Component Wear Condition Assessment Methods and Tools

Abstract

This invention relates to a method for determining the wear condition of components in a continuous flow engine. Furthermore, this invention relates to a computer program product for performing this method. Additionally, this invention relates to a system for performing the corresponding assessment. Furthermore, this invention relates to a maintenance tool for acquiring data for this method. Finally, this invention relates to the application of this method or maintenance tool during the maintenance of a continuous flow engine.

Description

Technical Field

[0001] This invention relates to a method for determining the wear condition of components in a continuous flow engine. Furthermore, this invention relates to a computer program product for performing this method. Additionally, this invention relates to a system for performing the corresponding assessment. Furthermore, this invention relates to a maintenance tool for acquiring data for this method. Moreover, this invention relates to the application of this method or maintenance tool during the maintenance of a continuous flow engine.

[0002] These and other problems are addressed by the products and methods disclosed below and in the claims. Further beneficial embodiments are disclosed in the dependent claims, further description, and drawings. These benefits can be used to adapt the corresponding solutions to specific needs or to solve additional problems. Summary of the Invention

[0003] According to one aspect, the present invention relates to a method for determining the wear condition of a portion of a component of a continuous flow engine.

[0004] The method includes the following steps:

[0005] —Identify various types of oxide layers and their characteristics, such as distance to the surface and thickness, where the oxide layer originates from the same material as the component.

[0006] —Using the characteristics of oxide layers to diagnose the wear condition of components.

[0007] Surprisingly, a particular layer arrangement resulting from the oxidation process has been observed, especially under extreme conditions provided by the hot gas path in a continuous flow engine. The oxide layers are substantially parallel to the surface. The term "substantially parallel to the surface" as used herein refers to an arrangement of oxide layers that are substantially parallel to the surface. For example, in a cross-section perpendicular to the surface, the distance from the centerline through the oxide layer to the surface differs from the average distance from the centerline to the surface by less than 10%, more preferably less than 5%, and even more preferably less than 3%. For example, components providing cavities include at least one outer surface and at least one inner surface. However, unless otherwise stated, the surface used herein refers to the nearest surface of the component. This results in a stacking of oxide layers, wherein a single oxide layer extends on at least a portion of the surface and from the surface into the interior. It is important to note herein, especially in such application cases, that the oxidation state itself is generally irrelevant to the characteristics of the component. In such applications, the component has already been replaced or refurbished before the oxidation level reaches a certain point, making the threat posed by oxidation to the use of the component reasonable. However, it is surprising to note that small amounts of oxidation and their specific structures allow for very accurate prediction of wear conditions and even allow for the deducting of previous use of the component. To advantageously predict a component's prior use, historical data and / or digital models of the component, such as digital twins, are used. This is particularly beneficial for applications such as continuous flow engines, where the ability to compare this reliability indication with the component's expected and / or simulated condition is highly advantageous. This allows for assurance of safe operation and reliable performance of the component until the next maintenance. It also allows for a significant reduction in the safety risks involved in ensuring the required reliability and performance of the corresponding equipment.

[0008] Typically, this continuous flow engine utilizes a continuous flow of fluid through the engine to rotate a rotor, where kinetic energy is converted into electrical energy, for example. This fluid flow can be generated, for example, by burning fuel using a burner in a gas turbine, or by boiling a liquid such as water in a steam generator. Examples of corresponding continuous flow engines are gas turbines and steam turbines. Furthermore, this continuous flow engine can be used, for example, as a compressor to compress the fluid flowing through it. The compressor can also be combined with a continuous flow engine for energy generation to increase the mass flow through the turbine section. Continuous flow engines are highly versatile and reliable devices, and are an important component of modern industry.

[0009] According to another aspect, the present invention relates to a computer program product tangibly contained in a machine-readable storage medium, the computer program product including instructions operable to cause a computing entity to perform the method of the present invention.

[0010] According to another aspect, the present invention relates to a system including a processor and a non-transitory computer-readable medium, the non-transitory computer-readable medium including computer-executable instructions that, when executed by the processor, cause the system to perform the following operations:

[0011] —Evaluate data regarding multiple oxide layers, where the oxide layers originate from the same material as the component.

[0012] —Using the characteristics of oxide layers to diagnose the wear condition of components.

[0013] According to another aspect, the present invention relates to a tool for measuring the maintenance of oxide layers using the method of the present invention.

[0014] The maintenance tools collect data on multiple oxide layers.

[0015] The data includes the location and thickness of multiple oxide layers, and / or the data can be used to determine the location and thickness of multiple oxide layers.

