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Gas turbine engines find widespread use for and further increases in operating temperature,
aircraft and marine propulsion and for land- even if only marginal, can profoundly reduce
based power generation. The engines consist of the service life of these blades.
an inlet duct followed in sequence by a com- Over the years, designers have actually been
pressor section, combustion chambers, high and able to achieve higher operating temperatures
low pressure turbine sections and an exhaust at the same time as improving the service life of
duct. Gas turbine engines operate on the sim-
ple principle of converting heat energy into
mechanical work, by taking a large volume of
air, compressing it to high pressure, mixing the
compressed air with fuel and then igniting it.
Propulsion or power generation is obtained by
the very rapid expansion of this ignited fuel-
air mixture through the turbine blades.
Thermodynamic efficiency is an important
consideration in gas turbine engine design, most
particularly for those turbines destined for the
aerospace market where the power:weight ratio
and fuel efficiency are of major concern. A sig-
nificant parameter in the equations which
describe thermodynamic efficiency is the tem-
perature difference that can be achieved across
the engine. Designers of turbine engines try to
maximise the operating temperature of the tur-
bine section of the engine, or more specifically,
the high pressure turbine section. However, there
are limitations. A turbine is composed of hun-
dreds of turbine blades which rotate at very high
speed on a series of coaxial disks. Operating Fig. 1 A 2-inch long high-pressure turbine blade
suesses and temperatures are therefore very high showing some of the multiple air cooling channels
the turbine blades. This has been accomplished improve thermodynamic efficiency and, signif-
through improvements in the engineering design, icantly, reduce nitrous oxide emissions.
manufacturing techniques and by the use of The cooling channels are produced by plac-
‘superalloy’materials. A significant feature in ing ceramic cores within the mould cavity in
the engineering design has been the incorpora- which the turbine blade is cast. These ceramic
tion of special cooling systems into the high pres- cores are subsequently dissolved out of the cast
sure turbine blades, see Figures 1 and 2. These turbine blade, leaving behind the required net-
cooling systems consist of a network of chan- work of cooling channels. Precise positioning of
nels within each blade which allow relatively the ceramic cores within the mould cavity, and
cold air to be pumped at pressure through the maintenance of that position throughout an elab-
centre of the blades. The air then flows out of orate series of mould preparations, firing and
numerous small holes in the blade surfaces, blade-casting processes are vital for achieving
enveloping the turbine blade in a film of cooler blade dimensional stabilityholerances. However,
air. This causes a reduction in the operating the ceramic cores have a very high length to
temperature of the turbine blade, without there diameter ratio and are only poorly supported
being any significant reduction in the operating within the mould cavity. To overcome this dif-
temperature or efficiency of the turbine engine. ficulty pinning wires are anchored in the mould
The technology of incorporatingcooling chan- cavity wall and butt against the ceramic cores.
nels within turbine blades has traditionally been The pinning wires are used to maintain core
applied to aircraft propulsion plant. More position.
recently designers of land-based gas turbines Platinum-based materials have traditionally
are showing interest in applying this technology been used for ceramic core pinning. Seven to
to create cleaner, more efficient power gener- ten pins, each of 5 to 10 mm long are typically
ating plant. The higher operating temperatures required for a 2 inch high-pressure aero-engine
that are possible using cored turbine blades turbine blade. Platinum-based materials are
Fig. 3 Schematic of a crosgsectionthrough a prepared mould showing the pinned ceramic cores
within the wax preform and the ceramic shell mould
used because of their proven ability to maintain ufactured by the precision casting process of
ceramic core position and subsequentlydissolve investment casting, also known as the ‘lost wax
into the turbine blade without any deleterious process’. Ceramic cores for the cooling chan-
effects on the structure or properties of the blade nels are positioned within a master mould pat-
material. Oxide dispersion strengthened plat- tern. Wax is then injected into the mould cav-
inum and, more recently, pure platinum have ity to produce a preform of the turbine blade.
seen extensive application in this area. Pinning wires are then pressed through the wax
A drawback to the more widespread use of to butt against the ceramic cores within the pre-
platinum-based pinning wires is the cost of the form. Next, the preform is coated with multi-
raw material. Recognising this, Johnson Matthey ple layers of ceramic, ultimately forming a thick
Technology Centre embarked on a programme casing around the preform with the pinning
of work to develop novel pinning wire materi- wires embedded in it. The assembly is heated
als (1). This paper discusses some of the func- to melt out the wax and then tired to strengthen
tional requirements of pinning wires and shows the ceramic. The result is a ceramic shell mould
how these have been met by alloy design. So far, containing a complex ceramic core pattern which
this work has led to the development of a range is held in position by pinning wires anchored in
of commercial, novel pinning wire alloys based the ceramic shell, see Figure 3. Finally, the
on palladium and specific refractory metals (2) mould assembly is preheated prior to casting
and the acceptance of one alloy by Rolls-Royce the turbine blade.
