Engineering Failure Analysis 9 (2002) 287301

www.elsevier.com/locate/engfailanal

Failure of turbine rotor blisk of an aircraft engine

S.K. Bhaumik*, T.A. Bhaskaran, R. Rangaraju, M.A. Venkataswamy,
M.A. Parameswara, R.V. Krishnan
Failure Analysis Group, Materials Science Division, National Aerospace Laboratories, PO Bag 1779, Bangalore 560 017, India
Received 19 March 2001; accepted 19 April 2001

Abstract
Cracks were observed at the trailing edge of the blades of a turbine rotor blisk of a gas turbine engine during
inspection following an endurance test. The integrally bladed disk was made of Mar-M-247 alloy, cast and hipped.
Visual inspection, micro and macro fractography, and metallography of the failed blades indicated that the failure was
caused by stress rupture at the trailing edge followed by fatigue crack propagation. A systematic analysis was carried
out to ascertain the cause for stress rupture. Microstructural studies revealed that the columnar grains at the blade root
airfoil region were oriented unfavorably leading to poor stress rupture property in the transverse direction. Coupled
with this, the high operating temperatures were responsible for the failure of the blade by stress rupture. It was
recommended that the casting parameters be controlled so that the columnar grains are oriented parallel to the principal stress axis of the blade. Coarse columnar grains with high aspect ratios in the longitudinal direction will improve
the stress rupture property. It was also suggested to monitor the operating temperature to see that it does not exceed
the specied temperature limit of the alloy. # 2002 Elsevier Science Ltd. All rights reserved.
Keywords: Failure analysis; Turbine blade failures; Stress rupture; Fatigue crack; Grain size

1. Introduction
Small gas turbines of 2000 or less shaft horsepower are widely used for both axial and radial ow turbine
stages with integrally bladed cast nickel base superalloy disks. The prime motivation for the use of integrally cast turbine stages has been the need to increase blade density or count when compared to the
inserted blade designs [1]. A turbine/disk rotor (blisk) as a one piece casting also oers a signicant cost
reduction compared to the conventional cast blade-dovetail-wrought disk rotor, and also avoids certain
stress problems caused by the dovetail type of blade mounting [2]. However, its drawback is that the
microstructure is rather dicult to tailor to suit locally variable service stressing conditions of such components. For example, a relatively coarse grained structure is desirable in the airfoils which must mainly
resist high temperature creep, whereas ne grains are desirable in the thick hub section, where moderate
temperature low cycle fatigue (LCF) is of prime importance [2,3].
* Corresponding author. Fax: 091-80-5270098.
E-mail address: subir@css.cmmacs.ernet.in (S.K. Bhaumik).
1350-6307/02/$ - see front matter # 2002 Elsevier Science Ltd. All rights reserved.
PII: S1350-6307(01)00017-6

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Over the last three decades, signicant progress has been made in the development of cast nickel base
superalloys and more so in the casting technology to obtain a tailored microstructure. Of the various cast
alloys with great potential, Mar-M-247 is widely used for the manufacture of rotor blisk. Mar-M-247 is a
nickel base, vacuum melted, cast superalloy with high g0 [Ni3 (Al, Ti. . .)] volume fraction (about 62%) and
high refractory element (Ta+W+Mo) content (  14 wt.%) [4]. The alloy, developed in the early 19700 s by
Danasi, Lund and others at Martin Metals Corporation, has high creep strength and good castability with
excellent oxidation resistance. Along with these inherent properties, the improved casting technology has
made it possible to produce cast blisks with high stress rupture properties in the blades as well as good
moderate temperature LCF in the disk. The challenging job in the fabrication of the integrally bladed disk as
a single piece is the control of microstructure at dierent locations of the blisk to optimize the high temperature properties as well as the fatigue properties. Service failure of these components can occur by creep,
stress rupture, fatigue or a combination of these if proper fabrication techniques are not practiced [25].
This paper deals with the analysis of failure of a blisk that took place during the development runs of an
aircraft engine for a specic application. The blades of the rotor blisk were found to develop cracks prematurely. On strip examination, it was found that a number of blades had developed cracks at the trailing
edge above the blade root platform. The failed disk was reported to have completed less than 400 min and
16 starts (including 5 endurance cycles of 46 min each) of engine run. The integrally bladed turbine disk
was made of Mar-M-247 alloy, cast and hipped. The nominal composition of the alloy is given in Table 1.