[0016] According to another aspect, the present invention relates to the application of the method or maintenance tool of the present invention during the maintenance of continuous-flow engines. Surprisingly, it has been noted that the maintenance tool of the present invention provides highly useful information, thereby enabling significant improvements in the maintenance of such engines. In particular, the possibility of obtaining data for assessing the wear condition of continuous-flow engines has proven highly beneficial. Furthermore, it has been surprisingly noted that the obtained information can be used in corresponding models to assess the future wear of continuous-flow engines, improving service and maintenance plans for such engines with significantly improved accuracy and reliability. Remarkably, it is even possible to measure components with protective coatings without removing the coating. Attached Figure Description

[0017] To simplify the understanding of the present invention, reference is made to the following detailed description and accompanying drawings, which are also described herein. The drawings should be understood not to limit the scope of the invention, but rather to disclose preferred embodiments that further explain the invention.

[0018] Figure 1 A schematic cross-sectional view of a component with multiple oxide layers stacked is shown, wherein the cross-section is perpendicular to the surface of the component.

[0019] Figure 2 A schematic cross-sectional view of a component with different stacks of multiple oxide layers is shown, wherein the cross-section is perpendicular to the surface of the component.

[0020] To simplify the understanding of the present invention, reference is made to the following detailed description and accompanying drawings, which are also described herein. The drawings should be understood not to limit the scope of the invention, but rather to disclose preferred embodiments that further explain the invention. Detailed Implementation

[0021] Unless otherwise stated, the embodiments described below preferably include at least one processor and / or data storage unit to implement the method of the present invention.

[0022] The present invention will now be exemplarily applied to continuous flow engines, such as compressors or gas turbines. Application of the invention in this field is particularly advantageous. More specifically, for example, the extreme requirements for the overall quality of components used in this field pose a significant challenge. Meanwhile, a large amount of data and experience has been collected, for example, to allow for the prediction of strain and wear of the corresponding components. Therefore, it is anticipated that in the near future, even more complex designs will be introduced into the market, with the expectation of simulating behavior with significantly improved accuracy and monitoring the wear of such components more precisely. In particular, monitoring behavior and providing reliable assessments of reliability and lifespan will be a challenge, despite a significant reduction in the amount of available data. According to other embodiments, preferably, the method of the invention is used for components of continuous flow engines, such as compressors, gas turbines, and steam turbines, more preferably gas turbines and steam turbines, and even more preferably gas turbines. It is noted that the method of the invention is particularly advantageously applied to components to be replaced during maintenance of such equipment.

[0023] According to one aspect, the present invention relates to a method as described above.

[0024] Obtaining high-precision information using destructive analysis methods is readily achievable. However, data with sufficient detail can also be obtained through non-destructive testing methods. According to other embodiments, preferably, non-destructive measurement methods are used to determine various types of oxide layers and their properties. Such non-destructive measurement methods do not damage or destroy components. This allows for the rapid and easily verifiable acquisition of information about the wear condition of components during maintenance. This measurement method is particularly advantageous for expensive components such as stator and rotor blades. Preferably, the measurement method utilizes physical analysis methods. For example, a particularly useful measurement is the use of eddy current measurements.

[0025] Of course, it is preferable to obtain as much information as possible. However, it is noted that sufficient information can also be obtained during a single step, making the method of the present invention particularly useful for maintenance operations, including using the method as an additional step to further improve service and provide additional possibilities for optimizing the maintenance process. According to other embodiments, it is preferred to use a single measurement method (preferably a single measurement) to perform the determination of multiple types of oxide layers and their characteristics. In this context, it is also noted that the measurements required to provide sufficiently high-quality data for cases such as hot gas path components of a continuous flow engine can be significantly reduced. Based on the defined strain generated by using a continuous flow engine, the number of measurements and measurement time required can be significantly reduced. For example, it is usually sufficient to measure the corresponding oxide layer stacks on the upstream side of the stator and rotor blades. In this document, in a view along the flow direction of the flow medium in a continuous flow engine, this measurement should be located in the middle region of the component. Here, very reliable and meaningful measurements can be performed, thereby allowing for the acquisition of detailed and reliable information about the wear condition of the component.

