Br, -t i

NASA 0R-159464
.... VOLUME 1 OF 2
^ m_e=^l_rW _1-_q53-1
(NASA-CB-159q6q) LON-COST N79-24121
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 0nclas
CSCI. 11P G3/26 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 Ai
I
Aeronautics and Space Administration, Lewis Research Center. It
presents the results of a Drogram conducted to establish
exotbermic heated casting technology for. the manufacture of low-
_._ cost, _irectionally-solidlfied, uncoole_ turbine blades for aas

[i tuzbine enqines. The program was conducted as part of the

:_-
[ Materlals_ for Advanced Turbine Enqines (MATE) Proqram under
_,
F_
Contract NAS3-20073.

[ - The authors wish to acknowledge the assistance and quidance

of _. L. Saunders, C. P. Blankenship, and R. L. Dreshfield of the
- Materials and Structures Division of NASA-Lewis Research Center.

Major contributions to the success of the program were ma4e bv C

M. PhioDs and R. J. Ouigg of Jetshapes, .Inc..............................................
L.

£11
 v

TABLE OF CONTENTS ..................................

INTRODUCTION 1
iI_;_r,_I_PAGB _N_ lgO? FILMED.
SUMMARY 4

TASK I - CASTING TECHNOLOGY 7

Exothermically-Heated Casting Sy__tem 7

Process Development 10 _

Casting t_ials and results 10

Exothermic behavior 27

Mechanical-property evaluations 29

Chemical analyses 40

Recommended Casting Practice 40

Wax assembly manufacture 42

Mold manufacture 42

Casting process 42

TASK II - ALLOY/PROCESS SELECTION 45

Scope 45

Test Material Production 45

Heat Treatment. Studies 48

Metallurgical Evaluation 53
Nondestructive evaluation (NDE) 53
Chemical analyses 63
Mechanical tests 68
Thermal fatigue tests 88
Dynamic modulus testing 92
Metallographic examination 95

Alloy Selection 101

V
 ,i

¥,

TABLE OF CONTENTS (Coned)

TASK I_I - ALLOY..PRORERT_Z_CHARACTERIZATION 102 k

Scope 102

- Test Material Production 102

PropertyTesting 103

i- TASK _=.,- BLADE DESIGN 154

Scope 154 ........ _"

_-- Preliminary Design - High Pressure Turbine (HPT) Blade 155

Aerodynamic design - preliminary design blade 155

Stress and thermal analyses 166

" Final Design - High-Pressure Turb%ne Blade 169

. Aerodynamic design - final design blade 169

: Thermal analysis 185

Stress analysis 185

Vibration analysis 191

L

Final Design - High-Pressure Turbine Vane 191

Aerodynamic design 191
J

Thermal analysis 203

Design parameters 203

Final Design -. Other Components 212

r

_ ; High-pressure turbine disk• 212

i - High-pressure turbine shroud 212

High-pressure turbine nozzle supports 216

v_

k
 Q_

,>

_; TABLE OF CONTENTS (Contd)

: : TASK V - COMPONENT MANUFACTURE 217 k

i S_ope 217
; : Blade Manufacture 217

!:J_: Special Engine Components Manufacture 226

ii _ COST AND WEIGHT OBJECTXVES 228

,,: : Engine Weight 229

_,- Manufacturing Costs 229

Direct Costs 230

Optimized Engine Costs 230

_ ' Total Costs 233

_. Engine Maintenance Costs 233

_- CONCLUSIONS 237
i:
APPENDIX A 241

--" APPENDIX_B ................. 245

vi_
 d
,b

LIST OF ILLUSTRATIONS.-

1 Simplified Schematic of Exothermically-Cast _

Directlonal-So_idification Casting Process .... 8

2 Task I Straight Spoke Mold Configuration 12

3 Task I Spiral Sp_ke Mold Con/iguration 14.................

4- Task I,.Mold 2 Blade& Showing GoodGrain

Structure in Bl_de "CY' with Undesirable Grain •.
Structure in the Other Three Blade Castings 16

5 Task I, Mold 4 Blades Showing Straight Columnar

Grains in Castings "C3" and '_C4" 18

6 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

7 Task I, Mold 10 Spoke "B" MacroetchedBlades

Showing Consistent Directional Grain Orientations 23

8 Suction Sides of the Injected Casting Waxes for

Task I Turbine Blades (Mag.: 1.5X) 25

9 Wax Assembly for Task I Mold 13. Waxes of the

Initial Design TFE731-3 Blade Used in Blade-
Root-Up Position 26

10. Mini-Bar Test Specimen 30

iI Longitudinal Orientation of Machined Mini-Bar

Test Specimen with Respect to Exothermically-
Cast DS TFE731-2 Turh/ne.Blade 31 ._

12 Standard Tensile Test Specimen 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

14 Wax Pattern Assembly for Exothermic

DS Casting Twenty Task II Preliminary
Design TFE731°,3 Turbine Blades 46

viii
 LIST DE ILLUSTRATIONS (Contd)

Title Page k
" 15 Wax Pattern Assembly for Exothermic DS Casting k
r:4 SiX Task II Tes_ Slabs 49

16 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) 54

l'A.__ 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

.18..........
Typical MAR-M 247 _asK II Exothermically Cast
DS Preliminary Design TFE711-3 Turbine_Blades 58

19 Typical NASA-TRW-R Task II Exothermically Cast

DS Preliminary Design TFE731-3 Turbine Blades 59 ....

20 Typical MAR-M 200+Hf Task II Exothermically Cast DS

Preliminary Design TFE731-3 Turbine Blades 60

21 Typical IN 792+Hf Task II Exothermically Cast DS

Preliminary Design TFE731-3 Turbine Blades 61

22 Cyclic Rupture Specimen 83

: 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

24 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

25 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

ix
 i
d

LZST OF ILLUSTRATIONS (Contd)

26 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) 94

-- 27 Typical M/crostructu_es of Exothermlcally Cast

_ DS Preliminary Design TFE_31-3 Turbine Blades ,
i_ of MAR-M 247. Kalllngs Etch. (Mag.: 100X) 97

2_ Typical Microstructures of Exothermically

__ Cast DS Preliminary Design TFE731-3 Turbine
Blades of MAR-M 200+Hf. Kalllngs Etch.
ii" (Mag.: 100X) 98
29 - Typical Microstructures of Exothe.rmically Cast DS
Preliminary Design TFE731-3 Turbine Blades of
[ NASA-TRW-R. Kalllngs Etch. (Mag.: 100X_ 99

30 Typical Microstructurez of Exothermically Cast DS

I Preliminary Design TFE731-3 Turbine Blades of
_ " IN 792+Hf. Kallings Etch. (Mag.: 100X) 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
TransverseProperties
Specimens Versus Temperature
From TaskforIII !
Machined
_ MAR-M 247 Exothermically Cast DS Preliminary
i : Design TFE731-3 Turbine Blades iii
33 Average Stress-Rupture Strength ef Dg MAR-M 247
i- Versus Equlaxed IN100, 0.178-cm (0.071_.-inch) _
MFB Test Specimens ........... 119

DS MAR-M 247, Longitudinal Data, 0.178-cm

(0.070-1nch) MFB Test Specimens 121

35 Larson-Mlller 0.5-Percent Creep Curve for

DS MAR-M 247, Longitudinal Data,_0.178-cm
(0.070-Inch) MFB Test Specimens 121

36 Larson-Miller 1.0-Percent Creep Curve for

I[ 34 Larson-Miller
DS MAR-M 247, Stress-Rupture
Longitudinal Curve0.178-cm
Data, for
(0.070-Tnch) MFB Test Specimens 122

RL
 LIST OF _LLUSTRATIONS-(Contd) .....................

Tit Pa_Lg...........
---A
37 Larso_-Miller 2.0-Percent C_eep Curv_ for K
DS MAR-M 247, Longitudinal Data, 0.178-cm
(0.070-1nch) MFB Test Specimens 112

38 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

39 .... Low-Cycle Fatigue of Exothermically Cast !

DS MAR-M 147. [Longitudinal. Data, i
1033_K (1400°E), Load Controlled,
A = 1.0, K_ = 1.8, Notched Uncoated
Test Specimens Machined from Separately
Cast Test Bars] 129

40 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

41 Lo_,:-Cycle Fatigue of Equiaxed IN100.

[1033°K (1400°F), Load Controlled
A = 1.0, K_ = 1.0, Smooth Uncoated
Test Specimens Machlned from Separately
Cast Test Bars] 130

42 ........
Thermal Expansion of Exothermically Cast DS
MAR-M 247 and NASA_TRW_R 138

43 _hermal Conductivity of Exothermlcally Cast DS

MAR_M 24_ and NASA-TRW-R 139

44 Schematic of AiResearch Oxidation

Hot-Corrosion Burner Rig 141

45 Oxidation/Hot-Corrosion Burner Rig 142

xi
_m

. L/ST OF ILLUSTRATIONS_ (Coned)

46 Task Ill, Hot-Corroslon Specimens after

310-Hours Exposure at ll00°K (1700°F)
to 5-ppm Synthetic Sea Salt Added to the
i Combustion Products of Jet-A Fuel 146

47 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

48 Microstructure of DS MAR-M 247 Stress-Rupture

Test Specimen No. 148-1 Tested at

_i The AcicularMPaPhase
I144°K/317 Formed
(1600_F/46 at
ksi)1255°K (1800°F)
for 1270 Hours.
is Absent 149 .......

49 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

i_- . 50 Microstructures
Test Specimen No.of 148-1.
DS MAR-MSpecimen
247 Stress-Rupture
was Tested

Hours. No Acicular Phase was Present.

_ Metallography
at I144°K 317 MPaby Micro-Met
(1600°F/46 Laboratories,
ksi) for 1270Inc. 151

51 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 Diagram Nomenclature 158

[ ..

i 53 Radial Distributions of Stator (_i)

and Rotor Exit Angles (_2) 159

-j

xii

=
 LIST OF ILLUSTRATIONS (Contd)

k
54-- -Vector Diagram Data for the Rotor 160 ......................
--_
55 Rotor Hub Section [R = 10.77 cm (4.24 in)]
Cylindrical Cut--- 161

56 Rotor Tip Section [R = 14.16 cm (5.57 in)]

Cylindrical Cut 161 j
I

5Y Rotor Stack at CG, Plane Sections 162

58 Area Distribution--of the RotOr Blade 163

59 Loading of the
the Rotor-Hub 163
60 Loading of Rotor Tip 165

61 Average Centrifugal Stress -- Preliminary MATE

HPT Blade Design 167

62 Metal Temperature -- Preliminary MATE HPT

Blade Design 167

63 Preliminary Stress-Ruptur_ Data, Directionally-

Solidified MAR-M 247 168

64 Critical Mach Numbers and Flow Angles

Versus Radius for the Stator 171

65 Crit'ical Math Numbers and Flow Angles

Versus Radius for the Rotor 172

66 Reaction Versus Radius 173

67 Rotor Relative Total Temperature

Nondimensionalized by the Inlet Absolute
Total Temperature Versus Radius 173

68 Velocity Triangles of the Final Design 174

69 Work Distribution 175

70 Rotor Hub Section [R = 10.77 cm (4.242 in.)] of

the MATE Final Design 176

71 Rotor Mean Section [R m 12.37 cm 14.872 in.I]

of the MATE Final Design 177

72 Rotor Tip Section [R = 14.16 cm (5.57 inches)]

of the MATE Final Design 178
xiii
 LIS'K-OE--I/_LUSTRATION S (Contd)

73 Final HPT Blade Area DistriDution 179

74 TrailingrEdge Blockages Versus Radius ......... 180

75 Rotor Hub Section Loading [R = 10.77-cm

(4.24 inches)],.of the Final Design 180

76 Rotor Mean. Section Loading (R = 12.37 cm

(4.87 inches)_ o£ the Final Design. 181

77 Rotor Tip Section Loading [R = 14.16 c_

(5.57 inehes_ of the Final Design 181

78 HPT Blade Temperatures -- Final Design MATE 186

79 Grid for Thermal Model 187

80 Shank Model Final MATEBlade Design 188

81 Minimum Stress-Rupture Life 189

82 Averge Stress Distributions for

Final MATE Blade Design 192

83 Final MATE Blade Airfoil Design 193

84 Final Blade Design -- Airfoil, Platform,

and Shank 194

85 Final MATE Blade Deslgn 195

86 _ressuze Side Stresses (KSI) and Deflections

at 2_,692 RPM 196

87 Suction Side Stresses (KSI) and Deflections

at 29,692 RPM 197

88 _inal MATE Blade Design Trailing-Edge

Stresses 198

89 Final MATE Design at 29,692 RPM 199

90 Equivalent Shank Stresses (KSI) -- Airfoil and

Platform Removed 200

91 Equivalent Shank Stresses (KSI) 201

xiv
 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 26-Vane Stator 206

94 Tip Section of 26-Vane Stator 206

95 Stack of the 26-Vane Stator (Plane

Sections) 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 with Cooled IN100 Blade 214

105 TFE731 Turbine with Uncooled DS MAR-M 247

Blades 215

106 Exothermically Cast DS TFE731-3 Turbine

Blade Castings for Project i Showing _.
Preliminary (Left) and Final (Right
Designs 218

107. 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

xv
• LIST OF ILLUSTRATIONS (Contd)

k
--_ i08- As-Cast and Finish-Machined Exothermically L%
Cast DS TFE7-31-3 Final Design Blades of i
MAR--M 247 223

109 Pressuze and Suction Sides, of Two

Finlsh-Machined Exothe_mically Cast
,_ DS TFE731-3 Final Design Blades- 224

" 110 Relative Blade Costs of the TFE731 HP Turbine

Blade Froduction Versus MATE DS 231 _

-_ xvi
- [
r
i • LIsT OF TABLES
im •

Table Title Page

'- I Task I Stress-Rupture Test Results on DS k

Cast Machined-From-Blade Test Specimens 34
i._
i II Task I Stress-Ruptu.re Test Results on DS
Cast Separately Cast Test Specimens 36

Ill T_sk L Stress-Rupture Test Results on Con-

ventionally Cast Equiaxed MAR-M 247 Test
Specimens-- 36

IV Task I Tensile Test Result_ on DS Cast

_-- Machined-From-Blade TestSpecimens 37

V Task- I
_, Tensile
Cast Test
Test Results on DS Cast
Separately Specimens 39

i :: VI Results of Bulk Chemical Analyses of Task I

Exothermlcally Cast DS MAR-M 247 Blades 41

VII Summary of Task II Mold Identifications 50

i i VIII Task II Heat-Treatment Process Summary 51

IX Summary of Task II 1255°K (1800°F) Stress-

[ _ Rupture Test Results 56

_ X Inspection Results of Task II Exothermlcally

_' Cast DS Preliminary Design TFE731-3 Turbine
Bleaes
_ XI Task II Chemical Analysis of MAR-M 247 64
of NASA-TRW-R 65
i XII Task II Chemical Analysis

XIII .... Task II Chemical Analysis of MAR-M 200+Hi 66

XIV Task II Chemical Analysis of IN 792+Hf 67

XV Task II Room-Temperature Tensile Test Results 69

XVI Task II I033°K (1400°F) Tensile Test Results 70

XVII Task II 1033°K (1400°F) Stress-Rupture Test

Results - Longitudinal Grain Orlentation 71
2

XVIII Task II I033°K (1400°F) Stress-Rupture Test

= _. Results - Transverse Grain Orlentatien 72

! xvli
 ¥

'i
LzsoFTABLES
(Contdl
_ Table Title Page

• XIX Task II 1255°K CIS00°F) Stress-Rupture Test

Resul_s - Longitudinal Grain Orientation 73

_,_: XX ...........
Task II 1255°K (1800°F) Stress-Rupture Test
_, Results - Transverse Grain Orientation 74
I
XXI Task II Room-TemperatureTensile Test Results 77

_ . XXII Task II i033°K (1400°F) Tensile Test ReSults 78

kt

Ii... XXIII Task II I033°K. (1400°F Stress-Rupture. Test

_. Results 79

,i! Results 80
i XXIV Ta_k II 1255°K- (1800°F) Stress-Rupture Test
XXV Task II 1255°K (1800°F) Stress-Rupture Test
% Results 81

_ • XXVI Task II i033°K (1400°F) Cyclic-Rupture Test

Results at Progressively Higher Stresses 84
r,
}....
_ .. XXVII Task II 1033°K (1400°F), 723.9 MPa (105 ksi)
_ " Cyclic-Rupture Test Results 84
!i
XXVIII Task II, i033°K (1400°F) Cyclic-Rupture Test
Results for Three Grain Orientations 85

XXIX Crack Propagation in the Equiaxed Grain

Blades 92

XXX Average Dynamic Modulus of Elasticity

o£ Task IIDS Cast Alloys 96

XXXI Inspection Results of TaSk IIl Exothermically ._

CaSt DS Preliminary Design TFE731-3
Turbine Blades 104

XXXII Chemical Analyses of Task III Exothermically

Cast DS MAR_M 247 Castings 105

XXXIII Chemical Analyses of Task III Exothermically

Cast DS MAR-M 200+Hf Castings 106

XXXIV Chemical Analyses of Task III Exothermically

l:i Cast DS NASA-TRW-R Castings 107

!.
I
: xviii
 LIST OF TABLES (Contd)

Table _itl______e Page

XXXV Task III Tensile Test Results on DS MAR-M 247

Turbine Blades 108

XXXVI. Task III Tensile Test Results on Separately

Cast Test Bars of DS MAR-M 247 114

XXXVII Task III TenSile Test Results on Separately

Cast Tesk Bars of DS NASA_TRW-R 115

XXXVIII Task If/ Tensile Test Results on Separately

Cast Test Bars of DS MAR-M.200+Hf 116

XXX_Task III Stress-Rupture Test Results on

MAR-M 247 TeSt Specimens 117

XL Task III Stress-Rupture Test Results on

MAR-200+Hf and NASA-.TRW=R.. 118

xLI Low-Cycle-Fatigue Test Results on DS.MAR.M..247 123

XLII Low Cycle-Fatigue Test Results. on

DS MAR-M 247 124

XLIII Low-Cycle-Fatigue Test Results on

NASA-TRW-R and Equiaxed IN100 125.

XLIV Low-Cycle-Fatlgue Test Results on

DS MAR-M 200+Hf 126

XLV Estimated Maximum Low-Cycle-Fatigue StreSs

Requiredto Produce Failure in Exothermically
Cast DS Alloys and Eq_iaxe_ IN100 127 ..................

XLVI High-Cycle-Fa.tigue Test Results

on DS MAR-M 247 131

XLVII High-Cycle-Fatlgue Test Results

on RT-21 Coated DS MAR-M 247 132

XLV_II-- High-Cycle-Fatlgue Tests Results

on DS MAR-M 247 133

XLIX High-Cycle-Fatlgue Test Results

on DS MAR-M 200 134

L High-Cycle-Fatlgue Test Results

on DS NASA-TRW-R Alloy 135

- xix
 •. LIST OF TABLES (CQntd) ,

Table Title Page ..................

\ ,
_- LI ..... Estimated. Endurance Limits of-DS Test _
_ Specimens Machined From Separately Cast
Test Bars 136

LII Modulus of Elasticity 140

LIII Task III 1311°K (1900QF) Oxidation

Test Results 144

LIV Task III 1200°K (1700°F) Hot-Corrosion

Test Results 145

-- LV Basic Stress-_upture Test History 147

•_ LVI Stator Exit Flow Angle Distribution -

Task IV Preliminary Design Blade 156

LVII Rotor Exit Relative Flow Angle Distribution -

_=_ Task IV Preliminary Design Blade 156

LVIII Preliminary Design DS High-Pressure Turbine

Blade Geometry and Aerodynamic Data 157

- LIX Calculated Stress-Rupture Life Showing

Section at Takeoff Conditions 166

:- LX Final Design TFE731-3 High-Pressure Turbine Blade

Geometry and Aerodynamic Data 170

LXI Design Data for the 26 Vane TFE731

- High-Pressure Turbine Stator.. 204

LXII 26-Vane TFE731 High-Pressure Turbine

Stator - Integrated Throat Area vs Stagger 205 ._

LXIII Design Parameters - Task IV TFE731-3

High-Pressure Turbine Nozzle Vane 213

LXIV Summary of t_e Yield of the Final Design

Directionally-Solidified TFE731-3 Turbine
Blades Cast in Task V. 225

LXV Changes in Engine Parameters to Fully Utilize

the DS Turbine Blades in the TFE731-3 227

•, LXVI Changes in Engine Parameters for Constant

Cruise Thrust to Fully Utilize the DS Turbine
Blades in the TFE731-3 232

- XX
 ¥

!_ INTRODUCTION

i The NASA Materials for Advanced Turbine Engines (MATE) Pro-

gram is a cooperative effort with industry to accelerate intro-

duction of new materials into aircraft turbine engines. As part
of this effort, AiResearch was authorized under NASA Contract
NAS3-20073 to develop a new technology for manufacturing low-cost
.J directionally-solldified uncooled_cast turbine blades.to reduce

I _* Cost
process

stage
and fuel consumption
development

through
in the TFE731-3
performed

component
Turbofan
included, those efforts
Engine.
required
The
to
*
from demonstration
the previously by demonstrated
engine test. feasibility
Portions
" carry the technology
!; of the overall effort included process scale-up, alloy evalua-
E
tions, mechanical property generation, hardware procurement,• and
full-scale engine test ingLto eYalua_e potential benefits.
I
!
t_ This report constitutes Volume 1 of a two-volume Project

_:_. Completion Report presenting the results of the investigations

Solidified Turbine Blades. This volume covers_ all Project 1

!i and tests performed under MATE Project I, Low-cost Directionally-

test analysis, which are the subjects of Volume 2 of this report.

i i tasks with the exceptions of full-scale engine testing and post-

I '-. The intent of Project 1 was to develop a process to produce
directionally-solidified, solid, uncooled turbine blades and to
design and substitute this blade for the hollow, air-cooled,
conventionally-cast turbine blade utilized in the high-pressure
turbine of the Garrett AiResearch TFE731-3 Turbofan Engine. The
project goals associated with this substitution were:

(i) A reduction in engine specific fuel consumption (SFC)

of at least 1.7 percent;
 (2) A reduction- in engine manufacturing costs of at
least 3.2 percent; %

(3) A reduction-in engine weight of at least 1 percent; 1

(4) A reduction in engine maintenance costs of at least 6.2

percent.

Project 1 was subdivided into the following seven tasks:

Task I - Casting Technology

Task II - Alloy/Process Selection
Task III - Property Characterization
Task IV - Blade Design
Task V - Component Manufacture
Task VI - Engine Test
TaskVII - Post-Test Analysis

In Task I, the exothermic directional-solidification (DS)

process was adapted to economically cast solid high-pressure tur-
bine blades o£ MAR-M 247 for the TFE731-3 Turbofan Engine, and
establish the levels of mechanical properties attainable.
During Task II, four candidate alloys (MAR-M 247, MAR-M 200+Hf,
IN 792+Hf, and NASA_TRW-R) were evaluated as exothermically cast
DS blades, and all except IN 792+Hf were selected for subsequent
test comparison. An improved heat treatment for MAR-M 247 incor-
porating a higher solution heat-treatment temperature was also
developed. In Task III, mechanical and physical properties of DS-
castings of the three selected alloys were further evaluated to
provide allowable stress levels for a redesigned turbine blade.
Mechanical properties determined included creep-rupture
strengths, tensile strengths, and high- and low-cycle-fatigue
strengths. Concurrently, Task IV was accomplished to adapt the

2
r

L
disk, and design the blade alrf_il and-blade root te best aocom-

":. modate the stress-rupture, tensile strength, and other properties _k

of the chosen alloys .to the test engine. Duping Task V, manufac-
ture of the hardware requlrsd to_upport the Task VI. englne test-
ing was accomplished. NASA-TRW-R, one of the three alloys,
demonstrated a castability problem in Task V-and was therefore
.... droppe_ from the project. Turbine blades manufactured from the

remaining tw_-.alloys, MAR-M 24/ and MAR-_ 200+Hf, were engine

tested.

The engine testing, performance, and post-englne-test eval-

uations of the turbine blades are described in Volume 2 of this
repQrt ..........

. 00000001-TSBC
 SUMMARY

_ The project accomplishments

exothermically-heated, included the development
directional-solidlflcation casting of pro-
the
s,,
cess into a viable process for producing solid TFE731-3 high-
_ i_ pressure turbine blades. _igh quality directlonally-solidified

blades of the new design were cast in the MAR-M 247 and
_'_ MAR-M 200eHf alloys. These blades were finish processed through ,

heat treatment, machining, and coating op_grations f-or the engine ti

test de@cribed in Volume 2 of this report. The blade cost por-
tion of the engine manufacturing cost goal of tnis project was
!ii._ achieved with projected volume production costs for the solid DS
blade being 58-percent of the cost of the cooled equiaxed IN100
blade. The engine weight reduction goal can be achieved in a
turbine redesign by eliminating the retainer plate used to
deliver the blade cooling air and redesigning the disk. These
changes were not incorporated in the engine test configuration
since reduced cooling air was required to utilize a production
; Waspaloy disk thus avoiding a new disk design and/o_ material.

the substitution of a more rugged, solid airfoil for the thin

The long-term
walled, maintenance cost
cooled blade currently goal
used. is expected to be realizedmore
This design provides by

resistance to foreign object damage (FOD) and more capability for

[
being recoated. The elimination of cooling air and the cooling
air circuit also avoids many operational problems over the life
%
of an engine.

_ _ Task I of the project established a directional-

solidification casting process for solid MAR-M 247 high-pressure
i turbine blades employing an exothermically heated ceramic mold.
Key _rocess elements established were the mold design, a furnace
ignition technique for the exothermically-heated molds, and
improved quality requirements for the exothermic material. Base-
[_ line tensile and stress-rupture strengths for DS MAR-M 247 tur-
bine blades were determined. Good reproducibility was shown for

! ,
the results o£ tests on 0.178-cm (0.070-inch) gauge diameter
minibars machined f_om the DS blades (MFB). ThisMFB minibar was
%
thus used for all--subsequent tensile and stress_rupture testing _
in this..p_oject.

Htilizing the DS casting process developed in Task.-I, tur-

bine blades and test slabs of four nickel-base, alloys (MAR-M 247,
MAR._ 200+Hf, IN 792+Hf, and NASA-TEW-R) were successfully cast
in _ask II. Casting process.yields and selected mechanica_nd
physical properties were determined for castings o£ the four
alloys, and a heat-treatment optimization study was conducted.
During the course of Task II, the IN,792+Hf alloy was dropped
from the project, as its stress-rupture strength was substan-
tially lower than those of the other three alloys. A solution
heat-treatment temperature of 1505°K (2250°F) was found to pro-
duce more uniform and higher stress-rupture llves, in MAR-M 247 DS
castings than did the 1494"K (2230°F) treatment previously _sed ............

Task III characterized, in greater detail, the mechanical

and physical properties of MAR-M 247, MAR-M 200+Hf, and ........
NASA-TRW-R DScast turbine blades and bars. Tensile and stress-
rupture tests were performed in both longitudinaland transverse
blade directions.

An uncooled turbine blade design tailored to the mechanical

properties of the strong DS cast alloys was developed in Task IV.
A preliminary design was developed early in the project, and a
final design, more thoroughly analyzed for the engine test condi-
tions, wasdeveloped later utilizing material property data from
Task Ill. To accommodate the uncooled final design blades, modi-
fications were made to the turbine disk, nozzle, and other tur-

bine section components of the TFE731-3 Engine.

5
 • , t"

!D_--• ,,•_

i.__t
_ _.

• •.. d

In Task V, the DS turbine blades and other unique components

for the engine test were manufactured. During the casting of k
._ thes_ blades,, a "hot tear" caetabillty problem with -£he _
NASA-TRW_R alloy was •encountered. The NASA-TRW-R alloy was thus
• e.liminated from further consideration, and only MAR-M 242 and
MAR-M 200+_f blades _w_xe p_oeessed into engine test parts.
i _., Approximately three-fourths of-the finish-processed blades--were I

MAR-M 247. .!

Task q_ subjected the DS-eask tuxbine blade_to engine test-

_ ing in a modified-TFE731-3 Turbofan Engine. Post-test evalua-

[ tions of the engine-tested turbine blades were performed in Task
VII. The engine testing and the post-test evaluations are
! reported separately in Volume 2. of this Project Completion
} .
Report.
[

![.

!L_
I
 TASK I - CASTING-TECHNOLOG_
Exothermically-Heated Casting System
[

The objective of T_ask I was to develop the capability to

i produce controlled_ directionally-solidified grain structure in

I, the uncooled high-pressure turbine blade for the test engine.

The low-cost, exothermically-heated casting system was .selected
to p.-,.duce the turbine blade. This process was selected based on
the success achieved in prior contract work performed by Detroit
Diesel Allison for the Air Force Materials Laboratory. (I) A
schematic of this process is shown in Figure i.

With this casting process, a lost-wax ceramic mold is manu-

factured that is open at the top for receiving the molten metal,

iiI and is also open (in a flat plane) on the bottom. After dewax and
i i_ firing this mold is fitted inside a preformed refractory sleeve
.... and surrounded with a suitable high-firing temperature exothermic
material. The exothermic material is packed around and over the

f tops of the airfoil mold and gating, leaving the top and bottom
openings of the mold exposed. The mold assembly is_then heated
by the heat released from ignition of the exothermic material to
a temperature above the melting point of the alloy to be cast.

Prior to pouring, the hot mold assembly is placed on a

water-cooled copper chill that provides.a bottom closure for the
mold. This chill establishes a verz steep temperature gradient
in the mold cavity. Since the bottom closure o£ the mold cavity
is formed by the chill, very rapid nucleation will occur in the
molten metalthat directly contacts the chill as the metal is
i
poured. Nucleation is prevented in portions of the mold at
greater distances away from the chill since heat released by the
exothermic material maintains the local mold temperature above

(1)Kanaby et al, "Directional So!idifcation of Superalloys";

AFML-TR-77-126, September 1977.

7
 :'OUR:
• LOAD PREHEATED MOLD INTO
CASTING FURNACE ON CHILL
PLATE
• EVACUATE FURNACE
• I_DU_I
• HOLD IN FURNACE FOR
DWELL TIME

Figure i. Simplified Schematic o_ Exothermically-Heated

Directional-Solldification Casting Process

8
 the melting point of the alloy. Therefore, those grains
nucleated at the chill plate that have a crystallographic
orientation favorable for rapid grain growth in the direction of %
the mold temperature gradient quickly develop a columnar grain _
structure that is perpendicular to the chill. In the ease of a
turbine blade casting, parallel grains [of (I00) crystalline
direction] grow in the spanwise direction of the blade.

Thin columnar growth continues as long as the vertical i

temperature gradient is steep enough to. preclude nucleation of
new grains ahead of the advancing solidification front. The
extent of growth of these columnar-oriented grains is limited
only by the relationship of the rate of heat extraction through
the solidified metal behind the advancing solidification front to
the rate of heat loss from the m_Iten metal ahead of the solidi-
fication front. The grain g_owth pattern in the casting will
revert to an equiaxed structure at some distance away from the
chill after the rate of heat extraction downward through the
casting is not significantly larger than that in some other
direction (for instance, horizontally through the mold wall).