2. Experimental details
The failed rotor blisk was subjected to uorescent dye penetrant inspection and the cracked blades and
crack locations were identied. These cracks were opened for fractographic examination by making cuts
from opposite direction of the cracks, and pulling the crack surfaces apart. The resulting fracture surfaces
were cleaned ultrasonically followed by stripping of cellulose replicas. The specimens for microstructural
study were cut from the blades which showed cracks, mounted on their face (concave side down), and prepared as per standard metallographic techniques. Fractographic and microstructural studies were carried
out using a scanning electron microscope (SEM, LEO 440I). Energy dispersive X-ray analysis was carried
Table 1
Composition of Mar-M-247 (wt.%)
Element

Minimum

Maximum

Co
W
Cr
Al
Ta
Hf
Ti
Mo
C
Zr
Mg
B
S
Si
Fe
Ni

9.0
9.5
8.0
5.3
2.8
1.2
0.9
0.5
0.13
0.03

0.01

11.0
10.5
8.8
5.7
3.3
1.6
1.2
0.8
0.17
0.08
0.20
0.02
0.015
0.2
0.5
Remainder

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out by EDX attached to the SEM. Quantitative metallographic measurements were performed using Image
Pro Plus software to determine the mean size and volume fraction of g0 precipitates. Hardness measurements on the blades were carried out using a SHIMADZU HSV-20 Vickers microhardness tester at a load
of 500 g. Specimens were also cut from blades of an unused blisk at locations where cracking was observed
in the failed blisks and prepared metallographically for comparative microstructural study.

3. Results
3.1. Fluorescent dye penetrant inspection
The failed turbine rotor blisk brought for investigation is shown in Fig. 1. Fluorescent dye penetrant
inspection revealed that a number of blades had developed cracks at the trailing edge. One such cracked
blade is marked in Fig. 1. The location of cracks was about 6-8 mm above the blade root platform. All
cracks were through thickness at the trailing edge and had progressed about 79 mm towards the leading
edge. The crack was found to have propagated in a zig zag manner near the trailing edge followed by a
smooth linear region towards the leading edge.
3.2. Macrofractography
Under a low power microscope, the crack surface was found discolored due to oxidation and exposure to
high temperatures. The fracture surface had two clearly distinguishable regions. Near the trailing edge, the
fracture surface was more oxidized and showed the presence of faceted fracture features. A little interior
towards the leading edge, the fracture surface had a smooth and dull appearance. Well dened beach
marks, typical of fatigue, could be seen in this region. These beach marks were observed only in the smooth
fracture region. The curvature of the beach marks indicated that the incremental crack growth had taken

Fig. 1. Photograph showing the turbine rotor blisk that had failed during the development run test. One of the cracked blades is
shown by an arrow.

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place from the edge of the faceted fracture zone. However, no features resembling delayed failure could be
seen in the faceted fracture zone.
3.3. Scanning electron microscopy/fractography
A low magnication SEM fractograph of the blade fracture surface is shown in Fig. 2. The faceted
fracture region, transgranular fracture region, and the fresh fracture region obtained by pulling the crack
surface apart are marked A, B and C respectively. A mixed mode of intergranular and cleavage fracture
was observed in region A (Fig. 3). The grains in this region were found to be large and elongated in the
transverse direction of the blade. Intergranular fracture was observed along almost all the grain boundaries
oriented in this direction. The fracture along the grain bodies was mainly by cleavage mode, which left
distinctive river patterns on the fracture surface. No evidence of fatigue striations were observed. From the
river patterns, the fracture origin could be traced to the concave side of the trailing edge [shown by an
arrow in Fig. 3(a)]. Careful examination of the river patterns on the individual grains indicated that all of
them had initiated at the grain boundaries on the left side of the micrograph [Fig. 3(b)], i.e. at the trailing
edge side, and propagated at an angle from the concave side to the convex side of the blade. The SEM
fractograph at the fracture initiation region is shown in Fig. 4. Intergranular cracking with extensive crack
branching was seen in this region. It is interesting to note that an inclined grain surface (shown by an
arrow) is created at the trailing edge as a result of intergranular fracture.
Cleavage mode of fracture was observed at the trailing edge of the blade having grains with high aspect
ratios. Beyond this region, the fracture surface was found to be smooth and the crack was found to have
propagated transgranularly. Well dened beach marks, typical of fatigue, were observed in this region
(Fig. 5). These beach marks were found to emanate from the edge of the region A, i.e. the faceted fracture
zone. At higher magnications, closely spaced striations could be seen (Fig. 6). Due to the presence of high
volume fraction of g0 precipitates, the striations were not clearly delineated.

Fig. 2. A low magnication photograph of the fracture surface. Faceted fracture region A, transgranular fracture region B, and
freshly opened fracture region C are indicated in the gure.

