-R
Test
Alloy
Results
Results
134
xix
Results
135
•.
_-
LIST
Table
LI .....
_
Estimated.
Specimens
Test Bars
OF TABLES
Endurance
Machined
LIII
Task
Test
III 1311°K
Results
(1900QF)
Task
Test
III 1200°K
Results
(1700°F)
of Elasticity
Stress-_upture
Oxidation
144
Hot-Corrosion
145
LV
Basic
•_
LVI
Stator Exit Flow Angle Distribution
Task IV Preliminary
Design Blade
LVIII
-
LIX
:-
LX
LXI
LXII
LXIII
LXIV
LXV
•,
-
LXVI
..................
\ ,
_
140
--
_=_
Page
136
Modulus
LVII
,
Title
Limits of-DS Test
From Separately
Cast
LII
LIV
(CQntd)
Test
History
147
156
Rotor Exit Relative
Task IV Preliminary
Flow Angle Distribution
Design Blade
Preliminary
Design
Blade Geometry
and
DS High-Pressure
Aerodynamic
Data
Calculated
Stress-Rupture
Life
Section
at Takeoff
Conditions
156
Turbine
157
Showing
166
Final Design TFE731-3
High-Pressure
Geometry
and Aerodynamic
Data
Turbine
Blade
170
Design Data for the 26 Vane TFE731
High-Pressure
Turbine
Stator..
204
26-Vane TFE731 High-Pressure
Turbine
Stator - Integrated
Throat Area vs Stagger
205
Design Parameters
- Task IV TFE731-3
High-Pressure
Turbine
Nozzle Vane
213
Summary of t_e Yield of
Directionally-Solidified
Blades Cast in Task V.
225
the Final
TFE731-3
Design
Turbine
Changes
in Engine Parameters
to Fully
the DS Turbine
Blades
in the TFE731-3
Utilize
Changes
in Engine Parameters
for Constant
Cruise Thrust
to Fully Utilize
the DS Turbine
Blades
in the TFE731-3
XX
227
232
._
¥
!_
INTRODUCTION
i
The
NASA
Materials
for Advanced
Turbine
Engines
gram is a cooperative
effort
with industry
to
duction
of new materials
into aircraft
turbine
of
this
effort,
NAS3-20073
.J
I
AiResearch
to develop
was
a new
directionally-solldified
authorized
technology
(MATE)
accelerate
engines.
introAs part
NASA
Contract
for manufacturing
low-cost
uncooled_cast
under
Pro-
turbine
blades.to
reduce
_*
Cost
and fuel consumption
in the TFE731-3
Turbofan
Engine.
The
process
development
performed
included, those efforts
required
to
"
stage
carry
!;
E
through
component
engine
test. feasibility
Portions
the
technology
from demonstration
the previously by demonstrated
of the overall
effort
included
process
scale-up,
alloy evaluations, mechanical
property
generation,
hardware
procurement,•
and
full-scale
engine
test ingLto
eYalua_e
potential
benefits.
This
report
constitutes
Volume
_:_.
Completion
Report
presenting
the
!i
Solidified
Turbine
and tests performed
Blades.
under MATE
This
volume
covers_ all Project
1
Project
I, Low-cost
Directionally-
I
!
t_
i i
I '-.
which
1
of
results
are the subjects
a
two-volume
of
the
investigations
test
analysis,
tasks
with the exceptions
of full-scale
engine testing
and postThe intent of Project
1 was to develop
a process
to produce
directionally-solidified,
design
and
substitute
conventionally-cast
turbine
of
project
goals
(i)
solid,
this
uncooled
blade
utilized
in
TFE731-3
Turbofan
with
this
A
reduction
in
engine
of
at
1.7
percent;
least
turbine
for
AiResearch
associated
2 of this
blade
turbine
the Garrett
of Volume
Project
the
hollow,
substitution
specific
blades
fuel
the
report.
and
to
air-cooled,
high-pressure
Engine.
The
were:
consumption
(SFC)
*
(2)
A
reduction-
least
in
engine
manufacturing
costs
of
at
3.2 percent;
(3)
A reduction-in
(4)
A reduction
%
engine
weight
in engine
of
at least
1 percent;
costs
of at least
maintenance
1
6.2
percent.
Project
1 was
subdivided
Task
I
- Casting
Task
II
- Alloy/Process
Task
III
- Property
Task
IV
- Blade
Task
V
- Component
Task
VI
- Engine
TaskVII
In
process
bine
I,
the
was adapted
blades
o£
MAR-M
Manufacture
Test
Analysis
247
During
II,
four
directional-solidification
for
cast
of
the
candidate
NASA_TRW-R)
were
DS
and
all except
IN 792+Hf
porating
a
developed.
In Task
III, mechanical
provide
allowable
the
three
stress
properties
tensile
strengths.
Concurrently,
Turbofan
(MAR-M
levels
were
selected
treatment
Task
for
redesigned
IV
for
further
included
high-
was
MAR-M
200+Hf,
and
cast
subsequent
247
incor-
was
properties
were
and
and
attainable.
temperature
alloys
a
Engine,
for MAR-M
and physical
determined
strengths,
247,
tur-
as exothermically
heat-treatment
selected
strengths,
2
heat
solution
of
Mechanical
improved
(DS)
high-pressure
properties
evaluated
higher
castings
TFE731-3
alloys
and
An
solid
mechanical
IN 792+Hf,
comparison.
tasks:
Characterization
to economically
levels
test
seven
Selection
exothermic
the
blades,
following
Design
establish
Task
the
Technology
- Post-Test
Task
into
also
of DS-
evaluated
turbine
to
blade.
creep-rupture
low-cycle-fatigue
accomplished
to adapt
the
r
L
disk,
":.
design
the
blade
alrf_il
and-blade
root
te best
aocom-
modate the stress-rupture,
tensile strength,
and
of the chosen alloys .to the test engine.
Duping
other properties
Task V, manufac-
ture of the hardware
VI. englne
ing
....
and
was
accomplished.
demonstrated
a
droppe_
the
from
remaining
tested.
The
uations
requlrsd
project.
engine
testing,
of
turbine
the
NASA-TRW-R,
castability
tw_-.alloys,
to_upport
the Task
one
problem
in
Turbine
blades
MAR-M
24/
and
performance,
blades
are
of
Task
V-and
test-
three
alloys,
was
therefore
manufactured
MAR-_
and
the
from
the
were
engine
post-englne-test
eval-
described
200+Hf,
in Volume
_k
2 of
this
repQrt ..........
.
00000001-TSBC
SUMMARY
_
s,,
The project
accomplishments
included
the development
the
exothermically-heated,
directional-solidlflcation
casting of process
into
a
viable
_ i_
pressure
_'_
blades
of
the
new
MAR-M 200eHf alloys.
!ii._
;
turbine
process
heat
test
treatment,
de@cribed
tion
of
the
achieved
blades.
producing
_igh
quality
design
were
These blades
solid
TFE731-3
high-
directlonally-solidified
cast
in
the MAR-M
were finish processed
247
and
through
,
machining,
and coating
op_grations f-or the engine
in Volume 2 of this report.
The blade cost por-
engine
with
manufacturing
cost
goal
of
tnis
project
was
for
the
DS
projected
volume
production
costs
58-percent
of the
cost
cooled
equiaxed
IN100
can
achieved
in
blade
being
blade.
The
turbine
redesign
by
deliver
the
blade
cooling
changes
were
not
since
reduced
Waspaloy
for
engine
weight
disk
reduction
eliminating
air
incorporated
cooling
thus
of
air
was
avoiding
a
the
goal
the
be
retainer
and
redesigning
in
the
engine
required
to
new
design
disk
solid
plate
the
test
a
used
disk.
ti
to
These
configuration
utilize
a
production
and/o_
material.
the substitution
of a more
rugged,
solid airfoil
for the thin
The
long-term
maintenance
cost
goal
is
expected
to
be
realizedmore
by
walled,
cooled blade currently
used.
This design provides
resistance
to foreign
object
damage
(FOD)
and more
capability
for
[
being
recoated.
air
circuit
of
an engine.
The
also
elimination
avoids
many
of
cooling
operational
air
and
problems
the
over
cooling
the
life
%
_ _
i
Task
the
turbine
employing
project
casting
blades
_rocess
ignition
improved
!
of
solidification
Key
[_
I
elements
technique
quality
line
tensile
and
bine
blades
were
,
process
an
for
the
were
the
MAR-M
a
directional-
247
high-pressure
heated
mold
stress-rupture
for
the exothermic
strengths
Good
for
ceramic
design,
exothermically-heated
requirements
determined.
solid
exothermically
established
for
established
a furnace
molds,
material.
DS MAR-M
reproducibility
mold.
was
and
Base-
247
tur-
shown
for
the
results
minibars
o£
tests
machined
f_om
on
0.178-cm
(0.070-inch)
the
DS blades
(MFB).
ThisMFB
tensile
and
stress_rupture
process
developed
thus used for all--subsequent
in this..p_oject.
Htilizing
bine
blades
MAR._
the
and test
200+Hf,
in _ask
casting
slabs
of four
IN 792+Hf,
II.
physical
DS
Casting
and
nickel-base,
NASA-TEW-R)
process.yields
properties
were
alloys,
and
a
During
the
course
of
Task
II,
project,
as
its
stress-rupture
from
the
tially
lower
than
heat-treatment
duce
more
castings
Task
and
rupture
blade
was
than
the
1494"K
(2230°F)
III
characterized,
in greater
properties
DScast
turbine
were
was
dropped
was
substan-
A
solution
found
to pro-
llves, in MAR-M
treatment
247 DS
previously
detail,
the
_sed ............
mechanical
of
MAR-M
247,
MAR-M
200+Hf,
blades
and
bars.
Tensile
and
performed
in both
four
conducted.
alloy
(2250°F)
stress-rupture
the
was
alloys.
higher
did
o£
three
1505°K
cast
mechanica_nd
strength
and
uncooled
of
final
blade
strong
DS cast
design
design,
tions,
turbine
the
preliminary
more
Ill.
was
longitudinaland
later
To accommodate
were
section
made
design
tailored
alloys
developed
thoroughly
wasdeveloped
fications
bine
of
other
247,
and ........
stress-
transverse
directions.
properties
Task
the
IN,792+Hf
_
tur-
successfully
study
uniform
tests
An
A
of
temperature
physical
NASA-TRW-R
those
the
%
testing
(MAR-M
castings
optimization
was
in Task.-I,
selected
for
diameter
minibar
alloys
were
and
determined
heat-treatment
gauge
utilizing
the
for
to
the
turbine
components
of
the
in
the
final
disk,
TFE731-3
in Task
project,
the engine
material
uncooled
the mechanical
was developed
early
analyzed
to
test
property
design
nozzle,
and
a
condi-
data
blades,
and
IV.
other
from
moditur-
Engine.
5
• ,
t"
!D_--•
,,•_
i.__t
_
_.
• •..
d
for
._
•
In Task V,
the engine
thes_
blades,,
"hot
tear"
alloy
was •encountered.
e.liminated
from
further
200+_f
Approximately
MAR-M
247.
Task
_
[
a
NASA-TRW_R
MAR-M
i _.,
the DS turbine blades and other unique
test were manufactured.
During
the
blades
_w_xe
p_oeessed
three-fourths
!
} .
[
![.
!L_
I
reported
Report.
problem
-£he
alloy
was
thus
only
MAR-M
242
and
engine
test
NASA-TRW-R
and
into
of-the
with
finish-processed
k
_
parts.
blades--were
I
.!
q_ subjected
The
The
consideration,
the DS-eask
ing in a modified-TFE731-3
tions of the engine-tested
VII.
caetabillty
components
casting
of
tuxbine
blade_to
engine
Turbofan
Engine.
Post-test
turbine blades were performed
engine
testing
separately
in
and
Volume
the
post-test
2. of
this
evaluain Task
evaluations
Project
test-
are
Completion
TASK
I - CASTING-TECHNOLOG_
Exothermically-Heated
Casting
System
[
The
i
produce
I,
the
The
objective
of
controlled_
directionally-solidified
uncooled
low-cost,
T_ask I
success
Diesel
of
With
Force
Materials
is shown
in Figure
process,
a lost-wax
that
is open
at the
for
top
to
grain
structure
in
test engine.
was .selected
selected
performed
based
on
by Detroit
Laboratory.
(I)
A
i.
ceramic
receiving
is manu-
molten
metal,
the
mold
and is also open (in a flat plane) on the bottom.
After dewax and
firing this mold is fitted inside a preformed
refractory
sleeve
and surrounded
with a suitable
high-firing
temperature
exothermic
tops
of
The
exothermic
material
the
airfoil
mold
openings
of
the
exposed.
by
heat
released
a temperature
above
the
Prior
to
mold
and
from
the
gating,
The
the
assembly
the
alloy
chill
establishes
a verz
steep
cavity.
Since
bottom
closure
is
formed
molten
the
chill,
metalthat
poured.
greater
by
directly
Nucleation
distances
exothermic
is
away
material
(1)Kanaby
et al,
AFML-TR-77-126,
very
rapid
the
maintains
"Directional
September
the
in
chill
the
bottom
material
placed
closure
a
the
gradient
the mold
will
on
for
temperature
o£
to
to be cast.
is
nucleation
contacts
prevented
from
heated
of
mold.
the
is_then
point
provides.a
the
bottom
exothermic
assembly
over
and
the
mold
and
top
of
hot
that
the
copper
This
chill
around
leaving
mold
ignition
melting
pouring,
is packed
water-cooled
in the mold
i
the
process
capability
was
work
casting
material.
f
process
contract
Air
the
blade
for the
casting
system
in prior
for
this
This
develop
this
factured
iiI
i i_
....
blade.
achieved
Allison
schematic
to
high-pressure
turbine
exothermically-heated
to p.-,.duce the turbine
the
was
occur
cavity
in
the
chill
as
the
metal
is
portions
of
the
mold
at
since
released
by
the
local
So!idifcation
1977.
heat
mold
of
temperature
above
Superalloys";
7
:'OUR:
• LOAD PREHEATED MOLD INTO
CASTING FURNACE ON CHILL
PLATE
• EVACUATE FURNACE
• I_DU_I
• HOLD IN FURNACE FOR
DWELL TIME
Figure
8
i.
Simplified
Schematic
o_
Directional-Solldification
Exothermically-Heated
Casting
Process
the
melting
nucleated
of
the
chill
at
orientation
the
point
mold
favorable
that
turbine
have
rapid
grain
growth
gradient
casting,
grow
grains
these
the
of
only
growth
of
the
extent
of
by
relationship
the
solidified
the
rate
of
fication
revert
to
the
of
grains
[of
direction
of
chill
after
casting
is
direction
g_owth
Turbine
that
of
produces
boundaries
foil.
a
parallel
This
at
heat
can
metal
ahead
pattern
in
some
larger
the
through
be
controlled
with
columnar
to the major
stress
increased
due
to the
absence
of
direction
of
highest
stress
that
preferred
stress-rupture
fracture
grain
through
axis
the
to
solidiwill
from
the
through
the
the mold
other
wall).
solidification
with
in the
root
grain
and
alr-
blade-temperature
boundaries
would
front
in some
structure
operational
capability
limited
away
that
i
The
casting
downward
horizontally
cast
is
of
distance
than
completely
provides
front.
solidification
extraction
significantly
blades
heat
the advancing
the
instance,
the
vertical
nucleation
of
extraction
of
grain
(for
blade.
the
rate
a
crystalline
solidification
the m_Iten
not
the
as long
as
to. preclude
from
rate
(I00)
ease
grains
structure
_
In
columnar-oriented
equiaxed
%
chill.
the
advancing
of
of
to
heat loss
an
direction
grain
behind
The
in the
columnar
metal
front.
crystallographic
a
spanwise
ahead
a
grains
develop
Thin
columnar
growth
continues
temperature
gradient
is steep enough
new
those
quickly
parallel
in the
Therefore,
that
is perpendicular
blade
direction]
alloy.
plate
for
temperature
structure
the
normal
ordinarily
to
the
provide
a
_
path.
7-
9
.L
.I
J
c
One
of
Development-
conclusions
.resulting
the
Process
fro_
the
Cos_/Benefit
the
MATE
Program
superior
cost
and fuel
AnalMs_s
(2) performed
by AiResearch
as
was
solid
turbine
blades
offer
cooled
turbine
blade.s
that
economy
relativs
Achievement
of
DS cast
to
b_ these
a low-cost
advantages
manufacturing
trol
over
_ask
I was to demonstrate
the
exothermic
under
desired
blade
subcontract
Je_shapes,
Task
process
the development
provides
englnes_
effective
con-
A major
objective,
of
and economic
advantages
of
in
J.
upon
demonstration
AiResearch
N.
small
a
was
performed
commercial
(Jetshapes).
The
foundry-goal
of
the
by Jetshapes,
was
to
evaluate
casting
for
establishment
of
a controlled
proces_
castings
mechanical
The
for
performed
variables
trial
technical
process.
to
for use in subsequent
ing
that
characteristics.
Inc.., Rockleigh,
I activity
of
is dependent
process
the
Easting
part
_
the
tasks.
This
followed
by
prQperties,
and
was
accomplished
evaluation
of
by manufactur-
their
quality
preliminary
and
then
developing
process
results.
The
Task
I
casting
trials
alloy
247
for
the
casting
of
provided
a minimum
of 15
the process
variables
eval-
controls.
Castin_
utilized
trials
the
and
nickel-base
MAR-M
molds
of blades
and test
bars.
Each- mold
bla_e
castings
and 4 test
bars.
Among
uated
were
temperatures,
mold
exothermic
material
processing
time ..............
Wax
blade
pattern
-
patterns
designs
were
availability
weight,
for
the
utilized
metal
temperatuzes,
exothermic
material
shell
TFE731-2
equiaxed
in
first
molds
and presumed
the
similarit_
12
thickness,
distribution,
existing
to.the
because
airfoil
(2)Comey,
D, "Cost/Benefit
Analysis,
Advanced
Material
Technologies,
Small Aircraft
Gas Turbine
Engines|
NASA
CR135265
(AIResearch
21-2391
, September
1977.
•
-
l0
and
uncooled
i
"
15
of
design
ij__-_¸_
i-C.-_'
_'_
that
would
TFE731-3
blade
design
baseline
mold
syste_utilized
i
(3)
This
binder
prince (firsti
coat
that
ing
The
back-up
process.
The
wax
patterns
established
under
developed
minimizes
metal-mold
coats,
which
were
of
a more
conventional
prime
coat,
in conjunction
conducted
during
the
program
because
the
Colal-P
binder.
useful
shelf
decrease
life
in the
of
surface
rescent-penetrant
quality
inspection,
was always
during
the pour-
mold
its
prime
coat
as
a
result
of
metal
and
this
prime
coat
in the
DS casting
binder
shelf
life
problem
by using
plastic
"gelling"
of
this
materials
used
for
I.
Molds
1 and
been
reduced
in all mixing
binder
is
zirconium-
back-up
coats,
relatively
short
and
a measurable
as evidenced
with
reactions
basic
the
by fluozirconium-
between
the
molten
The
Colal-P
to an acceptable
level
process.
storage
containers.
The
accelerated
by
contact
wi_t_bferrous
initial
was
cast
with
the exist-
based
on
previous
containers.
2.
i.:_
_
AiResearch-funded
to the TFE731-2
spokes
with
a
development
work.
The mold design,
as adapted
high-pressure
turbine blade design,
had 5 radial
central
downsprue
and pouring
cup
as shown
in
Figure
blades,
Four
casting
mold
ing
2.
practice"
The
_
_
"best
liners
has
the
noted
the
were
Jetshapes
system.
However,
silicate
Dieselin
standard
of castings,
was
reactions
the
of
k
program
silica-bonded
with
the
IV.
Detroit
metal
give
molds.of
utilizing
this
by
the molten
3
Task
throughout
binder
contacts
final
strength
and heat
conductivity
characteristics,
conventional
silica-bonded
alumina-silicate
mold
silicate
z
injected
alumina-flour
Evaluations
i-'
i_
_
C®IaI-P*
Allison
i
_
_'
produced-from
tested.
initial
the
:
engine
were
The
_
be
castings
_:
._ -
ultimatelK
with
the
procedure
airfoil
*Registered
trademark
of E.I. DuPont de
(3)Kanab¥ et al, "Automated
Directional
Superalloys,"
AFML-TR-75-.150,
1975)
chords
parallel,
Nemours and Company
Solidification
of
were
on
................
k
DOWNSPRUE
8LADES
/
_'_
MOLD BoI-rOM DIAMETER: 25.4 CM
(10 INCHES), APPROXIMATE
Figure
12
2.
Task
I
Straight
Spoke
Mold
IL
Configuration
¥
each
of
inch)
4 spokes,
diameter
accommodate
blades
the
fifth
spoke
test
bars.
This
test-bar
two
additional
the
with
in a root-down
Mold
No.
airfoil
chord
mic
material
against
parts.
six
1.587-cm
(0.625-
spoke
was
"Y"
shaped
to
mold
was
cast
with
the
The
orientation.
2 was
line
having
configured
_
to
arrangement
evaluate
effect
contact
of
to provide
the
a larger
surface
area
on
the
of
the
an
in-
exother-
blade
root
and
,
i
I
airfoil as compared
to the parallel-chord
arrangement.
limiting
diameter
of the insulating
sleeve used during
Due to the
exothermio
_i
firing,
This
that
each
i
5 spokes
be wound
in Figure
3.
Molds
cm
(I
chord-in-line
0.75
insulation
x
was
(1600°F)
for
for
entire
the
0.5
inch)]
Exomet
Isogard*
The
assembled
mold
allowed
"burn"
preheated
was
was
to
assembly,
The
matecial
process
mold
standard-size
30 minutes
was
was
and
lessen
to
were
an
insulated
Based
on
a water-cooled
interlock
15
metal
was
poured
after
a 3-minute
The
copper
chill
for
faced
with
grid
pattern
minutes
after
a shallow-groove,
for
ignition
these
increased
the
of
two
diamond-shaped
area
the
each
entire
exothe_mic,
The.
vacuum-mold
and
the
time.
been
0.317-cm
the
the
mold.
the
pump-down
the
exothermic
in the
with
and
observation,
for
had
shock
The
chill
molds
l144eK
thermal
furnace
and
an
temperature
top.
visual
chamber
contact
the
8 minutes
copper
to
elevated
"can"
on
the
exothermic
furnace
from
at
inside
the
possible
removed
in approximately
briquets
gas-fired
a uniform
continue.
complete
a
torch-ignited
with
to
in
of
[2.5 x 1.9 x 1.3
with
attain
molds
covered
placed
as shown
with
then
assembly
shap_
packed
ignition.
exothermic
required
2 were
sleeve.
material
during
in a spiral
I and
x
arrangement
newly
resur-
(0.125-inch)
casting.
This
grid pattern
did not incorporate
draft _n the grooves,
and consequently,
the solidified
castings
were
tightly
locked
into
the
*Registered
trademark
of
Exomet,
Inc.
13
._.
k
"4
t
I
-
i
DOWNSPRUE
_ .
--"
A
iC'4_
/t
8_DES
TESTBAR_
"-
_"
'
MOLD BOTTOM DIAMETER:
(10 INCHES)° APPROXIMATE
Figure
14
3.
Task
Z Spiral
25.4 CM
Spoke
Mold
Configuration
I
,,b
• ji'_
i
Vl
i
chill.
off to
The-mold
material
.and exothermic
cinder had to be broken
remove the individual
castings
from the chill .......
The chill
J
was
subsequently
machined
reworked
to
provide
adequate
draft
in
the
grooves.
_
}
All
individual
fOE
_zain
structure
h3d
an acceptable
grains
in the
castings
evaluation.
grain
root
airfoil_trailing
the
test
bars
and all
Mold
the
was
considered
bars
I are shown
were
employed
during
the
the blade
cavities
casting
next
It was
evident
process
were
mold
For
Mold
(spiral
spoke),
the
hold
time
after
casting
yield.
exothermic
3
In _addition,
exothermic
briquets
4 to
the
of
the
to
standard
size
briquets
mold
was
Each
as was
stopped
the
down.
used
vacuum
This
top
from
mold
of
pieces
were
the
as Mold
the
and
ambient
ignition
increase
of
the
mold
density,
same
with
procedure
as visible
the mold
was
filled
i.
the
as soon
metal
air
3 was
using
the pack,
the
4
Standard
size briquets
to 7.5 to l0 cm (3 to 4
manner
of
Mold
to fill
packing
same
interlock
reduced
the
in the
bottom
at
(0.75-inch)
used
Mold
However,
to
[l.9-cm
improve
ignited
and
observations
bars.
1 and 2.
in
especially
increased
test
and
cast
temperatures
low,
the
preheated
with Molds
coming
small
the innermost
blades.
the remainder
of the mold
the
the
blades
structure,
the blades
that
on
of
above
16
grain
of
was
dimensions]
inches)
the
material
maximum
particularly
for
were used to fill
of
exothermic
based
blade
gra:in structure
spoke)
from
top
and
(straight
cinder
above
2,
of
center.
temperature
Mold
the
of
too
1
chill
columnar
Four
Mold
to nucleation
above
Six
4.
the
due
acceptable.
to the
the pour
from
the
3 and
and
blades
However,
Molds
decreased,
the
distance
2.
was
macroetched
was
controlled
4.
2 were
of
acceptable.
in Figure
I and
This
edge.
a reasonably
test
None
at a considerable
the
2 had
Molds
structure.
from
from Mold
from
poured
temperature
was
flames
placed
in
after
pump-
exposure
time
15
_
<
Figure
16
4.
Task I, Mold 2 Blades Showing Good Grain Structure
Blade "C3" with Undesirable
Gra_.n Structure
in the
Other Three Blade Castings
in
i
"
[ ,
after
ignition
!
the
!
pouring_temperature
metal
temperature
The
i _
sary
to
i :
photograph
of
were
28°K
1 and
evaluation
molds
also
(50°F)
poured
higher
with
than
the
2.
\
these
castings
showed
that
the
mold and metal temperature
resulted
in improved columnar
but further process
modification
was considered
neoesimprove
the
grain
of castings
3.
i
The
approximately
for Molds
grain
increased
structure,
:
by 7 to 8 minutes.
Molds
5
molds
cast,
it
shell
system
high
temperature
from
and
The
30-minute
have
a gradual
oxidation
decrease
in available
exothermic._material
and
not
reache_
mold
the
had
preheat
metallic
heat
results
satisfactory
a
5.
sufficiently
directional
solidi-
period
at
i144°K
(1600°F)
may
of
exochermic
material
by
degradation
of
A ..............
the
with
fication.
level.
four
that,
completely
acceptable
of .the first
felt
for
an
in_Figure
on
the
to
4 is presented
Based
was
partial
Mold
6.
utilized,
caused
structure
the
constituents,
resulting
in
a
energy.
i
Molds
:
5
direct*furnace
cedure
evaluated
was
distribution
_-_
this
in the
___
=
i
___.
in
method_
(2000°F)
....
spoke)
utilizing
i
_
(straight
more
minutes
mold
was
was
t.hen cast
minutes
for
ignition
as a means
the
mold.
Eight
and
for exothermic
furnace
for
Mold
in
(radial
spoke)were
then
cast
at
1366°K
(2000°F).
This
pro-
5 was
one-half
igntion
before
6
of ensuring
vacuum
following
the
chamber
same
in the
furnace
5 minutes
in the
furnace,
then
before
being
flames
for
for
was
placed
to
The
_hen
energy
cast
at
mold
ignition,
removed.
Six
and the
and
Mold
and
burned
in
vacuum
6
one-half
the mold
removed
1366°K
left
pouring.
Seven
with
was
terminated,
metal
the
be
required
and
procedure.
required
minutes
were
3 minutes
were
tiona]. 5
first
to be detected.
the visible
the
maximum.thermal
the
minutes
an additional
elapsed
placed
and
burned
an addi-
chamber,
for
pou ring.
17
¥
CI
Figure 5.
18
<}
Task I, Mold 4 Blades Showing Straight Columnar
Grains in Castings "C3" and "C4"
Evaluation
of the g_ain
confirmed
that
molds
obtaining
better
columnar
also
indicated
in the
furnace
for
this
mold.
was
into
the
nearly
a monolithic
nearer
the
during
original
fusing
cavities.
These
shape
into
one
and
maximum
columnar
grains
the
central
to outer
The
ratio
of
the
mass
of
of
heat-absorbing
mold
material
in producing
these
fore
decided
that
the
downsprue
decreased
material
In
the
of
tempera-
lower.
and
had
It
This
in contact
sagged
some-
briquets,
that
temperature
correlated
well
obtained
on
the
material
to
the
believed
to
be
a ma_or
was
there-
was
was
individual
differences.-It
material
the potentially
at the center
of the
felt
exothermic
mold
a
locations.
temperature
ceramic
that
regions
to adjacent
of
indications
mold
individual
cluster,
briquets
mass.
from
heat
mold
continuous
of
thermic
the
radial
sintered
quality
factor
the
of
downsprue
their
mass
the
the center
from
castings
retain
near
what
the
6.
by briquets
blade
with
Figure
considerably
center
physical
in
appeared
the
these
in
burn
with
than
aided
indicated
fusing
of
ignition
Evidence
of
as
compared in tosupport
the pre-
in the outer
center
two
the
evidenced
rather
mass
total
these
to
material
was
from
shown
benefit
preheated
I144°K
temperature at had
been (1600_F).
obtained
attained
large
time
of
as
of the burned.exothermic
However,
tures
control
it was
a longer
furnace
ignition.
conclusion
briquets
(2000°F)
grain
that
of castings
after
Evaluation
•
the 1366"K
Results
vious higher
molds
much
structures
in the
available
the cluster,
and
bottom
local
half
of
space
for
exo-
also
acted
as a
sink.
addition,
grain
structure
fill
for
well
as from
the
at the center
there
in the
airfoil
were
indications
individual
cavities
blade
from
the
fillout
and
castings
that
the
rate
of
spokes,
as
varied
along
spoke-to-spoke
in a given
mold.
of
on
the cluster
the spokes
individual
The
with
slowest
the highest
fill
was
runner
19
-
.
i
.............
%
k
li-
Figure
ir
:
20
6.
Task I, Mold 5 Blade Castinqs
Showina
Desirable
Grain
Struct-ure Near the Outside
"A" Casting
of the Mold
Cluster
with Tralllnq-Edge
Nucleation
in the Interior
"D" Castings
FI
K,:
L
connection
on
i_
slower
fill rate gave.the
grain orientations.
This
largest
indicated
_,
growth
i_ a fastex-_f,ill
could
the
downsprue.
be obtained
The
blades
cast
with
the
apparent
angular
deviation
o£
that a better control
columnar
of grain
could
be
k
achieved.
problems
i
the
Molds
4.
i:_'
eliminate
_
provide
_ _
for
iii
both of these molds were packed with exothermic
material
and
and
Mold 8 (spiral
spoke)
were fabricated
in this as
fashion,
nace-ignited
at 1366°K
(2000°F)
(the same technique
used
assembly
the
the
the
faster
were
chill
6).
in
i
to reach
indicate_
grain
each
mold
7 and
the
vacuum
Evaluation
8
below
1366°K
before
structures
a sufficiently
high
temperature
but
two
molds
had
indications
associated
with
of gas
mold
and
in-gates
(straight
8 minutes
for
of castings
in mold
all
7
and
spoke)
to
the
to
furand
with
ignite,
first
5
pouring.
made
in
Mold
level,
additional
7 minutes
were
for transfer
to the copper
changes
structure
problem
chamber
_unners
furnace
An
and
observed
redesigned
with
to
of
required
(2000°F)
of the grain
the
area
8 both
was
pour-cup
cavity.
of the exothermic
burn.
for the flaming
to cease
in the
_,.
of
Molds
left
minutes
required
both
downsprue
cross-sectional
filling
5 and
anu
center
an increased
Molds
i
Molds
5 and 76 and
castings,
8.
To the
correct
mold
design
had
allowed
to produce
blades.
However,
evolution
due
firing
in Molds
in
7 and
the
good
mold
columnar
castings
from
to a manufacturing
a gas-fired
furnace
that
i
r
inadvertenly
had
a reducing
silicon-monoxide
sequently
vacuum|
was
this
5.
atmosphere.
(SiO)
on
the
evolved
as
a
SiO
the
fill
9
the
feasibility
of
using
the
in
place
(straight
mold
metal
used
was
spoke)
higher
poured
The
was
was
using
cast
zircon
......
sub-
poured
in some mold
Jetshapes-produced
previously
This
mold.
restricted
Mold
system.
the
the
9.
alumina
produced
when
Mold
the
of
eventually
gas
apparently
o_
inside
This
in
cavltle_.
to
evaluate
face
coat
thermal-conductivity
the
same
design
and
21
v
casting
procedures
structure
of
columnar
growth
quality
was
6.
poured
examples
sented
the
the
same
manner
grain
Figu[e
7.
blade
of
prior
molds
cast
7.
Molds
ll
produced
using
the
that
was
from
i
due
and
surface
the
exothermic
testing
prior
l0
of
castings
root
grains
into
result
to
erratic
i0
these
are
pre-
castings
Surface
was
have
shrink-
characteristic
12
were
the
last
molds
To
eliminate
the
plat_
cast
with
molds
with
the
blade-root
the
platform
failed
furnace.
in
these
exothermic
shrinkage.
material
was
ignite
after
to
To
up,.
obtain
molds
material
satis-
was
torch
indicated
characteristlcsfrom
the
mate-
molds.
made
in Molds
ii
and
of
the
grains
solidification
to
tip.
The
"sort-out"
nucleated
at
the
upper
portion
two
factors_
the
the
molds
this
and
Representative
exothermic
material
ignition
the
the
(2000°F)
of
prepared
Mold
prior
cast
These
1366°K
in
of
of
12.
the
blade
extended
primarily
perature
22
ii
7.
of
eliminated
behavior
was
Mold
and
were
change
directional
randomly-orlented
grains
molds
different
uniform
achieved
these
Subsequent
Examination
casting
down ..............
characteristics
this
in
blade-root
waxes.
ignition
the
in
This
blade
as anticipated,
on
good
observed.
TF_731-2
and
used
very
orientation.
1L
down,
substantially
that
produced
Molds
blade-root
castings,
indicated
spoke)
12.
the
time
grain
structure
was
the
and
shrinkage
Molds
the
as
directional
with
surface
on
grain
platforms
fo:m
Erratic
orientation
The
on
the
of
of
.
i
\
_i
essentially
the
evaluation
a d.gradat_on
(straight
age
rial
but
mold
l0
longitudinal
ignited.
this
Mold
desired
factory
An
10.
in
usual
from
7.
detected.
the
nhe
Mold
obtained,
visually
of
observed
for
castings
was
Mold
in
used
performance
of
chill
of
(i)
the
zone
and
these
12
the
indicated
was
not
between
the
desirea
airfoils.
DS
This
inadequate
mold
tem-
exothermic
material,
PRESSURESIDES
SUCTION SIDES
Figure 7.
Task I, Mold i0, Spoke "B" Macroetched Blades Showing
Consistent Directional G_aln Orientations
i
23
2.
_q
and
in
(2) slow
some
pouring
of
of[ the
neede_
loss
sufficient
satisfactory
were
obtained
and
testing
8.
of
sound
13,
of
the preliminary
The
waxes
were
both
root
and
down
or
conventional-
resulted
blade
adjustments
exothermic
material
used
to ensure
adequate
Spoke
1 had
2.54
mold
13,
each
made
from
new waxes
established
in
Task
IV.
extenslono
of
blades
in eithe=
injected
waxes
wax
for
in-gate
with
the
rootfor
the
preliminary
and
a
o£
to
3
1.50-cm
(0.625-inch)
high
round
fit
extensions.
large
rectangular
rate
were
in Figure
on
9.
high)
tip
extensions.
3.Sl-om
(l.5-inch)
Spoke
starter
3 molds.
x 1.5-inch
airfoil
12
a different
shown
by
and
superheat
had
(i.0 x 0.5
diameter
for tip
metal
as
the
blocks
pour
4 airfoils
high
ll
the last
rapid
configuration
x 3.Sl-cm
Molds
and molten
spoke
Spoke
from
were
to casting
preheat
blocks
cast
machining
of
the
Exomet
starter
airfoils
to permit
8 shows
prior
from
x 12.7
starter
12
experienced
rectangular
had
structures
design.
in process
New
ca_ting
and
problems
and/or
graln
and
design
Figure
casting
block
problems,
smoothly-transitioned
the
positions.
blade
resulting
these
molds
blade
to permit
On Mold
the molds
Despite
ii
These
with
TFE731-2
all molds.
into
speuimens.
uncooled
uncooled--5/FE731-3
The
test
Molds
i4 and 15.
tip
metal
superheat.
from
designed
root-up
molten
directionally-solidified
in blades
Molds
starter
the
4 had paired
blocks
and
twin
in-
gr_in
patterns
that
The
airfoils
pro-
blueprint
contour,
but
gates.
The
process
were
unlform
duced
on
on all of
Spokes
residual
.._
changes
I,
2,
caused
them
to
twist
chillplate
and
cut-off
shell
resulted
13
plete
fill
24
in a few
DS
castings
of Mold
13.
and
induced
Mold
in good
the
stresses
4
resulted
3
were
to
in the
paired
airfoil
castings
of Spoke
out
of
limits
after
knockout
from
from
the
runners.
in
some
castings.
metal
A hairline
leakage
ond
crack
a lack
the
in the
of
com-
%
°
L
• .
'__"
ill,
_--_
TFE731-2
BE_
TASK I --
CASTING WAX
MOLDS 1 THROUGH. 12
TFE731-3
TASK I --
CASTING WAX
MOLDS 13, 14, AND 15
-=.,.
Figure
8.
Suction
Sides of the Injected
Casting
Task I Turbine
Blades
(Mag.s l. SX)
Waxes
for
25
[
I-
SPOKE 4
SPOKE
STARTER
BLOCKS
TEST
BARS
Figure
26
9.
Task I, Mold i3 Wax Ass,_mbly for the Preliminary
Design of the Uncooled
TFE?31-3
Blade in the
Root-Up
Position.