Turbine blades can be cast with controlled solidification

that produces a completely columnar structure with grain
boundaries parallel to the major stress axis in the root and alr-
foil. This provides increased operational blade-temperature
capability due to the absence of grain boundaries normal to the _
direction of highest stress that would ordinarily provide a
preferred stress-rupture fracture path.

7-

.L
 .I

Process Development-

One of the conclusions .resulting fro_ the Cos_/Benefit _

AnalMs_s (2) performed by AiResearch as part of the MATE Program
was that solid DS cast turbine blades offer superior cost and fuel
economy relativs to cooled turbine blade.s for small englnes_
Achievement b_ these advantages is dependent upon the development
of a low-cost manufacturing process that provides effective con-
trol over desired blade characteristics. A major objective, of
_ask I was to demonstrate the technical and economic advantages of
the exothermic Easting process. The demonstration was performed
under subcontract to AiResearch in a commercial foundry--
Je_shapes, Inc.., Rockleigh, N. J. (Jetshapes). The goal of the
Task I activity performed by Jetshapes, was to evaluate casting
process variables for the establishment of a controlled proces_
for use in subsequent tasks. This was accomplished by manufactur-
ing trial castings followed by evaluation of their quality and
mechanical prQperties, and then developing preliminary process
controls.

Castin_ trials and results. The Task I casting trials

utilized the nickel-base alloy MAR-M 247 for the casting of 15
molds of blades and test bars. Each- mold provided a minimum of 15
bla_e castings and 4 test bars. Among the process variables eval-
uated were mold temperatures, metal temperatuzes, shell thickness,
exothermic material weight, exothermic material distribution, and
processing time ..............

Wax patterns for the existing TFE731-2 equiaxed uncooled

blade designs were utilized in the first 12 molds because of
pattern availability and presumed similarit_ to.the airfoil design
- i

" (2)Comey, D, "Cost/Benefit Analysis, Advanced Material

• Technologies, Small Aircraft Gas Turbine Engines| NASA
CR135265 (AIResearch 21-2391 , September 1977.

- l0
 ij__-_¸_ _'_

i-C.-_' that would ultimatelK be engine tested. The final 3 molds.of

castings were produced-from injected wax patterns utilizing the
initial TFE731-3 blade design established under Task IV. k

_: The baseline mold syste_utilized throughout this program was

the C®IaI-P* alumina-flour binder developed by Detroit Diesel-
Allison (3) This binder minimizes metal-mold reactions in the

prince (firsti coat that contacts the molten metal during the pour-
ing process. The back-up coats, which give the mold its basic ................

strength and heat conductivity characteristics, were Jetshapes

._ - conventional silica-bonded alumina-silicate mold system.

Evaluations of a more conventional silica-bonded zirconium-

silicate prime coat, in conjunction with standard back-up coats,

were conducted during the program because of the relatively short
useful shelf life of the Colal-P binder. However, a measurable
_ : decrease in the surface quality of castings, as evidenced by fluo-
i rescent-penetrant inspection, was always noted with the zirconium-
silicate prime coat as a result of reactions between the molten
metal and this prime coat in the DS casting process. The Colal-P
i-' binder shelf life problem has been reduced to an acceptable level
by using plastic liners in all mixing and storage containers. The
"gelling" of this binder is accelerated by contact wi_t_bferrous
z materials used for containers.

I. Molds 1 and 2. The initial mold was cast with the exist-

_ ing "best practice" casting procedure based on previous

i.:_ AiResearch-funded development work. The mold design, as adapted

_ _ to the TFE731-2 high-pressure turbine blade design, had 5 radial
_' spokes with a central downsprue and pouring cup as shown in
Figure 2. Four blades, with the airfoil chords parallel, were on

i_
_ _ *Registered trademark of E.I. DuPont de Nemours and Company
(3)Kanab¥ et al, "Automated Directional Solidification of
Superalloys," AFML-TR-75-.150, 1975)
i
 k

DOWNSPRUE

8LADES

_'_ MOLD BoI-rOM DIAMETER: 25.4 CM IL

(10 INCHES), APPROXIMATE

Figure 2. Task I Straight Spoke Mold Configuration

12
 ¥

each of 4 spokes, with the fifth spoke having six 1.587-cm (0.625-
inch) diameter test bars. This test-bar spoke was "Y" shaped to
accommodate the two additional parts. The mold was cast with the
blades in a root-down orientation. _

Mold No. 2 was configured to evaluate the effect of an in-

line airfoil chord arrangement to provide contact of the exother-

mic material against a larger surface area on the blade root and , i
I

airfoil as compared to the parallel-chord arrangement. Due to the _i

limiting diameter of the insulating sleeve used during exothermio
firing, This chord-in-line arrangement required that each of the i
5 spokes be wound in a spiral shap_ as shown in Figure 3.

Molds I and 2 were packed with standard-size [2.5 x 1.9 x 1.3

cm (I x 0.75 x 0.5 inch)] Exomet Isogard* briquets inside an
insulation sleeve. The assembled mold with the exothermic
material was then preheated in a gas-fired furnace to l144eK
(1600°F) for 30 minutes to attain a uniform elevated temperature
for the entire assembly, and to lessen possible thermal shock
during ignition. The molds were removed from the furnace and the
exothermic matecial was torch-ignited at the top. The entire
assembly was covered with an insulated "can" and the exothermic
process allowed to continue. Based on visual observation, the
"burn" was complete in approximately 8 minutes for each mold. The.
mold was placed on a water-cooled copper chill in the vacuum-mold
interlock 15 minutes after ignition of the exothe_mic, and the ._.
metal was poured after a 3-minute chamber pump-down time.

The copper chill for these two molds had been newly resur-
faced with a shallow-groove, diamond-shaped 0.317-cm (0.125-inch)
grid pattern for increased contact area with the casting. This

grid pattern did not incorporate draft _n the grooves, and conse-
quently, 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: 25.4 CM

(10 INCHES)° APPROXIMATE

' Figure 3. Task Z Spiral Spoke Mold Configuration

14
,,b

• ji'_

i
Vl
i

chill. The-mold material .and exothermic cinder had to be broken

off to remove the individual castings from the chill .......
The chill
J

was subsequently reworked to provide adequate draft in the

machined grooves. _
}

All individual castings from Molds I and 2 were macroetched

fOE _zain structure evaluation. None of the blades from Mold 1
h3d an acceptable grain structure. This was due to nucleation of
grains in the root at a considerable distance above the chill and
from the airfoil_trailing edge. However, the gra:in structure of
the test bars was considered acceptable. Six of the 16 blades
from Mold 2 had a reasonably controlled columnar grain structure,
and all the test bars were acceptable. Four of the blades cast in
Mold I are shown in Figure 4. It was evident that the temperatures
employed during the casting process were too low, especially at
the blade cavities next to the mold center.

2. Molds 3 and 4. For Mold 3 (straight spoke) and Mold 4

(spiral spoke), the hold time after exothermic material ignition
was decreased, and the pour temperature was increased to increase
the casting yield. In _addition, based on observations of the
exothermic cinder from Mold 2, small pieces [l.9-cm (0.75-inch)
maximum dimensions] of exothermic briquets were used to fill mold
4 to above the top of the blade to improve the packing density,
particularly for the innermost blades. Standard size briquets
were used to fill the remainder of the mold to 7.5 to l0 cm (3 to 4 _

inches) above the top of the test bars. Mold 3 was filled with
standard size briquets in the same manner as Mold i.

Each mold was preheated and ignited using the same procedure
as was used with Molds 1 and 2. However, as soon as visible flames

stopped coming from the bottom of the pack, the mold was placed in
the vacuum mold interlock and the metal was poured after pump-
down. This reduced the ambient air temperature exposure time

15
< Figure 4. Task I, Mold 2 Blades Showing Good Grain Structure in
Blade "C3" with Undesirable Gra_.n Structure in the
Other Three Blade Castings
16
i "

[ , after ignition by 7 to 8 minutes. The molds were also poured with

! the metal temperature approximately 28°K (50°F) higher than the
! pouring_temperature for Molds 1 and 2. \

The grain evaluation of these castings showed that the

increased mold and metal temperature resulted in improved columnar

structure, but further process modification was considered neoes-
i _ sary to improve the grain structure to an acceptable level. A ..............
i : photograph of castings from Mold 4 is presented in_Figure 5.

3. Molds 5 and 6. Based on the results of .the first four

molds cast, it was felt that, with the exothermic._material and
shell system utilized, the mold had not reache_ a sufficiently
high temperature for completely satisfactory directional solidi-
: fication. The 30-minute preheat period at i144°K (1600°F) may
have caused a gradual degradation of the exochermic material by
partial oxidation of metallic constituents, resulting in a
i decrease in available heat energy.
i
Molds 5 (straight spoke) and 6 (radial spoke)were then cast
: utilizing direct*furnace ignition at 1366°K (2000°F). This pro-
cedure was evaluated as a means of ensuring maximum.thermal energy
i distribution in the mold. Mold 5 was the first to be cast with
_-_ this method_ Eight and one-half minutes were required at 1366°K
(2000°F) for exothermic igntion to be detected. The mold was left
in the furnace for an additional 3 minutes and _hen removed. Six
more minutes elapsed before the visible flames terminated, and the
_ .... mold was placed in the vacuum chamber for metal pouring. Mold 6
was t.hen cast following the same procedure. Seven and one-half
___ minutes were required in the furnace for ignition, the mold burned
for 5 minutes in the furnace, then was removed and burned an addi-
= tiona]. 5 minutes before being placed in the vacuum chamber, for

pou ring.

17

___.
 ¥

CI
<}

Figure 5. Task I, Mold 4 Blades Showing Straight Columnar

Grains in Castings "C3" and "C4"

18
 Evaluation of the g_ain structures of castings from these two
molds confirmed that the 1366"K (2000°F) furnace ignition aided in
obtaining better columnar grain control as shown in Figure 6.
Results also indicated that it was of benefit to retain the mold

in the furnace for a longer time after ignition.

Evaluation of the burned.exothermic material indicated that a

vious higher
much molds preheated
temperature at had
I144°K
been (1600_F).
obtained Evidence
as compared in tosupport of
the pre-
this conclusion was the nearly total fusing of the individual
briquets into a monolithic mass in the outer radial regions of the .............
mold. However, nearer the center of the mold cluster, tempera-
tures attained during the burn appeared considerably lower. This
was evidenced by briquets near the center downsprue and in contact
with the center blade cavities. These briquets had sagged some-
what from their original shape and sintered to adjacent briquets,
rather than fusing into one continuous mass. It was felt that
these physical indications of maximum temperature correlated well
with the quality of columnar grains obtained on the individual
castings from the central to outer locations.

The ratio of the mass of exothermic material to the local

mass of heat-absorbing mold material was believed to be a ma_or

factor in producing these temperature differences.-It was there-
fore decided that the ceramic mold material in the bottom half of
the downsprue decreased the potentially available space for exo-
thermic material at the center of the cluster, and also acted as a
large heat sink.

In addition, there were indications from the fillout and

• grain structure in the individual blade castings that the rate of
fill for the airfoil cavities varied along individual spokes, as
well as from spoke-to-spoke in a given mold. The slowest fill was
at the center of the cluster on the spokes with the highest runner

19

- .

i
%

li-

Figure 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

i-
r
: 20
FI
K,:
L

i_
connection

slower
on the

fill rate gave.the

grain orientations. This
downsprue.

largest
indicated
The blades

angular
cast

deviation o£
that a better control
with the apparent

columnar
of grain k

_, growth could be obtained i_ a fastex-_f,ill could be achieved.

problems
i the Molds
4. Molds
5 and 76 and
castings,
8. To the
correct
mold assembly
the was observed
redesigned with
to
i:_' eliminate the center downsprue below the pour-cup level, and to
_ provide an increased cross-sectional area of _unners and in-gates

_ _ for faster filling of each mold cavity. Mold 7 (straight spoke)

both of these molds were packed with exothermic material and fur-
iii and Mold 8 (spiral
nace-ignited spoke)
at 1366°K were (the
(2000°F) fabricated in this as
same technique fashion,
used and
with
Molds 5 and 6). Molds 7 and 8 both required 8 minutes to ignite,
anu were left in the 1366°K (2000°F) furnace for the first 5

i minutes of the exothermic burn. An additional 7 minutes were

required for the flaming to cease and for transfer to the copper
chill in the vacuum chamber before pouring.

Evaluation of the grain structures of castings in Molds 7 and

_,. 8 indicate_ the changes made in mold design had allowed the mold
i to reach a sufficiently high temperature to produce good columnar
grain structure in all but two blades. However, castings from
both molds had indications of gas evolution due to a manufacturing
problem associated with mold firing in a gas-fired furnace that
i

inadvertenly had a reducing atmosphere. This eventually produced ......

silicon-monoxide (SiO) on the inside of the mold. The SiO sub-
sequently was evolved as a gas when the metal was poured in
vacuum| this apparently restricted the fill in some mold cavltle_.

5. Mold 9. Mold 9 (straight spoke) was cast to evaluate

the feasibility of using the Jetshapes-produced zircon face coat
in place o_ the previously used higher thermal-conductivity
alumina system. This mold was poured using the same design and

21

r
 v

casting procedures used for Mold 7. An evaluation of the grain . i

structure of the castings from this mold indicated that very good
columnar growth was obtained, but a d.gradat_on in casting surface \
quality was visually detected. _i

6. Mold 10. Mold l0 (straight spoke) was prepared and

poured in essentially the same manner as Mold 7. Representative

examples of the grain orientation produced in Mold i0 are pre-

sented in Figu[e 7. The grain structure of these castings have
the desired longitudinal directional orientation. Surface shrink-

age on the blade platforms was observed. This was characteristic

of prior molds cast with the blade-root down ..............

7. Molds ll and 12. Molds 1L and 12 were the last molds

produced using the TF_731-2 blade waxes. To eliminate the plat_

fo:m surface shrinkage characteristics of prior molds cast with

the blade-root down, these molds were cast with the blade-root up,.
and as anticipated, this change eliminated the platform shrinkage.

Erratic ignition behavior of the exothermic material was

observed on Molds ii and 12. These molds failed to ignite after

nhe usual time in the 1366°K (2000°F) furnace. To obtain satis-

factory castings, the exothermic material in these molds was torch

ignited. Subsequent testing of this exothermic material indicated

substantially different ignition characteristlcsfrom the mate-

rial used on the prior l0 molds.

Examination of the castings made in Molds ii and 12 indicated

that uniform directional solidification of the grains was not

achieved from blade root to tip. The "sort-out" zone between the
randomly-orlented grains nucleated at the chill and the desirea DS

grains extended into the upper portion of these airfoils. This

was primarily the result of two factors_ (i) inadequate mold tem-

perature due to erratic performance of the exothermic material,

22

i
 PRESSURESIDES

SUCTION SIDES

Figure 7. Task I, Mold i0, Spoke "B" Macroetched Blades Showing

Consistent Directional G_aln Orientations
i

23

2-

.
 _q

and (2) slow pouring of the molten metal into the molds resulting
in some loss of[ the neede_ superheat. Despite these problems, %
sufficient satisfactory directionally-solidified graln structures
were obtained in blades from Molds ii and 12 to permit machining
and testing of sound test speuimens.

8. Molds 13, i4 and 15. These molds were made from new waxes
of the preliminary uncooled blade design established in Task IV.
The waxes were designed with smoothly-transitioned extenslono of
both root and tip to permit the ca_ting of blades in eithe= root-
down or root-up positions. Figure 8 shows injected waxes for the
conventional- TFE731-2 blade and the wax for the preliminary
uncooled--5/FE731-3 blade design.

The casting problems experienced with Molds ll and 12

resulted in process adjustments prior to casting the last 3 molds.
New exothermic material from Exomet and a rapid pour rate were
used to ensure adequate mold preheat and molten metal superheat on
all molds. On Mold 13, each spoke o£ 4 airfoils had a different
starter block and/or in-gate configuration as shown in Figure 9.
Spoke 1 had 2.54 x 12.7 x 3.Sl-cm high (i.0 x 0.5 x 1.5-inch high)
rectangular starter blocks to fit the airfoil tip extensions.
Spoke 3 had 1.50-cm (0.625-inch) diameter by 3.Sl-om (l.5-inch)
high round starter blocks for tip extensions. Spoke 4 had paired
airfoils cast from large rectangular starter blocks and twin in-
gates.

The process changes resulted in good DS gr_in patterns that

were unlform on all of the castings of Mold 13. The airfoils pro-
duced on Spokes I, 2, and 3 were to blueprint contour, but
residual stresses induced in the paired airfoil castings of Spoke
.._ 4 caused them to twist out of limits after knockout from the
chillplate and cut-off from the runners. A hairline crack in the
Mold 13 shell resulted in some metal leakage ond a lack of com-
plete fill in a few castings.

24
 °

• . '__"

ill,

_--_ TFE731-2 CASTING WAX TFE731-3 CASTING WAX

BE_ TASK I -- MOLDS 1 THROUGH. 12 TASK I -- MOLDS 13, 14, AND 15

-=.,.

Figure 8. Suction Sides of the Injected Casting Waxes for

Task I Turbine Blades (Mag.s l. SX)

25

I-
 SPOKE 4

SPOKE

STARTER
BLOCKS

TEST
BARS

Figure 9. Task I, Mold i3 Wax Ass,_mbly for the Preliminary

Design of the Uncooled TFE?31-3 Blade in the
Root-Up Position.

26
 '¥J

Molds 14 and 15 had the same design as Mold 13, including the I

starter blocks. These molds were poured to establish the repro- k

ducibility of the Mold 13 processing, and to evaluate a lower _
silica-content binder for the casting shell. The introduction of
this new binder was imposed-upon Jetshapes because the supplier of
the previous binder material discontinued its production. The new
binder produced a thinner shell than the previous binder, and
after pouring, it was discovered that a small amount of zlnc-oxide
impurity in the new exothermic material had reacted with the
thinner shell and caused localized mold deterioration. This

thinner shell mold also exhibited localized cracking at_sharp Cor-

ners on the square starter blocks and along airfoil trailing ..........
edges. The thinner shell also slightly upset the good thermal
balance achieved in Mold 13.

The grain structure of castings produced in Molds 14 and 15

had satisfactory directional orientation in the turbine blade air-
foils and roots. A few stray grains nucleated and grew in the
risers attaching the blade roots to the in-gate system.

Exotherm_c behavior. The exothermic material utilized during

Task I was "Isogard Nuggets". This briquet-shaped material is a
special-blend of iron oxide taken from mill scale and iron ore,
with aluminum-metal particles and silicate binders. When the
briquets are heated to a sufficiently high temperature in air, %

molten aluminum-metal particles start reducing the iron-oxide

particles to a lower oxide state or to metallic iron, accompanied
by a considerable release of heat energy. A free flow of an
oxidizing atmosphere through the porous exothermic pack is neces-
sary for the reaction to proceed to completion. With heat losses
external to the mold minimized, the reaction is capable of pro-
ducing temperatures of 2033°K (3200°F) in the briquet pack. The
actual temperatures achieved during Task I were slightly lower as
a result of the heat sink capability of the mold system. As a
minimum, sufficient heat energy must be supplied by the preheat

27
 !
V

-->_ atmosphere and the exothermic reaction to raise the mold face-coat
to a_temperature above the melting point.-of_the alloy to be cast.
k
This requires a reasonably uniform distribution of the exothermlc

. material within the mold. The gating system was designed to

ensure that the local distribution of exother-mic material was
adequate to p_eheat the mass of the adjacent mold material to
_ maintain the required local vertical temperature gradients during
casd_ing solidification.

Several problems encountered during Task I were associated

either directly or indirectly with the exothermie material. An
early objective was-to develop a preheat cycle using a gas-fired
furnace to supp!y part of the required heat energy. This would
permit an increase in the total packing density of blade and test
bar molds to a maximum in the available space as a result of the
need for a smaller quantity of exothermic material. It was found
that long preheat times at moderate temperatures [e.g. I144°K
(i600°F)] prior to ignition of the exothermic material actually
reduced the amount of available exothermic heat due to a gradual
degradation of the exothermic material by partial oxidation of
metallic constituents and a slowed reaction of the aluminum with
the preheat atmosphere. The use of higher preheat temperatures
= '_ tended to promote very rapid self-ignition at the surface of the
exothermic material before adequate time had elapsed for the pre-
heat temperature to penetrate deeply into the mold assembly.

The best process evolved included a 1366°K (2000°F) gas-fired

_- preheat furnace, with an oxidizing atmosphere. This preheat level
; resulted in self-ignition at the top of the exothermic pack in 5
_ - to 7 minutes. The entire exothermic reaction was then allowed to

proceed to completion within the 1366°K (2000°F) furnace prior to

transfer of the mold to the vacuum casting furnace.

28
 An additional problem manifested--an occasional appearance i
of yellow particles on the mold surface caused by a metal-mold
reaction in local areas, and penetration of the mold by the molten k
alloy. Through chemical analysis, this problem was traced to a
zlnc-oxid_-impurity in the-iron ore used in manufacture of the
exothermic material. The supplier was able to eliminate this
problem by use of ore that did not contain zinc oxide ....

Mechanical-prope=ty evaluations. With the exception of Mold

l, which did not yield satisfactory blade castings, individual
blade castings and separately cast test bars were selected from
each mold for machining into test speclmens-for use in mechanical-
property evaluation. Prior to machining into test specimens, all ....
of the blade castings and separately cast test bars were solution ....
treated at 1494_K (2230°F) for 2 hours, and subsequently aged at
i144°K (1600°F) for 20 hours. The machined-from-blade (MFB)
("mini-bar") test specimens had a 0.178-cm (0.070-inch) gage
diameter and a 0.762-cm (0.300-inch) gage length configured as
shown in Figure 10. The location, with respect to the complete
blade casting, of the material slug removed for machining the
mini-bar test specimen is presented in Figure ii. Test specimens
machined from separately cast test bars (SCTB) had a standard
0.625-cm (0.250-inch) gage diameter and 3.18-cm (1.25-inch) gage
length as shown in Figure 12. TheSe specimens were machined from
the as-caSt 1.587-cm (0.625-inch) diameter test bars.

The MFB mini-bar and SCTB test specimens were subjected to

the following tests:

o Room-temperature tensile

o I033°K (1400°F) tensile

o I033°K (1400°F) stress-rupture at 724 and 758 MPa (105

and ii0 ksi)

29
 . .. ._= t W • _

• i_

J4_

0,30 R

0.315 0.178--(0.12) A f-- 0.317

10.1241 (0.0701
\ /Io,_, r

0.762

(0.300)
-

--
0.762

(0.300) c
-- 2.2k_
(0.90) _ J

DIMENSIONS IN CM (IN.)

_ Figure i0. Mini-Bar Test Speclmen

3O
ira,-+. _ .,. -- p '

%.

- +_ 1 ,+++_

+ !+ +
i 2 3 4+ "+'_= 5

! *

; i

i
i ,

[
!
%

_. + Figure ii. Longitudinal Orientation of Machined Mini-Bar Test

Specimen with Respect to Exothermlcally-Cast
- DS TFE731-2 Turbine Blade

"++
 0.048 R
(.0,189) 1.27
0.625 "_ /-" (o.5o)_-13 UNC '_-

(0.60)
'i.27 I (o.2so)j-_ I_
I • '-t- '1

.__ 2.22 3 18
(o.88) i - (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 at 207 and 221 MPa (30 +_

and 32 ksi) ......

Mechanical test results @enerated in Task I are summarized in k

Tables I through V.

Table I lists the stress_rupture test results of the MFB

mini-bar specimens+ S_resses were selected to produce failure in
approximately i00 hours. The 221 MPa (32 ksi) stress level shown
in Table I(c) for the 1255°K (1800°F) tests on MFB mini-bar test
specimens from Molds 7, 8 and 9 were inadvertently used in lieu of
_he intended 207 MPa (30 ksi) stress level. Stress=rupture lives
were determined for mini-bars machined from the remaining molds at
1255°K/207 MPa (1800°F/30 ksl) as listed in Table I(b) and for
minl-bars machined from all molds at 1033°K/724 MPa (1400°F/I05
ksi) as listed in Table I(a).

Table II lists the test results of stress-rupture tests on

specimens machined from separately cast test bars. The combined
data+shows excellent consistency in rupture lives, and excep-
tionally high ductility at the two test conditions. The data also
shows good correlation between the MFB mini-bar tests and the
SCTB tests at the 1255°K (1800°F) temperature level. Lives here
at 221 MPa (32 ksi) averaged 50.1 hours for minlbars and 52.4
hours for SCTBs.

Table III presents comparative test data obtained on standard

test specimens machined from separately cast test bars of conven-
tionally-cast equiaxed MAR-M 247. TheSe conventional castings
were made from one of the heats used to produce the DS castings.
Lower rupture lives and ductility are evident at 1255°K (1800°F)
when compared to the DS casting test data shown in Tables I and II.

33
+

_._
 i
TABLE I, TASK I STRESS-RUPTURE TEST RESULTS ON DS CAST MACHINED-
i FROM-BLADE TEST sPECIMENS
_" [Test specimens machined from ex0the_mically cast DS MAR-M 247
! blades after heat treatment at 14940K (2230"F) for 2 hours and
_ I144°K (1600°F) for 20 hours.] \

i-- Rupture Reduotlon

_-
i time, Elongation, of area,
Mold Specimen --hours
I I percent percent
(a_ Tests at I033°K/724 MPa (1400"F/I05 ksi)
- 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
i _ 6 A 202.0 14.1 18.5

_= : 6 B 192.3 20.5 25.3

7 A 76.1 13.3 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
j2

9 A 87.4 12.4 19.0

9 B 184.8 18.8 28.5

! i l0
11 A
A 150.1
29.6 12.0
16.3 15.2
25.0
!_ - ii B 24.1 10.8 12.8 :
12 A 160.3 9.3 18.4
12 B 15.9 11.7 17.5
mE_
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

34

i
L
 i

TABLE I. (CONCLDDED) un

Rupture Reduct ion k

time, Elongation, of area, _1
Mold Specimen hours percent ,n percent
(b) Tests at 1255°K/207 MPa (1800o_/30 ksi)
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 B 71.4 21.3 40.0
4 A 80.9 28.4 52.6
4 B 81.3 34.8 43.6
5 A 97.6 39.7 56.5
5 B 84.7 26.4 51.0
6 A 79.2 19.3 48.9
6 B 91.7 32.8 46.7
l0 A 79.1 36.5 48.4
i0 B 95.4 45.3 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 B 74.8 29.7 47.0
13 A 73.6 24.8 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
(c) Tests at 1255°K/ 221 MPa (1800OF/32 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 I STRF, RS-RUPT_E T_:ST RSSULT8 ON DS CAST S_['ARAT_SY ]
CAST TEST SI'ECIMF'N8 ,4
(Tost spoclmuns machlnod from oMothormlcnlly east DS MAP.-M 247
separately east test b_r, altar heat treatment at 1494"K
(2230eF) for 2 hours and ll44"K (1600"_') for 20 hourJ, k

Rupt uro eoduot ion '_ i

time, EIong_t ion, of a_oa,
_old hour8 pBrcB_t DO_CQnt
(a) Tests at I033"K/758 MPa (1400*P/If0 kal)
1 85.5 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 "
F
7 95.0 18.2 24.7 ,

8 109.1 20.6 24.3 ' .

9 95.7 20.6 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 23.1

(b) Tests at 1255oK4 ' 221 MPa (1800°F/32 ksl)

I 57.2 37.2 61.?
2 44.3 33.1 53.9
3 55.8 35.0 60.0
4 53.4 35.0 59.1
5 40.5 28.0 59.3
6 47.8 30.8 55.4
7 69.2 32.3 60.5
8 48.7 31.8 57.3
9 44.7 31.8 59.4
I0 54.9 34.4 55.7
•Ii 53.1 43.1 61.9
12 52.7 34.7 59.7
13 61.3 41.9 63.5 J
14 5n.8 49.7 65.2
15 51.7 33.4 59.0

-- i
TABLE llI. TASK I STRESS-RUPTURE TEST RES[_,TS ON CONVENTIONALLY
CAST EQUIAX_:D MAR-M 247 TEST SPECI_b_,NS

[Test speclmc-ns machined from separately cast trst bars of -

conventionally cast equlaxed MAR-M 247 made from one of the "'-
heats usud to produce the D8 eastlngs.]

8_r time, E1ongatlon, off area. ..

hours percent percent
no. Rupture I I Reductiun

(a) Tests at i033°K/758 HPa 11400°P/110 ksi)

75.1 5.0 6.8

(b) Tests at 1255°K/221 MPa (1800°F/32 ksi)

._ 20.3 10.1
10.5 18.9
15.3

36
 4

•%

TABLE IV. TASK I TENSILE TEST RESULTS ON DS CAST MACHINED'FROM-BLADE

TEST SPECIMENS

[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.]

Ultimate
tensile 0.2-Percent Reduction
strength, yield strength,! Elongation, of area,
Mold Specimen MPa (kei) MPa (ksi) percent percent
I _T

(a) Tests at 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
L
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 Failed in threads on loading --
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

__7 15 A 1082 (157) 874 (127) 13.4 14.8
15 B 989 (143) 820 (119) 13.5 19.3

37
 TABLE IV. 4CONCLUDED)

- Ultimate
tensile 0.2-Percent Reduction
strength, yield strength, Elongation, of area,
Mold iSpecimen MPa (ksi) MPa (ksi) percent percent
• • • f i i

4b) Tests at 1033°K (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 D Failed in threads on loading --

12 C 1145 (166) 978 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 I TENSILE TEST RESULTS ON D8 CAST SEPARATELY
CAST TEST SPECIMENS

[Test. specimens machined from sxothermlcally cast

DS _R-M 24_ separately cast test bars after heat
treatment at 1494°K (2230°F) for 2 hours and I144_K
(1600°F) for 20 hours.[
• i

Ultimate
tensile O.2-Parcent Reduction
, strength, yield strength, Elongation, of area,
Mold MPa (ksi) MPa (ksi) percent 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 I
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 NOt tested

(b) 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 tssted

39
 "t {

_ Tables IV and V list the room temperature and 1033°K(1400°F) ,,

i_ - tensile tests results for the MFB mind-bar and SCTB test speci-

! mens, respectively. _ith the exception of several low-ductility _

specimens, the.results appear to have normal scatter. The only
_ - planned tensile data not collected were the tests on separately

! ; cracks in bars
cast test these from-Molds
molds, some
14 of
and the
15. test
Due bars did no_
to metal fill
leakage com-
from
i'_ pletely and the available bars were used for the stress-rupture

i tests.

results from Molds 13, 14 and 15 best represent the capability of

ii: the process
Of the mechanical
developed in
test
Taskdata
I. listed in Tables I through V, the

Chemical Analyses. Chemical analyses of all blades cast were

[ performed to determine: (I) the overall chemistry in the root
_ - section of the blade, and (2) the hafnium content of the blades in
_, the root and airfoil tip sections.

Table VI lists the results of the bulk chemical analysis, the

analysis of each of the two MAR-M 247 master heats employed, and
the material specification limits. Table VI also presents the
results of hafnium analysis at the blade roots and airfoil tips.
With the exception of Mold Ii, where a spurious root analysis was
obtained, the reversal of the hafnium gradient for the blades cast
root-up is apparent.

Recommended Casting Practice

A basic set of process control guidelines evolved from the

MAR-M 247 process experiments of Task I that were considered sat-
isfactory for easting all four program alloys in Task If.