[0026] Furthermore, by including the three-dimensional (3D) form of the component at the measurement location, the information obtained from the data on oxide layer stacks can be further improved. According to other embodiments, this method preferably includes determining the 3D form of the component located at the oxide layer location. The improvement in analytical quality obtained from this data is remarkable. For optimal results, the conditions experienced by the components that significantly benefit from this extended analysis must be highly consistent. In this case, it has been shown that the conditions suitable for hot gas path components of a continuous flow engine are highly appropriate and fully utilize this extended method. Considering the specific form, such as the flow of the flow medium through such a continuous flow engine, allows for the calculation of the characteristics of the corresponding component providing the detected oxide layer and the simulation of the expected oxidation state to further refine the details. This allows for even better estimates and further reduces the safety margin required for planned maintenance schedules. In this document, the three-dimensional form can be obtained from a specific component or from corresponding data on-site, such as CAD data, and the corresponding oxide layer data can be assigned to the specific location where measurements are taken. It is also possible to instruct the corresponding field personnel to perform measurements at specific locations to obtain data on multiple oxide layers at a portion of a component providing a defined geometry.

[0027] Generally, it is noted that general benefits can be enhanced by automatically collecting additional data related to the measurement. According to other embodiments, another type of measurement (e.g., visual measurement) is preferably performed directly before, during, or after the oxide layer measurement. For example, maintenance tools used to implement the method of the invention can provide a camera that takes pictures to record where the oxide layer measurement is performed or to determine what the oxide layer surface looks like. Surprisingly, this simple additional information acquired during the measurement allows the acquired oxide layer data to be automatically assigned to the 3D form of the component, thereby allowing for further improvements to the measurement with minimal effort.

[0028] Surprisingly, important information can be gleaned even from very thin oxide layers. According to other embodiments, it is preferred that multiple oxide layers be located at a distance of up to 2 mm from the component surface, more preferably up to 0.12 mm, and even more preferably up to 0.7 mm. For applications such as the hot gas path of a continuous flow engine, measurements are preferably limited to a depth of up to 0.5 mm, and even more preferably up to 0.4 mm. In this document, the main portion of the oxide layer is typically much larger; however, it is noted that including some deeper measurements within the unaffected material is often beneficial. Oxide layers measured in this manner do not affect the use of such components. However, it is noted that this information can be used very reliably to detect previous use and to collect data on reliability simulations and life predictions.

[0029] As noted above, it is surprisingly advantageous to apply the method of the present invention to components used in continuous flow engines for many reasons. According to other embodiments, preferred components are those of continuous flow engines, such as turbine stator blades, turbine rotor blades, compressor stator blades, compressor rotor blades, heat shields, or combustors. Typically, preferred components are hot gas path components of continuous flow engines (such as steam turbines or gas turbines). For example, the combination of non-destructive and very rapid data acquisition allows for relationships such as those concerning lifespan, which is highly beneficial for such applications, significantly exceeding other applications that do not offer these requirements under such conditions.

[0030] Furthermore, it is noted that the method of the present invention can be applied particularly effectively to components made of metal or metal alloys. According to other embodiments, preferred portions of the component are made of metal or metal alloys, such as titanium and / or heat-resistant metal alloys, such as nickel superalloys. Surprisingly, it is also possible to identify partial oxidation that first consumes certain metals in the metal alloy, thereby allowing the method of the present invention to be applied particularly usefully to metal alloys such as nickel superalloys.

[0031] Furthermore, it is noted that information regarding the thickness of multiple oxide layers can be advantageously utilized. According to other embodiments, it is preferable to analyze the thickness of at least two oxide layers, wherein the thickness ratio of at least two oxide layers is determined, and wherein this ratio is compared with a control value to determine the wear condition of the component. This information can be advantageously used, for example, to obtain more detailed information about the component's previous uses. It appears that different types of uses result in different oxide layer structures, particularly including the relative thicknesses of the oxide layers relative to each other.

[0032] Furthermore, the acquired data can be compared with available data. According to other embodiments, it is preferable to compare and / or store the wear condition with a digital model of the component. This system is particularly useful when there is quick and reliable access to an available database containing the corresponding data. In this document, by identifying reference data in the database to, for example, examine previous use under the reference condition and / or examine the subsequent development of the reference component, the time and effort required for the corresponding simulations and calculations can be reduced at least significantly.

[0033] Surprisingly, the acquired data can also be used for lifetime prediction. According to other embodiments, the lifetime of a preferred component is determined based on data regarding the oxide layer and a wear model. For example, this wear model considers incremental layer growth according to the following formula (I): x(t+dt)-x(t)=(t+dt)*K0*e T(x(t)) -x(t)(I). Surprisingly, this prediction is possible despite the low impact of the oxide layer, which is typically irrelevant to actual lifetime. Normally, the actual lifetime of a component is determined by the characteristics of its overall mechanical integrity, such as those affected by internal recrystallization processes occurring within the component. However, a highly reliable lifetime prediction can be obtained through this indirectly affected oxide layer, which surprisingly allows for the deduction of the current state and anticipation of further development.

