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In this study the main causes of the failure of a GE-F9 second stage turbine blade were investigated. The stress distribution of the blade which has 6 cooling vents in three modes (with full cooling, closure of half of the cooling channels, and without cooling) was studied. A three dimensional model of the blade was built and the fluid flow on the blade was studied using the FVM method. The stress distribution due to centrifugal forces applied to the blade, temperature gradients and aerodynamic forces on the blade surface was calculated by the finite element model. The results show that the highest temperature gradient and as a result the highest stress value occurs for the semi-cooling state at the areas near the blade root and this status is true for the full cooling mode for the regions far from the root. However, the field observations showed that the failure occurred for the blade with the semi-cooling state (due to closure of some of the channels) at areas far from the root. It is discussed that the main factor of the failure is not the stress values being maximum because in the state of full cooling mode (the state with the maximum stress values) the temperature of the blade is the lowest state and as a result the material properties of the blade show a better resistance to phenomena like hot corrosion and creep.

Stress analysis of a second stage gas turbine blade under asymmetric thermal gradient