'¥J
Molds
starter
14 and 15 had
blocks.
ducibility
of
the
binder
this
was
binder
the previous
binder
molds
were
poured
pouring,
13
for
the casting
shell
discovered
the
the
evaluate
a
k
lower
_
introduction
of
because
the supplier
of
the
previous
a small
amount
The
new
binder,
and
of
zlnc-oxide
impurity
thinner
in the new
exothermic
material
shell
and caused
localized
mold
had reacted
with
the
deterioration.
This
thinner
shell
mold
cracking
the
square
starter
edges.
The
thinner
shell
balance
achieved
in Mold
13.
grain
structure
of
ners
on
The
had satisfactory
also
exhibited
and
roots.
A
few
risers
attaching
the
blade
Exotherm_c
Task
I was
of
oxide
are
molten
particles
by
a
the
thermal
taken
produced
a
and
in-gate
system.
material
mill
release
of
through
to metallic
heat
the
energy.
porous
the
reaction
to proceed
to completion.
external
to
the
minimized,
the
2033°K
(3200°F)
mold
ducing
temperatures
of
actual
temperatures
achieved
a
result
minimum,
of
the
heat
sufficient
sink
heat
during
capability
energy
must
is
and
iron
ore,
When
the
in
air,
accompanied
free
flow
pack
is
heat
the
mold
be
supplied
losses
pro-
pack.
The
lower
system.
by
an
of
slightly
of
of
is neces-
capable
briquet
I were
a
iron,
With
in the
Task
during
iron-oxide
A
reaction
the
the
exothermic
for
15
air-
in
temperature
reducing
..........
material
binders.
high
start
grew
utilized
scale
silicate
and
blade
nucleated
from
or
14
in the turbine
sufficiently
state
good
in Molds
briquet-shaped
and
oxide
atmosphere
upset
This
particles
to a lower
considerable
oxidizing
sary
to
aluminum-metal
slightly
to the
particles
heated
trailing
The exothermic
Nuggets".
iron
airfoil
grains
roots
Cor-
along
castings
stray
at_sharp
and
orientation
behavior.
aluminum-metal
briquets
also
"Isogard
special-blend
with
blocks
directional
foils
localized
I
repro-
its production.
than
that
including
The
Jetshapes
thinner
it was
to
shell.
discontinued
13,
to establish
and
material
a
as Mold
processing,
imposed-upon
binder
produced
after
design
Mold
silica-content
new
same
These
the
the
as
As
a
preheat
27
%
!
V
-->_
and
the exothermic
to a_temperature
above
reaction
the melting
to raise
the mold
point.-of_the
alloy
distribution
of
gating
was
face-coat
to be
cast.
k
This
.
_
requires
material
a reasonably
within
the
the
uniform
mold.
local
The
ensure
that
distribution
adequate
to
p_eheat
the
maintain
the
required
local
mass
of
system
of
the
vertical
the exothermlc
designed
exother-mic
adjacent
material
mold
temperature
to
was
material
gradients
to
during
casd_ing solidification.
Several
problems
encountered
either
directly
or
early
objective
was-to
furnace
to
permit
indirectly
an
supp!y
required
heat
in the
total
packing
density
in
the
available
space
of
exothermic
need
for
a smaller
quantity
that
long
preheat
times
degradation
metallic
the
to
of
the
exothermic
The
best
and
very
with
resulted
in self-ignition
to 7 minutes.
The entire
by
due
self-ignition
adequate
the
I144°K
actually
to
a gradual
into
the mold
elapsed
a 1366°K
for
This
the
1366°K
transfer
of the
to the
vacuum
(2000°F)
casting
the
the
pre-
preheat
level
pack in 5
allowed
to
furnace
furnace.
of
gas-fired
at the top of the exothermic
exothermic
reaction
was then
within
with
assembly.
(2000°F)
atmosphere.
of
temperatures
surface
had
included
an oxidizing
at
time
deeply
[e.g.
aluminum
the
the
found
oxidation
preheat
higher
of
partial
of
use
test
It was
material
heat
material
to completion
28
exothermic
exothermic
proceed
mold
material.
would
and
result
temperatures
the
This
of blade
as a
An
a gas-fired
energy.
The
evolved
;
-
using
of
to penetrate
preheat
cycle
associated
material.
reaction
rapid
_-
I were
a slowed
before
process
furnace,
of
exothermic
material
temperature
moderate
available
atmosphere.
to promote
at
ignition
constituents
preheat
tended
heat
of
exothermie
the
to a maximum
amount
the
with
of
molds
the
Task
a preheat
bar
reduced
during
develop
part
increase
(i600°F)] prior
= '_
_
atmosphere
prior
to
of
An additional
yellow
particles
reaction
in local
alloy.
Through
problem
on the
areas,
material.
problem
use
Mechanical-prope=ty
which
did not yield
l,
blade
each
castings
mold
property
of
the
and
at 1494_K
i144°K
(1600°F)
and
test
diameter
a
casting,
of
the
specimen
machined
from
separately
0.625-cm
(0.250-inch)
the
had
material
test
The
The
The
mini-bar
as-caSt
hours.
a
gage
in Figure
1.587-cm
MFB
mini-bar
following
tests:
diameter
12.
TheSe
(0.625-inch)
and
SCTB
test
specimens,
test
bars
were
and
test
length
respect
aged
tensile
o
I033°K
(1400°F)
tensile
o
I033°K
(1400°F)
stress-rupture
and
ksi)
to
3.18-cm
had
were
724
as
the
specimens
a
standard
(1.25-inch)
test
at
Test
gage
complete
machining
ii.
(SCTB)
the
at
(MFB)
configured
for
specimens
Room-temperature
all ....
(0.070-inch)
specimens
diameter
from
solution ....
subsequently
removed
o
ii0
into
gage
bars
this
use in mechanical-
in Figure
test
a
the
selected
machined-from-blade
slug
cast
of
eliminate
were
and
with
is presented
to
k
the exception
of Mold
castings,
individual
0.178-cm
location,
blade
the
2 hours,
i
oxide ....
bars
cast
(0.300-inch)
10.
to
speclmens-for
0.762-cm
in Figure
as shown
test
traced
manufacture
zinc
With
blade
for
specimens
shown
length
contain
separately
20
in
appearance
metal-mold
by the molten
was
able
to machining
(2230°F)
("mini-bar")
and
test
Prior
for
was
cast
into
castings
treated
not
problem
used
evaluations.
satisfactory
for machining
blade
did
separately
evaluation.
ore
supplier
that
of the mold
this
the-iron
The
of ore
occasional
caused
by a
penetration
analysis,
in
exothermic
by
and
chemical
zlnc-oxid_-impurity
manifested--an
mold
surface
machined
gage
from
bars.
were
subjected
to
and
758 MPa
(105
29
.
..
._=
t W
• _
• i_
J4_
0,30 R
0.315
10.1241
0.178--(0.12)
(0.0701
f--
A
\
0.762
/Io,_,
-
(0.300)
DIMENSIONS
_
Figure
3O
(0.300)
2.2k_
(0.90)
i0.
Mini-Bar
Test
_
IN CM (IN.)
Speclmen
r
c
0.762
--
--
0.317
J
ira,-+. _
.,.
--
p
'
¥
%.
-
+_
+
!+
i
!
1 ,+++_
2
3
4+
"+'_=
5
*
i
;
i
i
i
,
!
[
%
_.
+
-
"++
Figure
ii.
Longitudinal
Orientation
of Machined
Mini-Bar
Specimen
with Respect
to Exothermlcally-Cast
DS TFE731-2
Turbine
Blade
Test
+
0.048 R
(.0,189)
0.625
"_
(0.60)
'i.27
/-"
1.27
(o.5o)_-13 UNC
'_-
I (o.2so)
j-_ I_
I
• '-t'1
.__ 2.22
(o.88)
i -
3 18
(12._
3.18
(1.26)
- I
7,62
(3.oo)
-
DIMENSIONSIN CM (IN,)
Figure 12.
Standard Tensile Test S_eclmen .
32
..........
"
"'
00000001- TSD(
'"
..+
o
1255°K
(1800°P)
stress-rupture
and 32 ksi) ......
Mechanical
Tables
test
I through
Table
mini-bar
I
results
the
specimens+
i00
hours.
in Table
I(c)
for
the
specimens
from Molds
were
determined
minl-bars
machined
test
(1800°F)
tests
machined
from
tests
221
the
from
excellent
SCTB
MPa
(32
molds
test
cast
(1800°F)
averaged
III
presents
comparative
specimens
machined
from
tionally-cast
equiaxed
MAR-M
were
one
from
Lower
rupture
when
compared
lives
of
the
and
separately
247.
heats
ductility
to the DS casting
are
(1400°F/I05
bars.
tests
The
lives,
on
combined
and
excep-
The
data
also
tests
and
the
level.
for
Lives
here
and
52.4
minlbars
data
obtained
on standard
cast
test
of
TheSe
used
lives
I(b)
MPa
mini-bar
hours
of
for
test
test
in lieu
and
temperature
Table
test
stress-rupture
MFB
50.1
mini-bar
Table
conditions.
the
shown
in
test
between
level
at
at the
two
in
molds
rupture
SCTBs.
made
of
failure
the remaining
1033°K/724
results
for
test
at
MFB
Stress=rupture
in
1255°K
ksi)
listed
the
used
consistency
correlation
the
as
separately
ductility
at
on MFB
level.
ksl)
of
stress
stress
lists
good
in
(30 ksi)
Table
shows
I are summarized
inadvertently
I(a).
high
(30
9 were
in Table
tionally
221
to produce
1255°K
(1800°F/30
machined
selected
(32 ksi)
as listed
data+shows
were
221 MPa
all
II
and
results
The
from
specimens
hours
stress_rupture
for mini-bars
MPa
at
in Task
MPa
7, 8 and
207 MPa
1255°K/207
ksi)
@enerated
S_resses
approximately
intended
207
V.
lists
_he
at
bars
conventional
convencastings
to produce
the DS
castings.
evident
at 1255°K
(1800°F)
in Tables
I and
test data
shown
II.
33
+
_._
+_
k
TABLE
I,
TASK I STRESS-RUPTURE
TEST
FROM-BLADE
TEST sPECIMENS
i
_"
!
_
RESULTS
ON
DS CAST
[Test specimens
machined
from ex0the_mically
cast DS MAR-M
blades
after heat treatment
at 14940K
(2230"F) for 2 hours
I144°K
(1600°F) for 20 hours.]
i-_i
Rupture
time,
Specimen
Tests at
-
2
A
12.8
19.5
32.1
i :
2
B
46.7
18.1
23.5
3
A
14_.0
9.3
14.6
i
3
B
205.1
19.1
22.9
_
4
A
52.5
5.0
12.6
4
B
i00.1
19.0
25.6
5
A
197.4
19.8
22.5
5
B
269.9
27.6
31.2
_
6
A
202.0
14.1
18.5
_= :
6
7
B
A
192.3
76.1
20.5
13.3
25.3
20.5
7
B
64.0
12.3
18.8
8
A
95.2
10.9
22.9
8
B
25.7
i0.6
24.1
9
9
A
B
87.4
184.8
12.4
18.8
19.0
28.5
i
l0
11
A
A
150.1
29.6
12.0
16.3
15.2
25.0
!_ -
ii
12
B
A
24.1
160.3
10.8
9.3
12.8
18.4
12
B
15.9
11.7
17.5
13
A
133.9
13.8
19..0
13
B
179.3
16.8
18.6
14
A
137.3
17.4
24. i
14
B
130.7
15.2
28.9
_ \
15
A
125.5
15.6
22.7
F_
15
B
134.0
17.5
27.6
i
MPa
247
and
\
Reduotlon
of area,
Mold
(a_
:
--hours
I I
I033°K/724
Elongation,
i
MACHINED-
percent
percent
(1400"F/I05
ksi)
j2
!
mE_
_.,
34
i
L
:
i
¥
TABLE
I.
(CONCLDDED)
un
Rupture
time,
Elongation,
Specimen
(b) Tests at
hours
1255°K/207
percent
MPa
(1800o_/30
2
A
99.2
25..7
52.6
2
B
72.1
26.6
48.4
3
A
91.1
27.9
44.6
3
4
B
A
71.4
80.9
21.3
28.4
40.0
52.6
4
B
81.3
34.8
43.6
5
5
6
A
B
A
97.6
84.7
79.2
39.7
26.4
19.3
56.5
51.0
48.9
6
l0
i0
B
A
B
91.7
79.1
95.4
32.8
36.5
45.3
46.7
48.4
56.7
ll
A
86.6
31.0
47.1
ii
B
74.0
29.1
45.8
12
A
68.1
28.2
39.0
12
13
B
A
74.8
73.6
29.7
24.8
47.0
47.0
13
B
69.4
15.2
34.1
14
A
68.6
32.6
57.4
14
B
69.1
22.0
41.0
15
A
74.1
23.5
42.8
15
B
68.7
21.4
47.0
Mold
(c)
Tests
at
1255°K/
221 MPa
Reduct ion
of area,
,n percent
(1800OF/32
k
_1
ksi)
ksi)
7
A
56.4
18.3
50.6
7
B
46.4
17.9
47.0
8
A
52.7
16.1
46.8
8
B
49.5
17.6
51.0
9
A
47.0
19.4
48.2
9
B
48.6
17.3
46.8
35
TAIIL_: I|.
TASK
CAST
I STRF, RS-RUPT_E
TEST SI'ECIMF'N8
T_:ST RSSULT8
ON DS CAST
,4
(Tost
spoclmuns
machlnod
from oMothormlcnlly
east DS MAP.-M
separately
east test b_r, altar
heat treatment
at 1494"K
(2230eF)
for 2 hours
and ll44"K
(1600"_') for 20 hourJ,
_old
(a)
Rupt uro
time,
hour8
EIong_t ion,
pBrcB_t
at
MPa
I033"K/758
(1400*P/If0
12.7
17.8
2
83.9
13.6
20.0
3
85.2
_6.5
23.4
4
106.6
_4.2
19.1
5
148.6
13.7
19.1
6
107.8
15.4
24.0
7
95.0
18.2
24.7
8
9
109.1
95.7
20.6
20.6
24.3
24.3
I0
140.0
19.7
23.0
il
91.I
16.9
21.6
12
86.9
15.0
19.9
13
_33.0
17.4
22.8
14
_II.9
18.?
26.0
15
123.8
17.7
at
MPa
1255oK4 ' 221
61.?
53.9
60.0
4
5
6
53.4
40.5
47.8
35.0
28.0
30.8
59.1
59.3
55.4
7
8
9
I0
•Ii
12
69.2
48.7
44.7
54.9
53.1
52.7
32.3
31.8
31.8
34.4
43.1
34.7
60.5
57.3
59.4
55.7
61.9
59.7
13
14
15
61.3
5n.8
51.7
41.9
49.7
33.4
63.5
65.2
59.0
' .
J
-i
TEST RES[_,TS ON CONVENTIONALLY
247 TEST SPECI_b_,NS
[Test speclmc-ns
machined
from separately
cast trst bars
conventionally
cast equlaxed
MAR-M
247 made from one of
heats
usud to produce
the D8 eastlngs.]
8_r
no.
(a)
time,
hours
Rupture
Tests
at
I
E1ongatlon,
percent
i033°K/758
75.1
(b)
Tests
at
._ 20.3
36
HPa
5.0
1255°K/221
F
ksl)
37.2
33.1
35.0
I STRESS-RUPTURE
EQUIAX_:D MAR-M
"
23.1
(1800°F/32
57.2
44.3
55.8
TASK
CAST
'_ i
,
I
2
3
llI.
k
kal)
85.5
Tests
247
eoduot ion
of a_oa,
DO_CQnt
1
(b)
TABLE
Tests
]
S_['ARAT_SY
MPa
10.5
10.1
I
off area.
percent
Reductiun
11400°P/110
ksi)
6.8
(1800°F/32
15.3
18.9
ksi)
of
the
"'-
..
4
d
•%
TABLE
IV.
TASK
TEST
I TENSILE
SPECIMENS
TEST
RESULTS
ON DS CAST
MACHINED'FROM-BLADE
[Test speuimene
machined
from exothermieally
east DS MAR-M
247 blades
after heat treatment
at 1494°K
(2230°F) for 2
hours and 1144eK
(1600°F)
for 20 hours.]
Mold
Specimen
Ultimate
tensile
strength,
MPa (kei)
0.2-Percent
yield strength,!
MPa (ksi)
I
(a)
L
__7
-
Tests
at
Elongation,
percent
Reduction
of area,
percent
_T
Room
Temperature
3
A
1136
(165)
914
(133)
12.2
14.4
4
A
1163
(169)
891
(129)
11.9
14.8
5
A
1036
(150)
834
(1il)
11.4
17.7
5
B
991
(144)
822
(119)
12.8
15.9
6
A
1093
(159)
871
(126)
11.6
17.2
6
B
1067
(155)
849
(123)--
•10.5
15.5
7
A
1160
(168)
878
(127)
3.1
8.5
7
B
1149
(162)
820
(119)
9.1
13.8
7
C
980
(142)
726
(105)
i_.2,
30.1
8
A
1078
(156)
843
(122).
11.4
17.0
9
A
1070
(155)
821
(119)
14.9
26.1
9
B
1109
(161)
826
(120)
9.6
18.3
9
C
1025
(149}
846
(123}
9.0
17.2
i0
A
1179
(171)
934
(136)
13.0
15.7
i0
B
1049
(152)
878
(127}
11.6
13.3
ii
A
ii
B
850
(138)
829
(120)
9.1
13.1
12
A
1016
(147)
881
(128)
10.4
13.2
12
B
823
(119)
814
(118)
2.2
9.5
13
A
1005
(146)
894
(130)
8.2
10.9
13
B
1034
(150)
940
(136)
5.0
10.0
14
A
1118
(162)
880
(128)
11.7
13.2
14
B
1000
(145)
841
(122)
12.6
17_5
15
A
1082
(157)
874
(127)
13.4
14.8
15
B
989
(143)
820
(119)
13.5
19.3
Failed
in threads
on
loading
--
'_
37
TABLE
-
•
Mold
•
iSpecimen
Ultimate
tensile
strength,
MPa
(ksi)
• f
i
4b)
Tests
IV.
4CONCLUDED)
0.2-Percent
yield strength,
MPa (ksi)
at 1033°K
Elongation,
percent
Reduction
of area,
percent
i
(1400°Y)
3
B
1202
(174)
949
(138)
10.2
17.5
3
C
1153
(167)
907
(132)
7.6
15.7
4
E
1117
(162)
833
(121)
6.3
15.5
4
C
i070
4155)
847
(123)
9.0
13.9
5
C
1181
4171)
915
(133)
7.3
16.6
5
D
1026
(149)
790
(115)
6.4
14.8
6
C
1090
4158)
870
(126}
7.3
21.2
6
D
1093
(159
868
(126)
8.5
15.0
7
D
1104
(160)
828
4120)
14.1
21.4
7
E
1121
(163)
860
(125)
9.3
14o8
8
B
1076
(1561
869
(126)
6.8
i0.9
8
C
1034
(150)
846
4123)
7°6
15.5
8
D
I010
(147)
798
(116)
8.2
13,2
9
D
1116
4162)
891
4129)
6.9
11.7
10
C
1209
(175)
1019
(148)
11.5
15.6
i0
D
1172
(170)
991
(144)
8,6
8,8
ii
C
1050
(152)
854
(124)
6.8
11,2
II
12
D
C
1145
Failed in
(166)
threads
978
on loading
4_42)
8,0
-I1.9
12
D
1170
(_70)
994 ....(144)
9.0
11.5
13
A
1260
(183)
878
(127)
12.3
13.9
13
E
1105
4160)
932
4135)
8,8
17,0
14
A
1072
(156)
939
(136)
9.7
11.2
14
E
1141
(166)
963
(140)
9.2
10.5
15
A
991
(144)
824
(120}
3.7
13.4
15
B
1145
4166)
956
(139)
10.5
15.5
"
'
'_
38
00000001 TSEO
TABLE
V.
TASK
CAST
I TENSILE
TEST
TEST SPECIMENS
RESULTS
ON
D8
CAST
SEPARATELY
[Test. specimens
machined
from sxothermlcally
DS _R-M
24_ separately
cast test bars after
treatment
at 1494°K
(2230°F)
for 2 hours and
(1600°F)
for 20 hours.[
•
,
Mold
cast
heat
I144_K
i
Ultimate
tensile
strength,
MPa (ksi)
O.2-Parcent
yield strength,
MPa (ksi)
Elongation,
percent
Reduction
of area,
percent
f_
(a)
Tests
at
Room
Temperature
1
1147
(166)
856
(124)
12.8
14.8
!
2
1171
(170)
86¢
(125)
11.I
11.7
j
3
1218
(177)
854
(124)
12.1
12.2
i
4
1196
(173)
863
(125)
12.8
16.0
5
1254
(182)
872
(126)
13.3
14.2
6
1154
(167)
854
(124)
13.4
16.5
7
1172
(170)
832
(121)
12.5 ....
16.0
8
1182
(172)
845
(123)
15.0
16.5
9
1131
(164)
849
(123)
12.0
16.1
10
1231
(179)
896
(130)
13.1
14.4
ii
1153
(167)
887
(129)
12.9"
16.5
12
1232
(179)
914
(133)
12.3
13.8
13
1170
(170)
903
(131)
10.9
15.7
14,15
(b)
NOt tested
Tests at I033°K
(1400°F)
1
1172
(170)
973
(141)
8.3
12.4
2
1121
(163)
880
(128)
7.0
14.2
3
1173
(170)
956
(139)
13.3
20.8
4
1176
(171)
947
(137)
13.5
20.7
5
1082
(157)
845
(123)
16.4
26.4
6
1176
(171)
976
(142)
10.9
16.2
7
1150
(167)
9_i
(135)
16.2
23.7
8
1131
(164)
896
(130)
12.7
17.8
9
1123
(163)
925
(134)
2.9
4.6
i0
1188
(172)
951
(138)
13.5
19.5
ii
1180
(171)
962
(140)
11.5
15.1
12
1189
(173)
972
(141)
12.4
16.6
13
1207
(175)
965
(340)
ii.I
13.3
14,15
Not
I
tssted
39
"t
{
_
Tables
IV and V list
tests
temperature
!
mens,
respectively.
_ith the
specimens,
the.results
appear
_ -
planned
! ;
cracks
in bars
these from-Molds
molds,
some
did no_
fill
cast test
14 of
and the
15. test
Due bars
to metal
leakage
i'_
pletely
i
tests.
results
the
performed
available
from
Molds
13,
_ -
section
_,
the
to
and
Table
analysis
the
results
With
of
the
obtained,
root-up
A
MAR-M
speci-
bars
14 and
were
the
tests
were
used
best
represent
15
for
on
the
comfrom
stress-rupture
the
in Tables
separately
capability
I through
of
V,
the
analyses
of all blades
cast
were
determine:
(I)
overall
chemistry
the
root
each
the
and
(2) the hafnium
tip
sections.
the results
of
the
of
two MAR-M
specification
content
the bulk
heats
employed,
and
VI
also
presents
the
roots
and
airfoil
analysis
at
the
exception
of Mold
Ii,
where
a spurious
the
hafnium
gradient
Recommended
Casting
Practice
of
control
guidelines
of
Task
I that
program
alloys
reversal
of
in
the
Table
blade
blades
analysis,
247 master
limits.
in
of the
chemical
hafnium
the
test
Chemical
airfoil
material
SCTB
Analyses.
VI lists
of
and
,,
exception
of several
low-ductility
to have normal
scatter.
The only
in
test
Taskdata
I. listed
of the blade,
root
mind-bar
collected
the
process
Of the mechanical
developed
[
root
for
tips.
analysis
was
the blades
cast
is apparent.
basic
247
isfactory
i
not
and
Chemical
4O
data
the MFB
and 1033°K(1400°F)
tensile
tensile
for
room
i_ -
ii:
results
the
set
process
for
process
experiments
easting
all
four
evolved
were
from
considered
in Task
If.
the
sat-
_
m
U
m
ooooo
oo ooooo
_
m
i
ooooooooooo_
O0
41
i
:
Wax
assembly
manufacture.
The
wax
assembly
selected
for
the
consisted
of
an
%
casting
;i-L
._
of
uncooled
TFE731-3
turbine
blades
approximately
25-cm
(10-1nch)
diameter
cluster
arranged
in _ equally-spaced
spoke,
and assembled
to a
_adial
central
placed
on
high
0.625
inch)
starter
inum
ii
top
a
2.54=cm
cylindrical
extensions
vertically
oriented
were
plate
operations,
and
subsequently
plane
surface
mold.
The
parallel
A
short
to
a
to
each
"riser"
common
initially
and
blades
the
gate.
An
approximate
the
space
of
up.
The
on a wax-covered
as a frame
base
plate
alum-
in mold
to
form
dipping
the
flat-
were
oriented
with
their
roots
to
mold
spoke
axis.
and
perpendicular
on
top
each
the
blade
root
attached
cross-
by
0.5-inch)
for
spoke.
Each
runner
each
cup
by
under
exothermic
4-blade
was
con-
inverted-"Y"-shaped
(l.5-inch)
the assembly
each
an
unobstructed
the pour
spoke,
to
cup,
downspace
was
as well
as,
provide
r
final
was
(0.5-inch
3.8-cm
of
of
the open-bottom
1.27-cm
pour
surrounding
for packing
blade-root
spoke
central
in the center
by
in each
runner
left
(1-inch
of
by
to
a
diameter
flange
1.27-cm
nected
as
k
4 blades in each
Each blade was
base
extension
horizontal
served
waxes,
the
other
section
1.50-cm
extension,
The
bottom
by
20 blade
with
cup.
starter
plate.
DS
,
of
spokes,
pouring
of
open
areas
briquets.
I
Mold
_
manufacture.
The
Colal-P
alumina-flour
bonded
alumina-silicate
prime
open-bot_Qm
DS
Casting
cess,
the mold
formed
with
7
An
42
optical
was
followed
dips
dipped
with
by sufficient
the
silicon-
a 0.635-
to 0.825-
inshell
a gasthickness.
furnace
tc After
produce
the completed
autoclave
dewax-
as shown
in Figure
13.
process.
As
initial
step
was
then
to produce
mold
ceramic-fiber
the base
assembly
coat,
back-up
ing,(0.250the mold
was fired
cm
to 0.325-inch)
i
wax
placed
an
upright
insulating
the
on a metal
support
sleeve
placed
of
the sleeve
resting
sight
tube
of
made
in
was
DS
plate.
around
on top of the mold
dipped
shell
casting
material
proA pre-
the mold
base
flange.
was
placed
63
thzough
the wall
optical
temperature
thermic
briquets
were
poured
into
central
open-area
of
the mold
and
at least
10-cm
tem.
of
the
(a-inches)
mold
atmosphere
23
kg
temperature
minutes
exposure.
The
time
of
15 minutes
to permit
The
preheated
mold
the
mold
mold
water-cooled
copper
The
melting
melting
cycle
the
molten
coordinated
charge
which
foil.
vacuum-melt
with
alloy
the mold
be
stabilized
mold
chamber
was
chambers
perature
while
the
The
valve
between
the
two
at a molten
metal
temperature
was
poured
40@°F). above
took
place
cycle.
for
liquidus
metal
prior
cast
after
being
temperature
approximately
5 minutes,
cooling
44
The
the
25 minutes
was
which
to shakeout.
held
at
for
a
after
removed
total
"burn".
furnace
and
temperature,
and
placed
on
a
had
previously
been
was
performed
in
an
timing
of
this
heating
cycle
so
that
pouring
tem-
the
proper
pumped
down .....
opened,
and
the
of 195 ° to 220°K
of
7
The
was
in place
it was
5 to
the
chamber.
could
after
the
furnace
chill,
casting
from
sys-
required.
exothermic
checking
casting
the
induction-heated
was
After
to
furnace
furnace
the
clu_ters
Tkis
briquets
of
the
oxidizing-
(2000°F).
the
around
gating
gas-fired
removed
of
isolated
a
in
nickel
cycle
the blade
were
left
of
exo-
of briquets
was
layer
Suff.icien_
the
exothermic
the
for
ot
into
was
surface
sleeve
runner
the
was_ removed.
a single
top
13660K
assembly
into
with
all
completion
was_ transferred
grooved,
covered
at
ignited
plate
around
the
stabilized
firing.
insulatin_
placed
preheat
support
the
(50 pounds)
was
a reference
after
above
assembly
furnace
the
to provide
measurements
Approximately
_ne
sleeve
the
alloy.
the start
mold
(350 ° to
The
pouring
of the preheat
under
vacuum
on
from
the chamber
the chill
for air
;
TASK
II - ALLOY/PROCESS.
i._',
SELECTION
Scope
-
T_he major
,
in
objectives
exothermically
cast
of Task
II were
form,
establish
DS
to evaluate
a
heat
four alloys
treatment
these
alloys,
evaluate-their
metallurgical
characteristics,
select
the
alloys
the
greatest
potential
for
TFE731-3
two
showing
solid
high-pressure
four
nlckel-base--alloys
i-
turbine
blades
selected
(a)
MAR-M
(b)
NASA_TRW-R
F '
(C)
IN 792+Hf
[
(d)
MA -R=M 200+Hf
for
the
evaluation
for
for
and
use
engine.
as
The
were:
247
[
i--"
.
!
AS was
plished
the
with
case
with
the aid
Task
I, the
Task
II activity
of
Jetshapes,
Inc.
Test
Material
Production
was
accom"
i
_
,
The
-
of blade
castings
and
ations.
These
castings
were
produced in groups
one alloy
being
used
each
group.
i-'_
and
;
i5 •
process
sistent
_"
_
i_
the
were
mol@s
were
spokes with
for
were
four
cast,
used
8 molds
Task
in producing
of slab
employed
one
for
designed
for
each
castings
Similar
I recommended
mol4s
a total
of
each
of
16 molds
for Task
II evalu-
a typical
blade
of
four
exothermlc
group
of molds,
Practice.
to yield
20 DS blade
the
four
mold
wax
molds,
material
casting
alloys.
of a radial-spoke
_esign,
having
5
provision
for 4 turbine
bla_e castings
14 presents
13 shows
assembly.
were
controls
with
mold
Figure
_-
_lloys
Initially,
per
t
four
con-
castlnas
The
blade
eaually-spaced
in each spoke.
assembly,
and
Fiqure
two views
of a blade
mold
fabricated
from
this
These
first
four molds
were
cast
to evaluate
wax
the
45
00000001 TSEO
Figure
14 ....
Wax Pattern Assembly
Task II Preliminary
for Exothermic
DS Casting Twenty
Design TFE731-3
Turbine
BlaOes
46
----
'
+
lip
+
response
ef
the
procedures
several
developed
allays
with
MAR-M
the
curve
pleteau)
was
checked
for
alleys.
All
the
alloys
exhibited
ran¢+e of
17°K
lty
of
lation
I?55°K
errors)
of
utes.
ing
four
well
in
Task
the
the
target
pouring
four
in
used
a
in
temper-
and
the
k
reproducl-
a single
emissivity
four
within
recorder
were
at
I.
instal-
initial
packed
with
anO
exothermic,
13667K
(2000"F)
Ignition
times
using
exothermlc
to
7 minutes.
varied
from
4.5
in the
furance
for
a total
burn
approximately
related
the proce-
the
furnace
removed
anO
of
gas-flred
exothermic
under
of
and
all
molds
then
cooling
(cooling
plateau
than
to
II castings.
were
exothermic
less
alloys
They
directly
heat
a free_ing
for
used
remained
times
tempecature
master
is
control
Prior
pyrometer
Therefore,
molds
from
I.
each
optical
the
the
Task
was
in the
from
during
freezing
range
furnace-igni£ed
varied
of
the
process
for
developed
material
This
and
(uncorrected
first
sequentially
the
ga_ing
(2700°E)
Task
The
dures
of
process.
subseql/ent
All
(30°F).+
capability
t_e casting
ature
of
easting_
247
pouring
b_
initial
to the
15 min-
and held
in air
ceased.
This.additional
burn
6 minutes,+with
the
longer
smaller
pieces
Pumpdown,
pour,
1 minute
to
to a larger
material
in
the
vacuum,
and
removal
until
of
percentage
exothermic
from
within
the
prescrJSed
limits.
orientation
was
observed
on castings
of
pack.
the
chill
Generally
visible
plate
flamtime
were
satisfactory
of
all
four
alloys.
one
for
each
alloy,
all
grain
%
A second
using
the
same
material.
+
•
process
the
controls
etching
of
the
poorer
grain
material.
All
remaining
was
improved
retl)rn_d
quality
improved
to
was
material
a
the
lot
su_pller
in
this
group
on
all
four
input
from
the
material
from
the
heat
and
for use
a m_nimum
cast
exothermic
orientation
exothermic
was
of
made
inadequate
procured
had
second
castings
being
rial
The
and
cause
batch
ings.
molds,
probable
suspect
of
feur
significantly
exothermic
i
of
Grain
revealed
alloys,
group
exothermic
mate-
in subseauent
c_st-
burn
temperature
of
47
+-
_J
3050"F, as required
fication.
by the Detroit
Diesel
Allison
EMS197A
Speci4
#
The
final
eight
blade
molds
were
four, one mold per alloy in each group.
molds
were
also
cast,
_ _
for
u_e
in mechanical
_
mold
wax
assembly.
material
of
was
i_
_ i!
I
molds
per
testing.
A new
utilized
exothermic
alley,
Figure
lot of more
for
15
shows
uniform
these
bars
typical
slab
a
test
quality
16 molds.
lot
ignition
time plus exothermic
burn
time was 15 minutes
cases,
consistent
with the process
control
plan developed
in all
during
Task
have
I.
The
new
lot
lower
heat
output
Blades
of
generally
with
all
alloys
A
summary
of
the
growth
were,
exception
IN 792+Hf.
blades
and
the
sented
in Table
Six
different
heat
shown
in Table
VIII.
prior
to machining
results
of
tensile
XXVIII.
herein
under
Task
resulted
in
the
L i'
!
Evaluation
48
two
casting
first
groups
to
four
a
molds.
however,
cast
the
casting
for
II
Treatment
Studies
treatments
were
The
casting
the
identification
found
for
four
in
slabs
is
pre-
during
Task
II
applied
to
the
VII.
Heat
as
of
used
was
satisfactory
mold
lot
material
the
the
for
The
on
of
groups
5 minutes.
exothermic
than
the
4 to
in
new
furnace
within
ignited
The
total
furnace
consistently
the
treatments
mechanical
and
Task
test
stress-rupture
"Mechanical
following
of
heat
employed
were
specimens.
Tabulated
testing
-Tests!' in
included
XV
through
Tables
are
observatlons---and---conclusions,
II
mechanical
_j
exothermic
1366°K
air
material
casting
to provide
the
(2000°F)
_
•
two
then cast
in groups
of
In addition,
eight slab
property
test
all
data
__
Figure
15.
Wax
Six
Pattern
Task
II
Assembly
for
Test
Slabs
Exothermic
DS
Casting
49
---
51
referereod
to
treatment
the
original
nominal
Z494°K
(2230°F)
nolutlen
temperature:
k
Zq
•
MAR-M
247
appear
to
Room-temperature
be
treatment,
while
by
the
(%400°F)
and
1255°K
maximized
by
in
(2210°F)
MAR-N
1033°E
(1400°F)
be
by
treatment
solution
I033°K
(1400°F)
Both
solution
were
I033°K
strengths
were
treatment.
The
produced
at
test
heat
temperature
the
(2230°F)
w_th
test
(2250°F)
at
to
1494°g
both
stress-rupttlre
properties
insensitive
decreased
1505°K
(2250°F)
stress-rupture
_olution
the
l_ves
and
strengths
treatment.
(2250°F)
Tensile
to
treatment
yield
no
ImDrovem,.nt
properties.
appeared
ture
at
solution
(1800°F)
and
1505°K
1505°K
200+Hf
maximized
the
properties
same
the
mechanical
by
similar
lowered
1483°K
:
maximized
tensile
temperature
treatment,
tensile
but
(2210°F)
The
treatments
Rupsolution
1494°_
produced
the
were
treatment.
1483°K
temperaturee.
at
DroDertles
solution
the
solution
room
(2230°F)
equivalent
lives.
+
NASA-TRW-R
.
15050K
(2250°F)
room-temperature
tensile
strengths
and
maximized
(1400°F)
strengths.
This
was
an
The
- The
tensile
1505°K
increased
(2250°F)
rupture
solution
lives
at
solution
treatment
two
the
unexpected
temperature
the
lowered
also
1033°_
tren_.
moderately
test
temperatures.
solution
treatment
+ i+
•
_N
792+Hf
The
1505°K
(2250°F)
yieldeO
_,
slightly
higher
tensile
1494°K
(2230°F).
The
weaker
than
Based
_-
at
....
52
the
on
]505°K
the
apperent
other
and
alloy
three
'%
superlcr
(_.250°F)
rupttlre
was,
in
however,
than
the
' I
substantla+iv
stress-rumture.
r_.ults
solut:on
_trengths
achieved
temperature,
with
MAR-M
blades
247
were
}
D
mr
i
later
the
solution
treated
ob,ectlve
of determining
tlon
treatment
show
typical
T
at temperatures
"
The
lowest
primary
amount
at
of
hlgber
1483 °
incipient
DS
at
stress-rupture
(2210 °
highest
to _olu16 and
to
to solution
temperature,
treat
a
results
of
1255°K
o_
specimens
treated
at
these
herein
Tests".
A summ:_arv of
all
Task
I an4
Task
II stress--rupfure
results
on
247
specimens
at
1255_K
vario_s
solutlon-treatment
solution
temperature
of
1505°K
(2250°F)
cast
in Task
llI.
to
the alloys
Metallurgical
Evaluation
each
molds
from
of
the
to nondestructive
tests,
cast
evaluation,
and metallurgical
tests,
test
after
Jn Table
of the
Castincs
anical
is presented
results
i
"Mechanics!
(18009F)
of the overall
the
subjected
under
on revle_
application
_
temperatures
IX.
beat-treatment
during
was
selected
Task
II
che_ical
analysis,
Including
g raln
were
moth-
J
etch.