4O

i
 m

ooooo oo ooooo _
m

i ooooooooooo_

O0

41
 i

: Wax assembly manufacture. The wax assembly selected for the

%

casting of uncooled TFE731-3 turbine blades consisted of an

approximately 25-cm (10-1nch) diameter cluster of 20 blade waxes, k
arranged in _ equally-spaced _adial spokes, with 4 blades in each
spoke, and assembled to a central pouring cup. Each blade was
;i-- placed on top of a 2.54=cm high by 1.50-cm diameter (1-inch by

L
0.625 inch) cylindrical starter extension, blade-root up. The
._ starter extensions were vertically oriented on a wax-covered alum-
inum plate. The plate initially served as a frame in mold dipping
operations, and subsequently as a base plate to form the flat- r
plane bottom surface and the base flange of the open-bottom final
ii DS mold. The blades in each spoke were oriented with their roots
parallel to each other and perpendicular to the mold spoke axis.
A short "riser" extension on top of each blade root was attached
, to a common 1.27-cm by 1.27-cm (0.5-inch by 0.5-inch) cross-
section horizontal runner for each spoke. Each runner was con-
nected to the central pour cup by an inverted-"Y"-shaped down-
gate. An approximate 3.8-cm (l.5-inch) unobstructed space was
left in the center of the assembly under the pour cup, as well as,
the space surrounding each 4-blade spoke, to provide open areas
for packing of exothermic briquets.

I
Mold manufacture. The wax assembly was then dipped with the
Colal-P alumina-flour prime coat, followed by sufficient silicon-
_ bonded alumina-silicate back-up dips to produce a 0.635- to 0.825-

ing,(0.250-
cm the mold was fired
to 0.325-inch) inshell
a gasthickness.
furnace tc After
produce the completed
autoclave dewax-
i open-bot_Qm DS mold as shown in Figure 13.

Casting process. As an initial step in the DS casting pro-

cess, the mold was placed upright on a metal support plate. A pre-
formed ceramic-fiber insulating sleeve was placed around the mold
with the base of the sleeve resting on top of the mold base flange.

7 An optical sight tube made of dipped shell material was placed

42
63
thzough the wall of the sleeve to provide a reference surface for
optical temperature measurements after firing. Suff.icien_ exo-
thermic briquets were poured into the insulatin_ sleeve around the
central open-area of the mold and around all the blade clu_ters to
at least 10-cm (a-inches) above the top runner ot the gating sys-
tem. Approximately 23 kg (50 pounds) of briquets were required.

_ne mold assembly was placed into a gas-fired oxidizing-

atmosphere furnace stabilized at 13660K (2000°F). Tkis furnace
preheat temperature ignited the exothermic briquets after 5 to 7
minutes exposure. The mold was left in the furnace for a total
time of 15 minutes to permit completion of the exothermic "burn".

The preheated mold assembly was removed from the furnace and
the support plate was_ removed. After checking the temperature,
the mold was_ transferred into the casting furnace and placed on a
grooved, water-cooled copper chill, which had previously been
covered with a single layer of nickel foil.

The melting cycle of the casting alloy was performed in an

isolated induction-heated vacuum-melt chamber. The timing of this
melting cycle was coordinated with the mold heating cycle so that
the molten charge could be stabilized at the proper pouring tem-
perature while the mold chamber was being pumped down .....

The valve between the two chambers was opened, and the mold
was poured at a molten metal temperature of 195 ° to 220°K (350 ° to
40@°F). above the liquidus temperature of the alloy. The pouring
took place approximately 25 minutes after the start of the preheat
cycle. The metal cast was held in place under vacuum on the chill
for 5 minutes, after which it was removed from the chamber for air
cooling prior to shakeout.

44
 ; TASK II - ALLOY/PROCESS. SELECTION
i._', Scope

- T_he major objectives of Task II were to evaluate four alloys

, in exothermically cast DS form, establish a heat treatment for
these alloys, evaluate-their metallurgical characteristics, and
select the two alloys showing the greatest potential for use as
solid high-pressure turbine blades for the TFE731-3 engine. The
four nlckel-base--alloys selected for evaluation were:

i- (a) MAR-M 247

(b) NASA_TRW-R
F ' (C) IN 792+Hf
[ (d) MA -R=M 200+Hf
[

i--"

! . AS was the case with Task I, the Task II activity was accom-
plished with the aid of Jetshapes, Inc. "
i

Test Material Production

, The four _lloys were used in producing a total of 16 molds

_
- of blade castings and 8 molds of slab castings for Task II evalu-
i-'_ ations. These castings were produced in groups of four molds,
one alloy being used for each group. Similar exothermlc material
and process controls were employed for each group of molds, con-
;
i5 • sistent with the Task I recommended casting Practice.

_" Initially, four mol4s designed to yield 20 DS blade castlnas

per mold were cast, one for each of the four alloys. The blade

mol@s were of a radial-spoke _esign, having 5 eaually-spaced

t _ spokes with provision for 4 turbine bla_e castings in each spoke.
Figure 14 presents a typical blade mold wax assembly, and Fiqure

i_ 13 shows two views of a blade mold fabricated from this wax

_- assembly. These first four molds were cast to evaluate the

45

00000001 TSEO
Figure 14 ....
Wax Pattern Assembly for Exothermic DS Casting Twenty
Task II Preliminary Design TFE731-3 Turbine BlaOes

46

---- ' + lip +

 response ef the several allays to the ga_ing and process control
procedures developed with MAR-M 247 during Task I. Prior to
pouring the initial easting_ the freezing tempecature (cooling
curve pleteau) was checked for each master heat of the four k
alleys. All of the alloys exhibited a free_ing plateau within a
ran¢+e of 17°K (30°F).+ This range is less than the reproducl-
b_ lty capability of the optical pyrometer and recorder used in
t_e casting process. Therefore, a single target pouring temper-
ature of I?55°K (2700°E) (uncorrected for emissivity and instal-
lation errors) was used for all four alloys in the initial anO
subseql/ent Task II castings.

The first four molds were packed with exothermic, anO

sequentially furnace-igni£ed at 13667K (2000"F) using the proce-
dures developed in Task I. Ignition times of the exothermlc
material in the gas-flred furnace varied from 4.5 to 7 minutes.
All of the molds remained in the furance for a total of 15 min-
utes. They were then removed and held in air until visible flam-
ing from the exothermic burn ceased. This.additional burn time
varied from approximately 1 minute to 6 minutes,+with the longer
times directly related to a larger percentage of smaller pieces
of exothermic material in the exothermic pack. Pumpdown, pour,
cooling under vacuum, and removal from the chill plate were all
well within the prescrJSed limits. Generally satisfactory grain
orientation was observed on castings of all four alloys.

A second group of feur molds, one for each alloy, was cast
using the same process controls and a second lot of exothermic
material. Grain etching of the castings made in this group
revealed significantly poorer grain orientation on all four
alloys, the probable cause being inadequate heat input from the
exothermic material. All remaining exothermic material from the
i suspect batch was retl)rn_d to the su_pller and exothermic mate-
+ rial of improved quality was procured for use in subseauent c_st-
• ings. The improved material had a m_nimum burn temperature of

47

+-

_J
 3050"F, as required by the Detroit Diesel Allison EMS197A Speci-
fication. 4
#

The final eight blade molds were then cast in groups of _j

four, one mold per alloy in each group. In addition, eight slab
molds were also cast, two molds per alley, to provide test bars
_ _ for u_e in mechanical testing. Figure 15 shows a typical slab
_ mold wax assembly. A new lot of more uniform quality exothermic
material was utilized for casting these 16 molds. The new lot
of exothermic material consistently ignited in the 1366°K
(2000°F) air furnace within 4 to 5 minutes. The total furnace

_ ignition time plus exothermic burn time was 15 minutes in all

• cases, consistent with the process control plan developed during __
i_ Task I. The new lot of exothermic material was found to have a
lower heat output than the lot used on the first four molds.
Blades of generally satisfactory growth were, however, cast in
all alloys with the exception of IN 792+Hf.

A summary of the mold identification for the four casting

groups for blades and the two casting groups for slabs is pre-
sented in Table VII.

Heat Treatment Studies

Six different heat treatments were employed during Task II

as shown in Table VIII. The heat treatments were applied to the
casting prior to machining mechanical test specimens. Tabulated
results of the tensile and stress-rupture testing are included

_ i! XXVIII.
herein under Task II "Mechanical -Tests!' in Tables XV through
I

resulted in the following observatlons---and---conclusions, all

L i'
! Evaluation of the Task II mechanical property test data
48
Figure 15. Wax Pattern Assembly for Exothermic DS Casting
Six Task II Test Slabs

49
--- 51
 referereod to the original nominal Z494°K (2230°F) nolutlen

treatment temperature: k
Zq
MAR-M 247 Room-temperature tensile and yield strengths

appear to be maximized by the 1505°K (2250°F) solution

• treatment, while similar properties at I033°K (1400°F) were

lowered by the same solution treatment. Both I033°K

(%400°F) and 1255°K (1800°F) stress-rupture strengths were

}
maximized by the 1505°K (2250°F) solution treatment. The

1483°K (2210°F) _olution treatment produced no ImDrovem,.nt

in mechanical properties.

MAR-N 200+Hf Tensile properties at room temperature

appeared to be insensitive to heat treatment, but at the

1033°E (1400°F) test temperature the tensile DroDertles were

maximized by the 1494°g (2230°F) solution treatment. Rup-

ture l_ves decreased w_th the 1483°K (2210°F) solution

treatment at both test temperaturee. The 1494°_ (2230°F)

: and 1505°K (2250°F) solution treatments produced equivalent

stress-rupttlre lives.
+

NASA-TRW-R - The 15050K (2250°F) solution treatment lowered

room-temperature tensile strengths and maximized the 1033°_

(1400°F) tensile strengths. This was an unexpected tren_.

. The 1505°K (2250°F) solution temperature also moderately

increased rupture lives at the two test temperatures.

+ i+

• _N 792+Hf The 1505°K (2250°F) solution treatment yieldeO

_,

slightly higher tensile and rupttlre _trengths than the

1494°K (2230°F). The alloy was, however, ' I
substantla+iv
weaker than the other three in stress-rumture.

'%
Based on apperent superlcr r_.ults achieved with MAR-M 247

_- at the ]505°K (_.250°F) solut:on temperature, blades were

.... 52
 D

mr

later solution treated at 1519£K (2275°F) and 1533°K (2300°F), _Jth

the ob,ectlve of determining the tolerance of this alloy to _olu-
tlon treatment at these hlgber temperatures. Figures 16 and ]7 k
show typical micr.ostructures of DS MAR-M 247 sol L1tion treate_
T at temperatures in the range 1483 ° to 1533°K (2210 ° to 2300°F).
" The lowest temperature is obviously inadequate to solution treat i
primary gamma prime, while at the highest temperature, a small
amount of incipient melting occurs. Tabulated results of 1255°K

(1800°F) stress-rupture tests o_ specimens treated at these

higher temperatu=es are pre_ented herein under "Mechanics!
Tests". A summ:_arv of all Task I an4 Task II stress--rupfure test
i results on DS MAR-M 247 specimens at 1255_K (18009F) after
vario_s solutlon-treatment temperatures is presented Jn Table IX.

Based on revle_ of the overall results of the beat-treatment

study, the solution temperature of 1505°K (2250°F) was selected

for application to the alloys cast in Task llI.

Metallurgical Evaluation

_ Castincs from each of the molds cast during Task II were

_ - subjected to nondestructive evaluation, che_ical analysis, moth- J
--_ anical tests, and metallurgical tests, Including g raln etch.

T
Noneestructlve Evaluti¢n (NDE). All Task II blade castings
i,_w_ were macroetched t® show grain orientation, X-rayed, and fluor-
escent-penetrant inspected.

m
m.
Grain etch of the blade castlnos from the first group of
four molds, revealed that all four alloys responded well to the
selected process control procedures. The MAR-M 247 and the NASA-
TRW-R produced the finest and straightest columnar grain pat-
terns. The IN 792+Hf train structure was somewhat coarser but

._ was still acceptable. The rotor innermost (center) blades in the

h
53
 i! .
° .,_

'.
L:
(a) 1483°K (2210°F) (b) 1494°K (2230°F)

,.'.- '.__-..,,.. V. 2
. "! ,,,.. _.. "-4

FtcJuEe 16. Typtucal Htcrostruct:ures o_ DS MAR-H 247 rl'u_bine

Blades Solution T_eated £o_ Two Hours at the Indi-
cated TemperatuEes. Graln G_owth Direction 1s
Ve=tlcal. Kallln_s E_ch. (Hag.:100X)

54
(o) 1505°K (22500F)
 (a) 1519°K (22750F)

?
.+__._,, ,
,<.
,
• , el ,¥I_ ' • II . ,.
" IP- t-#,, Ii i_ti i i ° i.

- i...-:.;_::.-...+,
iPiilt" . ." it. _") '"_'- Ii ill ia ,_-

+ _i, i, .%.+ -- _D++++

.-:__t " '<'
p It_4 ,

:.. '"'_ ,,._ - _"" 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 II 1255"K (1800°F) STRESS-RUPTURE

TEST RESULTS
[Test specimens machined from Task II exothermically
cast DS MAR-M 247 turbine blades havihg various solu-
tion 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) Hours to rupture Number of tests

Longitudinal grain orientation tests at 207 MPa (50 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 at 186 MPa (27 ksi)

++ 1494 (2230) 101..3 - 136.7 4

1519 (2275) 97.3 - 173,0 4

1533 (2300) 147.5 - 202.3 4

• i

56

. 00000001-TSF
 _ _ I,¸ ,._,l --I _ _

Yq

i_ MAR-M 200+Hf mold exhibited some misoriented grains. This uacon-

trolled nucleation in flash from a hairline mold crack indicated
that the local mold temperature was slightly low in the center of

the mold cluster.

Grain etching of the castings made in the second group of

foul molds revealed significantly poorer grain orientation on all

i__[ four alloys. This was caused by inadequate heat input f_om the
r : exothermic material. This inadequate heat inpu.t disturbed the

_ thermal balance required to produce good DS castings. Despite r

_ - the relatively poor yield of this group of castings-, most of the
i__ blades had sufficiently sound, well-oriented grain areas to per-
I/
mit subsequent machining of test specimens for mechanical test-
ing.

Figures 18 through 21 show-typlcal r,'.acroetched blade cast-

ings selected from the last two molds cast from each of the
alloys. All of the alloys cast showed a good response to the
•casting process with the exception o{ IN 792+Hf. All of the
blades of this alloy reverted from DS to equiaxed grains in the
root sections in the last two molds cast (Molds 89 and i03),
which used the third lot of exothermic material.
I

In addition to grain etch, _ill Task II blade castings were

X-rayed and fluorescent-penetrant inspected (FPI). The accept/
reject standards used were those employed for solid IN100 TFE731- %

2 high-pressure turbine blades,_ the inspections being performed

by AiResearcn proauction Quality Assurance inspectors.

A summary of X-ray, FFI, and DS _rain inspection results is

presenteG in Table X. The yields are presented for each mold of
i each alloy, as well as overall yields for individual inspections
and for all inspections combined. Combined inspection results
rank the alloys as follows:

57
 i i LBi
PRESSURE SIDE

SUCTION SIDE

Flgure 18. Typical MAP-M 247 Task II Exothermically Cast

DS Preliminary Design TFE731-3 Turbine Blades

58
 d__

• ,,?

L;I ii11,.Ji
11 l

PRESSURE SIDE

i _

.
1 _
"Ļ_:'_ L.i
_

SUCTION SIDE
L

._; Figure 19. Typical NASA-TRW-R Task II Exothermically Cast DS

-- Preliminary Design TFE731-3 Turbine Blades

59
 PRESSURE SIDE ....................................................................................

SUCTION SIDE

Figure 20. Typical MAR-M 200+Hf Task II Exothermically Cast DS

Preliminary Design TFE731-3 Turbine Blades
60
 PRESSURE SIDE

SUCTION StDE

Figure 21. Typical IN 792+Hf Task II Exothermically Cast DS

Preliminary Design TFE731-3 Turbine Blades
61
 • _ l_ °
iii

i M mmmm moom ommo oooo

H _ _ Q _ O

_ ,_!

_ _ _o o_o ooo_ _o_

" m _
2
N _ oom_ ooom _ooo om_

? _1 0

_ 0

i .
 _!_T .¸_
_ T _._--_ .

(a) MAR-M 247- (best) _

(b) NASA-TRW-R_ ,4
(c) MAR-M 200+Hf

t (d) IN 792+Hf (poorest) _i

i-
Of the three evaluations, the X-ray results would be the most
I_ <iffioult to improve. The blades were generally rejected during
i X-ray due to high-density inclusions--presumably hafnium oxides.
iv.-
Of the _our alloys, the poorest X-ray yield was from MAR-M

i- 200 alloy with the highest hafniu_ content. FPI results

_ must be considered conservative since no attempt was made to

llI two molds

blend out of
any each alloydefects_
surface were cast
and with
thus exothermic material Thewith
improve yields. lasta
lower heat output than the initial molds, but only the IN 792+Hf
• alloy DS grain structure was affected. The other three alloys
exhibited a greater tolerance for variability in the heat output
of the exothermic material.

7
Chemical analyses. Chemical analyses were made of castings
from all molds. The results of these analyses are shown in

i__ Tables XI through XIV. These tables also show the material
source master heat identification and certified chemical analyses

_ii:
I of the master heats.

NO significant deviations were found in the chemistries of

the parts versus the chemistries of the master heats, except that
the parts tended to have lower hafnium contents than the master
heats. This was true of all the alloys except IN 792+Hf, which
makes the original certified hafnium content of this alloy sus-

_ pect. Tables XI through XIV also include hafnium analyses of the

root and tip of one blade from each blade mold cast in Task II.
The hafnium gradients apparently were lower than the sensitivity
of the analytical technique, since the conslstentl¥ higher haf-
nium level expected at the tips of these blades (cast root up)
was not demonstrated.

63

I !
++'+'_++_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 +-( ,,.I +-4 +,-I _I

o ,90 o o o
+-' +
_ o o o o ,o , _.
0 0 O _ O

v _ v _ _.

._-- • .,,
._+ +0 ..+: +_ ,_
0 + ++,.,+
_, -- _
o o o+ '°"o _ __°°+°+_ o
I°
_-- _ _.
° " " ++ _+ _ _ _.1

+'-- .+.I
,.
e,-I
,,,
w.l e,,l ,-4
".-
.I_ e-_
_ oo!+.
++,+

0 E_
++,
,, o ,.. ,-
o o
•
_ °
+" P+ _
u_
+o---_
_ ++

0 + _ +, ,- _ ,, o
G G ": o ' <_ <_ ,G o "+,
o o

,"+ ,",
,.., _ "
.-., _ +
,..+ _ ,"
,-,
Ip

I l,_ I 1 I J
,m ..., A ,-3
M

64
L_

,d
V,
66
Ii Meohonlcal
re+t°
i. ??ests on Specimens Machined .f,
rom Blades.. A number of _'i
blades were selected from the first eigh_ Task II molds and
+ divided into two g_oups for heat t_eatment. The heat_ treatments
(summarized in Table VIII) used were as follows:

_ |lear Treatment At Solution treated at 14940K (2230°F) fer

2 hours, followed by aging at I144°K
(1600°F) for 20 hour_.

i_; Heat Treatment B: 2 hours, followed

Solution treated by 1494°K
at a simulated alumin-
(2230"F) for
;.- ide coating thermal cycle of 5 hours st
i,: 1255°K (1800°F), and aging at ll44°K
(1600°F) for 20 hours.

=+, Test specimens conforming to the mlni-bar configuration used

in Task I, as shown in Figure il, were machined from blades from
both heat treatment groups. Bars were machined to provide separ-
ate specimens with- longitudinal (grain-growth direction) and
_ transverse orientation in all cases. The longitudinal specimens
were machined from airfoil sections of the castings and the
• transverse specimens from the root sections. Tensile tests were
conducted on specimens at room temperature and at 1033°K +.

(i400°F). Stress-rupture tests were conducted at 1033"K (1400°F)

and 1255°K (I800°F+). The results are presented in Tables +XV
through XX.

The room-temperature tensile test results are presented in

Table XV. As anticipated, the transverse-orientation strengths
were significantly lower than the longitudinal values. The coat-
" ing cycle did not significantly affect the strengths of any of
the alloys except IN 792+H£. The coating cycle was generally

t :

- O0000001-TSGO:
 D

, ,4

TABLE XV. TASK II ROOH_TEMpE_t_TURE TENSILE T_ST RESULTS

(Tant a_ec_.n_ns machined f_om exothe_m_eally east D$ pre-

llm_nary deB_gn TFE?21-2 t_rblne blades, Task II blade _ ;
casting Group. 1 and 2.)

U1timate
a b te_s£1e O.2-Percent Roductlon
Spect_n oEaL_ Heat strength, yleld.strength, Elongation, of area,
number orle_tatlun _reatment MPa (ksL) MPa (ksl} percent percel_t
II I I

(a) M^R-_ 247

62-4 L A. 984 (1433 _53 (1243 6.4 16.4

62-9 L A 944 (131) 872 (1263 6,2 12.3
62-4 T A 756 (i00} 747 (1083 4.5 16.1
62-9 T A ?67 (In} 756 (1103 9.3 16.4

62-14 L B 574 (1413 714 (1183 6.7 14.6

62-16 L B 9?2 _141) 830 (120) 6.0 13.5
62-14 T B 716 (104} 712 (1033 8.% 18.8
62-10 T B 790 (115) 738 (1073 8.9 37.9

(b} _SA-TRW-R

66-2 L A 994 (1443 860 (124) 5.6 13.1

66-8 L A 970 (1413 834 (121) 6.9 11.8
66-2 T A 763 (Iii) 756 (110} 1.8 4.0
66-8 T A 783 (1143 763 (1113 1.4 7.1

66-9 L B 972 (1413 829 (120) 6.5 9,7

66-18 L B 973 (141) 828 (120) 6.8 10.9
66-9 T B 749 (109) 712 (I03} 6.7 18.2
66-18 T B 727 (1063 711 (1033 3.9 10.2
i.

(c) MAR-H 20O+Hf

65-3 L A 772 (1123 771 (1123 5.8 15.9

65-6 L A 988 (143} 055 (1243 7.8 17.2
65-3 T A ?72 (112) 770 (112) 9.1 14.0
65-6 T A 056 (1243 022 (i19) 2.9 11.8

65-13 L B 923 (1343 812 (118) 8.? 16.4

65-16 L _ 968 (1403 822 (1193 7.3 15.7
65-13 T B 781 (113) 779 (1133 9.0 19.0
65-16 T B 828 (1203 757 (1103 11,7 26.5

(d} IH 792+Hf

64-7 L A 1109 (1613 91B (1333 7.0 19.5

64-11 L A 1107 (161) 919 (1333 5.6 11.0
64-? T A 822 (I19) 781 (I13) 5.2 12.3
64-11 T A 790 (116} 7?8 (1123 3.5 6.5

64-17 L 6 1056 (153) 853 (124} 6°? 13,8

72-19 L _ 1019 (1403 828 (120) 4.6 13.5
64-17 T B 767 (111) 741 (10B) 4.3 13.7
72-19 T _ 866 (126) 735 (i07_ I0.4 21.0

aL = Longltudlnal T = Transverse

bA = 1494°K {2230°F) for 2 hoots and I144"M (1600°F) for 20 hours

B = 1494°K (2230°F) for 2 hours, 1255"K (18000F} |¢.r 5 hOUES, and 1144°K (1600°_ ')
for 20 hours

69
 TkBLE _VI. 'CASK _ 1033"K (L400°F} TEHSILE TEST RESULTS _I
.- (Test epenlmene machined from exothe=mlcally cast DS p_elim£nary
design TFE731-3 turbine blades, Task %Z blade c_ting
Grou_s I and 2.) ,F

, tensile 0.2-Pc=cent Redhction

Specimen I Grain a Heat b Ultimate
strength, 'ield strength, ELongation, of area,
NO. I orientation t_eatment ;_a-(_sl) _a (kei) percent percent

Ca) MAH-_ 247

FI
62-8 L A 997 (145) 814 (118) 8.3 15.5 I
62-2 T A 816 11191 713 11031 5.5 22.2
_ 62.8 T k 732 11061 676 (981 6.7 14.8

- 62-13 L g 1091 (1SS) SS6 1129) 4.4 15.3

62-15 L B 952 (1381 773 (1121 7.0 27.3
62-13 T B 758 11101 683 1991 10.7 26.1
•- 62-15 T B 741 (108) 663 (96) 3.8 16.6

:: (b) NASA-TRW-R

66-5 L A 1042 (151) 832 (1211 4.6 21.4

7_-II L A 1109 (161) 880 (128) 12.5 22.8
.... 66-5 T A 745 (108) 684 (99) 5,5 15.7
71-11 T A 945 (137) 832 (1211 2.9 13.9
i
• 66-16 L E 1085 (1571 914 (133) 4.1 11.i
i 71-20 L B 1071 (155) 894 (130) 9.5 26.7
66-16 T B 765 (1111 722 (1051 6.4 9.3
71-20 T a 796 (1151 738 (1071 9.6 17.3

(c) MAR-_ 200+Hf

65-4 L A 1123 (i631 872 (1271 5.4 14.0

73-10 L A 1136 (1651 901 11_I) 7.3 16.4 !
65-4 T A
936 (1361 790 (115) 2,9 8.3 !
i 73-10 T A 761 1110) 709 11031 12.9 29.0

65-15 L 3 1117 (1621 909 (132} 5.2 13.8

73-17 L S 1110 (163_ _98 (1301 6.9 20,9
i : 65-15 T B 809 (1171 702 (102) 12.6 20.9
73-17 T H 882 (128) 760 11101 6.8 18.7

i_ ' (d) ZH 792+Hf

[- 64-8 L A 1111 11611 840 11221 11.0 33.5

72-7 L A 1067 (1551 ?79 (1131 14.4 28.0
_ . 64-8 T A 897 (130) 683 (99) 8.0 14.9
;i 72-7 T A 871 (1271 621 (90) 9.8 15.5

64-15 L B 2096 (1591 800 (i16} 13.0 28.5

72-12 L B 1089 (158) 778 (1131 7.7 18.3
64-15 T B 740 1109) 644 (93) 4.7 11.9
_. 72-12 T H 960 (139) 6S7 (1001 5.L l 14,0

a L = LongLtud_naL T _ Transverse

b A = 1494oK (22300F) foe 2 hours and I144OK (1600oF) foe 20 hours

i• 9 = 1494°K (2230"F) 2or 3 hours, 1255aK (1800"F) for 5 hours, and I144°K (1600°F)
for 20 hours

_ 70
 TABLE XVII. TASK _X I033°K (1400°F) STRESS-RUPTURE TEST RESULTS - '_
LONGITUDI_L GRAIN ORIENTATION

(Test specimens machined from exothermloally oaet DS

preliminary design TFE7_I-3 turbine blades,
Task II blade casting Groups i and 2.)

5 Hour s Reduct ion

Specimen Heat to Elongation, of area,
no. treatment ruptune percent percent

I033°K/724 MPa (1400°F/I05 ksi) Tests

_ MAR-M 247
62-1 A 79.9 10.6 18.1
62-7 A 12.4 14.0 19.0
62-12 B 55.7 Ii. 7 20.2
l
70-12 B 53.2 i0.0 28.9

=S NASA-TRW-R

66-4 A 79.1 9.2 34.7

: 71-6 A 29.2 12.1 36.9
66-14 B 34.8 9.6 26.1
_'i:- 71-14 E 36.4 11.2 29.4

f 65-2 A _R_ 200+Hf 6.7

18.2 18.1
73-8 A 77.1 12.1 23.9
: 65-12 B E7.3 E.8 21.2
73-13 B 59.4 11.6 31.2

I033°K/689 MPa (1400°F/100 ksi} Tests

IN 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 (1600°F) for 20 hours

B = 14q4°K (2230°F) for 2 hours, 1255°K (1800°F) for 5 hours,
and I144°K (1600"F) for 20 hours

/ 71
 TABLE XVIII. TASK II I033°K (1400°F) STRESS-RUPTURE TEST RESULTS -
TRANSVERSE GRAIN ORIENTATION

Test specimens machined from exothsrmically cast DE preliminary de-

siqn,TFE731-3 turbine blades, Task II blade casting Groups 1 and 2.)
Reduction
Specimen Heat a Stress t Hours to Elongation, of area,
no. 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 200+Hf

65-2 A 689 (I00) 5.0 4.6 14.4 J

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) for 2 hours and I144"K (1600°F) for

20 hours

B = 1494"K (2230"F) for 2 hours, 1255°K (1800"F) for 5 hours,

and I144°K (1600OF) for 20 hours

72
 TABLE XIX. TASK II 1255°K (1800°F) STRESS-RUPtURE TEST RESULTS -
LONGITUDINAL GRAIN ORIENTATION

(Test specimens machined from exothermically cast DS

"- preliminary design TFE731-3 turbine blades, Task II
4. blade casting Groups i and 2.)

• Hours Reduction
Specimen Heat a to Elongation, of area,
no. treatment rupture percent percent

1255°K/207 MPa (1800°_/30 ksi) Tests

=

_ MAR-M 247

62-6 A 63.7 20.1 49.7

70-19 A 69.7 18.2 44.0
62-10 B 61.8 14.1 34.9
70-10 B 68.1 7.8 21.6

NASA-TRW-R

66-3 A 49.1 17.1 44.5

71-i A 53.6 17.9 45.2
66-10 B 39.4 14.8 35.9
71-13 B 39.0 13.0 37.4

MAR-M 200+Hf

65-I A 58.9 14.5 47.0

_ 73-i A 59.7 15.5 43.1
65-9 B 46.9 19.6 49.3
73-11 B 73.5 18.8 37.4

; 1255°K/193 MPa (1800QF/28 ksi) Tests

IN 792+Hf

.. 64-i A 14.7 16.4 33.6

72-1 A 36.3 17.6 48.6
64-13 B 27.3 15.8 38.2
,' 72-9 B 29.0 15.5 42.7

a
A = 1494°K (2230°¥) for 2 hours and 1144°K (1600°F) for 20 hours
B = 1494°K (2230°F) for 2 hours, 1255°K (I800°F) for 5 hours,
and 1144°K (1600°F) for 20 hours

73
 I

± .q ,m ,

_". TABLE XX. TASK II 1255°K (i800°F) STRESS-RUPTURE TEST RESULTS -

i TRANSVERSE GRAIN ORIENTATION

.... (Test specimens machined from exothermically cast DS prelimlnary

design TFE731-3 turbine blades, Task II blade casting
_ Groups i and 2)
i

Reduction
: Specimen Heat a Stress Hours to Elongation, o_ area,
no. treatment MPa (ksi) rupture percent percent
MAR-M 247

'i 62-6 A 186 (27) 104.8 9.4 18.3

70-19 A 186 (27) 136.7 7.2 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
, L,

66-3 A 186 (27) 61.3 1.8 8.3

71-1 A 186 (27) 56.0 8.7 16.2
i_ _ 66-10 B 186 (27) 76.6 5.4 13.1
_: wl
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 A 186 (27) 95.7 16.4 25.5

65-9 B 186 (27) Iii.6 13.6 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

a A = 1494°K (2230°F) for 2 hours and 1144°K (1600°F) for

20 hours

and 1144°K (1600°F) for 20 hours

!;:il B = 1494°K (2230°F) for 2 hours, 1255°K (1800°F) for 5 hours,

_ 74
 ¥

beneficial to ductility, particularly in the transverse direc-

tion. O_iginally there seemed to be an identification problem
with specimen 65-3 of MAR-M 200 of the testing
%
appeared to be for a transverse orientation specimen rather than
a longitudinal one. Macroetching and inspection of the specimen r

inGicated that the identification, as presented, is correct.