[0034] The acquired information can also be used to adjust the maintenance system. According to other embodiments, wear status is preferably used to calculate the maintenance costs of equipment containing components. Surprisingly, lifespan prediction and wear prediction can be significantly improved, and therefore, the present invention allows for corresponding adjustments to maintenance costs. This provides significant technical benefits because the number of components that can be replaced can be reduced, and the uptime of the corresponding equipment containing the component can be increased without compromising reliability.

[0035] Furthermore, the method of the present invention can be used to adjust maintenance schedules. According to other embodiments, data on various types of oxide layers are preferably used to evaluate maintenance schedules and adjust maintenance plans. It is noted that the data thus obtainable allows for a very precise assessment of the current condition of components and checks whether the actual wear condition is comparable to the wear condition used to establish the maintenance plan. Based on this result, the maintenance plan can be adapted to reflect the actual wear of the components and the resulting expected overall maintenance requirements. Surprisingly, it is noted here that, based on historical data, reference components indicative of the overall wear of the equipment containing the components can be identified. This is often particularly effective for devices that provide very continuous component strain even as strain varies over time. An example of this embodiment is a continuous-flow engine such as a gas turbine.

[0036] Furthermore, the mechanical properties of a component can be determined, at least in part, using the method of the present invention. According to other embodiments, it is preferable to utilize data regarding various types of oxide layers to determine the mechanical properties of the component. For example, mechanical properties such as mechanical stability indicate, for instance, how much force can be applied without the risk of the component cracking or even breaking. This is quite surprising, as this mechanical property depends on many other characteristics, in which the oxide layer on the component surface plays only a very small role. However, it should be noted that, considering historical data, models, and simulations, surprisingly reliable data regarding oxide layers can also be obtained, whereas in other cases, such data can only be obtained through extensive testing and measurement, often including destructive measurements. Such destructive measurements will at least require repair steps to the component to provide a usable part again.

[0037] Two types of oxide layers are typically beneficial to examine, as follows. According to other embodiments, multiple types of oxide layers are preferred, including layers representing fully oxidized material and layers representing material partially penetrated by oxides. It is generally preferred that the multiple oxide layers also include a depleted material layer. Furthermore, it is generally preferred to locate the boundary to the unoxidized material. While it is not necessarily necessary to determine the thickness of this layer, and it may be possible to obtain the thickness of the layer indirectly using the location and thickness of the layers located thereon, obtaining this information is surprisingly beneficial for comparative and assurance purposes. Particularly for high-temperature resistant materials such as nickel superalloys, it is noted that different types of layers can be easily identified. This is assumed to be based on the microstructure of the corresponding material, which includes the commonly observed granular structure. During oxidation, the boundaries of the granular structure appear to act as barriers in this context, resulting in such granular structures resisting oxidation for a longer period. Based on the kinetics of oxygen diffusion into the material and the diffusion of metal ions in the surface direction, which are influenced by this granular structure, the location and thickness of the oxide layer containing this granular structure surprisingly allow for even more detailed deduction of the component's past use. It appears that the constraints within a continuous flow engine allow for significant insights, such as those from previous use. During normal use, oxidation is slow enough that the kinetic constraints of the corresponding granular structure components may only slow down overall oxidation by a small or negligible amount. However, under conditions of very high strain, oxidation progresses very rapidly, indicating an increased overall probability of crack formation and similar failures. Therefore, determining what type of oxide layer and in what quantity is available allows for the deducting of a component's past use, as well as for determining the component's future characteristics and assessing its future reliability.

[0038] Furthermore, it is noted that a non-uniform oxidation process can be observed, leading to the enrichment of specific metal oxides, such as aluminum oxide, chromium oxide, tantalum oxide, and / or other oxides of metals contained in the metal alloys of the component material. In this paper, the growth of corresponding oxide layers consisting of particularly enriched metal oxides or mixtures of metal oxides, or even solely of metal oxides or mixtures of metal oxides, surprisingly allows for significant insights into the past use of the component and how it will evolve in the future.

[0039] According to another aspect, the present invention relates to a computer program product tangibly contained in a machine-readable storage medium, the computer program product including instructions operable to cause a computing entity to perform the method of the present invention.