T
Noneestructlve
i,_w_
were
macroetched
escent-penetrant
m
m.
four
molds,
revealed
process
produced
terns.
The
still
IN
show
(NDE).
grain
All
Task
II blade
orientation,
X-rayed,
castlnos
the
castings
and
fluor-
inspected.
etch
TRW-R
was
t®
Grain
selected
._
Evaluti¢n
of
the
that
control
the
all
from
four
alloys
procedures.
The
finest
792+Hf
acceptable.
blade
and
train
The
structure
MAR-M
was
rotor innermost
first
responded
straightest
k
small
Tabulated
pre_ented
MAR-M
]7
2300°F).
are
DS
_Jth
sol L1tion treate_
inadequate
occurs.
tests
247
to 1533°K
the
alloy
Figures
MAR-M
is obviously
melting
this
temperatures.
in the range
while
of
(2300°F),
temperatu=es
for
--_
the tolerance
of
prime,
and 1533°K
higher
study,
-
(2275°F)
micr.ostructures
gamma
Based
_
these
temperature
(1800°F)
i
at 1519£K
group
247
well
to
of
the
and the NASA-
columnar
grain
pat-
somewhat
coarser
but
(center)
blades
in the
h
53
i! .
°
'.
(a) 1483°K (2210°F)
L:
FtcJuEe 16.
54
(b) 1494°K (2230°F)
,.'.- '.__-..,,..
V. 2
.
"-4
"!
,,,..
_..
Typtucal Htcrostruct:ures
o_ DS MAR-H 247 rl'u_bine
Blades Solution
T_eated £o_ Two Hours at the Indicated TemperatuEes.
Graln G_owth Direction 1s
Ve=tlcal.
Kallln_s E_ch.
(Hag.:100X)
(o) 1505°K (22500F)
.,_
(a) 1519°K (22750F)
?
.+__._,,
•
el
,
"
,¥I_
IP-
'
t-#,,
+
_i,
p
:..
i, .%.+
It_4
--
•
Ii
iPiilt" . ."
i...-:.;_::.-...+,
-
,<.
,
,
it.
II
i_ti
i
_") '"_'- Ii ill
ia
.
,.
i
° i.
,_-
_D++++
.-:__t
" '<'
_"" ii_"
:<+:
-. it:'+_Yi.
• i"
'_ .
'4"L"i
_
,
'"'_ ,,._ -
(b) 1533°K (23000F)
Figure
17.
Typical
P_icrostructures
of DS MAR-M 247 Turbine
Bla4es
Solution
Treated
for Two Hours at the Indicated
Temperatures.
Grain Growth Direction
is Vertical.
K_llinqs
Etch (Mag.:_00X)
55
I
_q
'%
+
i
TABLE
IX.
SUMMARY-OF
TASK
TEST
RESULTS
II
1255"K
(1800°F)
STRESS-RUPTURE
[Test specimens
machined
from Task II exothermically
cast DS MAR-M 247 turbine blades
havihg various
solution treatments.+
All were inert gas quenched
after
2 hours at the solution
temperatures,
then exposed
to
1255°K
(1800°F)
for 5 hours, air cooled,
and aged for
20 hours at I144"K
(1600°F)]
"
+_
+ -
Solution
+
treatment
temperature,
°K (°F)
Longitudinal
Hours
grain
to
orientation
rupture
tests
Number
at
207
MPa
of
(50
tests
ksi)
,n
-
1483
(2210)
53.7
-
75.1
2
--
1494
(2230)
51.0
-
99.2
29
1505
(2250)
85.2
-
98.5
2
1519
(2275)
79.9
-
125.0
4
1533
(2300)
79.7
-
126.8
4
•
Transverse
++
•
grain
orientation
tests
1494
(2230)
1519
(2275)
97.3
-
173,0
1533
(2300)
147.5
-
202.3
at
186
MPa
(27
101..3 - 136.7
ksi)
4
4
4
i
56
J
.
00000001-TSF
_
_ I,¸ ,._,l
--I
_
_
Yq
i_
MAR-M
200+Hf
mold
exhibited
misoriented
grains.
from
a hairline
mold
crack
indicated
slightly
low
in the
center
of
made
the
second
group
of
orientation
on
all
heat input f_om
inpu.t disturbed
the
the
trolled
nucleation
in
that
the
local
temperature
the
mold
cluster.
foul
mold
flash
some
the
was
Grain
etching
of
castings
molds
revealed
significantly
in
poorer
grain
i__[
r :
four alloys.
This was caused
by inadequate
exothermic
material.
This
inadequate
heat
_
_ -
thermal
balance
required
the relatively
poor yield
i__
blades
I/
mit
had
sufficiently
subsequent
This
uacon-
to produce
good DS castings.
Despite
of this group of castings-, most of the
sound,
well-oriented
machining
of
test
specimens
through
21
show-typlcal
grain
areas
to per-
mechanical
test-
r,'.acroetched blade
cast-
for
r
ing.
Figures
ings
18
selected
from
alloys.
All
•casting
process
blades
of
root
which
of
this
the
last
the
alloys
with
the
reverted
sections
in
last
used
third
the
molds
cast
cast
showed
a
good
IN
792+Hf.
equiaxed
exception
alloy
the
two
lot
from
two
of
o{
DS
molds
to
cast
exothermic
from
each
of
the
response
to
the
All
of
the
grains
in
the
89
i03),
(Molds
and
material.
I
In
addition
X-rayed
reject
and
2 high-pressure
by AiResearcn
_ill Task
used
were
those
employed
blades,_
the
proauction
Quality
Assurance
of X-ray,
in Table
X.
each
alloy,
as well
and
for
all
inspections
rank
the
alloys
as
FFI,
The
II blade
inspected
turbine
A summary
i
etch,
fluorescent-penetrant
standards
presenteG
to grain
for
The
accept/
solid
IN100
TFE731-
inspections
_rain
yields
are
presented
combined.
for
being
%
performed
inspectors.
DS
yields
were
(FPI).
and
as overall
castings
inspection
for
individual
Combined
results
each
mold
is
of
inspections
inspection
results
follows:
57
i
i LBi
PRESSURE SIDE
SUCTION SIDE
Flgure 18.
58
Typical MAP-M 247 Task II Exothermically Cast
DS Preliminary Design TFE731-3 Turbine Blades
d__
4
•
,,?
%
L;I ii11,.Ji
11 l
PRESSURE SIDE
i
_
1
.
"Ļ_:'_
_
L.i
_
SUCTION SIDE
L
._;
--
Figure
19.
Typical NASA-TRW-R
Preliminary
Design
Task II Exothermically
Cast
TFE731-3
Turbine
Blades
DS
59
PRESSURE SIDE ....................................................................................
SUCTION SIDE
Figure
60
20.
Typical MAR-M 200+Hf Task II Exothermically
Preliminary
Design TFE731-3
Turbine
Blades
Cast
DS
Figure
21.
PRESSURE
SIDE
SUCTION
StDE
Typical IN 792+Hf Task II Exothermically Cast DS
Preliminary Design TFE731-3 Turbine Blades
61
•
_
l_ °
iii
i
H
_
m
i .
_1
moom
ommo
_
_
Q
_
_
oooo
O
_o
o_o
ooo_
_o_
oom_
ooom
_ooo
om_
_
0
2
_
N
?
mmmm
,_!
_
"
M
_
0
_!_T .¸_
_
T _._--_ .
MAR-M 247- (best)
NASA-TRW-R_
(c)
MAR-M
t
(a)
(b)
(d) IN
_
,4
200+Hf
792+Hf
(poorest)
_i
iI_
Of the three
evaluations,
<iffioult
to improve.
The
the X-ray
results
would
be the most
blades were generally
rejected
during
i
iv.-
X-ray
inclusions--presumably
hafnium
poorest
was
Of
due
the
to high-density
_our
alloys,
the
X-ray
yield
oxides.
from
i_
200
must
llI
two molds
alloydefects_
were cast
material Thewith
blend
out of
any each
surface
and with
thus exothermic
improve yields.
lasta
•
alloy with the highest
hafniu_ content.
considered
conservative
since
no attempt
MAR-M
be
lower
heat
alloy
DS
output
grain
exhibited
of
the
from
i__
Tables
source
_ii:
I
of
I
exothermic
all
molds,
affected.
for
results
XIV.
These
identification
were
found
the master
hafnium
The
hafnium
of
the
nium
was
have
true
lower
of
all
certified
XI
through
of
one
gradients
analytical
level
not
was
original
tip
output
deviations
to
and
heat
made
of castings
are
shown
in
material
analyses
heats.
tended
root
alloys
in the
IN 792+Hf
tables
also
show
the
and certified
chemical
the
Tables
three
analyses
of
pect.
other
these
of
the chemistries
the
The
were
versus
makes
the
analyses
the parts
This
only
variability
Chemical
The
significant
parts
but
material.
XI through
master heat
heats.
_
was
analyses.
the master
initial
tolerance
molds.
NO
the
structure
a greater
Chemical
7
than
FPI results
was made
to
XIV
blade
also
apparently
at
the
since
tips
except
IN
include
of
mold
lower
the
of
hafnium
blade
were
heats,
than
content
each
chemistries
contents
alloys
hafnium
from
technique,
expected
the
in the
than
this
the
blades
which
alloy
analyses
cast
that
the master
792+Hf,
conslstentl¥
these
except
of
sus-
of
the
in Task
II.
sensitivity
higher
(cast
root
hafup)
demonstrated.
63
!
++'+'_++_L"_"_
_+¸' +.....
_ r.
l=l
I
I
I
I
i
I
I
I
I
I
I
I
I
I
I
I
I
I
I
)
I
I
l
I
l
l
l
0
_
O_
0
,'<
,,.I
+-4
+,-I
o
o
o
o
o
o
0
0
O
_
v
_
v
_I
+-(
o
,90
o
._--
• .,,
._+
_, --
_
° "
+'-0
.+.I
E_
0
_I
+-'
+
,o
,
_.
O
_
_.
+0 ..+: +_ ,_
0 + ++,.,+
o o o+ '°"o _ __°
°+°+
I°
_ o
_--
,.
,,,
e,-I
w.l
_
"
++ _+
e,,l
,-4
++,
,, o
o
,.. ,o
•
_
+
G
_
G
,o
+,
":
_.
_ _
"..I_
e-_
°
P+
+"
_
' <_
_.1
oo!+.
_
++,+
_
+o---_
_ ++
u_
,,
<_
o
,G o
o o
,"+
,",
,..,
_
"
.-.,
_
Ip
I
,m
l,_
...,
I
1
A
I
J
,-3
M
64
+
,..+
_
,"
,-,
"+,
L_
,d
V,
66
Ii
Meohonlcal
re+t°
+
i.
??ests on Specimens
blades
were
selected
from
Machined
.f,
rom Blades..
A number
of
the first
eigh_
Task
II molds
and
divided
heat
into
(summarized
_
two
g_oups
in Table
for
VIII)
|lear Treatment
At
used
t_eatment.
were
Solution
2
hours,
Heat
Treatment
Test
Bars
were
machined
to provide
t
groups.
with-
longitudinal
orientation
machined
(grain-growth
airfoil
sections
of
the
from
the
root
sections.
at
room
temperature
and
conducted
at 1033"K
on
(i400°F).
Stress-rupture
specimens
(I800°F+).
tests
The
were
results
are
from
separ-
direction)
longitudinal
conducted
used
blades
The
specimens
1255°K
configuration
cases.
from
in all
ll44°K
20 hours.
from
treatment
I144°K
at
machined
specimens
castings
Tensile
and
and
the
tests
were
at
1033°K
+.
(1400°F)
presented
in
Tables
+XV
results
presented
in
XX.
The
"
for
aging
were
transverse
Table
(1600°F)
and
il,
specimens
through
(1800°F),
in Figure
ate
and
1255°K
I, as shown
heat
fer
20 hour_.
to the mlni-bar
transverse
•
at
aging
conforming
both
were
by
specimens
in Task
_
(2230°F)
2 hours, followed
by 1494°K
a simulated
aluminSolution
treated
at
(2230"F)
for
ide coating
thermal
cycle of 5 hours st
B:
i,:
=+,
at 14940K
followed
for
heat_ treatments
follows:
treated
(1600°F)
i_;
;.-
as
The
_'i
room-temperature
XV.
As
anticipated,
tensile
the
significantly
lower
ing
cycle
significantly
affect
the
alloys
IN
The
not
except
792+H£.
are
transverse-orientation
were
did
than
test
the longitudinal
the
coating
strengths
values.
The
coat-
strengths
of
cycle
generally
was
any
of
:
-
O0000001-TSGO:
D
, ,4
TABLE XV.
TASK II
(Tant
a_ec_.n_ns
llm_nary deB_gn
casting Group.
ROOH_TEMpE_t_TURE
TENSILE
machined
f_om exothe_m_eally
TFE?21-2
t_rblne blades,
1 and 2.)
T_ST
Task
RESULTS
east
D$ preII blade
_ ;
U1timate
a
Spect_n
number
II
oEaL_
orle_tatlun
I
b
Heat
_reatment
te_s£1e
strength,
MPa (ksL)
(a) M^R-_
I
O.2-Percent
yleld.strength,
MPa (ksl}
Elongation,
percent
Roductlon
of area,
percel_t
247
62-4
62-9
62-4
62-9
L
L
T
T
A.
A
A
A
984
944
756
?67
(1433
(131)
(i00}
(In}
_53
872
747
756
(1243
(1263
(1083
(1103
6.4
6,2
4.5
9.3
16.4
12.3
16.1
16.4
62-14
62-16
62-14
62-10
L
L
T
T
B
B
B
B
574
9?2
716
790
(1413
_141)
(104}
(115)
714
830
712
738
(1183
(120)
(1033
(1073
6.7
6.0
8.%
8.9
14.6
13.5
18.8
37.9
(b}
_SA-TRW-R
66-2
66-8
66-2
66-8
L
L
T
T
A
A
A
A
994
970
763
783
(1443
(1413
(Iii)
(1143
860
834
756
763
(124)
(121)
(110}
(1113
5.6
6.9
1.8
1.4
13.1
11.8
4.0
7.1
66-9
66-18
66-9
66-18
L
L
T
T
B
B
B
B
972
973
749
727
(1413
(141)
(109)
(1063
829
828
712
711
(120)
(120)
(I03}
(1033
6.5
6.8
6.7
3.9
9,7
10.9
18.2
10.2
i.
(c) MAR-H
20O+Hf
65-3
65-6
65-3
65-6
L
L
T
T
A
A
A
A
772
988
?72
056
(1123
(143}
(112)
(1243
771
055
770
022
(1123
(1243
(112)
(i19)
5.8
7.8
9.1
2.9
15.9
17.2
14.0
11.8
65-13
65-16
65-13
65-16
L
L
T
T
B
_
B
B
923
968
781
828
(1343
(1403
(113)
(1203
812
822
779
757
(118)
(1193
(1133
(1103
8.?
7.3
9.0
11,7
16.4
15.7
19.0
26.5
(d} IH 792+Hf
64-7
64-11
64-?
64-11
L
L
T
T
A
A
A
A
1109
1107
822
790
(1613
(161)
(I19)
(116}
91B
919
781
7?8
(1333
(1333
(I13)
(1123
7.0
5.6
5.2
3.5
19.5
11.0
12.3
6.5
64-17
72-19
64-17
72-19
L
L
T
T
6
_
B
_
1056
1019
767
866
(153)
(1403
(111)
(126)
853
828
741
735
(124}
(120)
(10B)
(i07_
6°?
4.6
4.3
I0.4
13,8
13.5
13.7
21.0
aL = Longltudlnal
bA = 1494°K
{2230°F)
B = 1494°K (2230°F)
for 20 hours
T = Transverse
for 2 hoots and I144"M
(1600°F) for 20 hours
for 2 hours, 1255"K
(18000F} |¢.r 5 hOUES, and
1144°K
(1600°_ ')
69
TkBLE
.-
_VI.
1033"K
'CASK _
(Test epenlmene
machined
design TFE731-3 turbine
Grou_s
I and 2.)
(L400°F}
NO.
I
Grain
a
I orientation
Heat
-
•-
RESULTS
_I
,F
tensile
Ultimate
strength,
b
t_eatment
0.2-Pc=cent
'ield
strength,
;_a-(_sl)
Ca) MAH-_
_
TEST
from exothe=mlcally
cast DS p_elim£nary
blades, Task %Z blade c_ting
,
Specimen
TEHSILE
_a
ELongation,
(kei)
Redhction
of area,
percent
percent
247
FI
62-8
62-2
62.8
L
T
T
A
A
k
997
816
732
(145)
11191
11061
814
713
676
(118)
11031
(981
8.3
5.5
6.7
15.5
22.2
14.8
62-13
62-15
62-13
62-15
L
L
T
T
g
B
B
B
1091
952
758
741
(1SS)
(1381
11101
(108)
SS6
773
683
663
1129)
(1121
1991
(96)
4.4
7.0
10.7
3.8
15.3
27.3
26.1
16.6
(151)
(161)
(108)
(137)
832
880
684
832
(1211
(128)
(99)
(1211
4.6
12.5
5,5
2.9
21.4
22.8
15.7
13.9
::
I
(b) NASA-TRW-R
....
66-5
7_-II
66-5
71-11
L
L
T
T
A
A
A
A
1042
1109
745
945
66-16
L
E
1085
(1571
914
(133)
4.1
11.i
71-20
66-16
71-20
L
T
T
B
B
a
1071
765
796
(155)
(1111
(1151
894
722
738
(130)
(1051
(1071
9.5
6.4
9.6
26.7
9.3
17.3
i
•
i
(c) MAR-_
i
i
:
i_
'
L
L
T
A
A
A
.
_.
73-10
T
65-15
73-17
65-15
73-17
L
L
T
T
(i631
(1651
(1361
1110)
872
901
790
709
(1271
11_I)
(115)
11031
5.4
7.3
2,9
12.9
14.0
16.4
8.3
29.0
3
S
B
H
1117
1110
809
882
(1621
(163_
(1171
(128)
909
_98
702
760
(132}
(1301
(102)
11101
5.2
6.9
12.6
6.8
13.8
20,9
20.9
18.7
L
L
T
T
A
A
A
A
1111
1067
897
871
11611
(1551
(130)
(1271
840
?79
683
621
11221
(1131
(99)
(90)
11.0
14.4
8.0
9.8
33.5
28.0
14.9
15.5
64-15
L
B
2096
(1591
800
(i16}
13.0
28.5
72-12
64-15
L
T
B
B
1089
740
(158)
1109)
778
644
(1131
(93)
7.7
4.7
18.3
11.9
72-12
T
H
960
(139)
6S7
(1001
5.L
b A = 1494oK
9 = 1494°K
for 20
i•
70
ZH 792+Hf
64-8
72-7
64-8
72-7
a L = LongLtud_naL
_
A
1123
1136
936
761
(d)
[_
;i
65-4
73-10
65-4
200+Hf
(22300F)
(2230"F)
hours
l
14,0
I144°K
(1600°F)
T _ Transverse
foe 2 hours
and I144OK
(1600oF) foe 20 hours
2or 3 hours, 1255aK
(1800"F) for 5 hours, and
!
!
TABLE
XVII.
TASK _X I033°K (1400°F) STRESS-RUPTURE
LONGITUDI_L
GRAIN ORIENTATION
TEST
(Test specimens machined
from exothermloally
preliminary
design TFE7_I-3
turbine blades,
Task II blade casting Groups i and 2.)
5
Specimen
no.
Hour s
to
ruptune
Heat
treatment
I033°K/724
MPa
_
MAR-M
l
ksi)
'_
oaet DS
Tests
247
62-1
62-7
62-12
A
A
B
79.9
12.4
55.7
10.6
14.0
Ii. 7
18.1
19.0
20.2
70-12
B
53.2
i0.0
28.9
9.2
12.1
9.6
11.2
34.7
36.9
26.1
29.4
_R_
200+Hf 6.7
18.2
77.1
12.1
E7.3
E.8
18.1
23.9
21.2
=S
-
Reduct ion
of area,
percent
Elongation,
percent
(1400°F/I05
RESULTS
NASA-TRW-R
:
_'i:f
:
66-4
71-6
66-14
71-14
A
A
B
E
65-2
73-8
65-12
A
A
B
73-13
B
79.1
29.2
34.8
36.4
59.4
I033°K/689
MPa
11.6
(1400°F/100
IN
ksi}
31.2
Tests
792+Hf
p!
/
64-5
A
23.7
9.3
_1.7
72-4
A
31.6
ll.1
25.0
64-14
S
17.8
13.4
40.0
72-10
B
14.5
10.8
33.5
a A -- 1494°K
(2230"F)
for 2 hours,
and
I144°K
B = 14q4°K
(2230°F) for 2 hours, 1255°K
and I144°K
(1600"F) for 20 hours
(1600°F)
(1800°F)
for 20 hours
for 5 hours,
71
TABLE
XVIII.
TASK II I033°K
(1400°F) STRESS-RUPTURE
TRANSVERSE
GRAIN ORIENTATION
TEST
RESULTS
-
Test specimens
siqn,TFE731-3
Specimen
no.
machined from exothsrmically
cast DE preliminary
deturbine blades,
Task II blade casting Groups 1 and 2.)
Reduction
Heat a
Stress t
Hours to
Elongation,
of area,
treatment
MPa (ksi)
rupture
percent
percent
illi
MAR-M
247
i
62--1
A
689
(100)
3.7
3.9
15.1
62-7
A
621
(90)
70.0
4.4
10.9
82-12
B
689
(i00)
6.0
4.4
25.9
70-12
B
621
(90)
2_9.1
13.1
23.9
NASA-TRW-R
86-4
A
689
(i00)
9.9
4.4
22.9
71-6
A
621
(90)
10.2
ii.I
38.2
66-14
B
689
(100)
3.8
4.3
23.1
71-14
B
621
(90)
21.1
8.0
21.4
MAR-M
65-2
A
689
(I00)
5.0
4.6
14.4
73-8
A
621
(90)
579.1
6.7
18.7
65-12
B
689
(I00)
2.6
9.0
24.3
7.3-13
B
621
(90)
83.3
i0.0
18.7
2N
792+Hf
64-5
A
655
(95)
12.4
6.3
26.5
72-4
A
621
(90)
23.4
6.0
9.7
64-14
B
655
(95)
10.3
4.3
10.9
72-10
B
621
(90)
28.1
4.3
13.5
a
A = 1494°K
(2230°F)
20 hours
for
B = 1494"K
(2230"F) for
and I144°K
(1600OF)
72
200+Hf
2 hours
and
I144"K
2 hours, 1255°K
for 20 hours
(1600°F)
(1800"F)
for
for
5 hours,
J
TABLE
XIX.
TASK
II 1255°K
(1800°F)
STRESS-RUPtURE
LONGITUDINAL
GRAIN
ORIENTATION
TEST
(Test specimens
machined
from
exothermically
preliminary
design
TFE731-3
turbine
blades,
blade
casting
Groups
i and 2.)
"4.
•
Specimen
no.
Heat
a
treatment
1255°K/207
=
Hours
to
rupture
MPa
_
(1800°_/30
MAR-M
62-6
70-19
62-10
70-10
A
A
B
B
Elongation,
percent
ksi)
RESULTS
-
cast DS
Task
II
Reduction
of area,
percent
Tests
247
63.7
69.7
61.8
68.1
20.1
18.2
14.1
7.8
49.7
44.0
34.9
21.6
17.1
17.9
14.8
13.0
44.5
45.2
35.9
37.4
14.5
15.5
19.6
18.8
47.0
43.1
49.3
37.4
NASA-TRW-R
66-3
71-i
66-10
71-13
A
A
B
B
49.1
53.6
39.4
39.0
MAR-M
65-I
73-i
65-9
73-11
_
;
A
A
B
B
1255°K/193
58.9
59.7
46.9
73.5
MPa
(1800QF/28
IN
..
64-i
72-1
64-13
72-9
,'
A
A
B
B
a
A
B
= 1494°K
(2230°¥)
for
= 1494°K
(2230°F)
for
and 1144°K
(1600°F)
200+Hf
ksi)
Tests
792+Hf
14.7
36.3
27.3
29.0
16.4
17.6
15.8
15.5
33.6
48.6
38.2
42.7
2 hours
and 1144°K
(1600°F)
for 20 hours
2 hours,
1255°K
(I800°F)
for 5 hours,
for 20 hours
73
I
±
.q
_".
i
,m ,
TABLE
XX.
....
TASK II 1255°K
(i800°F) STRESS-RUPTURE
TRANSVERSE
GRAIN ORIENTATION
TEST
RESULTS
-
(Test specimens machined
from exothermically
cast DS prelimlnary
design TFE731-3
turbine blades, Task II blade casting
Groups i and 2)
_
i
Reduction
:
Specimen
no.
Heat
a
treatment
Stress
MPa (ksi)
MAR-M
'i
Hours to
rupture
Elongation,
percent
o_ area,
percent
247
62-6
70-19
A
A
186
186
(27)
(27)
104.8
136.7
9.4
7.2
18.3
21.6
62_i0
B
186
(27)
118.2
14.1
34.%
70-10
B
186
(27)
101.3
7.8
21.6
NASA-TRW-R
,
i_ _
_:
wl
L,
66-3
A
186
(27)
61.3
1.8
8.3
71-1
A
186
(27)
56.0
8.7
16.2
66-10
B
186
(27)
76.6
5.4
13.1
71-13
B
186
(27)
104.3
9,0
13.3
i
_4AR-M 200+Hf
65-1
A
186
(22)
98.6
4.4
15.5
73-1
65-9
A
B
186
186
(27)
(27)
95.7
Iii.6
16.4
13.6
25.5
15.9
73--11
B
186
(27)
103.6
3.5
12.0
IN 792+Hf
64-1
A
172
(25)
44.7
6.4
13.8
72-1
A
138
(20)
105.3
5.8
12.0
64-13
B
172
(25)
7.9
7.0
15.1
72-9
B
138
(20)
95.0
4.3
10.7
and 1144°K
(1600°F)
a
for 2 hours
and 1144°K
(1600°F) for 20 hours
B = 1494°K (2230°F) for 2 hours, 1255°K
!;:il
_
A = 1494°K
(2230°F)
20 hours
74
(1800°F)
for
for 5 hours,
¥
beneficial
tion.
to
ductility,
O_iginally
with
specimen
particularly
there
seemed
65-3
of
MAR-M
for
a transverse
to
be
in
the
transverse
an
identification
200
of
direcproblem
the
testing
%
appeared
to be
orientation
a longitudinal
one.
Macroetching
inGicated
that
the
identification,
Table
XVI
presents
of
alloys
All
this
the
to
(1400°F)
have
a
the
transverse
lower
than
the
longitudinal.
apparently
had
cycle
at this
no
effect
on
the
specimen
of the 1033°K
test
tensile
The
results.
strength
were
strength
stress-rupture
XVIiI.
The
in
Tables
XVII
and
result_
of
Table
XVII
indicate
weaker
than
the
other
MAE-M
200+Hf
simulated
scatter
of
were
three
or
sig-
coating
ductility
for
significantly
same
strength
the
for
strong
of
was
of
results
distribution
IN 792+Hf
caused
alloys
test
results
rupture
lives
NASA-TRW-R,
reduction
and weakened
given
due
in Table
XVIII
changes
in
this
was
the probfailures
to
lem. in selecting
initial
stress
levels
to yield
i00-hour
test
data.
The
illustrates
the
strongest
MAR-bl
247
in the
transverse
The
and MAR-M
1255°K
in Tables
four
XIX
200+Hf
and
the
data
are
for
data
of
the
four
show
stress
that
alloys
direction.
(1800°F)
alloys,
of
properties
prior
the
IN 792+Hf.
The
of
The
in
testing.
absence
reason
and
level.
this
the
main
a
are pre-
orientation
247,
apparently
a
longitudinal
MAK-M
cycle
the
tests
alloys.
coating
transverse-orientation
wide
that
essentially
The
Review
at
again
simulated
(1400°F)
sented
the
r
temperature.
Resul£s
in
than
is correct.
properties
tensile
rather
of
tensile
peak
and
nificantly
levels
inspection
as presented,
the I033_K
appeared
temperature,
and
specimen
XX.
stress-rupture
Once
again,
and
the other
grain
structure,
available
at
IN
three
heat
this
test
results
are reported
792+Hf
was
weakest
were
very
close
treatment,
point
the
in the
of
in strength.
and
program
mechanical
resulted
75
~.
in a decia_on..to
the
-- _
remainder,
ation
reduce
o_ Task
in subsequent
Blades
o£
evaluation
blades
were
group
@ubjected
Treatment
1483°K
II and
evaluatio_
eliminate
this
stronges_
selected
from
into
to
as
of
of
alloy
IN 792+H£
i
consider-
'_
from
fo_
k
three
divided
B
level
tasks,
the
were
the
the
three
solhtion
alloys
various
summaDized
Task
groups
treatment
in
(2210°F)
(Heat
Treatment
(Heat
Treatment
D_.
for
at
Table
chosen
further
II molds.
These
heat
treatment--one
14940K
VIII),
C),
for
(2230°F)
second
the
third
and
a
(Heat
group
of
at
1505°K
i
(2250°F)
of
_[
the
1255°K
groups
were
(1800°F)
for
(1600°F)
for
tion
test
of blades
5 hours
longitudinal
jected
to
tensile
each
tests
tests
i_
Specimens
o£
IN
-i
Treatment
D,
[1505QK
simulated
coating
of
viously
first
E
!
_
simulated
followed-by
were
two groups
coating
cycle
machined
from
the
group,
at room
with
The
temperature
at 1033=K
(1400°F)
and
1255°K
(1800°E_.
test
only
for
(2250°E)
solution
treatment
tensile
and
stress-rupture
through
XX
for
herein
76
(2300°F}
followed
Heat
by
the
tests
blades
a_e
tests
are
presen-
To facilitate
evaluation
of
selected
longitudinal
data pre-
presented
1533"K
from
sub-
aging]•
in :fables XV
Results ofmachined
stress-rupture
specimens
from
specimens
(1400°F),
selected
and
all
sac-
1033°K
were
cycle
airfoil
and
these Task ZI tests
is
Studies"
(see page 48).
and
of I144°K
were
A discussion
(2375°F)
of
specimens
II molds.
....
each
cycle
aging
of Task
247
treatment,
an
orientation.
XXL through
XXIV.
the tables include
reported
:
:
792+Hf,
the
ted. in Tables
these results,
--
a
heat-treatment
grain
stress-rupture
Results
to
specimens
of
having
and
subjected
solution
20 hours.
Mini-bar
i_
Following
specimens
from
the
of the results of
"Heat
under
Treatment
at 1255°K treated
(1800"F) aton 1519°K
MAR-M
solution
presented
in Table
XXV
,_.
TA_I_
XXZ,
TASK ZX ROOM-TI_MP_RATURE T_NSI|,_
(TQB_ SpOOi_OnQ _Qhlnod
frolflT_,k
hnvin9 hQnt troAtmont notod below.)
A
II
nxothQrmloally
Ultl_tQ
tensile
st_enth,
b
T_ST R_SULTS
DS tQrLlno
_t
0.2-portent
y£old
strength,
_l_d_
_lon_tLon
Reduction
£n arrow
(poo£_un
G_aln
{_o_t
no.
_rionta_ton
t_oatlnont
-_"
?0-3
L
C
1068
(155)
866
(Z26)
5.7
17,0
t
70-16
20-6
C
B
874
9?4
(127)
(141)
764
500
(114)
(I16)
13.4
15.9
24.3
29.2
62-11
B
1002
(145)
847
(123)
13.1
15,3
62-14c
_
9?4
(141)
614
(118)
6,7
14.6
62-16¢
B
972
(141)
630
(120)
6.0
13.5
(148)
890
(129)
8.7
15.7
578
_12_)
_.2
14.4
i
.
i
HAR-M
HPo
(k_£) 247
'
113-12
D
1017
f;_
62-I?
D
1005
(146)
HAR-M-200+Hf
73-_
i.
iJ
L
,.percent
(144)
809
(117)
8.9
11.5
73-6
73-5
C
B
1124
1062
(162)
(154)
885
880
(128)
(128)
10.0
10.4
16.2
19.8
73-7
B
966
(140)
851
(122)
10.6
21,6
65-16¢
65-13c
S
B
568
923
(140)
(134)
822
812
{119{
(i193
7.3
0.7
15._
16,4
73-2
D
995
(145)
872
(127)
13.1
15.5
C
?92
(115)
763
(111)
5.2
14.6
102-13
C
1005
(146)
809
(i17)
9.3
21.0
66-7
B
972
(141)
925
(120)
6.4
14.3
66-19
B
1110
(16_)
927
(155)
6,8
12.2
66-9 c
66-18c
B
B
972
923
(141)
(141)
829
828
(120)
(120)
6.3
6.B
9.7
10.9
66-1
D
851
(123)
?78
(113)
8.9
14,3
66-6
D
872
(127)
785
(114)
8.0
23.0
.'
64-?
L
c
L
B
1109
(161)
918
(133)
7.0
19.5
64-11,
B
1i07
C1611
919
(1231
5,6
ll.u
64-6
D
1118
(162)
918
(132)
5.9
15.5
103-8
D
1191
(171)
913
(132)
6.5
13.9
I
a
L - Longitudinal
T = Transverse
b
B = 1494°K (2230°F)
for _0 hours_
C = 1483vK (2210_F)
for
0 hours
D = 1505_K (22506F|
for 20 hours
c
D_ta
prevlously
for 2 hours,
plus
1255°K
(1800°F)
for 5 hours,
and I144°K
(1600cF)
for 2 hours,
plus
_255°M
(1900°F)
for 5 hours,
and
I144°K
(1600°F)
£or
plus
1255°K
(1800°F)
£or
and
1144°_
(1690°F}
reported
_ ho_rs,
lh Tables
XV through
XX
5 ho_[S_
i
I
percent.
989
j
_
(ksi)
C
66-12
:
HPa
[
q'ABL_
XXlI,
TASK
1013°K
II
(1400°]
.')
T_NSIL_
(To_t
_u_lmoJiB
machln_d
from T_sk
II ¢_xoI:he_mlcally
h_vi:_g huat
tr_atn_Qi_t not_d
beluw.|
IIoat
no_
o_ientation
_r_tm_
_
east
Jtr_ngth_
st_ngth_
_a
]_
(ksl_
MA_-_
l_i_l_
li_-_0
TEST
DS
(1_i_
(120|
li_-1
_
10_
(1_6_
0_9
il_-i_
D
8_
(1_7_
7_
6_-1_
_
10_1
(158_
6_-15
_
85_
D
D
6_?
_._
1_
19_0
(1_6_
_
1_._
(li0_
5°9
1_._
_86
(1_9_
_._
1_.1
(i_8_
_
(11_
_.0
_._
_8
(1_
_
(108_
1_.9
_
931
(135)
779
(i13)
7.3
13.2
I
6.0
14.7
I
broken
5.2
6.1
prior
J
5.2
15.8
MAR-M
'
65-14
104-15
104-6
C
65-15
_r_aa
_?
_
_6
104-5
in
p_
(1_7_
(i51|
_
bl..Jes
_lonqation_
101i
_0_
)0_10
tL|rbin_
(ksi_
¢
_
113--5
P_.Sl;LTS
200+Hf
C
iiii
(161)
094
(130)
B
C
B
1159
1105
(168)
(160)
959
902
(139}
{131)
(Specimen
B
1117
(163)
909
(132)
to
ii.0
17.6
testing)
65-17
D
933
(135)
795
(115)
8.9
I?.0
65-19
73-17
D
B
1115
]120
(162)
(163)
878
898
(127)
(130)
9.6
6.9
17.9
20.9
e i
I
NASA-TRW-R
102-5
L
C
1118
(162)
909
(132)
6.2
10.7
102-12
C
112!
(163)
807
(129)
5.2
12.2
71-4
B
1144
(166)
934
{135)
8.1
21.6
102-7
B
_017
(148)
856
(124|
4.8
12.2
66-16
o
B
1085
(157)
914
(133)
4.1
11.i
71-20
C
B
1057
(155)
894
(130)
9.5
26.?
71-3
D
1193
(173)
911
(132)
6.5
15.1
102-9
D
1160
(168)
957
(136]
4.4
]0.9
IN
B
I05_
(15_}
053
(124)
8.?
13.8
B
1019
(148)
828
(120)
4.6
11.5
64-16
D
1131
(164)
814
(118)
14.7
35.9
103-I
D
1126
(163}
767
(Iii)
10.8
25.5
C
72-19
¢
L
&
L
T
- Longitudinal
= Transverse
b
B
=
1494°K
for _0
(2230°F)
hours
for
2 hours,
plus
1255°K
(1800°F)
for
5
hours,
and
i144°K
(1600°F)
C
=
1485uK
for
28
(22106F)
hours.
for
2 hours,
plus
1255°K
(1800°F)
for
5 hours,
and
1144°K
(1600°F)
XV
through
XX.
c
78
64-17
792+Hf
Data
previously
reported
in Tables
_I
d
V
%
TABLE
XXIII,
TASK
II
1033°K
(1400°F)
STRESS-RUPTURE
(LongltudlNal
grain
orlsntatlon
tost
machined
from
Task
II exothermlcally
turbine
blades
having
heat
trea_4_el,t
below,)
I033"K/724
Spoelmon
Heat
t_o.
treatment
MPa
(1400°F/I05
a
C
C
B
B
B
B
D
D
b
b
b
b
Tests
E1ongatlon,
percent
]
Red,orlon
peroent
247
86.1
?2.6
75.6
11,1
55.7
53.2
127.1
80.6
C
C
8
8
B
B
D
D
_
Of area,
MAR-M
104-4
104-8
104-3
104-14
65-12
73-13
104-2
104-17
RESULTS
speclmon_
cast
DS
noted
to
rupture
HOURS
MAR-M
113-17
113-19
i13-6
62-18
62-12
70-12
113-15
62-20
ksi)
TEST
10.5
7.8
12.1
14.4
11.7
i0.0
9.4
10.2
24.5
25.0
24.8
28.9
20.2
28.9
24.3
21.8
23°4
9.8
9.6
9.4
8.8
Ii.6
13.5
10.5
36.9
24.8
21.0
22.3
21.2
31.2
24.1
24.5
11.5
8°7
9.9
II.5
9.6
II.2
9.2
9.7
31_3
29.6
26oi
29.1
26.1
29.4
25.2
25.3
200+Hf
67.8
61.3
107.?