Table XVI presents the I033_K (1400°F) tensile test results.

All of the alloys appeared to have a peak tensile strength at
this temperature, and the transverse properties were again sig-
nificantly lower than the longitudinal. The simulated coating
cycle apparently had no effect on tensile strength or ductility
at this temperature.

Resul£s of the 1033°K (1400°F) stress-rupture tests are pre-

sented in Tables XVII and XVIiI. The longitudinal orientation
result_ of Table XVII indicate that IN 792+Hf was significantly
weaker than the other three alloys. MAK-M 247, NASA-TRW-R, and
MAE-M 200+Hf were essentially of the same strength level. The
simulated coating cycle apparently caused a reduction in the
scatter of results for the strong alloys and weakened IN 792+Hf.
The transverse-orientation test results given in Table XVIII show
a wide distribution of rupture lives due to changes in stress
levels for this testing. The main reason for this was the prob-
lem. in selecting initial stress levels to yield i00-hour failures
in the absence of prior test data. The data illustrates that
MAR-bl 247 and MAR-M 200+Hf are the strongest of the four alloys
in the transverse direction.

The 1255°K (1800°F) stress-rupture test results are reported

in Tables XIX and XX. Once again, IN 792+Hf was the weakest of
the four alloys, and the other three were very close in strength.
Review of the grain structure, heat treatment, and mechanical
properties data available at this point in the program resulted

75
 ~.

in a decia_on..to reduce the level of evaluatio_ of IN 792+H£ fo_ i

the remainder, o_ Task II and eliminate this alloy from consider- '_

-- _ ation in subsequent tasks, k

Blades o£ the three stronges_ alloys chosen for further

evaluation were selected from the various Task II molds. These

blades were divided into three groups for heat treatment--one

group @ubjected to solhtion treatment at 14940K (2230°F) (Heat
Treatment B as summaDized in Table VIII), a second group at
1483°K (2210°F) (Heat Treatment C), and the third of 1505°K
i

(2250°F) (Heat Treatment D_. Following solution treatment, each

of the groups were subjected to a simulated coating cycle of
_[ 1255°K (1800°F) for 5 hours followed-by an aging cycle of I144°K
(1600°F) for 20 hours.

Mini-bar test specimens were machined from the airfoil sac-

i_ tion of blades of each heat-treatment group, with all specimens
having longitudinal grain orientation. The specimens were sub-
jected to tensile tests at room temperature and 1033°K (1400°F),
and stress-rupture tests at 1033=K (1400°F) and 1255°K (1800°E_.
i_ Specimens o£ IN 792+Hf, were selected for test only from Heat

-i Treatment D, [1505QK (2250°E) solution treatment followed by the

simulated coating cycle and aging]•

Results of the tensile and stress-rupture tests are presen-

ted. in Tables XXL through XXIV. To facilitate evaluation of ,_.

these results, the tables include selected longitudinal data pre-
-- viously reported in :fables XV through XX for specimens from the
first two groups of Task II molds. A discussion of the results of
"Heat
E these Task ZI tests is presented herein under Treatment
Studies" (see page 48).

! : 247 Results ofmachined

specimens stress-rupture
from tests
blades at 1255°K treated
solution (1800"F) aton 1519°K
MAR-M
.... (2375°F) and 1533"K (2300°F} a_e presented in Table XXV

_ : 76
 TA_I_ XXZ, TASK ZX ROOM-TI_MP_RATURE T_NSI|,_ T_ST R_SULTS

(TQB_ SpOOi_OnQ _Qhlnod frolflT_,k II nxothQrmloally _t DS tQrLlno _l_d_

hnvin9 hQnt troAtmont notod below.)

Ultl_tQ 0.2-portent
A b tensile y£old Reduction
(poo£_un G_aln {_o_t st_enth, strength, _lon_tLon £n arrow
i

i . no. _rionta_ton t_oatlnont HAR-M

HPo (k_£) 247 HPa (ksi) ,.percent percent. i
I

-_" ?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
' 113-12 D 1017 (148) 890 (129) 8.7 15.7

f;_ 62-I? D 1005 (146) 578 _12_) _.2 14.4

HAR-M-200+Hf

73-_ L C 989 (144) 809 (117) 8.9 11.5

i. 73-6 C 1124 (162) 885 (128) 10.0 16.2

73-5 B 1062 (154) 880 (128) 10.4 19.8
73-7 B 966 (140) 851 (122) 10.6 21,6

iJ 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

66-12 L 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

: j 66-9 c B 972 (141) 829 (120) 6.3 9.7

66-18c B 923 (141) 828 (120) 6.B 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-? c L B 1109 (161) 918 (133) 7.0 19.5

I
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

_ a L - Longitudinal
T = Transverse
b B = 1494°K (2230°F) for 2 hours, plus 1255°K (1800°F) for 5 hours, and I144°K (1600cF)
for _0 hours_
C = 1483vK (2210_F) for 2 hours, plus _255°M (1900°F) for 5 hours, and I144°K (1600°F)
for 0 hours
D = 1505_K (22506F| £or _ ho_rs, plus 1255°K (1800°F) £or 5 ho_[S_ and 1144°_ (1690°F}
for 20 hours

c D_ta prevlously reported lh Tables XV through XX

 q'ABL_ XXlI, TASK II 1013°K (1400°] .') T_NSIL_ TEST P_.Sl;LTS

(To_t _u_lmoJiB machln_d from T_sk II ¢_xoI:he_mlcally east DS tL|rbin_ bl..Jes

h_vi:_g huat tr_atn_Qi_t not_d beluw.|

IIoat Jtr_ngth_ st_ngth_ _lonqation_ in _r_aa

no_ o_ientation _r_tm_ _a (ksl_ ]_ (ksi_ p_

MA_-_ _?

l_i_l_ _ ¢ 101i (1_7_ _ (1_i_ 6_? 1_

li_-_0 _ _0_ (i51| _6 (120| _._ 19_0
li_-1 _ 10_ (1_6_ 0_9 (1_6_ _ 1_._
il_-i_ D 8_ (1_7_ 7_ (li0_ 5°9 1_._
6_-1_ _ 10_1 (158_ _86 (1_9_ _._ 1_.1 _I

6_-15 _ 85_ (i_8_ _ (11_ _.0 _._

)0_10 D _8 (1_ _ (108_ 1_.9 _

113--5 _ D 931 (135) 779 (i13) 7.3 13.2

MAR-M 200+Hf

104-5 ' C iiii (161) 094 (130) I 6.0 14.7

65-14 B 1159 (168) 959 (139} 5.2 ii.0

104-15 C 1105 (160) 902 {131) I 6.1 17.6
104-6 B (Specimen broken prior to testing)

65-15 C B 1117 (163) 909 (132) J 5.2 15.8

65-17 D 933 (135) 795 (115) 8.9 I?.0

65-19 D 1115 (162) 878 (127) 9.6 17.9
73-17 e i B ]120 (163) 898 (130) I 6.9 20.9
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 792+Hf

64-17 C L B I05_ (15_} 053 (124) 8.? 13.8

72-19 ¢ 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

& L - Longitudinal
T = Transverse

b B = 1494°K (2230°F) for 2 hours, plus 1255°K (1800°F) for 5 hours, and i144°K (1600°F)
for _0 hours
C = 1485uK (22106F) for 2 hours, plus 1255°K (1800°F) for 5 hours, and 1144°K (1600°F)
for 28 hours.

c Data previously reported in Tables XV through XX.

78
 d

TABLE XXIII, TASK II 1033°K (1400°F) STRESS-RUPTURE TEST RESULTS _

(LongltudlNal grain orlsntatlon tost speclmon_

machined from Task II exothermlcally cast DS
turbine blades having heat trea_4_el,t noted
below,)

I033"K/724 MPa (1400°F/I05 ksi) Tests

Spoelmon Heat a to Of area,

t_o. treatment HOURS

rupture E1ongatlon,
percent ] Red,orlon
peroent

MAR-M 247

113-17 C 86.1 10.5 24.5

113-19 C ?2.6 7.8 25.0
i13-6 B 75.6 12.1 24.8
62-18 B 11,1 14.4 28.9
62-12 b B 55.7 11.7 20.2
70-12 b B 53.2 i0.0 28.9
113-15 D 127.1 9.4 24.3
62-20 D 80.6 10.2 21.8

MAR-M 200+Hf

104-4 C 67.8 23°4 36.9

104-8 C 61.3 9.8 24.8
104-3 8 107.? 9.6 21.0
104-14 8 140.2 9.4 22.3
65-12 b B 87.3 8.8 21.2
73-13 b B 59.4 Ii.6 31.2
104-2 D 171.2 13.5 24.1
104-17 D 86.1 10.5 24.5

NASA-TRW-R

71-15 C 3?.5 11.5 31_3

102-8 C 87.6 8°7 29.6
6_-II B 38.3 9.9 26oi
71-5 B 42,1 II.5 29.1
66-14 b B 34.8 9.6 26.1
71-14 b B 36.4 II.2 29.4
66-13 D 58.5 9.2 25.2
102-11 I D 86.2 9.7 25.3

I033°K/669 MPa (1400aF/100 ksi) Tests

: _- IN 792+Hf
w

64-14 b I B 17.8 13.4 40.0

64-10 D 81.6 I0.0 21.9

: 103-15
72-10 b I D
,
17.2
14.5
7.3
10.8
25.4
33.5

a B = 1494OK (2230"F) for 2 hours, plus 1255°K (1800oF) fo_

5 hours, and 1144OK (1600OF) for 20 hours
C m 1483OK (2210oF) for 2 hours, plus 1255OK (1800°F) for
5 hours, and i144°K (1600OF) for 20 hours
D = 1505°K (2250°F) for 2 hours, plus 1255oK (18000F) for
,. 5 hou_s, and I144"K (1600°F) for 20 hoers
b
- Data previously reported in Tables XV through XX.

- 79
 ¥

(Longltu_inal gz_n ozlertation t_st specimens I \

i
machlne._ _¢om Task ZZ exothermloally _est DS
tu_Sine bla,'-os having _est treatment no_ed be_ov,., _ _i

1255"K/207 MP_ (}800°F/30 ksl) Testa

. r , •

Hours ReduetiorL
5pecimen He_t a to Elongation, of area,
no. treatment rupture percent percent
',I

MAR-H 247

i_3-3 I C 75.1 35.5 42.1

113-7 C 53.7 22.3 41.6
113-11 - B 56.0 15.5 39.9
113-18 B 6_._ 9.9 26.8
62-6 b ! B 6L% 14.I 34.9
70-19 b I B 68.1 7,8 21.6

113-4 D 98.5 40.0 53.2

113-2 1 D 85._ _ 22.0
,H 30.3
MRR_M 200+Hf

104-9 C 51.0 18.5 40.3

i04--1._ C 51.0 21.8 39.4
104-1 B 76 .5 20.5 26 .8
104-11 B 53.5 21.3 46.6
65-9 b B 46.9 19.6 49,3
79-11 b B 73.5 18.8 37.4
104-10 D 82.0 15.5 41.6
104-12 D 59.0 17.8 37.8

NASA-TRW-R

182-15 C 64.5 20.9 I 42.1

102-19 C 40.7 16.1 41.5
102-10 B 63.8 21.1 47.4
104-14 B 58.1 16.7 43.7
66-10 b B 39.4 14.8 "_5.9
71-13 b B 39.0 13.0 37.4
102-1 D 65.3 22.0 35.1
102-18 D 63.7 18.7 42.8

1255°K/193 MPa (1800oF/28 ksi) Testa

ZN 792+Hf

64-13 b B 27.3 15.8 38.2

72-9 b B 29.0 15.5 '42.7
I 64-2 D 36.5 18.3 42.4
103-18 D 38.6 16.8 41.6

a B = 14"_°K (2230°F) for 2 hours, plaa 1255°K (1800"F) for

5 hours, an_ I144°K (16000_ ') f.o= 20 hours
C m 1483VK '22_0°F) fo_ 2. hours, pl_ 1255°K (_800°F) fOr
5 hours, _ _d I_4"$°K (1600°F) for 2.0 hours
D m _505°K (2"5!,"?) _or 2. hours, ph13 1255°K (1800OF} for
5 hours, anC I_44_K (16OO°F) for 20 hours
b
Data _revlousl7 r_[Jo_..'_din Tables XV through XX.

80
 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
_i for 2 hours, follewed by inert _as quenching, then 1255OK (1800 °F) for
+ 5 houris, and I144_K (1600°P_ for 20 hours.)

Specimen Grain Stres_ Hoursto Elongation, Reduction of

no. Orientationa MPa (ksi) rupture perce_t area, percent

l_+ 1519OK 2275°F) solution 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) solution treatment

---< 70-6 L 207 (30) 79.7 4.9 9._
70-7 5 207 (30) 106.7 24.2 55.8

_-. _0-ii L 207 (30) 126.8 23.4 44.9 j

[i 70-17 L 207 (30) 83.5 24.6 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

a
L = Longitudinal
T = Transverse

81
 r4,:%_

i
o++

2.-- Tests on Specimens Machined from Slabs. The eight slab .... 4
molds cast for Ta_k II cyellc-ruptu_e te_tlng_provlded for 6 rec-
tangular slabs De4 mold, with 2 molds cast per alloy. These k
slabs-were 15.24-cm high, 7.62-cm wide and 1.27-cm thick. (6
"- inches by 3 inches by 0.5 inch), and were heat treated using a _'
solution temperature of 1494°K_(2230_F) for+2 hours followed by
_+ inert o_s auenchlng,
+. I • a simmlated coating cycle at 1255°K (1800"F)
for 5 hours and aging at I146°K (1600°F) for 20 hours.

Both smooth and notched test specimens were machined from

the slabs with separate specimens having longitudinal, transverse
_ and 45-degree a_raln'orierutatlons." The smooth test specimens had.+

i a standard 0.625-cm (0.25-inch) gage diameter and 3.175-cm (1.25-

i inch) gage length as shown in Figure 13). _he notched specimens
• had a nominal notch diameter of 0.452 cm (0.178-inch) and were

! otherwise configured as shown in Figure 22.

F_

i_ Initial cvcllc-rupture tests @t I033°K (1400°F) on smooth,

iongitudlnal-grain specimens machined from slabs indicated that

cyclic t+stlng did not degrade the stress-rupture life of the

+ alloys. Using a 10-second load, 90-second hold, and 10-second
O
unload cycle, smooth test _pec_mens were tested at progresively

? higher Stresses as shown in Table XXVI. Based on these results,

_hree tests were run on slmilar specimens at peak stresses of
_ 723.9 MPa (105 ksi). Results of these tests, as shown in Table
XXVII, indicated that the stresses were not sufficiently high to

_!_ produce the-rupture

the cyclic desired testing
100-hourwasfailure. Therefore,
accomplished at 758 the
MPa balance of
(110 ksi)
. +"

maximum stress for the longitudlnal-grain speclmens and 724 MPa

(].05 ksl) for the 45-degree-arain-orJented specimens.

The results of the cyclic-rupture testing at 1033°K (1400°F)

• on specimens machined from slabs are tabulated in TaDle XXVIII
and graphically compared in Figure 23. The bulk of the testing

82
 k

3.81 _,7.62 ,
(-1.51- '-I 0.95 - 17 UNC
5 ..,,._ 2:46 (0.375)

0.508 (0.172)
I (0.97) 0.452
0.95
(0.375)

I 0.317R
(0,251) 0.49S
(0.195)

2.46
(0.97)
0.636 NOTCH ROOT
(0.251) RADIUS
0.0'10
(0.006)

DIMENSIONS
IN CM
(INCHES)

Figure 22. Cycllc Rupture SpeCimen

'- 83
 ¥

|n

!' _TABLE XXVI. TASK I! 1033°K (1400°?) CYCLIC_RuPTURE TEST RESULTS

I AT PROGR_SSIVEL_ HIGHER• STRESSE_.
k
!.. [Smooth, longitudinal grain orientation tes_
!_:" specimens maehined from exothermically cast DS
slabs. Prior to machining, slabs were solution-
I' treated at 1494°K (223_°F) for 2 hours £ollowed

i'_ 5.hours,
by inert and
gas 1144°K (1600°F)
quenching, 1255TKfor(1800_F)
20 hours.]..
for

!_k Hours at the indicated

test stresses
m,

655 MPa 690-MPa 726 MPa Total

i- Allo_ (95 ksi) (i00 ksi) (105 ksi) hours
i! Mar-M 147_ 30_ .............
i00 67.4 467.4
! (Specimen 105)

Mar-M 200+Hf 300 100 73.2 473.2

_. (Specimen 97)
I. NASA-TRW-R 300 i00 Failed on 400.0

i (Specimen 101) loading

TABLE XXVII. TASK II I033°K (1400°F), 724 MPa (105 ksi)

CYCLIC-RUPTURE TEST RESULTS

[Smooth, longitudinal grain orientation test

specimens machined from exothermically cast DS
slabs. Prior to machining, slabs were solution-
treated 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

MAR-M 247
182.8 5678
(Specimen 106)

MAR-M 200+Hf 185.0 6046

(Specimen 98)

:_SA-TRW-R 158.2 5285

(Specimen 102)

84
 TABLE XXVIII. _ASK II, 1033"E (1400eF) CYCLIC_RUPTURE TEST RESULTS FOR
TBR_E GRAIN ORIENTATIONS
(TeSt spoci_ens machLnad from exothe_icell-y cast D8 slabs. Prior to machining,
r_ slabs wer_ solutionrt_ated at 1494°K (2230°F) fox 2 hours followed by _nert qas
:_, quel_chlng, 1255"K (18000F) for hours, and 1_44°K (160O'F) for 20 hou¢=.

i
L: . Maxl_u_ Cycles Reduction
" " stress, HOurs tG to E1ongatlon, of are_,

___I_ Specl_en I Ozlentatio_ Type Qf sp_imen 14Pa (ksi') f&llu_a failure perc_t p_rcent

50 L Smooth :758 (110) 09_9 2989 ?.3 11.6

53 L Smooth 758 (110) 89.8 2979 11.0 12.9
54- L Smooth 1758 (1_0) 97.6 3227 9.2 11.4
!_i! 49
I07 L
L Smooth
Smooth 758
:758 (110)
(Ii0) 216.7
122.? ?592
3915 6.0
8.7. II.5
10.1
_ 51 L Notched (K_-l.8) 758 (110) 187_0 6217
52 L Notched (K_"1,8) 1758 (110) 249.2 8351 -
_ii
\''_. 55 L Notched (K_-I.8) !758 (110) 234.0 7621 -
56 L Notched (K_-I,8| ,758 (110) 207,9 6967

_ 65 T Smooth
i724 (105) 93.1 3045 4.0 8.1
66 T Smooth ?24 (105) 57,2 1891 4.6 8.5
_. 67 T Notched (K -I.6) 724 (105) 229.9 71_3
80 T Notched (K_-I. 8) 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 45 _ NOtched (K_:I. 8) 724 (105) 87.9 2?92 -

60 45" NotchEd (K_'1.8) 724 (105) 112.1 3633

RAR-M 200+Nf

1 L _ Emoo_h 758 (I10) 180.3 5065 8.0 10.6

• 5 b Smooth 758 (110) 187,I 5249 ?.0 E.?

6 L Smooth 750 (110) 185,4 6074 ?.1 9.2

1O |5 e Smoo_h 724 (i05) 86.4 2900 4.3 8.5

132 45"
L I Smooth
Smooth 724
758 (109)
(i10) 105,8
266,3 3487
0726 2,9..-
6,6 7.2
9.1

,' 1: 46" Notched (K_1.0) 724 (108) 108,0 3327

12 65 _ Notched (K_:1.6) 724 (105; 217.7 7051

a L • Longitudinal
T m T_a_sve_se

I" 85
 I

86
i¸ ,_

I _
was Cone o_ the MAB-M 24? and NASA-TRW-R alloys, as an oxtensive J
! productioo backgrollnd exists for t_e DS cast MAR-M 200+Hf alloy,
_ - and previous _ogram data resulted in elimination of IN 792+Hf a_ k
_,i a candidate mate_gal. A basic purpose of the cyclic_rupture
testing was to provide data useful in design of the firtree- .,
attachment _egion of the _u_blne blade where high stresses ale
_ present: at various orientations where stress-concentrations
L.. exist.

The 'major conclusions drawn from the cyclic testing were:

i
!_ (a) MAE-M 247.was notch-strengthened in all three orien-
_ tations.

(b) NASA-TRW-R was notch-weakened in the longitudinal and

transverse orientations.

!!_ (c) The limited testing of the MAR-M 200+Hf revealed no

problems with this alloy.

(d) All three alloys were notch strengthened in- the 45-
deg_e_ orientation.

• Thermal _atique tests. Eight blades of each alloy were

selected from uhe final eight Task-If molds for use in conducting
thermal-fatigue tests. Following solution treatment at 1494°K
(2230°F), four blades of each alloy were coated with RT-21* alum-
inide coating at 1255"K {1800°F) for 5 hours, then aged at I144_K

(1600aF) for 20 hours. The remaining four blades were l_ft

uncoated ,(bare), but were subjected to a heat-treatment process
equivalent to that used for the coated blades. In addition, a

*A proprietary aluminide coating applied by the Chromalloy

_" Corporation; Orangeburg, New York.

88

_ _I _ _ _
 d

mold of equiaxed cast MAR-M 247 blades was cast to provide a a

baseline £or comparison o£ thermal-fatigue characterlstiGs with
the DS castings.

An initial• 1000-cycle thermal-fatigue test was conducted by

the Illinols Inshitute o_ +Technology Researcl% Institute (IITRI)
on bare and coated blades of all four alloys. The test was con-

ducted in fluidized beds wh£cn permitted cycling the blades

between 308°K (95°F) and 1228°K (L750°F). The blades were alter-
nately held for 3 minutes in each of the hot and cold beds.

Only one crack was found afte_ completion•_f the 1000-cycle

test. A second 1000-cycle test was then performed on the same
blades with cycle temperatures of 308°K (95°F) and 1283°K
(I_50°F), which was the highest temperature attainable on the
test equipment. A summary of the_ results of this higher temper-
ature test is as follows: .....

(a) MAR-M 247

Bare - First crack was observed after 500+cycles. The

crack' had grown to 0.076 cm (0.030 inch) at test com-
pletion.

Coated - No cracks were observed.

(b) MAR-M 200+Hf

: Bar.____ee
- First crack was observed after 200 cycles. The
±

crack had grown to 0.076 cm (0.030 inch) at test com-

pletion.

; Coated - The first crack had bee_ observed on the blade

pressure side after I000 cycles of the earlier 308°K

• (95°F) and 1228°K (1750°F) test. This crack had grown

89

L ..... _ , ..
ik to 0.508 cm (0.200 inch) after 300 cycles oK the second "I
_ + test [1283°]< (I850°F)]. A second coating crack was
observed_ on the blade suct_en side, after+_500 cycles _
of t4_e second test. This crack bad grown to 0.076 cm
(_0.03 inch) at test completion.

(o) N_ASA-T_W-_
__are - One_very tight crack was observed at tes: COm-
.L

pletion.
_ Coate__...__dd
-. No cracks were observed.

i_[l (d) IN 792+Hf

" - "_

Bare- A crack was observed after 50 cycles. Phe crack _

_ ; had grown to. 0.178 cm (0.070 inch) at test completion.

Coate__d -- No cracks were observed

:- Except for one blade, all of the coating cracks were located
at the trailing-edge platform intersection, which is a sharp
transition of thin,to-thick section that should generate maximum
'- thermal stresses. The sole exception was the coated MAR-M 200+Hf
_ blade that de_eiopea airfoil cracks. Figure 24 presents a typi-

Cal cal photograph of bare and coated MAR-M 247 blades before and
i_ / after testing.

As indicated by the summ_ry above, the thermal cycling

-- results show little to discriminate between the four alloys. To
further evaluate the thermal-fatigue c_aracter_stics of MAR-M

,_ 24_, two additional tests were conducted at IITRI. Each te_t

i_ ? used two equiaxed and two DS cast MAR-M 247 blades of identical
- design. Testing consisted of 1000 cycles between 122_°K (1750°F)
=; ,+ and 31L°K (100°F), _ollowed by another 1000 cycles between 1283"K

(1850°¥) and 311°K (100°_). The blades were alternately held in

! - the hot and cold beds three minutes each to stabilize tempera-
C turee.

_+- 90
2_

Ni_.: .... '....... +- i ...........

3

rJ

i̧•_ I_ i

.: COATED UNCOATED

(e) AS RECEWED ................................

e, • .
r

,..
COATED UNCOA r_D

(b) THERMALLY CYCLEO "',_.

Figure 24. Surface Appearance of DS MAR-M 247 Prelil,;_gary Des_'gn
T_E?31-3 Turbine Blades As-Received and Aft.'r 10e0
Thermal Cycles Between 308°K and 1228"K (95=F _nd
1751°F), and 1000 Thermal eycles Between 308=_ aod
1283°K (95°F and 1850°F). (Mag.= IX)
9_

_..... _ "'' 'ooooooo

_ No cracking was observed on any blaae a_ter the '' '"

I': c']c'les,
cycles. while the-DS
The two cast. blade;_
equia_..ed blade_ did not.
crackea A cr_cK the
duL'in0 ,_as se.':end
_,bservedi000
in

|i one equiaxed blade after 25 cjcles of the 1283°K, (1850°F) and

3£I°K (100°F) thermal cycling, and a crack was observed in the
other after 300 cycles. Crack propagation in the equiaxed grain
blades was as shown it:Table X'(IX: .......

XI:IX. CRACK PROPAGATION ?[N THE EQUIAXED GRAIN BLADES

F Number _ -- -.....crack
• Ave_sge length, cm (inch)
[of C_cle.s Blade _O.--I-4"---- Blade No. 16
25 - - 0.05---(0.02)
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)
,i000 .... 0.20 (0_08) ____ 0.20 (0.08 h

Figure 25 pl:esel;ts the four tested blades after completion

o._ the 2000 cycles of testing, and Figure 26 shows the crack_ in
the equiaxed blades.

Due to the fact that crack location is a function of blade

geometry, only a crude qualitative conc1_sion can be _eached--

that based on this testing the DS cast blades were more thermal-
fatigue resistant than the equiaxed blades.

_c modulus testing. Dynamic modulus of elasticity

tests were performed in triplicate on test specimens machined

92

/
 _ ........ 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 _¸ _.

(a) BLADE 14 (!VIAG.: 25X) --

--<

,_f._/ _:- , ......,.

. (hi BLADE 16 (MAG,: 25X)

Figure 26. Appearance of Thermal-Fatlgue CracKs at Trailzng Edge

Near Root of Eqlilaxed MAR-M 247 Blade Nos. ]._ and 16
_. after i000 Cycles at 1283"K (1850°F)
 from Task IIDS slab castings for each of the four alloys. The

test specimen configuration for thes_ tests was rectangular k

plates 10-cm long, 1.3_cm wide, and 0.13-cm thick (4 by 0.5 by
0.05 inches). Tests were conducted at room temperature and at
III°K (200°F) temperature increments from 811°K (1000°F) to
1255°K (1800°F). Averaged _esults of these tests are tabulated
in Table XXX. The maximum variation of individual test results
_: from the averages shown was 4 p_rcent, r

_- Metallo@raphic examination. Representative Task IIDS cast-

:. ings (blades root-up) from the four alloys were metallo-
t_: graphically examined in the root sn_ blade-tip areas before and
_-_: after heat treatment. Figures 27 through 30 illustrate the
results of this evaluation. The grain-growth direction as shown
' on these figures is vertical in all c_ses ....................

_=_
[
MAB=M 247 microstructu_es are presented
"
in. Figure 27 •

•+" Script carbides are evident in all _our p_]otos, and grain bound-
_ aries can-be seen in the as-cast structu:_es. The structure is

_ generally coarser at the root, sinc,_ the t,%ermal g_'adient during

• th_ _as_nq proccss was 9r6at_r at the bZac_e tip, %hich was near
_-_ the chill--plate,
!_. "'.

Figure 28 presents photomicrographs of MAR-M 20_:Hf blade

}_-: castings. The script carbices were also evident in this precur-
_va
__2 '+ -sot alloy uf MAR-M 247. Larger amounts o£ gamma/9_m_a
. prime
!9_ eutectic _'cre present in both _he _s+cast and heat-treated condi-
_ tions than were observed in MA_-M 247.

_-_:' Figure 29 presents the m/crostructuzes of the NASA-TRW-R

: -- alloy. This photomicrograph shows _ewer script _arbldes :han the

_,__ two MAR-M alloys. The amount of incipient melting observed in

_+ the root area after treatment ma_ indicate that. 1494°K (2230°F)
_i--_. is the upper limit for solution• treatment of th.[s alloy.

[_--. + . 95

..... " '_ ' i_'_l_'_-"_'r"ala_ _t_-:'--_'_"_m_'_'__9 T_

• ! --

+,,,.+, ............. . ....

98
 ;_":_ The IN 79.2+I_£ microstructures are depicted in Figure _0.
-_D _ Script carbldes were absent and inc'ipient meltlng occurred in the
i_ . root section of the blade, \

g2:
_ As a result of .the _ask II tests and e_alutions of the feur
_,. axloys, MARH4 247, MAN-M' 200+Hf, and NASA_TRW-R alloys were

,_. selecte_, for _urther evaluations in Task Ill. The IN 792+Hf

_: alloy was eliminated from the Task IIl effort due to its lower

l/i stress-rupture strength.

_2 :'.

Ni:
°
 +,,i

¥
I

TASK. III- ALLO¥..-PROPERTY CHARACTERIZATION

ScQpe
k

During Task III, the three selected alloys, MAR-M 247, ............
!/ NASA-TRW-R, and MAR-M 200+Hf, were further evaluated in DS cast
form to determine and document mechanical and physica) properties
_" to v_k_date the final design for the turbine blades. This was
accomplished by the manufacture of additional turbine blade _nd
process
_i test bar castings by Jetshapes using controls developed
_i du_ing _asks I and II, _followed by comprehensive testing of cast- .....

atories.
ings and test specimens _ by AiResearch and independent labor-

Test Material Production. Turbine blade and separatly cast

_i_ test bar molds

to provide were
material exothermioally
for Ta_k Ill DS cast with
evaluations. Aallnewthree alloys
7000-pound
neat of low-gas content MAR-M 247 was used for pouring all cast-
_-
. ings with this alloy. Oxygen content of this heat was 8 ppm; nitro-
gen was 4 ppm. Typical gas contents for normal remelt heats of
vacuum cast nlckel-base superalloys are 10- to 30-ppm oxygen and 15-
to 25-ppm nitrogen. Heats o£ the other alloys were the ones
procured for Task II.