[0040] The term "computer" refers to any electronic device that includes a processor, such as a general-purpose central processing unit (CPU), a dedicated processor, or a microcontroller. A processor is adapted to perform specific computational tasks, namely, to provide results for load skewing. A computer is capable of receiving data (input), executing a predetermined sequence of operations on the computer, thereby producing results (output) in the form of data or signals. Depending on the context, the term "computer" will specifically refer to a processor, or more generally to a processor associated with a set of interconnected components contained in a single housing or enclosure.

[0041] Computer program products can be processed in a distributed manner, such as certain steps being executed on a first computing entity (e.g., at a turbine) and other steps being executed on a second computing entity (e.g., on a central server).

[0042] Computer program products can be provided, placed on the market, used, introduced, and / or stored as computer program products (and therefore can be part of computer program products). Thus, computer program products can be located on storage media (computer-readable media, such as computer disks or memory sticks). Alternatively, computer program products can be provided via download through a corresponding network connection to a server that stores computer program products by providing a link to a server where the computer program products are stored. "Computer-readable medium" or "storage medium" can be any means capable of containing, storing, communicating, propagating, or transmitting a program used by or connected to an instruction execution system, apparatus, or device. Computer-readable media can be, for example, but not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, apparatus, devices, or propagation media. More specific examples (not an exhaustive list) of computer-readable media can include: electrical connections having one or more wires, portable computer disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM or flash memory), fiber optics, and portable optical disc read-only memory (CDROM).

[0043] The computer program product according to other embodiments is adapted to perform embodiments of the methods and systems of the present invention. It is equally naturally applicable to other aspects as described herein. In this context, it must be understood that each individual specific embodiment or combination thereof as described above can be used to modify the specified computer program product.

[0044] The computer program product may also include learning mechanisms to optimize results. According to other embodiments, the computer program product preferably utilizes machine learning to optimize the processing of data regarding the oxide layer. For example, examining the corresponding evaluations and results of control cases, including measurements at later time points, to verify the applicability of the current model and simulation system. Some augmenting machine learning mechanisms may also be utilized herein. It should be noted that the cost of doing so is the possibility of automatically, or even further, improving the results obtained using the computer program product of the present invention.

[0045] In this paper, it is noted that such machine learning processes can also be initiated even when historical data on corresponding patterns of oxide layers are lacking. Surprisingly, it is observed that further adjustments for specific application cases can be obtained by simulating the development of the oxide layer over the lifetime of a control component and comparing the final measured results with those stored in a database of the simulated component. This offers the possibility of significantly improving predictions by optimizing computations and simulations based on readily available historical data, and allowing, for example, the inventive method and computer program product to be specifically tailored for new application cases.

[0046] According to another aspect, the present invention relates to a storage device for providing a computer program product of the present invention, wherein the device stores the computer program product and / or provides the computer program product for further use. Examples of the storage device may be a database such as a distributed database, or data storage such as a hard disk drive or USB stick.

[0047] According to another aspect, the present invention relates to a system including a processor and a non-transitory computer-readable medium containing computer-executable instructions that, when executed by the processor, cause the system to perform the following operations:

[0048] —Evaluate data regarding multiple oxide layers, where the oxide layers originate from the same material as the component.

[0049] —Using the characteristics of oxide layers to diagnose the wear condition of components.

[0050] It is noteworthy that the system's ability to access historical data is generally beneficial. According to other embodiments, a preferred system includes a database, preferably a distributed database, containing historical data on at least one reference component and at least one wear condition of the reference component, wherein the historical data is used to assess the wear condition of the component based on data from multiple oxide layers. That is, for example, this is particularly advantageous for applications such as continuous flow engines. In this application, a large amount of data is collected over time for the same or a reference continuous flow engine, allowing reliance on our very extensive database. Surprisingly, it is noted that this historical data can be advantageously used to gain insight into the current state and significantly reduce the effort required to predict the future of the corresponding component. Quite surprisingly, it is noted that even historical data that does not contain information about the oxide layer itself can be advantageously utilized. In this document, current experience can be used to provide models and simulations to retrospectively provide data from historical cases. Furthermore, measurements can be taken at the current time and past states simulated, allowing historical data to be updated with corresponding information about the oxide layer. While this additional step may seem to offer limited help and require additional work, it is noted that it is surprisingly beneficial because it allows the provision of a historical database with such information. The simulation data can then be used for comparison with new measurements, where the reliability of the corresponding simulations is very high.

[0051] According to another aspect, the present invention relates to a maintenance tool for measuring oxide layers in the method of the invention, wherein the maintenance tool collects data on multiple oxide layers, wherein the data includes the location and thickness of multiple oxide layers, and / or can be used to determine the location and thickness of multiple oxide layers. Surprisingly, such tools have not been previously used in maintenance work. Using a tool that meets the requirements of this purpose is remarkably beneficial to maintenance work and allows for a significant increase in the service provided in this situation. In this document, the specific requirements of continuous flow engines, such as available data, the harsh conditions faced by components, and the required high reliability, make this maintenance tool capable of significantly improving the service provided to consumers.