140.2
87.3
59.4
171.2
86.1
NASA-TRW-R
71-15
102-8
6_-II
71-5
66-14
71-14
66-13
102-11
C
C
B
B
B
B
D
D
b
b
I
3?.5
87.6
38.3
42,1
34.8
36.4
58.5
86.2
I033°K/669
: _-
MPa
IN
(1400aF/100
ksi)
Tests
792+Hf
w
64-14
64-10
103-15
72-10 b
:
,.
b
I
B
17.8
13.4
40.0
I
D
D
,
81.6
17.2
14.5
I0.0
7.3
10.8
21.9
25.4
33.5
a B = 1494OK
(2230"F) for
5 hours, and 1144OK
C m 1483OK
(2210oF)
for
5 hours, and i144°K
D = 1505°K
(2250°F) for
5 hou_s, and I144"K
2 hours,
(1600OF)
2 hours,
(1600OF)
2 hours,
(1600°F)
plus 1255°K
for 20 hours
plus 1255OK
for 20 hours
plus 1255oK
for 20 hoers
(1800oF)
fo_
(1800°F)
for
(18000F)
for
b
-
-
Data
previously
reported
in Tables
XV through
XX.
79
¥
i
(Longltu_inal
gz_n
ozlertation
t_st
machlne._
_¢om Task ZZ exothermloally
tu_Sine
bla,'-os
having
_est
treatment
1255"K/207
.
MP_
(}800°F/30
ksl)
specimens
_est
DS
no_ed be_ov,., _
5pecimen
no.
He_t a
treatment
,
ReduetiorL
of area,
percent
Elongation,
percent
',I
MAR-H
i_3-3
I
113-7
113-11 113-18
62-6
b !
70-19 b
I
C
C
B
B
B
B
75.1
53.7
56.0
6_._
6L%
68.1
113-4
113-2
1
D
D
98.5
85._
MRR_M
C
51.0
i04--1._
C
51.0
104-1
104-11
65-9
76 .5
53.5
46.9
73.5
82.0
59.0
b
79-11 b
B
104-10
104-12
D
D
35.5
22.3
15.5
9.9
14.I
7,8
42.1
41.6
39.9
26.8
34.9
21.6
40.0
22.0
,H
53.2
30.3
18.5
21.8
20.5
21.3
19.6
18.8
15.5
17.8
40.3
39.4
26 .8
46.6
49,3
37.4
41.6
37.8
200+Hf
104-9
B
B
B
247
_
NASA-TRW-R
182-15
102-19
102-10
104-14
66-10
71-13
102-1
102-18
C
C
B
B
B
B
D
D
b
b
1255°K/193
MPa
ZN
I
64-13
72-9
64-2
103-18
b
b
20.9
16.1
21.1
16.7
14.8
13.0
22.0
18.7
64.5
40.7
63.8
58.1
39.4
39.0
65.3
63.7
B
B
D
D
(1800oF/28
I
a B = 14"_°K
(2230°F) for 2 hours,
5 hours, an_ I144°K
(16000_ ')
C m 1483VK
'22_0°F) fo_ 2. hours,
5 hours, _ _d I_4"$°K (1600°F)
D m _505°K
(2"5!,"?) _or 2. hours,
5 hours, anC I_44_K
(16OO°F)
ksi) Testa
15.8
15.5
18.3
16.8
38.2
'42.7
42.4
41.6
plaa 1255°K
(1800"F)
f.o= 20 hours
pl_
1255°K
(_800°F)
for 2.0 hours
ph13 1255°K
(1800OF}
for 20 hours
b
Data
80
_revlousl7
r_[Jo_..'_din
42.1
41.5
47.4
43.7
"_5.9
37.4
35.1
42.8
792+Hf
27.3
29.0
36.5
38.6
Tables
XV
through
i
Testa
r
Hours
to
rupture
I
XX.
for
fOr
for
•
\
_i
;
_i
+
TABLE XXV.
TASK Xl 1255°K
(1800 _P) STRESS-RUPtURE
T_ST RESULTS
(Test
specimens
machined
from Task II exothermically
cast DS Mar-M 247
turbine blades solution-treated
at 2 temperatures.
Solution
treatment
for 2 hours, follewed
by inert _as quenching,
then 1255OK
(1800 °F) for
5 houris, and I144_K
(1600°P_ for 20 hours.)
Specimen
no.
l_+
Grain
Orientationa
Stres_
MPa (ksi)
1519OK
2275°F)
Hoursto
rupture
solution
Elongation,
perce_t
Reduction
of
area, percent
treatment
-- +
70-2
L
207
(30)
12'5.0
28.5
57.4
--
70-9
L
207
(30)
105.7
27.7
49.7
70-14
L
207
(30)
79.9
24.6
44.6
70-20
L
207
(30)
116.0
26.+9
50.9
70-2T
T
186
(27)
173.0
21.0
37.9
70-9T
T
186
(27)
135.7
5.9
11.3
70-14T
T
186
(27)
97.3
6.8
12.5
70-20T
T
i_6
(27) ! 162.3
9.6
15.4
1533°K
(2300°F)
70-6
L
207
(30)
79.7
4.9
9._
70-7
5
207
(30)
106.7
24.2
55.8
_0-ii
70-17
L
L
207
207
(30)
(30)
126.8
83.5
23.4
24.6
44.9
45.2
70-6T
T
186
(27)
202.3
14.5
34.2
70-7T
T
186
(27)
173.3
13.9 ........
29.5
70-11T
T
186
(27)
147.5
6.5
13.9
70-17T
T
186
(27)
158.5
5.9
10.5
---<
_-.
[i
....
a
solution
treatment
j
_
L = Longitudinal
T = Transverse
81
r4,:%_
i
o++
2.-- Tests on Specimens
Machined
molds cast for Ta_k II cyellc-ruptu_e
tangular
slabs
slabs-were
"-
inches
_+
inert
for
mold,
15.24-cm
by
solution
De4
3
inches
high,
by
temperature
o_s
aging
Both
smooth
and
the
slabs
with
_
and
45-degree
i
a standard
•
at
I146°K
notched
Initial
cvcllc-rupture
iongitudlnal-grain
specimens
configured
cyclic
alloys.
t+stlng
Using
unload
cycle,
as
shown
723.9
MPa
XXVII,
.
cycle
at 1255°K
(1600°F)
for
gage
were
smooth
test
diameter
in Figure
tests @t
machined
smooth
O
test
(105
ksi).
indicated
that
_pec_mens
in Table
slmilar
Results
and
by
(1800"F)
from
transverse
specimens
3.175-cm
_he notched
(0.178-inch)
had.+
(1.25-
specimens
and were
22.
I033°K
(1400°F) on smooth,
from slabs indicated
that
were
tested
life of the
and 10-second
at
progresively
XXVI.
Based on these results,
specimens
at peak stresses
of
of
these
tests,
stresses
were
not
the
a
machined
longitudinal,
The
using
20 hours.
specimens
having
(6
followed
as
shown
sufficiently
in Table
high
to
produce
the-rupture
desired testing
100-hourwasfailure.
Therefore,
of
the cyclic
accomplished
at 758 the
MPa balance
(110 ksi)
+"
maximum
stress
(].05 ksl)
for
for
the
the
longitudlnal-grain
speclmens
45-degree-arain-orJented
and
724
MPa
specimens.
+
The
•
results
on
specimens
and
graphically
82
of
the cyclic-rupture
machined
from
compared
slabs
in Figure
are
23.
testing
at 1033°K
(1400°F)
tabulated
in
TaDle
XXVIII
the
testing
The
bulk
of
4
k
thick.
treated
did not degrade
the stress-rupture
a 10-second
load, 90-second
hold,
higher Stresses
as shown
_hree tests were run on
_!_
heat
inch) gage length as shown in Figure
13).
had a nominal
notch diameter
of 0.452
cm
i_
_
were
These
1.27-cm
coating
a_raln'orierutatlons."
otherwise
?
and
alloy.
hours
test
(0.25-inch)
per
eight slab ....
for 6 rec-
for+2
specimens
!
F_
+
and
1494°K_(2230_F)
separate
0.625-cm
cast
wide
inch),
a simmlated
and
i
2 molds
7.62-cm
0.5
of
+. I
•
auenchlng,
5 hours
with
from Slabs.
The
te_tlng_provlded
_'
k
5
I
0.95
(0.375)
I
3.81 _,7.62 ,
(-1.51..,,._ 2:46
0.508
(0.97)
'-I
0.95
- 17 UNC
(0.375)
(0.172)
0.452
0.317R
(0,251)
0.49S
(0.195)
2.46
(0.97)
0.636
(0.251)
NOTCH ROOT
RADIUS
0.0'10
(0.006)
DIMENSIONS
IN CM
(INCHES)
Figure 22.
'-
Cycllc Rupture SpeCimen
83
¥
|n
!'
I
_TABLE
XXVI.
!..
!_:"
TASK I!
1033°K
AT PROGR_SSIVEL_
(1400°?) CYCLIC_RuPTURE
HIGHER• STRESSE_.
I'
[Smooth,
longitudinal
grain orientation
specimens
maehined
from exothermically
slabs.
Prior to machining,
slabs were
treated at 1494°K
(223_°F)
for 2 hours
i'_
5.hours,
by
inert
and
gas
TEST
RESULTS
tes_
cast DS
solution£ollowed
1144°K
(1600°F)
20 hours.]..
quenching,
1255TKfor(1800_F)
for
!_k
Hours at
test
the indicated
stresses
m,
655 MPa
Allo_
Mar-M 147_
(Specimen
105)
(95 ksi)
(i00 ksi)
30_ .............
i00
i-
i!
!
Mar-M
200+Hf
_.
(Specimen
I.
NASA-TRW-R
i
(Specimen
TABLE
XXVII.
690-MPa
726
MPa
Total
(105 ksi)
67.4
hours
467.4
473.2
300
100
73.2
300
i00
Failed
97)
101)
on
400.0
loading
TASK II I033°K
CYCLIC-RUPTURE
(1400°F),
724 MPa
TEST RESULTS
(105 ksi)
[Smooth,
longitudinal
grain orientation
test
specimens
machined
from exothermically
cast DS
slabs.
Prior to machining,
slabs were solutiontreated at 1494°K
(2230°F) for 2 hours followed
by inert gas quenching,
1255°K
(1800°F)
for
5 hours,
and 1144°K
(1600°F) for 20 hours.]
Alloy
Hours
Cycle s
182.8
5678
MAR-M 200+Hf
(Specimen
98)
185.0
6046
:_SA-TRW-R
(Specimen
158.2
5285
MAR-M 247
(Specimen
84
106)
102)
k
TABLE
XXVIII.
_ASK II,
1033"E
(1400eF)
TBR_E GRAIN ORIENTATIONS
(TeSt
spoci_ens
machLnad
slabs
wer_
solutionrt_ated
quel_chlng,
1255"K
(18000F)
r_
:_,
from
at
for
!_i!
_
_ii
\''_.
_
_.
__
•
,'
Specl_en
Type
Qf
HOurs
14Pa (ksi')
tG
Prior
followed
for
20
FOR
to machining,
by _nert
qas
hou¢=.
Cycles
to
E1ongatlon,
Reduction
of are_,
f&llu_a
failure
perc_t
p_rcent
L
L
L
L
L
L
Smooth
Smooth
Smooth
Smooth
Smooth
Notched
(K_-l.8)
:758
758
1758
:758
758
758
(110)
(110)
(1_0)
(Ii0)
(110)
(110)
09_9
89.8
97.6
216.7
122.?
187_0
2989
2979
3227
?592
3915
6217
?.3
11.0
9.2
6.0
8.7.
11.6
12.9
11.4
10.1
II.5
52
55
56
L
L
L
Notched
Notched
Notched
(K_"1,8)
(K_-I.8)
(K_-I,8|
1758
!758
,758
(110)
(110)
(110)
249.2
234.0
207,9
8351
7621
6967
-
65
66
67
T
T
T
Smooth
Smooth
Notched
(K -I.6)
724
?24
724
(105)
(105)
(105)
93.1
57,2
229.9
3045
1891
71_3
4.0
4.6
8.1
8.5
80
T
Notched
72_
(105)
231.8
7514
57
45o
_ooth
?24 (109)
62.4
2023
5.5
13.9
50
45 _
Smooth
724
(105)
110,0
3496
3.4
11.7
59
60
45 _
45"
724
724
(105)
(105)
87.9
112.1
2?92
3633
-
RAR-M
200+Nf
Emoo_h
758
(I10)
180.3
5065
8.0
10.6
Smooth
Smooth
758
750
(110)
(110)
187,I
185,4
5249
6074
?.0
?.1
E.?
9.2
Smoo_h
Smooth
Smooth
724
724
758
(i05)
(109)
(i10)
86.4
105,8
266,3
2900
3487
0726
4.3
2,9..6,6
8.5
7.2
9.1
NOtched
NotchEd
_
sp_imen
Maxl_u_
stress,
RESULTS
50
53
54I07
49
51
(K_-I. 8)
(K_:I. 8)
(K_'1.8)
i
1
L
5
6
b
L
1O
132
|5 e
45"
L
1:
46"
Notched
(K_1.0)
724
(108)
108,0
3327
12
65 _
Notched
(K_:1.6)
724
(105;
217.7
7051
a
I"
I Ozlentatio_
TEST
exothe_icell-y
cast
D8 slabs.
1494°K
(2230°F)
fox
2 hours
hours,
and
1_44°K
(160O'F)
i
.
L:
" "
___I_
CYCLIC_RUPTURE
I
L • Longitudinal
T m T_a_sve_se
85
I
86
i¸
I
,_
_
!
_ _,i
was Cone o_ the MAB-M
productioo
backgrollnd
and
a
previous
candidate
testing
present:
exist.
data
resulted
mate_gal.
A
to
data
was
attachment
_
L..
_ogram
24? and NASA-TRW-R
alloys,
as an oxtensive
exists for t_e DS cast MAR-M
200+Hf alloy,
provide
_egion
at
of
the
various
basic
!!_
blade
orientations
drawn
from
all
the
longitudinal
transverse
orientations.
in
All
three
alloys
_atique
uhe final
thermal-fatigue
tests.
four
coating
uncoated
,(bare),
equivalent
to
20
*A proprietary
Corporation;
and
in- the
45-
alloy
were
eight
Task-If
molds
for
of each
alloy
were
hours.
The
remaining
but
subjected
E
L
_
solution
for
that
_
orien-
strengthened
of
were
used
aluminide
Orangeburg,
_I
three
no
blades
{1800°F)
88
_
were:
revealed
Eight
at 1255"K
for
testing
200+Hf
tests.
Following
blades
(1600aF)
MAR-M
notch
ale
orientation.
from
(2230°F),
were
stresses
in
notch-weakened
(d)
high
cyclic
was
_
for
the
each
use
in conducting
treatment
coated
5 hours,
with
then
four
at
1494°K
RT-21*
alum-
aged
blades
at I144_K
were
to a heat-treatment
coated
coating
applied
New York.
blades.
by
k
.,
firtree-
the
NASA-TRW-R
The
limited
testing
of the
problems
with this alloy.
the
stress-concentrations
(b)
(c)
a_
cyclic_rupture
of
where
where
of IN 792+Hf
the
design
notch-strengthened
selected
_"
in
MAE-M
247.was
tations.
Thermal
inide
useful
of
(a)
deg_e_
•
purpose
_u_blne
The 'major conclusions
i
!_
_
in elimination
J
In
l_ft
process
addition,
the Chromalloy
a
d
mold
of
baseline
the
DS
equiaxed
cast
£or comparison
on
initial• 1000-cycle
Illinols
bare
Inshitute
and
coated
ducted
in
fluidized
between
308°K
nately
held
Only
one
A
blades
with
ature
(a)
of
beds
and
crack
1228°K
was
found
alloys.
The
a
afte_
the
The
hot
alter-
1000-cycle
summary
of
crack' had
were
the
temperature
- First
blades
completion•_f
highest
Bare
the
beds.
the
247
con-
cold
of
MAR-M
was
and
temperatures
is as follows:
blades
by
(IITRI)
test
cycling
(L750°F).
of
conducted
Institute
permitted
in each
was
Researcl%
was
was
A
four
test
test
cycle
which
all
wh£cn
1000-cycle
equipment.
test
o_ +Technology
3 minutes
second
(I_50°F),
thermal-fatigue
blades
(95°F)
for
test.
test
was cast
to provide
a
characterlstiGs
with
castings.
An
the
MAR-M
247 blades
o£ thermal-fatigue
then
performed
308°K
the_ results
on
(95°F)
the
and
1283°K
attainable
of
this
on
higher
same
the
temper-
.....
crack
grown
was
observed
to 0.076
cm
after
(0.030
500+cycles.
inch)
at
The
test
com-
cycles.
The
at
com-
pletion.
(b)
:
Coated
- No
MAR-M
200+Hf
cracks
were
observed.
crack
was
observed
Bar.____ee
- First
after
200
±
crack
had
grown
to 0.076
cm
(0.030
had
bee_
inch)
test
pletion.
;
Coated
- The
pressure
•
(95°F)
side
and
first
crack
after
1228°K
I000
cycles
(1750°F)
test.
observed
of
the
This
on the blade
earlier
crack
had
308°K
grown
89
L
.....
_
,
..
ik
_
to 0.508
+
test
cm
[1283°]<
observed_
of
(0.200
after
(I850°F)].
on
the
t4_e second
(_0.03 inch)
inch)
blade
test.
at
A
cycles
second
suct_en
This
test
300
coating
side,
crack
oK the
second
crack
after+_500
bad
grown
"I
was
cycles
to
0.076
at
tes:
_
cm
completion.
(o) N_ASA-T_W-_
__are - One_very
tight
crack
was
observed
COm-
.L
pletion.
Coate__...__dd
-. No cracks
_
i_[l
(d)
IN 792+Hf
-
;
had
"_
A crack
grown
Except
at
the
for
of
thermal
_
blade
that
Cal
cal
photograph
i_ /
after
testing.
-
inch)
crack
at test
completion.
the coating
cracks
were
intersection,
which
is
of
observed
section
that
should
sole
exception
was
the
airfoil
cracks.
de_eiopea
Phe
a
generate
coated
Figure
located
maximum
MAR-M
200+Hf
24 presents
indicated
by
the
summ_ry
above,
the
thermal
results
show
to discriminate
between
the
four
further
evaluate
24_,
used
additional
tests
equiaxed
and two
were
conducted
at IITRI.
Each
te_t
DS cast MAR-M
247 blades of identical
Testing
of
two
two
!
(1850°¥)
the hot
31L°K
C
turee.
_+2_
90
+-
the
thermal-fatigue
consisted
(100°F),
_ollowed
and 311°K
(100°_).
and cold beds three
i
1000
before
between
1000
cycling
of
122_°K
cycles
The blades were alternately
minutes
each to stabilize
To
MAR-M
(1750°F)
between
...........
and
alloys.
c_aracter_stics
cycles
by another
blades
a typi-
MAR-M
little
247
sharp
coated
and
'.......
50 cycles.
and
=; ,+
Ni_.: ....
platform
The
of
(0.070
were
all
after
bare
design.
-
blade,
stresses.
As
,_
i_ ?
one
cm
thin,to-thick
'-
--
observed
cracks
trailing-edge
transition
was
to. 0.178
Coate__d -- No
:-
observed.
"
Bare_
were
1283"K
held in
tempera-
_
3
rJ
i
i̧•_
I_
.:
i
COATED
UNCOATED
(e)
AS RECEWED
................................
:
e,
•
.
r
,..
COATED
(b)
Figure
24.
UNCOA r_D
THERMALLY
CYCLEO
"',_.
Surface
Appearance
of DS MAR-M
247 Prelil,;_gary
T_E?31-3
Turbine
Blades
As-Received
and Aft.'r
Thermal
Cycles
Between
308°K
and 1228"K
(95=F
1751°F),
and
1000 Thermal
eycles
Between
308=_
1283°K
(95°F
and 1850°F).
(Mag.=
IX)
Des_'gn
10e0
_nd
aod
9_
_.....
_
"''
'ooooooo
_
No
cracking
was
observed
on
any
blaae
I':
c']c'les,
while
the-DS
cast. blade;_
not.
cycles.
The two
equia_..ed
blade_ did
crackea
|i
one equiaxed
blade after
25 cjcles
3£I°K
(100°F)
thermal
cycling,
and
other
after
blades
was
300
cycles.
Crack
as
shown
it:Table
XI:IX.
CRACK
PROPAGATION
F Number
_
the
'' '"
A
cr_cK the
,_as se.':end
_,bservedi000
in
duL'in0
of the
a crack
propagation
X'(IX:
--
a_ter
1283°K, (1850°F)
was observed
in
in
the
equiaxed
and
the
grain
.......
?[N THE
EQUIAXED
-.....crack
• Ave_sge
GRAIN
length,
cm
(inch)
[of C_cle.s
25
Blade
-
50
-
-
0.05
(0.02)
75
-
-
0_08
(0.09)
l_q
-
-
0.08
(0.05)
200
-
-
0.18
_0.07)
300
0.08
(0.03)
0.20
(0.08)
400
0.i0
(0.04)
0.20
(0.08)
500
0.10
(0.04)
0.20
(0.08)
700
0.18
(0.07)
0.20
(0.08)
0.20
(0_08) ____
0.20
(0.08 h
,i000
....
Figure
o._ the
the
25
2000
pl:esel;ts the
cycles
of
equiaxed
blades.
Due
the
to
only
a
that
on
this
based
fatigue
resistant
_c
tests
were
four
testing,
fact
geometry,
_O.--I-4"----
BLADES
that
crude
tested
and
crack
the
than
equiaxed
modulus
performed
testing.
in
Figure
DS
cast
is
blades
completion
the
crack_
a function
of
in
blade
can
be
_eached--
were
more
thermal-
blades.
Dynamic
triplicate
after
26 shows
conc1_sion
testing
the
blades
location
qualitative
Blade No. 16
0.05---(0.02)
on
modulus
test
92
/
of
elasticity
specimens
machined
_
........
q
.....
i
•
¥
BLADE 140-14
BLADE 138-19
EQUIAXED BLADES (M,_,G.:2X)
'
BLADE 14
BLADE 16
DS BLADES (MAG.: 2X)
FLqure
'
\
25,
Appearance of Equtaxed and DS MAR-_ 247 TFE73Z Turbine
BZades a_:te¢ Z000 Thermal CycZes beP.ween 31].°K and
1228=K (100=F ax=d 17500L'_)and i000 TherP._! Cy_!_.
Between 311"K and 1283°K (100=F and 18500F)
93
%
i _¸
_.
m
(a) BLADE 14
(!VIAG.: 25X)
--
--<
,_f._/ _:-
.
(hi BLADE 16
Figure
_.
26.
Appearance
of Thermal-Fatlgue
Near Root of Eqlilaxed MAR-M
after i000 Cycles at 1283"K
, ......,.
(MAG,:
25X)
CracKs
at Trailzng
Edge
247 Blade Nos. ]._ and 16
(1850°F)
from
Task
IIDS
slab
castings
for
each
of
the
four
alloys.
The
test
specimen
configuration
for
thes_
tests
was
rectangular
plates
10-cm long, 1.3_cm
wide, and 0.13-cm
thick
(4 by 0.5 by
_:
0.05
inches).
Tests
III°K
(200°F)
1255°K
(1800°F).
The
from
averages
Metallo@raphic
ings
t_:
graphically
examined
_-_:
after
heat
treatment.
results
of
on
these
_=_
[
this
•+"
Script
carbides
_
aries
can-be
_
generally
•
_-_
th_
the
in the
seen
root
The
_as_nq
proccss
chill--plate,
the
was
tests
and
at
(1000°F)
to
are
individual
tabulated
test
results
r
blade-tip
27
through
were
30
cast-
metallobefore
and
illustrate
the
direction
as
shown
c_ses ....................
in all
presented
"
_our
as-cast
in. Figure
p_]otos, and
structu:_es.
sinc,_ the
9r6at_r
IIDS
areas
grain-growth
are
root,
Task
alloys
sn_
in all
evident
at
these
four
Figures
in the
coarser
811°K
of
the
microstructu_es
are
from
Representative
from
is vertical
247
temperature
4 p_rcent,
evaluation.
figures
MAB=M
variation
was
root-up)
room
of
examination.
:.
'
(blades
_esults
maximum
shown
at
increments
Averaged
XXX.
_-
conducted
temperature
in Table
the
were
k
at
The
bound-
structure
t,%ermal g_'adient
the bZac_e tip,
!_.
grain
27 •
%hich
is
during
was
near
"'.
Figure
}_-:
_va
__2
'+
The
script
sot
uf
MAR-M
alloy
-
eutectic
_
tions
_-_:'
--
presents
castings.
!9_
:
28
_'cre present
photomicrographs
carbices
247.
were
Larger
in both
_he
than
were
observed
in MA_-M
Figure
29
presents
the
alloy.
This
The
evident
amounts
_s+cast
precur-
gamma/9_m_a
.
prime
heat-treated
condi-
247.
m/crostructuzes
shows
amount
of
in
blade
this
o£
and
20_:Hf
_ewer
of
script
incipient
the
NASA-TRW-R
_arbldes
melting
:han
the
observed
in
two
_+
_i--_.
the root area after treatment
ma_ indicate
that. 1494°K
(2230°F)
is the upper limit for solution• treatment
of th.[s alloy.
.....
alloys.
also
MAR-M
_,__
[_--. +
MAR-M
photomicrograph
of
95
.
"
'_
'
i_'_l_'_-"_'r"ala_
_t_-:'--_'_"_m_'_'__9
T_
• !
--
+,,,.+,
.............
. ....
98
;_":_
The
IN
79.2+I_£ microstructures
are
depicted
in
Figure
-_D _
Script carbldes were absent and inc'ipient meltlng occurred
i_
root section of the blade,
.
_0.
in the
\
g2:
_
As a result of .the _ask II tests and e_alutions
_,.
axloys,
,_.
selecte_, for
_:
alloy
l/i
_2
:'.
Ni:
°
MARH4
247, MAN-M' 200+Hf,
_urther
was eliminated
stress-rupture
evaluations
and
NASA_TRW-R
in Task
Ill.
from the Task IIl effort
strength.
of the feur
alloys
The
were
IN 792+Hf
due to its lower
+,,i
H
¥
I
TASK. III-
ALLO¥..-PROPERTY
CHARACTERIZATION
ScQpe
k
During
!/
NASA-TRW-R,
to
further
evaluated
in
cast
mechanical
design
for
accomplished
by
the
du_ing
bar
castings
_asks
atories.
ings
and
neat
of
low-gas
ings with
was
vacuum
this alloy.
cast
25-ppm
procured
The
was
additional
turbine
blade
_nd
process
controls
developed
gas
labor-
Turbine
blade
and
was
pouring
used
for
contents
for
Heats
all
cast-
heat was 8 ppm;
nitro-
normal
remelt
are 10- to 30-ppm
the
other
alloys
were
we-re of the
same
design
as those
molus
in each
spoke.
with
six
1.590-cm
(0.625-inch)
test
one
test
bar
was
provide
III
evaluations.
spokes
The
with
standard
In
102
providing
(1.5-1nch)
and 15-
the
ones
provisions
made
test
this
to
bar
special
for
mold
bars
mold,
in Task
root-up
blades
spiral
spokes
four
used
had
five
per
spoke.
In addition,
both
tapered
erosion-test
one
spiral
spoke
standard
bars was replaced
with a spoke having provisions
bars an4 large-diameter
thermal-conductivity
test bars
3.8-cm
of
II.
straight
a spoke
heats
oxygen
o£
If--five
with
cast
alloys
Aallnewthree
7000-pound
of this
nitrogen.
separatly
DS cast with
evaluations.
content
superalloys
mold
of cast- .....
independent
247
Oxygen
testing
and
nlckel-base
blade
This
AiResearch
MAR-M
Typical
for Task
blades.
by comprehensive
exothermioally
for Ta_k Ill
content
4 ppm.
turbine
the
using
Production.
test
bar molds
were
to provide
material
properties
Jetshapes
specimens _ by
Material
physica)
of
II, _followed
DS
and
manufacture
by
I and
test
Test
i_
247,
document
_i
i
MAR-M
and
final
"
alloys,
to determine
the
to
selected
were
v_k_date
gen
three
200+Hf,
test
_.
the
MAR-M
_i
_i_
III,
and
form
_"
Task
test
six
bars,
erosion-test
and
another
of
six
for two
for Task
bars.
spiral
spoke
was
replaced
............
i
view
of
supplier
of
the
and
one
test
the
Jetshapes
a
reported
Colal-P
bar
possibility
mold
mold
were
production
the
prime
coat
for
grain
these
molds
indicated
nondestructive
evaluation
r;old
fluorescent-penetrant
fewer
mold.
to meet
All
Task
testing
is
no
of
the
casting
in
castings
to
castings
grain
Table
XXXI.
on
o_
of
the
parts
from
differences,
indicated
the
than
247
was
was
r]
to X-ray,
i
of
this
level
of
lower
than
that
This
was
fluor-
the
preceding
low-gas
content
alloy
for
Task
III
on
blade
castings
and
the__use
of
analyses
were
performed
bars
from
Tasks.
k
newer
ColaI-P
Results
general
\
Colal-P
the
subjected
evaluations.
The
with
apparent
were
MAR-M
for
the
modification
results,
sufficient
requirements.
DS
made
mold
indications
blade
indications
on
attributed
were
and
presented
escent-penetrant
observed
there
the
blade
comparison
that
turbine
fluorescent-penetrant,
latest
evaluation
these
program
by
one
structure
Based
on
remaining
III
material,
using
initial
had
discontinuance
cast
While
two
of
prime-coat
Colal-P.
Jetshapes
procured
i
7
In
castings.
Chemical
separately
Results
cant
cast
are
test
reported
in
Tables
anomalies
were
found
in
Property
Testing_
all
XXXII
these
sample
molds
through
analyses
made
in
Task
XXXIV.
No
Ill.
signifi-
!
.............
t
i.
and
Tensile
transverse
(refer
-
testing.
to
grain
-
Tensile
orientation
MFB
247
Figure
ll)
of
tempe'ratures
from
room
temperature
these
are
tests
_
graphical
[
verse
form
strengths
strengths
and
tests
DS
MAR-M
on
hot5
mini-bar
test
conducted
at
to
1144"K
(1600°F).
Results
in
tabulated
form
in
31
and
32.
As
than
the
longitudinal,
were
lower
ductilities
were
specimens
were
presented
Figures
longitudinal
adequate
Table
XXXV,
anticipated,
the
_or
in
final
various
and
in
trans-
although
blade
of
all
design.
103
_"
I_,
_ .:_ l 1
_
, _, _!_1'_'_,
,-
R
_
n
I07
¥
_J
_m
TASLE
XXXV.
TASK
111 TEN_ZLE
flea] treatment:
(Test specimens
tu_bLns
bladoe,)
Spoclm_n
a
Grain
i;o.
2_rlentation
I_8-8
L
148-8
_59-9
1505°K
1255"K
1144°K
_z_m
machined
(oF)
RESULTS
(2250°F)
(1800"F)
(1600°P)
for
fOC
£or
,
ON
DS MAR-M
2 hours,
5 hours,
20 hours
exothermlcally
UltL_at¢
tensile
strength:
_emporaturo,
_°K
TEST
------NPa(ksi)
pluq
plus
D8 _relLminaty
design
0.2-percent
yield
strength,
IIPa
u
247 TUREIINE BLADES
(ksl)
?PE731-3
Elongations
..L- perce_t
Re_u_tlon
in aIeu,
percent
1100
(1601
885
(128)
5.9
12.5
L
1052
(153)
928
(135)
6.5
13.8
L
i027
(149}
918
(133)
4.6
13.4-
138-8T
T
843
(122)
825
(120)
5.6
15.9
148-8T
T
885
(128)
864
(125)
2.2
_,4
159-9T
T
660
(125)
853
(124)
2.9
11._
138-7
L
1016
(147)
892
(129)
7.i
13.3
140-7
L
1088
(158)
954
(128)
4.6
10_9
138-?T
T
873
(127)
837
(121)
3.8
9.0
140-?T
T
836
(121)
816
(118).
0.8
14.9
159-19
159-19T
L
T
1
i_71
058
(156)
(124)
_48
852
(i_8)
(124)
7.0
9.8
15.3
11.1
138-1
L
(1200)
i014
(147)
873
(127)
?.5
12.5
148-14
'159-10
L
L
I
1135
...... _..L137
(165)
(165)
968
927
(140)
(134)
6.2
4.2
10.9
10._
128-1T
159-10T
T .....
T
1
_3_--_,_120)
816
(118)
764 _.
_-7#_
(111)
(114)
9.5
9.8
14.5
14,6
138-10
148-_
L
L
(1400)
1103
1185
(160)
(172)
931
_86
-_%_5)
(143) "
5.0
4.4
12.%
14.0
159-13
148°14T
138-IOT
L
T
T
'1209
910
89F
(175)
(13_._
(130)
992
818
828
(144)
(i19)
(120)
5,_
6.8
4.4
14.9
15.7
10.9
148-5T
I
965
(140)
841
(122)
?.8
14._
159-13T
T
940
(136)
833
(121)
5.7
11.1
13b_
L
992
(144)
778
(I13)
8.9
17.2
140-I0
L
1006
(146)
773
(112)
?.0
15.3
148-2
L
967
(140)
836
(121)
11.1
13.4
J38-6T
T
820
(120)
736
(107)
12.8
21.2
140-IOT
T
89_
(129)
(II0)
148-2T
T
839
_
,6_
-.1
745
3.4
7.3
10.9
14.4
:
a
108
Room
Te_peratuEQ
811(1000)
!
|
922
'"
}033
1144
L = LongitudinaZ
T - T_anever_e
(1600)
[
(108)
.
,
,2,,
_.. 1103 (1601
=Z 965 (1401
827 11201
• AVG. - 30
I
--:
366
(2001
I
I
477
14001
I
589
16001
700
18001
/
I
|
I
811
922
1033
1144
110001 112001 114001 11600)
TEMPERATURE, OK (OF)
;'
";241 11801 /
--_ 1103
"
A, ]J.LTIMATE
TENSILESTRENGTH
1160; "i
r-.
_.
Y_
96-3.11401
027112o)_: ---
- 30
366
12001
477
14001
"
_;_:'-.
_--_-'
m_ ........
.....
--
B,
.=
= .... -_
700
18001
,,
811
922
1033
110001 112001 11400)
,,
I
1144
116001-
TEMPERATURE, °K (OF)
0.2-PERCENT YIELD STRENGTI-!
""-NOTE:
ALL SPECIMENSHEAT TREATED FOR:
-...... 1505_K (2250°F1 FO,'t 2 HOURS,
"Pt.,_S 1255°K (1800°F1 FOR 5 HOURS,
PLU_>"%t4Q°k 11690°F1 FOR 20 HOURS
Figure
_
589
16001
31,
Tensi.1_--.,Properti¢:s
Specimens
Machined
E:,Jothermically
Turbine
Blades
Versus
Temperature.
from Task
ITI. MAR-M
Cast
DS Preliminary
(Sheet
1 oF. 2)
of Lon_-_.tudinal
247
Design
TFE731-.3
109
q
'¥
i
15.0 .....
z
..-------_----.
s
%EL (A
_
AVG.- 3
0
...... I
366
(200)
I
'1'
477
(400)
589
(600)
_:C.
<_'<'15.0-
71_0
dll
9122
(800)
(1000)
(1200)
TEMPERATURE, OK tOF)
10_3
(1400)
11'44
(1600)
:
ELONGATION
_-,,
t
._AVG.)/_,_._
_z lO.O
O
gJ
5.0
AVG.- 3o
/e-
....
:
0
I
I
i
I
I
I
I
I
366
(200)
477
(400)
889
(600)
700
(800)
811
(1000)
922
(1200)
1033
(1400)
1144
(1600)
,
D.
TEMPI_RATURE, OK (OF)
REDUCTION OF AREA
<
_igure
i
110
31.
Tensile
Properties
Versus Temperature
of Longitudinal
Specimens
Machined
from Task III MAR-M 247
Exothermically
Cast DS Preliminary
Design TFE731-3
Turbine
Blades
(Sheet 2 Qf .2)
160,0
---'
140.0
UTS (AVG.)
12o.o
i
100,0
VG. - 30
80,0
-
!
I
366
(200)
477
(400)
A.
'1
I
I
"
I
589
700
811
922
(600)
(800)
(1000)
(1200)
TEMPERATURE, OK (OF)
ULTIMATE TENSILE STRENGTH
I
1033
(1400)
1144
(1600)
1033
(1400)
1144
(1600)
80.0
366
(200)
NOTE:
Figure
32,
477
(400)
589
700
811
922
(600)
(800)
(1000)
(1200)
TEMPERATURE, OK (°1_)
B. 0.2-PERCENT YIELD STRENGTH
ALL SPEC(MENS HEAT TREATED FOR:
1505°K (2250°F) FOR 2 HOURS,
PLUS 1265°K (1800°F) FOR 6 HOUR,_,
PLUS 1144°K (1600°F} FOR 20 HOURS
Tensile
Properties
Versus Temperature
for Transverse
Specimens
Machined
from Task III HAR-M 247
Exothermically
Cast DS Preliminary
Design TFE731-3
Turbine
Blades
(Sheet 1 of 2)
iii
- .........
I_m=--,----
"
nnc o0002TSC
i
,_
i
.....
:
15.0 "1
"
10.0 1
....
%
%EL IAVG.)
0
366
477
12001 . (4001
.
•.
