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A first stage turbine vane of a heavy-duty gas turbine engine, exhibiting an outward bulge of approximately 0.6 mm and a visible crack in the top coating, was delivered by the client for a detailed destructive failure investigation. The subject component was an experimental part used in a test field engine. The suction side wall of the casting was cut off to reveal a gaping crack on the inside of the aft cavity that was also visible by borescopic inspection. The cooling insert of the aft cavity was clean and did not have any blocked cooling holes. The cooling pattern on the inside wall of the aft cavity was unremarkable. No evidence whatever of impact damage was found on the suction side surface of the subject vane in the cracked region. The hypothesis as to the most probable root cause of the cracking that is still standing is a combination of low wall thickness, non-optimal process parameters for bond coat pre-heat, and potentially high thermal/mechanical loading during engine operation. It appears this is not a wide-spread phenomenon but rather an isolated occurrence.

Metallurgical Failure Analysis of Cracked First Stage Vane of Heavy-Duty Industrial Gas Turbine Engine for Power Generation