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Material Improvements Materials used in gas turbines have gone through many incremental improvements since the first practical turbines were developed in the 1940s. Most R&D efforts led to improved steel alloys for use in turbine vanes, blades, and inlet blocks. This R&D in turbine materials and coatings led to two important effects. First, gas turbines were better able to withstand high temperatures. These more rugged materials allowed for hotter inlet gas to enter the turbine’s first stage blades, leading to higher efficiencies. Second, material improvements led to an increase in rotor life and reliability. Gas and combined cycle plants could not have achieved popularity and larger market shares without solving problems such as premature blade cracking or component deformations. Together, the higher temperatures, higher efficiencies, and improved reliabilities have advanced the deployment of gas turbines in the power generation market. Material improvements have often been marked by iterative advancements through the years. In the 1950s and 1960s, materials were often selected from available in-house steam turbine and jet engine experiences. However, differences between industrial gas turbines and these other types of turbines eventually required that their material paths diverge. For example, aerospace turbines operate under significantly different conditions because turbojets operate in relatively pristine environments and situations for which light weight is a benefit. Many of their materials are not suitable for the corrosive operating environments of power generation gas turbines. Furthermore, jet engines are subject to strict government safety regulations which require inspections at short and regular intervals. In contrast, industrial gas turbines, subject to more commercial considerations, are expected to operate for longer periods of time with less rigorous inspection and maintenance. Steam turbines also differ significantly from gas turbines in their material needs. The main concern in steam turbine blade design is the structural integrity of large blades and dealing with the corrosion due to steam and water passing through the blades and vanes. In contrast, gas turbines have smaller blades which are subject to higher temperatures and different fluids passing through and around them. The unique problems and characteristics of power generation gas turbines required that their material evolution follow a different path of development. Progress in gas turbine material development often came in the form of alternative stainless steel or metal alloys that had improved heat characteristics. Different parts of gas turbines use a variety of alloy metals, including varying quantities of cobalt, nickel, and chromium. In turbine compressors, manufacturers vary in their metals and manufacturing methods, but initial blades are often made with stainless steel because it is strong and easy to machine.6 Compressors have not gone through many drastic changes in material over the years. As in cases from decades ago, tertiary row compressor blades may use a 12 percent chrome material because of its high strength, good corrosion resistance, and superior damping characteristics. One example of an addition comes from Westinghouse’s use of CuNiIn coating on the compressor blade roots to inhibit fretting.7 6 Interview with Lee McLurin, Westinghouse. 7 Bannister et. al. “Evolution of Westinghouse Heavy Duty Power Generation and Industrial Combustion Turbines,” Transactions of the ASME, April, 1996., p. 325 7PDF Image | Energy RD Performance: Gas Turbine Case Study
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