Intelligent Probes for Enhanced Non-Destructive Determination of Degradation in Hot-Gas-Path Components

65367 Life management of gas turbines is limited by the availability of reliable quantitative information about the material condition of critical components, including coating systems. This is particularly costly in the field where decisions regarding repair and reuse must be made quickly by available personnel. This project will develop high resolution, eddy current sensor arrays to provide reliable materials information in real-time at the plant site, including in situ inspection without component removal and increased inspection throughput at reduced total inspection costs. Phase I demonstrated: (i) characterization of aging of McrAlY coatings, (ii) detection of cracks and the determination of crack depth in coated and uncoated components, (iii) imaging damage on service exposed components, (iv) a four- or five-unknown algorithm to provide reliable quantitative characterization of different complex coatings systems, both aged unaged, and (v) substantial commercial demand among OEMs, utilities, rework/repair facilities, and service providers. Phase II will develop a methodology to predict the likelihood of failure before the next inspection from specific aging mechanisms, including creep, fatigue and corrosion. In particular, Phase II will (1) demonstrate a capability to predict failure likelihood from at least one specific aging mechanism, (2) demonstrate a capability to distinguish life-limiting cracks from inconsequential cracks, (3) develop a preliminary method for detection and characterization of corrosion and erosion-corrosion in syngas-fired HGP components, (4) enhance the capability of the demonstrated four-unknown algorithm, (5) demonstrate in situ crack detection and/or aging characterization capability without blade removal, and (6) develop decision support tools for materials, component, and fleet life management. Commercial Applications and Other Benefits as described by the awardee: The inspection of land-based gas turbines (including turbines operating on natural gas, sun, or oil) should be the primary market for this technology. In addition, air-based propulsion systems require improved coating and aging characterization.