Proceedings of 2017 IEEE
International Conference on Mechatronics and Automation
August 6 - 9, Takamatsu, Japan
Effects of Thermal and Mechanical Combined Load on
Blade Stress and Fatigue Life Characteristic
Hao Lin, Haipeng Geng, Hao Li, Xiangming Xu, Tingchen Du, Lie Yu
State Key Laboratory for Strength and Vibration of Mechanical Structures
Xian Jiaotong University
Xian, Shanxi 710049, P.R.China
lhhs36@icloud.com
Abstract - The turbine blade is the most important
component in the heavy-duty gas turbine. The common fatigue
failures of the blade include the thermal fatigue and mechanical
fatigue. Firstly, the finite element simulation of the blade is
carried out in the working condition including the centrifugal
load, high frequency vibration load and thermal load. According
to the simulation results of the combined load, the stress
distribution of the blade body is reasonable in the working
condition load; the stress level on the blade suction surface is
higher than the pressure surface; in the blade body, the maximum
Von Mises stress is 699.87 MPa, and the location of the minimum
fatigue life is close to the blade shroud. Above simulation results
is very useful for the structural design and fatigue experiment.
Secondly, the blade fatigue experiment is realized by building a
thermo-mechanical combined fatigue experiment system. The
stress and thermo-mechanical fatigue life characteristic are both
analyzed with this experiment system. Through the dynamic
stress experiment under the high and low cycle combined load,
the stress-time history in the blade body is obtained; through the
thermo-mechanical fatigue experiment, the fatigue crack of the
blade first appears in the middle of the blade exhaust side. Based
on these experiment results, the dynamic stress experiment data
and the combined fatigue failure mode are obtained. Lastly, a
nonlinear Gauss fitting expression between the fatigue life cycle
number and the vibration frequency of the high cycle load is
given for the fatigue life prediction. These results are significant
for the blade fatigue failure in the future.
Index Terms - Heavy duty gas turbine blade; Finite element
simulation; Thermo-mechanical combined fatigue; Stress
characteristic; Fatigue life
I. INTRODUCTION
The power generation efficiency of the heavy-duty gas
turbine is very high, and the current maximum efficiency has
been up to 60%. Furthermore, there are many advantages
including compact size, rapid start-up, smooth operation, high
reliability and low pollution emissions in the heavy-duty gas
turbine. Therefore, it has become the main part in the power
industry. In addition to the purposes of the power generation,
the heavy-duty gas turbines as industrial facility also have
great application prospects[1,2].
Turbine blades are the most significant component in the
gas turbine. The turbine blade is subjected to many kinds of
loads, including centrifugal load, temperature load, vibration
load, etc. With the corrosion of high temperature and oxidation
erosion, the operating conditions are very severe. So it is very
978-1-5090-6759-6/17/$31.00 2017 IEEE
important to evaluate the fatigue performance in a harsh
service environment. Not only the safety service of the super-
alloy blade may be guaranteed, but also the development and
production can be promoted[3,4]. The common fatigue failures
of the blade include the high cycle fatigue (HCF), the low
cycle fatigue (LCF), the thermal fatigue, the high and low
cycle combined fatigue (CCF) and so on[5,6].
In the NASA HOST (Hot Section Technology) program[7],
the viscoplastic constitutive and life model which considers the
long term and fatigue is the research emphasis; in 2011,
Europe also launched the PREMECCY program[8], which
aimed at the blade CCF and the development of the life
prediction theory and method to improve the blade reliability
and reduce maintenance costs.
Due to the extremely complex structure and service
conditions, many problems about the fatigue life of heavy-duty
gas turbine blades have not been clearly stated and effectively
solved. Among these problems, thermal and mechanical
combined fatigue is the main failure mode caused by the
complex multi-field of temperature and force[9,10]. So it is very
necessary to carry out the study on the thermal and mechanical
combined fatigue.
According to the different form of the experimental
object, the blade fatigue life experiment can be divided into
three types[10]: standard specimen, simulating parts and real
full scale blade. It is difficult to carry out the fatigue life
experiment of the real full-scale blade, while its experiment
result is very significant and useful. The technical difficulty
lies in how to simulate the load and the environment as close
to the real working condition as possible. At present, most of
fatigue experiments are based on the standard specimen and
simulating parts. So it is difficult to simulate the effect of
stress state, temperature and manufacturing technology on the
fatigue life. There are less studies on the experiment and
performance evaluation for real full scale gas turbine blades.
In conclusion, this paper takes the real full scale blade to
carry out the finite element simulation and experiments on the
thermal and mechanical combined fatigue. And the stress field
distribution, relationships between the stress and the high and
low cycle combined load, blade fatigue life and crack initiation
characteristics have been studied under the combined fatigue.
It is very significant for the blade to carry out the fatigue life
design, fatigue analysis and failure prevention.
II. FINITE ELEMENT SIMULATION ANALYSIS
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 The blade is a critical component that has characteristics In this paper, the tetrahedral element is used to establish
of the high temperature, high load and complex surface in the the finite element model of the blade. Because the tetrahedral
heavy duty gas turbine. So in the structure of the blade body, element can deal with the surface and curved shapes, and
there may be a high stress level which can lead to the failure of simulate the complex geometric model with sharp corners. The
the blade fatigue fracture. Therefore, when the blade strength mesh is refined at the blade edge, and finally there are
and fatigue life are analyzed, it is necessary to develop a finite 1283671 elements and 2123659 nodes in the finite element
element model about the blade stress and fatigue life. model.
The blade material called MAR-247 is oriented solidified
A. Blade Finite Element Analysis Theory
superalloy. And the high temperature creep strength can be
In the three-dimensional space coordinate system, the
improved by the high temperature single crystal directional
physical equation of the stress and strain for the orthotropic
crystallization technology of this material[12].
material are:
The parameters of the material properties are shown in the
H T
T
(1) following table I.
D 0 .
TABLE I
(2) PARAMETERS OF THE MATERIAL PROPERTIES
Thermal
In (1) and (2), is the stress matrix; is the strain
Elasticity Heat transfer Poison Yield
expansion Density
modulus coefficient ratio limit
coefficient
matrix; D and H is the elasticity matrix; is the 1.4e5 40 9e-6 8.5e-9
0.3
883
MPa kgm/(s3k) /K T/mm3 MPa
thermal expansion coefficient of the material; T is the The effect of the thermal stress on the blade fatigue life
temperature change value in the elastic body; 0 is the could not be neglected. Therefore, the temperature load of 600
o
deformation caused by the temperature and the its matrix form C is applied to the blade finite element model. In the gas
is 0 T 1,1,1, 0, 0, 0 .
T
turbine working condition, the blade centrifugal force
generated by the high speed rotation is the primary load. The
At any one of the blade elements, the relationship between centrifugal load is applied to the finite element model around
the strain and the node displacement is represented by the the turbine axis by a rotational speed, and the centrifugal load
geometric equation: is a rated speed of 6000 rpm. Due to the contact between the
B . (3) joint and the groove, the displacement boundary condition
should be non-linear. So the displacement boundary conditions

