Gas Turbine

Applications of
Thermo-Calc and DICTRA

Thermo-Calc Users Meeting
Aachen, 2010-09-09
Sebastian Piegert
E F PR GT EN M&T MPD3
Copyright © Siemens AG 2009. All rights reserved.

Outline
Introduction
Siemens Gas Turbines
Applications of Thermo-Calc and DICTRA

Base Material Characterisation
Braze Alloy Development and Heat Treatment Optimisation
Heat Treatment for a Welding Process
Summary

Page 2 2010-09-09 Sebastian Piegert Siemens Energy Sector F PR GT EN M&T MPD3
Introduction
Structure of Siemens
Industry
Healthcare
Energy
Source: Siemens
Introduction
Structure of Siemens Energy
Products and Solutions for Energy − in 6 Divisions
Oil & Gas Fossil Power Renewable Energy Power Power

Generation Energy Service Transmission Distribution

Introduction
Overall Vision of Siemens Energy Sector

Portfolio
SGT5-8000H 375
SGT5-4000F 292
SGT6-5000F 200
SGT6-4000F 187
SGT5-2000E 168
SGT6-2000E 113
SGT-800 47
SGT-700 30
SGT-600 25
SGT-500 17
SGT-400 13
SGT-300 8 SGT5-8000H
SGT-200 7
SGT-100 5
SGT-400
Large Gas Turbines Industrial Gas Turbines Values in MW @ ISO Conditions

SGT5-4000F (V94.3A) Gas Turbine
Compressor, 15 stage with CDA

airfoils in all stages and with side-wall
correction. One variable guide vane
Combustion Chamber
row. Developed with P&W.
Annular combustion chamber with 24
Compressor Turbine hybrid burners. Hot gas path with air
cooled metallic or ceramic heat shield
4 -stage turbine
Blade 1 and 2 single crystalline and
directionally solidified
Film-cooling of blades and vanes of
stage 1 and 2
Rotor with Hirth serration and
single tie bolt. Quick thermal
response because of rotor internal
flow passages.
24 Hybrid Burners
Excellent thermal balance due to:
- Quick and stiff rotor
- Conical turbine flow path
Due to thermal balance:
- Quick start up
- Hot restart capability
Air Cooled Turbine Blades and Vanes
γ’ precipitation hardened
Ni-based Superalloy
1500
1300 Melting Interval

e
t ur
Blade 1 of SGT5-4000F
r a
pe
Temperatur °C
e m
l etT
n T Material
1000
in eI = 85% Tm
rb
Tu
750
Co-Base Ni-Base Ni-Base - SX

Carbide Hardening γ/γ‘ γ/γ‘
500
1940 1950 1960 1970 1980 1990 2000
Jahr

Applications of Thermo-Calc and DICTRA
Heat Treatment Estimation of

Optimisation non Conformances
Braze Alloy Base Material

Development Characterisation
Base Alloy Coating-Substrate

Thermo-Calc Version S
Development Interaction with TTNi 7 Database
DICTRA 25 with MobNi1
Database

Base Material Characterisation – IN 738 LC
Tsol Tbraze
Fraction of phases vs T
1: γ
2: MC
Possible Calculations:
3: γ’
solvus temperatures
4: M23C6
amount of phases with respect to
5: M3B2
6: L
temperature
phase compositions
prediction of occurrence of
detrimental phases such as s, h etc.
Literature vs. Calculated Tsolv
1400
Applications:
1300
estimation of “allowed” service
1200
temperatures
T / °C
1100
definition of heat treatments
1000
influence of material non-
900 min conformances in regard to
800 max
TCC composition can be evaluated
700
M23C6
M3B2
Liq
Sol
γ‘
σ
MC
0 1 2 3 4 5 6 7 8 Copyright © Siemens AG 2009. All rights reserved.

Development of a Boron Free Braze
Scope:
Develop a boron free braze alloy to
avoid formation of brittle phases.
Binary Ni-Ge Phase Diagram
Tbraze
Approach:
use Ge as MPD
high solubility in Ni
forms a to γ’ isomorphous phase
(β-Ni3Ge)
Problem:
limited availability of phase diagrams
Ge not in database (TTNi7)

Braze Alloy Development
René 80 + XY wt.-% Ge(Si)
Issue:
1: γ Ge braze BfBX-5 with X wt.-% MPD
2: Laves low melting eutectics, condensed γ’
3: L and TCP phases remain in joint
4: γ’ poor mechanical properties at 850 °C
5: NiAl Action:
new alloy based on René 80
Y wt.-% Ge are adequate for a
↓Al - →Ti - ↓↓Mo - ↓W
liquidus lower than 1200 °C
detrimental blocky phases and
Modified Braze Alloy
condensed γ’ were found within joint