" The blade molus we-re of the same design as those used in Task
If--five straight spokes with provisions for four root-up blades
in each spoke. The standard test bar mold had five spiral spokes
with six 1.590-cm (0.625-inch) test bars per spoke. In addition,
one test bar mold was made to provide both tapered erosion-test

III evaluations. In this special mold, one spiral spoke of six

standard bars was replaced with a spoke having provisions for two
i bars an4 large-diameter thermal-conductivity test bars for Task

with a spoke providing six erosion-test bars.

i_ 3.8-cm (1.5-1nch) test bars, and another spiral spoke was replaced

102
 i

In view of a reported possibility of discontinuance by the

supplier of the Colal-P mold prime-coat material, one blade mold

and one test bar mold were cast using the latest modification o_ \

the Jetshapes production prime coat for comparison with the k

Colal-P. While initial grain structure evaluation of parts from
these two molds indicated that there were no apparent differences,

nondestructive evaluation of the casting indicated the Colal-P

r;old had fewer fluorescent-penetrant indications than the newer

Jetshapes mold. Based on these results, sufficient ColaI-P was r]

procured to meet remaining program requirements.

All Task III turbine blade castings were subjected to X-ray, i

fluorescent-penetrant, and DS grain evaluations. Results of this

testing is presented in Table XXXI. The general level of fluor-

i escent-penetrant indications on MAR-M 247 was lower than that

observed on castings made for the preceding Tasks. This was
attributed to the__use of the low-gas content alloy for Task III

castings.

Chemical analyses were performed on sample blade castings and

separately cast test bars from all molds made in Task Ill.

Results are reported in Tables XXXII through XXXIV. No signifi- !

cant anomalies were found in these analyses .............

Property Testing_

i. Tensile testing. - Tensile tests on hot5 longitudinal

and transverse grain orientation MFB mini-bar test specimens

(refer to Figure ll) of DS MAR-M 247 were conducted at various

- tempe'ratures from room temperature to 1144"K (1600°F). Results of

these tests are presented in tabulated form in Table XXXV, and in

7 _ graphical form in Figures 31 and 32. As anticipated, the trans-

[ verse strengths were lower than the longitudinal, although all

strengths and ductilities were adequate _or final blade design.

103
_" I_, _ .:_ l 1 _ , _, _!_1'_'_, ,-
 R n

_ I07
 ¥

_J _m , u
TASLE XXXV. TASK 111 TEN_ZLE TEST RESULTS ON DS MAR-M 247 TUREIINE BLADES

flea] treatment: 1505°K (2250°F) for 2 hours, pluq

1255"K (1800"F) fOC 5 hours, plus
1144°K (1600°P) £or 20 hours

(Test specimens machined _z_m exothermlcally D8 _relLminaty design ?PE731-3

tu_bLns bladoe,)

UltL_at¢ 0.2-percent
a tensile yield Re_u_tlon
Spoclm_n Grain _emporaturo, strength: strength, Elongations in aIeu,
i;o. 2_rlentation _°K (oF) ------NPa(ksi) IIPa (ksl) ..L- perce_t percent
I_8-8 L Room 1100 (1601 885 (128) 5.9 12.5
Te_peratuEQ

148-8 L 1052 (153) 928 (135) 6.5 13.8

_59-9 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 811(1000)
! 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 922 (1200) i014 (147) 873 (127) ?.5 12.5

148-14 L I 1135 (165) 968 (140) 6.2 10.9

'159-10 L '" ...... _..L137 (165) 927 (134) 4.2 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 L (1400) 1103 (160) 931 -_%_5) 5.0 12.%

148-_ L 1185 (172) _86 (143) " . 4.4 14.0
159-13
148°14T L
T }033 '1209
910 (175)
(13_._ 992
818 (144)
(i19) 5,_
6.8 14.9
15.7
138-IOT T 89F (130) 828 (120) 4.4 10.9
148-5T I 965 (140) 841 (122) ?.8 14._
159-13T T 940 (136) 833 (121) 5.7 11.1
13b_ L 1144 (1600) 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) ,6_ (II0)
-.1 3.4 10.9
148-2T T [ 839 _ 745 (108) 7.3 14.4

a L = LongitudinaZ
T - T_anever_e

108
 , ,2,,
_.. 1103 (1601

=Z 965 (1401

827 11201 • AVG. - 30 /

I I I I I | I

--: 366 477 589 700 811 922 1033 1144

(2001 14001 16001 18001 110001 112001 114001 11600)
TEMPERATURE, OK (OF)

;' ";241 11801 / " A, ]J.LTIMATE

TENSILESTRENGTH
--_ 1103 1160; "i
r-. Y_

_. 96-3.11401

027112o)_: -

--- - 30 ,, ,, I
366 477 589 700 811 922 1033 1144
12001 14001 16001 18001 110001 112001 11400) 116001-
" TEMPERATURE, °K (OF)
_;_:'-. B, 0.2-PERCENT YIELD STRENGTI-!
_--_--
' .=
m- ""-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 31, Tensi.1_--.,Properti¢:s Versus Temperature. of Lon_-_.tudinal
_ Specimens Machined from Task ITI. MAR-M 247
= .... -_ E:,Jothermically Cast DS Preliminary Design TFE731-.3
Turbine Blades (Sheet 1 oF. 2)

109
 q

'¥

15.0 .....

z ..-------_----. %EL (A

s _
AVG.- 3
0 ...... I I '1'
366 477 589 71_0 dll 9122 10_3 11'44 :
(200) (400) (600) (800) (1000) (1200) (1400) (1600)
_:- TEMPERATURE, OK tOF)
C. ELONGATION t

<_'<'15.0- _-,, ._AVG.)/_,_._

_z lO.O

O
gJ 5.0 AVG.- 3o

/e- ....
: 0 I I i I I I I I
366 477 889 700 811 922 1033 1144
(200) (400) (600) (800) (1000) (1200) (1400) (1600)
, TEMPI_RATURE, OK (OF)
D. REDUCTION OF AREA

<

_igure 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)

i 110
 160,0 ---'

140.0 UTS (AVG.)

12o.o
i

100,0 VG. - 30

80,0
! I '1 I I " I I
- 366 477 589 700 811 922 1033 1144
(200) (400) (600) (800) (1000) (1200) (1400) (1600)
TEMPERATURE, OK (OF)
A. ULTIMATE TENSILE STRENGTH

80.0
366 477 589 700 811 922 1033 1144
(200) (400) (600) (800) (1000) (1200) (1400) (1600)
TEMPERATURE, OK (°1_)
B. 0.2-PERCENT YIELD STRENGTH
NOTE: 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

Figure 32, 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

- ......... nnc o0002TSC

I_m=--,---- "
 i ,_
i

.....
: 15.0 "1 .... %

" 10.0 1 %EL IAVG.) _ )t

0
366 477 589
. 12001 . (4001 16001 (8001 110001 112001 114001 11600)
TEMPERATURE, OK l°F)
C. ELONGATION

•. 20.0 -I ""

-_ _ _RA1AVG.1

•, ._:__
15.o
10.0

°
'" 5.0 AVG.- ,
o

- 0 I ' I' i t I I l I
386 477 589 700 811 022 1033 1144
.... . :.._ 12001 (4001 16001 18001 110001 112001 114001 116001
i ': TEMPERATURE, OK (OF) ......
D. REDUCTION OF AREA

: Figure 32. 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)
112
i _; •' , _ ,,i_;

,_._" 0_635-cm (0.250-inch}

Additional _ensilediameter
testing test
on specimens
DS MAR-M machined
2_7 from separ-
was conducted on _
1 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 the SCTB specimen _esults exhibited 40- to 100-percent higher

I ductility, probably as a result of specimen geometry.

i_ Tensile test results of MFB mini-bar specimens and SCTB

specimens of DS NASA-TRW-R and MAR-M 200+Hf are tabulated in
. Tables XXXVII and XXXVI£1.--The strength and ductility patterns
for these alloys are similaD •to those-observed on MA_t-M 247.

2. Stress-rupture testing. - Stress-rupture testing was con-

[ : ducted at temperatures between i033°K (i400°P) and 1311°K
-- (1900°F) on MFB mini-bars with transverse a:,u longitudinal grain
orientations. Primary test emphasis was placed on MAR-M 247, the
strongest of the three alloys. Stress-rupture properties o£
NASA-TRW-R were characterized at- three temperatures, while the
MAR-M 200+Hf alloy was tested only at two temperatures. The results
of these tests are shown• in tabulated form in Tables XXXIX and XL.
As expected, the rupture-strength rankings were, in descending

TRW-R. The strengths of all three alloys were adequate for the final
Ii order of demonstrated st.reng_h--MAR-M 247, MAR-M 200+Hf, and NASA-
design turbine blades.

One of the major original goals of this Project was to obtain

' enough improvement in stress-rupture strength _)f DS MAP.-M 247 (or

"" another DS alloy) ove_. equiaxed IN100, to permit the replacem<nt
of the current cooled IN100 high-pressure turbine blades in the
TFE731-3 Engine with solid unreeled DS blades. Figure 33 preselts
data showing that this goal was achieved. The solid lines on
: this graph compare the average rupture strengths from mini-b,r
: test specimens of equiaxed IN100 (AiResearch data) and DS MAR-:.I
247 f_om Tasks I and II o£ this contract. The solid circles are

_: 113
 v.

TABLE XXXVII. TASK llI TENSILE TEST RESULTS ON SEPARATELY CAST TEST B_HS OF DS NASA-TRW-H
__ Heat tceatment_ 1505aH (2250°F) for 2 hours wi_h argon quenching, plus
12554K [1800°F) for 5 boues w_th &It cooling, plus
_i_ I144°K (1600°F] foe 20 houes with air conl[ng

SJltlmate Q.2-percent
tensile yieJd Reduction
Specimen Grai_ Temper_turej strength_ strength, E_onga_io_, in area,
NO. orlentatlo_ °K C-F) MPa (ksi) MPa (ksi) percent p_rcen_
Speci_%ens machlne4 fr0m initial design TFE731-I turbine blades

160-5 L RT INII (147i q_0 f138_ 7.2 9_8

174-3 L I 1016 (1472 927 f135) 6.9 9.5

168-5T
174-3T T
T I 858
837 [124)
[121} 839
832 [1_2]
(_2_) 4.0
3.2 8.6
?.2
168-6 5 i0_3 (14002 1028 (149) 867 [1282 13.4 24.1
174-4 L 1198 (I742 ]000 f145) 10.9 20.8

__ - 168-6T T 847 (1232 819 (I]9) 4.3 8.7

174-4T T 838 (|22_ 783 [I]42 3.7 ll.l
168-7 L 1144 (16002 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

Specimens machined from separately cast test bars

? 1117 L RT 1043 (151) 847 (123] 13.9 17,8

- 1144 L 1230 (1632 887 (129) If.? 13.2

_i 1174 L I101 (160) 874 (127) , _3.7 19.2

1118 L 1033 _J400) 1134 (165) 908 (1322 _ 12.1 24.2

1145 L _ I108 [1682 905 (1312 ] II._ _1,_

• " 1175
i146 L
5 1144 }
_16002 969
957 (14!)
(1392 721
710 (I05)
(I03| i 16,7
19.5 24.2
24.4

a L " Longitudinal
• T " TE altsv_rse

I15
 TABLE "': ;VIIi. 1lear TASK 111 "F_NRILE
treatment= TE_q 12250°F1
1%05°K _ESU[.T_ ON SEPARAI'_I.Y
for 2 houzs with CAST _EST auenchinq,
arqo,_ PARF _F D_r.l*,F
HA_-M _0t?41-f
1255°K (1800_P) for 5 h_ur_ wi_h _lr on.liner nl_*_

i _" I]44°K 11600°F1 fo_ 28 hour!; with a;r conlinq.

U1tim3_o 0.2-percent
• , R tensile yiel;l Reduction
Elon_aLion, in .tg..,le
Specimen (._axn "l'eN)e rl_l.lure
1 _ t_enqth strength,
_"" NO. Orientation HPa (kSi} ,t'a (k_') , perc,,_ |,_rceltt

i Specimens _achlned f_om 1_;itlal des£gn TVE?31-3 turbine blades

t:: 167-1 L R_ 912 ,1_21 84_ (122) 5.2 10.2

167-1T T 804 11171 789 t1141 2.8 7.0

! 186-4T
106-8 .r
L _ 760
971 (110}
11411 751
854 _18q)
(1241 4.6
6.1 6.8
10.-G
167-2 h 1033 (14001 1211 11761 1040 _15!1 4.3 12.5
!_ 186-7 L 1105 11601 I02_ 11491 4.4 17.9

167-2T T 04 I) (1_?) 76] 11101 3.4 6.8

186-7T T 841 (1221 747 (108) 3.4 7.6
_" 167-4 ]. 1144 (16C01 9_5 11_11 77_ (1131 10.2 I?.2

186-8 n 927 (1351 7%6 (1101 6,4 12.5

167-4T T
_i:: 812 (1181 718 (_04) ?.2 9.?
186-8T T. RS_ (124) 754 f1091 2.R 5.4

Specim_ _c._in_d [roin _r_tely Ca_t telt _r_

R25 b RT LlS? (1721 871 _12_1 11.2 1!.5

• R52
1181
L
L
1 1098
!088
(1591
11581
836
851
_1211
(1241
9.2
9.9
10._
11,8

l _; R82
R54 L
h 10l $ _
.(1400) _224
120"_ 1178)
1175) 973
985 11411
1143t 9.7
7.5 16.3
13.0

R26 L 1114 ._1600) qlo 11331 715 (_041 20.6 32,7

i: R83 _ _ _08 11321 716 ([U4_ 1_9 29.4

a L = Lo;,giLud;ndl

|:

i:: zz6

III
 TABLE XXXZX. TASR'I_I STRESS-RUPTURE TEST RESULTS ON MAP-M 247
TEST SPECIMENS

Heat treatment= 1505OK (2250=F) fo_ 2 hours wlth argon quenching, plus
....

_L'est specimens
1255°K
I144°K

maohined
(1800°F)
(1600°F)

from
for
for
5 hours• with slr cooling,
20 hours with air cooling

exothermically cast
plus

preliminary
I
desipn TFE731-3 turbine blades.)l Reduc- -
_pecimen Grain a Temperature, l Stress, Hours
to Elongation, oftion
area,
No. orientation °K (_F) I MPa (ksi) rupture percent percent ]
I m

140-9 L 1033 (1400) 724 (105) 309.1 14.2 16.8 i

148-6 L 669 (97) 1259.9 16.6 20.9
159-15 L 641 (93) 555.7 8.9 16.3
140-9T T 669 (97) 0.5 1.9 5.0
159-15T T 655 (95) 4.9 4.3 8.5
148-9T T 641 (93) 8.0 1.1 1.6 i
138-18T T 621 (90) 1155.2 13.5 17.9 !
148-6T T I 621 (90) 331.3 4.0 8.7
138-2 L 1144 (1600) 434 (63) 184.0 18.7 26.2
140-Ii L 345 (50) 774.3 20.7 37.0
].48-1 L 317 (46) 1270.0 30.8 41.4
140-11T T 448 (65) 104.1 6.4 10.9
i,_8-IT T 434 (63) 136.3 9.3 10.9
138-2T T 414 (60) 225.1 8.7 18.5
138-3 L 1200 (1700) 297 (43') 167.8 26.8 43.5
159-18 L | 255 (37) 320.0 27.9 48.0
: 138-3T T 276 (40) 169.3 8.8 11.7
159-18T T I 241 (35) 338.6 13.0 19.1 !
138-16 L 1255 (1800) 207 (30) 123.4 39.8 53.2
• 148-7 L 152 (22) 646.2 28.6 56.2
159-11 L 131 (19) 1678.3 25.2 48.2
14G-TT T 207 (30) 90.4 9.8 18.3
138-16T T 186 (27) 124.3 12.3 17.4 ,.
159-IIT T 1 172 (25) 227.4 8.7 13.8
_; 138-18 L 1311 (1900) 124 (18) 174,5 14.3 25.8
: 148-9 L 131]. (1900) 103 (15) 838.0 19.0 37.3

a L = Longltudlnal
T = Transverse

117
F :web

I_i

I'ADLE XL. TASK 111 STRESS-RUFTURE TL:ST RESULTS ON MAR--N 2006H£ AND
NASA-TRW-N
Heat troatmentl 1505°K (2250=F) Eor 2 hours with argon Quenching, plllS

. I144"_ (I_OOoP) for 20 houze with air cooling.

_! (Test specimens. maohined

1255_K Erol_ exotherm(cally
(1800°P) rot 5 *hours cast
_|th DS
air turbLne
cooling, blades)
plus
_|ou_a Reduction .
:_ _= 5pecime_ T_pe::_ture0 Stress, to EZongatlon, of aze_, !

__ : Nu,ber Grain orie,,tatio, a "K ('P) HPa (k,,)_upture ' percent percen,: t
- MAR-M 200+Hf
,.

168_8 L 1144 (1600) 434 (63) 171.7 15.3 28.7

168-8T T 414 (60) 168.1 6.7 10.2

_ .. 174-13_ T P 448 (65) 73.2 6.I 10.6

168-9 L 1255 (1800) 20_ (30) 103.1 23.1 38,0
_--_
i_ 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 I 18,<, (27) 128.5 4.3 6.6

NASA-TRW-R

16_-7 L 1033 (1400) _24 (I05) 85.0 6.2 14.9

186-8 L 641 (03) 455.9 10.8 19.0

r_

_ _ 167-7T T I 62[ (90) 0.i 2.6 5.0

_ 186-,, T P 5s6 (85) 811.0 +.5 12.4
_ _ 167-8 L 1144 (160U) 4;_ (63) 68.a 17.8 24.5
= . 186-11 L 317 (46, 619.3 29.6 35.0
16,-6_ , 4_4 <+0)63.6 6._ ,.,
_ ""
167-10 L 1255 (18001 207 (30) 50.5 18.5 39.4

I' 186-12

167-10T

186-12T

T _ Transverse
L

T
1-31

126

L72
(19)

(27)

(25)
832.8

65.?

|_=.9
22.0

3,?

7.8
51.q

5.6

t4.4

i a L • [_ongtt_dinal
 • TASK III DATA - 1144°K (1600°F) AND 1255°K (1800°F)

'_ 1000-HOUR LIFE AT INDICATED TEMPERATURE, TASK III DATA

... 483(70)
,_i 414(60). •

_,.... m 276(40) ,_
i.- IN-100 _ _/'/'- ,LbS B- 47
_ 20713.0)

, 138(20)_ DS MAR-M 247 __

1144°K 1
(1600°F) (1700OF) ._ 1255°K
(1800°F)

""
_, 69(lO,
40 42 44 46
41,1
48
,lit
50
462 54

_ LARSON-MILLER PARAMETER, P*
i
*P = T (20 + LOG t) x 10-3

!" WHERE:

Equiaxed
P = LARSON-MILLER PARAMETER
T = TEMPERATURE, °RANKINE
t = TEST TIME

IN100,
IN HOURS

0.178-cm (0.070-1nch) MFB 'lest

Specimens

i19
Figure 33. Average Stress-Rupttlre Strength of DS MAR-M 247 Versus

_i_" :

!,
 4

the _et_lol li44°K (160O°F} and 1255°K (1800°F} Task III data
polnt_. The h hJher strength leveln achieved in Task lIT are
attributed to the _ncreased solution temperature, 1505°K versus
1494°K (2250°F versus 2330°F}, use_ on the Task IIl eastir_s .......

Using the Task Ill MAR-M 247 rupture and uree_ test _ata, a
family _f _upture and creep curves were prepare@ b), reare_ion
analy._s using a least sauares Inethod. The curves were plotted as
average aDO minus three sigma curves. These curves _re presented
in Figures 34 through 37 for rupture, (0.5-, 1.0-, and 2.0-percent--
creep, respectively). These curves were utilized to validate the
final blade _esign life predictions. The acceptability point for
the DS MAR-M _47 specification is shown on Ficure 34.

3. Low-Cycle Fatigue Testina. - Load-controlled low-cvcle-

fatioue (LCF) tests were conducted at room temperature and at
1033°K (1400°F) on smooth and notch,0 test specimens machine@ from
separately cast test bars of the three DS cast alloys. LCF tests
were also conducted on smooth alumini@e-coated (RT-21) test sPeci-
mens of MAR-M 247. In adOition, LCF tests were performed on e_i-
axed IN100 at room te,_perature and at 1033°K (1400°F) to mrovi_e a
baseline for comparing the DS cast alloys with the esuiaxe_ mate-
rial currently being used for the TFE731-3 turbine bla_es.
Results of this testing are presented in Tables XLI throuqh XLIV.

Table XLV presents a comparison of the estimated maximum

stresses, for the several materials, that would produce LCF fail-
ures in 5,000 and 10,000 cycles, baseO on Task Ill data. _
advantage for any of the DS alloys is indicate@ at room temper-
ature. At 1033°K (1400°F) all three DS alloys show _reater LCF
strength than equiaxed IN100, with MAR-M 200+Hf, an_ MAR-M 247
superior to NASA-TRW-R. All three DS alloys showed notch-
strensthenlng at room temperature, add notch-weakening at 1033°w
(1400_F).

120

,+.

• 00000002-TSC14
 689(100) *

414(601 _G,
r,_

,P 276(40)
652(80) _AV ' k
3E AVG. - 30 " _k.

138(201

I
69(10) , , , I I"
37 30 4_ 4_ 46 47 ;9 6_ 6_
LARSON-MILLER PARAMETER, P = [T(OF.)_r460](20+Log t) x 10.3

Figure 34. Larson-Miller Stress-Rupture Curve for DS MAR-M 247,

Longitudinal Data, 0.178-cm (0.070-Inch) MFB Test
Specimens
68911001

4141601 AVG.

¢n AVG. - 3o _-
276(40)

cd
_,)
uJ
¢ 1381201

69(',0) , , , , , , ,
34 36 38 40 42 44 46 48 56
LARSON-MILLER PARAMETER, P = [T(°F)-N60](20+Log t) x 10-3

Figure 35. Larson-Miller 0.5-Percent Creep Curve for DS MAR-M 247,

Longitudinal Data, 0.178-cm (0.070-lnch) MPB Test
Specimens
121
 68811001 ......
5521801

414(6ol
] AvG.
_' 276(40)

AVG. - 30
138120)

69110) ', =r r *" , ,

35 37 39 _1 43 45 47 49 51
LAR$ON-MILLE_R PARAMETER, P = [T(°F)+460](20+Log t) x 10-3

Figure 36. 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
=- AVG..- 3(;

g 14(60) ./__.. ,,._,_ .

r, 138120)

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

--: Figure 37. Larson-Miller 2.0-Percent Creep Curve for DS MAR-M 247,
Longitudinal Data, 0.178-cm (0.070-Tnch) MFB Test
3pecimens
122
D L

--+W

TABI,R Xbl. LOW-CYCLE.-PATI_HE _E_T RESULTS ON DS MhR-M R47

Heat treatment: 1505°K (2250°P) for 2 hou_a_ plu_

1255"K (1800°P) for 5 hours, plus
I144_K (_600"F) for 20 hours
(Longitudinal grain orientation te_L =pecln.ena machined from se._aEate1_
cast tesk baEs)

Specimen
No. Te_;_oreJ
°K ('P) I
l _tPa
atress,
(ksl) Cyoles
failureto a I Remark_ .....

•+ " • (a) Uncoated smooth specimens [i

232 KT _36 (165) 620

_ 233
235 _I_ IL30
]104 (IbS)
(iG0)" 830
2,550
235 1103 (160) 2,780
231 1069 (155) 4.450
148 1034 (150) 5,300
._. 230 1034 (150) 6,580
I17 965 (140) 5,420
115 931 (135) 11,660
2 896 (130) 9,730
=::_ 1 896 (130) 12,930
I01 896 (130) 21,350

&-" 239 1033 (1400) 1138 (165) 690

243 1138 (165) 860
238 i138 (165) 1,810
106 1103 (160) 920
___ 104
4 1105
1034 (160)
(150) 2,180
3,020
3 1034 (150) 3,440
:_ 242 100O (145) I0,1_0
240 q65 (140) 7,730
237 965 (140) 9,080
236 _ 965 (140) 5,320
~ 24] _ 931 (135) 12+_30

_ (b) _+_-21 Cca_d smooth _pecimens

114 1033 1140_I 965 (1401 960

9 965+ (140) 1,410
"- 162
121
120
[
/
965
931
986
(140)
(I_5)
(130)
1,060
I,_90
2,690
-
149 896 (130) 2,800

+ 151 862 (125) 7,200

i_ - _ 1_8 l 827
8,2 (120)
(125) 31,590
24,830
m 122 827 (1_0) 29,240 Broke in threaded a_ea
• 10 J 896 _30) 6,310
i .

a Test parameters; Axial load control; sine wave form;

60 HZ f_equency; "A" ratio = 1,0

._ •

_. 123
K +' ,+t t
.,_

I
_ TABLE XLII. LOW-CYCLE-FATIGUE TEST RESULTS ON DS MAR-M 247

i; Heat treatment: 1505°K (2250°F) for-2 hours, plus

1255eK (1800°F) for 5 hoLJrs, Dlus
!_ i144°R (1600°F) for 20 hours
(Lo_uitu_Jn_l ¢iraln ozientatlon test specimens machined from
i separately cast test bars)

_+ Maximum Cycles a
[_ ',:._cimen Temperature, stress, to
Humber °K (oF) MPa (ksi) failure Remarks I
,i'i

Uncoated notched (Kt = 1.8) specimens

251 RT 1241 (180_ 1,630

I. 252 1241 (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

i 103 1034 (150) 6,550

247 965 (140) 10,400
248 I 965 (140) 13,660

7 1033 (1400) 1103 (160) 430

125 1103 (160) 920
107 1103 (160) -- Overloaded
132 1034 (150) 1,540

iL 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

259 I 758 (Ii0) 9,280

258 i 758 (II0) 16,500

a Test parameters; Axial load control; sine wave form;

! + 60 Hz frequency; "A" ratio = 1.0

_';- 124
 vI

TABLE XLIII. LOW-CYCLE-FATIGUE TEST RESULTS ON DS NASA-TRH-R

AND EOUIAXED INI00

(Longitudinal gra|n or|entatlo_ test speolmenB mschlnod from

separately cast test bars} _

Spocimen Te pera ure, stress, to a

MPa (ksi) failure Remarks
IIII
number_K(_F) MaximumlCyclea 1
NASA-TRW-R oncoated smooth specimens b

R1 RT 1138 (1651 140

R58 | 1103 (1601 230

R29 _000 (145} 4,140 l

R30 896 (130) 6,812

R2 1 1034 (1501 3,750
RS? ,, 827 (1201 , 15,O30
R31 1033 (1_00_ 1034 (1501 380

R59 | 966 (1401 1,520

R60 931 (1351 7,930

R3 896 (130) 13,600
R32
R4 I .. 965
827 (140}
(1201 2,460
.17,530

_SA-TRW-R uncoated no_hed (_ _.8) speclmensb

H61 RT 1172 (_701 1,270

R34 I 1138 (165] 1,920

R5 1034 (150) ?,010

R62 1000 (1451 9,440

R33 J 1103 (1601 3,340
R6 965 {1401 15f2_0
R64 1033 (1400) 1069 (1551 1,120

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 IN-100 uncoated Imo0th specimens o

13 RT 1069 (1551 1,700
I4 1034 (1501 5,970
I2 931 (1351 19,450

I1 931 (1351 20,340

I5 1.033 (1400 s 1069 (1551 160

_7 965 (1401 1,520

I6 896 (1301 4,440

18 327 (1201 7,850 I

a Test paldmetersz Axial load controll sine wave form;

60 Hz frequencys "A" ratio = _ N

b Heat treatmentl 1505°K (2250°F1 for 2 hours, plus

1255°K (1800OF1 for 5 hours, plus
1144°K (1600°F) for 20 hours,

c Ileat treatment_ 1255°K (1800°_1 for 5 hours, plus

1144°K (1600°F1 for 12 hours

125
iţ

! TABLE XLIV. LOW-CYCLE-FATIGUE TEST RESULTS ON DS MAR-M 200+Hf

i' lleat treatment, 1505"K (2250"F1 for 2 hours, plus

1255°K (1800°F) for 5 hours, plus
_= I144°K (1600°F) for 20 hours.

[Lon%Itudinal grain orlentat[on test specimens machlned from separately

is cast.t_at ba_s.)

" :_5_n Temperature, stress, to

_ OK (OF) MPa (ksi) failure a Remarks
.... t

(a_ Uncoated smooth specimens

rI
Mi_ RT I1½8 (165) 1.150
M20 1103 (160) ._,410
• . ..

M47 1069 (155) 3,010 "-

_-.. M48 1034 (150) 5,360 - . ..
= _"_- M77 I000 (145l 8,030
M76 965 (140l 14,290

M21 1033 400_ 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

[ L (b) Uncoated Notched (K : 1.8l specimens

M51 1207 (175} 4.190

M81 RT 1241 (180) 3,240

M24
M23 1172
1138 (170)
(165) 4.600
5,400

_1 M52 11o3 (16oI 7._6o

MS0 i0_9 (155) 10.730

i i M25 1033 (1400) 1103 (160) 1,570

i M54 1103 (160) 1,990

i i .53 11e_ 1160_ 3.15o

)._ M26 965 (140% 5,220
M82 896 (130% 11,240 Broke in threaded area.

_ ?" M83 89u (130% 27,110

a Test parantet('f_ Axial ]sad control) s_ne wave f_,:m;

60 Hz frequency; "A" ratio - 1.0

z_

k 2(_
127
 The I033°K (1400°F) LCF data on MAR-M 247 and iN100 is pre-
sented as least sgu_res'regression analysis curves in Figures 38 .
through 41. In all cases, the upper curve is the best fit of the
data, and the lower curve is the best fit minus three sigma. %+ +

4. High-cYcle fatigue testin@. - Axial-axlal high-cycle

fati[!ue load-controlled tests of test specimens machined in the
gr_ 'n-growth direction from separately cast test bars were per-
formeO on the three alloys, with results as presented in Tables
XLVI through L. MAR-M 247 tests were conducted on smooth _nd

notched (Kt = 3.0) test specimens at room temperature and at

I144°K (1600°F), and at "A" ratios of in£inity and 0.95. Testin_

of MAR-M 200+Hf was conducted on smooth and notched (Kt = 3.0)

test specimens at room temperature and l144°F (1600°F) at an "A"
ratio of infinity. Due to the elimination of NASA-TRW-R as a
program alloy in Task V, only room temperature tests on smooth
test specimens were conducted on this material.

A number of test specimens failed in the threaded area, par-

ticularly at room temperature. In an attempt to avoid this kina
of failure, _:evera] specimens were rem_chined to a minimum qaae
: diameter of 0.51 cm (0.20-inch) and silbjected to test. As can be
seen from the results included in Table XLIX. the attempted cor-
rective action did not succeed.

The room temperature and I144°K (]600°F) fatiaue strenaths of

both MAR-M 247 and MAR-M 200+Hf appear identical for smooth,
uncoated specimens. At I144°K (1600°F) both alloys are notch
weakened with MAR-M 200+Hf less affected than MAR-M 247.

The estimateO endurance limits for the specimens tested under

Tesk III are e yen{ in Table LI. The degree of unexpected scatter
in the test L'esults obtained precluded the ability to make a meat ++
ingful ._tatJst_cel analysis of the results obtain_c _.