In (3), B is the geometric matrix of the element; is of the finite element model are complex. And this paper
the displacement matrix. mainly consider the stress and strain problems in the blade
Through (2) and (3), the stress expression of the finite body, so the blade joint and shroud can be applied by a fixed
element is obtained: constraint. The blade finite element model is shown in the Fig.
D 0 D B D 0 . (4) 1.
The blades are subjected to the mechanical load in the
working condition, so the differential motion equation of the
mechanical load is expressed by
.. .
M { } C { } K { } F . (5)

In (5), M is the mass matrix; C is the damping

matrix; K is the stiffness matrix; F is the blade mechanical
load in the working condition.
Due to the thermal load in the blade, the expansion of
different locations will occur in different degrees. With the
structural constraints, the expansion can not occur freely and Fig. 1 Finite element model of the blade
result in the thermal stress. According to the principle of C. Simulation Results of Thermo-mechanical Stress
minimum potential energy, the equivalent node temperature In this paper, the blade stress calculation and analysis
load R is expressed by:
e
under the centrifugal load and the temperature load have been
accomplished. So the stress distribution of the blade body is
B D B dV B D dV (6)
T T
R
e
0 obtained, and each stress concentration area is found. Under
Ve Ve the centrifugal and temperature load, the stress distribution on
the blade pressure and suction surfaces are respectively shown
B. Blade Finite Element Model in the Fig. 2.

