Power - Fossil/Hydropower

Gas turbines/Single Client Projects (SCPs)/Case Studies

TWI conducts short-term project work and longer term research and development for its Industrial Member companies for product innovation, and to improve efficiency in all aspects of joining technology. As a result, Members from all industrial sectors can introduce novel designs, new fabrication or inspection techniques in order to improve business profitability or to enhance product safety and reliability.

TWI Industrial Members can also identify and contact individual specialists at TWI for answers to technical enquiries via our Contacts Online facility.

Single Client Projects (SCPs)

To respect confidentiality, generic titles of selected projects are given below:

Fabrication

Electron beam diffusion bonding of a titanium aluminide alloy
Chemical analysis and tensile tests on gas turbine base unit
Examination of the feasibility of EB welding of large diameter turbine shafts
Simple models for residual stresses in linear friction welds
High temperature thermal barrier coatings for gas turbine components
Welding of Hiduminium 54
Manufacturing and modelling of fabricated structural components (MMFSC)
Rotary friction welding nickel superalloys
Linear friction welding of single crystal turbine blade material

Repair and maintenance

CMSX4 turbine blade repair study
Examination of creep damaged HP turbine blades
Engine failure investigation
Advanced repair of gas turbine blades including IN738 and CMSX4 materials
Laser powder fusion repair of blades
Activated TIG repair of blades
Post-repair performance validation by creep and low cycle fatigue testing
Repair validation programme for vane assemblies including LCF testing of repairs and thermal modelling
A review of condition inspection and repair techniques for hot section gas turbine components
NDT of flame sprayed coating on turbine ring
Investigation of weld cracking during the manual TIG welding of cooling passages in Inco 82 turbine vanes
Failure investigation of a failed diffuser support ring from a gas turbine exhaust system
LP rotor disc failure investigation
Failure investigation of stainless steel fuel lines
Examination of failed nozzles. The examination of a number of stainless steel (AISI type 304) fuel injection nozzles from a gas turbine
Replication inspection of gas turbine rotor disc
Residual stress analysis of gas turbine exhaust cascade bend assemblies
Investigation into the mechanism of cracking from a gas turbine uptake system
Investigation of the cause of cracking in an exhaust diffuser support ring
Metallographic study of Inconel X750
Development and customisation of RISKWISETM RBI software for Gas Turbines
Investigation into the cause of cracking stainless steel parts
Metallurgical evaluation of turbine casings. The evaluation of the effect of over temperature running
Metallurgical and failure examination and lifing studies for compressor blades and rotors
An evaluation of electro-spark deposition for repaid of blade coatings
Repair of an Inconel 969 rotor
Repair of gas turbine blades
Repair of TiAl castings
Top face penetration control welding and in-line NDT

Full list of non-nuclear single clients projects

Case studies:

These case studies were written in collaboration with the customer concerned.

Full list of non-nuclear power case studies