Applied Chemical Engineering

Multi-material Al–Ni–316L functionally graded composites for turbine blade applications: Fabrication, mechanical characterization and fatigue behavior

Amjad M. Bader

College of Engineering, University of Diyala, Diyala, Iraq

Mohanad S. Hasan

College of Engineering, University of Diyala, Diyala, Iraq

Saad T. Faris

Bilad Alrafidain University College, Diyala, Iraq

Abdulwahab M. Al-Mushehdany

Bilad Alrafidain University College, Diyala, Iraq

DOI: https://doi.org/10.59429/ace.v9i1.5800

Keywords: Turbojet engines; turbine blades; functionally graded materials; mechanical characteristics

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Abstract

A turbine blade on an aircraft's jet engine is a component of the turbine section of turbojet engines. These blades extract energy from high-pressure gas flows and rising temperatures, making them subject to high-temperature gradients. Functionally graded materials are promising materials used in this research to improve blade performance in this challenging environment. This study analyzes the development, manufacturing, and characterization of multiple aluminium, nickel, and 316 steel alloys combined within multi-functionally graded materials that have been successfully fabricated using the powder metallurgical method. The three functionally graded material samples used in this study consist of five layers, starting with AL-NI (75% Ni to 25% Al) on one side and endi ng with Ni-AL and 316 steel (3.33% Ni to 33.33% Al to 33.33% steel) wt% on the other. After determining the mechanical characteristics of each layer of the functionally graded beam both before and after fatigue cracking, the natural frequency of the samples is calculated. As a result, it was found that the combination of 316L steel and particle concentration improved the mechanical properties of the Al-Ni alloy, making it a practical and lightweight alternative to steel structural elements. The 316L steel hybrid alloys showed favourable results in tensile tests and demonstrated stability in long-term fatigue tests. Additionally, the study found that fracture mechanics can accurately predict fatigue life, and that milled and blended Al-Ni-316L steel behaves similarly to a metal powder compact, with consolidation involving particle rearrangement and plastic deformation. The tensile tests carried out at 20°C demonstrated that Sample 2 had the best mechanical performance, with a yield strength of 679 MPa, ultimate tensile strength of 825 MPa, and elastic limit of 708 MPa, which are improvements of +12.6%, +11.7%, and +17.4% more than Sample 1, correspondingly. Fatigue-life experiments were carried out at a stress ratio R = –1, excitation frequencies of 25–27 Hz, and using loads ranging between 5.5–17 kN. The fatigue lives measured for a constant frequency corresponded to 55,000 cycles, while for random vibration patterns 2 and 3, they were 75,400 and 64,000 cycles, correspondingly. The longest fatigue life was demonstrated by Sample 2, showing a +37% improvement over Sample 1. The FGMs revealed stable first-mode natural frequencies around 25–27 Hz, while resonance was strongly affecting fatigue damage. The Al/Ni/Steel FGM compact specimen was also found to exhibit comparable yield and ultimate stress values to steel, thus enhancing its mechanical properties while reducing weight.

Keywords: Turbojet engines; Turbine blades; Functionally Graded Materials; Mechanical         Characteristics

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