[0052] For many application scenarios, integrating the system of the present invention is advantageous. According to other embodiments, preferred maintenance tools include the system of the present invention. This allows, for example, maintenance experts to work independently and flexibly provide the benefits of the methods of the present invention in the field without any communication with a central service location or database. Surprisingly, the corresponding field personnel being questioned find this very beneficial. For example, this allows for independence from the customer's internet connection or the mobile connectivity of the individual on site, which typically presents problems.

[0053] Typically, preferred maintenance tools also provide the possibility of storing data. According to other embodiments, preferred maintenance tools are adapted to temporarily and / or permanently, preferably temporarily, store historical data about a reference component. This allows, for example, an immediate assessment of the component's wear condition. In this document, such an immediate assessment may, for example, include first feedback regarding whether the current wear condition is expected or whether there is a significant deviation from the expected wear condition. For example, the expected wear condition may be based on a digital model of the component reflecting its characteristics and changes in the component during use.

[0054] According to another aspect, the present invention relates to the application of the method or maintenance tool of the present invention during the maintenance of continuous-flow engines. Surprisingly, it has been noted that the maintenance tool of the present invention provides highly useful information, thereby enabling significant improvements in the maintenance of such engines. In particular, the possibility of obtaining data for assessing the wear condition of continuous-flow engines has proven highly beneficial. Furthermore, it has been surprisingly noted that the obtained information can be used in corresponding models to assess the future wear of continuous-flow engines, thereby improving service and maintenance plans for such engines with significantly enhanced accuracy and reliability.

[0055] Furthermore, it is noted that certain specific characteristics are particularly advantageously identified for hot gas path components. According to other embodiments, the wear condition and / or lifespan, more preferably the lifespan, of the hot gas path components is preferably determined. These characteristics can be determined with astonishingly high accuracy. Additionally, the ability to easily determine these characteristics in a short time is particularly useful for applications involving continuous flow engines. In particular, the benefits gained from the ability to quickly and accurately determine the corresponding characteristics during maintenance are significant and valuable for both customers and companies providing maintenance services.

[0056] The invention has been described in more detail for illustrative purposes only. However, the invention should not be construed as limited to these embodiments, as they represent embodiments that provide benefits to solve a particular problem or meet a particular need. It should be understood that the scope of protection of the invention is defined only by the appended claims.

[0057] Figure 1 This diagram shows a cross-sectional view of a component with a stack of multiple oxide layers on its surface. The component is a turbine blade used in the hot gas path of a continuous flow engine and is made of a nickel superalloy. During its use, the outer region 1 is the hot gas path surrounding the turbine blade. This surface is part of oxide layer 2 extending from the surface into the component. Oxide layers 3 and 4 are located below oxide layer 2. The three oxide layers 2, 3, and 4 represent an oxide layer stack extending from the surface of the component to the unoxidized material 5 of the component.

[0058] Oxide layer 2 consists of fully oxidized material and has a thickness of approximately 0.017 mm. Oxide layer 3 contains fully oxidized material but also includes unoxidized material particles. Oxide layer 3 has a thickness of approximately 0.016 mm. Figure 1 Particles are not shown. Oxide layer 4 contains partially oxidized material and also particles of unoxidized material 5. Partial oxidation of oxide layer 4 results in specific enrichment of certain metal oxides within oxide layer 4. The thickness of oxide layer 4 is approximately 0.015 mm. Oxide layer 4 in certain metals that are initially oxidized is continuously depleted during the oxidation process before the boundary of oxide layer 3 extends downward into the region of fully oxidized material. On the other hand, the boundary of oxide layer 4 also extends downward into the unoxidized material 5, thereby increasing the thickness of the stacked layers of oxide layers 2, 3, and 4.

[0059] The particles contained in oxide layers 3 and 4 originate from the microstructure of unoxidized material. For kinetic reasons, the particles remain usable in oxide layers 3 and 4 even when the material surrounding them has been fully oxidized. The relatively large thickness of oxide layers 3 and 4, and the presence of particles from unoxidized material, indicate that the oxidation process is quite rapid. During the use of the component, oxidation progresses too quickly to allow these particles to oxidize along with the surrounding material.

[0060] Figure 1 The intermediate oxide layer located between oxide layer 4 and unoxidized material layer 5 is not shown. In this layer, a mixture of the initial depletion and unoxidized material regions can be obtained.