128
 I

"" 1655(240 ""

BEST FIT OF _'
L-.... ACTUAL DATA
_ 137fl(200 -,
C-

11031160 -

IE 827(120) ................
_:; _ BEST FIT MINUS
r,_
ua THREE SIGMA., _

2761401 _ I _, !
100 1000 10,000 100,000
CYCLES TO FAILURE
Figure 38. 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)
: BEST FIT OF
I ACTUAL DATA

r"
8271120-
_
_, 552(80
1379(200 "'
• B

'" THREE SIGMA

276(40)

0 I, I,
100 1000 10,000 100,0O0
• CYCLES TO FAILURE
• Figure 39. 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) -
_ • /'-- BEST FIT OF
- 1379(200) DATA

_ 11o3,1oo)
-
Ii _ 927(12o)
-
552180) ' t

i!: 276(40) BEST

F,T
MINUS THREE
SIGMA _
0 ,,, I I
100 1000 10,000 100,000
CYCLES TO FAILURE

__ Figure 40. 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)[ BEST FIT OF

137912001I_ / ACTUAL DATA

1103(1601

..,. F
_ _' ,52(so,
BEST
THREEF,TM,"O___j"
SIGMA "
276(40)

0 I I
100 1000 10,000 100 )00
CYCLES TO FAILURE

Figure 41. 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]

130
 m

--_ _'^_ xLvI, llt_(-_yCLE-Ph?I_U8 TBS¢ RESULq'S

OHD5 HAR-H247
Heat treatnu_nts 1_056K (2250"P) for 2 bourse plus
L25$'K (SBO0*_) for 5 hours, ptul
31446K (30 JO'¥) for 20 houri

[0.64-_m (O.25-inQh) Lcet specim ,-_. machined from eaparatoly _a|t t0ut bara.]
Atc_rn_inq
atreIIe CyC1o_
con_£guratton MPa (kel) to £allu_o Remarks

183-1 Sn,OQth 8_ 689 (100) 5,000

182-1 689 (100) 6,000 !
102 621 (00) 16r000
116 621 (90) 25.000
100-1 552 (00) 233000
153-1 552 (80) 55,000
" 139 517 (75) 42,000 Broke in threaded area i
118 483 (?0) 211,000
1_4 414 (60) 006,000
- lS0 348 {302 _e2O6,OOO Broke In _hreaded area
132 b 734,000
140-1 smooth 1144 (1600: 483 (?02 22,000 Broke in threaded area
105 483 (70} 70,000
107-1 434 (60) 214,000
125 414 (60( 389,000
128 379 (55) 486 000
-- 140 345 (S0) 504,000
182 345 (50) 226_000
134 376 (40) 867,000
160 276 (40) feet termlfiated,
" 157 207 (30) 10,000,000+ Test term(hated,

109 Notched R_ 552 (80) 9,000

- 108 (X t w 3) 552 (00) 13,000

111 483 (70} 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
i !70 172 (25) 3,189,000
152 Test term£h_ted,
" 165 Notched- 1144 (16002 483 (70) 4,000

_04 (K t - 3) 483 (70) 3,000

t_ 414 (60) 4,000
= : 1_,. -414 (60) S,000

~.- 1_4 345 (SO) 10,000

"_ 376 345 (50) 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) 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_. HIGh-CYClE-FATIGUE TEST RESULTS ON RT-21 COA_D DS MAR-M 247

_ Huat treatnmnt: 1505oK (2250e¥1 for 2 bourse p1_s

1255"K {1SOd°F) for 5 hours, plus
i" ; I144°K (1600°F) fO¢ 20 hours

i "" 10.64-Cm 10.25-1noh) test sp.clmens maohined "from separately hast test bars.}

A1ternat_ng

_ " Specimen A a _KPera u_e stress, Cycles

• number Confiurntion Ratio ,, (_P) MPa. (keel to failure Remarks

DI ._ 131 Smooth - RT 483 (70) 47,000

:-_' 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 terminated

202 241 (35) 10,dO0,0004 Test terminated

_-- ' 17 Smooth 1144 11600) 414 (60) 32,000

179
I',- 379 (55) 125,000
_i 16 414 (60) 293.000 Broke _n threaded area

18 545 (50) 1,435,000

.... 175 345 (50) 645,000

168 276 140) 3,672,000 Broke in threaded area

_ii " 171

136 310 (4s)
276 (401 23s,oodTest
30,000,0004 terminated

:, 139 241 1351 10,000,000_ Te_t terminated

137 207 130) 10,000,0004 Test te¢lulnated

" S A Ratio = alternatln_ stress

mean steels

_-

_ '

_ 132
J TABLE XLVIII. XIGH-CYCLE-FATIGUE TEST RESULTS ON DS MAR-M 247

HQat treatment: 1505"K (2250°F) foe 2 hours, plus

1295°K (180d'F) for 5 hours,plus
I144_K (1600°F) foe 20 h_ura

(0.64-cm (0.25-1nob) test speolmons ma=htnQd from separately cast tQlt bars.]

a Alter_atln_

Specimen
H.mh._ Configu_atlon A
Ratio T_KPera
.= urB
(_F) MPa8tress,
(ksi) to Cycles
failur_ ... R_mark_

130-I b SmOoth 0.95 RT 684 (100) 121,000

i i 154
129-1 b 689
621 (i00)
(80) 176,000
3?8,000

_-_ 133 b 621 (90) 438,000

128-I b ; 552 (00) 1,210,000
552 (80) 6e087,000 Broke in threaded area
110 b ;
126-1 b 483 (70) 1,566,000

129 b 483 (70) 2,884,000 I

128 b 448 (65) !0,000,000+;rest terminated
155 b 448 (65) i0,000,000 terminated
414 (60) I0,000,000+ Test terminated
- 126 b
156 b q 414 (60) ]0,000,000+ Test terminated

• 159-1 _aooth 0.95 1144 (16001 621 (901 71,000

187 586 (55) 646,000

186 512 [75) 10,000,000+

141 483 (70) 3,741,000
i l I08
104 552
483 (80)
(70) i0,000,000+
446,C00 Test terminated

i " 161 448 (65) 245,000

169 414 (60) 10,000,000+ Test terminated

• 166
142 414
448 (65)
(60) 10,000,000
8,319,000
144 i 377 (55) i0,000,000+ Te_t terminated
143 I- _ 345 (50) 446,000

a R Rat_o = alternati_ stre_s

b T_st speelmen remachlned to 0.508-am (0.200-Lnch) game dLamete_

133
 134

.+
 %,

TABLE LI. ESTIMATED ENDURANCE LIMITS OF DS TEST !

SPECiMEnS MACHINED FROM SEPARATELY CAST "_
TEST BARS

Estimated _
endurance limit
J

at 10 7 Cycles,
Temperature, Notched Coated
_i_.oy °K (oF) specimen specimen MPa (ksi)

R_sults at A = _

MAR-M 247 Room No No 310 (45)

IMAR_M 247 Room Yes No _ 138 (20)

i"

MAR-M 247 Room No _ Yes 241 (35)

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 at A = 0.q5

MAR-M 247 Room- No No 462 (67)

MAR-M 247 i144 (1600) No No 379 (55)

136
 ._mh

d,
J

:h

5. Phys_ical properties. Tests were conducted by Southern

Research Institute on.the thermal expansion and conductivity of
MAR-M 247 and NASA-TRW-R alloys in the fully heat-treated condi- k
_ _
!•[_
tion. Tests were made in triplicate and the thermal properties of
i_ the two alloys were virtually identical. The thermal expansion
i__- curves are presented in Figure 42 and the thermal conductivity
i curves in Figure 43.

i " Static modulus of elasticity was determined from the Task III
_ tensile test data. The static moduli are presented in Table LII
and compared to the dynamic moduli determined by Southern Research
" Institute in Task II on the same DS alloys. Results of the two
-__ methods of measurement generally agree at room temperature, but not
_ at elevated temperatures.
i

i_; ' 6. Oxidation and hot-corrosion testin 9. - Oxidation and hot-

i corrosion tests were conducted in an AiResearch test rig on sam-
:T-
!_t ples of coated and uncoated DS alloys.

!L
.... The test rig design is described in the following paragraphs,
i=_,. and is shown schematically in Figure 44 and in the photos of

i_- _ Figure 45. The burner rig is a version of an oxidation/hot-

_ corrosion burne_ rig that has been used extensively in industry to

Z, study hot corrosion of superalloys and coatings. The AiResearch

i' _ burner rig has the following features:

_<- o Automatic-temperature measurement and control with an

i - Ircon radiation pyrometer system" that can control tem-
perature either by fuel flow or airflow to within _I0°F.

o Automatic
points, in burner
addition cycling between
to controlled two temperature
automatic cycling set
to
room temperature by airblast.

" 137
 20

" i 15

' _ " 55
i
o_ oo1

!
i

367 478 589 700 811 922 1035 1144 1255

(200) (400) (600) (800) (1000) (1200) (i400) (1600) (1800)

TEMPERATURE, oK (OF)

i' b, NASA-TRW-R
[ Figure 42. Thermal Expansion of Exothermlc_lly Cast DS MAR-M 247
and NASA-TRW-R

_ r 138

!
r

LL ....... • - ._ .
 k

1A0(250) '"

1.12(200)

_0.56(100)
o.84115o)
_0.281501 -

_ 0 ' ''
0 , 0%120001
1366

_ 1.401250)

_ 1.1212001

>--0.84(1501

_ 0.6611001 '
-I

0.28150)
u,.I
"r'
I-
0 I I I I I I | I I
367 478 589 700 811 822 1033 1144 1256 1306
(200) (400) (600) 18001 11000) 112001 114001 116001 118001 120001
TEMPERATURE, OK (OF)

b. NASA-TRW-R
Figure 43. Thermal Conductivity E,_othermlcally Cast DS MAR-M 247
and NASA- TRW-R

- 139
 q

,,. USED FOR CYCLING BURNER AND

_" SEA SALT | AIR_UENCH NOZZLE .... I
I I '
F

ACTUATOR CONTROL I

' AIR- f SPECIMEN

ROTATION

'_ NOZZLE
IGNITION QUENCH ! _ MOTOR

IGNITER -_ if" SLIP RING

! AIR
SUPPLy :o :
ir _ SPECIMENS
FUEL

fr RADIATION
OVERTEM- PYROMETER ..............................
PERATURE
SHUTC SHUTOFF [_
!i ILTER CONTROL

-'_ CONTROLLER-
RECORDER
FUEL FLOW
CONTROL VALVE

f: TOTAL TEMP. TEMP.

•: TIME
TEST TIME
ONE TIME
TWO
t
Pig_re 44, Sohematic of AiResearch Oxidation
Hot-Corrosion Burner Rig
141
 TEST FACILITY CONTROLS ....................

OXIDATION/HOT-CORROSION BURNER RIG

-_. Figure 45. Oxidation/Hot-Corrosion Burner Rig

• 142
_-+ o Controlled addition of aqueous sea salt solutions, sul-
_ fur, or any other desired contaminant to the burner
._r flame.

o Sophisticated control system to allow continuous,+

unattended cyclic testing with automatic shutoff if
undesirable conditions develop during a test.

o Sample holders that normally hold eight test samples and

can be rotated at up to 2000 rpm to ensure that all sam-
ples are exposed to the same_hurner._conditions.

+- The oxidation/hot-corrosion burner rig test conditions and

test results are presented in Tables LIII and LIV. No significant
" degradation was observed on the coated MAR-M 247 samples after 510-
hours oxidation at 1311°K (1900°F) as shown in Table LIII. How-
ever, the uncoated MAR-M 247 sample was heavily attacked by hot
corrosion after 310 hours at 1200°K (1700°F) as shown in Table
LIV. Of the three coated alloys exposed in the same 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 alloys as shown in Figure 46 ....................................................

_--_. 7. Metallo_raphic examination. - With the assistance of

i .... Micro-Met
examination Laboratories
was performed of onLafayette,
three Indiana,
high-rupture-timemetallographic
MAR-M 247
stress-rupture specimens. The basic stress-rupture test history
(refer to Table XXXIX) was as shown in Table LV:

143

+
T
 L

D- ,I

BARE RT-21 COATED ALLOYS_ t

__ ;_ MAR-M247 MAR.,M247 MAR-M NASA-

200+Hf TRW-R
..

_ / FigUre 46. Exposure

Task III, atHot-Corrosion
1200°K (1700°F) to 5 ppm
Specimens Synthetic
after 310-HoursSea

Fuel
l_-i Salt Added to the Combustion Products of Jet-A

i "'" 146

"
k,r TABLE----LV' BASIC STRESS--RDPTDRE TEST HISTORY

i Specimen Test temperature, Stress, Rupture time _i

_ number OK (°F 1 MPa (ksi) hours

_: 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

, [

: Initial examination by AiResearch established that an

acicular phase formed during stress-rupture testing at 1255°K
(1800_F) as shown in Figure 47. The section examined was near the
fracture in the gauge length of test specimen 159-11. Examination
of another section in the thread area of the test specimen showed
the same acicular structure, suggesting that thermal exposure
! rather than stress, was the primary driving force in the formation
o£ this acicular phase. Stressed exposure of specimen 148-1 at
[i I144°K (1600°F) did not produce the acicular structure as indi-

)
cated by Figure 48.

extensive metallographlc work performed by Micro-Met Labor-

atories. These results confirmed the acioular phase formed at
ii 1255°KFigures 49 and
(1800°F), and identified
50 illustrate
it as some of the results
the M6Ccarbide phase. of This
the
evaluation included a second 1255°K (1800"F) stress-_upture speci-
men (148-7, 646.2-hours rupture time) from a different mold but of
the same heat as specimen 159-1. Both bars were further exposed
to a condition o£ 1283°K (1850°F) such that the total combined -
exposure time at 1255°K (1800°F) and 1283°K (1850°F) was approxi-
mately 1600 hours.

The general structure and the morphology of the acicular

phase is very similar in both 1255°K (1800°F) specimens, as shown
in Figure 49. In contrast, Figure 50 shows the structure of

147

m,
 (MAG.: 500X)

Figure 47. Microstructures of DS MAR-M 247 StresR-Rupture

Specimen No. 159-11 Tested at 1255°K/131 MPa
(1800°F/19 ksi) for 1678.3 Hours. Note Needles
of Acicular Phase

148
L V

(MAG.: IOOX)

Figure 48. Mierostructure of DS MAR-M 247 Stress-Rupture Test

Specimen No. 148-i Tested at ).144°K/317 MPa
(1600°F/46 ksl) .Jr 1270 Hours. The Acicular Phase
F_,rmed at 1255c_ (1800°F) is Absent

149

=,. . •
 t_

(MAG.: lO00X)

__ ,

(MAX.: IO00X)

Figure 49. 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
150 Specimens. Metallography by Micro-Met Laboratories_
Tnc.
.- (MAG.: i000X)

Figure 50, 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. No acicular phase was evident at either magnification \
(1000X or 3000X).
k

! _ Probable identification of the occurance of the acicular

I i, phase after stress and temperature exposure of 1255°K (1800°F) was

_c accomplishe_ by extraction and identification of second phases
i _" fro;_ the matrix of a new,DS MAR-M 247 blade (158-14) expose_ to
1283°K (1850°F) for I000 hours. The higher temperature was
i . selected to accelerate the kinetics of the plate formation. The
upper photo on Figure 51 depicts the acieular phase formed. The
lower photo depicts the-second phases in this bla_e after chemical
, - extraction from the matrix. The platelets- present in the

extracted residue were positively identified as M6C. In fully

heat-treated MAR-M 247, M6C forms with time at about 1255°K
(1800°F) from the script carbides oriainally present in the as-
cast and heat-treated structure. This structural chanae has no

adverse effect on either strength or _uctilitv, as evidenced by the

1255°K (1800°F) long-time stress-rupture tests on MAR-M 247.
The_e results were completely consistent _:ith Larson-Miller para-
metric llfe predictions made from shorter time test data.

152

!'
 (MAG.: 2000X)

(MAG.: 3000X)

FiguEe 51. 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
". q

• TASK IV - BLADE DESIGN 4

Scope k

Task IV _ncluded the design activity requiredfor the devel- J

. o2ment of a solid, uncooled, exothermically cast, DS high- :

pressure turbine blade for the TFE731-3 turbofan e_.gine. This

task was performed concurrently with Tasks I, If, and III. Two

blade designs were established in Task IV--the preliminary _"

(initial) design and the final design.

The preliminary design was established early in the program

• to provide a blade casting design suitable for use in the

development of the exothermic DS casting process and associated

material evaluations of Tasks I, II, and III. This design was

- based on preliminary MAR-M 247 data collected early in the pro-

.- gram.

Actual material properties and other data obtained from pre-

!iminary design blades cast in each of the four alloys during the

_ _-- performance of Tasks I, If, and III were used in establishing the
final blade design. The geometry of this design made it neces-
sary to modify the turbine disk, nozzle, and other turbine com-

ponents of the TFE731-3 Engine to permit effective integration of

_ the blade into the engine assembly. The redesign of these tur-

L b ine components was accomplished in Task IV.

154
i [-
 i

"i

E,

q
_,, Preliminary Design - High-Pressure TurBine (HPT) Blade

_ Aerodynam/c design - preliminary design blade. The prelimi- _i

nar_ blade design using only MAR-M-247 material properties was
_: established for design and casting purpgses while a comprehensive

i effort was in progress on the final airfoi_ design. Details of

i
ii the aerodynamic design of-the selected preliminary blade airfoil
_; are shown in _ables LVI through LVIII and Figures 52 through 59,

i " !
i, Vector diagram, _he flow path-used for the preliminary
':: blade design was the same as the existing TFE731 Engine with the

i!" vector diagram (see Figure 52 for nomenclature) defined as

follows:

(a) The radial distribution of the stator exit angle, =I'

_ and the rotor relative exit angle, _2t are shown in

Tables LVI and LVII and in Figure 52. In this blade,

_i increases while _2 decreases from hub-to-tip. This

i results in a higher hub reaction but lower twist, which

' is favorable from the viewpoint of stress and _ibra-

_ tion. (Twist is defined as the difference in stagger

angle between the tip and the hub).

(b) The vector diagram yields essentially the same pressure

ratio and corrected mass flow as.that o_..the _tandar_ ..

:: engine. The distribution of the relative critical Math

numbers, flow angles at the rotor inlet and exit, and

reaction are shown in Figure 54.

2. Blade qeometry, This blade design is generated from two

design sections, one at the hub [R = 10.77 cm (4.24 inches)] and

one at the tip [R = 14.16 cm (5.57 inches)], with a linear rela-

tionship in between. The geometry data defining the blade sec-

tions is presented in Table LVIZI.

_ 155
 L ,"i
_

V
J
ii

TABLE LVI. STATOR EXIT FLOW ANGLE DISTRIBUTION - TASK IV

PRELIMINARY DESIGN BLADF,

Radius_ R - Stator exit flow angle, _I'

cm (in.) deg.

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 FLOW ANGLE DISTRIBUTION

TASK IV PRELIMINARY DESIGN BLADE.
i

Radius, R I Rotor exit relative flow angle, _2'

cm (inll
= ] ,- 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

156

[
i:, WHERE,: STATION 1 IS STATOR V = ABSOLUTE VELOCITY
EXIT PLANE
W = RELATIVE VELOCITY

STATION 2 IS ROTQR U = BLADE VELOCITY

EXIT PLANE

U1 U2 __

Figure 52. Vector Diagram Nomenclature

158
-. 159
 R = 10.80 CM (4.24 IN.)

R = 14.16 CM (5.57 IN.)

Figure 57. Rotor Stack at CG, Plane Sections

162
 L;.

I': A 2_

1'5 F

: Figure 58. Area Distribution of the Rotor Blade

12C

: _i.
_ io(

Z
Z

_W 2c
Ig

I I I I
0 20 40 60 80 100
PERCENT AXIAL CHORD

Figure 59. Loading of the Rotor Hub

163
 Tile blade geometry of the hub and tip is shown in Figure 55 1
and 56, respectively. Figure 57 shows the stack with the blaoe _i
cente_of gravity as the stacking axis illustrating the low-t_i_t _
(14 degrees, 17 minutes) feature q£ this design. _k

A high camber with a large trailing-edge wedge angle helps

avoid blade vibration problems, especiallz in the tip region.
The 2reliminaty design blade had a camber of 92 degrees, and a
half-wedge angle of 6 degrees at the tip ......
The tip section of the f
preliminary design blade w.%s_ relatively thick [Tmax = 0.28 cm
(0.ii inch)], yielding an area ratio of 2.5:l_-tip. The
area distribution is shown in Figure 58.

3. Blade loading. The calculated loading of the two design

sections of the preliminary design blade are shown in Figures 59
and 60.

The hub section has a degree of reaction of 13.2 percent.

At this value it is inevitable that some deceleration will occur

in the rear portion of the suction_surface, beginning at an axial

chord position of 37.5 percent. The corresponding velocity ratio

for this deceleration process is 1.23, and the pressure ratio is !

1.19. For the tip section, where the reaction is relatively
high, it is possible to design a suction surface with continuous
acceleration.

None of the sections exhibit a supersonic region. The maxi-

mum values of the surface critical Mach number is 0.91 for the
hub and 0.81 for the tip. Therefore, the high trailing-edge
wedge angle will not cause the loading to deteriorate, as shown
in Figures 59 and 60.

164
T
 9*

: 165

L
 :r-

_" The trailing-edge blockage is 13 percent at the hub and 5.2

percent a_-_he tip, The huh values [12.2 percent at R - 10.77 cm

._ (4.24 inch)] is comparable to the ori@inal deslsn while the tip k

, i- value (8.5 percent) is lower than the original.

i : Stress and thermal analyses. With the area distribution of

; the blade as defined in Figure 58, the average centrifugal stress
,_=_ wa_; =alculated at the take-off condition for MAR-M 247. These

i " stresses are shown in Figure 61. Using the calculated stresses
! "-- and a_erage metal temperature of the uncoated blade as shown in

determined based on preliminary DS MAR-M 247 da%a as shown in

_i_ Figure 62, the stress-rupture life of the blade airfoil was
_ Figure 63. The calculated stress-rupture life is listed in
[

Table LIX.

_"
• TABLE LIX. CALCULATED STRESS-RUPTURE LIFE SHOWING
I_. CRITICAL SECTION AT TAKEOFF CONDITIONS
ii .... Normalized'-
: Calculated Stress-

'_ cm (inches) MPa (ksl) °K (°F_ Life

i! Radius, Stress, Temperature, Rupture
i_ 11.18 (4.40) 211.7 (30.7) 1193 (1688) 1.37

i 11.68 (4.60) a 189.6 (27.5) 1213 (1724) 1.00

'i 11.94
11.43 (4.70)
(4.50) 175.8
199.9 (25.5}
(29.0) 1215
1208 (1727)
(1714) 1.64
1.03
12.19 (4.80) 162.0 (23.5) 1215 (1727) 2.74

,,. a Critical Section

The calculated life for the critical section at take-off condi-

with reference to operation in the exp_cted environment of the

planned 150-hour cyclic engine test.

No effort was made in the preliminary design activity to

define a blade shank or platform.
tions was considered acceptable for the preliminary design blade

i[ : 166
 d

27_(4G

207(3_

13812(

0
HUB RADIUS TIP

Figure 61. Average Centrifugal Stress --

Preliminary MATE HPT Blade
Design

1255
¢" (tSOO) "-

(l?oo)

116001

_B55
(15oo) "
HUB RADIUS TIP

Figure 62. Metal Temperature -- Preliminary

MATE HPT Blade Design

167
 , ±,l

B ',¸¸ , '_

km _

_ 621190).

552(80) %

483(70) -

,i 414160)

3451503 'i
r_ L"

276(40)

" _
- . _ 2071301

7"

_ Ji"
. < .-

_ 1381201

691101
-- 42 44 46 48 50 52 54

LARSON-MILLER PARAMETEfi (C---201

Figure 63. Preliminary Stresr,-Ruptu_e Data, Di_.cctJoi;_]]y-

f;¢_]
idifJed MAR-M 247

; . I£S
 Final Design - High-Pressure Turbine Blade

•he final design of the uncooled exothermically cast

i directlonally-solidified high-pressure turbine blade for the k

_i TFE731-3 utilized the material properties of DS MAR-M 247 as 1
determined in Task III. This material was selected based on the

test results obtained in this project, plus excellent potential for

2 future hlgh-temperature applications_ in the gas turbLne industry.

As in all turbine blade designs, the final design was the result _7
il_ of m_ny interactions and tradeoffs between aerodynamics, metal

Only the final results of these analyses are presented herein.

!_!i-
_ I temperatures, stresses_ vibrations and other considerations.

_ _ Aerodynamic desiQn - final d_sign blade. Details of the

aerodynamics of the final design blade are presented i[[__Table_LX
and Figures 64 through 77.

__ i. Vector Diagram. A different vector diagram is required

for the final design blade even though the flow path is the same
as the original TFE731 high-pressure turbine.

Figures 64 through 67.present characteristic data of the

h mixed-out vector diagrams. Figure 64 shows the absolute critical
I .

Mach numbers and the flow angles at the stator inlet and exit.

i Figure 65 shows the relative critical Mach numbers and the

relative flow angles at the rotor inlet and exit, while Figure 66
shows the rotor reaction. The low twist diagram yields a high
hub reaction (14.3 percent), while the tip reaction is slightly
_ lower than previous designs. This reaction results in a higher
total relative temperature, T", in the hub region. T", non-
_ dimensionalized by the absolute total temperature at the turbine
inlet versus the radlus, is shown in Figure 67.

i 169
1-'/0
 JO,,
J
V
A UaBINNN HOVIN "IV-'_I.LLUO

P o o o o o
I t l I 0

\ _
°
"_

- \
1 "
_
ul

\ 1 o _i
\ °

I,- ",I_\ g_

'_°
i H ii, _

(8=J=IUD3O) t_ ':I'IONV MOq=I

171
 .. •i

ip

40
_,,. ,,V/M 1::t::ISIAINN
H3VlAI "IVDIJ.lUO -=IAI.LV3=IU
O 0 0

I I..... I I ,.l ®
_, \

;: ,7

[-

g
&

8
I
o
I I,,, ! I ii •

1"/2

-
 B0,

R_AGTI_N " _2

_.. ! 20

lr

1 --

• "_ HUE RADIUS T '_"

Figure 66. Reaction 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 J
0.92 , ,

0.91
[i HUB TIP
RADIUS AT ROTOR INLET

i':_ Figure 67. Rotor Relative Total Temperature Nondimensionalized

by the Inlet Absolu.te Total Temperature Versus
Raaius
173
 ¥

=i, R - 10,9 CM (4,3 IN,)

: " _,_ 38.5

° _,

:__ 195M/SEC IV_ HUB

1651 FT/SEC) .._1_ _

:'- R = 1'0.8 CM 14,2 IN.)

10;20°- 151_ _i

./ ,_ _- I MEAN

"-
_ -- R 12.4 CM 14,9 IN,)
1,9°
.,._ ._.
57"80- f
__
243 M/SEC
74_/_?_.
"_'_;
0

R " 14,1 CM 15,5 IN.) ..o_,_15_ '_ 3.5°

- R = 14.2 CM 15.6 IN.) 1543. FT/SECI _4,O

-_!- 165
M,S_C
j ,_, ""
i- Figure 68. Velocity
@/
Triangles of the Final Design

7 _7,
i '

i
 0. 0.25(0.10) 0.5(0.20)
CM (IN.)

Figure 70. Rotor llub Section [R = 10.77 cm (4.242 in.)] of the

MATE Final Design

176
 I I •- I
0 0.25(@.10) 0.6(0.20)
,,= CM (IN.) ..........

i [ Fig_e 71. Rotor Mean Section' [R = 12.37 em (4.872 in.)]

of--the MATE Final Design
177
 k

0 0.25(0.10) 0.5(0.20)
CM (IN_)

[,: _igure 72_--Roto_ Tip Section [R_--_14..t6 cm (5.57 inches)] of the

MATE Final Design

178
 ¥

1,0
HUB TIP -
RADIUS

Fiqure 73. Final HPT Blade Area Distribution

179

I_
 _0

w !

p-

HUB RADIUS TIP

Figure 74. Trailing-Edge Blockages Versus Radius .!

+i

0,60

0.40

0.2O-

_J
= o J. I-. . , I I ,.,
2O--- 40 W $0 _0
PERCENTAXtAI. CHORD

Figure 75 ......
Rotor Hub SecEion-Loading [R = i0.77 cm
(4.24 inches) ] of the-F_inal Design

180

++
!r

.... _ _.o©
0_c
i :"

!
i °- O2O

:? .T AX,AL
C.
Rotor 12.3
! Figure 76. Mean Seetion Loading
(4.87 inches)] of the Y_nal Design

t
i

,If /,
Figure,,. _ t_ _ip:i;;_;;L_F_ga t RDislg4 n 16 c'm
181

k- ........... _J ....
 I
¥

The velcckty triangles corx_sponding, to the_hub,, the--mean,

and_the--tip _t_eamlines are shown in-Figure 68. Low-twist aero-
dynamic design requires-little va_-iation of stagger--angles from k
hub to tip. To achieve this, the-radial variation-of both the

inlet and the exi_ blade angles, _l and _lmust be minimized. The
small radial variation of _I is obta/ned by-

(a) Increasing the stator exit flow angle at tip, and

reducing it at hub (E/sure 64.)" This ".,illyield a
highe_ relative inlet flow angle tO the rotor at the
tip, and decrease that at the hub._ This results in a
difference of only 15 degKees between hub and tip:
(Figure 65).

(b) Using negative incidence for_the tip portion: Negative

incidence will increase the inlet blade angle in the

tip region, resulting in a small variation of the inlet

blade angle.

The small radial variation of _2 is obtained by decreasing the

exit flow angle _2 at tip, and increasing it at hub, (Figure 65).

This design yields a work distribution as show_ in

Figure 6K. The cur_e shows the work distributions nondimen-
sionalized by th_ average value for the whole stage (Hm). The
work distribution provides nearly zero average exit swirl and
very low exit loss. For example, the mass-momentum avezaged
values_at_the__tu_hi_e_exit are_

Exit Swirl Angle m 1.81 degrees

Exit Absolute CDitical

Mach Number = 0.386

182

7
....... L............... L"=..... ,; - "
 2.- Blade-GeometrY, Three cylindrical des/gn sections are
/_° used-at the following radii to define this blade.'

Hub4-, R = 10.77, cm--(4_14-in.) k

Mear_: R = 12.38 cm (4.87 in.)-

Ti[>: R___ 14.16 cm (5.5-7 in.)

The inlet and exit conditions are- obtained- from the vector

-- diagram (see Figure 65)_,.......... '

The blade configuration is d/rected toward high camber_ low

twist= and. a. large trailing-edge wedge angle with. a .th_icker
trailing edge to avoid vibratory problems. However,_ a large
trailing-edge wedge angle and-a thick trailing edge can result in
a large efficiency _enalty, especially in_the transonic range.
Thez also tend to decrease the a_ea ratio if they result in a
larger ti_ area._-_The twist may e_entually be further decreased
by_mo_ing the tip nose down and the hub nose up, while maintain-
ing both the blade angles and 2_hroat width. The final blade
geometry was generated through a number of iterations to obtain
the best compromise between mechanical, thermal, and aerodynami_
requirements.