1349
 According to the blade stress calculation results, it can be As shown in the Fig. 3, the distribution nephogram of the
concluded that the stress distribution of the blade body is blade fatigue life is calculated. The results show that the
reasonable at the rated speed (6000 rpm), and the stress level minimum fatigue life is in the area close to the shroud and the
in the area close to the shroud is high. This area can be used as minimum fatigue life is 104.1767 .
the measurement point of the fatigue experiment. In addition
the stress level on the blade suction surface is higher than the
one on the blade pressure surface. The maximum equivalent
stress (Von Mises) in the blade body is 699.87 MPa, which
comes within the yield limit of the material. The strength
analysis of the blade is the prerequisite for the analysis of the
blade fatigue life. The maximum stress is a significant analysis
basis of the blade life calculation.
(a) Fatigue life distribution on the suction surface

(a) Stress distribution on the blade suction surface (MPa)

(b) Fatigue life distribution on the pressure surface
Fig. 3 Fatigue life distribution nephogram of the blade
According to the blade fatigue life calculation results, it
can be concluded that thermal stress has an important effect on
the fatigue life of the blade. The minimum fatigue life is in the
blade body close to the shroud. The simulation values can
provide a reference for the following experiment.

(b) Stress distribution on the blade pressure surface (MPa) III. THERMO-MECHANICAL FATIGUE LIFE EXPERIMENT
Fig. 2 Von Mises stress distribution of the blade body
A. Thermo-mechanical Combined Fatigue Experiment
D. Simulation Results of Thermo-mechanical Fatigue Life System
Blade fatigue fracture is caused by the generated dynamic Turbine blades are subjected to centrifugal loads, high
load. Even if the stress value is much smaller than the static frequency vibration loads and temperature loads under the real
strength of the material, it could still cause fatigue damage. working condition. When these loads act on the blade at the
The widely used prediction model based on the Manson- same time, the blade fatigue failure is a combined fatigue
Coffin theory and the linear damage accumulation method is problem rather than individually low or high cycle fatigue.
applied in this paper[13]. And the equivalent stress used in the This is a very important characteristic study on the blade
analysis is calculated from the previous finite element model. fatigue life[14]. In order to realize the combined fatigue
The formula of the fatigue life prediction is: experiment, a thermo-mechanical fatigue experiment system
eq f have been built. The composition of the system is shown in
2 N f 2 N
b c
. (7)
Fig. 4, and the thermo-mechanical fatigue experiment is
2 E
carried out based on this system with the real full scale blade.
In (7), eq / 2 is the Von Mises equivalent strain
amplitude; f is the fatigue strength coefficient; f is the
fatigue plastic coefficient; b is the fatigue strength exponent; c
is the fatigue plastic exponent; E is the elasticity modulus; N
is the fatigue life cycle number.
Because of the centrifugal load, the average stress m of
the blade is generally affected, and the average stress has a
great influence on the fatigue life. Therefore, it is necessary to
modify the fatigue strength coefficient in (8). The Morrow
correction formula is:
eq f m
2 N f 2 N .
b c
(8)
2 E Fig. 4 Thermo-mechanical combined fatigue experiment system