589
16001
(8001
110001 112001
TEMPERATURE,
OK l°F)
C. ELONGATION
20.0 -I
-_
_
•,
._:__
15.o
10.0
°
'"
11600)
l
I
""
_RA1AVG.1
5.0
-
AVG.-
0
I
'
386
12001
.... . :.._
i
':
I'
i
477
(4001
589
16001
D.
:
114001
Figure
112
32.
t
,
o
I
I
700
811
022
18001
110001 112001
TEMPERATURE, OK (OF)
REDUCTION OF AREA
1033
1144
114001 116001
......
Tensile
Properties
Versus
Temperature
for
Transverse
Speciemsn
Machined
from Task I_I
MAR-M 247 Exothermically
Cast DS Preliminary
Design TFE731-3
Turbine
Blades
(Sheet 2 of 2)
_ )t
i _; •'
,
_
,,i_;
,_._"
1
0_635-cm
(0.250-inch}
machined
from separAdditional
_ensilediameter
testing test
on specimens
DS MAR-M
2_7
was conducted
on
ately cast test bars (SCTB).
Results
of these tests are tabulated
LII
in Table XXXVI.
Tensile
and yield st_el%gths of the SCTB specimens
were 0- to 10-percent
lower than resalts.of
the MFB minl-ba_
tests
and
I
the
SCTB
ductility,
i_
specimen
probably
Tensile
test
specimens
of
Tables
XXXVII
.
for
these
2.
[ :
(1900°F)
results
MFB
of
are
similaD
orientations.
Primary
strongest
of
the
NASA-TRW-R
were
MAR-M
alloy
200+Hf
of
these
tests
As
expected,
test
three
specimens
•to those-observed
i033°K
emphasis
alloys.
was
SCTB
only
shown• in tabulated
a:,u longitudinal
grain
placed
on MAR-M
247,
the
properties
o£
temperatures,
the
rupture-strength
form
con-
1311°K
while
at two temperatures.
are
was
and
Stress-rupture
at- three
was tested
testing
(i400°P)
transverse
characterized
and
on MA_t-M 247.
- Stress-rupture
with
higher
geometry.
mini-bar
between
mini-bars
to 100-percent
MAR-M
200+Hf
are tabulated
in
strength
and ductility
patterns
testing.
temperatures
on MFB
40-
of specimen
DS NASA-TRW-R
and
and XXXVI£1.--The
alloys
at
exhibited
as a result
Stress-rupture
ducted
--
_esults
in Tables
rankings
The
XXXIX
were,
in
the
results
and
XL.
descending
TRW-R.
The strengths of all three alloys were adequate for the final
order of demonstrated
st.reng_h--MAR-M 247, MAR-M 200+Hf, and NASAdesign
turbine
blades.
Ii
One
'
""
of
the major
enough
improvement
another
DS alloy)
of
the
current
TFE731-3
Engine
original
with
IN100
solid
data
showing
that
this
:
this
graph
compare
the
:
test
specimens
247
_:
f_om
Tasks
of this
Project
was
to obtain
in stress-rupture
strength
_)f DS MAP.-M 247 (or
ove_. equiaxed
IN100,
to permit
the replacem<nt
cooled
of
goals
unreeled
goal
was
average
equiaxed
I and
high-pressure
II o£
IN100
this
turbine
DS blades.
achieved.
rupture
Figure
in
the
33 preselts
The
solid
strengths
from
mini-b,r
and
DS
(AiResearch
contract.
blades
data)
The
solid
lines
on
MAR-:.I
circles
are
113
_
%
_
v.
TABLE XXXVII.
__
TASK llI
TENSILE
Heat tceatment_
_i_
Specimen
NO.
Grai_
orlentatlo_
initial design
TFE731-I
turbine
Reduction
in area,
p_rcen_
blades
RT
INII
(147i
q_0
f138_
7.2
9_8
L
I
1016
(1472
927
f135)
6.9
9.5
168-5T
174-3T
168-6
T
T
5
I
858
837
1028
[124)
[121}
(149)
839
832
867
[1_2]
(_2_)
[1282
4.0
3.2
13.4
8.6
?.2
24.1
174-4
L
1198
(I742
]000
f145)
10.9
20.8
168-6T
174-4T
T
T
847
838
(1232
(|22_
819
783
(I]9)
[I]42
4.3
3.7
8.7
ll.l
168-7
L
978
[142)
792
(I151
10.7
20.0
174-8
L
986
(1432
806
(I17)
9.7
15.3
168-?T
T
841
(122}
747
(I08}
3.4
7.6
174-HT
T
861
(125[
802
{I162
3.5
9.0
1117
L
1144
L
1174
1118
L
L
1145
1175
i146
a
•
fr0m
E_onga_io_,
percent
L
-
"
Q.2-percent
yieJd
strength,
MPa
(ksi)
174-3
?
•
for 2 hours wi_h argon quenching, plus
for 5 boues
w_th &It cooling,
plus
foe 20 houes with air conl[ng
160-5
i0_3
1144
Specimens
_i
(2250°F)
[1800°F)
(1600°F]
SJltlmate
tensile
strength_
MPa (ksi)
Temper_turej
°K C-F)
Speci_%ens machlne4
__ -
TEST RESULTS ON SEPARATELY CAST TEST B_HS OF DS NASA-TRW-H
1505aH
12554K
I144°K
(14002
(16002
machined
RT
from separately
cast
test bars
1043
(151)
847
(123]
13.9
17,8
1230
(1632
887
(129)
If.?
13.2
1033 _J400)
I101
1134
(160)
(165)
874
908
(127)
(1322
,
_
_3.7
12.1
19.2
24.2
L
_
I108
[1682
905
(1312
]
II._
_1,_
L
5
1144 }
_16002
969
957
(14!)
(1392
721
710
(I05)
(I03|
i
16,7
19.5
24.2
24.4
L " Longitudinal
T " TE altsv_rse
y
L
I15
TABLE
"': ;VIIi. 1lear TASK
111 "F_NRILE
TE_q 12250°F1
_ESU[.T_
treatment=
1%05°K
1255°K
(1800_P)
i _"
I]44°K
•
Specimen
NO.
_""
,
(._axn
Orientation
i
Specimens
t::
!
!_
_"
167-1
L
167-1T
T
186-4T
106-8
.r
L
167-2
h
186-7
L
167-2T
186-7T
T
T
167-4
].
186-8
167-4T
n
T
186-8T
T.
i:
"l'eN)e
rl_l.lure
1
_achlned
f_om
R_
|:
i::
III
zz6
28
hour!;
with
a;r
conlinq.
0.2-percent
yiel;l
_ t_enqth
HPa (kSi}
strength,
,t'a
(k_')
_0t?41-f
,
Elon_aLion,
Reduction
in .tg..,le
perc,,_
|,_rceltt
1_;itlal
des£gn
TVE?31-3
turbine
912
,1_21
84_
(122)
5.2
blades
10.2
804
11171
789
t1141
2.8
7.0
_
760
971
(110}
11411
751
854
_18q)
(1241
4.6
6.1
6.8
10.-G
(14001
1211
11761
1040
_15!1
4.3
12.5
1105
11601
I02_
11491
4.4
17.9
04 I)
841
(1_?)
(1221
76]
747
11101
(108)
3.4
3.4
6.8
7.6
9_5
11_11
77_
(1131
10.2
I?.2
927
(1351
7%6
(1101
6,4
12.5
812
RS_
(1181
(124)
718
754
(_04)
f1091
?.2
2.R
9.?
5.4
1!.5
1033
1144
(16C01
_c._in_d
R25
b
R52
L
1181
L
1
R82
R54
L
h
R26
L
R83
_
a
fo_
U1tim3_o
tensile
Specim_
l _;
11600°F1
R
_i::
•
ON SEPARAI'_I.Y
_EST auenchinq,
PARF _F D_r.l*,F
HA_-M
for
2 houzs
with CAST
arqo,_
for
5 h_ur_
wi_h
_lr
on.liner
nl_*_
RT
[roin
_r_tely
Ca_t
telt
_r_
LlS?
(1721
871
_12_1
11.2
1098
(1591
836
_1211
9.2
10._
!088
11581
851
(1241
9.9
11,8
10l $ _
.(1400)
_224
120"_
1178)
1175)
973
985
11411
1143t
9.7
7.5
16.3
13.0
1114
._1600)
qlo
11331
715
(_041
20.6
32,7
_
_08
11321
716
([U4_
1_9
29.4
L = Lo;,giLud;ndl
TABLE
Heat
XXXZX.
TASR'I_I
STRESS-RUPTURE
TEST SPECIMENS
treatment=
1505OK
1255°K
I144°K
(2250=F)
(1800°F)
(1600°F)
_L'est specimens
maohined
from
....
desipn
_pecimen
No.
:
•
:
L
L
L
T
T
T
T
T
1033
138-2
140-Ii
].48-1
140-11T
i,_8-IT
138-2T
L
L
L
T
T
T
1144
138-3
L
1200
159-18
138-3T
159-18T
L
T
T
138-16
148-7
159-11
14G-TT
138-16T
159-IIT
L
L
L
T
T
T
1255
_; 138-18
148-9
L
L
a
fo_
for
for
RESULTS
(1400)
ON
MAP-M
247
2 hours wlth argon quenching,
plus
5 hours• with slr cooling,
plus
20 hours with air cooling
exothermically
TFE731-3
turbine
blades.)l
Grain a
Temperature,
l
orientation
°K (_F)
I
I
140-9
148-6
159-15
140-9T
159-15T
148-9T
138-18T
148-6T
TEST
cast
Stress,
MPa
(ksi)
Hours
to
rupture
Elongation,
percent
Reducoftion
area,
percent
(105)
(97)
(93)
(97)
(95)
(93)
(90)
(90)
309.1
1259.9
555.7
0.5
4.9
8.0
1155.2
331.3
14.2
16.6
8.9
1.9
4.3
1.1
13.5
4.0
16.8
20.9
16.3
5.0
8.5
1.6
17.9
8.7
(1600)
434
345
317
448
434
414
(63)
(50)
(46)
(65)
(63)
(60)
184.0
774.3
1270.0
104.1
136.3
225.1
18.7
20.7
30.8
6.4
9.3
8.7
26.2
37.0
41.4
10.9
10.9
18.5
(1700)
297
(43')
167.8
26.8
43.5
|
255
276
241
(37)
(40)
(35)
320.0
169.3
338.6
27.9
8.8
13.0
48.0
11.7
19.1
1
207
152
131
207
186
172
(30)
(22)
(19)
(30)
(27)
(25)
123.4
646.2
1678.3
90.4
124.3
227.4
39.8
28.6
25.2
9.8
12.3
8.7
53.2
56.2
48.2
18.3
17.4
13.8
1311 (1900)
131]. (1900)
124
103
(18)
(15)
174,5
838.0
14.3
19.0
25.8
37.3
I
(1800)
]
m
724
669
641
669
655
641
621
621
I
I
preliminary
i
i
!
!
,.
L = Longltudlnal
T = Transverse
117
F
:web
I_i
I'ADLE XL.
Heat
TASK 111 STRESS-RUFTURE
TL:ST RESULTS
NASA-TRW-N
troatmentl
1505°K
(2250=F)
Eor 2 hours with
(Test
specimens.
.
I144"_
_!
:_
_=
5pecime_
__
:
-
Nu,ber
maohined
1255_K
(I_OOoP)
T_pe::_ture0
Grain
orie,,tatio, a
for
20 houze
Erol_ exotherm(cally
(1800°P)
rot 5 *hours
"K
('P)
1144
(1600)
Stress,
ON MAR--N 2006H£
argon
with
cast
_|th
AND
Quenching,
plllS
cooling.
air
DS
air turbLne
cooling, blades)
plus
_|ou_a
to
'
HPa (k,,)_upture
MAR-M 200+Hf
EZongatlon,
Reduction
of aze_,
percent
percen,:
,.
_ ..
_--_
i_
168_8
L
434
(63)
171.7
15.3
28.7
168-8T
T
414
(60)
168.1
6.7
10.2
174-13_
T
168-9
L
P
448
(65)
73.2
6.I
10.6
(1800)
20_
(30)
103.1
23.1
38,0
174-15
L
152
(22)
528.9
18.0
49.4
168-9T
T
186
(27)
0.3
2.2
4.1
174-15T
T
18,<,
(27)
128.5
4.3
6.6
_24
(I05)
85.0
6.2
14.9
641
(03)
455.9
10.8
19.0
I
62[
(90)
0.i
2.6
(160U)
4;_
317
(63)
(46,
68.a
619.3
17.8
29.6
1255
I
NASA-TRW-R
16_-7
L
186-8
L
1033
(1400)
r_
_
_
167-7T
T
_
=
_
.
167-8
186-11
L
L
16,-6_
,
_
""
167-10
L
186-12
_
I'
i
186-,,
T
P
1144
5s6 (85) 811.0
4_4 <+0)63.6
24.5
35.0
,.,
(30)
50.5
18.5
39.4
L
1-31
(19)
832.8
22.0
51.q
167-10T
T
126
(27)
65.?
3,?
5.6
186-12T
T
L72
(25)
|_=.9
7.8
t4.4
a
L • [_ongtt_dinal
(18001
6._
5.0
12.4
207
T _ Transverse
1255
+.5
.
!
t
...
,_i
_,....
i.-
276(40)
_
20713.0)
_,
TASK III DATA - 1144°K (1600°F)
'_
1000-HOUR
TASK III DATA
,_
IN-100 _
138(20)_
_/'/'-
DS MAR-M 247
,LbS
B-
47
__
1144°K 1
(1600°F) (1700OF) ._ 1255°K
(1800°F)
42
_
46
41,1
,lit
48
50
LARSON-MILLER
PARAMETER, P*
44
462
54
i
*P = T (20 + LOG t) x 10-3
!"
_i_" :
!,
(1800°F)
•
69(lO,
40
""
AND 1255°K
LIFE AT INDICATED TEMPERATURE,
483(70)
414(60).
m
,
•
WHERE:
P = LARSON-MILLER PARAMETER
T = TEMPERATURE, °RANKINE
t = TEST TIME
Equiaxed
Specimens
Figure
33.
Average
IN100,
IN HOURS
0.178-cm
Stress-Rupttlre
(0.070-1nch)
Strength
MFB
of DS MAR-M
'lest
i19
247 Versus
4
V
the
_et_lol
polnt_.
li44°K
The
attributed
1494°K
h hJher
to
the
(2250°F
Using
family
using
average
aDO minus
in Figures
final
blade
_esign
DS MAR-M
_47
the
3.
fatioue
(LCF)
1033°K
(1400°F)
separately
also
mens
of MAR-M
axed
IN100
baseline
rial
temperature,
creep
curves
sauares
Inethod.
The curves
sigma
curves.
These
curves
37 for rupture,
(0.5-,
1.0-,
and
2.0-percent--
utilized
to
validate
were
curves
predictions.
The
is shown
test
were
on Ficure
at
on smooth
and
notch,0
test specimens
test
of
the
on smooth
247.
three
te,_perature
LCF
and
used
for
Table
XLV
presents
a
comparison
several
in
5,000
and
advantage
for
any
1033°K
10,000
of
the
DS
(1400°F)
strength
than
equiaxed
superior
to
NASA-TRW-R.
at
cycles,
room
alloys
all
IN100,
with
temperature,
sPeci-
were
performed
with
esuiaxe_
XLI
that
would
produce
is
MAR-M
add
Ill
indicate@
DS
three
Task
DS
bla_es.
throuqh
estimated
XLIV.
maximum
LCF
fail-
data.
_
at
room
show
_reater
alloys
200+Hf,
an_
alloys
showed
notch-weakening
a
mate-
turbine
the
on
on e_i-
to mrovi_e
of
three
All
test
TFE731-3
baseO
from
(RT-21)
in Tables
materials,
at
tests
the
presented
and
LCF
alloys
the
low-cvcle-
alloys.
(1400°F)
are
the
cast
for
machine@
at 1033°K
DS cast
being
tests
point
temperature
alumini@e-coated
In adOition,
the
DS
the
34.
conducted
bars
as
presented
acceptability
room
a
plotted
_re
were
tests
_ata,
b), reare_ion
- Load-controlled
testing
strensthenlng
uree_
prepare@
were
this
At
.......
and
for comparing
ature.
IIl eastir_s
rupture
of
ures
versus
Testina.
at room
for
1505°K
Fatigue
conducted
stresses,
are
247
life
currently
Results
lIT
MAR-M
specification
cast
were
Task
in
Task
These
Low-Cycle
data
the
three
respectively).
III
on
a least
creep,
Task
use_
and
34 through
(1800°F}
achieved
solution
2330°F},
Ill
_upture
1255°K
leveln
_ncreased
Task
analy._s
and
strength
versus
the
_f
(160O°F}
temper-
MAR-M
at
LCF
247
notch1033°w
(1400_F).
120
,+.
•
00000002-TSC14
689(100)
*
414(601
r,_
_G,
,P 276(40)
652(80)
3E
_AV
'
AVG. - 30 "
k
_k.
138(201
I
69(10)
,
37 30
4_
LARSON-MILLER
Figure
34.
Larson-Miller
Longitudinal
Specimens
4_
,
46
,
47
;9
I
I"
6_
6_
PARAMETER, P = [T(OF.)_r460](20+Log t) x 10.3
Stress-Rupture
Data, 0.178-cm
Curve for DS MAR-M 247,
(0.070-Inch)
MFB Test
68911001
4141601
AVG.
¢n
AVG. - 3o _276(40)
cd
_,)
uJ
¢
1381201
69(',0)
34
,
36
,
38
LARSON-MILLER
Figure
35.
Larson-Miller
Longitudinal
Specimens
,
40
PARAMETER,
,
42
,
44
,
46
P = [T(°F)-N60](20+Log
,
48
56
t) x 10-3
0.5-Percent
Creep Curve for DS MAR-M
Data, 0.178-cm
(0.070-lnch)
MPB Test
247,
121
68811001
......
5521801
414(6ol
]
AvG.
_' 276(40)
AVG. - 30
138120)
69110)
35
Figure
36.
',
=r
r
*"
,
,
37
39
_1
43
45
47
49
51
LAR$ON-MILLE_R PARAMETER, P = [T(°F)+460](20+Log t) x 10-3
Larson-Miller 1.0-Percent Creep Curve for DS MAR-M 247,
Longitudinal Data, 0.178-cm (0.070-Inchl_/IF_B_Test
Specimens
689(100) ',
5521801
_.-.._
,." ....._
,.
AVG
"_ 2761401
=-
g 14(60)
AVG..- 3(;
./__..
,,._,_
.
r, 138120)
--:
Figure
122
69(101
....
,
=, _,
L, =
,
,
,
36
38
40
42
44
46
48
50
52
LARSON-MILLE_ PARAMETER. P = [T(°F)+460J(20+Log t) x 10-3
37.
Larson-Miller 2.0-Percent Creep Curve for DS MAR-M 247,
Longitudinal Data, 0.178-cm (0.070-Tnch) MFB Test
3pecimens
D
L
--+W
TABI,R Xbl.
Heat
treatment:
LOW-CYCLE.-PATI_HE
1505°K
1255"K
I144_K
(Longitudinal
grain
cast tesk baEs)
Specimen
No.
•+ "
•
(2250°P)
(1800°P)
(_600"F)
orientation
I
_E_T
for
for
for
te_L
2 hou_a_
5 hours,
20 hours
=pecln.ena
Te_;_oreJ
°K ('P)
l
(a)
smooth
specimens
Uncoated
RESULTS
_tPa
atress,
(ksl)
ON
machined
from
Cyoles
failureto a
I
KT
_36
(165)
620
233
235
235
231
148
_I_
IL30
]104
1103
1069
1034
(IbS)
(iG0)"
(160)
(155)
(150)
830
2,550
2,780
4.450
5,300
._.
230
I17
115
2
1034
965
931
896
(150)
(140)
(135)
(130)
6,580
5,420
11,660
9,730
=::_
1
I01
896
896
(130)
(130)
12,930
21,350
1138
1138
i138
1103
(165)
(165)
(165)
(160)
690
860
1,810
920
1105
1034
1034
100O
q65
965
965
931
(160)
(150)
(150)
(145)
(140)
(140)
(140)
(135)
2,180
3,020
3,440
I0,1_0
7,730
9,080
5,320
12+_30
___
1033
104
4
3
242
240
237
236
24]
:_
~
_
114
9
162
121
120
"-
(1400)
_
_
(b)
_+_-21 Cca_d
1033
1140_I
[
/
smooth
965
965+
965
931
986
(1401
(140)
(140)
(I_5)
(130)
960
1,410
1,060
I,_90
2,690
2,800
149
896
(130)
151
862
(125)
7,200
i_ - _
m
•
1_8
122
10
827
8,2
827
896
(120)
(125)
(1_0)
_30)
31,590
24,830
29,240
6,310
i
._
_.
J
Remark_ .....
_pecimens
+
l
se._aEate1_
[i
232
239
243
238
106
R47
plu_
plus
_
&-"
DS MhR-M
Broke
in threaded
a_ea
.
a
Test
parameters;
Axial
load control;
sine
wave form;
60 HZ f_equency;
"A" ratio
= 1,0
•
123
K +'
,+t
t
.,_
4
I
_
TABLE
i;
XLII.
Heat
LOW-CYCLE-FATIGUE
treatment:
1505°K
1255eK
i144°R
!_
TEST
(2250°F)
(1800°F)
(1600°F)
(Lo_uitu_Jn_l
¢iraln ozientatlon
separately
cast test bars)
i
_+
[_
',:._cimen
Humber
test
RESULTS
MAR-M
247
for-2 hours, plus
for 5 hoLJrs, Dlus
for 20 hours
specimens
Maximum
stress,
MPa (ksi)
Temperature,
°K (oF)
ON DS
machined
Cycles a
to
failure
from
Remarks
,i'i
251
I.
_,;
i
Uncoated
RT
(180)
2,840
250
249
i172
1172
(170)
(170)
4,870
4,260
6
1138
(165)
5,070
244
1138
(165)
5,960
245
i103
(160)
6,530
246
1103
(160)
7,260
5
1034
(150)
4,210
103
247
1034
965
(150)
(140)
6,550
10,400
I
965
(140)
13,660
(1400)
1103
(160)
430
125
1103
(160)
920
107
1103
(160)
--
132
1034
(150)
1,540
253
1034
(150)
1,890
254
965
(140)
2,860
8
827
(120)
4,840
256
827
(120)
6,760
257
758
(ll0)
9,120
124
1033
259
I
758
(Ii0)
9,280
258
i
758
(II0)
16,500
a Test
_';-
specimens
1,630
1241
7
! +
(Kt = 1.8)
(180_
252
248
iL
notched
1241
parameters;
Axial
60 Hz
Overloaded
load control;
sine wave form;
frequency;
"A" ratio = 1.0
I
vI
TABLE
XLIII.
LOW-CYCLE-FATIGUE
TEST
AND EOUIAXED
INI00
(Longitudinal
gra|n or|entatlo_
separately
cast
test bars}
Spocimen
IIII
Te
pera
ure,
RESULTS
test
speolmenB
NASA-TRW-R
oncoated
1138
(1651
140
|
1103
(1601
230
_000
(145}
4,140
896
1034
827
1034
(130)
(1501
(1201
(1501
6,812
3,750
, 15,O30
380
966
(1401
1,520
R60
931
(1351
7,930
R3
896
(130)
13,600
965
827
(140}
(1201
2,460
.17,530
,,
1033
(1_00_
|
R59
R32
R4
..
I
_SA-TRW-R
uncoated
no_hed
RT
1172
(_701
1,270
R34
I
1138
(165]
1,920
R5
1034
(150)
?,010
R62
R33
R6
J
1000
1103
965
(1451
(1601
{1401
9,440
3,340
15f2_0
1,120
1033
(1400)
1069
(1551
R?
1034
(150}
1,050
R8
965
(140)
3,390
R36
896
(130}
4o9_0
R35
896
(130)
8,220
R63
827
(1201
9,110
Equlaxed
13
RT
IN-100
uncoated
(1551
I4
1034
(1501
5,970
I2
931
(1351
19,450
20,340
931
(1351
(1551
160
_7
965
(1401
1,520
I6
896
(1301
4,440
1.033
(1400 s
_.8)
speclmensb
specimens
o
1,700
1069
I5
b
l
Imo0th
1069
I1
specimens
(_
H61
R64
Remarks
smooth
RT
1
from
1
R58
R30
R2
RS?
R31
mschlnod
to
a
failure
R1
R29
NASA-TRH-R
_
stress,
MPa
(ksi)
MaximumlCyclea
number_K(_F)
ON DS
327
(1201
7,850
a
Test
paldmetersz
Axial
60 Hz
load
controll
frequencys
b
Heat
treatmentl
1505°K
1255°K
1144°K
(2250°F1
(1800OF1
(1600°F)
for
for
for
2 hours,
5 hours,
20 hours,
plus
plus
c
Ileat
treatment_
1255°K
1144°K
(1800°_1
(1600°F1
for
for
5 hours,
12 hours
plus
18
I
sine wave
form;
"A" ratio = _ N
125
iţ
!
TABLE
i'
lleat
XLIV.
LOW-CYCLE-FATIGUE
treatment,
1505"K
1255°K
I144°K
_=
[Lon%Itudinal
is
cast.t_at
"
:_5_n
_
grain
TEST
(2250"F1
(1800°F)
(1600°F)
orlentat[on
test
RESULTS
for
for
for
ON
DS MAR-M
200+Hf
2 hours,
plus
5 hours,
plus
20 hours.
specimens
machlned
from
separately
ba_s.)
Temperature,
OK
(OF)
stress,
MPa
(ksi)
to
failure
a
Remarks
....
t
(a_
Mi_
RT
M20
Uncoated
smooth
specimens
I1½8
(165)
1.150
1103
(160)
rI
._,410
• . ..
_-..
M47
M48
1069
1034
(155)
(150)
= _"_-
M77
I000
(145l
8,030
M76
965
(140l
14,290
1138
(165)
50
MSO
1103
(160)
1,530
M79
I069
(155l
4.720
M78
1069
(155l
6,730
H49
1034
(150)
7,020
M22
1034
(150)
12.980
[
M21
:-
1033
400_
L
(b)
M51
i
i
Notched
(K
:
1.8l
"- .
1207
(175}
4.190
(180)
3,240
M24
M23
1172
1138
(170)
(165)
4.600
5,400
M52
11o3 (16oI 7._6o
MS0
i0_9
(155)
10.730
1103
(160)
1,570
(160)
1,990
RT
M25
1033
(1400)
i
M54
1103
i i
.53
11e_ 1160_ 3.15o
)._
M26
M82
965
896
(140%
(130%
5,220
11,240
M83
89u
(130%
27,110
_
?"
a
z_
k 2(_
Test
parantet('f_
Axial
60 Hz
..
specimens
1241
M81
_1
Uncoated
3,010
5,360
Broke
]sad control)
s_ne wave
f_,:m;
frequency;
"A" ratio
- 1.0
in threaded
area.
127
The
I033°K
(1400°F)
least
sgu_res'regression
sented
as
through
41.
data,
and
LCF
data
In all
cases,
the
lower
curve
is the
the
on
upper
is
fit
minus
best
gr_ 'n-growth
separately
formeO
on
the
XLVI
through
three
L.
from
alloys,
MAR-M
(Kt = 3.0)
(1600°F),
and
with
247
ratio
of
program
test
in
specimens
of
Task
were
A number
ticularly
Due
of
at
failure,
V,
the
only
conducted
test
room
to
temperature.
_:evera]
specimens
action
The
both
room
not
and
uncoated
specimens.
At
I144°K
weakened
with
200+Hf
less
128
were
presented
conducted
in
on
per-
Tables
smooth
temperature
and 0.95.
_nd
and at
Testin_
of
NASA-TRW-R
area,
par-
In
attempt
to avoid
this
kina
a minimum
qaae
rem_chined
to
on
a
threaded
an
tests
as
in the
200+Hf
LI.
analysis
both
affected
in Table
than
smooth
degree
precluded
the
the
strenaths
for
alloys
MAR-M
results
smooth,
are
notch
tested
of unexpected
ability
of
247.
for the specimens
The
of
fatiaue
identical
(1600°F)
are
L'esults obtained
(]600°F)
appear
III
._tatJst_cel
bars
to make
obtain_c _.
.
%+ +
failed
limits
ingful
sigma.
material.
endurance
test
three
this
estimateO
in the
the
temperature
The
e yen{
fit of
room
I144°K
MAR-M
MAR-M
best
succeed.
temperature
247
38
and silbjected to test.
As can be
in Table XLIX. the attempted
cor-
and
Tesk
MAR-M
did
Figures
smooth
and notched
(Kt = 3.0)
and l144°F
(1600°F) at an "A"
were
diameter
of 0.51 cm (0.20-inch)
seen from the results
included
rective
as
elimination
on
specimens
is pre-
in
test
test specimens
at room
at "A" ratios of in£inity
infinity.
alloy
the
cast
were
of MAR-M
200+Hf was conducted
on
test specimens
at room temperature
iN100
- Axial-axlal
high-cycle
specimens
machined
in the
results
tests
and
curves
curve
testin@.
of test
direction
247
analysis
4.
High-cYcle
fatigue
fati[!ue load-controlled
tests
notched
I144°K
:
MAR-M
under
scatter
a meat ++
I
""
1655(240
L-....
_
""
137fl(200
BEST FIT OF
ACTUAL DATA
-,
_'
C-
11031160 IE 827(120)
_
r,_
ua
_:;
BEST FIT MINUS
THREE SIGMA.,
2761401 _
100
Figure
38.
................
_
I
_,
!
1000
10,000
CYCLES TO FAILURE
100,000
Low-Cycle
Fatigue
of Exothermically
Cast DS MAR-M 247.
[Longitudinal. Data, 1035=K
(1400°F), Load Controlled,
_
A = 1.0, Kt = 1.0, Smooth• Uncoated
Test Specimens
Machined
from Sep_@_rately Cast Test Bars]
1655(240)
:
I
BEST FIT OF
ACTUAL DATA
r"
8271120_
552(80
1379(200
_,
•
"'
B
'"
THREE SIGMA
276(40)
0
I,
I,
1000
10,000
CYCLES TO FAILURE
100
•
•
;,
'"
;
Figure
39.
100,0O0
Low-Cyqle
Fatigue
of Exothermically
Cast DS MAR-M 247.
[Longitudinal
Data, 1033°K
(1400°F), Load Controlled,
A = 1.0, Kt = 1.8, Notched
Uncoated
Test Specimens
Machined
from
Separately
Cast
Test
Bars]
129
r
,_,?"
_,,
_ •
-
1055(240)
/'-1379(200)
_ 11o3,1oo)
_ 927(12o)
-
Ii
552180)
i!:
__
BEST FIT OF
DATA
276(40)
0 ,,,
100
Figure
40.
'
BEST
F,T
_
MINUS THREE
SIGMA
I
I
1000
10,000
CYCLES TO FAILURE
100,000
Low-Cycle
Fatigue
of ExotheEmically
Cast DS MAR-M
247.
[Longitudinal
Data,
1033OK
(1400OF),
Load Controlled,
A = 1.0, K t = 1.0, Smooth
RT-21
Coated
Test Specimens
Machined_rom
Separately
Cast
Test
Bars]
=
".1655(240)[
137912001I_
BEST FIT OF
/
ACTUAL DATA
1103(1601
..,. F
_
_' ,52(so,
BEST
F,T
M,"O___j"
THREE
SIGMA
"
276(40)
0
100
Figure 41.
130
t
I
I
1000
10,000
CYCLES TO FAILURE
100 )00
Low-Cycle Fatigue of Equiaxed IN100.
[1033°K (1400°F),
Load Controlled, A = 1.0, Kt = 1.0, Smooth Uncoated
Test Specimens Machined from Separately Cast Test Bars]
m
m
4
--_
_'^_
Heat
[0.64-_m
xLvI,
treatnu_nts
(O.25-inQh)
llt_(-_yCLE-Ph?I_U8 TBS¢ RESULq'S
OHD5 HAR-H247
1_056K
L25$'K
31446K
Lcet
(2250"P)
for
(SBO0*_) for
(30 JO'¥) for
specim
,-_. machined from
Atc_rn_inq
atreIIe
MPa (kel)
con_£guratton
183-1
182-1
"
-
"
._
_-
--_
i
"
eaparatoly
to
_a|t
102
621
16r000
116
621
(90)
25.000
100-1
552
(00)
233000
153-1
552
(80)
55,000
139
517
(75)
42,000
118
483
(?0)
211,000
1_4
414
(60)
006,000
lS0
348
{302
_e2O6,OOO
(00)
b
483
(?02
22,000
105
107-1
smooth
483
434
(70}
(60)
70,000
214,000
125
414
(60(
389,000
128
140
379
345
(55)
(S0)
486 000
504,000
182
345
(50)
226_000
134
376
(40)
867,000
160
276
(40)
157
207
(30)
552
(80)
9,000
552
483
(00)
(70}
13,000
20,000
113
414
{60)
29,000
100
345
{_0_
01,000
145
345
(50)
72_000
14b
276
(40)
147,000
ZVJ"
276
(40(
180,000
_72
207
(302
390,000
147
207
(30)
519,000
!70
152
172
(25)
3,189,000
483
(70)
4,000
483
414
(70)
(60)
3,000
4,000
109
Notched
108
111
(X t
1144
(1600:
Remarks
!
Broke
in
threaded
area
Broke
In
_hreaded
area
Broke
in
threaded
area
R_
w 3)
165
Notched-
_04
t_
(K t -
1144
(16002
3)
10,000,000+
1_,.
-414
(60)
S,000
~."_
1_4
376
345
345
(SO)
(50)
10,000
15.000
17_
276
{40)
128_000
L93
278
(40)
180,000
109
207
(30)
1,389,000
192
207
(30)
2,543,000
203
272
(25)
)47,000
,90
338
(20)
--
bara.]
i
734,000
= :
.
t0ut
CyC1o_
£allu_o
5,000
6,000
140-1
--
8_
plus
ptul
689 (100)
689 (100)
132
Sn,OQth
2 bourse
5 hours,
20 houri
feet
termlfiated,
Test
term(hated,
Test
term£h_ted,
Test
terminated.
altern&t_
Teet
ep_c_._e_
:o_=h_ned
to
0.500-cm
(0.20C_£n_h)
_ge
diamet_r
131
_'-_,
" TABLE
XLVZ_.
_
i"
Huat
HIGh-CYClE-FATIGUE
TEST
treatnmnt:
(2250e¥1
{1SOd°F)
(1600°F)
1505oK
1255"K
I144°K
;
i ""
10.64-Cm
10.25-1noh)
test
sp.clmens
RESULTS
for
for
fO¢
ON
RT-21
2 bourse
5 hours,
20 hours
maohined
"from
COA_D
DS MAR-M
247
p1_s
plus
separately
hast
test
bars.}
A1ternat_ng
_
"
•
Specimen
number
DI
._
131
:-_'
_
.-•
"
_--
Smooth
-
to
Cycles
failure
Remarks
483
(70)
127
414
(60)
57,000
13
414
(60)
545,000
Broke
in
threaded
area
110
379
(55)
629,000
Broke
in
threaded
_rea
112
379
155)
1,018,000
Broke
in
threaded
area
123
345
(50)
1,316,000
BrQke
in threaded
area
163
345
(50)
1,076,000
Broke
in
threaded
area
167
276
(40)
7,320,000
Broke
in
threaded
area
197
241
(35)
10,000,000
202
241
(35)
10,dO0,0004
414
(60)
32,000
Test
terminated
I',-
179
16
379
414
(55)
(60)
125,000
293.000
18
175
545
345
(50)
(50)
1,435,000
645,000
168
276
140)
136
171
276
310 (401
(4s)
30,000,0004
139
241
1351
10,000,000_
Te_t
terminated
137
207
130)
10,000,0004
Test
te¢lulnated
"
S
_'
132
A
Ratio
=
11600)
terminated
_i
:,
1144
47,000
17
"
Smooth
RT
stress,
MPa.
(keel
'
_ii
_
Confiurntion
u_e
(_P)
_KPera
,,
_--
....
_
A a
Ratio
alternatln_
stress
mean
steels
3,672,000
Broke
Broke
23s,oodTest
_n
threaded
area
in
threaded
area
terminated
J
TABLE
XLVIII.
HQat
(0.64-cm
XIGH-CYCLE-FATIGUE
treatment:
(0.25-1nob)
test
130-I
b
i i
154
129-1
_-_
133
128-I
110
126-1
b
b
129
128
155
-
126
156
•
RESULTS
ON
DS MAR-M
(2250°F)
(180d'F)
(1600°F)
foe
for
foe
2 hours,
plus
5 hours,plus
20 h_ura
speolmons
ma=htnQd
from
separately
a
Specimen
H.mh._
TEST
1505"K
1295°K
I144_K
cast
247
tQlt
bars.]
Alter_atln_
Configu_atlon
A
Ratio
T_KPera
urB
.=
(_F)
SmOoth
0.95
RT
MPa8tress,
(ksi)
to Cycles
failur_
...
R_mark_
684
(100)
121,000
b
689
621
(i00)
(80)
176,000
3?8,000
b
b
621
552
(90)
(00)
438,000
1,210,000
552
(80)
6e087,000
483
(70)
1,566,000
b
b
483
448
(70)
(65)
2,884,000
!0,000,000+;rest
terminated
b
448
(65)
i0,000,000
terminated
414
(60)
I0,000,000+
Test
terminated
414
(60)
]0,000,000+
Test
terminated
Test
terminated
;
Broke
in threaded
b
b
q
159-1
621
(901
71,000
586
(55)
646,000
186
512
[75)
141
483
(70)
3,741,000
i l
I08
104
552
483
(80)
(70)
i0,000,000+
446,C00
i
161
448
(65)
245,000
169
166
142
414
414
448
(60)
(65)
(60)
10,000,000+
10,000,000
8,319,000
Test
terminated
377
(55)
i0,000,000+
Te_t
terminated
345
(50)
446,000
•
_aooth
0.95
144
i
143
I-
_
a
R Rat_o
= alternati_
b
T_st
speelmen
1144
(16001
I
187
"
area
;
10,000,000+
stre_s
remachlned
to
0.508-am
(0.200-Lnch)
game
dLamete_
133
134
.+
%,
TABLE
LI.