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Fig. 3. SEM fractographs showing the fracture region A. The fracturing has taken place by a mixed mode of intergranular and
cleavage fracture. The direction of river patterns on the cleaved grains indicates that the crack has propagated from the concave side
of the trailing edge [shown by an arrow in (a)] to the convex side at an angle. Intergranular fracturing is observed along all the grain
boundaries oriented in this direction (b).

3.4. Metallography
3.4.1. Failed blisk
The concave surface of the blade containing one of the fracture surfaces was metallographically polished
and examined under SEM. Extensive crack branching in the direction perpendicular to the fracture surface
was observed. One such crack is shown in Fig. 7. The crack branching was observed only in zone A, i.e. in
the faceted fracture region. No such crack branching was observed in zone B. The polished specimen was

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Fig. 4. SEM fractograph at the crack origin (trailing edge) showing a grain surface (arrow) created due to intergranular fracture.
Extensive crack branching can also be seen in this region.

etched and observed to examine the crack propagation path. It can be seen (Fig. 8) that the crack has
propagated mainly in transgranular fashion and by cleavage mode.
The microstructures of the blade adjacent to the fracture surface are shown in Figs. 910. No elongated
or blocky MC type carbides are seen in the blade material near the fracture surface. In general, the size,
morphology and distribution of the carbides were found to be satisfactory. The microstructure of the
polished and etched specimen, shown in Fig. 9(a), consisted of g nickel-rich solid solution containing a
dispersion of various sizes of g0 precipitates, discrete MC and M23C6 carbide particles, and g-g0 eutectic
pools. This kind of microstructure was observed in regions both near to and away from the fracture surface. It is interesting to note from Fig. 9(b) that the morphology of the g0 precipitates is of elliptical shape
with the major axis roughly aligned in a particular direction. The mean size and volume fraction of precipitates were measured to be about 1.2 mm and 0.32, respectively.
The orientation of the columnar grains with respect to the fracture surface is shown in Fig. 10. It can be
seen that they are aligned in the same direction as that of the crack propagation. To examine the overall
orientation of the columnar grains at the root region, one blade was polished metallographically on the
convex side containing a portion of the hub and rim, and etched to reveal the macrostructure. The macrophotograph of the etched blade is shown in Fig. 11. At the blade root region, the orientation of the
columnar grains was found to be like a fountain along the center line of the blade such that at the trailing
edge, the grains are elongated in the transverse direction. Schematically, such a microstructure can be
represented as shown in Fig. 12.
3.4.2. Unused blisk
The microstructures of the unused blisk at a location of the blade where the cracking was observed are
shown in Fig. 13. It consists of a g nickel solid solution, g0 precipitates, carbide particles and g-g0 eutectic
pools. The g0 precipitates are found to be very uniform in size and distribution, and exhibited typical
cuboidal shape. The mean size and the volume fraction of the g0 precipitates were measured to be 0.8 mm
and 0.48, respectively.

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Fig. 5. SEM fractographs showing transgranular fracture region B. Incremental crack growth as evidenced by the beach marks are
shown; (a) adjacent to the region, A and (b) adjacent to the freshly opened fracture surface region, C. It can be seen that the fatigue
crack has emanated from the edge of region A and propagated from trailing edge to leading edge.

3.5. Chemical analysis

Composition of the blade material was determined by EDX analysis in SEM. The results conform to the
composition of Mar-M-247.
3.6. Hardness measurements
Hardness measurements were conducted on both the failed and unused blades at identical locations
(about 6 mm from the blade root platform where the cracking was observed). The hardness values measured were HV 372 and HV 408 in the failed and unused blades respectively.

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Fig. 6. SEM fractographs showing fatigue striations; (a) near region A and (b) near region C. The striations are not clearly delineated
due to the presence of large volume fraction of g0 precipitates.

4. Analysis and discussion

4.1. Fractographic analysis
Fractographic study revealed that the fracture surface of the blade consisted of two distinctive fracture
zones. The blade at the trailing edge fractured in a mixed mode of intergranular and cleavage fracture.
Such fracture features were conned to the region of grains with large aspect ratios in the transverse
direction. Another feature to note here is that almost all the grain boundaries aligned in this direction have
cracked by intergranular mode, whereas the crack propagation from the trailing edge to the leading edge
has been predominantly by cleavage. From the river patterns on the cleaved grains, it was possible to

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Fig. 7. SEM micrograph showing the polished surface (in region A slightly away from the trailing edge) perpendicular to the crack
propagation direction. Extensive cracking in the longitudinal direction of the blade can be seen.