1350
 In the thermo-mechanical fatigue experiment system, there
is a high and low cycle combined fatigue device which
consists of the high cycle load part (HCLP) and the low cycle
load part (LCLP) to meet the requirements of the high and low
cycle combined fatigue. The structure of LCLP is shown in
Fig. 5. The blade shroud is kept within bounds by a shroud
constraint, and the centrifugal load of the blade is simulated by
the tensile force through a stretching equipment. On the other
hand, the input of the high frequency excitation force comes
true through the HCLP[15]. At the same time, the control
equipment includes the Arduino controller module, the servo
drive and some other controller units, as shown in Fig. 5. The
control equipment can adjust the vibration amplitude and
frequency to achieve the simulation of the blade working
vibration. And the control equipment can also realize the
automatic timing control of the tensile force to simulate the
start-stop of the turbine blade centrifugal force.
Fig. 5 Structure and equipment of LCLP
Meanwhile, in the thermo-mechanical fatigue experiment
system, there is a heating device to apply the temperature load
to the blade body. The temperature load is 600 o C , as the
same as the blade working temperature. The mode of the
heating device is electromagnetic induction heating through a
high frequency power supply. The temperature measurement is
realized through a temperature control part (the precision
is 5 o C ) and the real-time feedback adjustment can ensure
that the blade experiment temperature meets requirements. The
electromagnetic induction heating device is shown in Fig. 6.
Fig.6 Electromagnetic induction heating device
In conclusion, the new design of the thermo-mechanical
fatigue experiment system has many advantages. The
experiment system can simulate the load of complex service
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conditions at the same time. The experiment condition is
closer to the actual service conditions of the blade than before.
Furthermore, according to the needs of different service
conditions, the parameters of the experiment system can be
adjusted, and the different experiment load can be applied.
Thus, the experiment system is capable of satisfying the
dynamic stress experiment and the thermo-mechanical fatigue
experiment of the real full scale blade as stated below.
B. Dynamic stress experiment of high and low cycle
combined load
According to the finite element simulation results, the top,
middle and bottom of the blade suction surface are defined as
the measuring points, and the strain sensor is arranged in the
blade for the stress experiment of the high and low cycle
combined load. Totally there are eight measuring points,
including two points in the middle, two points in the bottom
and four points in the top. The location of measuring points is
shown in Fig. 7.
Fig.7 Location of measuring points in the blade
In the laboratory, the tensile force of the low cycle load
and the frequency of the high cycle load are changed
respectively to carry out the comparative experiment. During
the dynamic stress experiment, a data acquisition device is
used to collect the dynamic stress data continuously. After
processing the stress data, the interference signal in the
experiment has been filtered. And the stress values in the top,
middle and bottom of the blade are obtained as the Fig. 8,
which shows the curve of the experiment stress-time history.
Fig.8 Curve of the experiment stress-time history
According to the data of the experiment stress-time
history, the rainflow counting method[16] and the dynamic
stress data processing are both completed. Then the average
stress m can be get through:
m max min / 2 . (9)
In (9), max and min are the maximum and minimum
stress values in the experiment stress-time history.
Then the fatigue life under the high and low cycle combined
load can be obtained in (8) and (9). These results can conclude
the relationship between the blade fatigue damage and the high contribution to the fatigue damage accumulation. And the high
and low cycle combined load. cycle fatigue can not be ignored in many fatigue damage
factors[19].
C. Thermo-mechanical fatigue experiment
In this dynamic stress experiment, the low cycle load and
On the basis of the thermo-mechanical fatigue experiment
the vibration frequency of the high cycle load are taken as
system, the thermo-mechanical fatigue life experiment has
variables. The main purpose of the study is to analyze the
been carried out for real full scale blades. The experiment load
effect of vibration frequency on the fatigue life of the high and
spectrum sketch in the working condition is shown as the
low cycle combined fatigue. Therefore, the distribution of
fatigue experiment load sketch in Fig. 9, and includes the
fatigue life cycle number and its mathematics expression is
thermal load, low cycle load and high cycle load. The full
very essential for the combined fatigue characteristics of the
fatigue life load of the blade is simulated by the multiple
blade to accurately predict the fatigue life. According to the
cycles of blade fatigue experiment[17]. During the experiment
Gauss fitting, the results of the fitting are given as the Fig. 10.
the fatigue crack initiation of the blade is shown in Fig. 9.
According to the Fig. 10, it is found that in the curve of the
Through the experiment results, the form of blade failure
Gauss fitting, the relationship between the cycle number and
can be obtained under the thermo-mechanical fatigue. The
vibration frequency can be expressed as a Gauss function. It
crack first appears in the middle of the blade exhaust side.
suggests that the cycle number and vibration frequency both
This region is the fatigue risk zone of blades, so the fatigue
conform to the Gauss fitting, and its mathematical expression
crack initiation may first start from this region. In the working
is given as:
condition, the blade is subjected to strong centrifugal load, and
then the alternating vibration load and the high temperature A f fc
2

N f a0 exp 2 (10)
load are superimposed. The position of the blade fracture and
/ 2
the crack extended rate can be directly affected by the value
and distribution of the vibration stress[18]. In (10), N f is the fatigue life cycle number; f is the
high cycle vibration frequency; , A , , f c is the
a0
coefficient of Gauss function, which is listed in the following
table II.
TABLE II
COEFFICIENT OF FUNCTION AND FITTING COEFFICIENT