ESTIMATED
SPECiMEnS
TEST BARS
ENDURANCE
MACHINED
LIMITS OF DS TEST
FROM SEPARATELY
CAST
!
"_
Estimated
endurance
limit
_
J
at
_i_.oy
Temperature,
°K (oF)
Notched
specimen
R_sults
MAR-M
10 7 Cycles,
Coated
specimen
MPa
310
(45)
138
(20)
Yes
241
(35)
(ksi)
at A = _
247
Room
No
No
IMAR_M 247
Room
Yes
No
Room
No
_
i"
MAR-M
247
MAR-M
247
1144
(1600)
No
No
262
(38)
4AR-M
247
1144
(1600)
Yes
No
138
(20)
MAR-M
247
1144
(1600)
No
Yes
262
(38)
MAR-M
200+Hf
Room
No ....
NO
310
(45)
MAR-M
200+Hf
Room
Mes
No
124
(18)
MAR-M
200+HE--
i144
(1600)
No
No
262
(38)
MAR-M
200+Hf
i144
(1600)
Yes
No
193
(28)
Results
MAR-M
247
MAR-M
247
136
Roomi144
(1600)
_
at A = 0.q5
No
No
462
(67)
No
No
379
(55)
._mh
d,
J
:h
5.
Phys_ical
properties.
Research
Institute
on.the
MAR-M
247
_
_
!•[_
tion.
Tests
i_
the
i__-
curves
are
i
curves
in Figure
two
i "
_
and
alloys
tensile
were
test
were
by
conducted
Southern
expansion
and
in
the
fully
heat-treated
in triplicate
and
the
alloys
virtually
in
thermal
identical.
Figure
42
and
conductivity
The
the
of
condi-
properties
thermal
thermal
of
expansion
conductivity
43.
modulus
of elasticity
data.
and compared
"
made
presented
Static
thermal
NASA-TRW-R
were
Tests
The
static
to the dynamic
Institute
in Task
II on
-__
methods
of measurement
_
at elevated
was
moduli
moduli
the
determined
are
presented
determined
same
from
the Task
III
in Table
LII
by Southern
Research
alloys.
Results
agree
at room
temperature,
generally
DS
of
the
two
but not
temperatures.
i
i_;
'
i
:T-
6. Oxidation
and hot-corrosion
testin 9. - Oxidation
and hotcorrosion
tests were conducted
in an AiResearch
test rig on sam-
!_t
ples
!L
....
of coated
and
uncoated
The
test
rig design
is
shown
schematically
DS
is described
i=_,.
and
i_- _
_
Figure
45.
The
corrosion
burne_
Z,
study
hot
corrosion
of
i' _
burner
rig
has
following
_<i
o
-
perature
either
44
and
temperature
and
coatings.
in
paragraphs,
the
photos
of
oxidation/hotin industry
to
The
AiResearch
features:
measurement
pyrometer
by fuel
system"
flow
and
that
or airflow
Automatic
between
points,
in burner
addition cycling
to controlled
room
"
Figure
superalloys
radiation
in the following
is a version
of an
been used extensively
Automatic-temperature
Ircon
o
in
burner
rig
rig that has
the
alloys.
control
can
with
control
to within
an
tem-
_I0°F.
two temperature
automatic
cycling set
to
by airblast.
137
k
20
"
i
'
i
15
_
"
55
o_
oo1
!
i
367
478
589
922
1035
1144
1255
(200)
(400)
(600)
(800)
(1000)
(1200)
TEMPERATURE, oK (OF)
(i400)
(1600)
(1800)
i'
b,
[
_
700
r
Figure
42.
Thermal
Expansion
and NASA-TRW-R
138
r
.......
• -
._
NASA-TRW-R
of Exothermlc_lly
!
LL
811
.
Cast
DS MAR-M
247
k
1A0(250)
'"
1.12(200)
_0.56(100)
o.84115o)
_0.281501 -
_
0
'
0
''
,
1366
0%120001
_ 1.401250)
_ 1.1212001
>--0.84(1501
_ 0.6611001
'
-I
0.28150)
u,.I
"r'
I0
I
I
I
367
(200)
478
(400)
589
(600)
I
-
I
|
I
I
700
811
822
1033
1144
1256
1306
18001 11000) 112001 114001 116001 118001 120001
TEMPERATURE, OK (OF)
b.
Figure 43.
I
Thermal Conductivity
and NASA- TRW-R
NASA-TRW-R
E,_othermlcally Cast DS MAR-M 247
139
q
,,.
_"
SEA SALT
|
I
USED FOR CYCLING BURNER AND
AIR_UENCH NOZZLE ....
I
I
F
ACTUATOR
'
CONTROL
AIR-
'_
NOZZLE
QUENCH
IGNITION
!
f
SPECIMEN
ROTATION
_
MOTOR
if"
SLIP RING
_
SPECIMENS
IGNITER -_
!
AIR
SUPPLy
I
:o :
ir
FUEL
fr
OVERTEMPERATURE
SHUTOFF
SHUTC
!i
RADIATION
PYROMETER
ILTER
..............................
[_
CONTROL
-'_
CONTROLLERRECORDER
FUEL FLOW
CONTROL VALVE
f:
•:
TOTAL
TEMP.
TEMP.
TIME
TEST
TIME
ONE
TIME
TWO
t
Pig_re
44,
Sohematic
of
Hot-Corrosion
AiResearch
Oxidation
Burner
Rig
141
'
TEST FACILITY
CONTROLS ....................
OXIDATION/HOT-CORROSION
-_.
•
Figure
142
45.
Oxidation/Hot-Corrosion
BURNER RIG
Burner
Rig
_-+
o
Controlled
_
fur,
._r
any
other
of aqueous
desired
sea
salt
solutions,
contaminant
to
the
sulburner
flame.
o
Sophisticated
o
cyclic
undesirable
conditions
Sample
The
test
"
are
system
testing
hours
oxidation
ever,
the
corrosion
at up
to 2000
rpm
to ensure
burner
in Tables
and
all
sam-
test
conditions
and
and LIV.
No
significant
in Table
247
sample
at
1200°K
alloys
that
as shown
MAR-M
coated
samples
247 samples
uncoated
three
test
MAR-M
(1900°F)
Of the
rig
LIII
on the coated
hours
if
same_hurner._conditions.
1311°K
310
shutoff
a test.
eight
at
after
during
hold
to the
continuous,+
automatic
normally
exposed
was observed
with
allow
that
are presented
degradation
to
develop
oxidation/hot-corrosion
results
LIV.
holders
be rotated
ples
+-
control
unattended
can
was
heavily
(1700°F)
exposed
after
LIII.
How-
attacked
as
in the same
510-
shown
by
in
hot
Table
hot-corrosion
test, MAR-M
247+ showed
very
little
attack,• while
the coatings
failed
at areas
of lower
temperature
on the MAR-M
200+Hf
and
NASA-TRW-R
_--_.
i
or
addition
7.
....
alloys
as
shown
Metallo_raphic
Micro-Met
examination
in Figure
examination.
46 ....................................................
-
With
the
assistance
of
Laboratories
Indiana,
metallographic
was performed of onLafayette,
three
high-rupture-time
MAR-M
247
stress-rupture
specimens.
The
(refer
XXXIX)
as
to Table
was
basic
shown
stress-rupture
in Table
test
history
LV:
143
+
T
L
D-
,I
BARE
__ ;_
MAR-M247
RT-21 COATED ALLOYS_
MAR.,M247
MAR-M
200+Hf
t
NASATRW-R
..
t
_
/
FigUre
Exposure
1200°K
(1700°F)
to 5 ppm
Synthetic
Task
III, atHot-Corrosion
Specimens
after
310-HoursSea
Fuel
Salt
l_-i
i
46.
"'"
"
146
Added
to the Combustion
Products
of Jet-A
k,r
TABLE----LV' BASIC
temperature,
OK (°F 1
TEST
HISTORY
i
_
Specimen
number
_:
148-6
1033
(1400)
668
(97)
1259.9
148-1
1144
(1600)
317
(46)
1270.0
1.59-11
1255
(1800)
131
(19)
1678.3
,
Test
STRESS--RDPTDRE
Stress,
MPa
(ksi)
Rupture
time
hours
_i
,
[
:
!
Initial
acicular
phase
(1800_F)
as shown
fracture
in the gauge
)
ii
formed
by
in Figure
examined
of
test
specimen
159-11.
length
acicular
structure,
area
of
the
suggesting
test
force
acicular
phase.
Stressed
exposure
of
I144°K
(1600°F)
did
not
produce
cated
by Figure
48.
extensive
metallographlc
work
atories.
These
acicular
performed
confirmed
the
near
the
Examination
specimen
showed
in the formation
driving
results
was
1255°K
thermal
the primary
the
at
an
that
was
this
stress,
thread
that
testing
section
the
than
stress-rupture
The
in the
rather
established
47.
section
same
AiResearch
during
of another
o£
[i
examination
exposure
specimen
148-1
structure
as
by
Micro-Met
acioular
phase
at
indi-
Laborformed
at
49 and
and identified
50 illustrate
of the results
the
1255°KFigures
(1800°F),
it as some
the M6Ccarbide
phase. of This
evaluation
included a second 1255°K
(1800"F) stress-_upture
specimen
(148-7,
the
same
to
a condition
exposure
mately
in
heat
time
1600
The
phase
646.2-hours
time)
specimen
159-1.
1283°K
(1850°F)
o£
at 1255°K
(1800°F)
from
Both
a different
bars
such
mold
but
of
were
further
exposed
the
total
combined
that
and
1283°K
(1850°F)
was
approxi-
the
morphology
of
the
acicular
(1800°F)
specimens,
as shown
hours.
general
is very
Figure
as
rupture
49.
structure
and
similar
in both
1255°K
In
contrast,
Figure
50
shows
the
structure
of
147
m,
-
(MAG.:
Figure
148
47.
Microstructures
of DS MAR-M
Specimen
No. 159-11
Tested
(1800°F/19
ksi)
for 1678.3
of Acicular
Phase
500X)
247 StresR-Rupture
at 1255°K/131
MPa
Hours.
Note Needles
L
=,.
V
(MAG.:
Figure 48.
IOOX)
Mierostructure of DS MAR-M 247 Stress-Rupture
Specimen No. 148-i Tested at ).144°K/317 MPa
(1600°F/46 ksl) .Jr 1270 Hours.
The Acicular
F_,rmed at 1255c_ (1800°F) is Absent
Test
Phase
149
.
•
t_
(MAG.:
lO00X)
__
,
(MAX.:
Figure
150
49.
IO00X)
Microstructures
of DS MAR-M 247 Stress-Rupture
Test
Specimen
Nos. 159-11
[Tested at 1255°K/131
MPa
(1800°F/19 ksi) for 1678.3 Hours] and 148-7
[Tested
at 1255°K/151.7
MPa
(1800°F/22ksi)
for 646.2 Hours].
Specimens
were subsequently
Exposed
_t 1283°K
(1850°F) for a Total combined
Time of Approximately
1600 Hours.
The Acicular
Phase is Evldcnt
_n Both
Specimens.
Tnc.
Metallography
by
Micro-Met
Laboratories_
.-
(MAG.:
Figure
50,
i000X)
Hicrost_ctures
o_ DS HAR-M 247 Stress-Rupture
Test
Specimen
No, 148-i.
Specimen was Tested
at 1144°K
317 MPa (1600°P/46 ksi) _
_270 Hours.
No
Acicular
Phase was Present.
Metailography
by
Micro-Met
Laboratories,
Inc.
151
4a
d.,¸
_,
stress-rupture
specimen
148_i
tested
at
I144_K
(1600°F)
for
1270
I:
hours.
(1000X
No acicular
or 3000X).
phase
was
evident
at
either
magnification
\
k
! _
Probable
I i,
_c
phase after
accomplishe_
i _"
fro;_ the
1283°K
i .
, -
identification
of
(1850°F)
a new,DS
blade
The
to accelerate
the
kinetics
of
Figure
lower
photo
depicts
extraction
from
extracted
residue
51 depicts
the-second
the
of
the
were
adverse
effect
1255°K
(1800°F)
The_e
results
metric
llfe
were
acicular
The
was
formation.
The
phase
bla_e
platelets-
identified
formed.
after
The
chemical
present
as
to
temperature
plate
in this
expose_
M6C.
in
In
the
fully
M6C
forms
with
time
at about
1255°K
carbides
oriainally
present
in the as-
strength
long-time
completely
predictions
the
phases
structure.
on either
higher
acieular
positively
heat-treated
(158-14)
the
matrix.
heat-treated
MAR-M
247,
(1800°F)
from the script
!'
247
hours.
on
152
MAR-M
I000
photo
and
occurance
for
upper
cast
the
stress and temperature
exposure
of 1255°K
(1800°F) was
by extraction
and
identification
of second
phases
matrix
selected
of
made
This
structural
or _uctilitv,
stress-rupture
chanae
as evidenced
tests
on
MAR-M
consistent
_:ith Larson-Miller
from
time
shorter
test
data.
has
no
by the
247.
para-
FiguEe
51.
(MAG.:
2000X)
(MAG.:
3000X)
Acieular
Phase Formed in DS MAR-M 247 Specimen
159-14 After Exposure
to 1283°K
(1850°F) for 1000
Hours.
Upper Photo Shows Acicular
Phase in
Microstructure,
The Bottom Photo Shows the Second
Phases After Extraction
from the Matrix.
Metallography
by Micro-Met
Laboratories,
Inc.
153
O0000002-TSFO
vI
.I
".
•
TASK
IV
- BLADE
DESIGN
4
Scope
Task
.
o2ment
IV
of
a
task
performed
was
designs
provide
a
blade
development
of
the
-
based
.-
gram.
_
L
blade
design.
sary
to
modify
of
the
the
blade
into
b ine
components
Tasks
the
Tasks
TFE731-3
process
I,
II,
III.
data
and
and
e_.gine.
This
III.
Two
preliminary
_"
to
in
and
associated
design
early
the
in
was
the
pro-
pre-
four
alloys
during
the
the
used
this
permit
in
use
from
nozzle,
assembly.
program
obtained
of
disk,
the
data
were
geometry
in
other
III
accomplished
:
This
collected
and
was
high-
for
casting
If,
engine
DS
and
early
suitable
of
the
If,
DS
247
Engine
J
IV--the
established
each
turbine
devel-
design.
in
The
I,
Task
cast
I,
the
cast,
turbofan
Tasks
in
properties
blades
final
154
[-
material
of
with
design
exothermic
MAR-M
design
TFE731-3
was
casting
preliminary
performance
ponents
design
of
Actual
the
final
evaluations
on
!iminary
the
requiredfor
exothermically
established
and
preliminary
material
for
k
activity
concurrently
were
design
design
uncooled,
blade
The
to
the
solid,
turbine
(initial)
•
_ncluded
pressure
blade
_ _--
i
q
The
Task
in
establishing
design
and
other
effective
redesign
IV.
made
the
it
neces-
turbine
com-
integration
of
these
of
tur-
i
i
"i
E,
_,,
Preliminary
Design
- High-Pressure
_
Aerodynam/c
design
- preliminary
TurBine
design
(HPT)
blade.
nar_
blade
established
design
using
only MAR-M-247
material
for design
and casting
purpgses
while
i
i
ii
effort
in
progress
the
aerodynamic
design
_;
are
shown
_:
was
in _ables
on
the
final
of-the
LVI
airfoi_
selected
through
LVIII
q
Blade
The
prelimi-
_i
properties
was
a comprehensive
design.
Details
preliminary
blade
and
52
Figures
of
airfoil
through
59,
i "
!
i,
'::
blade
i!"
vector
follows:
Vector
design
diagram,
_he
flow
the
as
the
existing
Figure
52
for
nomenclature)
distribution
of
the
was
diagram
(a)
_
(see
The
radial
and
the
Tables
_i
i
'
same
rotor
LVI
and
increases
relative
exit
LVII
in
and
while
_2
results
in a higher
is favorable
from
_
(b)
defined
as
angle
between
the
tip
the
ratio
2.
diagram
yields
corrected
mass
engine.
The
distribution
numbers,
flow
angles
reaction
are
Blade
qeometry,
design
sections,
one
one
the
at
tionship
tions
_
and
and
in
tip
[R
at
in
angle,
the
hub
cm
flow
the
LVIZI.
angle,
=I'
shown
in
blade,
from
hub-to-tip.
This
but
of
lower
twist,
stress
and
difference
in
the
which
_ibrastagger
pressure
o_..the
_tandar_
critical
inlet
..
Math
and
exit,
and
is generated
from
two
54.
inches)],
data
same
relative
rotor
= 10.77
Table
as
this
the
[R
geometry
defined
are
In
as.that
design
The
the
hub).
blade
(5.57
_2t
52.
the
in Figure
This
= 14.16
between.
is presented
shown
at
with
exit
essentially
of
preliminary
Engine
stator
hub reaction
the
viewpoint
is
the
TFE731
decreases
(Twist
vector
for
Figure
tion.
The
::
path-used
cm
(4.24
with
defining
a
inches)]
linear
the
blade
and
relasec-
155
L
,"i
_
I
V
J
ii
TABLE
LVI.
STATOR EXIT FLOW ANGLE DISTRIBUTION
PRELIMINARY
DESIGN BLADF,
Radius_
R cm (in.)
Stator
exit
flow
deg.
angle,
10.985
(4.-325)
62.234
......
il.270
(4.437)
63.175
11.557
(4.550)
64.124
11.849
(4.665)
65.084
12.141
(4.780)
66.057
12_.441
(4.898)
68.060
13.063
(5.143)
69.097
13.385
(5.270)
70.167
13.721
(5.402)
71.276
14.072
(5.540)
72.434
TABLE -LVII.
ROTOR EXIT RELATIVE
TASK IV PRELIMINARY
- TASK IV
_I'
FLOW ANGLE DISTRIBUTION
DESIGN BLADE.
i
Radius,
R
cm (inll
=
156
[
I
]
Rotor
exit
relative
,-
flow
deg.
,m
10.275
(4.242)
-59.357
11.214
(4.415)
-58.757
11.613
(4.572,)
-58.242
11.984
(4.718)
-57.824
12.334
(4.856)
-57.411
12.667
(4.987)
-57.003
12.984
(5.112)
-56.609
13.292
(5.233)
-56.211
13.589
(5.350)
-55.788
13.876
(5.463)
-55.377
14.155
(5.573)
-54.957
angle,
_2'
i:,
WHERE,:
STATION
1 IS STATOR
EXIT PLANE
STATION
2 IS ROTQR
EXIT PLANE
V
=
ABSOLUTE
VELOCITY
W
=
RELATIVE
VELOCITY
U
=
BLADE
U1
Figure
158
52.
U2
Vector
Diagram
Nomenclature
VELOCITY
__
-.
159
R = 10.80 CM (4.24 IN.)
R = 14.16 CM (5.57 IN.)
Figure
162
57.
Rotor
Stack
at CG,
Plane
Sections
L;.
Z
I':
A 2_
1'5 F
:
Figure
58.
Area
Distribution
of the
Rotor
Blade
12C
:
_i.
_ io(
Z
Z
_W
2c
Ig
I
0
I
20
Figure
I
I
40
60
PERCENT AXIAL CHORD
59.
Loading
of
the
80
Rotor
100
Hub
163
Tile blade
and
56,
Figure
tip is shown
and
shows
as the stacking
axis
the
stack
q£
high
camber
a large
trailing-edge
blade
vibration
2reliminaty
design
angle
preliminary
inch)],
area
distribution
Blade
sections
of
blade
a camber
at the
an area
is shown
_i
the low-t_i_t
_
wedge
angle
the
helps
tip
region.
92
degrees,
and
tip ......
The
tip
section
of
the
[Tmax =
0.28
cm
of
in Figure
58.
thick
2.5:l_-tip.
calculated
preliminary
blaoe
of
ratio
The
the
1
_k
in
w.%s_ relatively
loading.
the
had
with
55
design.
especiallz
blade
yielding
this
problems,
of 6 degrees
design
(0.ii
3.
with
in Figure
illustrating
feature
half-wedge
At
hub
17 minutes)
A
and
the
57
gravity
(14 degrees,
The
of
respectively.
cente_of
avoid
geometry
loading
design
blade
a degree
of
are
of
a
The
the two
shown
design
in Figures
59
60.
The
hub
section
this
value
it is
in the rear
chord
inevitable
portion
position
has
of
of 37.5
that
reaction
of
13.2
some
deceleration
the suction_surface,
beginning
percent.
The
corresponding
percent.
will
occur
at an axial
velocity
ratio
for this deceleration
1.19.
For the tip
process
section,
is 1.23, and the pressure
ratio is
where
the reaction
is relatively
high,
to design
a suction
it is possible
surface
with
continuous
acceleration.
None
of
mum
values
hub
and
wedge
T
the sections
of
the
surface
0.81
for
the
angle
in Figures
164
f
will
not
59 and
60.
exhibit
tip.
cause
a supersonic
critical
Mach
number
Therefore,
the
loading
region.
the
to
is
high
0.91
The
maxi-
for
the
trailing-edge
deteriorate,
as
shown
!
9*
:
165
L
:r\
_"
The
percent
trailing-edge
a_-_he
._
, i-
(4.24
value
i :
;
the
,_=_
wa_; =alculated
i "
stresses
! "--
and
_i_
_
determined
Figure 62,
Figure 63.
tip,
blockage
The
huh
is 13
values
percent
[12.2
at
percent
the
and
5.2
at R - 10.77
cm
inch)]
is comparable
to the ori@inal
deslsn
(8.5 percent)
is lower than the original.
Stress
and thermal analyses.
blade as defined
in Figure 58,
are
a_erage
at
the
take-off
shown
in Figure
metal
temperature
while
the
tip
With the area distribution
of
the average centrifugal
stress
condition
61.
hub
Using
for
of the
MAR-M
247.
the
calculated
uncoated
blade
These
stresses
as
shown
in
based
on preliminary
DS MAR-M
247 da%a
as shown
in
the stress-rupture
life
of the blade
airfoil
was
The
calculated
stress-rupture
life
is
listed
in
[
Table
LIX.
_"
•
TABLE
LIX.
CALCULATED
I_.
CRITICAL
ii
:
i!
SECTION
AT
LIFE
TAKEOFF
'_
cm
(inches)
Radius,
i_
11.18
(4.40)
i
11.68
(4.60)
'i
11.94
11.43
12.19
,,.
a
MPa (ksl)
Stress,
....
Normalized'Stress-
°K (°F_
Temperature,
Life
Rupture
211.7
(30.7)
1193
(1688)
1.37
189.6
(27.5)
1213
(1724)
1.00
(4.70)
(4.50)
(4.80)
175.8
199.9
162.0
(25.5}
(29.0)
(23.5)
1215
1208
1215
(1727)
(1714)
(1727)
1.64
1.03
2.74
Critical
Section
a
The
calculated
life
with
reference
to
No
150-hour
effort
for
166
the
critical
operation
cyclic
was
define a blade shank
tions was considered
:
SHOWING
CONDITIONS
Calculated
planned
i[
STRESS-RUPTURE
made
in
engine
in
the
section
exp_cted
at
take-off
environment
condi-
of
the
activity
to
test.
the
preliminary
or platform.
acceptable
for
design
the preliminary
design
blade
k
d
27_(4G
207(3_
13812(
0
HUB
Figure
RADIUS
61.
Average
Centrifugal
Stress
Preliminary
MATE HPT Blade
Design
TIP
--
1255
¢" (tSOO)
"-
D
(l?oo)
116001
_B55
(15oo)
HUB
Figure
"
RADIUS
62.
TIP
Metal Temperature
-- Preliminary
MATE HPT Blade Design
167
, ±,l
B ',¸¸
, '_
km _
_
621190).
552(80)
%
483(70) -
,i
414160)
'i
3451503
r_ L"
276(40)
"
_
- .
_
2071301
7"
_ Ji"
. <
.-
_
1381201
691101
42
--
44
46
LARSON-MILLER
Figure
;
.
I£S
63.
Preliminary
f;¢_]
idifJed
48
50
PARAMETEfi
Stresr,-Ruptu_e
MAR-M
247
Data,
52
(C---201
Di_.cctJoi;_]]y-
54
•he
Final
Design
final
design
i
directlonally-solidified
_i
TFE731-3
utilized
determined
in Task
of
the
il_
As
of
!_!i_
I
Only the final
temperatures,
high-pressure
exothermically
turbine
the material
properties
III.
This material
was
cast
blade
of DS
selected
for
MAR-M
based
the
247 as
on the
desiQn
aerodynamics
of
the
and
Figures
64
through
for
i.
the
as
the
-
final
d_sign
design
blade
result
metal
blade.
of
the
Vector
Diagram.
A different
vector diagram
final design blade even though the flow path
is required
is the same
Figures
mixed-out
64
77.
high-pressure
through
vector
are
Details
i[[__Table_LX
TFE731
turbine.
67.present
characteristic
diagrams.
Figure
64 shows
the
angles
at
data
of
the absolute
the
critical
.
Mach
i
numbers
the
hub
_
flow
the
stator
inlet
and
Figure
65
shows
the
relative
critical
Mach
numbers
relative
flow angles at the rotor inlet and exit, while
shows
_
and
rotor
reaction
low
percent),
while
previous
designs.
This
than
total
relative
temperature,
dimensionalized
versus
The
(14.3
lower
inlet
reaction.
by
the
the
radlus,
T",
absolute
twist
the
diagram
exit.
and
the
Figure 66
yields
a high
slightly
tip
reaction
is
reaction
results
in a higher
in
total
is shown
1
_7
presented
original
final
k
plus excellent
potential
for
in the gas turbLne
industry.
results of these analyses
are presented
herein.
stresses_
vibrations
and
other
considerations.
Aerodynamic
__
I
Blade
in all turbine blade designs,
the final design was the
m_ny interactions
and tradeoffs
between
aerodynamics,
_ _
h
Turbine
uncooled
test results obtained
in this project,
future hlgh-temperature
applications_
2
i
- High-Pressure
the
hub
region.
temperature
in Figure
at the
T",
non-
turbine
67.
169
1-'/0
JO,,
V
J
A
UaBINNN HOVIN "IV-'_I.LLUO
P
o
o
o
o
I
t
l
I
0
o
\
-
I,-
_
1
\
\
1
"
_
ul
o _i
\
0
°
",I_\
g_
'_°
i H
(8=J=IUD3O) t_ ':I'IONV
°
"_
ii, _
MOq=I
171
..
•i
I
ip
40
_,,.
,,V/M
O
I
1::t::ISIAINN
H3VlAI "IVDIJ.lUO -=IAI.LV3=IU
0
0
I.....
I
I
,.l
®
_,
r
;:
,7
[-
-
g
&
I
8
1"/2
I
o
I,,,
!
I
ii
•
\
B0,
R_AGTI_N
_..
!
" _2
20
lr
1
• "_
--
HUE
RADIUS
Figure
66.
Reaction
T '_"
Versus
Radius
0.93
T"
•
RELATIVE
TOTAL
TEMPERATURE
AT
ROTOR
INLET
T'INLE T "ABSOLUTE
TOTAL
TEMPERATURE
AT ROTOR
INLET
1
T"
•
T'INLE T
0.92
,
J
,
0.91
HUB
[i
TIP
RADIUS
i':_
Figure
67.
AT ROTOR
Rotor Relative
Total
by the
Inlet
Absolu.te
Raaius
INLET
Temperature
Nondimensionalized
Total
Temperature
Versus
173
¥
=i,
:
R - 10,9 CM (4,3 IN,)
"
_,_
:__
195M/SEC IV_
1651 FT/SEC) .._1_
:'-
HUB
_
10;20°-
_
--
-
MEAN
12.4 CM 14,9 IN,)
1,9°
.,._ ._.
__
57"80- f
243 M/SEC
R " 14,1 CM 15,5 IN.)
..o_,_15_ '_
3.5°
R
R = 14.2 CM 15.6 IN.)
1543. FT/SECI
74_/_?_.
0
"_'_;
_4,O
165
M,S_C
j
,_,
""
@/
Figure
'
_i
,_ _- I
i-
7
151_
./
-_!-
i
_,
R = 1'0.8 CM 14,2 IN.)
"-
i
38.5
°
_7,
68.
Velocity
Triangles
of
the
Final
Design
0.
0.25(0.10) 0.5(0.20)
CM (IN.)
Figure
176
70.
Rotor llub Section
MATE Final Design
[R = 10.77
cm
(4.242
in.)] of
the
I
0
I
•-
I
0.25(@.10) 0.6(0.20)
,,=
CM (IN.) ..........
I
i
[
Fig_e
71.
Rotor Mean Section' [R = 12.37 em (4.872 in.)]
of--the MATE Final Design
177
k
I
i
F
!
0
[,:
_igure
178
72_--Roto_
MATE
0.25(0.10) 0.5(0.20)
CM (IN_)
Tip
Section
Final
Design
[R_--_14..t6
cm
(5.57
inches)]
of
the
I_
¥
1,0
HUB
TIP RADIUS
Fiqure
73.
Final
HPT
Blade
Area
Distribution
179
_0
w
!
p-
HUB
Figure
74.
RADIUS
Trailing-Edge
Blockages
TIP
Versus
Radius
.!
+i
0,60
0.40
0.2O_J
=
Figure
180
++
o
J.
2O---
75 ......
Rotor
(4.24
I-.
.
,
I
40
W
PERCENTAXtAI. CHORD
Hub
SecEion-Loading
inches)
] of
the-F_inal
I
$0
[R
,.,
= i0.77
Design
_0
cm
!r
....
_
_.o©
0_c
i :"
!
i °O2O
:?
.T AX,AL
C.
!
Figure
76.
Rotor
(4.87
Mean
Seetion
inches)]
of
12.3
Loading
the Y_nal
Design
[
t
i
k-
,If
Figure,,.
_ t_
/,
_ip:i;;_;;L_F_ga
t RDislg4
n 16
c'm
181
...........
_J
....
I
¥
The
velcckty
and_the--tip
_t_eamlines
dynamic
design
hub
tip.
to
triangles
and
small
radial
variation
highe_
relative
tip,
and
(Figure
Using
small
radial
exit
flow
angle
low
The
byflow
angle
at
hub
(E/sure
64.)"
This
".,illyield
inlet
flow
that
at
angle
the
tO
hub._
tip,
the
rotor
This
results
15
degKees
between
incidence
for_the
tip portion:
increase
the
resulting
variation
_2 at
design
The
exit
be minimized.
exit
only
will
inlet
in a small
of
_2
hub
blade
at
and
a
the
in a
and
tip:
Negative
angle
variation
is obtained
tip,
and
increasing
yields
a
work
shows
the
cur_e
sionalized
by th_
work distribution
very
the
in
the
of the inlet
angle.
The
6K.
at
both
k
65).
tip region,
Figure
stator
of
incidence
This
from
_l and _lmust
negative
blade
stagger--angles
angles,
decrease
difference
aero-
variation-of
is obta/ned
the--mean,
Low-twist
the-radial
the
it
68.
this,
of _I
reducing
in-Figure
the_hub,,
of
blade
Increasing
(b)
shown
to
va_-iation
achieve
the exi_
(a)
are
requires-little
To
inlet
corx_sponding,
For
distribution
work
example,
values_at_the__tu_hi_e_exit
Exit
Swirl
decreasing
it at hub,
(Figure
as
distributions
average
value for the
provides
nearly
zero
loss.
by
show_
mass-momentum
1.81
degrees
65).
in
nondimen-
whole stage
(Hm).
average
exit
swirl
the
the
The
and
avezaged
are_
Angle
Exit Absolute
Mach Number
m
CDitical
=
0.386
182
7
.......
L...............
L"=.....
,; - "
2./_°
Blade-GeometrY,
used-at
the
The
--
following
cm
(4.87
Ti[>:
R___ 14.16
cm
(5.5-7 in.)
and
exit
to
trailing-edge
Thez
avoid
wedge
larger
tend
ti_
angle
from
the
to
is
d/rected
and-a
toward
wedge
high
vector
angle
with.
problems.
thick
camber_
trailing
edge
decrease
the
a_ea
ratio
if
they
twist
may
e_entually
be
further
down
and
the
angles
and
2_hroat
width.
a number
of
tip nose
ing
the
blade
geometry
was
generated
the
compromise
through
between
in_the
can
especially
the
hub
mechanical,
a
However,_
_enalty,
by_mo_ing
best
in.)-
'
vibratory
area._-_The
both
k
are- obtained-
trailing-edge
efficiency
also
are
65)_,..........
configuration
edge
large
conditions
sections
blade.'
R = 12.38
and. a. large
trailing
this
Mear_:
(see Figure
twist=
to define
des/gn
R = 10.77, cm--(4_14-in.)
The blade
a
radii
cylindrical
Hub4-,
inlet
diagram
Three
nose
.th_icker
a
in
a
decreased
while
maintain-
final
iterations
and
in
range.
result
The
thermal,
large
result
transonic
up,
low
blade
to obtain
aerodynami_
requirements.
The
blade
geometry
in
Table
LX.
given
C-
Eigu_-es--70,_71
is shown-hn
""
Figur_
and
Figure
data
The
72--
fo_
three
these
three
design
the
sections
are
are- shown
in
sections
The_ area_distribution
7L3 and
design
trailing-edge
for plane
blockage
sections
is shown
in__
74.
183
T
The
i
lean
and
tilt
for
Radiu_,
cm (in.).
:_
:....
:
f-
this
Lean
_o CG
10.774
(_.242).........-_
12.375
[4_B7._)
14.155
(5.573)
blade
are__shown
Rela_iue
[c_ (in,)]
below:v
Tilt Relative
to CG. [cm (in.)]
(0)
-0-
0.0625"(0.0246)
A
(0).
0.0622.
(0.0245):.....................
-Q= ..................
(0]
0.1358
Pos.i.t_ue_learu is. tQward.the
direction_of
is.toward
the trailing
edge.
%
(0.0535)
rotation.
Positive
tilt
3.Roto_ Bl_de
Loading..
Figures
75. through
critical Mach number versus
axial distance
for the
7:7t_show the
three.design
_.7
sections.
is
/'
percent,
it is inevitable
tion
of
the
cause
separation
s_ction
the
I _.
is
hub
section
where
to have
This
the boundary
enough
surface.
to
the
reaction
a deceleration
surface.
of
high
mild
layer.
achieve
The
suction
critical
Mach
L4.3
in the rear
por-
deoeleration_will
The
reaction
a continuous
surface
only
of
of
not
the mean
acceleration
the
tip
of
section__has ...........
deceleration.
The
relative
Consequently,
_=
the
suction
suction
a minor
ii.
"
For
the
higher
on
_he
the
high
th/ckness
wedge
number
angle
subsonic
high
turning
at' the trailing
and
is
edge
ha_e
everywhere.
as
no adverse
well
as
effects
_7
-
loading_
The. resulting
hligher loading
in
,i_
stant suction
section.
surface
-
The
_
4.4
184
. . J
the
traillng-edge
percent
from
rear
portion,
velocity
near
blockage
hub-to-tlp
high
turning
resulting
the trailing
LX
to
in
con-
a nearly
a
edge
for
the
tip
between
_14.3
percent
to
and Figure
74).
ranges
(Table
contributes
i
Thermal-.Analysis.turbin_
gas
blade
s_ream
The
temperatures
are pzimarily_jdependent
re/ative,
blade/disk
effects-on
metal
to
the
(TGAsk,
relative
gas
uncooled
upon--the temperature
bla_e
firtre_,
rad_iation, and
blade-metal
temR@rature.
of, an
(TB)_,_
of_-the
Conduction
I
k
_,
the
_i
other fact_>r_ haw_only,
The-nominal.-total _as
m-inor
s_rea_
"I
temperatures
cozre-
I
Fisure-q-a.
temperatur_
i
' !
:
temperatures,
!
spondingblade-metal,
temperatures
(TMETAI) are shownln
Details-ofthe- thezmal
fini_lement
.model
and
into
,
....
£TB),
an&
!'I
resu_ts--ar.e_shown
determined
:_
:
in Figures
_considering
_
and
limited
8G..
These-temperatures
cooling
air_
blade/_isk_firtree_region.
Reduced
cooling
seal
platebecause:
for
the
uncooled
of
cooling
air
(a)
A
weze
(b)
retained
limited
Waspaloy
disk
Minimum
hardware
DS
blades
required
_
(c)
Stress
DS
design
"critical
I/4
and-1/3--span
and
design
required
for
the
adapting
the
production
TFE731-3
Engine
a limited
amount of vibra-
for
where
the
Pant
was
when
for
of
aimed
blade,__especially
the
i
the
design
philosophy
for
the
at
increasing
the
life
at
this
of
centrifugal
stress
life.
As
shown
life
in F_gu_e
81,
blade
(4.60
inches)
radius.
the
the
combination
streSs-ruptt_re
in
modes
Traditionally,
decreasing
the
HPT
vibratory
section".
temperature
blade
desired
seal plate provides
analysis_
the
is
forward
enginetesting
stronger
blade
DS
the
changes-were
the
damping
lower,
air. and
to°..the
£irtrees
to
The forward
tion
final
amount
supplied
were
by
_he
blade
section
is
increasing
c_itical-ssction
blade-metal
results
normalized
between
in minimum
_tress-rupture
occurs
at i1.68
cm
185
o
............................................
,
............
_ ......
L "" _'/
.
i
!
_.
'
(40) >1o'auN.I,VU3dWa.I,
186
:
II
!
1
i
i
•
I
I
I
Figure
79.
Grid
foe
Thermal
Model
187
i
TEMPERATURE,
Figure
188
80.
Shank
Model
Final
°F.
MATE
Blade
Design
qt
Figure
81.
Minimum
Stress-Rupture
Life
I/I
189
f_
o!