locate the crack initiation point, and it was traced to the concave side of the blade at the trailing edge
(Fig. 3a). The crack has originated at one of the grain boundaries, progressed intergranularly in the
transverse direction at an angle, and nally culminated in cleavage fracture in the adjacent columnar
grains. The cleavage features and extensive crack branching indicate that the crack has propagated relatively fast (Figs. 3 and 4). It does appear from the fractographic features that possibly, the grain boundary
sliding at elevated temperatures resulted in accumulation of a signicant amount of strain at grain
boundaries which resulted in cleavage fracture as well as crack branching in the perpendicular direction of
crack propagation.
Intergranular initiation and propagation of cracks are the principal mode of fracture in high temperature
creep. Void formation, cracking and other malignant events occur principally on grain boundaries normal
to the major stress axis of the blade [58]. The important microstructural features that dictate the elevated
temperature creep properties of superalloys are the grain size and the grain shape represented by grain
aspect ratio (GAR), which is a ratio of grain length to grain width. Since creep is a grain boundary phenomenon, it is well established [1,5,7,9] that columnar grains with high aspect ratio in the longitudinal
direction of the blades will improve stress rupture properties. The large columnar grains basically eliminate
the grain boundaries in the transverse direction, and thereby prevent the grain boundary sliding in this
direction.

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Fig. 8. SEM micrograph of the etched specimen showing a part of the branching secondary cracks shown in Fig. 7. It can be noted
that the cracks are transgranular and cleavage type.

However, in the failed blade in question, the grains are elongated in the transverse direction (Fig. 10).
This favors the grain boundary sliding in this direction and results in the accumulation of strain at the
grain boundary. This strain can be accommodated only through a process of mutual sliding displacement
between neighboring grains in the longitudinal direction [6]. The accommodation is facilitated when the
grain aspect ratio is less or near to one. In grains with high aspect ratios (>>1), the mutual sliding and
rotation of the grains are dicult, and, therefore, leads to fracturing of the grains when the fracture strain
is reached. In such a situation, the propagation of the crack is expected to be fast and also the fracture
mode changes from intergranular to cleavage [6].
The progress of the crack in the second stage is purely by transgranular mode. The incremental crack
growth is evidenced by the presence of closely spaced fatigue striations (Fig. 6). The change of (i) the
fracture mode from cleavage to transgranular and (ii) crack growth from relatively fast to slow, point
towards the local microstructural variation in the blade in the transverse direction. It appears from the
fracture surface that the crack has initiated at one of the grain boundaries at the concave side of the trailing
edge and propagated very fast towards the convex side at an angle. In the second stage, the resulting crack
in the blade has propagated by fatigue towards the leading edge.
4.2. Microstructural analysis
Microstructural analysis of the blade at the region of cracking revealed considerable microstructural
variation from trailing edge to the leading edge. Firstly, the columnar grain structure is ner with less aspect
ratio at the trailing edge, which is relatively thin, compared with the coarse columnar structure with high
aspect ratio at the leading edge (Fig. 11). Secondly, the columnar grains are oriented along the transverse
direction at the trailing edge, and are found to change gradually to longitudinal direction at the leading edge.
This microstructural variation is perhaps largely due to the diculty of maintaining uniform temperature
gradient during the casting of the integrally bladed disk with wide change in sections, particularly hub to
blade and trailing edge to leading edge areas. Microstructural features at the cracked area of the blade,
therefore, conrm that the two fracture zones are mainly due to the local microstructural variation and

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Fig. 9. SEM micrographs showing the microstructure in the failed blades near the fracture surface. It consists of g nickel-rich solid
solution containing a dispersion of various sizes of g0 precipitates, discrete MC and M23C6 carbide particles, and g-g0 eutectic pools (a).
The shape of the precipitates on the polished surface appears to be elliptical with major axes aligned roughly in a single direction and
perpendicular to major stress axis of the blade (b). The mean size and volume fraction of the precipitates are measured to be 1.2 mm
and 0.32, respectively.

have resulted due to two dierent modes of fracture. In the rst fracture zone, the crack extended from the
concave side of the trailing edge to the convex side at an angle approximately matching with the grain
boundaries in this direction (Figs. 3 and 10). The sharp crack thus produced acts as a notch for the initiation of fatigue crack.
Considering the fact that the engine has run only for 396 min, the changes in the shape and size of the g0
precipitates are substantial (Figs. 9 and 13). This indicates that the operating temperature of the engine has
exceeded the specied limit. Quantitative assessment and quantitative metallographic measurements

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Fig. 10. Macrophotograph showing the orientation of the columnar grains with respect to the fracture surface. It can be seen that they
are elongated in the same direction as that of crack propagation (i.e. transverse direction of the blade). FS: fracture surface, TE:
trailing edge, TD: transverse direction.