The blade geometry data fo_ these three design sections are
given in Table LX. The three design sections are- shown in
C- Eigu_-es--70,_71 and 72-- The_ area_distribution for plane sections
is shown-hn Figure 7L3 and the trailing-edge blockage is shown in__
"" Figur_ 74.

183
 T

The lean and tilt for this blade are__shown below:v

i Radiu_, Lean Rela_iue Tilt Relative %

cm (in.). _o CG [c_ (in,)] to CG. [cm (in.)] A

10.774 (_.242).........-_ (0) -0- (0).

12.375 [4_B7._) 0.0625"(0.0246) 0.0622. (0.0245):.....................
:_ 14.155 (5.573) -Q= ..................
(0] 0.1358 (0.0535)

:.... Pos.i.t_ue_learu is. tQward.the direction_of rotation. Positive tilt

: is.toward the trailing edge.

f- 3.- Roto_ Bl_de Loading.. Figures 75. through 7:7t_show the

critical Mach number versus axial distance for the three.design
_.7 sections. For the hub section where the reaction is only L4.3
/' percent, it is inevitable to have a deceleration in the rear por-
tion of the suction surface. This mild deoeleration_will not
cause separation of the boundary layer. The reaction of the mean
s_ction is high enough to achieve a continuous acceleration of
the suction surface. The suction surface of the tip section__has ...........

I _. a minor deceleration.

ii.
" The relative critical Mach number is subsonic everywhere.
Consequently, the high wedge angle and high turning as well as
_= the higher th/ckness at' the trailing edge ha_e no adverse effects
_7
on _he loading_ The. resulting high turning contributes to a
- hligher loading in the rear portion, resulting in a nearly con-

,i_ stant suction surface velocity near the trailing edge for the tip
section.

- The traillng-edge blockage ranges between _14.3 percent to

_ 4.4 percent from hub-to-tlp (Table LX and Figure 74).

184

. . J
 i
Thermal-.Analysis.- The metal temperatures of, an uncooled ....
, I
turbin_ blade are pzimarily_jdependent upon--the temperature of_-the k _,
gas s_ream re/ative, to the bla_e (TB)_,_ Conduction into the _i

blade/disk firtre_, rad_iation, and other fact_>r_ haw_only, m-inor "I

effects-on blade-metal temR@rature. The-nominal.-total _as s_rea_

: temperatures, (TGAsk, relative gas temperatures £TB), an& cozre- I

! spondingblade-metal, temperatures (TMETAI) are shownln Fisure-q-a. i

Details-of- the- thezmal fini_lement .model and temperatur_ ' !
!'I

resu_ts--ar.e_shown in Figures _ and 8G.. These-temperatures were

determined _considering limited cooling air_ supplied to°..the
blade/_isk_firtree_region. Reduced cooling air. and the forward
:_ seal plate- weze retained for the uncooled DS blade design
: because:

(a) A limited amount of cooling air is required for the

Waspaloy disk £irtrees

(b) Minimum hardware changes-were desired when adapting the

DS blades to the production TFE731-3 Engine for the i
required enginetesting

_ (c) The forward seal plate provides a limited amount of vibra-

tion damping for the HPT blade,__especially in the
lower, stronger vibratory modes

Stress analysis_ Pant of the design philosophy for the

final DS blade design was aimed at increasing the blade life at
the "critical section". Traditionally, this section is between
I/4 and-1/3--span where the combination of increasing blade-metal
temperature and decreasing centrifugal stress results in minimum
streSs-ruptt_re life. As shown by _he normalized _tress-rupture
life in F_gu_e 81, the blade c_itical-ssction occurs at i1.68 cm
(4.60 inches) radius.

185

............................................ , ............ _ ...... L "" _'/ .

i ' (40) >1o'auN.I,VU3dWa.I,

! 186

_.
: II
!

1
i

• I
I
I

Figure 79. Grid foe Thermal Model

187
i TEMPERATURE, °F.

Figure 80. Shank Model Final MATE Blade Design

188
 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.

wber-e_ CENT m _entrifugal stress at the-orltloal..sections

,, A = Cross section area of the critical sections i

1 ,1
! p = Den,Si-ty of blade material ......................
i
}

V = VOlume of blade material above critical_ sec- 1

tion 1

R = Radius to center of gravity of volume,.-.lV) _!

g = Gravitational constant.

= Rotational velocity of _he airfoil

To reduce the stress at this section two precepts were followed:

o Minimize-the area of..the blade, tip section--this tends I

to-reduce the load_.on_the critical_section_and there-
fore the stress

o Maximize the area of the critical-sectlon--this tends--

to reduce the stresses by increasing the area over

which the load is applied.

L90

L
 q

Using these-two ideas plus maintalaln_ areas at-a-minlmum

radially inward from.both the-tlp and crLt/cal_ectlons-results
i_ ths_lade cross-section area distribution as_shown earlier in.

Figure 73, and an average stress distribution as s_own in Figure k

82.

Results o£ the. detailed stress analysis are presented in .....

Fi_ure_83 through 9k. The finite-element, nodal breakdown_for.

the-stress-a_alysis is showa in Figures _3, 84 and 85. The equiv-

alent st.rees results-for both th_pressur_ and Suction..sides of
the_ airfoil are shown in Eigu_es 86 and 87, respectively, wi_h
the trailing-edge stress versus radius shown in Figure 88. The
equivalent.stress distribution and.defo_matlon of the critical
section is shown in Figure 89, and the equivalent stresses in the
shank region are shown in _'igures-90 and 91. The equivalent
stress is a calculated s_ress that-equates an existing triaxial
stress field _o an equivalent unlaxial stress, based on the dis-
tort/on energy theory of elasticity. This "equivalent" stress
can then be compared more realistically to available uniaxial
material strength data.

Vibration &nalysis. The final design of the uncooled high-

pressure turbine blade was designed to operate aerodynamically_
with a new 26-vane nozzle. Details of thi_ nozzle design a_e
co_ered in a subsequent section of this repQrt. The interference
viDration diagram for the final design blade, is shown in Figure
92.

_ Final-Design - High-Pressure Turbine Vane ."

Aerodynamic design. T_e stator vane was redesigned to match

the final design uncooled_ low twist high-pressu4e turbine blade.
The velocity triangles and vecto_ diagrams are shown in Figure
" 68. Design constants for this vane are as follows:

J
191
Figure 83. Final MATE Blade Airfoil Design

193
 Figure 84. Final Blade Design -- Airfoil,
-- Platform, and Shank

194
|

i-
v -

i Figure 85, Final MATE Blade Design

i - 195
_' _
 i;

I
[

"-_.... \

EQUIVALENT STRESS_ .................... DEFORMATION (MAGNIFIED)

Figure 86. Pressure Side Stresses (KSI) and Deflections at

29,692 RPM

196
•. Figure 87. Suction Side Stresses (KSI) and Deflections
.... at 29,692 RPM

- 197

L+
 0
HUB TIP
RADIUS

Figure 88. Final MATE Blade Design Traillng-Edge

Stresses

198
 ¥i

r_

DEFORMA.T.LO_ MAGNIFIED

EQUIVALENT STRESS (KSl)

Figure 89. Final MATE 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_, . 5
1-. SECTION 1 ......
SEGTION 3

i .

!:

";J{

i
t,

SECTION 2 SECTION 4

Figure 90. Equivalent Shank Stresses (KSI)-.-AirfoIl and

Platform Removod
$

2(10
 *f

I
i

46

SECTION C

Figure 91. Equivalent Shank Stresses (KSI)

201
 OPERATING .....
ENGINE
RANGE ___ 52/R EV
2X- NOZZLE
' VANES

_ 24 PE_

1ST COMPLEX
2O
N
2;
2ND TORSION
3 TM
i: • _J 26/REV
i._
'i _ 12 1ST TC,RSION NOZZLEvANES

l, n-

4 1ST FLEX 6/REV

(SHROUDS)

1.1(16) 2.1(20) _ 2.5(24)_ 2.9(28) 3A(32)

ROTOR SPEED , RAD/SEC (RPM) X 103

Figure 92. TFE731 Vibration Interference Diagram -- MATE

Final Design, DS MAR-M 247 Blades; Machined,
Heat Treated, and Coated

2O2
 • i

(a) The number-of vanes was fixed at 26

(b) Airfoil sections must have sufficle_t thickness to

allow for cooling _

(c) The axlal.-chord iel;g_h must fit the existing engine

flow path

Satisfying these conditions does not create any difficulty

at the tip (shroud) section, but for the hub sections some minor
. problems were encountered. A compromise was made to slightly
decrease the ma_ximum thickness.to obtain satisfactory loading
while utilizing a cooling tube with a smaller area at the hub.
Table LXI contains the geometry parameters necessary to generate
both the hub and tip design sections. Table LXIX shows the inte-
grated throat area versus stagger. Figures 93 and 94 show the
two design sections, while Figure 95 is a stack of plane sec-
tions. Vane loading is shown in Figure 96 and 97.

Thermal analysis. Details of the vane temperature calcula-

tions are shown in Figures 98 through 103. The pressure distri-
bution around th_ two vane sections (base and tip) are shown in
Figures 98 and 99, while Figures I00 and i01 show the heat-
transfer coefficients used in the thermal calculations. The

[ resulting calculated adiabatic wall temperatures are shown in

{
Figures 102 and 103 for t_e base and tip sections.

.. pesi£n parameters. Stress analys&s of cooled turbine vanes

is an inexact science. As the structures become more complex fo_
cooled or hollow air roils, the effects of thermal gradients, thor-
- mal transients, pressure distribution, and other factors become

more difficult to predict with the desired accuracy. Tradition-

ally, vane design is accomplished by comparing the design param-
eters of the new vane with an older proven design. When this is
accomplished, and an acceptable design is produced, the next step

203
,- [
=
 TABLE LXII. 26-VANE-'TEE731"" HIGH-PRESSURE TURBINE STATOR -
INTEGRATED THROAT •AREA--VS. ETAGGER

k
- Integrated- throat area
_s - (_) Design, between R = 10.985 cm (4.335 in._
de_rees 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

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
 ' ' I '' IS I
1.0Q "j " -- __ T

+::

-:
i

+
0,4_

0,00
0.,2C

Figure 96.
40
PERCENT

Stator
AXIAL

Hub
P.L0,
CHORO

Section Loading
t
I_0

1.00 ......

-+_ -.
im+o+::!O.l+
00 _0+

PERCENT
40

AXIAl, GHORD
g0 00 ,0
Figure 97. Stator Tip Section Loading

,,+

- 208

• • 00000 003 -TSC(

 .(

I
!
,IJ

°*,q
U

-_ o
_0

_m

iI)

o'1

2].0
 is to ¢onstruc_ the new _ane and--subject it to comprebensi$e
_: testing and evaluation. ._able LXIII-.shows the-result of the
parametric study between the new vane (26/nozzle), and the stand- %
ard-TFE731-3 vane ($6/nozzle). As can be seen in this Cable, the
new cooled 26=vane design compares favorably with the cooled pro-
duction vane.
5

Einal Design - Other Components ,

The high-pressure turbine sect/on of-the standard TFE731-3

Engine is. shown, in Figure_ 104-- Both. the final design of the DS
high=plessure turbine blade and the new- 26-vane high-pressure
turbine nozzlewere added to the high-pressure turbine section as
shown in Figure 105. This design requires _minimum number of
new parts, thus utilizing most of the existing engine test hard-
war e ................

Hi_ressure turbine disk - Part Number 3072748-1. The

h_gh-pressure turbine disk designed £or the uncooled DS turbine
blade utilizes the same disk. con.tour, fittree configuration, and
curvic coupling as the TFE731-3 disk. Only the rim area has been
•, changed to accept the new blade. With cooling air retained for
the disk firtree and the blade rim loadessentially unehanged_
the stresses in the disk have_not been appreciably affected by
this redesign.

Hi@h-pressure turbine shroud - Part Number 3072344-3, The

circumferential length of the high-pressure turbine shroud seg-
ments has been shortened to allow greater unrestrained ci_cumfer-
entlal expansion. The cooling air discharged out the blade tip
in the TFE731-3 blade design maintains the shroud segments at a
lower temperature than when they operate with the uncooled DS
blade. This higher metal temperature of the shrouds results in
greater linear expansion of the supported shroud segments, thus
requiring more clearance between segments.

212

F
213
L
/
) t

3O733

i : Figure 104. TF_731-3 Turbine wlth Cooled IHl00 Blade

;_
214

:, :t
 I

2E-VANE
LOW TWIST
$TATOR
3072724-1 )S
BLADE

3072746-1

3072411-1

3072748-1

Figure 105. TFE731 Turbine with Uncooled DS MAR-M 247 Blades

215
 _res__ su_:e turbine nozT._,e, supports - Part Numbers '_

3072743-I; 30727_4ri and 2"__3072745-I; and .307-274_66_1, New sup- k

i,
f
ports were prodused to adapt_ the 26-vane stator to the existing.• _
_ - high-pressure turbine structure, These-are all static components
with no significant stress/life problems,
 .,._

TASK V _ COMPONENT MANUFACTURE

Scope
"%

The objective of Task V was to accomplish the manufactur,_ and _:

quality acceptance of at least two complete sets of solid exother- -
mically cast DS high-pressure turbine blades for the TFE731-3
Engine for testing in Task Vl. In addition, this task included
th_ design, manufacture, and quality acceptance of a modified tur-
bine disk and other engine, components necessary to the installa-
tion of the DS turbine blades in the te_t engine.

The manufacture,_preliminary inspection, and quality certi-

fication of the blade castings were accomplished by Jetshapes.
The machining, coating, heat treatment, and final inspection of
the test blades, and the manufacture of the modified turbine disk
and other required engine parts were accomplished by AiResearch in
conjunction with production-qualified suppliers.

Blade Manufacture

I. Blade configuration. Two solid exothermically cast DS

TFE731-3 high-pressure turbine blade designs were produced in the
performance of Project i:

(a) The MATE preliminary design blade(AiResearch Drawing

SKP 17560), which was utilized for the casting efforts
in Tasks I,__I, and III.

(b) The MATE final design blade (AiResearch Drawing

3072749), which is the blade designed in Task IV and
manufactured in Task V.

Figure 106 shows the unmachined castings for each of these

designs. The large_ physical size of the final design casting is

217
 •2 _

Figure 106. Exothermically Cast DS TFE731-3 Turbine Blade

Castings for Project 1 Showing Preliminary
. (Left) and Final (Right) Designs

•_ 218

• ~
 J , r 1....

a_parent in this _igu_e. The largec casting is the r_sult of the

addition o£ extra machining stGck to both ends of. the. cast _ade
roo_ to p__ovide a casting that could be used to machine two dif-
ferent shank designs, k

2. Bla4_ Acgeptability Standards. Based on the results

ofTasks-/ through III, a-matterials Specifioation for MAR-M 24_,
and-an acceptability standard for. directionally-sol_difed.turbine
blades were prepared. These were • utilize_ for procurement af the
MA_E final deslgn blade tPart 3072749). The MAR-M 247 materials

=__ specification is included in this-document as Appendix A, and the

acceptability standards are included as Appendix B.

3. Mold Configuration. The first castings poured in 9ask_V

: _ were produced from MAR-M 247, MAR-M 200+Hf, and NASA-TRW-R alloys
employing a 20-blade mold. This mold--was developed in previous
tasks, and consisted of five radial spokes with provisions for
four blade castings per spoke. Due to the larger physical size of
the final design blade, it was necessary to modify this mold
con£iguratio_ to allow more room for exotherm_c material. After
_ trying several different configuration£, it was deter.mine_ that
the best mold design to exothermicallM cast. the final design
blades was a 15-blade_ mold having five radial s_gkes with p_vi-
sions for three blade castings in each spoke. This design allowed
i the proper ratio of exothermic material per casting to be main--
tained.

i To provide-assurance tha_ the modifie_ mold configuration had

not adversely affected the stress-rupture strength of the blades_
si_ longitudinal-grain-orientation mini-bar test specimens were
...... machined from DS MAR-M 247 blades of the final design configar-
ation. Each specimen was fzom a blade cast in a different mold,
and each was subjected to strauss-rupture testing at 1255°K/207 MPa
(1800°F/30 ksi). The tlmes-to-failure of these six speclmen_

219

L
 ill
:
----.......................
were__In hour-s: 77.7-, 17_9, I00_ 119.9, _84.7--anti 99.6.--Based-on
Task. I.II_daJ_,__ the_expected average life- of these- blades was
! approx/m_tely i00 hours_- The-ac.tual average __est llfe of the six
Task V specimens-was 93.3-hours_ In-Task I, the .average life of .k
similar test specimens machined from preliminary design blades and
." _.e_ted under the.same test conditions was 79.6 hours_ Thus,. t-he
_ Task -V-final design, blades, _wi_h the.lmp_.r_oved heat treatment- and
: - ref_i.neclhasting proc_ess, exhibited a 4Nin-imum .life-- equal .to or
- g:reater than the average life of blades produced earlier in the ,
program_

_: 4. Final material selections. Fluor escent-penetr ant '

inspecti_)n-of the NASA--TRW-R alloy blades cast in_T-ask-V revealed

} i crack:like indications on the thin .blade platfQnms_ Visual

inspection, at 10X and metallogr.aphy confirmed that cracks were
i_ present. None of the geomet_ically identical Task V blades_cast .

i in the other two alloys had a similar p_ob!em_ ........

i : Figure 107 shows an example of a cracked NASA-TRW_R alloy

5
blade and the. microstructure in the-cracked area_-T_e nature and ......

tear". This.-ca_ occur in thin cast sections when a highly_alloyed

"- ": location of the cnack is a typical example, of a casting "hot

cation due to inadequate hot strength of the g/_ain boundary.

i super_alloy_ separate_ (_ears) at a grain_boundaxy during, solidifi- !
-- App.roximately 90 p er_cent o£. the--NKSA-TRW-R castings clearly
: exhibited platform-hot tearS.. Since data generated in Tasks II
• an(i III indicated that NASA-TRW-R had the lowest strength of the
.... three alloys _riginally selected for-engine testing, i_t was eliml-- ."
nated from_ the engine test program rather than attempt to correct
its castabillty problem.- Blade castings planned for this alloy

test w.tth the same total number of castings.

..... were replaced with DS MAR-M 247 castings to support the engine

220
 (a) (MAG.: 1X) (b) (MAG.:..100X)

: t I _'_ _'_!,"_'_ '

(c) (MAG,: lX)

Figure i07. 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 Inter-
granular Path of the Crack

221

, +
 "
5.- Blade finishin___All MAR-M 2-47 and MAR-_ 200+Hf cast-
ir_a_wer.e solution.heat _reate_ i_a vacuum at L505°K _2250°F) for
two hour_s, followed-b Z inert gas quenching. The blades wex.e then
: fi_ish_machine_ t_ the final design confi@uration--estahLished in
%
Task IV. _igure 108 shows a typical MA/_-M- 247 blade as-cast and J
after finish machining. The pressure and suction-_sides-ol two
.. finishe_ blades are shown in Figure 109. After machining, all
blades were coated with the RT-21-_aluminide coating at 1255°K
(1800°F) fop 5 hours, followed by air-cooling, then aged for 20
hours at 1144°K (1600_F) and followed hy air-coDling.

6. Bi@de Acceptability t After the 15 blade---per-mold pro-

_- - cess had been refined, approximately 525 blades i_ _he three prO--

gram alloys were poured- at Jetshapes. .Screening inspectionS_to

AiResearch acceptability criteria were made at Jetshapes, while
final inspection was performed at AiResearch using p_oduction
quality assurance inspectors. Table LXIV summarizes the overall
• blade acceptabilit Z_ results, casting yields, and number of
finished blades required and accepted for engine testing.

Of the rejected .blades, all 21 of the NASA-TRW-R alloy blade

castings were r_ejected for platform hot tears found during fluor-
escent-penetrant inspection (FP_). Blades from the other two
alloys were-rejected for. _'combination of discrepancies: visual,
grain, EPI_ and X-ray_ In general, _here were more rejects of the
• MAR-M 200+Hf a/loy_ than MAR-M 247 for hafnium-oxide inclusions.
These manifested themselves as either high-density inclusions
- found by X-ray, or suxface indications found by FPI.. The bulk of
the rejections by AiResea_ch of parts shipped by Jetshapes were
for interpretations of the DS grain acceptability limits.

_ The 59-percent yield achieved by Jetshapes for the DS

MAR-M 247 blades was considered very good for a new blade design
at the beginning of the learning curve. Experience suggests that

222
 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 ' '71"
Figure IC9. Pressure and Suction Sides of TWo
Finish-Machined Exothermically Cast
DS TFE731-3 Final Design Blades

224
 TABLE L IV. SUMMARY OF THE YIELD OE THE FINAL DESIGN
DI/IECTiONALLY-SGLIDIFIED TFE731-3
TURBINE BLADES CAST--IN TASK V--

Alloy_

i
!, MAR-M
247 i 200+-_f
MARCM I NASA-TRW-
R ,rT?tal

Approximate number of 300 165 50 525

blades cast by
Jetshapes

Number of blades 199 ]_03 29 331

" shipped to A/Research
by Jetshapes

Number of blades 176 74 8 258

accepted by AiResearch

Approximate over-all 59 45 13 ---

yield (%)

Number of fi.ished 95 56 0a 151

blades accepted for
engine testing

- Number of finlshe_ 93 31 0a 124

blades _eqgired by
,-'[- contract

_ aNASA-TRW-R alloy eliminated-from Project i prior to machining

-'- blades.

225
i
 .F

this yield will improve to--?O-to 85 percent in p_oduction quanti-

ties .......... "

%
Special Engine Components Manufacture _i

As described.herein in Task. IV, Blade Design, certain parts

of the high-pressure turbine sectlon_required redesign, to adapt
the standard-TFE731.-3 design-to best accommodate the final blade
design of..the chosen, blade alloys_ As a-part of Task-V, the
i
required-, special- hardware was manufactur.ed._s shown-/n_ T.able LXV
for assembly into the test engine.

226
 TABLE LXV. SPECIAL_HIGH-PRESSURE TURBINE HARDWARE-
MA_OFAC_URED EOR TPE731_3 ENGINE TEST
OF EXOTHERMICALLY CA_T DS HIGH_PR_SSURE k
T//RBINE BLADES

Part Numbe_ Nomenclature Quantity ,

i I ] rllr | I I

i072748_i ......... High_preSsure turbine (HPT) Disk 1

3072_3 HPT shroud segment 6

3072T24-I HPT nozzle segment 13_

3072743-1 HPT nozzle.outer seal support 1

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 ring 1

227
 __._......_._.._ 4• rl. •_. _e-7 *_'•_'Lr_ _ _ḑJ•;, _

Im •_ vi

COST AND WEIGHT OBJECTIVES !

•_....

The Project 1 cost and. welght, goals (contractual objectives) %

are listed .-below.. The. SFC ob_.ect_ve will be discussed--in k,
Volume II of this report.

o Reduce engine.weight at leastz_._ercent

o Reduce engine manufacturing costs at.least 3.2 p_rcent i

o Reduce engine maintenance-costs • at least.6.2 perce_k ....

In the limited time available for this PrOject, it_ was

: o_viouSly_ not _easible to_chieve long-term production objectives.

However, several conclusions and projections- can be formulated-
witk reasonable confidence based on the knowledge gained-in manu-
_i i factu_ing and testing the uncooled DS HP turbine-blades.. Actual
• engine testing of the DS blades was accomplished in a modified
TFE731_3 Engine, with-hardware changes kept to a minimum to avoid
unrelated component development problems during the150-hour test.
I£ the turbin_ section of the engine were redesigned.-to fully
" utilize the uncooled DS turbine blade several majo_ changes could
be accomplished as listed below:

_ i.- O Eliminate the for

not required forward
the seal plate
DS blade, -this
since cooling
component air
can is
be
- eliminated.

blade material has superior properties as compared to ,"

I _ o Redesign the firtree connector
eq_giaxed - IN100,
since the DS MAR-M 247
.... _he prese.t production both-t_e circum-
ferentlal and axial dimensions of the fi_tree could be

_educed through a redesign of the firtree connector .............

228
 %,,

o- Redesign the HE turbine disk - since the rim load would

be substantially reduced due to the new blade/firtree
design, the turbine aisk could be redesigned utilizing a
stronger disk alloy to reduce* disk weight _ithout
ad_f_ecting engine life.

Engine Weight

Engine w_ight savings can be considered as either "actual"

weight reductions associated _ith changes that could be achieved
with compQnents in the current engine or weight savings that are
possible if the engine cycle pa;ameters such as bypass ratio and
pressure ratio are optimized. The "actual _ weight reduction cal-
culations are shown below. It is not necessary to consider the
optimized e_glne cycle to meet _the weight reduction goal.

Total Engine Weight (TEW) = 722 ibs

Eliminate Seal Plate = 3.1 ibs

Reduced Weight of Redesigned BPT D_sk = 4.3 ibs

Total Weight Re_uctlon (TWR) = 7.5 ibs
TWR 7.5
Total Engine Weight Reduction = T-_ =
= 1.04 percent

/'

Manufacturing Costs ,_

By replacing the production ceoled HP turbine blades with _'_

uncooled DS turbine blades, the overall manufacturing costs of the
TFE731-3 Engine can be reduced by more _han 3.2 percent. Two major
manufacturing cost factors are associated with this proposed change:

o Direct manufacturing cost savings to the HP turbine stage

fDom material and component design 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 Costs - The uncooled (solid) DS castings are higher _,,
yield, less expansive castings that. requime leas machining than
J
the conventional cooled. (cored) TFE731-3 HP turbine blades.
Figure 110 shows a relative cost comparison between the conven-
_ tional cooled INI00 HPT blade used in tha-TFE731-3 Engine and the

" MATE DS_blade designed in this projeqt for the TFE731 Engine. The ' i
ii
changes in configuration and processing will yield a-l.5-percent
engine manufacturing cost savings for production quantities. By

ii_ redesigning
MAR-M 247 DS the
blade HP turbinein
material disk rimto area
the utilize
and the stronger a
Incorporating
stronger disk material (such as Rene' 95), a 23-percent weight
earrings can be realized_ Tkls weight/cost savings is offset, how-
ever, by a 41-percent increase in raw material cost which results

i in no cost savings for the disk redesign. Since the redesigned HP

tUrbin_ blades and disk no longer require cooling, the entire cost
i
! associated with the HP turbine seal can-be eliminated resulting in
_
[
a 0.4-percent savings. Thus, a direct manufacturing cost savings
Of 1.9 percent can be realized by optimizing the HP turbine sec-
tion to fully utilize the characteristics of the uncooled
' DS MAR-M 247 turbine blades.

Optimized. Englne Costs --Table LXVI Summarize_ the change in

cycle parameters for the TFE731-3 Engine with DS blades. The
optimizQd cycle must be incorporated to fully utilize the charac-
teristics of the DS turbine blades.

230
 100 COATING

_ROCESSING
O AND
80 INSPECTION

n.
"r" ,

6O MACHINING i !
Z COATING _
C3
uJ
=J
O MACHINING
O 40
¢J

C/_TING

20 CASTING....
r_
uJ

0
PRODUCTION MATE DS
TFE731-3 TFE731
HPT BLADE HPT BLADE
(COOLED IN100) . (SOLID MAR-M 247)

Figure ii0. Relative Blade Costs of the TFE731 HP Turbine

Blade Production Versus MATE DS

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

p_oduction MATE Project 1

_.ngine Uncooled (Solid)
Baseline DS MAR-M 247
Cooled (Cored) Standa_:d Optimized
Parameter Equlaxeu INIU0 Cycle Cycle _

T4 o_, (OF) 1327 61930) 1327 (1930,) 1327(1930]

TSFC 0.818 0.814 0.721
Pressure Ratio (PR) 18.0 18,0 25.0
Bypass Ratzc (BPR) 2.7 2.7 4.6
.,. _ • .,: .... ; ......

AiResearch prepared a cost/benefit analysis (NASA CR135265)

as a part of the MATE Program Project 0. This document illus-
trates that scaling of engine weight, with changes in bypass
ratio, can be app!KQximated by the following relationship:

WF
_._ _ W_
W_C _
I 1 . B_Rnew
BPR_aseline )

whert: WE = Engine Weight

WE c = Engine Core Weight

BPR = Bypass Ratio

A weight breakdown for the TFE731-3 Engine showed that 50.5

_ercent pounds of the total engine weight is core weight. Using
this data, plus the bypass ratio shown in Table LXVI, the analyt-
ical model predicts that a 21-p_ercent weight savings can be
realized by optimizing the engine for DS blades. This is based on
the reality that as the bypass r_tio is increased at a constant
thrust, the size of the core and all of its components will
decrease.

232

.......
- " -- -- " 00000003-TSE[
 A

• h__coat model £or enginQ scaling purposes is simply:

,: Cost is proportional to Weight

J
TSia coat model is based on small welgJlt changes from the baseline
engine_ The calculated 21-percent weight savings is a very sig-
ni£icant weigh_ change, and could be accomplished only with exten_
siue redesign and technolosy changes-_o the. engine.. Therefore_ .....
the cost savings would probably not be as si_Dificant- as the
weight reduction due to the added costs to incorporate ad_ancexl
technology components. The significant change-in core sizewould,
- however, yield cost_savings that would reduce the overa_l engine
cost considerably more.than 1.3-percent.
L

Total Costs - Adding the cost savings due to cycle optimiza .......
tion (1.3 percent) to the direct manufacturing cost savings previ-
ously discussed (1.9 per_cent), yields a total engine manufacturing
cost reduction of at least 3.2-percent.

Engine Maintenance Costs

_ The engine maintenance cost is comprised of preventive maln-

tenance (inspectionl,.o,_rhaul, unscheduled maintentance (repair
of failures), and incorporation of service bulletins.

The baseline costs for preventive maintenance, overhaul, and

unscheduled maintenance are established from experience on similar
: applications. The incorporation og service bulletins is assumed -"
to be 5 percent of the sum of the engine preventive maintenance
cos%, overhaul cost, and unscheduled maintenance cost.-

"T

233
 I_•__ . . _ "*
'_,
!: The change in engine file (TBO} and--the resultant-effect in
1 a
cost can_ be deter.mine_ by using an- engine overhaul cost model that
may be expressed_ as _.composite toE-the entlre--engine._---_he-basic %
L
._ model for-engine over_%aul cost (EOC) is"

\M?.Bo +_ LB_Cj
Module(BMOC_
where:
t

, BMOC: ....... =--..-Baseline module overhaul cost (assumed at

one-third manufacturing• Cost) .

_ BMTBO = -Baseline module, tlme-between-ouerhau.l

-- MTBO ....= Module time-between-o_erhaul

j _ MMC = Module manufacturing cost

-- :
BMMC .... Baseline module manufacturing cost

'i The module cost in the equation above is expressed as a fraction

'A of engine cost.