The-nominal-blade
centrifugal
stresses
are
based
_n the
fol-
"J
Iowiag equation.
k
wber-e_
CENT
m
_entrifugal stress at the-orltloal..sections
,,
1
A
=
Cross
!
p
=
Den,Si-ty of
blade
material
V
=
VOlume
tion
of
blade
material
R
=
Radius
to center
g
=
Gravitational
=
Rotational
section
area
of
the critical
sections
i
,1
......................
i
}
To
reduce
o
the
stress
this
gravity
critical_
of
volume,.-.lV)
the
Maximize
to
reduce
which
the
sec-
_!
velocity
of
_he
airfoil
section
two precepts
were
followed:
tends
there-
stress
the
area
1
1
constant.
Minimize-the
area of..the blade, tip section--this
to-reduce
the load_.on_the critical_section_and
fore
o
at
of
above
of
the
the
stresses
load
is applied.
critical-sectlon--this
tends--
by
over
increasing
the
L90
L
area
I
q
Using
radially
these-two
inward
i_ ths_lade
Figure
ideas
plus
from.both
the-tlp
cross-section
73,
and
an
maintalaln_
and
areas
at-a-minlmum
crLt/cal_ectlons-results
distribution
as_shown
earlier
stress
distribution
as s_own
in Figure
average
area
in.
k
82.
Results
Fi_ure_83
o£
the. detailed
through
9k.
the-stress-a_alysis
alent
the
are
trailing-edge
section
region
stress
is a calculated
stress
field _o
tort/on
energy
material
are
co_ered
new
in
of
_
The
68.
design
respectively,
wi_h
in Figure
The
of
the equivalent
and
that-equates
unlaxial
88.
the
critical
stresses
in the
91.
The
an
existing
triaxial
based
the
stress,
This
realistically
of
equivalent
on
"equivalent"
to
available
of
the
dis-
stress
uniaxial
design
was
designed
to
operate
aerodynamically_
nozzle.
Details
of
thi_
nozzle
design
repQrt.
The
interference
for
The
section
the
Final-Design
the final
shown
The equiv-
Suction..sides
and.defo_matlon
and
breakdown_for.
final
blade
26-vane
Aerodynamic
87,
in .....
data.
&nalysis.
diagram
and
and
elasticity.
more
in a subsequent
viDration
92.
86
_'igures-90
s_ress
theory
turbine
a
89,
an equivalent
strength
pressure
with
shown
compared
Vibration
"
in Figure
presented
_3, 84 and 85.
radius
distribution
shank
be
versus
are
nodal
th_pressur_
in Eigu_es
stress
is shown
then
in Figures
both
shown
analysis
finite-element,
is showa
equivalent.stress
can
The
st.rees results-for
the_ airfoil
stress
of this
final
design
uncooled
blade, is shown
- High-Pressure
Turbine
design.
T_e
stator
vane
was
uncooled_
low
twist
high-pressu4e
high-
a_e
in Figure
Vane
."
redesigned
to match
turbine
velocity
triangles
and vecto_
diagrams
are shown
Design constants
for this vane are as follows:
blade.
in Figure
J
191
Figure
83.
Final
MATE
Blade
Airfoil
Design
193
Figure
--
194
84.
Final Blade Design -- Airfoil,
Platform,
and Shank
|
i
iv
-
t
i
Figure
i
-
_'
_
85,
Final
MATE
Blade
Design
195
i;
I
[
"-_....
EQUIVALENT
Figure
196
86.
\
STRESS_
Pressure
Side
29,692
RPM
....................
Stresses
DEFORMATION
(KSI)
and
Deflections
(MAGNIFIED)
at
•.
....
-
Figure
87.
Suction
Side Stresses
at 29,692 RPM
(KSI)
and Deflections
197
L+
0
HUB
TIP
RADIUS
Figure 88.
198
Final MATE Blade Design Traillng-Edge
Stresses
¥i
F
/
r_
DEFORMA.T.LO_ MAGNIFIED
I
d
EQUIVALENT
Figure
89.
Final
MATE
STRESS (KSl)
Design
at 29,692
RPM
199
liB"
._
_
SECTION 1
""
SECTION 3-'-7
--7
SECTION 2
SECTION 4
I
,
\_SECT,;SECT,ON
A
_-_SEC_'ION. C
(TOP OF FIRTREE)
:
"
-
t
65
8
_
_i_,
1-.
SECTION 1
.
......
SEGTION 3
i
i
\
.
!:
";J{
i
t,
SECTION 2
Figure
$
2(10
90.
Equivalent
Shank
Platform
Removod
SECTION 4
Stresses
(KSI)-.-AirfoIl
and
5
*f
I
i
46
SECTION C
Figure
91.
Equivalent
Shank
Stresses
(KSI)
201
OPERATING
ENGINE
RANGE
.....
___
'
_
24
2O
52/R EV
2X- NOZZLE
VANES
PE_
1ST COMPLEX
N
2;
2ND TORSION
3 TM
i: •
_J
26/REV
i._
'i
_ 12
l,
n-
4
1ST TC,RSION
1ST FLEX
1.1(16)
Figure
2O2
92.
2.1(20) _
2.5(24)_
2.9(28)
ROTOR SPEED , RAD/SEC (RPM) X 103
NOZZLEvANES
6/REV
(SHROUDS)
3A(32)
TFE731 Vibration
Interference
Diagram
-- MATE
Final Design, DS MAR-M 247 Blades;
Machined,
Heat Treated,
and Coated
•
(a)
The
number-of
(b)
Airfoil
sections
allow
(c)
for
.
the
axlal.-chord
flow
path
tip
(shroud)
encountered.
decrease
the
ma_ximum
Table
LXI
both
the
two
contains
throat
design
tions.
sufficle_t
iel;g_h must
A
around
Figures
98
and
two
99,
the
hub
to
was
obtain
slightly
satisfactory
loading
area
93
Details
98
vane
through
Figures
a
the
shows
stack
hub.
to generate
and
96 and
of the
sections
while
is
in Figure
at
necessary
Figures
95
minor
to
stagger.
Figure
some
made
a smaller
parameters
engine
difficulty
sections
LXIX
in Figures
th_
any
Table
is shown
bution
create
sections.
versus
analysis.
existing
not
with
geometry
loading
shown
thickness
the
compromise
tube
tip design
area
for
thickness.to
the
fit
does
but
while
Thermal
are
have
sections,
Vane
tions
must
_
a cooling
hub and
at 26
section,
were
utilizing
fixed
conditions
problems
grated
[
these
while
was
cooling
The
Satisfying
at
vanes
the
94
of
inte-
show
the
plane
sec-
97.
vane
temperature
calcula-
103.
The
distri-
(base
I00
and
pressure
and
tip)
i01
thermal
are
show
shown
in
the
heat-
calculations.
The
transfer
coefficients
used
in
the
resulting
calculated
adiabatic
wall
temperatures
and
tip
are
shown
in
{
Figures
..
102
and
pesi£n
-
103
for
t_e
parameters.
is an
inexact
cooled
or hollow
base
Stress
science.
As
analys&s
air roils,
the effects
pressure
distribution,
more
difficult
to predict
with
ally,
vane
design
eters
of
new
accomplished,
of
the
is accomplished
with
become
and
desired
proven
design
turbine
more
vanes
complex
fo_
gradients,
thor-
factors
become
other
accuracy.
by comparing
an older
and an acceptable
cooled
of thermal
transients,
vane
sections.
the structures
mal
the
Tradition-
the design
design.
is produced,
When
the
paramthis
next
is
step
203
,-
[
i
=
TABLE
LXII.
26-VANE-'TEE731"" HIGH-PRESSURE
INTEGRATED
THROAT •AREA--VS.
TURBINE
ETAGGER
STATOR
-
k
-
Integrated_s -
"
(_)
Design,
de_rees
throat
area
between R = 10.985 cm (4.335 in._
and 14.07 cm (5.54 in.), cm
(in._)
-4.0
i01.76-7_
(15.774)
-3.0
9_.180-
(15.218)
-2.0
94•.561
(14.657)
-1 .S ......
90.9.09
(14.901)
0
87.132
(13.521)
1.0
83.529
(12.947)
2.0
79.800
(12.369)
3.0-
74.103
(11.786)
4.0
72.258
(11..200)
205
¥_
I
•
::
"
_
_.1
i
i
O.U
•_ r_
-
_
M
t_
N
-
r
206
J
R=11cm (4.324
R=14cm (5,54 in.)
Figure
95.
Stack
o_the
26-Vane
Stator
(Plane
Sec£1ons)
207
E
' '
1.0Q
"j
"
+
+::
--
I ''
IS
__
t
0,4_
i
0,00
0.,2C
-
-:
Figure
1.00
-+_
40
PERCENT
96.
Stator
AXIAL
P.L0,
CHORO
Hub
Section
I_0
Loading
......
im+o+::!O.l+
00
-.
I
T
_0+
40
PERCENT
Figure
97.
AXIAl,
Stator
g0
00
GHORD
Tip
Section
,0
Loading
,,+
-
208
•
•
00000 003 -TSC(
.(
I
!
,IJ
°*,q
U
-_
o
_0
_m
o
iI)
o'1
2].0
_:
is to ¢onstruc_
the new
testing
and evaluation.
_ane
and--subject
._able
LXIII-.shows
parametric
the
study
ard-TFE731-3
new
cooled
duction
between
vane
new vane
(26/nozzle),
As
seen
($6/nozzle).
26=vane
design
it to comprebensi$e
the-result
of the
can be
compares
favorably
and the stand-
in this Cable,
with
%
the
the cooled
pro-
vane.
5
Einal
The
Engine
high-pressure
- Other
turbine
turbine
turbine
shown
nozzlewere
in
Figure
parts,
thus
blade
added
105.
Components
sect/on
is. shown, in Figure_ 104--
high=plessure
new
Design
of-the
Both. the
and
,
the
standard
final
design
new- 26-vane
to the high-pressure
This
utilizing
design
most
of
of
the
DS
high-pressure
turbine
section
as
_minimum
number
of
requires
the
TFE731-3
existing
engine
test
hard-
3072748-1.
The
war e ................
Hi_ressure
•,
turbine
Part
Number
designed
£or
the
turbine
blade
utilizes
the
curvic
coupling
as the TFE731-3
changed
same
new
blade.
firtree
and
the
blade
the
disk
have_not
turbine
shroud
the
stresses
this
redesign.
in
circumferential
has
length
been
of
the
shortened
entlal
expansion.
in
TFE731-3
lower
disk.
the
disk
the
disk. con.tour,
to accept
the
ments
disk
-
h_gh-pressure
Hi@h-pressure
The
blade
temperature
higher
than
when
metal
cooling
Part
greater
air
retained
for
affected
the
This
of
greater
linear
expansion
of
the
supported
requiring
more
clearance
between
segments.
out
the
The
shroud
seg-
ci_cumfer-
the
shroud
with
by
3072344-3,
unrestrained
operate
temperature
unehanged_
turbine
discharged
maintains
they
been
air
Number
and
has
appreciably
high-pressure
cooling
design
rim area
the
loadessentially
-
turbine
Only
been
to allow
DS
configuration,
With
rim
uncooled
fittree
blade.
212
F
disk
blade
segments
tip
at
a
the
uncooled
DS
shrouds
results
in
shroud
segments,
thus
213
L
i
)
t
3O733
:
Figure 104.
;_
:,
/
214
:t
TF_731-3
Turbine wlth Cooled IHl00 Blade
I
2E-VANE
LOW TWIST
$TATOR
3072724-1
)S
BLADE
3072746-1
%
I
3072411-1
3072748-1
Figure 105.
TFE731 Turbine with Uncooled
DS MAR-M 247 Blades
215
_res__
su_:e
turbine
3072743-I;
30727_4ri
and
f
i,
ports
prodused
to
_ -
high-pressure
with
were
no
turbine
significant
nozT._,e,
2"__3072745-I;
adapt_ the
structure,
stress/life
supports
-
Part
Numbers
and .307-274_66_1, New
26-vane
stator
These-are
all
problems,
to the
static
sup-
existing.•
components
'_
k
_
.,._
TASK
V _ COMPONENT
MANUFACTURE
Scope
"%
The
objective
of Task
quality
acceptance
of
mically
cast
DS
high-pressure
turbine
testing
in Task
In
and quality
Engine
for
th_ design,
disk
tion
of the
The
fication
at least
manufacture,
bine
and
other
DS
V was
two complete
Vl.
turbine
blades
of
the
machining,
the
test
coating,
heat
and other
required
conjunction
with
Blade
(a)
engine
parts
MATE
SKP
17560),
of a modified
necessary
te_t
large_
installa-
engine.
and
quality
accomplished
of
Two
and
the
solid
blade
by
certi-
Jetshapes.
final
inspection
of
modified
turbine
disk
by AiResearch
exothermically
designs
and
final
which
design
was
I,__I,
shows
the
in
were
cast
produced
DS
in the
i:
which
MATE
to
tur-
Manufacture
turbine
manufactured
The
acceptance
were
preliminary
3072749),
designs.
included
suppliers.
The
106
task
production-qualified
of Project
Figure
this
accomplished
configuration.
The
addition,
were
in Tasks
(b)
TFE731-3
the manufacture
high-pressure
performance
the
treatment,
Blade
I.
for
blades
inspection,
castings
and
sets of
and
exother-
in the
blade
blades,
the manufactur,_
solid
engine, components
manufacture,_preliminary
The
TFE731-3
to accomplish
utilized
design
the
in Task
V.
blade
blade
unmachined
physical
for
the
Drawing
casting
efforts
III.
is
the
blade(AiResearch
size
of
(AiResearch
designed
in
castings
for
the
design
final
Drawing
Task
each
of
IV
and
these
casting
is
217
_:
-
•2
_
L
I
Figure
.
•_
106.
Exothermically
Cast DS TFE731-3
Turbine
Blade
Castings
for Project
1 Showing
Preliminary
(Left) and Final
(Right) Designs
218
•
~
J
, r
1....
t
a_parent
addition
roo_
in this _igu_e.
The largec casting
is the r_sult of the
o£ extra machining
stGck to both ends of. the. cast _ade
to p__ovide a casting
ferent
shank
2.
=__
Bla4_
acceptability
blades
were
deslgn
produced
tasks,
These
blade
Based
were • utilize_
tPart
3072749).
The
The
first
dif-
247, MAR-M
20-blade
mold.
consisted
of
This
200+Hf,
MAR-M
five
radial
247
Due
the
final
design
blade,
it
was
necessary
more
room
for
several
different
mold
design
to
a 15-blade_
mold
blades
was
sions
for three
proper
exothermicallM
having
five
castings
in each
of
exothermic
material
ratio
was
per
size
this
of
mold
After
deter.mine_
cast. the
spoke.
for
material.
radial
blade
alloys
in previous
modify
exotherm_c
it
in 9ask_V
physical
to
the
provisions
to the larger
configuration£,
and
NASA-TRW-R
with
the
materials
A,
developed
spokes
spoke.
allow
24_,
af
poured
and
mold--was
per
to
results
for MAR-M
castings
castings
the
the
for procurement
blade
best
on
Specifioation
four
the
two
for. directionally-sol_difed.turbine
Configuration.
con£iguratio_
i
a-matterials
from MAR-M
a
and
trying
to machine
is included
in this-document
as Appendix
standards
are included
as Appendix
B.
Mold
employing
used
Standards.
standard
prepared.
final
were
_
III,
and-an
specification
acceptability
: _
be
k
Acgeptability
through
3.
could
designs,
ofTasks-/
MA_E
that
that
final
design
with
p_vi-
design
allowed
s_gkes
This
casting
to
be
main--
configuration
had
tained.
i
......
To provide-assurance
affected
tha_
not
adversely
the
si_
longitudinal-grain-orientation
the modifie_
stress-rupture
from
DS MAR-M
247
blades
ation.
Each
specimen
was
fzom
and each
was
subjected
ksi).
The
strength
mini-bar
machined
(1800°F/30
mold
of
the
a blade
of
test
final
the
blades_
specimens
design
configar-
cast in a different
to strauss-rupture
testing
tlmes-to-failure
of
at 1255°K/207
these
six
were
mold,
MPa
speclmen_
219
L
ill
----.......................
:
were__In
Task.
!
77.7-, 17_9,
Task
V
i00
hours_-
specimens-was
Task
-V-final
average
The-ac.tual
ref_i.neclhasting
-
g:reater
than
proc_ess,
the
life- of
average
In-Task
these-
blades
was
of
the
six
the .average
life
of
__est llfe
I,
machined
from preliminary
test conditions
was 79.6
design, blades,
-
119.9, _84.7--anti 99.6.--Based-on
93.3-hours_
similar test specimens
_.e_ted under the.same
."
I00_
I.II_daJ_,__ the_expected
approx/m_tely
_
:
hour-s:
_wi_h
the.lmp_.r_oved heat
exhibited
average
life
design
hours_
blades and
Thus,. t-he
treatment-
a 4Nin-imum .life--
of
blades
produced
.k
equal
earlier
and
.to or
in
the
Fluor escent-penetr
ant
,
program_
j
_:
4.
Final
inspecti_)n-of
}
i
material
selections.
NASA--TRW-R
alloy
the
blades
cast
in_T-ask-V
revealed
crack:like
inspection,
indications
at 10X and
on
the
thin
metallogr.aphy
.blade
platfQnms_
Visual
confirmed
that cracks
were
i_
present.
None
geomet_ically
identical
i
in the
i
:
other
Figure
of
the
two
alloys
had
107
shows
an
a similar
example
of
Task
'
V blades_cast
.
p_ob!em_ ........
a
cracked
NASA-TRW_R
alloy
5
blade
and
tear".
"-
":
This.-ca_ occur
location
cation
i
the. microstructure
of
due
the
in the-cracked
area_-T_e
in thin
cast
is
a
typical
example,
hot
strength
of
cnack
to inadequate
sections
when
:
exhibited
platform-hot
•
an(i III
....
three
alloys
nated
from_ the
.....
indicated
tearS..
that
_riginally
engine
castabillty
test
w.tth the
same
total
were
replaced
with
DS
220
generated
the
lowest
selected
for-engine
problem.-
Blade
number
MAR-M
rather
castings
casting
"hot
during, solidificastings
clearly
data
had
program
a
the g/_ain boundary.
NASA-TRW-R
test
its
Since
and ......
a highly_alloyed
of
super_alloy_ separate_
(_ears) at a grain_boundaxy
App.roximately
90 p er_cent o£. the--NKSA-TRW-R
--
nature
strength
testing,
than
in Tasks
i_t was
attempt
planned
of
II
the
eliml--
to correct
for
this
alloy
support
the
engine
of castings.
247
castings
to
!
."
,
(a)
(MAG.: 1X)
:
(b)
t
(c)
Figure i07.
I
(MAG.:..100X)
_'_ _'_!,"_'_
'
(MAG,: lX)
Photographs Illustrating "Hot Tear" Cracks Found
in the Platform Areas of Task V Exothermicaqly
Cast DS NASA-TRW-R Alloy Tu_blne Blade Castings.
Arrows on (A) and (C) Identify Typical Crack
Locations.
Photomicrograph
(B) Shows the Intergranular Path of the Crack
221
+
"
5.-
Blade
finishin___All
ir_a_wer.e solution.heat
two
:
_reate_
hour_s, followed-b
fi_ish_machine_
MAR-M
i_a
inert
gas
the
final
design
t_
Z
2-47 and MAR-_
vacuum
200+Hf
at L505°K
quenching.
The
cast-
_2250°F)
blades
for
wex.e then
confi@uration--estahLished
in
%
Task
IV.
after
..
_igure
finish
finishe_
were
(1800°F)
_- -
are
coated
fop
shown
with
5 hours,
Acceptability
cess
had
been
gram
alloys
refined,
were
by
at
acceptability
Jetshapes.
assurance
inspectors.
Table
blade
acceptabilit
Z_
casting
castings
rejected
were
EPI_
MAR-M
200+Hf
These
manifested
found
by X-ray,
for
interpretations
by
of
the DS
at
beginning
of
the
the
of
testing.
alloy
during
from
the
fluor-
other
discrepancies:
more
blade
two
visual,
rejects
of the
hafnium-oxide
inclusions.
either
high-density
inclusions
found
parts
very
by FPI..
shipped
by
by
good
curve.
The
bulk
Jetshapes
acceptability
achieved
learning
overall
number
found
were
while
for
grain
considered
was
222
of
yield
blades
of
prO--
p_oduction
and
engine
Blades
indications
59-percent
247
Jetshapes,
using
tears
20
pro-
three
summarizes
_here
247
as
AiResea_ch
MAR-M
the
MAR-M
themselves
rejections
_he
the NASA-TRW-R
hot
for
inspectionS_to
yields,
21 of
In general,
or suxface
at
AiResearch
for. _'combination
a/loy_ than
i_
all
.blades,
and X-ray_
the
made
LXIV
1255°K
blade---per-mold
for
(FP_).
grain,
15
accepted
inspection
were-rejected
The
results,
platform
alloys
_
at
r_ejected for
escent-penetrant
aged
.Screening
quality
the
then
blades
were
performed
and
at
the
inspection
required
coating
t
final
blades
all
machining,
hy air-coDling.
criteria
was
After
followed
525
and
two
air-cooling,
After
as-cast
suction-_sides-ol
109.
approximately
poured-
blade
RT-21-_aluminide
followed
Bi@de
and
Figure
the
and
MA/_-M- 247
pressure
in
6.
Of
-
The
(1600_F)
finished
•
a typical
at 1144°K
AiResearch
•
shows
machining.
blades
blades
hours
108
of
were
limits.
Jetshapes
for
the
for
blade
design
a new
Experience
suggests
DS
that
J
t
FigurelC8.
As-Cast
and Finish-Machined
Exothermically
Cast DS TFE731-3
Final Design Blades of
MAR-M 247
223
I
#'i
!
i:r]-iilt-_f TI,'I'I ii'7,i',i'l,i,'_l'l'l'r_i'-_l_i_
f
i,
I,
r
1
._._'._
si '
Figure
224
IC9.
'71"
Pressure
and Suction Sides of TWo
Finish-Machined
Exothermically
Cast
DS TFE731-3
Final Design Blades
TABLE
L IV.
SUMMARY
OF THE YIELD OE THE FINAL
DI/IECTiONALLY-SGLIDIFIED
TFE731-3
TURBINE
BLADES CAST--IN TASK V--
DESIGN
Alloy_
i
!,
MAR-M
247
i 200+-_f
MARCM
300
165
50
525
Number
of blades
shipped
to A/Research
by Jetshapes
199
]_03
29
331
Number
of blades
accepted
by AiResearch
176
74
8
258
over-all
59
45
13
---
of fi.ished
accepted
for
testing
95
56
0a
151
Number
of finlshe_
blades
_eqgired
by
contract
93
31
0a
124
eliminated-from
Project
Approximate
blades
cast
Jetshapes
"
Approximate
yield
(%)
Number
blades
engine
,-'[-
_
-'-
aNASA-TRW-R
blades.
number
by
alloy
of
I NASA-TRWR
i prior
,rT?tal
to machining
225
i
.F
this yield will
ties ..........
improve
to--?O-to 85 percent
in p_oduction
quanti"
%
Special
As
described.herein
of
the
the
standard-TFE731.-3
design
Engine
high-pressure
of..the
chosen,
Components
in Task. IV,
turbine
best
alloys_
required-, special-
hardware
was
for
the
engine.
226
assembly
into
test
Blade
_i
Design,
sectlon_required
design-to
blade
Manufacture
certain
redesign,
parts
to
adapt
accommodate
the
final
blade
As
of
Task-V,
the
a-part
manufactur.ed._s
shown-/n_
T.able LXV
i
TABLE
LXV.
SPECIAL_HIGH-PRESSURE
TURBINE
HARDWAREMA_OFAC_URED
EOR TPE731_3
ENGINE
TEST
OF EXOTHERMICALLY
T//RBINE
BLADES
CA_T
DS
HIGH_PR_SSURE
k
]
Part
Numbe_
Nomenclature
i
I
i072748_i
.........
High_preSsure
|
turbine
(HPT)
Disk
I I
1
3072_3
HPT
shroud
segment
6
3072T24-I
HPT
nozzle
segment
13_
3072743-1
HPT
nozzle.outer
seal
3072744-I_
H_T
nozzle
outer
retainer
l
3072-744-2
HPT
nozzle
outer
retainer
1
3-072745-i
HPT
nozzle_inner
retainer
1
307-2746--1
HPT
nozzle
anti-rotation
,
Quantity
] rllr
support
ring
1
1
227
__._......_._.._
4• rl. •_. _e-7
*_'•_'Lr_ _
Im
_ḑJ•;, _
•_
COST
AND
WEIGHT
vi
OBJECTIVES
!
•_....
The
are
Project
listed
Volume
engine
manufacturing
o
Reduce
engine
maintenance-costs
•
engine
the
utilize
to_chieve
i.-
conclusions
confidence
-
and
based
on
testing
of
DS
blades
Engine,
with-hardware
component
turbin_
section
uncooled
DS
of
the
turbine
as listed
for
the
this
was
3.2
k,
p_rcent
perce_k
PrOject,
production
can
knowledge
DS HP
to
problems
during
engine
were
blade
several
....
it_ was
formulated-
gained-in
turbine-blades..
kept
i
objectives.
be
accomplished
changes
development
at.least
projections-
uncooled
accomplished
O
discussed--in
• at least.6.2
long-term
the
the
costs
available
testing
the
be
%
leastz_._ercent
and
unrelated
I
_easible
reasonable
TFE731_3
_
time
several
factu_ing
at
limited
However,
will
objectives)
report.
Reduce
the
(contractual
ob_.ect_ve
o
not
be
SFC
engine.weight
o_viouSly_
I£
The.
Reduce
i
"
this
and. welght, goals
o
witk
_i
.-below..
II of
In
:
1 cost
in
manuActual
a modified
a minimum
to avoid
the150-hour
test.
redesigned.-to
fully
majo_
could
changes
below:
Eliminate
the for
forward
not required
the
seal
plate
DS blade,
-this
since
cooling
component
air
can
is
be
eliminated.
_
....
o
228
blade material
has superior
properties
Redesign
the
firtree
connector
since
_he prese.t production
eq_giaxed - IN100,
as compared
to
the
DS
MAR-M
247
both-t_e
circum-
ferentlal
and
axial
fi_tree
_educed
through
a
dimensions
redesign
of
of
the
the
firtree
could
connector
be
.............
,"
%,,
o-
Redesign
be
the
HE
turbine
substantially
design,
the
stronger
disk
turbine
disk
aisk
alloy
weight
with
savings
reductions
in
if
pressure
ratio
are
optimized.
culations
are
shown
below.
optimized
e_glne
cycle
Engine
Weight
Eliminate
Reduced
Total
Total
engine
Seal
Weight
Weight
new
blade/firtree
could
be redesigned
cycle
be
would
utilizing
a
disk
weight
_ithout
as
either
"actual"
considered
changes
that
or
pa;ameters
The
It
could
weight
such
as
is not
necessary
_the weight
BPT
D_sk
(TWR)
achieved
that
are
bypass
ratio
and
reduction
to
= 722
ibs
= 3.1
ibs
= 4.3
ibs
= 7.5
ibs
cal-
consider
reduction
Plate
of Redesigned
be
savings
"actual _ weight
(TEW)
Weight
load
Weight
engine
to meet
the
life.
_ith
Re_uctlon
Engine
to
engine
the current
possible
Total
the
due
reduce*
can
associated
compQnents
rim
to
Engine
w_ight
the
reduced
ad_f_ecting
Engine
- since
the
goal.
TWR
7.5
= T-_ =
= 1.04 percent
Reduction
/'
Manufacturing
By
replacing
the
uncooled
DS turbine
blades,
TFE731-3
Engine
manufacturing
o
cost factors
by more
and
cost
,_
HP
_han
blades
costs
3.2 percent.
with
savings
component
turbine
manufacturing
are associated
manufacturing
material
ceoled
the overall
can be reduced
Direct
fDom
production
Costs
this proposed
of
Two
the
major
change:
to the HP turbine
design
with
stage
changes.
229
T
"
_'_
o
Savings
achleve_.by__op_imizing
the
engine
cycle
param-
'_
J
et_rs
to reduce
the
core
engine
size
and welgh_,
k
D/rect
yield,
less
Costs
- The uncooled
(solid) DS
expansive
castings
that. requime
castings
are higher
leas machining
than
;
_,,
J
the
_
ii
"
conventional
Figure
110
tional
cooled
cooled.
shows
a
INI00
(cored)
TFE731-3
relative
cost
comparison
HPT
used
in tha-TFE731-3
blade
HP
turbine
between
blades.
the
conven-
Engine
and
the
MATE DS_blade
designed
in this projeqt
for the TFE731 Engine.
The
changes
in configuration
and processing
will yield a-l.5-percent
engine
ii_
manufacturing
redesigning
MAR-M
247 DS
stronger
savings
the
HP
turbinein
blade
material
disk
for
production
(such
as
earrings can be realized_
Tkls
weight/cost
by
a 41-percent
increase
Rene'
95), a
!
_
[
associated
with the HP turbine
a 0.4-percent
savings.
Thus,
Of
1.9
tion
'
percent
to
DS MAR-M
can
fully
247
parameters
optimizQd
cycle
teristics
of
i
230
realized
utilize
turbine
Optimized.
cycle
be
for
the DS
weight
is offset,
cost
which
how-
results
Since the redesigned
HP
cooling,
the entire cost
seal can-be eliminated
a direct manufacturing
optimizing
the
characteristics
HP
resulting
in
cost savings
turbine
of
the
Summarize_
the
sec-
uncooled
blades.
Englne
must
the
23-percent
in raw material
by
By
the
stronger a
Incorporating
savings
in no cost savings for the disk redesign.
tUrbin_ blades and disk no longer require
i
quantities.
disk rimto area
utilize
the
and
material
ever,
i
cost
Costs
--Table
LXVI
the
TFE731-3
Engine
be
incorporated
turbine
blades.
with
to fully
DS
utilize
change
blades.
in
The
the charac-
' i
100
COATING
80
_ROCESSING
AND
INSPECTION
O
n.
"r"
,
6O
MACHINING
!
i
Z
C3
COATING
_
uJ
=J
O
O
¢J
MACHINING
40
C/_TING
20
CASTING....
r_
uJ
0
PRODUCTION
TFE731-3
HPT BLADE
(COOLED IN100)
Figure
ii0.
.
MATE DS
TFE731
HPT BLADE
(SOLID MAR-M 247)
Relative
Blade Costs of the TFE731
Blade Production
Versus MATE DS
HP Turbine
231
• °
•
i
TABLE
LXVI.
CHANGES
IN ENGINE PARAME_'ERS FOR CONSTANT
CRUISE THRUST TO FULLY UTILIZE
TEE DS
TURBINE
BLA_)ES IN THE TFET-II-3
Parameter
T4 o_, (OF)
TSFC
Pressure
Ratio
Bypass
.,.
Ratzc
_
•
(BPR)
a part
of
trates
that
ratio,
can
.,:
prepared
the
Program
of
be app!KQximated
_._
WF
whert:
=
Engine
Weight
WE c
=
Engine
Core
BPR
=
Bypass
Ratio
weight
breakdown
_ercent
pounds
of
this
data,
ical
model
the
I
_
WE
A
realized
W_
W_C
_
plus
the
the bypass
predicts
by optimizing
reality
that
as
thrust,
the
decrease.
size
of
--
--
the
ratio
a
the
1
changes
in
illusbypass
relationship:
B_Rnew
.
BPR_aseline
TFE731-3
weight
shown
for
bypass
r_tio
core
and
Engine
)
showed
is core
in Table
21-p_ercent
the engine
the
with
following
engine
that
document
Weight
for
total
0.
weight,
by the
4.6
(NASA CR135265)
This
_
1327(1930]
0.721
25.0
analysis
Project
engine
1
2.7
......
;
a cost/benefit
MATE
scaling
1327
(1930,)
0.814
18,0
2.7
....
Project
Uncooled
(Solid)
DS MAR-M 247
Standa_:d
Optimized
Cycle
Cycle
1327 61930)
0.818
18.0
(PR)
AiResearch
as
MATE
p_oduction
_.ngine
Baseline
Cooled
(Cored)
Equlaxeu
INIU0
weight.
LXVI,
weight
all
This
increased
of
its
the
savings
DS blades.
is
that
at
50.5
Using
analytcan
be
is based
on
a constant
components
will
232
.......
-
"
"
00000003-TSE[
A
• h__coat
,:
model
Cost
£or
enginQ
scaling
is proportional
purposes
is simply:
to Weight
J
TSia
coat
model
engine_
The
ni£icant
weigh_
siue
redesign
the
cost
weight
cost
change,
and
to
components.
yield
weight
and could
technolosy
due
welgJlt changes
21-percent
would
reduction
however,
on small
calculated
savings
technology
-
is based
changes-_o
the
costs
added
more.than
Total
- Adding
only
be
as
to
very
with
that
reduce
core
the
sig-
exten_
Therefore_
as
incorporate
change-in
would
baseline
si_Dificant-
significant
cost_savings
is a
the. engine..
not
considerably
savings
be accomplished
probably
The
from the
.....
the
ad_ancexl
sizewould,
overa_l
engine
1.3-percent.
L
tion
(1.3 percent)
ously
discussed
cost
reduction
_
The
tenance
of
(1.9 per_cent),
of
engine
failures),
Maintenance
costs
The
5 percent
overhaul
for
is comprised
of
the
sum
of
the
cost,
and
unscheduled
savings
engine
.......
previ-
manufacturing
of preventive
maln(repair
bulletins.
maintenance,
are established
og
cost
optimiza
maintentance
of service
preventive
incorporation
to cycle
Costs
unscheduled
incorporation
baseline
a total
Engine
applications.
cos%,
yields
cost
due
manufacturing
3.2-percent.
maintenance
and
savings
at least
maintenance
be
cost
to the direct
unscheduled
to
the
(inspectionl,.o,_rhaul,
The
:
Costs
overhaul,
and
from
experience
on similar
service
bulletins
is
engine
preventive
maintenance
-"
assumed
maintenance
cost.-
"T
233
I_•__
!:
.
The
._
change
in
engine
cost
can_ be deter.mine_
may
be
model
by
.
file
(TBO}
using
an- engine
"*
'_,
and--the
expressed_
as _.composite
toE-the
for-engine
over_%aul
(EOC)
cost
_
resultant-effect
overhaul
cost
in
model
1
a
that
%
entlre--engine._---_he-basic
L
is"
Module(BMOC_
\M?.Bo +_ LB_Cj
where:
t
,
BMOC:
=--..-Baseline module
overhaul
cost
one-third
manufacturing•
Cost) .
.......
_
BMTBO
--
MTBO ....=
Module
time-between-o_erhaul
_
MMC
Module
manufacturing
--
BMMC ....
:
Baseline
module
j
'i
The
'A
of
module
=
=
-Baseline
cost
in
the
equation
above
effect
0£ engine
-- _
ing from
changes
in reliability
(MTBF_,
_"
i.
an engine
repair
cost {ERC) is:
cost
The
_,i
• =
unscheduled
Module
cost
is expressed
The
model.
cost
manufacturing
cost.
where
maintenance
can
basic
as
a fraction
on cost,
be determine_
result-
model
for
1+¼
MMTBF
by using
engine
S
BMRC
:
Basel/ne
module
repair
m_
BMMTBF
=
Baseline
module
mean-tlme-between-failure
_'i
MMTBF
:
Module
._.
Replacing
--'.,,
-
solid
unroOfed
configuratlon.
.
!
repair
j
_
_
at
module, tlme-between-ouerhau.l
engine
'"
(assumed
a hollow,
blade
Such
cost
mean-time-between-failure
thin
walled,
naturally
items
cooled
results
as
foreign
in
turbine
blade
with
a
a more
rugged
engine
object
damage
(FOD),
234
"'_
"
....
00000003-TSEO
m
I
recoati_g,_part/cle---erosion,
cooled
of
tu_hlne
the
su_plyiing
affects
blade
more
the
rugged
overhaul
(TBO)
percent,
the
lated
follows:
as
a solid
componenX.s
directly
this
blade-_ham
etc_,_
more
a£rfoil.
the
blade
life..
comp@nent
are
will
detrimental,
Also,._the
cooling,
increase
both
Baseline-Maintenance
change-
in
no
icn_er
%
assuming _ that
-the tlme-between-
and the mean-kime-between-failure.
resulting
a
reliability
air
Conservatively,.
to
(MTBF)
malntenance--cost
can
$ 600
X-106
by only
be
l0
calcu-
Cost*
i
!,
o
Engine
Inspection
o
Engine
Repair
804-X-106
o
Engine
Overhaul
3260
X 106
o
Incorporate
233
X 106
$4897
X 106
Service
Total
!
if _MMC
Bulletins
Cost----.
= 0"*
x
ERC-=
$_3!
X
01]
]N6
1(
MTBO
EOC
i
= $3260 X 106
if AMMC _ 0**
i.i
*Based on 25-year
life-cycle
jet flee£ of 4000 aircraft.
._
X MTBO I
costs
of
(' E ])I
:
"
+ ½
the
engines
for
a business
**Manufacturing
costs actually
decrease
when the DS turbine blades
are incorporated;
however,
for this analysis
the manufacturing
cost difference
was assumed
equal to zero.
235
-
.
,
•
EOC
= $2964
X 106
Revlse-d-/_aintenance
'k
Costs
--
iz
!
c
Engine--Lnspection
i
"_
Engine
Repair
i
o
Engine
Overhaul
o
incorporate--Ser.vice--Bullet/ns
Total
Reduced
Maintenance
$ 600
731-X
.
COSTS
Costs
=
233
X i06
$452&
X 106
4897 X 106 .--4528 X 196
= 7.5
236
106
29J54..X_lO6
4897
_
X 106
Percent
X 106
i
1
CONCLUSIONS
A
consistent
solidified
TFET_I-3
thermically
heated_mold_
process
produced
to.
high-pressure++
was
acceptable,
MAR-M
200+Hf;
IN 792+Hf_
tests
1800°F)
machined
fronDS,
four a_loys
alloys
and
A, 1505"K
MAR-M
247
the
(2250°F)
improved
the
baseline
tion
treatment.
the
showed-MAR--M
IN 792+Hf
strength
on MAR-M
247,
MAR-M
(i)
Mechanical
o
200+Hf,
The
in
four
structunes
The
10310K
alloys
were:
1255_K
(14009F
heat
treated
blades
and
and
of the four
_nd
treatment
developed
strength
of
the
solu-
(2230°F)
blade
design
data
as
DS
over
14940K
NASA-TRW-R
for
alloy
the
on MAR-M
was gener-
follows,
with
_
247.
properties.+
,-
Tensile
tests
I144°K
(16OO°F)
bars
i033°K
tudinal
in the
rang e of room
temperature
on
both
longitudinal
machined
from
blades.
