N. Jayaraman, D. J. Hornbach, P. S. Prevey, Lambda Technologies, Cincinnati, OH; J. Sides, R. Ravindranath, R. Chan, NAVAIR, Patuxent River, MD
Use of compressive residual stresses in turbine engine compressor parts is proving to be very useful for sustainment of parts prone to different damage conditions. The leading and trailing edge of blades and vanes are subject to fatigue cracking and foreign object damage (FOD). Both the blade dovetail and the rotor disk post contact surfaces are vulnerable to fretting damage, which leads to microcracking and mode I fatigue cracks. Low plasticity burnishing (LPB) has been shown to introduce controlled magnitude and distribution of compressive residual stresses to completely mitigate either FOD on the edges of vanes and blades or fretting-induced microcracks at the edge of bedding on the contact faces of the dovetails and rotor disk posts. Residual stress field design, specialized LPB tooling, quality assurance (QA) of the process exceeding six-sigma, and the ease of application of LPB as a simple machining process on the shop floor will be described. Benefits due to current applications of LPB to the US Navy and other naval groups internationally in improved damage tolerance and reduced total ownership costs of turbine engines will be highlighted.
Summary: Presentation will detail sustainment of compressor components via low plasticity burnishing (LPB). Focus will be on residual stress field design, LPB tooling, quality assurance and ease of application. Benefits to the US Navy in improved damage tolerance, sustainment, and reduced total ownership will be highlighted.