plc. This alloy is cheaper than platinum and has Turbine blade manufacture crucially requires
been shown to give comparable performance. the nucleation and growth of precisely controlled
microstructures. The grain structure within the
Turbine Blade Manufacture turbine-blade superalloy material is frequently
Turbine blades have a complex geometry and described by terms such as ‘equi-axed’, ‘direc-
contain many areas of double curvature. tionally solidified’ and ‘single crystal’. These
Therefore the blades have to be precisely man- characterisethe grain boundary length and thus
lmmersm
level
' /' /
"/
R - 8Y.W
to survive within the molten superalloy during are more related to the melting temperature of
casting of directionally solidified aero-engine the alloying element, rather than to the melting
blades. In the first experiments the recession temperature of the alloy itself.
rates in molten superalloys of a number of dif- This initial work demonstrated that prospec-
ferent platinum and refractory metal wires, tive new pinning wire materials do not need to
including oxide dispersion strengthened plat- survive in the molten superalloy for very long
inum (the standard pinning wire material) were to be successful. In fact, it emphasised the impor-
compared. tance of rapid dissolution in order to ensure that
The experimentsrevealed that when oxide dis- no concentration of pinning wire material exists
persion strengthened platinum wire of diame- anywhere within the turbine blade.
ter 1.4 mm (more than four times the cross-sec- Following these melt exposure tests, the exper-
tional area of standard pinning wire) was dipped imental programme next examined the oxida-
into molten nickel-based superalloy to a depth tion properties of samples and evaluated their
of about 20 mm for three seconds, the wire com- high temperature stability under vacuum.
pletely dissolved, see Figure 4. By comparison, Temperatures and times of exposure were
smaller diameter platinum-rhodium and plat- selected following consultation with major aero
inum-iridium wires suffered significant disso- engine manufacturers. Oxidation tests to sim-
lution and reduction in their length. While a ulate different ranges of mould firing conditions
platinum-8 per cent tungsten alloy also suffered were performed at 850°C for 18 hours and at
dissolution, t h i s was at a much slower rate than 1075°C for 8 hours. The same samples were
for the other alloys, and it still retained its orig- then placed under vacuum at 1475°C for up
inal length. Full results of these investigations to one hour. Tests were also conducted in air at
are shown in Table I. Clearly there is a rela- 950°C for 70 minutes followed by 30 minutes
tionship between the melting temperature and under vacuum at temperatures of 1500 to
the dissolution rate. It may also be suggested 1550°C. Results are shown in Tables I1,III and
that the dissolution rates of the platinum alloys IV.Samples were assessed by weight change,
Table IV
Assessment after 70 minutes at 950°C in Air (Stage 1)
and 30 minutes at 1500 to 1550°C under Vacuum (Stage 2)
Sample 0bservations
Pd-15YoMO Oxidation to 0.04 mrn depth after Stage 1; complete removal of oxide
layer by vaporisation after Stage 2, leaving behind a Pd-rich surface region
VI
TableVI
Table
Longitudinal Stress Rupture Properties
Nickel-based Pinning &mount of pinning Test Applied Sample Average
superalloy Nire used wire in superalloy. emperature. stress, size life,
wt. Yo OC MPa hours
AAisisaa proprietary
proprietary Ni-based
Ni-basedsuperalloy
superalloy used
usedfor
for directionally
directionallysolidified
solidifiedturbine
turbineblades
blades
Pd-l5%Mopinning
XX == Pd-15Y0Mo pinningwire
wire
YY = Pd-SO%Wpinning
= Pd-20Y0w pinning wire
wirewith
with 55ppm
m Pt
Ptcoating
coating
. Bibliography
E. Savitsky, V.Polyakova, N. Gorine and N. Roshan, P. G. Boswell and K. Majumdar, “New Palladium
“Physical Metallurgy of Platinurn Metals”, Pergamon Based Alloys”, Johnson Matthey Research Centre
Press Ltd., 1978 Final Report, Project 82J2/2, October 1981