Stress-rupture
of
with
turbine
generated
verse
o
Inc.
case
heat
established
to provide
the data
at
stress-rupture
data
of
a£_Jetshapes,
%
weakest.
Property
bulk
exo-
247 to be the-strongest
solution
the
using
and_.NASAz_RWTR,______
screening
on bars
directionally-
blades
nonfigurations_
Stress-rupture
of the
ated
turbine
diree-tional-grain
blade
MAR-M
solid_
deuelope_
turbine
24Z_
_i
p!oduce
alloys+ and +thnee
and
\
process
......
to
and
tests
1311°K
to
and
trans-
over
the
temperature
range
(1400 °
to
1900°F)
on
longi-
machined
from
transverse
bars
blades.
237
<
v!
o
Low--cycle-fAtigue
I033°K
o
o_
--Thermal.
expans/on
the-range of room
of.elasticity
the range
in-the
of
O
Dynamic
for 510
oxidation
hours.
resistance
o
Hot-corros/on
temperature
(bare
(1700°E)
solid
Engine
high-pressure
compatible
Minor
redesigns
were
as
disk,
shreuds,
and
at
......
7
directo 1144°K
I
coated)
1310°K
(1900°F)
resistance
at 1200°K
hours.
aerodynamic
MAR-M
with
was
designed
efficLency
24_.
this
incocporated
nozzle
aluminide
turbi'ne blade
using_directionally-solidified
aerody_namicall_
and
(sulfidation)
f.oz 310
£o maximize
grain-g_owth
room
resistance
A new
temperature
and thermal
conductivity__over
temperature- to 1255°K
1800=F).
Environmental
,
the
at_oom
properties
tion. over
(1600°E).
T_FE731=3
tests
(1600°-_).
Modulus
(3)
i
and
'
High-cycle-fatlgue
Physical
temperature
(1400°F) ....
I144_K
(2)
t-e_ts--at room
A
blade
on other
retainers,
and-bl_de
new-turbine
was
turbine
etc.,
for
also
the
life
nozzle
designed.
components
to allow
testing
for DS MAR-M
247
such
in
the--T2El31- 3 Engine.
:
Specif_icatiens
bine
of
blades
this
were
and acceptance
developed
and
are
criteria
incladed-_s-Appendiccs
tur-
A and
B
report.
238
...........
L
__
--
_
L
"IV
and
Exothermic
DS cast
NASA-TRW_R
were
blades
were
"hot tears"
._
wer_
turb_ne-blade_of-MAR-_M
cast
for
engine
ehmlna.ed
from-engine
in the platform.
testing.
of MAR_M
247 andMAR-M
finish
machining
and coating,
200+Hf,
NASA-_RW-R
consideration
blades
threugh
The
testing
Di£ectionallyrsol/dified
processed
243, MAR-M
due
to
and
200+Hf
were
made
a,ailable
for
TFE731_3
Englne__testlng.
Other-
turbine
hardware
required
for
the_ test
was
and
assembled
into
factory
test
MAR-M
247
HP
blades
Engine
would
_
?
into
a
engine.
The
incorporation
an
optimized
facturing
manufactured
cost
of
solid
cycle
DS
TFE731-3
reductions
exceeding
the
turbine
result
in
3.2-percent
manu-
Project
1
goal.
The
incorporation
into
the
existing
would
reduce
engine
goal
of
percent.
1.O
of
sol/d
TFE731-3
weight
DS
Engine
MAR-M
by 1.04
with
247
a
percent,
HP
turbine
redeslgne_
HP
exceeding
blades
turbine
the Project
1
i
Maintenance
247
i
HP
blade
turbine
costs
blades
of
a TFE731-3
would
durability,
exceeding
Engine
results
in Volume
test
II of
this
and
be reduced
_he
Project
post-test
Engine
7.5
wi_h
pgrcent
1 goal
of
evaluations
solid
due
6.2
DS
MAR-M
to greater
pezcent.
are
described
report.
239
,
.....
,
t
--
_k
k
¥
k
_I_ECED|I_IG
p_GEBLA_, I_OTFluMf-(_
:_;,)NQ;,PAGIt BI_dI_R mOT I;ILMF-t_
APRENDIX
A
MAR-M 247 MATERIAL
SPECIFICATION. _
(2 Pages)
241
-F
'.4
il
MAR-M
1.
APPENDIX
MATERIALS
247
APPLICATION
3.5
cast
I.I
MAR-M 247
£ea
east _lckel-base
superalloy used for t_blne
wheels_noseles,
and
blades,
a_ temperatures
upto
I800*F.
2,
APPLICABLE
D_MENTS
AiRssearch
3.5.1.1.
Speui_ens-may
area of th_ casting,
specified.
3,5,2
eithe_
Specifications
EMS52330
Masten
Preparation
}_5014
Marking
of
C5041
Surface
Cleaning
for Corrosion--and
2.1.2
_erospecs
AMS
2280
Treatments
Heat-
3.7
Castings
shall
as-cast
condition.
3.
TECHNICAL
REQUIREMENTS
3.1
Composition
Su@_estedAim
Range
Carbon
Chromium
Molybdenum
TantalumAluminum
Titanium
Hafnium
Boro_
sir_onlur_
_obalt
Tungsten
Manganese
Sulfur
silicon
IrOn
Nickel
0.15
8.25
0.70
3.00
5.50
1.SO
1.50
0.015
0.05
10,00
10.0O
----
0.13-0.17
8.00-8.8_
0.80-0.80
2.80-3.30
5.30-5.70
0.90-Zo20
1.20-1.60
0.01-0.02
0.03-0.08
9.00-1_.O0.9_0-i0.500,20 Max_
0.015 Max.
0.20
Ma_.
0.50 Max_
Remainder
Ee_alnder
shall be controlled
2280, Class
2.
3.7.1
Cast
20 hours at
in
3.2
Production
of master
heats,
remslting
master
heats
and pouring
of castings
shall
accomplished
under
vacuum,
shall
be
made
3.8.1
When specified,
a _aster
made from Class
111 materlal_
3.4
Castings
melted
3.4.1
metal
F08M
shall
be
be
and
3.6
All castings,
including
separately
cast test bars,
shall be cast into mo_ds
utili_ing
mold inoculation
as used fo_-graln
size control.
Specifi_atio_
Trace
Element
Control,
Nickel
Alloy Castings
3.3
A master
heat
Class
I material,
bars may
oversize
Alloys
Materlal
3.1.1
Trace
elements
accordance
with AMS
test
cast
3.5.A
Any metal
treatments,
such as superheatin_
and hot topping,
to be used oncastingw
shall also be used on separately
cast test bars when qualifying
the master
heat for use in those castings.
Requlremen_s
Rezi_tent
Separately
cast
cast _o size-or
an_
3.5.3
Separately
cast test bars ihall
be
cast into the same. type of refracJ_orMmold
as the castings
for which
the master
heat
is _o be used.
Nickel-BeseAlloys
i
be machined
from
unless .ot/te=wlse
Maohlned.
Classification
and Znspection of Castings
_
Heat
'
shel_ be
an_--tas_ed,
k
f_m% & part
extant
refer-
EMS52300
ii
east test-bars
master
heat
Separately
fr_m_rJf
3.5.1
If the configuration
perm_,
t6et
specimens
shall
also be machined
fro_ cast
parts.
.....
2.1
The following- documents
of this ipeclfication
to the
eno_
herein.
2.1.i
ASPE_IPZCATZON
poured
from
heat
only
master
heat
metal.
A master
heat
_s previously
of a single
furnace
charge.
of
be
be
from
re-
refined
aupplled
in the
be
heat
treated
for
3.8
Cash'partS
after
heat
a hardness
of NRC 30-40.
treat
shell
have
4.
PROCESS
parts
shall
1600*F.
CONTROL
4.1
Castings
withA±Research
required.
sha_l be cleaned
Specification
in accordance
C5041
as
4 _2
He_t treatment
shall
follow
al_ other
thermal
exposure_e.g.,
coating and brazing
operations,
which
may occur during
processin,
of parts.
5.
INSPECT/ON
5.1
All castings
shall be
trent-,
and E-ray-inspe_ted
wi_h _52300.
5.2
for
visually,
pensin accordance
The supplier
shell perform
all
cen£ermanee
to chemloal
limits.
EMS52330,§.3
The supplier
mechanical-_foperty
n_y
be
shall
perform
testing.
testing
all
5.3.1
Test specimens
shall be heat treated
for 20 hours
at 1600"F
prior
to testing.
i_[_][_
-_E_|RO
,
,
_,.
_.......
PAG_ I_J_K
rt_P_
trOT FitteD.
P5703-2
243
I
II
I
III I
I
" -
"
{
_
II
III
8.2.1
_1_en cmatinq_
for
makin9
_£ni_hed
o_
semif£niahed
parts ere produced
o_ pu_rchased
by the parts
suppiler,
the parts
supplier
ahell
inspect
castings
from eae_ master
heat
or master
heat
lot
represented
end shall
_.3.3
Tensilo
testa shall be pe_for.med
include
in the report
e statement
that the
wlth-a
strain
rate of 0.005
inch per inch _castings
conform,
or shell
Lnclude
copies
of
per mlnute
through
the yield
polnt_
at
laboratory
reports
showln_
the r_sults
of
which ti_e the strain
rate may he increes'ed
beets
to dete_mlne
conformance.
to a cross head speed of 0.2 inch per
1
5.3.2
_or
muchanleal.-proper_y
teeting_
soparately
cast tes_ specimens
shelf
have a
0.25-1nch=diamster_-gauqe
section
i inch long
between
r_dil,
-.
minute,
I
--
5.3.4
Stress-rupture
test specimens,
be tested
ucder
& constan_
stress
of
shall
I05_00
(_Sa_).
psi
at
a temperature
of
1400
:"
8,3
The supplier
shall
state
tn the report
the relatlv_
proportion
of revert
or virgin
martial
used in preparationof the master
he_t.
9.
5.3.5
_.cres§-ruptu_e
tes_
he tested
under
a constant
29,000
ps_ _t 1800--+5°F.-
-....
6.,
IDENTZF_CATION
AND
specimens
stress _f
•
_
7.
APPROVAL
OR
7.1
To assure
sample
castings
master
patterns
_rchaser_
_
t
_
_
"
_
CONTROL•
9.l
C_atlnge
shal_ be un_fo_in
quality
and condi_lon,
sound,
and free-from
foreign
materialS
a_d_from
internal_ andrexternal
imperfections
in excess
of,-those allowed
in
PACKING
PROCUREMENT
enlformity'of
quality,
from new or reworked
shall be approved
by
I
•
shall
6.1
Rash castling shall be identified,
wlth
paFt number
and master
heat number, in
accordance
with
speoifloation
HCS014.
I
QUALITY
_I
the
EMS52300
for the specific
class
and grade.
9.2
At the option
og AIResearch,
_ casting
eha_l he selecte_
f_om any _astings
received
andshall
be Inspecte_
in accordance
with
the appllca_le
re_ulremeots
for that-.part.
9.3
Parts
and material
the requirements
of this
shall be _cJected.
not conforming
specification
to
7.2
Supplier
shall use the same casting
technique,
including
rate of cooling
after
casting,
and, if heat treatment
is specified,
the same _eat-treatlng
procedure
for
)rod_ction
castings
as for approved
semple
caStings,
_-_
8.
•.
REPORTS
_
8.i
The supplier
of castings
shall
furnish
with each shipment
e rspeEt
listing
the
results
of the mechanical-property
tests,
results
of the chemical
analysis,
and a
statement
that the castlnqs
confor_
to the
requirements
of this speclflcatloh.
.
"_.
8.1.I
This. report
shall
include
the purchase
o_der
number,
masteI
heat number
and code
symbol,
if used, meterial
speeiflcetlon,
nu_ber
and
its revision
letter,
part n_er_
and
quantity
fro_ each heat.
•
•
I'
-
8.2
The supplier
of finished
or semifinlshed_.
parts
shall furnish
with each shipment
a
re_ort
showing
th_ purchase
order number,
materials
specification
number,
contractor
•
_--:
.......
i
,or othe_
direct
_
_.
,
!_n_mber,
a_d
\
!
w
FORM P5703 -2
-
244
supplier
quantit_.
of
caettnge_
pext
!
APPENDI_X-B.
ACCEPTANCE
STANDARDS
FOR
DIRECTIONALLY
SOLIDIFIED
TURBINE
BLADES
(7 Pages)_.
245
j_
APPENDIY_
. ACCEPTA_NCE
'<
I.
ST/tNDARDS
3.2.2
'"
f
i
_,
_R-M
247
l.l.1
MAR-M
247 is
superatlcy
used for
hozzles,
and blades
to
turbine
master
a cast,
nickel-base
turbine
wheels,
at temperatures
up
3.2.4
testing
Master
heats
shall
spool;hens machined
_"
;_
3.2.4.1
If the
allow
specimens
then blades
P/N
i, _
2,
along
clans
F
2_1
The following
documents
Of this specification
to the
A_PLICABLEDOCUMENTS
form a part
extent
refer-
3.3
enced_herein.
BLADES..
.
in
Speeifications
and pouring
under
be qualified
from blades.
by
blade design
does
not
to be machined
from it,
3072111
shall
be cast
with the other
blades
and test spashall-b_u-_achinad
from these
blades.
Grain-Orlentation
3.3.1
AiRese_ch
be
._
1800°F.
2.1.1
shall
3.2.3
Remelting
cf maate_
heats
of castings
shall
be accomplished
vacuum.
1.1.2
When cast 4_Lractlonally
soLldifled-there
is a signlflcan_
improvement
in
creep-rupture
properties
as compared
to
conventionally
cast m_tterial,
r
heat
blades.
i
The
accordance
with EMS52330_Class
Z.
The use of gates,
sprues,
risers,
or
rejected
castings
is not
_e_rmlttsd.
specification
sstablishas
the
standards
for directlonally
s_lidified
TURBIne..
FO__R DIRECT__I_ONALLY-SOLIDIF!_
APPLICATION
..I
This
acceptance
' 'v
B
Prior
to removal
of
DS
starter
I,_
etched
for a tims Sufficient
to lightly
reveal
grain blade
orientation.
material,the each
shall
be chemically
_ "
i -"
3.3.1.i
etching
Etchlng
solutions
procedures
are shown
and reco_ended
in Appendix
I.
3.3.2
shell
grain
EMS55447
Nickel Corrosion
ment,
Alloy
Castings,
- and
Resistant,
2.1.2
,
•
Military
MM-0011
Heat
Invest-
Specifications
Inspection,
Penetrant
Method
MIL-I-25135
Inspection
trent
Materials,
Pane-
MIL-STD-00453
Inspection
Material
Specificetion_
2280
3.
TECHNIC_
3.1
Composition
Trace
Element
of
3.2
Master
3.2.1
Heat
Control
chall
be
master
heat
metal.
3.2.1.I
A master
of
heat
a single
.........
FORM _5704-_"
No equlaxad
grains
are
permitted
in
the
into any
must
than
poured
3.4.1.1
2250"F
shall
b_
le00"F.
only
is previously
furnace
Heat
Treatment
3.4.1
All blades
shall be solution
heat
prior
to any abrasive
blasting
operation
removal
of the castings
from the mmld.
Requirements
Castings
metal
between
less
REQUIREMENTS
remelted
fined
or convergence
grains
shall _e
parallel
the airfoil.
3.3.7
A/I columnar
grains
which
extend
part of the finished
casting
dimensions
originate
within
a chill
zone no greater
3/16 inch above
_he chill
block
surface.
3.1.1
Chemical
co,uposition
shall be in
accordance
with EMS55447,
with
trace
elements
in accordance
with AMS 2280,
2.
be
of
3.3.5
The alrfoil
ntldspan chord
shall
consist
of a minimum
of 5 grains,
with no single
grain
exceeding
40% of the width.
3.4
Class
Columnar
grains
shall
15 ° of the major
axis
3.3.6
blade.
Radiographic
Aerospace
ARS
3.3.3
within
3.3.4
Divergence
any two coluntnar
than 20 °.
MIL-I-6866
2.1.3.
at
(Mu%R-M247)
The leading
and trailing
edges
consist
of a single
grain
with no
boundary
intersection
(termination)
trailing
edges.
the leading
and
treated
after
Solution
heat treat
blades
at
in vacuum
for 2 hours.
Blades
rapid
inert
gas cooled
to below
from
3.4.2
Following
s, _utlon
heat treat_nt,
blades
to be tested
Shall he given
a simulated
coating
cycle of 1800°F
+25 for 5 hours
and still
air
re-
charge,
ccoledt
hours.
followed-by
aging
at
1600°F
_25
for
20
.
247
I I
3.5
Motaliographio
II
I
Inspactio=
_
R
.....
3.5.1
A blade
from each heat treat
_ot mhall
be metallographlcally
examlnad
for incipient
melting
and gamma-prime
solutloning,
for
information
only.
A 500X photomiaroqraph
Of
a representative
area shaIZ be submitted
to
AiReseareh
Receiving
Snap, orlon
for transmittal
3.6
to Materlals
Mmchanie_l
Engineering.
3.6.I
Tensile
test specimens,
machined
from
fully heat treated
blades,
tested
at room
temperature
shall meet
the following
minimums:
Ultimate
tensile
strength
(ksi)
0._ percent
yield strength
(kel)
Elongation
(percent
in 4D)
Reduction
_f area
(percent
in 4D)
140
120
7.0
7.0
3.6.2
Stress-rupture
test specimens
machined
from fully
heat treaued
blades,
tested
at a. temperature
of 1400"F
and
stress
of 105,000
psi shell
have a-mlnlmu_
life
of
80
a
hours.
Surface
3.7.1
attack
0.0005
The maximum
depth o_ intergranular
allowable
after any processing
is
inch.
4.
PROCESS
CONTROL
4.1
Cooling
rate
shall
alloy
show no evidence
depletion,
or
5.4
Master
heats
shall be tested
by the
casting
supplier
for conformance
to
chemical
limits.
Chemical
tests
shell be
performed
on a blade
cast from the
mae_er
heat.
5.4.1
Overall
chemistry
may be determined
at any location
within
the blade.
Hafnium
shall
be determined
at both the tip and
the root of the blade.
5.7
A sample
from each heat-treat
lot
received
shall be inspected
by AiResearch
for intergranular
attack,
reeryst_llization,
alloy depletion,
and carbide
oxidation.
fast
4.2
shall
Solution
heat-treat
furnaces
by the casting
AiResearch.
supplier
to
and
7.
...
APPROVAL
OR
PROCUREMENT
7.i
Approval
of the supplier's
fixed
process
and prooes_
changes
shall
be in
accordance
with EMS52332.
8.
five blades
per condition).
load by weight
may be used.
8.1
The supplier
of castings
shall
furnish
to AiRaseareh
Receiving
Inspection
with _ach
shipment
a report
lis£1ng
the results
of the
mechanical-property
tests
for each
solutlon-heat-treat
lot and master
h_,at,
the results
of the chemical
analysis
from
one
casting
per master
heat _:epresenting
the part number
shipped,
and a statement
that the castings
conform
to the requiremonte of this specification.
A
simulated
INSPECTION
5.1
Visual
Inspection
Inspucted
in accordance
5.2
7
Fluorescent
- All
with
Penetrant
blades
shall
Table
I.
Inspection
be
REPORTS
5.2.1
All blades
shall
be processed
per
MIL-I-6866
with a Group
V or VI level
penetrant
per MIL-I-25135.
|i
FORM P5704-_
248
o
PACKING
production
heat treat capacity,
and test
to the mQchanical-property
requirements
5.
!
AND
6.1
Each casting
shall
be identified
with
part number
and master
heat number
in
accordance
with specification
MC5014.
4.2.1
To qualify
a furnace,
the casting
supplier
must heat treat
a minimum
of 15
blades
in a furnace
loaded
to the maximum
_
IDENTIFICATION
solution-heat-treat
temperature
shall be sufficiently
meet mechanical
properties,
be qualified
approved
by
in solvent.
5.3
Radiographic
Inspection
- All blades
shall
be radiographlcally
inspected
per
MIL-STD-00453
to tho acceptance
standards
defined
in Table
_II.
6.
from
dipped
or unsharp
by wiping
with a swab
5.6
The casting
supplier
shall
test two
blades
from each soluti0n-heat-treat
lot,
one in tensile
and one at the higher
tomperature
creep-rupture
conditions
of
EMS52332,
to verify
conformance
to uhe
mechanlcal-property
requirements.
condition
3.7.2
Blade
surfaces
of recrystallisation,
carbide
oxidation,
brush
indications
allowable
aoo_pt/
5.5
Master
heats
shall be tested
by the
casting
_upplier
for mechanical
properties.
A minimum
of three
specimens
for each test
condition
shall be tested.
3.6,3
Stress-rupture
test specimens
machined
from fully heat*treated
blades
tested
at 1800"F
_5" and a stress
of 30,000
psi
shall
have a minimum
llfe of 60 hou=s.
3.7
penmtrant
with the
and the
?able
_I.
5.2.3
Evaluation
Of smeared
indications
may be performed
thm indication
one timm only
or
Properties
I
I
5.2.2
Fluorescent
shall
be correlated
vlaual
imperfaitlons
re_ect
criteria
of
--
'
J
L
I
r
I
I
.......
i ..............
_
[8.1.1
This _epo_t Ihell
£noleda the puTchase o_de_ nemb_,
m_.er
heat non,bur end
cod_ symbol,
if used,
solutlon-heet-t_ea_
number, m_teriel
speoific_ion
number end..
iLs revision
_etto_,
pert number, end
quantity
from-each heat.
.
'
"
:'
:_
;:
8.2
The supplier
o_ finished
or
semifinished
pa_ts
shell furnleh with
each shipment • report showing the
purchase orde_ number,, materiels
specification
number, cent_ector or
othe_ d.Lrect
supplier o_ castings, part
nember,
and.quantity.
_
_,
8.2.1
When castings for making pares ere
produced o¢ purchased by the- parts suppliers_
the parts
supplle_ sh_ll inepeot eaetlnge
from each _aeter hee_o¢
master" heat lot
re_resented end shall Inolude in the =aport
e statement that the castings conform, or
eh_ll include
eoples o£ laboratoDy reports
ehowl_
the results.of tes_s to determine ..............
conformance.
_
9,
'
:
,
i
QUALITY
CONTROL
9.1 Castings shall be un¢=orm in quality
and condition, sound, and free f_om-foreign
materials and from In_ernal and external
imperfection in excess of those,allowed
in
this s_eeificatlon.
9.2
All parts received by AIR_searc_
after app#oval of the eupplier_s fixed
process ehal5 be sampled in accordance
with an established statistical control
plan.
The sample shell be submitted to
Materials Engineering on a CMR for
meehanioal-pcoperty
testing, verification
of chemistry, metallographic
examination,
and inspection of surface condition.
[
'
•
;
9.2.1
Failure to meet the fixed, process
established
control limits indicates probability of a fixed proces_ change.
(See
Approval or Procurement section.)
9.3
Parts and material not ¢onformlng
the requirements of this specification
shall be re_eoted,
tO
r
%,
I
FORM PSY04-_
249
-
I
J
•
I
"
II
I.
TABLE
Ill
VISUAL
A_EA
I
I
|
I
|
I[
AC_k%_CECnlTERIA0
V_SUAL
ZMPERFECTIONS
_I
II II
1 (7)_9)
_,
NONINTE_PREA
NEGATIVES
Z.
DIS_
Depth
Dis.
Height
P_SITZVES
(3)
(5)
.010
.010
.010
.005
.010
.020
.005
L
.015
(4)
PLATFOrmS
.OiO
.010
(61
TABLE
(i)
(2)
A
R
F
Max.
eL 5 per..25 x .2S
ares.
O
I
BASE
(I)
(2)
(3)
(4}
(5)
-
(6)
(7)
(8@
(9)
B
MaX
AS
CAST; (8)
i
MACH'.OlO
INED
m
250
of
lO
.25
_
ares.
_25
per
.020
.O05
Max. of 5 per
.25 x .25 .
area.
(6)
(8)
(6)
(8)
(8)
N/_
N/A
_ax0 Of
.25 x.25
5 per
area
generally
porosity,
conoentrated
in local
areas with no individual
indication
exceeding
.010 dla. x .010 depth.
Limited
to 2 areas per surface.
.OIG parting
line allowe_
in fillet
radii,
.003 max. On leading
and trailing
edges.
A cluster
of these
indications
not to exceed
.125 dis. and should
be separated
by .25 o_
good area.A cluster
of these
indications
should
not e_ceed
5 par .25 x .25 area and 2 area•
per
surfac.D.
Gate wltnees
of .030 allowed
on stock
added
surfaces,
Thru or like impe=fectione
appearing
on opposite_sides
are not a=ceptable
p_oviding
thel
are
interpretable.
Indications
which
will be removed
in machining
are acceptable.
_Inear,
cola shut, Or cEack-_ike
imper_ection•
are not acceptable.
F-C_M PI,704-,II ....
•
(8)
,.....
.010
i
_"
,
, ii
T
-
.
i
.a
Ir Iv,IM_t4_,.,ff_i,_,r,4*_sljmi
_
•
I
III
-
7
-_
1
am_
g
I
I.-_
TABLE I_.
FL[;OR/_SCENT PENETRA_
'_"
ACCEPTJ_J_
,
CJ¢IT_RI_.
'
P ENETRAN_
-2i-T"
;'
I_DXVIDUAL
BLEED 9UT
NO_T11_TE_ RETABLE (i) (2)
.010
Max. of 5 per
.25x,25
area
R "
,
i
-
E
O
A
L
E
.030
DiS. (5)
Max. of-lO
pe_
.25 x ,_5 area-
.030
Dis.
(5)
Max. of _ per
.25x.25area.
PLATFORMS
:'
_
I
i_
i
(4)
(4)
' '.(_lo Max.
,_L.s'per
._5.x.25 area
EASE i AS
_cH_
ZNED
•
:I
.
1,CAST
!
(I)
"
i _
} _.
(2)
(3)
i_. "
(4)
5)
}
(6)
,,
Generally porosity, concentrated
in local, areas with. no ind_vldual indication exceedIDg
.010 dla. x .O10 depth.
L_mited to 2 areas per surface.
Thru or like imperfections
appearing 3n opp3_ite sides are not acceptable providing they"
a_e interpretable.
Indications _hic_ will be removed in machining are acceptable.
A cluster of these indications not to exceed .125 dis. and should be separated by .25
of good area.
Linear,
cold shut, or
i <"
TABLE
____._
crack-like
ZII,
Imperfections. are not _coepteble.
RADIOGRAPHIC
BLADE
AREA
RADIOGRAPHIC
;
Elongate_
•
_v
i
_
ACCEPTANCE
.-
"Round
or oval ,
CRITERIA.
INDICATIONS
Spacing
Pactor
I
[ (_)
Limits
"_-
-.
i
A
non_
.020
2 areas _er
blade
5 x
_
e
.030
.040
(i) max. of 3
per blade
2 x
2 areas per
surface
5 x
:, ;_..
BASE
none
III
I
.020
•
II
r
(2)
Minimum spacin 9 bet_veen indications is determined by circumscribing
a circle
the. larger indication and multiplying
its diameter by the apacin_ factor.
(1)
Maximum oC two at a single
radial
•
,;
"
around
position.
i2"
!
_--, _
251
-i• rl
I
_
111•
rl|
i
.
.
i_||i
i
I
ACID ETCItING H_IODS
'_
Thi_dppendJx
o_£e_s_alte_nata
OLo|_i_g muthods
a_a utilized
to expose
gJ:ai,
bounda_ies
etch.
When specified,
the
l.epaetion,
methods
fo_ atchiL_g
cas_
blades
p_lor
to inupection.
Tha,_
to accomplish,
two _l_'L_oaes,
(L) to ohtal_l
an etoh-suf£1aient
prio_
to ._acrograin
lnapuction_
and /.2) to obtain
a cleanin_
cleaning
etch
sh_lL
be used`prior
to f_tuO=aacent-_enetrant
CAUTION:
and etching
of par_s
_ust
ventilat_on,
as toxic
fumes
M_xing of solutions
_dequa_e
exhaust
Method
£tohlng
Solution
Hurlatic
Acid- (20" Be)
Anhydrous Ferric Chloride_
Nitric-Acid
(42" Be)
WaterAdd ferric chloride
Add. _i_r Ic acid,
Add water.a)
b)
accomplished
liberated
in
from
an
_he
a_ea with
etchants.
I
:
'
l
2
3
be
are
100__.
80 gal
135 ibs
2 gel
_l_gal
FeCI3_ -
to murlatlc-aold,
Allow
A new. solution shall-he prepared when
i2 minutes.
DO no_ replenish to maintain volume,
Approx.
1 lt_er
757 ml
154 g
19 ml
106 ml
to dissolve ............
a suitable
etch is not obtained
within
Procedbre :
I.
2.
3_
Load parts in etching basket, keeping level below basket rim
_mmerse parts.basket
in etching solution maintained at room temperature
(75-I00'P).
Check p_-og_ess of etch after 6 minutes and every 2 _inutes thereafter by removing
one casting, rinsing, and visually inspecting progress of etch.
Once the etch
time required is established
for tllat particular run of castings,
the fol_owlng
loads can be run wlthout ohecklng°
Typical etching time is 6-10 minutes.
a)
4.
5.
6.
?,
8
Immersion_ _Ime for cleaning
etch
,
Method
Etching
shall be 20-30 seconds.
Re_ove from etchir_ solution and rinse in clean, cold water,
In_,et'se
Ln alkaline cleaner solution for 3 minutes.
Remove front cleaner and r_nse in clean° cold water.
Air+-water (tozzle scrub each individual casting clean.
Blow loaded basket free of excess water with air only.
2
Solution:
MU#l_tlc
acid
(20'
_e)
Glacial
acetic
acid
Nit=it acld_ (42" Be)
Ferric chloride
i.
2.
3.
90% by VOI
5% by VO_.
5% by vol.
to saturation
__
Ap_rox 2 liters
(1615 ml)
(85 ml)
(85 ml)
(12,5 lbs)----
Ad_ acetic acid--to m_ri_tlc acid while cautiously agltati_g
the mixture.
Gently heat the mlxtur_ and add sufficient ferric chloride to raise the boiling
point
tO 150-160"F,
Cool-saturated
solution
to<100*F,
then cautiously
add nit¢ic
acid
while
agitating
the atchant.
CAUTION:
Never add nLt_Jc
acld to the etchant..when
temperature
is
above 100_F,
a)
The etchant shall be discarded when
minutes to delineate the macrogtaln
the etohin_
structure.
time requires
more
than two
_rocedur_._
}.,... Pack parts in suitable
each other.
tray o¢ basket
as tha_ alrfoi_a
GO not come
in contact
I
FORM P5'704-_ "
252
'
with
.
_
-
. _.
_-.-_._._.._,._=E_.le.-.._.-..mw_..._,
_
k
2.
Ir_eree
in acid
atohau_
(_0
*IO°P)
for
4 minimum
qrain
st=u=ture
visible
te una-ldnd
aye.
Maximum
shrill be limited
_c two minutes.
Thu et_hant
Cr
i_ obLaining
uniform
etching
and
to mlnlai_e
thu
a)
X]_n_eL'_ion time
for
cleaning
etch
_hali
be
length
QE time
to bring
hm_roexposure
time
in
the
atchanC
pa_s
sh_ll
be-agitated
to aid
exli_sure
time.
I0-20
3,
4.
Rinse
thoroughly
in
running
tap water.
Desmut
by inunersln_
in concentrated
hydrogefl ps_.oxlda
brush
or alr-wate_
power
flush--surfaces
of the etched
5.
6.
Rinse
R_1_se
il_ running
in ho_- tap
tap water,
_t0_
and
seconds.
(HvO ?, 35 percent].
Hand
pa_t|
to _emove
residu_l
dry,
i
Etc_£ng
SoiutloR
:
acid
(20 _ Be)
Peroxide
(30-35%)
Murlatic
Hydrogen
90%
10%
b_ VOW,
b_v_1,
.(or eufficlent
qtu_ntity
to obtain
a satisfactory
etch}
i
1.
Add
hydrogen
a}
b]
Ma_e
up solution
Just prior
to usage,
Whenever
possible,
the etching
solutlon
_ontalner
should
be immersed
in a tap
water
rinse
tank foL- the purpose
of dleslp_ting
the heat
liberated
during
the
etching
process,
so that an etching
time cycle
can be establlehe_,
Th_ etchent
shall be discarded
when
the etching
time requires
more
than five
minutes
re delineate
the macrogEain
structure.
c)
Procedure
L
2,
peroxide
t_ mu_iatio
&ei_L while
cautiously
agitating
the
mixture,
!
Pack parts
in eulteble
tray or basket
so that airfoils
do not co_
each
other,
Ims_erse in acid et_hant
maintained
at room
temperature
(75-I00_P)
length
of time
(5 mln, _ax,)
to bring
mecrograln
structure
vleible
when
_nspecting
for grain
slze and casting
irregu_aritles,
a}
l,une_eion
in
time
running
for
tap
c_eanlng
3,
R_nse
4,
r_,_u_red
if residual
smut
is _ot
Rinse
in hot tap water
and dry,
water.
Hand
etch
sha_l
brushing
removed
be
_0-25
or
air-water
during
the
in contact
with
for a minimum
to unaided
eye
seconds.
rinse
power
f_uehing
may
be
c_cle.
i
l
_--'o..P_o441"---_------'
'-
'
__
" _
"_"-253
i
-
"."
1. Re_rt No,-CR-159464
4. Titleand Subtitle
I 2. G_ernmen_Accmion No,
3. Recipient's_talo9 No.
_,
5. Re_rt Oate
_ow-Cost
Dlrectionally-Solldifled
Volum_
1
Turbine
Blades,
January__979
6. Pc,loomingOr_ni/a_]on_de
a
.
i
'
7, AuthOr[S)
8. Perlorming
Or_nizadon ReportNo
L.W.
AiResearch
G.
_"
Sink
IZI
S. Hoppin,.
and
M.
FuJii
10.Wuk
t,
9. PerformingOtganizati_ NameandAdde_
A_esearoh
Manufacturing
Company
of Ar Izona
A Division
of The Garrett
Corporation
Phoenlx,
Arizona
85010
i
21-2953-1
UnitNo.
i
' '
'
t2. S_nsoring Agency_Name
and,Addr_s
i _;
National
Aeronautics
and
Washington,
D.C. 205.4.6
Space
11._ntractor GrantNo
NAS3-20073
.."_.
Ty_ of Re_rt and Period_ver_
Project
Completion
Report
Pro_ect
1
Administration
14.S_n_ring Agency_de
F_
15. _pplementar_ Notes
Project
:.-
! -
--
i
:'
i
;
"
-_
='
_-
.
:
Manaeer:
"
16.
Abstract.
A
low_cost
Robert
L. Dreshfiel_,
Materials
and Structures
NASA-Lewis
Research
Center,
Cleveland,
Ohio
process
for
manufacturing
high
Results
of
Project
1 showed
that
the
stress-rupture
strength
heated,
directionally-solidified
MAR-M
247 turbine
blades
exceeded
Lnd--that the performance
and cost reduction
goals were achieved.
•
-
1_.
S_urity
_assif.
[of
this
re_rt)
! [
'"
of
exothermically
program
objectives
18 DistributionStatement
Columnar-Grain
MAR-M
247
MAR-M
200+Hf
IN 792 + NP
NASA-TRW-R
i 20.
I
-
directionally-
Task I established
the basic processing
parameters
using MAR-M
247 and employing
the
exothermic
directional-_olidification
process
in trial
castings
of turbine
blades.
Task II evaluated
the nickel-based
alloys
MAR-M
247, MAR-M
200+Hf,
IN 792+Hf,
and
NASA-TRW-R
as directionally-solidified
cast blades.
Task III further
evaluated
the
three
alloys
with the highest
stress-rupture
strengths.
In Task IV a new turbine
blade,
disk, and associated
components
were
designed
using
previously
determined
material
properties.
Task V manufactured
sufficient
DS blades
and other hardware
for
Jthe required
engine
testing.
Task Vl subjected
exothermically-cast
directionallylsolldified
turbine
blades
of MAR-M
247 and MAR-M
200+Hf
to engine
test.
Task VII
analysed
the engine
test results
and compared
the results
to the originally
estab|llshed
goals.-
Turblne-Blade
Directlonal-Solidification
Alloy-Selection
Ni-base
Alloys
Investment
Casting
Rx_herm4e-_{_at{nq
;
strength
Turbofan
Engine.
This development
was the result
of Project
i of the Materials
for
solidified
high-pressure
turbine
blades
was successfully
developed
for the TFE731-3
Advance_Turbine
Engines
[MATE) Program,
a five-year
cooperative
Government/Industry
effort.
The goals of this project
were to:
(i) reduce
engine
specific
fuel consumption
(SFC} at least 1.7 percent;
(2) reduce
engine
manufacturing
Costs at least
3.2
percent;
(3) reduce
engine
weight
at least 1 percent;
and (4) reduce
engine
maintenance costs at least 6.2 percent.
These benefits
were anticipated
by the substitution
of
solid,
uncooled
directionally-solidified
turbine
blades
for
hollow,
cooled,
equlaxed-grain,
turbine
blades.
17. Key Word|(Sugg_edby Author(s))
--_ :
stress-rupture
Division
"
_curlty
Cl|s%i{.
Star
(Of
this
page]
Category
26
t
21.
_1o
of
P_g_
" Fo( sale by:he Nah0nal Techmc_l l=lfo:mat,onSe_v,_e Spr,,:_',e!e 'Vltg]rJln221_1
NA_A-C-Ib8(R_v. 10-7_)
=
I
22
Pr_e"
i