[0061] Data regarding oxide layers 2, 3, and 4 can be obtained by providing separate samples using a cutting component. However, in Figure 1 In the illustrated case, eddy current measurements were used to determine the characteristics of oxide layers 2, 3, and 4. It is noted that, for example, considering the specific composition of the component material, the progression of the corresponding oxidation process can be simulated for different types of oxidation. Surprisingly, the corresponding results allow for the evaluation of the measurements using, for example, eddy current testing, to identify the current wear state by simulating the expected results and deducing the actual layer structure applicable to the component. This allows for non-destructive measurement of the component while maintaining its operability. This allows for the inclusion of this analysis as an additional standard procedure during maintenance to continuously monitor the component's lifespan and detect relevant deviations, thereby significantly increasing the potential services provided.

[0062] In this paper, the method of the present invention, such as eddy current testing, allows the acquisition of desired data using a single measurement. This is also highly advantageous, as it significantly increases the speed of the corresponding tests, making them easier to implement during maintenance. Focusing on oxide layer stacking and utilizing it as an indication of the overall wear condition of a component is surprisingly reliable and allows for significant improvements in the maintenance services for continuous-flow engines such as gas turbines.

[0063] The rapid development of the oxide layer, resulting in different types of thick layers and particles including unoxidized material, indicates the use of high strain. The overall wear condition of the component exceeded expectations and should be attributed to unplanned usage, including rapid temperature changes, including temperatures slightly exceeding normal operating conditions. The ratio of oxide layer 3 to oxide layer 4 further confirms this development, and the fact that oxide layer 3 provides a thickness comparable to oxide layer 4 suggests that the application began some time ago and has been maintained for some period.

[0064] Considering the above, the component's lifespan model should be adapted to include more of the anticipated applications than originally considered. Historical databases are used to calculate updated lifespans and progression of wear states, and this information is used to adjust maintenance schedules. Technically optimized maintenance plans are again used to adjust maintenance costs to reflect increased equipment wear. This allows for improved service planning, enabling more flexible utilization of equipment including the components. Furthermore, for example, in cases where strain on the equipment should be increased by an extended period, it becomes possible to utilize the corresponding data collected during the final maintenance period to examine whether the application is likely to or could cause problems.

[0065] In this paper, the method can be implemented using a computer program product installed, for example, on a maintenance tool for performing corresponding measurements during maintenance, or in a distributed database connected to the maintenance tool. With the appropriate hardware and software configured for the maintenance tool, the condition of components can be directly assessed in the field, and necessary actions can be taken immediately during the same maintenance of a continuous flow engine.

[0066] Figure 2 A schematic cross-sectional view is shown of a component with different stacks of multiple oxide layers, wherein the cross-section is perpendicular to the surface of the component. Figure 1 Compared to the previous embodiment, this component is a turbine blade of a gas turbine made of the same material. However, the operating conditions are significantly different. The outer region 1' represents the hot gas path surrounding the turbine blade during operation. This surface is part of the oxide layer 2' extending from the surface into the component. Oxide layers 3' and 4' are located below oxide layer 2'. The three oxide layers 2', 3', and 4' represent an oxide layer stack extending from the surface of the component into the unoxidized material 5' of the component.

[0067] Oxide layer 2' consists of fully oxidized material and has a thickness of approximately 0.017 mm. Oxide layer 3' contains partially oxidized material and has a thickness of approximately 0.007 mm. Oxide layer 3', initially oxidized in certain metals, is continuously depleted during the oxidation process before extending downwards from the boundary of oxide layer 2' into the region of fully oxidized material. Oxide layer 4' comprises a mixture of areas where depletion begins and areas of unoxidized material. Oxide layer 4' has a thickness of approximately 0.009 mm and represents the initial oxidation of the unoxidized material layer 5' that grows non-uniformly into the material of the component.

[0068] and Figure 1 In contrast, the example shown does not contain unoxidized material particles in the oxide layer. This stems from the slower oxidation, allowing for slower growth of the oxide into the material, including particles contained within the microstructure. On the other hand, the oxide layer stack provides a significantly thick oxide layer 4'. In this paper, localized weaknesses (such as cracks) in the aforementioned oxide layer lead to localized growth of the oxide material into the unoxidized material layer 5'. Based on the overall slow growth of the oxide layer, such weaknesses that occur incidentally during the use of the component represent the primary source of localized oxidation. Conversely, due to the application of... Figure 1 The harsh conditions of the components shown lead to rapid oxide layer growth, resulting in low correlation between such processes based on the dominant processes.