Fig. 11. Macrophotograph showing the columnar grains at the blade root region. The columnar grains from the hub are like a
fountain along the center line of the blade such that at the trailing edge they are oriented in the transverse direction.

showed not only the coarsening of g0 precipitates but also their dissolution. Their mean size increased from
0.8 to 1.2 mm, while the volume fraction decreased from 0.48 to 0.32. This itself suggests that the operating
temperature was in the vicinity of the solvus temperature of g0 phase. Another important point to note here
is the shape of the precipitates. They appear elliptical on the polished surface with the major axes roughly
aligned in a single direction which is perpendicular to the major stress axis of the blade. This kind of

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Fig. 12. Schematic showing the orientation of the columnar grains at the leading and trailing edges in the blade root region of the
failed turbine rotor blisk. It can be noted that grain aspect ratio (GAR) at the trailing edge is more in the transverse direction (not to
scale).

directionality in conjunction with coarsening is known [10] to occur when superalloys undergo elevated
temperature creep deformation.
The high temperature strength of nickel base superalloys is derived from the high volume fraction of g0
precipitates. Quantitative data available in the literature [11] demonstrate that for a given volume fraction
of g0 precipitates, the rupture life of the alloy increases with the decrease in the g0 precipitate size. The
factors responsible for the improved creep rupture life are mainly the increase in the g-g0 interfacial area
and decrease in the interparticle spacing associated with a uniform distribution of ne g0 precipitates.
Changes in the morphology of the g0 precipitates are commonly observed in nickel base superalloys when
subjected to external stresses at elevated temperatures [10]. Coarsening of the g0 particles reduces the creep
resistance in these polycrystalline materials, because the overaged microstructure allows deformation to
occur by particle by-passing [12]. Moreover, the change of precipitates shape from cuboidal to spherical
indicates the reduction of lattice mismatch between the g-matrix and g0 , thereby facilitating the deformation process by providing easy passage for the dislocations [13].
4.3. Mechanism of failure
As discussed in the earlier sections, it is evident that the cracking at the trailing edge of the blade basically took place by stress rupture. The factors responsible for such cracking are the unfavorable columnar
grain orientation in the airfoil and high operating temperature. Once the initial crack is formed due to

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Fig. 13. SEM micrographs showing the microstructures of the blade from an unused blisk. It consists of a g nickel-rich solid solution,
g0 precipitates, MC and M23C6 carbide particles, and g-g0 eutectic pools (a). The g0 precipitates are uniform in size and distribution,
and exhibits typical cuboidal shape (b). The mean size and volume fraction of these precipitates are measured to be 0.8 mm and 0.48,
respectively.

stress rupture, it is natural that the crack will propagate under the cyclic loading experienced by the blade
during service. The presence of beach marks and striations conrms the second stage growth of the crack
by a fatigue mechanism. The direction of crack propagation is also indicative of two stage crack propagation by two dierent modes. In the rst stage, the crack has propagated from the concave side at the
trailing edge to the convex side at an angle at a relatively fast mode as indicated by the cleavage type
fracture features, whereas in the second stage, the crack has propagated from the trailing edge to the
leading edge by incremental crack growth. Therefore, the primary mechanism of failure of the blade is
stress rupture. This has subsequently led to crack propagation by fatigue under cyclic loading conditions.

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5. Conclusions
The failure of the turbine blisk is attributed to an improper microstructure at the blade airfoil section
and high operating temperature, which led to crack initiation at the trailing edge by stress rupture. The
subsequent crack growth is by fatigue under the cyclic loading conditions. The present study clearly brings
out the importance of microstructural control in promoting good stress rupture of the blisk.

6. Recommendations
(a) Care should be taken during the fabrication of the blisk to achieve columnar grains at the blade roots
oriented in the longitudinal direction of the blade. Coarse columnar grains with high aspect ratio in the
airfoil section will improve the elevated temperature strength and stress rupture property.
(b) Estimation of the temperature of the blade is required to see that the operating temperature is within
the specied limit of the alloy.

Acknowledgements
The authors wish to acknowledge Dr. A. C. Raghuram, former Head, Failure Analysis Group and
Deputy Head, Materials Science Division, NAL, for many useful discussions during the course of this study.
Mr. K. Baskar, Mr. C. R. Kannan and Ms. Kalavathi are acknowledged for metallographic, NDT and SEM
support respectively. The authors are grateful to Dr. T. S. Prahlad, Director, NAL, for permission to publish
this work.

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