The effect 0£ engine unscheduled maintenance on cost, result-

-- _ ing from changes in reliability (MTBF_, can be determine_ by using

_" an engine repair cost model. The basic model for engine repair
i. cost {ERC) is:

_,i • = Module MMTBF 1+¼ j

'" where S

_ BMRC : Basel/ne module repair cost

m_ BMMTBF = Baseline module mean-tlme-between-failure
_'i MMTBF : Module mean-time-between-failure

_ ._. Replacing a hollow, thin walled, cooled turbine blade with a

--'.,,
- solid unroOfed blade naturally results in a more rugged engine
configuratlon. Such items as foreign object damage (FOD),

. 234

! "'_

" .... 00000003-TSEO

 m

recoati_g,_part/cle---erosion, etc_,_ are more detrimental, to a

cooled tu_hlne blade-_ham a solid a£rfoil. Also,._the reliability
of the componenX.s su_plyiing the blade cooling, air no icn_er %
directly affects the blade life.. Conservatively,. assuming _ that
this more rugged comp@nent will increase both -the tlme-between-
overhaul (TBO) and the mean-kime-between-failure. (MTBF) by only l0
percent, the resulting change- in malntenance--cost can be calcu-
lated as follows:

Baseline-Maintenance Cost*

!, o Engine Inspection $ 600 X-106

o Engine Repair 804-X-106
o Engine Overhaul 3260 X 106
o Incorporate Service Bulletins 233 X 106

Total Cost----. $4897 X 106 i

! if _MMC = 0"*

x 01]
ERC-= $_3! X ]N6

EOC = $3260 X 106

if AMMC _ 0**
1( i.i
MTBO
X MTBO I
._
(' E ])I
+ ½
"
:
*Based on 25-year life-cycle costs of the engines for a business
jet flee£ of 4000 aircraft.
**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 'k

Revlse-d-/_aintenance Costs --
iz

! c Engine--Lnspection $ 600 X 106

i "_ Engine Repair 731-X 106
i o Engine Overhaul . 29J54..X_lO6
o incorporate--Ser.vice--Bullet/ns 233 X i06 i

Total COSTS $452& X 106

Reduced Maintenance Costs = 4897 X 106 .--4528 X 196

4897 X 106

= 7.5 Percent

_ 236
 1

CONCLUSIONS ...... _i

A consistent process to. p!oduce solid_ directionally-

solidified TFET_I-3 high-pressure++ turbine blades using exo- %
thermically heated_mold_ was deuelope_ a£_Jetshapes, Inc. The
process produced acceptable, diree-tional-grain structunes in four
alloys+ and +thnee turbine blade nonfigurations_ The alloys were:

MAR-M 24Z_ MAR-M 200+Hf; IN 792+Hf_ and_.NASAz_RWTR,______

Stress-rupture screening tests at 10310K and 1255_K (14009F

and 1800°F) on bars machined fronDS, case and heat treated blades
of the four a_loys showed-MAR--M 247 to be the-strongest of the four
alloys and IN 792+Hf the weakest.

A, 1505"K (2250°F) solution heat treatment developed for DS

MAR-M 247 improved the stress-rupture strength of the alloy over
the baseline strength established with the 14940K (2230°F) solu-
tion treatment.

Property data to provide turbine blade design data was gener-

ated on MAR-M 247, MAR-M 200+Hf, _nd NASA-TRW-R as follows, with _
the bulk of the data generated on MAR-M 247.
\

(i) Mechanical properties.+ ,-

o Tensile tests in the rang e of room temperature to

I144°K (16OO°F) on both longitudinal and trans- <
verse bars machined from blades.

o Stress-rupture tests over the temperature range

of i033°K to 1311°K (1400 ° to 1900°F) on longi-
tudinal and transverse bars machined from
blades.

237
 v!

o Low--cycle-fAtigue t-e_ts--at room temperature and i

I033°K (1400°F) .... '

o High-cycle-fatlgue tests at_oom temperature and

I144_K (1600°-_).

(2) Physical properties

o_ --Thermal. expans/on and thermal conductivity__over ......

the-range of room temperature- to 1255°K 1800=F).
7
Modulus of.elasticity in-the grain-g_owth direc-
tion. over the range of room temperature to 1144°K I
(1600°E).

(3) Environmental resistance (bare and aluminide coated)

O Dynamic oxidation resistance at 1310°K (1900°F)

for 510 hours.

o Hot-corros/on (sulfidation) resistance at 1200°K

, (1700°E) f.oz 310 hours.

A new solid high-pressure turbi'ne blade was designed for the

T_FE731=3 Engine £o maximize aerodynamic efficLency and-bl_de life
using_directionally-solidified MAR-M 24_. A new-turbine nozzle

aerody_namicall_ compatible with this blade was also designed.

Minor redesigns were incocporated on other turbine components such
as the disk, shreuds, nozzle retainers, etc., to allow testing in
the--T2El31- 3 Engine.

: Specif_icatiens and acceptance criteria for DS MAR-M 247 tur-

bine blades were developed and are incladed-_s-Appendiccs A and B
of this report.

238

........... L __ -- _ L
 "IV

Exothermic DS cast turb_ne-blade_of-MAR-_M 243, MAR-M 200+Hf,

and NASA-TRW_R were cast for engine testing. The NASA-_RW-R
_k
blades were ehmlna.ed from-engine testing consideration due to k
"hot tears" in the platform.

Di£ectionallyrsol/dified blades of MAR_M 247 andMAR-M 200+Hf

._ wer_ finish processed threugh machining and coating, and were made
a,ailable for TFE731_3 Englne__testlng. Other- turbine hardware
required for the_ test was manufactured and assembled into a
factory test engine.

_ The incorporation of solid DS MAR-M 247 HP turbine blades

?
into an optimized cycle TFE731-3 Engine would result in manu-
facturing cost reductions exceeding the 3.2-percent Project 1
goal.

The incorporation of sol/d DS MAR-M 247 HP turbine blades

into the existing TFE731-3 Engine with a redeslgne_ HP turbine

would reduce engine weight by 1.04 percent, exceeding the Project 1
goal of 1.O percent.

i
Maintenance costs of a TFE731-3 Engine wi_h solid DS MAR-M
247 HP turbine blades would be reduced 7.5 pgrcent due to greater
i blade durability, exceeding _he Project 1 goal of 6.2 pezcent.

Engine test results and post-test evaluations are described

in Volume II of this report.

239

, ..... , t --
 ¥

_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

APPENDIX A-
MAR-M 247 MATERIALS SPE_IPZCATZON

1. APPLICATION 3.5 Separately east test-bars shel_ be '

cast fr_m_rJf master heat an_--tas_ed,

I.I MAR-M 247 £ea east _lckel-base super- k

alloy used for t_blne wheels_noseles, and 3.5.1 If the configuration perm_, t6et
blades, a_ temperatures upto I800*F. specimens shall also be machined fro_ cast
parts.

2, APPLICABLE D_MENTS ..... 3.5.1.1. Speui_ens-may be machined from an_

area of th_ casting, unless .ot/te=wlse
2.1 The following- documents f_m% & part specified.
of this ipeclfication to the extant refer-
eno_ herein. 3,5,2 Separately cast test bars may be
eithe_ cast _o size-or cast oversize and
2.1.i AiRssearch Specifications Maohlned.

EMS52300 Classification and Znspec- 3.5.3 Separately cast test bars ihall be
tion of Castings _ cast into the same. type of refracJ_orMmold
as the castings for which the master heat
EMS52330 Masten Heat Preparation of is _o be used.

ii Nickel-BeseAlloys 3.5.A Any metal treatments, such as super-

}_5014 Marking Requlremen_s heatin_ and hot topping, to be used on-
castingw shall also be used on separately
C5041 Surface Cleaning Treatments cast test bars when qualifying the master
for Corrosion--and Heat- heat for use in those castings.
i Rezi_tent Alloys
3.6 All castings, including separately
2.1.2 _erospecs Materlal Specifi_atio_ cast test bars, shall be cast into mo_ds
utili_ing mold inoculation as used fo_-graln
AMS 2280 Trace Element Control, size control.
Nickel Alloy Castings
3.7 Castings shall be aupplled in the
3. TECHNICAL REQUIREMENTS as-cast condition.

3.1 Composition Su@_estedAim Range 3.7.1 Cast parts shall be heat treated for
20 hours at 1600*F.
Carbon 0.15 0.13-0.17
Chromium 8.25 8.00-8.8_ 3.8 Cash'partS after heat treat shell have
Molybdenum 0.70 0.80-0.80 a hardness of NRC 30-40.
Tantalum- 3.00 2.80-3.30
Aluminum 5.50 5.30-5.70 4. PROCESS CONTROL
Titanium 1.SO 0.90-Zo20
Hafnium 1.50 1.20-1.60 4.1 Castings sha_l be cleaned in accordance
Boro_ 0.015 0.01-0.02 withA±Research Specification C5041 as
sir_onlur_ 0.05 0.03-0.08 required.
_obalt 10,00 9.00-1_.O0.-
Tungsten 10.0O 9_0-i0.50- 4 _2 He_t treatment shall follow al_ other
Manganese -- 0,20 Max_ thermal exposure_e.g., coating and brazing
Sulfur -- 0.015 Max. operations, which may occur during processin,
silicon -- 0.20 Ma_. of parts.
IrOn 0.50 Max_
Nickel Ee_alnder Remainder 5. INSPECT/ON

3.1.1 Trace elements shall be controlled in 5.1 All castings shall be visually, pens-
accordance with AMS 2280, Class 2. trent-, and E-ray-inspe_ted in accordance
wi_h _52300.
3.2 Production of master heats, remslting of
master heats and pouring of castings shall be 5.2 The supplier shell perform all testing
accomplished under vacuum, for cen£ermanee to chemloal limits.

3.3 A master heat shall be made from EMS52330,§.3 The supplier shall perform all
Class I material, mechanical-_foperty testing.

3.8.1 When specified, a _aster heat n_y be 5.3.1 Test specimens shall be heat treated
made from Class 111 materlal_ for 20 hours at 1600"F prior to testing.

3.4 Castings shall be poured only from re- i_[_][_ , , _,. _....... rt_P_

melted master heat metal. -_E_|RO PAG_ I_J_K trOT FitteD.

3.4.1 A master heat _s previously refined
metal of a single furnace charge.

F08M P5703-2
243
 I II I III I I " - " { _ II III 1

5.3.2 _or muchanleal.-proper_y teeting_ 8.2.1 _1_en cmatinq_ for makin9 _£ni_hed o_ _I
soparately cast tes_ specimens shelf have a
semif£niahed parts ere produced o_ pu_rchased
0.25-1nch=diamster_-gauqe section i inch long
by the parts suppiler, the parts supplier I
between r_dil, ahell inspect castings from eae_ master heat •
or master heat lot represented end shall t
_.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
-. minute, -- 8,3 The supplier shall state tn the report _
the relatlv_ proportion of revert or virgin
5.3.4 Stress-rupture test specimens, shall martial used in preparation- of the master
I be tested ucder & constan_ stress of he_t.
I05_00 psi at a temperature of 1400 (_Sa_).
:" 9. QUALITY CONTROL•
5.3.5 _.cres§-ruptu_e tes_ specimens shall
-.... he tested under a constant stress _f 9.l C_atlnge shal_ be un_fo_in quality
29,000 ps_ _t 1800--+5°F.- and condi_lon, sound, and free-from foreign
materialS a_d_from internal_ andrexternal
6., IDENTZF_CATION AND PACKING imperfections in excess of,-those allowed in

I 6.1 Rash castling shall be identified, wlth EMS52300 for the specific class and grade.
paFt number and master heat number, in 9.2 At the option og AIResearch, _ casting
accordance with speoifloation HCS014. eha_l he selecte_ f_om any _astings received
• andshall be Inspecte_ in accordance with
_ 7. APPROVAL OR PROCUREMENT the appllca_le re_ulremeots for that-.part.

7.1 To assure enlformity'of quality, 9.3 Parts and material not conforming to
_ sample castings from new or reworked the requirements of this specification
master patterns shall be approved by the shall be _cJected.
_rchaser_

7.2 Supplier shall use the same casting

_-_ technique, including rate of cooling after
casting, and, if heat treatment is speci-
fied, 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
statement
of the chemical
that the castlnqs
analysis,
confor_
and a
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
I' quantity fro_ each heat.

- 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 supplier of caettnge_ pext
_ _. , !_n_mber, a_d quantit_.

\ !

FORM P5703 -2

- 244
 APPENDI_X-B.

ACCEPTANCE STANDARDS FOR

DIRECTIONALLY SOLIDIFIED TURBINE BLADES
(7 Pages)_.

245
 j_
APPENDIY_ B ' 'v
. ACCEPTA_NCE ST/tNDARDS FO__R DIRECT__I_ONALLY-SOLIDIF!_ TURBIne.. BLADES.. .
'< I. APPLICATION 3.2.2 The master heat shall be in
'" accordance with EMS52330_Class Z.
..I This specification sstablishas the The use of gates, sprues, risers, or
f acceptance standards for directlonally rejected castings is not _e_rmlttsd.
i s_lidified _R-M 247 turbine blades. ._
_, 3.2.3 Remelting cf maate_ heats and pouring
l.l.1 MAR-M 247 is a cast, nickel-base of castings shall be accomplished under
superatlcy used for turbine wheels, vacuum.
hozzles, and blades at temperatures up
to 1800°F. 3.2.4 Master heats shall be qualified by
- testing spool;hens machined from blades.
i 1.1.2 When cast 4_Lractlonally soLldifled--
r there is a signlflcan_ improvement in 3.2.4.1 If the blade design does not
_" creep-rupture properties as compared to allow specimens to be machined from it,
;_ conventionally cast m_tterial, then blades P/N 3072111 shall be cast
along with the other blades and test spa-
i, _ 2, A_PLICABLEDOCUMENTS clans shall-b_u-_achinad from these blades.

F 2_1 The following documents form a part 3.3 Grain-Orlentation

Of this specification to the extent refer-
enced_herein. 3.3.1 Prior to removal of DS starter

2.1.1 AiRese_ch Speeifications etched for a tims Sufficient to lightly

I,_ reveal
material,the each
grain blade
orientation.
shall be chemically

_ " 3.3.1.i Etchlng procedures and reco_ended

i -" etching solutions are shown in Appendix I.

3.3.2 The leading and trailing edges

shell consist of a single grain with no
grain boundary intersection (termination)
trailing edges.
EMS55447 Nickel Corrosion
ment, Alloy Castings,
- and Heat
Invest- at the leading and
Resistant, MM-0011 (Mu%R-M247) 3.3.3 Columnar grains shall be parallel
within 15 ° of the major axis of the airfoil.

3.3.4 Divergence or convergence between

any two coluntnar grains shall _e less
2.1.2 Military Specifications than 20 °.

, MIL-I-6866 Inspection, Penetrant Method of 3.3.5 The alrfoil ntldspan chord shall consist
• of a minimum of 5 grains, with no single grain
MIL-I-25135 Inspection Materials, Pane- exceeding 40% of the width.
trent

3.3.6 No equlaxad grains are permitted in the

MIL-STD-00453 Radiographic Inspection blade.

2.1.3. Aerospace Material Specificetion_ 3.3.7 A/I columnar grains which extend into any
part of the finished casting dimensions must
ARS 2280 Trace Element Control originate within a chill zone no greater than
3/16 inch above _he chill block surface.
3. TECHNIC_ REQUIREMENTS
3.4 Heat Treatment
3.1 Composition
3.4.1 All blades shall be solution heat treated
3.1.1 Chemical co,uposition shall be in prior to any abrasive blasting operation after
accordance with EMS55447, with trace removal of the castings from the mmld.
elements in accordance with AMS 2280,
Class 2. 3.4.1.1 Solution heat treat blades at
2250"F in vacuum for 2 hours. Blades
3.2 Master Heat Requirements shall b_ rapid inert gas cooled to below
le00"F.
3.2.1 Castings chall be poured only from
remelted master heat metal. 3.4.2 Following s, _utlon heat treat_nt, blades
to be tested Shall he given a simulated coating
3.2.1.I A master heat is previously re- cycle of 1800°F +25 for 5 hours and still air
fined metal of a single furnace charge, ccoledt followed-by aging at 1600°F _25 for 20
hours.

.........
FORM _5704-_"
.
247
 I I I II _ R I I

3.5 Motaliographio Inspactio= ..... 5.2.2 Fluorescent penmtrant indications

shall be correlated with the allowable
3.5.1 A blade from each heat treat _ot mhall vlaual imperfaitlons and the aoo_pt/
be metallographlcally examlnad for incipient re_ect criteria of ?able _I.
melting and gamma-prime solutloning, for
information only. A 500X photomiaroqraph Of 5.2.3 Evaluation Of smeared or unsharp
a representative area shaIZ be submitted to indications may be performed by wiping
AiReseareh Receiving Snap, orlon for trans- thm indication one timm only with a swab
mittal to Materlals Engineering. or brush dipped in solvent.

3.6 Mmchanie_l Properties 5.3 Radiographic Inspection - All blades

shall be radiographlcally inspected per
3.6.I Tensile test specimens, machined from MIL-STD-00453 to tho acceptance standards
fully heat treated blades, tested at room defined in Table _II.
temperature shall meet the following
minimums: 5.4 Master heats shall be tested by the
casting supplier for conformance to
Ultimate tensile strength (ksi) 140 chemical limits. Chemical tests shell be
0._ percent yield strength (kel) 120 performed on a blade cast from the
Elongation (percent in 4D) 7.0 mae_er heat.
Reduction _f area (percent in 4D) 7.0
5.4.1 Overall chemistry may be determined
3.6.2 Stress-rupture test specimens at any location within the blade. Hafnium
machined from fully heat treaued blades, shall be determined at both the tip and
tested at a. temperature of 1400"F and a the root of the blade.
stress of 105,000 psi shell have a-mlnlmu_
life of 80 hours. 5.5 Master heats shall be tested by the
casting _upplier for mechanical properties.
3.6,3 Stress-rupture test specimens mach- A minimum of three specimens for each test
ined from fully heat*treated blades tested condition shall be tested.
at 1800"F _5" and a stress of 30,000 psi
shall have a minimum llfe of 60 hou=s.

5.6 The casting supplier shall test two

3.7 Surface condition blades from each soluti0n-heat-treat lot,
one in tensile and one at the higher tom-
3.7.1 The maximum depth o_ intergranular perature creep-rupture conditions of
attack allowable after any processing is EMS52332, to verify conformance to uhe
0.0005 inch. mechanlcal-property requirements.

3.7.2 Blade surfaces shall show no evidence 5.7 A sample from each heat-treat lot
of recrystallisation, alloy depletion, or received shall be inspected by AiResearch
carbide oxidation, for intergranular attack, reeryst_llization,
alloy depletion, and carbide oxidation.
4. PROCESS CONTROL
6. IDENTIFICATION AND PACKING
4.1 Cooling rate from solution-heat-treat
temperature shall be sufficiently fast to 6.1 Each casting shall be identified with
meet mechanical properties, part number and master heat number in
accordance with specification MC5014.
4.2 Solution heat-treat furnaces shall
be qualified by the casting supplier and 7. APPROVAL OR PROCUREMENT
approved by AiResearch.
7.i Approval of the supplier's fixed
4.2.1 To qualify a furnace, the casting process and prooes_ changes shall be in
supplier must heat treat a minimum of 15 accordance with EMS52332.
blades in a furnace loaded to the maximum
production heat treat capacity, and test 8. REPORTS
_ to the mQchanical-property requirements
five blades per condition). A simulated 8.1 The supplier of castings shall furnish
load by weight may be used. to AiRaseareh Receiving Inspection with _ach
shipment a report lis£1ng the results of the
mechanical-property tests for each
5. INSPECTION solutlon-heat-treat lot and master h_,at,
the results of the chemical analysis from
5.1 Visual Inspection - All blades shall be one casting per master heat _:epresenting
! Inspucted in accordance with Table I. the part number shipped, and a statement
that the castings conform to the require-
5.2 Fluorescent Penetrant Inspection monte of this specification.
7
.- 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
J

L I r I I ....... i .............. _ i
[8.1.1 This _epo_t Ihell £noleda the puT-
. chase 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, 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 prob-
[ ability of a fixed proces_ change. (See
' Approval or Procurement section.)

• 9.3 Parts and material not ¢onformlng tO

the requirements of this specification
; shall be re_eoted, r

%, -

I
FORM PSY04-_
249
 I J • I " II Ill I I | I | I[ _"

TABLE I. VISUAL AC_k%_CECnlTERIA0

A_EA V_SUAL ZMPERFECTIONS

_I II II 1 (7)_9) _,
NONINTE_PRE-
A NEGATIVES P_SITZVES (3) (5) (61 TABLE (i) (2)
Z. DIS_ Depth Dis. Height
A
R .010 .010 .010 .005 Max. eL 5 per.-
F .25 x .2S
ares.
O

I MaX of lO per
B .015 .010 .020 .005
L (4) .25
ares. _ _25

Max. of 5 per
PLATFOrmS .OiO .010 .020 .O05 .25 x .25 .
area.

AS (6) (6) (8)

CAST; (8) (8) (8) (8)
BASE i ,.....
MACH'.OlO .010 N/_ N/A _ax0 Of 5 per
INED .25 x.25 area

(I) generally porosity, conoentrated in local areas with no individual indication exceeding
.010 dla. x .010 depth.
(2) Limited to 2 areas per surface.
(3) .OIG parting line allowe_ in fillet radii, .003 max. On leading and trailing edges.
(4} A cluster of these indications not to exceed .125 dis. and should be separated by .25 o_
good area.-
(5) A cluster of these indications should not e_ceed 5 par .25 x .25 area and 2 area• per
surfac.D.
- (6) Gate wltnees of .030 allowed on stock added surfaces,
(7) Thru or like impe=fectione appearing on opposite_sides are not a=ceptable p_oviding thel
are interpretable.
(8@ Indications which will be removed in machining are acceptable.
(9) _Inear, cola shut, Or cEack-_ike imper_ection• are not acceptable.

m i , , ii T - . i
F-C_M PI,704-,II ....

• 250
 .a

am_
Ir Iv,IM_t4_,.,ff_i,_,r,4*_sljmi _ • I III - 7 -_ 1 I g

I.--
_ TABLE I_. FL[;OR/_SCENT PENETRA_ ACCEPTJ_J_ CJ¢IT_RI_. , '

'_" P ENETRAN_

;'
-2i-T" R "
I_DXVIDUAL
BLEED 9UT
NO_T11_TE_ RE-
TABLE (i) (2)

E A .010 Max. of 5 per

, O .25x,25 area _

.030 Max. of-lO pe_

L E DiS. (5) .25 x ,_5 area-

PLATFORMS .030 Max. of _ per

i - :' Dis. (5) .25x.25- area.
I

i_ i EASE i AS (4) (4)

• _cH_
ZNED
' '.(_lo Max. ,_L.s'per
._5.x.25 area
:I 1,CAST . ,,

! (I) Generally porosity, concentrated in local, areas with. no ind_vldual indication exceedIDg
.010 dla. x .O10 depth.
" (2) L_mited to 2 areas per surface.
i _ (3) Thru or like imperfections appearing 3n opp3_ite sides are not acceptable providing they"
} _. a_e interpretable.
(4) Indications _hic_ will be removed in machining are acceptable.
i_. " 5) A cluster of these indications not to exceed .125 dis. and should be separated by .25
of good area.
} (6) Linear, cold shut, or crack-like Imperfections. are not _coepteble.
i <" TABLE ZII, RADIOGRAPHIC ACCEPTANCE CRITERIA.
- BLADE
RADIOGRAPHIC INDICATIONS
____._ AREA

; Elongate_ "Round Spacing

• _v .-
or oval , Limits Pactor
I [ (_)
i _ "_- -. III I • II
i A non_ .020 2 areas _er 5 x •
blade ,;

_ e .030 .040 (i) max. of 3 2 x

per blade r

:, - 2 areas per
BASE none .020 5 x
;_.. surface

(2) Minimum spacin 9 bet_veen indications is determined by circumscribing a circle around "
the. larger indication and multiplying its diameter by the apacin_ factor.

(1) Maximum oC two at a single radial position.

i2"
!

_--, _ 251
 -- . . i_||i i
i• rl I _ 111• rl| i I

ACID ETCItING H_IODS '_

Thi_dppendJx o_£e_s_alte_nata methods fo_ atchiL_g cas_ blades p_lor to inupection. Tha,_
OLo|_i_g muthods a_a utilized to accomplish, two _l_'L_oaes, (L) to ohtal_l an etoh-suf£1aient
to expose gJ:ai, bounda_ies prio_ to ._acrograin lnapuction_ and /.2) to obtain a cleanin_
etch. When specified, the cleaning etch sh_lL be used`prior to f_tuO=aacent-_enetrant
l.epaetion,

CAUTION: M_xing of solutions and etching of par_s _ust be accomplished in an a_ea with
_dequa_e exhaust ventilat_on, as toxic fumes are liberated from _he etchants.

Method I

£tohlng Solution :

' 100__. Approx. 1 lt_er

Hurlatic Acid- (20" Be) 80 gal 757 ml
Anhydrous Ferric Chloride_ FeCI3_ - 135 ibs 154 g
Nitric-Acid (42" Be) 2 gel 19 ml
Water- _l_gal 106 ml

l Add ferric chloride to murlatlc-aold, Allow to dissolve ............

2 Add. _i_r Ic acid,
3 Add water.-

a) A new. solution shall-he prepared when a suitable etch is not obtained within
i2 minutes.
b) DO no_ replenish to maintain volume,

Procedbre :

I. Load parts in etching basket, keeping level below basket rim

2. _mmerse parts.basket in etching solution maintained at room temperature (75-I00'P).
3_ 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) Immersion_ _Ime for cleaning etch shall be 20-30 seconds.
4. Re_ove from etchir_ solution and rinse in clean, cold water,
5. In_,et'se Ln alkaline cleaner solution for 3 minutes.
6. Remove front cleaner and r_nse in clean° cold water.
?, Air+-water (tozzle scrub each individual casting clean.
8 Blow loaded basket free of excess water with air only.

, Method 2

Etching Solution:

Ap_rox 2 liters
MU#l_tlc acid (20' _e) 90% by VOI (1615 ml)
Glacial acetic acid 5% by VO_. __ (85 ml)
Nit=it acld_ (42" Be) 5% by vol. (85 ml)
Ferric chloride to saturation (12,5 lbs)----

i. Ad_ acetic acid--to m_ri_tlc acid while cautiously agltati_g the mixture.
2. Gently heat the mlxtur_ and add sufficient ferric chloride to raise the boiling
point tO 150-160"F,
3. 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 the etohin_ time requires more than two
minutes to delineate the macrogtaln structure.

_rocedur_._

}.,... Pack parts in suitable tray o¢ basket as tha_ alrfoi_a GO not come in contact with
each other.

FORM P5'704-_ " '

252
 . _ - . _. _-.-_._._.._,._=E_.le.-.._.-..mw_..._, _
k

2. Ir_eree in acid atohau_ (_0 *IO°P) for 4 minimum length QE time to bring hm_ro-
qrain st=u=ture visible te una-ldnd aye. Maximum exposure time in the atchanC
shrill be limited _c two minutes. Thu et_hant Cr pa_s sh_ll be-agitated to aid
i_ obLaining uniform etching and to mlnlai_e thu exli_sure time.

a) X]_n_eL'_ion time for cleaning etch _hali be I0-20 seconds.

3, Rinse thoroughly in running tap water.

4. Desmut by inunersln_ in concentrated hydrogefl ps_.oxlda (HvO ?, 35 percent]. Hand
brush or alr-wate_ power flush--surfaces of the etched pa_t| to _emove residu_l

5. Rinse il_ running tap water,

6. R_1_se in ho_- tap _t0_ and dry,

i
Etc_£ng SoiutloR :

Murlatic acid (20 _ Be) 90% b_ VOW,

Hydrogen Peroxide (30-35%) 10% b_v_1, .(or eufficlent qtu_ntity
i to obtain a satisfactory
etch}

1. Add hydrogen peroxide t_ mu_iatio &ei_L while cautiously agitating the mixture,
a} Ma_e up solution Just prior to usage,
b] 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_,
c) Th_ etchent shall be discarded when the etching time requires more than five
minutes re delineate the macrogEain structure.

Procedure !

L Pack parts in eulteble tray or basket so that airfoils do not co_ in contact with
each other,
2, Ims_erse in acid et_hant maintained at room temperature (75-I00_P) for a minimum
length of time (5 mln, _ax,) to bring mecrograln structure vleible to unaided eye
when _nspecting for grain slze and casting irregu_aritles,
a} l,une_eion time for c_eanlng etch sha_l be _0-25 seconds.

3, R_nse in running tap water. Hand brushing or air-water power f_uehing may be
r_,_u_red if residual smut is _ot removed during the rinse c_cle.
4, Rinse in hot tap water and dry,

_--'o..P_o441"---_------' '- ' __ " _ "_"--

253

i -
 "- 1. Re_rt No,-- I 2. G_ernmen_Accmion No, 3. Recipient's_talo9 No.
CR-159464 _,
." 4. Titleand Subtitle 5. Re_rt Oate

_ow-Cost Dlrectionally-Solldifled Turbine Blades, January__979

Volum_ 1 6. Pc,loomingOr_ni/a_]on_de a
.
7, AuthOr[S) 8. Perlorming
Or_nizadon ReportNo
i ' L.W. Sink AiResearch 21-2953-1 t,
G. S. Hoppin,. IZI and M. FuJii 10.Wuk UnitNo.
_" 9. PerformingOtganizati_ NameandAdde_
A_esearoh Manufacturing Company of Ar Izona 11._ntractor GrantNo
i A Division of The Garrett Corporation
Phoenlx, Arizona 85010 NAS3-20073
.."_. Ty_ of Re_rt and Period_ver_
' ' ' Project Completion Report
i t2. S_nsoring Agency_Name
and,Addr_s Pro_ect 1
National Aeronautics and Space Administration 14.S_n_ring Agency_de F_

i _; Washington, D.C. 205.4.6

15. _pplementar_ Notes

Project Manaeer:
" Robert L. Dreshfiel_,
NASA-Lewis Research Materials
Center, and Structures
Cleveland, Ohio Division

:.- 16. Abstract.

! - A low_cost process for manufacturing high stress-rupture strength directionally-

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 consump-
tion (SFC} at least 1.7 percent; (2) reduce engine manufacturing Costs at least 3.2
i percent; (3) reduce engine weight at least 1 percent; and (4) reduce engine mainte-
:' nance costs at least 6.2 percent. These benefits were anticipated by the substitution
i of solid, uncooled directionally-solidified turbine blades for hollow, cooled,
; equlaxed-grain, turbine blades.

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 directionally-
_- . lsolldified 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.-

Results of Project 1 showed that the stress-rupture strength of exothermically

heated, directionally-solidified MAR-M 247 turbine blades exceeded program objectives
Lnd--that the performance
: and cost reduction goals were achieved.

17. Key Word|(Sugg_edby Author(s)) 18 DistributionStatement

Turblne-Blade Columnar-Grain Star Category 26

Directlonal-Solidification MAR-M 247
Alloy-Selection MAR-M 200+Hf
Ni-base Alloys IN 792 + NP
--_ : Investment Casting NASA-TRW-R
• Rx_herm4e-_{_at{nq i

; -
- 1_. S_urity _assif. [of this re_rt) i 20.

I "
_curlty Cl|s%i{. (Of this page]

" Fo( sale by:he Nah0nal Techmc_l l=lfo:mat,onSe_v,_e Spr,,:_',e!e 'Vltg]rJln221_1

t 21. _1o of P_g_

=
I 22 Pr_e"

! [ '" NA_A-C-Ib8(R_v. 10-7_)