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Damage Tolerance Improvement of Ti-6-4 Fan Blades with Low Plasticity Burnishing

From Lambda Technologies
 

 

Low plasticity burnishing (LPB) has been
demonstrated to increase the damage tolerance of Ti-
6Al-4V fan blades by an order of magnitude. First
stage Ti-6Al-4V fan blades were LPB processed using
a conventional 4-axis CNC machine tool. LPB
dramatically improved surface finish with negligible
blade distortion and produced compressive residual
stresses of -690 MPa (-100 ksi) through the entire
thickness of the blade leading edge. Fatigue testing
demonstrated that the deep compression of LPB
provided a 3X improvement in HCF endurance limit,
complete tolerance of FOD up to 1.3 mm (0.050 in.)
deep, and an order of magnitude improvement in
fatigue life. Damage tolerance for the TI-6AL-4V fan
blade was improved by an order of magnitude.
The benefit of the LPB generated compressive layer in
improving damage tolerance was confirmed using the
fatigue crack growth code AFGROW. Crack growth
modeling indicates tolerance of deeper FOD is
achievable with optimization of the depth and
magnitude of the residual stress field. LPB has been
demonstrated to be an effective and affordable means
of improving the damage tolerance of Titanium alloy
fan and compressor blades. Application of LPB
during manufacturing and overhaul operations could
significantly reduce the cost of engine inspection and
maintenance while improving fleet readiness.

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Product Announcements
Lambda Technologies - Low Plasticity Burnishing (LPB™)
LPB™ is a patented, mature, proven surface treatment for improving High-Cycle Fatigue (HCF), Stress Corrosion Cracking (SCC) and damage tolerance performance. (read more)
Lambda Technologies - Surface Enhancement
Surface enhancement offers a variety of benefits ranging from increased life to cost reduction when properly designed and optimized for the material and application. Strength and life can be increased... (read more)
Lambda Technologies - Surface Integrity Studies
Surface Integrity describes the influence of surface property and condition upon material performance. It has long been known that the method of surface finishing and the complex combination of... (read more)
Lambda Technologies - Controlled Plasticity Burnishing (CPB)
The same tools and control systems developed for low plasticity burnishing (LPB™) can of course be used to deliberately create higher amounts of cold work when warranted. (read more)
Metal Improvement Company - High-Tech Shot Peening Combats Metal Fatigue
Shot peening is a cold working process in which the surface of a metal part is bombarded with small spherical media called shot. Each piece of shot striking the metal acts as a tiny peening hammer... (read more)
Lambda Technologies - Fatigue Design Diagram (FDD) Analysis
Lambda's patented Fatigue Design Diagram (FDD) analysis provides quantitative determination of the optimal compressive residual stress distribution in a component necessary to alleviate typical damage... (read more)
Lambda Technologies - Finite Element Analysis (FEA)
Lambda Technologies provides finite element analysis (FEA) services in support of residual stress design and characterization. (read more)
Metal Improvement Company - Unique Laser Peening Services
The Metal Improvement Company laser peening process uses a unique Nd:glass, high output, high repetition laser combined with precision robotic manipulation. During the laser peening process, the laser... (read more)
Specialty Blades, Inc. - Fiber Chopping Blades
Specialty Blades is capable of producing a razor blade in any shape or size as part of our Endurium Line that is suitable for synthetic fiber cutting applications. (read more)
 
Topics of Interest
The deep stable layer of compressive residual stress produced by low plasticity burnishing (LPB) has been demonstrated in laboratory testing to improve damage tolerance in engine alloys IN718,... (Read More)
Low Plasticity Burnishing (LPB) is now established as a surface enhancement technology capable of introducing through-thickness compressive residual stresses in the edges of gas turbine engine blades... (Read More)
Mechanical surface treatments that introduce a layer of residual surface compression improve high cycle fatigue (HCF) performance. If the depth of compression extends through the thickness of blade or... (Read More)
This paper describes the application of Low Plasticity Burnishing (LPB) to increase the damage tolerance and fatigue strength of a Ti-6Al-4V fan blade that is fatigue life limited by the occurrence of... (Read More)
Low Plasticity Burnishing (LPB) has been applied to produce a layer of deep high magnitude compressive residual stress in the leading edge of Ti-6Al-4V first stage fan blades. The goal was to improve... (Read More)
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