Low cycle load(kN) 4 8 16

a0 48745 70 100
Fig.9 Blade fatigue crack initiation and fatigue experiment load sketch
A -2.7e7 2.9e5 2.4e8
IV. FREQUENCY-LIFE CHARACTERISTIC OF HIGH AND LOW
CYCLE COMBINED FATIGUE 441 46 87

Based on the dynamic stress experiment of the high and fc 81 -1.3 -119
low cycle combined load, the blade stress measurement is
Fitting coefficient 0.85014 0.99811 0.99952
carried out under the different levels of the vibration frequency
and low cycle load. According to the stress value obtained From the table II, it can be seen that in the different low
from the experiment, the equivalent fatigue life cycle number cycle load, three fitting coefficients are respectively 0.85014,
can be calculated and the results is shown as the point in Fig. 0.99811 and 0.99952. So the Gauss fitting is close to the real
10. trend factually.
It can be seen that the fatigue life of the blade is obviously
reduced when the high vibration load is superimposed on the
low cycle fatigue. And the stress value increases and the blade
fatigue life reduces, with the raise of the vibration frequency.
When the vibration frequency is small enough, the fatigue life
cycle of the blade can exceed the material fatigue life limit,
which is 107 cycles. This situation can be approximated that
the blade will not appear fatigue failure. In addition, through
the comparison of the fatigue life data in the same low cycle
load and different frequency, the dispersion of the high and
low cycle combined fatigue life is larger than the low cycle
fatigue. Because the stress amplitude of the high cycle fatigue
Fig.10 Gauss fitting of the high and low cycle combined fatigue life
is small, but the frequency is high in the combined fatigue
experiment. So the high cycle fatigue damage has an important Compared with the experiment on the standard bladelike
specimen, it is difficult to carry out the high and low cycle

1352
combined fatigue on the real full scale blade, because of the
complex experiment system, the load coupling influence and
long experiment period[20]. So based on the above analysis of
blade fatigue characteristics under the high and low cycle load,
the fatigue life of the superalloy blade can be studied in the
future. According to the fitting method, a complete curve of
the high and low cycle combined fatigue life can be got
through the experiment results under the centrifugal load and
some kinds of vibration frequency. It is of great significance to
shorten the research period and save the cost of the
experiment. So the method and conclusion have wide
application significance in the fatigue life design and failure
analysis on the blade.
V. CONCLUSIONS
According to the results of the finite element simulation
and real full scale blade fatigue experiment, the blade stress
characteristic and fatigue life under the thermo-mechanical
combined load are researched in detail. The blade fatigue
experiment is based on a thermo-mechanical combined fatigue
experiment system. The results of the simulation analysis and
experiment are obtained in the combined load condition
including the centrifugal load, high frequency vibration load
and thermal load. These results are very significant for the
fatigue analysis. The conclusions can be given as the following
items:
1) Thermo-mechanical simulation results based on the
stress and fatigue life are got. The stress distribution of the
blade body is reasonable. In addition, the blade stress level on
the suction surface is higher than the pressure surface. The
maximum Von Mises stress is 699.87 MPa in the blade body
closed to the blade shroud. And the location of the minimum
fatigue life is the same as the maximum stress.
2) A thermo-mechanical combined fatigue experiment
system have been built and the thermo-mechanical fatigue
experiment is carried out in this system with the real full scale
blade. Through the dynamic stress experiment of the high and
low cycle combined load, the stress-time history in the blade is
obtained. And through the thermo-mechanical fatigue
experiment, the fatigue crack of the blade first appears in the
middle of the blade exhaust side. The researches have great
reference value for the blade stress and fatigue life analysis in
the future.
3) A nonlinear Gauss fitting expression between the
fatigue life cycle number and the vibration frequency of the
high cycle load is given quantitatively. This conclusion has
great significance in the blade fatigue life prediction under the
high and low cycle combined load.
ACKNOWLEDGMENT
This work was supported by the Key Project of Chinese
National Programs for Fundamental Research and
Development (No.2013CB03570401) and Chinese National
Natural Science Foundation (No.51375366).
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