[0069] Use and Figure 1 The same maintenance tool was used to measure the oxide layer in the example. Figure 1 Conversely, the results allow for increased intervals between maintenance actions and reduced maintenance costs. Furthermore, the overall condition of the components and the indirectly determined low wear allow for more flexible use of the gas turbine. Even more extreme conditions are possible during emergencies, as the wear condition of the components indicates that high reliability and mechanical stability can still be provided to ensure safety, even during such use.

[0070] The scope of protection of this invention is defined by the appended claims and is not limited to the features explained in the specification or shown in the drawings.

Claims

1. A method for determining the wear condition of a continuous flow engine component, in, The method includes the following steps: —Identify various types of oxide layers (2, 3, 4, 2', 3', 4') and their characteristics extending from the surface of the component to the unoxidized material of the component, wherein the oxide layers (2, 3, 4, 2', 3', 4') originate from the same material as the component, and the various types of oxide layers are substantially parallel to the surface of the component. —The wear condition of the component is diagnosed by utilizing the characteristics of the oxide layers (2, 3, 4, 2', 3', 4'). The various types of oxide layers are determined based on the degree of oxidation.

2. The method according to claim 1, wherein, Non-destructive measurement methods were used to determine the various types of oxide layers (2, 3, 4, 2', 3', 4') and their properties.

3. The method according to claim 1 or 2, wherein, The determination of the various types of oxide layers (2, 3, 4, 2', 3', 4') and their characteristics is achieved using a single measurement method.

4. The method according to claim 1 or 2, wherein, The various types of oxide layers (2, 3, 4, 2', 3', 4') are located at a distance of up to 2 mm from the surface of the component.

5. The method according to claim 1 or 2, wherein, The component is a component of a continuous flow engine.

6. The method according to claim 5, wherein, The components are turbine stator blades, turbine rotor blades, compressor stator blades, compressor rotor blades, heat shields, or burners.

7. The method according to claim 1 or 2, wherein, Parts of the component are made of metal or metal alloy.

8. The method according to claim 7, wherein, Parts of the component are made of titanium and / or heat-resistant metal alloys.

9. The method according to claim 1 or 2, wherein, Analyze the thickness of at least two oxide layers (2, 3, 4, 2', 3', 4'). Specifically, the thickness ratio of the at least two oxide layers (2, 3, 4, 2', 3', 4') is determined, and The ratio is compared with a control value to determine the wear condition of the component.

10. The method according to claim 1 or 2, wherein, The lifespan of the component is determined based on data and wear models regarding the oxide layers (2, 3, 4, 2', 3', 4').

11. The method according to claim 1 or 2, wherein, The maintenance cost of the equipment containing the component is calculated using the wear condition.

12. The method according to claim 1 or 2, wherein, Data on the various types of oxide layers (2, 3, 4, 2', 3', 4') are used to assess maintenance schedules and adjust maintenance plans.

13. The method according to claim 1 or 2, wherein, The mechanical properties of the component are determined using data on the various types of oxide layers (2, 3, 4, 2', 3', 4').

14. A computer program product tangibly embodied in a machine-readable storage medium, comprising instructions operable to cause a computing entity to perform the method according to any one of claims 1 to 13.

15. A system comprising a processor and a non-transitory computer-readable medium containing computer-executable instructions, which, when executed by the processor, cause the system to perform operations including: —Evaluate data regarding multiple oxide layers (2, 3, 4, 2', 3', 4') of the unoxidized material extending from the surface of the continuous flow engine component to the component, wherein, The oxide layers (2, 3, 4, 2', 3', 4') are derived from the same material as the component, and the plurality of oxide layers are substantially parallel to the surface of the component. —The wear condition of the component is diagnosed by utilizing the characteristics of the oxide layers (2, 3, 4, 2', 3', 4'). The plurality of oxide layers are determined based on the degree of oxidation.

16. A maintenance tool for measuring the oxide layer according to any one of claims 1 to 13, in, The maintenance tool collects data on multiple oxide layers (2, 3, 4, 2', 3', 4') of unoxidized material extending from the surface of the continuous flow engine component to the component, the multiple oxide layers being substantially parallel to the surface of the component. The data includes the position and thickness of the plurality of oxide layers (2, 3, 4, 2', 3', 4'), and / or the data can be used to determine the position and thickness of the plurality of oxide layers (2, 3, 4, 2', 3', 4').

17. The application of the method according to any one of claims 1 to 13 or the maintenance tool according to claim 16 during continuous flow engine maintenance.

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