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Materials in other parts of the turbine have been changed more frequently as the state of the art advanced. This is certainly the case with stationary turbine blades (or vanes). Some early stationary blade designs used welded structures in AISI 310, a 25-20 austenitic stainless steel that had excellent resistance to both corrosion and to oxidation at elevated temperatures, but which had limited strength capabilities.8 Some turbojets then switched to higher strength, nickel-based alloys, but this proved to be unsuitable for industrial gas turbines because they either lacked corrosion and oxidation resistance or they were too difficult to weld with enough integrity. In the 1960s, engineers began to design these vanes with cobalt alloys for two reasons. First, cobalt alloys have high heat tolerances and can withstand high firing temperatures and corrosion with less cracking or warping. Second, cobalt alloys tend to have favorable welding characteristics. The welding ease of this metal can be extremely important when facing the inevitable fact that turbine vanes will occasionally crack with time and use. Having the ability to adequately repair a vane through welding is far preferable and less costly then having to replace the whole component. In this sense, material improvements in stationary blades and vanes have improved heat characteristics and increased rotor life by reducing turbine damage and allowing easier maintenance. Cobalt alloys are still used today, although the type of alloy has been improved to increase creep and oxidation resistance. Another set of improvements took place with a move to the use of more low-chromium alloys. This shift to use of 247 and 979 chromium alloys took place to enhance strength, even though use of these materials sacrificed some resistance to corrosion. Some turbine manufacturers have also increased their use of titanium, a particularly strong but expensive metal, in their gas turbine components. 9 Rotating turbine blades have also improved with progressions in their materials. These rotating blades tend towards nickel alloys, which also display improved properties with iterative change. Early designs used a variety of nickel-based alloys and even some 12 percent chrome material similar to that used for compressor blades. Development led to the more widespread use of some standard Inconel nickel alloys, which were necessary as firing temperatures increased. In another example, improving from 520 nickel alloy to 750 and 738 alloys have allowed some manufacturers to maintain or improve high heat tolerances while simultaneously improving their production characteristics.10 Among the most important production characteristics is the determination of whether a blade is cast or forged. Forging and machining a blade may be easier for some cases, but intricate designs and complex configurations may require that a blade be cast instead. Other times, there can be considerable difference between the ability to be able to cast a blade in a press than it is to painstakingly forge and machine one. The casting may be a simpler process that is less expensive. Some turbine material improvements, such as Westinghouse’s switch to 738 alloy, have led to the use of more “crystallized” metals that are directionally solidified and more amenable to successful and simple production. Metals used previously would be more likely to crack if they were cast because their internal structure is not as strong as today’s alloys.11 This incremental progression in alloys has been instrumental in improving gas turbines. 8 Bannister et. al. “Evolution of Westinghouse Heavy Duty Power Generation and Industrial Combustion Turbines,” Transactions of the ASME, April, 1996., p. 325. 9 Interview with Lee McLurin, Westinghouse. 10 Bannister et. al. “Evolution of Westinghouse Heavy Duty Power Generation and Industrial Combustion Turbines,” Transactions of the ASME, April, 1996. p. 326 11 Interview with Lee McLurin, Westinghouse. 8PDF Image | Energy RD Performance: Gas Turbine Case Study
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