1: γ
2: Laves
refinement by means of TCC
3: L Conclusion and Result:
4: γ’ reduction of refractory metals Mo/W
5: NiAl reduction of γ’ formers
microstructure is now homogeneous
Heat Treatment Development
Issue:
Two Cell Model
appropriate braze cycle not available

Model:
problem with moving interface
start of calculation with L (braze) and
γ (René 80)
expected phases attached to lower
Required Time for Solidification
René 80/BfBX-5 – 40/60 interface, i.e. joint centre, as inactive

René 80 + Y Ge
w0 = 200 µm
Result:
1204 °C/24 h isothermal single phase solidification
1204 °C/30 min + of old braze (BfBX-5) within 22 h
1140 °C/24 h
7h
significant reduction of tiso with René
80 based braze
Formation formation of Laves if Thold is
of Laves
significantly lowered
15 h
Weldability of Superalloys
high temperature strength – γ’

Mole Fraction of γ‘ in typical Superalloys
Ni3(Al,Ti)
corrosion and oxidation resistant
BUT very prone to cracking
in HAZ during welding (hot cracking)
solidification cracking
cracking due to remelting
hot cracking due to loss in
ductility
readly strain age cracking
weldable
Generally:
high γ’-content = higly prone to
cracking
3 Gew.-% ≤ cAl + ½ cTi
Ta, Nb, Hf form also γ’
Increase of Weldability
Beam welding (Laser, EB)

Low heat input
Micro-Plasma-Powder-Welding
Optimisation of welding parameters
Pre-heat treatment (solutioning,

overageing)
Heat treatment
Subsequent heat treatment
Hotbox-Welding
Ductile weld-fillers
Weld-fillers
(IN 625, IN 617, Hastelloy X)

DICTRA
Heat Treatment for Micro Cladding
moving Fact: γ‘ precipitation causes shrinkage

Model Geometry
γ interface
and hence induces tensile stresses
γ’ which can lead to cracking of weld
rγ’(T,t)
deposition.
Question: What heating rate is
641 nm favourable to avoid strain age
cracking?
3E-22
20 K/min Solution: &
min V
Precipitation Rate vs. T
2.5E-22 10 K/min K K
5 ≤T& ≤ 20
5 K/min min min
2E-22 Result:
V / m3/s
1.5E-22 low heating rate shall be applied

. 1E-22 high heating rates led to a shift of
5E-23 precipitation to higher temperatures
0
resulting in altered growth rate
total volume fraction precipitated
-5E-23
700 800 900 1000 deviates by only 10 %
T / °C Copyright © Siemens AG 2009. All rights reserved.
Summary
Major Advantages: Disadvantages:

speed up of investigations and non-validated material systems might
decrease time to market give inappropriate results
reduction of experimental testing some knowledge about the systems
“long term trials” within hours/days is required
definition of process windows even of mechanical properties cannot be
unknown systems possible predicted
calculation of stable and metastable
„real“ systems
versatile: any type of calculation
which is related to thermodynamics
and/or kinetics can be thought of
influence of distinct parameters on
the system can be studied separately
Disclaimer
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“believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations
and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which
are beyond Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual
results, performance or achievements of Siemens worldwide to be materially different from any future results, performance
or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties
arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and
interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products
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Applications of

Thermo-Calc and DICTRA

Copyright © Siemens AG 2009. All rights reserved.

 Siemens Gas Turbines

 Applications of Thermo-Calc and DICTRA

Copyright © Siemens AG 2009. All rights reserved.

Products and Solutions for Energy − in 6 Divisions

Oil & Gas Fossil Power Renewable Energy Power Power

Copyright © Siemens AG 2009. All rights reserved.

Copyright © Siemens AG 2009. All rights reserved.

Large Gas Turbines Industrial Gas Turbines Values in MW @ ISO Conditions

Copyright © Siemens AG 2009. All rights reserved.

 Compressor, 15 stage with CDA

1300 Melting Interval

Co-Base Ni-Base Ni-Base - SX

Copyright © Siemens AG 2009. All rights reserved.

Heat Treatment Estimation of

Braze Alloy Base Material

Base Alloy Coating-Substrate

Copyright © Siemens AG 2009. All rights reserved.

0 1 2 3 4 5 6 7 8 Copyright © Siemens AG 2009. All rights reserved.

Copyright © Siemens AG 2009. All rights reserved.

condensed γ’ were found within joint

 appropriate braze cycle not available

René 80/BfBX-5 – 40/60 interface, i.e. joint centre, as inactive

 high temperature strength – γ’

Beam welding (Laser, EB)

Pre-heat treatment (solutioning,

Copyright © Siemens AG 2009. All rights reserved.

moving Fact: γ‘ precipitation causes shrinkage

1.5E-22  low heating rate shall be applied

Major Advantages: Disadvantages:

Copyright © Siemens AG 2009. All rights reserved.

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