Surface enhancement technologies such as shot peening, laser shock peening, and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The x-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including the following. (1) The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing the fatigue benefit of thermal stability at engine temperatures. (2) An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. (3) Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. (4) Corrosion fatigue mitigation with LPB in Carpenter 450 steel. (5) Damage tolerance improvement in 17-4 PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.
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October 2006
Technical Papers
Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications
Paul S. Preve´y,
Paul S. Preve´y
Lambda Research, 5521 Fair Lane, Cincinnati, OH 45227
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Ravi A. Ravindranath,
Ravi A. Ravindranath
NAVAIR, 22195 Elmer Road, Building 106, Room 202-G, Patuxent River, MD 10670-1534
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Michael Shepard,
Michael Shepard
Wright Patterson AFB, 2230 Tenth Street, Ste. 1, Wright Patterson AFB, OH 45433-7817
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Timothy Gabb
Timothy Gabb
NASA Glenn Research Center, 21000 Brookpark Road, Building 49, Room 231, Cleveland, OH 44135-3191
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Paul S. Preve´y
Lambda Research, 5521 Fair Lane, Cincinnati, OH 45227
Ravi A. Ravindranath
NAVAIR, 22195 Elmer Road, Building 106, Room 202-G, Patuxent River, MD 10670-1534
Michael Shepard
Wright Patterson AFB, 2230 Tenth Street, Ste. 1, Wright Patterson AFB, OH 45433-7817
Timothy Gabb
NASA Glenn Research Center, 21000 Brookpark Road, Building 49, Room 231, Cleveland, OH 44135-3191
Contributed by the International Gas Turbine Institute (IGTI) of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received October 2002, final manuscript received March 2003. Assoc. Editor: H. R. Simmons. Paper Presented at the International gas Turbine and Aeroengine Congress and Exhibition, Atlanta, GA, June 16–19, 2003, Paper No. 2003-GT-38922.
J. Eng. Gas Turbines Power. Oct 2006, 128(4): 865-872 (8 pages)
Published Online: September 18, 2006
Article history
Received:
October 1, 2002
Revised:
March 1, 2003
Online:
September 18, 2006
Citation
Preve´y, P. S., Ravindranath, R. A., Shepard, M., and Gabb, T. (September 18, 2006). "Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications ." ASME. J. Eng. Gas Turbines Power. October 2006; 128(4): 865–872. https://doi.org/10.1115/1.1807414
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